Elements and Performance Criteria

Hazards
Hazards may include, but are not limited to:
asbestos lagging
chemical hazards
thermal hazards
manual handling hazards
machinery guard requirements
hot exposed steam pipe
leakage of steam
leakage of fuel
odour of gas
fumes from a liquid chemical spill
faulty/broken ladder or hand rail
working at heights
flammable liquids
fire and explosion
electrical hazards
work area:
illumination
excessive noise from machinery
spillage of oil
rubbish and combustibles
obstruction
Risk control methods
Risk control methods refer to the systematic process of eliminating or reducing the risk to personnel and property through the application of controls.
It includes the application of the hierarchy of control:
Elimination
Substitution
Isolation
Engineering controls
Administrative controls
Personal protective equipment
Appropriate standards
Appropriate standards may include, but are not limited to:
legislation
codes of practice
manufacturer specifications
Australian Standards
technical standards (International)
industry standards (where applicable)
Type of boiler
Type of standard boiler may include:
fire tube
water tube
once through boilers
waste heat
electrical
novel or unique
Standard boiler
Standard boiler includes:
vessel or an arrangement of vessels and interconnecting parts, wherein water is heated above atmospheric pressure by the application of:
fire
the products of combustion
electrical power
similar means
The boiler may have:
fixed and modulating combustion controls, fixed and modulated air supply, a single fuel source and will have:
valves
gauges
fittings
controls
boiler setting and directly associated equipment
Procedures
Procedures may include, but are not limited to:
manufacturer guidelines (e.g. instructions, specifications or checklists)
industry operating procedures
workplace procedures (e.g. work instructions, operating procedures or checklists)
Equipment
Equipment may include, but is not limited to:
gas monitoring equipment
water testing equipment
fire-fighting equipment
workplace first aid equipment
work platform and associated gear, such as walkways
Communication methods
Communication methods may include, but are not limited to:
verbal and non-verbal language
written instructions
signage
hand signals
listening
questioning to confirm understanding
appropriate worksite protocol
Appropriate personnel
Appropriate personnel may include, but are not limited to:
production workers
maintenance workers
supervisors and managers
other boiler operators
suppliers
colleagues
Records
Records may include, but are not limited to:
operating log books
maintenance records
records of faults and potential faults
isolation procedures
safe operating procedures
daily operating inspections
repairs carried out according to manufacturer recommendations and operating procedures
workplace record keeping requirements
details of any daily or periodic maintenance work
details of yearly programmed or additional maintenance work
Risk control measures
Risk control measures may include, but are not limited to:
barricades and controls
machine guarding
fall prevention
pedestrian controls
adequate illumination
noise controls
signage
personal protective equipment:
thermally insulated gloves
hard hat protection
ear protection (muffs or plugs)
chemical resistant gloves and apron
respiratory devices
eye protection
working protective gloves
whole body fire-resistant clothing
Communication equipment
Communication equipment may include, but is not limited to:
two way radios
mobile phones
intercoms
landline telephones
pagers
satellite phones
computers
Pre-start up checks
Pre-start up checks may include, but are not limited to:
testing warning lamps or visual warning indicators
control panel checks
checks of feedwater supply system
fuel supply/heat source system
operation and position of boiler valves
combustion air supply system
boiler water level
essential fittings and gauges
selection of personal protective equipment
inspection and location of inspection and explosion doors (where applicable)
identification of hazards and management of risks and maintenance problems
fire-fighting equipment
manufacturer recommendations and checklists
relevant records and logs
Start up
Start up may include, but is not limited to:
purge boiler furnace
heat input
warm-up reticulation system
venting the boiler of air
steam traps and steam line purge system operations
reticulation line pressure
steam usage and supply
Maintenance
Maintenance may include, but is not limited to:
leaking steam pipe
pressure gauge accuracy
exposed electrical wiring
defective illumination in the workplace
leaking fuel pump gland
leaks in high pressure feed line
leaking gauge glass mounting
leaking safety valve
isolation procedures, hardware and equipment
Faults
Faults may include, but are not limited to:
abnormal operating conditions
boiler tube failure
feedwater supply and/or other major auxiliary loss
wet steam
high dissolved oxygen
pH of water
high conductivity
actuator or valve mechanical or electrical fault/failure
instrument failure
steam leak
Diagnosed
Diagnosed may include, but is not limited to:
senses:
audio
smell
touch
visual
remote or local indicators and recorders
computers and alarms:
visible
audible
Operating log
Operating log may include, but is not limited to:
date and time of checking
each check, examination and results
printed and signed name of person who performed the checks
date and time of any lockout or equipment malfunction
results of tests on boiler or feedwater
changes in operation
Valves and fittings
Valves and fittings may include, but are not limited to:
safety valves
gauge glasses
main steam stop valve
feedwater stop valve
feed check valve
blow down valve
steam side/line drain valves
flame failure detection device
water level controller
boiler steam pressure gauge
Monitored
Monitored may include, but is not limited to:
water supply system
checks of steam reticulation line pressure
usage and supply of steam
quality of steam
combustion/heat source system and management
feedwater system
fuel system
combustion air supply
water level
boiler steam pressure
boiler and steam manifold valves (where fitted)
soot blowers (where fitted)
operation of control/safety devices, including control panels
Tested
Tested may include, but is not limited to:
response checks
standby plant ‘cut in’ tests
valve operating checks
hydrostatic tests
performance tests
alarm and protection tests
Tests
Tests may include, but are not limited to:
pH levels
conductivity
oxygen
TDS
hardness
other contaminants
Chemicals
Chemicals may include, but are not limited to:
oxygen scavenger
feedwater additives
other chemicals
hardness
condensate chemicals
pH buffers
Handover
Handover may include, but is not limited to:
previous load requirements
maintenance issue, including equipment isolated for maintenance
operational incidences
read operating log
general inspection of boiler to detect any defects
accept responsibility of boiler
noted equipment malfunctions
required equipment tests
Emergencies
Emergencies may include, but are not limited to:
tube failure
loss of water level
power failure
inadequate housekeeping
explosion
fire
bomb threat
terrorism
personal accidents
chemical spills
major steam leaks
major water leaks and flooding
natural disasters
oil spills
Appropriate emergency responses may include, but are not limited to:
identification of emergency
isolation of heat source
selection and application of appropriate fire-fighting equipment and personal protective equipment
notification of downstream users
operation of boiler only when safe to do so
notification of appropriate regulatory authorities, such as state, territory, federal and boiler manufacturer
Shut down
Shut down may include, but is not limited to:
checks of water level
cooling down process
valve settings
equipment isolation
boiler pressure/vacuum
fuel/heat source isolation in accordance with manufacturer recommendations
boiler post-purge
Storage mode
Storage mode may include, but is not limited to:
wet and dry storing
open or closed position

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
Successful assessment of this unit meets the competency requirements of the Model WHS Regulations, Part 4.5 High Risk Work.
State and territory WHS regulators have mandated use of the Assessment Instruments for this unit which have been endorsed by the national body responsible for WHS matters.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
Assessors must ensure that candidates can competently and consistently:
comply with WHS licensing legislation
effectively communicate and work safely with others in the work area
effectively conduct hazard identification and risk assessment procedures
effectively demonstrate the ability to identify harmful energy sources and the means to make them safe
effectively plan work, start up, monitor and shut down a boiler according to procedures
effectively conduct boiler diagnosis, testing and handover operation to other personnel.
Context of and specific resources for assessment
Assessment of the safe and effective application of knowledge and skill to workplace tasks (performance) must be undertaken using the endorsed Assessment Instruments.
Assessment of performance must be undertaken either in the workplace or in a realistically simulated workplace setting.
Assessors must ensure that assessment in the workplace is organised to ensure that all the required equipment and materials and a suitable working area are made available to suit the assessment and the workplace.
Assessment must occur under standard and authorised work practices, safety requirements and environmental constraints.
Assessment is to comply with relevant appropriate standard requirements.
Applicants must have access to:
personal protective equipment for the purpose of the Performance Assessment
appropriate boiler and equipment in safe condition
communication equipment (e.g. two way radios, mobile phones, landline telephones and computers, as applicable).
Method of assessment
Assessment must be conducted using the national WHS endorsed Assessment Instruments. These Instruments provide advice on their application.
The use of simulation in the assessment of this unit of competency may be acceptable in certain operational and safety circumstances.
Assessment should be conducted on a one-on-one basis with the assessor.
Assessment may be conducted in conjunction with the assessment of other units of competency.
Assessment methods must confirm consistency and accuracy of performance together with application of underpinning knowledge.
Assessment must confirm a reasonable inference that competency is not only able to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.
Guidance information for assessment
Further information about endorsed Assessment Instruments may be obtained from state/territory WHS regulators.