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Elements and Performance Criteria

1. Prepare and prepare for monitoring and maintaining furnace gas efficiency
   • Access, interpret and apply smelting documentation and ensure the work activity is compliant
   • Receive, interpret and clarify verbal and written shift changeover details
   • Establish and maintain communication with other personnel
   • Select appropriate personal protective equipment for the work activity
   • Select appropriate auxiliary equipment
   • Carry out equipment pre-start checks
   • Identify, address and report potential risks, hazards and environmental issues and implement control measures
   • Follow emergency procedures
   • Use approved dust suppression and extraction methods
   • Ensure adequate ventilation to work area before commencing the work activity
2. Maintain efficient operation of furnace gas plant and systems
   • Carry out plant and equipment start-up checks and procedures
   • Carry out monitoring and control on Distributed Control Systems (DCS)
   • Operate and maintain air operated breathing equipment for furnace off-line entry
3. Control furnace gas emissions
   • Carry out plant and equipment start-up checks and procedures
   • Monitor and operate accretion build-up removal equipment
   • Monitor and maintain furnace feed chutes and ensure they are free of blockages,
   • Collect samples of molten metal to confirm molten metal quantity and condition of molten metal bath
4. Maintain efficient operation of furnace air injection equipment
   • Carry out plant and equipment start-up checks and procedures
   • Monitor furnace conditions and operations to identify the correct, efficient operation of the furnace air injection equipment, and report to appropriate personnel
   • Identify variances to furnace and air injection equipment operation, record and repair where possible
   • Clean furnace air injection equipment/device without causing damage
   • Check and record furnace air injection equipment/device position, and recalibrate where outside operating parameters
5. Ensure supply of additives
   • Monitor and maintain condition of furnace feed materials
   • Monitor furnace additives supply and report to appropriate personnel
6. Maintain plant and equipment efficiency
   • Clean plant to maintain condition of all equipment
   • Interpret and respond to plant alarms, take corrective actions and notify appropriate personnel
   • Check and adjust plant condition
   • Install and control stand-by furnace burner equipment
   • Inspect air, gas, diesel and combustion supply equipment, report and rectify faults, damaged or inoperable equipment to appropriate personnel
   • Carry out minor plant maintenance and lubrication
   • Provide support for maintenance personnel
7. Shutdown plant and equipment
   • Shutdown or isolate plant/equipment
   • Perform post shutdown or isolation checks
   • Pass on shift changeover details to oncoming shift
8. Prepare and prepare for monitoring and maintaining furnace gas efficiency
   • Access, interpret and apply smelting documentation and ensure the work activity is compliant
   • Receive, interpret and clarify verbal and written shift changeover details
   • Establish and maintain communication with other personnel
   • Select appropriate personal protective equipment for the work activity
   • Select appropriate auxiliary equipment
   • Carry out equipment pre-start checks
   • Identify, address and report potential risks, hazards and environmental issues and implement control measures
   • Follow emergency procedures
   • Use approved dust suppression and extraction methods
   • Ensure adequate ventilation to work area before commencing the work activity
9. Maintain efficient operation of furnace gas plant and systems
   • Carry out plant and equipment start-up checks and procedures
   • Carry out monitoring and control on Distributed Control Systems (DCS)
   • Operate and maintain air operated breathing equipment for furnace off-line entry
10. Control furnace gas emissions
    • Carry out plant and equipment start-up checks and procedures
    • Monitor and operate accretion build-up removal equipment
    • Monitor and maintain furnace feed chutes and ensure they are free of blockages,
    • Collect samples of molten metal to confirm molten metal quantity and condition of molten metal bath
11. Maintain efficient operation of furnace air injection equipment
    • Carry out plant and equipment start-up checks and procedures
    • Monitor furnace conditions and operations to identify the correct, efficient operation of the furnace air injection equipment, and report to appropriate personnel
    • Identify variances to furnace and air injection equipment operation, record and repair where possible
    • Clean furnace air injection equipment/device without causing damage
    • Check and record furnace air injection equipment/device position, and recalibrate where outside operating parameters
12. Ensure supply of additives
    • Monitor and maintain condition of furnace feed materials
    • Monitor furnace additives supply and report to appropriate personnel
13. Maintain plant and equipment efficiency
    • Clean plant to maintain condition of all equipment
    • Interpret and respond to plant alarms, take corrective actions and notify appropriate personnel
    • Check and adjust plant condition
    • Install and control stand-by furnace burner equipment
    • Inspect air, gas, diesel and combustion supply equipment, report and rectify faults, damaged or inoperable equipment to appropriate personnel
    • Carry out minor plant maintenance and lubrication
    • Provide support for maintenance personnel
14. Shutdown plant and equipment
    • Shutdown or isolate plant/equipment
    • Perform post shutdown or isolation checks
    • Pass on shift changeover details to oncoming shift

Performance Evidence

Evidence is required to be collected that demonstrates a candidate’s competency in this unit. Evidence must be relevant to the roles within this sector’s work operations and satisfy all of the requirements of the performance criteria of this unit and include evidence that the candidate:

locates and applies relevant legislation, documentation, policies and procedures

works effectively with others to undertake and complete the monitoring and maintenance of furnace gas efficiency that meets all of the required outcomes including:

complying with written and verbal reporting requirements and procedures

communicating clearly and concisely with others to receive and clarify work instructions and coordinate work activities

demonstrates completion of the monitoring and maintenance of furnace gas efficiency that safely, effectively and efficiently meets all of the required outcomes on more than one (1) occasion including:

completing plant and equipment pre-start and start-up activities

operating, monitoring and maintaining equipment

inspecting equipment

monitoring and maintenance of feed chutes

performing post shut down and isolation checks

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Knowledge Evidence

The candidate must demonstrate knowledge in monitoring and maintaining furnace gas efficiency through:

applying combustion principles

identifying importance of flame patterns/flame impingement

applying methods of resolving combustion/gas problems

applying principles of furnace operation/ furnace components

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