FPPWEO330A
Co-ordinate and implement wet end shutdown

This unit describes the outcomes required to co-ordinate and implement wet end shutdown in the pulp and paper industry General 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 co-ordinate and implement wet end shutdown in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations

This unit generally applies to those who:

assess causes and effects of shutdown

implement shutdown procedures, and

record and report shutdown information

to meet safety, quality and productivity requirements

It does not include monitoring and controlling, starting up or troubleshooting and rectifying problems associated with wet end operations


Prerequisites

Not Applicable


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1. Assess causes and effects of shutdown

1.1. Causes and effects of shutdown are assessed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

1.2. Work area instructions or maintenance schedules are used to co-ordinate a planned shutdown

1.3. Cause of unplanned shutdown is identified and located

1.4. Effects of unplanned shutdown are assessed to determine impact on operations

1.5. Unplanned shutdown is communicated as required

2. Implement shutdown procedures

2.1. Shutdown procedures are implemented within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

2.2. Planned shutdown is implemented

2.3. Unplanned shutdown is responded to and rectified

2.4. Isolation requirements are implemented as required

2.5. Shutdown information is communicated to relevant personnel as required

3. Record and report shutdown information

3.1. Shutdown information is reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

3.2. Shutdown information is recorded, including corrective action as required

3.3. Shutdown information is reported to relevant personnel

Required Skills

This describes the skills and knowledge required for this unit.

Required skills

Uses required forms of communication in co-ordinating and implementing wet end operations shutdown

Reads and interprets required documentation, procedures and reports

Accesses, navigates and enters computer-based information

Interprets instruments, gauges and data recording equipment

Identifies and actions problems within level of responsibility

Identifies and monitors process control points

Identifies and responds appropriately to shutdown causes

Respond to problems associated with plant shutdown and unplanned shutdown to ensure safety quality and productivity

Coordinates and plans shutdown activity

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 wet end 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

Types, causes and effects of wet end shutdowns

Required responses to all unplanned shutdowns (e.g. power outage, mechanical breakdown, blockages, jamming, air supply, control system failure) to ensure safety quality and productivity

Process and procedures for plant shutdowns and unplanned shutdowns

Plant and machinery functions and operations

Emergency procedures and responses

Working knowledge of wet end plant, processes, layout and associated services sufficient to carry out shutdown activities within level of responsibility

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 wet end 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 co-ordinating and implementing of wet end shutdowns

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 wet end operations

Access to the full range of equipment involved in integrated continuous manufacturing wet end 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

Systems and functions in wet end operations may include:

stock approach systems

forming system

pressing systems

cleaning and screening system

Materials and supplies may include:

water

air

stock

chemicals

additives

steam

machine clothing

baled pulp

Equipment may include:

screens

forming section

water, chemical, vacuum or stock systems

former

pumps

consistency meter

flow meter

refiner

control valves

cleaning showers

chemical showers

presses

cleaners

waste hood recovery unit

computer systems

electronic screens and alarms

process control systems

fully automated, semi-automated, manually operated plant and equipment appropriate to the wet end process

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Hazards and risks involved in wet end operations may include:

steam and/or gas leaks

fires

nip points

compressed air

hot surfaces

electrical

entanglement

vehicle movement

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