Persons achieving competence in this unit will need to fulfil the applicable legislated rail safety requirements including acts and regulations from each state and territory together with any nationally approved compliance codes and/or guidelines.

Work is performed under some supervision, generally within a team environment. It involves the application of routine operational principles and procedures to the testing of rail using ultrasonic equipment as part of workplace activities across a variety of operational contexts within the Australian rail system.

ELEMENT

PERFORMANCE CRITERIA

1Determine test requirements

1.1 Test site is identified and prepared using appropriate procedures and materials

1.2 Preparation processes are carried out in accordance with the relevant procedures, statutory and OH&S requirements

2Conduct testing using hand directed equipment

2.1 The most appropriate ultrasonic test for the application is selected

2.2 Testing equipment is selected and prepared in accordance with standards and/or procedures

2.3 Ultrasonic test is carried out in accordance with relevant standards, specifications and OH&S requirements

2.4 Ultrasonic testing equipment is checked for proper function, maintained and stored in accordance with procedures, OH&S requirements and manufacturer instructions

3Conduct visual examination and measurement of rail and welds

3.1 Rail or weld is visually assessed for obvious defects

3.2 New welds are assessed for alignment and adjustment tolerance in accordance with standards and/or procedures

3.3 Weld repairs are assessed for alignment tolerance in accordance with standards and/or procedures

4Identify and classify defects

4.1 Indications are assessed and defects detected in accordance with standards and/or procedures

4.2 Defects are classified in accordance with standards and/or procedures

4.3 Defective welds and weld repairs are marked in accordance with standards and/or procedures

5Complete documentation

5.1 Test results are reported in accordance with standards and/or procedures

5.2 Required documentation is completed in accordance with workplace procedures

REQUIRED KNOWLEDGE AND SKILLS

This describes the essential knowledge and skills and their level required for this unit.

Required knowledge:

Relevant safety, OH&S and environmental procedures and regulations

Principles of ultrasonic testing

Ultrasonic probes, beam, their characteristics and screen display

Beam angles and probes required to locate various defect types

Fundamentals of rail and rail defects

Rail defects and rail defect classification

Workplace procedures for the ultrasonic testing of rail and welds

Problems that may occur during the ultrasonic testing of rail and welds, and action that can be taken to report or resolve the problems

Hazards that may exist during the ultrasonic testing of rail and welds, and ways of controlling the risks involved

Basic mechanical knowledge relevant to the ultrasonic testing of rail and welds

Relevant communication systems and procedures

Workplace protection

Hazardous situations and related personal protection measures

Relevant recording and documentation procedures

Required skills:

Read and interpret instructions, procedures, information, technical data, standards and drawings relevant to the ultrasonic testing of rail and welds

Interpret and follow operational instructions and prioritise work

Complete documentation related to the ultrasonic testing of rail and welds

Operate communication equipment to required protocol

Promptly report and/or rectify any identified problems, faults or malfunctions that may arise when testing rail and welds using ultrasonic equipment in accordance with regulatory requirements and workplace procedures

Implement contingency plans for unexpected events when testing rail and welds using ultrasonic equipment

Identify hazards associated with ultrasonic testing

Apply precautions and required action to minimise, control or eliminate hazards that may exist during work activities

Monitor work activities in terms of planned schedule

Modify activities depending on differing operational contingencies, risk situations and environments

Work systematically with required attention to detail without injury to self or others, or damage to goods or equipment

Select and use relevant hand tools, power tools and equipment

Adapt to differences in equipment in accordance with standard operating procedures

Select and use required personal protective equipment conforming to industry and OH&S standards

Identify, clean and prepare inspection areas for testing using appropriate procedures and materials

Visually assess inspection areas and identify and classify obvious discontinuities

Identify types of rail defects

Select probes to use to locate each type of defect

Check and maintain ultrasonic testing equipment

Set up probes for each type of test

Test with appropriate probes for each type of defect

Interpret screen indications

Locate, measure and assess defect size for all defect types

Use sizing definitions

Carry out additional visual and geometry assessments for field welds

Report test results

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required knowledge and skills, the range statement and the assessment guidelines for this Training Package.

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 and satisfy all of the requirements of the elements and performance criteria of this unit and include demonstration of applying:

the underpinning knowledge and skills

relevant legislation and workplace procedures

other relevant aspects of the range statement

Assessment must include exercises which demonstrate competent performance of the following in a range of situations:

determining test requirements

conducting testing using hand directed equipment

conducting visual examination and measurement of rail and welds

classifying defects

completing documentation

Context of and specific resources for assessment

Performance is demonstrated consistently over a period of time and in a suitable range of contexts

Resources for assessment include:

a range of relevant exercises, case studies and/or other simulated practical and knowledge assessment, and/or

access to an appropriate range of relevant operational situations in the workplace

In both real and simulated environments, access is required to:

relevant and appropriate materials and equipment, and

applicable documentation including workplace procedures, regulations, codes of practice and operation manuals

Method of assessment

Assessment of this unit must be undertaken by a registered training organisation

As a minimum, assessment of knowledge must be conducted through appropriate written/oral tests

Practical assessment must occur:

through activities in an appropriately simulated environment at the registered training organisation, and/or

in an appropriate range of situations in the workplace

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance.

Operations may be conducted:

by day or night

weather conditions specified in relevant standards

Work may be conducted in:

restricted spaces

exposed conditions

controlled or open environments

Work may involve exposure to:

chemicals

dangerous or hazardous substances

movements of equipment, goods and vehicles

Types of ultrasonic test and/or visual examination and measurement may vary according to:

location

rail mass or type

weld type

test requirement

Weld type may include:

new aluminothermic welds

flashbutt welds

head repair welds using wirefeed or 'stick' welding process

Test requirements may include:

acceptance testing (ultrasonic, geometric alignment and visual) of new aluminothermic welds

acceptance testing (ultrasonic, geometric alignment and visual) of new flashbutt welds

acceptance testing (ultrasonic, geometric alignment and visual) of new head repair welds

ultrasonic testing of plain rail and welds

Equipment may include:

ultrasonic testing units

ultrasonic probes

alignment gauges

tape measures

Materials may include:

coupling medium

marking pens/paint

Liaison may include:

internal or external personnel from other work areas (e.g. train controllers, electricians)

Communications equipment may include:

two-way radios

telephones/mobile phones

agreed audible or hand signal

Depending on work context, safety and personal protective equipment may include:

high visibility clothing

hearing protection

gloves

sunscreen

sunglasses

safety glasses

insect repellent

safety headwear

safety footwear

portable radios/mobile phones

hand lamps

flags

safety devices

Depending on the type of organisation concerned and the local terminology used, workplace procedures may include:

company procedures

enterprise procedures

organisational procedures

established procedures

Information/documents may include:

operational instructions, policies and workplace procedures

information provided by other workplace personnel

rail inspections and reports

relevant logs or record books

work orders

technical instructions

manufacturers or workplace equipment instructions and operation manuals

emergency procedure manuals

two-way radio/mobile phone operation procedures

QA plans, data and document control

conditions of service, legislation and industrial agreements including workplace agreements and awards

Applicable procedures and codes may include:

legislated rail safety requirements including acts and regulations from each applicable state and territory together with any nationally approved compliance codes and/or guidelines

relevant state/territory regulations, codes of practice and safeworking system requirements

relevant Australian Standards and related requirements, including AS 4292

relevant state/territory OH&S legislation

relevant state/territory environmental protection legislation

This unit contains employability skills.