Assessor Resource

PPMSTM440
Troubleshoot and rectify boiler plant systems

Assessment tool

Version 1.0
Issue Date: August 2019


This unit of competency describes the outcomes required to identify, diagnose, rectify and report faults in boiler plant systems, in the pulp and paper industry.

This unit applies to senior operators and production specialists who troubleshoot and rectify boiler plant systems, in a pulp or paper manufacturing facility. This typically involves working in a facility with complex integrated equipment and continuous operations.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)



Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Identify and diagnose causes of faults

1.1. Check and plan work within workplace health and safety (WHS) procedures, productivity requirements, risks and hazards identification, environmental workplace procedures and Standard Operating Procedures (SOP).

1.2. Interpret abnormal plant conditions and machine alarms to determine fault type and location.

1.3. Undertake physical inspections of plant, equipment and processes to identify faults.

1.4. Identify boiler type and locate cause and source of fault.

1.5. Isolate faulty plant, if possible, and confirm with production and maintenance.

1.6. Confirm diagnosis by access and reference to relevant historical data.

1.7. Communicate diagnosis to relevant personnel.

2. Rectify faults

2.1. Implement shutdown and isolation procedures.

2.2. Repair or replace faulty equipment.

2.3. Adjust process and systems to restore normal operations.

2.4. Communicate normal operations to relevant personnel.

3. Record and report operational data

3.1. Document troubleshooting process and responses to corrective actions, as required.

3.2. Document variations from standard specifications and boiler operating faults.

3.3. Communicate relevant information to appropriate personnel.

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide evidence that they can:

identify causes and effects of faults and corrective action on associated processes, at least twice in line with required enterprise intervals, for the boiler plant system in a pulp or paper manufacturing facility

identify system, quality and equipment faults within level of responsibility

implement isolation and access procedures

troubleshoot and rectify boiler plant systems

maintain a clean and hazard free work area

record and report on operational data

communicate effectively, through written and verbal means, the corrective actions undertaken.

A person competent in this unit must be able to demonstrate knowledge of:

troubleshooting methods that can be applied across boiler plant system faults

implications of pre operational checks including low water level alarm, high water level alarm, low water level, alarm lockout, hydrostatic test, burner management system and safety valve test

documentation and procedures relevant to troubleshooting steam boiler operations, in the pulp and paper industry including:

work health and safety (WHS) including load shifting licensing requirements

Standard Operating Procedures (SOP), risk and hazard identification, plant clearance, job safety analysis and permit systems

appropriate boiler/pressure vessel operator certification

confined space standards and regulations

productivity requirements and quality procedures

environmental sustainability requirements and practices

machinery and plant manufacturing operating manuals

enterprise policies and procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

manufacturer's specifications and maintenance documentation

Material Safety Data Sheets (MSDS)

operator's log and job sheets

incidents reports

steam generation system, processes and associated services sufficient to troubleshoot including plant layout, theory of operation, causes and effects of adjustments made to steam generation plant and processes and relationships between steam generation system, processes and associated services

the use of materials and supplies for boiler plant systems including chemicals, coal, oil, gas, additives, air, water, wood waste, steam recovery process products and power

key features of maintenance systems including operator level maintenance as per site agreements, operator maintenance schedules, maintenance suppliers and pro-active maintenance strategies

use of boiler water treatment system and reasons for treatment

use of electronic and other control systems, operation and application to make appropriate adjustments that control boiler plant operations.

The following resources must be made available:

access to the full range of equipment required for detecting and addressing faults associated with steam generation operations in a pulp or paper manufacturing facility

electronic control systems which includes Digital Control System (DCS), touch screens or robotics required for steam boiler operation

personal protective equipment suitable for troubleshooting steam boiler operations

applicable work health and safety (WHS) and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements

relevant personnel for the purposes of communicating information

sample workplace documentation, procedures and reports including Standard Operating Procedures (SOP), quality procedures ,environmental sustainability requirements/practices, plant manufacturing operating manuals, enterprise policies and procedures, oil or chemical spills and disposal guidelines, plant isolation documentation, safe work documentation.

Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Identify and diagnose causes of faults

1.1. Check and plan work within workplace health and safety (WHS) procedures, productivity requirements, risks and hazards identification, environmental workplace procedures and Standard Operating Procedures (SOP).

1.2. Interpret abnormal plant conditions and machine alarms to determine fault type and location.

1.3. Undertake physical inspections of plant, equipment and processes to identify faults.

1.4. Identify boiler type and locate cause and source of fault.

1.5. Isolate faulty plant, if possible, and confirm with production and maintenance.

1.6. Confirm diagnosis by access and reference to relevant historical data.

1.7. Communicate diagnosis to relevant personnel.

2. Rectify faults

2.1. Implement shutdown and isolation procedures.

2.2. Repair or replace faulty equipment.

2.3. Adjust process and systems to restore normal operations.

2.4. Communicate normal operations to relevant personnel.

3. Record and report operational data

3.1. Document troubleshooting process and responses to corrective actions, as required.

3.2. Document variations from standard specifications and boiler operating faults.

3.3. Communicate relevant information to appropriate personnel.

Not Applicable

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide evidence that they can:

identify causes and effects of faults and corrective action on associated processes, at least twice in line with required enterprise intervals, for the boiler plant system in a pulp or paper manufacturing facility

identify system, quality and equipment faults within level of responsibility

implement isolation and access procedures

troubleshoot and rectify boiler plant systems

maintain a clean and hazard free work area

record and report on operational data

communicate effectively, through written and verbal means, the corrective actions undertaken.

A person competent in this unit must be able to demonstrate knowledge of:

troubleshooting methods that can be applied across boiler plant system faults

implications of pre operational checks including low water level alarm, high water level alarm, low water level, alarm lockout, hydrostatic test, burner management system and safety valve test

documentation and procedures relevant to troubleshooting steam boiler operations, in the pulp and paper industry including:

work health and safety (WHS) including load shifting licensing requirements

Standard Operating Procedures (SOP), risk and hazard identification, plant clearance, job safety analysis and permit systems

appropriate boiler/pressure vessel operator certification

confined space standards and regulations

productivity requirements and quality procedures

environmental sustainability requirements and practices

machinery and plant manufacturing operating manuals

enterprise policies and procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

manufacturer's specifications and maintenance documentation

Material Safety Data Sheets (MSDS)

operator's log and job sheets

incidents reports

steam generation system, processes and associated services sufficient to troubleshoot including plant layout, theory of operation, causes and effects of adjustments made to steam generation plant and processes and relationships between steam generation system, processes and associated services

the use of materials and supplies for boiler plant systems including chemicals, coal, oil, gas, additives, air, water, wood waste, steam recovery process products and power

key features of maintenance systems including operator level maintenance as per site agreements, operator maintenance schedules, maintenance suppliers and pro-active maintenance strategies

use of boiler water treatment system and reasons for treatment

use of electronic and other control systems, operation and application to make appropriate adjustments that control boiler plant operations.

The following resources must be made available:

access to the full range of equipment required for detecting and addressing faults associated with steam generation operations in a pulp or paper manufacturing facility

electronic control systems which includes Digital Control System (DCS), touch screens or robotics required for steam boiler operation

personal protective equipment suitable for troubleshooting steam boiler operations

applicable work health and safety (WHS) and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements

relevant personnel for the purposes of communicating information

sample workplace documentation, procedures and reports including Standard Operating Procedures (SOP), quality procedures ,environmental sustainability requirements/practices, plant manufacturing operating manuals, enterprise policies and procedures, oil or chemical spills and disposal guidelines, plant isolation documentation, safe work documentation.

Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Check and plan work within workplace health and safety (WHS) procedures, productivity requirements, risks and hazards identification, environmental workplace procedures and Standard Operating Procedures (SOP). 
Interpret abnormal plant conditions and machine alarms to determine fault type and location. 
Undertake physical inspections of plant, equipment and processes to identify faults. 
Identify boiler type and locate cause and source of fault. 
Isolate faulty plant, if possible, and confirm with production and maintenance. 
Confirm diagnosis by access and reference to relevant historical data. 
Communicate diagnosis to relevant personnel. 
Implement shutdown and isolation procedures. 
Repair or replace faulty equipment. 
Adjust process and systems to restore normal operations. 
Communicate normal operations to relevant personnel. 
Document troubleshooting process and responses to corrective actions, as required. 
Document variations from standard specifications and boiler operating faults. 
Communicate relevant information to appropriate personnel. 
Check and plan work within workplace health and safety (WHS) procedures, productivity requirements, risks and hazards identification, environmental workplace procedures and Standard Operating Procedures (SOP). 
Interpret abnormal plant conditions and machine alarms to determine fault type and location. 
Undertake physical inspections of plant, equipment and processes to identify faults. 
Identify boiler type and locate cause and source of fault. 
Isolate faulty plant, if possible, and confirm with production and maintenance. 
Confirm diagnosis by access and reference to relevant historical data. 
Communicate diagnosis to relevant personnel. 
Implement shutdown and isolation procedures. 
Repair or replace faulty equipment. 
Adjust process and systems to restore normal operations. 
Communicate normal operations to relevant personnel. 

Forms

Assessment Cover Sheet

PPMSTM440 - Troubleshoot and rectify boiler plant systems
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

PPMSTM440 - Troubleshoot and rectify boiler plant systems

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: