This unit of competency is intended for simple kiln refractory maintenance such as may be performed by trained operators. It is intended to apply to one example of a refractory lined kiln only. For more general refractory lining competencies refer to the relevant refractories units (PMC552090 - 2095).

This unit of competency is typically performed by more experienced operators working either independently or as part of a work team. The competency covers the removal and replacement of a kiln refractory and also covers the preparation of materials and the removal of waste from repairs.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare for refractory replacement

1.1. Prepare and assemble, in accordance with specified requirements, materials used for the replacement of refractory

1.2. Prepare and assemble appropriate plant and equipment in accordance with specific needs and manufacturer's operating instructions

1.3. Notify appropriate personnel and ensure that required permits have been obtained

2. Replace refractory

2.1. Ensure that the removal of refractory and brickwork is performed in accordance with standard procedures/work instructions

2.2. Ensure that brickwork/refractory is replaced following standard procedures and work instructions

2.3. Ensure that waste from repairs to kiln is removed and disposed of correctly

2.4. Complete all records and permit procedures

Required skills

Required skills include:

recognising variance from specification and then analysing the problem to determine the level of appropriate action required, which is consistent with operating guidelines

implementing enterprise's standard procedures and work instructions and relevant regulatory requirements within appropriate time constraints and in a manner relevant to the operation of the process

reading and numeracyto interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

safe work practices

function of tools/equipment used

procedures used to prepare the kiln

procedures used to install refractory

first-line maintenance procedures required

correct removal and replacement of refractory and brickwork

correct preparation and assembly of materials and tools/equipment used

safely remove waste from repairs to kiln

distinguish between causes of faults such as:

refractory materials

refractory problems

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

It is essential that the process be understood and that the importance of critical material properties is known. 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:

replacement follows standard procedures

correct materials are used

permit and other health and safety procedures are followed.

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

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

Individual enterprises may choose to add prerequisites and co-requisites relevant to their processes.

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

Equipment

Equipment may include:

protective clothing, hearing protection, safety glasses and adequate ventilation

hand and power tools

mobile plant

refractory support mechanisms

Variations

This unit may vary according to:

length and type of kiln

the type of process, i.e. dry, wet, semi-wet, semi-dry

type of kiln maintenance being performed

method of waste disposal

Typical problems include:

Typical problems may include:

furnace/kiln problems

major refractory problems

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

Support

This unit contains employability skills.