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2024-05 Online GCC Factories Plant Engineering Exam Preparation Programme
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Welcome (6:10)
Webinar Registration Links
Class Recordings
Orientation recording (16 July 2024) (125:15)
Class One Recording (23 July 2024) (187:12)
Class Two Recording (13 Aug 2024) (180:40)
Class Three Recording (27 Aug 2024) (205:04)
Class Four Recording (3 Sep 2024) (179:56)
Class Five Recording (17 Sep 2024) (186:11)
WEEK 1 (16 - 22 July 2024): ORIENTATION ON 16 JULY 2024, 6 PM TO 8 PM + SAFETY MANAGEMENT
Week 1 Outline
Exam Preparation Guide
Introduction (1:57)
CONTEXT - GCC Factories Legal Framework (4:56)
CONTEXT - Competent person appointment in terms of GMR 2 (9:47)
CONTEXT - Obtaining the GCC factories (7:18)
CONTEXT - What is the GCC factories (1:46)
CONTEXT - Purpose of the GCC factories exams (1:54)
CONTEXT - Role of the certificated engineer (3:06)
CONTEXT - GCC Factories Context Summary (6:28)
CONTENT - Introduction (1:12)
CONTENT - Plant Engineering Exam Statistics (3:05)
CONTENT - Exam syllabus as defined by the DOL (3:15)
CONTENT - Plant Engineering Exam Structure (5:45)
CONTENT - Plant Engineering Past Exam Analysis (3:38)
CONTENT - GCC Factories Plant Engineering Content Summary (1:16)
STRATEGY - Introduction (0:31)
STRATEGY - Plant engineering exam preparation strategy (2:19)
STRATEGY - Exam preparation strategy implementation (3:00)
STRATEGY - How to answer exam type questions (9:25)
STRATEGY - Conclusion and next steps (2:32)
Module 1: Safety and Management
Introduction to Safety and Management (10:21)
ISO45001 L1 - ISO 45001 Structure (4:52)
ISO45001 L2 - Context of the organisation (6:10)
ISO45001 L3 - Leadership and Worker Participation (10:53)
ISO45001 L4 - Planning (10:26)
ISO45001 L5 - Support (9:34)
ISO45001 L6 - Operation (9:39)
ISO45001 L7 - Performance Evaluation (7:15)
ISO45001 L8 - Improvement (3:02)
Module 1 Additional Questions
ISO 45001 Introduction
ISO 45001 Scope
ISO 45001 Terms and definitions
ISO 45001 Context of the organisation
ISO 45001 Leadership and worker participation
ISO 45001 Planning
ISO 45001 Support
ISO 45001 Operation
ISO 45001 Performance evaluation
ISO 45001 Improvement
WEEK 2 (23 -29 JULY 2024): CLASS ONE ON 23 JULY 2024, 6 PM - 9 PM, STEAM GENERATORS
Week 2 Outline
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
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
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
Week 3 (30 July - 5 Aug 2024): Master Steam Generators
Week 3 Outline
Week 4 (6 - 12 Aug 2024): Review Electrical Technology
Week 4 Outline
Electricity Basics
Electricity Lesson 1.1 - Electricity value chain (7:17)
Electricity Lesson 1.2 - Basic electrical system (10:12)
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
Alternator summary
Alternators summary slides
Transmission Lines
Lesson 1.1 - Electricity value chain (4:28)
Lesson 1.2 - Electricity cost estimates
Lesson 1.3 - Transmission line regulations and standards
Lesson 2.1 - Transmission system components (1:16)
Lesson 2.2 - Function of various transmission components
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
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 (19:28)
Formative Quiz Assessment
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 (6:40)
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
Motors
Motors Workbook Download
Motor Lesson 1.1 - Basic construction (4:28)
Motor Lesson 1.2 - Motor ratings (4:12)
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
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 5 (13 - 19 AUG 2024): CLASS TWO ON 13 AUG 2024, 6 PM TO 9 PM, ELECTRICAL TECHNOLOGY
Week 5 Outline
WEEK 6 (20 - 26 AUG 2024): MASTER ELECTRICAL TECHNOLOGY
Week 6 Outline
WEEK 7 (27 AUG - 2 SEP 2024): CLASS THREE ON 27 AUG 2024, 6 PM TO 9 PM, ROTATING EQUIPMENT
Week 7 Outline
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
Compressors
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
Fans
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
WEEK 8 (3 - 9 SEP 2024): CLASS FOUR ON 3 SEP 2024, 6 PM TO 9 PM, THEORY OF MACHINES
Week 8 Outline
Passenger Conveyors
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
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
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 9 (10 - 16 SEP 2024): MASTER ROTATING EQUIPMENT
Week 9 Outline
Pumps and pipelines additional questions and answers
Additional pumps and pipelines questions
PP-Q1 Solution
PP-Q2 Solution
PP-Q3 Solution
PP-Q4 Solution
PP-Q5 Solution
Compressors additional questions and answers
Additional compressor questions
Additional compressor solutions
Fans additional questions and answers
Additional fan questions
Additional fan solutions
WEEK 10 (17 - 23 SEP 2024): CLASS FIVE ON 17 SEP 2024, 6 PM TO 9 PM, STRENGTH OF MATERIALS
Week 10 Outline
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 11 (24 - 30 SEP 2024): MASTER SECTION A
Week 11 Outline
WEEK 12 (1 - 7 OCT 2024) - MATCH EXAM PACE
Week 12 Outline
WEEK 13 (8 - 14 OCT 2024): MATCH EXAM PACE + PRE-EXAM REVISION DAY ONE, 14 OCT 2024, 6 PM TO 9 PM
Week 13 Outline
WEEK 14 (15 - 21 OCT 2024): PRE-EXAM REVISION DAY 2 TO 5 ON 15 - 18 OCT 2024, 6 PM TO 9 PM
Week 14 Outline
WEEK 15 (22 - 28 OCT 2024): MATCH EXAM PACE
Week 15 Outline
WEEK 16 (29 OCT - 4 NOV 2024): FINAL SELF-REVISION
Week 16 Outline
WEEK 17 (5 - 7 NOV 2024): FINAL SELF-REVISION + EXAM DAY ON 7 NOV 2024
Week 17 Outline
EXAM DAY - 7 NOVEMBER 2024
Good luck with the Exam!
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Boiler Lesson 3.3 - Statutory inspection
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