ELEMENT

PERFORMANCE CRITERIA

1 Prepare the ash separation system for operation

1.1 Materials are confirmed and available to meet 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 ash separation process is set to meet production requirements

1.5 Health and safety hazards/maintenance requirements are identified and reported to appropriate personnel according to workplace reporting procedures

2 Operate the ash separation process

2.1 The ash separation system is operated within limits of manufacturer's specifications to meet workplace requirements

2.2 The ash separation system is monitored to confirm performance is maintained within manufacturer's specifications to meet workplace requirements

2.3 The workplace meets housekeeping standards

3 Analyse and respond to abnormal performance

3.1 System operating conditions are monitored to identify causes of abnormal performance

3.2 Corrective action is taken in accordance with workplace procedures in response to hazards and abnormal plant performance

3.3 Emergency procedures are implemented as required according to workplace procedures and manufacturer's recommendations

4 Handover ash separation operations

4.1 Operating log is maintained in accordance with workplace procedures

4.2 Handover is carried out according to workplace procedure

4.3 System operators are aware of system and related equipment status at completion of handover

5 Complete ash separation operations

5.1 Ash is collected and disposed according to company procedures

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

5.3 Workplace information is recorded according to workplace recording requirements

Required skills include:

Ability to:

access workplace information ash separation requirements

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

confirm status of equipment and that services are available

conduct pre-start checks

demonstrate start-up procedures for preparing and operating each equipment component in the system

demonstrate safe chemical preparation and handling

monitor the ash separation system including visual inspection and conducting tests to monitor characteristics such as:

moisture content of ash going out of the system

available storage capacity of ash holding area

filter performance and condition

take corrective action in response to abnormal or unacceptable performance

report and/or record corrective action as required

demonstrate shift handover procedure and confirm that replacement operators are aware of equipment status and operating requirements prior to completing handover

record operating information

maintain work area to meet housekeeping standards

Required knowledge includes:

Knowledge of:

relevant state OHS legislation, standards and codes of practice relating to work responsibilities

safe work procedures including awareness of health and safety hazards related to operation of the ash removal system and associated control measures.

purpose and limitations of protective clothing and equipment

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

properties of ash or soot and the impact on filter operation

functions and operating principles of ash separation system and related equipment

relationship between vacuum, filter speed and cake permeability

operating requirements and parameters

test methods

common causes of variation and corrective action required

procedures for responding to emergency situations including safe shutdown procedure

handover and long term shut down and storage procedures

environmental issues and controls

procedures for containing and managing ash spills

housekeeping standards for the work area

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:

Conduct pre-start checks

Demonstrate start-up procedures

Demonstrate safe chemical preparation and handling

Monitor the ash separation system

Take corrective action in response to abnormal or unacceptable performance

Report and/or record corrective action

Demonstrate shift handover procedure

Record operating information

Maintain work area to meet housekeeping standards.

Context of and specific resources for assessment

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

Ash separation system and related equipment

Relevant codes and standards

Operating procedures and related advice on equipment operation

Personal protective clothing and equipment

Communication systems and equipment

Housekeeping standards and procedures

Workplace information recording systems, requirements 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, 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)

manufacturer's specifications.

Equipment

Equipment may include:

grate cleaning system

ash and soot blowing equipment

ash removal system

pumps

weirs

tanks

belt and rotary filters

chemical addition systems

clarifier.

Hazards

Hazards typically include working with airborne particulates containing silica, chemical handling and use of hot water.

Ash separation

Ash separation may involve use of clarifiers followed by a filter, use of screens or by filter only.

Services

Services may include:

power and mill

general mill water supply

instrumentation air.

Chemicals

Chemicals may include:

caustic soda

flocculants.

Tests

Typical test requirements include:

pH

settling tests

clarity or turbidity.

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.

Equipment operation and monitoring

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

Teamwork

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

Information systems

Information systems may be print or screen based.