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Elements and Performance Criteria

  1. Prepare rails, crossings or switches for welding
  2. Assemble and set up welding equipment
  3. Assemble and set up gouging and grinding equipment
  4. Remove defect
  5. Perform welding operation
  6. Check weld conformance
  7. Complete post-operative checks and documentation

Required Skills

This section describes the knowledge and skills required for this unit

Required knowledge

Acceptance standards for weld repairs on rail

Authorisationapproval processes and procedures

Documentation and recordkeeping requirements

Fundamentals of tram 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 the problems

Relevant communication systems and procedures

Relevant safety occupational health and safety OHampS and environmental procedures and regulations

Track standards for tram rail crossing and switch condition and surface profile

Workplace procedures for removing defects by gouging grinding and welding rail using an electric welding process

Required skills

Communicate effectively with others when welding rail using an electric welding process

Complete documentation related to welding rail using an electric welding process

Implement contingency plans for unexpected events when welding rail using an electric welding process

Interpret and follow operational instructions and prioritise work when welding rail using an electric welding process

Modify activities depending on differing operational contingencies risk situations and environments

Monitor work activities in terms of planned schedule

Operate and adapt to differences in equipment in accordance with standard operating procedures

Operate communications equipment to required protocol

Read and interpret technical data drawings instructions and manuals relevant to welding rail using an electric welding process

Report andor rectify any identified problems faults or malfunctions that may occur when welding rail using an electric welding process in accordance with regulatory requirements and organisational procedures

Select and use hand tools power tools and equipment

Select and use required personal protective equipment PPE

Work collaboratively with others when welding rail using an electric welding process

Work systematically with required attention to detail without injury to self or others or damage to goods or equipment

Evidence Required

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required knowledge and skills the range statement and the assessment guidelines for this Training Package

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 and satisfy all of the requirements of the elements and performance criteria of this unit and include demonstration of applying

the required knowledge and skills

relevant legislation and workplace procedures

other relevant aspects of the range statement

Assessment must include exercises which demonstrate competency in the following in a range of situations

preparing items for welding according to workplace requirements

assembling and setting up welding gouging and grinding equipment and preparing consumables

performing welding grinding gouging and testing operations on rails crossings or switches

ensuring weld conforms to organisational requirements

completing documentation in accordance with organisational requirements

Context of and specific resources for assessment

Performance must be demonstrated consistently over a period of time and in a suitable range of contexts

Resources for assessment include

a range of relevant exercises case studies andor other simulated practical and knowledge assessment andor

access to an appropriate range of relevant operational situations in the workplace or

simulated environment using actual components tools and equipment

In both real and simulated environments access is required to

relevant and appropriate materials and equipment and

applicable documentation including workplace procedures regulations codes of practice and operation manuals

Method of assessment

As a minimum assessment of knowledge must be conducted through appropriate writtenoral tests

Practical assessment must occur

through activities in an appropriately simulated environment andor

in an appropriate range of situations in the workplace


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.

Work may involve exposure to:

chemicals

dangerous or hazardous substances

movements of equipment, goods and vehicles

Types of weld repairs may vary according to:

welding process location

rail mass or type

crossing and switch type

rail, switch and crossing material

Welding process may include:

flux core arc welding

manual metal arc welding

Welding equipment may include:

electric welders

generators

wirefeed welding unit

electrode holder

robotic welder

Equipment may include:

mechanical handling/lifting equipment

hand tools including impact wrenches, tie tampers, gauges, track jacks, spiking hammers and bars

oxy/LPG gouging equipment

manual or mechanical grinder

wire brushes

cutting and boring equipment

fastening equipment

fume extraction equipment

on-line respirator

Materials may include:

flux core wire

welding electrodes

grinding discs

Liaison may include:

internal or external personnel from other work areas (e.g. train controllers, signal technicians)

Communications equipment may include:

two-way radios

telephones/mobile phones

agreed audible or hand signal

Depending on the work context, safety and personal protective equipment may include:

high visibility clothing

long pants and shirts

hearing protection

long gloves

spats

sunscreen

sunglasses

welding helmet

safety glasses

insect repellent

safety headwear

safety footwear

portable radios/mobile phones

hand lamps

flags

safety devices

special PPE

Information/documents may include:

operational instructions

information provided by other workplace personnel

rail inspections reports

work orders

technical instructions

manufacturer or workplace equipment instructions and operation manuals

emergency procedure manuals

two-way radio/mobile phone operation procedures

conditions of service, legislation and industrial agreements including workplace agreements and awards

Applicable procedures and codes may include:

legislated rail safety requirements including acts and regulations from each applicable state and territory together with any nationally approved compliance codes and/or guidelines

organisational policies and procedures

local authority regulations and procedures relevant

relevant state/territory OH&S legislation

relevant state/territory environmental protection legislation