NTISthis.com

Evidence Guide: PMAOPS323 - Operate and monitor heating furnace

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

 

PMAOPS323 - Operate and monitor heating furnace

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

Prepare for work

  1. Receive and give shift handover
  2. Identify work requirements
  3. Identify and control hazards
  4. Coordinate with appropriate personnel
  5. Check for recent work undertaken on furnace
  6. Note any outstanding/incomplete work
  7. Check operational status of furnace
Receive and give shift handover

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify work requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and control hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coordinate with appropriate personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check for recent work undertaken on furnace

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Note any outstanding/incomplete work

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check operational status of furnace

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up furnace

  1. Perform pre-start-up checks
  2. Start up individual items of equipment and the entire furnace system
  3. Start up from standby and after maintenance
  4. Increase temperature steadily with no surges or lulls
  5. Stabilise furnace to produce required heat within required time
Perform pre-start-up checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up individual items of equipment and the entire furnace system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up from standby and after maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Increase temperature steadily with no surges or lulls

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Stabilise furnace to produce required heat within required time

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and control the heating furnace

  1. Complete routine checks, logs and paperwork
  2. Recognise the signs of potential and actual problems
  3. Take action to minimise the impact of potential and actual problems
  4. Monitor condition of heat transfer components (if any) and take action required by procedures
  5. Monitor fuel/air supplies and ratios and take action in accordance with procedures
  6. Trim furnace in accordance with procedures
Complete routine checks, logs and paperwork

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recognise the signs of potential and actual problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take action to minimise the impact of potential and actual problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor condition of heat transfer components (if any) and take action required by procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor fuel/air supplies and ratios and take action in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Trim furnace in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change heating rates

  1. Predict from rates and schedule when a transition will be required
  2. Give advanced notice of transition to work team
  3. Trim plant in a manner which prepares it for the change
  4. Manage changes smoothly and in a timely manner
Predict from rates and schedule when a transition will be required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Give advanced notice of transition to work team

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Trim plant in a manner which prepares it for the change

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Manage changes smoothly and in a timely manner

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain furnace effectiveness

  1. Monitor furnace and its component plant items frequently and critically throughout shift using measured/indicated data and senses
  2. Describe impacts of any changes upstream and downstream
  3. Recognise actual and developing situations which may require action
  4. Apply operational knowledge to resolve problems
  5. Take other appropriate actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation
  6. Follow through items initiated until final resolution has occurred
Monitor furnace and its component plant items frequently and critically throughout shift using measured/indicated data and senses

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Describe impacts of any changes upstream and downstream

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recognise actual and developing situations which may require action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply operational knowledge to resolve problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take other appropriate actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow through items initiated until final resolution has occurred

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down furnace

  1. Determine type of shutdown required
  2. Give advance warning of shutdown where possible
  3. Changeover individual items of equipment
  4. Shut down individual items of equipment and the entire furnace system
  5. Shut down to a stand-by condition, if required
  6. Shut down in an emergency, when required.
Determine type of shutdown required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Give advance warning of shutdown where possible

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Changeover individual items of equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down individual items of equipment and the entire furnace system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down to a stand-by condition, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down in an emergency, when required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Isolate and de-isolate furnace system and individual items

  1. Isolate furnace system and or any component plant item
  2. Make safe for required work
  3. Check furnace/plant item is ready to be returned to service
  4. De-isolate and prepare furnace/plant item for return to service
Isolate furnace system and or any component plant item

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make safe for required work

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check furnace/plant item is ready to be returned to service

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

De-isolate and prepare furnace/plant item for return to service

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare for work

1.1

Receive and give shift handover

1.2

Identify work requirements

1.3

Identify and control hazards

1.4

Coordinate with appropriate personnel

1.5

Check for recent work undertaken on furnace

1.6

Note any outstanding/incomplete work

1.7

Check operational status of furnace

2

Start up furnace

2.1

Perform pre-start-up checks

2.2

Start up individual items of equipment and the entire furnace system

2.3

Start up from standby and after maintenance

2.4

Increase temperature steadily with no surges or lulls

2.5

Stabilise furnace to produce required heat within required time

3

Monitor and control the heating furnace

3.1

Complete routine checks, logs and paperwork

3.2

Recognise the signs of potential and actual problems

3.3

Take action to minimise the impact of potential and actual problems

3.4

Monitor condition of heat transfer components (if any) and take action required by procedures

3.5

Monitor fuel/air supplies and ratios and take action in accordance with procedures

3.6

Trim furnace in accordance with procedures

4

Change heating rates

4.1

Predict from rates and schedule when a transition will be required

4.2

Give advanced notice of transition to work team

4.3

Trim plant in a manner which prepares it for the change

4.4

Manage changes smoothly and in a timely manner

5

Maintain furnace effectiveness

5.1

Monitor furnace and its component plant items frequently and critically throughout shift using measured/indicated data and senses

5.2

Describe impacts of any changes upstream and downstream

5.3

Recognise actual and developing situations which may require action

5.4

Apply operational knowledge to resolve problems

5.5

Take other appropriate actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation

5.6

Follow through items initiated until final resolution has occurred

6

Shut down furnace

6.1

Determine type of shutdown required

6.2

Give advance warning of shutdown where possible

6.3

Changeover individual items of equipment

6.4

Shut down individual items of equipment and the entire furnace system

6.5

Shut down to a stand-by condition, if required

6.6

Shut down in an emergency, when required.

7

Isolate and de-isolate furnace system and individual items

7.1

Isolate furnace system and or any component plant item

7.2

Make safe for required work

7.3

Check furnace/plant item is ready to be returned to service

7.4

De-isolate and prepare furnace/plant item for return to service

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare for work

1.1

Receive and give shift handover

1.2

Identify work requirements

1.3

Identify and control hazards

1.4

Coordinate with appropriate personnel

1.5

Check for recent work undertaken on furnace

1.6

Note any outstanding/incomplete work

1.7

Check operational status of furnace

2

Start up furnace

2.1

Perform pre-start-up checks

2.2

Start up individual items of equipment and the entire furnace system

2.3

Start up from standby and after maintenance

2.4

Increase temperature steadily with no surges or lulls

2.5

Stabilise furnace to produce required heat within required time

3

Monitor and control the heating furnace

3.1

Complete routine checks, logs and paperwork

3.2

Recognise the signs of potential and actual problems

3.3

Take action to minimise the impact of potential and actual problems

3.4

Monitor condition of heat transfer components (if any) and take action required by procedures

3.5

Monitor fuel/air supplies and ratios and take action in accordance with procedures

3.6

Trim furnace in accordance with procedures

4

Change heating rates

4.1

Predict from rates and schedule when a transition will be required

4.2

Give advanced notice of transition to work team

4.3

Trim plant in a manner which prepares it for the change

4.4

Manage changes smoothly and in a timely manner

5

Maintain furnace effectiveness

5.1

Monitor furnace and its component plant items frequently and critically throughout shift using measured/indicated data and senses

5.2

Describe impacts of any changes upstream and downstream

5.3

Recognise actual and developing situations which may require action

5.4

Apply operational knowledge to resolve problems

5.5

Take other appropriate actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation

5.6

Follow through items initiated until final resolution has occurred

6

Shut down furnace

6.1

Determine type of shutdown required

6.2

Give advance warning of shutdown where possible

6.3

Changeover individual items of equipment

6.4

Shut down individual items of equipment and the entire furnace system

6.5

Shut down to a stand-by condition, if required

6.6

Shut down in an emergency, when required.

7

Isolate and de-isolate furnace system and individual items

7.1

Isolate furnace system and or any component plant item

7.2

Make safe for required work

7.3

Check furnace/plant item is ready to be returned to service

7.4

De-isolate and prepare furnace/plant item for return to service

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

undertake checks and observations and use data and own senses to monitor process and equipment and maximise performance

perform pre-start checks, start-up/shutdown procedures, isolations and de-isolations, and maintenance checks

predict impact of a change in one unit/area on other plant units/areas and take appropriate action

predict the need for process changes and prepare and manage smooth transitions

identify early warning signs of equipment/processes needing attention or with potential problems and take action

identify hazards and risks and apply risk control procedures.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the production unit and functions of each

principles of operation of plant/equipment

interactions between plant items/processes

systems’ operating parameters, integrity limits, product specifications and tolerances, temperature, pressure and flow

process-specific science (physics and chemistry) to the level of being able to interpret the science and extract factors controlling the process and product, including heating fluid (if any) properties

operational shutdown processes and procedures, including cooling down, furnace pressure/vacuum and fuel/heat source isolation

the processes for starting a furnace, including heat input, warm-up of the reticulation system, systems operation, reticulation line pressure, heating fluid usage and supply, and ancillary equipment

shutdown processes and procedures for internal inspection, including confirming furnace cooling down, vacuum/pressure, fuel/heat source isolation, and removal of combustion equipment and water from furnace

procedures for monitoring a furnace, including heating fluid reticulation line pressure/temperature, usage, supply and quality of heating fluid, combustion/heat source system, fuel system, combustion air supply, operation of control/safety devices, combustion management system, and ancillary equipment

function, purpose and location of ancillary equipment

various modes of furnace storage and reasons for selecting a particular mode

types and purpose of furnace fittings

function and troubleshooting of major components and their problems and problem resolution

hierarchy of control

hazards that may arise in the job/work environment, and:

their possible causes

potential consequences

appropriate risk controls.

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used, and include one or more of the following:

legislative requirements, including work health and safety (WHS)

industry codes of practice and guidelines

environmental regulations and guidelines

Australian and other standards

licence and certification requirements

All operations to which this unit applies are subject to stringent health, safety and environment (HSE) requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and HSE requirements, the HSE requirements take precedence.

Hazards

Hazards include one or more of the following:

electricity

gas

gases and liquids under pressure

structural hazards

structural collapse

equipment failures

industrial (machinery, equipment and product)

equipment or product mass

noise, rotational equipment or vibration

plant services (steam, condensate and cooling water)

working at heights, in restricted or confined spaces, or in environments subjected to heat, noise, dusts or vapours

flammability and explosivity

hazardous products and materials

unauthorised personnel

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

extreme weather

other hazards that might arise

Situations requiring action

Situations requiring action include one or more of the following:

fuel variations (rate and quality)

heating requirements change

coke, soot and scale build up

flame pattern

weather conditions

Non-routine problems

Non-routine problems are unexpected problems, or variations of previous problems and must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person

Operational knowledge includes one or more of the following:

procedures

training

technical information such as journals, engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

Start up/shut down

Start up/shut down includes the following:

start up and shut down to/from normal operating conditions

start up and shut down to/from isolated, cold or empty

start up and shut down to/from other conditions/situations experienced on the plant

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, include one or more of the following:

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant

Operate

Operate is to monitor, adjust/make change to the production unit and/or its component items to meet specifications, by one or both of the following:

manually in the plant

using local controller in the plant

This competency does not require the operation of a central control panel.

Product

Product includes anything produced by a process step and so includes:

intermediate products, such as the product from one process step, which then becomes the feed for another

Pre-operational checks

Pre-operational checks include one or more of the following:

heat exchange fluid feed supply

fuel supply/heat source

furnace valves - their operation and position

combustion air supply and combustion equipment

Ancillary equipment

Ancillary equipment includes one or more of the following:

economiser

economiser relief valves

air heater

feed heater

main heating fluid stop valve

feed pumps

fans

Monitor

Monitor includes one or more of the following systems and conditions:

heating fluid pressure and temperature

flame and combustion conditions

heating fluid feed and return systems

fuel system

combustion management system

heating fluid management system

heating fluid manifold fittings

soot blowers