Application
This unit of competency describes the outcomes required to check, monitor, operate and shutdown water systems, in a pulp or paper manufacturing facility.
The unit applies to production operators and technicians who start up monitor and operate water systems. 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. Conduct local inspections and pre-operational safety checks | 1.1. Check plant and equipment in accordance with productivity requirements, workplace health and safety (WHS) requirements, environmental sustainability and safe working requirements and practices, Standard Operating Procedures (SOP), and housekeeping requirements. 1.2. Remove isolations. 1.3. Confirm availability of materials and supplies for water system. 1.4. Determine plant status and requirements. 1.5. Confirm sequencing for plant start up. |
2. Start up water systems | 2.1. Start up water system according to Standard Operating Procedures (SOP). 2.2. Observe the water system for correct startup operational response. 2.3. Detect startup variation conditions and take corrective action. |
3. Monitor and control water systems | 3.1. Monitor the operation of the water system through routine checks. 3.2. Take water samples and test to maintain quality, as required. 3.3. Identify variations from operational parameters. 3.4. Restore water system to standard operational parameters. 3.5. Conduct operator level maintenance, as required. |
4. Conduct a water system shutdown | 4.1. Confirm shutdown plan and communicate to relevant personnel. 4.2. Implement shutdown procedures. 4.3. Leave plant in a safe condition for isolation, as required. |
5. Respond to an unplanned shutdown | 5.1. Identify the cause of shutdown and action as required. 5.2. Complete sequence for shutdown of systems, in the plant. 5.3. Communicate action taken to relevant personnel. 5.4. Leave plant in a safe condition for isolation, as required. |
6. Record and report water systems information | 6.1. Record water systems information, as required. 6.2. Record problems and related action and communicate 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:
inspect, start up and monitor water systems, at least twice in line with required enterprise intervals, and conduct required testing and sampling to maintain optimum production capacity
follow safe working practices when operating water systems
respond to planned and unplanned shutdowns with water systems
use electronic and other control systems to control equipment during operations
communicate effectively, through written and verbal means, with others, in the work area when operating water systems.
Evidence of Knowledge
A person competent in this unit must be able to demonstrate knowledge of:
workplace documentation and procedures relevant to water systems, in the pulp and paper industry and covering:
work health and safety (WHS) procedures including activity or task specific high risk load, shifting and small boat licensing requirements, plant clearance, job safety analysis and permit systems
Standard Operating Procedures (SOP) and housekeeping procedures for plant manufacturing, including confined space requirements
production instructions including maintenance logs, job sheets and operating logs
quality procedures and environmental sustainability requirements and practices
oil or chemical spills and disposal guidelines
water and chemical regulations
emergency procedures and responses
plant isolation documentation
process for plant shutdowns and unplanned shutdowns
Material Safety Data Sheets (MSDS)
impact of different types of water sources including raw, mains or recycled water on water systems
appropriateness of sampling and testing checks for sludge consistency, pH, conductivity, flocculation, colour, suspended solids, caustic strength, alkalinity, impurities, brine, bacteria, colour and acid strength
operating parameters, variation and associated adjustments for water system, plant, processes, layout and associated services, sufficient to carry out startup and shutdown activities
required responses to all unplanned shutdowns, including power outage, mechanical breakdown, blockages, jamming, air supply and control system failure, to ensure safety quality and productivity
purpose, standards and procedures as per site agreements for sampling and testing process for plant and system operations, and process monitoring
implications of the use of water types including fresh water, treated water, de-mineralised water, softened water, filtrate-clarified water, potable water, dilution water (filtrate) ex-vacuum system waste water (effluent), white water (ex-machine) and cloudy water , on water systems
how to identify and respond to hazards and risks of water systems including:
confined space
hazardous chemicals and materials
biological hazards and environmental hazards
heat, height and slippery surfaces
pressures, fumes and electrical equipment
compressed air, nip points and flooding
key features of maintenance systems including operator level maintenance as per site agreements, operator maintenance schedules, maintenance suppliers and pro-active maintenance strategies
use of equipment and electronic and other control systems, operation and application to make appropriate adjustments that control the water system within level of responsibility.
productivity requirements including energy efficiency, waste minimization, evaporation minimisation, including landfill and waste water reduction , consideration of resource utilisation, including fibre efficiency, minimising delays, chemical recovery maximization, line speed, and handovers
water systems including de-alkalinisation plant, de-mineralisation plant, water softening plant, chemical treatment plant, reverse osmosis plant, clarifier plant chillers, water storage systems, filtration systems, cooling towers, condensers and potable water plant
materials and supplies including chemicals and filtering mediums.
Assessment Conditions
The following resources must be made available:
access to the full range of equipment required to operate water systems in a pulp or paper manufacturing facility
test and diagnostic equipment
personal protective equipment required for operating water systems
relevant personnel for the purposes of communicating information
template operating log and documents for recording operation of the water system and maintenance requirements
organisational workplace health and safety and standard operating procedures.
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. |
Writing skills to: | record log sheet entries, incident reports and system faults access, navigate and enter computer based information for operation of water systems. |
Oral communication skills to: | select and use appropriate spoken communication strategies with work teams and other personnel on site, when operating water systems. |
Reading skills to: | read and interpret documentation, procedures and reports. |
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 |
Range Statement
Not Applicable
Sectors
Pulp and Paper Manufacturing