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Evidence Guide: FPPSTM4A - 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

 

FPPSTM4A - 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.

  1. Plant assessments and system alarm systems are interpreted to determine fault type and location.
  2. Routine physical inspections of plant and processes are made to identify faults.
  3. Cause and source of problem is identified and located.
  4. Faulty plant is isolated, if possible, and confirmed with production and maintenance.
  5. Relevant historical data is accessed/referred to, to confirm diagnosis.
  6. Diagnoses are communicated to relevant personnel.
  7. Work is completed within OH&S, Standard Operating Procedures (SOP), environmental and safe working requirements and practices.
Plant assessments and system alarm systems are interpreted to determine fault type and location.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Routine physical inspections of plant and processes are made to identify faults.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cause and source of problem is identified and located.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Relevant historical data is accessed/referred to, to confirm diagnosis.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnoses are communicated to relevant personnel.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Work is completed within OH&S, Standard Operating Procedures (SOP), environmental and safe working requirements and practices.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify systems/plant equipment faults.

  1. Emergency stop/shutdown, isolation and lock-out procedures are initiated prior to fault rectification.
  2. Faulty equipment/instrumentation is isolated and caused to be repaired/replaced.
  3. Fine tuning adjustments to process and systems are made to return to specifications.
  4. Restoration of machine/system to normal operation is verified and communicated to relevant personnel.
  5. Work is completed within OH&S, SOP, environmental and safe working requirements and practices.
Emergency stop/shutdown, isolation and lock-out procedures are initiated prior to fault rectification.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Faulty equipment/instrumentation is isolated and caused to be repaired/replaced.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Fine tuning adjustments to process and systems are made to return to specifications.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Restoration of machine/system to normal operation is verified and communicated to relevant personnel.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Work is completed within OH&S, SOP, environmental and safe working requirements and practices.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify product quality and distribution faults.

  1. Product quality faults/variations are identified by observation, systematic sampling and testing.
  2. Samples for a range of tests are taken according to established enterprise procedures and SOP.
  3. Test results are interpreted and operations are adjusted to correct variations from specification.
  4. Out of specification product is dealt with according to SOP.
  5. Work is completed within OH&S, SOP, environmental and safe working requirements and practices.
Product quality faults/variations are identified by observation, systematic sampling and testing.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Samples for a range of tests are taken according to established enterprise procedures and SOP.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test results are interpreted and operations are adjusted to correct variations from specification.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Out of specification product is dealt with according to SOP.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Work is completed within OH&S, SOP, environmental and safe working requirements and practices.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Record and report operational data.

  1. Variations from standard specification and machine operation faults are documented/logged.
  2. Indications of performance variance are entered into log.
  3. Assessment and evaluation of causes of variations and corrective action undertaken is recorded as required.
  4. Relevant information is communicated to appropriate personnel to prepare for modification to the plant output.
Variations from standard specification and machine operation faults are documented/logged.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Indications of performance variance are entered into log.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessment and evaluation of causes of variations and corrective action undertaken is recorded as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Relevant information is communicated to appropriate personnel to prepare for modification to the plant output.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Explains types, causes and effects of plant shutdowns.

Explains plant start-up and shutdown procedures.

Describe plant operation and control mechanisms.

Outlines impact and effect of inappropriate responses to shut.

Explains causes and effects of system faults and rectification requirements.

Implements troubleshooting guides and diagnostic procedures.

Diagnoses production and quality faults, effects and causes.

Gathers, analyses and interprets data.

Conducts routine checking procedures during plant/systems operation.

Explains types and purpose of tests.

Sets up and operates test equipment.

Explains sampling and testing procedures.

Interprets test results.

Logs and records data.

Demonstrates keyboarding and computer access skills.

Uses effective communication.

Explains boiler water treatment system and reasons for treatment.

Explains statutory responsibilities.

Identifies causes of shutdown and responds appropriately.

Initiates isolations and lock-outs in compliance with SOP.

Identifies, locates and rectifies or causes to be rectified operational and quality faults.

Confirms and maintains required production throughput after restart.

Maintains plant operation within specification.

Communicates with appropriate personnel.

Works within OH&S, SOP, environment and safe working requirements and practices.

Electrical Power Generation

FPPEPG1A: Manage a power generation system start-up.

FPPEPG2A: Monitor and control power generation system.

FPPEPG3A: Co-ordinate power generation system shutdown.

FPPEPG4A: Conduct a technical inspection of power generation plant and equipment.

FPPEPG5A: A Troubleshoot and rectify power generation system.

Please note:

A single Range Statement has been prepared to cover all Units in Electrical Power Generation. The actual context/conditions for each Unit would be drawn from the mill's customised version of this Range Statement.

The competencies in this unit refer to those related to the management and operation of power generation and includes steam turbine driven alternators, auxiliary plant, electricity generation, regulation and distribution systems used in the pulp and paper making industry.

Materials/supplies:

water

steam

electricity

gas

Equipment:

Equipment appropriate to power generation processes, and may include the following:

boilers

high and low voltage transformers

steam/gas turbines

and switchboards

water systems and auxiliary plant

circuit breakers

AC/DC generation and distribution systems

protective equipment

measuring/recording equipment

Legislation, policy and procedures:

OH&S

appropriate endorsed operator

environmental and statutory legislation

licences

enterprise policies and procedures

local power authority policies and procedures

Standard Operating Procedures (SOP)

Documentation/procedures/reports:

operational logs/reports

maintenance logs

SOP documentation

Materials Safety Data Sheets (MSDS)

Process and instrument diagrams

Maintenance:

as per site agreement

maintenance schedules

maintenance systems

Sampling/testing:

plant/system operations and process steam supply monitoring

as per site agreements

Technology:

full and semi automated plant and equipment

manually operated plant and equipment

controlled systems - PLC or DCS

electronic measuring and monitoring equipment

Communication channels:

internal/external suppliers and customers

maintenance services

team members

product/services co-ordinator

Explains types, causes and effects of plant shutdowns.

Explains plant start-up and shutdown procedures.

Describe plant operation and control mechanisms.

Outlines impact and effect of inappropriate responses to shut.

Explains causes and effects of system faults and rectification requirements.

Implements troubleshooting guides and diagnostic procedures.

Diagnoses production and quality faults, effects and causes.

Gathers, analyses and interprets data.

Conducts routine checking procedures during plant/systems operation.

Explains types and purpose of tests.

Sets up and operates test equipment.

Explains sampling and testing procedures.

Interprets test results.

Logs and records data.

Demonstrates keyboarding and computer access skills.

Uses effective communication.

Explains boiler water treatment system and reasons for treatment.

Explains statutory responsibilities.

Identifies causes of shutdown and responds appropriately.

Initiates isolations and lock-outs in compliance with SOP.

Identifies, locates and rectifies or causes to be rectified operational and quality faults.

Confirms and maintains required production throughput after restart.

Maintains plant operation within specification.

Communicates with appropriate personnel.

Works within OH&S, SOP, environment and safe working requirements and practices.

Electrical Power Generation

FPPEPG1A: Manage a power generation system start-up.

FPPEPG2A: Monitor and control power generation system.

FPPEPG3A: Co-ordinate power generation system shutdown.

FPPEPG4A: Conduct a technical inspection of power generation plant and equipment.

FPPEPG5A: A Troubleshoot and rectify power generation system.

Please note:

A single Range Statement has been prepared to cover all Units in Electrical Power Generation. The actual context/conditions for each Unit would be drawn from the mill's customised version of this Range Statement.

The competencies in this unit refer to those related to the management and operation of power generation and includes steam turbine driven alternators, auxiliary plant, electricity generation, regulation and distribution systems used in the pulp and paper making industry.

Materials/supplies:

water

steam

electricity

gas

Equipment:

Equipment appropriate to power generation processes, and may include the following:

boilers

high and low voltage transformers

steam/gas turbines

and switchboards

water systems and auxiliary plant

circuit breakers

AC/DC generation and distribution systems

protective equipment

measuring/recording equipment

Legislation, policy and procedures:

OH&S

appropriate endorsed operator

environmental and statutory legislation

licences

enterprise policies and procedures

local power authority policies and procedures

Standard Operating Procedures (SOP)

Documentation/procedures/reports:

operational logs/reports

maintenance logs

SOP documentation

Materials Safety Data Sheets (MSDS)

Process and instrument diagrams

Maintenance:

as per site agreement

maintenance schedules

maintenance systems

Sampling/testing:

plant/system operations and process steam supply monitoring

as per site agreements

Technology:

full and semi automated plant and equipment

manually operated plant and equipment

controlled systems - PLC or DCS

electronic measuring and monitoring equipment

Communication channels:

internal/external suppliers and customers

maintenance services

team members

product/services co-ordinator

Required Skills and Knowledge

Not applicable.

Range Statement

The competencies described in this group of units relate to those functions inclusive of the following boiler types:

Please note:

A single Range Statement has been prepared to cover all Units in Steam Generation. The actual context/conditions for each Unit would be drawn from the mill's customised version of this Range Statement.

. fire tube

. saturated boiler

. water tube

. super heated

and may be operated in conjunction with other steam driven plant and operations including:

. paper making machines

. turbines

. digesters

. heating plant

Materials/supplies:

. chemicals

. coal

. oil

. gas

. additives

. air

. water

. wood waste

. steam

. recovery process products

. power

Equipment:

Equipment appropriate to steam generation processes and may include the following:

. boiler and auxiliary plant

. boiler heating systems

. 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

. flare detection equipment

. hand and power tools

Legislation, policy and procedures:

. OH&S

. environmental and statutory legislation

. enterprise policies and procedures

. Standard Operating Procedures (SOP)

. appropriate boiler/pressure vessel operator certification

Documentation/procedures/reports:

. SOP

. job sheets

. grade specifications

. manufacturer's specifications

. maintenance logs

. statutory requirements

. Materials Safety Data Sheets (MSDS)

. operator's log

. process and instrument diagrams

Maintenance:

. as per site agreement

. maintenance schedules

. maintenance systems

Sampling/testing: [excludes FPPSTM3A]

. feed water quality

. assessments of process operations

Technology:

. fully automated, semi automated, manually operated plant and equipment

. enter/extract computer data, electronic screens and alarms, analogue and digital instrumentation

Communication channels:

. internal/external customers and suppliers

. statutory authorities

. team members

. maintenance/services co-ordinators

. maintenance services

The competencies described in this group of units relate to those functions inclusive of the following boiler types:

Please note:

A single Range Statement has been prepared to cover all Units in Steam Generation. The actual context/conditions for each Unit would be drawn from the mill's customised version of this Range Statement.

. fire tube

. saturated boiler

. water tube

. super heated

and may be operated in conjunction with other steam driven plant and operations including:

. paper making machines

. turbines

. digesters

. heating plant

Materials/supplies:

. chemicals

. coal

. oil

. gas

. additives

. air

. water

. wood waste

. steam

. recovery process products

. power

Equipment:

Equipment appropriate to steam generation processes and may include the following:

. boiler and auxiliary plant

. boiler heating systems

. 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

. flare detection equipment

. hand and power tools

Legislation, policy and procedures:

. OH&S

. environmental and statutory legislation

. enterprise policies and procedures

. Standard Operating Procedures (SOP)

. appropriate boiler/pressure vessel operator certification

Documentation/procedures/reports:

. SOP

. job sheets

. grade specifications

. manufacturer's specifications

. maintenance logs

. statutory requirements

. Materials Safety Data Sheets (MSDS)

. operator's log

. process and instrument diagrams

Maintenance:

. as per site agreement

. maintenance schedules

. maintenance systems

Sampling/testing: [excludes FPPSTM3A]

. feed water quality

. assessments of process operations

Technology:

. fully automated, semi automated, manually operated plant and equipment

. enter/extract computer data, electronic screens and alarms, analogue and digital instrumentation

Communication channels:

. internal/external customers and suppliers

. statutory authorities

. team members

. maintenance/services co-ordinators

. maintenance services