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Evidence Guide: PMC557097 - Specify and monitor repairs to refractory installations

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

 

PMC557097 - Specify and monitor repairs to refractory installations

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

Confirm repair specification

  1. Check repair specification against agreed set of requirements for the repair
  2. Identify discrepancies or conflicts in requirements
  3. Confirm repair requirements and specifications
Check repair specification against agreed set of requirements for the repair

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify discrepancies or conflicts in requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm repair requirements and specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Design installation process

  1. Determine refractory materials to be repaired
  2. Determine refractory material to be used in making the repair
  3. Determine repair installation/application requirements
  4. Determine installation equipment requirements
  5. Determine anchor/keying/adhesion requirements
  6. Determine repair method
  7. Determine post repair application requirements
  8. Determine temporary support or shores required
  9. Design formwork if required
  10. Design scaffolding or other internal access needs if required
  11. Design external access/egress means if required
  12. Identify installation health, safety and environmental (HSE) hazards
  13. Determine appropriate hazard controls
  14. Check for discrepancies or conflicts in the designs and take appropriate action
Determine refractory materials to be repaired

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine refractory material to be used in making the repair

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine repair installation/application requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine installation equipment requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine anchor/keying/adhesion requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine repair method

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine post repair application requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine temporary support or shores required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Design formwork if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Design scaffolding or other internal access needs if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Design external access/egress means if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify installation health, safety and environmental (HSE) hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine appropriate hazard controls

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check for discrepancies or conflicts in the designs and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare for installation

  1. Specify repair procedure
  2. Liaise with relevant stakeholders
  3. Modify specification if needed
  4. Ensure correct ordering of requirements
  5. Identify time critical items for the installation
  6. Identify other items critical to the success of the project
  7. Identify or develop measures to monitor all critical items
  8. Prepare repair specification
Specify repair procedure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with relevant stakeholders

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Modify specification if needed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure correct ordering of requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify time critical items for the installation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify other items critical to the success of the project

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify or develop measures to monitor all critical items

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare repair specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor installation

  1. Ensure requirements meet specification/contract
  2. Ensure hazard controls are in place and effective
  3. Monitor work to installation specification
  4. Take appropriate action on non-conformances as required
  5. Report during project as required
  6. Complete end of project documentation on completion
Ensure requirements meet specification/contract

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure hazard controls are in place and effective

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor work to installation specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take appropriate action on non-conformances as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report during project as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete end of project documentation on completion

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 repair specification

1.1

Check repair specification against agreed set of requirements for the repair

1.2

Identify discrepancies or conflicts in requirements

1.3

Confirm repair requirements and specifications

2

Design installation process

2.1

Determine refractory materials to be repaired

2.2

Determine refractory material to be used in making the repair

2.3

Determine repair installation/application requirements

2.4

Determine installation equipment requirements

2.5

Determine anchor/keying/adhesion requirements

2.6

Determine repair method

2.7

Determine post repair application requirements

2.8

Determine temporary support or shores required

2.9

Design formwork if required

2.10

Design scaffolding or other internal access needs if required

2.11

Design external access/egress means if required

2.12

Identify installation health, safety and environmental (HSE) hazards

2.13

Determine appropriate hazard controls

2.14

Check for discrepancies or conflicts in the designs and take appropriate action

3

Prepare for installation

3.1

Specify repair procedure

3.2

Liaise with relevant stakeholders

3.3

Modify specification if needed

3.4

Ensure correct ordering of requirements

3.5

Identify time critical items for the installation

3.6

Identify other items critical to the success of the project

3.7

Identify or develop measures to monitor all critical items

3.8

Prepare repair specification

4

Monitor installation

4.1

Ensure requirements meet specification/contract

4.2

Ensure hazard controls are in place and effective

4.3

Monitor work to installation specification

4.4

Take appropriate action on non-conformances as required

4.5

Report during project as required

4.6

Complete end of project documentation on completion

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Confirm repair specification

1.1

Check repair specification against agreed set of requirements for the repair

1.2

Identify discrepancies or conflicts in requirements

1.3

Confirm repair requirements and specifications

2

Design installation process

2.1

Determine refractory materials to be repaired

2.2

Determine refractory material to be used in making the repair

2.3

Determine repair installation/application requirements

2.4

Determine installation equipment requirements

2.5

Determine anchor/keying/adhesion requirements

2.6

Determine repair method

2.7

Determine post repair application requirements

2.8

Determine temporary support or shores required

2.9

Design formwork if required

2.10

Design scaffolding or other internal access needs if required

2.11

Design external access/egress means if required

2.12

Identify installation health, safety and environmental (HSE) hazards

2.13

Determine appropriate hazard controls

2.14

Check for discrepancies or conflicts in the designs and take appropriate action

3

Prepare for installation

3.1

Specify repair procedure

3.2

Liaise with relevant stakeholders

3.3

Modify specification if needed

3.4

Ensure correct ordering of requirements

3.5

Identify time critical items for the installation

3.6

Identify other items critical to the success of the project

3.7

Identify or develop measures to monitor all critical items

3.8

Prepare repair specification

4

Monitor installation

4.1

Ensure requirements meet specification/contract

4.2

Ensure hazard controls are in place and effective

4.3

Monitor work to installation specification

4.4

Take appropriate action on non-conformances as required

4.5

Report during project as required

4.6

Complete end of project documentation on completion

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, data

confirm repair specifications meet refractory requirements

determine refractory installation process to meet repair specifications

plan the repair installation project

develop repair specification, including:

technical specification

hazard controls and residual hazards

installation schedule

measures for monitoring critical items

monitor the installation conformance to specifications and take action on non-conformances

complete project documentation and reports

communicate technical information verbally and in writing/drawings

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

customer representatives

technical experts

regulators

management

refractory designer

refractory installer

materials and equipment suppliers

contractors

apply complex and/or theoretical mathematical calculations, statistics

solve complex problems within or arising from the repair design and/or installation.

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

common installation methods and ways of repairing them

common modes of refractory failure and their implications for repair

properties of all common refractory materials, including:

cementitious refractories

clay refractories

ceramic fibre

other refractories

application and principles of repair methods, including:

cold repair

hot repair

direct repair

controlled repair (e.g. through controlled gunning)

repair from inside the vessel

repair by injection through the vessel wall

application and limitations of anchors and anchoring systems, including:

anchor bolts

through anchors

retention clips

application and limitations of installation equipment, including:

compactors

rams

gunning systems

equipment for lifting and placing precast blocks

temporary support for roofs and arches

spreader jacks

application and limitations of post repair requirements for different refractory systems, including:

drying

curing

control of moisture and or temperature

striking of formwork

removal of scaffolding or other access/egress provisions

application and limitations of shores, including:

dead shores

raking shores

flying shores

formwork design and construction

scaffolding design and construction

calculations relevant to specifications

project planning and management

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 hazards

Identification of HSE hazards requires consideration of:

exposure to heat

exposure to dust

exposure to refractory materials

confined space entry

working with equipment

working at heights

ultra-violet (UV) and other welding hazards

disposal of waste, scrap and excess materials

manual handling hazards.