Elements and Performance Criteria

Compliance and other documentation may include:
certification documentation
approval documentation
legislative, organisation and site requirements and procedures
manufacturer’s specifications 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
determine that there is no evidence of carbon build-up on or heating of joints that may suggest a leakage of exhaust gas
check that the positive exhaust flametrap and exhaust gas cooling system is clean
check that the floats used for the low water shutdown in the exhaust system conditioner/flame trap/spark arrester are free, clean, unobstructed and correctly installed
check that the static water level on any water-based exhaust system conditioner/flame trap/spark arrester is at or above the level indicated
checking materials and gaskets/seals
the conformity of threads and fasteners to registration and/or certification drawings
Testing may include:
conduct exhaust conditioner/ flametrap, low-water, shutdown tests (i.e. both low water test systems are tested separately)
check that the engine system shuts down at or higher than the minimum shutdown water level and record the water levels after shut-down.
conduct gas tightness tests for all joints within the exhaust system Note: A soapy water test may meet this requirement
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
Exhaust systems may include:
exhaust manifolds
turbo-chargers or superchargers
pipe work
hoses
joints
fastenings
exhaust flametraps, which may include:
positive flametraps, (with temperature sensors)
water-based flametraps, (with water level sensors and test valves)
spark arrestor
exhaust cooling system, which may include:
water bath
air dilution
heat exchanger
water Injection
monitoring or shutdown devices
surface temperature control systems
catalytic converters, including DOCs and SCRs
fume diluters and forced-air systems
particulate filters
replacement element-type filters
exhaust gas recirculation
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
underground 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
Diagnose faults may include:
root cause analysis
troubleshooting techniques
Routine maintenance is to include:
servicing, including:
cleaning, including the gas path of any exhaust system
conditioner
flametrap and/or
spark arrestor
checking and filling lubricants, fuel and water
adjusting
replacing
Overhaul may include:
removal
dismantling
cleaning
inspecting
replacing, eg:
gaskets
fasteners
testing, including:
flatness
measuring dimensions
hydrostatic
reassembly
reinstallation, (e.g. cleaned or new exhaust positive flametrap assembly)
Records may include:
inspection and test results
defect identified
defect rectification carried out
item consumed
hazard/risk management reports

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 exhaust 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 exhaust systems on diesel engine systems
working with others to undertake and complete the inspection, testing and maintenance of exhaust systems on diesel engine systems that meets all of the required outcomes
consistent timely completion of the inspection, testing and maintenance of exhaust 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 exhaust systems on diesel engine systems
Guidance information for assessment
Consult the SkillsDMC User Guide for further information on assessment including access and equity issues.