This unit of competency applies to technicians who are responsible for designing simple or small refractory installations or repairs. They apply the principles of heat transfer, thermal expansion, abrasion and structures along with a knowledge of refractory materials and installation techniques to the design to yield a product which will meet a rigid technical specification.

This unit covers a refractory design for a situation which can be achieved by the application of standard products/components in a standard manner. It does not cover innovative products/ applications nor those situations where the design must be done by a registered engineer, although it may involve working with an engineer on a design

This will typically be done by an individual technician working in liaison with customers, installers and technical experts.

ELEMENT

PERFORMANCE CRITERIA

1. Establish the suitability of resources

1.1. Check all information conforms with resources

1.2. Record discrepancies in information

1.3. Report any inaccuracies in information to the person in charge

1.4. Identify and select materials, components, tools and equipment

2. Undertake mechanical design

2.1. Determine strength requirements

2.2. Determine operating temperature range

2.3. Select materials/mix with appropriate mechanical strength

2.4. Identify hazards of materials and processes to be used and apply hierarchy of control to control hazards

2.5. Determine expansion which will occur for this material

2.6. Adjust material/mix to be suitable for temperatures

3. Undertake thermal design

3.1. Determine heat flow through the refractory

3.2. Determine interface temperatures for multi-component linings

3.3. Use simple software

3.4. Determine interface bonding/anchor issues

4. Specify refractory design

4.1. Specify materials to be used

4.2. Specify installation method to be used

4.3. Confirm specification meets customer needs and installer requirements

Required skills

Required skills include:

adjusting/correcting/responding to work requirements

identifying and resolving problems

using simple software for calculations

working in a team or individually, as required

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

heat flow calculations

awareness of other relationships involved with these calculations

refractory materials and their properties

refractory installation techniques

structural strength of refractories

thermal expansion of refractories

methods of tying refractories

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

The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency.

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

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this unit of competency.

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

Consistent performance should be demonstrated. In particular look to see that:

the technical aspects of the design are identified and an appropriate solution is proposed.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation or case studies/scenarios may be required to allow for timely assessment of parts of this unit of competency. Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. A bank of scenarios/case studies/what ifs and questions will be required to probe the reasoning behind observable actions.

Method of assessment

It may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

It may be appropriate to assess this unit concurrently with other relevant units.

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.

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.

Procedures

All operations are performed in accordance with standard procedures and work instructions

Refractory materials

Refractory materials are those materials that have a resistance to temperature and include:

alumina silicate materials (clay)

silliminites

bauxite

synthetic aggregates

silica

magnesite

dolomite

chrome ores

Refractory installation techniques

Refractory installation techniques include:

bricks, blocks

mouldables

castable

spray/gunned application

Occupational health and safety (OHS)

All operations are subject to stringent OHS requirements and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and OHS requirements, the OHS requirements take precedence

Unit sector

Operational/technical

This unit contains employability skills.