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Elements and Performance Criteria

1. Identify and diagnose causes of faults.
   • Plant assessments and system alarm systems are interpreted to determine fault type and location.
   • Routine physical inspections of plant and processes are made to identify faults.
   • Cause and source of problem is identified and located.
   • Faulty plant is isolated, if possible, and confirmed with production and maintenance.
   • Relevant historical data is accessed/referred to, to confirm diagnosis.
   • Diagnoses are communicated to relevant personnel.
   • Work is completed within OH&S, Standard Operating Procedures (SOP), environmental and safe working requirements and practices.
2. Rectify systems/plant equipment faults.
   • Emergency stop/shutdown, isolation and lock-out procedures are initiated prior to fault rectification.
   • Faulty equipment/instrumentation is isolated and caused to be repaired/replaced.
   • Fine tuning adjustments to process and systems are made to return to specifications.
   • Restoration of machine/system to normal operation is verified and communicated to relevant personnel.
   • Work is completed within OH&S, SOP, environmental and safe working requirements and practices.
3. Rectify product quality and distribution faults.
   • Product quality faults/variations are identified by observation, systematic sampling and testing.
   • Samples for a range of tests are taken according to established enterprise procedures and SOP.
   • Test results are interpreted and operations are adjusted to correct variations from specification.
   • Out of specification product is dealt with according to SOP.
   • Work is completed within OH&S, SOP, environmental and safe working requirements and practices.
4. Record and report operational data.
   • Variations from standard specification and machine operation faults are documented/logged.
   • Indications of performance variance are entered into log.
   • Assessment and evaluation of causes of variations and corrective action undertaken is recorded as required.
   • Relevant information is communicated to appropriate personnel to prepare for modification to the plant output.

Required Skills

Not applicable

Evidence Required

Explains types causes and effects of plant shutdowns

Explains plant startup and shutdown procedures

Describe plant operation and control mechanisms

Outlines impact and effect of inappropriate responses to shut

Explains causes and effects of system faults and rectification requirements

Implements troubleshooting guides and diagnostic procedures

Diagnoses production and quality faults effects and causes

Gathers analyses and interprets data

Conducts routine checking procedures during plantsystems operation

Explains types and purpose of tests

Sets up and operates test equipment

Explains sampling and testing procedures

Interprets test results

Logs and records data

Demonstrates keyboarding and computer access skills

Uses effective communication

Explains boiler water treatment system and reasons for treatment

Explains statutory responsibilities

Identifies causes of shutdown and responds appropriately

Initiates isolations and lockouts in compliance with SOP

Identifies locates and rectifies or causes to be rectified operational and quality faults

Confirms and maintains required production throughput after restart

Maintains plant operation within specification

Communicates with appropriate personnel

Works within OHampS SOP environment and safe working requirements and practices

Electrical Power Generation

FPPEPGA Manage a power generation system startup

FPPEPGA Monitor and control power generation system

FPPEPGA Coordinate power generation system shutdown

FPPEPGA Conduct a technical inspection of power generation plant and equipment

FPPEPGA A Troubleshoot and rectify power generation system

Please note

A single Range Statement has been prepared to cover all Units in Electrical Power Generation The actual contextconditions for each Unit would be drawn from the mills customised version of this Range Statement

The competencies in this unit refer to those related to the management and operation of power generation and includes steam turbine driven alternators auxiliary plant electricity generation regulation and distribution systems used in the pulp and paper making industry

Materialssupplies

water

steam

electricity

gas

Equipment

Equipment appropriate to power generation processes and may include the following

boilers

high and low voltage transformers

steamgas turbines

and switchboards

water systems and auxiliary plant

circuit breakers

ACDC generation and distribution systems

protective equipment

measuringrecording equipment

Legislation policy and procedures

OHampS

appropriate endorsed operator

environmental and statutory legislation

licences

enterprise policies and procedures

local power authority policies and procedures

Standard Operating Procedures SOP

Documentationproceduresreports

operational logsreports

maintenance logs

SOP documentation

Materials Safety Data Sheets MSDS

Process and instrument diagrams

Maintenance

as per site agreement

maintenance schedules

maintenance systems

Samplingtesting

plantsystem operations and process steam supply monitoring

as per site agreements

Technology

full and semi automated plant and equipment

manually operated plant and equipment

controlled systems PLC or DCS

electronic measuring and monitoring equipment

Communication channels

internalexternal suppliers and customers

maintenance services

team members

productservices coordinator

Explains types causes and effects of plant shutdowns

Explains plant startup and shutdown procedures

Describe plant operation and control mechanisms

Outlines impact and effect of inappropriate responses to shut

Explains causes and effects of system faults and rectification requirements

Implements troubleshooting guides and diagnostic procedures

Diagnoses production and quality faults effects and causes

Gathers analyses and interprets data

Conducts routine checking procedures during plantsystems operation

Explains types and purpose of tests

Sets up and operates test equipment

Explains sampling and testing procedures

Interprets test results

Logs and records data

Demonstrates keyboarding and computer access skills

Uses effective communication

Explains boiler water treatment system and reasons for treatment

Explains statutory responsibilities

Identifies causes of shutdown and responds appropriately

Initiates isolations and lockouts in compliance with SOP

Identifies locates and rectifies or causes to be rectified operational and quality faults

Confirms and maintains required production throughput after restart

Maintains plant operation within specification

Communicates with appropriate personnel

Works within OHampS SOP environment and safe working requirements and practices

Electrical Power Generation

FPPEPGA Manage a power generation system startup

FPPEPGA Monitor and control power generation system

FPPEPGA Coordinate power generation system shutdown

FPPEPGA Conduct a technical inspection of power generation plant and equipment

FPPEPGA A Troubleshoot and rectify power generation system

Please note

A single Range Statement has been prepared to cover all Units in Electrical Power Generation The actual contextconditions for each Unit would be drawn from the mills customised version of this Range Statement

The competencies in this unit refer to those related to the management and operation of power generation and includes steam turbine driven alternators auxiliary plant electricity generation regulation and distribution systems used in the pulp and paper making industry

Materialssupplies

water

steam

electricity

gas

Equipment

Equipment appropriate to power generation processes and may include the following

boilers

high and low voltage transformers

steamgas turbines

and switchboards

water systems and auxiliary plant

circuit breakers

ACDC generation and distribution systems

protective equipment

measuringrecording equipment

Legislation policy and procedures

OHampS

appropriate endorsed operator

environmental and statutory legislation

licences

enterprise policies and procedures

local power authority policies and procedures

Standard Operating Procedures SOP

Documentationproceduresreports

operational logsreports

maintenance logs

SOP documentation

Materials Safety Data Sheets MSDS

Process and instrument diagrams

Maintenance

as per site agreement

maintenance schedules

maintenance systems

Samplingtesting

plantsystem operations and process steam supply monitoring

as per site agreements

Technology

full and semi automated plant and equipment

manually operated plant and equipment

controlled systems PLC or DCS

electronic measuring and monitoring equipment

Communication channels

internalexternal suppliers and customers

maintenance services

team members

productservices coordinator

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Range Statement

The competencies described in this group of units relate to those functions inclusive of the following boiler types:

Please note:

A single Range Statement has been prepared to cover all Units in Steam Generation. The actual context/conditions for each Unit would be drawn from the mill's customised version of this Range Statement.

. fire tube

. saturated boiler

. water tube

. super heated

and may be operated in conjunction with other steam driven plant and operations including:

. paper making machines

. turbines

. digesters

. heating plant

Materials/supplies:

. chemicals

. coal

. oil

. gas

. additives

. air

. water

. wood waste

. steam

. recovery process products

. power

Equipment:

Equipment appropriate to steam generation processes and may include the following:

. boiler and auxiliary plant

. boiler heating systems

. fuel and fuel delivery system plant

. dust removal and combustion waste

. fuel management system

. extraction systems

. water distribution systems

. compressed air systems

. steam temperature control plant

. chemical dosing system

. water treatment system

. flare detection equipment

. hand and power tools

Legislation, policy and procedures:

. OH&S

. environmental and statutory legislation

. enterprise policies and procedures

. Standard Operating Procedures (SOP)

. appropriate boiler/pressure vessel operator certification

Documentation/procedures/reports:

. SOP

. job sheets

. grade specifications

. manufacturer's specifications

. maintenance logs

. statutory requirements

. Materials Safety Data Sheets (MSDS)

. operator's log

. process and instrument diagrams

Maintenance:

. as per site agreement

. maintenance schedules

. maintenance systems

Sampling/testing: [excludes FPPSTM3A]

. feed water quality

. assessments of process operations

Technology:

. fully automated, semi automated, manually operated plant and equipment

. enter/extract computer data, electronic screens and alarms, analogue and digital instrumentation

Communication channels:

. internal/external customers and suppliers

. statutory authorities

. team members

. maintenance/services co-ordinators

. maintenance services

The competencies described in this group of units relate to those functions inclusive of the following boiler types:

Please note:

A single Range Statement has been prepared to cover all Units in Steam Generation. The actual context/conditions for each Unit would be drawn from the mill's customised version of this Range Statement.

. fire tube

. saturated boiler

. water tube

. super heated

and may be operated in conjunction with other steam driven plant and operations including:

. paper making machines

. turbines

. digesters

. heating plant

Materials/supplies:

. chemicals

. coal

. oil

. gas

. additives

. air

. water

. wood waste

. steam

. recovery process products

. power

Equipment:

Equipment appropriate to steam generation processes and may include the following:

. boiler and auxiliary plant

. boiler heating systems

. fuel and fuel delivery system plant

. dust removal and combustion waste

. fuel management system

. extraction systems

. water distribution systems

. compressed air systems

. steam temperature control plant

. chemical dosing system

. water treatment system

. flare detection equipment

. hand and power tools

Legislation, policy and procedures:

. OH&S

. environmental and statutory legislation

. enterprise policies and procedures

. Standard Operating Procedures (SOP)

. appropriate boiler/pressure vessel operator certification

Documentation/procedures/reports:

. SOP

. job sheets

. grade specifications

. manufacturer's specifications

. maintenance logs

. statutory requirements

. Materials Safety Data Sheets (MSDS)

. operator's log

. process and instrument diagrams

Maintenance:

. as per site agreement

. maintenance schedules

. maintenance systems

Sampling/testing: [excludes FPPSTM3A]

. feed water quality

. assessments of process operations

Technology:

. fully automated, semi automated, manually operated plant and equipment

. enter/extract computer data, electronic screens and alarms, analogue and digital instrumentation

Communication channels:

. internal/external customers and suppliers

. statutory authorities

. team members

. maintenance/services co-ordinators

. maintenance services

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