Understand the processes, inputs and variables in mechanical pulping

1
Understand the processes, inputs and variables in
mechanical pulping
2
Understand the processes, inputs and variables in
mechanical pulping
Modules
Topics
Notional Hours
23 10 10 10 8 12 12 10 5 100
PE401 Understanding mechanical pulping processes
PE401 Understanding the process feedstock,
intermediate and final products
PE401 Understanding variations in the process
PE401 Understanding variations in the process
PE401 Understanding the purpose of auxiliary
systems associated with the process
PE401 Understanding Operating Procedures in the
process
PE401 Applying Standard Operating Procedures to
the process
PE401 Applying first line maintenance
PE401 Applying SHE in the process
Total Notional Hours
3
US U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 Understanding mechanical pulping processes
Be able to explain the chemical/mechanical
processes taking place as well as the basic
principles of diffusion in wood/liquid interface
in the mechanical pulping process
Understand the principles for mass balancing and
energy balances and how these are applied in the
processes
Understand the basic properties and
characteristics of all chemicals used and
produced in the process
Understand the fundamental operating principles
associated with each of the types of processes
Be able to trace the basic process flow within
each of the types of mechanical pulping processes
(GWD, TMP, CTMP)
Be able to identify each of the major pieces of
process equipment
Understand the purpose of these processes and how
it fits into the overall process
4
Topic Specification PE401 The mechanical
pulping processes
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 these processes and
  how it fits into the overall process
• Are able to identify each of the major pieces of
  process equipment
• Are able to trace the basic process flow within
  each of the types of mechanical pulping processes
  (GWD, TMP, CTMP)
• Understand the fundamental operating principles
  associated with each of the types of processes
• Understand the basic properties and
  characteristics of all chemicals used and
  produced in the process
• Understand the principles for mass balancing and
  energy balances and how these are applied in the
  processes
• Are able to explain the chemical / mechanical
  processes taking place as well as
  the basic principles of diffusion
  in wood / liquid interface
  in the mechanical pulping process

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 process flow
  through all the processes
• 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 these processes
• the different equipment used
• the fundamental operating principles associated
  with each of the types of processes
• the basic properties and characteristics of all
  chemicals used and produced in the processes
• the principles for mass balancing and energy
  balances and how these are applied in the
  processes
• the chemical / mechanical processes taking place
  as well as the basic principles of diffusion in
  wood / liquid interface in the mechanical pulping
  process
• 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 U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 Understanding the process feedstock,
intermediate and final 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 reasons for quality standards in
raw materials, intermediates and final products
Understand the properties of the feedstock,
intermediate and final products
Know the typical specifications for the
feedstock, intermediate and final products in
each of the processes
Know the suppliers of feedstock and the customers
for the products produced.
6
Topic Specification PE401 The process
feedstock, intermediate 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
  customers for the product produced.
• Know the typical specifications for the
  feedstock and final products in each of the
  processes
• Understand the properties of the feedstock and
  final products
• Understand the reasons for quality standards in
  raw materials, intermediates 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
Interview experts
HOW
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
• the typical grades and properties of the
  feedstock
• the typical properties and specifications used
  for the final products
• the customers for the product produced
• the reasons for quality standards in raw
  materials, intermediates and final products
• Draw-up a quality checklist/spreadsheet with
  throughputs, specifications, typical results and
  reasons for each specification
• Carry out quality checks on the final product
  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 U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 Understanding variations in the processes
Know the effect of variations and deviations on
the processes and products
Understand what process variations could occur in
the processes
Understand how a deviation in the properties of
the feedstock will impact on the processes
Understand what feedstock variations could occur
in the processes
Be able to complete all log sheets
8
Topic Specification PE401 Variations in the
processes
Learning Activities
Topic assessment criteria
Assignment Description
Use Multi media
WHAT

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

Individual or group training. Use the
information on the feedstock 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

• Learners are supplied with log sheets and
  assisted to complete them with the help of a
  production specialist
• Individually list the feedstock and process
  variations that could occur and the effect each
  type of variation could have on the final product
  and / or in downstream processes or products
• In a facilitated discussion at the site, identify
  and list 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

Group Discussions
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 U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 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
mechanical pulping process
10
Topic Specification PE401 Apply sampling
practices
Learning Activities
Topic assessment criteria
Assignment Description
Use Multi media
WHAT

• The assessor will observe and confirm that
  learners
• Understand the principles of sampling used in
  the mechanical 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 mechanical 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 U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 Understanding the purpose of the auxiliary
systems associated with the processes
Understand the re-usage of low energy steam in
the mechanical pulping process
Understand the fundamental operating principles
associated with each auxiliary system
Be able to trace the flows in the auxiliary
systems
Be able to identify each piece of equipment in
each auxiliary system associated with this process
Understand the purpose, use and application of
each auxiliary system and how it fits into the
process
12
Topic Specification PE401 Purpose of auxiliary
systems associated with the processes
Learning Activities
Topic assessment criteria
Assignment Description
Use Multi media
WHAT

• The assessor will observe and confirm that
  learners
• Understand the purpose of each auxiliary system
  as well as the fundamental operating principles
  associated with the system.
• Are able to identify the components and trace
  the flow of each system.
• Understand the re-usage of low energy steam in
  the mechanical pulping 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

• Inspect the equipment and determine the
  interaction of each auxiliary system (e.g. steam)
  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 of the system is
• how it supports the process
• the different components of the system, and
• the fundamental operating principles of the
  system
• the re-usage of low energy steam in the
  mechanical pulping process
• Compile all the obtained information in a short
  report

Group Discussions
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 U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 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 PE401 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. 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
15
US U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 Applying Standard Operating Procedures to
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 PE401 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 U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 Applying first line maintenance
Be able to carry out maintenance and
pre-maintenance duties on the processes
Know documentation requirements for maintenance
functions
18
Topic Specification PE401 Applying 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
• Are able to carry out maintenance and
  pre-maintenance duties on the processes.

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 U0009 Understand the processes, inputs and
variables in mechanical pulping

PE401 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 PE401 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 processes.
• Are able to identify all potential hazards in
  the processes and indicate actions to reduce /
  avoid / minimise the impact of these 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

• 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