Level 2 Certificate in Process Technology Qualification

Level 2 Certificate in Process Technology Qualification handbook 0603 Version 2.3 (October 2011) May 2006

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 www.city-and-guilds.co.uk or from our Customer Relations team by phoning 020 7294 2800 or e-mailing [email protected] City & Guilds publications These are available from Publications Sales City & Guilds 1 Giltspur Street London EC1A 9DD T +44 (0)20 7294 2850 F +44 (0)20 7294 3387 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. ©2005 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)20 7294 2468 or fax +44 (0)20 7294 2400

Contents Page Level 2 Certificate in Process Technology 4 General information 7 General structure 7 Assessment and quality assurance 7 Course design 8 Centre and Qualification approval 8 Registration and certification 9 External verification 9 Guidance notes on assessment 10 What is provided by City & Guilds 10 On-line assessment requirements 10 Guidance for marking 11 What centres need to do 12 The Award 13 Test specifications – Core Units 15 Test specifications – Pathway Mandatory and Optional Units 17 Learning outcomes – Core Units 21 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 201 Process Science Unit 202 Calculations Unit 203 Health & Safety and Environmental Issues Unit 204 Communications/IT Unit 205 Process Chemistry* Unit 206 Process Plant and Process Plant Services* Unit 207 Processing Solids Unit 208 Processing Fluids Unit 209 Principles of Laboratory Analysis Unit 210 Special Processes (Level 2) Unit 211 Instrumentation, Measurement and Control Unit 212 Metals Processing (Level 2) Unit 213 Iron Making and Basic Oxygen Steel Making (Level 2) Unit 214 Electric Arc Steel making, refining and casting (Level 2) Unit 215 Primary Working in the Steel Industry (Level 2) Unit 216 Finishing Working Processes (Level 2) Unit 217 Foundry Working Processes Unit 218 Process Control, Inspection and Testing of Metal Production Unit 219 Metallurgy of Iron and Steel Production (Level 2) Unit 220 Testing and properties of Metals and Alloys Unit 221 Coating and Surface Treatment of Metals Unit 222 Non-ferrous Metals and Alloys Unit 223 Chemistry for Petroleum Operations Unit 224 Petroleum Technology Unit 225 Using PLC Based Systems

4 Level 2 Certificate in Process Technology 0603

Level 2 Certificate in Process Technology (0603)

Introduction This award is aimed at candidates who are following Modern Apprenticeship programmes require evidence towards the underpinning knowledge of an N/SVQ seeking a technical certificate 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 Process Technology Level 2, while containing additional skills and knowledge which go beyond the scope of the National Occupational Standards. Candidates must follow ONE of four Process Technology pathways. Successful candidates will receive a certificate endorsed with their chosen pathway: Level 2 Certificate in Process Technology-Chemical process Level 2 Certificate in Process Technology-Metal production Level 2 Certificate in Process Technology-Petroleum operations Level 2 Certificate in Process Technology-Open

Level 2 Certificate in Process Technology 0603 5

Routes Chemical Process, Metal Production, Petroleum Operations, and Open. To gain the Level 2 Certificate in Process Technology, candidates must undertake assessments for all 4 core units (units 201 to 204) plus an additional 5 unit credits from within a single industrial sector route. These 5 units must include the mandatory units for the chosen industrial sector route. A total of 9 unit credits in all are required to achieve the award, including the associated assessments of multiple choice test(s) or assignments. Common units Unit 201: Process Science Unit 202: Calculations Unit 203: Health & Safety and Environmental Issues Unit 204: Communications/IT (Level 2) Mandatory units for routes (* indicates a double unit): Chemical Process Unit 205: Process Chemistry* Unit 206: Process Plant and Process Plant Services*

Metal Production Unit 212: Metals Processing (Level 2) Petroleum Operations Unit 206: Process Plant and Process Plant Services* Unit 223: Chemistry for Petroleum Operations Unit 224: Petroleum Technology (Level 2) Open Unit 206: Process Plant and Process Plant Services*

Unit 210: Special Processes (Level 2)


Optional units for routes (* indicates a double unit): Chemical Process Unit 207: Processing Solids Unit 208: Processing Fluids Unit 209: Principles of Laboratory Analysis Unit 210: Special Processes (Level 2) Unit 211: Instrumentation, Measurement and Control Metal Production Unit 213: Iron Making and Basic Oxygen Steel Making (Level 2) Unit 214: Electric Arc Steel Making, Refining and Casting (Level 2) Unit 215: Primary Working in the Steel Industry (Level 2) Unit 216: Finishing Working Processes (Level 2) Unit 217: Foundry Working Processes Unit 218: Process Control, Inspection and Testing of Metal Production Unit 219: Metallurgy of Iron and Steel Production (Level 2) Unit 220: Testing and Properties of Metals and Alloys Unit 221: Coating and Surface Treatment of Metals Unit 222: Non-ferrous Metals and Alloys Unit 206: Process Plant and Process Plant Services* Unit 211: Instrumentation, Measurement and Control Petroleum Operations Unit 208: Processing Fluids Unit 209: Principles of Laboratory Analysis Unit 210: Special Processes (Level 2) Unit 211; Instrumentation, Measurement and Control Open Unit 209: Principles of Laboratory Analysis Unit 211: Instrumentation, Measurement and Control Unit 225: Using PLC Based Systems

Please note: The test specifications for the Core Units are provided on pages 15-16 The test specifications for the pathway mandatory and optional units are provided on pages 17-20 The individual learning outcomes for the Core Units are given on pages 21-38 The individual learning outcomes for the Pathway mandatory and Otional units are provided on the City & Guilds website. This is to enable candidates wishing to specialise on a pathway route to access the information to that particular pathway. Information on the Pathway and optional units is available in downloadable format.


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 online multiple choice tests. This applies to common units 201 and 202. 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 core unit 204.

Centre set assignments, which must be developed in line with City & Guilds assignment templates.

Monitoring and quality assurance of assignments will be undertaken by City & Guilds through the external verification system.

Quality assurance includes initial centre approval, Qualification approval, the centre's 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 Qualification approval. Assessment components are graded (Pass, Credit, Distinction). For candidates with particular requirements, centres should refer to City & Guilds policy document Access to assessment, candidates with particular requirements.


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: i.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 Qualification approval Centres wishing to offer City & Guilds qualifications must gain approval. New centres must apply for centre and Qualification approval. Existing City & Guilds centres will need to get specific Qualification approval to run this Award. Full details of the process for both centre and Qualification approval are given in Providing City & Guilds qualifications - a guide to centre and Qualification approval which is available from City & Guilds’ regional offices.


Registration and certification Candidates must be registered at the beginning of their course. Centres should submit registrations using Form S (Registration), under Qualification 0603. 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. 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. City & Guilds reserves the right to suspend an approved centre, or withdraw its approval from an approved centre to conduct a particular City & Guilds Qualification or particular City & Guilds Qualifications, 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 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 http://www.city-and-guilds.co.uk 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.

http://www.city-and-guilds.co.uk/�


Guidance notes on assessment Section 1- Introduction The City & Guilds Level 2 Process Technology Award 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 multiple-choice online test for EACH of the core units 201 and 202 One City & Guilds centre devised assignment, based on an assignment template for core unit 203 One City & guilds set assignment for core unit 204 One centre devised assignment based on an assignment template provided for EACH of the other units. 2.1 What is provided by City & Guilds City & Guilds will provide on-line, on-demand testing using multiple choice questions, for the core units 201 and 202. City & Guilds will provide an assignment template for core unit 203. City & Guilds will provide an assignment and marking guide for core unit 204. City & Guilds will also provide an assignment template for each of the other units. Please note: Assignment templates for the centre-devised units will be available from City & Guilds. An assignment and marking guide for core unit 204 will be provided on the City & Guilds website. 2.2 Assessment of Core units The core units 201 and 202 will be assessed by externally set multiple choice tests. These tests will be available online through the City & Guilds GOLA system from September 2005. Each test will comprise of multiple choice items in accordance with the test specifications provided. 2.2.1 On Line assessment requirements The entire test will be conducted via the candidate’s VDU. All data relating to the assessment will be held by City & Guilds with results and performance feedback being delivered back to the approved centre. City & Guilds will continue to apply its rigorous quality control procedures to the production, editing, marking, moderating and revision of all questions whilst at the same time applying a robust security system to prevent assessments being accessed or drawn down by unauthorised persons or for purposes beyond those authorised. 2.2.2 GOLA registration Centres are required to register as a GOLA centre before any tests can be scheduled. The form for this is available from the website www.city-and-guilds.co.uk/e-assessment A centre only needs to register once for GOLA

http://www.city-and-guilds.co.uk/e-assessment�


2.2.3 Further information There is a GOLA helpline number - centre enquiries and technical enquiries about GOLA can be directed to this number 0845 241 0070. Centres can also e-mail: [email protected]. The following leaflets are available: A centre’s guide to global on-line assessment A centre’s guide to technical requirements for global on-line assessment A centre’s guide to administering global on-line assessment A learner’s guide to global on-line assessment. Centres looking for general information about GOLA or copies of the GOLA leaflets are advised to use the website www.city-and-guilds.co.uk/e-assessment. 2.3 Assessment of core unit 204 This unit is assessed by a City & Guilds devised assignment to the published specification. 2.4 Assessment of the 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 learning outcomes and template provided by City & Guilds. The resultant level of candidate achievement will be graded. Assignments will provide opportunities for candidates to be assessed for a sample range of the knowledge statements required for the unit. 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. 2.4.1 Assignment templates Detailed assignment templates for each mandatory and optional unit are provided as a separate document by City & Guilds. The relevant learning outcomes to accompany each unit are also provided on the website. 2.4.2 Guidance for Marking Detailed marking and grading criteria are provided for each assignment in the Marking Criteria section of the assignment. 2.4.3 Marking assignments The grades that should be awarded for the underpinning knowledge are as follows Pass 50-64% Credit 65-79% Distinction 80 – 100% Note : As Unit 203 is the Health & Safety unit this shall be a Pass / Fail unit. PASS MARK WILL BE 75%

mailto:[email protected]�

http://www.city-and-guilds.co.uk/e-assessment�


2.4.4 Underpinning knowledge questions for the other units Assignments for the 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. 2.4.5 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. 2.5 What centres need to do 2.5.1 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 Qualification (see Guidance for marking section on page 11) 2.5.2 Assessment of assignments All centre-set assignments should be assessed by the centre’s External Verifier.


The Award For the award of a certificate, candidates must successfully complete the assessments for all four core units and the chosen mandatory and optional units Core units Assessment components required

Unit 201 Process Science 0603-02-201 On-line multiple choice

Unit 202 Calculations 0603-02-202 On-line multiple choice

Unit 203 Health & Safety and Environmental Issues

0603-02-203 Centre set

Unit 204 Communications and IT 0603-02-204 City & Guilds set Assignment

Pathway mandatory and optional units

Unit 205 Process Chemistry 0603-02-205 Centre set

Unit 206 Process Plant and Process Plant Services


Unit 207 Processing Solids 0603-02-207 Centre set

Unit 208 Processing Fluids 0603-02-208 Centre set

Unit 209 Principles of Laboratory Analysis


Unit 210 Special Processes (Level 2) 0603-02-210 Centre set

Unit 211 Instrumentation, Measurement and Control


Unit 212 Metals Processing (Level 2) 0603-02-212 Centre set

Unit 213 Iron Making and Basic Oxygen Steel Making (Level 2)


Unit 214 Electric Arc Steel making, refining and casting (Level 2) 0603-02-214 Centre set

Unit 215 Primary Working in the Steel Industry (Level 2)



Unit 216 Finishing Working Processes (Level 2)


Unit 217 Foundry Working Processes 0603-02-217 Centre set

Unit 218 Process Control, Inspection and Testing of Metal Production


Unit 219 Metallurgy of Iron and Steel Production (Level 2)


Unit 220 Testing and Properties of Metals and Alloys


Unit 221 Coating and Surface Treatment of Metals


Unit 222 Non-ferrous Metals and Alloys


Unit 223 Chemistry for Petroleum Operations


Unit 224 Petroleum Technology (Level 2)


Unit 225 Using PLC Based Systems



Test Specifications: Core Units The knowledge requirements for the Core Units 201 and 202 will be assessed by a multiple choice test. Subject Process Technology Level 2 Paper No. 0603-02-201 Paper title Process science Assessment method GOLA online test Duration 30 minutes No of items 20 Outcome No of items % 01 describe the composition and properties of

matter 4 20

02 apply the concepts of force, energy, work and power

8 40

03 explain the thermal properties of solids, liquids and gases

4 20

04 describe the nature and application of electricity

4 20

Totals 20 100 Subject Process Technology Level 2 Paper No. 0603-02-202 Paper title Calculations in the Process Industries Assessment method: Gola online test Duration 30 minutes No of items 20 Outcome No of items % 01 perform simple arithmetic operations 8 40

02 solve problems involving simple formulae 8 40

03 interpret graphical data 4 20

Totals 20 100


Units 203 and 204 assessment weightings are given as a general guideline for the delivery and assessment of units. Subject Process Technology Level 2 Paper No. 0603-02-203 Paper title Health & safety and environmental issues Assessment method Centre set assignment Unit Outcome % 203 01. State the importance of personal health, safety and

environmental issues in the workplace and the regulations relating to these matters

02. Comment on the factors that contribute to the maintenance of standards of health and safety within an organisation 03. Explain the importance of accurate communications and records

with regard to health, safety and welfare in the workplace

30 30 30

Total 100 Subject Process Technology Level 2 Paper No. 0603-02-204 Paper title Communications and IT Assessment method City & Guilds set assignment Unit Outcome % 204 1. Interpret and summarise information from technical documentation.

2. Use standard features of a word-processing package to enhance the appearance and legibility of technical documentation. 3. Record, organise and develop information using a spreadsheet package.

30 35 35

Total 100


Test Specifications: Pathway mandatory and optional units

Assignment specifications The knowledge requirements for the following units will be assessed by a centre-set assignment or series of assignments. Process Chemistry: 0603-02-205 Unit Outcome % 205 1. Describe the structure of atoms, elements and compounds and use

chemical symbols to represent them. 2. Apply fundamental scientific laws to the construction and use of balanced chemical equations. 3. Explain the meaning and application of solubility and the use of solubility curves. 4. Describe the application and importance of electrochemical principles. 5. Describe the structure, classification and properties of carbon compounds.

20 25 20 15 20

Total 100 Process Plant and Process Plant Services: 0603-02-206 Unit Outcome % 206 1. Describe the construction, operation and duties of pipes and

equipment in pipework systems. 2. Describe the construction, operating principles and uses of heat exchange equipment. 3. Identify impurities in raw water and describe how they can be removed. 4. Describe the production, distribution and uses of steam. 5. Describe the production and uses of air, compressed air and vacuum. 6. Distinguish between a.c. and d.c. electrical supplies with respect to production, characteristics and uses.

25 20 15 20 5-15-10 10

Total 100 Processing Solids: 0603-02-207 Unit Outcome % 207 1. Demonstrate an understanding of the scientific and technological

principles associated with the processing of solid materials. 2. Describe the construction, operation and application of equipment used in the processing of solid materials. 3. Identify the health and safety aspects associated with processing solid materials.

20 65 15–

Total 100 Processing Fluids: 0603-02-208 Unit Outcome % 208 1. Demonstrate an understanding of the scientific and technological

principles associated with the processing of fluids. 2. Describe the construction, operation and application of equipment used in the processing of fluids. 3. Identify the health and safety aspects associated with the processing of fluids.

20 65 15

Total

100


Principles of Laboratory Analysis: 0603-02-209 Unit Outcome % 209 1. Demonstrate a knowledge of fundamental items of laboratory

equipment. 2. Understand terms commonly used in chemical analysis. 3. Understand the principles of acid/base titration. 4. Understand potential hazards in the use and disposal of laboratory chemicals. 5. Describe elements of the quality system in a laboratory.

10 30 30 20 10

Total 100 Special Processes (Level 2): 0603-02-210 Unit Outcome % 210 1. Demonstrate an understanding of personal responsibility within the

overall process operation. 2. Demonstrate an understanding of the main unit operations within a selected process. 3. Provide details of raw materials, intermediate and final products. 4. Demonstrate a commercial awareness of the selected process.

20 50 20 10

Total 100 Instrumentation, Measurement and Control: 0603-02-211 Unit Outcome % 211 1. Describe the purpose of instrumentation within an industrial process

system and the factors that govern its use. 2. Demonstrate an understanding of Pressure measurement, and describe the operation of a range of pressure measuring instruments. 3. Demonstrate an understanding of Temperature measurement, and describe the operation of a range of temperature measuring instruments. 4. Demonstrate an understanding of Level measurement, and describe the operation of a range of level measuring instruments. 5. Demonstrate an understanding of Flow measurement, and describe the operation of a range of flow measuring instruments. 6. Demonstrate an understanding of the measurement of Viscosity, Density and Humidity, and describe the operation of a range of suitable measuring instruments. 7. Demonstrate a knowledge and understanding of Instrumentation practices. 8. Demonstrate a knowledge and understanding of open and closed loop control systems.

10 15 5 – 15 5 – 15 10 – 20 5 – 15 5 – 15 15 – 25

Total 100 Metals Processing (Level 2): 0603-02-212 Unit Outcome % 212 1. Outline how a metal is produced from a metal ore.

2. Outline how a metal is refined. 3. Outline how a metal is cast. 4. Outline how a metal is initially shaped. 5. Outline the finishing process for a metal. 6. Outline the main testing methods for a metal.

5 – 15 15 – 25 5 – 15 15 – 25 15 – 25 15 – 25

Total 100 Iron Making and Basic Oxygen Steel Making (Level 2): 0603-02-213 Unit Outcome % 213 1. Describe the production of metallurgical coke from coal.

2. Outline the sources, mining and preparation of iron ore. 3. Outline the construction and operation of an Iron Blast Furnace. 4. Outline the Basic Oxygen Steel making process.

10 – 20 10 – 20 30 – 40 30 – 40

Total 100


Electric Arc Steel Making, Refining and Casting (Level 2): 0603-02-214 Unit Outcome % 214 1. Describe the operation of an Electric Arc Steel making Furnace and

the production of steel from scrap. 2. Outline the Secondary and Special Steel making processes. 3. Describe the Chemistry of Iron making and Steel making. 4. Describe the processes of continuous and ingot casting.

45 – 55 15 – 25 15 – 25 5 – 15

Total 100 Primary Working in the Steel Industry (Level 2): 0603-02-215 Unit Outcome % 215 1. Describe the types of furnaces used to heat steel for Rolling and

Forging operations. 2. Describe the Primary Rolling process. 3. Describe the hot forging of steel sections. 4. Describe the operation of hot plate and strip mills.

20 – 30 20 – 30 20 – 30 20 – 30

Total 100 Finishing Working Processes (Level 2): 0603-02-216 Unit Outcome % 216 1. Describe the production of steel tubes and pipes.

2. Describe the operation of cold strip mills. 3. Describe the operation of hot bar and rod mills. 4. Describe the operation of wire and section mills.

20 – 30 20 – 30 20 – 30 20 – 30

Total 100 Foundry Working Processes 0603-02-217 Unit Outcome % 217 1. Describe the methods of melting metals for casting.

2. Describe the process of pattern making. 3. Describe the production of sand moulds. 4. Describe the die casting process. 5. Describe the finishing processes for castings.

15 – 25 15 – 25 15 – 25 15 – 25 15 – 25

Total 100 Process Control, Inspection and Testing of Metal Production: 0603-02-218 Unit Outcome % 218 1. Describe the main methods of material inspection.

2. Describe the requirements of checking machinery. 3. Outline the methods of basic process control. 4. Describe the main methods of checking finished product.

20 – 30 20 – 30 20 – 30 20– 30

Total 100 Metallurgy of Iron and Steel Production (Level 2): 0603-02-219 Unit Outcome % 219 1. Describe the metallurgical principles involved in the production of

steel from iron ore and from scrap. 2. Describe the chemistry of making plain carbon steels. 3. Describe the process of solidification of metals. 4. Describe the hot working of metal. 5. Describe the metallurgical principles of cold working steel.

15 – 25 15 – 25 15 – 25 15 – 25 15 – 25

Total 100 Testing and properties of metals and alloys: 0603-02-220 Unit Outcome % 220 1. Describe the mechanical testing of metals.

2. Describe the non-destructive testing of metals. 3. Describe some commonly used ferrous alloys. 4. Describe some commonly used non-ferrous alloys.

20 – 30 20 – 30 20 – 30 20– 30

Total 100


Coating and Surface Treatment of Metals: 0603-02-221 Unit Outcome % 221 1. Describe the principles of coating and surface treatment of metals.

2. Describe the range of coatings available for corrosion protection. 3. Describe the range of coatings available for improving surface properties.

45 – 55 20 – 30 20 – 30

Total 100 Non-Ferrous Metals and Alloys: 0603-02-222 Unit Outcome % 222 1. Describe how aluminium, copper and zinc are produced from an

ore. 2. Describe how aluminium, copper and zinc are refined. 3. Describe the processing of non-ferrous metals and alloys. 4. List the main properties of the widely used non-ferrous metals and alloys. 5. Describe the main industrial applications of non-ferrous metals and alloys.

10 – 20 5 – 15 10 – 20 25 – 35 25 – 35

Total 100 Chemistry for Petroleum Operations: 0603-02-223 Unit Outcome % 223 1. Describe the structure of atoms, elements and compounds and use

chemical symbols to represent them. 2. Apply fundamental scientific laws to the construction and use of balanced chemical equations. 3. Describe the structure, classification and properties of carbon compounds.

25 – 35 35 – 45 25 – 35

Total 100 Petroleum Technology (Level 2): 0603-02-224 Unit Outcome % 224 1. Describe the formation of crude oil and gas and the geological

formations that contain them. 2. Describe the principles and methods of oil & gas exploration. 3. Describe the construction, operating principles and uses of oil and gas production platforms and distribution systems both on and off shore. 4. Describe the key functions of refineries and associated processing units, their key products and their uses.

10 – 20 5 – 15 45 – 55 20 – 30

Totals 100 Using PLC Based Systems: 0603-02-225 Unit Outcome % 225 1. Install, connect up and test a PLC installation.

2. Plan and develop a simple PLC program and enter the program into the PLC. 3. Execute the PLC program effectively. 4. Check that the PLC program meets the required specification.

10 – 30 20 – 40 20 – 40 10 – 20

Total 100


Learning Outcomes: Core Units The individual learning outcomes for the Core units 201-204 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 http://www.city-and-guilds.co.uk



Unit 201: Process Science

Rationale This unit provides the essential science required for an understanding of the technology used in the process industries. Outcomes There are four outcomes to this unit. The candidate will be able to: Describe the composition and properties of matter. Apply the concepts of force, energy, work and power. Explain the thermal properties of solids, liquids and gases. Describe the nature and application of electricity. Connections with other awards This unit contributes towards the knowledge and understanding of the following N/SVQs: Level 2 Chemical, Pharmaceutical and Petrochemical Manufacture Level 2 Metal Processing and Allied Operations. Assessment The outcomes for this unit will be assessed using evidence from an on-line multiple choice test. The underpinning knowledge requirements are listed for each outcome. The on-line multiple choice examination, based on the test specification, will assess these outcomes.


Unit 201 Process Science Outcome 1: Describe the composition and properties of matter Underpinning knowledge The candidate will be able to:

1. describe the three states of matter. 2. describe the nature of changes in the state of matter. 3. explain the significance of ‘fixed points’, ie melting point, boiling point. 4. state the effects of impurities upon the ’fixed points’ of a substance. 5. state the effects of changes in pressure upon the ’fixed points’ of a substance. 6. explain what is meant by the terms

a atom b element c molecule d compound e mixture.

7. name and recognise the chemical symbols of the elements a aluminium b argon c calcium d carbon e chlorine f helium g hydrogen h iodine i iron j lead k mercury l nitrogen m oxygen n potassium o silicon p sodium q sulphur r tin s uranium t zinc.

8. describe the structure of the atom in terms of electrons, protons and neutrons. 9. state atomic number and the relative atomic mass of a given atom given its atomic structure. 10. define density and relative density and perform simple density and relative density calculations. 11. explain the meaning of the terms

a viscosity b viscosity index.

12. state the SI unit of viscosity. 13. state the significance of viscosity in relation to the processing and transportation of fluids in

industry.


Unit 201 Process Science Outcome 2: Apply the concepts of force, energy, work and power Underpinning knowledge The candidate will be able to:

1. recognise the common forms of energy as:

a heat b electrical c chemical d nuclear e gravitational f potential g kinetic.

2. state the law of conservation of energy. 3. give examples of energy conversion. 4. define energy as the capacity for doing work. 5. distinguish between the terms ‘mass’ and ‘weight’. 6. calculate the work done in moving a mass through a given distance. 7. calculate the kinetic energy of a mass moving at a constant velocity. 8. calculate the potential energy of a mass at a given height. 9. solve simple problems involving potential and kinetic energy. 10. define power as energy per unit time. 11. calculate the power generated in performing work in a given time. 12. define pressure and state the relationship between absolute, relative and atmospheric pressure. 13. calculate the pressure due to a column of liquid. 14. solve simple problems involving volumetric flow rate. 15. state the significance of laminar and turbulent flow. 16. use the SI unit and quantity symbols for

a mass b force c energy d power e velocity f acceleration g pressure h volumetric flowrate.

17. use the litre, bar and tonne as alternative metric units. 18. apply the multiples and sub-multiples of a unit

a micro b milli c centi d deci e kilo f mega.


Unit 201 Process Science Outcome 3: Explain the thermal properties of solids, liquids and gases Underpinning knowledge

The candidate will be able to:

1. distinguish between heat and temperature. 2. explain the terms

a sensible heat b latent heat.

3. use the SI units of a heat b temperature c specific latent heat d specific heat capacity.

4. convert between Celsius and absolute (Kelvin) temperatures. 5. calculate the heat transferred to or from a body using the relationship

Q = mass x specific heat capacity x temperature change. 6. solve problems relating to the linear expansion of a material given its coefficient of expansion. 7. describe how heat energy is transferred by

a conduction b convection c radiation.

8. distinguish between heat conductors and insulators and give examples of each. 9. state the effect of surface colour on the reflection and absorption of heat. 10. apply Boyle’s law, Charles’ law and the combined gas equation to simple problems. 11. explain the terms

a evaporation b condensation c sublimation.

12. explain the terms a humidity b relative humidity c dew point and state their temperature dependence.


Unit 201 Process Science Outcome 4: Describe the nature and application of electricity Underpinning knowledge The candidate will be able to:

1. explain the terms

a conductor b insulator in terms of the flow of electrons in a solid.

2. describe and give applications of conversions of energy a electromagnetic b electrochemical c thermoelectric d piezoelectric e photoelectric f electrostatic.

3. apply the equations V = IR, P = VI and Q = It using the correct SI quantity and unit symbols. 4. calculate the total resistance of two resistors in series or parallel. 5. distinguish between direct and alternating current. 6. state the purpose of

a rectifiers b transformers c fuses.

7. identify the hazards associated with static electricity and state means of prevention.


Unit 202: Calculations Rationale

This core unit is designed to give candidates the arithmetic skills required to complete the Level 2 progression award in Process Plant and provide the basis for progression to the Level 3 award. Outcomes There are three outcomes to this unit. The candidate will be able to: Perform simple arithmetic operations. Solve problems involving simple formulae. Interpret graphical data. Connections with other awards This unit contributes towards the knowledge and understanding of the following N/SVQs: Level 2 Chemical, Pharmaceutical and Petrochemical Manufacture Level 2 Metal Processing and Allied Operations. Assessment The outcome for this unit will be assessed using evidence from an on-line multiple-choice test. written test. The underpinning knowledge requirements are listed for each outcome. The on-line multiple-choice question examination, based on the test specification, will assess these outcomes.


Unit 202 Calculations Outcome 1: Perform simple arithmetic operations Underpinning knowledge The candidate will be able to:

1. identify the numerator and denominator of a fraction. 2. convert fractions to decimals and vice versa. 3. calculate the average of a set of numbers. 4. carry out simple calculations involving percentages. 5. carry out simple calculations involving ratio and proportion. 6. carry out simple calculations involving fractions and decimals. 7. use a calculator to evaluate expressions involving

a addition b subtraction c multiplication d division e squares f square roots.

8. identify the order in which arithmetic operations should be performed and correctly enter them on a calculator.


Unit 202 Calculations Outcome 2: Solve problems involving simple formulae Underpinning knowledge The candidate will be able to:

1. represent numeric quantities using algebraic symbols. 2. form an equation from a given set of instructions. 3. evaluate formulae from given data. 4. transpose simple formulae for a given subject. 5. transpose formulae involving brackets. 6. solve problems involving the formulae for the areas of

a rectangles b triangles c circles d compound areas.

7. solve problems involving the formulae for the volumes of a cuboids b cylinders c spheres d compound volumes.


Unit 202 Calculations Outcome 3: Interpret graphical data Underpinning knowledge The candidate will be able to:

1. convert given data to relative frequency percentages. 2. represent data on a pie chart. 3. construct a tally chart (frequency distribution table) from given raw data. 4. group data in class intervals. 5. represent data on a histogram. 6. construct a linear graph from given data. 7. determine the gradient of a straight-line graph. 8. draw the ‘best-fit’ straight line from given experimental data. 9. apply the operations of interpolation and extrapolation to given data.


Unit 203: Health, Safety and Environmental Issues Rationale High standards of health, safety and environmental care are essential to the success of an organisation. Both individuals (employees) and organisations (employers) benefit from effective and efficient health, safety and environmental management systems. This unit will provide candidates with an awareness of health, safety and environmental issues and some of the important legislation relating to them. The unit also covers the need for effective communication and accurate record keeping. Outcomes There are three outcomes to this unit. The candidate will be able to: State the importance of personal health, safety and environmental issues in the workplace and the regulations relating to these matters. Comment on the factors that contribute to the maintenance of standards of health and safety within an organisation. Explain the importance of accurate communications and records with regard to health, safety and welfare in the workplace. Connections with other awards This unit will provide the underpinning knowledge and understanding in health, safety and environmental issues that will form an integral part of a wide range of Level 2 and Level 3 Qualifications relating to the Agricultural, Chemical processing, Engineering, Commercial and Retail sectors of industry. Assessment The outcome for this unit will be assessed via a centre-set assignment, based on an assignment template. The underpinning knowledge requirements are listed for each outcome. The centre-set assignment, based on the test specification will assess these outcomes.


Unit 203: Health, Safety and Environmental Issues Outcome 1: State the importance of personal health, safety and environmental issues in the workplace and the regulations relating to these matters. Underpinning knowledge The candidate will be able to:

1. state the prime objectives of the Health and Safety at Work Act 1974. 2. list the employee’s general duties under the Health and Safety at Work Act 1974. 3. list workplace regulations that are applicable for the following

a environmental protection b use of machinery c hazardous substances d electrical equipment e manual handling f portable tools and equipment g lifting equipment h working at height.

4. identify organisational procedures that are applicable to workplace activities. 5. state the individual’s responsibilities in monitoring and maintaining health and safety. 6. explain the importance of accident prevention in the workplace. 7. identify and describe active and pro-active health and safety management systems in the workplace.


Unit 203 Health, Safety and Environmental Issues Outcome 2: Comment on the factors that contribute to the maintenance of standards of health and safety within an organisation. Underpinning knowledge The candidate will be able to:

1. define hazard and risk and describe why these are important issues in reducing accidents within an

industrial organisation. 2. state where hazards might exist in an industrial organisation, how to assess them and the hierarchy

of control measures that could be implemented to minimise the risk. 3. describe how to conduct a risk assessment and hazard identification exercise. 4. state the requirements for the safe use and storage of equipment and materials. 5. state what action(s) an individual should take in the following emergency situations

a fire b toxic gas release c environmentally harmful spillage d accident involving fellow employees.

6. describe what is meant by a “Permit To Work” system and explain why regulations and procedures controlling such systems should not be breached.

7. state the differences between hazardous and non-hazardous materials and waste. 8. state the Personal Protective Equipment (PPE) to be worn to control the risks from the following

hazards: noise, dusts, corrosive and toxic chemicals, falling objects, welding fume, ultra violet radiation.

9. describe safe manual handling techniques. 10. explain the necessity of establishing and maintaining good working relationships with others and

how this can be achieved. 11. describe how to deal with incidents affecting the health of others and when not to exceed ones own

limitations when administering emergency first aid. 12. describe the types of fire fighting equipment that may be found in a workplace and explain their uses

and limitations a fire hose b portable fire extinguishers:

i carbon dioxide (CO2) ii foam iii water iv dry powder

c fire blankets d sprinkler systems.


Unit 203 Health, Safety and Environmental Issues Outcome 3: Explain the importance of accurate communications and records with regards to health, safety and welfare in the workplace. Underpinning knowledge The candidate will be able to: 1. state how to communicate clearly and effectively and recognise the degree of urgency. 2. state the importance of accuracy when dealing with messages. 3. explain the importance of accuracy and legibility in relation to health and safety records. 4. describe the importance and use of an “accident reporting” system and the statistical evidence such

a system may contain. 5. state the importance of respecting and maintaining confidentiality. 6. state the purpose of health and safety records and procedures.


Unit 204 Communications and Information Technology (Level 2) Rationale This core unit is designed to develop candidates’ workplace communication skills and enable them to utilise information technology to develop and produce technical documentation. The unit also provides the basis for progression to the Level 3 award in Communications and Information Technology. Outcomes There are three outcomes to this unit. The candidate will be able to: Interpret and summarise information from technical documentation. Use standard features of a word-processing package to enhance the appearance and legibility of technical documentation. Record, organise and develop information using a spreadsheet package. Connections with other awards This unit should contribute evidence for Information Technology and Communications at Key Skills Level 2. Assessment The outcome for this unit will be assessed using evidence from: Practical activities These are listed for each outcome. The assessment will be by means of a centre-set assignment for each outcome.


Unit 204 Communications and Information Technology (Level 2) Outcome 1: Interpret and summarise information from technical documentation Practical activities The candidate will be able to:

1. extract the salient points from a technical document when reading it for a given purpose. 2. précis the information from a technical document for a given purpose.

Underpinning knowledge The candidate will be able to:

1. communicate clearly and effectively about a technically relevant topic. 2. identify the relevant points in a document when reading for a given purpose. 3. identify appropriate methods of communicating written information

a memorandum b email c letter d technical report.

4. interpret information from documents that include charts, graphs and diagrams. 5. produce documents that are accurate in terms of spelling, punctuation and grammar. 6. use language in a document that is appropriate to its context and intended readers. 7. structure a document in a logical manner. 8. maintain the relevance of the information throughout a document.


Unit 204 Communications and Information Technology (Level 2) Outcome 2: Use standard features of a word-processing package to enhance the appearance and legibility of technical documentation Practical activities The candidate will be able to: use a word-processing software package to enhance the appearance and legibility of technical documentation. Underpinning knowledge The candidate will be able to:

1. select suitable fonts and font size for body text, headings and sub-headings. 2. use tabulation and justification to align text. 3. insert bullet points and numbering. 4. use text boxes and tables to position information. 5. apply software spelling and grammar checks to a text.


Unit 204 Communications and Information Technology (Level 2) Outcome 3: Record, organise and develop information using a spreadsheet package Practical activities The candidate will be able to: use a spreadsheet to develop and display information. Underpinning knowledge The candidate will be able to:

1. insert row and column headings. 2. set the format of the cells of a spreadsheet for the appropriate purpose. 3. apply cell protection. 4. copy and paste cells. 5. link cells between worksheets. 6. use the mathematical operators ‘+’, ‘–’, ‘’, ‘÷’ in a formula. 7. write a formula using a cell reference. 8. add (or ‘sum’) the numbers in a range of cells. 9. represent a data set in a graphical form

a pie chart b line graph c bar chart.


Relationship to NVQ units Unit No

Title This award contributes towards the knowledge and understanding of the following elements of the 0787 N/SVQ in Chemical, Pharmaceutical and Petrochemical Manufacture Level 2

This award contributes towards the knowledge and understanding of the following elements of the 0671 NVQ in Metal Processing and Allied Operations Level 2

This award contributes towards the knowledge and understanding of the following elements of the 0667 N/SVQ in Processing Operations: Hydrocarbons

201 Process Science Units 208, 209, 210, and 213 to 216.

Units 001, 002, 006 and 008 to 023

Units 102, 106, 109.

202 Calculations Units 203, 206, 208, 213. Units 006, 044

Unit 106.

203 Health & Safety and Environmental Issues

All units 201 to 216. Units 001, 002, 015, 042, 043 and 070

All units 102 to 109.

204 Communications and IT

All units 201 to 216. Units 002, 006

All units 102 to 109.

205 Process Chemistry Units 208, 209, 210, 213, 214, 215.

Units 008 to 014

Not Applicable

206 Process Plant and Process Plant Services

All units 201 to 216. Unit 001 Units 105 to 109.

207 Processing Solids All units 201 to 216. Unit 008, 017, 023, 039, 041, 052 to 054, 070 to 074, 080 and 081

Not Applicable

208 Processing Fluids All units 201 to 216. Not Applicable

Units 105 to 109.

209 Principles of Laboratory Analysis

Units 208, 213, 214, 215. Not Applicable

Not Applicable

210 Special Processes (Level 2)

All units 201 to 216. Not Applicable

All units 102 to109.

211 Instrumentation, Measurement and Control

Units 203, 204, 206, 207 and 213 to 216.

Units 006, 044

Units 105 to 109.

212 Metals Processing (Level 2)

Not Applicable Units 016 to 019, 021, 023

Not Applicable

213 Iron Making and Basic Oxygen Steel Making (Level 2)

Not Applicable Units 008, 011, 016, 070 and 072

Not Applicable

214 Electric Arc Steel making, refining and casting (Level 2)

Not Applicable Units 017 to 019 Not Applicable

215 Primary Working in the Steel Industry (Level 2)

Not Applicable Units 008, 012 to 014 Not Applicable

216 Finishing Working Processes (Level 2)

Not Applicable Units 034, 035, 036 and 037 Not Applicable


217 Foundry Working Processes

Not Applicable Not Applicable Not Applicable

218 Process Control, Inspection and Testing of Metal Production

Not Applicable Units 001, 002 Not Applicable

219 Metallurgy of Iron and Steel Production (Level 2)

Not Applicable Unit 081 Not Applicable

220 Testing and Properties of Metals and Alloys

Not Applicable Units 001, 002, 006, 011, 072, 073, 080 and 081

Not Applicable

221 Coating and Surface Treatment of Metals


222 Non-ferrous Metals and Alloys


223 Chemistry for Petroleum Operations

Not Applicable Not Applicable Units 102, 105, 106, 107, 108, 109.

224 Petroleum Technology Not Applicable Not Applicable Units 102, 105, 106, 107, 108, 109.


Level 2 Certificate in Process Technology (0603-02) Identification of Key Skills summary relationship table Unit No

Communication Application of Number

Information Technology

Working with others

Improving own learning and performance

Problem Solving

201 N2.1 N2.2 N2.3

LP2.1 LP2.2 LP2.3

202 N2.1 N2.2 N2.3

LP3.1 LP3.2 LP3.3

203 C2.1b C2.2

IT2.1 IT2.2 IT2.3

LP3.1 LP3.2 LP3.3

204 C2.2 IT2.1 IT2.2 IT2.3

LP3.1 LP3.2 LP3.3

205 N2.1 N2.2 N2.3

LP3.1 LP3.2 LP3.3

206 N2.1 N2.2 N2.3

LP3.1 LP3.2 LP3.3

207 C2.1a LP3.1 LP3.2 LP3.3

PS2.1

208 C2.1a N2.1 LP3.1 LP3.2 LP3.3

PS2.1

209 N2.1 N2.2 N2.3

LP3.1 LP3.2 LP3.3

210 C2.1b C2.2

IT2.1 IT2.3

LP3.1 LP3.2 LP3.3

211 N2.1 N2.2 N2.3

LP3.1 LP3.2 LP3.3

212 C2.2 C2.3

LP3.1 LP3.2 LP3.3

213 C2.3 LP3.1 LP3.2 LP3.3

214 C2.1 C2.3

LP3.1 LP3.2 LP3.3

215 C2.1 LP3.1 LP3.2 LP3.3

216 C2.1 C2.3

LP3.1 LP3.2 LP3.3

217 C2.2 C2.3

LP3.1 LP3.2 LP3.3

218 C2.1 C2.2

LP3.1 LP3.2 LP3.3

219 C2.1 C2.3

LP3.1 LP3.2 LP3.3

220 C2.1 C2.3

LP3.1 LP3.2 LP3.3

221 C2.1 C2.3

LP3.1 LP3.2 LP3.3

222 C2.1 C2.3

LP3.1 LP3.2 LP3.3


223 N2.1 N2.2 N2.3

LP3.1 LP3.2 LP3.3

224 LP3.1 LP3.2 LP3.3

225 C2.2 IT2.2


Level 2 Certificate in Process Technology (0603-02) Identification of opportunities for evidence generation of moral, ethical, spiritual, European dimension, Environmental education and Health and safety Units Spiritual, Moral,

Ethical, Social and Cultural

Environmental Health and Safety

European Development

201 X X 202 203 X X 204 205 X 206 X X 207 X X 208 X X 209 X X 210 X X X X 211 X 212 X X 213 X X X 214 X X 215 X X 216 X X 217 X X 218 X X 229 X X 220 X X 221 X X 222 X X 223 X 224 X X 225 X


Level 2 Certificate in Process Technology (0603-02) Further information Further information regarding centre/Qualification approval or any aspect of assessment of the award should be referred to the relevant City & Guilds regional/national office: Region

Telephone

Facsimile

City & Guilds London and South East

020 7294 8139

020 7294 2419

City & Guilds Southern

020 7294 2677

020 7294 2412

City & Guilds South West

01823 722200

01823 444231

City & Guilds East Anglia

01480 308300

01480 308325

City & Guilds East Midlands

01773 842900

01773 833030

City & Guilds West Midlands

0121 503 8900

0121 359 7734

City & Guilds North East

0191 402 5100

0191 402 5101

City & Guilds North West

01925 897900

01925 897925

City & Guilds Yorkshire

0113 380 8500

0113 380 8525

City & Guilds Northern Ireland

028 9032 5689

028 9031 2917

City & Guilds Scotland

0131 226 1556

0131 226 1558

City & Guilds Wales

02920 748600

02920 748625

City & Guilds Head Office – Customer Relations

020 7294 2800

020 7294 2400

Website http://www.city-and-guilds.co.uk SP-02-0603


Documents

Level 2 Certificate in Process Technology Qualification