Assessor Resource

PMC554090
Undertake simple refractory design

Assessment tool

Version 1.0
Issue Date: May 2024


This unit of competency covers the skills and knowledge required to undertake simple refractory design. It applies to refractory design that can be achieved by the application of standard products/components in a standard manner and that is not required to be done by a registered engineer.

This unit of competency applies to operators who are required to confirm technical requirements for the refractory and determine the materials and installation methods to meet those requirements.

This unit of competency applies to technician applying specialised theoretical and technical knowledge and well developed skills in situations that require autonomy, discretion and judgement. The person may work alone or as a member of a team or group and will work in liaison with customers, installers, engineers and technical experts, as appropriate.

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

Establish the suitability of resources

1.1

Check all information conforms with resources

1.2

Record discrepancies in information

1.3

Report any inaccuracies in information to the person in charge

1.4

Identify and select materials, components, tools and equipment

2

Undertake mechanical design

2.1

Determine strength requirements

2.2

Determine operating temperature range

2.3

Select materials/mix with appropriate mechanical strength

2.4

Identify hazards of materials and processes to be used and apply hierarchy of control to control hazards

2.5

Determine expansion which will occur for this material

2.6

Adjust material/mix to be suitable for temperatures

3

Undertake thermal design

3.1

Determine heat flow through the refractory

3.2

Determine interface temperatures for multi-component linings

3.3

Use simple software

3.4

Determine interface bonding/anchor issues

4

Specify refractory design

4.1

Specify materials to be used

4.2

Specify installation method to be used

4.3

Confirm specification meets customer needs and installer requirements

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

read and interpret technical reports, technical specifications and data

confirm technical requirements for refractory

determine and specify materials and installation to meet mechanical and thermal requirements

communicate technical information verbally and in writing/drawings

communicate with internal and external stakeholders, including one or more of:

customer representatives

technical experts

engineers

refractory installer

apply complex and/or theoretical mathematical calculations

identify hazards and apply relevant hazard controls.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to fulfil their job role, including knowledge of:

properties of all common refractory materials

application and limitations of installation techniques, including:

bricks, blocks

mouldables

castable

spray/gunned application

heat flow calculations

key factors in refractory design, including:

heat transfer

thermal expansion

abrasion

structural strength

methods of tying refractories

heat transfer calculations (resistances in series and parallel)

regulatory framework

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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

The collection of performance evidence is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real project in an operational workplace. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur using a sufficiently rigorous simulated environment that reflects 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 demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

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 shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall 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

Establish the suitability of resources

1.1

Check all information conforms with resources

1.2

Record discrepancies in information

1.3

Report any inaccuracies in information to the person in charge

1.4

Identify and select materials, components, tools and equipment

2

Undertake mechanical design

2.1

Determine strength requirements

2.2

Determine operating temperature range

2.3

Select materials/mix with appropriate mechanical strength

2.4

Identify hazards of materials and processes to be used and apply hierarchy of control to control hazards

2.5

Determine expansion which will occur for this material

2.6

Adjust material/mix to be suitable for temperatures

3

Undertake thermal design

3.1

Determine heat flow through the refractory

3.2

Determine interface temperatures for multi-component linings

3.3

Use simple software

3.4

Determine interface bonding/anchor issues

4

Specify refractory design

4.1

Specify materials to be used

4.2

Specify installation method to be used

4.3

Confirm specification meets customer needs and installer requirements

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.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent 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 such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

manufacturer's technical information

job cards

drawings

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 must be identified and controlled. Identifying hazards requires consideration of:

health and safety risks

sustainability risks

regulatory risks.

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

read and interpret technical reports, technical specifications and data

confirm technical requirements for refractory

determine and specify materials and installation to meet mechanical and thermal requirements

communicate technical information verbally and in writing/drawings

communicate with internal and external stakeholders, including one or more of:

customer representatives

technical experts

engineers

refractory installer

apply complex and/or theoretical mathematical calculations

identify hazards and apply relevant hazard controls.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to fulfil their job role, including knowledge of:

properties of all common refractory materials

application and limitations of installation techniques, including:

bricks, blocks

mouldables

castable

spray/gunned application

heat flow calculations

key factors in refractory design, including:

heat transfer

thermal expansion

abrasion

structural strength

methods of tying refractories

heat transfer calculations (resistances in series and parallel)

regulatory framework

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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

The collection of performance evidence is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real project in an operational workplace. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur using a sufficiently rigorous simulated environment that reflects 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 demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

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 shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall 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
Check all information conforms with resources 
Record discrepancies in information 
Report any inaccuracies in information to the person in charge 
Identify and select materials, components, tools and equipment 
Determine strength requirements 
Determine operating temperature range 
Select materials/mix with appropriate mechanical strength 
Identify hazards of materials and processes to be used and apply hierarchy of control to control hazards 
Determine expansion which will occur for this material 
Adjust material/mix to be suitable for temperatures 
Determine heat flow through the refractory 
Determine interface temperatures for multi-component linings 
Use simple software 
Determine interface bonding/anchor issues 
Specify materials to be used 
Specify installation method to be used 
Confirm specification meets customer needs and installer requirements 

Forms

Assessment Cover Sheet

PMC554090 - Undertake simple refractory design
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

PMC554090 - Undertake simple refractory design

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: