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Elements and Performance Criteria

1. Identify materials as being compatible for welding
   • Identify materials as polyethylene (PE) from specifications and work site instructions
   • Identify PE materials and pipes supplied as being compatible for welding from specifications
2. Calculate appropriate pipe welding parameters
   • Identify welding machine type and operating data
   • Identify pipe materials and dimensions
   • Perform welding parameter calculations for individual welding machines and pipe details
   • Prepare field operational sheets as per enterprise requirements
3. Maintain and calibrate welding equipment
   • Set up welding equipment and work area
   • Ensure safety equipment is available and operational
   • Identify non-conformance, report and rectify
   • Check operation and calibrate where required, heating, trimming, and pressure systems
4. Perform welding to required standard
   • Assemble pipeline components in welding machine
   • Clean, align and trim pipe ends
   • Perform heating, welding, and cooling phases using calculated welding parameters
   • Monitor and record achieved weld parameters for each joint according to enterprise requirements
   • Clean up equipment when completed according to enterprise procedures
   • Clean up work site, dispose of scrap materials according to enterprise procedures
   • Use personal protective equipment (PPE) according to enterprise requirements
5. Assess quality of completed joints
   • Identify quality requirements for joints
   • Assess joints against specification requirements, and report results
   • Identify and report non-conformances according to enterprise requirements

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Regulatory framework	The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used. Applicable legislation, regulations, standards and codes of practice include: health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, manual handling and hazardous materials Australian/international standards relevant to the materials being used and products being made, including one or more of: AS/NZS 4130:2009 Polyethylene (PE) pipes for pressure applications, or its replacement AS/NZS 4131:2010 Polyethylene (PE) compounds for pressure pipes and fittings, or its replacement AS/NZS 4401:2006 Plastics piping systems for soil and waste discharge (low and high temperature) inside buildings - Polyethylene (PE), or its replacement AS/NZS 5065:2005 Polyethylene and polypropylene pipes and fittings for drainage and sewerage applications, or its replacement ISO 21307:2011 Plastics pipes and fittings -- Butt fusion jointing procedures for polyethylene (PE) pipes and fittings used in the construction of gas and water distribution systems or its replacement any relevant licence and certification requirements. 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 such requirements the legislative requirements take precedence.
Procedures	All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of: emergency procedures work instructions standard operating procedures (SOPs) safe work method statements (SWMS) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant.
Tools and equipment	Tools and equipment include: hydraulic activated butt welding machines pipe supports measurement devices, including one or more of: pressure gauges timers temperature probes callipers computer-based pressure/temperature monitors cleaning equipment spray equipment. Additional tools and equipment will be selected as required from: hand tools used in this process hoists/lifting equipment not requiring any special permits or licences manual handling, aids such as hand carts and trolleys relevant PPE.
Hazards	Hazards must be identified and controlled. Identifying hazards requires consideration of: power tools, leads and power supplies hazardous products and materials cutting equipment sharp edges, swarf and scrap protrusions or obstructions slippery surfaces, spills or leaks rotational equipment or vibration smoke, dust, vapours or other atmospheric hazards high temperatures electricity gas gases and liquids under pressure structural hazards equipment failures machinery, equipment and product mass other hazards that might arise.
Problems	Routine and non-routine problems must be resolved. Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to: determine problems needing action determine possible fault causes develop solutions to problems which do not have a known solution follow through items initiated until final resolution has occurred report problems outside area of responsibility to designated person. Non-routine problems are unexpected problems or variations of previous problems and include one or more of: variations in quality emergency situations intermittent faults. Operational knowledge includes one or more of: procedures training technical information, such as journals and engineering specifications remembered experience relevant knowledge obtained from appropriate people. Routine problems are predictable and have known solutions and include one or more of: variable PE materials and pipes as supplied equipment malfunction or wear and tear variable field site conditions.

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret designs, plans, patterns, procedures, job specifications, instruments/control panels, material labels and safety data sheets (SDS)

plan the welding process and sequence tasks

use mathematics to calculate welding parameters

set up butt welding equipment and materials/components to meet specifications

operate the equipment to weld the materials

monitor key variables, including:

temperature

pressure

alignment

colour and uniformity

surface finish/appearance

tolerance for weld/joint

consistency of weld

product output rate

mechanical strength of weld (e.g. tensile strength results)

product integrity and general conformance to specification

make adjustments to remedy faults and nonconformity

maintain output and product quality using appropriate instruments, controls, test information and readings

calibrate equipment according to procedures

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

recognise early warning signs of equipment/processes needing attention or with potential problems

distinguish between causes of problems, including:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

materials properties

process variables

raw material variations/contamination

process abnormalities

procedural errors

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records.

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Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

function and operating principles of butt welding equipment, components and ancillary equipment

types and application of butt welding processes and their effect on the welded product

impact of variations in welding process variables and raw materials on product quality and production output

factors which may affect product quality or production output and appropriate remedies

characteristics of materials and their behaviour in relation to welding process variables and stages of production

quality requirements at each production stage

common adjustments in process variables and their impact on product quality and production output

impact of variations in raw materials and equipment operation in relation to final product

possible changes to materials properties to better suit specific process requirements

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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