- MEM04001B - Operate melting furnaces
Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners
MEM04001B Mapping and Delivery Guide
Operate melting furnaces
Version 1.0
Issue Date: June 2024
Qualification | - |
Unit of Competency | MEM04001B - Operate melting furnaces |
---|---|---|---|
Description | This unit covers operating a metal melting furnace. | ||
Employability Skills | This unit contains employability skills. | ||
Learning Outcomes and Application | This unit applies to the operation of singular or multi, coke, oil, gas fired or electric furnaces, the melting of a range of metals, and operational maintenance. Furnaces would primarily be used for continuous or staged bulk melting/smelting of metals, holding of hot liquids, or the melting of metals for production processes e.g. casting/moulding, galvanising, etc.Band: AUnit Weight: 4 | ||
Duration and Setting | X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting. |
||
Prerequisites/co-requisites | Path 1MEM13004B Work safely with molten metals/glass | ||
Competency Field | Casting and moulding |
Development and validation strategy and guide for assessors and learners | Student Learning Resources | Handouts Activities |
Slides PPT |
Assessment 1 | Assessment 2 | Assessment 3 | Assessment 4 | |
---|---|---|---|---|---|---|---|---|
Elements of Competency | Performance Criteria | |||||||
Element: Select materials |
| |||||||
Element: Start up furnace |
| |||||||
Element: Charge furnace |
| |||||||
Element: Monitor furnace |
| |||||||
Element: Tap or unload the furnace |
| |||||||
Element: Shut down furnace |
|
Evidence Required
List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.
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. | |
Overview of assessment | A person who demonstrates competency in this unit must be able to operate a melting furnace. Competency in this unit cannot be claimed until all prerequisites have been satisfied. |
Critical aspects for assessment and evidence required to demonstrate competency in this unit | Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts. |
Context of and specific resources for assessment | This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, that is the candidate is not in productive work, then an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate. This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with operating melting furnaces or other units requiring the exercise of the skills and knowledge covered by this unit. |
Method of assessment | Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials. |
Guidance information for assessment |
Submission Requirements
List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here
Assessment task 1: [title] Due date:
(add new lines for each of the assessment tasks)
Assessment Tasks
Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.
Required skills |
Look for evidence that confirms skills in: reading and interpreting routine information on written job instructions, specifications, standard operating procedures relevant test data sheets and other standard workplace forms. May include drawings for furnace operation following oral instruction entering routine and familiar information onto proformas and standard workplace forms identifying faults and areas for routine repair of the furnace and performing routine maintenance as necessary following procedures for starting and closing down the furnace deciding on charge materials weighing charge materials feeding materials into furnace measuring metal temperature and correcting as necessary sampling for chemical, carbon equivalent and wedge tests degassing as necessary deslagging/drossing tapping the metal |
Required knowledge |
Look for evidence that confirms knowledge of: refractory conditions, faults, and routine repair condition of cooling water supply starting procedures for different types of furnaces metallic charge materials and alloying elements weighing procedures and scale types correct order of loading of different charge materials thermocouple condition monitoring and adjustment mechanism for furnace interpretation of carbon equivalent and wedge test results degassing procedures including tablet, lance and other procedures coagulant agents, application procedures and slag removal procedures close-down procedures applicable industry standards, national/Australian standards, NOHSC guides, State/Territory regulatory codes of practice/standards use and application of personal protective equipment safe work practices and procedures hazards and control measures associated with operating melting furnaces |
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. 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. | |
Furnace | Singular or multi, coke, oil, gas fired or electric induction, arc and resistance furnaces |
Operational maintenance | Routine lubrication, cleaning, routine repair/repointing of refractory |
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.
Observation Checklist
Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice | Yes | No | Comments/feedback |
---|---|---|---|
Requisitions are completed as required according to standard operating procedures. | |||
Charge analysis is undertaken in accordance with standard operating procedures. | |||
The charge analysis is converted to furnace charge weight using standard operating procedures. | |||
Charge is weighed according to standard operating procedures. | |||
Furnace is inspected for any defects or damage. | |||
Routine operational maintenance of furnace is undertaken to standard operating procedures. | |||
Furnace is started up to standard operating procedures. | |||
Faults are reported according to standard operating procedures. | |||
Emergency/safety procedures are identified and followed as necessary. | |||
Materials are pre-heated if required according to standard operating procedures. | |||
Materials are charged into furnace using standard operating procedures. | |||
Suitable areas for emergency unloading of molten metal are identified and kept available. | |||
Furnace is maintained at optimum operating condition to standard operating procedures. | |||
Sample for chemical analysis is taken and remedial action is applied as required to standard operating procedures. | |||
Furnace is drossed and/or degassed to standard operating procedures. | |||
Temperature of metal is checked and adjustment made if necessary. | |||
Quantity of the required metal is identified. | |||
Tap rate is carried out to standard operating procedures. | |||
Tapping or unloading is undertaken and completed safely according to standard operating procedures. | |||
Shut-down of furnace is completed to standard operating procedures. | |||
Routine operational maintenance of furnace is undertaken to standard operating procedures. |
Forms
Assessment Cover Sheet
MEM04001B - Operate melting furnaces
Assessment task 1: [title]
Student name:
Student ID:
I declare that the assessment tasks submitted for this unit are my own work.
Student signature:
Result: Competent Not yet competent
Feedback to student
Assessor name:
Signature:
Date:
Assessment Record Sheet
MEM04001B - Operate melting furnaces
Student name:
Student ID:
Assessment task 1: [title] Result: Competent Not yet competent
(add lines for each task)
Feedback to student:
Overall assessment result: Competent Not yet competent
Assessor name:
Signature:
Date:
Student signature:
Date: