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. Towards Competency. A Blended Delivery Traineeship Program. Alcoa's Experience. Alcoa Power Plants in WA. Function of Power HousesProvide to the respective refineries:ElectricityCompressed airSteamCondensate. Major Plant in the Power Houses:17 NW Shelf Natural Gas Fired Boilers13 Steam Turbines and Generators 1 Gas Turbine 4 Co-generation Gas Turbines supplying 630MW to the Western Australian Southwest Interconnected Grid3 Heat Recovery Steam Generators
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1. Alcoa World AluminaWestern Australia Operations Powerhouse Operator Traineeship
3. Alcoa Power Plants in WA Function of Power Houses
Provide to the respective refineries:
Electricity
Compressed air
Steam
Condensate
4. Major Plant in the Power Houses:
17 NW Shelf Natural Gas Fired Boilers
13 Steam Turbines and Generators
1 Gas Turbine
4 Co-generation Gas Turbines supplying 630MW to the Western Australian Southwest Interconnected Grid
3 Heat Recovery Steam Generators – 2 co-generation Alcoa Power Plants in WA
6. Alcoa In Australia In 300 locations across 34 countries
Alcoa has been in Australia since the early 1960s
Alcoa currently mines more than 29 million tons of bauxite per year
Alcoa produces 8 million tons of alumina per year (13% of total world demand)
Alcoa produces 545,000 tons of aluminium per year
In Australia Alcoa has:
2 bauxite mines
3 refineries
2 smelters
2 rolling mills
7,500 direct jobs (6,000 employees, 1,500 contractors)
7. Need for a Traineeship High turn-over of operators
Changing economic climate
Experienced operators are hard to find
A significant number of current operators are close to retirement age
Training time for a power plant operator:
2 years for outside operations
Another 2 years for a control room operator
Provision of training to a national standard
A structure for training current operators
8. Key features:
Trained and assessed to ESI Generation Certificate III (IV) in Operations
32 units of competency covering Boilers, Steam Turbines, Gas Turbines and HRSGs
Formal Traineeship registered with the WA Department of Training
Use of the Alcoa internal RTO
Blended delivery training
Flexible learning program
Mentoring by shift trainers and operators
The Traineeship
9. 7 Trainees across 3 sites
5 Male and 2 Female
Ages 22 to 43
10. The Training and Assessment Process
12.
Purpose of presentation:
Demonstrate their knowledge of systems and equipment within their own plant
Share site knowledge of each others plant
Learning together
15. Essential Knowledge and Skills Training Program
Key Features:
Off site training provided by Oakley Training Services
Web based learning via GPiLearn
Trainer led plant lessons
The length of the training block is designed to be the right length for the learning required
16. First Training Block:
8 days
50 GPiLearn lessons and tests
Trainer led training
How to use GPiLearn
Main parts of a Power Plant
How to trace and sketch systems
Reading PI&D drawings
Following Training Blocks:
8 training blocks
1 to 7 days
1 to 42 GPiLearn lessons and tests
Trainer led training on the systems relating to the unit of competency being learnt
17. GPiLearn lessons and tests:
PF0401 - Fuels
PF0402 - Chemistry of Combustion
OP0501 - Major components of the fuel system
OP0503 - The flow path of fuel through the fuel system
OP0507 - Association of temperature and viscosity in burning of fuel oil
OP1001 - Fans associated with the boiler
OP1002 - Function of fans associated with the boiler
OP1004 - Function of the major components of the fans
OP1006 - Function of the air pre-heater
OP1008 - Functions of the major components of the air pre-heater
27. Training session on the draught and fuel systems:
Describe the function of the systems
Describe the operation of the systems
Describe the main plant and equipment
Describe the basic control functions
Conduct a plant walk down
Show GUS display of the system
Draught and Fuel System of a conventional power plant.
33. Internal Assignment
Develop essential knowledge of plant systems and equipment
Training and assessment by the Shift Trainer
Operational Checklist
Demonstrate competence in the workplace
Demonstrate safe operation of plant and equipment
Training and assessment by the Shift Trainer
Safe Working Procedures
Demonstrate and perform tasks in accordance with procedures
39. Assessment based on evidence from:
Web Based Learning
Plant Lessons
Internal Assignments
Operational check lists
Review of Safe Work Procedures completed
Interview with Trainee
42. Key Features:
LMS Traccess 7.1
All Traccess LMS Client users access Traccess LMS via ‘Thin Client’
Thin Client is a terminal server which means that the application runs from a central server to all users
The Thin Client sends “screen shots” from the application (Traccess) server to the user’s desktop