Prepare chemical additives used in the pulp and paper industry

1
Prepare chemical additives used in the pulp and
paper industry
2
Prepare chemicals additives used in the pulp and
paper industry
Modules
Topics
Notional Hours
32 16 16 18 18 12 8 120
PE406 Understanding the preparation of chemical
additives
PE406 The feedstock, intermediate and final
products of the process
PE406 Variations in the process of chemical
additive preparation
PE406 Understanding Operating Procedures in the
process
PE406 Implementing Operating Procedures in the
process
PE406 First line maintenance
PE406 Applying SHE in the process
Total Notional Hours
3
US PP004 Prepare chemical additives used in the
pulp and paper industry

PE406 Understanding the preparation of chemical
additives
Understand the fundamental operating principles
of each additive system
Be able to trace the material flow through the
additive system
Be able to identify each piece of equipment in
this process
Understand the purpose of each chemical additive
prepared and how it fits into the overall process
4
Topic Specification PE406 Understanding the
preparation of chemical additives
Learning Activities
Topic assessment criteria
Assignment Description
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
US PP004 Prepare chemical additives used in the
pulp and paper industry

PE406 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
Topic Specification PE406 Feedstock,
intermediate products and final products
Learning Activities
Topic assessment criteria
Assignment Description
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
US PP004 Prepare chemical additives used in the
pulp and paper industry

PE406 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
Topic Specification PE406 Process variations in
the preparation of chemical additives
Learning Activities
Topic assessment criteria
Assignment Description
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

1. Learners are supplied with log sheets and
   assisted to complete them with the help of a
   production specialist.
2. Individually list the feedstock variations that
   could occur and the effect each type of variation
   could have on the chemical additives produced
3. 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
4. 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
US PP004 Prepare chemical additives used in the
pulp and paper industry

PE406 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
Topic Specification PE406 Understanding
Standard Operating Procedures
Learning Activities
Topic assessment criteria
Assignment Description
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.
Use Multi media
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

1. Learners are supplied with the operating
   procedures for the plant and individual equipment
   and any other relevant plant rules and
   regulations
2. 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.
3. Procedures and sequences are studied in detail
   (esp. emergency procedures) or in terms of key
   steps as required. Practical understanding and
   knowledge is essential.
4. Learners should compile a file containing an
   index (with subheadings / keywords as necessary)
   of each procedure
5. 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
US PP004 Prepare chemical additives used in the
pulp and paper industry

PE406 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
Topic Specification PE406 Implementing
Standard Operating Procedures
Learning Activities
Topic assessment criteria
Assignment Description
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
US PP004 Prepare chemical additives used in the
pulp and paper industry

PE406 Perform first line maintenance
Be able to carry out maintenance and
pre-maintenance duties in this plant
Know documentation requirements for maintenance
functions
14
Topic Specification PE406 Perform first line
maintenance
Learning Activities
Topic assessment criteria
Assignment Description
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

1. Learners are supplied with documentation required
   for first line maintenance on the plant and
   machines.
2. A discussion / demonstration of typical first
   line maintenance procedures and their sequence is
   facilitated in the chemical additive plant
3. A checklist is drawn up
4. Under supervision, carry out pre-maintenance and
   maintenance duties on equipment as prescribed
5. 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
US PP004 Prepare chemical additives used in the
pulp and paper industry

PE406 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
Topic Specification PE406 Applying SHE in the
process
Learning Activities
Topic assessment criteria
Assignment Description
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
HOW
Interview experts
Attend lectures

1. Learners are supplied with a copy of the safety
   procedures and the relevant section of the OHS
   Act
2. Learners individually undertake a plant
   inspection and identify all potential hazards.
   They also assess the potential impact of the
   plant on the environment.
3. 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.
4. Recommendations are made to reduce / avoid these
   hazards, the impact of possible hazards and the
   plants impact on the environment.
5. 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