Prepare chemical additives used in the pulp and paper industry

1Commissioned by PAMSA and German Technical Co-Operation

National Certificate in Paper & Pulp Manufacturing NQF Level 4

Prepare chemical

additives used in the pulp and paper industry



Prepare chemicals additives used in the pulp and paper industry

ModulesTopics

P&P4ELBasics of chemical

additives

P&P4ELMaintenance

P&P4ELSHE

P&P4ELStandard Operating

Procedures

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

Total Notional Hours

BE402 Understanding Operating Procedures in the process

BE402 Implementing Operating Procedures in the process

BE402 First line maintenance

BE402 Applying SHE in the process

32

16

16

18

18

12

8

120

Notional Hours



Critical Cross-field OutcomesIdentify and solve

problems

Work effectively with others

Communicate effectively

Organise and manage myself and

my activitiesCollect, analyse,

organise and critically evaluate

informationUse 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

Be able to trace the material flow through the additive system

Be able to identify each piece of equipment in this process

Understand the fundamental operating principles of each additive system

Understand the purpose of each chemical additive prepared and how it

fits into the overall process


National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: BE402 Understanding the preparation of chemical additives

Learning Activities Topic assessment criteria

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

Assignment Description

WHAT

HOW

1. Learners are provided with relevant plant and equipment information / manuals

2. Inspect the plant and determine the flow of material through the plant

3. 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

4. Draw a basic layout sketch of this area5. 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 plant6. Learners complete a questionnaire to

indicate findings

Notional Hours

32

Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation.

Co

lle

ct

Info

rma

tio

n

Use Multi media

Self Study

Plant investigation

Media search

Interview experts

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Group Discussions

Sketch

Case studies

Use checklists

Develop recommendations

Ex

ec

ute

, te

st

an

d

ev

alu

ate

Job assignment

Make presentation

Complete documents

Draft a report

Complete a questionnaire




problems








critically


Use mathematics


development

Know the typical specifications for the feedstock and final products

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

Know the suppliers of feedstock and the internal customers for each of the chemical

additives supplied.


Understand the properties of each feedstock and final product


National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: BE402 Feedstock, intermediate products and final products



• 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


WHAT

HOW

Notional Hours

16

Individual or group training. Obtain basic product and supplier information by discussions with production experts. Apply knowledge in a practical quality check.

1. Learners are supplied with information on feedstock quality

2. 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

3. Draw-up a quality checklist for the final product

4. Carry out quality checks on the final product using the checklist and report results.

Co

lle

ct

Info

rma

tio

n

Use Multi media

Self Study

Media search

Interview experts

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Group Discussions

Educational games

Case studies

Use checklists


Ex

ec

ute

, te

st

an

d

ev

alu

ate

Job assignment

Make presentation

Draft a report

Plant investigation

Complete documents





problems








critically


Use mathematics


development

Know the effect of variations and deviations on each chemical additive produced

BE402

Understanding process variations in the preparation of chemical additives

Understand what process variations could occur in the process

Be able to complete all 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


National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: BE402 Process variations in the preparation of chemical additives



• 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


WHAT

HOW

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

Notional Hours

16

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.

Co

lle

ct

Info

rma

tio

n

Use Multi media

Self Study

Media search

Interview experts

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Group Discussions

Educational games

Case studies

List / Tabulate


Ex

ec

ute

, te

st

an

d

ev

alu

ate

Job assignment

Make presentation

Draft a report

Plant investigation

Complete documents





problems








critically


Use mathematics


development

BE402

Understanding Operating Procedures in the preparation of chemical additives


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

Understand the sequence and reasons for every pre-

check

Understand the reasons for having pre-check-, start-up-, normal running-, shutdown- and deviation correction

procedures

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 reason for correcting deviations

Understand the sequence and reasons for start-up

procedures


National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: BE402 Understanding “Standard Operating Procedures”



• 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


WHAT

HOW

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

Notional Hours

18

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.

Co

lle

ct

Info

rma

tio

n

Use Multi media

Self Study

Media search

Interview experts

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Group Discussions

Summarise

Use checklists


Ex

ec

ute

, te

st

an

d

ev

alu

ate

Job assignment

Make presentation

Complete documents

Draft a report

Complete a theoretical test

Plant investigation

Educational games




problems








critically


Use mathematics


development

BE402

Implementing Standard Operating Procedures in the preparation of

chemical additives


Be able to do pre-checks on the process

Be able to shut the process down

Be able to start the process up

Be able to maintain normal running conditions

Be able to monitor the process

Be able to bring process variations under control

Be able to bring product variations under control

Be able to use and interpret instrument readings


National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: BE402 Implementing “Standard Operating Procedures”



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


WHAT

HOW

1. 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 down2. Complete any relevant pre-check, start-up,

etc. reports as normally required.3. A practical test will proof competence

Notional Hours

18

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

Co

lle

ct

Info

rma

tio

n

Use Multi media

Self Study

Media search

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Group Discussions

Case studies

Use checklists


Ex

ec

ute

, te

st

an

d

ev

alu

ate

Job assignment

Make presentation

Complete documents

Draft a report

Complete a practical test

Expert demonstration

Plant investigation

Summarise




problems








critically


Use mathematics


development

Be able to carry out maintenance and pre-maintenance duties in this plant

BE402

Perform first line maintenance

Know documentation requirements for maintenance functions



National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: BE402 Perform first line maintenance



• 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.


WHAT

HOW

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.

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 up4. Under supervision, carry out pre-

maintenance and maintenance duties on equipment as prescribed

5. Complete pre-maintenance and maintenance reports / log sheets

Notional Hours

12

Co

lle

ct

Info

rma

tio

n

Use Multi media

Self Study

Media search

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Case studies

Use checklists


Ex

ec

ute

, te

st

an

d

ev

alu

ate

Job assignment

Make presentation

Complete documents

Draft a report

Complete a test/questionnaire

Expert demonstration

Plant investigation

Group Discussions

Summarise




problems








critically


Use mathematics


development

Know the safety standards, procedures and safety equipment relevant to the process

Be able to identify all potential hazards and indicate actions to reduce/avoid hazards

Know the relevant sections of the OHS Act

BE402

Applying SHE in the process

Understand the application of fire prevention, lock-out and emergency procedures

Understand the potential environmental impact of the process



National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: BE402 Applying SHE in the process



• 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.


WHAT

HOW

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 plant’s impact on the environment.

5. A short presentation on the findings is made.

Notional Hours

8

Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact.

Co

lle

ct

Info

rma

tio

n

Use Multi media

Self Study

Media search

Interview experts

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Group Discussions

Educational games

Case studies

Use checklists


Ex

ec

ute

, te

st

an

d

ev

alu

ate

Job assignment

Make presentation

Complete documents

Draft a report

Complete a test/questionnaire

Plant investigation

Documents

Prepare chemical additives used in the pulp and paper industry