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2023-06 Online GCC Factories Plant Engineering Exam Preparation Programme
Week 1 (4 - 10 July 2023): Orientation on 4 July 2023 + Safety Management
Week 1 Outline
GCC Plant Online Class Orientation Recording (87:18)
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? (2:56)
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 Online Consultation Bookings
Palucraft Success Rate (4:53)
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
June 2022, Nov 2022, and June 2023 Exam Papers
Team Palucraft
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
Safety Incidents
Eskom Hydrogen Explosion
Boksburg LPG Gas Tanker Explosion
Texas City Refinery Explosion
Eskom Kusile Chimney Collapse
CAIA Useful Presentations
Auditing the Control Room
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
Ageing Assets Management
OHS Management System Exam Type Questions and Answers
BONUS - Possible ISO 45001 exam questions and solutions
Week 2 (11 - 17 July 2023): Electricity basics, DC machines, Transformers, Motor basics, Transmission lines, SANS 10142
Week 2 Outline
Class One Student Preparation
Class One (18 July 2023) Lesson Plan
Class One Examples
Electricity Basics
Electricity Lesson 1.1 - Electricity value chain (7:17)
Electricity Lesson 1.2 - Basic electrical system (5:06)
Electricity Lesson 1.4 - Simple AC circuits (9:54)
Electrictiy Lesson 1.3 - Simple DC circuit (8:40)
Electricity Lesson 1.5 - Power in AC circuits (10:17)
Formative Quiz Assessment
AC and DC Generator Practice Questions and Solutions
Alternators summary slides
AC and DC generator practice questions
AC and DC generator Question 1
AC and DC generator Question 2
AC and DC generator Question 3
AC and DC generator Question 4
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 Questions and Solutions
Transformer Practice Questions
Transformer Question 1 Solution
Transformer Question 2 Solution
Transformer Question 3 Solution
Transformer Question 4 Solution
Transformer Question 5 Solution
Transformer Question 6 Solution
Transformer Question 7 Solution
Transformer Question 8 Solution
Transformer Question 9 Solution
Transformer Question 10 Solution
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
Induction Motors Practice Questions and Solutions
Induction Motors practice questions
Induction motor Q1 Solution
Induction motor Q2 Solution
Induction motor Q3 Solution
Induction motor Q4 Solution
Induction motor Q5 Solution
Direct Current Machines
DC Machine 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
Transmission Line Practice Questions and Solutions
Transmission Practice Questions
Transmission Q1 Solution
Transmission Q2 Solution
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
Week 3 (18 - 24 July 2023): Online Class 1 - Electrical Technology Exam Type Questions
Week 3 Outline
What to expect in the upcoming exam?
Class One Recording (124:43)
Class One Catchup Lecture Recording (205:39)
Week 4 (25 - 31 July 2023): Thermodynamics basics, steam generators, heat transfer
Week 4 Outline
What to Expect in the Upcoming Exam?
Class Two Student Preparation
Class Two (1 Aug 2023) Student Preparation
Class Two Examples
Boilers (Steam Generators) - Basic Operation
Boiler workbook
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)
Boilers Lesson 1.6 - Combustion losses and ash (1:41)
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)
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 Lesson 1.10 - Heat loss by flue gases & equivalent evaporation (3:12)
Boiler Example 3 - Calculate the boiler thermal efficiency and equivalent evaporation (24:09)
Formative Quiz Assessment
Function of Other 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
Week 5 (1 - 7 Aug 2023): Online Class 2 - Applied Thermodynamics Exam Type Questions
Week 5 Outline
What to expect in the exam?
Class Two Recording (189:25)
Week 6 (8 - 14 Aug 2023): Strength of materials (columns, shafts, pressure vessels, etc.)
Week 6 Outline
Class Three Student Preparation
Class Three (15 Aug 2023) Lesson Plan
Class Three Examples
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
Week 7 (15 - 21 Aug 2023): Online Class 3 - Strength of Materials
Week 7 Outline
What to expect in the exam?
Class Three Recording (229:57)
Week 8 (22 - 28 Aug 2023): Pumps, fans, compressors
Week 8 Outline
Class Four Student Preparation
Class Four (29 Aug 2023) Lesson Plan
Class Four Examples
Pumps
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 (3:27)
Lesson 2.4 - Bernoulli (4:22)
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
Fans
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
Lesson 1.1 - Fan system components (1:43)
Compressors
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
Lesson 1.1 - Compressor system components (1:00)
Week 9 (29 Aug - 4 Sep 2023): Online Class 4 - Fluid Mechanics
Week 9 Outline
Class Four Recording (230:53)
Week 10 (5 - 11 Sep 2023): Theory of machines (lifts, conveyors, drives)
Week 10 Outline
Class Five Student Preparation
Class Five (12 Sep 2023) Preparation
Class Five Examples
Passenger Conveyors
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
Lesson 1 - Types of elevators (1:35)
Material Conveyors
Lesson 1 - Uses of conveyor belts (1:28)
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
Lesson 2 - Conveyor components (2:39)
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
Week 11 (12 - 18 Sep 2023): Online Class 5 - Theory of Machines
Week 11 Outline
Class Five Recording (197:36)
What to expect in the exam?
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 12 (19 - 25 Sep 2023): Master Question 1
Week 12 Outline
Week 13 (26 Sep - 2 Oct 2023): Master Question 3 (Safety Management)
Week 13 Outline
Week 14 (3 - 9 Oct 2023): Master Electrical Technology
Week 14 Outline
Week 15 (10 - 16 Oct 2023): Master Strength of Materials and Theory of Machines
Week 15 Outline
Week 16 (17 - 23 Oct 2023): Master Fluid Mechanics
Week 16 Outline
Week 17 (24 - 30 Oct 2023): Revision
Week 17 Outline
Week 18 (31 Oct - 6 Nov 2023): Revision
Week 18 Outline
Exam Day: 9 Nov 2023
All the best with the exam!
Release of Exam Results: TBC (approx. 15 Jan 2024)
Remember to check your exam results
June 2022, Nov 2022, and June 2023 Exam Papers
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