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Plastics Industry Pipe Association of Australia Ltd

Plastics, Rubber and Cablemaking Training Package

(PMB98 changed to PMB01)

Australasian Polyolefin Pipeline System Inc. (AusPoly) and Manufacturing Learning Australia (MLA) are pleased to announce the release of the Plastics, Rubber and Cablemaking Training Package PMB01. Competency standards PMBWELD301A through PMBWELD311A within the package specifically refer to plastic pipe design, welding and installation. This will enable competent workers to gain Nationally accredited qualifications which incorporate plastic pipe design, welding and installation.

Training Packages are flexible, national products developed by industry to ensure quality training outcomes meet current and emerging vocational skill needs. National standards define the competencies required for effective performance in the workplace. A competency comprises the specification of knowledge and skill and the application of that knowledge and skill at an industry level, to the standard of performance required in employment. Competency standards can be either industry or enterprise based.

Manufacturing Learning Australia

Manufacturing Learning Australia (MLA) is the national industry training body representing the process manufacturing industries. Its coverage includes major industry sectors, one of which is plastics, rubber and cablemaking (ANZSIC classifications 255 and 2852).

While there are plastics and rubber awards in different States, employees in this industry might also be employed under the metals and engineering award, some other award, or a non-award arrangement. This Training Package was designed to allow for these different arrangements to use it as part of their award/agreement, but has not been designed to fit any specific award.

Generally there are no process manufacturing-specific licensing or other regulatory arrangements. There is a growing need for formal assessment and recognition of the competency to weld plastics pipes which is being imposed by certain State regulatory authorities with responsibility for plastic pipe installation. At this stage, this is on a unit of competency basis, and the relevant units of competency (identified by the ‘WELD’ tag in their codes) have been included in the revised Training Package (PMB01) under Certificate III in Process Manufacturing PMB 3 04 01.

Australian Qualifications Framework

The competency standards in this Training Package are benchmarks for assessment and are the basis of the nationally recognised Australian Qualifications Framework (AQF), qualifications, and statements of attainment issued by Registered Training Organisations (RTOs).

Assessment within the National Training Framework is defined as the process of collecting evidence and making judgements about whether competency has been achieved. The purpose of assessment is to confirm whether an individual can perform to the standards expected in the workplace, as expressed in the competency standards.

Nationally endorsed competency standards define the knowledge and skills required in particular industries and occupations. The competencies in the Training Package are categorised into:

    • core
    • production
    • support.

Core competencies are those which are essential to all sectors of the industry.

Production competencies are those which relate specifically to the equipment and processes employed by this industry to produce products. It is these competencies which contain the knowledge and skills required to operate the plant at the specified level. These competencies are referred to as ‘technical’ in higher level qualifications.

Support competencies are those other competencies required by the industry in order to complete real jobs, but which are not specific to the equipment and processes of this industry and do not contain significant industry specific knowledge or skills.

Certificate III in Process Manufacturing PMB 3 04 01

The Process Manufacturing Certificate III is for:

      • production support workers (people working in the industry and filling the vital production support roles, but who may not have the opportunity to develop competence in the units of competency related directly to producing products)
      • those employees who operate across more than one category within the plastics, rubber and cablemaking industry or divide their time between ‘specialised processes’ and working elsewhere where required

To be awarded a Certificate III in Process Manufacturing, competency must be achieved in a total of 21 units of competency comprised of:

      • all 5 core competencies
      • at least 8 competencies from the production and/or support lists below
      • other competencies relevant to the learner’s workplace. These may be production or support competencies from this Training Package, and up to 6 competencies from another endorsed Training Package.

Support competencies for this Certificate include:

Pipe welding

PMBWELD301A

Butt weld polyethylene plastic pipelines

PMBWELD302A

Electrofusion weld polyethylene pipelines

PMBWELD303A

Install polyethylene (non-pressure) drainage pipelines

PMBWELD304A

Design polyethylene (non-pressure) drainage pipelines

PMBWELD305A

Install polyethylene plastic pressure pipelines

PMBWELD306A

Design polyethylene plastic pressure pipelines

PMBWELD307A

Install high temperature plastic pressure pipelines

PMBWELD308A

Install PVC plastic pressure pipelines

PMBWELD309A

Weld plastics using extrusion and injection techniques

PMBWELD310A

Design PVC plastic pressure pipelines

PMBWELD311A

Design high temperature plastic pressure pipelines

Extracts from PMBWELD301A are shown here to give an indication of the training package contents.

PMBWELD301A - Butt weld polyethylene plastic pipelines

This competency covers the butt welding of polyethylene (PE) plastics 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. 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. It also includes the operation of all relevant ancillary equipment.

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.

The end applications include pipelines used for transmission of gaseous and water based fluids.

Specifications include national standards for materials (AS/NZS 4130, and AS/NZS 4131), workplace specifications and instructions, and government codes and regulations.

This competency requires the use of:

    • hydraulic activated butt welding machines, and pipe supports
    • measurement devices including pressure gauges, timers, temperature probes, calipers and computer based pressure/temperature monitors
    • cleaning fluids and spray equipment
    • calculators
    • relevant safety equipment
    • comprehensive work instructions.

Typical hazards include:

    • hazardous cleaning fluids
    • pipe material handling
    • heavy stationary and moving machinery, cutting and heating components.

Routine problems include:

    • variable PE materials, and as supplied pipes
    • equipment malfunction, wear and tear
    • variable field site conditions.

All operations are required to be performed in accordance with standard procedures and work instructions. Consistent achievement of required weld quality standards is critical.

Elements and Performance Criteria

  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.

  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/ procedures.

  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.

  4. Perform welding.

    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.

  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.

 

For Further information please contact :
Plastics Industry Pipe Association of Australia Ltd
Suite 246, 813 Pacific Hwy, Chatswood NSW 2067
or email plasticspipe@pipa.com.au

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