ELEMENT

PERFORMANCE CRITERIA

1 Prepare the clarification process for operation

1.1 Raw juice is and available to meet production requirements

1.2 Services are confirmed as available and ready for operation

1.3 Equipment is checked to confirm readiness for use

1.4 The clarification process is set to meet production requirements

2 Operate and monitor the clarification process

2.1 The clarification process is started up and operated according to company procedures

2.2 Control points are monitored to confirm performance is maintained within specification

2.3 Clarified product meets specifications

2.4 Equipment is monitored to confirm operating condition

2.5 Out-of-specification product, process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure

2.6 The workplace meets housekeeping standards

2.7 Workplace information is recorded according to workplace recording requirements

3 Handover the clarification process

3.1 Workplace records are maintained in accordance with workplace procedures

3.2 Handover is carried out according to workplace procedure

3.3 Clarification operators are aware of system and related equipment status at completion of handover

4 Shut down the clarification process

4.1 The appropriate shut down procedure is identified

4.2 The clarification system is shut down according to workplace procedures

4.3 The clarification system is prepared for storage in shut down mode

4.4 Maintenance requirements are identified and reported according to workplace reporting procedure

Required skills include:

Ability to:

access workplace information to identify production requirements

select, fit and use personal protective clothing and/or equipment

confirm supply of necessary materials and services

prepare lime, flocculant and saccharate for addition

liaise with other work areas

confirm equipment status and condition

set up and start up the process in both automatic and manual modes

undertake visual inspections and conducting tests to monitor characteristics such as:

juice temperatures

steam pressure

condensate flow and quality

throughput

juice pH

ESJ turbidity

addition rates

raw juice quality

clarifier mud levels and quality

equipment condition

monitor supply and flow of materials to and from the process

take corrective action in response to out-of-specification results

record workplace information

demonstrate shift handover procedure

shut down equipment in response to an emergency situation

demonstrate an operational shut down procedure

prepare equipment for cleaning/maintenance

maintain work area to meet housekeeping standards

Required knowledge includes:

Knowledge of:

purpose and basic principles of clarification including heating, liming, juice degasification and flocculant addition

the circuit flow of this process and relationship to related processes including the consequences of poor clarification on downstream processes

the effect of recycle streams on the clarification process

the purpose and role of materials added

effect of faulty preparation of materials

quality characteristics of raw juice and of clarified product

the impact of dextran on sugar quality

the function of the incubation tank and starch removal

the effect of addition rates on the process

the effect of variation in process parameters

conditions that can cause deterioration in juice

significance and method of monitoring control points within the process

equipment purpose and basic operating principles of juice clarification equipment

operating requirements and parameters

services used

common causes of variation and corrective action required

hazards and controls

purpose and limitations of protective clothing and equipment

lock out and tag out procedures

procedures and responsibility for reporting problems

environmental issues and controls

waste handling requirements and procedures

recording requirements and procedures

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.

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

Evidence of ability to:

prepare lime, flocculant and saccharate for addition

set up and start up the process in both automatic and manual modes

monitor the process and equipment operation

take corrective action in response to out-of-specification results

record workplace information

demonstrate shift handover procedure

shut down equipment in response to an emergency situation

Context of and specific resources 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

Juice clarification equipment

Materials including raw juice to be clarified

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

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

Method of assessment

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

SUG202A Collect and prepare samples

SUG213A Perform standard tests

FDFOP2030A Operate a process control interface

Guidance information for assessment

To ensure consistency in one's 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.

Policies and procedures

Work is carried out in accordance with company policies and procedures, licensing requirements, manufacturer's recommendations, legislative requirements, codes of practice and industrial awards and agreements.

Codes of practice

Codes of practice include the Sugar Milling Operations Industry Code of Practice.

Workplace information

Workplace information can include:

Standard Operating Procedures (SOPs)

specifications

production schedules

manufacturer's specifications.

Clarification equipment

Clarification equipment may include:

tanks

juice pumps

juice heaters

flash tank

lime storage and mixing plant

saccharate tank

flocculant addition system

clarifier.

Equipment status

Confirming equipment status involves

conducting relevant pre-start checks

confirming that housekeeping standards are met

all safety guards are in place

equipment is operational.

It may also involve checking operation/calibration of measuring instrumentation.

Equipment operation and monitoring

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

Services

Services may include:

power

steam

water

compressed and instrumentation air.

Clarification materials

Materials can include lime

flocculants

enzymes

phosphoric acid

saccharate

preservatives.

Tests

Where tests are conducted as part of operation, typical requirements are for pH and thymol testing.

Process monitoring

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

Control points

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

Teamwork

Work may require the ability to work within a team environment.

Information systems

Information systems may be print or screen based.