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Elements and Performance Criteria

1. Prepare the crystalliser station for operation
   • Massecuite is confirmed and available to meet production requirements
   • Services are confirmed as available and ready for operation
   • Equipment is checked to confirm readiness for use
   • The crystallisers are set up to meet production requirements
2. Operate and monitor crystalliser station
   • The crystallisation station is started up and operated according to company procedures
   • Control points are monitored to confirm performance is maintained within specification
   • C massecuite feed to fugals meets specification
   • Equipment is monitored to confirm operating condition
   • Out-of-specification process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure
   • The workplace meets housekeeping standards
3. Handover the crystalliser station
   • Workplace records are maintained in accordance with workplace procedures
   • Handover is carried out according to workplace procedure
   • Crystalliser station operators are aware of system and related equipment status at completion of handover
4. Shut down the crystalliser station
   • The appropriate shut down procedure is identified
   • The crystalliser station is shut down according to workplace procedures
   • The crystalliser station is prepared for storage in shut down mode
   • Maintenance requirements are identified and reported according to workplace reporting procedure

Required Skills

Not applicable

Evidence Required

The assessment process must address all of the following items of evidence

Ability to

Access workplace information to identify production requirements

Select fit and use personal protective clothing andor equipment

Confirm supply of necessary materials and services

Confirm equipment status and condition

Start up from empty and start up from full

Maintain required levels in the crystallisers

Follow cooling and reheating profiles

Start up and operate in both automatic and manual modes

Monitor the process and equipment operation to maintain the process within the required parameters This typically involves monitoring

throughput

loads on crystalliser drives

sugar crystal size and distribution

massecuite conductivity

massecuite dilution rates

end of cooling and reheating temperatures

stocks of C massecuite to match pan stage throughput

equipment condition

Detect and report water leaks from crystalliser coils

Take corrective action in response to outofspecification results

Report andor record corrective action as required

Record workplace information

Demonstrate shift handover procedure

Shut down equipment in response to an emergency situation

Demonstrate an operational shut down procedure

Prepare equipment for cleaningmaintenance

Maintain work area to meet housekeeping standards

May include the ability to

Use process control systems

Clean and sanitise equipment

Take samples and conduct tests

Knowledge of

Purpose and basic principles of crystallisation This includes a basic understanding of crystal growth and super saturation of solutions

The effect of C molasses dilution on C massecuite viscosity

The effect on C molasses purity of variation in

end of cooling and reheating temperatures

residence time

The effect of C massecuite conditioning on low grade fugal performance

the circuit flow of this process and relationship to related processes

equipment purpose and basic operating principles of crystallization equipment

the risks and consequences of pipe failure related to massecuite decomposition

Services used

Operating requirements and parameters

requirements when starting up full crystallisers containing cold massecuite

requirements when shutting down full crystallisers containing hot massecuite

Significance and method of monitoring control points within the process

Common causes of variation and corrective action required

Hazards and controls

Lock out and tag out procedures

shut down sequence including massecuite pumps and reheaters

Requirements of both operational and long term shut down conditions to ensure the equipment is left in a safe state for the period of the shutdown and to minimise any delays in future start up

Procedures and responsibility for reporting problems

Environmental issues and controls

Waste handling requirements and procedures

Recording requirements and procedures

May include knowledge of

Basic operating principles of process control where relevant This includes the relationship between control panels and systems and the physical equipment

Cleaning and sanitation procedures

Sampling and testing procedures

Relationship with other standards

Prerequisite units

There are no prerequisite units for this competency standard

Coassessment of related units

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

SUGPCPSA Collect and prepare samples

SUGPPSTA Conduct standard tests

SUGZPCIA Operate a process control interface

Resources required for assessment

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

Operating procedures and related advice on equipment operation including advice on safe work practices and environmental requirements

Personal protective clothing and equipment

Product and process specifications and operating parameters

Crystalliser station equipment

Materials including C massecuite and services as required

Material Safety Data Sheets where appropriate

Housekeeping standards and procedures

Advice on environmental management issues relevant to work responsibilities

Workplace information recording systems requirements and procedures

They may also require access to

Cleaning procedures sampling schedule and procedures and maintenance procedures and tools depending on the work requirements

Assessment requirements

For information on how to assess this competency standard and who can assess refer to the Assessment Guidelines for this Training Package

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Range Statement

The range statement indicates the context for demonstrating competence. This statement is a guide and unless otherwise indicated, items may or may not apply as required by the work context.

Work is carried out in accordance with company policies and procedures, manufacturer's recommendations, legislative requirements, codes of practice and industrial awards and agreements. Codes of practice include the Sugar Milling Operations Industry Code of Practice

Workplace information can include Standard Operating Procedures (SOPs), specifications, production schedules and manufacturer's specifications

The crystalliser station may include low grade pan receiver, massecuite pumps, batch and continuous crystallisers, reheater, molasses lubrication system and hot and cold water systems

Confirming equipment status involves conducting relevant pre-start checks, confirming that cleaning standards are met, all safety guards are in place and equipment is operational. It may also involve checking operation/calibration of measuring instrumentation

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

Services may include power, water, compressed and instrumentation air

Where tests are conducted as part of operation a typical requirement is observation using a microscope

Monitoring the process may involve the use of production data such as performance control charts

Control points refer to those key points in a work process which must be monitored and controlled

Work may require the ability to work within a team environment

Information systems may be print or screen based

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