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 weld rail using the flashbutt 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

1Perform pre-operational equipment checks

1.1 Detailed pre-operational equipment checks are conducted as per manufacturers specifications and/or local maintenance schedules

1.2 Deficiencies with equipment are identified and rectified in accordance with workplace procedures

1.3 Relevant persons are notified of problems and documentation is completed

2Prepare rail for welding

2.1 Weld location is checked to confirm suitability for welding in accordance with workplace standards

2.2 Track preparation for welding is arranged (if required) in accordance with workplace procedures and standards

2.3 Rail ends are prepared for welding in accordance with workplace procedures and standards

3Carry out flashbutt welding

3.1 Flashbutt welding equipment is prepared for use

3.2 Flashbutt welding unit is clamped to rail ensuring accurate alignment

3.3 Equipment is operated in accordance with machine operation instructions and workplace procedures to achieve appropriate quality standard

3.4 Warning systems are monitored and responded to appropriately during operation to maintain correct functionality of equipment

3.5 Track restoration is arranged (where required) in accordance with workplace procedures and standards

3.6 Weld is profile-ground to ensure smooth running surface in accordance with workplace procedures and standards

4Check weld conformance

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

4.2 Finished ground weld area is checked for conformance to rail profile and geometry acceptance standards

5Perform post-operational equipment checks

5.1 Post-operational equipment checks are conducted in accordance with manufacturers specifications or local maintenance schedules to identify defects and maintenance requirements

5.2 Deficiencies with equipment are identified and rectified in an appropriate manner to maintain correct functionality of equipment

5.3 Relevant persons are notified of problems and/or documentation is completed in accordance with instructions and the relevant codes of practice

6Complete documentation

6.1 Required documentation and/or recording 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

Workplace procedures for the operation of flashbutt welding equipment

Workplace procedures for the welding of rail using the flashbutt welding process

Problems that may occur during use of the flashbutt welding process and equipment, and action that can be taken to report or resolve the problems

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

Basic technical knowledge relevant to flashbutt welding

Rail welding standards

Emergency procedures

Characteristics of relevant plant and equipment, transport, structures, hardware and components used in work activities

Materials identification, handling and storage

Hazardous situations and related personal protection measures

Relevant recording and documentation procedures

Required skills:

Communicate effectively with others when welding rail using the flashbutt welding process

Read and interpret instructions, procedures, route information and signs relevant to welding of rail using the flashbutt welding process and equipment

Interpret and follow operational instructions and follow scheduled work process when welding rail using the flashbutt welding process

Complete documentation related to work activities

Operate communication equipment to required protocol

Work collaboratively with others when welding rail using the flashbutt welding process

Promptly report and/or rectify any identified problems, faults or malfunctions when welding rail using the flashbutt welding process in accordance with regulatory requirements and workplace procedures

Plan the scheduled work including predicting consequences and identifying improvements

Implement contingency plans for unexpected events when using the flashbutt welding process and equipment

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 equipment

Carry out required welding operations

Select and use relevant hand and portable power tools

Handle rail safely

Check compliance between work and job specifications

Implement required fire control procedures

Select and use required personal protective equipment

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

Operate flashbutt welding equipment (for which certificated and licensed)

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:

ensuring equipment is operating correctly

preparing equipment for operation

operating equipment correctly

checking finished welds for conformance

completing documentation/records correctly

successfully performing a minimum of 25 welds

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 possible weather conditions

Work may be conducted in:

restricted spaces

exposed conditions

controlled or open environments

Work may involve:

exposure to chemicals, and dangerous or hazardous substances

movements of equipment, goods and vehicles

Flashbutt welding equipment may include:

rail mounted flashbutt welders

stationary flashbutt welders used in field

Equipment may include:

rail tensor

welding records

rail shears

timekeeping records

rail profile grinder, angle grinder

incident reporting data

electric generator

track inspection reports

gas heating/cutting equipment

welding equipment

rail friction saw

hand tools

Safety hazards may include:

fire risk

poor weather

rail tensor failure (broken pins etc.)

flash damage to eyes

burns

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

fire retardant overalls or long sleeved shirt and long pants

hearing protection

gauntlet type gloves

sunscreen

welding goggles

sunglasses

safety glasses

insect repellent

safety headwear

safety footwear

portable radios/mobile phones

hand lamps

flags

safety devices

Information/documents may include:

operational instructions, policies and workplace procedures

local authority regulations and procedures

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 Australian Standards and related requirements, including AS 4292

relevant state/territory OH&S legislation

relevant state/territory environmental protection legislation

ADG Code and associated requirements

relevant fire regulations

Liaison may include:

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

Information may be provided:

electronically

in writing, via forms/documents/plans

orally, via face-to-face communications

This unit contains employability skills.