Inspect, test and maintain exhaust systems on diesel engine systems Evidence Guide

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Evidence Guide: RIIDES305 - Inspect, test and maintain exhaust systems on diesel engine systems

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

RIIDES305 - Inspect, test and maintain exhaust systems on diesel engine systems

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

Plan for inspection, testing and/or maintenance tasks

Access, interpret and apply compliance and other documentation relevant to the inspection, testing and maintenance of exhaust systems on diesel engine systems
Obtain, interpret and clarify work requirements for the satisfactory completion of tasks
Resolve coordination requirements with others at the site prior to commencing and during work activities

Access, interpret and apply compliance and other documentation relevant to the inspection, testing and maintenance of exhaust systems on diesel engine systems

Completed
Date:

Teacher:

Evidence:

Obtain, interpret and clarify work requirements for the satisfactory completion of tasks

Completed
Date:

Teacher:

Evidence:

Resolve coordination requirements with others at the site prior to commencing and during work activities

Completed
Date:

Teacher:

Evidence:

Prepare for inspection, testing and/or maintenance tasks

Inspect and prepare work area in coordination with others
Identify and obtain items and toolsrequired for the safe, effective and efficient conduct of the tasks.
Identify and arrange support required for completion of tasks
Select and usepersonal protection equipment appropriate to the task
Carry out required equipment pre-start procedures
Carry out required isolation and lock-out of all equipment necessary for the safe execution of tasks
Recognise and respond to hazardous and emergency situations

Inspect and prepare work area in coordination with others

Completed
Date:

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Evidence:

Identify and obtain items and toolsrequired for the safe, effective and efficient conduct of the tasks.

Completed
Date:

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Evidence:

Identify and arrange support required for completion of tasks

Completed
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Evidence:

Select and usepersonal protection equipment appropriate to the task

Completed
Date:

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Evidence:

Carry out required equipment pre-start procedures

Completed
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Evidence:

Carry out required isolation and lock-out of all equipment necessary for the safe execution of tasks

Completed
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Recognise and respond to hazardous and emergency situations

Completed
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Evidence:

Carry out inspection of exhaust systems

Carry out inspection of exhaust systems on diesel engine systems
Carry out inspection and fault finding of exhaust system flame traps for effectiveness of explosion protection
Carry out inspection and fault finding of exhaust gas cooling systems
Carry out inspection and fault finding of exhaust system joints
Diagnose and record existing or identified faults

Carry out inspection of exhaust systems on diesel engine systems

Completed
Date:

Teacher:

Evidence:

Carry out inspection and fault finding of exhaust system flame traps for effectiveness of explosion protection

Completed
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Evidence:

Carry out inspection and fault finding of exhaust gas cooling systems

Completed
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Evidence:

Carry out inspection and fault finding of exhaust system joints

Completed
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Evidence:

Diagnose and record existing or identified faults

Completed
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Evidence:

Carry out testing of exhaust systems

Select and operate testing equipment and methods in an appropriate, safe, effective and efficient manner
Carry out testing and fault finding of exhaust systems on diesel engine systems
Carry out testing of exhaust system flametraps for effectiveness of explosion and fire protection
Carry out leak testing of exhaust system joints for effectiveness of explosion and fire protection
Test and report on the performance of exhaust emission treatment devices
Identify and record existing or potential faults, including blockages and constrictions

Select and operate testing equipment and methods in an appropriate, safe, effective and efficient manner

Completed
Date:

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Evidence:

Carry out testing and fault finding of exhaust systems on diesel engine systems

Completed
Date:

Teacher:

Evidence:

Carry out testing of exhaust system flametraps for effectiveness of explosion and fire protection

Completed
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Evidence:

Carry out leak testing of exhaust system joints for effectiveness of explosion and fire protection

Completed
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Evidence:

Test and report on the performance of exhaust emission treatment devices

Completed
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Evidence:

Identify and record existing or potential faults, including blockages and constrictions

Completed
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Evidence:

Carry out routine maintenance of exhaust systems

Select and use maintenance items, tools and equipment
Rectify diagnosed and identified faults
Carry out routine maintenance of exhaust systems on diesel engine systems in accordance with the work requirements
Carry out routine maintenance of exhaust system flametraps for effectiveness of explosion protection
Carry out routine maintenance of exhaust system joints for effectiveness of explosion and fire protection

Select and use maintenance items, tools and equipment

Completed
Date:

Teacher:

Evidence:

Rectify diagnosed and identified faults

Completed
Date:

Teacher:

Evidence:

Carry out routine maintenance of exhaust systems on diesel engine systems in accordance with the work requirements

Completed
Date:

Teacher:

Evidence:

Carry out routine maintenance of exhaust system flametraps for effectiveness of explosion protection

Completed
Date:

Teacher:

Evidence:

Carry out routine maintenance of exhaust system joints for effectiveness of explosion and fire protection

Completed
Date:

Teacher:

Evidence:

Carry out the overhaul of exhaust systems

Select and use overhaul items, tools and equipment
Carry out overhaul of exhaust systems in accordance with the work requirements and Australian Standards

Select and use overhaul items, tools and equipment

Completed
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Evidence:

Carry out overhaul of exhaust systems in accordance with the work requirements and Australian Standards

Completed
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Evidence:

Complete post-work activity requirements

Tidy up the work area
Dispose of used oil, lubricant and other waste
Return and secure all tools and re-usable items
Report outcomes of inspection, testing, maintenance and overhaul tasks to appropriate person
Complete and maintain inspection, testing and maintenance records

Tidy up the work area

Completed
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Evidence:

Dispose of used oil, lubricant and other waste

Completed
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Evidence:

Return and secure all tools and re-usable items

Completed
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Evidence:

Report outcomes of inspection, testing, maintenance and overhaul tasks to appropriate person

Completed
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Evidence:

Complete and maintain inspection, testing and maintenance records

Completed
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Evidence:

Assessed

Teacher: ___________________________ Date: _

Signature: ________________________________________________

Comments:

Instructions to Assessors

Evidence Guide

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 worksite operations and satisfy all of the requirements of the performance criteria, required skills and knowledge and the range statement of this unit and include evidence of the following: knowledge of the requirements, procedures and instructions for the inspection, testing and maintenance of exhaust systems on diesel engine systems implementation of requirements, procedures and techniques for the safe, effective and efficient completion of the inspection, testing and maintenance of exhaust systems on diesel engine systems working with others to undertake and complete the inspection, testing and maintenance of exhaust systems on diesel engine systems that meets all of the required outcomes consistent timely completion of the inspection, testing and maintenance of exhaust systems on diesel engine systems that safely, effectively and efficiently meets the required outcomes
Context of and specific resources for assessment	This unit must be assessed in the context of the work environment. Where personal safety or environmental damage are limiting factors, assessment may occur in a simulated environment provided it is realistic and sufficiently rigorous to cover all aspects of workplace performance, including task skills, task management skills, contingency management skills and job role environment skills. The assessment environment should not disadvantage the participant. For example, language, literacy and numeracy demands of assessment should not be greater than those required on the job. Customisation of assessment and delivery environment to sensitively accommodate cultural diversity. Aboriginal people and other people from a non English speaking background may have second language issues. Assessment of this competency requires typical resources normally used in a resources and infrastructure sector environment. Selection and use of resources for particular worksites may differ due to the site circumstances. Where applicable, physical resources should include equipment modified for people with disabilities. Access must be provided to appropriate learning and/or assessment support when required.
Method of assessment	This unit may be assessed in a holistic way with other units of competency. The assessment strategy for this unit must verify required knowledge and skill and practical application using more than one of the following assessment methods: written and/or oral assessment of the candidate’s required knowledge observed, documented and/or first hand testimonial evidence of the candidate’s: implementation of appropriate requirement, procedures and techniques for the safe, effective and efficient achievement of required outcomes consistently achieving the required outcomes first hand testimonial evidence of the candidate: working with others to undertake and complete the inspection, testing and maintenance of exhaust systems on diesel engine systems
Guidance information for assessment	Consult the SkillsDMC User Guide for further information on assessment including access and equity issues.

Required Skills and Knowledge

Required skills

Specific skills are required to achieve the performance criteria in this unit, particularly for the application in the various circumstances in which this unit may be applied.

This includes the ability to carry out the following to safely, effectively and efficiently inspect, test and maintain exhaust systems on diesel engine systems:

apply legislative requirements and procedures

apply surface and underground worksite hazard identification and risk management requirements and procedures

apply task hazard identification and risk management requirements and procedures

apply hazard and emergency procedures

apply technical literacy

interpret and apply technical and scientific/industry terminology

identify health effects of emissions and nominate controls to minimise potential health effects

apply site health and safety requirements and procedures

apply site environmental requirements and procedures

apply site quality requirements and procedures

apply site communication requirements and procedures

apply manufacturer’s requirements and procedures

communicate with those providing support

apply work area and equipment inspection procedures

apply work area safeguarding options and requirements

apply isolation and lock-out requirements and procedures

apply site service and maintenance reporting requirements and procedures

apply inspection requirements and procedures

apply testing requirements and procedures

apply fault finding techniques

apply maintenance requirements and procedures

work wearing appropriate personal protective equipment

use tools for inspection, testing and maintenance

use calibrated/verified instruments

Required knowledge

Specific knowledge is required to achieve the Performance Criteria of this unit, particularly its application in a variety of circumstances in which the unit may be used.

This includes knowledge of the following to safely, effectively and efficiently inspect, test and maintain exhaust systems on diesel engine systems:

site risk, statutory compliance, health, safety, environmental, quality and communication requirements and procedures

site and manufacturer’s requirements and procedures

provisions of AS/NZS3584.1,2 and 3 relating to exhaust systems, fasteners, joints and flametraps

potential hazards in the use of diesel engine systems in underground coal mines, including:

explosions

fire, and

emissions

limitations on allowable maintenance, including:

service

adjust

replace

repair

overhaul

work in hazardous environments

limitations on allowable modifications and their required controls and procedures

methods to limit surface temperatures for;

exhaust manifold design and fitment

adaptor pipe

possible failure modes in maintenance procedures and practices required to provide controls (including, flametraps, cooling systems, treatment systems, filtration)

the heat energy generating characteristics of forced induction systems and the control measures provided to manage surface temperatures, including; maintenance, testing and monitoring

causes of the degradation of heat exchanger performance;

function and performance criteria and protection employed in exhaust, including;

cooling

flametrap

spark arrestor

emissions reduction

fire-protection

explosion protection

types of flametraps permitted by the relevant Standard, including;

water-based flametraps

positive flametraps

properties and functional characteristics of exhaust flametraps, including;

positive flametraps

water-based flametraps

failure modes and inherent risks and hazards for each type of exhaust flametrap

operational and installation requirements for heat exchangers when installed in conjunction with positive flametraps

maintenance processes and procedures required to ensure ongoing safe operation

importance of the application of appropriate components and fasteners, including the selection of appropriate bolts, studs, threads and washers to specific applications within a diesel engine system including the provisions of AS/NZS3584.3 relating to fasteners

the types of joints that may be integral to the design and maintenance of a diesel engine system, including;

fixed connection

open joints

the factors that determine the selection of joint types

the requirements for interposed gaskets and seals in joints, including;

materials

dimensions

form and shape

items required to be used in performance of inspection, testing and maintenance tasks

tools required for the performance of inspection, testing and maintenance tasks

provisions of AS/NZS3584.1, 2 and 3 relating to fasteners and joints

recognise the requirements and performance of various types of fasteners, including bolts, studs, threads and washers

site inspection, testing and maintenance support requirements and availability

site work area inspection requirements

site work area safeguarding options and requirements

site isolation and lock-out requirements and procedures

site hazard and emergency procedures

site inspection, testing and maintenance reporting requirements and procedures

site inspection, testing and maintenance record procedures

site requirements and procedures for working in isolation

site requirements for the use of personal protective equipment

Range Statement

Compliance and other documentation may include:	certification documentation approval documentation legislative, organisation and site requirements and procedures manufacturer’s specifications and guidelines Australian Standards, including: AS/NZS3584 and AS 4291 codes of practice Employment and Workplace Relations legislation Equal Employment Opportunity and Disability Discrimination legislation
Inspection may include:	checking the marking of parts/components determine that there is no evidence of carbon build-up on or heating of joints that may suggest a leakage of exhaust gas check that the positive exhaust flametrap and exhaust gas cooling system is clean check that the floats used for the low water shutdown in the exhaust system conditioner/flame trap/spark arrester are free, clean, unobstructed and correctly installed check that the static water level on any water-based exhaust system conditioner/flame trap/spark arrester is at or above the level indicated checking materials and gaskets/seals the conformity of threads and fasteners to registration and/or certification drawings
Testing may include:	conduct exhaust conditioner/ flametrap, low-water, shutdown tests (i.e. both low water test systems are tested separately) check that the engine system shuts down at or higher than the minimum shutdown water level and record the water levels after shut-down. conduct gas tightness tests for all joints within the exhaust system Note: A soapy water test may meet this requirement measurement of joints for dimensional compliance, surface finish, flatness
Maintenance is:	the combination of actions carried out to retain a diesel engine system in, or to restore it to, conditions in which it is able to meet the requirements of the relevant specification and perform its required function
Maintenance may include authorised:	service adjusting replacing repair overhaul modification
Exhaust systems may include:	exhaust manifolds turbo-chargers or superchargers pipe work hoses joints fastenings exhaust flametraps, which may include: positive flametraps, (with temperature sensors) water-based flametraps, (with water level sensors and test valves) spark arrestor exhaust cooling system, which may include: water bath air dilution heat exchanger water Injection monitoring or shutdown devices surface temperature control systems catalytic converters, including DOCs and SCRs fume diluters and forced-air systems particulate filters replacement element-type filters exhaust gas recirculation
Diesel engine systems are:	diesel engines for underground coal mines and their: inlet systems exhaust systems cooling systems starting systems shut-down and protection systems electrical or electronic devices
Work requirements may come from briefings, handovers, and work orders and may include:	nature and scope of tasks procedures to be applied quality standards to be applied available resources achievement targets operational conditions site layout out-of-bounds areas designated safe areas explosion-risk zones hazardous areas other hazards and potential hazards obtaining permits required worksite inspection requirements lighting conditions plant or equipment defects coordination requirements or issues
Others may include:	other maintenance personnel support providers contractors underground production personnel mobile or fixed plant operators
Inspect and prepare work area may include:	determining if the proposed work area is a designated safe area identification of explosion-risk zones identification of hazardous areas identification of hazards, including: workshop work area hazard underground work area hazards work activity hazards fire explosion emissions selection and implementation of control measures for the hazards identified safeguarding site and non-site personnel by: erection of barricades and posting of signs selection of appropriate equipment to ensure personnel safety and protection
Items may include:	authorised replacement parts fasteners as specified in manufacturer’s drawings, which may include: tensile strength head and nut configuration thread form and engagement corrosion resistance (materials) coatings (materials and application) tolerances for fits and threads tolerances for mating surfaces dimensions of clearance holes fixing torques lubricants and anti-seize compounds used packing materials
Tools may include:	hand tools power tools special tools testing equipment
Support may include:	other site personnel contractors cranes other lifting equipment
Personal protection equipment may include:	hard hats eye protection hearing protection breathing apparatus gas/fume masks prescribed footwear
Pre-start procedures include:	checking: cleanliness, particularly coal dust diesel and other flammable liquid leaks coolant leaks in radiator or radiator hoses coolant level that guards are in place and secure engine oil level is correct conduct exhaust conditioner/flametrap, low-water, shutdown tests
Hazardous and emergency situations may include:	working alone personal injury fire explosions emissions electrical noise dust noxious gases environmental chemical
Diagnose faults may include:	root cause analysis troubleshooting techniques
Routine maintenance is to include:	servicing, including: cleaning, including the gas path of any exhaust system conditioner flametrap and/or spark arrestor checking and filling lubricants, fuel and water adjusting replacing
Overhaul may include:	removal dismantling cleaning inspecting replacing, eg: gaskets fasteners testing, including: flatness measuring dimensions hydrostatic reassembly reinstallation, (e.g. cleaned or new exhaust positive flametrap assembly)
Records may include:	inspection and test results defect identified defect rectification carried out item consumed hazard/risk management reports

NTISthis.com

Evidence Guide: RIIDES305 - Inspect, test and maintain exhaust systems on diesel engine systems

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

RIIDES305 - Inspect, test and maintain exhaust systems on diesel engine systems

Plan for inspection, testing and/or maintenance tasks

Prepare for inspection, testing and/or maintenance tasks

Carry out inspection of exhaust systems

Carry out testing of exhaust systems

Carry out routine maintenance of exhaust systems

Carry out the overhaul of exhaust systems

Complete post-work activity requirements

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

Instructions to Assessors

Teacher: ___________________________ Date: _