Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

PMBWELD301 Mapping and Delivery Guide
Butt weld polyethylene plastic pipelines

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMBWELD301 - Butt weld polyethylene plastic pipelines
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to butt weld polyethylene (PE) plastic pipelines. It applies to welding undertaken in the field and in factory conditions. Pipelines may be for transmission of gas or liquids.This unit of competency applies to experienced operators who are required to calculate appropriate welding parameters to be used, set up equipment, perform butt weld, assess joints against specifications and solve problems within area of responsibility.This unit of competency applies to an experienced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The operator may work alone or as a member of a team or group and will work in liaison with other shift team members, team leader and supervisor, as appropriate.No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

In all plants it may be appropriate to assess this unit concurrently with units such as:

teamwork

communication.

Where the assessee does not currently possess evidence of competency in PMBPROD287 Weld plastics materials, it may be co-assessed with this unit.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant

will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start and stop procedures and responding to problems

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.
Prerequisites/co-requisites
Competency Field Welding
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Identify materials as being compatible for welding
  • Identify materials as polyethylene (PE) from specifications and work site instructions
  • Identify PE materials and pipes supplied as being compatible for welding from specifications
       
Element: Calculate appropriate pipe welding parameters
  • Identify welding machine type and operating data
  • Identify pipe materials and dimensions
  • Perform welding parameter calculations for individual welding machines and pipe details
  • Prepare field operational sheets as per enterprise requirements
       
Element: Maintain and calibrate welding equipment
  • Set up welding equipment and work area
  • Ensure safety equipment is available and operational
  • Identify non-conformance, report and rectify
  • Check operation and calibrate where required, heating, trimming, and pressure systems
       
Element: Perform welding to required standard
  • Assemble pipeline components in welding machine
  • Clean, align and trim pipe ends
  • Perform heating, welding, and cooling phases using calculated welding parameters
  • Monitor and record achieved weld parameters for each joint according to enterprise requirements
  • Clean up equipment when completed according to enterprise procedures
  • Clean up work site, dispose of scrap materials according to enterprise procedures
  • Use personal protective equipment (PPE) according to enterprise requirements
       
Element: Assess quality of completed joints
  • Identify quality requirements for joints
  • Assess joints against specification requirements, and report results
  • Identify and report non-conformances according to enterprise requirements
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identify materials as being compatible for welding

1.1

Identify materials as polyethylene (PE) from specifications and work site instructions

1.2

Identify PE materials and pipes supplied as being compatible for welding from specifications

2

Calculate appropriate pipe welding parameters

2.1

Identify welding machine type and operating data

2.2

Identify pipe materials and dimensions

2.3

Perform welding parameter calculations for individual welding machines and pipe details

2.4

Prepare field operational sheets as per enterprise requirements

3

Maintain and calibrate welding equipment

3.1

Set up welding equipment and work area

3.2

Ensure safety equipment is available and operational

3.3

Identify non-conformance, report and rectify

3.4

Check operation and calibrate where required, heating, trimming, and pressure systems

4

Perform welding to required standard

4.1

Assemble pipeline components in welding machine

4.2

Clean, align and trim pipe ends

4.3

Perform heating, welding, and cooling phases using calculated welding parameters

4.4

Monitor and record achieved weld parameters for each joint according to enterprise requirements

4.5

Clean up equipment when completed according to enterprise procedures

4.6

Clean up work site, dispose of scrap materials according to enterprise procedures

4.7

Use personal protective equipment (PPE) according to enterprise requirements

5

Assess quality of completed joints

5.1

Identify quality requirements for joints

5.2

Assess joints against specification requirements, and report results

5.3

Identify and report non-conformances according to enterprise requirements

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

read and interpret designs, plans, patterns, procedures, job specifications, instruments/control panels, material labels and safety data sheets (SDS)

plan the welding process and sequence tasks

use mathematics to calculate welding parameters

set up butt welding equipment and materials/components to meet specifications

operate the equipment to weld the materials

monitor key variables, including:

temperature

pressure

alignment

colour and uniformity

surface finish/appearance

tolerance for weld/joint

consistency of weld

product output rate

mechanical strength of weld (e.g. tensile strength results)

product integrity and general conformance to specification

make adjustments to remedy faults and nonconformity

maintain output and product quality using appropriate instruments, controls, test information and readings

calibrate equipment according to procedures

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

recognise early warning signs of equipment/processes needing attention or with potential problems

distinguish between causes of problems, including:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

materials properties

process variables

raw material variations/contamination

process abnormalities

procedural errors

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

function and operating principles of butt welding equipment, components and ancillary equipment

types and application of butt welding processes and their effect on the welded product

impact of variations in welding process variables and raw materials on product quality and production output

factors which may affect product quality or production output and appropriate remedies

characteristics of materials and their behaviour in relation to welding process variables and stages of production

quality requirements at each production stage

common adjustments in process variables and their impact on product quality and production output

impact of variations in raw materials and equipment operation in relation to final product

possible changes to materials properties to better suit specific process requirements

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identify materials as being compatible for welding

1.1

Identify materials as polyethylene (PE) from specifications and work site instructions

1.2

Identify PE materials and pipes supplied as being compatible for welding from specifications

2

Calculate appropriate pipe welding parameters

2.1

Identify welding machine type and operating data

2.2

Identify pipe materials and dimensions

2.3

Perform welding parameter calculations for individual welding machines and pipe details

2.4

Prepare field operational sheets as per enterprise requirements

3

Maintain and calibrate welding equipment

3.1

Set up welding equipment and work area

3.2

Ensure safety equipment is available and operational

3.3

Identify non-conformance, report and rectify

3.4

Check operation and calibrate where required, heating, trimming, and pressure systems

4

Perform welding to required standard

4.1

Assemble pipeline components in welding machine

4.2

Clean, align and trim pipe ends

4.3

Perform heating, welding, and cooling phases using calculated welding parameters

4.4

Monitor and record achieved weld parameters for each joint according to enterprise requirements

4.5

Clean up equipment when completed according to enterprise procedures

4.6

Clean up work site, dispose of scrap materials according to enterprise procedures

4.7

Use personal protective equipment (PPE) according to enterprise requirements

5

Assess quality of completed joints

5.1

Identify quality requirements for joints

5.2

Assess joints against specification requirements, and report results

5.3

Identify and report non-conformances according to enterprise requirements

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, manual handling and hazardous materials

Australian/international standards relevant to the materials being used and products being made, including one or more of:

AS/NZS 4130:2009 Polyethylene (PE) pipes for pressure applications, or its replacement

AS/NZS 4131:2010 Polyethylene (PE) compounds for pressure pipes and fittings, or its replacement

AS/NZS 4401:2006 Plastics piping systems for soil and waste discharge (low and high temperature) inside buildings - Polyethylene (PE), or its replacement

AS/NZS 5065:2005 Polyethylene and polypropylene pipes and fittings for drainage and sewerage applications, or its replacement

ISO 21307:2011 Plastics pipes and fittings -- Butt fusion jointing procedures for polyethylene (PE) pipes and fittings used in the construction of gas and water distribution systems or its replacement

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Tools and equipment

Tools and equipment include:

hydraulic activated butt welding machines

pipe supports

measurement devices, including one or more of:

pressure gauges

timers

temperature probes

callipers

computer-based pressure/temperature monitors

cleaning equipment

spray equipment.

Additional tools and equipment will be selected as required from:

hand tools used in this process

hoists/lifting equipment not requiring any special permits or licences

manual handling, aids such as hand carts and trolleys

relevant PPE.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

power tools, leads and power supplies

hazardous products and materials

cutting equipment

sharp edges, swarf and scrap

protrusions or obstructions

slippery surfaces, spills or leaks

rotational equipment or vibration

smoke, dust, vapours or other atmospheric hazards

high temperatures

electricity

gas

gases and liquids under pressure

structural hazards

equipment failures

machinery, equipment and product mass

other hazards that might arise.

Problems

Routine and non-routine problems must be resolved.

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Non-routine problems are unexpected problems or variations of previous problems and include one or more of:

variations in quality

emergency situations

intermittent faults.

Operational knowledge includes one or more of:

procedures

training

technical information, such as journals and engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

Routine problems are predictable and have known solutions and include one or more of:

variable PE materials and pipes as supplied

equipment malfunction or wear and tear

variable field site conditions.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Identify materials as polyethylene (PE) from specifications and work site instructions 
Identify PE materials and pipes supplied as being compatible for welding from specifications 
Identify welding machine type and operating data 
Identify pipe materials and dimensions 
Perform welding parameter calculations for individual welding machines and pipe details 
Prepare field operational sheets as per enterprise requirements 
Set up welding equipment and work area 
Ensure safety equipment is available and operational 
Identify non-conformance, report and rectify 
Check operation and calibrate where required, heating, trimming, and pressure systems 
Assemble pipeline components in welding machine 
Clean, align and trim pipe ends 
Perform heating, welding, and cooling phases using calculated welding parameters 
Monitor and record achieved weld parameters for each joint according to enterprise requirements 
Clean up equipment when completed according to enterprise procedures 
Clean up work site, dispose of scrap materials according to enterprise procedures 
Use personal protective equipment (PPE) according to enterprise requirements 
Identify quality requirements for joints 
Assess joints against specification requirements, and report results 
Identify and report non-conformances according to enterprise requirements 

Forms

Assessment Cover Sheet

PMBWELD301 - Butt weld polyethylene plastic pipelines
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

PMBWELD301 - Butt weld polyethylene plastic pipelines

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: