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

TLIW3016 Mapping and Delivery Guide
Weld rail using flashbutt welding process

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency TLIW3016 - Weld rail using flashbutt welding process
Description
Employability Skills
Learning Outcomes and Application This unit involves the skills and knowledge required to weld rail using the flashbutt welding process in accordance with safeworking and regulatory requirements, and workplace procedures. It includes performing pre-operational and post-operational equipment checks, preparing rail for welding, carrying out flashbutt welding, checking weld conformance and completing all required documentation. People achieving competence in this unit will need to fulfil the applicable state/territory legislated rail safety requirements and to comply with relevant codes of practice and/or guidelines.Work is performed under some supervision, generally within a team environment. It involves the application of routine operational principles and procedures when welding rail using the flashbutt 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.

Practical assessment of twenty five (25)successful flashbutt welds in an appropriate range of situations in the rail corridor workplace is required.

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: Perform pre-operational equipment checks
       
Element: Detailed pre-operational equipment checks are conducted in accordance with manufacturer specifications and/or local maintenance schedules
       
Element: Deficiencies with equipment are identified and rectified in accordance with workplace procedures
       
Element: Relevant persons are notified of problems and documentation is completed
       
Element: Prepare rail for welding
       
Element: Weld location is checked to confirm suitability for welding in accordance with workplace standards
       
Element: Track preparation for welding is arranged as required in accordance with workplace procedures and standards
       
Element: Rail ends are prepared for welding in accordance with workplace procedures and standards
       
Element: Carry out flashbutt welding
       
Element: Flashbutt welding equipment is prepared for use
       
Element: Flashbutt welding unit is clamped to rail ensuring accurate alignment
       
Element: Equipment is operated in accordance with machine operation instructions and workplace procedures to achieve appropriate quality standard
       
Element: Warning systems are monitored and appropriately responded to during operation to maintain correct functionality of equipment
       
Element: Track restoration is arranged as required in accordance with workplace procedures and standards
       
Element: Weld is profile-ground to ensure smooth running surface in accordance with workplace procedures and standards
       
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 profile and geometry acceptance standards
       
Element: Perform post-operational equipment checks
       
Element: Post-operational equipment checks are conducted to identify defects and maintenance requirements, in accordance with manufacturer specifications or local maintenance schedules
       
Element: Deficiencies with equipment are identified and rectified in an appropriate manner to maintain correct functionality of equipment
       
Element: Relevant persons are notified of problems and/or documentation is completed in accordance with instructions and relevant codes of practice
       
Element: Complete documentation
       
Element: Required documentation and/or record keeping procedures and processes are confirmed
       
Element: Documentation and/or records are filled in legibly and proofread
       
Element: Documentation and/or records are processed in accordance with workplace procedures
       


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

Perform pre-operational equipment checks

1.1

Detailed pre-operational equipment checks are conducted in accordance with manufacturer specifications and/or local maintenance schedules

1.2

Deficiencies with equipment are identified and rectified in accordance with workplace procedures

1.3

Relevant persons are notified of problems and documentation is completed

2

Prepare rail for welding

2.1

Weld location is checked to confirm suitability for welding in accordance with workplace standards

2.2

Track preparation for welding is arranged as required in accordance with workplace procedures and standards

2.3

Rail ends are prepared for welding in accordance with workplace procedures and standards

3

Carry out flashbutt welding

3.1

Flashbutt welding equipment is prepared for use

3.2

Flashbutt welding unit is clamped to rail ensuring accurate alignment

3.3

Equipment is operated in accordance with machine operation instructions and workplace procedures to achieve appropriate quality standard

3.4

Warning systems are monitored and appropriately responded to during operation to maintain correct functionality of equipment

3.5

Track restoration is arranged as required in accordance with workplace procedures and standards

3.6

Weld is profile-ground to ensure smooth running surface in accordance with workplace procedures and standards

4

Check weld conformance

4.1

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

4.2

Finished ground weld area is checked for conformance to rail profile and geometry acceptance standards

5

Perform post-operational equipment checks

5.1

Post-operational equipment checks are conducted to identify defects and maintenance requirements, in accordance with manufacturer specifications or local maintenance schedules

5.2

Deficiencies with equipment are identified and rectified in an appropriate manner to maintain correct functionality of equipment

5.3

Relevant persons are notified of problems and/or documentation is completed in accordance with instructions and relevant codes of practice

6

Complete documentation

6.1

Required documentation and/or record keeping procedures and processes are confirmed

6.2

Documentation and/or records are filled in legibly and proofread

6.3

Documentation and/or records are processed in accordance with workplace procedures

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 25 separate occasions and include:

applying relevant safeworking and workplace procedures

carrying out required welding operations

checking compliance of work with job specifications

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

implementing contingency plans

implementing required fire control workplace procedures

interpreting and following operational instructions and following scheduled work process

modifying activities depending on operational contingencies, risk situations and environments

monitoring work activities in terms of planned schedule

operating flashbutt welding equipment in accordance with workplace procedures

planning scheduled work including predicting consequences and identifying improvements

reading and interpreting relevant instructions, procedures, route information and signs

reporting and/or rectifying identified problems, faults or malfunctions, in accordance with workplace procedures

selecting and using required personal protective equipment

working collaboratively with others

working systematically with required attention to detail without injury to self or others, or damage to 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:

characteristics of relevant plant and equipment, transport, structures, hardware and components used in work activities

emergency management plan

hazardous situations and related personal protection measures

hazards that may exist when welding rail using the flashbutt welding process, and ways of controlling the risks involved

materials identification, handling and storage safety data sheets (SDSs)/material safety data sheets (MSDSs) and/or manufacturer instructions

problems that may occur when using the flashbutt welding process and equipment, and action that can be taken to report or resolve these problems

rail welding industry standards

relevant recording and documentation procedures

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

technical knowledge relevant to flashbutt welding

workplace procedures for operating flashbutt welding equipment

workplace procedures for welding rail using the flashbutt 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 describe the essential outcomes.

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

1

Perform pre-operational equipment checks

1.1

Detailed pre-operational equipment checks are conducted in accordance with manufacturer specifications and/or local maintenance schedules

1.2

Deficiencies with equipment are identified and rectified in accordance with workplace procedures

1.3

Relevant persons are notified of problems and documentation is completed

2

Prepare rail for welding

2.1

Weld location is checked to confirm suitability for welding in accordance with workplace standards

2.2

Track preparation for welding is arranged as required in accordance with workplace procedures and standards

2.3

Rail ends are prepared for welding in accordance with workplace procedures and standards

3

Carry out flashbutt welding

3.1

Flashbutt welding equipment is prepared for use

3.2

Flashbutt welding unit is clamped to rail ensuring accurate alignment

3.3

Equipment is operated in accordance with machine operation instructions and workplace procedures to achieve appropriate quality standard

3.4

Warning systems are monitored and appropriately responded to during operation to maintain correct functionality of equipment

3.5

Track restoration is arranged as required in accordance with workplace procedures and standards

3.6

Weld is profile-ground to ensure smooth running surface in accordance with workplace procedures and standards

4

Check weld conformance

4.1

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

4.2

Finished ground weld area is checked for conformance to rail profile and geometry acceptance standards

5

Perform post-operational equipment checks

5.1

Post-operational equipment checks are conducted to identify defects and maintenance requirements, in accordance with manufacturer specifications or local maintenance schedules

5.2

Deficiencies with equipment are identified and rectified in an appropriate manner to maintain correct functionality of equipment

5.3

Relevant persons are notified of problems and/or documentation is completed in accordance with instructions and relevant codes of practice

6

Complete documentation

6.1

Required documentation and/or record keeping procedures and processes are confirmed

6.2

Documentation and/or records are filled in legibly and proofread

6.3

Documentation and/or records are processed in accordance with workplace procedures

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

TLIW3016 - Weld rail using flashbutt welding process
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

TLIW3016 - Weld rail using flashbutt welding process

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: