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Elements and Performance Criteria

1. Plan for conveyor belt replacement.
   • Review belt specifications and work order documentation.
   • Identify hazards and risk controls.
   • Review plan to ensure that downtime is minimised, materials are used economically and quality standards are met.
   • Ensure that all permissions and permits have been obtained.
   • Ensure that all required equipment, tools and materials are available and have been checked for condition, quality and compliance tags.
   • Ensure that a safe work area has been established.
2. Remove and replace conveyor belt.
   • Examine the conveyor system for and eliminate sources of potential belt damage.
   • Facilitate removal of conveyed materials from the belt
   • Identify and eliminate any residual dangerous or hazardous substances or contaminants.
   • Ensure conveyor equipment is disengaged and locked out.
   • Remove tension from belt, as required.
   • Set up equipment to appropriately support the removal and replacement of belt, without unnecessary twisting or bending.
   • Remove existing belt and track replacement belt onto rollers.
   • Store removed belt appropriately.
   • Ensure new belt is spliced according to procedures.
3. Commission conveyor belt.
   • Inspect belt condition for imperfections or irregularities.
   • Start conveyor or monitor start up to procedures.
   • Monitor and adjust tracking, speed and tensions as required.
   • Observe belt in operation and identify conditions which may require emergency shutdown of equipment.
   • Give appropriate notice of any impending shut down to procedures.
   • Follow shutdown procedures.
4. Clean work area.
   • Clean work area and return to approved condition.
   • Follow all waste and recycling procedures.
   • Complete documentation
5. Anticipate and solve problems
   • Recognise a problem or a potential problem.
   • Determine problems needing priority action.
   • Refer problems outside area of responsibility to appropriate person, with possible causes.
   • Seek information and assistance as required to solve problems.
   • Solve problems within area of responsibility.
   • Follow through items initiated until final resolution has occurred.

Required Skills

This describes the essential skills and knowledge and their level required for this unit

Application of knowledge of the materials equipment and process sufficient to recognise material and equipment conditions which may lead to out of specification production For example pulling plates are fitted as required to ensure the belt tracks properly

Knowledge of organization procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards

Application of the knowledge of managing risks using the hierarchy of controls applied to belt replacement Application of approved hazard control safety procedures and the use of PPE in relation to handling materials equipment operation and cleanup

Competence includes the ability for the practical completion of the job to apply andor explain

function and operating principles of conveyor systems and ancillary equipment

impact of incorrect or faulty joining processes

planning process to ensure that belt is removed and replaced in the correct sequence of operations and applying the required procedures

production workflow sequences and inherent hazards with conveyors

stresses and tensions on working belts and the common failure causes

correct selection and use of equipment materials processes and procedures

ensure that all equipment is certified as required for the intended duty

products materials and material characteristics for splicing belts

effects of temperature pressure and time on the curing process

changes in conveyor and joining materials during the joining process

Competence also includes the ability to

plan own work including predicting consequences and identifying improvements

identify factors which may affect product quality or production output and appropriate remedies

identify when the operator is able to rectify faults and when assistance is required

Language literacy and numeracy requirements

This unit requires the ability to read and interpret typical product specifications job sheets and material labels as provided to operators

Writing is required to the level of completing workplace forms

Numeracy is also required eg to determine the number of belt sections required to form a continuous belt for a given conveyor length

Evidence Required

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge the range statement and the assessment guidelines for this training package

Overview of assessment

A holistic approach should be taken to the assessment

Assessors must be satisfied that the person can consistently perform the unit as a whole as defined by the Elements Performance Criteria and skills and knowledge

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

It is essential that competence is demonstrated in the knowledge and skills defined in this unit These may include the ability to

identify critical materials properties and belt removal and replacement process characteristics

identify hazards in the removal and replacement process and put in place appropriate controls

plan own work process within workplace procedures and explain the reasons for the steps in the process

take appropriate action to observe equipment materials and products for out of specification results make adjustments and identify problems to be reported

Consistent performance should be demonstrated For example look to see that

production quality and output standards are met consistently

problems are anticipated from process observations

problems are efficiently resolved

the removal and replacement process runs consistently and smoothly

Assessment method and context

Assessment will occur in the field on an industrial conveyor belt installation

Competence in this unit may be assessed

on a processing plant allowing for operation under all normal and a range of abnormal conditions

in a situation allowing for the generation of evidence of the ability to recognise anticipate and respond to problems

by using a suitable simulation andor a range of case studiesscenarios

through a combination of these techniques

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practicalsimulation or similar assessment Assessors need to be aware of any cultural issues that may affect responses to questions

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy language and literacy capacity of the assessee and the work being performed

Specific resources for assessment

This section should be read in conjunction with the Range Statement for this unit of competency Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation A bank of case studiesscenarios and questions will also be required to the extent that they form part of the assessment method Questioning may take place either in the workplace or in an adjacent quiet facility such as an office or lunchroom No other special resources are required

Access must be provided to appropriate learning andor assessment support when required Where applicable physical resources should include equipment modified for people with disabilities

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Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts.

Where reference is made to industry codes of practice and/or Australian/international standards, the latest version must be used.

Context

This competency applies to the removal and replacement of conveyor belts. It includes the operation of all relevant additional equipment where that equipment is integral to the belt removal and replacement process. The competency unit includes the use of manual handling aids such hand winches and portable lifting gear, and of powered equipment/aids for some aspects.

Procedures

All operations are performed in accordance with procedures.

Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

Tools and equipment

This competency covers different types of conveyor belts, including:

steel cord belts

fabric reinforced ply belts

solid woven belts.

The competency includes use of equipment and tools such as:

portable power generators and vulcanising equipment

knives and other cutting instruments

belt winders, belt stands and winches

clips, pulling plates, steel cables (certified as required)

portable hoists/lifting equipment not requiring any special permits or licences

hand tools (such as spanners, wrenches, hammers)

power operated hand tools (such as drills, cutting disks, sanders)

relevant personal protective equipment

Hazards

Typical hazards include:

unpredicted belt movements

equipment malfunctions

manual handling hazards

lifting, tracking and securing hazards

equipment operation hazards

damaged material hazards.

Problems

'Anticipate and solve problems' means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.

Typical process and product problems may include:

weight of the belting to be removed and replaced

obstructions and impediments to removal and fitting on new belt

worn or malfunctioning rollers, drums or propulsion equipment

lack of accessibility

lack of required human resources

tool problems

variations in materials and/or contamination of materials

processing problems.

Variables

Key variables to be monitored include:

belt condition

belt location

gradient of belt

types of scrapers

skirting systems used

degree of damage

weight of the belt

forces acting on the conveyor belt

environmental conditions

lock-out of equipment.

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