Application
This unit applies to operators who prepare and start up stock preparation systems 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 inspect and prepare systems for startup, and start up stock preparation operations to meet safety, quality and productivity requirements It does not include monitoring and controlling, shutting down or troubleshooting and rectifying stock preparation systems |
Prerequisites
Not Applicable
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Determine production requirements | 1.1. Production requirements are determined within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 1.2. Planned production requirements are confirmed and communicated to relevant personnel 1.3. Availability of machine supplies are 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. Isolations are removed as required 2.3. Operational settings are made and confirmed 2.4. Pre-startup checks are completed 2.5. Monitoring devices and systems are checked and confirmed operational 2.6. Faults are identified and rectified, as required 2.7. Raw material supply requirements are staged ready for use as required 2.8. Operational readiness is confirmed and communicated to relevant personnel |
3. Start up stock preparation operations | 3.1. Stock preparation operations are started up within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 3.2. Stock, chemical and water systems startups are coordinated and implemented as required 3.3. System functions are confirmed by monitoring plant, equipment and control systems/display monitors 3.4. Test samples taken and test results interpreted and recorded as required 3.5. Process operation is communicated to relevant personnel 3.6. Production start up details are documented 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 stock preparation systems Reads and interprets required documentation, procedures and reports Interprets instruments, gauges and data recording equipment Accesses, navigates and enters computer-based information Identifies and actions problems within level of responsibility Takes samples, conducts tests, interprets and records results Identifies and monitors process control points Plans and organises startup Maintains situational awareness in the work area 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 stock preparation systems including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping Relevant forms of communication Basic problem-solving techniques consistent with level of responsibility Sampling and testing process for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements Working knowledge of stock preparation plant, processes, layout and associated services sufficient to carry out startup activities within level of responsibility Quality requirements 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 stock preparation systems, 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 the preparation and startup of stock preparation systems |
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 stock preparation systems Access to the full range of equipment involved in integrated continuous manufacturing of stock preparation systems 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 |
Systems and functions involved in stock preparation may include: | refining systems blending system proportioning system broke system stock chests water chests cleaning system water recovery system chemical and additive plants bale handler broke baler wire coiler |
Materials and supplies may include: | water stock compressed air chemicals additives steam baled pulp |
Equipment may include: | refiners pumps valves chests agitators pulpers screens cleaners showers disc deckers consistency controllers screw press water recovery equipment computer systems electronic screens and alarms process control systems fully automated, semi-automated, manually operated plant and equipment appropriate to stock preparation systems |
Electronic control systems may include: | Digital Control System (DCS) touch screens robotics |
Hazards and risks involved in stock preparation may include: | steam and/or gas leaks fires nip points compressed air hot surfaces electrical entanglement slip hazards/falls energy pressures chemicals fumes confined spaces dust |
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 |
Documentation, procedures and reports may include: | SOP site policy and procedures environmental sustainability requirements/practices plant manufacturing operating manuals confined space requirements vendor documentation reference manual grade specifications quality procedures oil or chemical spills and disposal guidelines plant isolation documentation housekeeping safe work documentation e.g. plant clearance, job safety analysis, permit systems maintenance logs job sheets operating log production instructions Materials Safety Data Sheets (MSDS) process and instrument diagrams |
Maintenance may include: | operator level maintenance as per site agreements operator maintenance schedules maintenance systems maintenance suppliers pro-active 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 production/service co-ordinators internal/external customers and suppliers maintenance services operational management statutory authorities |
Situational awareness may include | awareness of: traffic pedestrians location of equipment product hazards obstructions 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. standard operating procedures, 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