ELEMENT

PERFORMANCE CRITERIA

1. Identify range of utilities and services used by mill

1.1 Establish distributed services used in mill.

1.2 Ensure schematics showing location and distribution of services are available and understood by key personnel.

1.3 Categorise services as critical to mill operation or ancillary.

1.4 Develop contingency strategies in the event of failure of a critical service for the mill.

2. Review mill electric power system for start-up and power demand management

2.1 Identify mains supply terminal, input voltage and electricity supplier.

2.2 Identify mill transformers and distribution to sub-mains.

2.3 Identify back–up generation and supply system including automatic and manual operation conditions.

2.4 Identify location of mill equipment and areas supplied by each sub-main and switchboard.

2.5 Identify key features and requirements of installed electrical safety systems including lock off and isolation switches.

2.6 Obtain maximum demand and diversity factor (power factor correction) and identify implications for mill operations.

2.7 Establish motor control and start up procedures according to manufacturer, engineer and supply authority procedures.

3. Review scope of hydrocarbon fuel use by mill

3.1 Identify capacity and fuel use of any on-site boilers.

3.2 Identify emergency generators and their fuel source.

3.3 Identify other fuel powered equipment and processes.

3.4 Identify location of fuel reservoirs/tanks and review against mill strategy for the prevention of dust explosions.

4. Identify type and location of mill controls

4.1 Identify mill operations and equipment controlled automatically.

4.2 Identify mill operations and equipment controlled through central process control stations/ terminals.

4.3 Identify mill operations and equipment controlled manually.

4.4 Establish back up strategies for mill control in the event of failure of control equipment.

5. Control pneumatic conveying system

5.1 Determine processes where negative or positive pressure is required.

5.2 Monitor air speed and volume requirements for conveying tasks.

5.3 Select air speed and volume appropriate for exhausts.

5.4 Balance negative pressure systems.

5.5 Monitor for abnormal increases in blowline pressure.

5.6 Determine cleaning intervals for dust collectors.

6. Control wheat damping and conditioning

6.1 Monitor adequacy of water supply.

6.2 Determine if feedforward or feedback system is used.

6.3 Supervise moisture testing of wheat.

6.4 Set damping system controls for desired moisture level taking into account feed rate and lying in time.

7. Establish strategies and practices for efficient use of power and automation

7.1 Maximise throughput to mill capacity where possible.

7.2 Ensure manufacturers’ maintenance and lubrication schedules are followed.

7.3 Ensure standard operating procedures for controls and workstations are developed and up to date.

Required skills include:

Ability to:

integrate equipment maintenance and lubrication strategies with production requirements

interpret manuals, other technical information, diagrams and drawings

identify maximum power demand for mill

identify typical range of power demand for mill taking into account scope of equipment and average production requirements.

Required knowledge includes:

Knowledge of:

types of electric motors and their advantages and disadvantages

motor control and motor protection strategies

mechanical power transmission types and principles including:

direct drives

belt drives

chain drives

gears

factors influencing the velocity of particles in free air and in positive and negative air streams

design principles used in exhaust systems for fans, ductwork and dust collectors

advantages and disadvantages of axial flow, propeller and centrifugal fans

advantages and disadvantages of forward, backward and radial bladed rotors

purpose and function of instrumentation including:

proximity switches

position sensors

transducers

tachometers

flow meters

weighers

load cells

bin level indicators

pressure switches

PLCs, SCADA (System Control And Data Acquisition systems) and other programmable instrumentation and systems.

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.

Overview of assessment

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this Unit must be achieved in accordance with food safety standards and regulations.

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

Evidence of ability to:

identify mill equipment and its location and function

determine control equipment and control options for mill

establish risk management and contingency strategies for mill power and automation.

Context of and specific resources for assessment

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

personal protective clothing and equipment

work procedures, including advice on safe work practices, food safety, quality and environmental requirements

equipment manuals including operating parameters

specifications, control points and processing parameters.

break and reduction roll process and related equipment and services

conditioned grain suitable for the break and reduction roll process

sampling schedules and test procedures and equipment as required

documentation and recording requirements and procedures

cleaning procedures, materials and equipment as required.

Method of assessment

This Unit should be assessed together with core Units and other Units of Competency relevant to the function or work role.

Guidance information for assessment

To ensure consistency of performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

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. 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.

Mill

The term mill is used to refer to the whole mill site including the actual milling equipment, equipment used for associated processes, and transport, warehouse, maintenance, testing and administration facilities.

Fuel

Fuel refers to hydrocarbon energy sources consumed on site including coal, gas (LNG/LPG), diesel, petrol, fuel oil etc.

Equipment may include:

rollers

purifiers

sifters

gravity feeds

pneumatic feeds

pumps

transformers, switchboards, motors and circuit protection.

Balancing negative pressure air systems

Balancing of negative air pressure systems may be done manually or through setting and monitoring of automatic air control valves.