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Evidence Guide: PMC552030 - Operate a firing kiln

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

 

PMC552030 - Operate a firing kiln

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

Prepare the firing equipment

  1. Determine the firing requirements from the production program
  2. Identify and set up the kiln cars or furniture
  3. Ensure kiln refractories are within specification, including kiln cars, kiln lining and refractories at burners, as appropriate
  4. Ensure the firing equipment is safe to use
  5. Check for fuel feed obstructions and clear burner pathways
  6. Ensure products are set or stacked to specification
  7. Ensure correct stacking pattern is used
  8. Ensure adequate space is allowed around each item
  9. Use kiln space effectively
Determine the firing requirements from the production program

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and set up the kiln cars or furniture

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure kiln refractories are within specification, including kiln cars, kiln lining and refractories at burners, as appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure the firing equipment is safe to use

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check for fuel feed obstructions and clear burner pathways

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure products are set or stacked to specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure correct stacking pattern is used

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure adequate space is allowed around each item

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use kiln space effectively

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor kiln operation

  1. Monitor kiln firing to ensure temperature rise and fall rate is to specification
  2. Monitor and record kiln car movement, or kiln contents
  3. Monitor and adjust kiln heating equipment (elements or burners) and record temperature gradient details
  4. Monitor the kiln atmosphere
  5. Monitor for correct operation of kiln
  6. Move kiln car or kiln contents to the appropriate storage area
  7. Check and record condition of products leaving the kiln
Monitor kiln firing to ensure temperature rise and fall rate is to specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and record kiln car movement, or kiln contents

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and adjust kiln heating equipment (elements or burners) and record temperature gradient details

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor the kiln atmosphere

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor for correct operation of kiln

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Move kiln car or kiln contents to the appropriate storage area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and record condition of products leaving the kiln

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify routine problems

  1. Identify the range of faults that can occur during the operation
  2. Determine and rectify fault causes in accordance with procedures/work instructions
  3. Identify and rectify equipment failure causes in accordance with procedures/work instructions
  4. Ensure appropriate records and log books of equipment operations are maintained to meet procedures/work instructions
  5. Identify non-routine problems and report to designated person
Identify the range of faults that can occur during the operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine and rectify fault causes in accordance with procedures/work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and rectify equipment failure causes in accordance with procedures/work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure appropriate records and log books of equipment operations are maintained to meet procedures/work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify non-routine problems and report to designated person

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control hazards

  1. Identify hazards in kiln work area
  2. Assess the risks arising from those hazards
  3. Implement measures to control those risks in line with procedures and duty of care
Identify hazards in kiln work area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess the risks arising from those hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement measures to control those risks in line with procedures and duty of care

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 the firing equipment

1.1

Determine the firing requirements from the production program

1.2

Identify and set up the kiln cars or furniture

1.3

Ensure kiln refractories are within specification, including kiln cars, kiln lining and refractories at burners, as appropriate

1.4

Ensure the firing equipment is safe to use

1.5

Check for fuel feed obstructions and clear burner pathways

2

Load kiln

2.1

Ensure products are set or stacked to specification

2.2

Ensure correct stacking pattern is used

2.3

Ensure adequate space is allowed around each item

2.4

Use kiln space effectively

3

Monitor kiln operation

3.1

Monitor kiln firing to ensure temperature rise and fall rate is to specification

3.2

Monitor and record kiln car movement, or kiln contents

3.3

Monitor and adjust kiln heating equipment (elements or burners) and record temperature gradient details

3.4

Monitor the kiln atmosphere

3.5

Monitor for correct operation of kiln

3.6

Move kiln car or kiln contents to the appropriate storage area

3.7

Check and record condition of products leaving the kiln

4

Rectify routine problems

4.1

Identify the range of faults that can occur during the operation

4.2

Determine and rectify fault causes in accordance with procedures/work instructions

4.3

Identify and rectify equipment failure causes in accordance with procedures/work instructions

4.4

Ensure appropriate records and log books of equipment operations are maintained to meet procedures/work instructions

4.5

Identify non-routine problems and report to designated person

5

Control hazards

5.1

Identify hazards in kiln work area

5.2

Assess the risks arising from those hazards

5.3

Implement measures to control those risks in line with procedures and duty of care

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Prepare the firing equipment

1.1

Determine the firing requirements from the production program

1.2

Identify and set up the kiln cars or furniture

1.3

Ensure kiln refractories are within specification, including kiln cars, kiln lining and refractories at burners, as appropriate

1.4

Ensure the firing equipment is safe to use

1.5

Check for fuel feed obstructions and clear burner pathways

2

Load kiln

2.1

Ensure products are set or stacked to specification

2.2

Ensure correct stacking pattern is used

2.3

Ensure adequate space is allowed around each item

2.4

Use kiln space effectively

3

Monitor kiln operation

3.1

Monitor kiln firing to ensure temperature rise and fall rate is to specification

3.2

Monitor and record kiln car movement, or kiln contents

3.3

Monitor and adjust kiln heating equipment (elements or burners) and record temperature gradient details

3.4

Monitor the kiln atmosphere

3.5

Monitor for correct operation of kiln

3.6

Move kiln car or kiln contents to the appropriate storage area

3.7

Check and record condition of products leaving the kiln

4

Rectify routine problems

4.1

Identify the range of faults that can occur during the operation

4.2

Determine and rectify fault causes in accordance with procedures/work instructions

4.3

Identify and rectify equipment failure causes in accordance with procedures/work instructions

4.4

Ensure appropriate records and log books of equipment operations are maintained to meet procedures/work instructions

4.5

Identify non-routine problems and report to designated person

5

Control hazards

5.1

Identify hazards in kiln work area

5.2

Assess the risks arising from those hazards

5.3

Implement measures to control those risks in line with procedures and duty of care

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

set up, configure, start and operate the firing equipment according to procedures

monitor and adjust the equipment to meet product quality and production output specifications

load and stack products into kiln

identify hazards and apply relevant hazard controls

apply safety procedures

recognise out-of-specification products, process problems and materials faults

recognise routine and non-routine problems

identify when the operator is able to rectify problems, when assistance is required and who is the appropriate source for assistance

take action to resolve problems or report them to appropriate personnel

distinguish between possible causes of routine problems, including:

raw material variations

mechanical abnormalities

electrical/instrument reading variations

process abnormalities

communicate effectively with team/work group and supervisors

read and interpret product specifications, job sheets, procedures, material labels and safety information

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate under routine only supervision and to solve routine problems, including knowledge of:

principles of firing process

functions, limitations and principles of operation of firing equipment

composition and nature of raw materials and finished product

importance of stacking patterns

stages and critical transitions during the firing process

basic physics, and where appropriate chemistry, relevant to the equipment/process/materials

the potential effects of variations in raw materials and process conditions in relation to quality of product/output

factors which may affect product quality or production output and appropriate remedies

routine problems, their probable causes and relevant corrective actions

organisation procedures relevant to the work environment/job role

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.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent 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 such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

job cards

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.

Tools and equipment

Tools and equipment include:

firing kiln

programmable logic controllers (PLC), if fitted

instrument panels (local)

measuring and recording equipment

kiln cars, racking or other kiln furniture

ancillary equipment that is integral to the process.

Problems/known solutions

Routine problems must be resolved by applying known solutions.

Routine problems/known solutions are predictable and include one or more of:

ensuring moisture content of product prior to firing is within specification

furnace temperature profile variations

drying variations

distribution of product in kiln or on kiln car

correct transition through quartz inversion, as appropriate

distortion of refractories or mechanical failures.

Known solutions are drawn from one or more of:

procedures

training

remembered experience.

Non-routine problems must be reported according to according to relevant procedures.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

high temperatures

smoke, dust, vapours or other atmospheric hazards

weight, shape, volume of materials to be handled

hazardous products and materials

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

electricity

gas

gases and liquids under pressure

noise

rotational equipment or vibration

plant services (steam, condensate, cooling water, etc)

structural hazards

equipment failures

machinery, equipment and product mass

limited head spaces or overhangs

working at heights

working in restricted or confined spaces

other hazards that might arise.

Records and reports

Records include one or more of:

log books/sheets

electronic records

job/work sheets

other records used for the smooth running of the plant.

Reports include one or more of:

paper or electronic-based logs and reports

verbal/radio reports

reporting items found which require action.