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Elements and Performance Criteria

1. Prepare the cooling tower/s for operation
   • Tower cleaning procedures are followed and cleaning records completed
   • Chemicals are available and delivery systems are ready for operation
   • Make up water supply is available and meets quality requirements
   • Pre-operational checks are conducted
   • Health and safety hazards / maintenance requirements are identified and reported to appropriate personnel according to workplace reporting procedures
2. Start and monitor cooling tower
   • The cooling tower system is started according to workplace procedures and manufacturer's recommendations
   • Plant is operated within limits of manufacturer's specifications to meet workplace requirements
   • Equipment is monitored to confirm operating condition and cleanliness
   • Water quality is monitored, tested and adjusted as required
   • The workplace meets housekeeping standards
3. Analyse and respond to abnormal performance
   • Water condition and plant operating conditions are analysed to identify causes of abnormal performance
   • Corrective action is taken in accordance with workplace procedures in response to Hazards, out-of-specification test results and/or abnormal plant performance
   • Emergency procedures are implemented as required according to workplace procedures and manufacturer's recommendations
4. Shutdown and clean the cooling water system
   • The cooling water system is cleaned according to workplace cleaning schedule and to meet legal requirements
   • The timing and sequencing of cooling water system shut down meets production requirements
   • Maintenance requirements are identified and reported according to workplace reporting procedure
5. Record information
   • Workplace information is recorded according to workplace recording requirements

Required Skills

Not applicable

Evidence Required

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

Ability to

Access workplace information on cooling water requirements

Select fit and use personal protective clothing andor equipment

Confirm status of equipment that it is clean ready for operation and services are available

Prepare and handle chemicals safely This includes following correct preparation handling and storage procedures and use of appropriate protective clothing and equipment

Conduct prestart checks This typically include checking

raw water supply

tower condition and cleanliness

spray and pond condition

all safety guards and covers are in place and operational

drains are closed

chemicals are available

Liaise with other work areas to advise of users of cooling system status

Demonstrate set up and start up procedures in both manual and automatic modes

Monitor cooling water system operation This typically includes visual inspections and conducting tests to monitor characteristics such as

chemical addition rates and residuals

water quality

blow down rate

temperatures

water distribution

signs of fouling and corrosion

equipment condition including fans sprays and pumps

water level and makeup flow

Take corrective action in response to outofspecification results

Report andor record corrective action as required

Demonstrate procedure to clean and shut down cooling water system

Demonstrate use of emergency cooling water supply system

Maintain workplace records including cleaning records and chemical usage

Maintain work area to meet housekeeping standards

May include ability to

Use process control systems

Knowledge of

Relevant state OHS legislation standards and codes of practice relating to work responsibilities

Purpose and basic principles of evaporative cooling and water treatment in order to prevent corrosion and microbiological fouling

Cooling water system layout

The effect of make up water quality on blow down rates and fouling rates

The impact of variables including cooling water failure and high water temperature and plant operation

Purpose of chemicals used

Consequences of system fouling and typical causes

Safe work procedures including awareness of health and safety hazards related to cooling water system operation and associated control measures Hazards typically include handling chemicals manual handling risks of working with warm water systems Legionella

Hierarchy of hazard control measures

Purpose and limitations of protective clothing and equipment

Methods used to render equipment safe to inspect maintain andor clean including lockout tagout and isolation procedures

Water quality test procedures

Typical causes of water contamination and corrective action required

Equipment purpose and basic operating principles of cooling water system and related equipment This includes pumps valves tower and fans It may also include the dosing system

Operating requirements and parameters

Cleaning methods and procedures

Procedures for operating emergency cooling water system

Environmental issues and controls Includes those relating to chemical andor container disposal and any overflow of the system to waters of the state

Requirements to liaiseadvise related work areas

Housekeeping standards for the work area

Reporting and recording systems This includes both statutory and workplace requirements

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

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

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

Cooling water system and related equipment

Chemicals

Relevant codes and standards

Operating procedures and related advice on equipment operation

Personal protective clothing and equipment

Communication systems and equipment

Housekeeping standards and procedures

Workplace information recording systems requirements and procedures

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, licensing requirements, codes of practice, legislative requirements, industrial awards and agreements and Australian Standard AS3666, parts I, II and III. Codes of practice include the Sugar Milling Operations Industry Code of Practice

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

Equipment may include the tower, spray ponds supply pump and return pump, chemical addition systems and blow down system. Typically a number of cooling towers would be located on site. They may be integrated or stand-alone

Operation and monitoring of equipment and processes may require the use of control panels and systems

Typical tests may include pH, total dissolved solids (TDS), conductivity, standard plate count (SPC), Legionella and tests specific to chemicals used

Work may require the ability to work within a team environment

Information systems may be equipment-based or remote from the cooling tower

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