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

SUGPOES2A Mapping and Delivery Guide
Operate an extraction station

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency SUGPOES2A - Operate an extraction station
Description This is a Specialist unit. It covers the preparation and operation of an extraction station. In order to demonstrate competence in this unit the operator also be competent to operate turbines and reciprocating engines where required.
Employability Skills Not applicable.
Learning Outcomes and Application Not applicable.
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: Prepare the extraction process for operation
  • Cane is confirmed and available to meet production requirements
  • Services are confirmed as available and ready for operation
  • Equipment is checked to confirm readiness for use
  • The extraction process is set to meet production requirements
       
Element: Operate and monitor the extraction process
  • The extraction process is started up and operated according to company procedures
  • Control points are monitored to confirm performance is maintained within specification
  • Bagasse meets specifications
  • Equipment is monitored to confirm operating condition
  • Out-of-specification bagasse, process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure
  • The workplace meets housekeeping standards
       
Element: Handover the extraction station
  • Workplace records are maintained in accordance with workplace procedures
  • Handover is carried out according to workplace procedure
  • Extraction station operators are aware of system and related equipment status at completion of handover
       
Element: Shut down the extraction system
  • The appropriate shut down procedure is identified
  • The extraction system is shut down according to workplace procedures
  • The extraction system is prepared for storage in shut down mode
  • Maintenance requirements are identified and reported according to workplace reporting procedure
       


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 assessment process must address all of the following items of evidence.

Ability to:

1. Access workplace information to identify production requirements

2. Select, fit and use personal protective clothing and/or equipment

3. Confirm supply of necessary materials and services

4. Confirm equipment status and condition

5. Liaise with other work areas - specifically boilers and evaporator station

6. Demonstrate start up procedures after an extended stop and after a short stop

7. Start up and operate in both automatic and manual modes

8. Monitor the process and equipment operation to maintain the process within the required parameters. This typically involves monitoring:

temperatures

steam pressure

throughput

chute height

torques/mill loads

added water flows

feeding characteristics of cane

equipment condition including lubrication systems and vibration levels

9. Monitor supply and flow of cane to the process and bagasse and juice from the process

10. Take corrective action in response to out-of-specification results

11. Report and/or record corrective action as required

12. Record workplace information

13. Demonstrate shift handover procedure

14. Shut down equipment in response to an emergency situation

15. Demonstrate an operational shut down procedure

16. Prepare equipment for cleaning/maintenance

17. Maintain work area to meet housekeeping standards

May include the ability to:

18. Use process control systems

19. Clean equipment

20. Take samples and conduct tests

Knowledge of:

21. Purpose and basic principles of extraction including shredder operation, mills and diffusers as required in the workplace

22. The circuit flow of this process and relationship between extraction, boilers and evaporation

23. Effect on extraction of:

cane quality

added water

mill operation

24. Consequences of poor lubrication

25. Role of cooling water for equipment operation

26. Quality characteristics of bagasse and their effect on boiler operation

27. Equipment purpose and basic operating principles of extraction equipment

28. Services used

29. Operating requirements and parameters

30. Significance and method of monitoring control points within the process

31. Common causes of variation and corrective action required

32. Hazards and controls

33. Purpose and limitations of protective clothing and equipment

34. Lock out and tag out procedures

35. Requirements of both operational and long term shut down conditions to ensure the equipment is left in a safe state for the period of the shutdown and to minimise any delays in future start up

36. Procedures and responsibility for reporting problems

37. Environmental issues and controls

38. Waste handling requirements and procedures

39. Recording requirements and procedures

May include knowledge of:

40. Basic operating principles of process control where relevant. This includes the relationship between control panels and systems and the physical equipment

41. Cleaning procedures

42. Sampling and testing procedures

Relationship with other standards

Pre-requisite units

The pre-requisites for this competency standard are:

SUGPOTB2A Operate a turbine

Co-assessment of related units

Other units of competency relevant to the work role should be assessed in conjunction with this unit. This may include:

SUGPCPS2A Collect and prepare samples

SUGPPST2A Conduct standard tests

SUGZPCI2A Operate a process control interface

Resources required for assessment

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

Operating procedures and related advice on equipment operation including advice on safe work practices and environmental requirements

Personal protective clothing and equipment

Product and process specifications and operating parameters

Extraction station equipment

Materials and services as required

Material Safety Data Sheets where appropriate

Housekeeping standards and procedures

Advice on environmental management issues relevant to work responsibilities

Workplace information recording systems, requirements and procedures

They may also require access to:

Cleaning procedures, sampling schedule and procedures and maintenance procedures and tools depending on the work requirements.

Assessment requirements

For information on how to assess this competency standard and who can assess, refer to 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.

Not applicable.

The range statement indicates the context for demonstrating competence. This statement is a guide and unless otherwise indicated, items may or may not apply as required by the work context.

Work is carried out in accordance with company policies and procedures, manufacturer's recommendations, legislative requirements, codes of practice and industrial awards and agreements. Codes of practice include the Sugar Milling Operations Industry Code of Practice

Workplace information can include Standard Operating Procedures (SOPs), specifications, production schedules and manufacturer's specifications

Extraction equipment may include shredder, cane carriers, mills, diffuser, juice pumps, juice screen, lubrication systems, cooling water system, maceration system, steam turbines and hydraulic drives

Confirming equipment status involves conducting relevant pre-start checks, confirming that cleaning standards are met, all safety guards are in place and equipment is operational

Services may include power, steam, water, compressed and instrumentation air

Operation and monitoring of equipment and processes typically requires the use of control panels and systems

Services may include power, water, compressed and instrumentation air

Monitoring the process may involve the use of production data such as performance control charts

Control points refer to those key points in a work process which must be monitored and controlled

Work may require the ability to work within a team environment

Information systems may be print or screen based

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
Cane is confirmed and available to meet production requirements 
Services are confirmed as available and ready for operation 
Equipment is checked to confirm readiness for use 
The extraction process is set to meet production requirements 
The extraction process is started up and operated according to company procedures 
Control points are monitored to confirm performance is maintained within specification 
Bagasse meets specifications 
Equipment is monitored to confirm operating condition 
Out-of-specification bagasse, process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure 
The workplace meets housekeeping standards 
Workplace records are maintained in accordance with workplace procedures 
Handover is carried out according to workplace procedure 
Extraction station operators are aware of system and related equipment status at completion of handover 
The appropriate shut down procedure is identified 
The extraction system is shut down according to workplace procedures 
The extraction system is prepared for storage in shut down mode 
Maintenance requirements are identified and reported according to workplace reporting procedure 

Forms

Assessment Cover Sheet

SUGPOES2A - Operate an extraction station
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

SUGPOES2A - Operate an extraction station

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: