National Certificate in Paper & Pulp Manufacturing NQF Level 4
Produce crude
tall oil by the
acidification of
Kraft soap
skimming
Commissioned by PAMSA
and German Technical Co-Operation
1
National Certificate in Paper & Pulp Manufacturing NQF Level 4
Produce crude tall oil by the
acidification of Kraft soap skimming
Topics
Modules
Notional Hours
RE405
40
Understanding the production of crude tall oil
P&P4EL
Basics of crude tall
oil
RE405
The feedstock and final products of the process
16
RE405
Variations in the process
18
P&P4EL
RE405
Understanding Operating Procedures in the process
24
Standard Operating
Procedures
RE405
Implementing Operating Procedures in the process
24
P&P4EL
RE405
First line maintenance
16
Maintenance
RE405
Applying SHE in the process
12
P&P4EL
Total Notional Hours
Commissioned by PAMSA
and German Technical Co-Operation
150
SHE
2
National Certificate in Paper & Pulp Manufacturing NQF Level 4
US: CR001
Produce crude tall oil by the acidification of Kraft soap
skimming
Critical Cross-field Outcomes
RE405
Understanding the production of crude
tall oil
Identify and solve
problems
Work effectively with
others
Communicate effectively
Understand the fundamental operating
principles of the process
Organise and manage
myself and my activities
Collect, analyse, organise
and critically evaluate
information
Be able to identify each piece of
equipment in this process
Be able to trace the material
flow through the process
Understand the purpose of this process and
how it fits into the overall process
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
Commissioned by PAMSA
and German Technical Co-Operation
3
National Certificate in Paper & Pulp Manufacturing NQF Level 4
Topic Specification: RE405
Execute, test and
evaluate
Analyse, plan and
make decisions
Collect Information
Learning Activities
Use Multi media
Self Study
Plant investigation
Media search
Understanding the production of crude tall oil
Assignment Description
W
H
A
T
Individual or group training. Do self
study to develop key plant operation
questions. Answers are obtained by
discussions with production experts
and plant investigation.
Interview experts
HOW
Attend lectures
Group Discussions
Sketch
Case studies
Use checklists
Develop
recommendations
Job assignment
Make presentation
Complete documents
Draft a report
Complete a
questionnaire
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
production of crude tall oil 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 tall oil 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
6. Complete questionnaire to indicate findings
Commissioned by PAMSA
Topic assessment criteria
The assessor will observe and confirm
that learners:
• Understand the purpose of this process
and how it fits into the overall process
• Are able to identify each piece of
equipment in this process
• Are able to trace the material flow
through the process
• Understand the fundamental operating
principles of the process
and German Technical Co-Operation
Notional
Hours
40
4
National Certificate in Paper & Pulp Manufacturing NQF Level 4
US: CR001
Produce crude tall oil by the acidification of Kraft soap
skimming
Critical Cross-field Outcomes
RE405
Understanding the feedstock and
final products of the process
Identify and solve
problems
Work effectively with
others
Be able to carry out sampling and quality
checks on the feedstock and final
products
Communicate effectively
Organise and manage
myself and my activities
Understand the properties of the
feedstock and final products
Collect, analyse, organise
and critically evaluate
information
Know the typical specifications for the
feedstock and final products
Use science and
technology effectively and
critically
Know the suppliers of feedstock and the
external customers for the product
produced.
Demonstrate an
understanding of the
world as a set of related
systems
Use mathematics
Learner and societal
development
Commissioned by PAMSA
and German Technical Co-Operation
5
National Certificate in Paper & Pulp Manufacturing NQF Level 4
Topic Specification: RE405
Execute, test and
evaluate
Analyse, plan and
make decisions
Collect Information
Learning Activities
Use Multi media
Self Study
Plant investigation
Media search
The feedstock and final products of the process
Assignment Description
W
H
A
T
Individual or group training. Obtain
basic product and supplier information
by discussions with production
experts. Apply knowledge in a practical
quality check.
Interview experts
HOW
Attend lectures
Group Discussions
Educational games
Case studies
Use checklists
Develop
recommendations
Job assignment
Make presentation
Complete documents
Draft a report
Complete a
questionnaire
1. Learners are supplied with information on
feedstock quality
2. Have a facilitated group discussion in the
tall oil 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 external 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.
Commissioned by PAMSA
Topic assessment criteria
The assessor will observe and confirm
that learners:
• Know the suppliers of feedstock and the
external 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
and German Technical Co-Operation
Notional
Hours
16
6
National Certificate in Paper & Pulp Manufacturing NQF Level 4
US: CR001
Produce crude tall oil by the acidification of Kraft soap
skimming
Critical Cross-field Outcomes
RE405
Understanding variations in the
process
Know the effect of variations and deviations
on the process and products
Identify and solve
problems
Work effectively with
others
Communicate effectively
Organise and manage
myself and my activities
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
Be able to complete all log sheets
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
Commissioned by PAMSA
and German Technical Co-Operation
7
National Certificate in Paper & Pulp Manufacturing NQF Level 4
Topic Specification: RE405
Collect Information
Learning Activities
Use Multi media
Self Study
Plant investigation
Media search
Variations in the process
Assignment Description
W
H
A
T
Interview experts
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.
Execute, test and
evaluate
Analyse, plan and
make decisions
HOW
Group Discussions
Educational games
List / Tabulate
Develop
recommendations
Job assignment
Make presentation
Complete documents
Draft a report
Complete a
questionnaire
The assessor will observe and confirm
that learners:
• Are able to complete log sheets.
• Understand what feedstock variations
could occur in the process.
• Understand what feed stock variations
and process deviations can occur.
Attend lectures
Case studies
Topic assessment criteria
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 tall oil
3. In a facilitated discussion at the tall oil
site, identify and list process deviations
that could occur and the effect each type
of deviation could have on the tall oil
4. Tabulate all variations and deviations,
their effects and the broad rectification
action required and compile all the
information into a report
Commissioned by PAMSA
• Know what the effect of variations and
deviations on the process and products is.
• Know the broad rectification action
required
and German Technical Co-Operation
Notional
Hours
18
8
National Certificate in Paper & Pulp Manufacturing NQF Level 4
US: CR001
Produce crude tall oil by the acidification of Kraft soap
skimming
Critical Cross-field Outcomes
RE405
Understanding Operating Procedures in
the process
Identify and solve
problems
Understand the sequence and reason for correcting
deviations
Work effectively with
others
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 precheck
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
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
Commissioned by PAMSA
and German Technical Co-Operation
9
National Certificate in Paper & Pulp Manufacturing NQF Level 4
Topic Specification: RE405
Execute, test and
evaluate
Analyse, plan and
make decisions
Collect Information
Learning Activities
Use Multi media
Self Study
Plant investigation
Media search
Assignment Description
W
H
A
T
Interview experts
Educational games
Summarise
Use checklists
Develop
recommendations
Job assignment
Make presentation
Complete documents
Draft a report
Complete a
theoretical test
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.
HOW
Attend lectures
Group Discussions
Understanding “Standard Operating Procedures”
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 confirm
understanding
Commissioned by PAMSA
Topic 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
and German Technical Co-Operation
Notional
Hours
24
10
National Certificate in Paper & Pulp Manufacturing NQF Level 4
US: CR001
Produce crude tall oil by the acidification of Kraft soap
skimming
Critical Cross-field Outcomes
RE405
Implementing Standard Operating
Procedures in 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
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
Commissioned by PAMSA
and German Technical Co-Operation
11
National Certificate in Paper & Pulp Manufacturing NQF Level 4
Topic Specification: RE405
Execute, test and
evaluate
Analyse, plan and
make decisions
Collect Information
Learning Activities
Use Multi media
Self Study
Plant investigation
Media search
Implementing “Standard Operating Procedures”
Assignment Description
W
H
A
T
Expert demonstration
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
HOW
Group Discussions
Case studies
Use checklists
Develop
recommendations
Job assignment
Make presentation
Complete documents
Draft a report
Complete a practical
test
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
Attend lectures
Summarise
Topic assessment criteria
• monitor the process
• maintain normal running conditions
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 confirm understanding
Commissioned by PAMSA
• bring process and product variations
under control
• shut the process down
and German Technical Co-Operation
Notional
Hours
24
12
National Certificate in Paper & Pulp Manufacturing NQF Level 4
US: CR001
Produce crude tall oil by the acidification of Kraft soap
skimming
Critical Cross-field Outcomes
RE405
Perform first line maintenance
Identify and solve
problems
Work effectively with
others
Communicate effectively
Organise and manage
myself and my activities
Be able to carry out maintenance and
pre-maintenance duties in this plant
Collect, analyse, organise
and critically evaluate
information
Use science and
technology effectively and
critically
Know documentation requirements for
maintenance functions
Demonstrate an
understanding of the
world as a set of related
systems
Use mathematics
Learner and societal
development
Commissioned by PAMSA
and German Technical Co-Operation
13
National Certificate in Paper & Pulp Manufacturing NQF Level 4
Topic Specification: RE405
Execute, test and
evaluate
Analyse, plan and
make decisions
Collect Information
Learning Activities
Use Multi media
Self Study
Plant investigation
Media search
Perform first line maintenance
Assignment Description
W
H
A
T
Expert demonstration
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.
Attend lectures
Topic assessment criteria
The assessor will observe and confirm
that learners:
• Understand the documentation
requirements for maintenance functions in
the tall oil area.
• Are able to carry out maintenance and
pre-maintenance duties on the equipment.
HOW
Group Discussions
Summarise
Case studies
Use checklists
Develop
recommendations
Job assignment
Make presentation
Complete documents
Draft a report
Complete a
test/questionnaire
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 tall oil
plant
3. A checklist is drawn up
4. Under supervision, carry out premaintenance and maintenance duties on
equipment as prescribed
5. Complete pre-maintenance and
maintenance reports / log sheets
Commissioned by PAMSA
and German Technical Co-Operation
Notional
Hours
16
14
National Certificate in Paper & Pulp Manufacturing NQF Level 4
US: CR001
Produce crude tall oil by the acidification of Kraft soap
skimming
Critical Cross-field Outcomes
RE405
Identify and solve
problems
Applying SHE in the process
Work effectively with
others
Understand the potential environmental
impact of the process
Communicate effectively
Be able to identify all potential hazards and
indicate actions to reduce/avoid hazards
Collect, analyse, organise
and critically evaluate
information
Know the relevant sections of the OHS Act
Use science and
technology effectively and
critically
Understand the application of fire prevention,
lock-out and emergency procedures
Know the safety standards, procedures and
safety equipment relevant to the process
Organise and manage
myself and my activities
Demonstrate an
understanding of the
world as a set of related
systems
Use mathematics
Learner and societal
development
Commissioned by PAMSA
and German Technical Co-Operation
15
National Certificate in Paper & Pulp Manufacturing NQF Level 4
Topic Specification: RE405
Execute, test and
evaluate
Analyse, plan and
make decisions
Collect Information
Learning Activities
Use Multi media
Self Study
Plant investigation
Media search
Applying SHE in the process
Assignment Description
W
H
A
T
Interview experts
Learners obtain information through
self study. Individuals evaluate the
plant area for safety features, potential
hazards and environmental impact.
HOW
Attend lectures
Group Discussions
Educational games
Case studies
Use checklists
Develop
recommendations
Job assignment
Make presentation
Complete documents
Draft a report
Complete a
test/questionnaire
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.
Commissioned by PAMSA
Topic assessment criteria
The assessor will observe and confirm
that learners:
• Know the relevant OHS Act, safety
standards, procedures, and equipment in
the tall oil 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.
and German Technical Co-Operation
Notional
Hours
12
16