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

PMC557093A Mapping and Delivery Guide
Design a refractory_ceramic component

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency PMC557093A - Design a refractory_ceramic component
Description This unit of competency covers confirming the application and conditions of use of the proposed component and then designing the most appropriate component for that use. It is intended for refractory experts who will most likely also have some management responsibility.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit of competency requires the application of knowledge about types of refractories, refractory properties and uses to the design of an appropriate refractory/ceramic component for a specified end use. This may be manufactured in a jobbing shop environment, or it may be a routine product manufactured by batch or continuous means. This unit does NOT cover the selection of the refractory material which is covered by PMC557090A Select refractory materials for an application. The units are obviously related and it may be appropriate to consider both concurrently.This unit applies to individuals who will be designing a refractory component. They may be working in liaison with other refractory specialists or they may be the sole refractory specialist for this job/in their organisation. They will typically be liaising with a range of other technical experts as well as management and maybe accounts. The components could be a refractory sleeve for a valve in an engine, a refractory tip for a flame lance or other application requiring a refractory component of a product.This unit may apply to individuals working for an organisation which supplies refractory components, is a refractory consulting organisation or a client organisation which buys and uses the refractory component.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field
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: Confirm required end use
  • Liaise with relevant stakeholders
  • Confirm the end use conditions for the refractory
  • Define interface requirements with the product
  • Identify discrepancies or conflicts in requirements
  • Negotiate a consistent set of requirements for the refractory component
       
Element: Undertake preliminary design
  • Undertake required mechanical design calculations
  • Undertake the required heat transfer calculations
  • Undertake relevant thermal expansion calculations
  • Determine implications for refractory material selection
  • Liaise with refractory material selector
  • Prepare preliminary designs of component
       
Element: Compare possible design solutions
  • Compare the preliminary designs with the set of requirements
  • Rank possible design solutions
  • Identify health, safety and environment (HSE) risks of top ranked possible refractory designs
  • Estimate the cost of top ranked possible refractory designs
       
Element: Design refractory component
  • Liaise with relevant stakeholders
  • Determine customer issues of relevance to the refractory designs
  • Determine manufacturing issues of relevance to the refractory designs
  • Review short list ranking
  • Recommend optimum refractory component design for the end use
       
Element: Develop design and technical specification for recommended refractory component
  • Determine suitable format for design and specification
  • Prepare design and specification
  • Review specification with refractory material selector, production and customer
  • Modify design and specification if required
  • Publish design and specification in required format to required people/organisations
       


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.

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

Assessment of this unit should include demonstrated competence in a workplace based project or a simulated workplace project.

Access should be available to all normally accessed tables, data etc which would be available to and used by a competent refractory specialist performing this assignment.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Competence must be demonstrated in the ability to design an appropriate refractory system and write the required specification.

Context of and specific resources for assessment

Assessment may occur on the job or in an appropriately simulated environment. Access is required to real or appropriately simulated situations, including work areas, materials and equipment, and to information on workplace practices and OHS practices.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed assessment guidelines of the Manufactured Mineral Products Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods which include direct observation of tasks should also include questioning on underpinning knowledge to ensure its correct interpretation and application.

Assessment may be applied under project related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.


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.

Required skills

Required skills include:

solving problems

communicating at all levels

using organisation knowledge system

analysing

interpreting data

negotiating

technical reporting

technical drawing - possibly computer aided drafting (CAD)

Required knowledge

Required knowledge includes:

properties of all common refractory materials

typical limitations and applications of all common refractory materials when used as components

manufacturing methods for refractory components and their advantages, disadvantages, typical uses and limitations

heat transfer calculations (resistances in series and parallel)

mechanical calculations (stress/strain, modulus, stiffness, shear, strength of refractory materials and physical properties of refractory materials)

thermal expansion (calculation of and allowance for)

methods of fixing refractory components to products

basic metal product manufacturing methods and possible uses for refractory components and their impact on component design

methods of reuse, recycling and disposal of refractory components at the end of their life and the differences for different types of refractory components

critical refractory component specifications

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. 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.

Stakeholders

Stakeholders may include:

customer representatives

technical experts

regulators

refractory designer

refractory installer

End use conditions

End use conditions may include:

surface temperature of refractory

required temperature gradient through refractory/outside surface temperature

chemical condition (e.g. pH)

mechanical condition (e.g. impingement)

temperature or other cycling

Types of refractory components

Typical types of refractory components include:

shafts

bearing plates/rings

nozzles and tips

valves and valve seats

crucibles and crucible linings

shelving

Ranking of possible designs

Ranking should be based on:

how well they meet the technical requirements of the end use

HSE risks

HSE risks should include focus on the comparative health, safety and environmental risks of the refractory systems under consideration.

Risks would include risks during:

manufacture

component installation

use

repair

removal and disposal at end of life

Cost of refractory component

Cost of refractory components should be total costs and should include:

material costs

manufacturing cost

installation costs

repair costs

life cycle costs

Optimum refractory component design

The optimum refractory component design would be:

that system which best delivers the technical requirement at the lowest cost and the least HSE risk

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
Liaise with relevant stakeholders 
Confirm the end use conditions for the refractory 
Define interface requirements with the product 
Identify discrepancies or conflicts in requirements 
Negotiate a consistent set of requirements for the refractory component 
Undertake required mechanical design calculations 
Undertake the required heat transfer calculations 
Undertake relevant thermal expansion calculations 
Determine implications for refractory material selection 
Liaise with refractory material selector 
Prepare preliminary designs of component 
Compare the preliminary designs with the set of requirements 
Rank possible design solutions 
Identify health, safety and environment (HSE) risks of top ranked possible refractory designs 
Estimate the cost of top ranked possible refractory designs 
Liaise with relevant stakeholders 
Determine customer issues of relevance to the refractory designs 
Determine manufacturing issues of relevance to the refractory designs 
Review short list ranking 
Recommend optimum refractory component design for the end use 
Determine suitable format for design and specification 
Prepare design and specification 
Review specification with refractory material selector, production and customer 
Modify design and specification if required 
Publish design and specification in required format to required people/organisations 

Forms

Assessment Cover Sheet

PMC557093A - Design a refractory_ceramic component
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

PMC557093A - Design a refractory_ceramic component

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: