ELEMENT

PERFORMANCE CRITERIA

1. Plan and prepare for furnace operations

1.1. Access, interpret and apply compliance documentation relevant to the work activity

1.2. Receive, interpret and clarify shift changeover details

1.3. Establish and maintain communications with other personnel using approved communication methods

1.4. Select personal protective equipment appropriate for work activities

1.5. Identify, address and report potential risks and hazards

1.6. Identify, address and report environmental issues

1.7. Check records and record outstanding maintenance inspections and identified defects

2. Start-up furnace

2.1. Complete computer systems and equipment pre-start checks

2.2. Start-up furnace according to operating procedures

2.3. Stabilise system to produce in-specification product at specified rates

3. Monitor and control the smelting process

3.1. Complete routine checks, log and paper work

3.2. Recognise the signs of potential and actual problems

3.3. Take action to minimise the impact on safety, health, the environment and business of potential and actual problems

3.4. Monitor and trim plant to achieve required rates and quality while maximising plant efficiency

3.5. Operate furnace according to operating requirements and procedures

4. Shutdown furnace

4.1. Determine type of shutdown required

4.2. Give warning of shutdown

4.3. Shutdown furnace system according to established operating procedures for type of shutdown

Required skills

Specific skills are required to achieve the Performance Criteria of this unit, particularly for its application in the various circumstances in which this unit may be used. This includes the ability to carry out the following, as required to operate furnaces:

apply legislative, organisation and site requirements and procedures for operating furnaces

operate computers

apply precautions necessary for safe working

use protective clothing and equipment

apply operating procedures

report faults

recognise limits of authority

apply team working practices

communicate information

use hand and power tools

Required knowledge

Specific knowledge is required to achieve the Performance Criteria of this unit, particularly for its application in the various circumstances in which this unit may be used. This includes knowledge of the following, as required to operate furnaces:

principles of operation

furnace components:

insulation (refractory)

physics of operation

chemistry of operation

importance of flame patterns/flame impingement

methods of resolving problem

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to worksite operations and satisfy all of the requirements of the performance criteria, required skills and knowledge and the range statement of this unit and include evidence of the following:

knowledge of the requirements, procedures and instructions for operating furnaces

implementation of requirements, procedures and techniques for the safe, effective and efficient completion of furnace operations

working with others to undertake and complete the furnace operations in a way that meets all of the required outcomes

consistent timely completion of furnace operations that safely, effectively and efficiently meets the required outcomes

Context of and specific resources for assessment

This unit must be assessed in the context of the work environment. Where personal safety or environmental damage are limiting factors, assessment may occur in a simulated environment provided it is realistic and sufficiently rigorous to cover all aspects of workplace performance, including task skills, task management skills, contingency management skills and job role environment skills.

Assessment of this competency requires typical resources normally used in a resources and infrastructure sector environment. Selection and use of resources for particular worksites may differ due to the site circumstances.

The assessment environment should not disadvantage the participant. For example, language, literacy and numeracy demands of assessment should not be greater than those required on the job.

Customisation of assessment and delivery environment to sensitively accommodate cultural diversity.

Aboriginal people and other people from a non English speaking background may have second language issues.

Where applicable, physical resources should include equipment modified for people with disabilities. Access must be provided to appropriate learning and/or assessment support when required.

Method of assessment

This unit may be assessed in a holistic way with other units of competency. The assessment strategy for this unit must verify required knowledge and skill and practical application using more than one of the following assessment methods:

written and/or oral assessment of the candidate's required knowledge

observed, documented and/or first hand testimonial evidence of the candidate's:

implementation of appropriate requirement, procedures and techniques for the safe, effective and efficient achievement of required outcomes

consistent achievement of required outcomes

first hand testimonial evidence of the candidate's:

working with others to undertake and complete the furnace operations

Guidance information for assessment

Consult the SkillsDMC User Guide for further information on assessment including access and equity issues.

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Relevant compliance documentation may include:

legislative, organisational and site requirements and procedures

manufacturer's guidelines and specifications

Australian standards

Employment and workplace relations legislation

Equal Employment Opportunity and Disability Discrimination legislation

Legislation may include Acts and regulations dealing with:

mining safety and health

mine inspection

OHS

explosives

environment

Site environmental issues may include:

drainage

dust and fumes

emissions

hazardous chemicals

noise

run-off

spills

waste management and disposal

water quality

Equipment pre-start checks may include:

availability of equipment

detection of conditions that are unusual

job requirements

personnel availability

levels

pressures

flows

vibration

communications

agitators

cameras and monitoring

interlocks

distribution control system

launders

hydraulic systems

pumps and pumping systems

screen, pipe, valve

valves

visual and audible warning devices and lights

suppression systems

motors

availability of oxygen and blower and plant air

cooling water supply

fans and draft systems

Furnaces may include:

thermal cracking furnaces

catalytic cracking furnaces

cabin type

cylindrical or vertical

fixed - vertical/cylindrical (horizontal)

rotary - vertical/cylindrical (horizontal)

Furnace equipment may include:

pumps

valves

utilities and services

heat exchangers and/or scrubbers

Furnace problems may include:

temperature too high or low during smelting

gas, oil, oxygen, coal and air flow too low during smelting

shell leaks

fuel flow too low or high, surging

level in furnace too high or low

metal splashes

feed not to specifications

emissions not to standard

metallurgy not to standard

Monitoring may include:

blockages and spillages

feed rates

overloads

pressures

power draw

wear and tear

emissions

levels

temperatures

moisture content

on-stream analysis (OSA)

filtering

corrosion

Type of shutdown may include:

planned - maintenance; scheduled

unplanned - services failure; break-out; environmental

Combustion components may be:

diesel

natural gas

oxygen

oil

blower air

Equipment indicator readings may include:

current

flow

levels

pressure

weight

speed

unusual noises

vibrations