Operate Chilled Water System

7/28/2019 Operate Chilled Water System

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NationalSkills

Standard

Copyright WDA 2003Updated on December

Industry Chemical Process

Reference CPS-028-2-0403

Job Function Operate utilities for chemical

Level NSC-2

Unit of Competence Operate chilled water system

manufacturing plant


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UNIT OF COMPETENCE

Operate chilled water system

LEVEL

NSC-2

SN ELEMENTS OF COMPETENCE

1 Prepare to operate chilled water system

2 Start-up chilled water system

3 Monitor and maintain chilled water system

4 Shut down chilled water system


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ELEMENT OF COMPETENCE


UNIT OF COMPETENCE

NSC-2 Operate chille

PERFORMANCE CRITERIA UNDERPINNING KNOWLEDGE RANGE EVI

Field preparation

Personal protectiveequipment

Safety helmet

Safety shoes

Safety goggles

Ear plugs

Gloves

Overalls

Plant and equipment

Pumps

Valves

Piping system

Compressor

Lubrication system

Evaporator

Condenser

Heat exchanger(absorber)

Refrigeration system

Electricity supply

Tanks and vessels

Cooling tower

Cooling water system Chemical treatment

systems

Control instruments


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UNIT OF COMPETENCE



Valves, actuators anddampers

- Electric

- Hydraulic

- Pneumatic

- Manual

Compressed air systems

Filters

Strainers

Pressure control devices

Water analysers

Drum screens andcleaning systems

Documentation

Safety checklist

Shift log

Health, safety andenvironmental hazards

Pressure build up

Compressor and pumpfailure

Hose rupture or leakage

Faulty instruments

Toxic and hazardous

materials

Appropriate person

Supervisor


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UNIT OF COMPETENCE



Relevant process units

- Utility plants

- Process plants

Environment

Operating plant


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UNIT OF COMPETENCE



- Condenser

- Refrigerant

Water analysers

Auxiliary safety andcontrol equipment

Non-conformances andabnormalities

Failure and malfunction

- Pump

- Actuator

- Valve

- Dampers

- Control equipment

Electricity supply failure

Instrument air supplyfailure

Water supply failure

Water quality

Excessive vibration

- Pumps

- Motors

High filter and strainerdifferential pressure

Pressure build up

System leakage

Water temperature

Toxic and hazardousmaterials


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UNIT OF COMPETENCE



Communication mode

Walkie-talkie

Appropriate person

Supervisor


- Utility plants

- Process plants

Environment

Operating plant


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UNIT OF COMPETENCE



1 Chilled water system operation is monitored and maintained inaccordance with given work instructions and established organisationalprocedures

2 Plant and equipment are routinely inspected to ensure good workingcondition in accordance with established organisational procedures

Chilled water tank is monitored

Refrigeration system, compressor and lubrication is monitored

Water level and quality, pumps and heat exchanger are monitored

3 Operating parameters for temperature, flow, pressure and level aremonitored and maintained in accordance with establishedorganisational procedures

4 Water samples are tested to ensure water quality falls within prescribedspecifications in accordance with established organisational procedures

5 Abnormalities encountered during monitoring and maintaining ofcondensate system are rectified, documented and reported toappropriate person in accordance with established organisationalprocedures

6 Relevant industrial health and safety precautions are adhered to duringmonitoring and maintaining of chilled water system in accordance withestablished organisational procedures

7 Where monitoring and maintaining of chilled water system cannot becarried out or completed, appropriate person is informed

1 Organisational procedures relatedto monitoring and maintainingoperation of chilled water system

2 Organisational procedures relatedto inspection of plant and equipment

3 Operating parameters fortemperature, flow, pressure andlevel

4 Organisational procedures relatedto water quality

5 Abnormalities and faults in plantand equipment

6 Organisational procedures relatedto industrial health and safety

Organisational procedures

Monitoring andmaintaining operation ofchilled water system

Inspection of plant andequipment

Water quality

Industrial health andsafety

Monitoring chilled watersystem and equipment

Chilled water tank

Pumps, valves andactuators

Heat exchanger

Filter

Strainer


Operating parameters

- Pressure

- Flow

- Temperature

- Level

Water quality

- Nitrate

- pH

- Water conductivity

- Total dissolvedsolids


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UNIT OF COMPETENCE



Abnormalities and faults inplant and equipment

Failure and malfunction

- Pump

- Actuator

- Valve

- Dampers

- Control equipment

Electricity supply failure

Instrument air supplyfailure

Water supply failure

Water quality Excessive vibration

- Pumps

- Motors

High filter and strainerdifferential pressure

Pressure build up

System leakage

Water temperature

Toxic and hazardousmaterials

Industrial health and safetyprecautions

Use of personalprotective equipment

Use of safety checklistand inspections


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UNIT OF COMPETENCE




Safety helmet

Safety shoes

Safety goggles

Ear plugs

Gloves

Overalls

Appropriate person

Supervisor


- Utility plants- Process plants

Environment

Operating plant


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4 Shut down chilled water system

UNIT OF COMPETENCE



Use of blind tracking list

Relevant permit to work

Abnormalities in shut down

Plant and equipment

- Failure

- Faults

- Damage

- Malfunction

Documentation

Safety checklist

Job report Shift log

Communication mode

Walkie-talkie

Appropriate person

Supervisor


- Utility plants

- Process plants

Environment

Operating plant


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II ASSESSMENT PLAN

A Performance

CANDIDATE NAME NRICJOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE

NSC-2 Operate chilled wa

COMPETENT*ASSESSMENT PERFORMANCE CRITERIA

YES NOREM

A Prepare to operate chilled water system

1 Reference is made to process and instrumentation diagrams,commissioning procedures and technical manuals related to plantand equipment prior to commencement of work activities

2 Chilled water system operational pre-requisites and any givenwork instructions are clarified with appropriate person

3 Appropriate personal protective equipment is worn in accordancewith established organisational procedures

1 Practical test

Given the following:

Chilled water system ormock-up

Process and

instrumentation diagrams

Equipment lists

Technical specifications

Safety checklists

System operation manuals

Materials Safety DataSheets

Commissioning procedures


Walkie talkie

Perform the following taskswithin 1 hour 20 minutes:

Prepare to operate chilledwater system within 20minutes

4 Inspection and field walk-down is carried out to verify plant andequipment status in accordance with established organisationalprocedures

Plant and related equipment are checked

Valve status is checked

Line-up status is checked

Service and utility supply are checked

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NOREM

5 Potential health, safety and environmental hazards are rectifiedand documented in accordance with established organisationalprocedures

6 Where potential health, safety and environmental hazards cannotbe rectified, appropriate person is informed

7 Preparation to operate chilled water system is carried out andcompleted in accordance with industrial health and safetyprocedures

8 Where preparation to chilled water system cannot be carried outor completed, appropriate person is informed

B Start-up chilled water system

9 Start-up of chilled water system is carried out in accordance withgiven work instructions and established organisationalprocedures

Start-up chilled watersystem within 20 minutes

Monitor and maintainchilled water system within20 minutes

Shut down chilled watersystem within 20 minutes

10 Communication with appropriate persons from relevant processunits is carried out in accordance with established organisationalprocedures

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NOREM

11 Chilled water system is lined up in accordance with systemrequirements and established organisational procedures

Tank

Pump

Heat exchanger

Safety and drain valves

12 Refrigeration, chilled and cooling water systems are checked toensure proper line up and integration in accordance with systemrequirements and established organisational procedures

13 Chemical injection dosage to chilled water system is adjusted andmaintained in accordance with established organisationalprocedures

14 Water quality analysers are commissioned in accordance withestablished organisational procedures

2 Oral test

Oral questions to coverperformance criteria 5, 6, 8, 17,18, 23, 25, 33 and 36

Candidates are required toanswer 9 oral questions in 15minutes

Sample Questions forPerformance Criteria

5 What should be done if apotential safety hazard isdiscovered duringpreparation to operatechilled water system?

6 What should be done if anabnormality in plantequipment cannot beimmediately rectified?

8 What should be done ifpreparation to operatechilled water systemcannot be carried out or

completed?15 Instrument controls are commissioned and checked for

functionality in accordance with established organisationalprocedures

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NOREM

16 Control system is set to appropriate pressure, temperature, leveland flow settings in accordance with established organisationalprocedures

17 Non-conformances and abnormalities are identified, rectified anddocumented in accordance with established organisationalprocedures

18 Where start-up of chilled water system cannot be carried out orcompleted, appropriate person is informed

C Monitor and maintain chilled water system

19 Chilled water system operation is monitored and maintained inaccordance with given work instructions and establishedorganisational procedures

17 What should be done if anabnormality in refrigerationsystem is identified duringstart-up of chilled watersystem?

18 What should be done ifstart-up of chilled watersystem cannot becompleted?

23 What should be done if anabnormality in temperatureis identified duringmonitoring of chilled watersystem operation?

25 What should be done ifchilled water quality cannotbe maintained?

33 What should be done if anabnormality in chilled watersystem equipment isdiscovered during shutdown?

36 What should be done ifshut down of chilled water

system cannot becompleted?

20 Plant and equipment are routinely inspected to ensure goodworking condition in accordance with established organisationalprocedures

Chilled water tank is monitored

Refrigeration system, compressor and lubrication ismonitored

Water level and quality, pumps and heat exchanger aremonitored

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NOREM

21 Operating parameters for temperature, flow, pressure and levelare monitored and maintained in accordance with establishedorganisational procedures

22 Water samples are tested to ensure water quality falls withinprescribed specifications in accordance with establishedorganisational procedures

23 Abnormalities encountered during monitoring and maintaining ofcondensate system are rectified, documented and reported toappropriate person in accordance with established organisationalprocedures

24 Relevant industrial health and safety precautions are adhered toduring monitoring and maintaining of chilled water system inaccordance with established organisational procedures

25 Where monitoring and maintaining of chilled water system cannotbe carried out or completed, appropriate person is informed

D Shut down chilled water system

26 Shut down of chilled water system is carried out in accordancewith given work instructions and established organisationalprocedures

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NOREM

27 Shut down sequence and system status are clarified withappropriate person in accordance with established organisationalprocedures

28 Safety precautions are adhered to and personal protectiveequipment is worn in accordance with established organisationalprocedures

29 Communication with appropriate persons from relevant processunits is carried out in accordance with established organisationalprocedures

30 Chilled water equipment operation is stopped and chilled watersystem is isolated in accordance with established organisationalprocedures


Pumps

Heat exchanger

31 Chilled water system is depressured and chilled water is drained,where required, in accordance with established organisationalprocedures

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NOREM

32 Inspection of plant and equipment is carried out to confirm status,and to ensure proper shut down, depressurisation and drainagein accordance with established organisational procedures

33 Abnormalities encountered during shut down of chilled watersystem are rectified, documented and reported to appropriateperson in accordance with established organisational procedures

34 Shut down of chilled water system is accurately documented inaccordance with established organisational procedures

35 Shut down of chilled water system is carried out and completed inaccordance with industrial health and safety procedures

36 Where shut down of chilled water system cannot be carried out orcompleted, appropriate person is informed

E Complete work activities within time scale

37 Work activities are completed within agreed time scale for the unitof competence

* Please tick


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B Knowledge

CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE

NSC-2 Operate chilled w

COMPETENT*ASSESSMENT UNDERPINNING KNOWLEDGE

YES NORE


1 Process and instrumentation diagrams and technical manuals

2 Organisational procedures related to commissioning of chilledwater system

3 Chilled water system operational pre-requisites

4 Personal protective equipment

3 Oral / Written test

Candidates are required toanswer 31 questions in 45minutes.

At least one question will be setfor each knowledge item.

Sample questions are given at

Annex A.

5 Organisational procedures related to industrial health and safety

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NORE

6 Organisational procedures related to safety checks, pre-operational inspection and field-walk down

7 Chemical process plants, chilled water systems and equipment

8 Health, safety and environmental hazards

9 Organisational procedures related to documentation

10 Organisational procedures related to preparation to operate chilledwater system


11 Organisational procedures related to start-up of chilled watersystem

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NORE

12 Parts, functions and operation of chilled water system andequipment

13 Organisational procedures related to communications

14 Organisational procedures related to line up of chilled watersystem

15 Organisational procedures related to chemical injection dosage

16 Organisational procedures related to commissioning of wateranalysers

17 Organisational procedures related to start-up of control system

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NORE

18 Non-conformances and abnormalities


19 Organisational procedures related to monitoring and maintainingoperation of chilled water system

20 Organisational procedures related to inspection of plant andequipment

21 Operating parameters for temperature, flow, pressure and level

22 Organisational procedures related to water quality

23 Abnormalities and faults in plant and equipment

* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NORE



25 Organisational procedures related to shut down of chilled watersystem


27 Organisational procedures related to communications

28 Organisational procedures related to isolation, depressurisationand drainage of chilled water system


* Please tick


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CANDIDATE NAME NRIC

JOB TITLE TELEPHONE

COMPANY

UNIT OF COMPETENCE



YES NORE

30 Abnormalities in shut down

31 Organisational procedures related to documentation

* Please tick


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I certify that the candidate has/has not achieved all thecompetencies required in this unit of competence.

I have audited the assessment and certified tconducted as stipulated by the skills standar

Remarks Remarks

Assessor Signature Supervising Assessor Signature

Assessor Name Supervising Assessor Name

Telephone Telephone

Date Date


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ANNEX A - SAMPLE QUESTIONS

SN UNDERPINNING KNOWLEDGE QUESTIONS

1


Process and instrumentation diagrams and technical manuals 1 Why is it necessary to refer to process and instrumentation diagrams chilled water system?

2 Organisational procedures related to commissioning of chilledwater system

2 What are commissioning procedures?

3 Chilled water system operational pre-requisites 3 What operational pre-requisites should be in place prior to operation o

4 Personal protective equipment 4 List the personal protective equipment required to be worn prior to fiesystem.

5 Organisational procedures related to industrial health and safety 5 What industrial health and safety procedures related to personal proteobserved prior to commencement of work activities?


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6 Organisational procedures related to safety checks, pre-operational inspection and field-walk down

6 Explain how a field-walk down is conducted.

7 Chemical process plants, chilled water systems and equipment 7 Explain the operation of a chilled water system in a chemical plant.

8 Health, safety and environmental hazards 8 List three safety hazards related to chilled water system.

9 Organisational procedures related to documentation 9 Explain what must be documented during preparation to operate chille

10 Organisational procedures related to preparation to operate chilledwater system

10 Explain the main tasks required to be performed when preparing to op

11


Organisational procedures related to start-up of chilled watersystem

11 What must be checked when starting-up chilled water system?


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12 Parts, functions and operation of chilled water system andequipment

12 Why is the purpose of a heat exchanger in a chilled water system?

13 Organisational procedures related to communications 13 How is communication between field and console technicians usually

14 Organisational procedures related to line up of chilled watersystem

14 Explain how a chilled water system is lined up.

15 Organisational procedures related to chemical injection dosage 15 Explain how chemical injection dosage is set and monitored.

16 Organisational procedures related to commissioning of wateranalysers

16 Explain the function of a water analyser.

17 Organisational procedures related to start-up of control system 17 Explain how control system is commissioned.


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18 Non-conformances and abnormalities 18 List three common faults or abnormalities found in chilled water syste

19


Organisational procedures related to monitoring and maintainingoperation of chilled water system

19 Explain the routine tasks performed during monitoring and maintainin


20 Explain how chilled water system is inspected or checked.

21 Operating parameters for temperature, flow, pressure and level 21 Where can information relating to required operating parameters for televel be found?

22 Organisational procedures related to water quality 22 Explain why water quality is important in a chilled water system.

23 Abnormalities and faults in plant and equipment 23 List one common fault during monitoring and maintaining chilled waterectified.


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24 Organisational procedures related to industrial health and safety 24 List two safety precautions which should be observed during monitoriwater system.

25


Organisational procedures related to shut down of chilled watersystem

25 How often is shut down of chilled water system carried out, and what down?

26 Organisational procedures related to industrial health and safety 26 List two important safety procedures which must be observed during ssystem.

27 Organisational procedures related to communications 27 Who are the parties involved in shut down of chilled water system, anout?

28 Organisational procedures related to isolation, depressurisationand drainage of chilled water system

28 How is chilled water system isolated?


29 What should be checked after shut down of chilled water system?


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30 Abnormalities in shut down 30 List three abnormalities in plant and equipment which can occur after system.

31 Organisational procedures related to documentation 31 What must be documented after shut down of chilled water system?


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Operate Chilled Water System

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