Process Controller- Mineral Processing

Curriculum Document Curriculum Code Curriculum Title

313912-004 Mineral Beneficiation Process Controller: (Mineral Processing)

DRAFT CURRICULUM – JUNE 2014 Page 1 Process Controller- Mineral Processing

Table of Contents

SECTION 1: CURRICULUM OVERVIEW

Occupational Information

Associated Occupations

Mineral Beneficiation Process Controller Occupation or Specialisation Addressed by this Curriculum

Mineral Beneficiation Process Controller: Mineral Processing

Alternative Titles used by Industry

Plant Operator

Technical Official

Plant Controller

Process Operator

Occupational Qualification – Curriculum (V05-August2014) Page 2 Process Controller- Mineral Processing Curriculum Information

Relation of this Curriculum to the Occupation and Qualification Progression

Notes Regarding the Progression:

The qualification covers the work executed by the “inside and outside” process controllers, the learning covers both NQF level 3 and 4 learning material and the qualification is pitched at NQF 4. This qualification builds on the entry level qualification “Process Controller: Materials Handling” and will build the competence of learners to execute the work of a process controller in a mineral extraction operation where use is made of physical separation and hydrometallurgical processes.

The qualification will enable the learner to gain the knowledge, develop the skills and be exposed to the work experience required to work in a process plant and to monitor and control all processing equipment. The learning covers the physical mineral processing (Milling, screening, flotation and separation) it also includes the key Hydrometallurgical processes and it covers the key aspects of refining.

Learners will gain the knowledge, skills and experience to operate plants in a safe and efficient manner and to apply the required communication skills unique to working in a processing plant environment. Learners will also learn all the basics of equipment start up, shut down and operational monitoring from a physical (in the plant) and from a control room perspective. This qualification will provide learners with a portable qualification that they can apply in any mineral processing operation.

The practical skills focus on developing the typical skills required to operate the given type of process. The site specific processes will vary from operation to operation and will be covered in detail during the work experience component.

Occupational Qualification – Curriculum (V05-August2014) Page 3 Process Controller- Mineral Processing Curriculum Structure

Knowledge Subjects

Number Title NQF Level Credits 313912-003-KS-01 Mineral Processing 4 25

Total Knowledge Credits: 25

Practical Skills Modules

Number Title NQF Level Credits 313912-004-PM-01 Monitor and control the physical separation processes – This 4 8 includes the following type of processes:  Milling;  Separation Processes  Gravity Processes  Thickening Processes 313912-004-PM-02 Monitor and controlFiltration the Processeshydrometallurgical processes – This 4 14 includes the following type of processes:  Leaching;  Froth Flotation;  Adsorption;

313912-004-PM-03 Physically monitorElution the make-up, storage and 4 3 distribution of reagents

Total Practical Skill Credits: 25

Work Experience Modules

Number Title NQF Level Credits 313912-002-WM-01 Exposure to all the sections in the mineral processing plant in the 4 50 specific operation.

Total Work Experience Credits: 50

TOTAL QUALIFICATION CREDITS: 100 Knowledge Percentage: 25% Practical Skills Percentage: 25% Workplace Percentage: 50%

International Comparability

Occupational Qualification – Curriculum (V05-August2014) Page 4 Process Controller- Mineral Processing

Benchmarking was done against the NVQ from Britain, the Australian and New Zealand Qualifications Frameworks. African countries with manufacturing facilities (including SADC countries) were scanned for applicable qualifications or training programmes and it was found that there are currently no relevant qualifications being offered in any of these countries.

A comparison with the British qualification was included, because the British chemical industry is similar to mineral beneficiation and is very well developed and the NVQ is an educational structure comparable to the NQF. An internet search revealed that the City & Guilds Level 4 NVQ in Chemical, Pharmaceutical and Petro-Chemical Operations focuses on providing Technical Support training. The qualification contains compulsory core units consisting of safety, teamwork, work handover; three compulsory units related to technical support; and a choice of five elective units from a range with a high quality component, emergencies, energy optimisation and problem solving.

AUSTRALIA: The Australian processing industry is of a similar size and sophistication as the South African industry. For this reason a comparison with the Australian qualification was included, as well as the AQF being an educational structure comparable to the NQF. An internet search of the AQF revealed that the Australian Certificate IV in Process Plant Technology contains the same compulsory core units on communication, safety, quality and work procedures as per the previous Unit Standard based Qualification.

Further no relevant qualification could be found, apart from the Australian Centre for Energy and Process Training (ACEPT) which is a leading provider of process operations training, offering AQTF qualifications for the Australian oil and gas, mineral and chemical processing industries. This ensures a higher standard of workers and facilitates industry expansion. Developed from collaboration between industry and State and Federal governments, and led by an industry advisory board comprising representatives from leading resource-driven companies, ACEPT is Australia's foremost provider of flexible training solutions for process plant operations, using:  Qualifications from the chemical, hydrocarbons and oil refining training package.  State-of-the-art equipment.  Training that is quality assured under the Australian Quality Training Framework (AQTF).  Highly experienced trainers from industry.

BRITAIN:

The competencies required for Minerals Processing are very similar to those required in the Chemical field.

The curriculum components from the City & Guilds Level 4 NVQ in Chemical, Pharmaceutical and Petro-Chemical Manufacturing covers the following elements, this illustrates the similarity. The proposed occupational qualifications that have been developed here cover all of these components and can therefore be considered as equivalent to this qualification.

 Controlling Process Operations.  Technical Support.  Safety.  Teamwork.  Work handover.  Preparing, controlling, maintaining, restoring and completing processing operations.  Quality management.  Cleaning and preparing equipment.  SHEQ.  Problem solving.  Risk assessment.  Quality control.

NEW ZEELAND:

Research in the NZQA showed that a Certificate in Energy and Chemical Plant (Process Operation) (level 4) is registered. This qualification allows for optional strands in Refrigeration, Steam Generation, Ancillary Operations, Geothermal, Waste Management and Co-Generation. The basic Process Operation qualification contains 9 compulsory NZQA core unit standards consisting of 1 workplace communication NZQA unit standard and 8 processing operations and safety NZQA unit standards, totaling 58 credits. If the learner wants to gain competence in one of the strands mentioned above, a further range of elective NZQA unit standards specific to that area of specialisation has to be chosen. For example; NZQA 81311 Mineral and Stone Treater and 81311 Non-Metalic Mineral Products, Kiln or Furnace Operation. These qualifications covers a broader set of specialisation areas. However the core components are similar to our qualification.

Both local and international qualifications place high emphasis on safety with a range of theory and practical training relating to hazards, emergencies and environmental protection.

The Mineral Beneficiation Process Controller Qualification compares well with the best international qualifications and training programmes offered. The compulsory technical content incorporated in the qualification will serve to support qualifying learners to make better informed, autonomous decisions within a more compact timeframe than international learners and will increase transportability of the qualification considerably.

Entry Requirements

The purpose of occupational qualifications are to create opportunities for people to access learning that will give them an occupational competence and that could eventually articulate into higher education . The learning in the qualification is pitched at NQF levels 3 and 4. In order to achieve this objective the following entry requirements are proposed:

Educational/Experiential 1. A general education certificate at NQF level 4 with mathematics and/or science or an equivalent occupational qualification at NQF 3; 2. Completion of the Foundational Learning Competence is an eligibility requirement and candidates will not be able to gain access to the final external assessment without proving that they have successfully completed the FLC; 3. Learners must comply with the relevant Occupational Health and security requirements in order to complete the practical skills and work experience. 4. Successful completion of the Mineral Beneficiation Process Controller (Materials Handling) qualification.

Assessment Quality Partner Information

SECTION 2: OCCUPATIONAL PROFILE

Title: Mineral Beneficiation Process Controller: (Extractive Metallurgy)

OFO Code: 313912-003

Occupational Purpose Operate, monitor and control the operational efficiency of a mineral processing plant physically and from a control room. (Mineral Processing is major division in the science of extractive metallurgy, the science and art of extracting metals from ores, refining them and preparing them for use.)

Occupational Tasks

TASK 01: Monitoring and controlling the mineral processing processes physically in the plant and from a control room (NQF Level: 4)

Task Details

TASK 01: Monitoring and controlling the extractive metallurgical processes (NQF Level: 4)

Unique Product or Service  Raw materials processed

Occupational Responsibilities

 Monitor and Control the physical separation processes (Which may include one or more of the following)

 Monitor and control the milling and classification processes  Monitor and control the gravity and centrifugal processes  Monitor and control dense medium separation  Monitor and control the liquid/solid separation processes o Thickening o Filtering o Settling o Counter current decantation  Monitor and control the electrostatic precipitation processes  Magnetic separation

 Monitor and control the hydrometallurgical Extraction processes (Which may include one or more of the following) o Monitoring and controlling the adsorption processes o Monitor and control the froth flotation processes o Monitor and control the elution processes o Monitor and control the leaching processes o Monitor and control the regeneration process

 Physically monitor the makeup, storage and distribution of reagents

Context  Exposure to the full spectrum of mineral processing and metallurgical processes in the specific operation.

Monitor and Control the physical separation processes  Monitor and control the milling and classification processes  Monitor and control the gravity and centrifugal processes  Monitor and control dense medium separation  Monitor and control the liquid/solid separation processes o Thickening o Filtering o Settling o Counter current decantation  Monitor and control the electrostatic precipitation processes  Magnetic separation

Monitor and control the hydrometallurgical Extraction processes  Monitoring and controlling the chemical separation processes o Precipitation o Distillation o Adsorption o Crystallization o solvent extraction o hydrolysis o Chemical reduction  Monitor and control the elution processes  Monitor and control the leaching processes o Monitor and control bacterial leaching process  Monitor and control the regeneration process  Monitor and control the electro winning processes

Occupational Qualification – Curriculum (V05-August2014) Page 8 Process Controller- Mineral Processing SECTION 3: CURRICULUM COMPONENT SPECIFICATIONS SECTION

3A: KNOWLEDGE SUBJECT SPECIFICATIONS List of Knowledge Subjects for which Specifications are included Number Title NQF Level Credits 313912-003-KS-02 Extraction Metallurgy 4 25 Total Knowledge Credits: 25

313912-004-KS-01: Extractive Metallurgy

Purpose of the Knowledge Subject The focus of the learning in this module is on building the learners understanding of the key theories, concepts and principles required to monitor and control an extractive metallurgical ore beneficiation process.

Topics included in this subject: TOPIC NUMBER TOPIC TITLE WEIGHT CREDITS 313912-004-KS-01:01 Tailing/waste disposal processes (Basic) 3

313912-004-KS-01:02 Principles of the various chemical processes and 16 interactions that take place in an extractive metallurgical process (Intermediate) 313912-004-KS-01:03 Metallurgical principles of mineral extraction using different 6 techniques (Intermediate)

TOTAL TOPIC CREDITS: 25 313912-004-KS-01:01 – Tailing disposal processes (Basic) (Credits: 3)

Topic Elements to be covered include: 1. Identify the different types of tailings and describe the various methods of recycling or storing tailings; 2. Explain the environmental considerations and related regulatory requirements when dealing with tailings; 3. Describe the various processes for neutralising chemicals in tailings; 4. Describe the key parameters of tailings and indicate why these parameters are important (density etc); 5. Describe the process and importance of water management when dealing with tailings; 6. Identify and describe the use of the equipment required for the safe and efficient recycling and storage of tailings; 7. Describe the operating principles of tailings dams and indicate how this impacts on the position of depositing tailings into the dams; 8. Describe the impact of pumping distances on the effective transfer of tailings material into a tailings storage facility.

Internal Assessment Criteria: Given a range of questions regarding the safe and environmentally sound disposal of processing tailings as well as possible answers to the questions learners will, without reference to learning material, be able to answer 100% of the questions relating to the legislative requirements correctly and 80% of the questions relating to productivity and efficiency issues.

313912-004-KS-01:02 – Metallurgical principles of mineral processing using different techniques (Intermediate) (Credits: 16)

Topic Elements to be covered include: j. Describe what the various chemical processes are (Dissolving, Concentrating; Precipitation; Calcination; Neutralising; distillation; adsorption; elutriation); 2. Explain the interaction between the various processes; 3. Identify and explain the sampling analysis parameters for each of the products after each chemical process; 4. Describe the main deviations from standard and indicate what must be done to rectify them;

Internal Assessment Criteria: Given typical problems that can be experienced during mineral processing relevant to the chemical and metallurgical dynamics that takes place learners will, without reference to the learning material, be able to accurately; a. Identify the root causes of the problems; b. Indicate how the process control activities could contribute to resolving the problems; c. Describe the potential downstream implications of the problems; d. Describe what actions can be taken to prevent a re-occurrence of these problems.

313912-004-KS-01:03 –Metallurgical principles of mineral extraction using different techniques (Intermediate) (Credits: 3)

Topic Elements to be covered include: 1. Explain what is meant by product separation and why this is important in the beneficiation process; 2. Identify and list the typical equipment used in the separation process; 3. Define the basic metallurgical principles used in the separation processes: a. Settling theory; b. Use of gravity; c. Need to create an appropriate medium; d. Use of centrifugal force; e. Use of X-ray fluorescence; f. Use of hydrophobics; g. Use of magnetics; h. Density of particles; i. Effect of particle size and shape; j. Use of screening.

Internal Assessment Criteria:

Given a range of typical problems that a process controller in a mineral processing facility will be confronted with regarding the processes listed in the topic learners will be able to: a. Identify the root causes of the problems; b. Indicate how the process control activities could contribute to resolving the problems; c. Describe the potential downstream implications of the problems; d. Describe what actions can be taken to prevent a re-occurrence of these problems.

Provider Accreditation Requirements for the Subject: Physical Requirements:

Occupational Qualification – Curriculum (V05-August2014) Page 10 Process Controller- Mineral Processing - Proven access to suitable learning facilities, tools and equipment to professionally deliver the learning as specified in the curriculum. Proven access to all the simulations, controlled work environments and demonstrations as set out in the given statements for the practical skills in the curriculum

Human Resources Requirements: - Facilitators of learning must be in possession of a national qualification in mineral processing practices at least at NQF 4 or industry recognised certificate with two years post qualification experience as a process controller or at least 5 years practical experience in a recognised mineral processing plant as a process controller and/or foreman - Facilitators of learning must be in possession of a OD ETDP certificate at NQF level 4 or recognised equivalent

Legal Requirements: - Providers of learning must comply with all OHS requirements

SECTION 3B: PRACTICAL SKILL MODULE SPECIFICATIONS

List of Practical Skills Modules for which Specifications are included:

Number Title NQF Level Credits 313912-004-PM-01 Monitor and control the physical separation processes – This 4 8 includes the following type of processes:  Milling;  Separation Processes  Gravity Processes  Thickening Processes 313912-004-PM-02 Monitor and controlFiltration the Processeshydrometallurgical processes – This 4 14 includes the following type of processes:  Leaching;  Froth Flotation;  Adsorption;

313912-004-PM-03 Physically monitorElution the make-up, storage and 4 3 distribution of reagents

Total Practical Skill Credits: 25

Occupational Qualification – Curriculum (V05-August2014) Page 11 Process Controller- Mineral Processing 313912-004-PM-01- Monitor and control the physical separation processes – This includes the following type of processes:  Milling;  Separation Processes  Gravity Processes  Thickening Processes  Filtration Processes (NQF Level: 4)

Purpose of the Module:

List of Practical Skills Included in this Module: Number Title Credits 313912-004-PM-01-PS01 Physically monitor and control the physical separation processes – 4 This includes the following type of processes:  Milling;  Separation Processes  Gravity Processes  Thickening Processes 313912-004-PM-01-PS02 Stop, start and Filtrationmonitor the Processes operation of the physical separation 4 processes from a control room – This includes the following type of processes:  Milling;  Separation Processes  Gravity Processes  Thickening Processes  Filtration Processes

313912-002-PM-01-PS01: Physically monitor and control the physical separation processes – This includes the following type of processes (Credits: 4)

Scope of Practical Skill:

Given: Given a simulated or controlled work environment with all the equipment required for the operations, a set volume of material, all consumables and the relevant media.

Be Able to: 1. Physically inspect all the storage facilities, feeding/transport systems and the equipment and report any defects; 2. Physically inspect the operational readiness of all the auxiliary equipment required for milling; 3. Check that there is sufficient reagents available for the processes 4. Manually start all the equipment in the correct sequence 5. Observe and monitor the flow of material from the storage facilities to the equipment 6. Take readings from the relevant instrumentation, record and interpret what action is required 7. Complete the required log sheets 8. Communicate effectively to all up and down stream stakeholders. Applied Knowledge

1. Equipment inspection processes and techniques 2. Effective communication techniques

Occupational Qualification – Curriculum (V05-August2014) Page 12 Process Controller- Mineral Processing 3. Processes and techniques for identifying and dealing with problems in the sections

Internal Assessment: 1. Observe and evaluate the extent to which learners follow the standard operating procedures for startup, stop and monitoring of the process 2. Evaluate the accuracy, completeness and relevance of information recorded on the log sheets 3. Evaluate the timeliness, quality and accuracy of the communication 4. Evaluate the extent to which learners correctly identify the causes of problems and initiate the appropriate corrective actions.

313912-004-PM-01-PS02 Stop, start and monitor the operation of the physical separation processes from a control room (Credits: 4) Scope of Practical Skill:

Given: Given a fully operational control room with a computerised control system and operating sections

Be Able to: 1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator. 2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions 3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator. 4. Check grinding media levels in the mill and take appropriate actions to correct if needed 5. Access the computerised control system and read and interpret the status of the sections on the system 6. In sequence start the milling operation from the control room 7. Stop, start and monitor the operation of the auxiliary systems associated with the sections 8. Stop the mill for maintenance and emergency situations 9. Set the operating parameters according to production requirements and efficiency requirements for the sections 10. Complete the control room activity log sheet and shift reports 11. Extract data from the system relating to operational efficiencies and record the information on the log sheets 12. Respond to alarms 13. On the computer system monitor the flow of material and take action to deal with problems and deviations 14. Communicate with all stakeholders that the processes will be started 15. Communicate with the relevant stakeholders to supply raw material if required 16. Monitor cyclone over and under flow Applied Knowledge 1. Techniques for operating a computerised control system 2. Communication techniques 3. Problem identification and solving techniques

Internal Assessment:

1. Observe and evaluate the extent to which learners follow the standard operating procedures for startup, stop and monitoring of the process 2. Evaluate the accuracy, completeness and relevance of information recorded on the log sheets 3. Evaluate the timeliness, quality and accuracy of the communication 4. Evaluate the extent to which learners correctly identify the causes of problems and initiate the appropriate corrective actions.

Occupational Qualification – Curriculum (V05-August2014) Page 13 Process Controller- Mineral Processing Provider Accreditation Requirements: Physical Requirements: - Proven access to suitable learning facilities, tools and equipment to professionally deliver the learning as specified in the curriculum. Proven access to all the simulations, controlled work environments and demonstrations as set out in the given statements for the practical skills in the curriculum

313912-004-PM-02: Monitor and control the hydrometallurgical processes – This includes the following type of processes:  Leaching;  Froth Flotation;  Adsorption;  Elution

List of Practical Skills Included in this Module: Number Title Credits 313912-004-PM-02-PS01 Physically monitor and control the Monitor and control the 7 hydrometallurgical processes: -This may include the following processes:  Leaching;  Froth Flotation;  Adsorption;  Elution 313912-004-PM-02-PS02 Stop, start and monitor the operation of the hydrometallurgical 7 from a control room – This may include the following type of processes:  Leaching;  Froth Flotation;  Adsorption;  Elution

313912-002-PM-02-PS01: Physically monitor and control the hydrometallurgical processes: (Credits: 7)

Given: Given a simulated or controlled work environment with all the equipment required for the operations, a set volume of material, all consumables and the relevant media.

Be Able to:

Occupational Qualification – Curriculum (V05-August2014) Page 14 Process Controller- Mineral Processing 1. Physically inspect all the storage facilities, feeding/transport systems and the equipment and report any defects; 2. Physically inspect the operational readiness of all the auxiliary equipment required for the processes; 3. Check that there is sufficient reagents available for the processes; 4. Manually start all the equipment in the correct sequence; 5. Observe and monitor the flow of material from the storage facilities to the equipment; 6. Take readings from the relevant instrumentation, record and interpret what action is required; 7. Complete the required log sheets; 8. Communicate effectively to all up and down stream stakeholders. Applied Knowledge

1. Equipment inspection processes and techniques 2. Effective communication techniques 3. Processes and techniques for identifying and dealing with problems in the sections

Internal Assessment: 1. Observe and evaluate the extent to which learners follow the standard operating procedures for startup, stop and monitoring of the process 2. Evaluate the accuracy, completeness and relevance of information recorded on the log sheets 3. Evaluate the timeliness, quality and accuracy of the communication 4. Evaluate the extent to which learners correctly identify the causes of problems and initiate the appropriate corrective actions.

313912-004-PM-02-PS02 Stop, start and monitor the operation of the hydrometallurgical processes from a control room (Credits: 7) Scope of Practical Skill:

Given: Given a fully operational control room with a computerised control system and operating sections

Be Able to: 1. Check the levels of raw materials in the storage facilities on the system and confirm the levels with the outside operator; 2. On an ongoing basis identify problems, identify the causes and take appropriate corrective actions; 3. Check the availability and readiness of all equipment and machinery on the system and confirm the status with the outside operator; 4. Check media levels in the processes where required and take appropriate actions to correct if needed; 5. Access the computerised control system and read and interpret the status of the sections on the system; 6. In sequence start the operations from the control room; 7. Stop, start and monitor the operation of the auxiliary systems associated with the sections; 8. Stop the sections for maintenance and emergency situations; 9. Set the operating parameters according to production requirements and efficiency requirements for the sections; 10. Complete the control room activity log sheet and shift reports; 11. Extract data from the system relating to operational efficiencies and record the information on the log sheets; 12. Respond to alarms; 13. On the computer system monitor the flow of material and take action to deal with problems and deviations; 14. Communicate with all stakeholders that the processes will be started; 15. Communicate with the relevant stakeholders to supply raw material if required;

Occupational Qualification – Curriculum (V05-August2014) Page 15 Process Controller- Mineral Processing 16. Monitor cyclone over and under flow. Applied Knowledge 1. Techniques for operating a computerised control system 2. Communication techniques 3. Problem identification and solving techniques

Internal Assessment:

1. Observe and evaluate the extent to which learners follow the standard operating procedures for startup, stop and monitoring of the process 2. Evaluate the accuracy, completeness and relevance of information recorded on the log sheets 3. Evaluate the timeliness, quality and accuracy of the communication 4. Evaluate the extent to which learners correctly identify the causes of problems and initiate the appropriate corrective actions.

Provider Accreditation Requirements: Physical Requirements: - Proven access to suitable learning facilities, tools and equipment to professionally deliver the learning as specified in the curriculum. Proven access to all the simulations, controlled work environments and demonstrations as set out in the given statements for the practical skills in the curriculum

313912-004-PM-03-Physically monitor the make-up, storage and distribution of reagents (NQF Level: 3)

Purpose of the Module:

Occupational Qualification – Curriculum (V05-August2014) Page 16 Process Controller- Mineral Processing The focus of the learning in this module is on providing learners an opportunity to practice the skills required to monitor the makeup and storage of the reagents required for the various processes.

List of Practical Skills Included in this Module: Number Title Credits 313912-004-PM-03-PS01 Identify and safely handle a range of reagents 4

313912-004-PM-03-PS01: Identify and safely handle a range of reagents (Credits: 4)

Given: Given a simulated or controlled work environment with a range of reagents, storing facilities and all equipment.

Be Able to: 1. Receive, record and store the reagents 2. Identify the reagents and interpret the material safety data sheet for the specific reagent 3. Oversee the offloading of reagents from different types of road or rail transportation 4. Complete and capture all the required documentation 5. Use a given recipe to make up a range of reagents

Applied Knowledge 1. Use of MSDS (Material safety data sheets)

Internal Assessment: 1. Observe and evaluate the extent to which learners follow the appropriate procedures for receiving, handling and storing reagents 2. Evaluate the completeness and accuracy of all the required documentation

SECTION 3C: WORK EXPERIENCE MODULE SPECIFICATIONS

List of Work Experience Module Specifications Number Title NQF Level Credits 313912-004-WM-01 Exposure to the full range of mineral processes specific to the 4 60 operation

Total Work Experience Credits: 60

313912-001-WM-01- Exposure to the full mineral processing

Purpose of the Module

List of Experiences included in this module Number Title Credits 313912-002-WM-03-01 Conduct all the physical work required in the plant for a period of 32 sixteen shifts 313912-002-WM-03-02 Operate all plant sections and achieve all the required efficiency and 48 production targets over a period of six months

313912-004-WM-01-01: Conduct all the physical work required in the section for a period of six months

Guidelines for Work Experience 1. Participate in shift hand over processes in the workplace and complete all required hand over documentation; 2. Inspect and operate (stop, start, monitor and control) all the equipment in all the sections on the plant, complete all checklists and report as per site specific requirements; 3. Deal with emergency situations, take appropriate action and communicate effectively; 4. Prepare the equipment for planned maintenance; 5. Report defects and initiate corrective action as per the site specific requirements; 6. Execute minor first line maintenance as specified in site specific requirements; 7. Execute all required housekeeping duties as required on the plant; 8. Comply with all site specific health and safety requirements; 9. Comply with all site specific operating procedures, rules and codes of practice; 10. Identify changes in working conditions and initiate the appropriate actions as per site specific requirements; Contextual Workplace Knowledge 1. Site specific codes of practice, operating procedures standards and rules; 2. Site specific hazards and risks associated with all the sections and the related equipment of the plant; 3. Site specific vision, mission and production objectives; 4. Site specific operating parameters for all the equipment in all the sections on the plant; 5. Plant flow and the use of the product by the up and down stream processes; 6. Site specific quality and quantity requirements for each stage of the production process; 7. Site specific security requirements; 8. Site specific management communication and reporting processes 9. Site specific techniques for operating the equipment and processes for each of the sections

Supporting Evidence

1. Shift reports 2. Learner generated observation report 3. Completed planned task observations and risk assessments 4. Production reports and trends 5. Supervisor generated performance reports

313912-004-WM-01-02: Operate the plant from a control room for a period of six months

Guidelines for Work Experience 1. Participate in shift hand over processes in the workplace and complete all required hand over documentation; 2. Review all shift reports and initiate appropriate action at the start of the shift; 3. Complete shift handover activities and control (stop, start, monitor and control) all the equipment in all the sections on the plant, complete all checklists and report as per site specific requirements; 4. Deal with emergency situations, take appropriate action and communicate effectively; 5. Operate equipment for maintenance purposes as required by maintenance staff; 6. Oversee the preparation of the equipment for planned maintenance; 7. Report defects and deviations and initiate corrective action as per the site specific requirements; 8. Execute all required housekeeping duties as required; 9. Comply with all site specific health and safety requirements; 10. Comply with all site specific operating procedures, rules and codes of practice; 11. Identify changes in working conditions and initiate the appropriate actions as per site specific requirements; 12. Prepare reports and execute all required calculations as per site requirements;

Contextual Workplace Knowledge 1. Site specific codes of practice, operating procedures standards and rules; 2. Site specific hazards and risks associated with all the sections and the related equipment of the plant; 3. Site specific vision, mission and production objectives; 4. Site specific operating parameters for all the equipment in all the sections on the plant; 5. Plant flow and the use of the product by the up and down stream processes; 6. Site specific quality and quantity requirements for each stage of the production process; 7. Site specific security requirements; 8. Site specific management communication and reporting processes

Supporting Evidence 1. Shift reports 2. Learner generated observation report 3. Completed planned task observations and risk assessments 4. Production reports and trends (Computerised control system reports) 5. Supervisor generated performance reports 6. Clearance certificates and permits as per site specific requirements

Occupational Qualification – Curriculum (V05-August2014) Page 20