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Elements and Performance Criteria

  1. Plan and prepare for operations
  2. Identify and control hazards
  3. Ensure appropriate authorisations have been obtained/issued
  4. Identify work flow path (interruptions or bottlenecks) blockage
  5. Conduct pre-start requirements to procedures
  6. Conduct isolation as appropriate for pre-start inspections
  7. Prepare equipment for operation
  8. Complete routine equipment checklists
  9. Complete reports as required for equipment inspections
  10. Start up reduction cell to procedures
  11. Monitor equipment operation and check operational variables are within parameters
  12. Verify equipment performance throughout the process
  13. Adjust equipment/variables in accordance with procedures
  14. Apply operating principles to identify problems and take action
  15. Shut down reduction cell as required
  16. Conduct routine housekeeping activities
  17. Recognise and respond to emergencies should one arise
  18. Complete records as required for equipment operation and performance
  19. Isolate and de-isolate plant
  20. Make safe for required work
  21. Check plant is ready to be returned to service
  22. De-isolate and prepare plant for return to service

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used, and include one or more of the following:

legislative requirements, including work health and safety (WHS)

industry codes of practice and guidelines

environmental regulations and guidelines

Australian and other standards

licence and certification requirements

All operations to which this unit applies are subject to stringent health, safety and environment (HSE) requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and HSE requirements, the HSE requirements take precedence.

Equipment and tools

Equipment and tools include one or more of the following:

reduction cell (pot)

carbon anodes

bake out equipment

cell tending equipment

hand tools

harnesses and slings

materials handling equipment

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, include one or more of the following:

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Hazards

Hazards include one or more of the following:

open furnace pits, ring main risers, fire shaft pit, riser shaft and natural gas

heat (e.g. burns, dehydration and heat stress)

energy sources (e.g. hydraulic, pneumatic and electric)

high pressure piping and valves

pinch and crush points

moisture

banned items

mobile equipment and pedestrian interaction

furnace emissions

suspended loads and roller conveyors

hazardous materials (e.g. reactive alumina, kaowool, tar and pitch)

molten materials

equipment failures

industrial (machinery, equipment and product)

equipment or product mass

noise, rotational equipment or vibration

other hazards that might arise

Routine problems

Routine problems must be resolved by applying known solutions.

Routine problems are predictable and include one or more of the following:

tap out

out-of-parameter operation or product

fluctuation in temperature, power consumption or product movement

instruments and equipment requiring cleaning

equipment mechanical and electrical problems

flow path blockages

out-of-parameter emissions

unavailability of equipment, personnel or material

Known solutions are drawn from one or more of the following:

procedures

training

remembered experience

historical data and records of common faults

troubleshooting lists and directives

site procedures

Non-routine problems must be reported according to according to relevant procedures.

Instrument/electrical systems

Instrument/electrical systems include one or more of the following:

bake out equipment

emergency shutdown systems

fire systems

pressure and temperature control systems

communications systems

utility systems

Operate

Operate is to monitor, adjust/make change to the production unit and/or its component items to meet specifications, by one or both of the following:

manually in the plant

using local controller in the plant

Pre-start checks

Pre-start checks will conform to site procedures or equipment pre-start checklist. They must be completed before the equipment is operated unless stated in the procedures.

Reports and records

Reports and records include one or more of the following:

routine inspections (daily readings and monthly checks)

scheduled maintenance activities

computer readouts locally or in the control room

shift log sheet

mandatory or statutory inspections

hazard, accident and incident reports

quality inspection reports of the product

Shutdown procedures

Shutdown procedures must follow equipment and site-authorised checklist and will typically include the following:

communication to supply and delivery areas

communication to impacting areas

obtaining appropriate authorisations

rescheduling operations

liaison with maintenance teams

Start-up procedures

Start-up procedures must conform to site procedures and will typically include the following:

safety and pre-start checks

accessing shift logs and equipment records

pre-shift briefing information

records and reports from the previous shift

Work requirements

Work requirements will be identified from one or more of the following:

shift briefings

shift logs

supervisor or crew leader meetings

toolbox talks

handover details

Performance Evidence

relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

prepare the refurbished or repaired cell for start-up

bake out the cathode lining

start up the cell and transfer bath

monitor equipment conditions and maintenance requirements and take action

monitor process parameters and performance and make adjustments according to procedures

recognise early warning signs of equipment/processes needing attention or with potential problems and take action to ensure a timely return to full performance

isolate and de-isolate equipment

identify hazards and apply hazard control procedures

respond to emergencies

apply housekeeping procedures, including cleaning the area, removal of contaminants, safety inspections and rectification of issues that could compromise safety.

Knowledge Evidence

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the reduction cell process and functions of each

basic principles of operation of main equipment items, including cathode bed, anodes and adjusters, feeders, bath conditions and current distribution

basic understanding of the product specifications, including depth of cover and uniformity of aluminium layer, and variations required on the input and output side

basic understanding of the bake process (gas bake or resistor bake)

the cell preparation process, including cathode bed, thermocouples, feeders, fittings and connections, bake process, anode installation, bath transfer and shunt removal

isolating a problem to an item of equipment/stage of process

process parameters and limits (e.g. temperature, moisture, pressure and flow)

emergency responses, including those related to:

tap outs

leak/loss of containment

evacuation due to fire or open cell circuit

loss of power

excessive emissions of fumes or particulate

equipment failure

typical hazards associated with reactive alumina, tar, pitch, kaowool, suspended loads and heat stress, and how to recognise them

correct use of personal protective equipment (PPE), including specific insulated boots, heat resistant material, full-ventilated suits, full-face masks and other situation-specific equipment.