Assessor Resource

RIIDES305
Inspect, test and maintain exhaust systems on diesel engine systems

Assessment tool

Version 1.0
Issue Date: March 2024


This unit is appropriate for those undertaking the inspection, testing and maintenance of diesel engine systems for underground coal mines

This unit covers the inspection, testing and maintenance of exhaust systems of diesel engine systems for underground coal mines to provide a means of confirming the effectiveness of their explosion and fire protection and emission control. It includes: planning and preparing for and carrying out of exhaust system inspection, testing, routine maintenance and overhaul tasks; and the completion of post-work requirements

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

Prerequisites

Metal, mechanical, electrical or automotive trades or mechanical or electrical engineering


Employability Skills

This unit contains employability skills.




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.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to worksite operations and satisfy all of the requirements of the performance criteria, required skills and knowledge and the range statement of this unit and include evidence of the following:

knowledge of the requirements, procedures and instructions for the inspection, testing and maintenance of exhaust systems on diesel engine systems

implementation of requirements, procedures and techniques for the safe, effective and efficient completion of the inspection, testing and maintenance of exhaust systems on diesel engine systems

working with others to undertake and complete the inspection, testing and maintenance of exhaust systems on diesel engine systems that meets all of the required outcomes

consistent timely completion of the inspection, testing and maintenance of exhaust systems on diesel engine systems that safely, effectively and efficiently meets the required outcomes

Context of and specific resources for assessment

This unit must be assessed in the context of the work environment. Where personal safety or environmental damage are limiting factors, assessment may occur in a simulated environment provided it is realistic and sufficiently rigorous to cover all aspects of workplace performance, including task skills, task management skills, contingency management skills and job role environment skills.

The assessment environment should not disadvantage the participant. For example, language, literacy and numeracy demands of assessment should not be greater than those required on the job.

Customisation of assessment and delivery environment to sensitively accommodate cultural diversity.

Aboriginal people and other people from a non English speaking background may have second language issues.

Assessment of this competency requires typical resources normally used in a resources and infrastructure sector environment. Selection and use of resources for particular worksites may differ due to the site circumstances.

Where applicable, physical resources should include equipment modified for people with disabilities.

Access must be provided to appropriate learning and/or assessment support when required.

Method of assessment

This unit may be assessed in a holistic way with other units of competency. The assessment strategy for this unit must verify required knowledge and skill and practical application using more than one of the following assessment methods:

written and/or oral assessment of the candidate’s required knowledge

observed, documented and/or first hand testimonial evidence of the candidate’s:

implementation of appropriate requirement, procedures and techniques for the safe, effective and efficient achievement of required outcomes

consistently achieving the required outcomes

first hand testimonial evidence of the candidate:

working with others to undertake and complete the inspection, testing and maintenance of exhaust systems on diesel engine systems

Guidance information for assessment

Consult the SkillsDMC User Guide for further information on assessment including access and equity issues.


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.

Required skills

Specific skills are required to achieve the performance criteria in this unit, particularly for the application in the various circumstances in which this unit may be applied.

This includes the ability to carry out the following to safely, effectively and efficiently inspect, test and maintain exhaust systems on diesel engine systems:

apply legislative requirements and procedures

apply surface and underground worksite hazard identification and risk management requirements and procedures

apply task hazard identification and risk management requirements and procedures

apply hazard and emergency procedures

apply technical literacy

interpret and apply technical and scientific/industry terminology

identify health effects of emissions and nominate controls to minimise potential health effects

apply site health and safety requirements and procedures

apply site environmental requirements and procedures

apply site quality requirements and procedures

apply site communication requirements and procedures

apply manufacturer’s requirements and procedures

communicate with those providing support

apply work area and equipment inspection procedures

apply work area safeguarding options and requirements

apply isolation and lock-out requirements and procedures

apply site service and maintenance reporting requirements and procedures

apply inspection requirements and procedures

apply testing requirements and procedures

apply fault finding techniques

apply maintenance requirements and procedures

work wearing appropriate personal protective equipment

use tools for inspection, testing and maintenance

use calibrated/verified instruments

Required knowledge

Specific knowledge is required to achieve the Performance Criteria of this unit, particularly its application in a variety of circumstances in which the unit may be used.

This includes knowledge of the following to safely, effectively and efficiently inspect, test and maintain exhaust systems on diesel engine systems:

site risk, statutory compliance, health, safety, environmental, quality and communication requirements and procedures

site and manufacturer’s requirements and procedures

provisions of AS/NZS3584.1,2 and 3 relating to exhaust systems, fasteners, joints and flametraps

potential hazards in the use of diesel engine systems in underground coal mines, including:

explosions

fire, and

emissions

limitations on allowable maintenance, including:

service

adjust

replace

repair

overhaul

work in hazardous environments

limitations on allowable modifications and their required controls and procedures

methods to limit surface temperatures for;

exhaust manifold design and fitment

adaptor pipe

possible failure modes in maintenance procedures and practices required to provide controls (including, flametraps, cooling systems, treatment systems, filtration)

the heat energy generating characteristics of forced induction systems and the control measures provided to manage surface temperatures, including; maintenance, testing and monitoring

causes of the degradation of heat exchanger performance;

function and performance criteria and protection employed in exhaust, including;

cooling

flametrap

spark arrestor

emissions reduction

fire-protection

explosion protection

types of flametraps permitted by the relevant Standard, including;

water-based flametraps

positive flametraps

properties and functional characteristics of exhaust flametraps, including;

positive flametraps

water-based flametraps

failure modes and inherent risks and hazards for each type of exhaust flametrap

operational and installation requirements for heat exchangers when installed in conjunction with positive flametraps

maintenance processes and procedures required to ensure ongoing safe operation

importance of the application of appropriate components and fasteners, including the selection of appropriate bolts, studs, threads and washers to specific applications within a diesel engine system including the provisions of AS/NZS3584.3 relating to fasteners

the types of joints that may be integral to the design and maintenance of a diesel engine system, including;

fixed connection

open joints

the factors that determine the selection of joint types

the requirements for interposed gaskets and seals in joints, including;

materials

dimensions

form and shape

items required to be used in performance of inspection, testing and maintenance tasks

tools required for the performance of inspection, testing and maintenance tasks

provisions of AS/NZS3584.1, 2 and 3 relating to fasteners and joints

recognise the requirements and performance of various types of fasteners, including bolts, studs, threads and washers

site inspection, testing and maintenance support requirements and availability

site work area inspection requirements

site work area safeguarding options and requirements

site isolation and lock-out requirements and procedures

site hazard and emergency procedures

site inspection, testing and maintenance reporting requirements and procedures

site inspection, testing and maintenance record procedures

site requirements and procedures for working in isolation

site requirements for the use of personal protective equipment

Compliance and other documentation may include:

certification documentation

approval documentation

legislative, organisation and site requirements and procedures

manufacturer’s specifications and guidelines

Australian Standards, including: AS/NZS3584 and AS 4291

codes of practice

Employment and Workplace Relations legislation

Equal Employment Opportunity and Disability Discrimination legislation

Inspection may include:

checking the marking of parts/components

determine that there is no evidence of carbon build-up on or heating of joints that may suggest a leakage of exhaust gas

check that the positive exhaust flametrap and exhaust gas cooling system is clean

check that the floats used for the low water shutdown in the exhaust system conditioner/flame trap/spark arrester are free, clean, unobstructed and correctly installed

check that the static water level on any water-based exhaust system conditioner/flame trap/spark arrester is at or above the level indicated

checking materials and gaskets/seals

the conformity of threads and fasteners to registration and/or certification drawings

Testing may include:

conduct exhaust conditioner/ flametrap, low-water, shutdown tests (i.e. both low water test systems are tested separately)

check that the engine system shuts down at or higher than the minimum shutdown water level and record the water levels after shut-down.

conduct gas tightness tests for all joints within the exhaust system Note: A soapy water test may meet this requirement

measurement of joints for dimensional compliance, surface finish, flatness

Maintenance is:

the combination of actions carried out to retain a diesel engine system in, or to restore it to, conditions in which it is able to meet the requirements of the relevant specification and perform its required function

Maintenance may include authorised:

service

adjusting

replacing

repair

overhaul

modification

Exhaust systems may include:

exhaust manifolds

turbo-chargers or superchargers

pipe work

hoses

joints

fastenings

exhaust flametraps, which may include:

positive flametraps, (with temperature sensors)

water-based flametraps, (with water level sensors and test valves)

spark arrestor

exhaust cooling system, which may include:

water bath

air dilution

heat exchanger

water Injection

monitoring or shutdown devices

surface temperature control systems

catalytic converters, including DOCs and SCRs

fume diluters and forced-air systems

particulate filters

replacement element-type filters

exhaust gas recirculation

Diesel engine systems are:

diesel engines for underground coal mines and their:

inlet systems

exhaust systems

cooling systems

starting systems

shut-down and protection systems

electrical or electronic devices

Work requirements may come from briefings, handovers, and work orders and may include:

nature and scope of tasks

procedures to be applied

quality standards to be applied

available resources

achievement targets

operational conditions

site layout

out-of-bounds areas

designated safe areas

explosion-risk zones

hazardous areas

other hazards and potential hazards

obtaining permits required

worksite inspection requirements

lighting conditions

plant or equipment defects

coordination requirements or issues

Others may include:

other maintenance personnel

support providers

contractors

underground production personnel

mobile or fixed plant operators

Inspect and prepare work area may include:

determining if the proposed work area is a designated safe area

identification of explosion-risk zones

identification of hazardous areas

identification of hazards, including:

workshop work area hazard

underground work area hazards

work activity hazards

fire

explosion

emissions

selection and implementation of control measures for the hazards identified

safeguarding site and non-site personnel by:

erection of barricades and posting of signs

selection of appropriate equipment to ensure personnel safety and protection

Items may include:

authorised replacement parts

fasteners as specified in manufacturer’s drawings, which may include:

tensile strength

head and nut configuration

thread form and engagement

corrosion resistance (materials)

coatings (materials and application)

tolerances for fits and threads

tolerances for mating surfaces

dimensions of clearance holes

fixing torques

lubricants and anti-seize compounds used

packing materials

Tools may include:

hand tools

power tools

special tools

testing equipment

Support may include:

other site personnel

contractors

cranes

other lifting equipment

Personal protection equipment may include:

hard hats

eye protection

hearing protection

breathing apparatus

gas/fume masks

prescribed footwear

Pre-start procedures include:

checking:

cleanliness, particularly coal dust

diesel and other flammable liquid leaks

coolant leaks in radiator or radiator hoses

coolant level

that guards are in place and secure

engine oil level is correct

conduct exhaust conditioner/flametrap, low-water, shutdown tests

Hazardous and emergency situations may include:

working alone

personal injury

fire

explosions

emissions

electrical

noise

dust

noxious gases

environmental

chemical

Diagnose faults may include:

root cause analysis

troubleshooting techniques

Routine maintenance is to include:

servicing, including:

cleaning, including the gas path of any exhaust system

conditioner

flametrap and/or

spark arrestor

checking and filling lubricants, fuel and water

adjusting

replacing

Overhaul may include:

removal

dismantling

cleaning

inspecting

replacing, eg:

gaskets

fasteners

testing, including:

flatness

measuring dimensions

hydrostatic

reassembly

reinstallation, (e.g. cleaned or new exhaust positive flametrap assembly)

Records may include:

inspection and test results

defect identified

defect rectification carried out

item consumed

hazard/risk management reports

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
Access, interpret and apply compliance and other documentation relevant to the inspection, testing and maintenance of exhaust systems on diesel engine systems 
Obtain, interpret and clarify work requirements for the satisfactory completion of tasks 
Resolve coordination requirements with others at the site prior to commencing and during work activities 
Inspect and prepare work area in coordination with others 
Identify and obtain items and toolsrequired for the safe, effective and efficient conduct of the tasks. 
Identify and arrange support required for completion of tasks 
Select and usepersonal protection equipment appropriate to the task 
Carry out required equipment pre-start procedures 
Carry out required isolation and lock-out of all equipment necessary for the safe execution of tasks 
Recognise and respond to hazardous and emergency situations 
Carry out inspection of exhaust systems on diesel engine systems 
Carry out inspection and fault finding of exhaust system flame traps for effectiveness of explosion protection 
Carry out inspection and fault finding of exhaust gas cooling systems 
Carry out inspection and fault finding of exhaust system joints 
Diagnose and record existing or identified faults 
Select and operate testing equipment and methods in an appropriate, safe, effective and efficient manner 
Carry out testing and fault finding of exhaust systems on diesel engine systems 
Carry out testing of exhaust system flametraps for effectiveness of explosion and fire protection 
Carry out leak testing of exhaust system joints for effectiveness of explosion and fire protection 
Test and report on the performance of exhaust emission treatment devices 
Identify and record existing or potential faults, including blockages and constrictions 
Select and use maintenance items, tools and equipment 
Rectify diagnosed and identified faults 
Carry out routine maintenance of exhaust systems on diesel engine systems in accordance with the work requirements 
Carry out routine maintenance of exhaust system flametraps for effectiveness of explosion protection 
Carry out routine maintenance of exhaust system joints for effectiveness of explosion and fire protection 
Select and use overhaul items, tools and equipment 
Carry out overhaul of exhaust systems in accordance with the work requirements and Australian Standards 
Tidy up the work area 
Dispose of used oil, lubricant and other waste 
Return and secure all tools and re-usable items 
Report outcomes of inspection, testing, maintenance and overhaul tasks to appropriate person 
Complete and maintain inspection, testing and maintenance records 

Forms

Assessment Cover Sheet

RIIDES305 - Inspect, test and maintain exhaust systems on diesel engine systems
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Assessment Record Sheet

RIIDES305 - Inspect, test and maintain exhaust systems on diesel engine systems

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