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 welding of rail using an electric welding process as part of workplace activities across a variety of operational contexts within the Australian rail system.

Operators of mechanised equipment must have undertaken training and, where appropriate, hold the relevant licence, permit or certificate and be recognised as competent for the class of machinery being used.

ELEMENT

PERFORMANCE CRITERIA

1Prepare rails, crossings or switches for welding

1.1 Weld repair area is identified and assessed in accordance with standards and procedures

1.2 Welding equipment and consumables are prepared and checked for serviceability

1.3 Weld repair area is prepared for welding in accordance with workplace standards and procedures

1.4 Track components are assembled/aligned to specification where required

2Assemble and set up welding equipment

2.1 Welding machine settings are adjusted to meet welding process requirements

2.2 Accessories and consumables are selected for use

2.3 Welding equipment is assembled and set up for welding

3Perform welding operation

3.1 Weld metal is applied to repair area to meet specification in accordance with standards and procedures

3.2 Welded area is cleaned in preparation for grinding

4Check weld conformance

4.1 Finish ground weld area is visually inspected for surface finish and defects

4.2 Finish ground weld area is checked for conformance to rail/crossing/switch profile acceptance standards

5Complete post-operative checks and documentation

5.1 Welding equipment is checked for serviceability

5.2 Defective equipment is replaced

5.3 Documentation on work undertaken is completed in accordance with workplace requirements

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

Workplace procedures for the welding of rail using an electric welding process

Problems that may occur during the welding of rail using an electric welding process, and action that can be taken to report or resolve the problems

Hazards that may exist during the welding of rail using an electric welding process, and ways of controlling the risks involved

Fundamentals of track and components

Track standards for rail, crossing and switch condition and surface profile

Acceptance standards for weld repairs on rail

Relevant communication systems and procedures

Authorisation/approval processes and procedures

Documentation and record keeping requirements

Required skills:

Communicate effectively with others when welding rail using an electric welding process

Read and interpret technical data, drawings, instructions and manuals relevant to the welding of rail using an electric welding process

Interpret and follow operational instructions and prioritise work when welding rail using an electric welding process

Complete documentation related to the welding of rail using an electric welding process

Operate communication equipment to required protocol

Work collaboratively with others when welding rail using an electric welding process

Promptly report and/or rectify any identified problems, faults or malfunctions that may occur when welding rail using an electric welding process in accordance with regulatory requirements and workplace procedures

Implement contingency plans for unexpected events when welding rail using an electric welding process

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

Operate and adapt to differences in equipment in accordance with standard operating procedures

Select and use required personal protective equipment

Select and use hand tools, power tools and equipment

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:

preparing items for welding according to workplace requirements

assembling and setting up welding equipment and preparing consumables

performing welding operation on rails, crossings or switches

ensuring weld conformance to workplace requirements

completing documentation in accordance with workplace requirements

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

in all weather conditions

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 weld repairs may vary according to:

welding process location

rail mass or type

crossing and switch type

rail, switch and crossing material

Welding process may include:

flux core arc welding

manual metal arc welding

Welding equipment may include:

electric welders

generators

wirefeed welding unit

electrode holder

robotic welder

Equipment may include:

mechanical handling/lifting equipment

hand tools including impact wrenches, tie tampers, gauges, track jacks, spiking hammers and bars

wire brushes

rail thermometers and/or 'thermomelt' crayons

cutting and boring equipment

fastening equipment

fume extraction equipment for use with welding manganese

Materials may include:

flux core wire

welding electrodes

Liaison may include:

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

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

company procedures

enterprise procedures

organisational procedures

established procedures

Communications equipment may include:

two-way radios

telephones/mobile phones

agreed audible or hand signal

Depending on the 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 when welding manganese

Information/documents may include:

operational instructions, policies and workplace procedures

local authority regulations and procedures

information provided by other workplace personnel

rail inspections and reports

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:

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

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.