1 Prepare 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

2 Assemble and set up welding equipment

2.1 Welding equipment is set up and adjusted to meet welding process requirements

2.2 Accessories and consumables are selected for use

3 Assemble and set up gouging and grinding equipment

3.1 Gouging and grinding equipment is assembled and set up

3.2 Equipment settings are adjusted to meet process requirements

3.3 Accessories and consumables are selected for use

4 Remove defect

4.1 Appropriate method to be used to remove the defect is identified in accordance with organisational standards and procedures

4.2 Defect is removed using identified method in accordance with organisational standards and procedures

5 Perform welding operation

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

5.2 Welded area is cleaned in preparation for grinding

5.3 Welded area is ground in accordance with organisational standards and procedures

6 Check weld conformance

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

6.2 Finished ground weld area is checked for conformance to rail/crossing/switch profile acceptance standards

7 Complete post-operative checks and documentation

7.1 Equipment is checked for serviceability

7.2 Defective equipment is replaced and/or reported for servicing/repair in accordance with organisational policies and procedures

7.3 Documentation on work undertaken is completed in accordance with organisational requirements

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

Required knowledge:

Acceptance standards for weld repairs on rail

Authorisation/approval processes and procedures

Documentation and recordkeeping requirements

Fundamentals of tram track and components

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

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

Relevant communication systems and procedures

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

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

Workplace procedures for removing defects by gouging, grinding and welding rail using an electric welding process

Required skills:

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

Complete documentation related to welding rail using an electric welding process

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

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

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

Monitor work activities in terms of planned schedule

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

Operate communications equipment to required protocol

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

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 organisational procedures

Select and use hand tools, power tools and equipment

Select and use required personal protective equipment (PPE)

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

Work systematically with required attention to detail without injury to self or others, or damage to goods or 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 required knowledge and skills

relevant legislation and workplace procedures

other relevant aspects of the range statement

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

preparing items for welding according to workplace requirements

assembling and setting up welding, gouging and grinding equipment and preparing consumables

performing welding grinding, gouging and testing operations on rails, crossings or switches

ensuring weld conforms to organisational requirements

completing documentation in accordance with organisational requirements

Context of and specific resources for assessment

Performance must be 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 or

simulated environment using actual components, tools and equipment

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:

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

oxy/LPG gouging equipment

manual or mechanical grinder

wire brushes

cutting and boring equipment

fastening equipment

fume extraction equipment

on-line respirator

Materials may include:

flux core wire

welding electrodes

grinding discs

Liaison may include:

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

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

Information/documents may include:

operational instructions

information provided by other workplace personnel

rail inspections reports

work orders

technical instructions

manufacturer or workplace equipment instructions and operation manuals

emergency procedure manuals

two-way radio/mobile phone operation procedures

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

organisational policies and procedures

local authority regulations and procedures relevant

relevant state/territory OH&S legislation

relevant state/territory environmental protection legislation