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Evidence Guide: FDFSUG216A - Operate a crystalliser station process

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

FDFSUG216A - Operate a crystalliser station process

What evidence can you provide to prove your understanding of each of the following citeria?

Prepare the crystalliser station for operation

  1. Massecuite is confirmed and available to meet production requirements
  2. Services are confirmed as available and ready for operation
  3. Equipment is checked to confirm readiness for use
  4. The crystallisers are set up to meet production requirements
Massecuite is confirmed and available to meet production requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Services are confirmed as available and ready for operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Equipment is checked to confirm readiness for use

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The crystallisers are set up to meet production requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate and monitor crystalliser station

  1. The crystallisation station is started up and operated according to company procedures
  2. Control points are monitored to confirm performance is maintained within specification
  3. C massecuite feed to fugals meets specification
  4. Equipment is monitored to confirm operating condition
  5. Out-of-specification process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure
  6. The workplace meets housekeeping standards
The crystallisation station is started up and operated according to company procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control points are monitored to confirm performance is maintained within specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

C massecuite feed to fugals meets specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Equipment is monitored to confirm operating condition

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Out-of-specification process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The workplace meets housekeeping standards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Handover the crystalliser station

  1. Workplace records are maintained in accordance with workplace procedures
  2. Handover is carried out according to workplace procedure
  3. Crystalliser station operators are aware of system and related equipment status at completion of handover
Workplace records are maintained in accordance with workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Handover is carried out according to workplace procedure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Crystalliser station operators are aware of system and related equipment status at completion of handover

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down the crystalliser station

  1. The appropriate shut down procedure is identified
  2. The crystalliser station is shut down according to workplace procedures
  3. The crystalliser station is prepared for storage in shut down mode
  4. Maintenance requirements are identified and reported according to workplace reporting procedure
The appropriate shut down procedure is identified

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The crystalliser station is shut down according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The crystalliser station is prepared for storage in shut down mode

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintenance requirements are identified and reported according to workplace reporting procedure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed.

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

Evidence of ability to:

start up from empty or from full in manual and automatic modes

monitor the process and equipment operation

detect and report water leaks from crystalliser coils

demonstrate shift handover procedure

shut down equipment in response to an emergency situation

demonstrate an operational shut down procedure.

Context of and specific resources for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

Operating procedures and related advice on equipment operation including advice on safe work practices and environmental requirements

Personal protective clothing and equipment

Product and process specifications and operating parameters

Crystalliser station equipment

Materials including C massecuite and services as required

Material Safety Data Sheets where appropriate

Housekeeping standards and procedures

Advice on environmental management issues relevant to work responsibilities

Workplace information recording systems, requirements and procedures.

They may also require access to:

Cleaning procedures, sampling schedule and procedures and maintenance procedures and tools depending on the work requirements.

Method of assessment

Other units of competency relevant to the work role should be assessed in conjunction with this unit. This may include:

SUG202A Collect and prepare samples

SUG213A Perform standard tests on a cane sample

FDFOP2030A Operate a process control interface.

Guidance information for assessment

To ensure consistency in one's performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

Required Skills and Knowledge

Required skills include:

Ability to:

access workplace information to identify production requirements

select, fit and use personal protective clothing and/or equipment

confirm supply of necessary materials and services

confirm equipment status and condition

start up from empty and start up from full

maintain required levels in the crystallisers

follow cooling and reheating profiles

start up and operate in both automatic and manual modes

monitor the process and equipment operation to maintain the process within the required parameters including monitoring:

throughput

loads on crystalliser drives

sugar crystal size and distribution

massecuite conductivity

massecuite dilution rates

end of cooling and reheating temperatures

stocks of C massecuite to match pan stage throughput

equipment condition

detect and report water leaks from crystalliser coils

take corrective action in response to out-of-specification results

report and/or record corrective action as required

record workplace information

demonstrate shift handover procedure

shut down equipment in response to an emergency situation

demonstrate an operational shut down procedure

prepare equipment for cleaning/maintenance

maintain work area to meet housekeeping standards

Required knowledge includes:

Knowledge of:

purpose and basic principles of crystallisation including a basic understanding of crystal growth and super saturation of solutions

the effect of C molasses dilution on C massecuite viscosity

the effect on C molasses purity of variation in:

end of cooling and reheating temperatures

residence time

the effect of C massecuite conditioning on low grade fugal performance

the circuit flow of this process and relationship to related processes

equipment purpose and basic operating principles of crystallization equipment

the risks and consequences of pipe failure related to massecuite decomposition

services used

operating requirements and parameters

requirements when starting up full crystallisers containing cold massecuite

requirements when shutting down full crystallisers containing hot massecuite

significance and method of monitoring control points within the process

common causes of variation and corrective action required

hazards and controls

lock out and tag out procedures

shut down sequence including massecuite pumps and re-heaters

requirements of both operational and long term shut down conditions to ensure the equipment is left in a safe state for the period of the shutdown and to minimise any delays in future start up

procedures and responsibility for reporting problems

environmental issues and controls

waste handling requirements and procedures

recording requirements and procedures

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.

Policies and procedures

Work is carried out in accordance with company policies and procedures, licensing requirements, manufacturer's recommendations, legislative requirements, codes of practice and industrial awards and agreements.

Codes of practice

Codes of practice include the Sugar Milling Operations Industry Code of Practice.

Workplace information

Workplace information can include:

Standard Operating Procedures (SOPs)

manufacturer's specifications.

Crystalliser station

The crystalliser station may include:

low grade pan receiver

massecuite pumps

batch and continuous crystallisers

re-heater

molasses lubrication system

hot and cold water systems.

Equipment status

Confirming equipment status involves

conducting relevant pre-start checks

confirming that housekeeping standards are met

all safety guards are in place

equipment is operational.

It may also involve checking operation/calibration of measuring instrumentation.

Equipment operation and monitoring

Operation and monitoring of equipment and processes typically requires the use of control panels and systems.

Services

Services may include:

power

water

compressed and instrumentation air.

Tests

Where tests are conducted as part of operation a typical requirement is observation using a microscope.

Process monitoring

Monitoring the process may involve the use of production data such as performance control charts.

Control points

Control points refer to those key points in a work process which must be monitored and controlled.

Teamwork

Work may require the ability to work within a team environment.

Information systems

Information systems may be print or screen based.