Application
This unit of competency describes the outcomes required to shut down steam boilers in planned, unplanned and emergency situations and to inspect, maintain and store boilers.
The unit applies to production operators and technicians who shut down and bank steams boilers in a pulp or paper manufacturing facility. This typically involves working in a facility with complex integrated equipment and continuous operations.
No licensing, legislative, regulatory, 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. Shut down, inspect and maintain boiler. | 1.1. Follow organisational safety and standard operating procedures to initiate appropriate isolations and shut down boiler and ancillary plant. 1.2. Prepare boiler for inspection. 1.3. Establish condition of boiler to ensure safe removal of equipment. 1.4. Inspect boiler and complete routine preventative maintenance. 1.5. Clean boiler internally and externally in line with environmental protection practices. 1.6. Record and report maintenance requirements. |
2. Store boiler in shutdown mode. | 2.1. Establish storage time and condition of storage. 2.2. Store boiler in safe condition for access in line with manufacturer's specifications. 2.3. Analyse stored boiler water and chemicals when boiler is stored for extended periods. |
3. Respond to unplanned or emergency shutdowns. | 3.1. Respond to shutdown requirement immediately. 3.2. Follow organisational safety procedures to maintain safety of personnel and plant during emergency shutdown situations. 3.3. Identify and locate cause of shutdown. 3.4. Monitor and maintain continuing plant operation in safe working mode. 3.5. Notify relevant personnel to rectify and make plant ready for restart. |
4. Record and report shutdown data. | 4.1. Record shutdown and corrective action processes. 4.2. Report shutdown information to relevant personnel. |
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:
co-ordinate planned shutdowns of a steam boiler within a pulp and paper manufacturing facility, at least twice in line with required enterprise intervals, and complete the following tasks after shut down:
inspect the boiler and complete routine preventative maintenance
clean the boiler internally and externally
analyse stored boiler water and chemicals
complete basic records for shutdown processes and maintenance requirements
respond to unplanned or emergency shutdowns, which can be a real time event or by scenario, and implement responses appropriate to the cause and complete a basic report on corrective action processes.
Evidence of Knowledge
A person competent in this unit must be able to demonstrate knowledge of:
boiler plant layout
purpose, features and operation of these types of boilers and associated fuel types and delivery systems:
fire tube
water tube
operation and application of electronic and other control systems
boiler water treatment system and reasons for treatment
purpose of, and processes for analysing stored boiler water and chemicals
key features and purpose of equipment required to shut down and store a steam boiler
types, causes and effects of, and required emergency and other responses to, unplanned boiler shutdowns:
power outage
mechanical breakdown
blockages
jamming
air supply
control system failure
methods used to:
test boiler operations and diagnose faults
clean boilers internally and externally
safely handle and store boiler house chemicals
organisational procedures:
standard operating procedures specific to boiler shutdown
workplace health and safety with particular emphasis on equipment lock out, use of personal protective equipment and handling hazardous substances
communication reporting lines
recording and reporting shutdown processes and maintenance requirements.
Assessment Conditions
The following resources must be made available:
a boiler which can be fire or water tube type
fully automated, semi-automated, manually operated plant and equipment required for shutting down boiler operation in a pulp or paper manufacturing facility
testing equipment for boiler water and chemicals
maintenance tools and equipment and consumables for boilers
personal protective equipment suitable for maintaining and shutting down a boiler
relevant personnel for the purposes of communicating information
template documents for recording shutdown processes and maintenance requirements
organisational workplace health and safety and standard operating procedures for boiler shutdown.
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 basic numerical settings on instruments and gauges involving pressures, flows and temperatures. |
Reading skills to: | interpret detailed familiar workplace health and safety and standard operating procedures. |
Writing skills to: | complete accurate basic records for shutdown processes and maintenance requirements. |
Problem solving skills to: | use and assess sensory information (sight, sound, touch, smell, vibration, temperature) to respond to boiler faults. |
Range Statement
Not Applicable
Sectors
Pulp and Paper Manufacturing