FPPEPG440A Troubleshoot and rectify power generation system

Release: 1

FPPEPG440A Troubleshoot and rectify power generation system

Modification History

Not Applicable

Unit Descriptor

Unit descriptor	This unit describes the outcomes required to troubleshoot and rectify power generation systems 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

Application of the unit	This unit applies to persons who troubleshoot and rectify power generation systems in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations This unit generally applies to those who: identify and diagnose causes of faults rectify faults rectify power quality and distribution faults, and record and report operational data to meet safety, quality and productivity requirements It does not include managing a power generation system startup, shutdown or monitoring and controlling power generation systems

Licensing/Regulatory Information

Refer to Unit Descriptor

Pre-Requisites

Not Applicable

Employability Skills Information

Employability skills	This unit contains employability skills

Elements and Performance Criteria Pre-Content

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.

Elements and Performance Criteria

ELEMENT	PERFORMANCE CRITERIA
1. Identify and diagnose causes of faults	1.1. Causes of faults are identified and diagnosed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 1.2. Abnormal plant conditions and system alarms are interpreted to determine fault type and location 1.3. Physical inspections of plant and processes are made to identify faults 1.4. Cause and source of fault is identified and located 1.5. Relevant historical data is accessed/referred to, to confirm diagnosis 1.6. Diagnoses are communicated to relevant personnel
2. Rectify faults	2.1. Faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 2.2. Shutdown and isolation procedures are implemented as required 2.3. Faulty equipment is repaired or replaced 2.4. Adjustments to process and systems are made to restore normal operations 2.5. Restoration to normal operation is verified and communicated to relevant personnel
3. Rectify power quality and distribution faults	3.1. Power quality and distribution faults are rectified within OHS, SOP, environmental and safe working requirements and practices 3.2. Power quality faults/variations are identified by observation, systematic sampling and testing 3.3. Measurements are taken and tests conducted according to established enterprise procedures and SOP 3.4. Power quality is adjusted whilst generator is on-line to correct variations from specification
4. Record and report operational data	4.1. Operational data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 4.2. Variations from required production output and systems operation faults are documented 4.3. Troubleshooting process and corrective actions are recorded 4.4. Relevant information is communicated to appropriate personnel

Required Skills and Knowledge

REQUIRED SKILLS AND KNOWLEDGE
This describes the skills and knowledge required for this unit.
Required skills
Identifies, accesses and interprets relevant historical and operational data and information Uses required forms of communication in troubleshooting and rectifying power generation systems 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 Communicates effectively with personnel to assist with analysis and resolution of operational problems Assists others to identify and resolve operational problems in the workplace Identifies and actions systems, quality and equipment faults within level of responsibility Identifies causes and effects of faults and corrective action on associated processes Selects and uses appropriate troubleshooting methods Takes timely corrective action to maximise safety, quality and productivity Undertakes necessary calculations to aid troubleshooting as required Identifies and monitors process control points Maintains situational awareness in the work area Perform tests and interprets and records results as required Uses measuring equipment as required Identifies and responds appropriately to shutdown causes Initiates and applies isolations and lockouts as required Maintains required power outputs consistently to specification Conducts routine checking procedures during plant and systems operation Uses tools and equipment Operates high risk equipment as required Analyses and uses sensory information to adjust process to maximise 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 system operation including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping Relevant forms of communication Detailed knowledge of power generation system, processes and associated services sufficient to troubleshoot including: plant layout theory of operation causes and effects of adjustments made to power generation plant and processes relationships between power generation system, processes and associated services An appropriate range of troubleshooting methods Sampling and testing processes for plant and system operations, and process steam supply monitoring - purpose, standards and procedures as per site agreements Types, causes and effects of power generation plant shutdowns Effect of steam quality on turbine operation Operational tolerances of the turbine system and the effect of operating outside these tolerances AC/DC generation principles Output control and regulation principles Power factor characteristics, effects and correction techniques Electrical isolation procedures Principles of operation of transformers and circuit protection systems Power distribution 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 power generation systems, within level of responsibility

Evidence Guide

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 troubleshooting and rectifying power generation systems
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

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 operator endorsement requirements 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

Unit Sector(s)

Not Applicable