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

FPPREC440A Mapping and Delivery Guide
Troubleshoot and rectify chemical recovery operations

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency FPPREC440A - Troubleshoot and rectify chemical recovery operations
Description This unit describes the outcomes required to troubleshoot and rectify chemical recovery operations in the pulp and paper industry General legislation, regulatory, licensing and certification requirements applicable to this unit are detailed in the range statementSpecific high risk (and non-high risk) load shifting licensing requirements for this unit may be applicable and are to be met separately and prior to the achievement of this unit
Employability Skills This unit contains employability skills
Learning Outcomes and Application This unit applies to operators who troubleshoot and rectify chemical recovery operations in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operationsThis unit generally applies to those who:identify and analyse causes of faultsrectify process problems, equipment and product quality faults, andrecord and report system performance and product quality datato meet safety, quality and productivity requirementsIt does not include monitoring, controlling, starting up or shutting down chemical recovery operations
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Not Applicable
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: Identify and analyse causes of faults
  • Causes of faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements
  • Warning devices are interpreted to determine fault type and location
  • Samples for a range of tests are taken
  • Quality faults and variations are identified by observation, systematic sampling and testing
  • Sampling and testing results are interpreted to identify variations from specifications or schedule
  • Causes and sources of process problems or equipment faults are identified, located and analysed
  • Relevant sources of information are accessed and interpreted to assist analysis
       
Element: Rectify process problems and equipment faults
  • Process problems and equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Operator level on-line adjustments are conducted
  • Plant is shut down and isolation procedures are implemented prior to fault rectification
  • Hazardous conditions are identified, appropriate action is taken and the conditions communicated to relevant personnel
  • Faulty equipment is isolated or bypassed, repaired or replaced as required
  • Plant and equipment are returned to normal operation as required
  • Action taken is communicated to relevant personnel
       
Element: Rectify product quality faults
  • Product quality is rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Out-of-specification product is controlled
  • Faults and causes are rectified if appropriate, or recommendations made for further action
  • Further tests are conducted as required
       
Element: Report and record system performance and product quality data
  • System performance and product quality data is reported and recorded within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Variations from process specification are recorded
  • Actions undertaken to troubleshoot and rectify faults are recorded
  • Details of hazardous conditions or situations are documented as required
  • Relevant information is communicated to appropriate personnel
       


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

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

Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of:

the required knowledge and skills tailored to the needs of the specific workplace

applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements

applicable aspects of the range statement

practical workplace demonstration of skills in troubleshooting and rectifying chemical recovery operations

Context of and specific resources for assessment

A workplace assessment must be used to assess:

the application of required knowledge on the job

the application of skills on the job, over time and under a range of typical conditions that may be experienced in chemical recovery operations

Access to the full range of equipment involved in integrated continuous manufacturing of chemical recovery operations in a pulp or paper mill is required

Method of assessment

A combination of assessment methods should be used. The following examples are appropriate for this unit:

observation of applied skills and knowledge on the job

workplace demonstrations via a mock-up or simulation that replicate part/s of the job

answers to written or verbal questions about specific skills and knowledge

third-party reports from relevant and skilled personnel

written evidence e.g. log sheet entries, checklist entries, test results

Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job)

A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended

Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package


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.

This describes the skills and knowledge required for this unit.

Required skills

Identifies, accesses and interprets relevant historical and operational data

Uses required forms of communication in troubleshooting and rectifying chemical recovery operations

Communicates effectively with personnel to assist with analysis and resolution of operational problems

Prepares detailed written information

Reads and interprets required documentation, procedures and reports

Interprets instruments, gauges and data recording equipment

Assists others to identify and resolve operational problems in the workplace

Accesses, navigates and enters computer-based information

Identifies and actions systems, quality and equipment faults within level of responsibility

Identifies causes and effects of faults and corrective action on associated processes

Selects and uses appropriate troubleshooting methods

Takes timely corrective action to maximise safety, quality and productivity

Undertakes necessary calculations to aid troubleshooting as required

Takes samples, conducts tests, interprets and records results if required

Uses measuring equipment as required

Maintains situational awareness in the work area

Handles emergencies or crash shutdowns

Operates high risk (and non-high risk) load shifting equipment as required

Analyses and uses sensory information to adjust process to maximise safety, quality and productivity

Uses electronic and other control systems to control equipment and processes as required

Required knowledge

Procedures, regulations and legislative requirements relevant to chemical recovery operations including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Use and handling requirements of chemicals used; their purpose, effects, MSDS and SOP

Relevant forms of communication

Detailed knowledge of chemical recovery plant, processes and associated services sufficient to troubleshoot including:

plant layout

theory of operation

causes and effects of adjustments made to chemical recovery plant and processes

relationships between chemical recovery plant, processes and associated services

An appropriate range of troubleshooting methods

Sampling and testing processes for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements

Causes and effects of unplanned shutdown and appropriate responses

Maintenance system as it applies to chemical recovery operations

Application of high risk (and non-high risk) load shifting equipment as required

Sensory information that indicates a deviation from standard operating parameters

Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control the chemical recovery, within level of responsibility

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.

Productivity requirements may include:

energy efficiency

waste minimisation

evaporation minimisation, including landfill and waste water reduction

environmentally safe waste disposal

consideration of resource utilisation, including fibre efficiency

minimising delays

chemical recovery maximisation

meeting key performance indicators

line speed

handovers

quality checks

meeting output targets i.e. net tonnes per employee per annum

machine/process time availability i.e. time the machine or process is making product

machine/process production rate

Chemical recovery processes may include:

evaporator operations

condensate stripper

lime mud treatment

Wet Air Oxidation (WAO)

causticising plant operations

recovery boiler operations

direct alkali reduction system (DARS) operations

foul gas and condensate incineration

Chemicals may include:

white liquor

green liquor

black liquor

condensates

non-condensable gases

thick liquor

spent liquor

quench liquor

weak wash

anthraquinone (AQ)

caustic

magnesium oxide

sulphur

Materials and supplies may include:

steam

compressed air

chemicals

water

power

Equipment may include:

power or steam generation

pneumatic systems

water supply systems and equipment

process plant

pumps and transfer equipment

mechanical, hydraulic and electrical systems

process monitoring and management equipment

mobile equipment (e.g. skid steer, forklift, elevated work platform, loaders)

computer systems

electronic screens and alarms

process control systems

analogue and digital instruments

fully automated, semi-automated, manually operated plant and equipment appropriate to chemical recovery operations

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Legislation, regulatory, licensing and certification requirements may include:

OHS and environmental requirements (local, state and commonwealth)

activity or task specific high risk (and non-high risk) load shifting licensing requirements

hazardous chemical handling

Documentation, procedures and reports may include:

SOP

quality procedures

environmental sustainability requirements/practices

plant manufacturing operating manuals

work instructions and orders

incident reports

log sheets and shift reports

oil or chemical spills and disposal guidelines

plant isolation documentation

safe work documentation (e.g. plant clearance, job safety analysis, permit systems)

emergency operational procedures (EMOs)

process and instrument diagrams

non-conformance reports

Maintenance may include:

operator level maintenance as per site agreement

maintenance systems

operator maintenance schedules

maintenance suppliers

proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

team members

internal or external customers and suppliers

maintenance services

production/services co-ordinator

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstruction

unexpected movement

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

Forms of communications may include:

written e.g. log books, emails, incident and other reports, run sheets, data entry

reading and interpreting documentation e.g. SOP, manuals, checklists, drawings

verbal e.g. radio skills, telephone, face to face, handover

non-verbal e.g. hand signals, alarms, observations

signage e.g. safety, access

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
Causes of faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 
Warning devices are interpreted to determine fault type and location 
Samples for a range of tests are taken 
Quality faults and variations are identified by observation, systematic sampling and testing 
Sampling and testing results are interpreted to identify variations from specifications or schedule 
Causes and sources of process problems or equipment faults are identified, located and analysed 
Relevant sources of information are accessed and interpreted to assist analysis 
Process problems and equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Operator level on-line adjustments are conducted 
Plant is shut down and isolation procedures are implemented prior to fault rectification 
Hazardous conditions are identified, appropriate action is taken and the conditions communicated to relevant personnel 
Faulty equipment is isolated or bypassed, repaired or replaced as required 
Plant and equipment are returned to normal operation as required 
Action taken is communicated to relevant personnel 
Product quality is rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Out-of-specification product is controlled 
Faults and causes are rectified if appropriate, or recommendations made for further action 
Further tests are conducted as required 
System performance and product quality data is reported and recorded within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Variations from process specification are recorded 
Actions undertaken to troubleshoot and rectify faults are recorded 
Details of hazardous conditions or situations are documented as required 
Relevant information is communicated to appropriate personnel 

Forms

Assessment Cover Sheet

FPPREC440A - Troubleshoot and rectify chemical recovery operations
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:

Signature:

Date:


Assessment Record Sheet

FPPREC440A - Troubleshoot and rectify chemical recovery operations

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:

Signature:

Date:

Student signature:

Date: