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Evidence Guide: SUGPCSP2A - Operate a crystalliser station process

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

 

SUGPCSP2A - Operate a crystalliser station process

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

Prepare the crystalliser station for operation

  1. Massecuite is confirmed and available to meet production requirements
  2. Services are confirmed as available and ready for operation
  3. Equipment is checked to confirm readiness for use
  4. The crystallisers are set up to meet production requirements
Massecuite is confirmed and available to meet production requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Services are confirmed as available and ready for operation

Completed
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Teacher:
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Equipment is checked to confirm readiness for use

Completed
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The crystallisers are set up to meet production requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Operate and monitor crystalliser station

  1. The crystallisation station is started up and operated according to company procedures
  2. Control points are monitored to confirm performance is maintained within specification
  3. C massecuite feed to fugals meets specification
  4. Equipment is monitored to confirm operating condition
  5. Out-of-specification process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure
  6. The workplace meets housekeeping standards
The crystallisation station is started up and operated according to company procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Control points are monitored to confirm performance is maintained within specification

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

C massecuite feed to fugals meets specification

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Equipment is monitored to confirm operating condition

Completed
Date:

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Evidence:

 

 

 

 

 

 

 

Out-of-specification process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure

Completed
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Evidence:

 

 

 

 

 

 

 

The workplace meets housekeeping standards

Completed
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Handover the crystalliser station

  1. Workplace records are maintained in accordance with workplace procedures
  2. Handover is carried out according to workplace procedure
  3. Crystalliser station operators are aware of system and related equipment status at completion of handover
Workplace records are maintained in accordance with workplace procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Handover is carried out according to workplace procedure

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Crystalliser station operators are aware of system and related equipment status at completion of handover

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Shut down the crystalliser station

  1. The appropriate shut down procedure is identified
  2. The crystalliser station is shut down according to workplace procedures
  3. The crystalliser station is prepared for storage in shut down mode
  4. Maintenance requirements are identified and reported according to workplace reporting procedure
The appropriate shut down procedure is identified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

The crystalliser station is shut down according to workplace procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

The crystalliser station is prepared for storage in shut down mode

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Maintenance requirements are identified and reported according to workplace reporting procedure

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

The assessment process must address all of the following items of evidence.

Ability to:

1. Access workplace information to identify production requirements

2. Select, fit and use personal protective clothing and/or equipment

3. Confirm supply of necessary materials and services

4. Confirm equipment status and condition

5. Start up from empty and start up from full

6. Maintain required levels in the crystallisers

7. Follow cooling and reheating profiles

8. Start up and operate in both automatic and manual modes

9. Monitor the process and equipment operation to maintain the process within the required parameters. This typically involves monitoring:

throughput

loads on crystalliser drives

sugar crystal size and distribution

massecuite conductivity

massecuite dilution rates

end of cooling and reheating temperatures

stocks of C massecuite to match pan stage throughput

equipment condition

10. Detect and report water leaks from crystalliser coils

11. Take corrective action in response to out-of-specification results

12. Report and/or record corrective action as required

13. Record workplace information

14. Demonstrate shift handover procedure

15. Shut down equipment in response to an emergency situation

16. Demonstrate an operational shut down procedure

17. Prepare equipment for cleaning/maintenance

18. Maintain work area to meet housekeeping standards

May include the ability to:

19. Use process control systems

20. Clean and sanitise equipment

21. Take samples and conduct tests

Knowledge of:

22. Purpose and basic principles of crystallisation. This includes a basic understanding of crystal growth and super saturation of solutions

23. The effect of C molasses dilution on C massecuite viscosity

24. The effect on C molasses purity of variation in:

end of cooling and reheating temperatures

residence time

25. The effect of C massecuite conditioning on low grade fugal performance

the circuit flow of this process and relationship to related processes

equipment purpose and basic operating principles of crystallization equipment

the risks and consequences of pipe failure related to massecuite decomposition

26. Services used

27. Operating requirements and parameters

requirements when starting up full crystallisers containing cold massecuite

requirements when shutting down full crystallisers containing hot massecuite

28. Significance and method of monitoring control points within the process

29. Common causes of variation and corrective action required

30. Hazards and controls

31. Lock out and tag out procedures

32. shut down sequence including massecuite pumps and reheaters

33. Requirements of both operational and long term shut down conditions to ensure the equipment is left in a safe state for the period of the shutdown and to minimise any delays in future start up

34. Procedures and responsibility for reporting problems

35. Environmental issues and controls

36. Waste handling requirements and procedures

37. Recording requirements and procedures

May include knowledge of:

38. Basic operating principles of process control where relevant. This includes the relationship between control panels and systems and the physical equipment

39. Cleaning and sanitation procedures

40. Sampling and testing procedures

Relationship with other standards

Pre-requisite units

There are no pre-requisite units for this competency standard.

Co-assessment of related units

Other units of competency relevant to the work role should be assessed in conjunction with this unit. This may include:

SUGPCPS2A Collect and prepare samples

SUGPPST2A Conduct standard tests

SUGZPCI2A Operate a process control interface

Resources required for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

Operating procedures and related advice on equipment operation including advice on safe work practices and environmental requirements

Personal protective clothing and equipment

Product and process specifications and operating parameters

Crystalliser station equipment

Materials including C massecuite and services as required

Material Safety Data Sheets where appropriate

Housekeeping standards and procedures

Advice on environmental management issues relevant to work responsibilities

Workplace information recording systems, requirements and procedures

They may also require access to:

Cleaning procedures, sampling schedule and procedures and maintenance procedures and tools depending on the work requirements.

Assessment requirements

For information on how to assess this competency standard and who can assess, refer to the Assessment Guidelines for this Training Package.

Required Skills and Knowledge

Not applicable.

Range Statement

The range statement indicates the context for demonstrating competence. This statement is a guide and unless otherwise indicated, items may or may not apply as required by the work context.

Work is carried out in accordance with company policies and procedures, manufacturer's recommendations, legislative requirements, codes of practice and industrial awards and agreements. Codes of practice include the Sugar Milling Operations Industry Code of Practice

Workplace information can include Standard Operating Procedures (SOPs), specifications, production schedules and manufacturer's specifications

The crystalliser station may include low grade pan receiver, massecuite pumps, batch and continuous crystallisers, reheater, molasses lubrication system and hot and cold water systems

Confirming equipment status involves conducting relevant pre-start checks, confirming that cleaning standards are met, all safety guards are in place and equipment is operational. It may also involve checking operation/calibration of measuring instrumentation

Operation and monitoring of equipment and processes typically requires the use of control panels and systems

Services may include power, water, compressed and instrumentation air

Where tests are conducted as part of operation a typical requirement is observation using a microscope

Monitoring the process may involve the use of production data such as performance control charts

Control points refer to those key points in a work process which must be monitored and controlled

Work may require the ability to work within a team environment

Information systems may be print or screen based