Modification History
New unit - Release 1
Unit Descriptor
This unit of competency covers the skills and knowledge needed to break and make flanged joints using hand tools. It also includes solving problems with flanged pipe jointing processes and equipment.
Application of the Unit
This unit applies to an operator who has a responsibility for breaking and making flanged joints (e.g. for isolation purposes) in accordance with a site’s flange management procedures. The operator would further:
- ensure they were working within their skill level
- ensure the nature of the intervention was clearly understood before work commenced
- make certain the site was accessible and safe and that all necessary authorities had been obtained
- monitor the progress of the work and refer any escalation
- recommission the flange joint after the work and inspection is completed.
This unit applies to an individual working alone or as part of a team or group and working in liaison with other shift team members and the control room operator as appropriate.
It may be appropriate to access other units with this unit, such as:
- PMASUP244A Prepare and isolate plant.
ASME PCC-1-2010 Guidelines for Pressure Boundary Bolted Flange Joint Assembly provides technical information and guidance relevant to this unit.
This unit does not cover the use of hydraulic torqueing and power tools.
Licensing/Regulatory Information
Not applicable.
Pre-Requisites
Not applicable.
Employability Skills Information
This unit contains employability skills.
Elements and Performance Criteria Pre-Content
Elements describe the essential outcomes of a unit of competency. |
Performance criteria describe the performance needed to demonstrate achievement of the element. Assessment of performance is to be consistent with the evidence guide. |
Elements and Performance Criteria
1 |
Plan and prepare for job |
1.1 |
Identify work requirements |
1.2 |
Inspect job site |
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1.3 |
Confirm isolations have been completed to standard |
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1.4 |
Confirm hazard controls |
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1.5 |
Coordinate with appropriate personnel |
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1.6 |
Select appropriate tools |
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1.7 |
Check calibration and certification of tools as required |
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1.8 |
Re-check that work requirements fit within skill level |
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1.9 |
Complete checklists and records as required |
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 |
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2.3 |
Connect any required drain lines |
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2.4 |
Undo nuts in accordance with procedures |
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2.5 |
Split flange and drain pipe as required |
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2.6 |
Identify any skills escalation required |
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2.7 |
Manage open pipe |
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2.8 |
Complete checklists and records as required |
3 |
Inspect flange and components |
3.1 |
Inspect removed gasket |
3.2 |
Assess cold pull and refer if required |
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3.3 |
Assess degree of misalignment and refer if required |
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3.4 |
Clean and inspect flange surface both front and back |
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3.5 |
Check studs and nuts |
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3.6 |
Confirm compliance of components and refer as required |
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3.7 |
Identify any problems and take appropriate action |
4 |
Make flange joint in accordance with flange management procedure |
4.1 |
Select appropriate gasket |
4.2 |
Check all components are to specification |
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4.3 |
Apply lubricant as required |
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4.4 |
Complete initial assembly of joint |
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4.5 |
Insert blind as required |
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4.6 |
Attach drain if required |
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4.7 |
Re-check the gasket |
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4.8 |
Re-check alignment |
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4.9 |
Tighten using appropriate hand tools to procedure |
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4.10 |
Use torque calibration charts as required |
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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 |
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5.3 |
Confirm joint integrity as required |
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5.4 |
Complete checklists and records as required |
Required Skills and Knowledge
This section describes the skills and knowledge required for this unit. |
Required skills |
Required skills include:
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Required knowledge |
Required knowledge of flange jointing principles and typical problems to a level needed to break and make flanged joints using hand tools, includes:
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Evidence Guide
The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package. |
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Critical aspects for assessment and evidence required to demonstrate competency in this unit |
Critical aspects for assessment and evidence include:
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Context of and specific resources for assessment |
Assessment of this competency will occur over a range of situations which will include typical disruptions to normal, smooth operation. This will require access to a plant over a period of time, or a suitable method of gathering evidence of operating ability. Where safety, lack of opportunity or significant cost is an issue, an industry-based simulation may be employed to assist the process. |
Guidance information for assessment |
Assessment processes and techniques must be appropriate to the language, competency and safety requirements of the site and consistent with workplace systems or procedures. |
Range Statement
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included. |
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Context |
This competency includes breaking and making flange joints using hand tools. It does not include the use of:
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Work requirements |
Work requirements may include but are not limited to:
Work requirements may come from briefings, handovers, and work orders and may include:
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Job site |
Inspecting job site may include but is not limited to identifying:
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Control hazards |
Control hazards may include but is not limited to:
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Implement hazard controls |
Implementing hazard controls may include but is not limited to:
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Manage open pipe |
Manage open pipe includes:
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Inspect components |
Inspecting flange components may include but is not limited to:
Refer to appendices of ASME PCC-1-2010 Guidelines for Pressure Boundary Bolted Flange Joint Assembly for technical details |
Components |
Components may include but are not limited to:
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Check studs and nuts |
Checking studs and nuts may include but is not limited to checking:
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Initial assembly of joint |
Initial assembly of joint may include but is not limited to:
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Blinds |
Blinds may include but are not limited to:
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Refer |
Refer means to refer the issue to the person with the required skills, knowledge and/or authority to deal with the matter |
Procedures |
Procedures may be written, verbal, computer-based or in some other form. They may include but are not limited to:
Procedures would be expected to comply with any relevant government regulations. |
Checklists and records |
Checklists and records may include:
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Appropriate action |
Appropriate action includes but is not limited to:
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Typical problems |
Typical problems may include but are not limited to:
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Remedial actions |
Remedial actions may include but are not limited to:
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Health, safety and environment (HSE) |
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 HSE requirements, the HSE requirements take precedence. |
Unit Sector(s)
Competency field |
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Unit sector |
Support |
Custom Content Section
Not applicable.