Practical and on-the-job training for coreless induction furnace operators at necsa's smelter plant, area 26

Necsa requires a suitably qualified and experienced training service provider to deliver practical and on-the-job training to the operators of the coreless induction furnace and associated equipment at its Smelter Plant.

• Site: Necsa Smelter Plant, Area 26.
• Plant covered: 125 kg / 100 kW coreless induction furnace, 2 × 4-ton induction furnaces and their supporting subsystems.
• Aim: give operators supervised hands-on experience under normal operating conditions and build the ability to run pre-operational checks, start up and shut down, monitor parameters, melt and cast, spot abnormal conditions, respond to emergencies and carry out basic operational troubleshooting.
• Supporting systems in scope: power supply, cooling water, emergency cooling water, off-gas, refractory lining, charge material preparation, casting system, ladle handling, sampling and de-slagging.
• The programme must combine supervised hands-on work, demonstrations, operational exercises and competency assessment, aligned with Necsa's approved operating procedures, safety requirements and applicable regulation.
• Outcome: operators who can demonstrate competence across normal, abnormal and emergency conditions, with documented evidence of training, assessment results and competency supplied to Necsa.

No points system, preference formula or minimum qualifying score is set out. Selection turns on the suitability of the training provider and its trainers.

Trainer requirements (minimum)

• Substantial hands-on experience operating coreless induction furnaces.
• Proven record of delivering practical, on-the-job operator training.
• Working knowledge of metallurgy and furnace chemistry.
• Practical grasp of furnace electrical systems and controls, instrumentation and process monitoring, and the mechanical systems of induction furnaces.
• Experience in furnace maintenance and operational troubleshooting, refractory and lining condition monitoring, furnace safety and emergency response, and competency-based operator assessment.
• Relevant industrial training background.

Preferred

• Professional certifications and registration with recognised training authorities, including Merseta where applicable.

Evidence to submit

• Trainer CVs plus proof of qualifications, experience and competence, for Necsa review before training starts.

Assessment of operators

• Each operator is assessed individually against defined competency criteria through practical demonstration.
• Attendance alone does not constitute successful completion; competence must be demonstrated.
• Gaps are recorded, additional coaching or reassessment is provided, and results are documented.
• Participant feedback is collected and the effectiveness of the training method is reviewed.
• A final training report is submitted to Necsa.

Purpose

• Practical and on-the-job training for the personnel who will operate the coreless induction furnace and its supporting plant at Necsa's Smelter Plant.

Location

• Necsa Smelter Plant, Area 26. Training uses the actual plant equipment and systems wherever it is safe and operationally practicable.

Equipment covered

• 125 kg / 100 kW coreless induction furnace.
• 2 × 4-ton induction furnaces.
• Supporting subsystems: power supply, cooling water, emergency cooling water, off-gas, refractory lining, charge material preparation, casting system, ladle handling, sampling and de-slagging.

Practical scope

• Furnace preparation and pre-operational inspections; charge material selection, preparation and loading.
• Start-up, sintering of the refractory lining, melting and process control, shutdown.
• Monitoring and recording of operating parameters; molten metal temperature measurement; power and process parameter monitoring.
• Tapping and casting; slag management and de-slagging; sampling and sample preparation.
• Operation and monitoring of cooling water, emergency cooling water, off-gas and auxiliary systems.
• Lining and refractory condition monitoring; identification of wear, coil-related faults and potential run-out conditions.
• Recognition of abnormal conditions, first-line corrective action, basic troubleshooting, safe isolation and escalation of faults to maintenance.
• Emergency start/stop, response to furnace and plant emergencies, safe handling of molten metal.
• Production data recording and reporting, housekeeping, application of approved SOPs.
• Operators are not trained or authorised for maintenance work outside their defined roles and approved procedures.

Safety content to be applied practically

• Pre-task risk assessment and job hazard analysis, toolbox talks, tag-in/tag-out and isolation, job cards and authorisations.
• PPE/PPC; electrical safety and arc flash awareness; safe work around high electrical energy, cooling water, compressed air and off-gas systems.
• Fire prevention and emergency response; response to cooling water failure, loss of electrical power, off-gas or ventilation failure, refractory failure.
• Environmental and radiological protection requirements; incident and near-miss reporting; evacuation and emergency communication.

Method

• Hands-on work on live plant equipment, trainer demonstration followed by supervised operator practice, individual participation, on-the-job coaching.
• Exercises covering normal, abnormal and emergency conditions; group problem-solving; troubleshooting drills.
• Individual competency assessment, documentation of activities per operator, gap identification and reassessment where competence is not shown.
• Theoretical input only where it directly supports the practical work, never as a substitute for hands-on training.
• A detailed training plan and methodology must be submitted for Necsa approval before training begins.

Duration and scheduling

• The provider proposes the overall duration, number and length of sessions, split between theory, demonstration and hands-on work, sequence of activities, operators per session, equipment covered, assessment activities and completion date.
• The schedule is subject to Necsa review and approval before training starts.

Participants

• Furnace operators involved in running the coreless induction furnace and associated systems.
• Necsa advises the anticipated number of participants; the provider recommends group sizes that allow adequate hands-on exposure and individual assessment.
• Final numbers and grouping are agreed with Necsa before training starts.

Deliverables

• Training plan and programme covering objectives, methodology, content, practical activities, schedule, equipment, arrangements, assessment method and trainer details.
• Training materials: manuals, presentations, practical guides, handouts, checklists, assessment tools and exercises, submitted for Necsa approval where required.
• Supervised practical training for all nominated operators.
• Individual competency assessment for every operator.
• Individual competency portfolio per operator: attendance, activities completed, assessment records and results, gaps identified, corrective training given and final competency status.
• Approved attendance records for all sessions.
• Competency certificates for operators meeting the standard, stating the scope of competence assessed.
• Final training report: activities, dates and attendance, operators trained, activities completed, assessment results, individual status, gaps, additional training, observations, recommendations and a conclusion on overall effectiveness.

Division of responsibility

• Provider: plan and schedule, qualified trainers, delivery, materials and assessment tools, safe conduct, assessment, records, certificates, final report, communication of gaps and recommendations.
• Necsa: plant access subject to availability and safety, approved SOPs and procedures, site induction and safety requirements, nomination of operators and their availability, PPE/PPC, approval of plan, schedule and materials, monitoring and review of records.
• Participants: full attendance, active participation, adherence to Necsa safety and operational rules, use of PPE/PPC, work only under the supervision level the trainer authorises, participation in assessments, reporting of unsafe conditions, demonstration of competence before independent work.

The provider must propose a method built around hands-on learning and demonstrated operator competence.

Minimum method elements

• Practical training on the actual plant equipment wherever operationally and safely practicable.
• Trainer demonstration followed by supervised operator practice.
• Individual participation by each operator in practical activities.
• On-the-job coaching by suitably qualified and experienced trainers.
• Exercises covering normal operating conditions, abnormal operating conditions, and emergency response where safe and practicable.
• Group discussion and problem-solving exercises.
• Review and application of Necsa SOPs and work instructions.
• Practical troubleshooting exercises.
• Individual competency assessment and documentation of each operator's completed activities.
• Identification of individual competency gaps, with additional coaching or reassessment where competence is not initially shown.

Controls

• A detailed training plan and methodology must be submitted for Necsa approval before training starts.
• An individual training and competency portfolio is prepared for each participant.
• Theoretical instruction is permitted only where it directly supports the practical work and may not replace hands-on training.
• The provider proposes duration, number and length of sessions, the theory/demonstration/hands-on split, sequence of activities, operators per session, equipment covered, assessment activities and completion date; the schedule requires Necsa approval before training starts.

The provider must be suitably qualified and experienced, and must field trainers who can demonstrate competence in induction furnace and smelter operations.

Trainer minimum requirements

• Extensive practical experience in coreless induction furnace operations.
• Demonstrable experience in practical and on-the-job operator training.
• Knowledge and practical understanding of metallurgy and furnace chemistry.
• Practical knowledge of furnace electrical systems and controls.
• Practical knowledge of instrumentation and process monitoring.
• Knowledge of the mechanical systems associated with induction furnaces.
• Experience in furnace maintenance and operational troubleshooting.
• Experience in furnace refractory and lining condition monitoring.
• Experience in furnace safety and emergency response.
• Experience in competency-based operator assessment.
• Relevant industrial training experience.

Preferred

• Appropriate professional certifications and registration with recognised training authorities, including Merseta where applicable.

Evidence

• Trainer CVs and evidence of relevant qualifications, experience and competence must be submitted for Necsa review before training commences.

Quality is controlled through documented competence rather than attendance.

• Every operator is assessed individually against defined competency criteria, with practical demonstration of the tasks relevant to their role.
• An individual competency portfolio is compiled per operator: attendance records, practical activities completed, assessment records and results, gaps identified, corrective or additional training given, and final competency status.
• Approved attendance records for all sessions are submitted to Necsa.
• Competency certificates are issued only to operators who meet the required standard, and state the scope of competence assessed.
• Where an operator does not demonstrate competence, additional coaching or reassessment follows.
• A final training report is submitted on completion, covering activities, dates and attendance, operators trained, activities completed, assessment results, individual status, gaps, additional training, key observations, recommendations and a conclusion on overall training effectiveness.
• Training materials, including assessment tools and checklists, are submitted to Necsa for review and approval where required.
• The training plan, methodology and schedule require Necsa approval before training commences.

Trainer competence

• Trainers must show extensive practical coreless induction furnace operating experience and a demonstrable record in practical, on-the-job operator training.
• Required knowledge areas: metallurgy and furnace chemistry, furnace electrical systems and controls, instrumentation and process monitoring, mechanical systems of induction furnaces, maintenance and troubleshooting, refractory and lining condition monitoring, furnace safety and emergency response, competency-based assessment.
• Registration with recognised training authorities, including Merseta where applicable, and relevant professional certifications are preferred.

Evidence required before training starts

• Trainer CVs and proof of qualifications, experience and competence, submitted for Necsa review.
• Detailed training plan, methodology and schedule, submitted for Necsa approval.
• Training materials submitted for approval where required.

Site compliance

• Training must align with Necsa's approved operating procedures, safety requirements and applicable regulatory requirements.
• Providers and participants must comply with Necsa safety procedures, site induction, PPE/PPC and radiological protection requirements.
• No CSD registration, tax compliance, B-BBEE level, CIDB grading or local content threshold is stated.

Safety is taught as applied practice, not theory, and must align with Necsa's approved procedures and applicable regulatory requirements.

Practical safety content

• Pre-task risk assessment and job hazard analysis; pre-task safety discussions and toolbox talks.
• Tag-in/tag-out, isolation requirements, job card systems and authorisations.
• PPE and PPC requirements.
• Safe handling of molten metal; safe charging, tapping and casting.
• Electrical safety, arc flash hazard awareness and safe work around high electrical energy.
• Safe work with cooling water, compressed air and off-gas systems.
• Fire prevention and emergency response.
• Response to furnace emergencies, cooling water failure, loss of electrical power, off-gas or ventilation failure, and refractory failure with potential furnace run-out.
• Environmental and radiological safety requirements.
• Hazard identification and risk assessment; reporting of incidents, near misses and unsafe conditions.
• Emergency evacuation and communication procedures.
• Compliance with Necsa safety procedures and workplace rules.

Obligations

• The provider must ensure practical training is conducted safely and that emergency response exercises run only where safe and practicable.
• Necsa supplies site-specific safety and induction requirements and the required PPE/PPC.
• Participants follow all Necsa safety and operational requirements, use the required PPE/PPC, work only under the supervision level the trainer authorises, and report unsafe conditions.

No scoring formula, preference point system or minimum qualifying score is stated. The basis for judging a provider is trainer capability and the rigour of its competency assessment.

Trainer capability

• Extensive practical coreless induction furnace operating experience.
• Demonstrable practical and on-the-job operator training record.
• Metallurgy and furnace chemistry knowledge.
• Furnace electrical systems and controls, instrumentation and process monitoring, and induction furnace mechanical systems.
• Furnace maintenance and troubleshooting, refractory and lining condition monitoring, furnace safety and emergency response.
• Competency-based operator assessment and relevant industrial training experience.
• Preferred: professional certifications and registration with recognised training authorities, including Merseta where applicable.
• Trainer CVs and evidence of qualifications, experience and competence must be submitted for Necsa review before training starts.

Assessment of operators

• Each operator is assessed individually against defined competency criteria by practical demonstration.
• Results are documented, gaps identified, and additional coaching or reassessment provided where competence is not shown.
• Attendance alone does not count as successful completion.
• Participant feedback is gathered and the effectiveness of the training method reviewed.
• A final training report is submitted to Necsa.

Necsa requires a suitably qualified and experienced training service provider to deliver practical and on-the-job training for furnace operators at the Smelter Plant, Area 26.

• Training must use the actual plant equipment and systems where operationally and safely practicable.
• Content must align with Necsa-approved operating procedures, safety requirements and applicable regulatory requirements.
• The detailed technical basis is the attached Scope of Work for Practical/On-the-Job Training, Document No. NLM-URT-26/001, Rev. 00.

Closing

• Date: 13 November 2026
• Time: 10:00

Compulsory site briefing

• None

Quotation validity

• 90 days from the closing date

Enquiries

• Name: Catherine Matima
• Email: [email protected]

Submission

• Method: email
• Submission email: [email protected]

Enquiry rules

• All queries must be in writing to the nominated contact.
• No other Necsa employee may be approached for information.

Submission method

• Email only, to [email protected]
• Quotation validity: 90 days from the closing date
• Quotations must be completed in full; an incomplete quotation may be disqualified

Returnable documents

• Tax Clearance Certificate or SARS-issued tax pin.
• SBD 4 (Declaration of Interest): discloses any director or shareholder employed by the state or connected to staff at Necsa.
• B-BBEE certificate, or a qualifying sworn affidavit where the bidder is an EME.
• Letter of Good Standing from the Compensation Fund (COID), only where the nature of the work requires it.
• Trainer CVs with evidence of relevant qualifications and experience.
• Any other certificate or document called for in the RFQ.

Disqualification risks

• Submitting after the closing date and time.
• Omitting proof of B-BBEE status — preference points for specific goals are then forfeited.
• Directing enquiries to any Necsa employee other than the nominated contact; this may disqualify the bid.
• Leaving the quotation incomplete.

Two-phase evaluation.

Phase 1 — Functionality / technical (100 points)

• Assessed on technical, performance, quality and risk criteria.
• Minimum qualifying score: 80/100. A bid scoring below 80 is non-responsive and is not evaluated further.
• A response that does not show the bidder can deliver an acceptable technical solution is rejected at this stage.

Phase 2 — Price and specific goals (80/20 system)

• Price: 80 points.
• Specific goals (B-BBEE status level): 20 points.

B-BBEE points under the 80/20 system

• Level 1: 20
• Level 2: 18
• Level 3: 14
• Level 4: 12
• Level 5: 8
• Level 6: 6
• Level 7: 4
• Level 8: 2
• Non-compliant: 0

Other evaluation notes

• No B-BBEE proof submitted means no specific-goal points are claimed.
• Necsa may require a bidder to substantiate any specific-goals claim before or after adjudication.
• Necsa may cancel or reject any quotation, decline to award to the lowest bidder, split the award between bidders, or make no award.

Purpose

• Practical and on-the-job training of furnace operators at the Necsa Smelter Plant, Area 26.
• Training must use the actual plant equipment and systems where it is operationally and safely practicable, and align with Necsa-approved operating procedures, safety requirements and applicable regulations.

Equipment and systems covered

• 125 kg / 100 kW coreless induction furnace.
• Two 4-ton induction furnaces.
• Associated plant subsystems: power supply, cooling water, emergency cooling water, off-gas, refractory lining, charge material preparation, casting system, ladle handling, sampling and de-slagging.

Practical training content

• Furnace preparation and pre-operational inspections.
• Charge material preparation, selection and loading.
• Refractory condition monitoring and sintering.
• Start-up, operation, process control and shutdown.
• Monitoring and recording of power, temperature and other operating parameters.
• Molten metal temperature measurement, tapping and casting.
• Slag management, de-slagging, sampling and sample preparation.
• Operation and monitoring of cooling water, emergency cooling water and off-gas systems.
• Identifying abnormal operating conditions and taking first-line action.
• Emergency start/stop and response to furnace and plant emergencies.
• Safe handling of molten metal under approved SOPs and work instructions.
• Production data recording, operational reporting and housekeeping.
• Basic operational maintenance within the operator's authorised scope.

Safety, SHEQ and compliance content

• Pre-task risk assessments and toolbox talks.
• Isolation and tag-in/tag-out requirements.
• PPE/PPC, electrical and arc-flash safety, high-energy work controls.
• Molten-metal safety, cooling-water and off-gas safety, fire prevention.
• Emergency response, evacuation and communication procedures.
• Environmental and radiological safety requirements.
• Incident and near-miss reporting.

Maintenance awareness and troubleshooting

• Recognition of abnormal equipment conditions, common furnace problems, potential coil failures, refractory deterioration, cooling-water leaks or failures, off-gas problems and abnormal electrical or instrumentation conditions.
• First-line actions, safe isolation and escalation to maintenance personnel.
• Maintenance work outside the operator's authorised role must not be performed.

Methodology

• Competency-based: trainer demonstrations, supervised hands-on practice, on-the-job coaching, normal and abnormal operating exercises, emergency exercises where safe, troubleshooting exercises and individual competency assessments.
• A detailed training plan and schedule must be submitted for Necsa approval before training starts.

Deliverables

• Detailed training plan and programme.
• Training manuals, practical guides, checklists and assessment tools.
• Supervised practical training for all nominated operators.
• Individual competency assessment and competency portfolio for each operator.
• Attendance records.
• Competency certificates for operators meeting the required standard.
• Final training report covering activities, attendance, practical activities completed, assessment results, competency status and gaps, additional training or reassessment, observations and recommendations.

Trainer requirements

• Qualified and experienced in coreless induction furnace and smelter operations, practical operator training, metallurgy and furnace chemistry, furnace electrical systems and controls, instrumentation and process monitoring, mechanical systems, refractory and lining condition monitoring, troubleshooting, furnace safety and competency-based assessment.
• CVs and evidence of qualifications and experience must be submitted.

Duration and schedule

• The bidder proposes the overall duration, number and length of sessions, theory/demonstration/practical balance, sequence of activities, operators per session, equipment covered, assessment activities and completion date.
• The schedule is subject to Necsa review and approval.

Reference document

• Necsa Scope of Work for Practical/On-the-Job Training, Document No. NLM-URT-26/001, Rev. 00, forms part of the RFQ and is the detailed technical basis.
• Any ambiguity or omission must be raised in writing with the Necsa contact before the quotation is submitted.

Pricing

• All prices must include all applicable taxes.
• Prices must be fixed and firm.
• Prices must include freight, insurance until acceptance, duty where applicable, and disbursements.

Payment

• Payment is made in accordance with Necsa's General Conditions of Purchase.

Procurement thresholds

• Quotations above R30 000 are evaluated on the PPPFA 80/20 system, with a functionality scorecard where applicable.
• Requirements above R1 million go through the full tender process.

Other

• No goods or services may be delivered to Necsa without an official Necsa purchase order.

Statutory and registration evidence

• Tax Clearance Certificate or SARS-issued tax pin.
• B-BBEE certificate, or a qualifying sworn affidavit for EMEs. Without it, no specific-goal preference points are awarded.
• Letter of Good Standing from the Compensation Fund (COID), only where applicable to the nature of the work.

Returnable declarations

• SBD 4 (Declaration of Interest): discloses whether any director, shareholder or controlling party is employed by the state or connected to anyone at Necsa.

Contracting framework

• The RFQ is subject to Necsa's General Conditions of Purchase, the Preferential Procurement Policy Framework Act 2000, the Preferential Procurement Regulations 2022, the General Conditions of Contract, and any applicable special conditions.
• Responding confirms the bidder is conversant with and accepts these conditions and the attached technical information and specifications.

Conduct requirements

• Enquiries must go only to the nominated contact person; approaching any other Necsa employee may disqualify the bid.
• No gift, payment, loan, reward, inducement or other advantage may be offered to any Necsa employee or representative; doing so is a material breach and grounds for immediate termination.