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Elements and Performance Criteria

  1. Plan and prepare for casting operations
  2. Prepare moulds/launder system
  3. Cast metal
  4. Remove cast metal
  5. Shutdown in sequence and/or isolate equipment
  6. Carry out housekeeping activities

Required Skills

Required skills

Specific skills are required to achieve the Performance Criteria of this unit particularly for its application in the various circumstances in which this unit may be used This includes the ability to carry out the following as required to cast ingots

apply legislative organisation and site requirements and procedures for casting ingots

deal with hazards

receive and deploy materials

monitoring and adjustment in process

handle chemicals safely

facilitate smooth product flow

communicate skills

deal with faults and variances

Required knowledge

Specific knowledge is required to achieve the Performance Criteria of this unit particularly for its application in the various circumstances in which this unit may be used This includes knowledge of the following as required to cast ingots

precautions necessary to ensure safety

potential dangers inherent in specific plant and equipment

safe working procedures and systems

fume extraction requirements and methods

power unit requirements

specifications of moulds bottom plates trumpets ingots anodes bullion

application of process to different base metals

teemingtapping schedules

ingot anode and bullion weight and markers relationship

specification and use of tiles

storage and scheduling requirements for production

plant requirements

service requirements and specifications

fault finding

materials specifications

limits of authority

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

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 casting ingots

implementation of requirements procedures and techniques for the safe effective and efficient completion of casting ingots

working with others to undertake and complete the casting of ingots in a way that meets all of the required outcomes

consistent timely completion of the casting of ingots 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

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

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

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

consistent achievement of required outcomes

first hand testimonial evidence of the candidates

working with others to undertake and complete the casting of ingots

Guidance information for assessment

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


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. Bold italicised wording, if used in the performance criteria, is detailed below. 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.

Relevant compliance documentation may include:

legislative, organisational and site requirements and procedures

manufacturer's guidelines and specifications

Australian standards

Employment and workplace relations legislation

Equal Employment Opportunity and Disability Discrimination legislation

Legislation may include Acts and regulations dealing with:

mining safety and health

mine inspection

OHS

explosives

environment

Personal protective equipment may include:

helmet

safety footwear

hearing protection

gloves

eye/face protection

respiratory protection

heat resistant clothing

Site environmental issues may include:

drainage

dust and fumes

emissions

hazardous chemicals

noise

run-off

spills

waste management and disposal

water quality

Mould and/or launder system preparation equipment may include:

air chisel

burning bars

jackhammers

hand hammer

explosives

forklift/crane

Preparing moulds or launder systems may include:

levelling

clamping in place

peening and chipping

removal of broken lugs

checking for wear, straight shaft

condition of seals

powdering the mould

Mould and/or launder system faults may include:

moulds not level

metal under mould

mould bowed or cracked

dry slurry

insufficient refractory (on launders)

burners not operating

Moulds may include stools, or other launder and ladle systems.

Teeming/tapping may include:

up-run

down-hill

double hole

single hole

Monitoring of cast may include:

launders

ladles

tun dishes

water and slurry sprays

correct height of cast in mould

checked lug area for slurry build up

Problems with cast may include:

over/unfilled ladles or moulds

build up splash

mould hot spots

stuck anodes

temperature of mould too cold

slurry wrong density

wheel losing home position

wheel inhibited (stops/ stuck)

metal incorrect temperature on furnace roll down

Defective moulds and bottom plates may include:

scrappy top

badly cracked

wet

incorrectly seated

cracks

excess slurry

Shutdown procedures may include:

drain casting ladles

turn off water, air and slurry sprays/burners

blow out moulds

flush slurry sprays

remove launders

release air

Production documentation may include:

tonnages

quality

analysis/testing

identity

tracking

Services may include:

electricity

air

water

gas

fuel oil

Hazards may include:

rail and road movement

cranes

molten metal

hot materials

noise

air pollution

sharp objects

moving machinery

heights

falling objects

gases

chemicals

Raw materials may include those involved in:

mould and stool construction

Appropriate authority may include:

maintenance engineering personnel

management

Fault and variances may occur in:

product

plant

equipment