This unit applies to operators who monitor and control pulping operations in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations

This unit generally applies to those who:

monitor and control processes

monitor and maintain the plant, and

record and report process data

to meet safety, quality and productivity requirements

It does not include starting up, shutting down or troubleshooting and rectifying pulping plant operations

ELEMENT

PERFORMANCE CRITERIA

1. Monitor and control processes

1.1. Processes are monitored and controlled within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

1.2. Production requirements are checked at start of shift to plan day's activities as required

1.3. Operational status is confirmed by inspection, observations and other information

1.4. Supplies and supply systems are monitored to ensure availability and suitability

1.5. Sampling and testing is conducted

1.6. Storage levels are monitored and controlled

1.7. Process variables are monitored and controlled to ensure efficient operation

1.8. Discharges are monitored to meet environmental requirements

2. Monitor and maintain plant

2.1. Plant is monitored and maintained within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

2.2. Plant variations are interpreted and actioned if required

2.3. Plant inspections are undertaken to maintain production

2.4. Test equipment is calibrated and maintained if required

2.5. Plant adjustments are made to maintain production and quality schedules

2.6. Operator level preventative maintenance schedules are carried out as required

3. Record and report process data

3.1. Process data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

3.2. Process data is interpreted and recorded

3.3. Process problems and equipment faults are reported

3.4. Problems or variations with systems or product are communicated to relevant personnel

3.5. Hazardous conditions are documented and communicated to relevant personnel

3.6. Problems with environmental releases are recorded and reported as required

This describes the skills and knowledge required for this unit.

Required skills

Uses required forms of communication in monitoring and controlling pulping operations

Reads and interprets required documentation, procedures and reports

Accesses, navigates and enters computer-based information

Interprets instruments, gauges and data recording equipment

Identifies and actions problems within level of responsibility

Takes samples, conducts tests, interprets and records results if required

Uses measuring equipment as required

Identifies and monitors process control points

Maintains situational awareness in the work area

Operates high risk (and non-high risk) load shifting equipment as required

Carries out operator level maintenance as required

Analyses and uses sensory information to adjust process to maintain safety, quality and productivity

Uses electronic and other control systems to control equipment and processes as required

Required knowledge

Procedures, regulations and legislative requirements relevant to pulping operations including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Causes and effects of process variation between upstream and downstream customers

Basic problem-solving techniques consistent with level of responsibility

Sampling and testing processes for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements

Pulping in-process tests and procedures

Working knowledge of pulping plant, processes, layout and associated services including operating parameters, variation and associated adjustments within level of responsibility

Quality requirements

Application of high risk (and non-high risk) load shifting equipment, as required

Sensory and other information that indicates a deviation from standard operating parameters

Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control the pulping operations, within level of responsibility

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

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

Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of:

the required knowledge and skills tailored to the needs of the specific workplace

applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements

applicable aspects of the range statement

practical workplace demonstration of skills in monitoring and controlling pulping operations

Context of and specific resources for assessment

A workplace assessment must be used to assess:

the application of required knowledge on the job

the application of skills on the job, over time and under a range of typical conditions that may be experienced in pulping operations

Access to the full range of equipment involved in integrated continuous manufacturing of pulping plant operations in a pulp or paper mill is required

Method of assessment

A combination of assessment methods should be used. The following examples are appropriate for this unit:

observation of applied skills and knowledge on the job

workplace demonstrations via a mock-up or simulation that replicate part/s of the job

answers to written or verbal questions about specific skills and knowledge

third-party reports from relevant and skilled personnel

written evidence e.g. log sheet entries, checklist entries, test results

Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job)

A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended

Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package

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.

Productivity requirements may include:

energy efficiency

waste minimisation

evaporation minimisation, including landfill and waste water reduction

environmentally safe waste disposal

consideration of resource utilisation, including fibre efficiency

minimising delays

chemical recovery maximisation

meeting key performance indicators

line speed

handovers

quality checks

meeting output targets i.e. net tonnes per employee per annum

machine/process time availability i.e. time the machine or process is making product

machine/process production rate

Operational parameters may include:

flows

temperatures

pressures

through put

consistencies

amps

set points

valve settings

levels

interlocks

Storage levels may include:

vats

chests

silos

tanks

bins

piles

Pulping processes - chemical, mechanical and semi-chemical pulping may include:

bleaching plant operations

refining

chip preparation

cleaning or washing systems

chemical preparation and treatment

pulp lapping production

stock distribution and storage

digester operations

mechanical pulping systems

Products of these processes may include:

bleached or unbleached pulp

fluff pulp

crumbed pulp

baled, rolled or sheet pulp

slushed pulp

Materials and supplies may include:

woodchips

pulp

steam

water

chemicals

power

Equipment may include:

power and steam systems

hydraulic and electrical systems

chemical delivery and processing systems

conveyors and pump distribution equipment

pneumatic systems

process plant

materials handling equipment

hand and power tools

computer systems

electronic screens and alarms

process control systems

analogue and digital instruments

fully automated, semi-automated, manually operated plant and equipment appropriate to pulping operations

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Legislation, regulatory, licensing and certification requirements may include:

OHS and environmental requirements (local, state and commonwealth)

as applicable, activity or task specific high risk (and non-high risk) load shifting licensing requirements

relevant endorsed licences

hazardous chemical handling

air and gas discharges

safety instructions

Documentation, procedures and reports may include:

SOP

work instructions or purchase orders

environmental sustainability requirements/practices

plant manufacturing operating manuals

quality procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

safe work documentation e.g. plant clearance, job safety analysis, permit systems

log sheets and shift reports

work orders

delivery or distribution documentation

tally or production records

incident reports

Materials Safety Data Sheets (MSDS)

process and instrumentation diagrams

Maintenance may include:

operator level maintenance as per site agreement

operator maintenance schedules

calibrating test equipment

maintenance systems

maintenance suppliers

proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

internal or external

customers and suppliers

team members

maintenance services

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstruction

unexpected movement

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

Forms of communications may include:

written e.g. log books, emails, incident and other reports, run sheets, data entry

reading and interpreting documentation e.g. SOP, manuals, checklists, drawings

verbal e.g. radio skills, telephone, face to face, handover

non-verbal e.g. hand signals, alarms, observations

signage e.g. safety, access

This unit contains employability skills