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

PMC557097A Mapping and Delivery Guide
Specify and monitor repairs to refractory installations

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency PMC557097A - Specify and monitor repairs to refractory installations
Description This unit of competency covers developing the specification for a refractory repair and then monitoring that repair to ensure it complies with the specification. 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 of refractory materials, installation and failure modes to determine an appropriate repair method. It covers repairs to all types of refractories. This unit does NOT cover the investigation of refractory failures, refer to PMC557094A Investigate refractory failures. The units are obviously related and it may be appropriate to consider both concurrently.This unit applies to individuals who may design a refractory installation and may also monitor the installation of refractory, or they may be repair specialists. 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.This unit may apply to individuals working for an organisation which supplies and installs refractories, is a refractory consulting organisation or a client organisation which buys and uses the refractory.
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 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 environment (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.

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 select an appropriate material 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

investigating

analysing

interpreting data

negotiating

technical reporting

Required knowledge

Required knowledge includes:

properties of all common refractory materials

common installation methods and ways of repairing them

common modes of refractory failure and their implications for repair

anchors and anchoring systems used in repairs

keying and adhesion methods used in repairs

installation equipment such as lifting and placement aids and gunning equipment

post placement requirements for different repairs

formwork design and construction

scaffolding design and construction

relevant terms

relevant calculations

project planning and management

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.

Refractory materials

Refractory materials may include one or more of:

cementitious refractories

clay refractories

ceramic fibre

other refractories

Repair methods

Repair methods include:

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

Shores

Shores may include:

dead shores

raking shores

flying shores

Installation equipment

Installation equipment may include one or more of:

vibrators

compactors

rams

gunning systems

equipment for lifting and placing precast blocks

temporary support for roofs and arches

spreader jacks

Anchors and keys

Types of anchors may include:

anchor bolts

through anchors

retention clips

Keys include cut mechanical keys

Adhesion may include:

chemical and other means of ensuring a bond between the repair and the refractory substrate

Post repair requirements

Post repair requirements may include:

drying

curing

control of moisture and/or temperature

striking of formwork

removal of scaffolding or other access/egress provisions

HSE hazards

HSE hazards may include:

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

Hazard control

Appropriate hazard control should be determined by:

applying the hierarchy of control

Stakeholders

Stakeholders may include:

customer representatives

technical experts

regulators

refractory designer

materials and equipment suppliers

contractors

Requirements

Requirements include:

materials

equipment

contractors

Time critical items

Time critical items are those items which if not completed on time will cause the project to run overtime and may be determined from:

critical path analysis

long lead time items

other techniques

Repair specification

Repair specification should include:

technical specification

hazard controls and residual hazards

installation schedule

measures monitoring critical items

End of project documentation

End of project documentation may include:

operating and/or maintenance procedures

technical specification

routine monitoring requirements

project review report:

what was intended

what was achieved

achieved costs

achieved timing

significant project issues

possible improvements

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 environment (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

PMC557097A - 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

PMC557097A - 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: