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

TLIW0036 Mapping and Delivery Guide
Apply electric welding process to rail

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency TLIW0036 - Apply electric welding process to rail
Description
Employability Skills
Learning Outcomes and Application This unit involves the skills and knowledge required to weld rails, crossings and switches using an electric welding process in accordance with rail industry standards, safeworking and regulatory requirements, and workplace procedures.It includes using non-destructive testing to locate defects; preparing rails, crossings or switches for welding; gouging or grinding; setting up welding equipment; performing welding operations; checking weld conformance; and completing required documentation. These processes are used to repair rail surface defects and restore rail profile to plain rail, crossings and switches. People achieving competence in this unit will need to fulfil applicable state/territory legislated rail safety requirements and to comply with rail industry standards, codes of practice and/or guidelines.Work is performed under some supervision, generally in a team environment. It involves the application of routine operational principles and procedures when welding rail using an electric welding process, as part of workplace activities across a variety of operational contexts within the Australian rail system.Operators of mechanised equipment must have undertaken training and, where appropriate, hold the relevant licence, permit or certificate and be recognised as competent for the class of machinery being used.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.

As a minimum, assessors must satisfy applicable regulatory requirements, which include requirements in the Standards for Registered Training Organisations current at the time of assessment.

As a minimum, assessment must satisfy applicable regulatory requirements, which include requirements in the Standards for Registered Training Organisations current at the time of assessment.

Assessment must occur in workplace operational situations or, where this is not available, in simulated workplace operational situations that replicate rail corridor workplace conditions.

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.

Resources for assessment include:

a range of relevant exercises, case studies and/or simulations

relevant and appropriate materials, tools, equipment and personal protective equipment currently used in industry

applicable documentation including workplace procedures, regulations, rail industry standards, SDSs/MSDSs, codes of practice and operation manuals.
Prerequisites/co-requisites
Competency Field W – Equipment and Systems Operations
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: Prepare rails, crossings or switches for welding
       
Element: Weld repair area is identified and assessed in accordance with standards and procedures
       
Element: Welding equipment and consumables are prepared and checked for serviceability
       
Element: Hazards are identified, risks are assessed and control measures are implemented
       
Element: Weld repair area is prepared for welding in accordance with workplace standards and procedures
       
Element: Track components are assembled or aligned to specification as required
       
Element: Use non-destructive testing
       
Element: Appropriate non-destructive testing method is selected in accordance with workplace requirements
       
Element: Non-destructive testing method is used to identify and locate defects in accordance with rail industry standards and organisational procedures
       
Element: Assemble and set up welding equipment
       
Element: Welding equipment is set up and adjusted to meet welding process requirements
       
Element: Accessories and consumables are selected for use
       
Element: Assemble and set up gouging and grinding equipment
       
Element: Gouging and grinding equipment is assembled and set up
       
Element: Equipment settings are adjusted to meet process requirements
       
Element: Remove defects
       
Element: Appropriate method to be used to remove defect is identified in accordance with organisational standards and procedures
       
Element: Defect is removed using identified method in accordance with organisational standards and procedures
       
Element: Perform welding operation
       
Element: Weld metal is applied to repair area to meet specifications in accordance with standards and procedures
       
Element: Welded area is cleaned in preparation for grinding
       
Element: Welded area is ground in accordance with organisational standards and procedures
       
Element: Check weld conformance
       
Element: Finished ground weld area is visually inspected for surface finish and defects
       
Element: Finished ground weld area is checked for conformance to rail, crossing or switch profile acceptance standards
       
Element: Complete post-operative checks and documentation
       
Element: Equipment is checked for serviceability
       
Element: Defective equipment is replaced and reported for servicing or repair in accordance with organisational policies and procedures
       
Element: Documentation on work undertaken is completed and processed in accordance with organisational 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

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

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

1

Prepare rails, crossings or switches for welding

1.1

Weld repair area is identified and assessed in accordance with standards and procedures

1.2

Welding equipment and consumables are prepared and checked for serviceability

1.3

Hazards are identified, risks are assessed and control measures are implemented

1.4

Weld repair area is prepared for welding in accordance with workplace standards and procedures

1.5

Track components are assembled or aligned to specification as required

2

Use non-destructive testing

2.1

Appropriate non-destructive testing method is selected in accordance with workplace requirements

2.2

Non-destructive testing method is used to identify and locate defects in accordance with rail industry standards and organisational procedures

3

Assemble and set up welding equipment

3.1

Welding equipment is set up and adjusted to meet welding process requirements

3.2

Accessories and consumables are selected for use

4

Assemble and set up gouging and grinding equipment

4.1

Gouging and grinding equipment is assembled and set up

4.2

Equipment settings are adjusted to meet process requirements

4.3

Accessories and consumables are selected for use

5

Remove defects

5.1

Appropriate method to be used to remove defect is identified in accordance with organisational standards and procedures

5.2

Defect is removed using identified method in accordance with organisational standards and procedures

6

Perform welding operation

6.1

Weld metal is applied to repair area to meet specifications in accordance with standards and procedures

6.2

Welded area is cleaned in preparation for grinding

6.3

Welded area is ground in accordance with organisational standards and procedures

7

Check weld conformance

7.1

Finished ground weld area is visually inspected for surface finish and defects

7.2

Finished ground weld area is checked for conformance to rail, crossing or switch profile acceptance standards

8

Complete post-operative checks and documentation

8.1

Equipment is checked for serviceability

8.2

Defective equipment is replaced and reported for servicing or repair in accordance with organisational policies and procedures

8.3

Documentation on work undertaken is completed and processed in accordance with organisational requirements

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria on at least five separate occasions and include:

applying relevant workplace procedures

ensuring weld conformance to organisational requirements

identifying job hazards and taking required action to minimise, control or eliminate identified hazards

implementing contingency plans

interpreting and following operational instructions and prioritising work when welding rail using an electric welding process

modify activities depending on operational contingencies, risk situations and environments

monitoring work activities in terms of planned schedule

operating and adapting to differences in equipment in accordance with operating procedures

performing welding, grinding, gouging and testing operations on rails, crossings and switches in accordance with rail industry standards and/or workplace requirements

preparing items for welding in accordance with workplace requirements

reading and interpreting relevant technical data, drawings, instructions and manuals

reporting and rectifying problems, faults and malfunctions within limits of own role, in accordance with organisational procedures

selecting and using hand tools, power tools and equipment

selecting and using required personal protective equipment

using non-destructive (liquid penetrant or magnetic particle) testing equipment, gouging equipment and hand grinding equipment in accordance with safety data sheets (SDSs)/material safety data sheets (MSDSs), manufacturer instructions and workplace procedures

working systematically with required attention to detail without injury to self or others, or damage to goods or equipment.

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

authorisation/approval processes and procedures

documentation and record keeping requirements

fundamentals of 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 these problems

rail industry acceptance standards for weld repairs on rail

relevant rail danger zones

relevant safety, work health and safety (WHS)/occupational health and safety (OHS) and environmental procedures and regulations

track industry standards for rail, crossing and switch condition and surface profile

workplace procedures, safety data sheets (SDSs)/material safety data sheets (MSDSs) and manufacturer instructions for non-destructive (liquid penetrant or magnetic particle) testing of rail

workplace procedures for removing defects by gouging, grinding and welding rail using an electric welding process.

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

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

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

1

Prepare rails, crossings or switches for welding

1.1

Weld repair area is identified and assessed in accordance with standards and procedures

1.2

Welding equipment and consumables are prepared and checked for serviceability

1.3

Hazards are identified, risks are assessed and control measures are implemented

1.4

Weld repair area is prepared for welding in accordance with workplace standards and procedures

1.5

Track components are assembled or aligned to specification as required

2

Use non-destructive testing

2.1

Appropriate non-destructive testing method is selected in accordance with workplace requirements

2.2

Non-destructive testing method is used to identify and locate defects in accordance with rail industry standards and organisational procedures

3

Assemble and set up welding equipment

3.1

Welding equipment is set up and adjusted to meet welding process requirements

3.2

Accessories and consumables are selected for use

4

Assemble and set up gouging and grinding equipment

4.1

Gouging and grinding equipment is assembled and set up

4.2

Equipment settings are adjusted to meet process requirements

4.3

Accessories and consumables are selected for use

5

Remove defects

5.1

Appropriate method to be used to remove defect is identified in accordance with organisational standards and procedures

5.2

Defect is removed using identified method in accordance with organisational standards and procedures

6

Perform welding operation

6.1

Weld metal is applied to repair area to meet specifications in accordance with standards and procedures

6.2

Welded area is cleaned in preparation for grinding

6.3

Welded area is ground in accordance with organisational standards and procedures

7

Check weld conformance

7.1

Finished ground weld area is visually inspected for surface finish and defects

7.2

Finished ground weld area is checked for conformance to rail, crossing or switch profile acceptance standards

8

Complete post-operative checks and documentation

8.1

Equipment is checked for serviceability

8.2

Defective equipment is replaced and reported for servicing or repair in accordance with organisational policies and procedures

8.3

Documentation on work undertaken is completed and processed in accordance with organisational requirements

Range is restricted to essential operating conditions and any other variables essential to the work environment.

Non-essential conditions can be found in the Companion Volume Implementation Guide.

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
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Forms

Assessment Cover Sheet

TLIW0036 - Apply electric welding process to rail
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

TLIW0036 - Apply electric welding process to rail

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: