The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment for this unit of competency will be on an operating plant. The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency. Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation may be required to allow for timely assessment of parts of this competency unit (eg Elements 2, 5). Simulation should be based on the actual plant and will include walk-throughs of the relevant competency components. Simulations may also include the use of case studies/scenarios and role plays.

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

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

The emphasis should be on the ability to stay out of trouble rather than on recovery from a disaster.

Consistent performance should be demonstrated. In particular look to see that:

emergency responses are known

hazards are recognised and all site requirements to reduce or remove hazards are known and completed as part of the job

early warning signs of equipment/processes needing attention or with potential problems are recognised, that is, monitoring systems in the carbon anode baking process, including equipment, material handling systems and mobile equipment.

These aspects may be best assessed using a range of scenarios/case studies/what-ifs as the stimulus with a walk-through forming part of the response. These assessment activities should include a range of problems, including new, unusual and improbable situations that may have been generated from the past incident history of the plant, incidents on similar plants around the world, hazard analysis activities and similar sources.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations. A bank of scenarios/case studies/what-ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units. Consider co-assessment with other relevant units.

This competency may be assessed in conjunction with:

MSAPMOHS200A Work safely

MSAPMOHS110A Follow emergency response procedures

PMASUP237B Undertake crane, dogging and load transfer operations

TDTD1097B Operate a forklift

MSAPMSUP205A Transfer loads

or other units which are relevant to the job.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.

This describes the essential skills and knowledge and their level, required for this unit.

Required skills

Competence includes being able to demonstrate the following:

efficient and effective operation of plant/equipment

hazard analysis

completing plant records

communication

problem solving

Competence includes responding to emergency situations such as:

open furnace pits

ring main risers

fire shaft pit

riser shaft

natural gas usage

rain and water in electrical ducts

explosions due to loss of draft

evacuation due to fire

loss of power

excessive emissions of fumes or particulate

equipment failure

recognising hazards associated with reactive alumina, tar, pitch, kaowool, suspended loads and heat stress.

Troubleshooting a range of problems which could include:

anode baking equipment

anode stacker cranes

conveyors

rotators

burner tips

port plates

equipment failure.

Required knowledge

Competence includes a comprehensive understanding of the carbon bake process and equipment principles and typical problems to a level needed to control the operation, and recognise and resolve operational problems. In particular it includes:

awareness of hazardous materials, recognition of spills or escapes, personal protective equipment required, isolation and clean up requirements

and knowledge of:

all items on a schematic of the carbon bake process and the function of each

basic principles of operation of main equipment items, including scrubbers, port plates, thermocouples and burner tips

basic physics of operation, including effects of temperature, conveyor speed and time on anode quality

basic understanding of the product specifications and variations required on the input and output side

isolating a problem to an item of equipment/stage of process

methods of resolving problems.

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. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs if the candidate, accessibility of the item, and local industry and regional contexts.

Codes of practice/ standards

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Appropriate action

Appropriate action includes:

determining problems needing action

determining 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 to designated person.

Emergency responses

Emergency responses include those related to:

rain and water in electrical ducts

explosions due to loss of draft

evacuation due to fire

loss of power

excessive emissions of fumes or particulates

equipment failure

leaks/loss of containment

equipment failure

hazards and incidents, site safety procedures

flow path blockages

authorisations and communication processes for normal and emergency situations must follow site procedure

Equipment and tools

Equipment and tools may include:

hand tools

harnesses and slings

materials handling equipment.

Hazards

Hazards may include:

open furnace pits, ring main risers, fire shaft pit, riser shaft, natural gas

heat (burns, dehydration and heat stress)

energy sources, eg hydraulic, pneumatic and electric

high pressure piping and valves

pinch and crush points

moisture

banned items

mobile equipment and pedestrian interaction

furnace emissions

suspended loads and roller conveyors

hazardous materials, eg reactive alumina, kaowool, tar and pitch

molten materials.

Hazard control measures

Hazard control measures should follow the hierarchy of control, be specific to the hazard and work area and include relevant Personal Protective Equipment

Housekeeping

Housekeeping procedure may include cleaning the area, removal of contaminants, safety inspections and rectification of issues that could compromise safety.

Instrument/electrical systems

Instrument/electrical systems may include:

emergency shutdown systems

fire systems

pressure and temperature control systems

communications systems

utility systems.

Isolation

Isolation refers to the complete isolation of the equipment from all sources of power or energy or isolate process flows and movement of machinery such to render it safe to work on as per site procedure.

Monitor and adjust operational variations

Monitor and adjust operational variations using troubleshooting techniques may refer to the use of:

historical data and records of common faults

troubleshooting lists and directives

site procedures.

Out-of-parameter issues

Out-of-parameter issues, faults and problems may include:

temperature and oxygen fluctuations

production line speed variations

variation of product specification on the input and output side

electrical problems

instruments and equipment requiring cleaning

equipment mechanical problems

flow path blockages

out-of-parameter emissions

unavailability of equipment, personnel or material.

Personal protective equipment

Personal Protective Equipment (PPE) requirements relate to the specified PPE for the task or job to be undertaken. PPE may include specific insulated boots, heat resistant material, full-ventilated suits, full-face masks or situation specific equipment.

Procedures

Procedures may be written, verbal, computer-based or in some other form. They include:

all work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (eg Responsible Care) and government regulations.

Pre-start checks

Pre-start checks relate to the required site or equipment pre-start checklist and must be completed before the equipment is operated or as otherwise stated in the procedures.

Reports and records

Reports and records may include:

routine inspections (daily readings, monthly checks)

scheduled maintenance activities

computer readouts locally or in the control room

shift log sheet

mandatory or statutory inspections

hazard, accident and incident reports

quality inspection reports of the product.

Shutdown procedures

Shut down procedure must follow equipment and site authorised checklist and may include

communication to supply and delivery areas

communication to impacting areas

obtaining appropriate authorisations

rescheduling operations

liaison with maintenance teams.

Start up procedures

Start up procedure will conform to site procedure and include:

safety and pre-start checks

accessing shift logs and equipment records

pre-shift briefing information

records and reports from the previous shift.

Work requirements

Work requirements includes shift briefings, shift logs supervisor or crew leader meetings, toolbox talks and handover details.

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State 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.

Persons are required to have skills in hazard identification, assessment and application of control measures, eg spills and leaks identified, contained and cleaned up. Exposure to hazardous materials requires minimal personal contact, recognition of hazards and appropriate controls.