SAQA 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.
SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD: 

Apply integrated process control methods 
SAQA US ID UNIT STANDARD TITLE
244100  Apply integrated process control methods 
ORIGINATOR
Chemical Industries SGB 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Manufacturing and Assembly 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 4  NQF Level 04  15 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Reregistered  2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

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 unit standard does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
Learners who demonstrate competence as described in the outcomes of this unit standard will be able to explain a complete process in detail.

A person credited with this unit standard is able to:
  • Demonstrate understanding of an entire process.
  • Describe the functioning of each piece of equipment in the process.
  • Use process control options in the process.
  • Control the process to within process and product parameters.
  • Control the process for maximum efficiency.

    This will ensure that the control of a processing operation is performed in accordance with procedures and accepted work practices. This competence will enhance the learner's employability and career options in all occupations where knowledge of an integrated process operation is needed. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    National Certificate Chemical Operations NQF Level 3 or equivalent, including communication and mathematical literacy, NQF Level 3. 

    UNIT STANDARD RANGE 
    The context of this unit standard includes a complete process, from the point of receiving a commodity raw material to the point of supplying a commercially saleable product.

    The level assigned to this unit standard is appropriate because the process requires a wide range of cognitive skills and offers a considerable choice of solutions. A broad knowledge base incorporating some theoretical concepts, analytical interpretation of information, informed judgement and a range of sometime innovative responses to concrete but often unfamiliar problems are employed. 

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Demonstrate understanding of an entire process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    A freehand process flow diagram (PFD), showing all equipment in the process. 
    ASSESSMENT CRITERION RANGE 
  • Equipment is correctly labelled and numbered.
  • Flow directions of process streams are indicated.
  • Basic contents of all process streams are indicated.
  • Key valves and control valves are indicated.
     

  • ASSESSMENT CRITERION 2 
    The process is described in accordance with workplace procedures. 
    ASSESSMENT CRITERION RANGE 
    The process description includes:
  • Raw materials used, products produced, additives and other materials used in the process.
  • The process from raw material feed to final product produced.
  • All transformations and conversions taking place.
  • Side streams to the point where it crosses the process borders.
  • Key utilities used in the process.
     

  • ASSESSMENT CRITERION 3 
    The purpose of each piece of equipment is described in terms of own workplace and in accordance with workplace procedures. 
    ASSESSMENT CRITERION RANGE 
    Included are all major pieces of equipment from the point of raw material feed to the finished product(s) and including relevant side streams to the point where it leaves the process boundaries.
     

    ASSESSMENT CRITERION 4 
    All equipment is identified on-site. 

    SPECIFIC OUTCOME 2 
    Describe the functioning of each piece of equipment in the process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Basic freehand drawings are made of each piece of equipment. 
    ASSESSMENT CRITERION RANGE 
    Freehand drawings should include all major equipment, main features, physical form, components, process flow direction, utilities, labels, arrows and symbols.
     

    ASSESSMENT CRITERION 2 
    The basic operating principle of the equipment is described with the assistance of the freehand drawings. 

    ASSESSMENT CRITERION 3 
    Each piece of equipment, its components and process flows (where possible) are identified on-site. 

    ASSESSMENT CRITERION 4 
    The basic operating principles of the equipment are described on-site. 

    SPECIFIC OUTCOME 3 
    Use process control options in the process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    A freehand process and instrumentation diagram (P&ID) is sketched, showing all instruments and instrument loops forming part of the process. 

    ASSESSMENT CRITERION 2 
    All instruments and equipment used for process control purposes are identified on-site and their basic purpose explained as applicable to own workplace. 
    ASSESSMENT CRITERION RANGE 
    Instruments and equipment should include but are not limited to control valves, manual valves, power regulators, on/off switches, scales, alarms and trips.
     

    ASSESSMENT CRITERION 3 
    The process logic of each control loop is explained in terms of own workplace. 

    ASSESSMENT CRITERION 4 
    Process and product conditions are monitored and basic process adjustments are made as required to ensure product quality. 

    ASSESSMENT CRITERION 5 
    Automated process control techniques are used to control the process. 
    ASSESSMENT CRITERION RANGE 
    Automated process control techniques include but are not limited to:
  • Split ranges and trims.
  • Cascade control.
  • Quality analysers.
  • Ratio/mass flow controls.
  • Interlocks and logics.
     

  • SPECIFIC OUTCOME 4 
    Control the process to within process and product parameters. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Equipment operating parameters are listed and explained in accordance with workplace procedures. 

    ASSESSMENT CRITERION 2 
    Product specifications are listed and explained in accordance with workplace procedures. 
    ASSESSMENT CRITERION RANGE 
    Product specifications should include but are not limited to physical properties, composition and impurities.
     

    ASSESSMENT CRITERION 3 
    Systems to monitor product quality are described in accordance with workplace procedures. 
    ASSESSMENT CRITERION RANGE 
    Determination of product quality includes but is not limited to in-line quality analysers, sampling, on-site analyses and laboratory analysis.
     

    ASSESSMENT CRITERION 4 
    Process parameters are listed and explained in accordance with workplace procedures. 
    ASSESSMENT CRITERION RANGE 
    Process parameters should include but are not limited to power level, temperature, pressure, pressure drop, flow-rate and level.
     

    ASSESSMENT CRITERION 5 
    Process data is monitored and analysed (potential deviation analysis) to identify trends and deviations from product, process or equipment specifications. 

    ASSESSMENT CRITERION 6 
    Corrective action is taken to address deviations and trends. 

    SPECIFIC OUTCOME 5 
    Control the process for maximum efficiency. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Optimal process parameters are listed in accordance with workplace procedures. 

    ASSESSMENT CRITERION 2 
    Interdependence of different process parameters is explained in accordance with workplace procedures. 

    ASSESSMENT CRITERION 3 
    Suggestions are made of how to maintain process, product and equipment integrity and efficiency during different process scenarios. 

    ASSESSMENT CRITERION 4 
    Plant data is collected and analysed to determine areas for possible improvement or areas where losses and non-conformances are encountered in accordance with workplace procedures. 

    ASSESSMENT CRITERION 5 
    Process trends are identified that may affect the product quality or process efficiency. 

    ASSESSMENT CRITERION 6 
    Adjustments are made in order to optimise the process taking the interdependence of variables into consideration. 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • An assessor, accredited with a relevant NQF Level 4 or higher qualification, will assess the learner's competency.
  • Anyone assessing a learner or moderating the assessment of a learner against this Qualification must be registered as an Assessor with the relevant ETQA. 

  • UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    Embedded knowledge is reflected within the assessment criteria of each specific outcome. 

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    The learner is able to identify and solve problems in which responses display that responsible decisions, using critical and creative thinking, have been made by:
  • Process adjustments are made.
  • Corrective action is taken to address deviations and trends.

    Refer to the following Specific Outcome/s:
  • Use process control options in the process.
  • Control the process to within process and product parameters.
  • Control the process for maximum efficiency. 

  • UNIT STANDARD CCFO WORKING 
    Work effectively with others as a member of a team, group, organisation or community by:
  • Make process adjustments with the assistance of colleagues.

    Refer to the following Specific Outcome/s:
  • Use process control options in the process.
  • Control the process to within process and product parameters.
  • Control the process for maximum efficiency. 

  • UNIT STANDARD CCFO ORGANISING 
    The learner is able to organise and manage himself and his activities responsibly and effectively by:
  • Interdependence of process aspects is systematically analysed.
  • Control loops are systematically analysed.
  • Drawings are logically constructed.
  • Data is systematically collected and organised.

    Refer to all Specific Outcomes. 

  • UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information by:
  • Process and product data is collected.
  • Process parameters are listed.
  • Data and trends are analysed and interpreted.

    Refer to the following Specific Outcome/s:
  • Use process control options in the process.
  • Control the process to within process and product parameters.
  • Control the process for maximum efficiency. 

  • UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively by using mathematical and/or language skills in the modes of oral and/or written presentations by:
  • Making process drawings.
  • Process details are clearly described.

    Refer to all Specific Outcomes. 

  • UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically, showing responsibility towards the environment and health of others when:
  • Every aspect of the process has a considerable technology component.

    Refer to all Specific Outcomes. 

  • UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems by:
  • All outcomes are directed at an integrated approach to process control.

    Refer to all Specific Outcomes. 

  • UNIT STANDARD CCFO CONTRIBUTING 
    Contribute to the full personal development of each learner and the social and economic development of the society at large.
  • Evident in all Specific Outcomes. 

  • UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    N/A 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  78529   Further Education and Training Certificate: Chemical Operations  Level 4  NQF Level 04  Reregistered  2021-06-30  As per Learning Programmes recorded against this Qual 
    Elective  63929   National Certificate: Spirits Production  Level 3  NQF Level 03  Reregistered  2023-06-30  FOODBEV 
    Elective  48659   Further Education and Training Certificate: Grain Milling  Level 4  NQF Level 04  Reregistered  2023-06-30  AgriSETA 
    Elective  58779   Further Education and Training Certificate: Production Technology  Level 4  NQF Level 04  Reregistered  2023-06-30  MERSETA 
    Elective  61949   Further Education and Training Certificate: Pulp and Paper Operations  Level 4  NQF Level 04  Passed the End Date -
    Status was "Reregistered" 
    2015-06-30  FPMSETA 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    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.
     
    1. MPACT 
    2. SAPPI LTD 



    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.