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Evidence Guide: RIIPSM308A - Monitor and maintain furnace gas efficiency

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

 

RIIPSM308A - Monitor and maintain furnace gas efficiency

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

Prepare for plant and equipment operation

  1. Access, interpret and apply compliance documentation relevant to the work activity
  2. Receive, interpret and clarify shift changeover details
  3. Establish and maintain communication with other personnel using approved communication methods
  4. Select personal protective equipment appropriate for work activities
  5. Select appropriate auxiliary equipment for work activities
  6. Carry out equipment pre-start checks to ensure equipment is ready for operation
  7. Identify, address and report potential risks and hazards
  8. Identify, address and report environmental issues
  9. Follow emergency procedures to ensure safety of personnel and plant
  10. Use approved dust suppression and extraction methods
  11. Ventilate work area before entry
Access, interpret and apply compliance documentation relevant to the work activity

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Receive, interpret and clarify shift changeover details

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Establish and maintain communication with other personnel using approved communication methods

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select personal protective equipment appropriate for work activities

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select appropriate auxiliary equipment for work activities

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out equipment pre-start checks to ensure equipment is ready for operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify, address and report potential risks and hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify, address and report environmental issues

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow emergency procedures to ensure safety of personnel and plant

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use approved dust suppression and extraction methods

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ventilate work area before entry

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain efficient operation of furnace gas plant and systems

  1. Carry out plant and equipment start-up checks and procedures according to plant/equipment configurations and system requirements
  2. Carry out monitoring and control on DCS
  3. Operate and maintain air operated breathing equipment for furnace off-line entry
Carry out plant and equipment start-up checks and procedures according to plant/equipment configurations and system requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out monitoring and control on DCS

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate and maintain air operated breathing equipment for furnace off-line entry

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control furnace gas emissions

  1. Carry out plant and equipment start-up checks and procedures according to plant/equipment configurations and system requirements
  2. Monitor and operate accretion build-up removal equipment to ensure efficient operation of air injection equipment
  3. Monitor furnace feed chutes for blockages and maintain to ensure optimum production
  4. Take samples of molten metal to confirm molten metal quantity and condition of molten metal bath
Carry out plant and equipment start-up checks and procedures according to plant/equipment configurations and system requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and operate accretion build-up removal equipment to ensure efficient operation of air injection equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor furnace feed chutes for blockages and maintain to ensure optimum production

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take samples of molten metal to confirm molten metal quantity and condition of molten metal bath

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain efficient operation of furnace air injection equipment

  1. Carry out plant and equipment start-up checks and procedures according to plant/equipment configuration and system requirements
  2. Monitor furnace conditions and operations to identify the correct, efficient operation of the furnace air injection equipment, and report to Control Room Operator
  3. Identify furnace inefficiencies and furnace air injection equipment and change/replace where necessary, ensuring minimum furnace down-time
  4. Clean furnace air injection equipment/device without causing damage
  5. Check and record furnace air injection equipment/device position, and recalibrates where outside operating parameters
Carry out plant and equipment start-up checks and procedures according to plant/equipment configuration and system requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor furnace conditions and operations to identify the correct, efficient operation of the furnace air injection equipment, and report to Control Room Operator

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify furnace inefficiencies and furnace air injection equipment and change/replace where necessary, ensuring minimum furnace down-time

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean furnace air injection equipment/device without causing damage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and record furnace air injection equipment/device position, and recalibrates where outside operating parameters

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure supply of additives

  1. Monitor and maintain condition of furnace feed materials
  2. Monitor furnace additives supply and report to Control Room Operator for action
Monitor and maintain condition of furnace feed materials

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor furnace additives supply and report to Control Room Operator for action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain plant and equipment efficiency

  1. Clean plant to maintain condition of all equipment to ensure safe and efficient operations
  2. Identify and report hazards to maintain a safe working environment
  3. Interpret and respond to plant alarms, take remedial actions and notify appropriate personnel
  4. Check and adjust plant condition to maintain efficient operation
  5. Install and control stand-by furnace burner equipment to maintain safe furnace refractory temperatures
  6. Inspect air, gas, diesel and combustion supply equipment and replace/report faults, damaged or inoperable equipment to appropriate personnel
  7. Carry out minor plant maintenance and lubrication tasks
  8. Provide support for maintenance personnel where necessary to organisation's requirements
Clean plant to maintain condition of all equipment to ensure safe and efficient operations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and report hazards to maintain a safe working environment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Interpret and respond to plant alarms, take remedial actions and notify appropriate personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and adjust plant condition to maintain efficient operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Install and control stand-by furnace burner equipment to maintain safe furnace refractory temperatures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inspect air, gas, diesel and combustion supply equipment and replace/report faults, damaged or inoperable equipment to appropriate personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out minor plant maintenance and lubrication tasks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Provide support for maintenance personnel where necessary to organisation's requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shutdown plant and equipment

  1. Shutdown or isolate plant/equipment based on process and safety requirements
  2. Perform post shutdown or isolation checks
  3. Pass on shift changeover details to oncoming shift
Shutdown or isolate plant/equipment based on process and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform post shutdown or isolation checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pass on shift changeover details to oncoming shift

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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 monitor and maintain furnace gas efficiency

implementation of requirements, procedures and techniques for the safe, effective and efficient completion of monitor and maintain furnace gas efficiency

working with others to undertake and complete the monitoring and maintenance of furnace gas efficiency in a way that meets all of the required outcomes

consistent timely completion of monitoring and maintenance of furnace gas efficiency 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 monitoring and maintenance of furnace gas efficiency

Guidance information for assessment

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

Required Skills and Knowledge

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 monitor and maintain furnace gas efficiency:

apply legislative, organisation and site requirements and procedures for monitoring and maintaining furnace gas efficiency

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 monitor and maintain furnace gas efficiency:

principles of furnace operation/ furnace components

gas paths

insulation (refractory)

combustion principles

importance of flame patterns/flame impingement

methods of resolving combustion/gas problems

ability to isolate problem to item of equipment

Range Statement

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

environment

Auxiliary equipment may be anything that is portable and mobile that is not part of the fixed infrastructure, and may include:

weighers

compressors

distribution control systems

feeders

gantry cranes and attachments and other mobile equipment

hand and power tools

hoses (water and air)

pumps

Pre-start checks may include:

availability of equipment

detection of conditions that are unusual

job requirements

personnel availability

walk through plant

communications

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-up checks may include:

draft systems

cameras and monitors

checking distribution control system (DCS)

chutes

display instruments, lights and gauges

equipment stop engine lights

hydraulic system

isolations

lighting

suppression systems/valves

visual and audio warning devices and lights

Monitoring may include:

blockages and spillages

feed rates

overloads

pressures

power draw

wear and tear

emissions

levels

temperatures

moisture content

on-stream analysis (OSA)

filtering

corrosion

indicators including"

alarms

distribution control systems

mimic panel

screens

temperature

flow

weight

pressure

Furnaces may be:

fixed - vertical/cylindrical

rotary - vertical/cylindrical

Equipment and plant cleaning methods may include:

degreasing

forced air

sweeping

Plant condition may include:

air ingress to furnace

fuel flow too low or too high, surging

discharge of flue dust

molten metal splashes

moisture levels incorrect

Burners may be:

diesel

natural gas

Minor plant maintenance may include:

lubrication

minor adjustments to operational plant

cleaning plant, equipment and work area

installation/removal of devices to allow safe maintenance

fixing leaks