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Evidence Guide: PMAOPS323A - 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

 

PMAOPS323A - Operate and monitor heating furnace

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

Prepare for work.

  1. Identify work requirements
  2. Identify and control hazards
  3. Coordinate with appropriate personnel
Identify work requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and control hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coordinate with appropriate personnel

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 appropriate action to minimise the impact of potential and actual problems
  4. Monitor condition of heat transfer components (if any) and take appropriate action
  5. Monitor fuel/air supplies and ratios and take appropriate action
  6. Trim furnace as required.
Complete routine checks, logs and paperwork

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recognise the signs of potential and actual problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take appropriate action to minimise the impact of potential and actual problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor condition of heat transfer components (if any) and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor fuel/air supplies and ratios and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Trim furnace as required.

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. Frequently and critically monitor all plant throughout shift
  2. Use measured/indicated data and smell, sight, sound and feel as appropriate to monitor plant
  3. Identify critical equipment/processes and tune their performance
  4. Identify issues likely to impact on performance and take appropriate action
  5. Predict impact of a change in one unit/area on other plant units/areas and communicate this to relevant people
Frequently and critically monitor all plant throughout shift

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use measured/indicated data and smell, sight, sound and feel as appropriate to monitor plant

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify critical equipment/processes and tune their performance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify issues likely to impact on performance and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Predict impact of a change in one unit/area on other plant units/areas and communicate this to relevant people

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down furnace.

  1. Determine type of shut down required
  2. Give advance warning of shut down where possible
  3. Change over 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 shut down required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Give advance warning of shut down where possible

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change over 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 plant
  2. Make safe for required work
  3. Check plant is ready to be returned to service
  4. Prepare plant for return to service.
Isolate plant

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make safe for required work

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check plant is ready to be returned to service

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare plant for return to service.

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, the Range Statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment of this unit should include demonstrated competence on actual plant and equipment in a work environment. The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency. Assessment will occur over a range of situations which will include a range of problems, problem causes and environments.

Simulation may be required to allow for assessment of parts of this unit. Simulation should be based on the actual problems and should include the use of case studies/ scenarios and role plays.

This unit of competency requires a significant body of knowledge which will be assessed through questioning and the use of what-if scenarios.

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

Competence must be demonstrated in the ability to define and analyse the problem as well as deal with the stakeholders. The stakeholders should be satisfied with the solution, as well as the solution being technically sound.

Consistent performance should be demonstrated. In particular look to see that:

different types of problems can be analysed and resolved

different types of stakeholders can be satisfied

the range of possible causes can be identified and analysed and the most likely cause determined

appropriate action is taken.

These aspects may be best assessed using a range of scenarios/case studies/what-ifs. These assessment activities should include a range of problems, including new, unusual and improbable situations which may have been generated from the past history and similar sources.

Context of and specific resources for assessment

Assessment will require a suitable method of gathering evidence of problem solving ability over a range of situations. A bank of scenarios/case studies/what-ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.

Required Skills and Knowledge

This describes the essential skills and knowledge and their level, required for this unit.

Required skills

Look for evidence that confirms skills in:

following, standard operating procedures and statutory requirements

performing preoperational checks of furnace

performing maintenance checks

orally reporting routine information

identifying hazards, hazardous situations and control measures

using personal protective clothing and equipment

selecting the most appropriate prevention/control measure for a given situation

starting up furnaces, including those fitted with associated equipment such as economisers

monitoring furnaces, including checks of combustion management system and economiser operation

checking operating status

recording routine and familiar information in operating log and other standard workplace forms

using testing equipment

responding to typical emergency situations

notifying downstream users

performing operational and inspection shut-down, including procedures for associated equipment, such as economisers

isolating furnace from any common connection between the furnace and other furnaces on line and all access points required for inspection

Required knowledge

Look for evidence that confirms knowledge of:

pre-operational checks

procedures for identifying and reporting maintenance requirements

statutory requirements and workplace procedures for identifying and reporting hazards in the work area

use and application of personal protective equipment

safe work practices and procedures

prevention and control measures

the processes for starting a furnace, such as heat input, warm up of the reticulation system, systems operation, reticulation line pressure, heating fluid usage and supply, associated equipment such as economisers

the process for confirming operational status of furnace

procedures for maintaining an operating log and communicating furnace status

procedures for communicating furnace status and operation

principles of furnace operation - single and battery

furnace fittings

preparing furnace for inspection

heating fluid feed systems

procedures for monitoring a furnace, such as 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, associated equipment such as economisers

function, purpose and location of associated equipment, such as economiser, air heater, feed heater, economiser relief valves, main stop valve

procedures such as identification of emergency isolation of heat source, operation of furnace, selection and application of fire fighting equipment and notification of downstream users

operational shut-down processes and procedures, such as cooling down, furnace pressure/ vacuum and fuel/heat source isolation

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

isolation procedures and safety issues

procedures for cleaning furnace internally and externally

various modes of furnace storage, which may include integral associated equipment such as economisers

the reasons for selecting particular storage mode

procedures for storing a furnace in shut-down mode

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. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs if the candidate, accessibility of the item, and local industry and regional contexts.

Codes of practice/ standards

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Furnace shut down

Furnace shutdown may be for:

operational shut down

inspection shut down

maintenance/cleaning shut down

other

Pre-operational checks

Heat exchange fluid feed supply, fuel supply/heat source, furnace valves - their operation and position, combustion air supply and combustion equipment

Furnace

Modulating combustion air supply, modulating single heat source, modulating firing rate, economisers, single and battery

Appropriate action

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person.

Procedures

Procedures may be written, verbal, computer-based or in some other form. They include:

all work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (eg Responsible Care) and government regulations.

Hazards

Chemical and thermal hazards, manual handling, machine guarding, illumination of work area, rubbish and combustible materials, heat transfer fluid and fuel leaks etc.

Associated equipment

Economiser, economiser relief valves, air heater, feed heater, main heating fluid stop valve, feed pumps, fans

Monitored

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

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State 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.