ELEMENT

PERFORMANCE CRITERIA

1. Prepare for holding furnace operations

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. Check and test remote control and monitoring systems for correct operation

1.8. Plan and put work area ventilation in place

2. Operate and monitor holding furnace operations

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

2.2. Monitor holding furnace operations

2.3. Monitor and receive matte and/or slag flow from furnace

2.4. Control furnace rotation/tilting within recommended rate and angle parameters to efficiently separate matte and slag

2.5. Control main and secondary burner operation to hold constant, recommended matte and slag temperature

2.6. Carry out holding furnace drive equipment diagnoses to monitor and maintain correct, safe operation

2.7. Check on holding furnace operations at regular intervals during the shift and rectify identified faults

2.8. Plan and organise matte supply to converter with other personnel and adjust tonnage to meet requirements

2.9. Maintain cleanliness of spouts to allow consistent, continuous flow of molten metal

3. Discharge matte and slag to matte and slag pots

3.1. Ensure pot area is clear of personnel and machinery before pouring commences

3.2. Position pot correctly to avoid splash, spillage or damage

3.3. Rotate vessel/pot at correct angle to ensure an even flow of matte and slag

3.4. Assess matte and slag levels and pour slag and dispose of matte ensuring that pot is not overfilled

3.5. Take and measure samples to ensure the slag and matte quantity is in an acceptable range

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 control molten metal in a holding furnace/vessel:

apply legislative, organisation and site requirements and procedures for controlling molten metal in a holding furnace/vessel

troubleshoot

apply precautions necessary for safe working

use protective clothing and equipment

apply operating procedures

report faults

recognise limits of authority

apply team working practices

communicate information

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 controlling molten metal in a holding furnace/vessel:

principles of holding vessel/furnace operation

characteristics of molten metal (basic)

molten metal pouring procedures

furnace components and function

troubleshooting

combustion principles

importance of flame patterns/flame impingement

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

pot positioning

sampling

decanting

despatch of waste products

storage and scheduling requirements for production

plant requirements for various schedules

service requirements and specifications

fault finding, rectification and reporting

materials specifications

standard operating procedures

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 controlling molten metal in a holding furnace/vessel

implementation of requirements, procedures and techniques for the safe, effective and efficient completion of controlling molten metal in a holding furnace/vessel

working with others to undertake and complete the controlling of molten metal in a holding furnace/vessel in a way that meets all of the required outcomes

consistent timely completion of controlling molten metal in a holding furnace/vessel 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 controlling of molten metal in a holding furnace/vessel

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

Hazards may include:

mobile plant/cranes

molten metal

hot materials

noise

air pollution

sharp objects

moving machinery

heights

falling objects

gases

Environmental issues may include:

drainage

dust (dump)

emissions

flora and fauna

hazardous chemicals

noise

recycling

run-off/spills

waste management and disposal

water quality

Monitoring may include:

blockages and spillages

feed rates

overloads

pressures

power draw

wear and tear

emissions

levels

temperatures

on-stream analysis (OSA)

filtering

corrosion

Furnace problems may include:

temperatures too high or too low during oxidation and charging

air flow too low for burners

fuel flow too low or too high, surging

level in furnace too high or low

metal splashes

feed not to specification

matte grade

Fault and variances may occur in:

product

plant

equipment

Burners may be:

diesel

natural gas

Pre-start checks may include:

availability of equipment

detection of conditions that are unusual

job requirements

levels

pressures

flows

communications

cameras and monitoring

interlocks

distribution control system

launders

hydraulic systems

pumps and pumping systems

screen, pipe, valve

visual and audible warning devices and lights

suppression systems

motors

availability of oxygen and plant air

cooling water supply

diesel supply

fans and draft systems

compressors

Equipment indicator readings may include:

current

flow/levels

pressure

speed

Maintenance may include:

lubrication

minor adjustments to operational plant

cleaning plant, equipment and work area

Indicator readings may include:

alarms

distribution control systems

mimic panel

screens

temperature

flow

weight

pressure