Elements and Performance Criteria

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. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs if the candidate, accessibility of the item, and local industry and regional contexts.
Codes of practice/ standards
Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.
Appropriate action
Appropriate action includes:
determining problems needing action
determining possible fault causes
rectifying problem using appropriate solution within area of responsibility
following through items initiated until final resolution has occurred
reporting problems outside area of responsibility to designated person.
Emergency responses
Emergency responses include those related to:
evacuation due to fire
loss of power
excessive emissions of fumes or particulate
major oil spill
equipment failure
Equipment and tools
Equipment and tools may include:
hand tools
harnesses and slings
materials handling equipment.
Hazards
Hazards may include:
heat (burns, dehydration and heat stress)
energy sources, eg hydraulic, pneumatic and electric
high pressure piping and valves
pinch and crush points
moisture
banned items
mobile equipment and pedestrian interaction
suspended loads and roller conveyors
hazardous materials, eg heat transfer fluid (HTF), tar and pitch, coal tar pitch volatiles (CTPV).
Hazard control measures
Hazard control measures should follow the hierarchy of control, be specific to the hazard and work area and include relevant Personal Protective Equipment.
Housekeeping
Housekeeping procedure may include cleaning the area, removal of contaminants, safety inspections and rectification of issues that could compromise safety.
Instrument/electrical systems
Instrument/electrical systems may include:
emergency shutdown systems
fire systems
pressure and temperature control systems
communications systems
utility systems.
Isolation
Isolation refers to the complete isolation of the equipment from all sources of power or energy or isolate process flows and movement of machinery such to render it safe to work on as per site procedure.
Monitoring systems
Monitoring systems in the carbon anode forming process may include:
monitoring bearing lubrication
monitoring pre-heat distribution of the anode
monitoring moisture content of the anode
monitoring strainers on the anode cooling system
monitoring the cooling tower
monitoring anode forming
mobile equipment condition
checks on pitch pump, paste mixer and cleaning discharge for irregularities
monitoring paste build-up on scale doors, cover weight and mould seals
vacuum former failure
monitoring abnormal trends in the operation of equipment or product specification
screens, samplers, grates, grids, fume scrubbers, weight feeders, and dust collection systems.
Monitor and adjust operational variations
Monitor and adjust operational variations using troubleshooting techniques may refer to the use of:
historical data and records of common faults
troubleshooting lists and directives
site procedures.
Procedures
Procedures may be written, verbal, computer-based or in some other form. They include:
all work instructions
standard operating procedures
formulas/recipes
batch sheets
temporary instructions
any similar instructions provided for the smooth running of the plant.
For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (eg Responsible Care) and government regulations.
Out-of-parameter issues
Out-of-parameter issues, faults and problems may include:
out-of-parameter operation or product
fluctuation in temperature, power consumption or product movement.
vibe plate distribution and cleaning
inspections on the compaction station
blocked strainers on the anode cooling system
paste belt irregularities
anode cooling system not operating properly.
jam-ups on power and free conveyors
instruments and equipment requiring cleaning
equipment mechanical and electrical problems
flow path blockages
out-of-parameter emissions
unavailability of equipment, personnel or material.
Personal protective equipment
Personal Protective Equipment (PPE) requirements relate to the specified PPE for the task or job to be undertaken. PPE may include specific insulated boots, heat resistant material, full-ventilated suits, full-face masks or situation specific equipment.
Pre-start checks
Pre-start checks relate to the required site or equipment pre-start checklist and must be completed before the equipment is operated or as otherwise stated in the procedures.
Reports
Reports and records may include:
routine inspections (daily readings, monthly checks)
scheduled maintenance activities
computer readouts locally or in the control room
shift log sheet
mandatory or statutory inspections
hazard, accident and incident reports
quality inspection reports of the product.
Shutdown procedures
Shut down procedure must follow equipment and site authorised checklist and may include:
communication to supply and delivery areas
communication to impacting areas
obtaining appropriate authorisations
rescheduling operations
liaison with maintenance teams.
Start-up procedures
Start-up procedure will conform to site procedure and include:
safety and pre-start checks
accessing shift logs and equipment records
pre-shift briefing information
records and reports from the previous shift.
Work requirements
Work requirements includes shift briefings, shift logs supervisor or crew leader meetings, toolbox talks and handover details.
Health, safety and environment (HSE)
All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.
Persons are required to have skills in hazard identification, assessment and application of control measures, eg spills and leaks identified, contained and cleaned up. Exposure to hazardous materials requires minimal personal contact, recognition of hazards and appropriate controls.

EVIDENCE GUIDE
The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for the Training Package.

Overview of assessment
Assessment for this unit of competency will be on an operating plant. The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency. Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.
Simulation may be required to allow for timely assessment of parts of this competency unit (eg Elements 2, 5). Simulation should be based on the actual plant and will include walk-throughs of the relevant competency components. Simulations may also include the use of case studies/scenarios and role plays.

Critical aspects for assessment and evidence required to demonstrate competency in this unit
Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.
The emphasis should be on the ability to stay out of trouble rather than on recovery from a disaster.
Consistent performance should be demonstrated. In particular look to see that:
emergency responses are known
hazards are recognised and all site requirements to reduce or remove hazards are known and completed as part of the job
early warning signs of equipment/processes needing attention or with potential problems are recognised, ie monitoring systems in the carbon anode forming process, including equipment, material handling systems and mobile equipment.
These aspects may be best assessed using a range of scenarios/case studies/what-ifs as the stimulus with a walk-through forming part of the response. These assessment activities should include a range of problems, including new, unusual and improbable situations that may have been generated from the past incident history of the plant, incidents on similar plants around the world, hazard analysis activities and similar sources.

Context of and specific resources for assessment
Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations. A bank of scenarios/case studies/what-ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Method of assessment
In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units. Consider co-assessment with other relevant units.
This competency may be assessed in conjunction with:
MSAPMOHS200A Work safely
MSAPMOHS110A Follow emergency response procedures
TDTD1097B Operate a forklift.
Other units which are relevant to the job.

Guidance information for assessment
Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.