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Evidence Guide: RIIDES306 - Inspect, test and maintain safety shutdown 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

 

RIIDES306 - Inspect, test and maintain safety shutdown 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

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

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

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Identify and arrange support required for completion of tasks

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Select and usepersonal protection equipmentappropriate to the task

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out required equipment pre-start and inspection procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Recognise and respond to hazardous and emergency situations

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out inspection of safety shutdown systems

  1. Carry out inspection of engine safety shutdown systems (fuel shutdown systems)
  2. Carry out inspection of emergency safety shutdown systems
  3. Carry out inspection of manual fuel shut-off valves
  4. Carry out inspection of safety shutdown systems sensing devices
  5. Carry out inspection of hoses, tubes cables and connectors associated with safety shutdown systems
  6. Diagnose and record existing or identified faults
Carry out inspection of engine safety shutdown systems (fuel shutdown systems)

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out inspection of emergency safety shutdown systems

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out inspection of manual fuel shut-off valves

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out inspection of safety shutdown systems sensing devices

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out inspection of hoses, tubes cables and connectors associated with safety shutdown systems

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Diagnose and record existing or identified faults

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out testing of safety shutdown systems

  1. Select and operate testing equipment and methods
  2. Carry out testing and fault finding of engine safety shutdown systems (fuel shutdown systems)
  3. Carry out testing and fault finding of emergency safety shutdown systems
  4. Carry out testing and fault finding of manual fuel shut-off valves
  5. Carry out testing and fault finding of safety shutdown systems sensing devices
  6. Diagnose, record and rectify existing identified faults
Select and operate testing equipment and methods

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out testing and fault finding of engine safety shutdown systems (fuel shutdown systems)

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out testing and fault finding of emergency safety shutdown systems

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out testing and fault finding of manual fuel shut-off valves

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out testing and fault finding of safety shutdown systems sensing devices

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Diagnose, record and rectify existing identified faults

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out routine maintenance of safety shutdown systems

  1. Select and use maintenance items, tools and equipment
  2. Rectify diagnosed and identified faults
  3. Carry out routine maintenance of engine safety shutdown systems (fuel shutdown systems)
  4. Carry out routine maintenance of emergency safety shutdown systems
  5. Carry out routine maintenance of manual fuel shut-off valves
  6. Carry out routine maintenance of safety shutdown systems sensing devices
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 engine safety shutdown systems (fuel shutdown systems)

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out routine maintenance of emergency safety shutdown systems

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out routine maintenance of manual fuel shut-off valves

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out routine maintenance of safety shutdown systems sensing devices

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out the overhaul of safety shutdown systems

  1. Select and use overhaul items, tools and equipment
  2. Carry out overhaul of safety shutdown systems in accordance with work requirements and Australian Standards
Select and use overhaul items, tools and equipment

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Carry out overhaul of safety shutdown systems in accordance with work requirements and Australian Standards

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Complete post-work activity requirements

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

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Dispose of used oil, lubricant and other waste

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Return and secure all tools and re-usable items

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Complete and maintain inspection, testing and maintenance records

Completed
Date:

Teacher:
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 safety shutdown 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 safety shutdown systems on diesel engine systems

working with others to undertake and complete the inspection, testing and maintenance of safety shutdown systems on diesel engine systems that meets all of the required outcomes

consistent timely completion of the inspection, testing and maintenance of safety shutdown 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 safety shutdown 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 as required to safely, effectively and efficiently inspect, test and maintain safety shutdown systems on diesel engine systems:

apply legislative, organisation and site 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 site health and safety requirements and procedures

apply site environmental requirements and procedures

apply site quality requirements and procedures

read, explain and apply:

technical information including scheduled drawings

site/legislative requirements

records and reports

apply registration/certification information and implement conditions and recommendations

apply feedback procedures

apply technical and routine reporting requirements and procedures

apply investigation procedures

apply technical literacy, including reading and interpreting fluidic and logic schematic drawings

interpret and apply technical and scientific/industry terminology

analyse the function of the devices within an integrated system

operate manual fuel shutoff valve

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, as required to safely, effectively and efficiently inspect, test and maintain safety shutdown 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

legislative requirements and procedures

site and legislative safety inspection requirements

provisions of relevant Standards and guidelines

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

engine system shut-down devices required by AS/NZS3584.1&2

water-bath level monitoring devices, including the methods employed to determine minimum safe shut-down levels and the testing methods and procedures required to confirm compliance

functionality and performance of the various type of ‘automatic safety shutdown systems, including;

pneumatically operated

engine oil (pressure) operated

a mix of pneumatic and engine oil (pressure) operated

electrically or electronically operated

failure modes of safety shutdown systems, including

contamination

incorrect adjustment

unauthorised adjustment

testing procedures required to detect failures

recommended maintenance procedures required to reduce the probability of failures

features, function and performance of electrical / electronic safety shutdown system and sufficient knowledge of the Group I explosion protection techniques used for devices to identify a component failure by inspection (only) and to seek expert competent advice, such as;

Ex.d – flameproof

Ex.i a-b – intrinsic safety

Ex.m a-b – dncapsulation

Ex.e - increased safety

Ex.o - oil immersion

Ex.s - special protection

requirements for cables and connections used for electrical / electronic safety shutdown system, including those nominated in AS/NZS4871.6

features, function, performance of the various type of ‘emergency stop systems, including;

strangler valves in the air intake system

inert gas injection

decompression

operation of the manual fuel shut off valve

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 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

inspecting the fuel shutdown linkages to ensure they are in good condition and fully operative

Testing may include:

conducting exhaust conditioner/flametrap, low-water, shutdown tests (both low water test systems are tested separately)

checking that all gauges and indicators are operating correctly and are clearly visible

checking the proper operation and function of;

low oil engine pressure detection sensor

coolant loss protection sensor

coolant over temperature protection sensor

confirming that the manual fuel valve operates correctly to stop the diesel within the time determined by the original type testing including a reasonable margin

test that the air receiver safety (pressure relief) valves are in place, not blocked/seized and operating correctly

checking the engine system shuts down at, or higher than, the minimum shutdown water level, (record the water levels after shut-down)

testing the emergency safety shutdown system to ensure that the engine stops under the operation of the emergency safety shutdown system working in isolation of other engine safety shutdown systems, record the time taken for the engine to stop with the engine running at high idle, (Note: The diesel engine system manufacturer may provide test instructions to minimise the risk of engine damage during testing (see AS/NZS3584.2)

checking the proper operation and function of the low oil engine pressure detection sensor, and recording the engine oil pressure at the time of shutdown

checking the proper operation and function of the coolant loss detection sensor, and recording the time taken to cause the engine to shut down

checking the proper operation and function of the coolant over-temperature sensor, and recoring the coolant temperature at which the engine shut down, (Note: Testing this sensor by defeating other sensors and overheating the diesel engine system may be hazardous or cause damage to the diesel engine system. It is recommended that the sensor be removed from the engine and tested in heated water while remaining connected to the engine shutdown system)

checking the proper operation and function of the exhaust gas over-temperature sensor, and recording the exhaust temperature at which the engine shut down

confirming that all of the engine shutdown system fault indicators properly indicate each of the faults simulated in the foregoing tests

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

Safety shutdown systems may include:

engine safety shutdown system (fuel shutdown system), including:

manual actuation system

fault indication system

emergency safety shutdown system, may be:

a strangler valve

inert gas injection

decompression

manually actuated

automatically operated

manual fuel shut-off valve

sensing devices, including:

engine cooling system

engine oil pressure

water-based flametraps

exhaust cooling

particulate filter

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

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, and

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

Others may include:

other maintenance personnel

support providers

contractors

underground production personnel

mobile or fixed plant operators

Items may include:

authorised replacement parts

fasteners as specified in manufacturer’s drawings

packing materials

Tools may include:

hand tools

power tools

special tools

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 and inspection procedures include:

checking:

cleanliness, particularly coal dust

diesel and other flammable liquid leaks

coolant leaks in radiator or radiator hoses

coolant level

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

adjusting

replacing

Overhaul may include:

removal

dismantling

cleaning

inspecting

replacing, eg:

valves sensors exhaust gas recirculation

particulate filters

replacement element-type filter testing, including:

individual devices system operation and function reassembly

reinstallation

Records may include:

inspection and test results

defect identified

defect rectification carried out

item consumed

hazard/risk management reports