Application
This unit applies to operators who troubleshoot and rectify 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: identify and analyse causes of faults rectify process problems, equipment and product quality faults, and record and report system performance and product quality data to meet safety, quality and productivity requirements It does not include monitoring, controlling, starting up or shutting down chemical recovery operations |
Prerequisites
Not Applicable
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Identify and analyse causes of faults | 1.1. Causes of faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 1.2. Warning devices are interpreted to determine fault type and location 1.3. Samples for a range of tests are taken 1.4. Quality faults and variations are identified by observation, systematic sampling and testing 1.5. Sampling and testing results are interpreted to identify variations from specifications or schedule 1.6. Causes and sources of process problems or equipment faults are identified, located and analysed 1.7. Relevant sources of information are accessed and interpreted to assist analysis |
2. Rectify process problems and equipment faults | 2.1. Process problems and equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 2.2. Operator level on-line adjustments are conducted 2.3. Plant is shut down and isolation procedures are implemented prior to fault rectification 2.4. Hazardous conditions are identified, appropriate action is taken and the conditions communicated to relevant personnel 2.5. Faulty equipment is isolated or bypassed, repaired or replaced as required 2.6. Plant and equipment are returned to normal operation as required 2.7. Action taken is communicated to relevant personnel |
3. Rectify product quality faults | 3.1. Product quality is rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 3.2. Out-of-specification product is controlled 3.3. Faults and causes are rectified if appropriate, or recommendations made for further action 3.4. Further tests are conducted as required |
4. Report and record system performance and product quality data | 4.1. System performance and product quality data is reported and recorded within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 4.2. Variations from process specification are recorded 4.3. Actions undertaken to troubleshoot and rectify faults are recorded 4.4. Details of hazardous conditions or situations are documented as required 4.5. Relevant information is communicated to appropriate personnel |
Required Skills
This describes the skills and knowledge required for this unit. |
Required skills |
Identifies, accesses and interprets relevant historical and operational data Uses required forms of communication in troubleshooting and rectifying chemical recovery operations Communicates effectively with personnel to assist with analysis and resolution of operational problems Prepares detailed written information Reads and interprets required documentation, procedures and reports Interprets instruments, gauges and data recording equipment Assists others to identify and resolve operational problems in the workplace Accesses, navigates and enters computer-based information Identifies and actions systems, quality and equipment faults within level of responsibility Identifies causes and effects of faults and corrective action on associated processes Selects and uses appropriate troubleshooting methods Takes timely corrective action to maximise safety, quality and productivity Undertakes necessary calculations to aid troubleshooting as required Takes samples, conducts tests, interprets and records results if required Uses measuring equipment as required Maintains situational awareness in the work area Handles emergencies or crash shutdowns Operates high risk (and non-high risk) load shifting equipment as required Analyses and uses sensory information to adjust process to maximise 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 Use and handling requirements of chemicals used; their purpose, effects, MSDS and SOP Relevant forms of communication Detailed knowledge of chemical recovery plant, processes and associated services sufficient to troubleshoot including: plant layout theory of operation causes and effects of adjustments made to chemical recovery plant and processes relationships between chemical recovery plant, processes and associated services An appropriate range of troubleshooting methods Sampling and testing processes for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements Causes and effects of unplanned shutdown and appropriate responses Maintenance system as it applies to chemical recovery operations 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 the chemical recovery, 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 troubleshooting and rectifying 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) load shifting 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