Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

PPMSPR440 Mapping and Delivery Guide
Troubleshoot and rectify stock preparation systems

Version 1.0
Issue Date: December 2021


Qualification -
Unit of Competency PPMSPR440 - Troubleshoot and rectify stock preparation systems
Description
Employability Skills
Learning Outcomes and Application This unit of competency describes the outcomes required to identify and analyse causes of system, equipment and product faults and to rectify and report on problems in the stock preparation area of a pulp or paper manufacturing facility. The unit applies to senior operators and production specialists who troubleshoot and rectify stock preparation systems. This typically involves working in a facility with complex integrated equipment and continuous operations.No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

The following resources must be made available:

access to the full range of equipment involved in integrated continuous manufacturing of stock preparation systems in a pulp or paper manufacturing facility

organisational workplace health and safety and standards for stock preparation systems in a pulp or paper mill

testing equipment for stock

maintenance tools and equipment and consumables for stock preparation equipment

personal protective equipment suitable for inspecting and rectifying faulty stock preparation equipment and product

relevant personnel for the purposes of communicating information

template documents for recording system and product faults, diagnostic and corrective action processes operating procedures for inspecting and rectifying faulty stock preparation equipment and product.

Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.

Prerequisites/co-requisites
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities
Slides
PPT
Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Identify and analyse causes of system faults
  • Complete routine visual or physical walk around inspections of plant to identify system faults in line with organisational safety and standard operating procedures.
  • Interpret alarm system alerts and observations to diagnose fault type.
  • Access plant operating logs to assist diagnosis.
  • Sample and test stock for variations from quality specifications; interpret and record results.
  • Analyse all information collected to identify fault type and location.
  • Report fault and communicate proposed actions to rectify.
       
Element: Rectify system and equipment faults.
  • Follow organisational safety and standard operating procedures to shut down and isolate equipment prior to fault rectification.
  • By-pass faulty equipment where the process allows.
  • Repair or replace faulty equipment and make corrective system adjustments.
  • Complete routine preventative maintenance as required.
  • Restore system operations and advise relevant personal of return to normal operation.
       
Element: Rectify product quality faults.
  • Identify variations in specified quality of stock, chemicals and water through routine visual observations.
  • Sample and test stock for variations from quality specifications; interpret and record results.
  • Adjust processes to rectify out-of-specification product.
       
Element: Record and report faults and rectification process
  • Document system and product faults.
  • Record and report diagnostic and corrective action processes to relevant personnel
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Identify and analyse causes of system faults

1.1. Complete routine visual or physical walk around inspections of plant to identify system faults in line with organisational safety and standard operating procedures.

1.2. Interpret alarm system alerts and observations to diagnose fault type.

1.3. Access plant operating logs to assist diagnosis.

1.4. Sample and test stock for variations from quality specifications; interpret and record results.

1.5. Analyse all information collected to identify fault type and location.

1.6. Report fault and communicate proposed actions to rectify.

2. Rectify system and equipment faults.

2.1. Follow organisational safety and standard operating procedures to shut down and isolate equipment prior to fault rectification.

2.2. By-pass faulty equipment where the process allows.

2.3. Repair or replace faulty equipment and make corrective system adjustments.

2.4. Complete routine preventative maintenance as required.

2.5. Restore system operations and advise relevant personal of return to normal operation.

3. Rectify product quality faults.

3.1. Identify variations in specified quality of stock, chemicals and water through routine visual observations.

3.2. Sample and test stock for variations from quality specifications; interpret and record results.

3.3. Adjust processes to rectify out-of-specification product.

4. Record and report faults and rectification process

4.1. Document system and product faults.

4.2. Record and report diagnostic and corrective action processes to relevant personnel

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide evidence that they can:

identify and rectify faults in plant, equipment and product quality and system performance, at least twice in line with required enterprise intervals, relevant to stock preparation systems

select and use appropriate trouble shooting methods in stock preparation systems

use electronic and other control systems, including portable control devices, touch screens or robotics to control equipment and processes as required during troubleshooting

communicate effectively and working safely with others, in the work area when rectifying stock preparation systems

identify, analyse causes and rectify system and equipment faults for stock preparation system types including:

refining system

blending system

proportioning system

broke system

cleaning system

water recovery system

chemical and additive plants

sample and test stock for variations from quality specifications

on the completion of fault rectification jobs, complete accurate detailed records for system and product faults, diagnostic and corrective action processes.

A person competent in this unit must be able to demonstrate knowledge of:

system layout for stock preparation systems

purpose, features and operation of stock preparation system plant, operating parameters and allowable variations

operation and application of electronic and other control systems

relationships between all components of stock preparation plant, processes and associated services

troubleshooting methods that can be applied across system and problem faults in stock preparation systems including:

equipment faults

deviations from operational specifications for equipment

deviations from quality specifications for stock

stock preparation processes and equipment required to:

shut down equipment

restore system operation

purpose of, and processes for sampling and testing stock quality, plant and system operations

quality requirements for different types of stock

effect of process adjustments on stock quality and productivity

safe handling of materials and chemicals

organisational procedures:

standard operating procedures specific to inspecting and rectifying faulty stock preparation equipment and product

workplace health and safety with particular emphasis on equipment lock out, use of personal protective equipment and handling hazardous substances

communication reporting lines

recording and reporting system and product faults, diagnostic and corrective action processes.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Identify and analyse causes of system faults

1.1. Complete routine visual or physical walk around inspections of plant to identify system faults in line with organisational safety and standard operating procedures.

1.2. Interpret alarm system alerts and observations to diagnose fault type.

1.3. Access plant operating logs to assist diagnosis.

1.4. Sample and test stock for variations from quality specifications; interpret and record results.

1.5. Analyse all information collected to identify fault type and location.

1.6. Report fault and communicate proposed actions to rectify.

2. Rectify system and equipment faults.

2.1. Follow organisational safety and standard operating procedures to shut down and isolate equipment prior to fault rectification.

2.2. By-pass faulty equipment where the process allows.

2.3. Repair or replace faulty equipment and make corrective system adjustments.

2.4. Complete routine preventative maintenance as required.

2.5. Restore system operations and advise relevant personal of return to normal operation.

3. Rectify product quality faults.

3.1. Identify variations in specified quality of stock, chemicals and water through routine visual observations.

3.2. Sample and test stock for variations from quality specifications; interpret and record results.

3.3. Adjust processes to rectify out-of-specification product.

4. Record and report faults and rectification process

4.1. Document system and product faults.

4.2. Record and report diagnostic and corrective action processes to relevant personnel

Not Applicable

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Complete routine visual or physical walk around inspections of plant to identify system faults in line with organisational safety and standard operating procedures. 
Interpret alarm system alerts and observations to diagnose fault type. 
Access plant operating logs to assist diagnosis. 
Sample and test stock for variations from quality specifications; interpret and record results. 
Analyse all information collected to identify fault type and location. 
Report fault and communicate proposed actions to rectify. 
Follow organisational safety and standard operating procedures to shut down and isolate equipment prior to fault rectification. 
By-pass faulty equipment where the process allows. 
Repair or replace faulty equipment and make corrective system adjustments. 
Complete routine preventative maintenance as required. 
Restore system operations and advise relevant personal of return to normal operation. 
Identify variations in specified quality of stock, chemicals and water through routine visual observations. 
Sample and test stock for variations from quality specifications; interpret and record results. 
Adjust processes to rectify out-of-specification product. 
Document system and product faults. 
Record and report diagnostic and corrective action processes to relevant personnel 

Forms

Assessment Cover Sheet

PPMSPR440 - Troubleshoot and rectify stock preparation systems
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

PPMSPR440 - Troubleshoot and rectify stock preparation systems

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: