FPPREC320A
Prepare and start up chemical recovery operations

This unit describes the outcomes required to prepare and start up chemical recovery operations in the pulp and paper industryGeneral legislation, regulatory, licensing and certification requirements applicable to this unit are detailed in the range statementSpecific high risk (and non-high risk) load shifting licensing requirements for this unit may be applicable and are to be met separately and prior to the achievement of this unit

Application

This unit applies to operators who prepare and start up chemical recovery operations in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations

This unit generally applies to those who:

determine production requirements for chemical recovery

inspect and prepare systems for startup

start up operations, and

establish and stabilise the production and quality processes

to meet safety, quality and productivity requirements

It does not include shutting down, monitoring and controlling or troubleshooting and rectifying chemical recovery operations.


Prerequisites

Not Applicable


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1. Determine production requirements for chemical recovery

1.1. Production requirements for chemical recovery are determined within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

1.2. Processing rates for production are determined and communicated to relevant personnel

1.3. Availability of incoming supplies to meet production requirements are determined

1.4. Readiness and availability of facilities to receive process product and/or by-products is confirmed

2. Inspect and prepare systems for startup

2.1. Systems are inspected and prepared for startup within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

2.2. Pre-startup checks are completed

2.3. Operational settings are made and confirmed against specification requirements

2.4. Delivery systems are set for operation

2.5. Monitoring devices and systems are checked and confirmed operational

2.6. Identified faults are rectified

2.7. Production ready status is confirmed with relevant personnel

3. Startup operations

3.1. Startup operations are completed within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

3.2. Systems are activated and confirmed operational

3.3. Equipment startups are co-ordinated for production

3.4. Process operation is communicated to relevant personnel

3.5. Production startup details are recorded as required

4. Establish and stabilise the production and quality processes

4.1. Production and quality processes are established and stabilised within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

4.2. Chemical recovery systems are monitored and adjusted to rectify variations from specifications

4.3. Samples are taken as required and appropriately actioned

4.4. Product tests are verified as within specification where applicable

4.5. System operation, production and quality data is recorded as required

Required Skills

This describes the skills and knowledge required for this unit.

Required skills

Uses required forms of communication in preparing and starting up chemical recovery operations

Reads and interprets required documentation, procedures and reports

Confirms production ready status with team members, suppliers and customers

Accesses, navigates and enters computer-based information

Interprets instruments, gauges and data recording equipment

Identifies and actions problems within level of responsibility

Responds to faults of process flow-through systems if required

Identifies and monitors process control points

Maintains situational awareness in the work area

Removes isolations

Conducts pre-startup checks of plant and equipment including instrumentation

Determines chemical recovery requirements (e.g. temperatures, oxidation, combustion and evaporation rates) for operation

Conducts checks to ensure availability of incoming supplies

Conducts checks to ensure readiness and availability of facilities to receive process product and/or by-products

Inputs operational settings (e.g. set points) in preparation for startup in accordance with SOP

Activates and confirms operation of chemical recovery system according to SOP

Makes process control adjustments to stabilise production and quality

Conducts routine maintenance checks

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

Uses measuring equipment as required

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

Analyses and uses sensory information to adjust process to maintain and co-ordinate 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 chemical recovery 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

Relationships within the chemical recovery area members and with the area's suppliers and customers

Basic problem-solving techniques consistent with level of responsibility

Cause and affects of operational equipment faults

Working knowledge of chemical recovery operations, processes, layout and associated services sufficient to carry out startup activities within level of responsibility

Control points of the preparation for startup procedure

Purpose of the process controls and how the changes affect the operation's variables

Control points of the startup procedure

Purpose of each of the steps in the preparation of the chemical recovery system for production

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

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

Sensory 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 chemical recovery operations, within level of responsibility

Evidence Required

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 preparing and starting up chemical recovery 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 chemical recovery operations

Access to the full range of equipment involved in integrated continuous manufacturing of chemical recovery 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


Range Statement

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

Chemical recovery processes may include:

evaporator operations

condensate stripper

lime mud treatment

Wet Air Oxidation (WAO)

causticising plant operations

recovery boiler operations

direct alkali reduction system (DARS operations)

foul gas and condensate incineration

Chemicals may include:

white liquor

green liquor

black liquor

condensates

non-condensable gases

thick liquor

spent liquor

quench liquor

weak wash

anthraquinone (AQ)

caustic

magnesium oxide

sulphur

Materials and supplies may include:

steam

compressed air

chemicals

water

power

Equipment may include:

power or steam generation

pneumatic systems

water supply systems and equipment

process plant

pumps and transfer equipment

mechanical, hydraulic and electrical systems

process monitoring and management equipment

mobile equipment (e.g. skid steer, forklift, elevated work platform, loaders)

computer systems

electronic screens and alarms

process control systems

analogue and digital instruments

fully automated, semi-automated, manually operated plant and equipment appropriate to chemical recovery 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)

activity or task specific high risk (and non-high risk) licensing requirements

hazardous chemical handling

Documentation, procedures and reports may include:

SOP

quality procedures

environmental sustainability requirements/practices

plant manufacturing operating manuals

work instructions and orders

incident reports

log sheets and shift reports

oil or chemical spills and disposal guidelines

plant isolation documentation

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

emergency operational procedures (EMOs)

process and instrument diagrams

non-conformance reports

Maintenance may include:

operator level maintenance as per site agreement

maintenance systems

operator maintenance schedules

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:

team members

internal or external customers and suppliers

maintenance services

production/services co-ordinator

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


Sectors

Not Applicable


Employability Skills

This unit contains employability skills


Licensing Information

Refer to Unit Descriptor