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

UEPOPS434B Mapping and Delivery Guide
Shut down a heat recovery steam generator unit

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency UEPOPS434B - Shut down a heat recovery steam generator unit
Description 1)Scope:1.1) DescriptorThis unit deals with the skills and knowledge required to a shutdown of an in-service Heat Recovery Steam Generator unit.Shut down a Heat Recovery Steam Generator unit (with or without supplementary firing) to a “Boxed up” condition will require the hot gas inlet and cold gas outlet dampers to be closed and the Steam/water drum to be pressurised at normal working level prior to a Hot /Warm restart or to be in a de-pressurised state in preparation for a short/long term outage.
Employability Skills 5) The required outcomes described in this unit of competency contain applicable facets of Employability Skills. The Employability Skills Summary of the qualification in which this unit of competency is packaged will assist in identifying Employability Skill requirements.
Learning Outcomes and Application 2)This unit is intended to augment formally acquired competencies.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Prerequisite Unit(s)4) Competencies4.1)Granting of competency in this unit shall be made only after competency in the following unit(s) has/have been confirmed.Where pre-requisite pathways have been identified. All competencies in the Common Unit Group must be have been completed.Common Unit GroupUnit Code Unit TitleUEPOPS333B Operate and monitor H.R.S.G. hot gas control systemUEPOPS408B Shut down a gas turbineLiteracy and numeracy skills4.2) Participants are best equipped to achieve this unit if they have reading, writing and numeracy skills indicated by the following levels. A description of what each level entails is provided in Section 2.3.1 Language, Literacy and Numeracy.Reading4Writing4Numeracy4
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: Plan and prepare work
  • Safety issues are identified to comply with enterprise/site requirements
  • Work requirements are identified from relevant personnel and documentation
  • Pre-operational checks are carried out on plant according to manufacturer’s recommendations and site requirements
  • Where appropriate, the teams and individuals roles and responsibilities within the team are identified and, where required, assist in the provision of the on-the-job training
       
Element: Operate plant
  • Supplementary firing system is placed in and out of service in accordance with enterprise, manufacturer’s and site requirements.
  • Gas turbine exhaust gas flow and power output are adjusted to achieve required steam temperature, pressure and flow conditions, observing operating requirements.
  • Feedwater flows are adjusted to achieve required steam conditions and demand while observing operating requirements
  • Heat Recovery Steam generator drains and vents are operated in accordance with enterprise, manufacturer’s and site requirements to depressurise and drain the steam/water space and heat exchange elements as required.
  • Heat Recovery Steam Generator is maintained in the required out of service condition in accordance with enterprise, manufacturer’s and site requirements.
  • Boiler water quality is maintained within the required parameters to prevent corrosion of the drums, headers and heat exchange elements
  • Plant is operated within limits of plant design, enterprise or site requirements
  • Plant is monitored and observed to detect deviations from required operating conditions
  • Corrective action is taken to rectify abnormalities in accordance with manufacturer’s and enterprise/site procedures
       
Element: Test plant operation
  • Tests are performed in accordance with defined procedures applicable to the operational test
  • System and plant is observed for correct operational response
  • Corrective action is taken when response is not in accordance with documentation, plant integrity or personnel safety requirements
  • Plant is returned to required operational status upon completion of test
       
Element: Analyse system faults
  • Causes of abnormal plant operating conditions are identified by analysing the technical and operational information in a logical and sequential manner
  • Corrective action taken is in accordance with enterprise/site procedures
  • Plant integrity and personnel safety is maintained through consultation with appropriate personnel, and reference to plant, technical and operational documentation
  • Appropriate personnel are notified when defects are detected
       
Element: Complete documentation
  • Documentation is updated and plant problems, movements, abnormalities and status are reported and logged in accordance with enterprise/site procedures
       


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.

9) This provides essential advice for assessment of the competency standard unit and must be read in conjunction with the Performance Criteria and the Range Statement of the unit and the Training Package Assessment Guidelines.

The Evidence Guide forms an integral part of this competency standard unit and shall be used in conjunction with all components parts of this unit and, performed in accordance with the Assessment Guidelines of this Training Package.

Overview of Assessment

9.1)

Longitude competency development approaches to assessment, such as Profiling, require data to be reliably gathered in a form that can be consistently interpreted over time. This approach is best utilised in Apprenticeship programs and reduces assessment intervention. It is the Industry preferred model for apprenticeships. However, where summative (or final) assessment is used it is to include the application of the competency in the normal work environment or, at a minimum, the application of the competency in a realistically simulated work environment. It is recognised that, in some circumstances, assessment in part or full can occur outside the workplace. However, it must be in accord with Industry and regulatory policy.

Methods chosen for a particular assessment will be influenced by various factors. These include the extent of the assessment, the most effective locations for the assessment activities to take place, access to physical resources, additional safety measures that may be required and the critical nature of the competencies being assessed.

The critical safety nature of working with electricity, electrical equipment, gas or any other hazardous substance/material carries risk in deeming a person competent. Hence, sources of evidence need to be ‘rich’ in nature so as to minimise error in judgment.

Activities associated with normal every day work have a bearing on the decision as to how much and how detailed the data gathered will contribute to its ‘richness’. Some skills are more critical to safety and operational requirements while the same skills may be more or less frequently practised. These points are raised for the assessors to consider when choosing an assessment method and developing assessment instruments. Sample assessment instruments are included in the Assessment Guidelines of this Training Package.

Critical aspects of evidence required to demonstrate competency in this unit

9.2)

Before the critical aspects of evidence are considered all pre-requisites shall be met.

Evidence for competence in this unit shall be considered holistically. Each element and associated Performance Criteria shall be demonstrated on at least two occasions in accordance with the “Assessment Guidelines – UEP12”. Evidence shall also comprise:

A representative body of work performance demonstrated within the timeframes typically expected of the discipline, work function and industrial environment. In particular this shall incorporate evidence that shows a candidate is able to:

Implement Occupational Health and Safety workplace procedures and practices including the use of risk control measures as specified in the Performance Criteria and Range Statement

Apply sustainable energy principles and practices as specified in the Performance Criteria and Range Statement

Demonstrate an understanding of the essential knowledge and associated skills as described in 6) Essential Knowledge and Associated Skills of this unit

Demonstrate an appropriate level of employability skills

Conduct work observing the relevant Anti-Discrimination legislation, regulations, polices and workplace procedure

Demonstrated performance across a representative range of contexts from the prescribed items below:

The knowledge and application of relevant sections of occupational, health and safety legislation; statutory legislation; enterprise/site safety procedures; enterprise/site standard operating procedures and safe operating principles; enterprise/site emergency procedures

The knowledge of principles and techniques of operation of heat recovery steam generator plant and equipment

The knowledge of operational testing of plant

The knowledge of system components and the manner in which these components interact with other plant and equipment

The knowledge of cooling and de-pressurising requirements

The knowledge of the principles of heat recovery steam generator and feedwater sampling and chemical treatment

The ability to prepare and plan work

The ability to prepare plant/equipment for operation

The ability to operate plant/equipment in accordance with enterprise/site standard operating procedures and safe operating principles

The ability to analyse plant faults

Dealing with an unplanned event by drawing on essential knowledge and skills to provide appropriate solutions incorporated in the holistic assessment with the above listed items.

Context of and specific resources for assessment

9.3)

This unit should be assessed as it relates to normal work practice using procedures, information and resources typical of a workplace. This should include:

OHS policy and work procedures and instructions

Suitable work environment, facilities, equipment and materials to undertake actual work as prescribed by this unit.

Competency Standards should be assessed in the workplace or simulated workplace and under the normal range of workplace conditions.

Assessment of this unit will be supported with documentary evidence, by means of endorsement stating type and application of work.

In addition to the resources listed above in Context of assessment’, evidence should show competency working in limited spaces with different types of plant and equipment as well as different structural/construction types and methods and in a variety of environments.

Method of assessment

9.4)

This unit shall be assessed by methods given in Section 1.3.00 Assessment Guidelines.

Note:

Competent performance with inherent safe working practices is expected in the Industry to which this unit applies. This requires that the specified essential knowledge and associated skills are assessed in a structured environment which is primarily intended for learning/assessment and incorporates all necessary equipment and facilities for learners to develop and demonstrate the essential knowledge and skills described in this unit.

Concurrent assessment and relationship with other units

9.5)

There are no recommended concurrent assessments with this unit, however in some cases efficiencies may be gained in terms of learning and assessment effort being concurrently managed with allied competency standard units where listed.

UEPOPS341B Shut down a steam turbine


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.

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

Evidence shall show that knowledge has been acquired shutting down a heat recovery steam generator unit

All knowledge and skills detailed in this unit should be contextualised to current industry practices and technologies.

The extent of the Essential Knowledge and Associated Skills required follows:

KS01-PO434B Shut down a heat recovery steam generator unit

T1 Evidence shall show that knowledge has been acquired for safe working practices of:

Relevant environmental, occupational health and safety legislation and regulations

Enterprise procedures

Plant drawings and manufacturers manuals

Introduction to and typical arrangements of power production plant

Relevant plant and equipment, its location and operating parameters

Relevant state and territory regulations

Electric motor types and characteristics

Pump and compressor types and characteristics

Valve, damper and actuator types and characteristics

Switchgear types and characteristics

Electrical protection types and characteristics

Electrical principles

Process control principles

Plant process control systems

a.c. generators types and characteristics

Transformers types and characteristics

Duct burners types and characteristics

H.R.S.G construction and principles

Thermodynamics

Properties of Matter

Enterprise recording procedures

Control and data acquisition systems

Computers and software

Mechanical and electrical supervisory,

Alarm, protection and control equipment

The principles of control of steam temperature and pressure throughout the full range of heat recovery steam generation operation up to and including maximum continuous rating

Heat recovery steam generator efficiency

Principles of heat recovery steam generator steam and feedwater chemical treatment

The arrangement of the heat recovery steam generator gas path and water and steam circuits

Fuel conditioning and supplementary firing equipment

The heat recovery steam generator system components and their interaction with other plant and equipment external to that covered by this competency.

a.c. and d.c. electrical distribution systems

Station water distribution systems

Fire protection control systems

Compressed air systems

Auxiliary supply systems

T2 Specific skills needed to achieve the Performance Criteria:

Interpret plant drawings and manufacturers manuals

Apply relevant state and territory regulations

Apply enterprise recording procedures

Identify plant status

Prepare plant/equipment for operation

Organise resources

Operate HRSG plant and equipment

Apply temperature and pressure reducing techniques and principles

Apply diagnostic and testing techniques

Identify and respond to abnormal plant operating conditions

Plan and prioritise work

Use relevant hand tools

Communicate effectively

Apply data analysis techniques and tools

10) This relates to the competency standard unit as a whole, providing the range of contexts and conditions to which the Performance Criteria apply. It allows for different work environments and situations that will affect performance.

Plant and equipment may include: gas turbines; gas turbine emission control equipment; gas turbine exhaust gas control dampers; heat recovery steam generators and auxiliary plant; heat recovery steam generator supplementary duct firing equipment; fuel delivery systems; fuel management systems; flame detection equipment; steam temperature control equipment; a.c. and d.c. electrical distribution systems; electrical switchgear; electric motors; electric motor driven pumps and fans; diesel engine driven auxiliary plant; feedwater chemical dosing equipment, station water distribution systems; hydraulic power oil systems; compressed air systems; distributed control systems; supervisory, protection, alarm and control equipment.

Safety standards may include relevant sections of Occupational Health and Safety legislation, enterprise safety rules, relevant State and federal legislation, national standards for plant and Australian standards.

Information and documentation sources may include verbal or written communications; enterprise safety rules documentation; enterprise operating instructions; computer-based and computer accessed documentation; enterprise/site standing and operating instructions; enterprise log books; manufacturer’s operation and maintenance manuals; and equipment and alarm manuals.

Technical and operational indicators may include stimuli (auditory, olfactory, tactile, visual), local indicators and recorders, computers and alarms (visible and/or audible).

Communications may be by direct personal interaction or by means of telephone, verbal or text-based telephone messaging, two way radio, pager, computer (electronic mail) and/or operating logs (written or verbal).

Appropriate personnel for consultation, giving or receiving direction may include: supervisor/team leader or equivalent, power plant operations personnel or equivalent, technical and engineering officers or equivalent, maintenance staff, other operating staff or equivalent, system controller/network controller, field operator, restricted H.V. operators, independent generators and customers and contractor staff.

Operating environment may be remote from the plant and equipment being operated, (in cases where operation is assisted by remote indication of operating parameters and plant status), during inclement or otherwise harsh weather conditions, in hot/wet/noisy/dusty/elevated/confined or enclosed areas or during night periods.

Plant operations (systems requirements) may include: HRSG emergency trip; HRSG shutdown, with or without turbine bypass or by using forced cooling procedures; shutdown to “boxed up” condition with the flue gas circuit closed at hot gas inlet and cold gas outlet and steam/water circuit pressurised; shutdown to “depressurised” condition with the flue gas circuit open at hot gas inlet and cold gas outlet and steam/water circuit de-pressurised and/or drained.

Faults and abnormal operating conditions may include: Gas Turbine trip, excessively high or low steam/water drum level, loss of a major auxiliary; loss of electrical supply to switchboards, drive motors or valve actuators; feedwater chemical operating limits exceeded; automatic control loop(s) malfunctions; high temperatures on/in, heat recovery steam generator heating surfaces/tubes/headers, low temperatures on/in, heat recovery steam generator heating surfaces/tubes/headers; High/low superheater or reheater steam temperatures; high temperatures on/in: motor and/or pump bearings, lubricating oil or motor windings; heat exchange element tube leaks; excessive drum water level split; excessively high heating/cooling rates; loss of flame on supplementary firing combustors; fuel delivery system malfunction; fuel preparation and delivery systems fires; high differential pressures on oil/air filters and strainers; failed field devices; failed/malfunctioning actuators/dampers/valves; feedwater pumps malfunctions; heat recovery steam generator protection operation.

Generic terms are used throughout this Training Package for vocational standard shall be regarded as part of the Range Statement in which competency is demonstrated. The definition of these and other terms are given in Section 2.1 Preliminary Information and Glossaries.

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
Safety issues are identified to comply with enterprise/site requirements 
Work requirements are identified from relevant personnel and documentation 
Pre-operational checks are carried out on plant according to manufacturer’s recommendations and site requirements 
Where appropriate, the teams and individuals roles and responsibilities within the team are identified and, where required, assist in the provision of the on-the-job training 
Supplementary firing system is placed in and out of service in accordance with enterprise, manufacturer’s and site requirements. 
Gas turbine exhaust gas flow and power output are adjusted to achieve required steam temperature, pressure and flow conditions, observing operating requirements. 
Feedwater flows are adjusted to achieve required steam conditions and demand while observing operating requirements 
Heat Recovery Steam generator drains and vents are operated in accordance with enterprise, manufacturer’s and site requirements to depressurise and drain the steam/water space and heat exchange elements as required. 
Heat Recovery Steam Generator is maintained in the required out of service condition in accordance with enterprise, manufacturer’s and site requirements. 
Boiler water quality is maintained within the required parameters to prevent corrosion of the drums, headers and heat exchange elements 
Plant is operated within limits of plant design, enterprise or site requirements 
Plant is monitored and observed to detect deviations from required operating conditions 
Corrective action is taken to rectify abnormalities in accordance with manufacturer’s and enterprise/site procedures 
Tests are performed in accordance with defined procedures applicable to the operational test 
System and plant is observed for correct operational response 
Corrective action is taken when response is not in accordance with documentation, plant integrity or personnel safety requirements 
Plant is returned to required operational status upon completion of test 
Causes of abnormal plant operating conditions are identified by analysing the technical and operational information in a logical and sequential manner 
Corrective action taken is in accordance with enterprise/site procedures 
Plant integrity and personnel safety is maintained through consultation with appropriate personnel, and reference to plant, technical and operational documentation 
Appropriate personnel are notified when defects are detected 
Documentation is updated and plant problems, movements, abnormalities and status are reported and logged in accordance with enterprise/site procedures 

Forms

Assessment Cover Sheet

UEPOPS434B - Shut down a heat recovery steam generator unit
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

UEPOPS434B - Shut down a heat recovery steam generator unit

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: