ELEMENT

PERFORMANCE CRITERIA

1. Prepare for furnace tapping

1.1. Access, interpret and apply compliance documentation relevant to the work activity

1.2. Establish and maintain communication with other personnel using approved communication methods

1.3. Select personal protective equipment appropriate for work activities

1.4. Identify, address and report potential risks and hazards

1.5. Identify, address and report environmental issues

1.6. Follow emergency procedures to ensure safety of personnel and plant

1.7. Use approved dust suppression and extraction methods

1.8. Ventilate work area before entry

1.9. Check availability and operational readiness of all tools and equipment required for tapping

1.10. Set up equipment ready for tapping to standard work procedures

1.11. Correctly position holding vessels/ladles in readiness to receive molten metal and slag

2. Tap molten metal from furnace

2.1. Carry out plant and equipment start-up checks and procedures according to plant/equipment configurations and system requirements

2.2. Drill, or make tap hole with oxy lance, and establish molten metal flow

2.3. Ignite burners and correctly apply to ensure molten metal does not solidify

2.4. Identify and control interference with molten metal flow to ensure quality and production targets

2.5. Take samples at appropriate bath heights for metallurgical testing to quality requirements

3. Complete tapping process

3.1. Insert and secure tap-hole seal to stop molten metal flow

3.2. Clean and clear tapping area of potential safety hazards

3.3. Clean and stow all tools and equipment in readiness for next tapping operation

3.4. Pass on shift changeover details to oncoming shift

4. Maintain tapping equipment

4.1. Obtain and/or manufacture tap-hole seals to specification

4.2. Replace temperature monitoring equipment to furnace safety and operational parameters

4.3. Remove and install tapping blocks to furnace safety and operational parameters

4.4. Provide support for maintenance personnel when required to organisation's requirements

Required skills

Specific skills are required to achieve the Performance Criteria of this unit, particularly for its application in the various circumstances in which this unit may be used. This includes the ability to carry out the following, as required to tap furnaces:

apply legislative, organisation and site requirements and procedures for tapping furnaces

troubleshoot

work with/handle high temperature materials

identify hazards

interpret reports,

use lifting techniques

monitor system/plant

report defects

use fault finding, rectification and reporting techniques

use safe work practices

use hand and power tools

Required knowledge

Specific knowledge is required to achieve the Performance Criteria of this unit, particularly for its application in the various circumstances in which this unit may be used. This includes knowledge of the following, as required to tap furnaces:

principles of furnace operation

characteristics of molten metal

molten metal tapping procedures

furnace tapping components

trouble shooting

combustion principles

hazards associated with hot molten metal

safe working procedures with molten metal

protective equipment for working with hot materials

potential dangers inherent in specific plant and equipment

safe working procedures and systems

dobie bar and clay gun positioning

sampling methods

despatch of waste products

plant requirements for various schedules

service requirements and specifications

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

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 tapping furnaces

implementation of requirements, procedures and techniques for the safe, effective and efficient completion of furnace tapping

working with others to undertake and complete the furnace tapping in a way that meets all of the required outcomes

consistent timely completion of furnace tapping 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.

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.

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.

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

consistent achievement of required outcomes

first hand testimonial evidence of the candidate's:

working with others to undertake and complete the furnace tapping

Guidance information for assessment

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

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.

Relevant compliance documentation may include:

legislative, organisational and site requirements and procedures

manufacturer's guidelines and specifications

Australian standards

Employment and workplace relations legislation

Equal Employment Opportunity and Disability Discrimination legislation

Legislation may include Acts and regulations dealing with:

mining safety and health

mine inspection

OHS

explosives

environment

Personal protective equipment may include:

helmet

safety footwear

hearing protection

gloves

eye/face protection

respiratory protection

heat resistant clothing

Hazards may include:

cranes

molten metal

hot materials

noise

air pollution

sharp objects

moving machinery

heights

falling objects

hot gases

Environmental issues may include:

drainage

dust (dump)

emissions

hazardous chemicals

noise

recycling

run-off

spills

waste management and disposal

water quality

Equipment and plant cleaning methods may include:

degreasing

forced air

sweeping

Equipment indicator readings may include:

current

flow

level

pressure

speed

unusual noise

vibration

Start-up checks and procedures may include:

availability of equipment

detection of conditions that are unusual

job requirements

levels

communications

interlocks

distribution control system

launders

hydraulic systems

pumps and pumping systems

pipes and flanges

drive belts

valves

visual and audible warning devices and lights

suppression systems

Burners may be:

diesel

natural gas

Furnaces may be:

fixed - vertical/cylindrical

rotary - vertical/cylindrical

Furnace problems may include:

temperatures too high or too low

level in furnace too high or low

metal splashes

feed not to specification

foaming

solidification

un-burnt feed

contamination (e.g. ceramics, bricks)

poor metallurgical conditions

poor feed mix

poor feed moisture control

Maintenance may include:

lubrication

minor adjustments to operational plant

cleaning plant, equipment and work area

installation/removal of devices

making furnace accessories

Services may include:

electricity

air

cooling water

potable water

gas

diesel

Fault and variances may occur in:

product

plant

equipment