Understand the operating principles, processes and variables associated with chemical pulping

1
Understand the operating principles, processes
and variables associated with chemical pulping
2
Understand the operating principles, processes
and variables associated with chemical pulping
Modules
Notional Hours
28 12 12 12 10 14 14 12 6 120
PC403 Understanding the chemical pulping process
PC403 Understanding the quality requirements of
chemical pulping feedstock and products
PC403 Understanding variations in the process
PC403 Applying sampling practices
PC403 Understanding the use of utilities in the
chemical pulping processes
PC403 Understanding Operating Procedures in the
process
PC403 Applying Standard Operating Procedures to
the process
PC403 Applying first line maintenance
PC403 Applying SHE in the process
Total Notional Hours
3
US U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 Understanding the chemical pulping process
Be able to explain the fundamental chemical
processes underlying each of the alternative
chemical pulping processes
Understand the basic properties and
characteristics of all chemicals used in the
process
Understand the basic principles of diffusion in
wood liquid interface
Understand the principles for mass balancing,
mass transfer, combustion, heat transfer and how
these are applied in the recovery process
Understand the fundamental operating principles
of each of the types of pulping processes
Be able to trace the material flow through each
of the types of pulping processes
Be able to identify each piece of equipment in
each of the major pulping processes
Understand the basic advantages and disadvantages
of each of the pulping processes
Understand the purpose of this process and how it
fits into the overall process
4
Topic Specification PC403 The chemical pulping
process
Learning Activities
Topic assessment criteria
Assignment Description
Individual or group training. Do self study to
develop key plant operation questions. Answers
are obtained by discussions with production
experts and plant investigation.
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
• Understand the basic advantages and
  disadvantages of each of the pulping processes
• Are able to identify each piece of equipment in
  each of the major pulping processes
• Are able to trace the material flow through each
  of the types of pulping processes
• Understand the principles for mass balancing,
  mass transfer, combustion, heat transfer and how
  these are applied in the recovery process
• Understand the fundamental operating principles
  of each of the types of pulping processes
• Understand the basic principles of diffusion in
  wood liquid interface
• Understand the basic properties and
  characteristics of all chemicals used in the
  processes
• Are able to explain the
  fundamental chemical processes
  underlying each of the
  alternative chemical pulping
  processes

Self Study
Plant investigation
Collect Information
HOW
Media search
Interview experts

• 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 this process
  fits into the overall process, specifically
  noting suppliers and customers of this plant
• Draw a basic layout sketch of this area
• In a discussion with a plant specialist,
  identify
• the purpose of the process
• the basic advantages and disadvantages of each of
  the pulping processes
• the different equipment used in the process
• the fundamental operating principles of each
  piece of equipment and the total plant
• the principles for mass balancing, mass transfer,
  combustion, heat transfer and how these are
  applied in the recovery process
• the basic properties and characteristics of all
  chemicals within this process
• the basic principles of diffusion in wood liquid
  interface
• the fundamental chemical processes underlying
  each of the alternative chemical pulping
  processes
• Learners complete a questionnaire to indicate
  findings

Attend lectures
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 U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 Understanding the quality requirements of
chemical pulping feedstock and products
Be able to construct a spreadsheet with
throughputs, specifications, typical results and
reasons for each specification
Be able to carry out quality checks on the
feedstock and final products
Understand the properties of the feedstock,
intermediate and final products
Know the typical specifications for the
feedstock, intermediate and final products
Understand the reasons for quality standards in
raw materials, intermediates and final products
Know the suppliers of feedstock and the customers
for the products produced.
6
Topic Specification PC403 Quality requirements
of chemical pulping feedstock and products
Learning Activities
Topic assessment criteria
Assignment Description
Use Multi media
WHAT

• PC403he assessor will observe and confirm that
  learners
• Know the suppliers of feedstock and the
  customers for the products produced.
• Understand the reasons for quality standards in
  raw materials, intermediates and final products
• Know the typical specifications for the
  feedstock, intermediate and final products
• Understand the properties of the feedstock,
  intermediate and final products
• Are able to carry out quality checks on the
  feedstock and final products
• Are able to construct a spreadsheet with
  throughputs, specifications, typical results and
  reasons for each specification

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
HOW
Interview experts
Attend lectures

• Learners are supplied with information on
  feedstock quality
• Have a facilitated group discussion in the plant
  to determine
• by whom feedstock is supplied and routes into the
  plant
• PC403he reasons for quality standards in raw
  materials, intermediates and final products
• the typical grades and properties of the
  feedstock
• the typical properties and specifications used
  for the intermediate and final products
• the customers for the products produced
• Construct a spreadsheet with throughputs,
  specifications, typical results and reasons for
  each specification
• Carry out quality checks on the final products
  using the checklist/spreadsheet and report
  findings

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 U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 Understanding variations in the process
Know the effect of variations and deviations on
the process and products
Understand what process variations could occur in
the process
Understand how a deviation in the properties of
the feedstock will impact on the process
Understand what feedstock variations could occur
in the process
Be able to complete all log sheets
8
Topic Specification PC403 Variations in the
process
Learning Activities
Topic assessment criteria
Assignment Description
Use Multi media
WHAPT

• The assessor will observe and confirm that
  learners
• Are able to complete all log sheets.
• Understand what feedstock variations could occur
  in the process
• Understand how a deviation in the properties of
  the feedstock will impact on the process
• Understand what process variations could occur
  in the process
• Know the effect of variations and deviations on
  the process and products

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 final products and / or in
  downstream processes or products
• In a facilitated discussion at the site, identify
  and list process deviations that could occur and
  the effect each type of deviation could have on
  the final products 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
US U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 Applying sampling practices
Be able to interpret the test results in terms of
the impact on the process and customers
Be able to construct a basic spreadsheet for
sources and sample results
Be able to do sampling according to plant
standards
Understand the principles of sampling used in the
chemical pulping process
10
Topic Specification PC403 Apply sampling
practices
Learning Activities
Topic assessment criteria
Assignment Description
Use Multi media
WHAPC403

• The assessor will observe and confirm that
  learners
• Understand the principles of sampling used in
  the chemical pulping process
• Are able to do sampling according to plant
  standards
• Are able to construct a basic spreadsheet for
  different sources and sample results
• Are able to interpret the test results in terms
  of the impact on the process and customers

Learners are given a short lecture on the
statistical basis of sampling practice. Sampling
is demonstrated and then done under supervision.
A spreadsheet showing required and typical
feedstock and final product qualities is drawn up.
Self Study
Plant investigation
Collect Information
Expert demonstration
Interview experts
Attend lectures
Group Discussions
HOW
Educational games
Case studies
Analyse, plan and make decisions

• Learners are given a lecture on the statistical
  basis of sampling practice and tied into the
  sampling practice in the chemical pulping area.
• A typical sampling procedure is outlined and a
  simple checklist compiled
• Learners view a demonstration of sampling and
  take a full range of samples under supervision
• The results of samples are compared to
  specifications and typical values previously
  obtained
• A short report outlines findings

List / tabulate
Develop recommendations
Job assignment
Make presentation
Complete documents
Execute, test and evaluate
Draft a report
Complete a test
11
US U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 Understanding the use of utilities in the
chemical pulping processes
Understand the fundamental operating principles
associated with the utility systems
Be able to identify each piece of equipment in
each utility system associated with this process
Understand the purpose, use and application of
each utility system and how it fits into the
process
12
Topic Specification PC403 The use of utilities
in the chemical pulping processes
Learning Activities
Topic assessment criteria
Assignment Description
Use Multi media
WHAT

• The assessor will observe and confirm that
  learners
• Understand the purpose, use and application of
  each utility system as well as the fundamental
  operating principles associated with the systems.
• Are able to identify the components of the
  systems.

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
Group Discussions

• Inspect the equipment and determine the
  interaction of each auxiliary system with the
  plant
• Draw a block diagram showing the main components
  of each auxiliary system relevant to the plant.
• In a discussion with a specialist on the
  auxiliary system, identify
• what the purpose, use and application of each
  utility system is
• how it supports the process
• the different components of the systems, and
• the fundamental operating principles of each
  system
• Compile all the obtained information in a short
  report

Sketch
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 test/questionnaire
13
US U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 Understanding Operating Procedures in the
process
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
14
Topic Specification PC403 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

• 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. PC403he 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
15
US U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 Applying Standard Operating Procedures on
the process
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
16
Topic Specification PC403 Applying 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 implements 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 and 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
17
US U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 Applying first line maintenance
Be able to carry out maintenance and
pre-maintenance duties on the process
Know documentation requirements for maintenance
functions
18
Topic Specification PC403 Applying first line
maintenance
Learning Activities
Topic assessment criteria
Assignment Description
Use Multi media
WHAPC403

• The assessor will observe and confirm that
  learners
• Understand the documentation requirements for
  maintenance functions
• Are able to carry out maintenance and
  pre-maintenance duties on the process.

Individual or group training. Study given
materials regarding first line maintenance. A
discussion / demonstration of first line
maintenance duties are facilitated at the plant.
Carry out first line maintenance under
supervision.
Self Study
Plant investigation
Collect Information
Media search
Expert demonstration
Attend lectures
Group Discussions
HOW
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 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
19
US U0001 Understand the operating principles,
processes and variables associated with chemical
pulping

PC403 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
20
Topic Specification PC403 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 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
  plants 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