1. 1 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor

2. 2 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 ModulesTopics P&P4CR Basics of the fluidised bed process P&P4CR Maintenance P&P4CR SHE P&P4CR Standard Operating Procedures RC405Understanding the combustion of spent pulping liquor RC405The feedstock and final products of the process RC405Variations in the process Total Notional Hours RC405Understanding Operating Procedures in the process RC405Implementing Operating Procedures in the process RC405First line maintenance RC405Applying SHE in the process Notional Hours RC405Purpose of auxiliary systems in the process P&P4CR Auxiliary systems Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor 56 20 24 16 32 24 16 220

3. 3 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development RC405 Understanding the fluidised bed process Be able to trace the material flow through the process Be able to identify each piece of equipment in this process Understand the fundamental operating principles of the process Understand the purpose of this process and how it fits into the overall process Understand the basic properties and characteristics of all chemicals within this process Understand the chemical reactions taking place in the processes US: CR008Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor

4. 4 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: RC405 Understanding the fluidised bed process Learning ActivitiesTopic 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 fundamental operating principles of the process Understand the basic properties and characteristics of all chemicals within this process Understand the chemical reactions taking place in the processes Assignment Description WHATWHAT 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 fluidised bed process fits into the papermaking process, specifically noting suppliers and customers of this plant 4.Draw a basic layout sketch of this area 5.In a discussion with a plant specialist, identify: the purpose of the process the different equipment used in the process, the fundamental operating principles of each piece of equipment and the total plant the basic properties and characteristics of all chemicals within this process the chemical reactions taking place in the processes 6.Learners complete a questionnaire to indicate findings Notional Hours 56 Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation. Collect Information Use Multi media Self Study Plant investigation Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a questionnaire

5. 5 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development Know the typical specifications for the feedstock and final products Understand the properties of the feedstock and final products RC405 Understanding the feedstock and final products of the process Be able to carry out sampling and quality checks on the feedstock and final products Know the suppliers of feedstock and the customers for the product produced. US: CR008Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor

6. 6 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: RC405 The feedstock and final products of the process Learning ActivitiesTopic assessment criteria 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 Understand the properties of the feedstock and final products Are able to carry out sampling and quality checks on the feedstock and final products Assignment Description WHATWHAT HOW Notional Hours 20 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 fluidised bed 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 customers for the product produced 3.Draw-up a sampling and quality checklist for the final product 4.Carry out sampling and quality checks on the final product using the checklist and report results. Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Plant investigation Complete documents Complete a questionnaire

7. 7 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development Be able to complete all log sheets US: CR008Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor Know the effect of variations and deviations on the process and products RC405 Understanding variations in the process 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

8. 8 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: RC405 Variations in the process Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Are able to complete log sheets. Understand what feedstock variations and process deviations can occur. Know what the effect of variations and deviations on the process and products is. Know the broad rectification action required Assignment Description WHATWHAT 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 product and / or in downstream processes or products 3.In a facilitated discussion at the fluidised bed 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 24 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. Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies List / Tabulate Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Plant investigation Complete documents Complete a questionnaire

9. 9 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development RC405 Understanding the purpose of any auxiliary systems associated with the combustion of spent pulping liquor Be able to trace the flows in the auxiliary system Be able to identify each piece of equipment associated with the combustion of spent pulping liquor Understand the fundamental operating principles associated with this auxiliary system Understand the purpose of the system and how it fits into the process US: CR008Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor

10. 10 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: RC405 Purpose of auxiliary systems Learning ActivitiesTopic assessment criteriaAssignment Description WHATWHAT HOW Notional Hours 16 The assessor will observe and confirm that learners: Understand the purpose of the system and how it fits into the process Are able to identify each piece of equipment (the components of the system) associated with the combustion of spent pulping liquor Are able to trace the flows in the auxiliary system Understand the fundamental operating principles associated with this auxiliary system 1.Inspect the equipment and determine the interaction of each auxiliary system with the machine 2.Draw a block diagram showing the main components of each auxiliary system relevant to the machine. 3.In a discussion with a specialist on each 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 each auxiliary system 4.Compile all the obtained information in a short report Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation. Collect Information Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Use Multi media Plant investigation Summarise

11. 11 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use 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: CR008Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor RC405 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

12. 12 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: RC405 Understanding “Standard Operating Procedures” Learning ActivitiesTopic assessment criteria 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 Assignment Description WHATWHAT 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 32 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. Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Summarise Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a theoretical test Plant investigation Educational games

13. 13 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use 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: CR008Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor RC405 Implementing Standard Operating Procedures in 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

14. 14 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: RC405 Implementing “Standard Operating Procedures” Learning ActivitiesTopic assessment criteria 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 Assignment Description WHATWHAT 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 down 2.Complete any relevant pre-check, start-up, etc. reports as normally required. 3.A practical test will proof competence Notional Hours 32 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 Collect Information Use Multi media Self Study Media search Attend lectures Analyse, plan and make decisions Group Discussions Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a practical test Expert demonstration Plant investigation Summarise

15. 15 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development Be able to carry out maintenance and pre-maintenance duties in this plant RC405 Perform first line maintenance Know documentation requirements for maintenance functions US: CR008Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor

16. 16 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: RC405Perform first line maintenance Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Understand the documentation requirements for maintenance functions in the plant area. Are able to carry out maintenance and pre-maintenance duties on the equipment. Assignment Description WHATWHAT 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 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 Notional Hours 24 Collect Information Use Multi media Self Study Media search Attend lectures Analyse, plan and make decisions Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Expert demonstration Plant investigation Group Discussions Summarise

17. 17 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal 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 RC405 Applying SHE in the process Understand the application of fire prevention, lock-out and emergency procedures Understand the potential environmental impact of the process US: CR008Produce chemical compounds by converting spent organic and inorganic pulping by-products using a fluidised bed reactor

18. 18 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: RC405 Applying SHE in the process Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the relevant OHS Act, safety standards, procedures, and equipment in the fluidised bed area. 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. Assignment Description WHATWHAT 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 16 Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact. Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Plant investigation