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.

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

Critical aspects for assessment and evidence include:

monitoring flare systems

shutting down/starting up flare systems

recognising and solving flare system problems.

Context of and specific resources for assessment

Assessment of this competency will occur over a range of situations which will include typical disruptions to normal, smooth operation. This will require access to a plant over a period of time, or a suitable method of gathering evidence of operating ability. Where safety, lack of opportunity or significant cost is an issue, an industry-based simulation may be employed to assist the process.

Guidance information for assessment

Assessment processes and techniques must be appropriate to the language, competency and safety requirements of the site and consistent with workplace systems or procedures.

Required skills

Required skills include:

observing

recognising conditions which indicate a problem

implementing enterprise procedures within time constraints and in a manner relevant to the correct use of the equipment

conveying information relevant to the operation clearly and effectively

maintaining appropriate levels of quality assurance

reading and numeracy to interpret/complete workplace documents and technical information

Required knowledge

Required knowledge of flare system principles and typical problems to a level needed to monitor and operate flare systems, includes:

organisation’s procedures

duty of care obligations

hierarchy of control

communication protocols, e.g. radio, phone, computer, paper and permissions/ authorities

typical issues causing problems and the resolution of those problems

routine problems, faults and their symptoms and the corrective action to be taken

knock on/escalation potential

process materials likely to be flared and the conditions which will lead to flaring

function and troubleshooting for flare system

relevant environmental requirements

types of flare system equipment and their principles of operation and start-up/shutdown, and reasons for the different types

flare system hazards

inert gas purging and flame out potential

relevant alarms, causes and responses

significance of the exclusion zone

how the flare system is integrated into the operation of the plant

flare system purging requirements and methods

indicators and consequences of poor combustion (as relevant)

operations in abnormal conditions

environmental licence exceedance reporting

use of logs and routine reading

trip/emergency system actions

pilot/flare ignition systems

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. 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.

Context

This competency includes all flare system components from the safety relief valve to the flare inclusive. It may include but is not limited to:

elevated flare

ground flare

vents (sometimes called ‘cold flare’)

Flare system components

Flare system components may include but are not limited to:

safety relief devices

headers (warm/cold, high pressure/low pressure (HP/LP) and wet/dry)

knock out drum

flare tip (single point, multipoint and enclosed)

stack seals

pilot system

blowers

steam systems

monitoring instrumentation

recovery systems

drains

pumps

pilot fuel/emergency fuel systems

purge systems

interlocks and other safety systems

ignition systems

liquid burners/systems, as relevant

Hazards

Flare system hazards may include but are not limited to:

access and exclusion zone

heat

blow backs

leaks/loss of containment (LOC)

ineffective isolations

inadequate ventilation

air ingress

liquid carryover

high liquid levels in knock out pots/separation vessels

contraction and expansion (cold vapours)

dislodgement of burning coke

noise

cryogenic temperatures

radiation

liquid hammer

Visual inspection

Visual inspection may include but is not limited to:

pilot flame condition

burn pattern

ice on header lines

vessel levels

damage or deterioration

smoke density

Required actions

Required actions arising from an inspection may include but are not limited to:

checking and adjusting pilot fuel/air ratio

ensuring complete combustion

finding and rectifying sources of liquid in header line

draining/pumping out pots

making a maintenance request

environmental reporting

Prepare for shutdown

Prepare for shutdown may include but is not limited to:

notification to other relevant plants/units of planned shutdown

bringing standby flare on line

isolation of system at appropriate points

purging of systems

shutting down relevant components

Prepare for start-up

Preparing for start-up may include but is not limited to:

notification to other relevant plants/units of planned start-up

checking integrity of components

valves correctly lined up

deisolating of system

purging of system

pilot fuel system ready

Abnormal conditions

Abnormal conditions may include but are not limited to:

weather

loss of pilot fuel

loss of utilities

flame out

high flare system back pressure

cross connection between dissimilar systems

Flare system problems

Flare system problems may include but are not limited to:

iced lines

high levels in pots/vessels

smoke from flare

flame out

lack of header purge flow

flash back

inconsistent header composition

blockage

cold feed to warm header

Procedures

Procedures may be written, verbal, computer-based or in some other form. They may include but are not limited to:

all work instructions

standard operating procedures

checklists

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant

good operating practice as may be defined by industry codes of practice

Procedures would be expected to comply with any relevant government regulations.

Logs and reports

Logs and reports may include:

paper or electronic based

verbal/radio reports

reporting items found which require action

Appropriate action

Appropriate action includes but is not limited to:

determining problems needing action

accessing and applying relevant technical and plant data

applying appropriate problem solving techniques to determine possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility/ability to resolve to designated person

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.