ELEMENT

PERFORMANCE CRITERIA

1 Prepare for cleaning

1.1 Chemical stocks are available to meet cleaning and sanitation requirements

1.2 Services are confirmed as available and ready for operation

1.3 Equipment is checked to confirm readiness for use

1.4 Equipment shutdown is planned and equipment is taken off line for cleaning

1.5 The plant is set for the cleaning cycle

2 Operate and monitor the cleaning process

2.1 The cleaning cycle is undertaken according to company procedures

2.2 The cleaning process is monitored to confirm cleaning meets company requirements

2.3 Cleaning data is recorded according to workplace recording requirements

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

3 Dispose of waste and return plant to operating condition

3.1 Cleaning chemicals are flushed from plant and disposed of according to company procedures

3.2 Plant is set up to meet operational requirements

Required skills include:

Ability to:

access workplace information such as the cleaning schedule to identify cleaning requirements

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

confirm supply of necessary materials and services

handle cleaning and sanitation agents safely including following correct handling and preparation procedures and use of appropriate protective clothing and equipment

prepare cleaners and sanitisers as required

pace production and/or liaise with related work areas to take equipment off-line with minimal disruption to production

prepare equipment for cleaning including rendering equipment safe to clean, correctly positioning equipment such as valves, pipes, vents and taps, selecting appropriate cleaning cycle (CIP), removing waste and or dismantling equipment

clean equipment according to cleaning process cycle and procedures including starting up and operating the CIP process in both automatic and manual modes

monitor the process and equipment operation to maintain the cleaning process within the required parameters

return plant to operating order

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

advise affected work areas of cleaning schedule and progress

maintain and store chemicals and related equipment as required

carry out relevant checks and inspections to confirm effectiveness of cleaning

sort, collect, treat, recycle or dispose of waste

record cleaning information

maintain work area to meet housekeeping standards

Required knowledge includes

Knowledge of:

purpose and basic principles of cleaning in place (in-line) including the use and functions of caustic and acid solutions and cleaning sequence and stages as required in the workplace

terminology relating to the chemicals solutions used

safe work procedures including appropriate signage of cleaning activities and safe handling and storage of cleaners and sanitisers used

purpose and limitations of protective clothing and equipment

cleaning and sanitation requirements for work area including different levels of cleaning requirements depending on the reason for cleaning

methods used to render equipment safe to clean including lock-out, tag-out and isolation procedures

equipment settings required for cleaning and for operating respectively

basic operating principles of process control where relevant including the relationship between control panels and systems and the physical equipment

inspection points for cleaning and sanitation

consequences of contamination of process flows by cleaning solutions

types of waste generated by both the production and the cleaning process and related collection, treatment and disposal requirements

environmental consequences of incorrect waste disposal procedures

requirements to liaise/advise related work areas

reporting and recording 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.

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

Evidence of ability to:

handle cleaning and sanitation agents safely

clean equipment according to cleaning process cycle and procedures

return plant to operating order

carry out relevant checks and inspections to confirm effectiveness of cleaning.

Context of and specific resources for assessment

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

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

Personal protective clothing and equipment

Equipment to be cleaned and related cleaning system

Cleaning schedule or advice and related Standard Operating Procedures

Chemicals and/or automated chemical addition system

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:

Sampling and testing schedules and procedures.

Method of assessment

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

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, 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)

manufacturer's specifications.

Equipment

Equipment cleaned may include

evaporators

pans

heaters

filters

chemical mixing and storage equipment

pumps and pipes.

Services

Services may include:

power

water

steam

compressed and instrumentation air.

Tests

Where tests are conducted as part of operation a typical requirement is measurement of pH and condensate quality

Process monitoring

Monitoring the process depends on the cleaning requirements. It may include monitoring:

condensate quality (evaporators, heaters and pans)

vacuum and brix (evaporators)

time

storage tank levels

chemical strength

cycle time

temperatures.

Control panels and systems

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

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.