Prepare chemical additives used in the pulp and paper industry

1. Prepare chemical additives used in the pulp and paper industry

2. P&P4EL Basics of chemical additives P&P4EL SHE P&P4EL Standard Operating Procedures P&P4EL Maintenance Prepare chemicals additives used in the pulp and paper industry Topics Modules Notional Hours 32 16 16 18 18 12 8 120 BE402 Understanding the preparation of chemical additives BE402 The feedstock, intermediate and final products of the process BE402 Variations in the process of chemical additive preparation BE402 Understanding Operating Procedures in the process BE402 Implementing Operating Procedures in the process BE402 First line maintenance BE402 Applying SHE in the process Total Notional Hours

3. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: PP004 Prepare chemical additives used in the pulp and paper industry BE402 Understanding the preparation of chemical additives Understand the fundamental operating principles of each additive system Be able to identify each piece of equipment in this process Be able to trace the material flow through the additive system Understand the purpose of each chemical additive prepared and how it fits into the overall process

4. Notional Hours 32 Topic Specification: BE402 Understanding the preparation of chemical additives Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Understand the purpose of this process and how it fits into the overall process • Are able to identify each piece of equipment in this process • Are able to trace the material flow through the process • Understand the basic properties and characteristics of all chemicals within each additive system • Understand the fundamental operating principles of the process Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation. Self Study Plant investigation Collect Information Media search Interview experts HOW Attend lectures • Learners are provided with relevant plant and equipment information / manuals • Inspect the plant and determine the flow of material through the plant • Draw a block diagram to show where the preparation of chemical additives fits into the papermaking process, specifically noting suppliers and customers of this plant • Draw a basic layout sketch of this area • In a discussion with a chemical additive specialist, identify: • the purpose of the process • the different equipment used in the process, • the basic properties and characteristics of all chemicals within each additive system • the fundamental operating principles of each piece of equipment and the total plant • Learners complete a questionnaire to indicate findings Group Discussions Sketch Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a questionnaire

5. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: PP004 Prepare chemical additives used in the pulp and paper industry BE402 Understanding the feedstock, intermediate products and final products of the process Be able to carry out quality checks on the feedstock and final products Understand the properties of each feedstock and final product Know the typical specifications for the feedstock and final products Know the suppliers of feedstock and the internal customers for each of the chemical additives supplied.

6. Notional Hours 16 Topic Specification: BE402 Feedstock, intermediate products and final products Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Know the suppliers of feedstock and the internal customers for each of the chemical additives supplied. • Know the typical specifications for the feedstock and final products • Understand the properties of the feedstock and final products • Are able to carry out quality checks on the feedstock and final products Individual or group training. Obtain basic product and supplier information by discussions with production experts. Apply knowledge in a practical quality check. Self Study Plant investigation Collect Information Media search Interview experts HOW Attend lectures • Learners are supplied with information on feedstock quality • Have a facilitated group discussion in the chemical additive area to determine: • by whom feedstock is supplied and routes into the plant • the typical grades and properties of the feedstock • the typical properties and specifications used for the final products • the internal customers for the product produced • Draw-up a quality checklist for the final product • Carry out quality checks on the final product using the checklist and report results. Group Discussions Educational games Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a questionnaire

7. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: PP004 Prepare chemical additives used in the pulp and paper industry BE402 Understanding process variations in the preparation of chemical additives Know the effect of variations and deviations on each chemical additive produced Understand what process variations could occur in the process Understand how a variation in the properties of each feedstock will impact on the chemical additives produced Understand what feedstock variations could occur in the process Be able to complete all log sheets

8. Notional Hours 16 Topic Specification: BE402 Process variations in the preparation of chemical additives Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Are able to complete log sheets. • Understand what feedstock variations could occur in the process • Understand how a variation in the properties of each feedstock will impact on the chemical additives produced • Know what the effect of variations and deviations on the process and products is. • Know the broad rectification action required Individual or group training. Use the information on the feed stock obtained earlier to list quality variations. A facilitated discussion to identify possible process deviations and the downstream effects. Self Study Plant investigation Collect Information Media search Interview experts HOW Attend lectures Group Discussions • Learners are supplied with log sheets and assisted to complete them with the help of a production specialist. • Individually list the feedstock variations that could occur and the effect each type of variation could have on the chemical additives produced • In a facilitated discussion at the chemical additive site, identify and list process deviations that could occur and the effect each type of deviation could have on the final product and / or in downstream processes or products • Tabulate all variations and deviations, their effects and the broad rectification action required and compile the information into a report Educational games Case studies Analyse, plan and make decisions List / Tabulate Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a questionnaire

9. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: PP004 Prepare chemical additives used in the pulp and paper industry BE402 Understanding Operating Procedures in the preparation of chemical additives Understand the sequence and reason for correcting deviations Understand the sequence and reason for shut-down and emergency shut-down procedures Understand the reason for maintaining normal running conditions and the consequences of losses caused by inefficient operation Understand the sequence and reasons for every pre-check Understand the sequence and reasons for start-up procedures Understand the reasons for having pre-check-, start-up-, normal running-, shutdown- and deviation correction procedures Understand the different responsibilities in terms of compiling, authorization, layout / format and safety procedures contained in the Standard Operating Procedures Know any other plant / process rules and regulations applicable to the plant Know the purpose of Standard Operating Procedures

10. Notional Hours 18 Topic Specification: BE402 Understanding “Standard Operating Procedures” Learning Activities Assignment Description Topic assessment criteria Use Multi media A facilitated group discussion is used to clarify the logic behind controlled procedure systems. Individual procedures are studied in detail or in terms of key steps as indicated. Indices and summaries for procedures are created for easy future reference. WHAT • The assessor will observe and confirm that learners: • Know the purpose of these procedures • Know other applicable plant rules and regulations • Understand the reason for responsibility control and document control procedures • Understand the reasons for having • pre-checks • start-up procedures • maintaining normal running condition procedures and the consequences of losses caused by inefficient operation • shut-down and emergency shut-down procedures • correcting deviation procedures • Know procedures and sequences in detail or in terms of key steps as required Self Study Plant investigation Collect Information Media search Interview experts Attend lectures HOW Group Discussions • Learners are supplied with the operating procedures for the plant and individual equipment and any other relevant plant rules and regulations • In a facilitated group, the document control system is shortly explained. The purpose of the procedures, responsibility control, document control and having procedures for each operating phase (pre-check, etc.) is discussed and summarised. • Procedures and sequences are studied in detail (esp. emergency procedures) or in terms of key steps as required. Practical understanding and knowledge is essential. • Learners should compile a file containing an index (with subheadings / keywords as necessary) of each procedure • A theoretical test will proof competence Educational games Summarise Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a theoretical test

11. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: PP004 Prepare chemical additives used in the pulp and paper industry BE402 Implementing Standard Operating Procedures in the preparation of chemical additives Be able to bring product variations under control Be able to shut the process down Be able to bring process variations under control Be able to maintain normal running conditions Be able to monitor the process Be able to start the process up Be able to do pre-checks on the process Be able to use and interpret instrument readings

12. Notional Hours 18 Topic Specification: BE402 Implementing “Standard Operating Procedures” Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Are able to: • use and interpret instrument readings • do pre-checks on the process • start the process up • monitor the process • maintain normal running conditions • bring process and product variations under control • shut the process down Group or individual training sessions where, through demonstration, the learner first observes the implementation of operating procedures and then implement the procedures himself under supervision Self Study Plant investigation Collect Information Media search Expert demonstration Attend lectures HOW Group Discussions Summarise • By using relevant checklists and operating procedures, learners will first observe and then, under supervision, implement the following procedures: • do pre-checks on the process • start the process up • use and interpret any instrument readings • monitor the process • maintain normal running conditions • bring process variations under control • bring product variations under control • shut the process down • Complete any relevant pre-check, start-up, etc. reports as normally required. • A practical test will proof competence Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a practical test

13. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: PP004 Prepare chemical additives used in the pulp and paper industry BE402 Perform first line maintenance Be able to carry out maintenance and pre-maintenance duties in this plant Know documentation requirements for maintenance functions

14. Notional Hours 12 Topic Specification: BE402 Perform first line maintenance Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Understand the documentation requirements for maintenance functions in the chemical additive area. • Are able to carry out maintenance and pre-maintenance duties on the equipment. Individual or group training. Study given materials regarding first line maintenance. A discussion / demonstration of first line maintenance duties are facilitated at the machine. Carry out first line maintenance under supervision. Self Study Plant investigation Collect Information Media search Expert demonstration Attend lectures HOW Group Discussions Summarise Case studies Analyse, plan and make decisions • Learners are supplied with documentation required for first line maintenance on the plant and machines. • A discussion / demonstration of typical first line maintenance procedures and their sequence is facilitated in the chemical additive plant • A checklist is drawn up • Under supervision, carry out pre-maintenance and maintenance duties on equipment as prescribed • Complete pre-maintenance and maintenance reports / log sheets Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a test/questionnaire

15. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: PP004 Prepare chemical additives used in the pulp and paper industry BE402 Applying SHE in the process Understand the potential environmental impact of the process Be able to identify all potential hazards and indicate actions to reduce/avoid hazards Know the relevant sections of the OHS Act Understand the application of fire prevention, lock-out and emergency procedures Know the safety standards, procedures and safety equipment relevant to the process

16. Notional Hours 8 Topic Specification: BE402 Applying SHE in the process Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Know the relevant OHS Act, safety standards, procedures, and equipment in the chemical additive plant. • Understand the application of fire prevention, lock-out and emergency procedures in the plant, as well as the potential environmental impact of the process. • Are able to identify all potential hazards in the process and indicate actions to reduce / avoid / minimise the impact of hazards. Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact. Self Study Plant investigation Collect Information Media search Interview experts HOW Attend lectures • Learners are supplied with a copy of the safety procedures and the relevant section of the OHS Act • Learners individually undertake a plant inspection and identify all potential hazards. They also assess the potential impact of the plant on the environment. • Learners should also sketch the area and indicate the position of all safety equipment and safety features (e.g. alarm buttons, emergency exists) on it. • Recommendations are made to reduce / avoid these hazards, the impact of possible hazards and the plant’s impact on the environment. • A short presentation on the findings is made. Group Discussions Educational games Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a test/questionnaire