Application
This unit applies to operators who shut down and bank steam boiler/s in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations This unit generally applies to those who: prepare boiler for shutdown conduct boiler inspection and maintenance store boiler in shutdown mode respond to unplanned or emergency shutdowns, and record and report shutdown data to meet safety, quality and productivity requirements It does not include managing steam boiler startup, monitoring and controlling boiler operation or troubleshooting and rectifying boiler plant systems |
Prerequisites
Not Applicable
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Prepare boiler for shutdown | 1.1. Boiler is prepared for shutdown within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements |
1.2. Maintenance requirements are identified and reported | |
1.3. Appropriate isolations are initiated | |
1.4. Faulty plant is isolated/contained where possible to allow continued production as required | |
1.5. Boiler and ancillary plant are shut down | |
2. Conduct boiler inspection and maintenance | 2.1. Boiler inspection and maintenance is conducted within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements |
2.2. Boiler is prepared for inspection | |
2.3. Condition of boiler is established to ensure safe removal of equipment | |
2.4. Inspections and maintenance is carried out | |
2.5. Internal and external cleaning of boiler and fittings are undertaken as required | |
3. Store boiler in shutdown mode | 3.1. Boiler is stored in shutdown mode within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements |
3.2. Storage time and condition of storage are established | |
3.3. Boiler is stored in a safe condition for access in accordance with manufacturer's specifications | |
3.4. Stored boiler water and chemicals are analysed and handled when boiler is stored for extended periods | |
4. Respond to unplanned or emergency shutdowns | 4.1. Unplanned or emergency shutdowns are responded to within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements |
4.2. Shutdown requirement is responded to immediately | |
4.3. Emergency conditions are complied with in accordance with legislative and enterprise procedures, where applicable | |
4.4. Cause of shutdown is identified and located where possible | |
4.5. Immediate safety of personnel and plant is ensured | |
4.6. Continuing plant operation is monitored and maintained in safe working conditions and customers are notified | |
4.7. Relevant personnel are notified to rectify and make plant ready for restart | |
5. Record and report shutdown data | 5.1. Shutdown data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements |
5.2. Shutdown information is recorded, including corrective action as required | |
5.3. Shutdown information is reported to relevant personnel as required |
Required Skills
This describes the skills and knowledge required for this unit. |
Required skills |
Uses required forms of communication in shutting down and banking steam boiler/s Reads and interprets required documentation, procedures and reports within level of responsibility Accesses, navigates and enters computer-based information Interprets instruments, gauges and data recording equipment Interprets specifications and customer orders Prepares written information and enters data to support groups and teams Identifies and actions problems within level of responsibility Identifies and monitors process control points Implements boiler bank, standby or store procedures Sets up boiler and/or re-starts within appropriate time Conducts pre-operational checks Identifies and responds appropriately to shutdown causes Respond to problems associated with plant shutdown and unplanned shutdown to ensure safety quality and productivity Coordinates and plans shutdown activity Maintains situational awareness in the work area Uses measuring equipment as required Operates high risk equipment as required Analyses and uses sensory information to adjust process to maintain and co-ordinate safety, quality and productivity Uses electronic and other control systems to control equipment and processes as required |
Required knowledge |
Procedures, regulations and legislative requirements relevant to steam generation operations including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping Relevant forms of communication Basic problem-solving techniques consistent with level of responsibility Working knowledge of steam generation plant, processes, layout and associated services sufficient to carry out shutdown activities within level of responsibility Types, causes and effects of steam boiler shutdowns Required responses to all unplanned shutdowns (e.g. power outage, mechanical breakdown, blockages, jamming, air supply, control system failure) to ensure safety quality and productivity Process and procedures for plant shutdowns and unplanned shutdowns Plant and machinery functions and operations Emergency procedures and responses Boiler water treatment system and reasons for treatment Operation of plant and systems Application of high risk equipment as required Sensory information that indicates a deviation from standard operating parameters Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control boiler plant operations, within level of responsibility |
Evidence Required
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 | Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of: the required knowledge and skills tailored to the needs of the specific workplace applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements applicable aspects of the range statement practical workplace demonstration of skills in the shutting down and banking of steam boilers |
Context of and specific resources for assessment | A workplace assessment must be used to assess: the application of required knowledge on the job the application of skills on the job, over time and under a range of typical conditions that may be experienced in steam generation operations Access to the full range of equipment involved in integrated continuous manufacturing of steam generation operations in a pulp or paper mill is required |
Method of assessment | A combination of assessment methods should be used. The following examples are appropriate for this unit: observation of applied skills and knowledge on the job workplace demonstrations via a mock-up or simulation that replicate part/s of the job answers to written or verbal questions about specific skills and knowledge third-party reports from relevant and skilled personnel written evidence e.g. log sheet entries, checklist entries, test results Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job) A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package |
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. | ||
Productivity requirements may include: | energy efficiency waste minimisation evaporation minimisation, including landfill and waste water reduction environmentally safe waste disposal consideration of resource utilisation, including fibre efficiency minimising delays chemical recovery maximisation meeting key performance indicators line speed handovers quality checks meeting output targets i.e. net tonnes per employee per annum machine/process time availability i.e. time the machine or process is making product machine/process production rate | |
Boiler types may include: | fire tube water tube and may be operated in conjunction with other steam driven plant and operations including: paper making machines turbines digesters evaporators heating plant | |
Pre-operational checks may include: | low water level alarm high water level alarm low water level alarm lockout hydrostatic test burner management system safety valve test | |
Materials and supplies may include: | chemicals coal oil gas additives air water wood waste steam recovery process products power | |
Equipment may include: | boiler and auxiliary plant boiler heating systems steam distribution system fuel and fuel delivery system plant dust removal and combustion waste fuel management system extraction systems water distribution systems compressed air systems steam temperature control plant chemical dosing system water treatment system flame detection equipment hand and power tools computer systems electronic screens and alarms process control systems analogue and digital instrumentation fully automated, semi-automated, manually operated plant and equipment appropriate to steam generation operations | |
Electronic control systems may include: | Digital Control System (DCS) touch screens robotics | |
Legislation, regulatory, licensing and certification requirements may include: | OHS and environmental requirements (local, state and commonwealth) activity or task specific high risk licensing requirements appropriate boiler/pressure vessel operator certification confined space standards and regulations | |
Documentation, procedures and reports may include: | SOP quality procedures environmental sustainability requirements/practices plant manufacturing operating manuals oil or chemical spills and disposal guidelines plant isolation documentation safe work documentation e.g. plant clearance, job safety analysis, permit systems enterprise policies and procedures job sheets manufacturer's specifications maintenance documentation statutory requirements Materials Safety Data Sheets (MSDS) operator's log process and instrument diagrams | |
Maintenance may include: | operator level maintenance as per site agreements operator maintenance schedules maintenance systems maintenance suppliers proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM) | |
Actions may include: | process adjustments reporting to authorised person rectifying problem within level of responsibility | |
Communications may include | interaction with: internal/external customers and suppliers team members production/service coordinators maintenance services operational management statutory authorities | |
Situational awareness may include | awareness of: traffic pedestrians location of equipment product hazards obstruction unexpected movement | |
Forms of communication may include: | written e.g. log books, emails, incident and other reports, run sheets, data entry reading and interpreting documentation e.g. SOP, manuals, checklists, drawings verbal e.g. radio skills, telephone, face to face, handover non-verbal e.g. hand signals, alarms, observations signage e.g. safety, access | |
Sensory information may include: | visual sound feel touch smell vibration temperature |
Sectors
Not Applicable
Employability Skills
This unit contains employability skills |
Licensing Information
Refer to Unit Descriptor