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Evidence Guide: PMC557093 - Design a refractory/ceramic component

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

 

PMC557093 - Design a refractory/ceramic component

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

Confirm required end use

  1. Liaise with relevant stakeholders
  2. Confirm the end use conditions for the refractory
  3. Define interface requirements with the product
  4. Identify discrepancies or conflicts in requirements
  5. Negotiate a consistent set of requirements for the refractory component
Liaise with relevant stakeholders

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm the end use conditions for the refractory

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Define interface requirements with the product

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify discrepancies or conflicts in requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Negotiate a consistent set of requirements for the refractory component

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undertake preliminary design

  1. Undertake required mechanical design calculations
  2. Undertake the required heat transfer calculations
  3. Undertake relevant thermal expansion calculations
  4. Determine implications for refractory material selection
  5. Liaise with refractory material selector
  6. Prepare preliminary designs of component
Undertake required mechanical design calculations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undertake the required heat transfer calculations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undertake relevant thermal expansion calculations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine implications for refractory material selection

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with refractory material selector

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare preliminary designs of component

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Compare possible design solutions

  1. Compare the preliminary designs with the set of requirements
  2. Rank possible design solutions
  3. Identify health, safety and environmental (HSE) risks of top ranked possible refractory designs
  4. Estimate the cost of top ranked possible refractory designs
Compare the preliminary designs with the set of requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rank possible design solutions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify health, safety and environmental (HSE) risks of top ranked possible refractory designs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Estimate the cost of top ranked possible refractory designs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Design refractory component

  1. Liaise with relevant stakeholders
  2. Determine customer issues of relevance to the refractory designs
  3. Determine manufacturing issues of relevance to the refractory designs
  4. Review shortlist ranking
  5. Recommend optimum refractory component design for the end use
Liaise with relevant stakeholders

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine customer issues of relevance to the refractory designs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine manufacturing issues of relevance to the refractory designs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Review shortlist ranking

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recommend optimum refractory component design for the end use

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Develop design and technical specification for recommended refractory component

  1. Determine suitable format for design and specification
  2. Prepare design and specification
  3. Review specification with refractory material selector, production and customer
  4. Modify design and specification if required
  5. Publish design and specification in required format to required people/organisations
Determine suitable format for design and specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare design and specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Review specification with refractory material selector, production and customer

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Modify design and specification if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Publish design and specification in required format to required people/organisations

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

Confirm required end use

1.1

Liaise with relevant stakeholders

1.2

Confirm the end use conditions for the refractory

1.3

Define interface requirements with the product

1.4

Identify discrepancies or conflicts in requirements

1.5

Negotiate a consistent set of requirements for the refractory component

2

Undertake preliminary design

2.1

Undertake required mechanical design calculations

2.2

Undertake the required heat transfer calculations

2.3

Undertake relevant thermal expansion calculations

2.4

Determine implications for refractory material selection

2.5

Liaise with refractory material selector

2.6

Prepare preliminary designs of component

3

Compare possible design solutions

3.1

Compare the preliminary designs with the set of requirements

3.2

Rank possible design solutions

3.3

Identify health, safety and environmental (HSE) risks of top ranked possible refractory designs

3.4

Estimate the cost of top ranked possible refractory designs

4

Design refractory component

4.1

Liaise with relevant stakeholders

4.2

Determine customer issues of relevance to the refractory designs

4.3

Determine manufacturing issues of relevance to the refractory designs

4.4

Review shortlist ranking

4.5

Recommend optimum refractory component design for the end use

5

Develop design and technical specification for recommended refractory component

5.1

Determine suitable format for design and specification

5.2

Prepare design and specification

5.3

Review specification with refractory material selector, production and customer

5.4

Modify design and specification if required

5.5

Publish design and specification in required format to required people/organisations

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Confirm required end use

1.1

Liaise with relevant stakeholders

1.2

Confirm the end use conditions for the refractory

1.3

Define interface requirements with the product

1.4

Identify discrepancies or conflicts in requirements

1.5

Negotiate a consistent set of requirements for the refractory component

2

Undertake preliminary design

2.1

Undertake required mechanical design calculations

2.2

Undertake the required heat transfer calculations

2.3

Undertake relevant thermal expansion calculations

2.4

Determine implications for refractory material selection

2.5

Liaise with refractory material selector

2.6

Prepare preliminary designs of component

3

Compare possible design solutions

3.1

Compare the preliminary designs with the set of requirements

3.2

Rank possible design solutions

3.3

Identify health, safety and environmental (HSE) risks of top ranked possible refractory designs

3.4

Estimate the cost of top ranked possible refractory designs

4

Design refractory component

4.1

Liaise with relevant stakeholders

4.2

Determine customer issues of relevance to the refractory designs

4.3

Determine manufacturing issues of relevance to the refractory designs

4.4

Review shortlist ranking

4.5

Recommend optimum refractory component design for the end use

5

Develop design and technical specification for recommended refractory component

5.1

Determine suitable format for design and specification

5.2

Prepare design and specification

5.3

Review specification with refractory material selector, production and customer

5.4

Modify design and specification if required

5.5

Publish design and specification in required format to required people/organisations

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

analyse and interpret technical reports, technical specifications and data

confirm requirements for refractory end use conditions, including:

surface temperature of refractory

required temperature gradient through refractory/outside surface temperature

chemical condition (e.g. pH)

mechanical condition (e.g. impingement)

temperature or other cycling

communicate technical information verbally and in writing/drawings

communicate with internal and external stakeholders, including one or more of:

customer representatives

technical experts

regulators

management

refractory material selector

refractory installer

determine optimum refractory installation by evaluating criteria, including:

alignment to technical requirements of the end use

preliminary design calculations

installation, repair or removal issues

cost (material, manufacturing, installation, repair, life cycle)

health, safety and environmental (HSE) risks (manufacture, installation, use, repair, removal and disposal)

relative benefits/costs/risks of block/precast, monolithic/castable, gunite/shotcrete, refractory coating and multilayer (e.g. hard face over insulating refractory) refractory linings

negotiate with relevant stakeholders and document agreed requirements and design and technical specifications

apply complex and/or theoretical mathematical calculations

solve complex problems to determine design and specification which best deliver the technical requirement at the lowest cost and the least HSE risk

develop technical drawings manually or with computer-aided drafting (CAD).

Must provide evidence that demonstrates knowledge relevant to their job sufficient to fulfil their job role, including knowledge of:

properties of all common refractory materials

typical limitations and applications of all common refractory materials when used as components

manufacturing methods for refractory components and their advantages, disadvantages, typical uses and limitations

heat transfer calculations (resistances in series and parallel)

mechanical calculations (stress/strain, modulus, stiffness, shear, strength of refractory materials and physical properties of refractory materials)

thermal expansion (calculation of and allowance for)

methods of fixing refractory components to products

basic metal product manufacturing methods, their possible uses for refractory components and their impact on component design

methods of reuse, recycling and disposal of refractory components at the end of their life and the differences for different types of refractory components

critical refractory component specifications

regulatory framework

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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.

Applicable legislation, regulations, standards and codes of practice include:

HSE legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent 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 such requirements the legislative requirements take precedence.

HSE and other risks

Identification of HSE and other risks includes consideration of:

health and safety risks

sustainability risks

regulatory risks

business risks.