Application
This unit of competency describes the outcomes required to plan, prepare, manage and report on steam boiler start ups, in the pulp and paper industry.
This unit applies to production operators and technicians who manage steam boiler startups, in a pulp and paper manufacturing facility. This typically involves working in a facility with complex integrated equipment and continuous operations.
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. Conduct pre-operational safety checks | 1.1. Confirm plant status and boiler types through inspections, observation and other information. 1.2. Plan operational safety checks according to work health and safety (WHS), productivity requirements, 1.3. Identify and report potential work area hazards and implement control measures. 1.4. Establish work and output requirements. 1.5. Conduct pre operational and safety checks on equipment. 1.6. Remove isolations. 1.7. Confirm availability of process supplies. |
2. Conduct startup procedures | 2.1. Establish pre-light conditions. 2.2. Start boiler and bring on-line. 2.3. Monitor boiler condition during startup to detect abnormal conditions. 2.4. Observe system and plant for correct operational response. 2.5. Detect deviations from required operating conditions and rectify using corrective action. |
3. Record and report start up activities | 3.1. Document responses to corrective actions, as required. 3.2. Record and report on start up information, 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:
manage a steam boiler startup, at least twice in line with required enterprise intervals, in a pulp and paper manufacturing facility, by:
checking, setting up and starting the boiler within an appropriate time frame
implementing isolation and access procedures
identifying and actioning problems
identifying and monitoring process control points
maintaining a clean and hazard free work area
recording and reporting on operational data
communicating effectively, through written and verbal means, and working safely with others, in the work area.
Evidence of Knowledge
A person competent in this unit must be able to demonstrate knowledge of:
implications of pre operational checks including low water level alarm, high water level alarm, low water level, alarm lockout, hydrostatic test, burner management system and safety valve test
documentation and procedures relevant to steam boiler startups, in the pulp and paper industry including:
work health and safety (WHS) including high risk load shifting licensing requirements, plant clearance, job safety analysis and permit systems
appropriate boiler/pressure vessel operator certification
confined space standards and regulations
productivity requirements
quality procedures
Standard Operating Procedures (SOP)
environmental sustainability requirements and practices
machinery and plant manufacturing operating manuals
enterprise policies and procedures
oil or chemical spills and disposal guidelines
plant isolation documentation
job sheets and operator's log
manufacturer's specifications and maintenance documentation
Material Safety Data Sheets (MSDS)
incidents reports
the use of materials and supplies for boiler startups including chemicals, coal, oil, gas, additives, air, water, wood waste, steam recovery process products and power
hazards and risks identification
maintenance systems including operator level maintenance as per site agreements, operator maintenance schedules, maintenance suppliers and pro-active maintenance strategies
processes, layout and associated services relevant to steam generation plant and sufficient to carry out startup activities within level of responsibility
boiler water treatment system and reasons for treatment
electronic and other control systems, operation and application to make appropriate adjustments that control steam generation systems.
Assessment Conditions
The following resources must be made available:
access to the full range of equipment required to start up steam boiler operations in a pulp or paper manufacturing facility
electronic control systems which includes Digital Control System (DCS), touch screens or robotics required for steam boiler startup
personal protective equipment suitable for managing a steam boiler startup
applicable WHS and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements
relevant personnel for the purposes of communicating information
sample workplace documentation, procedures and reports including SOP, quality procedures, environmental sustainability requirements/practices, plant manufacturing operating manuals, enterprise policies and procedures, oil or chemical spills and disposal guidelines, plant isolation documentation, safe work documentation.
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 instruments, gauges and data recording equipment use measuring equipment. |
Oral communication skills to: | select and use appropriate spoken communication strategies with work colleagues and other personnel on site to manage steam boiler start up. |
Reading skills to: | read and interpret documentation, procedure manuals and customer orders relevant to steam boilers. |
Writing skills to: | record start up activities accurately and legibly, using correct technical vocabulary. |
Problem solving skills to: | maintain situational awareness in the work area analyse and use sensory information to adjust process to maintain and co-ordinate safety, quality and productivity. |
Technology skills to: | use electronic and other control systems to control equipment and processes. access, navigate and enter computer based information. |
Range Statement
Not Applicable
Sectors
Pulp and Paper Manufacturing