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Elements and Performance Criteria

  1. Prepare the high grade fugal station for operation
  2. Operate and monitor high grade fugal station
  3. Handover the high grade fugal station
  4. Shut down the high grade fugal station

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

Follow start up procedure

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 visual inspections and conducting tests to monitor characteristics such as

fugal load

sugar and molasses quality

crystal in A B molasses

A B molasses purity

A B molasses density

molasses stock level

sugar temperature pol and moisture

fugal speed

atmospheric conditions

cycle times including spin and wash times

wash water temperature

basket charge

dry air and sugar flows

sugar dust levels

equipment condition including drip gate operation

Control station throughput and A B balance to meet pan stage throughput Take corrective action in response to outofspecification results

Shut down and clean fugals according to schedule or as indicated by equipment monitoring

Control drier airflows to achieve target sugar temperature and moisture

Report andor record corrective action as required

Record workplace information

Demonstrate shift handover procedure

Shut down equipment in response to an emergency situation

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 high grade fugal station operation This includes sugar drying and operation of batch and continuous fugals as required in the workplace

Terminology relating to sugar and molasses quality

Sugar industry quality standards for each brand of sugar

The circuit flow of this process and relationship to related processes

Factors that affect throughput and recovery This includes the relationship between sugar pol and throughput and the balance between A and B fugals

The effect of massecuite quality on fugal operation and the effect of variation in operating parameters on the fugal output

Equipment purpose and basic operating principles of high grade fugal equipment

Services used

Operating requirements and parameters

Significance and method of monitoring control points within the process

Common causes of variation and corrective action required

Hazards and controls

Purpose and limitations of protective clothing and equipment

Lock out and tag out procedures

Shut down sequence including massecuite feed 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

High grade fugal station equipment

Materials including 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

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

High grade fugal equipment may include high grade fugals (batch and/or continuous), molasses pipes, tanks and pumps, massecuite feed pump, distributor, fugal water and steam system, sugar screw or belt, sugar conveyor system, drier and fans and air conditioners, sugar scrubber and sugar bin

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 pol and moisture by near infra-red. Molasses density may also be required.

Sugar industry quality standards are determined at state level

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