Unit of competency details

Elements describe the essential outcomes of a unit of competency.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide.

1. Plan for inspection, testing and/or maintenance tasks

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

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

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

2. Prepare for inspection, testing and/or maintenance tasks

2.1 Inspect and prepare work area  in coordination with others 

2.2 Identify and obtain items  and  tools required for the safe, effective and efficient conduct of the tasks.

2.3 Identify and arrange support  required for completion of tasks

2.4 Select and usepersonal protection equipment appropriate to the task

2.5 Carry out required equipment pre-start procedures 

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

2.7 Recognise and respond to hazardous and emergency situations 

3. Carry out inspection of inlet systems

3.1 Carry out inspection of inlet systems on diesel engine systems

3.2 Carry out the inspection of inlet system flame traps for effectiveness of explosion protection

3.3 Carry out the inspection of inlet system joints for effectiveness of explosion and fire protection

3.4 Diagnose  and record existing or identified faults, including blockages and constrictions

4. Carry out testing of inlet systems

4.1 Select and operate testing equipment and methods

4.2 Carry out testing and fault finding of inlet systems on diesel engine systems

4.3 Carry out testing and fault finding of inlet system flame traps to ensure effectiveness of explosion protection

4.4 Carry out leak testing and fault finding of inlet system joints to ensure effectiveness of explosion and fire protection

4.5 Carry out testing of the operation of any forced induction systems  to confirm their correct operation

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

5. Carry out routine maintenance of inlet systems

5.1 Select and use maintenance items, tools and equipment

5.2 Rectify diagnosed and identified faults

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

5.4 Carry out routine maintenance of inlet system flame traps to ensure effectiveness of explosion protection

5.5 Carry out routine maintenance of inlet system joints to ensure effectiveness of explosion and fire protection

6. Carry out the overhaul of inlet systems

6.1 Select and use overhaul items, tools and equipment

6.2 Carry out overhaul  of inlet systems on diesel engine systems in accordance with work requirements and Australian Standards

7. Complete post-work activity requirements

7.1 Tidy up the work area

7.2 Dispose of used oil, lubricant and other waste

7.3 Return and secure all tools and re-usable items

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

7.5 Complete and maintain inspection, testing and maintenance records 

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 inlet 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 technical literacy
• interpret and apply technical and scientific/industry terminology
• 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
• 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
• select appropriate bolts, studs, threads and washers to specific applications within a diesel engine system
• use tools
• 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 inlet systems on diesel engine systems:

• site risk, statutory compliance, health, safety, environmental, quality, (including quality information), and communication requirements and procedures
• use of site & manufacturer’s requirements and procedures
• provisions of AS/NZS3584.2 and 3 relating to inlet systems flametraps (for explosion protected diesel engine systems)
• the failure modes of the inlet system that may affect the explosion protection characteristics and the emissions from diesel engine systems
• potential hazards in the use of diesel engine systems including:
• explosions
• fire, and
• emissions
• the relative performance (including emissions) of increased air induction systems
• systems for the reduction of the harmful emissions from diesel engines
• functions of the management and treatment systems and principles employed to limit the creation of and to manage harmful emissions from diesel engines
• the function, performance criteria and protection employed in inlet (induction) systems, including;
• function
• features, including;
• fire-protection
• explosion protection
• emergency stop
• fitment (including location)
• induction boosted considerations, including:
• temperature considerations
• the effect on emissions
• the effect on performance
• the effect of induction cooling (after cooling)
• inlet filters
• the features and the requirements for maintenance of the inlet manifold, including;
• function,
• features, and
• fitment (including the requirements for gaskets and seals)
• requirements and test requirements for inlet flametraps and the issues related to;
• fitting assemblies into housings
• maintenance (including cleaning)
• routine inspection
• types of flametraps permitted and the performance features of each type
• the types of joints that may be integral to the design and maintenance of a diesel engine system, including;
• fixed connection
• open joints
• the requirements for interposed gaskets and seals in joints, including
• materials
• dimensions
• form and shape
• limitations on allowable maintenance, including:
• service
• adjust
• replace
• repair
• overhaul
• work in hazardous environments
• limitations on allowable modifications and their required controls and procedures
• 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

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 inlet 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 inlet systems on diesel engine systems
• working with others to undertake and complete the inspection, testing and maintenance of inlet systems on diesel engine systems that meets all of the required outcomes
• consistent timely completion of the inspection, testing and maintenance of inlet 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 inlet systems on diesel engine systems

Guidance information for assessment

• Consult the SkillsDMC User Guide for further information on assessment including access and equity issues.

Compliance and other documentation may include:: 

• certification documents
• registration documents
• legislative, organisation and site requirements and procedures
• manufacturer’s specifications, drawings, instructions 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
• determining the air filter element is clean
• inspecting the inlet flametrap for cleanliness damage or deterioration (clean or replace as required)
• checking materials and gaskets/seals
• the conformity of threads and fasteners to registration and/or certification drawings

Testing may include: 

• testing inlet flametrap for cleanliness damage or deterioration
• conducting gas tightness tests for all joints within the inlet system
• 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

Inlet systems may be referred to as induction systems and may be: 

• naturally aspirated
• induction boosted:
• turbo-charged
• super-charged

Inlet systems include: 

• air filtration
• inlet flametrap
• inlet manifold
• pipe-work and hoses
• joints

Inlet systems may include: 

• turbo-charger, or
• super-charger, and
• strangler valve
• gas systems
• intercoolers or after coolers

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
• under-ground 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

Fault  diagnosis may include:

• root cause analysis
• troubleshooting techniques

Forced induction systems  may include:

• super-charging
• turbo-charging

Routine maintenance  is to include:

• servicing, including:
• cleaning, including:
• emptying air intake pre-cleaner
• cleaning air filter elements
• cleaning air intake flametraps
• checking and filling lubricants, fuel and water
• adjusting
• replacing, including:
• air intake pre-cleaner
• air filter elements
• cleaned or new air intake flametraps

Overhaul  may include:

• removal
• dismantling
• cleaning
• inspecting
• replacing, eg:
• gaskets
• fasteners
• testing, including:
• flatness
• measuring dimensions
• hydrostatic
• reassembly
• reinstallation

Records  may include:

• inspection and test results
• defect identified
• defect rectification carried out
• item consumed
• hazard/risk management reports