Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

FDFGR4004A Mapping and Delivery Guide
Establish and supervise dust control procedures in a grain processing enterprise

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FDFGR4004A - Establish and supervise dust control procedures in a grain processing enterprise
Description This Unit applies to the establishment and supervision of dust control procedures in a grain milling enterprise. It includes procedures for the identification of risk factors, establishment of preventative and hygiene measures, use of explosion relief and fire suppression systems and arranging training for employees.
Employability Skills This Unit contains employability skills.
Learning Outcomes and Application This Unit applies to managers and supervisors in grain related enterprises including flour and stock feed mills and grain storage facilities, who have responsibility for the development and detailed implementation of dust control and dust explosion prevention strategies in a grain related enterprise. For milling enterprises, this Unit goes beyond the overview level included in the Unit FDFGR4005A Manage mill logistics and support services.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Nil.
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Monitor dust explosion risk factors
  • Establish and monitor procedures for detecting potential explosive atmosphere.
  • Set procedures for reporting visible dust leaks.
  • Establish and enforce no smoking policy.
  • Establish and monitor reporting regime for potential ignition sources.
  • Establish and supervise manual and automatic temperature, smoke and moisture monitoring for all grain, flour, feed and other byproduct storage.
  • Establish systems to minimise fungal and insect infestation caused temperature increases.
       
Element: Establish dust control procedures
  • Install and monitor dust aspiration or suction ventilation systems.
  • Establish dust checking procedures for all confined spaces.
  • Establish monitoring procedures for dust collector performance and output.
  • Establish procedures for resealing of all dust leaks.
  • Undertake random and periodical checks on performance of dust control procedures.
  • Assess and approve any variation in cleaning and hygiene procedures.
  • Minimise storage of combustible materials in mill.
  • Establish minimum dust levels for mandatory use of personal protective equipment.
  • Establish procedures for monitoring and control of environmental dust release.
       
Element: Integrate equipment use, monitoring and maintenance with dust control procedures
  • Establish regular cleaning schedule for all surfaces in contact with graining or flour.
  • Establish mill equipment condition monitoring schedule with maintenance department.
  • Establish regular lubrication schedules for bearings, pulleys, shafts and other moving and friction surfaces.
  • Use anti-static materials where possible.
  • Establish approval, tagging and monitoring procedures for use of all portable tools and equipment in mill.
       
Element: Establish fire and dust explosion suppression systems
  • Review adequacy of current dust control and dust explosion relief equipment and arrange for any required maintenance.
  • Arrange for any required additional dust control/dust explosion relief equipment in existing protected areas.
  • Investigate potential for use of fire and explosion suppression systems in areas not currently protected.
  • Locate and establish inspection regime for all explosion relief panels.
  • Set test and maintenance procedures for all existing fire and explosion suppression systems.
       
Element: Supervise dust and fire control training
  • Identify fire and dust wardens for mill areas.
  • Establish emergency procedures.
  • Identify dust and fire control content for use in induction training.
  • Identify training needs of existing employees.
  • Establish dust and fire control training arrangements.
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this Unit must be achieved in accordance with food safety standards and regulations.

Critical aspects for assessment and evidence required to demonstrate competency in this Unit

Evidence of ability to:

assess equipment and processes for dust explosion and fire risk

into dust and fire control procedures into standard operating procedures for all employees

identify dust and fire control training requirements

consult with internal department heads and external organisations on dust control procedures.

Context of and specific resources for assessment

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

personal protective clothing and equipment

work procedures, including advice on safe work practices, food safety, quality and environmental requirements

equipment manuals including operating parameters

specifications, control points and processing parameters

break and reduction roll process and related equipment and services

conditioned grain suitable for the break and reduction roll process

sampling schedules and test procedures and equipment as required

documentation and recording requirements and procedures

cleaning procedures, materials and equipment as required.

Method of assessment

This Unit should be assessed together with core Units and other Units of Competency relevant to the function or work role.

Guidance information for assessment

To ensure consistency of performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required skills include:

Ability to:

analyse areas and equipment in grain enterprises for dust and fire risk

schedule housekeeping, training, and maintenance procedures to achieve objectives while minimising impact on production including:

scheduling maintenance for dust suppression systems and equipment and explosion relief panels

bin/silo inspections and cleaning

control potential ignition sources

assess automatic and manual monitoring techniques against enterprise needs.

Required knowledge includes:

Knowledge of:

technologies and techniques for controlling grain dust in grain milling, handling and storage facilities including:

pneumatic dust collection

housekeeping

enclosing of equipment

use of liquid additives

misting and fogging (where permitted)

advantages and disadvantages of mechanical and pneumatic product conveying

types of bin/silo and exhaust designs and implications for dust generation and control

requirements for a grain dust explosion to occur including typical sources in a grain enterprise of:

oxygen

ignition

fuel

contained space

effects of fungal and pest infestation on grain and flour temperature

minimum explosive concentrations (MEC) for grain dust in the milling or storage operation ( will vary according to the type of grain and particle size)

location of bin explosion relief panels

explosion suppression systems

confined space procedures and regulations.

The range statement relates to the Unit of Competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Mill

The term mill is used to refer to the whole mill site including the actual milling equipment, equipment used for associated processes, and transport, warehouse, maintenance, testing and administration facilities.

Dust

Dust refers to grain, flour and other combustible particles found in a grain enterprise that are capable of suspension in air.

Potential ignition sources

Potential ignition sources are any sources that may generate sparks or sufficient heat to start combustion and include:

naked flames

welding

equipment sparking

hot equipment ( motors etc.)

smoking

hot spots in grain and flour storage

static electricity.

Dust and fire control training arrangements may include:

appointment of internal trainers

training delivered by equipment suppliers

appointment of an external training provider

setting an allocation for dust and fire control training in the training budget

rostering of employees for training

establishing training records

conduct of drills and exercises.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Establish and monitor procedures for detecting potential explosive atmosphere. 
Set procedures for reporting visible dust leaks. 
Establish and enforce no smoking policy. 
Establish and monitor reporting regime for potential ignition sources. 
Establish and supervise manual and automatic temperature, smoke and moisture monitoring for all grain, flour, feed and other byproduct storage. 
Establish systems to minimise fungal and insect infestation caused temperature increases. 
Install and monitor dust aspiration or suction ventilation systems. 
Establish dust checking procedures for all confined spaces. 
Establish monitoring procedures for dust collector performance and output. 
Establish procedures for resealing of all dust leaks. 
Undertake random and periodical checks on performance of dust control procedures. 
Assess and approve any variation in cleaning and hygiene procedures. 
Minimise storage of combustible materials in mill. 
Establish minimum dust levels for mandatory use of personal protective equipment. 
Establish procedures for monitoring and control of environmental dust release. 
Establish regular cleaning schedule for all surfaces in contact with graining or flour. 
Establish mill equipment condition monitoring schedule with maintenance department. 
Establish regular lubrication schedules for bearings, pulleys, shafts and other moving and friction surfaces. 
Use anti-static materials where possible. 
Establish approval, tagging and monitoring procedures for use of all portable tools and equipment in mill. 
Review adequacy of current dust control and dust explosion relief equipment and arrange for any required maintenance. 
Arrange for any required additional dust control/dust explosion relief equipment in existing protected areas. 
Investigate potential for use of fire and explosion suppression systems in areas not currently protected. 
Locate and establish inspection regime for all explosion relief panels. 
Set test and maintenance procedures for all existing fire and explosion suppression systems. 
Identify fire and dust wardens for mill areas. 
Establish emergency procedures. 
Identify dust and fire control content for use in induction training. 
Identify training needs of existing employees. 
Establish dust and fire control training arrangements. 

Forms

Assessment Cover Sheet

FDFGR4004A - Establish and supervise dust control procedures in a grain processing enterprise
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

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Assessment Record Sheet

FDFGR4004A - Establish and supervise dust control procedures in a grain processing enterprise

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

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Date:

Student signature:

Date: