PPMREC320
Prepare and start up chemical recovery operations


Application

This unit of competency describes the outcomes required to prepare and start up chemical recovery operations in a pulp or paper manufacturing facility. This work typically involves complex integrated equipment and continuous operations.

The unit applies to production operators and technicians who establish the production and quality processes after preparing and starting up chemical recovery systems. This typically involves working in a facility with complex integrated equipment and continuous operations.

Licensing, legislative, regulatory, or certification requirements apply to this unit in some states and territories at the time of publication and may differ according to jurisdiction.


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. Determine production requirements for chemical recovery

1.1. Determine processing rates for production and communicate to relevant personnel

1.2. Determine availability of incoming supplies to meet production requirements

1.3. Confirm readiness and availability of facilities to receive process product and/or by-products

2. Inspect and prepare systems for startup

2.1. Complete pre-startup checks in line with work health and safety (WHS) regulations, environmental and safe working requirements/practices.

2.2. Identify and deal with hazards according to safe workplace procedures

2.3. Confirm operational settings against specification requirements

2.4. Set delivery systems for operation according to standard operating procedures (SOPs)

2.5. Check monitoring devices and systems and confirm as operational

2.6. Rectify faults that have been identified

2.7. Confirm production ready status with relevant personnel

3. Start up operations

3.1. Activate systems and confirm as operational

3.2. Co-ordinate equipment startups for production

3.3. Communicate process operation to relevant personnel

3.4. Record production startup details as required

4. Establish and stabilise the production and quality processes

4.1. Monitor and adjust chemical recovery systems to rectify variations from specifications

4.2. Take samples as required and action appropriately

4.3. Verify product tests as within specification where applicable

4.4. Record system operation, production and quality data as required

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 evidence that they can:

prepare and start up chemical recovery processes, at least twice in line with required enterprise intervals, which requires the ability to:

conduct checks to ensure availability of incoming supplies

remove isolations to activate startup

conduct pre-startup checks of plant and equipment including instrumentation

conduct checks to ensure readiness and availability of facilities to receive process product and/or by-products

determine chemical recovery requirements (temperatures, oxidation, combustion and evaporation rates) for operation

input operational settings (set points) in preparation for startup in accordance with Standard Operating Procedures (SOPs)

activate and confirm operation of chemical recovery system according to SOP

make process control adjustments to stabilise production and quality

take samples of product, conduct tests, interpret and record results to regulate product consistency and quality

during the startup process, demonstrate safe use for different types of chemicals

use electronic and other control systems to control equipment and processes.


Evidence of Knowledge

A person competent in this unit must be able to demonstrate knowledge of:

relationships within the chemical recovery area members and with the area's suppliers and customers

cause and effects of operational equipment faults

working knowledge of chemical recovery operations, processes, layout and associated services sufficient to carry out startup activities

control points of the preparation for startup procedure

control points of the startup procedure

purpose of the process controls and how the changes affect the operation's variables

purpose of each of the steps in the preparation of the chemical recovery system for production

sampling and testing process for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements.


Assessment Conditions

The following resources must be made available:

access to the full range of chemicals and equipment required to start up chemical recovery operations in a pulp or paper manufacturing facility

personal protective equipment required for operating chemical recovery systems

pumps and transfer equipment

mechanical, hydraulic and electrical systems

process monitoring and management equipment

relevant personnel for the purposes of communicating information.

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 are not explicit in the performance criteria

Learning skills to:

plan activities at start of shift

determine chemical recovery requirements for operation (temperatures, oxidation, combustion and evaporation rates).

Numeracy skills to:

interpret and verify test results

interpret instruments, gauges and data recording equipment.

Communication skills to:

interpret non-verbal instructions including hand signals, signage and alarms.

Oral communication skills to:

communicate processing rates and process operation.

Reading skills to:

interpret documentation, procedures and reports, including SOPs, quality procedures, plant manufacturing operating manuals, work instructions and orders.

Writing skills to:

record system operation, production and quality data

navigate and enter computer-based information to complete log sheets, incident and shift reports.

Problem solving skills to:

maintain situational awareness in the work area.


Range Statement

Not Applicable


Sectors

Pulp and Paper Manufacturing