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Elements and Performance Criteria

  1. Plan for inspection, testing and/or maintenance tasks
  2. Prepare for inspection, testing and/or maintenance tasks
  3. Carry out inspection of safety shutdown systems
  4. Carry out testing of safety shutdown systems
  5. Carry out routine maintenance of safety shutdown systems
  6. Carry out the overhaul of safety shutdown systems
  7. Complete post-work activity requirements

Required Skills

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 as required to safely effectively and efficiently inspect test and maintain safety shutdown systems on diesel engine systems

apply legislative organisation and site 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 site health and safety requirements and procedures

apply site environmental requirements and procedures

apply site quality requirements and procedures

read explain and apply

technical information including scheduled drawings

sitelegislative requirements

records and reports

apply registrationcertification information and implement conditions and recommendations

apply feedback procedures

apply technical and routine reporting requirements and procedures

apply investigation procedures

apply technical literacy including reading and interpreting fluidic and logic schematic drawings

interpret and apply technical and scientificindustry terminology

analyse the function of the devices within an integrated system

operate manual fuel shutoff valve

apply site communication requirements and procedures

apply manufacturers 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 lockout 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 calibratedverified 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 as required to safely effectively and efficiently inspect test and maintain safety shutdown systems on diesel engine systems

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

site and manufacturers requirements and procedures

legislative requirements and procedures

site and legislative safety inspection requirements

provisions of relevant Standards and guidelines

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

engine system shutdown devices required by ASNZSamp

waterbath level monitoring devices including the methods employed to determine minimum safe shutdown levels and the testing methods and procedures required to confirm compliance

functionality and performance of the various type of automatic safety shutdown systems including

pneumatically operated

engine oil pressure operated

a mix of pneumatic and engine oil pressure operated

electrically or electronically operated

failure modes of safety shutdown systems including

contamination

incorrect adjustment

unauthorised adjustment

testing procedures required to detect failures

recommended maintenance procedures required to reduce the probability of failures

features function and performance of electrical electronic safety shutdown system and sufficient knowledge of the Group I explosion protection techniques used for devices to identify a component failure by inspection only and to seek expert competent advice such as

Exd flameproof

Exi ab intrinsic safety

Exm ab dncapsulation

Exe increased safety

Exo oil immersion

Exs special protection

requirements for cables and connections used for electrical electronic safety shutdown system including those nominated in ASNZS

features function performance of the various type of emergency stop systems including

strangler valves in the air intake system

inert gas injection

decompression

operation of the manual fuel shut off valve

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 ASNZS and 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 lockout 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

Evidence Required

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 safety shutdown 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 safety shutdown systems on diesel engine systems

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

consistent timely completion of the inspection testing and maintenance of safety shutdown 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 andor 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 andor oral assessment of the candidates required knowledge

observed documented andor first hand testimonial evidence of the candidates

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 safety shutdown systems on diesel engine systems

Guidance information for assessment

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


Range Statement

Compliance and other documentation 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

inspecting the fuel shutdown linkages to ensure they are in good condition and fully operative

Testing may include:

conducting exhaust conditioner/flametrap, low-water, shutdown tests (both low water test systems are tested separately)

checking that all gauges and indicators are operating correctly and are clearly visible

checking the proper operation and function of;

low oil engine pressure detection sensor

coolant loss protection sensor

coolant over temperature protection sensor

confirming that the manual fuel valve operates correctly to stop the diesel within the time determined by the original type testing including a reasonable margin

test that the air receiver safety (pressure relief) valves are in place, not blocked/seized and operating correctly

checking the engine system shuts down at, or higher than, the minimum shutdown water level, (record the water levels after shut-down)

testing the emergency safety shutdown system to ensure that the engine stops under the operation of the emergency safety shutdown system working in isolation of other engine safety shutdown systems, record the time taken for the engine to stop with the engine running at high idle, (Note: The diesel engine system manufacturer may provide test instructions to minimise the risk of engine damage during testing (see AS/NZS3584.2)

checking the proper operation and function of the low oil engine pressure detection sensor, and recording the engine oil pressure at the time of shutdown

checking the proper operation and function of the coolant loss detection sensor, and recording the time taken to cause the engine to shut down

checking the proper operation and function of the coolant over-temperature sensor, and recoring the coolant temperature at which the engine shut down, (Note: Testing this sensor by defeating other sensors and overheating the diesel engine system may be hazardous or cause damage to the diesel engine system. It is recommended that the sensor be removed from the engine and tested in heated water while remaining connected to the engine shutdown system)

checking the proper operation and function of the exhaust gas over-temperature sensor, and recording the exhaust temperature at which the engine shut down

confirming that all of the engine shutdown system fault indicators properly indicate each of the faults simulated in the foregoing tests

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

Safety shutdown systems may include:

engine safety shutdown system (fuel shutdown system), including:

manual actuation system

fault indication system

emergency safety shutdown system, may be:

a strangler valve

inert gas injection

decompression

manually actuated

automatically operated

manual fuel shut-off valve

sensing devices, including:

engine cooling system

engine oil pressure

water-based flametraps

exhaust cooling

particulate filter

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

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, and

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

Others may include:

other maintenance personnel

support providers

contractors

underground production personnel

mobile or fixed plant operators

Items may include:

authorised replacement parts

fasteners as specified in manufacturer’s drawings

packing materials

Tools may include:

hand tools

power tools

special tools

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 and inspection procedures include:

checking:

cleanliness, particularly coal dust

diesel and other flammable liquid leaks

coolant leaks in radiator or radiator hoses

coolant level

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

adjusting

replacing

Overhaul may include:

removal

dismantling

cleaning

inspecting

replacing, eg:

valves sensors exhaust gas recirculation

particulate filters

replacement element-type filter testing, including:

individual devices system operation and function reassembly

reinstallation

Records may include:

inspection and test results

defect identified

defect rectification carried out

item consumed

hazard/risk management reports