valve refurb Task Observation

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					   123boc                                     Valve Refurbishment Assessment - RUK
A Member of the Linde Group




                                   Valve Refurbishment

                              Task Observation Checklist


Task Observed
Performing valve strip and inspection procedures (checklist 1)
Perform post inspection procedures (checklist 2)



Trainee Details

Name:

Reference / Registration Number:
(if applicable)




Agreed Timescale for observation

Agreed assessment date / time:        Date:                      Time:




Issue 1 Revision 0                                                         Page 1 of 8
   123boc                                        Valve Refurbishment Assessment - RUK
A Member of the Linde Group




Conduct the Task Observation


            General
            Use one or more of the attached observation checklists for the Task Observation.


            Establish workstation availability with line management (if relevant).


            Remember, the aim is "Can the trainee safely work unsupervised".


            Avoid having pre-conceived ideas about a trainee’s abilities – you can only assess
            what you see on the day.


            Put the trainee at ease.


            Ask additional questions and record the trainee’s answers.


            It is acceptable to reword a question if you think that the trainee does not
            understand the requirement but do not ask leading questions or keep digging for
            answers that are clearly not forthcoming.


            Remain as unobtrusive as possible during observations but ask relevant questions at
            key stages of the task to clarify the trainee’s knowledge.




Issue 1 Revision 0                                                                      Page 2 of 8
   123boc                                            Valve Refurbishment Assessment - RUK
A Member of the Linde Group




               Determine trainee's competency to carry out valve
               strip and inspection procedures:
                                                                                        N/A
               OBSERVATION CHECKLIST 1
               Observe the trainee:

               Wearing the correct PPE:

               PPE worn:

               Check that the trainee is not wearing a watch, any jewellery
               or other items that could catch on any equipment

               Note: If this is not correct, immediately terminate the
               observation
               Removing all traces of PTFE tape from the valve stem


               Examining the valve for:


                     Bends
                     Deformities
                     Corrosion
                     Heavily marked/scored bodies
                     Cracks
                     Damaged stripped threads
                     Heat damage
                     Fire damage
                     Blue/black deposits in the top of the dip tube threaded
                      hole.


               Bead-blast valves until surfaces are clean:


                     Avoiding excessive metal removal
                     Checking the stamp markings are legible
                     Not blasting the pocket surrounding the valve spindle
                      square drive
                     blowing out the valve with nitrogen to remove residual
                      shot/debris.


               Removing and scrapping the RPV




Issue 1 Revision 0                                                                Page 3 of 8
   123boc                                                   Valve Refurbishment Assessment - RUK
A Member of the Linde Group




               Removing and examining the gland nut assembly:


                     Checking for:
                             damage to spindle key flats
                             excessive lateral play between spindle and gland nut
                             freedom of rotational movement
                             O-ring condition
                     Retaining serviceable items and scrapping unserviceable
                      items


               Correctly using BOC thread gauges to check for:


                     Distortion
                     Elongation


               Correctly using BOC rotary comparator to check the valve
               body for:


                     Bend
                     Misalignment


               Using Go-No Go gauge to check outlet thread


               Visual checking threads for:


                     Ovality
                     Burrs
                     Stretch


               Examining the valve internally for:


                     Wear and pitting
                     Scoring on thread flanks
                     Blue/black deposits in the top of the dip tube threaded
                      hole



Comments:




Issue 1 Revision 0                                                                       Page 4 of 8
   123boc                                         Valve Refurbishment Assessment - RUK
A Member of the Linde Group




               Determine trainee's competency to carry out post
               inspection procedure:
                                                                                     N/A
               OBSERVATION CHECKLIST 2
               Observe the trainee:

               Wearing the correct PPE:

               PPE worn:


               Check that the trainee is not wearing any jewellery or other
               items that could catch

               Note: If this is not correct, immediately terminate the
               observation
               Degreasing valve bodies and inner spindles that pass the
               examination


               Using dry air or nitrogen to make sure inner spindle and
               valve stem passages are free from debris


               Fitting a new inner spindle


               Fitting a serviceable or new gland nut assembly and
               tightening the gland nut to the correct torque.


               Exercising the valve from open to close and back to open.
               Making sure it operates freely.


               Fitting the RPV into the valve outlet and tightening to the
               correct torque.


               Stamping valves with year and month of refurbishment and
               branch identification code.


               Fitting caps/plugs to valve outlets and stem threads


               Correctly packing valves in a valve transportation pallet



Comments:




Issue 1 Revision 0                                                             Page 5 of 8
   123boc                                    Valve Refurbishment Assessment - RUK
A Member of the Linde Group




               ASSESSORS OVERALL COMMENTS:




                              GENERIC ADDITIONAL QUESTIONS
                              (to be asked at time of observation)



              ADDITIONAL QUESTIONS:


  



  



  




Issue 1 Revision 0                                                        Page 6 of 8
   123boc                                  Valve Refurbishment Assessment - RUK
A Member of the Linde Group




Post Assessment Feedback


Suggested approach:



Feedback to be given immediately after assessment, to be constructive, to be
non-judgmental and to be balanced.



Ask trainee how they thought the assessment went.



Point out areas where the trainee was correct.



Point out areas where the trainee needed to supply additional evidence of their
competence (use the assessment standard and/or procedures, as required, for specific
feedback).



Tell the trainee the overall outcome of the assessment and complete the Assessment
Outcome record.



If they have satisfied the requirements of the unit assessment their supervisor is to be
informed. The supervisor is to organise for the trainee to be signed off for any related
IMSS practical assessments as competent to carry out the task(s) unsupervised.



If they have not satisfied the unit assessment requirements, then further training /
coaching may be arranged for them and their supervisor informed (Note: the trainee may
just need to supply additional evidence rather than be retrained).



Replace the model answers sheets with the trainee’s answers to form the complete
assessment record.



Retain a copy of this assessment document as required by each business unit and
individual employee needs (for example, they may be developing a portfolio for a National
Qualification).




Issue 1 Revision 0                                                                  Page 7 of 8
   123boc                                      Valve Refurbishment Assessment - RUK
A Member of the Linde Group




                                  VALVE REFURBISHMENT

                              TASK OBSERVATION OUTCOME



The trainee has satisfied all the requirements for task        Yes            No   
observation




If ‘NO’, are the shortcomings classified as:        Critical            Non-critical   

If ‘NO’ what further training or evidence is required




Trainee Name:                            Reference / Registration Number (if applicable):



Trainee Signature:                       Date:



Assessor Name:                           Reference / Registration Number (if applicable):



Assessor Signature:                      Date:




Trainee Comments or suggestions for improvement to task(s) or the assessment
process:




Issue 1 Revision 0                                                                      Page 8 of 8

				
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