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

PMC557097 Mapping and Delivery Guide
Specify and monitor repairs to refractory installations

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency PMC557097 - Specify and monitor repairs to refractory installations
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to specify and monitor repairs to refractory installations. This unit of competency applies to operators who are required to confirm the repair requirements; design and document the repair installation method, materials, equipment and other specifications; and monitor the installation to ensure it meets specifications. This unit of competency applies to senior technicians or those in similar roles who are required to analyse and synthesise advanced theoretical and technical knowledge and apply independent judgement to high-level technical issues and complex problems. The individual may work in liaison with other refractory specialists or they may be the sole refractory specialist for this job or in their organisation.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.

It may be appropriate to assess this unit is conjunction with

PMC557094 Investigate refractory failures.

The collection of performance evidence is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real project in an operational workplace. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur using 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 Technical
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 repair specification
  • Check repair specification against agreed set of requirements for the repair
  • Identify discrepancies or conflicts in requirements
  • Confirm repair requirements and specifications
       
Element: Design installation process
  • Determine refractory materials to be repaired
  • Determine refractory material to be used in making the repair
  • Determine repair installation/application requirements
  • Determine installation equipment requirements
  • Determine anchor/keying/adhesion requirements
  • Determine repair method
  • Determine post repair application requirements
  • Determine temporary support or shores required
  • Design formwork if required
  • Design scaffolding or other internal access needs if required
  • Design external access/egress means if required
  • Identify installation health, safety and environmental (HSE) hazards
  • Determine appropriate hazard controls
  • Check for discrepancies or conflicts in the designs and take appropriate action
       
Element: Prepare for installation
  • Specify repair procedure
  • Liaise with relevant stakeholders
  • Modify specification if needed
  • Ensure correct ordering of requirements
  • Identify time critical items for the installation
  • Identify other items critical to the success of the project
  • Identify or develop measures to monitor all critical items
  • Prepare repair specification
       
Element: Monitor installation
  • Ensure requirements meet specification/contract
  • Ensure hazard controls are in place and effective
  • Monitor work to installation specification
  • Take appropriate action on non-conformances as required
  • Report during project as required
  • Complete end of project documentation on completion
       


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

Confirm repair specification

1.1

Check repair specification against agreed set of requirements for the repair

1.2

Identify discrepancies or conflicts in requirements

1.3

Confirm repair requirements and specifications

2

Design installation process

2.1

Determine refractory materials to be repaired

2.2

Determine refractory material to be used in making the repair

2.3

Determine repair installation/application requirements

2.4

Determine installation equipment requirements

2.5

Determine anchor/keying/adhesion requirements

2.6

Determine repair method

2.7

Determine post repair application requirements

2.8

Determine temporary support or shores required

2.9

Design formwork if required

2.10

Design scaffolding or other internal access needs if required

2.11

Design external access/egress means if required

2.12

Identify installation health, safety and environmental (HSE) hazards

2.13

Determine appropriate hazard controls

2.14

Check for discrepancies or conflicts in the designs and take appropriate action

3

Prepare for installation

3.1

Specify repair procedure

3.2

Liaise with relevant stakeholders

3.3

Modify specification if needed

3.4

Ensure correct ordering of requirements

3.5

Identify time critical items for the installation

3.6

Identify other items critical to the success of the project

3.7

Identify or develop measures to monitor all critical items

3.8

Prepare repair specification

4

Monitor installation

4.1

Ensure requirements meet specification/contract

4.2

Ensure hazard controls are in place and effective

4.3

Monitor work to installation specification

4.4

Take appropriate action on non-conformances as required

4.5

Report during project as required

4.6

Complete end of project documentation on completion

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:

analyse and interpret technical reports, technical specifications, data

confirm repair specifications meet refractory requirements

determine refractory installation process to meet repair specifications

plan the repair installation project

develop repair specification, including:

technical specification

hazard controls and residual hazards

installation schedule

measures for monitoring critical items

monitor the installation conformance to specifications and take action on non-conformances

complete project documentation and reports

communicate technical information verbally and in writing/drawings

communicate and negotiate agreements with internal and external stakeholders, including one or more of:

customer representatives

technical experts

regulators

management

refractory designer

refractory installer

materials and equipment suppliers

contractors

apply complex and/or theoretical mathematical calculations, statistics

solve complex problems within or arising from the repair design and/or installation.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to fulfil their job role, including knowledge of:

common installation methods and ways of repairing them

common modes of refractory failure and their implications for repair

properties of all common refractory materials, including:

cementitious refractories

clay refractories

ceramic fibre

other refractories

application and principles of repair methods, including:

cold repair

hot repair

direct repair

controlled repair (e.g. through controlled gunning)

repair from inside the vessel

repair by injection through the vessel wall

application and limitations of anchors and anchoring systems, including:

anchor bolts

through anchors

retention clips

application and limitations of installation equipment, including:

compactors

rams

gunning systems

equipment for lifting and placing precast blocks

temporary support for roofs and arches

spreader jacks

application and limitations of post repair requirements for different refractory systems, including:

drying

curing

control of moisture and or temperature

striking of formwork

removal of scaffolding or other access/egress provisions

application and limitations of shores, including:

dead shores

raking shores

flying shores

formwork design and construction

scaffolding design and construction

calculations relevant to specifications

project planning and management

regulatory framework

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

Confirm repair specification

1.1

Check repair specification against agreed set of requirements for the repair

1.2

Identify discrepancies or conflicts in requirements

1.3

Confirm repair requirements and specifications

2

Design installation process

2.1

Determine refractory materials to be repaired

2.2

Determine refractory material to be used in making the repair

2.3

Determine repair installation/application requirements

2.4

Determine installation equipment requirements

2.5

Determine anchor/keying/adhesion requirements

2.6

Determine repair method

2.7

Determine post repair application requirements

2.8

Determine temporary support or shores required

2.9

Design formwork if required

2.10

Design scaffolding or other internal access needs if required

2.11

Design external access/egress means if required

2.12

Identify installation health, safety and environmental (HSE) hazards

2.13

Determine appropriate hazard controls

2.14

Check for discrepancies or conflicts in the designs and take appropriate action

3

Prepare for installation

3.1

Specify repair procedure

3.2

Liaise with relevant stakeholders

3.3

Modify specification if needed

3.4

Ensure correct ordering of requirements

3.5

Identify time critical items for the installation

3.6

Identify other items critical to the success of the project

3.7

Identify or develop measures to monitor all critical items

3.8

Prepare repair specification

4

Monitor installation

4.1

Ensure requirements meet specification/contract

4.2

Ensure hazard controls are in place and effective

4.3

Monitor work to installation specification

4.4

Take appropriate action on non-conformances as required

4.5

Report during project as required

4.6

Complete end of project documentation on completion

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:

HSE legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

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.

HSE hazards

Identification of HSE hazards requires consideration of:

exposure to heat

exposure to dust

exposure to refractory materials

confined space entry

working with equipment

working at heights

ultra-violet (UV) and other welding hazards

disposal of waste, scrap and excess materials

manual handling hazards.

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
Check repair specification against agreed set of requirements for the repair 
Identify discrepancies or conflicts in requirements 
Confirm repair requirements and specifications 
Determine refractory materials to be repaired 
Determine refractory material to be used in making the repair 
Determine repair installation/application requirements 
Determine installation equipment requirements 
Determine anchor/keying/adhesion requirements 
Determine repair method 
Determine post repair application requirements 
Determine temporary support or shores required 
Design formwork if required 
Design scaffolding or other internal access needs if required 
Design external access/egress means if required 
Identify installation health, safety and environmental (HSE) hazards 
Determine appropriate hazard controls 
Check for discrepancies or conflicts in the designs and take appropriate action 
Specify repair procedure 
Liaise with relevant stakeholders 
Modify specification if needed 
Ensure correct ordering of requirements 
Identify time critical items for the installation 
Identify other items critical to the success of the project 
Identify or develop measures to monitor all critical items 
Prepare repair specification 
Ensure requirements meet specification/contract 
Ensure hazard controls are in place and effective 
Monitor work to installation specification 
Take appropriate action on non-conformances as required 
Report during project as required 
Complete end of project documentation on completion 

Forms

Assessment Cover Sheet

PMC557097 - Specify and monitor repairs to refractory installations
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

PMC557097 - Specify and monitor repairs to refractory installations

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: