Manufacturing, Engineering and Technology Fabrication and Extraction

Catalytic Converter Decommissioning For Cyclic Maintenance Procedures Training

SAQA US 110422 | NQF 2 | Credits 8 | Duration 5 Days
From $1,242 per delegate

Description

This course equips maintenance personnel with the knowledge and skills to safely decommission catalytic converters during cyclic maintenance procedures. It covers regulatory requirements, environmental impact, and decommissioning techniques to ensure compliance with South African standards.

Learning Outcomes

  • Apply legislative and environmental regulations governing catalytic converter decommissioning.
  • Demonstrate safe decommissioning procedures for catalytic converters within cyclic maintenance schedules.
  • Analyze the environmental impact of catalytic converter disposal and implement mitigation measures.
  • Evaluate the condition of catalytic converters to determine decommissioning readiness.
  • Implement documentation and reporting procedures for decommissioning activities.
  • Design a cyclic maintenance plan that incorporates catalytic converter decommissioning steps.

Target Audience

This course is designed for maintenance technicians, engineers, and supervisors involved in cyclic maintenance of industrial equipment, particularly in sectors such as mining, manufacturing, and energy.

Prerequisites

None — open enrollment.

Course Outline

Day 1: Introduction to Catalytic Converters and Decommissioning

Objectives:
• Understand the function and components of catalytic converters.
• Identify legal and environmental requirements for decommissioning.
• Explain the cyclic maintenance procedures context.
• Recognize safety hazards and PPE requirements.

Topics:
• Overview of catalytic converter types and operation.
• Role of catalytic converters in emission control.
• Regulatory framework: SA legislation and SAQA standards.
• Introduction to cyclic maintenance procedures.
• Safety protocols: hazardous materials, heat, and mechanical risks.
• Personal protective equipment (PPE) selection and use.
• Environmental impact and waste management principles.
• Documentation and record-keeping basics.

Day 2: Pre-Decommissioning Assessment and Preparation

Objectives:
• Conduct pre-decommissioning inspections.
• Assess converter condition and contamination levels.
• Prepare tools, equipment, and work area.
• Develop a decommissioning plan aligned with cyclic maintenance.

Topics:
• Inspection techniques: visual, thermal, and diagnostic tools.
• Identifying catalyst poisoning and physical damage.
• Tool selection: cutting, removal, and handling equipment.
• Work area setup: ventilation, containment, and fire safety.
• Decommissioning procedure planning.
• Material handling and storage for removed converters.
• Risk assessment and mitigation strategies.
• Permits and authorization requirements.

Day 3: Decommissioning Techniques and Procedures

Objectives:
• Perform safe removal of catalytic converters.
• Apply cutting and separation methods.
• Handle and store decommissioned units correctly.
• Follow cyclic maintenance scheduling.

Topics:
• Step-by-step removal procedures for various vehicle types.
• Cutting techniques: saws, torches, and hydraulic tools.
• Separation of substrate from shell.
• Handling hazardous residues and catalysts.
• Temporary replacement and bypass options.
• Integration with cyclic maintenance schedules.
• Quality checks during and after decommissioning.
• Troubleshooting common issues.

Day 4: Post-Decommissioning Procedures and Compliance

Objectives:
• Complete post-decommissioning inspections.
• Ensure compliance with environmental regulations.
• Document and report decommissioning activities.
• Manage waste and recycling processes.

Topics:
• Post-removal system inspection: exhaust, sensors, and ECU.
• Emission testing and verification.
• Environmental compliance: waste classification and disposal.
• Recycling options for metals and ceramic substrates.
• Documentation: logs, certificates, and maintenance records.
• Reporting to relevant authorities.
• Auditing and continuous improvement.
• Case studies on compliance failures.

Day 5: Practical Integration and Assessment

Objectives:
• Apply all skills in a simulated decommissioning scenario.
• Demonstrate proficiency in safety and procedure.
• Complete documentation and reporting.
• Prepare for certification assessment.

Topics:
• Full decommissioning simulation on training vehicle.
• Supervised practice of removal and handling.
• Completing inspection and compliance checklists.
• Mock audit and feedback session.
• Review of key learning points.
• Written and practical assessment.
• Certification requirements and next steps.
• Course evaluation and Q&A.

Practicals

16 hours of practicals To be conducted online or on-campus or in-house
Overview

Hands-on practicals are essential for developing safe and competent decommissioning skills. Learners will practice removal techniques, use specialized tools, and complete documentation under supervision, ensuring readiness for real-world cyclic maintenance procedures.

Practical Activities
  • Pre-Decommissioning Inspection and Setup — Learners inspect a catalytic converter on a training rig, assess condition, and prepare the work area with proper safety measures. (3h)
  • Catalytic Converter Removal and Handling — Under supervision, learners remove a catalytic converter using cutting tools, handle hazardous materials, and store the unit safely. (5h)
  • Post-Removal Inspection and Compliance — Learners inspect the exhaust system, perform emission checks, and complete all required documentation and waste management steps. (4h)
  • Simulated Full Decommissioning Cycle — Learners perform a complete decommissioning procedure from start to finish, integrating all previous skills, under timed conditions. (4h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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