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2025-01 GCC Factories Plant Engineering Programme
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Welcome (6:10)
Webinar Registration Links
Class Live Recordings
Orientation (13 Feb 2025) (162:54)
Class One (25 Feb 2025)
Class Two (11 March 2025)
Class Three (25 March 2025)
Class Four (8 April 2025)
Class Five (15 April 2025)
Revision Week Recordings
Day 1 Revision Class (12 May 2025)
Day 2 Revision Class (13 May 2025)
Day 3 Revision Class (14 May 2025)
Day 4 Revision Class (15 May 2025)
Day 5 Revision Class (16 May 2025)
WEEK 1 (11 - 17 FEBRUARY 2025): ORIENTATION ON 13 FEBRUARY 2025, 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)
ILO-OHS 2001 - Guideline to OHSMS
Get a copy of ISO 45001 standard
ISO 45001 Basics for the GCC Factories Exam
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)
Other Safety and Management Topics
Fundamentals of Fire Protection in Industrial Settings
Fire protection provisions in the OHS Act and its regulations
Project management
Financial management
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
[BONUS] Possible ISO 45001 exam questions and answers
WEEK 2 (18 -24 FEBRUARY 2025): STEAM GENERATOR BASICS
Week 2 Outline
Recap on Thermodynamics - What to expect in the upcoming exam?
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
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
CAIA Useful Presentations
Ageing Assets Management
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
Safety Incidents
Eskom Hydrogen Explosion
Boksburg LPG Gas Tanker Explosion
Texas City Refinery Explosion
Eskom Kusile Chimney Collapse
Examples of incidents in South Africa
WEEK 3 (25 FEB - 3 MAR 2025): CLASS ONE ON 25 FEBRUARY 2025, 6 PM - 9 PM + MASTER STEAM GENERATORS
Week 3 Outline
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 4 (4 - 10 MAR 2025): ELECTRICAL TECHNOLOGY BASICS
Week 4 Outline
Electrical Technology - What to expect in the upcoming exam?
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 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 2.1 - Transmission system components (1:16)
Lesson 2.2 - Function of various transmission components
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
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 5 (11 - 17 MARCH 2025): CLASS TWO ON 11 MAR 2025, 6 PM TO 9 PM, ELECTRICAL TECHNOLOGY + MASTER ELECTRICAL TOPICS
Week 5 Outline
WEEK 6 (18 - 24 MARCH 2025): ROTATING EQUIPMENT BASICS + PRACTICE QUESTIONS
Week 6 Outline
Rotating equipment - What to expect in the upcoming exam?
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
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
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
Fans additional questions and answers
Additional fan questions
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
Compressors additional questions and answers
Additional compressor questions
WEEK 7 (25 - 31 MARCH 2025): CLASS THREE ON 25 MAR 2025, 6 PM TO 9 PM + MASTER ROTATING EQUIPMENT
Week 7 Outline
WEEK 8 (1 - 7 APR 2025): THEORY OF MACHINES AND STRENGTH BASICS
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
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 9 (8 - 14 APR 2025): CLASS FOUR, 8 APRIL 2025, 6 PM TO 9 PM + MASTER THEORY
Week 9 Outline
WEEK 10 (15 - 21 APR 2025): CLASS FIVE ON 15 APRIL 2025, 6 PM TO 9 PM + MASTER STRENGTH OF MATERIALS
Week 10 Outline
WEEK 11 (22 - 28 APRIL 2025): MASTER SECTION A
Week 11 Outline
WEEK 12 (29 APR - 5 MAY 2025) - MATCH EXAM PACE
Week 12 Outline
WEEK 13 (6 - 12 MAY 2025): MATCH EXAM PACE + PRE-EXAM REVISION DAY ONE, 12 MAY 2025, 6 PM TO 9 PM
Week 13 Outline
WEEK 14 (13 - 19 MAY 2025): PRE-EXAM REVISION DAY 2 TO 5 ON 13 - 16 MAY 2025, 6 PM TO 9 PM
Week 14 Outline
WEEK 15 (20 - 26 MAY 2025): MATCH EXAM PACE
Week 15 Outline
WEEK 16 (27 - 28 MAY 2025): FINAL SELF-REVISION
Week 16 Outline
EXAM DAY - 29 MAY 2025
Good luck with the Exam!
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ISO 14121-1: Safety of Machinery - Risk Assessment Requirements
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