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Elements and Performance Criteria

1. Perform pre-operational equipment checks
2. Detailed pre-operational equipment checks are conducted in accordance with manufacturer specifications and/or local maintenance schedules
3. Deficiencies with equipment are identified and rectified in accordance with workplace procedures
4. Relevant persons are notified of problems and documentation is completed
5. Prepare rail for welding
6. Weld location is checked to confirm suitability for welding in accordance with workplace standards
7. Track preparation for welding is arranged as required in accordance with workplace procedures and standards
8. Rail ends are prepared for welding in accordance with workplace procedures and standards
9. Carry out flashbutt welding
10. Flashbutt welding equipment is prepared for use
11. Flashbutt welding unit is clamped to rail ensuring accurate alignment
12. Equipment is operated in accordance with machine operation instructions and workplace procedures to achieve appropriate quality standard
13. Warning systems are monitored and appropriately responded to during operation to maintain correct functionality of equipment
14. Track restoration is arranged as required in accordance with workplace procedures and standards
15. Weld is profile-ground to ensure smooth running surface in accordance with workplace procedures and standards
16. Check weld conformance
17. Finished ground weld area is visually inspected for surface finish and defects
18. Finished ground weld area is checked for conformance to rail profile and geometry acceptance standards
19. Perform post-operational equipment checks
20. Post-operational equipment checks are conducted to identify defects and maintenance requirements, in accordance with manufacturer specifications or local maintenance schedules
21. Deficiencies with equipment are identified and rectified in an appropriate manner to maintain correct functionality of equipment
22. Relevant persons are notified of problems and/or documentation is completed in accordance with instructions and relevant codes of practice
23. Complete documentation
24. Required documentation and/or record keeping procedures and processes are confirmed
25. Documentation and/or records are filled in legibly and proofread
26. Documentation and/or records are processed in accordance with workplace procedures

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 25 separate occasions and include:

applying relevant safeworking and workplace procedures carrying out required welding operations checking compliance of work with job specifications identifying job hazards and taking required action to minimise, control or eliminate identified hazards implementing contingency plans implementing required fire control workplace procedures interpreting and following operational instructions and following scheduled work process modifying activities depending on operational contingencies, risk situations and environments monitoring work activities in terms of planned schedule operating flashbutt welding equipment in accordance with workplace procedures planning scheduled work including predicting consequences and identifying improvements reading and interpreting relevant instructions, procedures, route information and signs reporting and/or rectifying identified problems, faults or malfunctions, in accordance with workplace procedures selecting and using required personal protective equipment working collaboratively with others working systematically with required attention to detail without injury to self or others, or damage to 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:

characteristics of relevant plant and equipment, transport, structures, hardware and components used in work activities emergency management plan hazardous situations and related personal protection measures hazards that may exist when welding rail using the flashbutt welding process, and ways of controlling the risks involved materials identification, handling and storage safety data sheets (SDSs)/material safety data sheets (MSDSs) and/or manufacturer instructions problems that may occur when using the flashbutt welding process and equipment, and action that can be taken to report or resolve these problems rail welding industry standards relevant recording and documentation procedures relevant safety, work health and safety (WHS)/occupational health and safety (OHS) and environmental procedures and regulations technical knowledge relevant to flashbutt welding workplace procedures for operating flashbutt welding equipment workplace procedures for welding rail using the flashbutt welding process.

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