This unit of competency covers the skills and knowledge required to operate a furnace for the primary purpose of causing, inducing or facilitating a chemical reaction such as cracking, smelting or other very high temperature processes. The furnace will typically be directly fired or may use the feed as the fuel.

This unit of competency applies to operations technicians who are required to demonstrate a significant understanding of the process and the equipment operation in order to identify and rectify operational problems, predict the potential impact of furnace output on the operation of the whole plant, facilitate output changes, and operate ancillary equipment, such as:

pumps

valves

fans and dampers

utilities and services

heat exchangers

scrubbers

fuel systems

tapping systems.

This unit of competency covers furnaces and furnace processes, such as:

thermal cracking

catalytic cracking

reforming

reduction

cabin type

cylindrical or vertical.

This unit of competency applies to an individual operating independently in a plant with local control or in liaison with the control room operator in a plant with a centralised control panel such as distributed control system (DCS) type controls.

This unit of competency applies to an individual working alone or as part of a team or group and working in liaison with other shift team members and the control room operator, as appropriate.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

use data and own senses to monitor plant and maximise performance

perform pre-start checks, start-up/shutdown, and isolations and de-isolations

apply process knowledge to monitor and predict the need for adjustments to system components

predict impact of a change in one unit/area on other plant units/areas and take appropriate action

identify hazards and risks and apply risk control procedures

identify early warning signs of equipment/processes needing attention or with potential problems

resolve routine and non-routine problems.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the furnace system and functions of each

principles of operation of plant/equipment, including combustion principles, draft, burner design, excess air/flue CO/CO2, and flame patterns/flame impingement

process-specific science (physics, chemistry and biochemistry) to the level of being able to interpret the science and extract factors controlling the process and product and by-product production rate and quality (e.g. for chemistry interpret the equation for factors controlling rate and yield and also interfering reactions, such as by-products)

methods of changing production rate and process variables

impact of external factors (e.g. variations in weather)

interactions between plant items/processes

systems’ operating parameters, integrity limits, product specifications and tolerances, such as temperature, pressure, flow and pH

function and troubleshooting of major components and their problems

hierarchy of control

hazards that may arise in the job/work environment, and:

their possible causes

potential consequences

appropriate risk controls.

The unit should be assessed holistically and the judgement of competence based on a holistic assessment of the evidence.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operations

will typically include a supervisor/third-party report focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of industrial style furnace causing a reaction

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible, or where personal safety or environmental damage are limiting factors, assessment must occur in a sufficiently rigorous simulated environment reflecting realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from one or more of:

walk-throughs

pilot plant operation

demonstration of skills

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence (provided a record is kept) or through an independent process, such as workbooks, written assessments or interviews (provided a record is kept).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition, the assessor or anyone acting in subject matter expert role in assessment must demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they must assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on-the-job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.

This section describes those language, literacy, numeracy and employment skills that are essential to performance.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Operations