Application
This unit applies to operators who troubleshoot and rectify 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: identify and analyse causes of systems and quality faults rectify systems, equipment and product quality faults, and record and report process performance and product quality data to meet safety, quality and productivity requirements It does not include monitoring and controlling, starting up or shutting down stock preparation systems |
Prerequisites
Not Applicable
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Identify and analyse causes of systems and quality faults | 1.1. Causes of systems and quality 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. Alarm systems and observations are interpreted to determine fault type and location 1.3. Routine inspections of plant and processes are made to identify faults 1.4. Sampling and testing results are interpreted to identify variations from operating parameters 1.5. Cause and source of problem is identified and located 1.6. Relevant sources of information are accessed and interpreted to assist analysis 1.7. Information is communicated to relevant personnel |
2. Rectify systems and equipment faults | 2.1. Systems and equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 2.2. Equipment is shut down and isolated prior to fault rectification if required 2.3. Faulty equipment is by-passed where the process allows 2.4. Faulty equipment is repaired or replaced as required 2.5. Corrective adjustments are made to equipment 2.6. Operator level maintenance is undertaken as required 2.7. Restoration to normal operation is verified and communicated to relevant personnel |
3. Rectify product quality faults | 3.1. Product quality faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 3.2. Product quality faults or variations are identified by observation inspection and testing 3.3. Samples for a range of tests are taken 3.4. Test results are interpreted and processes are adjusted to correct variations from specification |
4. Record and report process performance and product quality data | 4.1. Process performance and product quality data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 4.2. Variations from specifications are documented 4.3. Performance variations are documented 4.4. Corrective actions are recorded 4.5. Out-of-specification product is dealt with 4.6. 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 and information Uses required forms of communication in troubleshooting and rectifying stock preparation systems Communicates effectively with personnel to assist with analysis and resolution of operational problems 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 systems, quality and equipment faults within level of responsibility Assists others to identify and resolve operational problems in the workplace Identifies causes and effects of faults and corrective action on associated processes Takes samples, conducts tests, interprets and records results Selects and uses appropriate troubleshooting methods Takes timely corrective action to maximise safety, quality and productivity Undertakes necessary calculations to aid troubleshooting as required Uses measuring equipment as required 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 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 stock preparation systems 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 stock preparation plant, processes and associated services sufficient to troubleshoot including: plant layout theory of operation causes and effects of adjustments made to stock preparation plant and processes relationships between stock preparation plant, processes and associated services An appropriate range of troubleshooting methods Sampling and testing process 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 Mill maintenance system as it applies to stock preparation plant and processes 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 troubleshooting and rectifying 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