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Elements and Performance Criteria

1. Identify and diagnose causes of faults
   • 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.
2. Rectify faults
   • Implement shutdown and isolation procedures.
   • Repair or replace faulty equipment.
   • Adjust process and systems to restore normal operations.
   • Communicate normal operations to relevant personnel.
3. Record and report operational data
   • 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.
4. Identify and diagnose causes of faults
   • 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.
5. Rectify faults
   • Implement shutdown and isolation procedures.
   • Repair or replace faulty equipment.
   • Adjust process and systems to restore normal operations.
   • Communicate normal operations to relevant personnel.

Range Statement

Not Applicable

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Performance Evidence

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.

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Knowledge Evidence

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.

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