Application
This unit of competency describes the outcomes required to assess and execute planned and unplanned shutdowns in the pulp and paper industry. This typically involves working in a facility with complex integrated equipment and continuous operations.
The unit applies to operators and technicians who co-ordinate the shutdown of coated paper processes in a pulp or paper manufacturing facility. Coated paper processes describe a range of systems and sub systems including tail feed systems, chemical and material batching, laminating and coating, splicing, clay plant operation, calendaring, pre-reeler operations, super calendaring, rewindering and drying systems.
No licensing, legislative or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
ELEMENTS | PERFORMANCE CRITERIA |
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions. |
1. Implement planned shutdown procedures | 1.1. Identify planned shutdown of coated paper process from work area instructions or maintenance schedules. 1.2. Follow coated paper process materials and supplies shutdown procedures, as required. 1.3. Manage plant or system shutdowns in accordance with production requirements, relevant workplace health and safety (WHS) procedures, risks and hazards identification and environmental workplace procedures. 1.4. Implement isolation and lock out requirements, according to standard operating procedures (SOP) and housekeeping requirements. 1.5. Ensure plant integrity and personnel safety by following WHS procedures. 1.6. Communicate planned shutdown information to relevant personnel as required. 1.7. Wash and clean plant and equipment for restart. |
2. Assess the cause and effect of an unplanned shutdown | 2.1. Assess the cause and effect of an unplanned shutdown within WHS and environmental procedures, SOP and housekeeping requirements. 2.2 Identify abnormal operating conditions by analysis of technical and operational information. 2.3. Determine the effects of abnormal conditions to enable appropriate adjustments and rectification. 2.4. Locate the source of the cause of the shutdown, to ensure rectification. 2.5. Notify appropriate personnel, when abnormal operating conditions prevail. 2.6. Identify safety issues relevant to an unplanned shut down. |
3. Record and report shutdown data | 3.1. Record and report shutdown data within WHS and environmental procedures, SOP, and housekeeping requirements. 3.2. Record assessment and evaluation of causes and corrective actions, as required. 3.3. Communicate relevant information to appropriate personnel in accordance with operational requirements. |
Evidence of Performance
A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide sufficient evidence that they can undertake planned and unplanned shutdowns, at least twice in line with required enterprise intervals, by:
implementing planned equipment and plant shutdown procedures for coated paper processes and following workplace schedules and requirements
implementing isolation and lock out requirements according to standard operating procedures (SOP)
following procedures to communicate with relevant personnel and preparing equipment for restart after a planned shutdown
using and interpreting electronic control systems, including Digital Control System (DCS), touch screens or robotics to control equipment and processes during shutdowns
assessing the cause and effect of an unplanned shutdown for coated paper processes and rectifying abnormal conditions causing a shutdown
communicating with stakeholders about shutdowns, including internal and external customers and suppliers, team members, production/service co-ordinators, maintenance services, operator support personnel, operational management and statutory authorities
selecting and using appropriate forms of communication, from written or verbal, to inform about shutdown causes and corrective action, according to SOP
recording and reporting on shutdowns and corrective actions, in accordance with organisational requirements.
Evidence of Knowledge
A person competent in this unit must be able to demonstrate knowledge of:
documentation and procedures relevant to plant and system shutdowns for coated paper processes including:
work health and safety (WHS)
Standard Operating Procedures (SOP)
productivity requirements
quality procedures
environmental sustainability requirements/practices
machinery and plant manufacturing operating manuals
enterprise policies and procedures
Material Safety Data Sheets (MSDS)
oil or chemical spills and disposal guidelines
plant isolation documentation
safe work documentation including plant clearance, job safety analysis, permit systems, product specifications and schedules, emergency procedures and responses
maintenance logs
job sheets
site agreements
safety instructions
process and instrument diagrams
machine manuals
troubleshooting guides
incidents reports
plant and equipment and their functions for coated paper processes
types, causes and effects of coated paper processes and related materials used in coated paper processes including chemicals and polymers, power, water, additives, steam, labels, felts, equipment, gas, accessories (parts) and air
base paper coated paper processes, system layout and associated services sufficient to carry out shutdown activities
production needs including output targets, production scheduling quality requirements, resources and energy use, waste minimisation
processes and procedures for plant shutdowns and unplanned shutdowns
required responses to all unplanned shutdowns (power outage, mechanical breakdown, blockages, jamming, air supply, control system failure) to ensure safety quality and productivity
operation and application of electronic and other control systems, to make appropriate adjustments that control coated paper processes.
Assessment Conditions
The following resources must be made available:
access to the full range of equipment involved in integrated continuous manufacturing of coated paper processes in a pulp or paper manufacturing facility
electronic screens and alarms, process control systems, analogue and digital instrumentation for coated paper processes
equipment, machinery and resources to co-ordinate the shutdown of coated paper systems
applicable work health and safety (WHS) and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements
personal protective equipment required for operating coated paper processes
relevant personnel for the purposes of communicating information
sample workplace documentation on work health and safety (WHS) procedures, risks and hazards identification procedures, environmental and safe working requirements/practices, SOP and housekeeping requirements.
Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.
Assessor requirements
Assessors must:
hold the appropriate assessor competency standards as outlined in regulations; and
be able to demonstrate vocational competencies at least to the level being assessed; and
be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.
Foundation Skills
This section describes those core and employment skills that are essential to performance and are not explicit in the performance criteria. | |
Numeracy skills to: | interpret digital instruments, gauges and data recording equipment during shutdowns. |
Reading skills to: | read and interpret diagrams on equipment in operational manuals read and follow instructions in safety and equipment manuals when undertaking shutdowns. |
Writing skills to: | complete forms and records accurately and legibly using correct technical vocabulary. |
Technology skills to: | use electronic and other control systems to control equipment and processes for shutdowns |
Problem solving skills to: | maintain situational awareness in the work area analyse and use sensory information to adjust process and to maintain and co-ordinate safety and quality. |
Range Statement
Not Applicable
Sectors
Pulp and Paper Manufacturing