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Elements and Performance Criteria

1. Prepare for welding
2. Weld requirements are identified from specifications and/or technical drawings
3. Rail surface is correctly prepared using tools and techniques appropriate to the material and process
4. Materials are assembled/aligned to specifications as required
5. Track is measured prior to commencement of welding
6. Welding machine settings and consumables are identified from job requirements, welding procedures, specifications and/or technical drawings
7. Hazards are identified, risks are assessed and control measures are implemented
8. Assemble and set up equipment
9. Welding equipment is assembled and set up safely and correctly in accordance with operating procedures
10. Defective equipment is tagged and replaced in accordance with organisational and manufacturer specifications
11. Weld rail using submerged arc process
12. Pad, butt and fillet welds are deposited correctly in flat and fillet welds in horizontal position in accordance with specifications
13. Joints are cleaned to specifications using techniques and tools appropriate to the defect, material and process
14. Inspect welds and correct faults
15. Weld joints are visually inspected against specifications
16. Track is measured to ensure welded track is within accepted tolerances
17. Weld defects are identified and remedial action is taken, where required
18. Defects are removed with minimum loss of sound metal using techniques and tools appropriate to the defect, material and process
19. Maintain weld records
20. Weld records are filled in legibly and proofread
21. Weld records are processed in accordance with organisational procedures

Range Statement

Range is restricted to essential operating conditions and any other variables essential to the work environment.

Non-essential conditions can be found in the Companion Volume Implementation Guide.

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria on at least five separate occasions and include:

applying relevant legislation and workplace procedures assembling and setting up welding equipment and preparing consumables in accordance with safety data sheets (SDSs)/material safety data sheets (MSDSs), manufacturer instructions and workplace procedures ensuring weld conforms to organisational requirements identifying job hazards and taking required action to minimise, control or eliminate identified hazards interpreting and following operational instructions modifying activities depending on operational contingencies, risk situations and environments preparing items for welding in accordance with workplace requirements.

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Knowledge Evidence

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

authorisation/approval processes and procedures documentation and record keeping requirements hazards that may exist when welding rail using submerged welding process and ways of controlling the risks involved problems that may occur when welding rail using submerged welding process and action that can be taken to report or resolve these problems rail industry acceptance standards for weld repairs on tram/light rail track relevant rail danger zones relevant safety, work health and safety (WHS)/occupational health and safety (OHS) and environmental procedures and regulations SDSs/MSDSs and manufacturer instructions workplace procedures for welding rail on tram/light rail systems using submerged arc welding process track industry standards for rail condition and surface profile.

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