1. 1 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Understand the process and variables in drying paper, board and tissue products

2. 2 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Understand the process and variables in drying paper, board and tissue products ModulesTopics BC405Understanding drying processes BC405 Applying first line maintenance BC405 Understanding the drying process feedstock and products BC405 Understanding variations in the process BC405 Applying Standard Operating Procedures to the process Total Notional Hours BC405 Applying SHE in the process BC405 Understanding Operating Procedures in the process P&P4CR Basics of the drying process P&P4CR Maintenance P&P4CR SHE P&P4CR Standard Operating Procedures Notional Hours TUnderstanding variations in the process BC405 Understanding the purpose of auxiliary systems associated with the process P&P4CR Auxiliary systems BC405 Applying sampling principles 23 10 8 12 10 5 100 P&P4CR Quality

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 BC405 Understanding drying processes Be able to trace the material flow through these processes Be able to identify each piece of equipment in these processes Understand the purpose of these processes and how it fits into the overall process Understand the fundamental operating principles associated with each of the three types of drying processes Understand the basic properties and characteristics of size press additives applied in the drying processes US: U0003Understand the process and variables in drying paper, board and tissue products Be able to explain the inter fiber bonding taking place in the different drying processes Understand the principles for moisture removal energy balance, mass balance, radiation theory and how these are applied in the processes

4. 4 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405 The drying processes Learning ActivitiesTopic assessment criteria 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 piece of equipment in these processes Are able to trace the material flow through the processes Understand the fundamental operating principles associated with each of the three types of drying processes Understand the basic properties and characteristics of size press additives applied in the drying processes. Understand the principles for moisture removal energy balance, mass balance, radiation theory and how these are applied in the processes Are able to explain the inter fiber bonding taking place in the different drying 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 this process fits into the overall 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 these processes the different equipment used the fundamental operating principles associated with each of the three types of drying processes the basic properties and characteristics of size press additives the principles for moisture removal energy balance, mass balance, radiation theory and how these are applied in the processes the inter fiber bonding taking place in the different drying processes. 6.Learners complete a questionnaire to indicate findings Notional Hours 23 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 in each of the process Understand the properties of the feedstock (pressed web) and final products BC405 Understanding the drying process feedstock and products Know the suppliers of feedstock and the customers for the products produced. US: U0003Understand the process and variables in drying paper, board and tissue products Be able to carry out quality checks on the feedstock (pressed web) and final products Be able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification

6. 6 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405 The drying process feedstock and products Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the suppliers of feedstock and the customers for the products produced. Know the typical specifications for the feedstock and final products in each of the processes Understand the properties of the feedstock (pressed web) 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 Assignment Description WHATWHAT HOW Notional Hours 10 Individual or group training. Obtain basic product and supplier information by discussions with production experts. Apply knowledge in a practical quality check. 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 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 The 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 3.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

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 Know the effect of variations and deviations on the processes and products BC405 Understanding variations in the processes Understand what process variations could occur in the processes Be able to complete all log sheets Understand how a deviation in the properties of the feedstock will impact on the processes Understand what feedstock variations could occur in the processes US: U0003Understand the process and variables in drying paper, board and tissue products

8. 8 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405 Variations in the processes Learning ActivitiesTopic assessment criteria 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 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 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 3.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 4.Tabulate all variations and deviations, their effects and the broad rectification action required and compile the information into a report Notional Hours 10 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. 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 BC405 Applying sampling practices Understand the principles of sampling used in the drying 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 US: U0003Understand the process and variables in drying paper, board and tissue products

10. 10 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405 Apply sampling practices Collect Information Use Multi media Self Study Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Case studies List / tabulate Develop recommendations Execute, test and evaluate Make presentation Complete documents Draft a report Complete a test Learning ActivitiesTopic assessment criteriaAssignment Description WHATWHAT HOW Notional Hours 10 Plant investigation Educational games The assessor will observe and confirm that learners: Understand the principles of sampling used in the drying 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 drying 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

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 BC405 Understanding the purpose of the auxiliary systems associated with the processes Be able to trace the flows in the auxiliary system Be able to identify each piece of equipment in each auxiliary system associated with this process Understand the fundamental operating principles associated with each auxiliary system Understand the purpose of each auxiliary system and how it fits into the process US: U0003Understand the process and variables in drying paper, board and tissue products

12. 12 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405 Purpose of auxiliary systems associated with the process 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 Learning ActivitiesTopic assessment criteriaAssignment Description WHATWHAT HOW Notional Hours 8 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. 1.Inspect the equipment and determine the interaction of each auxiliary system (e.g. steam) 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 of the system is how it supports the process the different components of the system, and the fundamental operating principles of the system 4.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

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 BC405 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 US: U0003Understand the process and variables in drying paper, board and tissue products

14. 14 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405 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 12 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

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 BC405 Applying Standard Operating Procedures to 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 US: U0003Understand the process and variables in drying paper, board and tissue products

16. 16 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405 Applying “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 and 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 12 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 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

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 Be able to carry out maintenance and pre-maintenance duties on the processes BC405 Applying first line maintenance Know documentation requirements for maintenance functions US: U0003Understand the process and variables in drying paper, board and tissue products

18. 18 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405Applying first line maintenance Learning ActivitiesTopic assessment criteria 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. 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 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 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 10 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

19. 19 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 BC405 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: U0003Understand the process and variables in drying paper, board and tissue products

20. 20 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BC405 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 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. 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 5 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