Application
This unit applies to operators who manage steam boiler startup in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations This unit generally applies to those who: conduct pre-operational safety checks and conduct startup procedures to meet safety, quality and productivity requirements It does not include monitoring and controlling boiler operation, shutting down and banking steam boiler or troubleshooting and rectifying boiler plant systems |
Prerequisites
Not Applicable
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Conduct pre-operational safety checks | 1.1. Pre-operational safety checks are conducted within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements |
1.2. Plant status is confirmed by inspection, observations and other information | |
1.3. Potential work area hazards are identified, reported and prevention or control measures implemented | |
1.4. Work and output requirements are established | |
1.5. Pre-operational and safety checks are conducted | |
1.6. Isolations are removed | |
1.7. Availability of process supplies are confirmed | |
2. Conduct startup procedures | 2.1. Startup procedures are conducted within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements |
2.2. Pre-light conditions are established | |
2.3. Boiler condition during startup is monitored to detect abnormal conditions | |
2.4. Boiler is started and brought on-line | |
2.5. System and plant is observed for correct operational response | |
2.6. Deviations from required operating conditions are detected and corrective action undertaken to rectify | |
2.7. Responses to corrective actions are documented as required | |
2.8. Startup information is recorded and reported as required |
Required Skills
This describes the skills and knowledge required for this unit. |
Required skills |
Uses required forms of communication in managing a steam boiler startup Reads and interprets required documentation, procedures and reports Interprets instruments, gauges and data recording equipment Prepares written information and enters data to support groups and teams Interprets specifications and customer orders Accesses, navigates and enters computer-based information Identifies and actions problems within level of responsibility Identifies and monitors process control points Maintains situational awareness in the work area Implements isolation and access procedures Maintains a clean and hazard free work area Sets up and starts boiler within an appropriate time Uses measuring equipment as required Operates high risk 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 steam generation 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 Basic problem-solving techniques consistent with level of responsibility Working knowledge of steam generation plant, processes, layout and associated services sufficient to carry out startup activities within level of responsibility Boiler water treatment system and reasons for treatment Pre-operational checks and requirements Application of high risk 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 steam generation 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 managing a steam boiler startup |
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 steam generation operations Access to the full range of equipment involved in integrated continuous manufacturing of steam generation 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 | |
Boiler types may include: | fire tube water tube and may be operated in conjunction with other steam driven plant and operations including: paper making machines turbines digesters evaporators heating plant | |
Pre-operational checks may include: | low water level alarm high water level alarm low water level alarm lockout hydrostatic test burner management system safety valve test | |
Materials and supplies may include: | chemicals coal oil gas additives air water wood waste steam recovery process products power | |
Equipment may include: | boiler and auxiliary plant boiler heating systems steam distribution system fuel and fuel delivery system plant dust removal and combustion waste fuel management system extraction systems water distribution systems compressed air systems steam temperature control plant chemical dosing system water treatment system flame detection equipment hand and power tools computer systems electronic screens and alarms process control systems analogue and digital instrumentation fully automated, semi-automated, manually operated plant and equipment appropriate to steam generation 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 licensing requirements appropriate boiler/pressure vessel operator certification confined space standards and regulations | |
Documentation, procedures and reports may include: | SOP quality procedures environmental sustainability requirements/practices plant manufacturing operating manuals oil or chemical spills and disposal guidelines plant isolation documentation safe work documentation e.g. plant clearance, job safety analysis, permit systems enterprise policies and procedures job sheets manufacturer's specifications maintenance documentation statutory requirements Materials Safety Data Sheets (MSDS) operator's log process and instrument diagrams | |
Maintenance may include: | operator level maintenance as per site agreements operator maintenance schedules 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/external customers and suppliers team members production/service coordinators maintenance services operational management statutory authorities | |
Situational awareness may include | awareness of: traffic pedestrians location of equipment product hazards obstruction unexpected movement | |
Forms of communication 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 | |
Sensory information may include: | visual sound feel touch smell vibration temperature |
Sectors
Not Applicable
Employability Skills
This unit contains employability skills |
Licensing Information
Refer to Unit Descriptor