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Elements and Performance Criteria

  1. Confirm repair specification
  2. Design installation process
  3. Prepare for installation
  4. Monitor installation

Required Skills

Required skills

Required skills include

solving problems

communicating at all levels

using organisation knowledge system

investigating

analysing

interpreting data

negotiating

technical reporting

Required knowledge

Required knowledge includes

properties of all common refractory materials

common installation methods and ways of repairing them

common modes of refractory failure and their implications for repair

anchors and anchoring systems used in repairs

keying and adhesion methods used in repairs

installation equipment such as lifting and placement aids and gunning equipment

post placement requirements for different repairs

formwork design and construction

scaffolding design and construction

relevant terms

relevant calculations

project planning and management

Evidence Required

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package

Overview of assessment

Assessment of this unit should include demonstrated competence in a workplace based project or a simulated workplace project

Access should be available to all normally accessed tables data etc which would be available to and used by a competent refractory specialist performing this assignment

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

Competence must be demonstrated in the ability to select an appropriate material and write the required specification

Context of and specific resources for assessment

Assessment may occur on the job or in an appropriately simulated environment Access is required to real or appropriately simulated situations including work areas materials and equipment and to information on workplace practices and OHS practices

Where applicable reasonable adjustment must be made to work environments and training situations to accommodate ethnicity age gender demographics and disability

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

Method of assessment

Assessment must satisfy the endorsed assessment guidelines of the Manufactured Mineral Products Training Package

Assessment methods must confirm consistency and accuracy of performance over time and in a range of workplace relevant contexts together with application of underpinning knowledge

Assessment methods which include direct observation of tasks should also include questioning on underpinning knowledge to ensure its correct interpretation and application

Assessment may be applied under project related conditions real or simulated and require evidence of process

Assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance but is able to be transferred to other circumstances

Assessment may be in conjunction with assessment of other units of competency where required

Guidance information for assessment

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


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. 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) may also be included.

Refractory materials

Refractory materials may include one or more of:

cementitious refractories

clay refractories

ceramic fibre

other refractories

Repair methods

Repair methods include:

cold repair

hot repair

direct repair

controlled repair (e.g. through controlled gunning)

repair from inside the vessel

repair by injection through the vessel wall

Shores

Shores may include:

dead shores

raking shores

flying shores

Installation equipment

Installation equipment may include one or more of:

vibrators

compactors

rams

gunning systems

equipment for lifting and placing precast blocks

temporary support for roofs and arches

spreader jacks

Anchors and keys

Types of anchors may include:

anchor bolts

through anchors

retention clips

Keys include cut mechanical keys

Adhesion may include:

chemical and other means of ensuring a bond between the repair and the refractory substrate

Post repair requirements

Post repair requirements may include:

drying

curing

control of moisture and/or temperature

striking of formwork

removal of scaffolding or other access/egress provisions

HSE hazards

HSE hazards may include:

exposure to heat

exposure to dust

exposure to refractory materials

confined space entry

working with equipment

working at heights

ultra-violet (UV) and other welding hazards

disposal of waste, scrap and excess materials

manual handling hazards

Hazard control

Appropriate hazard control should be determined by:

applying the hierarchy of control

Stakeholders

Stakeholders may include:

customer representatives

technical experts

regulators

refractory designer

materials and equipment suppliers

contractors

Requirements

Requirements include:

materials

equipment

contractors

Time critical items

Time critical items are those items which if not completed on time will cause the project to run overtime and may be determined from:

critical path analysis

long lead time items

other techniques

Repair specification

Repair specification should include:

technical specification

hazard controls and residual hazards

installation schedule

measures monitoring critical items

End of project documentation

End of project documentation may include:

operating and/or maintenance procedures

technical specification

routine monitoring requirements

project review report:

what was intended

what was achieved

achieved costs

achieved timing

significant project issues

possible improvements