1. Plan for inspection, testing and/or maintenance tasks

1.1 Access, interpret and apply compliance and other documentation relevant to the inspection, testing and maintenance of cooling systems on diesel engine systems

1.2 Obtain, interpret and clarify work requirements for the satisfactory completion of tasks

1.3 Resolve coordination requirements with others at the site prior to commencing and during work activities

2. Prepare for inspection, testing and/or maintenance tasks

2.1 Inspect and prepare work area in coordination with others

2.2 Identify and obtain items and tools required for the safe, effective and efficient conduct of the tasks

2.3 Identify and arrange support required for the safe, effective and efficient completion of the tasks

2.4 Select and use personal protection equipment appropriate to the task

2.5 Carry out required equipment pre-start and inspection procedures

2.6 Carry out isolation and lock-out of all equipment necessary for the safe execution of tasks

2.7 Recognise and respond to hazardous and emergency situations

3. Carry out inspection of cooling systems

3.1 Inspect cooling systems on diesel engine systems

3.2 Diagnose and record existing or identified faults

3.3 Report outcomes of inspection to appropriate person

4. Carry out testing of cooling systems

4.1 Select and operate testing equipment and methods

4.2 Carry out testing and fault finding of cooling systems

4.3 Diagnose and record existing identified faults

4.4 Recognise and respond to hazardous and emergency situations

4.5 Report outcomes of testing to appropriate person

5. Carry out maintenance of cooling systems

5.1 Select and use maintenance items, tools and equipment

5.2 Rectify diagnosed and identified faults

5.3 Carry out maintenance of cooling systems on diesel engine systems in accordance with the work requirements

5.4 Recognise and respond to hazardous and emergency situations

6. Complete post-work activity requirements

6.1 Tidy up the work area

6.2 Dispose of used oil, lubricant and other waste

6.3 Return and secure all tools and re-usable items

6.4 Complete and maintain inspection, testing and maintenance records

Required skills

Specific skills are required to achieve the performance criteria in this unit, particularly for the application in the various circumstances in which this unit may be applied.

This includes the ability to carry out the following as required to inspect, test and maintain cooling systems on diesel engine systems:

apply legislative, organisation and site requirements and procedures

apply site risk, statutory compliance, health, safety, environmental, quality and communication requirements and procedures

apply site and manufacturer’s requirements and procedures

apply surface and underground worksite hazard identification and risk management requirements and procedures

apply task hazard identification and risk management requirements and procedures

apply technical literacy

interpret and apply technical and scientific/industry terminology

communicate with those providing support

apply work area and equipment inspection procedures

apply work area safeguarding options and requirements

apply isolation and lock-out requirements and procedures

apply hazard and emergency procedures

apply site service and maintenance reporting requirements and procedures

work wearing appropriate personal protective equipment

use tools for inspection, testing and maintenance

use calibrated/verified instruments

Required knowledge

Specific knowledge is required to achieve the Performance Criteria of this unit, particularly its application in a variety of circumstances in which the unit may be used.

This includes knowledge of the following, as required to inspect, test and maintain cooling systems on diesel engine systems:

site risk, statutory compliance, health, safety, environmental, quality and communication requirements and procedures

limitations on allowable maintenance including work in hazardous environments

limitations on allowable modifications and the required controls and procedures

provisions of AS/NZS3584.1, 2 and 3 relating to fasteners and joints

recognise the requirements and performance of various types of fasteners, including bolts, studs, threads and washers

site and manufacturer’s requirements and procedures

items required to be used in performance of inspection, testing and maintenance tasks

tools required for the performance of inspection, testing and maintenance tasks

site inspection, testing and maintenance support requirements and availability

site work area inspection requirements

site work area safeguarding options and requirements

site isolation and lock-out requirements and procedures

site hazard and emergency procedures

critical temperatures and explosion limits for gasses, dusts and hydro-carbon liquids that may be encountered by a diesel engine system in an underground coal mines, including;

coal dust

methane

diesel fuel

margins of safety provided by all relevant Legislation, Regulation, Standards and Guidelines are applied to surface and exhaust gas temperatures

methods to limit temperatures including; maintenance, testing and monitoring for;

exhaust manifold design & fitment

adaptor pipe

exhaust flametrap and/or cooler

turbochargers

air compressors

possible failure modes maintenance procedures and practices required to provide controls

causes of temperature rise as a gas is compressed, including:

intake system to air compressors and failure modes resulting in excessive temperatures

output side of air compressors and failure modes resulting in excessive temperatures

risks and consequences of carbon build-up in the air stream (fittings, valves and hoses) types of heat exchange including;

shell and tube

plate

plate and fin

causes of the degradation of heat exchanger performance, caused by;

build up of the products of combustion on the ‘gas’ side of heat exchangers

build up of salts, chlorides and other materials on the ‘coolant’ side of heat exchangers

temperature controls applied to prevent the exhaust gas stream from exceeding nominate maximum temperatures

materials including elastomeric hoses, metallic and synthetic fittings employed in critical components subject to temperature rise under the designed conditions of operation

automatic shutdown controls, which may include;

the design of the system and the ‘safety margin’ provided in the design for some deterioration in performance

coolant flow monitoring devices

coolant temperature monitoring devices

coolant loss monitoring devices

direct exhaust gas temperature monitoring devices

water-bath level monitoring devices

site inspection, testing and maintenance reporting requirements and procedures

site inspection, testing and maintenance record procedures

site requirements and procedures for working in isolation

site requirements for the use of personal protective equipment

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

The evidence required to demonstrate competency in this unit must be relevant to worksite operations and satisfy all of the requirements of the performance criteria, required skills and knowledge and the range statement of this unit and include evidence of the following:

Knowledge of the requirements, procedures and instructions for the inspection, testing and maintenance of cooling systems on diesel engine systems.

Implementation of requirements, procedures and techniques for the safe, effective and efficient completion of the inspection, testing and maintenance of cooling systems on diesel engine systems

Working with others to undertake and complete the inspection, testing and maintenance of cooling systems on diesel engine systems that meets all of the required outcomes.

Consistent timely completion of the inspection, testing and maintenance of cooling systems on diesel engine systems that safely, effectively and efficiently meets the required outcomes.

Context of and specific resources for assessment

This unit must be assessed in the context of the work environment. Where personal safety or environmental damage are limiting factors, assessment may occur in a simulated environment provided it is realistic and sufficiently rigorous to cover all aspects of workplace performance, including task skills, task management skills, contingency management skills and job role environment skills.

The assessment environment should not disadvantage the participant. For example, language, literacy and numeracy demands of assessment should not be greater than those required on the job.

Customisation of assessment and delivery environment to sensitively accommodate cultural diversity.

Aboriginal people and other people from a non English speaking background may have second language issues.

Assessment of this competency requires typical resources normally used in a resources and infrastructure sector environment. Selection and use of resources for particular worksites may differ due to the site circumstances.

Where applicable, physical resources should include equipment modified for people with disabilities.

Access must be provided to appropriate learning and/or assessment support when required.

Method of assessment

This unit may be assessed in a holistic way with other units of competency. The assessment strategy for this unit must verify required knowledge and skill and practical application using more than one of the following assessment methods:

written and/or oral assessment of the candidate’s required knowledge

observed, documented and/or first hand testimonial evidence of the candidate’s:

implementation of appropriate requirement, procedures and techniques for the safe, effective and efficient achievement of required outcomes

consistently achieving the required outcomes

first hand testimonial evidence of the candidate:

working with others to undertake and complete the inspection, testing and maintenance of cooling systems on diesel engine systems

Guidance information for assessment

Consult the SkillsDMC User Guide for further information on assessment including access and equity issues.

Compliance and other documentation may include:

certification documentation, or

approval documentation

legislative, organisation and site requirements and procedures

manufacturer’s specifications and guidelines

Australian Standards, including: AS/NZS3584 and AS 4291

codes of practice

Employment and Workplace Relations legislation

Equal Employment Opportunity and Disability Discrimination legislation

Inspection is to include:

checking for coolant leaks in radiator (core and tanks) and radiator hoses

visually check that the coolant level is correct

checking for coolant leaks in water pumps, thermostats (housing) or from hoses associated with the jacket water cooling of air compressors, manifolds, manifold/conditioner adaptor pipes, etc

checking that the hoses are in a good condition, correctly fitted, clamped and restrained

checking that the radiator core is clean

Testing may include:

checking the proper operation and function of the coolant loss detection sensor, and record the time taken to cause the engine to shut down

Checking the proper operation and function of the coolant over-temperature sensor, and record the coolant temperature at which the engine shut down.
NOTE Testing this sensor by defeating other sensors and overheating the diesel engine system may be hazardous or cause damage to the diesel engine system. It is recommended that the sensor be removed from the engine and tested in heated water while remaining connected to the engine shutdown system.

Maintenance is:

the combination of actions carried out to retain a diesel engine system in, or to restore it to, conditions in which it is able to meet the requirements of the relevant specification and perform its required function

Maintenance is to include:

service

adjust

replace

Maintenance may include:

repair

overhaul

modify

draining and replacing the engine coolant and ensuring that the correct coolant formulation is used

Cooling systems may include:

exhaust manifolds

compressors or turbo chargers

piping

joints

exhaust flame traps

exhaust filters

Diesel engine systems are:

diesel engines for underground coal mines and their:

inlet systems

exhaust systems

cooling systems

starting systems

shut-down and protection systems

electrical or electronic devices

Work requirements may come from briefings, handovers, and work orders and may include:

service and maintenance schedules

production requirements

nature and scope of tasks

achievement targets

operational conditions

operational requirements

site layout and out of bounds areas

worksite inspection requirements

plant or equipment defects

hazards and potential hazards

coordination requirements or issues

Others may include:

yard persons

processing plant operators

mobile plant operators

other maintenance personnel

Inspect and prepare work area may include:

determining if the proposed work area is a designated safe area

identification of hazards, including:

workshop work area hazard

underground work area hazards, and

work activity hazards

selection and implementation of control measures for the hazards identified

safeguarding site and non-site personnel by:

erection of barricades and posting of signs

selection of appropriate equipment to ensure personnel safety and protection

Items may include:

replacement parts

fasteners

packing materials

Tools may include:

hand tools

power tools

special tools

testing equipment

Support may include:

other site personnel

contractors

cranes

other lifting equipment

Personal protection equipment may include:

hard hats

eye protection

hearing protection

breathing apparatus

gas/fume masks

prescribed footwear

Pre-start and inspection procedures include:

checking:

cleanliness, particularly coal dust

diesel and other flammable liquid leaks

coolant leaks in radiator or radiator hoses

coolant level

that guards are in place and secure

engine oil level is correct

conduct Exhaust Conditioner/Flametrap, low-water, shutdown tests

Hazardous and emergency situations may include:

working alone

personal injury

fire

explosions

electrical

noise

dust

environmental

chemical

Diagnose faultsmay include:

Root cause analysis

Troubleshooting techniques

Records may include:

inspection and test results

defect identified

defect rectification carried out

item consumed

hazard/risk management reports