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Elements and Performance Criteria

1. Prepare the boiler for operation
   • Health and safety hazards / maintenance requirements are identified and reported to appropriate personnel according to workplace reporting procedures
   • The boiler is purged according to workplace procedure
   • Services are confirmed and available
   • Pre-operational checks are conducted to confirm operational status of boiler and related equipment
2. Start and monitor boiler operation
   • The boiler is started and brought on line safely according to workplace procedures and manufacturer's specifications
   • Plant is operated within limits of manufacturer's specifications to meet workplace requirements
   • Equipment is monitored to confirm operating condition
   • Water quality is tested and adjusted as required
   • Sluice water is circulated to remove ash from boiler according to specification
   • The workplace meets housekeeping standards
3. Analyse and respond to abnormal performance
   • Operating data 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 plant performance
   • Emergency procedures are implemented as required according to workplace procedures and manufacturer's recommendations
4. Handover boiler operations
   • Workplace records are maintained in accordance with statutory requirements and workplace procedures
   • Handover is carried out according to workplace procedure
   • Boiler operators are aware of boiler status and related equipment at completion of handover
5. Carry out an operational shutdown
   • The boiler is shut down according to workplace procedures and manufacturer's recommendations
   • Maintenance requirements are identified and reported according to workplace reporting procedure
6. Shutdown the boiler and prepare for an internal inspection
   • The boiler is shut down according to workplace procedures and manufacturer's recommendations
   • The boiler is cleaned internally and externally according to workplace procedures and manufacturer's recommendations
   • Valves and fittings are removed in preparation for maintenance
7. Store boiler in shutdown mode
   • The boiler is stored in the appropriate storage mode according to workplace procedures and manufacturer's recommendations
8. 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 combustion and operating requirements

Select fit and use personal protective clothing andor equipment

Identify and report hazards and potential hazards in the work area

Confirm status of boiler and related equipment including the fuel supply system ash removal and services

Demonstrate purge procedure

Conduct prestart checks This typically include checking

feed water supply and system

fuel supply system

fans and dampers

inspection doors

boiler valves operation and position

combustion air supply system

boiler water level

Liaise with other work areas to advise of boiler status

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

Monitor boiler operation This typically includes monitoring

steam reticulation line pressure

boiler steam pressure

steam supplyusage

condensate tank level

bagasse levels

feedwater levels and pressure

fuel levels

boiler load

water quality

furnace pressure

ash pit level and removal system

balance draft system

superheater temperature

drum levels

equipment condition

Conduct water quality test

Take corrective action in response to outofspecification results

Report andor record corrective action as required

Demonstrate shift handover procedure and confirm that replacement operators are aware of all relevant issues prior to completing handover

Demonstrate procedure to take boiler off line

Demonstrate procedure to shut down and clean the boiler

Demonstrate removal of valves and fittings to prepare the boiler for inspection

Demonstrate procedure to store boiler

Demonstrate emergency procedures and related restart This includes use of emergency fuel supply

Maintain workplace records

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

Safe work procedures including awareness of health and safety hazards related to boiler operation and associated control measures Hazards typically include working around hot surfaces manual handling fuel and steam leaks

Purpose and limitations of protective clothing and equipment

Hierarchy of hazard control measures

Duty of care of the boiler operator

Purpose and basic principles of combustion and boiler operation This includes principles of heat transfer and properties of steam

Boiler system layout and steam cycle

The purpose of purging a boiler

The effect of fuel quality on boiler operation

Impact of ash removal on efficient boiler operation and impact of sluice water flow

Relationship to other processes This includes an understanding of the impact of sudden load changes on boiler pressure and plant operation

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 watercondensate contamination and corrective action required

Equipment purpose and basic operating principles This includes high pressure feed pumps fuel supply system and dual fuel systems as required by boiler type

Operating requirements and parameters

Procedures for responding to emergency situations This includes safe shutdown procedure

Handover and long term shut down and storage procedures

Cleaning procedures and grate dumping

Environmental issues and controls This includes an understanding of sluice water usage

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

Boiler and related equipment This includes fuel supply grate cleaning and ash removal systems

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

Boiler operators holding a ticket in Basic Boiler Operation from the relevant state regulatory authority will be granted equivalence in this unit SUGPOBBAOperate a boiler basic for the purpose of issuing a qualification

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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, licensing requirements, 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) and manufacturer's specifications

Boiler (basic) and related equipment may be fully or partly attended, and include single fixed combustion air supply, non modulating single heat source and fixed firing rate.

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

Services can include fuel supply of bagasse, coal, gas, oil or other fuel types, steam, mill and instrumentation air, cooling water, general mill water supply and cooling water

Confirming equipment status involves conducting relevant pre-start checks, confirming that cleaning standards are met, all safety guards and manholes are in place and equipment is operational

Internal cleaning is carried out in accordance with statutory requirements regarding confined space entry and does not typically include chemical cleaning

Work may require the ability to work within a team environment

Information systems may be print or screen based

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