ELEMENT

PERFORMANCE CRITERIA

1 Prepare the cooling tower/s for operation

1.1 Tower cleaning procedures are followed and cleaning records completed

1.2 Chemicals are available and delivery systems are ready for operation

1.3 Make-up water supply is available and meets quality requirements

1.4 Pre-operational checks are conducted

1.5 Health and safety hazards/maintenance requirements are identified and reported to appropriate personnel according to workplace reporting procedures

2 Start and monitor cooling tower

2.1 The cooling tower system is started according to workplace procedures and manufacturer's recommendations

2.2 Plant is operated within limits of manufacturer's specifications to meet workplace requirements

2.3 Equipment is monitored to confirm operating condition and cleanliness

2.4 Water quality is monitored, tested and adjusted as required

2.5 The workplace meets housekeeping standards

3 Analyse and respond to abnormal performance

3.1 Water condition and plant operating conditions are analysed to identify causes of abnormal performance

3.2 Corrective action is taken in accordance with workplace procedures in response to hazards, out-of-specification test results and/or abnormal plant performance

3.3 Emergency procedures are implemented as required according to workplace procedures and manufacturer's recommendations

4 Shutdown and clean the cooling water system

4.1 The cooling water system is cleaned according to workplace cleaning schedule and to meet legal requirements

4.2The timing and sequencing of cooling water system shut down meets production requirements

4.3 Maintenance requirements are identified and reported according to workplace reporting procedure

5 Record information

5.1 Workplace information is recorded according to workplace recording requirements

Required skills include:

Ability to:

access workplace information on cooling water requirements

select, fit and use personal protective clothing and/or equipment

confirm status of equipment, that it is clean and ready for operation and services are available

prepare and handle chemicals safely including following correct preparation, handling and storage procedures and use of appropriate protective clothing and equipment

conduct pre-start checks including checking:

raw water supply

tower condition and cleanliness

spray and pond condition

all safety guards and covers are in place and operational

mechanical integrity of pumps, drives and fans

drains are closed

chemicals are available

liaise with other work areas to advise of users of cooling system status

demonstrate set up and start up procedures in both manual and automatic modes

monitor cooling water system operation including visual inspections and conducting tests to monitor characteristics such as:

chemical addition rates and residuals

water quality

blow-down rate

temperatures

water distribution

signs of fouling and corrosion

equipment condition including fans, sprays and pumps

water level and make-up flow

take corrective action in response to out-of-specification results

report and/or record corrective action as required

demonstrate procedure to clean and shut down cooling water system

demonstrate use of emergency cooling water supply system

maintain workplace records including cleaning records and chemical usage

maintain work area to meet housekeeping standards

Required knowledge include:

Knowledge of:

relevant state OHS legislation, standards and codes of practice relating to work responsibilities

purpose and basic principles of evaporative cooling and water treatment in order to prevent corrosion and microbiological fouling

cooling water system layout

the effect of make-up water quality on blow down rates and fouling rates

the impact of variables including cooling water failure and high water temperature and plant operation

purpose of chemicals used

consequences of system fouling and typical causes

safe work procedures including awareness of health and safety hazards related to cooling water system operation and associated control measures

hierarchy of hazard control measures

purpose and limitations of protective clothing and equipment

methods used to render equipment safe to inspect, maintain and/or clean including lock-out, tag-out and isolation procedures

water quality test procedures

typical causes of water contamination and corrective action required

equipment purpose and basic operating principles of cooling water system and related equipment including pumps, valves, tower and fans and dosing system

operating requirements and parameters

cleaning methods and procedures

procedures for operating the emergency cooling water system

environmental issues and controls including those relating to chemical and/or container disposal and any overflow of the system to waters of the state

requirements to liaise/advise related work areas

housekeeping standards for the work area

reporting and recording systems including both statutory and workplace requirements

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed.

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

Evidence of ability to:

confirm status of equipment

demonstrate set up and start up procedures

monitor cooling water system operation

undertake visual inspections and conduct tests to monitor cooling water system operation

clean and shut down cooling water system.

Context of and specific resources for assessment

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

Cooling water system and related equipment

Chemicals

Relevant codes and standard Operating procedures and related advice on equipment operation

Personal protective clothing and equipment

Communication systems and equipment

Housekeeping standards and procedures

Workplace information recording systems, requirements and procedures.

Method of assessment

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

FDFOP2030A Operate a process control interface.

Guidance information for assessment

To ensure consistency in one's performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

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. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Policies and procedures

Work is carried out in accordance with company policies and procedures, manufacturer's recommendations, licensing requirements, codes of practice, legislative requirements, industrial awards and agreements and Australian Standard AS3666, parts I, II and III.

Codes of practice

Codes of practice include the Sugar Milling Operations Industry Code of Practice.

Workplace information

Workplace information can include:

Standard Operating Procedures (SOPs)

manufacturer's specifications.

Hazards

Hazards typically include handling chemicals, manual handling, risks of working with warm water systems (Legionella).

Equipment

Equipment may include:

the tower

spray ponds

supply pump and return pump

chemical addition systems and blow down system.

Typically a number of cooling towers would be located on site. They may be integrated or stand-alone.

Equipment operation and monitoring

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

Tests

Typical tests may include:

pH

total dissolved solids (TDS)

conductivity

standard plate count (SPC)

Legionella

tests specific to chemicals used.

Teamwork

Work may require the ability to work within a team environment.

Information systems

Information systems may be print or screen based.