Unit of competency details

Unit descriptor 

This unit describes the outcomes required to co-ordinate a power generation system shutdown in the pulp and paper industry

General legislation, regulatory, licensing and certification requirements applicable to this unit are detailed in the range statement

Specific high risk licensing requirements for this unit may be applicable and are to be met separately and prior to the achievement of this unit

Application of the unit 

This unit applies to operators who co-ordinate a power generation system shutdown in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations

This unit generally applies to those who:

• assess cause and effects of shutdown
• implement shutdown procedures, and
• record and report shutdown data

to meet safety, quality and productivity requirements

It does not include managing a power generation system startup, monitoring and controlling power generation systems or troubleshooting and rectifying power generation systems

Employability skills 

This unit contains employability skills

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. Assess cause and effects of shutdown

1.1. Cause and effects of shutdown is assessed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

1.2. Work area instructions or maintenance schedules are used to co-ordinate a planned shutdown

1.3. Cause of unplanned shutdown is identified and located

1.4. Effects of unplanned shutdown are assessed to determine impact on operations

1.5. Faulty plant is isolated/contained where possible to allow continued production as required

1.6. Unplanned shutdown is communicated to appropriate personnel and power authorities as required

2. Implement shutdown procedures

2.1. Shutdown procedures are implemented within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

2.2. Process supplies shutdown procedures are followed as required

2.3. Planned shutdown is implemented

2.4. Unplanned shutdown is responded to and rectified

2.5. Isolation requirements are implemented as required

2.6. Inspections are undertaken as required

3. Record and report shutdown data

3.1. Shutdown data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

3.2. Shutdown information is recorded, including corrective action as required

3.3. Shutdown information is reported to relevant personnel and power authorities as required

REQUIRED SKILLS AND KNOWLEDGE 

This describes the skills and knowledge required for this unit.

Required skills 

• Uses required forms of communication in co-ordinating a power generation system shutdown
• 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
• Responds to monitoring and warning devices
• Communicates with customers and other relevant personnel
• Identifies and actions problems within level of responsibility
• Identifies and responds appropriately to shutdown causes
• Responds to problems associated with plant shutdown and unplanned shutdown to ensure safety quality and productivity
• Coordinates and plans shutdown activity
• Identifies and monitors process control points
• Maintains situational awareness in the work area
• Uses measuring equipment as required
• Uses tools and equipment
• 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 power generation systems 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
• Types, causes and effects of power generation plant 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
• Working knowledge of power generation plant, processes, layout and associated services sufficient to carry out shutdown activities within level of responsibility
• Electrical isolation procedures
• Principles of transformers and circuit protection systems within level of responsibility
• Power factor characteristics and effects
• Power systems testing and test procedures
• Power distribution systems
• AC/DC generation principles
• Output control and regulation principles
• Effect of steam quality on turbine operation
• Operational tolerances of the turbine system and the effect of operating outside these tolerances
• 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 power generation systems, within level of responsibility

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 

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 co-ordinating a power generation system shutdown

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 power generation system operations

Access to the full range of equipment involved in integrated continuous manufacturing for power generation systems 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

Management and operation of power generation may include:

• availability of required supplies
• electricity generation
• regulation and distribution systems

Materials and supplies may include:

• water
• air
• steam
• electricity
• gas

Equipment may include:

• boilers
• high and low voltage transformers
• steam or gas turbine driven alternators
• switchboards
• water systems and auxiliary plant
• circuit breakers
• AC/DC generation and distribution systems
• protective equipment
• measuring and recording equipment
• computer systems
• electronic screens and alarms
• process control systems
• analogue and digital instrumentation
• fully automated, semi-automated, manually operated plant and equipment appropriate to the power generation process

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
• appropriately endorsed operator licensing
• local power authority rules and regulations

Documentation, procedures and reports may include:

• SOP
• quality procedures
• environmental sustainability requirements/practices
• plant manufacturing operating manuals
• enterprise policies and procedures
• oil or chemical spills and disposal guidelines
• plant isolation documentation
• safe work documentation e.g. plant clearance, job safety analysis, permit systems
• operational logs and reports
• maintenance logs
• Materials Safety Data Sheets (MSDS)
• process and instrument diagrams

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