This competency unit typically covers items of equipment, such as:

carbon anode aluminium spray station

molten aluminium delivery

conveyors, power and free

aluminium melting furnace (may require MEM04001B Operate melting furnaces)

cranes (may require PMASUP237B Undertake crane, dogging and load transfer operations)

The plant technician would:

operate the aluminium spray station

operate molten aluminium delivery system

recognise and respond to 'out-of-parameter' issues

respond to emergency situations

identify and control hazards in the workplace.

Generally the operator would be part of a team during start up and shut down procedures and would be expected to be capable of demonstrating competence in all parts of this unit. At all times they would be liaising and cooperating with other members of the team.

This unit does not require the operation of a central control panel

ELEMENT

PERFORMANCE CRITERIA

1. Plan and prepare for operations.

1.1. Interpret and confirm work requirements before proceeding

1.2. Identify and control hazards

1.3. Ensure appropriate authorisations have been obtained/issued

1.4. Identify work flow path blockages (interruptions or bottlenecks)

2. Conduct pre-start requirements to procedures.

2.1. Conduct routine pre-start equipment checks

2.2. Conduct isolation as appropriate for pre-start inspections

2.3. Prepare equipment for operation

2.4. Complete routine equipment checklists

2.5. Complete reports as required for equipment inspections.

3. Conduct operations to procedures.

3.1. Start up aluminium spray station equipment

3.2. Monitor equipment operation and check operational variables are within parameters.

3.3. Verify equipment performance throughout the process

3.4. Apply operating principles to identify problems and take appropriate action

3.5. Shut down aluminium spray station equipment as required

3.6. Conduct routine housekeeping activities

3.7. Complete records as required for equipment operation and performance.

4. Isolate and de-isolate plant

4.1. Isolate plant

4.2. Make safe for required work

4.3. Check plant is ready to be returned to service

4.4. Prepare plant for return to service

This describes the essential skills and knowledge and their level, required for this unit.

Required skills

Competence includes being able to demonstrate the following:

efficient and effective operation of plant/equipment

hazard analysis

completing plant records

communication

problem solving.

Competence includes responding to emergency situations such as:

evacuation due to fire

loss of power

excessive emissions of fumes or particulate

equipment failure

recognising hazards associated with reactive alumina, tar, pitch, kaowool, suspended loads and heat stress.

Troubleshooting a range of problems which could include:

anode spray equipment

anode stacker cranes

conveyors

rotators

equipment failure.

Required knowledge

Competence includes a comprehensive understanding of the carbon anode aluminium spray process and equipment principles and typical problems to a level needed to control the operation, and recognise and resolve operational problems. In particular it includes:

awareness of hazardous materials, recognition of spills or escapes, personal protective equipment required, isolation and clean up requirements

and knowledge of:

all items on a schematic of the carbon anode aluminium spray station process and the function of each

basic principles of operation of main equipment items, including molten aluminium delivery, power and free conveyors, spray station

basic understanding of the product specifications, including depth of cover and uniformity of aluminium layer, and variations required on the input and output side

isolating a problem to an item of equipment/stage of process

methods of resolving problems.

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment for this unit of competency will be on an operating plant. The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency. Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation may be required to allow for timely assessment of parts of this competency unit (eg Elements 2, 5). Simulation should be based on the actual plant and will include walk-throughs of the relevant competency components. Simulations may also include the use of case studies/scenarios and role plays.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

The emphasis should be on the ability to stay out of trouble rather than on recovery from a disaster.

Consistent performance should be demonstrated. In particular look to see that:

emergency responses are known.

hazards are recognised and all site requirements to reduce or remove hazards are known and completed as part of the job.

early warning signs of equipment/processes needing attention or with potential problems are recognised, that is, monitoring systems in the carbon anode spraying process including equipment, material handling systems and mobile equipment.

These aspects may be best assessed using a range of scenarios/case studies/what-ifs as the stimulus with a walk-through forming part of the response. These assessment activities should include a range of problems, including new, unusual and improbable situations that may have been generated from the past incident history of the plant, incidents on similar plants around the world, hazard analysis activities and similar sources.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations. A bank of scenarios/case studies/what-ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units. Consider co-assessment with other relevant units.

This competency may be assessed in conjunction with:

MSAPMOHS200A Work safely

MSAPMOHS110A Follow emergency response procedures

PMASUP237A Undertake crane, dogging and load transfer operations

TDTD1097B Operate a forklift

MSAPMSUP205A Transfer loads

Other units which are relevant to the job.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.

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. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs if the candidate, accessibility of the item, and local industry and regional contexts.

Codes of practice/ standards

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Appropriate action

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person.

Emergency responses

Emergency responses include those related to:

evacuation due to fire

loss of power

excessive emissions of fumes or particulate

major oil spill

equipment failure

Equipment and tools

Equipment and tools may include:

hand tools

harnesses

crucible transport equipment

EWE

forklift

furnace tending vehicle

other materials handling equipment (fixed and mobile).

Hazards

Hazards may include:

heat (burns, dehydration and heat stress)

energy sources, eg hydraulic, pneumatic and electric

high pressure piping and valves

pinch and crush points

moisture

banned items

mobile equipment and pedestrian interaction

suspended loads and roller conveyors

hazardous materials, eg reactive alumina, kaowool, tar and pitch

molten materials.

Hazard control methods

Hazard control measures should follow the hierarchy of control, be specific to the hazard and work area and include relevant Personal Protective Equipment

Housekeeping

Housekeeping procedure may include cleaning the area, removal of contaminants, safety inspections and rectification of issues that could compromise safety.

Instrument/electrical systems

Instrument/electrical systems may include:

emergency shutdown systems

fire systems

pressure and temperature control systems

communications systems

utility systems.

Isolation

Isolation refers to the complete isolation of the equipment from all sources of power or energy or isolate process flows and movement of machinery such to render it safe to work on as per site procedure.

Monitoring systems

Monitoring systems may include:

monitoring the operation of crucibles, crucible transport equipment, furnaces

monitoring the effectiveness of the process

monitoring abnormal trends in the operation of equipment or product specification.

Monitor and adjust operational variations

Monitor and adjust operational variations using troubleshooting techniques may refer to the use of:

historical data and records of common faults

troubleshooting lists and directives

site procedures.

Out-of-parameter issues

Out-of-parameter issues, faults and problems may include:

out-of-parameter operation or product

fluctuation in temperature, power consumption or product movement.

instruments and equipment requiring cleaning

equipment mechanical and electrical problems

flow path blockages

out-of-parameter emissions

unavailability of equipment, personnel or material.

Personal protective equipment

Personal Protective Equipment (PPE) requirements relate to the specified PPE for the task or job to be undertaken. PPE may include specific insulated boots, heat resistant material, full-ventilated suits, full-face masks or situation specific equipment.

Pre-start checks

Pre-start checks relate to the required site or equipment pre-start checklist and must be completed before the equipment is operated or as otherwise stated in the procedures.

Procedures

Procedures may be written, verbal, computer-based or in some other form. They include:

all work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (eg Responsible Care) and government regulations.

Shutdown procedures

Shut down procedure must follow equipment and site authorised checklist and may include

communication to supply and delivery areas

communication to impacting areas

obtaining appropriate authorisations

rescheduling operations

liaison with maintenance teams.

Reports and records

Reports and records may include:

routine inspections (daily readings, monthly checks)

scheduled maintenance activities

analysis of furnace metal specifications

computer readouts locally or in the control room

shift log sheet

mandatory or statutory inspections

hazard, accident and incident reports

quality sample records of the product.

Start up procedures

Start up procedure will conform to site procedure and include:

safety and pre-start checks

accessing shift logs and equipment records

pre-shift briefing information

records and reports from the previous shift.

Work requirements

Work requirements includes shift briefings, shift logs supervisor or crew leader meetings, toolbox talks and handover details.

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.

Persons are required to have skills in hazard identification, assessment and application of control measures, eg spills and leaks identified, contained and cleaned up. Exposure to hazardous materials requires minimal personal contact, recognition of hazards and appropriate controls.

Unit sector

Operational/technical

This unit contains employability skills.