Unit of competency details

Elements describe the essential outcomes of a unit of competency.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide.

ELEMENT

PERFORMANCE CRITERIA

1 Prepare the low grade fugal station for operation

1.1 Massecuite is conditioned to meet production requirements

1.2 Services are confirmed as available and ready for operation

1.3 Equipment is checked to confirm readiness for use

1.4 The low grade fugal station is set up to meet production requirements

2 Operate and monitor low grade fugal station

2.1 The low grade fugal station is started up and operated according to company procedures

2.2 Control points are monitored to confirm performance is maintained within specification

2.3 C sugar and C molasses meet specification

2.4 Equipment is monitored to confirm operating condition

2.5 Out-of-specification process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure

2.6 The workplace meets housekeeping standards

3 Handover the low grade fugal station

3.1 Workplace records are maintained in accordance with workplace procedures

3.2 Handover is carried out according to workplace procedure

3.3 Low grade fugal station operators are aware of system and related equipment status at completion of handover

4 Shut down the low grade fugal station

4.1 The appropriate shut down procedure is identified

4.2 The low grade fugal station is shut down according to workplace procedures

4.3 The low grade fugal station is prepared for storage in shut down mode

4.4 Maintenance requirements are identified and reported according to workplace reporting procedure

Required skills include:

Ability to: 

• access workplace information to identify production requirements
• select, fit and use personal protective clothing and/or equipment
• confirm supply of necessary materials and services
• confirm equipment status and condition
• follow start up procedure
• start up and operate in both automatic and manual modes
• monitor:

• fugal load
• magma and molasses quality
• crystal formation in C molasses
• massecuite feed temperatures
• equipment condition including screen condition and vibration
• magma and molasses purity
• molasses temperature and brix
• magma tank stock level and remelt rates

• control station throughput to meet factory throughput
• take corrective action in response to out-of-specification results
• shut down and clean fugals according to schedule or as indicated by equipment monitoring
• report and/or record corrective action as required
• record workplace information
• demonstrate shift handover procedure
• shut down equipment in response to an emergency situation
• demonstrate an operational shut down procedure
• prepare equipment for cleaning/maintenance
• maintain work area to meet housekeeping standards

Required knowledge includes:

Knowledge of: 

• purpose and basic principles of low grade fugal operation including C molasses cooling and storage and operating efficiencies for low grade fugals
• terminology such as brix and purity
• the effect of C molasses dilution and temperature on C massecuite viscosity
• the effect of C massecuite conditioning on low grade fugal performance
• the circuit flow of this process and relationship to related processes
• factors that affect throughput and recovery including the relationship between crystalliser throughput, magma stock and remelt rate
• equipment purpose and basic operating principles of low grade fugal equipment
• services used
• operating requirements and parameters
• significance and method of monitoring control points within the process
• common causes of variation and corrective action required
• hazards and controls
• purpose and limitations of protective clothing and equipment
• lock out and tag out procedures
• requirements of both operational and long term shut down conditions to ensure the equipment is left in a safe state for the period of the shutdown and to minimise any delays in future start up
• procedures and responsibility for reporting problems
• environmental issues and controls
• waste handling requirements and procedures
• recording requirements and procedures

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

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed.

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

Evidence of ability to:

• access workplace information to identify production requirements
• follow start up procedure
• start up and operate in both automatic and manual modes
• monitor the process and equipment operation to maintain the process
• control station throughput to meet factory throughput
• take corrective action in response to out-of-specification results
• shut down and clean fugals
• report and/or record corrective action as required
• shut down equipment in response to an emergency situation
• demonstrate an operational shut down procedure
• prepare equipment for cleaning/maintenance.

Context of and specific resources for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

• Operating procedures and related advice on equipment operation including advice on safe work practices and environmental requirements
• Personal protective clothing and equipment
• Product and process specifications and operating parameters
• Low grade fugal station equipment
• Materials including massecuite and services as required
• Material Safety Data Sheets where appropriate
• Housekeeping standards and procedures
• Advice on environmental management issues relevant to work responsibilities
• Workplace information recording systems, requirements and procedures.

They may also require

• Cleaning procedures, sampling schedule and procedures and maintenance procedures and tools depending on the work requirements.

Method of assessment

Other units of competency relevant to the work role should be assessed in conjunction with this unit. This may include:

• SUG202A Collect and prepare samples
• SUG213A Perform standard tests on a cane sample
• FDFOP2030A Operate a process control interface.

Guidance information for assessment

To ensure consistency in one's performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

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.

Policies and procedures 

Work is carried out in accordance with company policies and procedures, licensing requirements, manufacturer's recommendations, legislative requirements, codes of practice and industrial awards and agreements.

Codes of practice 

Codes of practice include the Sugar Milling Operations Industry Code of Practice.

Workplace information 

Workplace information can include:

• Standard Operating Procedures (SOPs)
• specifications
• production schedules
• manufacturer's specifications.

Fugal equipment 

Low grade fugal equipment may include:

• low grade fugals
• massecuite feed pump
• distributor
• fugal water and steam system
• magma screw and pump
• molasses pump and cooler
• magma remelt system
• molasses tank.

Equipment status 

Confirming equipment status involves

• conducting relevant pre-start checks
• confirming that housekeeping standards are met
• all safety guards are in place
• equipment is operational.

It may also involve checking operation/calibration of measuring instrumentation.

Services 

Services may include:

• power
• water
• steam
• compressed and instrumentation air.

Tests 

Where tests are conducted as part of operation typical requirements are observation using a microscope and product density.

Equipment operation and monitoring 

Operation and monitoring of equipment and processes typically requires the use of control panels and systems.

Process monitoring 

Monitoring the process may involve the use of production data such as performance control charts.

Control points 

Control points refer to those key points in a work process which must be monitored and controlled.

Teamwork 

Work may require the ability to work within a team environment.

Information systems 

Information systems may be print or screen based.