UEPMNT404B
Maintain complex mechanical pumps

1)Scope:1.1) DescriptorThis unit deals with the skills and knowledge required to undertake the installation and maintenance of multi-stage centrifugal pumps, axial flow compressors, fans and blowers.

Application

2)

This unit is intended to augment formally acquired competencies. It is suitable for employment-based programs under an approved contract of training.


Prerequisites

Prerequisite Unit(s)

4)

Competencies

4.1)

Granting of competency in this unit shall be made only after competency in the following unit(s) has/have been confirmed.

Where pre-requisite pathways have been identified. All competencies in the Common Unit Group must be have been completed.

Common Unit Group

Unit Code

Unit Title

UEPMNT304B

Maintain Mechanical Pumps

MEM18006C

Repair and fit engineering components

MEM09002B

Interpret technical drawing

MEM12023A

Perform Engineering Measurements

MEM18001C

Use hand tools

MEM18002B

Use power tools/hand held operations

MEM18003C

Use tools for precision work

MEM18055B

Dismantle, replace and assemble engineering components

Literacy and numeracy skills

4.2)

Participants are best equipped to achieve this unit if they have reading, writing and numeracy skills indicated by the following levels. A description of what each level entails is provided in Section 2.3.1 Language, Literacy and Numeracy.

Reading

4

Writing

4

Numeracy

4


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1

Plan and prepare for the work

1.1

Work requirements are identified from request/work orders or equivalent and clarified/confirmed with appropriate parties or by site inspection

1.2

Occupational Health and Safety standards, statutory requirements, relevant Australian standards, codes of practice, manufacturer specifications , environmental requirements and enterprise procedures are identified, applied and monitored throughout the work procedure

1.3

Resources required to satisfy the work plan are identified, obtained and inspected for compliance with the job specifications

1.4

Relevant plans, drawings and texts are selected and interpreted in accordance with the work plan

1.5

Correct size, type and quantity of materials/components are determined, obtained and inspected for compliance with the job specifications

1.6

Work is planned in detail including sequencing and prioritising and considerations made, where appropriate, for the maintenance of plant security and capacity in accordance with system/site requirements

1.7

Co-ordination requirements, including requests for isolations where appropriate, are resolved with others involved, affected or required by the work

1.8

Potential hazards are identified and prevention and/or control measures are selected in accordance with the work plan and site procedures

1.9

Work area is prepared in accordance with work requirements and site procedures

1.10

Where appropriate, the teams and individuals roles and responsibilities within the team are identified and, where required, assist in the provision of on-the-job training

2

Remove pumps for maintenance

2.1

Required isolations are confirmed, where appropriate, in accordance with site requirements

2.2

Pump is disconnected in accordance with the work plan

2.3

Pump is removed in a manner which will assist in replacement in accordance with the work plan

2.4

Pump is inspected for abnormalities in accordance with the work plan

3

Maintain pumps

3.1

Maintenance is performed in accordance with manufacturer specifications and site procedures

3.2

Pump is dismantled for maintenance in accordance with manufacturer specifications and site procedures

3.3

Sketches are made, data noted and components marked for identification and/or re-assembly in accordance with job requirements and site procedures

3.4

New components are obtained and inspected for compliance with manufacturer specifications

3.5

Dimensional inspection is performed with precision measuring devices to ensure compliance with specifications and results recorded in accordance with job requirements and site procedures

3.6

Pump is reassembled applying appropriate principles and techniques in accordance with manufacturer specifications and site requirements

3.7

Modifications/alterations are undertaken in accordance with site requirements

4

Replace/install pumps

4.1

Site is prepared for pump replacement in accordance with the work plan

4.2

Pump is replaced in accordance with the work plan and manufacturer specifications

4.3

Pump is levelled, aligned, coupled and connected in accordance with the work plan

4.4

All fastening are torqued in accordance with manufacturer specifications and site requirements

4.5

Machinery/plant and pump are test run, monitored and adjusted as required in accordance with manufacturer specifications and site requirements

5

Complete the work

5.1

Work is completed and appropriate personnel notified in accordance with site/enterprise requirements

5.2

Work area is cleared of waste, cleaned, restored and secured in accordance with site/enterprise procedures

5.3

Plant, tools and equipment are maintained and stored in accordance with site/enterprise procedures

5.4

Work completion details are finalised in accordance with site/enterprise procedures

Required Skills

8) This describes the Essential Skills and Knowledge and their level, required for this unit.

Evidence shall show that knowledge has been acquired in maintaining complex mechanical pumps.

All knowledge and skills detailed in this unit should be contextualised to current industry practices and technologies.

The extent of the Essential Knowledge and Associated Skills required follows:

KS01-PM 404B Complex mechanical pumps

T1 Evidence shall show that knowledge has been acquired for safe working practices of:

Relevant Environmental, Occupational Health and Safety legislation and regulations

Relevant plant and equipment, its location and operation

Technical drawings and manufacturers manuals

Introduction to and typical arrangements of power production plant

Pumps and compressors

Precision measuring equipment

Seals and gaskets

Quality assurance/quality control

Specialised tools and jigs

Advanced balancing, levelling and alignment techniques

Rigging and lifting equipment

Materials and components of pumps

Fluid dynamics

Torque techniques

Data recording techniques

Hand and portable power tools

Diagnostic and testing techniques

Heating techniques

Defined tolerances and fits

Isolation procedures

Insulation materials

Complex/multistage pumps, compressors

T2 Specific skills needed to achieve the Performance Criteria:

Apply Relevant Environmental, Occupational Health and Safety legislation and regulations

Interpret Technical drawings and manufacturers manuals

Identify and use precision measuring equipment

Manufacture and install seals and gaskets

Apply fluid dynamics principles

Use specialised tools and jigs

Apply advanced level and alignment techniques

Identify and select materials and components

Apply data analysis techniques

Identify and apply correct torque techniques

Use hand and portable hand tools

Apply diagnostic and testing techniques

Use heat application equipment

Apply dismantling and reassembling techniques

Work to defined tolerances

Recognise worn/damaged components

Apply effective maintenance procedures

Communicate effectively.

Evidence Required

9) This provides essential advice for assessment of the competency standard unit and must be read in conjunction with the Performance Criteria and the Range Statement of unit and the Training Package Assessment Guidelines.

The Evidence Guide forms an integral part of this competency standard unit and shall be used in conjunction with all components parts of this unit and, performed in accordance with the Assessment Guidelines of this Training Package.

Overview of Assessment

9.1)

Longitude competency development approaches to assessment, such as Profiling, require data to be reliably gathered in a form that can be consistently interpreted over time. This approach is best utilised in Apprenticeship programs and reduces assessment intervention. It is the Industry’s preferred model for apprenticeships. However, where summative (or final) assessment is used it is to include the application of the competency in the normal work environment or in a realistically simulated work environment. It is recognised that, in some circumstances, assessment in part or full can occur outside the workplace. However, it must be in accord with Industry and regulatory policy.

Methods chosen for a particular assessment will be influenced by various factors. These include the extent of the assessment, the most effective locations for the assessment activities to take place, access to physical resources, additional safety measures that may be required and the critical nature of the competencies being assessed.

The critical safety nature of working with electricity, electrical equipment, gas or any other hazardous substance/material carries risk in deeming a person competent. Hence, sources of evidence need to be ‘rich’ in nature so as to minimise error in judgment.

Activities associated with normal every day work have a bearing on the decision as to how much and how detailed the data gathered will contribute to its ‘richness’. Some skills are more critical to safety and operational requirements while the same skills may be more or less frequently practiced. These points are raised for the assessors to consider when choosing an assessment method and developing assessment instruments. Sample assessment instruments are included in the Assessment Guidelines of this Training Package.

Critical aspects of evidence required to demonstrate competency in this unit

9.2)

Before the critical aspects of evidence are considered all pre-requisites shall be met.

Evidence for competence in this unit shall be considered holistically. Each element and associated Performance Criteria shall be demonstrated on at least two occasions in accordance with the “Assessment Guidelines – UEP12”. Evidence shall also comprise:

A representative body of work performance demonstrated within the timeframes typically expected of the discipline, work function and industrial environment. In particular this shall incorporate evidence that shows a candidate is able to:

Implement Occupational Health and Safety workplace procedures and practices including the use of risk control measures as specified in the Performance Criteria and Range Statement

Apply sustainable energy principles and practices as specified in the Performance Criteria and Range Statement

Demonstrate an understanding of the essential knowledge and associated skills as described in 6) of this unit

Demonstrate an appropriate level of employability skills

Conduct work observing the relevant Anti Discrimination legislation, regulations, polices and workplace procedures

Demonstrated performance across a representative range of contexts from the prescribed items below:

The knowledge and application of relevant sections of: Occupational Health and Safety legislation; Statutory legislation; Enterprise/site safety procedures; Enterprise/site emergency procedures

Preparation and planning of work

Removal techniques

Maintenance techniques and procedures

Installation techniques and procedures

Completion of work procedures

Dealing with an unplanned event by drawing on essential knowledge and skills to provide appropriate solutions incorporated in the holistic assessment with the above listed items.

Context of and specific resources for assessment

9.3)

This unit should be assessed as it relates to normal work practice using procedures, information and resources typical of a workplace. This should include:

OHS policy and work procedures and instructions.

Suitable work environment, facilities, equipment and materials to undertake actual work as prescribed by this unit.

Competency Standards should be assessed in the workplace or simulated workplace and under the normal range of workplace conditions.

Assessment of this unit will be supported with documentary evidence, by means of endorsement stating type and application of work.

In addition to the resources listed above in Context of assessment’, evidence should show competency working, in limited spaces, with different types of plant and equipment as well as different structural/construction types and methods and in a variety of environments.

Method of assessment

9.4)

This unit shall be assessed by methods given in 1.3.00 Assessment Guidelines.

Note: Competent performance with inherent safe working practices is expected in the Industry to which this unit applies. This requires that the specified essential knowledge and associated skills are assessed in a structured environment which is primarily intended for learning/assessment and incorporates all necessary equipment and facilities for learners to develop and demonstrate the essential knowledge and skills described in this unit.

Concurrent assessment and relationship with other units

9.5)

There are no recommended concurrent assessments with this unit, however in some cases efficiencies may be gained in terms of learning and assessment effort being concurrently managed with allied competency standard units where listed.

UEPMNT304B Maintain mechanical pumps


Range Statement

10) This relates to the competency standard unit as a whole providing the range of contexts and conditions to which the Performance Criteria apply. It allows for different work environments and situations that will affect performance.

Complex pumps may include multistage centrifugal pumps, multistage compressors and positive displacement pumps

Pump drives may include electrical, internal combustion, hydraulic, pneumatic or steam.

Tools may include micrometers, verniers, dial test indicators, slip gauges, hand tools, hydraulic spanners, customised mandrels, digital height gauges, internal micrometers, depth gauges, air grinders, jigs and fixtures, customised spanners, thermal blankets, induction heaters, thermal crayons, digital thermometers, oxyacetylene gear and appropriate lifting devices.

Details of maintenance may be clarified by diagnosis and workplace inspection.

Maintenance can include repair, inspection, modification, lubrication, servicing, test running, identifying and replacing defective components.

Plant and equipment may include jigs for dismantling and oxyacetylene heating equipment.

Materials may include liquid nitrogen.

Work completion details may include plant and maintenance records, job cards, check sheets, on device labelling updates and reporting and/or documenting equipment defects.

Work site environment may be affected by nearby plant or processes e.g. chemical, heat, dust, noise and oil.

Isolations can refer to electrical/mechanical or other associated processes.

Generic terms are used throughout this Training Package for vocational standard shall be regarded as part of the Range Statement in which competency is demonstrated. The definition of these and other terms are given in Section 2.1 Preliminary Information and Glossaries.


Sectors

Not applicable.


Employability Skills

5)

The required outcomes described in this unit of competency contain applicable facets of Employability Skills. The Employability Skills Summary of the qualification in which this unit of competency is packaged will assist in identifying Employability Skill requirements.


Licensing Information

License to practice

3)

The skills and knowledge described in this unit do not require a licence to practise in the workplace. However, practice in this unit is subject to regulations directly related to Occupational Health and Safety and where applicable contracts of training such as apprenticeships and the like.