Autoplay
Autocomplete
Previous Lesson
Complete and Continue
2023-04 DBN GCC Factories Plant Weekend Classes
Week 1 (11 - 17 Feb 2023): Contact Session One on 11 Feb 2023 + Safety Management
Welcome to Week 1
GCC Plant Weekend Class Introduction Presentation
Team Palucraft
Download Student Logbook (7:35)
View and download the Course Brochure
View and Download Course Terms and Conditions
How to Get Help from Palucraft
Where will the Classes be Held?
Programme Schedule - How will the Programme be Delivered? (1:42)
How do I use the Learner Management System?
How do I Download and Install Chrome? (1:00)
About the Study Material (2:36)
One-On-One GCC Consultation Bookings
Palucraft Success Rate (2:18)
Where to Write the Exam?
How to Manage Attendance of the Plant and OHS Programme?
Download steam tables
How long will I have access to the LMS?
How do I Access the Videos Offline?
Remember to Register to Write the Exam
Practice Exam Distribution
2022 Exam Papers
CONTEXT - Why are we writing the GCC Factories Plant Engineering Exam?
CPD1-INTRO-1 Course Description (6:45)
CPD1-S1-L0 Introduction (1:57)
CPD1-S1-L1 GCC Factories Legal Framework (4:56)
CPD1-S1-L2 Competent person appointment in terms of GMR 2 (9:47)
CPD1-S1-L3 Obtaining the GCC factories (7:18)
CPD1-S1-L4 What is the GCC factories (1:46)
CPD1-S1-L5 Purpose of the GCC factories exams (1:54)
CPD1-S1-L6 Role of the certificated engineer (3:06)
CPD1-S1-L7 GCC Factories Context Summary (6:28)
CONTENT - What is the important content you need to learn for the GCC Factories Plant Engineering Exam?
CPD1-S2-L0 Introduction (1:12)
CPD1-S2-L1 Plant Engineering Exam Statistics (3:05)
CPD1-S2-L2 Exam syllabus as defined by the DOL (3:15)
CPD1-S2-L3 Plant Engineering Exam Structure (5:45)
CPD1-S2-L4 Plant Engineering Past Exam Analysis (3:38)
CPD1-S2-L5 GCC Factories Plant Engineering Content Summary (1:16)
STRATEGY - What is the best approach to ensuring I pass the first time?
CPD1-S3-L0 Introduction (0:31)
CPD1-S3-L1 Plant engineering exam preparation strategy (2:19)
CPD1-S3-L2 Exam preparation strategy implementation (3:00)
CPD1-S3-L3 How to answer exam type questions (9:25)
CPD1-S4-L0 Conclusion and next steps (2:32)
OHSMS - Introduction
OSHMS S1L1 - Course Introduction (2:11)
ILO-OSH 2001 SH 2001 - Guideline to OHSMS
Get a copy of the ISO 45001 standard
OHSMS - Context of the OHS Management System
OHSMS S2L1 - Duties of the Employer (1:34)
OHSMS S2L2 - Why is OHSMS important? (1:41)
OHSMS S2L3 - What is an OHSMS? (1:25)
OHSMS S2L4 - OHSMS Standards (1:14)
OSMS S2L5 - ISO 45001 Vs OSHAS 18001 (2:56)
OHSMS S2L6 - ISO 45001 Structure (2:40)
OHSMS S2L7 - ISO 45001 important concepts (2:52)
Formative Quiz Assessment
OHSMS - Class Project
OHSMS S3L1 - Class Project (2:29)
OHSMS S3L2 - Class Project Example (3:29)
OHSMS S3L3 - Class project demonstration (12:15)
OHSMS - Context of the Organisation, Leadership, and Worker Participation
OHSMS S4L1 - Context of the Organisation (1:24)
OHSMS S4L2 - Leadership and Worker Participation (0:45)
OHSMS S4L3 - Demonstrating Leadership (11:39)
OHSMS S4L4 - Interested Parties (2:32)
Formative Quiz Assessment
OHSMS - Establishing and Maintaining the OHS Policy
OHSMS S5L1 - OHS Policy (1:30)
OHSMS S5L2 - Establish the OHS Policy (1:10)
OHSMS S5L3 - Document the OHS Policy (0:16)
OHSMS S5L4 - Communicate the OHS Policy (2:15)
OHSMS S5L5 - Available to Interested Parties (0:52)
OHSMS S5L6 - Top Management Commitment (3:13)
OHSMS S5L7 - Organisation Size, Purpose, and Context (2:27)
OHSMS S5L8 - OHS Risks, Opportunities, and Objectives (0:42)
OHSMS S5L9 - OHS Policy Elements (1:02)
Formative Quiz Assessment
OHSMS - Leadership and Worker Participation
OHSMS S6L1 - Roles, Responsibilities, and Authorities (10:50)
OHSMS S6L2 - Worker Consultation and Participation (1:54)
OHSMS S6L3 - Needs & Expectations of Interested Parties (1:20)
OHSMS S6L4 - Establishing an OHS Policy (0:23)
OHSMS S6L5 - Assigning Organisational Roles (0:28)
OHSMS S6L6 - Fulfill Legal Requirements (1:25)
OHSMS S6L7 - Establish OHS Objectives (0:43)
OHSMS S6L8 - Control Outsourcing (0:58)
OHSMS S6L9 - Monitoring and Evaluation (0:50)
OHSMS S6L10 - Establish an Audit Programme (0:30)
OHSMS S6L11 - Ensure Continual Improvement (1:26)
OHSMS S6L12 - Worker Consultation and Participation Mechanisms (3:35)
OHSMS S6L13 - Hazards, Risks, and Opportunities (0:26)
OHSMS S6L14 - Train Workers (4:13)
Formative Quiz Assessment
OHSMS - OHS Management System Planning
OHSMS S7L1 - Planning Components (2:13)
OHSMS S7L2 - Planning general requirements (5:08)
OHSMS S7L3 - Process Approach Example (7:04)
OHSMS S7L4 - Hazard Identification (3:13)
OHSMS S7L5 - Hazard Identification Example (4:01)
OHSMS S7L6 - Risk Assessment (3:04)
OHSMS S7L7 - Opportunity Assessment (3:21)
OHSMS S7L8 - Determine Legal and Other Requirements (7:35)
OHSMS S7L9 - Planning Action (5:45)
OHSMS S7L10 - OHS Objectives (5:17)
OHSMS S7L11 - Planning to Achieve OHS Objectives (3:26)
Formative Quiz Assessment
OHSMS - OHS Management System Support
OHSMS S8L1 - OHSMS Support Overview (2:18)
OHSMS S8L2 - Resources (7:08)
OHSMS S8L3 - Competency (6:39)
OHSMS S8L4 - Awareness (3:07)
OHSMS S8L5 - Communication (8:05)
OHSMS S8L6 - Documented Information (10:24)
Formative Quiz Assessment
OHSMS - OHS Management System Operation
OHSMS S9L1 - Operations General Requirements (1:14)
OHSMS S9L2 - Eliminating Hazards and Reducing OHS Risks (1:44)
OHSMS S9L3 - Management of Change (2:14)
OHSMS S9L4 - Procurement (5:34)
OHSMS S9L5 - Emergency Preparedness and Response (3:27)
Formative Quiz Assessment
OHSMS - OHS Management System Performance Evaluation
OHSMS S10L1 - Monitoring, Measurement, Analysis, and Performance Evaluation (7:44)
OHSMS S10L2 - Evaluation of Compliance (3:37)
OHSMS S10L3 - Internal audit (10:22)
OHSMS S10L4 - Management Review (3:18)
Formative Quiz Assessment
OHSMS - OHS Management System Improvement
OHSMS S11L1 - General (0:59)
OHSMS S11L2 - Incident, nonconformity and corrective action (6:04)
OHSMS S11L3 - Continual Improvement (4:00)
Formative Quiz Assessment
Other Safety and Management Considerations
Root Cause Analysis
Risk Based Inspections
Behavioural Safety
Risk Assessment Tools
Fire Protection
Project Management
Safety Checklist Guidelines
ISO 14121-1: Safety of Machinery - Risk Assessment Requirements
Possible ISO 45001 exam type questions
Week 2 (18 - 24 Feb 2023): Master accident prevention, fire safety, project management, ISO 45001
Week 2 Outline
What to expect in the upcoming exam?
CAIA Useful Presentations
Auditing the Control Room
Ageing Assets Management
Contractor Management – Case Study A Process Safety Consultant’s Perspective
Critical Success Factors for Effective Incident Investigation
Emergency Preparedness and Response
Management of Change
Operational Readiness
PSM Lagging and Leading Indicators
Responsible Care Process Safety Part 1
Responsible Care Process Safety
Standard Operating Procedures
Class Two Student Preparation
Class Two (25 Feb 2023) Lesson Plan
Class Two Examples
Transformer Examples
Week 3 (25 Feb - 3 Mar 2023): Class 2 - Electrical Technology
Week 3 Outline
Electricity Basics
Electricity Lesson 1.1 - Electricity value chain (7:17)
Electricity Lesson 1.2 - Basic electrical system (5:06)
Electrictiy Lesson 1.3 - Simple DC circuit (8:40)
Electricity Lesson 1.4 - Simple AC circuits (9:54)
Electricity Lesson 1.5 - Power in AC circuits (10:17)
Formative Quiz Assessment
Transformers
Transformer workbook download
Transformer Lesson 1.1 - Basic operation (11:37)
Transformer Lesson 1.2 - Equivalent circuit (4:15)
Transformer Lesson 1.3 - Voltage regulation (9:16)
Transformer Lesson 1.4 - Transformer efficiency (5:01)
Transformer Lesson 1.5 - Transformers in parallel (12:49)
Transformer Lesson 1.6 - Fault levels (9:44)
Formative Quiz Assessment
Transformer Practice Question Solutions
Transformer TRS1 - Primary current, Power factor
Transformer TRS2 - Transformer efficiency
Transformer TRS3 - Voltage regulations
Transformer TRS4 - Short-circuit test diagram
Transformer TRS5 - Impedance referred to the secondary, Voltage regulation, Efficiency
Transformer TRS6 - Open and short circuit test readings
Motors
Motors Workbook Download
Motor Lesson 1.1 - Basic construction (4:28)
Motor Lesson 1.2 - Motor ratings (2:06)
Motor Lesson 1.3 - Motor equivalent circuit (1:50)
Motor Lesson 1.4 - Power factor correction (1:43)
Motor Lesson 1.5 - Three phase motor (3:50)
Motor Lesson 1.6 - Induction motor torque and power (4:56)
Motor Lesson 1.7 - Synchronous motors (11:03)
Formative Quiz Assessment
Direct Current Machines
DC Machines Workbook Download
DC Machines Lesson 1.1 - Types of DC machines (3:19)
DC Machines Lesson 1.2 - DC machine working principle (5:38)
DC Machines Lesson 1.3 - DC machine basic construction (5:36)
DC Machines Lesson 1.4 - DC machine circuit (3:38)
DC Machine Lesson 1.5 - Types of DC motors (3:20)
DC Machines Lesson 1.6 - DC motors speed and torque (5:15)
DC Machines Lesson 1.7 - DC motors maintenance (4:55)
Formative Quiz Assessment
Transmission Lines: Introduction
Lesson 1.1 - Electricity value chain (4:28)
Lesson 1.2 - Electricity cost estimates
Lesson 1.3 - Transmission line regulations and standards
Transmission Line Basic Construction
Lesson 2.1 - Transmission system components (1:16)
Lesson 2.2 - Function of various transmission components
Transmission Line Analysis
Lesson 3.1 - Three phase delta connection
Lesson 3.2 - Transmission line circuit (2:50)
Lesson 3.3 - Resistance
Lesson 3.4 - Inductive reactance
Lesson 3.5 - Capacitive reactance
Lesson 3.6 - Transmission line classification
Lesson 3.7 - Nominal pi
Lesson 3.8 - Nominal T
SANS 10142 Summaries
Section 3 - Definitions
Section 5 - Fundamental requirements
Section 6 - Installation requirements
Section 7 - Special installation or locations
Section 8 - verification and certification
Annex B - MV installation safety report
Annexure F - Conduit sizing
Annexure I - SPDs for LV protection
Annexure K - Earthing arrangements
Venue Change Notice (20 Feb 2023)
Class Venue at Town Lodge Umhlanga
Week 4 (4 - 10 Mar 2023): Master Electrical Technology
Week 4 Outline
What to expect in the upcoming exam?
Class Three Student Preparation
Class Three (11 March 2023) Lesson Plan
Class Three Examples
Boilers (Steam Generators) - Basic Operation
Recap, reminder and high-level view of boilers (1:05)
Boiler Workbook Download
Boiler Lesson 1.1 - Different types of steam boiler configurations
Boilers Lesson 1.2- The simple boiler model (5:28)
Boilers Lesson 1.3 - Water treatment (8:13)
EXTENDED READING: Boiler water treatment
Boilers Lesson 1.4 - Evaporator (3:25)
Boilers Lesson 1.5 - Fuel, air, and combustion (4:06)
Boiler Example 1 - Calculate the air mass flow rate per kg of fuel (11:14)
Boiler Example 2 - Calculate the flue gas mass flow rate (4:03)
Boilers Lesson 1.6 - Combustion losses and ash (1:41)
Boiler Lesson 1.7 - Steam and condensate return (1:58)
Boilers Lesson 1.8 - The simplified boiler model for the exam (2:46)
Boiler Lesson 1.9 - Temperature-enthalpy diagram & boiler efficiencies (4:37)
Boiler Example 3 - Calculate the boiler thermal efficiency and equivalent evaporation (24:09)
Boiler Lesson 1.10 - Heat loss by flue gases & equivalent evaporation (3:12)
Formative Quiz Assessment: Boiler Operation
Function of Boiler Components
Throttling Calorimeter
Sample cooler
Mobrey Level Controller
Desuperheaters
Steam Traps
Steam Safety Valves
Boiler Feedwater Pump
Deaerator
Steam Drum
Blowdown Vessel
Superheaters
Waterwalls
Airheater
Economiser
FD/ID Fan
Heat Transfer
Boiler Lesson 2.1 - Boiler plant heat transfer (2:00)
Boiler Lesson 2.2 - Heat transfer mechanisms (1:49)
Boiler Lesson 2.3 - Plane wall heat transfer (1:34)
Boilers Lesson 2.4 - Hollow cylinder heater transfer (2:04)
Boilers Lesson 2.5 - The simple heat exchanger (3:52)
Boiler Lesson 2.6 - Parallel and counterflow heat exchanger (1:49)
Boiler Example 4 - Calculate heat transfer rate (10:47)
Boiler Maintenance and Inspections
Boiler Lesson 3.1 - Inspection & testing (10:44)
Boiler Lesson 3.2 - Repairs & modifications (2:54)
Boiler Lesson 3.3 - Statutory inspection (4:26)
Boiler Lesson 3.4 - Internal inspection (1:44)
Boiler Lesson 3.5 - Items to check every 8-hours shift (0:54)
Boiler Lesson 3.6 - How to increase boiler plant efficiency (1:44)
Formative Quiz Assessment: Boiler Maintenance and Inspections
Week 5 (11 - 17 Mar 2023): Class 3 - Applied Thermodynamics
Week 5 Outline
Week 6 (18 - 24 Mar 2023): Master steam generators
Week 6 Outline
What to expect in the upcoming exam?
Class Four Student Preparation
Class Four (25 Mar 2023) Lesson Plan
Class Four Examples
Pump and Pipeline Systems
Pumps Lesson 1 - Pumping system components (7:25)
Lesson 2.1 - Fluid properties (5:57)
Lesson 2.2 - Flow types (5:05)
Lesson 2.3 - Friction in pipes (6:54)
Lesson 2.4 - Bernoulli (8:44)
Lesson 3.1 - Pump power (6:00)
Lesson 3.2 - Pump selection parameters (3:47)
Lesson 3.3 - Pump affinity laws (6:18)
Lesson 4.1 - What can go wrong?
Lesson 4.2 - Pump maintenance considerations
Formative Quiz Assessment: Pumps
Fan and Ducting System
Lesson 1.1 - Fan system components (1:43)
Lesson 1.2 - Types of fans (1:05)
Lesson 1.3 - Types of ducts (1:16)
Lesson 2.1 - Energy losses in ducts (2:38)
Lesson 2.2 - Duct design techniques (2:21)
Lesson 2.3 - Energy efficiency and duct design considerations (1:43)
Lesson 3.1 - Fan power and efficiency (2:01)
Lesson 3.2 - Parameters involved in fan selection (2:17)
Lesson 3.3 - Fan affinity laws (5:57)
Lesson 4.1 - What can go wrong?
Lesson 4.2 - Fan maintenance considerations
Formative Quiz Assessment: Fans
Compressor and Piping System
Lesson 1.1 - Compressor system components (1:00)
Lesson 1.2 - Types of compressors (0:44)
Lesson 1.3 - Compressed air piping (0:48)
Lesson 2.1 - Flow of air overview (0:33)
Lesson 2.2 - Properties of air (1:14)
Lesson 2.3 - Compressed air processes (3:36)
Lesson 3.1 - Compressor selection criteria
Lesson 3.2 - Maintenance considerations
Formative Quiz Assessment: Compressors
Strength of Materials
Lesson 1 - Stress and strain (6:02)
Lesson 2 - Evaluating strength of materials (3:59)
Lesson 3 - Stainless steel and bearing failures (2:37)
Lesson 4 - Bearing lubrication oil analysis (1:21)
Lesson 5 - Beams (4:02)
Example - Cantilever beam (1:55)
Lesson 6 - Columns (2:08)
Lesson 7 - Steel wires and chains (2:12)
Lesson 8 - Shafts (1:19)
Formative Quiz Assessment: Strength
Week 7 (25 - 31 Mar 2023): Class 4 - Strength and Fluids
Week 7 Outline
Week 8 (1 - 7 Apr 2023): Master pumps, fans, and compressors
Week 8 Outline
What to expect in the upcoming exam?
Class Five Student Preparation
Class Five (15 April 2023) Lesson Plan
Class Five Examples
Passenger Lifts
Lesson 1 - Types of elevators (1:35)
Lesson 2 - Elevator sizing and specification (2:07)
Lesson 3 - Elevator maximum speed (1:44)
Lesson 4 - Elevator power to accelerate load (4:44)
Lesson 5 - Load on guides (3:26)
Lesson 6 - Drum torque (4:01)
Formative Quiz Assessment: Lifts
Material Conveyors
Lesson 1 - Uses of conveyor belts (1:28)
Lesson 2 - Conveyor components (2:39)
Lesson 3 - Safety around a conveyor belt system (1:23)
Lesson 4 - Conveyor system protection devices (3:43)
Lesson 5 - Conveyor belt tension (2:15)
Lesson 6 - Conveyor belt width (4:51)
Formative Quiz Assessment: Conveyors
Vehicle Dynamics
Lesson 1 - Driving axle
Lesson 2 - Load shift when accelerating & decelerating
Lesson 3 - Load transfer when cornering
Lesson 4 - Superelevation
Example - superelevation
Formative Quiz Assessment: Vehicle Dynamics
Solutions to Workbook Exercises
Solutions to Boiler Workbook Exercises
Solutions to DC Motor Workbook Exercises
Solutions to Motor Workbook Exercises
Solutions to Transformer Workbook Exercises
Week 9 (8 - 14 Apr 2023): Master pumps, fans, compressors, and strength
Week 9 Outline
Week 10 (15 - 21 Apr 2023): Class 5 - Theory of Machines
Week 10 Outline
What to expect in the upcoming exam?
Week 11 (22 - 28 Apr 2023): Master Question 1
Week 11 Outline
Week 12 (29 Apr - 5 May 2023): Master Question 2
Week 12 Outline
Week 13 (6 - 12 May 2023): Master Question 3
Week 13 Outline
Week 14 (13 - 19 May 2023): Master Electrical Technology
Week 14 Outline
Week 15 (20 - 26 May 2023): Master Strength of Materials and Theory of Machines
Week 15 Outline
Week 16 (27 - 31 May 2023): Revision
Week 16 Outline
Exam Day: 1 June 2023
All the best with the exam!
Release of Exam Results: 21 July 2023
Remember to check your exam results
GCC Plant Weekend Class Introduction Presentation
Lesson content locked
If you're already enrolled,
you'll need to login
.
Enroll in Course to Unlock