Occupational Certificate: Industrial Thermoprocessing Gas Technician

Purpose

The purpose of this qualification is to prepare a learner to operate as an Industrial Thermoprocessing Gas Technician.

Industrial Thermoprocessing Gas Technicians install, construct, inspect, maintain, repair and commission industrial Thermoprocessing gas installations which comply with safety and other legal requirements. (Thermoprocessing is applicable to natural-, bio- or liquefied petroleum gas contexts).

A qualified learner will be able to

• Construct and install thermoprocessing gas systems as per scope of work in a domestic, commercial and industrial environment.
• Commission industrial thermoprocessing gas systems and conduct a handover session with the end-user on completion of the installation.
• Inspect industrial thermoprocessing gas systems to detect defects and potential risks and maintain or modify the systems to achieve operational safety and optimum performance and reliability, including fault finding.

Rationale

The South African gas industry is highly regulated and legislation requires gas installers to have formally recognised qualifications. It is a growing industry with an increasing demand for gas systems in domestic, commercial and industrial settings and offers a green alternative to fossil generated energy.

South Africa experiences a rising energy demand and deals with a range of challenges and opportunities in the sustainable provision of energy. As Government sought accelerated growth to address the current energy crisis facing the country, it launched its ambitious gas-to-power programme. This initiative is supported by National Energy Regulator of South Africa (NERSA), South African Gas Association (SAGA), DTI and Department: Energy.

The gas-to-power landscape in South Africa has moved even further forward with the recent initiative for the development of a 600MW gas-fired power plant. Current government focus includes the strengthening of regional co-operation and cross border infrastructure being vital to the success of the long-term development of gas to power. Within this context, the development and registration of the National Certificate: Industrial Thermoprocessing Gas Technician becomes a national imperative which will serve the economy and society.

This qualification has been designed to meet the training needs expressed by the industrial natural, bio- or liquefied petroleum (Thermoprocessing) gas industry and will contribute towards the development of competence in the installation and maintenance of natural and biogas equipment and systems in domestic, commercial and industrial contexts.

A person qualifying as an Industrial Thermoprocessing Gas Technician can be classified as a craftsman and will be equipped to follow an independent career in industrial natural, bio- or liquefied petroleum (Thermoprocessing) installations and maintenance. Many learners for this qualification are likely to be learner-installers in small independent gas companies and it is foreseen that the learners will eventually be able to independently run their own industrial natural, bio- or liquefied petroleum (Thermoprocessing) installation and maintenance operations.

This qualification will contribute to the full development of the learner within the industrial natural, bio- or liquefied petroleum gas installation industry by providing recognition, further mobility and transportability within the gas field. The skills, knowledge and understanding demonstrated within this qualification are essential for social and economic transformation and will contribute to progression and economic growth within the gas installation and maintenance fraternity.

Typical learners who may enrol for this qualification have completed or been successfully RPL'ed for the Occupational Certificate: Commercial Natural Gas Practitioner, NQF Level 4. Through the employment of competent installation personnel, employers and, in turn, the field and sub-field, will have confidence that this critical work in the industry is efficiently carried out.

The qualification, the Occupational Certificate: Gas Practitioner (including its part qualifications) is registered on the NQF. This Qualification with its part qualifications prepares Gas Practitioners to operate within the compressed gas context. The Occupational Certificate: Gas Practitioner is designed to meet the training needs expressed by the gas industry for the following gas categories: flammable gases, food and beverage gases, inert gases, medical gases, oxidant gases and speciality gases and Thermoprocessing Gas Technicians operate only in the natural gas environment. Furthermore, the Thermoprocessing Gas Technician has 261 credits, thus justifying being a standalone qualification. Having said this, no similar qualification already registered on the NQF has been noted. Qualifying learners will be registered (licenced) with the relevant body based on achievement of the exit level outcomes of this qualification and relevant years of work experience.

Recognition of Prior Learning (RPL)

RPL for Access

Learners will gain access to the qualification through RPL for access as provided for in the QCTO RPL Policy. RPL for access is conducted by accredited education institution, skills development provider or workplace accredited to offer that specific qualification/part qualification.

RPL for Credits

Learners who have acquired competencies of the modules of a qualification or part qualification will be credited for modules through RPL.

RPL for access to the External Integrated Summative Assessment

Accredited providers and approved workplaces must apply the internal assessment criteria specified in the related curriculum document to establish and confirm prior learning. accredited providers and workplaces must confirm prior learning by issuing a statement of result.

Entry Requirements

Occupational Certificate: Commercial Natural Gas Practitioner, NQF Level 4.

This qualification is made up of the compulsory Knowledge, Practical Skills and Work Experience Modules

Knowledge Modules

• 642603-001-00-KM-01-Basic Gas Science, Technology and Thermoprocessing Gas Systems, Level 2, 6 Credits.
• 642603-001-00-KM-02-Intermediate Gas Science for Thermoprocessing Gas Systems, Level 4, 4 Credits.
• 642603-001-00-KM-03- Gas Science and Physics for Industrial Thermoprocessing Gas Installations, Level 4, 10 Credits.
• 642603-001-00-KM-04-Industrial Thermoprocessing Gas Technology and Systems, Level 5, 17 Credits.
• 642603-001-00-KM-05 Industrial Thermoprocessing Gas Systems Drawings and Design Interpretation, Level 5, 13 Credits.
• 642603-001-00-KM-06-Industrial Thermoprocessing Gas System Installation and Construction, Level 5, 9 Credits.
• 642603-001-00-KM-07- Industrial Thermoprocessing Gas System Maintenance, Decommissioning and Re-commissioning, Level 5, 5 Credits.
• 642603-001-00-KM-08-Occupational Health, Safety, Risk, Environment and Quality in the Industrial Gas Industry, Level 4, 13 Credits.
• 642603-001-00-KM-09-Industrial Thermoprocessing Gas Installation Business Practices, Level 4, 4 Credits.
• 642603-001-00-KM-10-Electrical Burner Management System for Thermoprocessing Gas Systems, Level 5, 12 Credits.
• 642603-001-00-KM-11-Tools, Equipment and Machinery used in Thermoprocessing Gas Installations, Level 2, 4 Credits.
• 642603-001-00-KM-12-Pipe Welding for Thermoprocessing Gas Installations, Level 3, 8 Credits.

Total number of credits for Knowledge Modules: 105

Practical Skill Modules

• 642603-001-00-PM-01-Maintain and Use Tools, Equipment and Machinery for Installation of Thermoprocessing Gas Systems, Level 2, 5 Credits.
• 642603-001-00-PM-02-Weld and Gas Cut Components for Thermoprocessing Gas Installations, Level 3, 37 Credits.
• 642603-001-00-PM-03-Construct Pipe Work for Thermoprocessing Gas Installations, Level 3, 5 Credits.
• 642603-001-00-PM-04-Construct and Install a Legally and Code Compliant Industrial Thermoprocessing Gas System, Level 5, 20 Credits.
• 642603-001-00-PM-05-Inspect, Test and Confirm Thermoprocessing Gas System Compliance with Design and Scope Parameters, Level 5, 16 Credits.
• 642603-001-00-PM-06-Assess Thermoprocessing Gas Equipment or System, Troubleshoot Problems and Repair or Replace Faulty Equipment or System, Level 5, 20 Credits.

Total number of credits for Practical Skill Modules: 103

Work Experience Modules

• 642603-001-00-WM-01-Industrial Thermoprocessing Gas System On-Site Construction and Installation, Level 5, 25 Credits.
• 642603-001-00-WM-02-Industrial Thermoprocessing Gas System Commissioning, Certification and Handover Processes, Level 5, 12 Credits.
• 642603-001-00-WM-03-Corrective, Planned and Statutory Maintenance Processes of Industrial Thermoprocessing Gas Systems, Level 5, 16 Credits.

Total number of credits for Work Experience Modules: 53

1. Compile a bill of materials for a legally compliant industrial thermoprocessing gas system.
2. Assemble and construct an industrial thermoprocessing gas system based on volume, pressure and integrity according to gas system demand which is legal and code compliant.
3. Commission and conduct a final sign-off of a legally and code compliant industrial thermoprocessing gas system.
4. Conduct fault finding and take remedial action on an industrial thermoprocessing gas system to maintain safe working condition of the system.
5. Comply with safety and quality industry codes and legal aspects when installing an industrial thermoprocessing gas system and working with industrial thermoprocessing gas.
6. Demonstrate an understanding of the underpinning theory of gas and industrial thermoprocessing gas systems.

Associated Assessment Criteria for Exit Level Outcome 1

ELO 1: Compile a bill of materials for a legally compliant industrial thermoprocessing gas system using information gathering, sorting and analysing methods.

• Analyse a set of piping and instrumentation diagrams (P&ID) drawings to determine the material and equipment.
• Analyse the designs, scope of work, site lay-out and isometric drawings of the end-user industrial thermoprocessing gas system to determine Thermo bill of materials.
• Compile a list of exclusions to mitigate risk related to the construction and installation of an industrial thermoprocessing petroleum gas system.
• Define a clear scope of work based on findings.

Associated Assessment Criteria for Exit Level Outcome 2

ELO 2: Assemble and construct an industrial thermoprocessing gas system based on volume, pressure and integrity according to gas system demand adhering to legal and code compliance requirements.

• Conduct a risk assessment of the installation which includes references to working at heights and confined spaces, pneumatic pressure testing, lockout procedures and permit to work.
• Position main equipment for industrial thermoprocessing gas systems according to the gas system design.
• Interconnect and assemble industrial thermoprocessing petroleum gas installation components such as pipelines, pressure, and safety accessories to form a complete system.
• The installation of an industrial thermoprocessing gas system, is legal and is code compliant.
• Conduct applicable pressure tests and leak tests to prove the integrity of the industrial thermoprocessing gas system.

Associated Assessment Criteria for Exit Level Outcome 3

ELO 3: Commission and conduct a final sign-off of a legally and code compliant industrial thermoprocessing gas system.

• Conduct pre-commissioning checks of the industrial thermoprocessing gas system to ensure compliance to the design.
• Purge the industrial thermoprocessing gas system by introducing an inert gas into the system to remove sufficient amounts of oxygen to ensure that the oxygen level is below the lower explosive limit.
• Introduce the fuel gas into the system to ensure the sufficient amount of gas is present for light-off.
• Conduct a functionality test to confirm gas shut-off and functionality of all safety equipment.
• Conduct start-up and performance checks confirming all safety measures are operational including interlocks.
• Prepare and finalise a certificate of compliance for the thermoprocessing gas system to be issued and hand-over documentation.

Associated Assessment Criteria for Exit Level Outcome 4

ELO 4: Conduct fault finding and take remedial action on an industrial thermoprocessing gas system to maintain safe working condition of the system.

• Apply fault finding techniques to detect defects and potential risks and to determine the root cause of failure of the industrial thermoprocessing gas system.
• Compile a typical maintenance plan for the industrial thermoprocessing gas system which includes planned and statutory maintenance requirements to maintain operational safety and optimum performance and reliability.
• Conduct de-commissioning and make safe procedures prior to maintenance of an industrial thermoprocessing gas system.
• Conduct statutory maintenance on an industrial thermoprocessing gas system according to legal requirements.
• Recommission gas into an industrial thermoprocessing gas system and return the gas system to normal operating conditions.

Associated Assessment Criteria for Exit Level Outcome 5

ELO 5: Comply with safety and quality industry codes and legal aspects when installing an industrial thermoprocessing gas system and working with industrial thermoprocessing gas.

• Define site safety concepts and analyse compliance in terms of the industrial thermoprocessing gas system.
• Define and analyse occupational health, safety, risk and environment compliance.
• Identify applicable thermoprocessing gas regulations, legislation and standards. and explain the application to an industrial thermoprocessing gas installation.
• Analyse quality principles in the industrial thermoprocessing gas industry.

Associated Assessment Criteria for Exit Level Outcome 6

ELO 6: Analyse and evaluate the underpinning theory of gas and industrial thermoprocessing gas systems using appropriate methodologies.

• Describe gas properties of a range of gases with reference to the specific thermoprocessing gas system.
• Analyse industrial thermoprocessing gas systems and identify components and explain the function of each.
• Define principles related to the design of an industrial thermoprocessing gas installation.
• Explain the interpretation of instruction handbook.
• Analyse the function of pipes, pressure, and safety accessories in relation to an industrial thermoprocessing gas system.
• Define principles regarding installing an industrial thermoprocessing gas system.
• Identify gas equipment and describe function thereof.
• Instrument control loops are defined and analysed in terms of an industrial thermoprocessing gas system.
• Identify pipelines and network systems and evaluate their functions in terms of an industrial thermoprocessing gas system.
• Describe the functions and application of engineering hand tools and power machines.
• Evaluate important considerations in terms of the maintenance of an industrial thermoprocessing gas installation.
• Define and describe welding principles, equipment, and consumables.

Integrated Assessment

Formative Assessment

The Skills Development Provider will use the curriculum to guide them on the stipulated internal assessment criteria and weighting. They will also apply the scope of practical skills and applied knowledge as stipulated by the internal assessment criteria. This formative assessment together with work experience leads to entrance in the integrated external summative assessment.

Summative Assessment

The external integrated summative assessment will be conducted through a combination of a written assessment and practical tasks conducted at QCTO accredited assessment centres. The practical assessment will be concluded at the assessment centre and assessed by an assessor registered with the AQP.

A learner who attempted the assessment will be given recognition for those assessment tasks in which he/she has been found competent and not be retested in those tasks provided that

• The learner is competent in at least 70% of the assessment tasks given during the assessment; and
• The recognition will be retained by the candidate for a maximum of 3 attempts or 18-months from the date of successful completion of the test tasks whichever comes first.