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Elements and Performance Criteria

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

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 inspection and conducting tests to monitor characteristics such as

stirrer load

pan vacuum

sugar crystal size and distribution

pan station product purities

pan station stock levels including receiver stocks

high grade fugal times including spin and wash times

steam pressure

boiling formula

pan circulation

supersaturation

equipment condition

Control station throughput and A B balance to meet factory throughput through pan scheduling

Prepare magma and grain for highlow grade seed production

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

Prepare slurry for seed production

Add process additives as required by pan performance

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

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 pans station operation This includes the basic principles of crystallisation and may relate to operation of batch and continuous pans 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 the balance between A B and C pans and the effect of cane quality and boiling formula

Factors that affect flow of massecuite through the system

The effect of massecuite quality on fugal operation

Relationship between boiling point and pressure in the pans station

Equipment purpose and basic operating principles of pans station equipment including vacuum pumps and condensers

Operating requirements and parameters

Services used

Significance and method of monitoring control points within the process

Common causes of variation and corrective action required

Shut down sequence including massecuite pumps and stock management

OHS hazards and controls

Purpose and limitations of protective clothing and equipment

Lock out and tag out procedures

Procedures and responsibility for reporting problems

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

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

Pans station equipment

Materials including molasses and liquor 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

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

Pans equipment may include pans (batch and/or continuous), molasses pipes, tanks and pumps, massecuite pump, water and steam system, receivers, vacuum pumps and remelt 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

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

Services may include power, water, steam, compressed and instrumentation air

Where tests are conducted as part of operation a typical requirement is observation by microscope and product density

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