Assessor Resource

PMASMELT266
Deliver molten metal

Assessment tool

Version 1.0
Issue Date: May 2024


This unit of competency covers the skills and knowledge required to transport molten metal, such as used in the aluminium smelting process, using mobile transport equipment and crucibles.

This unit of competency applies to operators who are required to collect filled crucibles for transportation, move the crucible to required location, transfer/siphon molten metal to the destination furnace, and recognise and respond to 'out-of-parameter' issues.

This unit of competency applies to an individual working alone or as part of a team or group and working in liaison with other shift team members and the control room operator, as appropriate. The operator would be part of a team during start-up and shutdown procedures.

This unit of competency does not require the operation of a central control panel.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)



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 describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Plan and prepare for operations

1.1

Interpret and confirm work requirements before proceeding

1.2

Identify and control hazards

1.3

Ensure appropriate authorisations have been obtained/issued

2

Conduct pre-start requirements to procedures

2.1

Conduct routine pre-start equipment checks

2.2

Conduct isolation as appropriate for pre-start inspections

2.3

Prepare equipment for operation

2.4

Complete routine equipment checklists

2.5

Complete reports as required for equipment inspections

3

Conduct metal delivery operations to procedures

3.1

Start up equipment as required

3.2

Monitor equipment operation and check operational variables are within parameters

3.3

Verify equipment performance throughout the process

3.4

Apply operating principles to resolve identified problems and take action

3.5

Shut down equipment as required

3.6

Conduct routine housekeeping activities

3.7

Recognise and respond to emergencies should one arise

3.8

Complete records as required for equipment operation and performance

4

Isolate and de-isolate plant

4.1

Isolate plant

4.2

Make safe for required work

4.3

Check plant is ready to be returned to service

4.4

De-isolate and prepare plant for return to service

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

collect filled crucibles for transportation and move to required location

transfer/siphon molten aluminium to the destination furnace

monitor equipment conditions and maintenance requirements and take action

monitor process parameters and performance and make adjustments according to procedures

recognise early warning signs of equipment/processes needing attention or with potential problems and take action to ensure a timely return to full performance

isolate and de-isolate equipment

identify hazards and apply hazard control procedures

respond to emergencies

apply housekeeping procedures, including cleaning the area, removal of contaminants, safety inspections and rectification of issues that could compromise safety.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the siphon equipment, delivery equipment and functions of each

basic principles of operation of main equipment items, including siphoning equipment and crucible transport equipment

basic understanding of the product specifications and variations required on the input and output side

process parameters and limits (e.g. temperature)

emergency responses, including those related to:

leak/loss of containment

evacuation due to fire or open cell circuit

loss of power

excessive emissions of fumes or particulate

major oil spill

equipment failure

typical hazards associated with heat, electricity, hydraulics and pneumatics and high pressure piping and valves, pinch and crush points on conveyor systems, mobile equipment, hazardous materials, banned items, suspended loads and hydration and heat stress, and how to recognise them

correct use of personal protective equipment (PPE), including specific insulated boots, heat resistant material, full-ventilated suits, full-face masks and other situation-specific equipment.

The unit should be assessed holistically and the judgement of competence based on a holistic assessment of the evidence.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant

will typically include a supervisor/third party-report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start-up and shutdown procedures and responding to problems

may use industry-based simulation for part only of the unit where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible, or where personal safety or environmental damage are limiting factors, assessment must occur in a sufficiently rigorous simulated environment reflecting realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from one or more of:

walk-throughs

pilot plant operation

demonstration of skills

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence (provided a record is kept) or through an independent process, such as workbooks, written assessments or interviews (provided a record is kept).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition, the assessor or anyone acting in subject matter expert role in assessment must demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they must assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on-the-job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, 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 describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Plan and prepare for operations

1.1

Interpret and confirm work requirements before proceeding

1.2

Identify and control hazards

1.3

Ensure appropriate authorisations have been obtained/issued

2

Conduct pre-start requirements to procedures

2.1

Conduct routine pre-start equipment checks

2.2

Conduct isolation as appropriate for pre-start inspections

2.3

Prepare equipment for operation

2.4

Complete routine equipment checklists

2.5

Complete reports as required for equipment inspections

3

Conduct metal delivery operations to procedures

3.1

Start up equipment as required

3.2

Monitor equipment operation and check operational variables are within parameters

3.3

Verify equipment performance throughout the process

3.4

Apply operating principles to resolve identified problems and take action

3.5

Shut down equipment as required

3.6

Conduct routine housekeeping activities

3.7

Recognise and respond to emergencies should one arise

3.8

Complete records as required for equipment operation and performance

4

Isolate and de-isolate plant

4.1

Isolate plant

4.2

Make safe for required work

4.3

Check plant is ready to be returned to service

4.4

De-isolate and prepare plant for return to service

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used, and include one or more of the following:

legislative requirements, including work health and safety (WHS)

industry codes of practice and guidelines

environmental regulations and guidelines

Australian and other standards

licence and certification requirements

All operations to which this unit applies are subject to stringent health, safety and environment (HSE) requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and HSE requirements, the HSE requirements take precedence.

Equipment and tools

Equipment and tools include one or more of the following:

crucibles

siphoning equipment

mobile transporting equipment

harnesses and slings

materials handling equipment

hand tools

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, include one or more of the following:

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Hazards

Hazards include one or more of the following:

heat (e.g. burns, dehydration and heat stress)

energy sources (e.g. hydraulic, pneumatic and electric)

electromagnetic effects

high pressure piping and valves

pinch and crush points

moisture

banned items

mobile equipment and pedestrian interaction

suspended loads and roller conveyors

hazardous materials (e.g. chlorine)

molten materials

equipment failures

industrial (machinery, equipment and product)

equipment or product mass

noise, rotational equipment or vibration

other hazards that might arise

Routine problems

Routine problems must be resolved by applying known solutions.

Routine problems are predictable and include one or more of the following:

delivery of molten metal from reduction cells to clean crucible

pipe failures (e.g. cracks and blockages)

venturi and siphon system failure

siphoning suction equipment failure

out-of-parameter operation or product

fluctuation in temperature, power consumption or product movement

instruments and equipment requiring cleaning

equipment mechanical and electrical problems

flow path blockages

out-of-parameter emissions

unavailability of equipment, personnel or material

Known solutions are drawn from one or more of the following:

procedures

training

remembered experience

historical data and records of common faults

troubleshooting lists and directives

site procedures

Non-routine problems must be reported according to according to relevant procedures.

Instrument/electrical systems

Instrument/electrical systems include one or more of the following:

emergency shutdown systems (ESD)

fire systems

pressure and temperature control systems

communications systems

utility systems

Operate

Operate is to monitor, adjust/make change to the production unit and/or its component items to meet specifications, by one or both of the following:

manually in the plant

using local controller in the plant

Pre-start checks

Pre-start checks will conform to site procedures or equipment pre-start checklist. They must be completed before the equipment is operated unless stated in the procedures.

Reports and records

Reports and records include one or more of the following:

routine inspections (daily readings and monthly checks)

scheduled maintenance activities

computer readouts locally or in the control room

shift log sheet

mandatory or statutory inspections

hazard, accident and incident reports

quality inspection reports of the product

Shutdown procedures

Shutdown procedures must follow equipment and site-authorised checklist and will typically include the following:

communication to supply and delivery areas

communication to impacting areas

obtaining appropriate authorisations

rescheduling operations

liaison with maintenance teams

Start-up procedures

Start-up procedures must conform to site procedures and will typically include the following:

safety and pre-start checks

accessing shift logs and equipment records

pre-shift briefing information

records and reports from the previous shift

Work requirements

Work requirements will be identified from one or more of the following:

shift briefings

shift logs

supervisor or crew leader meetings

toolbox talks

handover details

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

collect filled crucibles for transportation and move to required location

transfer/siphon molten aluminium to the destination furnace

monitor equipment conditions and maintenance requirements and take action

monitor process parameters and performance and make adjustments according to procedures

recognise early warning signs of equipment/processes needing attention or with potential problems and take action to ensure a timely return to full performance

isolate and de-isolate equipment

identify hazards and apply hazard control procedures

respond to emergencies

apply housekeeping procedures, including cleaning the area, removal of contaminants, safety inspections and rectification of issues that could compromise safety.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the siphon equipment, delivery equipment and functions of each

basic principles of operation of main equipment items, including siphoning equipment and crucible transport equipment

basic understanding of the product specifications and variations required on the input and output side

process parameters and limits (e.g. temperature)

emergency responses, including those related to:

leak/loss of containment

evacuation due to fire or open cell circuit

loss of power

excessive emissions of fumes or particulate

major oil spill

equipment failure

typical hazards associated with heat, electricity, hydraulics and pneumatics and high pressure piping and valves, pinch and crush points on conveyor systems, mobile equipment, hazardous materials, banned items, suspended loads and hydration and heat stress, and how to recognise them

correct use of personal protective equipment (PPE), including specific insulated boots, heat resistant material, full-ventilated suits, full-face masks and other situation-specific equipment.

The unit should be assessed holistically and the judgement of competence based on a holistic assessment of the evidence.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant

will typically include a supervisor/third party-report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start-up and shutdown procedures and responding to problems

may use industry-based simulation for part only of the unit where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible, or where personal safety or environmental damage are limiting factors, assessment must occur in a sufficiently rigorous simulated environment reflecting realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from one or more of:

walk-throughs

pilot plant operation

demonstration of skills

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence (provided a record is kept) or through an independent process, such as workbooks, written assessments or interviews (provided a record is kept).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition, the assessor or anyone acting in subject matter expert role in assessment must demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they must assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on-the-job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work

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
Interpret and confirm work requirements before proceeding 
 
 
Conduct routine pre-start equipment checks 
 
 
 
 
Start up equipment as required 
 
 
 
 
 
 
 
 
 
 
 

Forms

Assessment Cover Sheet

PMASMELT266 - Deliver molten metal
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

PMASMELT266 - Deliver molten metal

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: