This unit applies to the operation of singular or multi, coke, oil, gas fired or electric furnaces, the melting of a range of metals, and operational maintenance. Furnaces would primarily be used for continuous or staged bulk melting/smelting of metals, holding of hot liquids, or the melting of metals for production processes e.g. casting/moulding, galvanising, etc.

Band: A

Unit Weight: 4

Path 1

MEM13004B

Work safely with molten metals/glass

ELEMENT

PERFORMANCE CRITERIA

1. Select materials

1.1. Requisitions are completed as required according to standard operating procedures.

1.2. Charge analysis is undertaken in accordance with standard operating procedures.

1.3. The charge analysis is converted to furnace charge weight using standard operating procedures.

1.4. Charge is weighed according to standard operating procedures.

2. Start up furnace

2.1. Furnace is inspected for any defects or damage.

2.2. Routine operational maintenance of furnace is undertaken to standard operating procedures.

2.3. Furnace is started up to standard operating procedures.

2.4. Faults are reported according to standard operating procedures.

3. Charge furnace

3.1. Emergency/safety procedures are identified and followed as necessary.

3.2. Materials are pre-heated if required according to standard operating procedures.

3.3. Materials are charged into furnace using standard operating procedures.

3.4. Suitable areas for emergency unloading of molten metal are identified and kept available.

4. Monitor furnace

4.1. Furnace is maintained at optimum operating condition to standard operating procedures.

4.2. Sample for chemical analysis is taken and remedial action is applied as required to standard operating procedures.

4.3. Furnace is drossed and/or degassed to standard operating procedures.

4.4. Temperature of metal is checked and adjustment made if necessary.

5. Tap or unload the furnace

5.1. Quantity of the required metal is identified.

5.2. Tap rate is carried out to standard operating procedures.

5.3. Tapping or unloading is undertaken and completed safely according to standard operating procedures.

6. Shut down furnace

6.1. Shut-down of furnace is completed to standard operating procedures.

6.2. Routine operational maintenance of furnace is undertaken to standard operating procedures.

Required skills

Look for evidence that confirms skills in:

reading and interpreting routine information on written job instructions, specifications, standard operating procedures relevant test data sheets and other standard workplace forms. May include drawings for furnace operation

following oral instruction

entering routine and familiar information onto proformas and standard workplace forms

identifying faults and areas for routine repair of the furnace and performing routine maintenance as necessary

following procedures for starting and closing down the furnace

deciding on charge materials

weighing charge materials

feeding materials into furnace

measuring metal temperature and correcting as necessary

sampling for chemical, carbon equivalent and wedge tests

degassing as necessary

deslagging/drossing

tapping the metal

Required knowledge

Look for evidence that confirms knowledge of:

refractory conditions, faults, and routine repair

condition of cooling water supply

starting procedures for different types of furnaces

metallic charge materials and alloying elements

weighing procedures and scale types

correct order of loading of different charge materials

thermocouple condition monitoring and adjustment mechanism for furnace

interpretation of carbon equivalent and wedge test results

degassing procedures including tablet, lance and other procedures

coagulant agents, application procedures and slag removal procedures

close-down procedures

applicable industry standards, national/Australian standards, NOHSC guides, State/Territory regulatory codes of practice/standards

use and application of personal protective equipment

safe work practices and procedures

hazards and control measures associated with operating melting furnaces

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

A person who demonstrates competency in this unit must be able to operate a melting furnace. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

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

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, that is the candidate is not in productive work, then an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate.

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with operating melting furnaces or other units requiring the exercise of the skills and knowledge covered by this unit.

Method of assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. 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.

Furnace

Singular or multi, coke, oil, gas fired or electric induction, arc and resistance furnaces

Operational maintenance

Routine lubrication, cleaning, routine repair/repointing of refractory

Unit sector

Casting and moulding

This unit contains employability skills.