1 Prepare materials for welding

1.1 Weld requirements are identified from specifications and/or technical drawings

1.2 Material is correctly prepared using tools and techniques appropriate to the material and process

1.3 Materials are assembled/aligned to specifications, where required

1.4 Track is measured prior to commencement of welding

2 Select welding machine settings and consumables

2.1 Welding machine settings and consumables are identified from job requirements, welding procedures, specifications and/or technical drawings

3 Assemble and set up welding equipment

3.1 Welding equipment is assembled and set up safely and correctly to standard operating procedures

3.2 Any defective equipment is tagged and replaced in accordance with organisational and/or manufacturer specifications

4 Weld rail using submerged arc process

4.1 Pad, butt and fillet welds are deposited correctly in flat, and fillet welds in horizontal position, to specification

4.2 Joints are cleaned to specifications using techniques and tools appropriate to the defect, material and process

5 Inspect welds and correct faults

5.1 Weld joints are visually inspected against specifications

5.2 Track is measured to ensure welded track is within accepted tolerances

5.3 Weld defects are identified and remedial action is taken, where required

5.4 Defects are removed with minimum loss of sound metal using techniques and tools appropriate to the defect, material and process

6 Maintain weld records as required

6.1 Weld records are maintained in accordance with organisational procedures

This section describes the knowledge and skills required for this unit.

Required knowledge:

Acceptance standards for weld repairs on tram/light rail track

Authorisation/approval processes and procedures

Documentation and recordkeeping requirements

Hazards that may exist when welding rail using submerged welding process, and ways of controlling the risks involved

Problems that may occur when welding rail using submerged welding process, and action that can be taken to report or resolve problems

Relevant communication systems and procedures

Relevant safety, occupational health and safety (OH&S) and environmental procedures and regulations

Track standards for rail condition and surface profile

Required skills:

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

Communicate effectively with others

Interpret and follow operational instructions

Modify activities depending on operational contingencies, risk situations and environments

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

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 required 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:

preparing and setting up traffic management plan

preparing items for welding according to workplace requirements

assembling and setting up welding equipment and preparing consumables

ensuring weld conforms to organisational requirements

completing documentation in accordance with organisational requirements

Context of and specific resources for assessment

Performance is demonstrated 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

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, 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.

Work may involve exposure to:

movement of equipment, materials and vehicles

Basic track measurements may include:

length, depth, width, diameter

track gauge

length of weld

Measuring equipment may include:

tape measures

track gauge

Materials may include:

flux core wire

welding electrodes

grinding discs

Track layout may include:

plain track

turnouts

special trackwork including catchpoints, expansion switches, diamond crossings and slips

Communication 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

long pants and shirts

hearing protection

long gloves

spats

sunscreen

sunglasses

welding helmet

safety glasses

insect repellent

safety headwear

safety footwear

portable radios/mobile phones

hand lamps

flags

safety devices

special PPE

Information/documents may include:

operational instructions, policies and workplace procedures

local authority regulations and procedures

work orders

information provided by other workplace personnel

rail inspections and timekeeping records

trackworker standard manual

technical instructions

manufacturer or workplace equipment operation manuals and specifications

emergency procedure manuals

two-way radio/mobile phone operation procedures

Applicable regulations and legislation may include:

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

local authority regulations

relevant state/territory OH&S and environmental protection legislation