Modification History
Not applicable.
Unit Descriptor
Unit descriptor
This competency covers the butt welding of polyethylene (PE) plastic pipes and pipeline components under industrial conditions both in the field and in factory conditions.
This competency is performed by operators as part of a work team.
Application of the Unit
Application of this unit
This competency applies to operators who are involved in the butt welding of polyethylene (PE) pipes and pipeline components to required quality assurance demands whilst maintaining personal and immediate site safety. The key features in attaining the required quality are:
- identifying materials being used in the installation as compatible for welding
- calculating appropriate welding parameters to be used
- maintaining and calibrating welding equipment
- performing welding
- assessing quality of welded joints made.
End applications include pipelines for transmitting gas and liquids.
Licensing/Regulatory Information
Not applicable.
Pre-Requisites
Prerequisites
This unit has no prerequisites.
Employability Skills Information
Employability Skills
This unit contains employability skills.
Elements and Performance Criteria Pre-Content
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ELEMENT Elements describe the essential outcomes of a unit of competency |
PERFORMANCE CRITERIA Performance criteria describe the required performance needed to demonstrate achievement of the element. Assessment of performance is to be consistent with the evidence guide. |
Elements and Performance Criteria
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ELEMENT ELEMENT |
PERFORMANCE CRITERIA Performance criteria describe the required performance needed to demonstrate achievement of the element. Assessment of performance is to be consistent with the evidence guide. |
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1. Identify materials as being compatible for welding. |
1.1 Identify materials as polyethylene (PE) from specifications and work site instructions. 1.2 Identify PE materials and pipes supplied as being compatible for welding from specifications. |
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2. Calculate appropriate pipe welding parameters. |
2.1 Identify welding machine type and operating data. 2.2 Identify pipe materials and dimensions. 2.3 Perform welding parameter calculations for individual welding machines and pipe details. 2.4 Prepare field operational sheets as per enterprise requirements. |
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3. Maintain and calibrate welding equipment. |
3.1 Set up welding equipment and work area. 3.2 Ensure safety equipment is available and operational. 3.3 Identify non-conformance, report and rectify. 3.4 Check operation and calibrate where required, heating, trimming, and pressure systems. |
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4. Perform welding to required standard. |
4.1 Assemble pipeline components in welding machine. 4.2 Clean, align and trim pipe ends. 4.3 Perform heating, welding, and cooling phases using calculated welding parameters. 4.4 Monitor and record achieved weld parameters for each joint as per enterprise requirement. 4.5 Clean up equipment when completed as per enterprise procedures. 4.6 Clean up work site, dispose of scrap materials as per enterprise procedures. 4.7 Use personal protective equipment as per enterprise requirements. |
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5. Assess quality of completed joints. |
5.1 Identify quality requirements for joints 5.2 Assess joints against specification requirements, and report results 5.3 Identify and report non-conformances as per enterprise requirements. |
Required Skills and Knowledge
This describes the essential skills and knowledge and their level required for this unit.
Knowledge and understanding of PE materials and pipeline components as described in national standards to recognise welding compatibility and suitability.
Knowledge of detailed work instructions necessary to perform butt welding, and the ability to implement within required parameters to attain required quality outcomes.
Competence includes the ability to:
- identify materials being used
- calculate welding parameters for individual machines and pipeline components
- maintain and adjust operating conditions in welding machine
- set up and maintain safe working environment
- operate welding machine within required parameters
- assess quality of completed joints
- identify and rectify fault causes arising from machine operation and component variables
- establish and maintain quality records.
Language , literacy and numeracy requirements
Read material which is sequenced for instructions, explanations, information or opinions.
Write short and simple messages about routine tasks or activities, or complete forms.
Use hands-on real-life materials and pictures/diagrams based on personal experience and prior knowledge.
Use several pieces of related mathematical information.
Read, write and speak whole numbers and money sums, recognise and interpret simple fractions, decimals and percentages, use simple data, grid references.
Use simple grammatical forms and vocabulary to give instructions, give explanations, ask questions and express viewpoints.
Clarify intended meaning by asking for repetition when listening, and varying speed and changing tone or emphasis when speaking.
Use strategies such as providing verbal and non-verbal feedback in order to show interest or attitude.
Evidence Guide
The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, the range statement and the assessment guidelines for this training package.
Overview of assessment
A holistic approach should be taken to the assessment.
Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
It is essential that the weld quality meets the requirements of the standard. This may require testing of the weld in accordance with the standard.
Assessment method and context
Assessment will occur using industrial plastic pipes and welding equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
- using appropriate, industrial equipment, situations and polymers
- in a situation allowing for the generation of evidence of the ability to recognise, anticipate and respond to problems
- by using a suitable simulation and/or a range of case studies/scenarios
- through a combination of these techniques.
In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment. Assessors need to be aware of any cultural issues that may affect responses to questions.
Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.
Specific resources for assessment
This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.
Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.
Range Statement
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. Add any 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.
Where reference is made to industry codes of practice and/or Australian/international standards, the latest version must be used.
Context
This competency unit includes the butt welding of polyethylene (PE) pipeline components using hydraulic activated welding machines. The end applications include pipelines used for transmission of gaseous and water based fluids.
It also includes the operation of all relevant ancillary equipment.
Specifications include national standards for materials (including but not limited to AS/NZS 4130, AS/NZS 4131, AS/NZS 4401 and AS/NZS 5065), workplace specifications and instructions, and government codes and regulations.
Procedures
All operations are performed in accordance with procedures.
Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.
Tools and equipment
This competency includes use of equipment and tools such as:
- hydraulic activated butt welding machines, and pipe supports
- measurement devices, including pressure gauges, timers, temperature probes, callipers and computer-based pressure/temperature monitors
- cleaning fluids and spray equipment
- calculators
- relevant safety equipment
- comprehensive work instructions.
Hazards
Typical hazards include:
- hazardous cleaning fluids
- pipe material handling
- heavy stationary and moving machinery
- cutting and heating components.
Problems
'Anticipate and solve problems' means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.
Typical process and product problems may include:
- variable PE materials, and pipes as supplied
- equipment malfunction or wear and tear
- variable field site conditions.
Unit Sector(s)
Not applicable.
