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Elements and Performance Criteria

  1. Plan and prepare for job
  2. Break flange in accordance with flange management procedure
  3. Inspect flange and components
  4. Make flange joint in accordance with flange management procedure
  5. Finish the job

Range Statement

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.

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:

gases and liquids under pressure

structural hazards

equipment failures

industrial (machinery, equipment and product)

equipment or product mass

plant services (steam, condensate and cooling water)

limited head spaces or overhangs

working at heights, in restricted or confined spaces, or in environments subjected to heat, dusts or vapours

flammability and explosivity

hazardous products and materials

unauthorised personnel

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

extreme weather

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:

seal/gasket leaks

pressure loss/low flow

blockages/build-up/fouling

erosion/wear

ancillary equipment problems

studs incorrectly tensioned

worn threads

misalignments

cold pull

isolation failure

leak test failure

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

procedures

training

remembered experience

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

Action

Action in response to problems includes the following:

determining problems needing action

accessing and applying relevant technical and plant data

applying appropriate problem solving techniques to determine possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility/ability to resolve to designated person

Action also requires one or more of the following:

replacing existing components with new components

carrying out minor maintenance within operator's skill level

identifying and reporting problems outside operator's competence

identifying and controlling hazards related to flange joints

Work requirements

Work requirements include one or more of the following:

flange and gasket specifications

stud and nut specification

process line and process materials

parts and equipment required

local detectors requiring isolation

required skill level

conflicting work

Work requirements come from briefings, handovers, and work orders and include one or more of the following

compliance documentation

product specifications

nature and scope of tasks

achievement targets

operational conditions

lighting conditions

plant or equipment defects

hazards and potential hazards

coordination requirements or issues

Job site

Inspecting job site includes identifying one or more of the following:

location

authorisations required

access and egress needs

hazards

recent work undertaken on joint

flange type (matches specification)

Implementing hazard controls

Implementing hazard controls includes one or more of the following:

selection and use of appropriate personal protective equipment (PPE)

obtaining appropriate authorisations

checking required isolations

controlling other work in area

controlling access to area

using gas tester

verifying and confirming isolation

safe flange breaking procedure (line of fire)

Inspecting components

Inspecting flange components includes one or more of the following:

asbestos in gaskets

signs of damage, defects or deterioration in all components

cleanliness and correct surface roughness of mating surfaces

alignment

Refer to appendices of ASME PCC-1-2013 Guidelines for pressure boundary bolted flange joint assembly, for technical details.

Components

Components include the following:

studs

nuts

washers

gaskets

other components as appropriate to the job/work environment

Checking studs and nuts

Checking studs and nuts includes one or more of: the following

integrity of studs and nuts

fit of nut to stud

need for new studs and nuts

conformance

Initial assembly of joint

Initial assembly of joint includes one or more of the following:

aligning joint

inserting studs

assembling nuts to studs

inserting and aligning gasket

Blinds

Blinds include one or more of the following:

blinds

blanks

spectacle/goggle blinds

Appropriate personnel

Appropriate personnel will be someone with the required skills, knowledge and/or authority to deal with the matter, including one or both of the following:

a supervisor

an engineer

Checklists and records

Checklists and records may include one or more of the following:

paper or electronic-based

verbal/radio reports

reporting items found which require action


Performance Evidence

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:

replace existing components with new components

carrying out minor maintenance within own skill level

identify and report problems outside own competence

identify and control hazards related to flange joints

inspect job site to confirm:

location

authorisations required

access and egress needs

recent work undertaken on joint

flange type matches specification

inspect flange components to check for:

contaminants

signs of damage, defects or deterioration in all components

cleanliness and correct surface roughness of mating surfaces

alignment

correct specifications.


Knowledge Evidence

Evidence must be provided that demonstrates knowledge of:

flange and gasket types as applicable

principles of how flanged joints seal

tool types and applications

organisation’s flange management procedure

hierarchy of control

communication protocols (e.g. radio, phone, computer, paper and permissions/authorities)

routine problems, faults and their symptoms, and the corrective action to be taken

process materials and conditions at the location of the flange

using flange tags/completeness tags

relevant environmental requirements

relevant parts of ASME PCC-1-2013 Guidelines for pressure boundary bolted flange joint assembly.