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Elements and Performance Criteria

1. Prepare rails, crossings or switches for welding
2. Weld repair area is identified and assessed in accordance with standards and procedures
3. Welding equipment and consumables are prepared and checked for serviceability
4. Hazards are identified, risks are assessed and control measures are implemented
5. Weld repair area is prepared for welding in accordance with workplace standards and procedures
6. Track components are assembled or aligned to specification as required
7. Use non-destructive testing
8. Appropriate non-destructive testing method is selected in accordance with workplace requirements
9. Non-destructive testing method is used to identify and locate defects in accordance with rail industry standards and organisational procedures
10. Assemble and set up welding equipment
11. Welding equipment is set up and adjusted to meet welding process requirements
12. Accessories and consumables are selected for use
13. Assemble and set up gouging and grinding equipment
14. Gouging and grinding equipment is assembled and set up
15. Equipment settings are adjusted to meet process requirements
16. Remove defects
17. Appropriate method to be used to remove defect is identified in accordance with organisational standards and procedures
18. Defect is removed using identified method in accordance with organisational standards and procedures
19. Perform welding operation
20. Weld metal is applied to repair area to meet specifications in accordance with standards and procedures
21. Welded area is cleaned in preparation for grinding
22. Welded area is ground in accordance with organisational standards and procedures
23. Check weld conformance
24. Finished ground weld area is visually inspected for surface finish and defects
25. Finished ground weld area is checked for conformance to rail, crossing or switch profile acceptance standards
26. Complete post-operative checks and documentation
27. Equipment is checked for serviceability
28. Defective equipment is replaced and reported for servicing or repair in accordance with organisational policies and procedures
29. Documentation on work undertaken is completed and processed in accordance with organisational requirements

Range Statement

Range is restricted to essential operating conditions and any other variables essential to the work environment.

Non-essential conditions can be found in the Companion Volume Implementation Guide.

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria on at least five separate occasions and include:

applying relevant workplace procedures ensuring weld conformance to organisational requirements identifying job hazards and taking required action to minimise, control or eliminate identified hazards implementing contingency plans interpreting and following operational instructions and prioritising work when welding rail using an electric welding process modify activities depending on operational contingencies, risk situations and environments monitoring work activities in terms of planned schedule operating and adapting to differences in equipment in accordance with operating procedures performing welding, grinding, gouging and testing operations on rails, crossings and switches in accordance with rail industry standards and/or workplace requirements preparing items for welding in accordance with workplace requirements reading and interpreting relevant technical data, drawings, instructions and manuals reporting and rectifying problems, faults and malfunctions within limits of own role, in accordance with organisational procedures selecting and using hand tools, power tools and equipment selecting and using required personal protective equipment using non-destructive (liquid penetrant or magnetic particle) testing equipment, gouging equipment and hand grinding equipment in accordance with safety data sheets (SDSs)/material safety data sheets (MSDSs), manufacturer instructions and workplace procedures working systematically with required attention to detail without injury to self or others, or damage to goods or equipment.

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Knowledge Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of:

authorisation/approval processes and procedures documentation and record keeping requirements fundamentals of track and components hazards that may exist when welding rail using an electric welding process and ways of controlling the risks involved problems that may occur when welding rail using an electric welding process and action that can be taken to report or resolve these problems rail industry acceptance standards for weld repairs on rail relevant rail danger zones relevant safety, work health and safety (WHS)/occupational health and safety (OHS) and environmental procedures and regulations track industry standards for rail, crossing and switch condition and surface profile workplace procedures, safety data sheets (SDSs)/material safety data sheets (MSDSs) and manufacturer instructions for non-destructive (liquid penetrant or magnetic particle) testing of rail workplace procedures for removing defects by gouging, grinding and welding rail using an electric welding process.

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