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Elements and Performance Criteria

  1. Prepare the boiler for operation
  2. Start and monitor boiler operation
  3. Analyse and respond to abnormal performance
  4. Handover boiler operations
  5. Carry out an operational shutdown
  6. Shutdown the boiler and prepare for an internal inspection
  7. Store boiler in shutdown mode
  8. Record information

Required Skills

Required skills include

Ability to

access workplace information on combustion and operating requirements

select fit and use personal protective clothing andor equipment

identify and report hazards and potential hazards in the work area

confirm status of boiler and related equipment including the fuel supply system ash removal and services

demonstrate purge procedure

conduct prestart checks including checking

feed water supply and system

fuel supply system

fans and dampers

inspection doors

boiler valves operation and position

combustion air supply system

boiler water level

liaise with other work areas to advise of boiler status

demonstrate setup and startup procedures in both manual and automatic modes

monitor boiler operation including monitoring

steam reticulation line pressure

boiler steam pressure

steam supplyusage

condensate tank level

bagasse levels

feedwater levels and pressure

fuel levels

boiler load

water quality

furnace pressure

ash pit level and removal system

balance draft system

superheater temperature

drum levels

equipment condition

conduct water quality test

take corrective action in response to outofspecification results

report andor record corrective action as required

demonstrate shift handover procedure and confirm that replacement operators are aware of all relevant issues prior to completing handover

demonstrate procedure to take boiler off line

demonstrate procedure to shutdown and clean the boiler

demonstrate removal of valves and fittings to prepare the boiler for inspection

demonstrate procedure to store boiler

demonstrate emergency procedures and related restart including the use of emergency fuel supply

maintain workplace records

maintain work area to meet housekeeping standards

Required knowledge includes

Knowledge of

relevant state OHS legislation standards and codes of practice relating to work responsibilities

safe work procedures including awareness of health and safety hazards related to boiler operation and associated control measures

purpose and limitations of protective clothing and equipment

hierarchy of hazard control measures

duty of care of the boiler operator

purpose and basic principles of combustion and boiler operation including principles of heat transfer and properties of steam

boiler system layout and steam cycle

the purpose of purging a boiler

the effect of fuel quality on boiler operation

impact of ash removal on efficient boiler operation and impact of sluice water flow

relationship to other processes including an understanding of the impact of sudden load changes on boiler pressure and plant operation

purpose and limitations of protective clothing and equipment

methods used to render equipment safe to inspect maintain andor clean including lockout tagout and isolation procedures

water quality test procedures

typical causes of watercondensate contamination and corrective action required

equipment purpose and basic operating principles including high pressure feed pumps fuel supply system and dual fuel systems as required by boiler type

operating requirements and parameters

procedures for responding to emergency situations including safe shutdown procedure

handover and long term shut down and storage procedures

cleaning procedures and grate dumping

environmental issues and controls including an understanding of sluice water usage

requirements to liaiseadvise related work areas

housekeeping standards for the work area

reporting and recording systems including both statutory and workplace requirements

Evidence Required

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package

Overview of assessment

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of ability to

confirm status of boiler and related equipment including the fuel supply system ash removal and services

demonstrate purge procedure

conduct prestart checks

liaise with other work areas to advise of boiler status

demonstrate set up and start up procedures in both manual and automatic modes

conduct water quality test

take corrective action in response to outofspecification results

report andor record corrective action

demonstrate emergency procedures and related restart

Context of and specific resources for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to

Boiler and related equipment This includes fuel supply grate cleaning and ash removal systems

Relevant codes and standards

Operating procedures and related advice on equipment operation

Personal protective clothing and equipment

Communication systems and equipment

Housekeeping standards and procedures

Workplace information recording systems requirements and procedures

Method of assessment

Other units of competency relevant to the work role should be assessed in conjunction with this unit This may include

FDFOPA Operate a process control interface

FDFOP2030A Operate a process control interface

Guidance information for assessment

To ensure consistency in ones performance competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances cases and responsibilities and where possible over a number of assessment activities

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Policies and procedures

Work is carried out in accordance with company policies and procedures, licensing requirements, manufacturer's recommendations, legislative requirements, codes of practice and industrial awards and agreements.

Codes of Practice

Codes of practice include the Sugar Milling Operations Industry Code of Practice.

Workplace information

Workplace information can include

Standard Operating Procedures (SOPs)

manufacturer's specifications.

Boilers [basic]

Boiler (basic) and related equipment may be

fully or partly attended, and include

single fixed combustion air supply

non-modulating single heat source

fixed firing rate.

Operation and monitoring of equipment and processes typically requires the use of control panels and systems.

Hazards

Hazards typically include:

working around hot surfaces

manual handling

steam, hot gasses and fuel leaks.

Services

Services can include fuel supply of bagasse, coal, gas, oil or other fuel types, steam, mill and instrumentation air, cooling water, general mill water supply and cooling water.

Equipment status

Confirming equipment status involves:

conducting relevant pre-start checks

confirming that cleaning standards are met

all safety guards and manholes are in place

equipment is operational.

Internal cleaning

Internal cleaning is carried out in accordance with statutory requirements regarding confined space entry and does not typically include chemical cleaning.

Teamwork

Work may require the ability to work within a team environment.

Information systems

Information systems may be print or screen based.