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

1Commissioned by PAMSA and German PC403echnical Co-Operation

National Certificate in Paper & Pulp Manufacturing NQF Level 4

Understand the operating principles,

processes and variables

associated with chemical pulping



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

Modules

PC403 Understanding the chemical pulping process

PC403 Understanding the use of utilities in the chemical pulping processes

PC403 Applying first line maintenance

PC403 Understanding the quality requirements of chemical pulping feedstock and products

PC403 Understanding variations in the process

PC403 Applying Standard Operating Procedures to the process

Total Notional Hours

PC403 Applying SHE in the process

PC403 Understanding Operating Procedures in the process

P&P4CRBasics of chemical

pulping

P&P4CRMaintenance

P&P4CRUtilities

P&P4CRSHE

P&P4CRStandard Operating

Procedures

Notional Hours

PC403 Applying sampling practices

28

12

12

12

10

14

14

12

6

120

P&P4CRQuality



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

PC403

Understanding the chemical pulping process

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 purpose of this process and how it fits into the overall process

Understand the fundamental operating principles of each of the types of pulping processes

Understand the basic properties and characteristics of all chemicals used in the process

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

Be able to explain the fundamental chemical processes underlying each of the alternative chemical pulping processes

Understand the basic principles of diffusion in wood liquid interface

Understand the basic advantages and disadvantages of each of the pulping processes

Understand the principles for mass balancing, mass transfer, combustion, heat

transfer and how these are applied in the recovery process


National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: PC403 The chemical pulping process

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• 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

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 this process fits into the overall process, specifically noting suppliers and customers of this plant

4. Draw a basic layout sketch of this area5. 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

6. Learners complete a questionnaire to indicate findings

Notional Hours

28

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, intermediate and final products

Understand the properties of the feedstock, intermediate and final products

PC403

Understanding the quality requirements of chemical pulping feedstock and products

Be able to carry out quality checks on the feedstock and final products

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

Be able to construct a spreadsheet with throughputs, specifications, typical results and

reasons for each specification


National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: PC403 Quality requirements of chemical pulping feedstock and products


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


WHAT

HOW

Notional Hours

12

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 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 produced3. Construct a spreadsheet with throughputs,

specifications, typical results and reasons for each specification

4. Carry out quality checks on the final products using the checklist/spreadsheet and report findings

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 the process and products

PC403

Understanding variations in the process

Understand what process variations could occur in the process

Be able to complete all log sheets

Understand how a deviation in the properties of the feedstock will impact

on the process

Understand what feedstock variations could occur in the process



National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: PC403 Variations in the process


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


WHAPT

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 final products and / or in downstream processes or products

3. 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

4. Tabulate all variations and deviations, their effects and the broad rectification action required and compile the information into a report

Notional Hours

12

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

PC403

Applying sampling practices

Understand the principles of sampling used in the chemical pulping process

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



National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: PC403 Apply sampling practices

Co

lle

ct

Info

rma

tio

n

Use Multi media

Self Study

Interview experts

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Group Discussions

Case studies

List / tabulate


Ex

ec

ute

, te

st

an

d

ev

alu

ate

Make presentation

Complete documents

Draft a report

Complete a test

Learning Activities Topic assessment criteriaAssignment Description

WHAPC403 HOW

Notional Hours

12

Plant investigation

Educational games


• 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.

1. Learners are given a lecture on the statistical basis of sampling practice and tied into the sampling practice in the chemical pulping area.

2. A typical sampling procedure is outlined and a simple checklist compiled

3. Learners view a demonstration of sampling and take a full range of samples under supervision

4. The results of samples are compared to specifications and typical values previously obtained

5. A short report outlines findings

Expert demonstration

Job assignment




problems








critically


Use mathematics


development

PC403

Understanding the use of utilities in the chemical pulping processes

Be able to identify each piece of equipment in each utility system associated with this

process

Understand the fundamental operating principles associated with the utility

systems

Understand the purpose, use and application of each utility system and how it

fits into the process



National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: PC403 The use of utilities in the chemical pulping processes

Co

lle

ct

Info

rma

tio

n

Self Study

Media search

Interview experts

Attend lectures

An

aly

se

, p

lan

an

d

ma

ke

de

cis

ion

s

Group Discussions

Sketch

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

Learning Activities Topic assessment criteriaAssignment Description

WHAT

HOW

Notional Hours

10


• 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.

1. Inspect the equipment and determine the interaction of each auxiliary system with the plant

2. Draw a block diagram showing the main components of each auxiliary system relevant to the plant.

3. 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 system4. Compile all the obtained information in a

short report

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

Plant investigation

Summarise




problems








critically


Use mathematics


development

PC403

Understanding Operating Procedures in the process

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: PC403 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. PC403he 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

14

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

PC403

Applying Standard Operating Procedures on the process

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: PC403 Applying “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 and product variations under

control• shut the process down2. Complete any relevant pre-check, start-up,

etc. reports as normally required3. A practical test will proof competence

Notional Hours

14

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

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


Plant investigation

Summarise




problems








critically


Use mathematics


development

Be able to carry out maintenance and pre-maintenance duties on the

process

PC403

Applying first line maintenance

Know documentation requirements for maintenance functions



National Certificate in Paper & Pulp Manufacturing NQF Level 4Topic Specification: PC403 Applying first line maintenance



• Understand the documentation requirements for maintenance functions

• Are able to carry out maintenance and pre-maintenance duties on the process.


WHAPC403 HOW

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.

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 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



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

PC403

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: PC403 Applying SHE in the process



• 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.


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

6

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


Plant investigation

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

Documents