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

PPMSTM320 Mapping and Delivery Guide
Manage steam boiler start up

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency PPMSTM320 - Manage steam boiler start up
Description
Employability Skills
Learning Outcomes and Application This unit of competency describes the outcomes required to plan, prepare, manage and report on steam boiler start ups, in the pulp and paper industry. This unit applies to production operators and technicians who manage steam boiler startups, in a pulp and paper manufacturing facility. This typically involves working in a facility with complex integrated equipment and continuous operations. No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

The following resources must be made available:

access to the full range of equipment required to start up steam boiler operations in a pulp or paper manufacturing facility

electronic control systems which includes Digital Control System (DCS), touch screens or robotics required for steam boiler startup

personal protective equipment suitable for managing a steam boiler startup

applicable WHS and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements

relevant personnel for the purposes of communicating information

sample workplace documentation, procedures and reports including SOP, quality procedures, environmental sustainability requirements/practices, plant manufacturing operating manuals, enterprise policies and procedures, oil or chemical spills and disposal guidelines, plant isolation documentation, safe work documentation.

Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.
Prerequisites/co-requisites
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: Conduct pre-operational safety checks
  • Confirm plant status and boiler types through inspections, observation and other information.
  • Plan operational safety checks according to work health and safety (WHS), productivity requirements,environmental and safe working requirements, Standard Operating Procedures (SOP) and house keeping requirements.
  • Identify and report potential work area hazards and implement control measures.
  • Establish work and output requirements.
  • Conduct pre operational and safety checks on equipment.
  • Remove isolations.
  • Confirm availability of process supplies.
       
Element: Conduct startup procedures
  • Establish pre-light conditions.
  • Start boiler and bring on-line.
  • Monitor boiler condition during startup to detect abnormal conditions.
  • Observe system and plant for correct operational response.
  • Detect deviations from required operating conditions and rectify using corrective action.
       
Element: Record and report start up activities
  • Document responses to corrective actions, as required.
  • Record and report on start up information, as required.
       


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.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Conduct pre-operational safety checks

1.1. Confirm plant status and boiler types through inspections, observation and other information.

1.2. Plan operational safety checks according to work health and safety (WHS), productivity requirements,environmental and safe working requirements, Standard Operating Procedures (SOP) and house keeping requirements.

1.3. Identify and report potential work area hazards and implement control measures.

1.4. Establish work and output requirements.

1.5. Conduct pre operational and safety checks on equipment.

1.6. Remove isolations.

1.7. Confirm availability of process supplies.

2. Conduct startup procedures

2.1. Establish pre-light conditions.

2.2. Start boiler and bring on-line.

2.3. Monitor boiler condition during startup to detect abnormal conditions.

2.4. Observe system and plant for correct operational response.

2.5. Detect deviations from required operating conditions and rectify using corrective action.

3. Record and report start up activities

3.1. Document responses to corrective actions, as required.

3.2. Record and report on start up information, as required.

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide evidence that they can:

manage a steam boiler startup, at least twice in line with required enterprise intervals, in a pulp and paper manufacturing facility, by:

checking, setting up and starting the boiler within an appropriate time frame

implementing isolation and access procedures

identifying and actioning problems

identifying and monitoring process control points

maintaining a clean and hazard free work area

recording and reporting on operational data

communicating effectively, through written and verbal means, and working safely with others, in the work area.

A person competent in this unit must be able to demonstrate knowledge of:

implications of pre operational checks including low water level alarm, high water level alarm, low water level, alarm lockout, hydrostatic test, burner management system and safety valve test

documentation and procedures relevant to steam boiler startups, in the pulp and paper industry including:

work health and safety (WHS) including high risk load shifting licensing requirements, plant clearance, job safety analysis and permit systems

appropriate boiler/pressure vessel operator certification

confined space standards and regulations

productivity requirements

quality procedures

Standard Operating Procedures (SOP)

environmental sustainability requirements and practices

machinery and plant manufacturing operating manuals

enterprise policies and procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

job sheets and operator's log

manufacturer's specifications and maintenance documentation

Material Safety Data Sheets (MSDS)

incidents reports

the use of materials and supplies for boiler startups including chemicals, coal, oil, gas, additives, air, water, wood waste, steam recovery process products and power

hazards and risks identification

maintenance systems including operator level maintenance as per site agreements, operator maintenance schedules, maintenance suppliers and pro-active maintenance strategies

processes, layout and associated services relevant to steam generation plant and sufficient to carry out startup activities within level of responsibility

boiler water treatment system and reasons for treatment

electronic and other control systems, operation and application to make appropriate adjustments that control steam generation systems.

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.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Conduct pre-operational safety checks

1.1. Confirm plant status and boiler types through inspections, observation and other information.

1.2. Plan operational safety checks according to work health and safety (WHS), productivity requirements,environmental and safe working requirements, Standard Operating Procedures (SOP) and house keeping requirements.

1.3. Identify and report potential work area hazards and implement control measures.

1.4. Establish work and output requirements.

1.5. Conduct pre operational and safety checks on equipment.

1.6. Remove isolations.

1.7. Confirm availability of process supplies.

2. Conduct startup procedures

2.1. Establish pre-light conditions.

2.2. Start boiler and bring on-line.

2.3. Monitor boiler condition during startup to detect abnormal conditions.

2.4. Observe system and plant for correct operational response.

2.5. Detect deviations from required operating conditions and rectify using corrective action.

3. Record and report start up activities

3.1. Document responses to corrective actions, as required.

3.2. Record and report on start up information, as required.

Not Applicable
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
Confirm plant status and boiler types through inspections, observation and other information. 
Plan operational safety checks according to work health and safety (WHS), productivity requirements,environmental and safe working requirements, Standard Operating Procedures (SOP) and house keeping requirements. 
Identify and report potential work area hazards and implement control measures. 
Establish work and output requirements. 
Conduct pre operational and safety checks on equipment. 
Remove isolations. 
Confirm availability of process supplies. 
Establish pre-light conditions. 
Start boiler and bring on-line. 
Monitor boiler condition during startup to detect abnormal conditions. 
Observe system and plant for correct operational response. 
Detect deviations from required operating conditions and rectify using corrective action. 
Document responses to corrective actions, as required. 
Record and report on start up information, as required. 

Forms

Assessment Cover Sheet

PPMSTM320 - Manage steam boiler start up
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

PPMSTM320 - Manage steam boiler start up

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: