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Evidence Guide: PMASUP245 - Break and make flanged joints using hand tools

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

PMASUP245 - Break and make flanged joints using hand tools

What evidence can you provide to prove your understanding of each of the following citeria?

Plan and prepare for job

  1. Identify work requirements
  2. Inspect job site
  3. Confirm isolations have been completed to standard
  4. Confirm hazard controls
  5. Coordinate with appropriate personnel
  6. Select appropriate tools
  7. Check calibration and certification of tools in accordance with procedures
  8. Re-check that work requirements fit within skill level
  9. Complete required checklists and records
Identify work requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inspect job site

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm isolations have been completed to standard

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm hazard controls

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coordinate with appropriate personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select appropriate tools

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check calibration and certification of tools in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Re-check that work requirements fit within skill level

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete required checklists and records

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Break flange in accordance with flange management procedure

  1. Implement hazard controls
  2. Prepare tools, drip trays, and so on, with appropriate care
  3. Connect any required drain lines
  4. Undo nuts in accordance with procedures
  5. Split flange and drain pipe as required
  6. Identify any skills escalation required
  7. Manage open pipe to ensure contents are not contaminated or damaged
  8. Complete checklists and records as required
Implement hazard controls

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare tools, drip trays, and so on, with appropriate care

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Connect any required drain lines

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undo nuts in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Split flange and drain pipe as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify any skills escalation required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Manage open pipe to ensure contents are not contaminated or damaged

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete checklists and records as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inspect flange and components

  1. Inspect removed gasket for indications of flange problems
  2. Assess cold pull and refer to appropriate personnel if required
  3. Assess degree of misalignment and refer to appropriate personnel if required
  4. Clean and inspect flange surface both front and back
  5. Check studs and nuts
  6. Confirm compliance of components and refer to appropriate personnel as required
  7. Identify any problems and take action
Inspect removed gasket for indications of flange problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess cold pull and refer to appropriate personnel if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess degree of misalignment and refer to appropriate personnel if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean and inspect flange surface both front and back

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check studs and nuts

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm compliance of components and refer to appropriate personnel as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify any problems and take action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make flange joint in accordance with flange management procedure

  1. Select appropriate gasket
  2. Check all components are to specification
  3. Apply lubricant as required
  4. Complete initial assembly of joint
  5. Insert blind, blank or spectacle/goggle blind as required
  6. Attach drain if required
  7. Re-check the gasket
  8. Re-check alignment
  9. Tighten using appropriate hand tools to procedure
  10. Use torque calibration charts as required
  11. Complete checklists and records as required
Select appropriate gasket

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check all components are to specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply lubricant as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete initial assembly of joint

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Insert blind, blank or spectacle/goggle blind as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Attach drain if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Re-check the gasket

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Re-check alignment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tighten using appropriate hand tools to procedure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use torque calibration charts as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete checklists and records as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Finish the job

  1. Make a final check of joint alignment
  2. Organise required checks
  3. Confirm joint integrity as required
  4. Complete checklists and records as required
Make a final check of joint alignment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Organise required checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm joint integrity as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete checklists and records as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Plan and prepare for job

1.1

Identify work requirements

1.2

Inspect job site

1.3

Confirm isolations have been completed to standard

1.4

Confirm hazard controls

1.5

Coordinate with appropriate personnel

1.6

Select appropriate tools

1.7

Check calibration and certification of tools in accordance with procedures

1.8

Re-check that work requirements fit within skill level

1.9

Complete required checklists and records

2

Break flange in accordance with flange management procedure

2.1

Implement hazard controls

2.2

Prepare tools, drip trays, and so on, with appropriate care

2.3

Connect any required drain lines

2.4

Undo nuts in accordance with procedures

2.5

Split flange and drain pipe as required

2.6

Identify any skills escalation required

2.7

Manage open pipe to ensure contents are not contaminated or damaged

2.8

Complete checklists and records as required

3

Inspect flange and components

3.1

Inspect removed gasket for indications of flange problems

3.2

Assess cold pull and refer to appropriate personnel if required

3.3

Assess degree of misalignment and refer to appropriate personnel if required

3.4

Clean and inspect flange surface both front and back

3.5

Check studs and nuts

3.6

Confirm compliance of components and refer to appropriate personnel as required

3.7

Identify any problems and take action

4

Make flange joint in accordance with flange management procedure

4.1

Select appropriate gasket

4.2

Check all components are to specification

4.3

Apply lubricant as required

4.4

Complete initial assembly of joint

4.5

Insert blind, blank or spectacle/goggle blind as required

4.6

Attach drain if required

4.7

Re-check the gasket

4.8

Re-check alignment

4.9

Tighten using appropriate hand tools to procedure

4.10

Use torque calibration charts as required

4.11

Complete checklists and records as required

5

Finish the job

5.1

Make a final check of joint alignment

5.2

Organise required checks

5.3

Confirm joint integrity as required

5.4

Complete checklists and records as required

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Plan and prepare for job

1.1

Identify work requirements

1.2

Inspect job site

1.3

Confirm isolations have been completed to standard

1.4

Confirm hazard controls

1.5

Coordinate with appropriate personnel

1.6

Select appropriate tools

1.7

Check calibration and certification of tools in accordance with procedures

1.8

Re-check that work requirements fit within skill level

1.9

Complete required checklists and records

2

Break flange in accordance with flange management procedure

2.1

Implement hazard controls

2.2

Prepare tools, drip trays, and so on, with appropriate care

2.3

Connect any required drain lines

2.4

Undo nuts in accordance with procedures

2.5

Split flange and drain pipe as required

2.6

Identify any skills escalation required

2.7

Manage open pipe to ensure contents are not contaminated or damaged

2.8

Complete checklists and records as required

3

Inspect flange and components

3.1

Inspect removed gasket for indications of flange problems

3.2

Assess cold pull and refer to appropriate personnel if required

3.3

Assess degree of misalignment and refer to appropriate personnel if required

3.4

Clean and inspect flange surface both front and back

3.5

Check studs and nuts

3.6

Confirm compliance of components and refer to appropriate personnel as required

3.7

Identify any problems and take action

4

Make flange joint in accordance with flange management procedure

4.1

Select appropriate gasket

4.2

Check all components are to specification

4.3

Apply lubricant as required

4.4

Complete initial assembly of joint

4.5

Insert blind, blank or spectacle/goggle blind as required

4.6

Attach drain if required

4.7

Re-check the gasket

4.8

Re-check alignment

4.9

Tighten using appropriate hand tools to procedure

4.10

Use torque calibration charts as required

4.11

Complete checklists and records as required

5

Finish the job

5.1

Make a final check of joint alignment

5.2

Organise required checks

5.3

Confirm joint integrity as required

5.4

Complete checklists and records as required

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

replace existing components with new components

carrying out minor maintenance within own skill level

identify and report problems outside own competence

identify and control hazards related to flange joints

inspect job site to confirm:

location

authorisations required

access and egress needs

recent work undertaken on joint

flange type matches specification

inspect flange components to check for:

contaminants

signs of damage, defects or deterioration in all components

cleanliness and correct surface roughness of mating surfaces

alignment

correct specifications.

Evidence must be provided that demonstrates knowledge of:

flange and gasket types as applicable

principles of how flanged joints seal

tool types and applications

organisation’s flange management procedure

hierarchy of control

communication protocols (e.g. radio, phone, computer, paper and permissions/authorities)

routine problems, faults and their symptoms, and the corrective action to be taken

process materials and conditions at the location of the flange

using flange tags/completeness tags

relevant environmental requirements

relevant parts of ASME PCC-1-2013 Guidelines for pressure boundary bolted flange joint assembly.

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used, and include one or more of the following:

legislative requirements, including work health and safety (WHS)

industry codes of practice and guidelines

environmental regulations and guidelines

Australian and other standards

licence and certification requirements

All operations to which this unit applies are subject to stringent health, safety and environment (HSE) requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and HSE requirements, the HSE requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, include one or more of the following:

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant

Hazards

Hazards include one or more of the following:

gases and liquids under pressure

structural hazards

equipment failures

industrial (machinery, equipment and product)

equipment or product mass

plant services (steam, condensate and cooling water)

limited head spaces or overhangs

working at heights, in restricted or confined spaces, or in environments subjected to heat, dusts or vapours

flammability and explosivity

hazardous products and materials

unauthorised personnel

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

extreme weather

other hazards that might arise

Routine problems

Routine problems must be resolved by applying known solutions.

Routine problems are predictable and include one or more of the following:

seal/gasket leaks

pressure loss/low flow

blockages/build-up/fouling

erosion/wear

ancillary equipment problems

studs incorrectly tensioned

worn threads

misalignments

cold pull

isolation failure

leak test failure

Known solutions are drawn from one or more of the following:

procedures

training

remembered experience

Non-routine problems must be reported according to according to relevant procedures.

Action

Action in response to problems includes the following:

determining problems needing action

accessing and applying relevant technical and plant data

applying appropriate problem solving techniques to determine possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility/ability to resolve to designated person

Action also requires one or more of the following:

replacing existing components with new components

carrying out minor maintenance within operator's skill level

identifying and reporting problems outside operator's competence

identifying and controlling hazards related to flange joints

Work requirements

Work requirements include one or more of the following:

flange and gasket specifications

stud and nut specification

process line and process materials

parts and equipment required

local detectors requiring isolation

required skill level

conflicting work

Work requirements come from briefings, handovers, and work orders and include one or more of the following

compliance documentation

product specifications

nature and scope of tasks

achievement targets

operational conditions

lighting conditions

plant or equipment defects

hazards and potential hazards

coordination requirements or issues

Job site

Inspecting job site includes identifying one or more of the following:

location

authorisations required

access and egress needs

hazards

recent work undertaken on joint

flange type (matches specification)

Implementing hazard controls

Implementing hazard controls includes one or more of the following:

selection and use of appropriate personal protective equipment (PPE)

obtaining appropriate authorisations

checking required isolations

controlling other work in area

controlling access to area

using gas tester

verifying and confirming isolation

safe flange breaking procedure (line of fire)

Inspecting components

Inspecting flange components includes one or more of the following:

asbestos in gaskets

signs of damage, defects or deterioration in all components

cleanliness and correct surface roughness of mating surfaces

alignment

Refer to appendices of ASME PCC-1-2013 Guidelines for pressure boundary bolted flange joint assembly, for technical details.

Components

Components include the following:

studs

nuts

washers

gaskets

other components as appropriate to the job/work environment

Checking studs and nuts

Checking studs and nuts includes one or more of: the following

integrity of studs and nuts

fit of nut to stud

need for new studs and nuts

conformance

Initial assembly of joint

Initial assembly of joint includes one or more of the following:

aligning joint

inserting studs

assembling nuts to studs

inserting and aligning gasket

Blinds

Blinds include one or more of the following:

blinds

blanks

spectacle/goggle blinds

Appropriate personnel

Appropriate personnel will be someone with the required skills, knowledge and/or authority to deal with the matter, including one or both of the following:

a supervisor

an engineer

Checklists and records

Checklists and records may include one or more of the following:

paper or electronic-based

verbal/radio reports

reporting items found which require action