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Evidence Guide: MSFGG4007 - Manage glass processing plant shutdown and re-start

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

 

MSFGG4007 - Manage glass processing plant shutdown and re-start

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

Manage shutdown sequence

  1. Glass plant safety systems are checked and verified to ensure that the unit has been made safe
  2. The reason for, or cause of, the plant shutdown is identified by troubleshooting the system and utilising all available data and information systems
  3. Confirmation of the identified shutdown is obtained from operators to verify both the nature and the reliability of the shutdown
  4. Procedures are initiated to rectify the fault or shutdown cause through either repair of the operational fault or readjustment before returning the system to start-up status
Glass plant safety systems are checked and verified to ensure that the unit has been made safe

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The reason for, or cause of, the plant shutdown is identified by troubleshooting the system and utilising all available data and information systems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirmation of the identified shutdown is obtained from operators to verify both the nature and the reliability of the shutdown

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Procedures are initiated to rectify the fault or shutdown cause through either repair of the operational fault or readjustment before returning the system to start-up status

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct start-up process

  1. All start-up permissives are satisfied prior to start-up process being commenced
  2. Start-up is conducted according to procedures and in a safe and efficient manner, ensuring a return to normal operation is achieved
All start-up permissives are satisfied prior to start-up process being commenced

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start-up is conducted according to procedures and in a safe and efficient manner, ensuring a return to normal operation is achieved

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Document shutdown and start-up process

  1. All logs and workplace documentation relating to the shutdown/start-up process are completed ensuring all details, actions and responses are accurately recorded
  2. Any further ongoing production problems are recorded and reported to appropriate persons or authority
All logs and workplace documentation relating to the shutdown/start-up process are completed ensuring all details, actions and responses are accurately recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Any further ongoing production problems are recorded and reported to appropriate persons or authority

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

Manage shutdown sequence

1.1

Glass plant safety systems are checked and verified to ensure that the unit has been made safe

1.2

The reason for, or cause of, the plant shutdown is identified by troubleshooting the system and utilising all available data and information systems

1.3

Confirmation of the identified shutdown is obtained from operators to verify both the nature and the reliability of the shutdown

1.4

Procedures are initiated to rectify the fault or shutdown cause through either repair of the operational fault or readjustment before returning the system to start-up status

2

Conduct start-up process

2.1

All start-up permissives are satisfied prior to start-up process being commenced

2.2

Start-up is conducted according to procedures and in a safe and efficient manner, ensuring a return to normal operation is achieved

3

Document shutdown and start-up process

3.1

All logs and workplace documentation relating to the shutdown/start-up process are completed ensuring all details, actions and responses are accurately recorded

3.2

Any further ongoing production problems are recorded and reported to appropriate persons or authority

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Manage shutdown sequence

1.1

Glass plant safety systems are checked and verified to ensure that the unit has been made safe

1.2

The reason for, or cause of, the plant shutdown is identified by troubleshooting the system and utilising all available data and information systems

1.3

Confirmation of the identified shutdown is obtained from operators to verify both the nature and the reliability of the shutdown

1.4

Procedures are initiated to rectify the fault or shutdown cause through either repair of the operational fault or readjustment before returning the system to start-up status

2

Conduct start-up process

2.1

All start-up permissives are satisfied prior to start-up process being commenced

2.2

Start-up is conducted according to procedures and in a safe and efficient manner, ensuring a return to normal operation is achieved

3

Document shutdown and start-up process

3.1

All logs and workplace documentation relating to the shutdown/start-up process are completed ensuring all details, actions and responses are accurately recorded

3.2

Any further ongoing production problems are recorded and reported to appropriate persons or authority

Consistently:

recognise early warning signs of equipment/processes needing attention or with potential problems

determine and analyse the range of possible plant problem causes and the most likely cause

take appropriate action to ensure a timely return to full performance

recognise obvious problems in related plant areas and make an appropriate contribution made to their solution

Shutdown and re-start a glass processing plant safety and efficiently

Communicate ideas and information to enable confirmation of work requirements and specifications and the reporting of work outcomes and problems

Avoid backtracking, work flow interruptions or wastage

Work with others and in a team by recognising dependencies and using cooperative approaches to optimise work flow and productivity

Principles of operation of glass processing plant/equipment

Interactions between plant units within the entire plant

The architecture and location of the glass process/production equipment

Specific glass plant process operations

Interactions between glass plant items/processes

Glass product specifications and tolerances

Hierarchy of control and basis of control for glass plant/s

Communication protocols (e.g. radio, phone, computer, paper and permissions/authorities)

Routine glass processing plant problems, faults and their resolution

Relevant alarms and actions

Complex process drawings (e.g. piping and instrumentation diagrams (P&ID), probability of failure on demand (PFD), and cause and effect)

Plant process idiosyncrasies

Correct methods of starting, stopping, operating and controlling glass processing plants

Corrective action appropriate to the problem cause

Function and troubleshooting of major glass processing plant components and their problems

Process control philosophies and strategies

Emergency shutdown procedures

Physics, chemistry and mathematics relevant to the process

Range Statement

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

Reasons for glass processing plant shutdown include:

planned (e.g. for maintenance or other planned work)

unplanned (e.g. in response to a plant upset or equipment failure)

emergency (e.g. in response to an automatic shutdown sequence or plant trip)

Shutdown includes:

shutdown 'to cold' (e.g. complete plant shutdown and purging of all process materials from equipment)

short shutdown to allow minor work 'warm shutdown' (e.g. partial shutdown, with retention of some or all of process materials)

managing a plant trip and restart 'hot shutdown' (e.g. short duration shutdown in response to a plant upset or trip)

Shutdown actions include:

coordinating the shift team

implementing emergency procedures

using the permit to work system (for repairs required)

performing all operations according to procedures

Relevant personnel include:

panel technicians

outside technicians

technicians seconded to a shutdown role

other relevant personnel

Work health and safety (WHS) requirements include:

Commonwealth, state or territory legislation and regulations

organisational safety policies and procedures

the use of personal protective equipment and clothing

firefighting equipment

first aid equipment

hazard and risk control and elimination of hazardous materials and substances

manual handling, including lifting and carrying

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person

Procedures include:

work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any instructions provided for the smooth running of the plant

written, verbal or computer-based procedures

Glass plant/equipment include:

glass laminating plant

glass toughening plant

insulated glass plant

glass silvering plant

glass printing plant

cutting (including water jet), seaming, edge grinding and computer numerically controlled (CNC) milling

Organisational requirements include:

legal, organisational and site guidelines, policies and procedures relating to own role and responsibility

quality assurance

procedural manuals

quality and continuous improvement processes and standards

WHS procedures

emergency and evacuation

ethical standards

recording and reporting

access and equity principles and practices

equipment use, maintenance and storage

environmental management (waste disposal, recycling and re-use guidelines)