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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED QUALIFICATION: 

Occupational Certificate: Fossil Power Plant Process Controller 
SAQA QUAL ID QUALIFICATION TITLE
97384  Occupational Certificate: Fossil Power Plant Process Controller 
ORIGINATOR
Development Quality Partner - EWSETA 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY NQF SUB-FRAMEWORK
-   OQSF - Occupational Qualifications Sub-framework 
QUALIFICATION TYPE FIELD SUBFIELD
Occupational Certificate  Field 06 - Manufacturing, Engineering and Technology  Manufacturing and Assembly 
ABET BAND MINIMUM CREDITS PRE-2009 NQF LEVEL NQF LEVEL QUAL CLASS
Undefined  210  Not Applicable  NQF Level 06  Regular-ELOAC 
REGISTRATION STATUS SAQA DECISION NUMBER REGISTRATION START DATE REGISTRATION END DATE
Reregistered  EXCO 0425/24  2018-07-01  2025-12-30 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2026-12-30   2029-12-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This qualification does not replace any other qualification and is not replaced by any other qualification. 

PURPOSE AND RATIONALE OF THE QUALIFICATION 
Purpose:
The purpose of this qualification is to prepare a learner to operate as a Fossil Power Plant Process Controller. A Fossil Power Plant Process Controller manages, supervises and controls the application of resources, operations, processes and activities within the energy conversion processes in a power generating plant effectively and efficiently to ensure a continuous, reliable supply of electrical energy to the national grid and/or internal reticulation system. A qualified learner will be able to:
  • Manage, monitor and control the availability of raw materials and disposal of combustion waste and the auxiliary plants/services required within the electrical production processes.
  • Manage, supervise and control the application of resources, operations, processes and activities within the energy conversion processes in a steam generating plant effectively and efficiently to ensure a continuous, reliable supply of heat energy to the turbo generating/process plant.
  • Manage, supervise and control the application of resources, operations, processes and activities within the energy conversion processes in a turbine or process plant effectively and efficiently to ensure a continuous, reliable supply of energy to the electrical generating or process plant.
  • Manage, supervise and control the application of resources, operations, processes and activities within the energy conversion processes and systems to generate and supply electricity to the stakeholders and to supply adequate electrical supplies for own auxiliaries.

    Rationale:
    Learners obtaining this qualification will be recognised on a national level for performing process control activities on a power plant. This qualification will ensure professionalism, proficiency and excellence in the control of Power Plant Generation Units. It will also assist in changing perceptions on the status and functional levels of Process Controllers in Power Plant Generation. The qualification will enable the learners to feel pride and self-worth, and enhance their morale.

    Value-adding to the employer will be manifested in the competence of the employee in terms of safe, sound and efficient operations performed by the Process Controller. This qualification will provide standards for Recognition of Prior Learning of existing Process Controller competence throughout the industry and allow credits to be obtained in cross-functional learning fields.

    This qualification is based on the power generation industry needs in building competence in the workplace for Fossil Power Plant Process Operations.

    The qualification has been developed to cater for the needs of power plant process control in contexts such as sugar processing and SASOL as these contexts are significantly limited in what is expected from a power plant controller in the Fossil, Hydro and Nuclear contexts. Since this qualification is now specific to a single context, (as per OFO), these gaps are now addressed in the qualification and therefore demonstrates an increase in complexity, which places the qualification at NQF Level 6. This qualification will provide the learner with accessibility to be employed within the process control function on fossil-fired power plant units. Other considerations in the national interests addressed by this Qualification are:
  • Building individual capacity in this specialised profession.
  • Ensuring entry, progression and mobility into Life Long Learning in this specific learning field.
  • Addressing Power Plant Operations Industry's specific employment requirements.
  • Enhancing professional competence on a national level.
  • Providing an avenue of upliftment for the previously disadvantaged into this professional discipline.
  • Enhancing social and economic development.

    Typical learners will include Power Station employees that have completed the relevant Operator Qualification. The power generating industry is currently investing huge amounts of capital in the training of power plant operators. In addition this qualificationwilladdress the following which will contribute to good environmental practices:
  • Basic Environmental Procedures.
  • Air Quality Management according to procedures and administrative requirements.
  • Water Quality Management.
  • Waste Management.
  • Soil/Land Quality Management.
  • Environmental Management System. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    Recognition of Prior Learning (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 or certifying a Work Experience Record.RPL for access to the qualification: Accredited providers and approved workplaces may recognise prior learning against the relevant access requirements.

    Entry Requirements:
    Learners are required to have the following in order to be considered for admission:
  • Further Education and Training Certificate: Power Plant Operations at NQF Level 4 SAQA ID: 61569.
  • Senior Certificate (SC) or National Senior Certificate with a pass in Mathematics, Science and English Language.
  • National Vocational Certificate. 
    		•

    RECOGNISE PREVIOUS LEARNING? 
    Y 

    QUALIFICATION RULES 
    This qualification is made up of the following compulsory Knowledge and Practical Skill Modules:
    Knowledge Modules:
  • 313102000-KM-01, Power plant chemistry and efficiency principles, NQF Level 4, 2.Credits.
  • 313102000-KM-02, Power plant chemistry and efficiency principles, NQF Level 5, 7 Credits.
  • 313102000-KM-03, Power plant chemistry and efficiency principles, NQF Level 6, 4 Credits.
  • 313102000-KM-04, Power plant instrumentation and control systems, NQF Level 5, 15 Credits.
  • 313102000-KM-05, Statutory and regulatory requirements pertaining to a power plant, NQF Level 5, 10 Credits.
  • 313102000-KM-06, Statutory and regulatory requirements pertaining to a power plant, NQF Level 6, 8 Credits.
  • 313102000-KM-07, Electrical theories, concepts and reticulation systems., NQF Level 4, 9 Credits.
  • 313102000-KM-08, Electrical theories, concepts and reticulation systems., NQF Level 5, 15 Credits.
  • 313102000-KM-09, Fossil Power Plant Unit Operations, NQF Level 6, 20 Credits.
  • 313102000-KM-10, Shift communication and integrated business improvement, NQF Level 4, 3 Credits.
  • 313102000-KM-11, Operating processes and practices, NQF Level 5, 3 Credits.
    Total number of credits for Knowledge Modules: 96.

    Practical Skill Modules:
  • 313102000-PM-01, Coordinate the availability of raw materials and disposal of combustion waste, NQF Level 5, 6 Credits.
  • 313102000-PM-02, Operate, control and monitor heat transfer process/systems in steam generating plant operations from a control room/panel, NQF Level 6, 30 Credits.
  • 313102000-PM-03, Operate, control and monitor energy conversion processes and systems in a turbine or process plant, NQF Level 6, 30 Credits.
  • 313102000-PM-04, Operate, monitor and control process and systems to generate and supply electricity to the national grid and to supply adequate electrical supplies for safe unit operation, NQF Level 6, 6 Credits.
    Total number of credits for Practical Skill Modules: 72.

    This qualification also requires the following Work Experience Modules:
  • 313102000-WM-01, Inventory management from a control room/panel, NQF Level 5, 6 Credits.
  • 313102000-WM-02, Energy conversion and heat transfer process, NQF Level 6, 15 Credits.
  • 313102000-WM-03, Start-up and synchronising of steam turbines and auxiliaries, NQF Level 6, 15 Credits.
  • 313102000-WM-04, Electricity generation processes according to system demand requirements, NQF Level 6, 6 Credits.
    Total number of credits for Work Experience Modules: 42. 
    		•

    EXIT LEVEL OUTCOMES 
    1. Interpret or diagnose events and conditions based on alarms and indications during normal, out of normal and emergency operations on a Fossil Power Plant.
    2. Apply procedures, references and technical specifications during normal, out of normal and emergency operations on a Fossil Power Plant.
    3. Operate a Fossil Power Plant safely during normal, out of normal and emergency conditions from a controlled environment.
    4. Communicate and interact with other role players during normal, out of normal and emergency operations on a Fossil Power Plant.
    5. Perform status monitoring during out of normal and emergency operations on a Fossil Power Plant.
    6. Integrate and apply human performance practices on a Fossil Power Plant.
    7. Source and use control room documentation on a Fossil Power Plant.
    8. Recognise and understand the integration and functionality of all plant systems on a Fossil Power Plant.
    9. Evaluate the strategies in incidents, out of normal and emergency operations on a Fossil Power Plant.
    10. Interact as a functional member of the team on a Fossil Power Plant. 

    ASSOCIATED ASSESSMENT CRITERIA 
    Associated Assessment Criteria for Exit Level Outcome 1:
  • Recognition of normal and out of normal plant trends is used for diagnosis of plant conditions.
  • Prioritisation of actions is based on diagnosis of plant conditions.
  • An emergency condition on a fossil power plant is recognised and diagnosed.
  • Prioritisation of actions of emergency plant conditionsis diagnosised.

    Associated Assessment Criteria for Exit Level Outcome 2:
  • The correct procedures and technical specification to control a Fossil Power Plant in all conditions is referenced.
  • Compliance with procedures in an accurate and timely manner is achieved.

    Associated Assessment Criteria for Exit Level Outcome 3:
  • Controls are located and manipulated in an accurate and timely manner.
  • The system operation, including set-points, interlocks and automatic actions, is accurately described and applied.
  • Ability to take manual control when automatic control fails is demonstrated.
  • Correct reference material (prints, books and charts) to aid in diagnosing and classifying events and conditions are used.
  • Correctly diagnosed plant conditions based on all indicators (trends, alarms, visual parameters, instrumentation and check sheets) is demonstrated.

    Associated Assessment Criteria for Exit Level Outcome 4:
  • System status is analysed and evaluated, and clear and accurate information is provided.
  • Information is received from stakeholders and accurately responded to.
  • Instructions from the supervisor are received and accurately carried out.

    Associated Assessment Criteria for Exit Level Outcome 5:
  • Correct alarm response procedures are identified, based on monitoring critical parameters and corrective actions are taken.
  • Out of normal trends and status are recognised.

    Associated Assessment Criteria for Exit Level Outcome 6:
  • Effective self-checking is applied (STAR) using the company's recognised methodology.
  • The application of operating best practices is demonstrated.
  • Team briefs are conducted as per company requirements.
  • Stress management principles and concepts are defined, and techniques appropriate to the situation are applied.
  • Conflict management principles and concepts are defined, and techniques appropriate to the situation are applied.
  • Place keeping (dealing with distractions) principles and concepts are defined, and techniques appropriate to the situation are applied.
  • Compliance, awareness and promotion of good safety practices are assessed for appropriateness.

    Associated Assessment Criteria for Exit Level Outcome 7:
  • The appropriate procedure is located in a timely manner.
  • Procedures are correctly applied, including following procedural steps in the correct sequence,: abiding by procedural cautions, limitations and rules of usage;selecting correct paths on decisions blocks;place keeping to deal with distractions/interruptions and the correct transitioning between procedures.
  • Plant conditions that are addressed in technical specifications are recognised and evaluated.

    Associated Assessment Criteria for Exit Level Outcome 8:
  • The purpose and the functions of all plant systems are evaluated.
  • The purpose and the integrated function of all the equipment that make up the plant system are explained.
  • The instrumentation and control function of all plant systems are distinguished.

    Associated Assessment Criteria for Exit Level Outcome 9:
  • The strategy to mitigate all accident, out of normal and emergency operations is justified based on specific plant conditions.
  • Major action steps in incident, out of normal and emergency operations procedures are outlined.
  • The basis for procedure steps used in accidents, out of normal and emergency operations procedures is justified.

    Associated Assessment Criteria for Exit Level Outcome 10:
  • Feedback is solicited from team members to foster an effective, team-oriented approach to problem-solving and decision-making, and is incorporated into problem-solving and decision-making strategies.
  • The individual's role is clarified and contributions are in accordance with his/her role and responsibility.
  • Effective shift handover techniques are applied.

    Integrated Assessment:
    Integrated Formative Assessment:
    The skills development provider will use the Curriculum to guide the learners 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 leads to entrance into the integrated external summative assessment.

    Integrated Summative Assessment:
    An external integrated summative assessment, conducted through the relevant QCTO Assessment Quality Partner, is required for the issuing of this qualification. The external integrated summative assessment will focus on the Exit Level Outcomes and Associated Assessment Criteria. 
    		•

    INTERNATIONAL COMPARABILITY 
    The qualification is based on a study conducted by Eskom on various European countries with leading power producers. The German model (with minor changes) was adopted as the basis for this qualification and the Silver Seal Operator qualification was registered and accredited by the Eskom and Allied Industries Training Board (EAITB).This qualification only covers the fossil component of the Silver Seal Operator Qualification.

    The British Columbia Institute of Technology offers a Basic Power Plant Training Program. The Certificate program that can be taken module at a time. It is a highly respected program developed in cooperation with Georgia Pacific and now widely used by large organisations like Nippon Paper as well.

    The Basic Power Plant Training program consists of seventeen modules covering critical areas of the plant including:
  • Boilers.
  • Instrumentation and control systems.
  • Water.
  • Steam.
  • Condensate systems.
  • Auxiliary systems.

    Module titles:
  • Overview of the Pulp and Papermaking Process.
  • Overview of the Power and Recovery areas.
  • Introduction to Boilers.
  • Power Plant Science.
  • Instrumentation.
  • Oil and Gas Fired Boilers.
  • Stoker Fired Boilers.
  • Wood Waste.
  • Coal.
  • Pulverised Coal Firing.
  • Ash Removal Systems.
  • Boiler Controls.
  • Power Plant Auxiliary Equipment.
  • Water Processing and Conditioning.
  • Steam Distribution System.
  • Condensate System.
  • Boiler Feedwater System.
  • Steam Turbines.
  • Electrical Production and Distribution.

    The Industrial Skills Training institution in the United Kingdom, TPC Training Systems provides a qualification that covers energy principles and boiler maintenance, explains coal, oil, and natural gas combustion, and how to conserve energy through improved combustion control. The qualification covers the basic steam generation system, how thermal energy is converted into electrical energy, components of the system, and design features for gaining thermal efficiency. The TPC Training system offers a comprehensive Training Needs Analysis survey tool that covers hundreds of core knowledge areas for maintenance positions. TPC Training Systems is authorised by International Association for Continuing Education and Training (IACET) to offer the a range of industrial skills training as solutions to help build a better, safer, more efficient workforce.

    Specific Learning Objectives for this qualification:
  • Describe the basic concepts involved in converting energy to electricity through a steam power plant.
  • Explain why air is important in combustion and describe how air is heated.
  • Describe the basic design of a boiler.
  • List the methods commonly used to create efficiency in a boiler.

    Conclusion:
    The finding is that this qualification is aligned to international training and certification programmes delivered by training providers. 
    		•

    ARTICULATION OPTIONS 
    The qualification articulates vertically and horizontally as follows:

    Horizontal Articulation:
    Possible horizontal articulation is possible with occupational qualification currently in the process of being developed, namely:
  • Occupational Certificate: Nuclear Power Plant Process Controller, NQF Level 6.

    Vertical Articulation:
  • Occupational Certificate: Power Plant Operations Manager, NQF Level 7 - to be developed following the registration of this qualification. 
    		•

    MODERATION OPTIONS 
    N/A 

    CRITERIA FOR THE REGISTRATION OF ASSESSORS 
    N/A 

    NOTES 
    Qualifying for external assessment:
    In order to qualify for the external summative assessment learners must have a copy of a completed and signed Statement of Work Experience as well as proof of successful completion of the Knowledge and Practical modules.

    Additional legal or physical entry requirements:
    None

    Criteria for the accreditation of providers:
    Accreditation of providers will be done against the criteria as reflected in the relevant curriculum on the QCTO website.
    The curriculum title and code is: 313102000: Fossil Power Plant Process Controller.

    This qualification covers the following trades as recorded on the NLRD:
  • This is not a trade.

    Part Qualifications:
  • None. 
    		•

    LEARNING PROGRAMMES RECORDED AGAINST THIS QUALIFICATION: 
     
    NONE 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS QUALIFICATION: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    NONE 


    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.