How to prepare a Career Episode Report for Professional Engineers?
Skilled Engineers applying to Engineers Australia must submit three career episode reports as part of their competency demonstration report (CDR) (CERs). Engineers Australia’s Career Episode Report provides extensive information on the technical and other abilities that an engineer utilized for the project mentioned. In your career episodes, you must exhibit your professional abilities. Here is an example of a Career Episode Report for a Professional Engineer.
PART-I INTRODUCTION
Career Episode 1.1
The career episode is based on the project “BUCHI Unit for Protein Analysis.” I completed this assignment while working as an Executive Trainee in the Manufacturing Department. The XXX is the name of the firm where I worked at the time (name and location of company). The project was completed successfully between September of 2014 and December of the same year.
PART-II BACKGROUND
Career Episode 1.2
XXX (Company Name) is a division of XXX (Company Name) with headquarters in XXX (Company’s Location). Both firms operate separately and have separate headquarters; XXX (Company Name) is based in DLF XXX (location), whereas Pharmaceuticals is based in XXX (Location). The XXX location became the mother factory in India, producing Horlicks and its variations for the Indian market. The facility has a capacity of roughly 100,000 metric tons per year. XXX (Company Name) has three distinct manufacturing locations that produce the same product, but XXX (Company Name) outperforms incapacity. Protein calculations are crucial in the food and chemical industries.
The process, however, involves the handling of chemicals such as sulfuric acid and organic liquids, and the previous equipment utilized in the process had heated surfaces and was not shockproof. As a result, it is regarded critical to improving the safety of the analyst and the efficiency of the protein calculation system in terms of energy savings, which is being done in this project.
Career Episode 1.3
The main gist of this project is to improve the BUCHI Unit for Protein Analysis’s efficiency. The following are the project’s particular objectives:
Career Episode 1.4
Under the direction of Mr X, I completed this project for the organization XXX (Company Name and Location). This project’s organizational structure should be defined in depth.
Career Episode 1.5
The following are the tasks and responsibilities that I fulfilled while working on this project:
PART-III PERSONAL ENGINEERING ACTIVITY
Career Episode 1.6
My theoretical knowledge obtained throughout my undergraduate study was converted into practical applications, which are described below:
Career Episode 1.7
The fumes produced during the protein-digesting process must be kept under control. I researched different publications, papers, and studies on the issue of operator safety throughout procedures. Condensation zones are defined as hot surfaces and regions dangerous to the operator and cannot be entered without adequate verification throughout the operation.
The condensation zones are set to avoid acids from splashing on the operator. The discharge of acid fumes into the air was hazardous, so I researched ways to regulate the fumes and convert them into a less harmful substance or gas that might be used in other applications. I discovered that the vapours could be concentrated and collected in a tank. I researched the pollution control standards that a food and beverage manufacturing firm must follow.
Career Episode 1.8
I chose the materials required to meet the specifications of the new system design. I went with a system with a shock and heat-proofing body. I placed fireclay on the plates of the BUCHI system’s surface to act as insulation. For a fill level sensor, I employed a Hall Effect sensor. A safety sensor is selected that continually checks the system’s temperature and stops heating when the temperature reaches a crucial limit. The specific dosage of sulfuric acid is chosen since this acid is potent, and the protein analysis method necessitates the analyst’s handling of the acid.
This method necessitates the use of chemically resistant, thermally, and shockproof glass. So I went with the Borosilicate glass 3.3, which has all of the essential characteristics. Infrared rays were used as the system’s heating medium.
Career Episode 1.9
In the foremost part of my research, I tackled the difficulties associated with unregulated heating. The previous method included gas burners to heat the glass tubes used in protein calculations. The heating system was manually regulated, resulting in bursting and chemical leakage in some circumstances if not adequately monitored. Because of the unregulated heating system, the analyst may suffer safety concerns in some circumstances.
The new system, known as the BUCHI system, was created by me. It was outfitted with safety sensors that continually monitored the system’s temperature. Infrared rays were used as the heating medium in this case. When the temperature exceeds a certain level, the safety sensor activates, and the heating is turned off. The risk of rupture and chemical leakage is much decreased in this controlled environment.
Career Episode 1.10
Following that, I investigated the hot surface and electric shock issues in the system. The old system was an open system with heated surfaces that might burn you. There was also a significant possibility of electric shocks. It is highly risky for an analyst to handle the glass tubes while working on the system, even with safe handling equipment. I created a novel system with unique stress absorption and a thermally resistant body.
The plates on the surface of the BUCHI system were insulated by inserting a fireclay. I ran the calculations to determine the size of the new system such that it took less time to complete one cycle than the prior system. This covered the size of the tubes and the critical temperature limit at which the heating would halt. I worked out the crucial temperature limit.
Career Episode 1.11
Sulfuric acid was the primary chemical utilized in the protein-digesting process, resulting in acid vapours’ emission. I built the channel for the acid fumes to exit from the system to ensure adequate condensation and use the least amount of space. Then I devised a system that included a suction device linked to all of the tubes coming from their mouths. The suction unit aimed to suck out the hazardous vapours, removing the potential for these vapours to mix with the laboratory air and reduce the risk. On the other hand, the present arrangement had a chimney built on the top of the chamber, but there was a risk that the acid fumes would not leave correctly and might mix with the laboratory air. If the analyst breathed the gases, they would be in danger. As a result, I presented the new approach while keeping these aspects in mind.
Career Episode 1.12
I took into account all of the designs mentioned above procedures before installing the new system. The installation in XXX (Company Name) went off without a hitch. The installation of the BUCHI unit increased the analyst’s safety and the protein calculating system’s efficiency in terms of energy savings. Under the supervision of the safety manager, I also commissioned the new system. Following that, I tested the system’s functionality. I initially test the system on the water to ensure that all of the system’s components are in good working order. After some hits and tries, the testing came out positive. The suction device was checked to see whether there was any fume leakage. The tests were successful, and no vapours were detected in the laboratory air or, as a result, in the surrounding air.
Career Episode 1.13
After the testing was finished, the new system was put into the entire operation. Because the test findings were all positive, the new system was approved for usage. Then, for maximum productivity, I did periodic maintenance on the new system. I was in charge of the daily maintenance, which included turning the system units on and off. I also performed weekly maintenance, which included lubricating the moving parts. I was in charge of the calendar maintenance because the sensors could only be used for 2000–3000 hours.
Career Episode 1.14: Technical difficulties
The glass that was being utilized for the chemical analysis at the time was not resistant to acids, alkalis, or organic compounds. It did not additionally absorb the shocks. This a significant health risk to the analyst. After careful consideration with the lab attendant and the process engineer, I determined that the glass should be chemically resistant, thermally stable, and shockproof. Chemically, Borosilicate glass 3.3 possessed all of the essential characteristics, which DURAN eventually delivered.
The vapours sent into the atmosphere by sulfuric acid and other organic liquids polluted the environment. Even after running it through the sucking tube, it was dangerous to do so since it presented various health risks to people and the wildlife in the area. As a result, I opted to utilize a sulfuric acid condenser, which was then collected in a tank.
Career Episode 1.15
With the help and supervision of my supervisor, I completed my time as an executive trainee. The knowledge I gained from the Safety Manager about the safety requirements for working in such a system assisted me in designing the line and using other safety accessories appropriately. The lab attendants assisted me in analyzing the current system and inform us of the potential hazards they experience in their daily operations. I also collaborated with Mr A, the process engineer, and Mr B, the Quality Analyst, to identify possible hazards in the existing and new systems.
I used to have weekly meetings with the plant manager every Monday after the morning meeting to discuss progress, ongoing concerns, and allocated tasks for the week. Every Tuesday morning, I would meet with my Manager, Mr X, to go over the critical issues. In doing so, I followed the company’s laws and regulations while maintaining my standards and ethics throughout the assignment. Because sulfuric acid vapours are highly toxic, the established limits of the acid are utilized to calculate the acceptable exposure limit, which is 0.1mg/m3 to 3mg/m3 STEL.
PART-IV SUMMARY
Career Episode 1.16
Working on a chemical analysis project has never been easy since we must examine various factors and conditions to complete an activity. The handling of hazardous chemicals and organic liquids is part of a chemical process. Working on this project allowed me to use my academic knowledge in a natural setting. During this assignment, I learned time management and self-discipline. The previous system had safety problems, but the new system checks all safety issues, and the environmental impact is also minimal due to the many accessories utilized to check all CCPs.
The project was well-managed, and the project goals and objectives were met on time. However, the time required for this project was increased by one month to complete all safety inspections. I used my analytical abilities to reach a fair conclusion. The Manufacturing, Quality, and Engineering teams were in charge of the whole project. To attain our objectives, we collaborated as a group. My involvement in the project entailed using the proper materials and equipment to maximize productivity.
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