Level 3 Certificate in Process Technology Qualification handbook Version 2.3 (October 2011) May 2006

Transcription

1 Level 3 Certificate in Process Technology Qualification handbook 0603 Version 2.3 (October 11) May 06

2 City & Guilds is the UK s leading provider of vocational qualifications, offering over 500 awards across a wide range of industries and progressing from entry level to the highest levels of professional achievement. With over 8500 centres in 100 countries, City & Guilds is recognised by employers worldwide for providing qualifications that offer proof of the skills they need to get the job done. The City & Guilds Group includes City & Guilds Pitman Qualifications, specialising in IT, office-based qualifications and English as a second language awards, and ILM (the Institute of Leadership & Management) providing management qualifications, learning materials and membership services. City & Guilds also manages the Process Technology Council Examinations on behalf of the Process Technology Council General information about City & Guilds is available on our website or from our Customer Relations team by phoning or ing enquiry@city-and-guilds.co.uk City & Guilds publications These are available from Publications Sales City & Guilds 1 Giltspur Street London EC1A 9DD T +44 (0) F +44 (0) Equal opportunities City & Guilds fully supports the principle of equal opportunities and we are committed to satisfying this principle in all our activities and published material. A copy of our Equal Opportunities Policy statement Access to assessment is available on our website or from Customer Relations. Every effort has been made to ensure that the information contained in this publication is true and correct at the time of going to press. However, City & Guilds products and services are subject to continuous development and improvement and the right is reserved to change products and services from time to time. City & Guilds cannot accept liability for loss or damage arising from the use of information in this publication. 05 The City and Guilds of London Institute. All rights reserved. City & Guilds is a trademark of the City and Guilds of London Institute. City & Guilds, 1 Giltspur Street, London, EC1A 9DD, telephone +44 (0) or fax +44 (0)

3 Contents Page Level 3 Certificate in Process Technology 5 General information 9 General structure 9 Assessment and quality assurance 9 Course design 10 Centre and scheme approval 10 Registration and certification 11 External verification 11 Guidance notes on assessment 12 What is provided by City & Guilds 12 Guidance for marking 13 What centres need to do 14 The Award Test specifications Core Units 18 Test specifications Supplementary Units 19 Test specifications Pathway Mandatory and Optional Units 21 Learning outcomes Core Units 28 Relationship to NVQ standards 38 Key skills 41 Identification of moral, spiritual and ethical issues 43 European dimension, environmental, education and health and safety Further information 44 Units (* denotes a double unit): Unit 301: Mathematics for Industry Unit 302: Communications and Information Technology (Level 3) Unit 303: Process Chemistry* Unit 304: Heat Transfer and Fluid Flow * Unit 305: Steam Generation and Distribution Unit 306: Distillation in the Process Industries Unit 307: Evaporation in the Process Industries Unit 308: Crystallisation in the Process Industries Unit 309: Mixing and Blending of Solids and Fluids Unit 310: Water for Industry Unit 311: Process Control and Fault Diagnosis Unit 312: Compressors and Compression Technology Unit 313: Drying in the Process Industries Unit 314: Separation of Insoluble Solids from Liquids Unit 3: Size Reduction in the Process Industries Unit 316: Gas Treatment in the Process Industries Unit 317: Process Quality Unit 318: Sampling and Laboratory Analysis Unit 319: Special Processes (Level 3) Unit 3: Metals Processing (Level 3) * Unit 321: Iron making and Basic Oxygen Steel making (Level 3) Unit 322: Electric Arc Steel Making, Refining and Casting (Level 3) Unit 323: Primary Working in the steel Industry (Level 3) Unit 324: Finishing Working Processes (Level 3) Unit 3: High Technology Processing of Metals Unit 326: Metallurgy of Iron and Steel Production (Level 3) Unit 327: Metallurgy of Ferrous Metals and Alloys Unit 328: Metallurgy of Non-ferrous Metals and Alloys Unit 329: Corrosion and Heat Resistant Materials

4 Unit 330: Process Control (Metals)* Unit 331: Effective Working Relationships* Unit 332: Petroleum Technology (Level 3) Unit 333: Mathematics for Higher Education* Unit 334: Mechanical Engineering Science* Unit 335: Electrical Engineering Science*

5 Level 3 Certificate in Process Technology (0603) Introduction This award is aimed at candidates who are following Modern Apprenticeship programmes or require evidence towards the underpinning knowledge of an N/SVQ seeking a technical certificate or wish for career progression within the Process Technology industry. Without evidence of formal qualifications, candidates must be able to demonstrate prior adequate knowledge and experience necessary to complete the course. This award is designed to contribute towards the knowledge and understanding for the N/SVQs in the industry at Level 3, while containing additional skills and knowledge which go beyond the scope of the National Occupational Standards. Candidates must follow one of five Process Technology pathways. Successful candidates will receive a certificate endorsed with their chosen pathway: Level 3 Certificate in Process Technology-Chemical process Level 3 Certificate in Process Technology-Metal production Level 3 Certificate in Process Technology-Petroleum operations Level 3 Certificate in Oil and Gas Process Technology (Upstream) Level 3 Certificate in Process Technology-Open Level 3 Supplementary Studies Level 3 Certificate in Process Technology

6 Routes Chemical Process, Metal Production, Petroleum Operations, Open and Supplementary To gain the Level 3 Certificate in Process Technology, candidates must undertake assessments for both core units (units 301 and 302) plus an additional 7 units from within a single industrial sector route. These 7 units must include the mandatory units for the chosen industrial sector route. A total of 9 units in all are required to achieve the award, plus the associated assessments. Common units Unit 301: Mathematics for Industry Unit 302: Communications and Information Technology (Level 3) Mandatory units for routes (* indicates a double unit): Chemical Process Unit 303: Process Chemistry * Unit 304: Heat Transfer and Fluid Flow * Metal Production Unit 3: Metals Processing (Level 3) * Petroleum Operations Unit 303: Process Chemistry * Unit 304: Heat Transfer and Fluid Flow * Unit 332: Petroleum Technology (Level 3) Open Unit 317: Process Quality Unit 319: Special Processes (Level 3) 6 Level 3 Certificate in Process Technology 0603

7 Optional units for routes (* indicates a double unit): Chemical Process Unit 305: Steam Generation and Distribution Unit 306: Distillation in the Process Industries Unit 307: Evaporation in the Process Industries Unit 308: Crystallisation in the Process Industries Unit 309: Mixing And Blending of Solids And Fluids Unit 310: Water for Industry Unit 311: Process Control and Fault Diagnosis Unit 312: Compressors and Compression Technology Unit 313: Drying in the Process Industries Unit 314: Separation of Insoluble Solids from Liquids Unit 3: Size Reduction in the Process Industries Unit 316: Gas Treatment in the Process Industries Unit 317: Process Quality Unit 318: Sampling and Laboratory Analysis Unit 319: Special Processes (Level 3) Metal Production Unit 321: Iron Making and Basic Oxygen Steel Making (Level 3) Unit 322: Electric Arc Steel Making, Refining and Casting (Level 3) Unit 323: Primary Working in the Steel Industry (Level 3) Unit 324: Finishing Working Processes (Level 3) Unit 3: High Technology Processing of Metals Unit 326: Metallurgy of Iron and Steel Production (Level 3) Unit 327: Metallurgy of Ferrous Metals and Alloys Unit 328: Metallurgy of Non-ferrous Metals and Alloys Unit 329: Corrosion and Heat Resistant Materials Unit 330: Process Control (Metals) * Unit 331: Effective Working Relationships * Petroleum Operations Unit 305: Steam Generation, Distribution and Use Unit 306: Distillation in the Process Industry Unit 311: Process Control and Fault Diagnosis Unit 312: Compressors and Compression Technology Unit 316: Gas Treatment in the Process Industry Unit 317: Process Quality Unit 318: Sampling and Laboratory Analysis Unit 319: Special Processes (Level 3) Level 3 Certificate in Process Technology

8 Open Unit 304: Heat Transfer and Fluid Flow * Unit 305: Steam Generation and Distribution Unit 310: Water for Industry Unit 311: Process Control and Fault Diagnosis Unit 312: Compressors and Compression Technology Unit 318: Sampling and Laboratory Analysis Unit 331: Effective Working Relationships * Supplementary Studies Additional optional Level 3 units are also offered as Supplementary Studies. These are not required for the Level 3 Certificate in Process Technology but may be undertaken by any candidate from any of the industrial sector routes who wishes to progress to higher level qualifications. Candidates would normally study the common unit plus one or both of the optional units as required for a particular course of study. (* indicates a double unit.) Common unit Unit 333: Mathematics for higher education* Optional units Unit 334: Mechanical Engineering Science* Unit 335: Electrical Engineering Science* Please note: The test specifications for the Core Units are provided on page 18 The test specifications for the Supplementary Units are provided on page 19- The test specifications for the Pathway Mandatory and Optional Units are provided on pages The individual learning outcomes for the Core Units are given on pages The individual learning outcomes for the Pathway mandatory and optional units are provided on the City & Guilds website. This is to enable candidates wishing to specialise on a pathway route to access the relevant information. Information on the Pathway and optional units is available in downloadable format. 8 Level 3 Certificate in Process Technology 0603

9 General information This Award has been designed by City & Guilds to support government initiatives towards the National Qualifications Framework. It can contribute towards the knowledge and understanding required for the related N/SVQ while not requiring or proving evidence of occupational competence. These awards can be used as a technical certificate within a modern apprenticeship scheme. General structure The Award is made up of units expressed in a standard format. Each unit is preceded by details of the structure of the unit aims and general coverage of the unit relationship of the unit to the appropriate N/SVQ/ National Occupational Standards outcomes assessment methods. Assessment and quality assurance National standards and rigorous quality assurance are maintained by the use of: City & Guilds set and marked written tests. This applies to common unit 301 and supplementary units 333, 334 and 335. City & Guilds assignments, marked by the centre according to externally set marking criteria, with quality assurance provided by the centre and monitored by City & Guilds external verification system, to ensure that national standards are maintained. This applies to common unit 302. Centre set assignments, which must be developed in line with City & Guilds assignment templates. Monitoring of assignments will be undertaken by City & Guilds through the external verification system. Quality assurance includes initial centre approval, scheme approval, the centres own procedures for monitoring quality and City and Guilds' ongoing monitoring by an External Verifier. Details of City & Guilds criteria and procedures, including roles of centre staff and External Verifiers can be found in Providing City & Guilds Qualifications - a guide to centre and scheme approval. For candidates with particular requirements, centres should refer to City & Guilds policy document Access to assessment, candidates with particular requirements. Level 3 Certificate in Process Technology

10 Course Design Teacher/assessors should familiarise themselves with the structure and content of the award before designing an appropriate course; in particular they are advised to consider the knowledge and understanding requirements of relevant N/SVQs where applicable. City & Guilds does not itself provide courses of instruction or specify entry requirements. As long as the requirements for the award are met, tutors/assessors may design courses of study in any way that they feel best meets the needs and capabilities of the candidates. Units are broadly the same size and centres may deliver them in any order they wish. Centres may wish to introduce other topics as part of the programme which will not be assessed through the qualifications, eg to meet local needs. It is recommended that centres cover the following in the delivery of the course, where appropriate Key Skills (such as Communication, Application of Number, Information technology, Working with others, Improving own learning and performance, Problem solving) Health and safety considerations, in particular the need to impress to candidates that they must preserve the health and safety of others as well as themselves Spiritual, moral, social and cultural issues Environmental education European dimension. It is recommended that 270 hours should be allocated for the core, mandatory and optional units required for certification. This may be on a full time, part time or distance learning basis. No specific prior qualifications, learning or experience are required for candidates undertaking the qualification. However, the nature of both the learning and assessment required for the qualification is such that, at both Levels 2 and 3, candidates will need basic literacy and numeracy skills: e the ability to read and interpret written tasks and to write answers in a legible and understandable form. Candidates will also need to be able to organise written information clearly and coherently, although they will not be assessed for spelling or grammatical accuracy unless this is part of the assessment criteria. Centre and scheme approval Centres wishing to offer City & Guilds qualifications must gain approval. New centres must apply for centre and scheme approval. Existing City & Guilds centres will need to get specific scheme approval to run this Award. City & Guilds reserves the right to suspend an approved centre, or withdraw its approval from an approved centre to conduct a particular City & Guilds scheme or particular City & Guilds schemes, for reasons of debt, malpractice or for any reason that maybe detrimental to the maintenance of authentic, reliable and valid qualifications or that may prejudice the name of City & Guilds. Full details of the process for both centre and scheme approval are given in Providing City & Guilds qualifications - a guide to centre and scheme approval which is available from City & Guilds regional offices. 10 Level 3 Certificate in Process Technology 0603

11 Registration and certification Candidates must be registered at the beginning of their course. Centres should submit registrations using Form S (Registration), under scheme/complex When assignments have been successfully completed, candidate results should be submitted on Form S (Results submission). Centres should note that results must NOT be submitted to City & Guilds until the external verifier is satisfied that the required standard has been attained. Written tests are available twice each year during June and December. Candidates must be entered for written (timetabled) components using Form S (and examination month entered in the dated entry box. Candidates achieving one or more assessment components will receive a Certificate of Unit Credit listing the assessment components achieved together with the grade (D, C or P). Candidates achieving the number and combination of assessment components required for the award will, in addition, be issued a Certificate. Certificates are not graded. Full details on all the above procedures, together with dates and times of written tests will be found in the Directory of Vocational Awards published annually by City & Guilds. This information also appears on City & Guilds Web site External verification An External Verifier will make an annual visit to the centre and their role includes the following: monitoring internal quality assurance systems and sampling assessment activities, methods and records acting as a source of advice and support promoting best practice providing prompt, accurate and constructive feedback to all relevant parties on the operation of centres assessment systems. Level 3 Certificate in Process Technology

12 Guidance notes on assessment Section 1- Introduction The City & Guilds Level 3 Certificate in Process Technology is designed to provide opportunities for candidates to gain accreditation for their individual level of understanding of the underpinning knowledge relevant to the appropriate industrial sector. Section 2 Assessment In order to gain the full certificate candidates must complete One short answer written paper for core unit 301 One City & Guilds set assignment template centre marked for core unit 302 One centre set assignment based on an assignment template provided for each mandatory and optional unit taken comprising of short answer questions. 2.1 What is provided by City & Guilds City & Guilds will provide short answer papers March, June, October and December - for core unit 301. City & Guilds will provide an assignment template and marking guide for core unit 302. City & Guilds will also provide an assignment template for each optional unit. City & Guilds will also provide short answer papers March, June, October and December for common unit 333 and optional units 334 and Assessment of core unit 301 The core unit 301 will be assessed by externally set short answer question papers. Each test will comprise of short answer items in accordance with the test specifications provided. 2.2 Assessment of core unit 302 This unit is assessed by a City & Guilds assignment template to the published specification. Centres are to mark assignments and submit marks to City & Guilds via S Form. 2.3 Assessment of common unit 333 The common unit 333 will be assessed by externally set short answer question papers. Each test will comprise of short answer items in accordance with the test specifications provided. 2.4 Assessment of optional units 334 and 335 The optional units 334 and 335 will be assessed by externally set short answer question papers. Each test will comprise of short answer items in accordance with the test specifications provided. 2.3 Assessment of all other units In each mandatory and optional unit there are a number of learning outcomes and each of these learning outcomes specifies a number of knowledge statements. EACH mandatory and optional unit should be assessed by the use of an assignment. The assignment should be produced by the centre in accordance with the template provided by City & Guilds. The resultant level of candidate achievement will be graded. 12 Level 3 Certificate in Process Technology 0603

13 Assignments will provide opportunities for candidates to be assessed for a sample range of the knowledge statements required for the unit. Assignments will usually consist of short answer questions. The range of assignments developed by the centre for each unit should ensure that all the knowledge statements for all the outcomes are assessed as the centre uses a range of assignments over a period of time. City & Guilds will provide assignment templates from which centres should produce the assignments for the units contained in this award. Centres are required to use the templates provided by City & Guilds. City & Guilds will provide quality assurance via its outreach verifier system. For details on the role of the External Verifier, see page 10 External Verification. 2.4 Assignment templates Detailed assignment templates for each mandatory and optional unit are available from City & Guilds. The relevant learning outcomes to accompany each unit are also provided on the website Guidance for Marking Detailed marking and grading criteria are provided for each assignment in the Marking Criteria section of the assignment Marking assignments The grades that should be awarded are as follows Pass 50 64% Credit 65 79% Distinction % Underpinning knowledge questions for the mandatory and optional units Assignments for mandatory and option units MUST consist of underpinning knowledge questions and are designed to sample the underpinning knowledge of the unit. The questions included in the assignments in accordance with City & Guilds guidelines should be taken under supervision as assessors need to ensure the answers to the questions are the candidate s own work. To preserve the integrity and useful life of the questions, candidates should NOT be given their answer sheets. A candidate s success in a written assessment should be recorded by a statement from the centre, quoting the relevant unit number or areas of knowledge assessed, which can then be used by candidates as evidence. Original completed answer sheets should be kept for auditing purposes by the assessor in their own assessment records of candidates performance. Please refer to City & Guilds General Regulations for confirmation of the period of time in which records should be maintained to meet regulatory requirements Feedback Assessors must ensure that candidates understand why a particular grade has been given for the award. If a candidate s work is selected for verification, samples of work must be available to the appointed external verifier. Level 3 Certificate in Process Technology

14 2.5 What centres need to do Producing assignments to assess the other units Centres need to produce papers to the given template for each mandatory/optional unit and a separate mark scheme (see Guidance for marking section on page 9) Submission of assignments All centre-set assignments will be assessed by the centre s External Verifier. 14 Level 3 Certificate in Process Technology 0603

15 The Award For the award of a certificate, candidates must successfully complete the assessments for both core units and the seven chosen optional/mandatory units Core units Assessment components required Unit 301 Mathematics for Industry Written-short answer Dated Exam Unit 302 Communications and Information Technology (Level 3) Assignment Centre marked Pathway optional/mandatory units Unit 303 Process Chemistry Centre set Unit 304 Heat Transfer and Fluid Flow Centre set Unit 305 Steam Generation and Distribution Centre set Unit 306 Distillation In the Process Industry Centre set Unit 307 Unit 308 Unit 309 Evaporation In the Process Industry Crystallisation in the Process Industry Mixing And Blending of Solids And Fluids Centre set Centre set Centre set Unit 310 Water for Industry Centre set Unit 311 Process Control and Fault Diagnosis Centre set Unit 312 Compressors and Compression Technology Centre set Unit 313 Drying in the Process Industry Centre set Unit 314 Separation of Insoluble Solids from Liquids Centre set Unit 3 Size Reduction in the Process Industry Centre set Level 3 Certificate in Process Technology

16 Unit 316 Gas Treatment Centre set Unit 317 Process Quality Centre set Unit 318 Sampling and Laboratory Analysis Centre set Unit 319 Special Processes (Level 3) Centre set Unit 3 Metals Processing (Level 3) Centre set Unit 321 Iron Making and Basic Oxygen Steel Making (Level 3) Centre set Unit 322 Electric Arc Steel Making, Refining and Casting (Level 3) Centre set Unit 323 Primary Working (Level 3) Centre set Unit 324 Finishing Working Processes (Level 3) Centre set Unit 3 Unit 326 Unit 327 Unit 328 Unit 329 High Technology Processing of Metals Metallurgy of Iron and Steel Production (Level 3) Metallurgy of Ferrous Metals and Alloys Metallurgy of Non-ferrous Metals and Alloys Corrosion and Heat Resistant Materials Centre set Centre set Centre set Centre set Centre set Unit 330 Process Control (metals) Centre set Unit 331 Effective Working Relationships Centre set Unit 332 Petroleum Technology (Level 3) Centre set 16 Level 3 Certificate in Process Technology 0603

17 Unit 333 Mathematics for Higher Education Written test Dated Exam Unit 334 Mechanical Engineering Science Unit 335 Electrical Engineering Science Unit 336 Oil and Gas Extraction Unit 337 Separation processes Written test Dated Exam Written test Dated Exam Written test Dated Exam Written test Dated Exam Unit 338 Water injection processes in Oil and Gas Written test Dated Exam Unit 339 Produced water Treatment processes in Oil and Gas Written test Dated Exam Unit 340 Gas treatment processes in Oil and Gas Written test Dated Exam Unit 341 Gas compression processes in Oil and Gas Written test Dated Exam Unit 342 Production of engineering drawings Written test Dated Exam Unit 343 Floating Production Storage and Offloading Vessels Written test Dated Exam Unit 344 Metering and Pigging Written test Dated Exam Unit 345 Liquefied Natural Gas and Natural Gas Liquids processes in Oil and Gas Written test Dated Exam Level 3 Certificate in Process Technology

18 Test Specifications: Core units Subject Process Technology Level 3 Paper No Paper title Assessment method Mathematics for Industry Written short-answer test Duration 2 hours Dated Exam No of items 10 Outcome No of items % 01 Make numerical approximations, make and 3 30 use unit conversion tables. 02 Calculate areas, volumes and flow rates Illustrate and interpret statistical data Apply the basic rules of algebra to solve problems Totals Subject Process Technology Level 2 Paper No Paper title Communications and IT (Level 3) Assessment method City & Guilds set assignment (EV Checked) Centre Marked Weighting given as a general guideline for the delivery and assessment of units Communications and IT (Level 3): Produce a technical report on an industrially relevant issue. 2. Use a word-processing package to develop a technical report that includes tabular, graphical, symbolic and pictorial information. 3. Obtain, organise and store information in an electronic form Level 3 Certificate in Process Technology 0603

19 Test Specifications: Supplementary units Subject Process Technology Level 3 Paper No Paper title Assessment method Mathematics Written short-answer test Dated Exam Duration 2.30 hours No of items Outcome No of items % 01 Apply algebraic methods to the solution of 9 45 problems. 02 Use graphical techniques Use trigonometric functions and rules to solve problems. 04 Apply differential and integral calculus to the solution of problems. 5 3 Totals 100 Subject Process Technology Level 3 Paper No Paper title Assessment method Mechanical Engineering Science Written short-answer Dated Exam Duration 2.30 hours No of items Outcome No of items % 01 Demonstrate an understanding of stress and 3 strain. 02 Analyse force systems using vectors and 2 10 moments. 03 Demonstrate an understanding of linear and 4 angular motion. 04 Demonstrate an understanding of work, 3 energy and power. 05 Analyse the use of lifting machines Demonstrate an understanding of 3 temperature, heat and the effect of temperature on contained gases, e the gas laws. 07 Demonstrate an awareness of the properties 3 of electricity. Totals 100 Subject Process Technology Level 3 Level 3 Certificate in Process Technology

20 Paper No Paper title Electrical Engineering Science Assessment method Written short-answer Dated Exam Duration 2.30 hours No of items Outcome No of items % 01 Apply the laws of physics to simple problems 4 involving energy, matter and motion. 02 Analyse d.c. circuits Apply the laws of electrostatics and solve 2 10 problems involving capacitors. 04 Apply the laws of electromagnetism to solve 2 10 problems involving the operation of the electric motor, generator and transformer. 05 Apply a.c. circuit theory to series RLC circuits Demonstrate an appreciation of the operation 3 of d.c. power supplies. Totals 100 Level 3 Certificate in Process Technology 0603

21 Test Specifications: Pathway mandatory and optional units Assessment specifications Assessment weightings given as general guideline The knowledge requirements for the following units will be assessed by a centre set short answer paper. Process Chemistry: Describe the structure and properties of elements, mixtures, compounds, crystals and alloys. 2. Explain and illustrate the importance of chemical equilibrium and energy changes in reactions involved in manufacturing processes. 3. Demonstrate an understanding of the processes involved in electrolysis and galvanic corrosion. 4. Explain the structure, classifications and properties of carbon compounds and polymers. Heat Transfer and fluid flow: Demonstrate an understanding of the principles of heat transfer and energy conservation. 2. Apply the basic principles of heat transfer to the construction, operation and efficient use of heat exchange equipment. 3. Describe the health and safety hazards associated with heat transfer operations and explain the precautions which will minimise them. 4. Demonstrate an understanding of characteristics and basic principles of fluid flow. 5. Apply the basic principles of fluid flow to the construction and operation of systems for transporting and controlling fluids in pipeline systems. 6. Describe the health and safety hazards associated with the transfer of fluids in pipework systems and explain the precautions necessary to minimise them. Level 3 Certificate in Process Technology

22 Steam Generation and Distribution: Demonstrate an understanding of the theory, principles and practice of steam generation and distribution. 2. Describe the construction, operation and control of equipment used in industry for generating and distributing high and low pressure steam. 3. Describe and explain the function of essential ancillary equipment required by boiler plant. 4. Demonstrate a knowledge of the safety hazards associated with the production and distribution of the various grades of steam and describe the precautions necessary to minimise them Distillation In the Process Industry: Demonstrate an understanding of the theory, principles and practice of separation of liquid mixtures by distillation techniques. 2. Describe the construction, operation and application of distillation equipment used in industry. 3. List and explain the function of ancillary equipment required by distillation plant. 4. Demonstrate a knowledge of the safety hazards associated with distillation processes and the precautions necessary to minimise them. Evaporation In the Process Industry : Demonstrate an understanding of the scientific principles and practice involved in efficient evaporation operations. 2. Describe the construction, operation, control and application of equipment used in industry for evaporation processes. 3. List and explain the function of essential ancillary equipment used in evaporation operations. 4. Demonstrate a knowledge of the safety hazards associated with evaporation processes and the precautions necessary to minimise them. Crystallisation In the Process Industry: Demonstrate an understanding of principles behind the production of crystals, from saturated solutions, and how they affect the techniques of crystallisation. 2. Describe the construction, operation, control and applications of industrial crystallisation equipment. 3. List and explain the function of essential ancillary equipment required by crystallisation plant. 4. Demonstrate a knowledge of the safety hazards associated with crystallisation processes and indicate the procedures necessary to minimise them Level 3 Certificate in Process Technology 0603

23 Mixing and Blending of Solids and Fluids: State the factors that affect the mixing and blending of solids and fluids and explain how they influence the choice of equipment and technique. 2. Describe the construction, operation and application of equipment used in the mixing and blending of solids and fluids 3. List the hazards associated with mixing and blending equipment and state the precautions which will minimise them Water for Industry: Demonstrate an understanding of typical impurities in water and treatments required to render water fit for its intended purpose Demonstrate an understanding of the chemical and biological considerations associated with water technology Demonstrate a knowledge of environmental issues relating to the use of water in industry. Process Control and Fault Diagnosis: Describe the fundamentals of a control system Describe the various components that constitute a control system. 3. Compare the different types of computer control systems and their relative advantages and disadvantages. 4. Demonstrate a logical approach to fault finding. Compressors and Compression Technology: Demonstrate an understanding of the use of compressed gases in process industries and the basic principles of gas compression. 2. Describe the construction, operation and control of centrifugal and positive displacement compressors. 3. Demonstrate a knowledge of the hazards associated with compressor operation and the precautions necessary to minimise them. Drying and calcining in the process industry : Describe the construction, operation, application and control of drying equipment. 3. Describe and explain the function of essential ancillary equipment required by drying operations. 4. Demonstrate a knowledge of the problems and safety hazards associated with drying operations and the precautions necessary Demonstrate an understanding of the principles and mechanisms of drying and the reasons for this operation to minimise them. 50 Level 3 Certificate in Process Technology

24 Separation of Insoluble Solids from Liquids: Demonstrate an understanding of the principles, techniques and methods used to separate insoluble solids from liquids. 2. Describe the construction, operation, control and application of equipment used in the separation of insoluble solids from liquids. 3. Demonstrate an understanding of the safety hazards associated with the separation of insoluble solids from liquids and the precautions necessary to minimise them Size Reduction In the Process Industry : Demonstrate an understanding of the principles of size reduction and the reasons for carrying out this operation in process industries. 2. Describe the construction, operation, application and control of size reduction equipment Demonstrate an understanding of the problems, process faults and safety hazards associated with size reduction operations and the precautions necessary to minimise them. 10 Gas Treatment In the Process Industry : Demonstrate an understanding of the principles behind gas treatment together with the reasons for carrying out this operation in process industries Describe the construction, operation, control and application of gas treatment systems Demonstrate an understanding of the problems and safety hazards associated with gas treatment operations and the precautions necessary to minimise them. Process Quality: Analyse the main factors influencing Quality Assurance in Process Industries. 2. Describe the consequences of not achieving quality standards. 3. Explain how quality standards apply to Process Industries. 4. Explain the differences between on-line and off-line quality control procedures. 5. Describe how customer feedback can be used to assess quality performance. Sampling and Laboratory Analysis: Understand the principles of representative sampling. 2. Understand common methods of analysis. 3. Describe how to assess risks associated with the use, storage and disposal of laboratory chemicals. 4. Explain the principles of quality procedures in the laboratory Level 3 Certificate in Process Technology 0603

25 Special Processes (Level 3): Describe in detail the industry and the processes within which they work. 2. Demonstrate knowledge of any specialised techniques and equipment associated with their process. 3. Demonstrate a generalised knowledge of the methods and modes of material transfer into and out of the processing plant. 4. Describe the use of utilities within their company and their influence on the process. Metals Processing (Level 3): Describe the production processes used to obtain metals from a metal ores. 2. Demonstrate an understanding of the casting processes for ferrous and non-ferrous metals. 3. Explain how primary and secondary rolling mills are used for the initial shaping of metals. 4. Contrast hot and cold finishing processes and comment on why each is used. 5. Explain how the quality of a metal is ascertained and describe testing techniques used in this process. Iron Making and Basic Oxygen Steel Making: Discuss the production of metallurgical coke and reducing gases from natural gas. 2. Describe in detail the sourcing and preparation of iron ore. 3. Discuss the operation and developments of The Iron Blast Furnace. 4. Describe in detail the operation of a Basic Oxygen Steel making Furnace. Electric arc Steel Making, Refining and Casting (Level 3): Explain the operation of an Electric Arc Steel making Furnace and the process of producing steel from scrap. 2. Describe Secondary and Special Steel making processes. 3. Demonstrate a knowledge of the Chemistry of Steel making. 4. Explain the process of continuous casting. Primary Working in the steel industry (Level 3) : Explain the process of heating of steel and other metals for Rolling and Forging operations. 2. Explain and discuss the Primary Rolling of steel. 3. Discuss the hot forging of steel and other metal sections. 4. Describe the developments in hot plate and strip mills Level 3 Certificate in Process Technology

26 Finishing Working Processes (Level 3): Compare welded and seamless pipe manufacture. 2. Describe the process variables in the operation of cold strip mills. 3. Compare process variables in the operation of hot bar and rod mills. 4. Describe the operation of steel and non-ferrous wire and section mills. High Technology Processing of Metals: Describe the process of hot isostatic pressing. 2. Describe the process of continuous strip casting. 3. Compare and contrast the processes of laser welding, electron beam welding, and friction stir welding. 4. Describe the processes of extrusion and powder metallurgy. 5. Comment on innovative techniques in the metal's industry. Metallurgy of Iron and Steel Production (Level 3): Describe the metallurgical principles involved in the production of steel from iron ore and from scrap, including chemical reactions and heat balance. 2. Describe the chemistry of making alloy steels. 3. Describe the process of solidification of a metal alloy. 4. Discuss in detail the hot working of steel. 5. Discuss the metallurgical principles of cold rolling and cold drawing steel. Metallurgy of Ferrous Metals and Alloys: Describe the metallurgical structure of ferrous alloys. 2. Explain the process of solidification ferrous alloys. 3. Explain the effect of carbon in iron and the application of the iron - iron carbon thermal equilibrium diagram in the steel industry. 4. Explain how ferrous metals and alloys are tested and the application of the test data. Metallurgy of non-ferrous Metals and Alloys: Describe the grain structure of non-ferrous alloys. 2. Describe the process of solidification of non-ferrous metals and alloys. 3. Describe the properties and uses of aluminium and its alloys. 4. Describe the properties and uses of copper and its alloys. 5. Describe the properties and uses of zinc, lead and tin. 6. Describe the properties and uses of platinum, silver and gold. 7. Explain how non-ferrous metals are tested Level 3 Certificate in Process Technology 0603

27 Corrosion and Heat resistant Materials: Explain the principles of metallic corrosion and heat resistance. 2. Describe the range of stainless steels and higher alloyed nickel based materials. 3. Describe the range of copper based corrosion resistant materials. 4. Discuss the choice of corrosion resistant materials or process Process Control (Metals): Explain company level approaches to process control. 2. Discuss methods for the control of individual processes. 3. Outline approaches to the management of processes in supply chains. 4. Describe some generic approaches to process improvement. 5. Describe and use some specific analytical techniques. Effective Working Relationships: Outcome % Describe the key features that distinguish different organisational structures. 2. Describe key elements of personal behaviour to achieve customer care. 3. Describe how to achieve effective communication with others. 4. Describe how effective teams and team working can be developed. 5. Describe the additional characteristics and behaviour of effective team leaders. 6. Explain how leaders effectively manage the performance of team members. 7. Outline the key elements of effective discipline and grievance procedures. 8. Explain how change can be effectively managed. Petroleum Technology (level 3): Explain the key processes involved in enhanced oil recovery (EOR). 2. Describe the detailed construction and operation of the key elements of oil and gas production platforms and distribution systems both on and off shore. 3. Describe in detail the construction and key features of the following refinery process units and explain their principles and modes of operation. Separation in Oil and Gas Identify the purpose of separation. 2. Detail reservoir fluids. 3. Describe the principles of separation. 4. Describe the different types of separators. 5. Detail how separators are constructed and how they function. 6. Describe multi-stage separation. 7. Detail separator control. 8. Detail the operation of separators. 9. Detail separator process problems. 10. Introduce new separator technology Level 3 Certificate in Process Technology

28 Mechanical Engineering Science Demonstrate an understanding of stress and strain. Analyse force systems using vectors and moments. Demonstrate an understanding of linear and angular motion. Demonstrate an understanding of work, energy and power. Analyse the use of lifting machines. Demonstrate an understanding of temperature, heat and the effect of temperature on contained gases, ie the gas laws. Demonstrate an awareness of the properties of electricity. Electrical Engineering Science Apply the laws of physics to simple problems involving energy, matter and motion. Analyse d.c. circuits. Apply the laws of electrostatics and solve problems involving capacitors. Apply the laws of electromagnetism to solve problems involving the operation of the electric motor, generator and transformer. Apply a.c. circuit theory to series RLC circuits. Demonstrate an appreciation of the operation of d.c. power supplies Oil and Gas Extraction Introduce learners to the basic underlying concepts of gas treatment 2. Detail the problems associated with water in gas streams 3. Detail the process of liquid desiccant dehydration 4. Detail the process of solid desiccant dehydration 5. Detail alternative gas dehydration processes 6. Detail the acid gas removal unit 7. Detail the removal of various other impurities in raw gas streams Separation processes in oil and gas Detail the different types of compressors and how they function 2. Detail the different compression systems 3. Detail reciprocating compressors 4. Detail centrifugal compressors 5. Detail surge 6. Describe the start-up and shutdown process 7. Detail the innovations in compressor technology Water injecton processes in Oil and Gas To provide an introduction to water injection 28 Level 3 Certificate in Process Technology 0603

29 Detail reservoirs and rock properties Explain the process of waterflooding Identify and describe the impurities present in injection water Identify and describe the different types of water injection systems Illustrate a water injection system Detail the types of tests done to ensure water quality Detail how both a basic well and a water injection well are constructed Detail the start-up and shutdown process of a water injection system Produced Water Treatment processes in Oil and Gas Discuss the origin and composition of produced water Detail the four produced water production streams Describe the various problems associated with produced water Describe the various water disposal methods Detail the principles of produced water treatment Discuss the equipment used in produced water treatment Describe the different produced water treatment systems Describe produced water management Gas Treatment processes in Oil and Gas Introduce learners to the basic underlying concepts of gas treatment Detail the problems associated with water in gas streams Detail the process of liquid desiccant dehydration Detail the process of solid desiccant dehydration Detail alternative gas dehydration processes Detail the acid gas removal unit Detail the removal of various other impurities in raw gas streams Gas compression processes in Oil and Gas Detail the different types of compressors and how they function Detail the different compression systems Detail reciprocating compressors Detail centrifugal compressors Detail surge Describe the start-up and shutdown process Detail the innovations in compressor technology Petroleum Technology (level 3): Provide an introduction to Production Engineering Drawings 2. Detail Process Flow Schemes 3. Detail Process Flow Diagrams Level 3 Certificate in Process Technology

30 4. Detail Piping and Instrument Drawings 5. Explain how to read process diagrams 6. Provide a detailed explanation of process systems 7. Provide a detailed explanation of instrument systems Petroleum Technology (level 3): Provide an overview of FPSO s 2. Provide an overview of station keeping on an FPSO 3. Identify why stability is important on an FPSO 4. Describe the use of turrets on a FPSO 5. Detail the production and offloading of oil on a FPSO 6. Detail the oil and gas processing facilities on the FPSO 7. Identify and describe the marine systems on the FPSO 8. Detail the manning strategies on the FPSO Metering and pigging Provide an introduction to the field of metering 2. Detail the different gas metering principles of flow measurement 3. Describe in detail the gas metering process 4. Describe in detail the oil metering process 5. Detail the different metering operations 6. Detail the different sampling systems 7. Detail the pigging process Liquefied Natural Gas and Natural Gas Liquid Processes in Oil and Gas Provide an overview of gas liquids 2. Detail the various chemical and physical properties of gas liquids 3. Describe in detail Liquefied Petroleum Gas (LNG) 4. Detail the recovery of Natural Gas Liquids (NGL) 5. Detail how impurities are removed from natural gas 6. Detail the liquefaction of natural gas 7. Detail the different ways in which gas liquids are stored onshore 8. Detail the different ways in which gas liquids are stored offshore 9. Address the Health, Safety and Environmental (HSE) issues of gas liquids 30 Level 3 Certificate in Process Technology 0603

31 Learning Outcomes: Core Units The individual learning outcomes for the Core units 301 and 302 are given as follows. The learning outcomes for the Pathway mandatory and optional units are provided on the City & Guilds website. These are listed under each Pathway route. Information on each unit is available in downloadable format. This is to enable candidates wishing to specialise on a pathway route to access information relevant to that pathway. To access this information, please go to Level 3 Certificate in Process Technology

32 Unit 301: Mathematics for Industry Rationale This unit is designed to give candidates the mathematical skills and knowledge needed for a general understanding of the unit operations and processes throughout the process industries. Outcomes There are four outcomes to this unit. The candidate will be able to: Make numerical approximations, make and use unit conversion tables. Calculate areas, volumes and flow rates. Illustrate and interpret statistical data. Apply the basic rules of algebra to solve problems. Connections with other awards This unit contributes towards the knowledge and understanding of the following N/SVQs: Level 3 Chemical, Pharmaceutical and Petrochemical Manufacture Level 3 Refinery Field Operations Level 3 Refinery Operations (Control Room) Level 3 Metal Processing and Allied Operations. Assessment The outcomes for this unit will be assessed using evidence from a written test. The underpinning knowledge requirements are listed for each outcome. A short answer question paper based on the test specification will assess these outcomes. 32 Level 3 Certificate in Process Technology 0603