Troubleshoot and rectify boiler plant systems Evidence Guide

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Evidence Guide: FPPSTM440A - Troubleshoot and rectify boiler plant systems

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

FPPSTM440A - Troubleshoot and rectify boiler plant systems

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

Identify and diagnose causes of faults

Causes of faults are identified and diagnosed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements
Abnormal plant conditions and system alarms are interpreted to determine fault type and location
Physical inspections of plant and processes are made to identify faults
Cause and source of fault is identified and located
Faulty plant is isolated, if possible, and confirmed with production and maintenance
Diagnosis is confirmed by access and reference to relevant historical data
Diagnoses are communicated to relevant personnel

Causes of faults are identified and diagnosed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

Completed
Date:

Teacher:

Evidence:

Abnormal plant conditions and system alarms are interpreted to determine fault type and location

Completed
Date:

Teacher:

Evidence:

Physical inspections of plant and processes are made to identify faults

Completed
Date:

Teacher:

Evidence:

Cause and source of fault is identified and located

Completed
Date:

Teacher:

Evidence:

Faulty plant is isolated, if possible, and confirmed with production and maintenance

Completed
Date:

Teacher:

Evidence:

Diagnosis is confirmed by access and reference to relevant historical data

Completed
Date:

Teacher:

Evidence:

Diagnoses are communicated to relevant personnel

Completed
Date:

Teacher:

Evidence:

Rectify faults

Faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
Shutdown and isolation procedures are implemented as required
Faulty equipment is repaired or replaced
Adjustments to process and systems are made to restore normal operations
Normal operation is communicated to relevant personnel

Faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
Date:

Teacher:

Evidence:

Shutdown and isolation procedures are implemented as required

Completed
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Evidence:

Faulty equipment is repaired or replaced

Completed
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Evidence:

Adjustments to process and systems are made to restore normal operations

Completed
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Evidence:

Normal operation is communicated to relevant personnel

Completed
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Evidence:

Record and report operational data

Operational data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
Variations from standard specification and boiler operation faults are documented
Troubleshooting process and corrective actions are recorded
Relevant information is communicated to appropriate personnel

Operational data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
Date:

Teacher:

Evidence:

Variations from standard specification and boiler operation faults are documented

Completed
Date:

Teacher:

Evidence:

Troubleshooting process and corrective actions are recorded

Completed
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Evidence:

Relevant information is communicated to appropriate personnel

Completed
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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
Critical aspects for assessment and evidence required to demonstrate competency in this unit	Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of: the required knowledge and skills tailored to the needs of the specific workplace applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements applicable aspects of the range statement practical workplace demonstration of skills in troubleshooting and rectifying boiler plant systems
Context of and specific resources for assessment	A workplace assessment must be used to assess: the application of required knowledge on the job the application of skills on the job, over time and under a range of typical conditions that may be experienced in steam generation operations Access to the full range of equipment involved in integrated continuous manufacturing of steam generation operations in a pulp or paper mill is required
Method of assessment	A combination of assessment methods should be used. The following examples are appropriate for this unit: observation of applied skills and knowledge on the job workplace demonstrations via a mock-up or simulation that replicate part/s of the job answers to written or verbal questions about specific skills and knowledge third-party reports from relevant and skilled personnel written evidence e.g. log sheet entries, checklist entries, test results Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job) A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package

Required Skills and Knowledge

This describes the skills and knowledge required for this unit.

Required skills

Identifies, accesses and interprets relevant historical and operational data and information

Uses required forms of communication in troubleshooting and rectifying boiler plant systems

Reads and interprets required documentation, procedures and reports within level of responsibility

Accesses, navigates and enters computer-based information

Interprets instruments, gauges and data recording equipment

Communicates effectively with personnel to assist with analysis and resolution of operational problems

Assists others to identify and resolve operational problems in the workplace

Identifies and actions systems, quality and equipment faults within level of responsibility

Identifies causes and effects of faults and corrective action on associated processes

Identifies and responds to causes of shutdowns

Determines quality faults, effects and causes

Selects and uses appropriate troubleshooting methods

Uses troubleshooting guides and processes

Takes timely corrective action to maximise safety, quality and productivity

Undertakes necessary calculations to aid troubleshooting as required

Identifies and monitors process control points

Maintains situational awareness in the work area

Perform tests and interpret and record results as required

Confirms and maintains required production throughput after restart

Initiates isolations in accordance with SOP

Conducts routine checking procedures during plant and systems operation

Maintains plant operation within specification

Uses measuring equipment as required

Operates high risk equipment as required

Analyses and uses sensory information to adjust process to maximise safety, quality and productivity

Uses electronic and other control systems to control equipment and processes as required

Required knowledge

Procedures, regulations and legislative requirements relevant to steam generation operations including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Detailed knowledge of steam generation system, processes and associated services sufficient to troubleshoot including:

plant layout

theory of operation

causes and effects of adjustments made to steam generation plant and processes

relationships between steam generation system, processes and associated services

An appropriate range of troubleshooting methods

Types, causes and effects of plant shutdowns

Impact and effect of inappropriate responses to shutdown

Plant startup and shutdown procedures

Plant operation and control mechanisms

Boiler water treatment system and reasons for treatment

Application of high risk equipment as required

Sensory information that indicates a deviation from standard operating parameters

Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control boiler plant operations, within level of responsibility

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.
Productivity requirements may include:	energy efficiency waste minimisation evaporation minimisation, including landfill and waste water reduction environmentally safe waste disposal consideration of resource utilisation, including fibre efficiency minimising delays chemical recovery maximisation meeting key performance indicators line speed handovers quality checks meeting output targets i.e. net tonnes per employee per annum machine/process time availability i.e. time the machine or process is making product machine/process production rate
Boiler types may include:	fire tube water tube and may be operated in conjunction with other steam driven plant and operations including: paper making machines turbines digesters evaporators heating plant
Pre-operational checks may include:	low water level alarm high water level alarm low water level alarm lockout hydrostatic test burner management system safety valve test
Materials and supplies may include:	chemicals coal oil gas additives air water wood waste steam recovery process products power
Equipment may include:	boiler and auxiliary plant boiler heating systems steam distribution system fuel and fuel delivery system plant dust removal and combustion waste fuel management system extraction systems water distribution systems compressed air systems steam temperature control plant chemical dosing system water treatment system flame detection equipment hand and power tools computer systems electronic screens and alarms process control systems analogue and digital instrumentation fully automated, semi-automated, manually operated plant and equipment appropriate to steam generation operations
Electronic control systems may include:	Digital Control System (DCS) touch screens robotics
Legislation, regulatory, licensing and certification requirements may include:	OHS and environmental requirements (local, state and commonwealth) activity or task specific high risk licensing requirements appropriate boiler/pressure vessel operator certification confined space standards and regulations
Documentation, procedures and reports may include:	SOP quality procedures environmental sustainability requirements/practices plant manufacturing operating manuals oil or chemical spills and disposal guidelines plant isolation documentation safe work documentation e.g. plant clearance, job safety analysis, permit systems enterprise policies and procedures job sheets manufacturer's specifications maintenance documentation statutory requirements Materials Safety Data Sheets (MSDS) operator's log process and instrument diagrams
Maintenance may include:	operator level maintenance as per site agreements operator maintenance schedules maintenance systems maintenance suppliers proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)
Actions may include:	process adjustments reporting to authorised person rectifying problem within level of responsibility
Communications may include	interaction with: internal/external customers and suppliers team members production/service coordinators maintenance services operational management statutory authorities
Situational awareness may include	awareness of: traffic pedestrians location of equipment product hazards obstruction unexpected movement
Forms of communication may include:	written e.g. log books, emails, incident and other reports, run sheets, data entry reading and interpreting documentation e.g. SOP, manuals, checklists, drawings verbal e.g. radio skills, telephone, face to face, handover non-verbal e.g. hand signals, alarms, observations signage e.g. safety, access
Sensory information may include:	visual sound feel touch smell vibration temperature

NTISthis.com

Evidence Guide: FPPSTM440A - Troubleshoot and rectify boiler plant systems

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

FPPSTM440A - Troubleshoot and rectify boiler plant systems

Identify and diagnose causes of faults

Rectify faults

Record and report operational data

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

Instructions to Assessors

Teacher: ___________________________ Date: _