Application
This unit is appropriate for those working in an operational role at worksites within:
Metalliferous mining
Prerequisites
Not applicable.
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Prepare for plant and equipment operation | 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 communication with other personnel using approved communication methods 1.4. Select personal protective equipment appropriate for work activities 1.5. Select appropriate auxiliary equipment for work activities 1.6. Carry out equipment pre-start checks to ensure equipment is ready for operation 1.7. Identify, address and report potential risks and hazards 1.8. Identify, address and report environmental issues 1.9. Follow emergency procedures to ensure safety of personnel and plant 1.10. Use approved dust suppression and extraction methods 1.11. Ventilate work area before entry |
2. Maintain efficient operation of furnace gas plant and systems | 2.1. Carry out plant and equipment start-up checks and procedures according to plant/equipment configurations and system requirements 2.2. Carry out monitoring and control on DCS 2.3. Operate and maintain air operated breathing equipment for furnace off-line entry |
3. Control furnace gas emissions | 3.1. Carry out plant and equipment start-up checks and procedures according to plant/equipment configurations and system requirements 3.2. Monitor and operate accretion build-up removal equipment to ensure efficient operation of air injection equipment 3.3. Monitor furnace feed chutes for blockages and maintain to ensure optimum production 3.4. Take samples of molten metal to confirm molten metal quantity and condition of molten metal bath |
4. Maintain efficient operation of furnace air injection equipment | 4.1. Carry out plant and equipment start-up checks and procedures according to plant/equipment configuration and system requirements 4.2. Monitor furnace conditions and operations to identify the correct, efficient operation of the furnace air injection equipment, and report to Control Room Operator 4.3. Identify furnace inefficiencies and furnace air injection equipment and change/replace where necessary, ensuring minimum furnace down-time 4.4. Clean furnace air injection equipment/device without causing damage 4.5. Check and record furnace air injection equipment/device position, and recalibrates where outside operating parameters |
5. Ensure supply of additives | 5.1. Monitor and maintain condition of furnace feed materials 5.2. Monitor furnace additives supply and report to Control Room Operator for action |
6. Maintain plant and equipment efficiency | 6.1. Clean plant to maintain condition of all equipment to ensure safe and efficient operations 6.2. Identify and report hazards to maintain a safe working environment 6.3. Interpret and respond to plant alarms, take remedial actions and notify appropriate personnel 6.4. Check and adjust plant condition to maintain efficient operation 6.5. Install and control stand-by furnace burner equipment to maintain safe furnace refractory temperatures 6.6. Inspect air, gas, diesel and combustion supply equipment and replace/report faults, damaged or inoperable equipment to appropriate personnel 6.7. Carry out minor plant maintenance and lubrication tasks 6.8. Provide support for maintenance personnel where necessary to organisation's requirements |
7. Shutdown plant and equipment | 7.1. Shutdown or isolate plant/equipment based on process and safety requirements 7.2. Perform post shutdown or isolation checks 7.3. Pass on shift changeover details to oncoming shift |
Required Skills
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 monitor and maintain furnace gas efficiency: apply legislative, organisation and site requirements and procedures for monitoring and maintaining furnace gas efficiency troubleshoot 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 monitor and maintain furnace gas efficiency: principles of furnace operation/ furnace components gas paths insulation (refractory) combustion principles importance of flame patterns/flame impingement methods of resolving combustion/gas problems ability to isolate problem to item of equipment |
Evidence Required
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 monitor and maintain furnace gas efficiency implementation of requirements, procedures and techniques for the safe, effective and efficient completion of monitor and maintain furnace gas efficiency working with others to undertake and complete the monitoring and maintenance of furnace gas efficiency in a way that meets all of the required outcomes consistent timely completion of monitoring and maintenance of furnace gas efficiency 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 monitoring and maintenance of furnace gas efficiency |
Guidance information for assessment | Consult the SkillsDMC User Guide for further information on assessment including access and equity issues. |
Range Statement
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 |
Auxiliary equipment may be anything that is portable and mobile that is not part of the fixed infrastructure, and may include: | weighers compressors distribution control systems feeders gantry cranes and attachments and other mobile equipment hand and power tools hoses (water and air) pumps |
Pre-start checks may include: | availability of equipment detection of conditions that are unusual job requirements personnel availability walk through plant communications |
Environmental issues may include: | drainage dust (dump) emissions flora and fauna hazardous chemicals noise recycling run-off spills waste management and disposal water quality |
Start-up checks may include: | draft systems cameras and monitors checking distribution control system (DCS) chutes display instruments, lights and gauges equipment stop engine lights hydraulic system isolations lighting suppression systems/valves visual and audio warning devices and lights |
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 indicators including" alarms distribution control systems mimic panel screens temperature flow weight pressure |
Furnaces may be: | fixed - vertical/cylindrical rotary - vertical/cylindrical |
Equipment and plant cleaning methods may include: | degreasing forced air sweeping |
Plant condition may include: | air ingress to furnace fuel flow too low or too high, surging discharge of flue dust molten metal splashes moisture levels incorrect |
Burners may be: | diesel natural gas |
Minor plant maintenance may include: | lubrication minor adjustments to operational plant cleaning plant, equipment and work area installation/removal of devices to allow safe maintenance fixing leaks |
Sectors
Smelting
Competency Field
Refer to Unit Sector(s).
Co-Requisites
Not applicable.
Employability Skills
This unit contains employability skills.
Licensing Information
Refer to Unit Descriptor.