This unit specifies the outcomes required to operate a reciprocating steam engine for licensing purposes, which includes the operation of steam equipment where the steam acts upon a piston under pressure.

Reciprocating steam engine means equipment that is driven by steam acting on a piston causing the piston to move and includes and expanding (steam) reciprocating engine.

High risk work is classed as the operation of a reciprocating steam engine where the diameter of any piston exceeds 250 millimetres.

This unit requires the operator to plan the work, carry out pre-operational safety checks, start the reciprocating steam engine, monitor the reciprocating steam engine operation, carry out shut down of reciprocating steam engine for operational and maintenance purposes.

A person performing this work is required to hold a reciprocating steam engine operation high risk work (HRW) licence.

Licensing/Regulatory information

This unit is based on the licensing requirements of Part 4.5 of the Model Work Health and Safety (WHS) Regulations, HRW and meets Commonwealth, state and territory HRW licensing requirements.

Any alteration to this unit would result in a unit that would not be acceptable to Work, Health and Safety (WHS)/Occupational Health and Safety (OHS) regulators for the purpose of licensing.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

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

1

Plan work

1.1

Types of operations to be conducted for a reciprocating steam engine are assessed and prepared

1.2

Personal Protective Equipment (PPE) is selected for use, ensuring statutory requirements and procedures are followed

1.3

Hazards and potential hazards in work area are identified and assessed for risk and controls recommended are consistent with appropriate standards

1.4

Pre-operational safety checks of reciprocating steam engine and equipment are conducted, in accordance with statutory requirements and procedures

1.5

Maintenance requirements and equipment faults are identified and reported, in accordance with procedures

1.6

Communication methods are identified according to procedures

2

Start reciprocating steam engine

2.1

Controls are implemented for hazards in work area consistent with industry standards

2.2

Start-up checks are performed and the reciprocating steam engine is brought on line safely, in accordance with statutory requirements and procedures

2.3

Maintenance requirements are identified and reported, in accordance with procedures

3

Monitor reciprocating steam engine operation

3.1

Reciprocating steam engine is monitored, in accordance with statutory requirements and workplace procedures, including undertaking operational checks

3.2

Operating log is maintained clearly and accurately, in accordance with statutory requirements and procedures

3.3

Information regarding reciprocating steam engine, its status and operation is communicated clearly in accordance with procedures

4

Shutdown reciprocating steam engine

4.1

Engine is shut down in accordance with statutory requirements and procedures, including shut down checks and shut down checks for maintenance

4.2

Reciprocating steam engine is isolated in accordance with procedures

4.3

Maintenance requirements are identified, recorded and reported in accordance with procedures

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Range is restricted to essential operating conditions and any other variables essential to the work environment.

Non-essential conditions may be found in the Companion Volume Implementation Guide.

appropriate standards must include

but not be limited to:

codes of practice

legislation

Australian Standards

manufacturers’ specifications

communicated and/or communication must include

but are be limited to:

verbal

written

telephone

two-way radio

log records

computer record systems

emergencies must include

but not be limited to:

fire

bomb threat

terrorism

personal accidents

chemical spills

major steam leaks

major water leaks

flooding

natural disasters

equipment must include

but not be limited to:

engine and auxiliary plant

engine lubrication and power or control oil systems

hydraulic oil system

pump

compressed air system

steam supply system

cylinder exhaust system

computers with equipment control functions

supervisory, alarm, protection and control equipment

relevant maintenance equipment

including equipment for:

lock out for protecting operators and co-workers from accidental injury

emergency shutdown stopping

extinguishing fires

organisational first aid requirements

evacuation

equipment faults must include

but not be limited to:

abnormal operating conditions

loss of a major auxiliary

excessively high engine and engine valves heating rates or differentials

high engine bearing temperatures or vibration

high pressure heater malfunctions

mechanical or electrical faults or failure

failed field devices

engine protection

hazards must include

but not be limited to:

chemical hazards

thermal hazards

manual handling hazards

guarding of machinery requirements

illumination of work area

rubbish and combustibles in area

leakage of steam

leakage of fuel

obstructions in work area

fire

noise

vibration

water

working at heights

operational checks must include

but not be limited to:

supply and quality of steam and line pressure

exhaust system

safety devices

speed governor

vibration level

lubrication system

operation and function of valves and fittings

cylinder drainage system

operation of control and/or safety devices

Personal Protective Equipment (PPE) must include

but not be limited to:

prescribed under legislation, regulation and codes of practice

workplace policies and practices

hard hat

safety boots

gloves

high visibility clothing

breathing, hearing, sight, skin and sun protection

fall arrest equipment such as harnesses and lanyards, horizontal life lines and inertia reel

preoperational safety checks may include

but not be limited to:

supply steam system

position and operation of engine valves

lubrication system

cylinder drainage system

exhaust system

auxiliary equipment

safety devices

over speed shut down

pressure relief devices

speed governor

procedures must include

but not be limited to:

manufacturers' guidelines (e.g. instructions, specifications or checklists)

industry operating procedures

workplace procedures (e.g. work instructions, operating procedures and checklists)

operation of steam equipment must include

where the steam acts upon a piston under pressure where this action of the steam forces the piston to move.

the definition includes all expanding (steam) reciprocating engines, with any piston diameter of greater than 250 millimetres

recorded must include

but not be limited to:

operations and maintenance of reciprocating steam engine equipment

difficulties or issues

environmental issues

recommendations for future work

results

costs

hazards

incidents or injuries

dangerous occurrences or equipment

malfunctions using log books

proformas

production reports

maintenance records

shutdown checks must include

but not be limited to:

steam supply

cooling process

load on engine

cylinder drains

auxiliary equipment

shutdown checks for maintenance must include

but not be limited to:

checks of cooling down process

isolation of steam

isolation from any common connection

opening of all access points required for inspection

a simulator must include

a device used especially in training to reproduce the conditions of the working situation, enabling tasks to be learned and practised safely and economically

start-up checks must include

but not be limited to:

heat input

steam supply system

steam traps and steam line purge systems operation

engine warmed up

lubrication system

drainage system

operation and position of engine valves and fittings

operation of auxiliary equipment

freedom of rotation of engine

warm up of reticulation system

reticulation line pressure

testing must include

but not be limited to:

loss of a major auxiliary controls response checks

standby plant cut-in tests

valves operating checks

on load engine valve and emergency governor operation test

performance tests

valve operation tests

alarm and protection tests

Electricity generation

Licensing There are no prerequisite units.