ELEMENT

PERFORMANCE CRITERIA

1. Plan and prepare for converter operation

1.1. Access, interpret and apply compliance documentation relevant to the work activity

1.2. Receive, interpret and clarify shift changeover details

1.3. Establish and maintain communications with other personnel using approved communication methods

1.4. Select personal protective equipment appropriate for work activities

1.5. Check and test control and monitoring systems for correct operation

1.6. Select appropriate type of auxiliary equipment for work activities and check for availability

1.7. Carry out computer systems and equipment pre-start checks to ensure equipment is ready for operation

1.8. Identify, address and report potential risks and hazards

1.9. Identify, address and report environmental issues

1.10. Follow emergency procedures to ensure safety of personnel and plant

1.11. Ensure approved dust suppression and extraction methods are in place

1.12. Ensure work area is adequately ventilated

2. Start-up converter

2.1. Perform pre-start checks

2.2. Carry out start-ups from standby and after maintenance according to established operating procedures

2.3. Carry out first charge to established procedures to protect personnel and plant

2.4. Stabilise the system within operating parameters

3. Monitor and control the process

3.1. Complete routine checks, logs and paperwork

3.2. Recognise and respond to signs of potential and actual problems

3.3. Monitor condition of metal and take action to maintain production schedule and quality

3.4. Monitor availability of feeds and take action to maintain production schedule and quality

3.5. Monitor and maintain blast air flow to converter at optimum level

3.6. Monitor and maintain converter oxygen at optimum level

3.7. Monitor cooling medium flow to converter to maintain safe converter temperatures

3.8. Maintain metal and gas temperatures at safe levels

3.9. Control and monitor converter movement

3.10. Monitor and control rate and amount of additives to molten metal

3.11. Respond to warning alarms and lights and take action to rectify

3.12. Control and monitor metal and slag blow process and pouring

3.13. Complete log sheets

4. Maintain plant availability

4.1. Monitor plant throughout shift

4.2. Use measured/indicated data and sight e to identify issues likely to impact on plant availability

4.3. Predict impact of change in one unit/area on other plant unit/areas and communicate to relevant people

4.4. Test trips and alarms

4.5. Inspect converter plant and rectify and/or report faults

4.6. Maintain furnace temperature during non-operating periods

4.7. Operate Tuyere punching

4.8. Prepare plant for maintenance as required

5. Shutdown converter

5.1. Determine type of shutdown required and give warning

5.2. Shutdown furnace in required sequence according to established procedures

5.3. Leave plant in a condition ready to restart

Required skills

Specific skills are required to achieve the Performance Criteria of this unit, particularly for its application in the various circumstances in which this unit may be used. This includes the ability to carry out the following, as required to operate converters:

apply legislative, organisation and site requirements and procedures for operating converters

troubleshoot

apply precautions necessary for safe working

use protective clothing and equipment

apply operating procedures

report faults

recognise limits of authority

apply team working practices

communicate information

use hand and power tools

Required knowledge

Specific knowledge is required to achieve the Performance Criteria of this unit, particularly for its application in the various circumstances in which this unit may be used. This includes knowledge of the following, as required to operate converters:

principles of converter operation

first charge procedures

conversion process

converter configuration, components and operation

auxiliary equipment type, purpose operation

air, water and oxygen systems and purpose

personal protective equipment

additives

metal and slag blow purpose and method

combustion principles

trouble shooting of converter problems

safe working

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

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

The evidence required to demonstrate competency in this unit must be relevant to worksite operations and satisfy all of the requirements of the performance criteria, required skills and knowledge and the range statement of this unit and include evidence of the following:

knowledge of the requirements, procedures and instructions for operating converters

implementation of requirements, procedures and techniques for the safe, effective and efficient completion of converter operations

working with others to undertake and complete the converter operations in a way that meets all of the required outcomes

consistent timely completion of converter operations that safely, effectively and efficiently meets the required outcomes

Context of and specific resources for assessment

This unit must be assessed in the context of the work environment. Where personal safety or environmental damage are limiting factors, assessment may occur in a simulated environment provided it is realistic and sufficiently rigorous to cover all aspects of workplace performance, including task skills, task management skills, contingency management skills and job role environment skills.

Assessment of this competency requires typical resources normally used in a resources and infrastructure sector environment. Selection and use of resources for particular worksites may differ due to the site circumstances.

The assessment environment should not disadvantage the participant. For example, language, literacy and numeracy demands of assessment should not be greater than those required on the job.

Customisation of assessment and delivery environment to sensitively accommodate cultural diversity.

Aboriginal people and other people from a non English speaking background may have second language issues.

Where applicable, physical resources should include equipment modified for people with disabilities. Access must be provided to appropriate learning and/or assessment support when required.

Method of assessment

This unit may be assessed in a holistic way with other units of competency. The assessment strategy for this unit must verify required knowledge and skill and practical application using more than one of the following assessment methods:

written and/or oral assessment of the candidate's required knowledge

observed, documented and/or first hand testimonial evidence of the candidate's:

implementation of appropriate requirement, procedures and techniques for the safe, effective and efficient achievement of required outcomes

consistent achievement of required outcomes

first hand testimonial evidence of the candidate's:

working with others to undertake and complete the converter operations

Guidance information for assessment

Consult the SkillsDMC User Guide for further information on assessment including access and equity issues.

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.

Relevant compliance documentation may include:

legislative, organisational and site requirements and procedures

manufacturer's guidelines and specifications

Australian standards

Employment and workplace relations legislation

Equal Employment Opportunity and Disability Discrimination legislation

Legislation may include Acts and regulations dealing with:

mining safety and health

mine inspection

OHS

explosives

Communications may include:

radio

telephone

PA system

charging sirens

alarms

clear calls

Personal protective equipment may include:

helmet

safety footwear

hearing protection

gloves

eye/face protection

respiratory protection

heat resistant clothing

Auxiliary equipment may include:

belts

compressors

distribution control systems

gantry cranes and attachments and other mobile equipment

hand and power tools

hoses (water and air)

pump systems

conveyors

cranes

Pre-start checks may include:

computer systems and equipment

availability of equipment

detection of unusual conditions

job requirements

personnel availability

walk through plant

communications

feed supply

Hazards may include:

cranes

molten metal

hot materials

noise

air pollution

sharp objects

moving machinery

heights

falling objects

gases

automatic equipment start-up

Site environmental issues may include:

drainage

dust (dump)

emissions

flora and fauna

hazardous chemicals

noise

recycling

run-off

spills

waste management and disposal

water quality

Start-ups may include:

air systems

cameras and monitors

checking interlocks

checking distribution control system (DCS)

display instruments, lights and gauges

isolations

lighting

suppression systems

valves

visual and audio warning devices and lights

Maintenance may include:

minor adjustments to operational plant

cleaning plant, equipment and work area

installation/removal of devices to allow safe maintenance

First charge procedures refers to

the initial start-up of new and refurbished vessels

Converter problems can include:

uncontrolled emissions (gas or metal)

electrical/mechanical failures

standard of product received

additives not up to standard

Cooling media may include:

water

air

Type of shutdown may include:

hot shutdown for scheduled on-line maintenance

cool shutdown to minimise temperature for refurbishment

Burners may be:

diesel

natural gas