Assessor Resource

PMC557094
Investigate refractory failures

Assessment tool

Version 1.0
Issue Date: May 2024


This unit of competency covers the skills and knowledge required to investigate refractory failures, degradation and deterioration in order to recommend appropriate action.

This unit of competency applies to operators who are required to negotiate agreed requirements for the investigation; determine, collate and analyse relevant data to identify cause/s of deterioration or failure; and make recommendations to improve refractory life.

This unit of competency applies to senior technicians or those in similar roles who are required to analyse and synthesise advanced theoretical and technical knowledge and apply independent judgement to high-level technical issues and complex problems. The individual may work in liaison with other refractory specialists or they may be the sole refractory specialist for this job or in their organisation.

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

Confirm purpose of investigation

1.1

Liaise with relevant stakeholders

1.2

Confirm the purpose of the investigation

1.3

Draft or clarify the investigation brief

1.4

Identify discrepancies or conflicts in requirements

1.5

Negotiate a consistent set of requirements for the investigation

2

Collect appropriate data

2.1

Determine information and data requirements for investigation

2.2

Identify health, safety and environmental (HSE) risks from data collection

2.3

Obtain necessary authorisations to collect required data

2.4

Ensure sampling/data collection meets required standard

2.5

Evaluate data for completeness and identify discrepancies and aberrations

2.6

Collate valid data as appropriate

3

Analyse data

3.1

Identify deterioration/failure modes

3.2

Determine causes of deterioration/failure

3.3

Identify refractory issues leading to excessive deterioration or failure

3.4

Identify process issues leading to excessive deterioration or failure

3.5

Identify other issues leading to excessive deterioration or failure

4

Make recommendations

4.1

Draft possible recommendations to improve refractory life

4.2

Discuss causes of failure and recommendations with relevant stakeholders if appropriate

4.3

Ensure information obtained meets the agreed purpose of the investigation and take appropriate action

4.4

Determine required format for reporting of investigation, causes and recommendations

4.5

Report as required to required people/organisations

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:

analyse and interpret technical reports, technical specifications and data

confirm purpose of investigation, including one (1) or more of:

routine monitoring of the 'wear and tear' deterioration of a refractory

investigation of suspected degradation of a refractory still in use

investigation of a catastrophic refractory failure

investigation to support an insurance or other claim

investigation requested by a third party (e.g. for a dispute)

technical investigation aimed at better understanding the refractory in use and so improving the refractory

determine information and data requirements, sampling/data collection methods and related authorisations

collate and analyse data to determine causes of failure/deterioration

communicate technical information verbally and in writing/drawings

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

customer representatives

technical experts

regulators

management

refractory designer

refractory installer

document investigation, causes and recommendations

apply complex and/or theoretical mathematical calculations, statistics

solve complex problems within or arising from the investigation.

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

typical limitations and applications of all common refractory materials

installation methods and their impacts on refractory failure

common refractory repairs and their impacts on refractory failure

causes of refractory deterioration, degradation and failure

identification and causes of common failure modes, including:

spalling

corrosion

abrasion

impact/compression/tension

thermal shock

benefits and limitations and health, safety and environmental (HSE) risks of information/data gathering methods, including:

examining samples of failed refractory

collecting data of a refractory in use

collecting observations of a refractory in use

examining an entire refractory installation after it has been shutdown

one set of data collection

a planned series of data collection at specified intervals over a specified period

discussions/interviews with stakeholders

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.

It may be appropriate to assess this unit in conjunction with:

PMC554091 Analyse refractory failures.

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

Confirm purpose of investigation

1.1

Liaise with relevant stakeholders

1.2

Confirm the purpose of the investigation

1.3

Draft or clarify the investigation brief

1.4

Identify discrepancies or conflicts in requirements

1.5

Negotiate a consistent set of requirements for the investigation

2

Collect appropriate data

2.1

Determine information and data requirements for investigation

2.2

Identify health, safety and environmental (HSE) risks from data collection

2.3

Obtain necessary authorisations to collect required data

2.4

Ensure sampling/data collection meets required standard

2.5

Evaluate data for completeness and identify discrepancies and aberrations

2.6

Collate valid data as appropriate

3

Analyse data

3.1

Identify deterioration/failure modes

3.2

Determine causes of deterioration/failure

3.3

Identify refractory issues leading to excessive deterioration or failure

3.4

Identify process issues leading to excessive deterioration or failure

3.5

Identify other issues leading to excessive deterioration or failure

4

Make recommendations

4.1

Draft possible recommendations to improve refractory life

4.2

Discuss causes of failure and recommendations with relevant stakeholders if appropriate

4.3

Ensure information obtained meets the agreed purpose of the investigation and take appropriate action

4.4

Determine required format for reporting of investigation, causes and recommendations

4.5

Report as required to required people/organisations

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:

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.

HSE and other risks

Identification of HSE and other risks includes consideration of:

health and safety risks

sustainability risks

regulatory risks

business 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:

analyse and interpret technical reports, technical specifications and data

confirm purpose of investigation, including one (1) or more of:

routine monitoring of the 'wear and tear' deterioration of a refractory

investigation of suspected degradation of a refractory still in use

investigation of a catastrophic refractory failure

investigation to support an insurance or other claim

investigation requested by a third party (e.g. for a dispute)

technical investigation aimed at better understanding the refractory in use and so improving the refractory

determine information and data requirements, sampling/data collection methods and related authorisations

collate and analyse data to determine causes of failure/deterioration

communicate technical information verbally and in writing/drawings

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

customer representatives

technical experts

regulators

management

refractory designer

refractory installer

document investigation, causes and recommendations

apply complex and/or theoretical mathematical calculations, statistics

solve complex problems within or arising from the investigation.

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

typical limitations and applications of all common refractory materials

installation methods and their impacts on refractory failure

common refractory repairs and their impacts on refractory failure

causes of refractory deterioration, degradation and failure

identification and causes of common failure modes, including:

spalling

corrosion

abrasion

impact/compression/tension

thermal shock

benefits and limitations and health, safety and environmental (HSE) risks of information/data gathering methods, including:

examining samples of failed refractory

collecting data of a refractory in use

collecting observations of a refractory in use

examining an entire refractory installation after it has been shutdown

one set of data collection

a planned series of data collection at specified intervals over a specified period

discussions/interviews with stakeholders

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.

It may be appropriate to assess this unit in conjunction with:

PMC554091 Analyse refractory failures.

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
Liaise with relevant stakeholders 
Confirm the purpose of the investigation 
Draft or clarify the investigation brief 
Identify discrepancies or conflicts in requirements 
Negotiate a consistent set of requirements for the investigation 
Determine information and data requirements for investigation 
Identify health, safety and environmental (HSE) risks from data collection 
Obtain necessary authorisations to collect required data 
Ensure sampling/data collection meets required standard 
Evaluate data for completeness and identify discrepancies and aberrations 
Collate valid data as appropriate 
Identify deterioration/failure modes 
Determine causes of deterioration/failure 
Identify refractory issues leading to excessive deterioration or failure 
Identify process issues leading to excessive deterioration or failure 
Identify other issues leading to excessive deterioration or failure 
Draft possible recommendations to improve refractory life 
Discuss causes of failure and recommendations with relevant stakeholders if appropriate 
Ensure information obtained meets the agreed purpose of the investigation and take appropriate action 
Determine required format for reporting of investigation, causes and recommendations 
Report as required to required people/organisations 

Forms

Assessment Cover Sheet

PMC557094 - Investigate refractory failures
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

PMC557094 - Investigate refractory failures

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: