benvanas.co.zabenvanas.co.za/downloads/MQA/pages/CONTROLLERS/… · Web viewTOTAL TOPIC CREDITS: 66. 313912-001-KS-02:01 -Principles for determining the quality specifications for

Beneficiation Plant Controller: Lump Ore

Curriculum DocumentCurriculum Code Curriculum Title

313912-001 Mineral Beneficiation Process Controller: (Lump Ore Beneficiation)

V03-DRAFT CURRICULUM Page 1


Table of ContentsSECTION 1: CURRICULUM OVERVIEW.......................................................................................................................1

Associated Occupations...........................................................................................................................................1

Occupation or Specialisation Addressed by this Curriculum....................................................................................1

Alternative Titles used by Industry...........................................................................................................................1

Curriculum Information................................................................................................................................................2

Relation of this Curriculum to the Occupation and Qualification..............................................................................2

Progression..............................................................................................................................................................2

Notes Regarding the Progression:...........................................................................................................................2

Curriculum Structure....................................................................................................................................................2

SECTION 2: OCCUPATIONAL PROFILE.......................................................................................................................5

Title: Mineral Beneficiation Process Controller: (Lump Ore.........................................................................................5

Beneficiation)...............................................................................................................................................................5

OFO Code: 313912-001...........................................................................................................................................5

Occupational Purpose..............................................................................................................................................5

Occupational Tasks..................................................................................................................................................5

Task Details.................................................................................................................................................................5

TASK 01: Ensuring compliance with all Occupational Health, Safety and Environmental requirements to minimise the operational risk in the plant. (NQF Level: 4).......................................................................................5

TASK 02: Monitoring and controlling the availability of raw materials to achieve production targets for a designated production period. (NQF Level: 4).........................................................................................................5

TASK 03: Monitoring and controlling the raw material beneficiation processes in a lump ore beneficiation plant. (NQF Level: 4)..........................................................................................................................................................6

313912-001-KS-01: Occupational Health and Safety..............................................................................................7

313912-001-KS-02: Mineral Beneficiation (I)...........................................................................................................9

SECTION 3B: PRACTICAL SKILL MODULE SPECIFICATIONS.............................................................................19

313912-001-PM-01-Monitor the Occupational Health, Safety and environmental compliance in the beneficiation processes (NQF Level: )...........20

313912-001-PM-02-Monitor and verify the availability of raw materials (NQF Level: )..........................................25

313912-001-PM-03-Facilitate the smooth flow of raw material by means of the material handling and transportation systems and equipment (NQF Level:..............................................................................................27

)..............................................................................................................................................................................27

313912-001-PM-04-Check and report the quality/parameters of the available raw material (NQF Level: )..........31

313912-001-PM-05-Determine the raw material requirements to achieve the production targets (NQF Level: )..34

313912-001-PM-06-Monitor and control the raw materials blending processes (NQF Level: ).............................36

313912-001-PM-07-Start, monitor, control and stop all size reduction equipment (NQF Level: ).........................39

313912-001-PM-08-Start, monitor, control and stop all Separation, de-watering and classification equipment (NQF Level: )..........................................................................................................................................................42



313912-001-PM-09-Report operating conditions of size reduction equipment (NQF Level: )...............................46

313912-001-PM-10-Monitoring and controlling the handling and storage of the processed product (1st stage beneficiation) (NQF Level: )...................................................................................................................................48

313912-001-PM-11-Monitoring and controlling the dispatch of the processed product.........................................52

313912-001-PM-12-Monitor and control the removal and disposal of waste products. (NQF Level: )..................55

SECTION 3C: WORK EXPERIENCE MODULE SPECIFICATIONS........................................................................56

313912-001-WM-01 - Exposed to risk management processes for all areas of the plant.....................................56

313912-001-WM-02 - Exposure to the full raw material handling processes for the specific site..........................60

313912-001-WM-03 - Exposure to the full range of raw materials in the site specific processes..........................61

313912-001-WM-04 - EXPOSURE to the raw material reduction processes........................................................62

313912-001-WM-05 - EXPOSURE to the separation, de-watering and classification processes.........................63

313912-001-WM-06 - EXPOSURE to the final product handling, storage and dispatch processes......................64


Occupational Curriculum - Feb 24 - 2014 - 09:43:01 1 of 74


SECTION 1: CURRICULUM OVERVIEW

Occupational Information

Associated Occupations

Occupation or Specialisation Addressed by this Curriculum

Alternative Titles used by Industry



Curriculum Information

Relation of this Curriculum to the Occupation and QualificationProgression

Notes Regarding the Progression:

Curriculum Structure

Knowledge Subjects

Number Title NQF Level Credits

313912-001-KS-02 Occupational Health and Safety 4 5313912-001-KS-02 Mineral Beneficiation (I) 4 11313912-001-KS-02 Process Plant Management (I) 4 66

Total Knowledge Credits: 82

Practical Skills Modules


313912-001-PM-01 Monitor the Occupational Health, Safety and environmental compliance in the beneficiation processes

11

313912-001-PM-02 Monitor and verify the availability of raw materials 6




313912-001-PM-03 Facilitate the smooth flow of raw material by means of the material handling and transportation systems and equipment

18

313912-001-PM-04 Check and report the quality/parameters of the available raw material

6

313912-001-PM-05 Determine the raw material requirements to achieve the production targets

6

313912-001-PM-06 Monitor and control the raw materials blending processes 0313912-001-PM-07 Start, monitor, control and stop all size reduction equipment 6313912-001-PM-08 Start, monitor, control and stop all Separation, de-watering and

classification equipment0

313912-001-PM-09 Report operating conditions of size reduction equipment 0313912-001-PM-10 Monitoring and controlling the handling and storage of the

processed product (1st stage beneficiation)0

313912-001-PM-11 Monitoring and controlling the dispatch of the processed product(NOT APPLICABLE TO DIAMONDS)

0

313912-001-PM-12 Monitor and control the removal and disposal of waste products. 0

Total Practical Skill Credits: 53

Work Experience Modules


313912-001-WM-01 Exposed to risk management processes for all areas of the plant 0313912-001-WM-02 Exposure to the full raw material handling processes for the

specific site0

313912-001-WM-03 Exposure to the full range of raw materials in the site specific processes

0

313912-001-WM-04 EXPOSURE to the raw material reduction processes 0313912-001-WM-05 EXPOSURE to the separation, de-watering and classification

processes0

313912-001-WM-06 EXPOSURE to the final product handling, storage and dispatch processes

0

Total Work Experience Credits: 0

TOTAL QUALIFICATION CREDITS: 135Knowledge Percentage: 61% Practical Skills Percentage: 39% Workplace Percentage: 0%

International ComparabilityNational Qualification sites on the Internet were explored in order to find qualifications related to Lump Ore Beneficiation. Australia: National Training Information Services (www.ntis.gov.au)MNM 20203 certificate II in metallurgical mining operations. New Zealand: The New Zealand Qualification Authority (www.nzqa.govt.nz)Extractive metallurgical processes Metalliferous gold Scotland: The Scottish Qualification Authority (www.sqa.org.uk) USA: The Quality Assurance System of Higher Education (www.cqaie.org.us)Although coal beneficiation was mentioned on several countries, no record of a certificate could be found. In Australia no relevant qualification could be found In New Zealand only Gold and Alluvial Gold qualifications could be found. These qualifications have very little in common with Lump Ore Beneficiation because of both process and content differences.

http://www.sqa.org.uk/



Entry Requirements

Assessment Quality Partner Information



SECTION 2: OCCUPATIONAL PROFILE

Title: Mineral Beneficiation Process Controller: (Lump OreBeneficiation)

OFO Code: 313912-001

Occupational Purpose

Operate, monitor and control the operational efficiency of the Lump Ore benificiation process and the processing equipment

Occupational Tasks

o TASK 01: Ensuring compliance with all Occupational Health, Safety and Environmental requirements to minimise the operational risk in the plant.

o (NQF Level: 4)o TASK 02: Monitoring and controlling the availability of raw materials to achieve

production targets for a designated production period.o (NQF Level: 4)o TASK 03: Monitoring and controlling the raw material beneficiation processes in a

lump ore beneficiation plant. (NQF Level: 4)

Task Details

TASK 01: Ensuring compliance with all Occupational Health, Safety and Environmental requirements to minimise the operational risk in the plant. (NQF Level: 4)

Unique Product or Service All risks eliminated or managed during the production process

Occupational Responsibilities Monitor the Occupational Health, Safety and environmental compliance in the beneficiation

processes

Context Exposed to risk management processes for all areas of the plant

TASK 02: Monitoring and controlling the availability of raw materials to achieve production targets for a designated production period. (NQF Level: 4)

Unique Product or Service Sufficient raw materials available for processing

Occupational Responsibilities Monitor and verify the availability of raw materials Facilitate the smooth flow of raw material by means of the material

handling and transportation systems and equipment



Check and report the quality/parameters of the available raw material

Determine the raw material requirements to achieve the production targets Monitor and control the raw materials blending processes

Context Exposure to the full raw material handling processes for the specific site Exposure to the full range of raw materials in the site specific processes

TASK 03: Monitoring and controlling the raw material beneficiation processes in a lump ore beneficiation plant. (NQF Level: 4)

Unique Product or Service Raw materials beneficiated to meet required quality standards

Occupational Responsibilities Start, monitor, control and stop all size reduction equipment Start, monitor, control and stop all Separation, de-watering and classification equipment Report operating conditions of size reduction equipment Monitoring and controlling the handling and storage of the processed product (1st

stage beneficiation) Monitoring and controlling the dispatch of the processed product (NOT

APPLICABLE TO DIAMONDS) Monitor and control the removal and disposal of waste products.

Contexto EXPOSURE to the raw material reduction processeso EXPOSURE to the separation, de-watering and classification processeso EXPOSURE to the final product handling, storage and dispatch processes

SECTION 3: CURRICULUM COMPONENT SPECIFICATIONS SECTION 3A: KNOWLEDGE SUBJECT SPECIFICATIONS

List of Knowledge Subjects for which Specifications are included


313912-001-KS-01 Occupational Health and Safety 4 5313912-001-KS-02 Mineral Beneficiation (I) 4 11313912-001-KS-03 Process Plant Management (I) 4 66

Total Knowledge Credits: 82



313912-001-KS-01: Occupational Health and Safety

Purpose of the Knowledge Subject

Topics included in this subject:

TOPIC NUMBER TOPIC TITLE WEIGHT CREDITS

313912-001-KS-01:01 Concepts and application principles of all occupational health, safety and environmental requirements related to the beneficiation process. (Intermediate)

5

TOTAL TOPIC CREDITS: 5

313912-001-KS-02:01 -Concepts and application principles of all occupational health, safety and environmental requirements related to the beneficiation process. (Intermediate) (Credits: 5)

Topic Elements to be covered include:1. Identify all relevant legislation applicable to mineral beneficiation (NQF Level: 4)2. Identify which inspections are required and describe the purpose and process of each of them: a. Inspections of PPE; b. Inspections of Machines including guarding, tools and equipment; c. Inspection of the environment; d. Dealing with changing situations (NQF Level: 4)3. Explain the purpose and application of incident and accident investigations: a. What needs to be investigated; b. How to conduct the investigations; c. Who must be involved in the investigations; d. Reporting processes (internal and external); e. Processes for implementing corrective actions. (NQF Level: 3)4. Explain what is meant by an environmental management system: a. Who the stakeholders are; b. Roles and responsibilities of the stakeholders; c. Structure of the reporting systems; d. Processes for follow up and review; e. Processes to implement corrective actions. (NQF Level: 5)5. Give an overview of the applicable international and national standard systems and requirements (NQF Level: 5)6. Explain what is meant by emergency preparedness and response: a. Identify emergencies; b. immediate actions to be taken; c. Evacuation procedures; d. Requirements for reporting (NQF Level: 3)7. Explain the consequences of non-compliance to the regulatory requirements (NQF Level:4)8. Explain the purpose of the relevant legislation (NQF Level: 4)



9. Describe the roles and responsibilities of employers and employees regarding safety, health and environmental practices in the workplace (NQF Level: 3)10. Describe the process of Hazard identification, risk assessment and control: a. What is risk management; b. Key terms used in risk management (Hazard, risk, consequence, probability etc); c. Roles and responsibilities; d. The various processes (NQF Level: 4)11. Describe what is meant by behavioural safety and give examples of how this is applied in the workplace (NQF Level: 4)12. Explain what is meant by an occupational health and safety management system: a. Who the stakeholders are; b. Roles and responsibilities of the stakeholders; c. Structure of the reporting systems; d. Processes for follow up and review; e. Processes to implement corrective actions. (NQF Level: 5)13. Describe the process for doing task observations and indicate how the information out of these observations will be used. (NQF Level: 4)

Internal Assessment Criteria:

Provider Accreditation Requirements for the Subject:

Physical Requirements:

Human Resources Requirements:

Legal Requirements:

Critical Topics to be Assessed Externally for the Knowledge Subject:

Exemptions:



313912-001-KS-02: Mineral Beneficiation (I)




313912-001-KS-02:01 Use and application of the products and the reasons for lump ore beneficiation. (Intermediate)

1

313912-001-KS-02:02 Overview of the total production flow (Intermediate) 2313912-001-KS-02:03 Read, interpret and draw a flow diagramme of the plant

(Intermediate)4

313912-001-KS-02:04 Characteristics of the various types of raw materials(Segregation, Bulk density, friability, etc (Basic)

3

313912-001-KS-02:05 Principles and methods used for the mixing and blending of products and raw materials (Intermediate)

1


313912-001-KS-02:01 -Use and application of the products and the reasons for lump ore beneficiation. (Intermediate) (Credits: 1)

Topic Elements to be covered include:1. Explain what is meant by beneficiation and indicate the various stages of beneficiation(NQF Level: 1)2. Identify what the main lump ore products are that we produce in the country (NQF Level:1)3. Name the main uses of the various minerals and how they impact on the economy (NQF Level: 1)


313912-001-KS-02:02 -Overview of the total production flow(Intermediate) (Credits: 2)

Topic Elements to be covered include:1. Identify and describe the purpose of the various sections in a generic beneficiation process (NQF Level: 1)2. Identify the main equipment that will be used at each stage of the generic process (NQF Level: 1)3. Describe the interactions between the various processes and give examples of how problems in the various sections could affect the up and down stream processes (NQF Level: 1)




313912-001-KS-02:03 -Read, interpret and draw a flow diagramme of the plant (Intermediate) (Credits: 4)

Topic Elements to be covered include:1. Identify all the plant process related ISO symbols that are used in a typical plant flow diagramme 2. Name all the equipment indicated on the diagramme and explain their purpose (NQF 3. Identify the operational parameter measuring points indicated on the diagramme(Sampling points, weight meters, flow meters etc) 4. Indicate the flow of the different types of material streams through the process 5. Draw a flow diagramme for a generic beneficiation plant


313912-001-KS-02:04 -Characteristics of the various types of raw materials (Segregation, Bulk density, friability, etc (Basic) (Credits: 3)

Topic Elements to be covered include:1. Explain what is meant by the various properties of raw materials (At least Segregation,Bulk Density, friability, specific gravity, particle size, moisture content, hardness, angle of repose, size distribution, cohesion and adhesion) 2. Describe the implications of the various properties on material flow 3. Describe the basic methods used to identify various types of raw materials


313912-001-KS-02:05 -Principles and methods used for the mixing and blending of products and raw materials (Intermediate) (Credits: 1)

Topic Elements to be covered include:1. Explain what is meant by blending and mixing and the importance thereof (NQF Level: 1)2. Describe the basic processes used for blending and mixing (NQF Level: 1)3. Identify the typical equipment that will be used for blending and mixing (NQF Level: 1)4. Explain the consequences of sub-standard blending and mixing processes (NQF Level: 1)5. Explain how the materials for blending and mixing is determined (NQF Level: 1)

Internal Assessment Criteria:Provider Accreditation Requirements for the Subject:



Legal Requirements:


Exemptions:



313912-001-KS-03: Process Plant Management (I)




313912-001-KS-03:01 Principles for determining the quality specifications for final products and the various methodologies associated with it (Intermediate)

3

313912-001-KS-03:02 Purpose and application principles of all the materials handling and transportation equipment (Basic)

8

313912-001-KS-03:03 Security processes and requirements for the labeling, storage and dispatch of the final product (Intermediate)

313912-001-KS-03:04 Principles and concepts of systems thinking and cause and effect analysis (Basic)

2

313912-001-KS-03:05 Operating principles of all the product handling systems and equipment (NOT APPLICABLE TO DIAMONDS)(Intermediate)

313912-001-KS-03:06 Concepts and operating principles of process logical control systems (Basic)

12

313912-001-KS-03:07 Factors that effect the efficiency of the process (Intermediate) 1313912-001-KS-03:08 Analyse and interpret trends and related statistical

information and identify corrective action(Basic)4

313912-001-KS-03:09 Metallurgical principles of product separation using different techniques and media(Intermediate)

4

313912-001-KS-03:10 Operating principles and design efficiencies of all the equipment used in the separation, de-watering and classification processes (Components, functions, types etc) (Intermediate)

16

313912-001-KS-03:11 Operating principles of production reporting and the generic structures and implications of production reports (Basic)

2

313912-001-KS-03:12 Concepts and principles of conducting trouble shooting on equipment and machines and corrective actions required to optimise production (Intermediate)

3

313912-001-KS-03:13 Principles of sampling and sampling analysis and the need for effective sampling throughout the process (Basic)

313912-001-KS-03:14 Operating principles of a range of crushing and screening equipment (Intermediate)

12

313912-001-KS-03:15 Executing the basic calculations to determine the efficiency of the size reduction processes (Percentages, feed rates, throughput, screening efficiency) (Basic)

1

313912-001-KS-03:16 Principles of waste handling and the associated regulatory requirements (Basic)

1




313912-001-KS-03:17 Overview of the requirements relevant to the loading of various types of products. (Basic) (?)


313912-001-KS-02:01 -Principles for determining the quality specifications for final products and the various methodologies associated with it (Intermediate) (Credits: )

Topic Elements to be covered include:1. Explain what is meant by quality, quality control and quality management stystems2. Explain what sampling is and how the results of sampling is used in the quality management process 3. Identify and describe the different methods of sampling (grab, belt cut, automatic sampling, stockpile sampling etc.) 4. Explain the logic behind setting up a sampling programme; a. sampling points, b. Frequency of sampling, c. Sample size, d. Need for accuracy and precision 5. Explain the process of sampling (Taking samples, preparing samples, transportation of samples, types of analysis by laboratory, processing of sample results, re-sampling if required) 6. Explain the consequences of incorrect sampling practices 7. Describe the use of on line analysers 8. Explain how methods and factors that will impact on the quality of the final product: a. Blending and mixing b. Machine setting; c. Operating parameters; d. Raw Material quality


313912-001-KS-02:02 -Purpose and application principles of all the materials handling and transportation equipment (Basic) (Credits: 8)

Topic Elements to be covered include:1. Identify and describe the different types of material handling equipment a. Mobile liftingand transporting equipment; b. Conveying systems (stackers, reclaimers); c. Feeders and screens; d. Pumping systems; e. Storage systems ( silos, bins, hoppers etc.) f. Crushing and breaking systems; g. Washing system h. Classifying systems 2. List and describe the main components of each of the systems 3. Describe the key operating principles of each of the systems: a. Purpose, b. How it works, c. Energy source; d. Auxiliary systems and controls (includes instrumentation and safety systems) e. Inspections and maintenance. 4. Explain what is meant by operating parameters and indicate how the parameters are determined: a. Capacity; b. Throughput, c. Efficiency.5. Identify and describe the key factors that will influence the operating efficiency, throughput and capacity of the equipment




313912-001-KS-02:03 -Security processes and requirements for the labeling, storage and dispatch of the final product (Intermediate) (Credits: )

Topic Elements to be covered include:1. Workplace specific (NQF Level: 1)


313912-001-KS-02:04 -Principles and concepts of systems thinking and cause and effect analysis (Basic) (Credits: 2)

Topic Elements to be covered include:1. Explain what is meant by a operational system and how the interrelationship between various system components impact on final results 2. Explain the process for using the cause and effect principle to identify the root causes of problems 3. Describe the typical management process (PLOC) 4. Explain how to make effective decisions when choosing between various alternative solutions (Needs analysis) 5. Describe the process for action planning and protecting action plans (PREVENTATIVE AND CONTINGENCY ACTIONS)


313912-001-KS-02:05 -Operating principles of all the product handling systems and equipment (NOT APPLICABLE TO DIAMONDS)(Intermediate) (Credits: )

Topic Elements to be covered include:1. SITE SPECIFIC (NQF Level: 1)




313912-001-KS-02:06 -Concepts and operating principles of process logical control systems (Basic) (Credits: 12)

Topic Elements to be covered include:1. Explain what is meant by Process Logic Controller and what the main purpose of a PLC(SCADA) is in a beneficiation plant 2. Identify and describe the advantages of using programmed logic controllers in a beneficiation plant 3. Explain the process of manual process control in the event of PLC failure 4. Explain the protocols that can be taken to bypass programmed process steps when required 5. Describe the process for manually operating the PLC from the remote control boxes in the sections on the plant 6. Explain the protocols for conducting fault finding in the beneficiation process using thePLC 7. Explain what the appropriate actions are relating to alarm conditions 8. Describe the basic risks associated with the use of PLC and indicate how a process controller will mitigate these risks: a. Bypassing the system without authorization; b. Sabotage; c. Misuse of the computer system; d. System failure; e. Loss of manual operating skills; f. Misleading instrument readings 9. Describe the main characteristics of a typical PLC (interlocks, stop and start, loops, lock out procedures, changing of set points)


313912-001-KS-02:07 -Factors that affect the efficiency of the process (Intermediate) (Credits: 1)

Topic Elements to be covered include:1. Explain what is meant by process efficiency 2. Identify the various internal and external factors that could impact on the efficiency of the process: a. People; b. Machinery/equipment; c. Environmental issues 3. Indicate what actions must be taken to prevent the various controllable factors from impacting on the process4. Describe the corrective actions that must be taken when things go wrong


313912-001-KS-02:08 -Analyse and interpret trends and related statistical information and identify corrective action (Basic) (Credits: 4)

Topic Elements to be covered include:1. Explain what is meant by statistical analysis 2. Explain the meaning of key statistical terms: a. Ratios, b. Percentages; c. averages; d. mean; e. frequency; f. mode; g. trend 3. Interpret various forms of graphs a. Line; b. Bar charts; c. Pie charts; d, Scatter graphs4. Use raw data to manually develop basic graphs 5. Use a spreadsheet computer based programme to input data and extract basic graphs6. Identify statistical conformance and deviations from the expected norms and report them appropriately




313912-001-KS-02:09 -Metallurgical principles of product separation using different techniques and media (Intermediate) (Credits: 4)

Topic Elements to be covered include:1. Explain what is meant by product separation and why this is important in the beneficiationprocess 2. Identify and list the typical equipment used in the separation process3. 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; g. Density of particles; h. Effect of particle size and shape; i. Use of screening


313912-001-KS-02:10 -Operating principles and design efficiencies of all the equipment used in the separation, de- watering and classification processes (Components, functions, types etc) (Intermediate) (Credits: 16)

Topic Elements to be covered include:1. Identify and list the main components of the equipment used in the process 2. Identify and list the factors that will influence the efficiency and capacity of the equipment used in the process 3. Describe the basic operational principles of the equipment within the process 4. Describe the interaction between the individual pieces of equipment in order to achieve the optimum production efficiency


313912-001-KS-02:11 -Operating principles of production reporting and the generic structures and implications of production reports (Basic) (Credits: 2)

Topic Elements to be covered include:1. Describe the importance of accurate and timeously reporting of production related information.2. Identify and describe the typical production reporting process and the key elements of such a process (what must be reported)3. Describe the consequences of failure to report and inaccurate reporting. 4. Explain the principles for effectively maintaining manual and electronic reporting systems5. Identify and list all the regulatory required registers and lists that must be maintained6. Identify and list all the typical shift based reports that must be maintained


313912-001-KS-02:12 -Concepts and principles of conducting trouble shooting on equipment and machines and corrective actions required to optimise production (Intermediate) (Credits:3)

Topic Elements to be covered include:1. Explain the steps that must be followed to conduct trouble shooting on machinery and equipment 2. Describe the principles for using checklists (Pre start, operational and shut down)



3. Explain the use of permits when work is done on machinery and equipment: a. list total range of permits; b. When permits must be issued; c. authorisation of permits; d. Safety actions that must be done before permits are issued; e. Sign off and closure of permits; f. Filing and safe keeping of permits 4. Identify the leading indicators of defects and potential defects on machinery and equipment 5. Explain the procedures for reporting defects


313912-001-KS-02:13 -Principles of sampling and sampling analysis and the need for effective sampling throughout the process (Basic) (Credits: )

Topic Elements to be covered include:1. DUPLICATED REMOVE (NQF Level: 1)




313912-001-KS-02:14 -Operating principles of a range of crushing and screening equipment (Intermediate) (Credits: 12)

Topic Elements to be covered include:1. Describe the application of the basic empirical laws and general theories of size reduction.(For example RITTINGERS LAW, KICKS LAW, BOND theory of reduction) 2. Identify and list all the key equipment used for crushing and screening 3. Identify the factors that influence the efficiency and capacity of the screening process and indicate the possible corrective actions where appropriate: a. Size of the screen; b. Size distribution of the feed; c. Open area of the screen; d. Slope of the screen; e. Operating Speed of the screen; f. Throw of the screen; g. Obstruction of the screen area; h. Excessive Moisture in the feed; i. Feed rate to the screen; j. Circulating load; k. Viscosity of the material; l. design flaws/incorrect selection of equipment4. Explain why we use different types of crushers 5. Identify the process efficiency indicators that will indicate typical causes of problems in the process 6. Identify the key components of the various machines 7. Describe the operating principles of the equipment 8. Explain the operating parameters for the equipment including the need for different stages in the crushing process: a. crushing gaps; b. processes for making adjustments; c processes for replacing screens and screen decks; d. feed rates; e. Open areas on screens; f. indicators for auxiliary equipment; g. Speed of equipment h. Screen aperture size9. Identify and explain the factors that will influence the efficiency of the crushing processes: a. feed rate; b. moisture content; c. Size of the feed material; d. tramp material; e. Required product size; f. Crusher gaps; g. efficiency of pre-screening; h. Lack of proper maintenance (worn and damaged components); i. Circulating load (Crushing ratio); j. excessive dust generation; k. Drive motor amps (over and under loading - crusher capacity)l. incorrect distribution of feed m. poorly operating auxiliary equipment n. Non-adherance to crusher specifications (choke feed) o. Design flaws/incorrect selection of equipment


313912-001-KS-02:15 -Executing the basic calculations to determine the efficiency of the size reduction processes (Percentages, feed rates, throughput, screening efficiency) (Basic) (Credits: 1)

Topic Elements to be covered include:1. Using given data calculate screening efficiencies and circulating load, crushing ratios.2. Using given data calculate the area of the screen and determine the volume capacity of the

screen?


313912-001-KS-02:16 -Principles of waste handling and the associated regulatory requirements (Basic) (Credits: 1)

Topic Elements to be covered include:1. Explain the necessity of waste handling and pollution control in a beneficiation operation2. Identify the different types of waste generated in a beneficiation process (including tailings and slurry)3. Explain the general principles of waste separation 4. Identify the different types of equipment required for effective waste handling 5. Describe the consequences of not adhering to effective waste management principles and regulatory requirements including codes of practices and guidelines.



6. Describe the minimum criteria for the deposition of waste


313912-001-KS-02:17 -Overview of the requirements relevant to the loading of various types of products. (Basic) (?) (Credits: )

Topic Elements to be covered include:

Internal Assessment Criteria:Provider Accreditation Requirements for the Subject:



Legal Requirements:


Exemptions:



SECTION 3B: PRACTICAL SKILL MODULE SPECIFICATIONS

List of Practical Skills Modules for which Specifications are included:


313912-001-PM-01 Monitor the Occupational Health, Safety and environmental compliance in the benificiation processes

11

313912-001-PM-02 Monitor and verify the availability of raw materials 6313912-001-PM-03 Facilitate the smooth flow of raw material by means of the

material handling and transportation systems and equipment18

313912-001-PM-04 Check and report the quality/parameters of the available raw material

6

313912-001-PM-05 Determine the raw material requirements to achieve the production targets

6

313912-001-PM-06 Monitor and control the raw materials blending processes 0313912-001-PM-07 Start, monitor, control and stop all size reduction equipment 6313912-001-PM-08 Start, monitor, control and stop all Separation, de-watering and

classification equipment0

313912-001-PM-09 Report operating conditions of size reduction equipment 0313912-001-PM-10 Monitoring and controlling the handling and storage of the

processed product (1st stage beneficiation)0

313912-001-PM-11 Monitoring and controlling the dispatch of the processed product(NOT APPLICABLE TO DIAMONDS)

0

313912-001-PM-12 Monitor and control the removal and disposal of waste products. 0

Total Practical Skill Credits: 53



313912-001-PM-01-Monitor the Occupational Health, Safety and environmental compliance in the beneficiation processes (NQF Level: )

Purpose of the Module:

List of Practical Skills Included in this Module:

Number Title Credits

313912-001-PM-01-PS01 Conduct all start of shift procedures 3313912-001-PM-01-PS02 Identify health, safety and environmental hazards and risks in

the lump ore beneficiation environment (includes risk assessments)

2

313912-001-PM-01-PS03 Ensure that all people entering the environment complies with relevant Safety health and Environmental standards and regulatory requirements.

3

313912-001-PM-01-PS04 Identify problems with the operational efficiency of all health and safety equipment and devices (Ongoing inspections)

3

313912-001-PM-01-PS01 Conduct all start of shift procedures(Credits: 3)

Scope of Practical Skill:

Given:Given a simulated or controlled work environment with a team of staff required to operate a lump ore beneficiation plant.

Be Able to:1. Conduct an inspection to check that all team members are fit for work and that all requiredPPE is available and in acceptable condition2. Conduct a health and safety discussion3. Deal with employees that are unfit for work4. Present and discuss the production results and explain the target for the day5. Communicate special instructions and management briefs6. Determine the availability of staff members and take action to deal with absenteeism(Attendance registers)7. Deal with employee issues, questions and complaints

Critical Activities to be Assessed Externally:



Applied Knowledge1. Techniques of conducting inspections of work teams to determine fitness for work.2. Standards for acceptable PPE3. Techniques and processes for dealing with unfit employee (Emotional stress, health conditions, intoxication etc.)4. Techniques for conducting start of shift meetings5. Processes and techniques of interpreting management instructions.

Internal Assessment:1. Observe the extent to which the learners conduct the start of shift process and meeting according to the procedures and covers all the required activities2. Observe the extent to which the learners use the appropriate communication processes and behaviours to facilitate the appropriate interactions during the start of shift processes.3. Evaluate that the learners complete the start of shift procedures within a set time period and cover all the required discussions and inspections.4. Evaluate the completeness and accuracy of the records kept of the start of shift process.

313912-001-PM-01-PS02 Identify health, safety and environmental hazards and risks in the lump ore beneficiation environment (includes risk assessments) (Credits: 2)


Given:Given a simulated and controlled plant environment with a range of hazards covering all the major categories of hazards as specified by relevant regulatory requirements and standard checklists/mini risk assessment documents related to a range of typical tasks executed in the plant.

Be Able to:1. Identify all the potential hazards present in the simulated work areas;2. Capture and record all the hazards accurately and correctly on the given hazard identification documents;3. Describe and accurately categorise the risks according to the standard risk assessment processes (Five by five matrix);4. Explain the controls required to mitigate the identified risks;5. Complete a standard hazard assessment report indicating the job specific hazards per job tasks.


Applied Knowledge1. Generally accepted techniques for conducting Hazard and risk assessments (e.g. JHA,HAZOP etc)2. Techniques and processes for identifying and managing hazards and risks (e.g. applying



SLAM (STOP, LOOK, ASSESS and MANAGE)TARP (Trigger, Action, Response, Plan)

Internal Assessment:1. Test understanding of all the applied knowledge - learners must, without reference to learning material explain and describe the use of all the techniques and give examples of how these techniques are applied.2. Learners must describe the process that must be followed to do hazard and risk assessments and indicate how a person must prepare themselves before conducting hazard assessments;3. Learners must, without reference to learning material, identify all the hazards stipulated in the simulation and accurately describe the associated risks and controls indicating the potential consequences of these risks.4.

313912-001-PM-01-PS03 Ensure that all people entering the environment complies with relevant Safety health and Environmental standards and regulatory requirements. (Credits: 3)


Given:Given a. Appropriate PPE; b. Specialised Safety Equipment; c. Permits and entrycertification/documents; d. Reporting and related records required; e. policies and procedures for entering work areas in the plant; f. Scenarios of a range of people needing to enter specific work areas, the scenarios must include normal employees, visitors, contractors, maintenance staff and management.

Be Able to:1. Check and verify that the persons are authorised to enter the work area2. Physically check that the persons entering the work area complies with all the health, safety and environmental requirements;3. Complete all the required documentation giving people access to the various work environments;4. Explain the monitoring and reporting processes to ensure compliance with the entry and exit authorisations5. Explain the emergency procedures that must be activated related to people entering the work areas6. Explain any specific rules and procedures to applicable people entering specified areas where required


pplied Knowledge1. Techniques and processes for checking the operating efficiency of specialised/area specific personal safety equipment carried by the individual (Gas monitors, dust monitors, rescue packs etc)2. Processes required for the completion of regulatory required permits and reports

Internal Assessment:



1. Identify all PPE and area specific safety equipment related deviations and indicate what must be done to correct them2. Correctly verify all the required authorisations and correctly complete all the documentation.3. Without reference to learning material correctly explain all the required rules, test understanding and deal with questions and objections.

313912-001-PM-01-PS04 Identify problems with the operational efficiency of all health and safety equipment and devices (Ongoing inspections) (Credits: 3)


Given:Given simulated or controlled work environments where all the major/commonly installed safety devices are present and a range of scenarios where the devices are activated.

Be Able to:1. Identify and describe the purpose and application of all of the major devices;2. Describe the actions required when the safety devices are activated;3. Identify defective safety devices and describe the processes to be followed to rectify any defects;4. Test the operational efficiency of all the installed safety devices;5. Explain the normal procedures for the ongoing monitoring and testing of the devices.6. Complete all required checklists and documentation.


Applied Knowledge1. Techniques for inspecting and testing the safety devices2. Reporting processes to deal with defective safety devices3. Processes for responding to alarms/device activation

Internal Assessment:1. Demonstrate the operation and use of all the specialised/area specific safety equipment according to the manufacturers specifications.2. Correctly complete all the required checklists and documentation3. Without reference to learning material describe the various techniques for inspecting and testing the safety devices and correctly explain what must be done where defects in the devices are detected.



Provider Accreditation Requirements:Physical Requirements:


Legal Requirements:

Exemptions:



313912-001-PM-02-Monitor and verify the availability of raw materials (NQF Level: )




313912-001-PM-02-PS01 Determine the levels of raw material in the storage facilities on the control system

4

313912-001-PM-02-PS02 Physically inspect levels of raw material in storage facilities/stockpiles

2

313912-001-PM-02-PS01 Determine the levels of raw material in the storage facilities on the control system (Credits: 4)


Given:Given an operating control room with appropriate process control systems with various raw materials and various levels of the raw materials.

Be Able to:1. Access the control systems and identify all the raw materials2. Read and record the levels of all the raw materials3. Select the appropriate raw material storage facilities4. Identify and describe the raw material process flow with all the facilities and equipment in the process5. Manage the levels of raw material in the system (including blending)6. Extract the data required from the system to calculate throughputs, flows and stock levels.7. Calculate and record throughputs, flows and stock levels8. Report and discuss the raw material stock levels


Applied Knowledge1. Techniques to access and operate the appropriate computer based control systems2. Techniques for calculating throughputs, flows and stock levels3. Processes for managing stock levels in the raw material system4. Processes and techniques of manipulating and managing the raw material flow



Internal Assessment:1. Without reference to learning material demonstrate all the techniques for accessing and managing the raw materials using a computer based control system.2. Maintain the required raw material stock levels in the system according to the operating requirements to achieve the set production for a specified production period.3. Correctly calculate and record all the required throughputs, flows and stock levels

313912-001-PM-02-PS02: Physically inspect levels of raw material in storage facilities/stockpiles (Credits: 2)


Given:Given access to a simulated or controlled work environment with an operating raw material process flow containing a range of storage facilities.

Be Able to:1. Explain the interaction (e.g. interlocks, feed rates, capacity etc) between the various components in the system2. Identify and describe the various raw material storage facilities3. Physically inspect each of the storage facilities and determine the level of raw materials in the facility4. Record and report the stock levels in the facilities5. Check the physical condition of the storage facilities and the relevant measuring equipment and instrumentation6. Select the appropriate raw material


Applied Knowledge1. Techniques and processes for the safe inspection of raw material storage facilities2. Techniques and processes for checking instrumentation and measuring equipment3. Techniques for identifying and selecting various raw materials

Internal Assessment:1. Without reference to learning material demonstrate the inspection of raw material storage facilities and explain the reason for the selection and monitoring of raw material levels in an integrated system.2. Evaluate the accuracy of the reported raw material levels





Legal Requirements:

Exemptions:

313912-001-PM-03-Facilitate the smooth flow of raw material by means of the material handling and transportation systems and equipment (NQF Level:)




313912-001-PM-03-PS01 Identify and report the hazards and risks associated with the raw material handling and transportation processes and take appropriate action

313912-001-PM-03-PS02 Inspect and confirm the availability and running condition of raw material handling and transporting equipment.

2

313912-001-PM-03-PS03 Execute the startup and shut down procedures for all raw material handling and transportation equipment

4

313912-001-PM-03-PS04 Monitor the running of the raw materials handling and transportation equipment

12

313912-001-PM-03-PS01 Identify and report the hazards and risks associated with the raw material handling and transportation processes and take appropriate action (Credits: )


Given:Given a simulated or controlled work area

Be Able to:1. COVERED IN PS01Critical Activities to be Assessed Externally: Applied Knowledge




313912-001-PM-03-PS02 Inspect and confirm the availability and running condition of raw material handling and transporting equipment. (Credits: 2)


Given:Given a simulated or controlled work environment with specific production targets, production scenarios and a range of material handling and transportation equipment.

Be Able to:1. Select the most appropriate equipment required to achieve the production targets2. Name and describe all the equipment available in the specific production area.3. Oversee the conducting of pre-use inspections on the available equipment and report defects4. Monitor and ensure that the required repairs and maintenance is completed


Applied Knowledge1. Techniques for conducting pre-use inspections on mobile and stationary material handling and transportation equipment2. Interlocking processes between the various components of the raw material supply system

Internal Assessment:1. Without reference to learning material describe the relevant techniques and processes for checking the availability and readiness of raw material handling and transportation equipment.2. Evaluate that all the pre-use checklists have been completed accurately and that all defects and substandard conditions are correctly recorded, reported and that the appropriate corrective actions were taken.

313912-001-PM-03-PS03: Execute the startup and shut down procedures for all raw material handling and transportation equipment (Credits: 4)


Given:Given a simulated or controlled work environment with all the main categories of raw material handling and transportation equipment (Mobile Loaders, conveyors, overhead loaders and transportation equipment, stackers and reclaimers)



Be Able to:1. Execute start up procedures for the applicable equipment using a computer based control system2. Execute manual start up procedures for all the equipment3. Execute all required up and down stream communication for the startup and shut down of the equipment4. Execute normal and emergency shutdown procedures using a computer based control system5. Execute normal and emergency manual shut down procedures


Applied Knowledge1. Techniques for accessing the computer based control system.2. Start up and shut down methodologies and sequences for all the relevant raw material transportation and handling equipment3. Techniques and processes for emergency shut downs4. Manual start up shut down and operating procedures for all stationary raw material handling and transportation equipment

Internal Assessment:1. Without reference to learning materials describe the relevant processes, techniques and sequences correctly indicating the consequences of inappropriate start up and shut down sequences.2. Observe the extent to which the learner complies with the laid down start up, shut down and emergency procedures all procedures must be followed correctly and in the correct sequence.

313912-001-PM-03-PS04 Monitor the running of the raw materials handling and transportation equipment (Credits: 12)


Given:Given a simulated or controlled work environment with all the main categories of raw material handling and transportation equipment (Mobile Loaders, conveyors, overhead loaders and transportation equipment, stackers and reclaimers) and a range of production scenarios and targets.

Be Able to:1. Monitor the performance of the equipment using the computer based control system.2. Take appropriate actions to increase or decrease throughputs and flows to achieve the required production targets.3. Complete all required reports and documentation4. Execute all required up and down stream communication



5. Conduct physical inspections to monitor the performance of the plant and equipment6. Take appropriate action to respond to deviations from standard7. Maintain the appropriate raw material levels in all the storage facilities.8. Conduct problem solving on process related issues and concerns9. Respond to alarms and emergency situation10. Execute the required shift hand over communications and activities


Applied Knowledge1. Problem solving and fault finding techniques2. Communication and shift hand over techniques3. Techniques to manipulate and manage the process to achieve production targets4. Emergency response processes

Internal Assessment:1. Without reference to learning materials describe the relevant processes, techniques and methods correctly giving appropriate examples of what must be done to manage the process optimally in order to achieve the required production targets.2. Observe the extent to which the learner ensures compliance with all the standards, procedures and operating requirements no deviation from the laid down procedures are allowed.3. Evaluate the achievement of the required production results during the specified operating period. At least 80% of the targets must be achieved4. Evaluate the extent to which all required documentation and communication is completed correctly.



Legal Requirements:

Exemptions:



313912-001-PM-04-Check and report the quality/parameters of the available raw material (NQF Level: )




313912-001-PM-04-PS01 Take raw material samples from various sample points 2313912-001-PM-04-PS02 Record and interpret sample results 4313912-001-PM-04-PS03 Identify the appropriate actions to be taken on sample results

and action them

313912-001-PM-04-PS01 Take raw material samples from various sample points (Credits: 2)


Given:Given a simulated or controlled work environment with access to a full range of sampling points, all the raw materials, all the required sampling tools and the appropriate PPE.

Be Able to:1. Identify the correct sampling points to take samples from.2. Select the appropriate sampling methods and tools3. Physically take a range of samples from a full range of sampling points (Liquid samples and solid)4. Place the samples in the appropriate containers and label the samples for analysis by the laboratory.5. Complete all required sampling documentation.


Applied Knowledge1. Techniques for taking various types of samples (Belt cuts, discharge, crusher samples, blended material samples, equipment efficiency samples)2. Techniques for using specialised sampling equipment3. Processes for applying appropriate sample programmes (Sample size, sample schedules, types of products etc)



4. Techniques and processes of labeling and identifying the different samples

Internal Assessment:1. Without reference to learning material explain all the required techniques and give examples of where the various techniques will be used and the consequences of not following the sampling processes correctly.2. Observe the extent to which the learners follow the correct sampling procedures and apply the appropriate safe working practices when taking samples.

313912-001-PM-04-PS02 Record and interpret sample results(Credits: 4)


Given:Given a full range of sample results including accurate and inaccurate sample results.

Be Able to:1. Check the sample results against the set standards and identify deviations.2. Record the received sample results in an appropriate logsheet3. Conduct a trend analysis of the sample results and highlight possible discrepancies4. Determine the possible causes of deviations and report appropriate corrective actions


Applied Knowledge1. Processes for recording sampling results2. Analysis techniques to analyse and interpret sampling results3. Techniques for conducting basic statistical analysis of sample results

Internal Assessment:1. Evaluate the extent to which the learners accurately records, analyses and interprets the sample results according to a set interpretation process and standard. (all results must be correctly recorded and all calculations correctly executed)2. Evaluate that the most appropriate corrective actions were selected and correctly reported.

313912-001-PM-04-PS03 Identify the appropriate actions to be taken on sample results and action them (Credits: )




Given:

Be Able to:1. COVERED IN THE PREVIOUS SKILL


Applied Knowledge




Legal Requirements:

Exemptions:



313912-001-PM-05-Determine the raw material requirements to achieve the production targets (NQF Level: )




313912-001-PM-05-PS01 Read and interpret the production requirements and maintenance schedules

2

313912-001-PM-05-PS02 Monitor the feed rates and take appropriate action to correct deviations

4

313912-001-PM-05-PS01 Read and interpret the production requirements and maintenance schedules (Credits: 2)


Given:Given scenarios relating to the operating situation in the plant and the operation and all required production and maintenance schedules and results. (Requirements and actual)

Be Able to:1. Determine the current status of the actual production compared with the required production. (Actual vs target)2. Interpret a forecast of results for the next week based on the current results and trends3. Develop a schedule of actions to ensure that the required production results are achieved in the short and medium term (Shift by shift)


Applied Knowledge1. Basic forecasting techniques2. Planning and scheduling techniques (POLC)3. Problem solving techniques4.

Internal Assessment:1. Evaluate the extent to which the produced schedule meets the generally accepted standards for scheduling and the feasibility of the proposed forecast and actions achieving the desired results.2. Evaluate the accuracy of the interpreted production results (Plan vs actual)



313912-001-PM-05-PS02 Monitor the feed rates and take appropriate action to correct deviations (Credits: 4)Scope of Practical Skill:

Given:Given a simulated or controlled work environment providing learners access to a fully operating plant and plant control system covering the conditions relevant to a full shift cycle

Be Able to:1. Access the plant monitoring system and determine the feed rates of raw material at all the stages of the lump ore process for a full shift period.2. Make appropriate process adjustments to ensure that the required outputs and feed rates are maintained3. Report and record all process changes and deviations4. Respond to emergency situations5. Take action to deal with deviations6. Complete the end of shift report7.


Applied Knowledge1. Techniques for operating a lump ore processing plant2. Techniques for monitoring the feed stock levels and take appropriate action to ensure that the feed stock levels are retained at the appropriate levels.3. Techniques for managing stress

Internal Assessment:1. Give examples of the application of the various techniques to impact positively on the achievement of production results and describe the consequences of non-compliance with the prescribed production processes.2. Observe the extent to which the learners follow all the operating procedures and protocols.3. Observe the appropriate reaction of the learners to emergency situations, breakdowns and deviations.



Legal Requirements:

Exemptions:



313912-001-PM-06-Monitor and control the raw materials blending processes (NQF Level: )




313912-001-PM-06-PS01 Interpret the blending requirements and control the blending process to achieve the required production targets

313912-001-PM-06-PS02 Monitor the operation of blending equipment (i.e. Stacker, grab, reversible conveyor, tripper car, mobile equipment, manual tools, reclaimer)

313912-001-PM-06-PS03 Check that the blended products are placed into the correct storage facilities

313912-001-PM-06-PS04 Take samples of the blended products and interpret sample results and initiate corrective action where required

313912-001-PM-06-PS01 Interpret the blending requirements and control the blending process to achieve the required production targets (Credits: )


Given:THIS SILL WILL ONLY BE PART OF WORK EXPERIENCE NOT IN PRACTICAL SKILLS.Given various scenarios relating to production situations where the blending of various raw materials are needed to achieve set production targets.

Be Able to:1. Identify the different types of raw materials that must be blended.2. Apply the given formulas and determine the tonnages that must be blended3. Physically check the feed-stock available


Applied Knowledge




313912-001-PM-06-PS02 Monitor the operation of blending equipment (i.e. Stacker, grab, reversible conveyor, tripper car, mobile equipment, manual tools, reclaimer) (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-06-PS03 Check that the blended products are placed into the correct storage facilities (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-06-PS04 Take samples of the blended products and interpret sample results and initiate corrective action where required (Credits: )




Given:

Be Able to:


Applied Knowledge




Legal Requirements:

Exemptions:



313912-001-PM-07-Start, monitor, control and stop all size reduction equipment (NQF Level: )




313912-001-PM-07-PS01 Inspect all size reduction equipment for defects prior to start up (Includes making appropriate settings)Identify and take corrective action to correct deviations.

3

313912-001-PM-07-PS02 Start up the size reduction equipment and machines 3313912-001-PM-07-PS03 Monitor the operating efficiency of all size reduction equipment

and machines Identify potential equipment problems by checking the parameters of the discharged product

313912-001-PM-07-PS04 Identify sub standard conditions and take corrective action(Ensure that maintenance is done)

313912-001-PM-07-PS01 Inspect all size reduction equipment for defects prior to start up (Includes making appropriate settings) Identify and take corrective action to correct deviations. (Credits: 3)


Given:Given a simulated or controlled work environment with all required size reduction equipment and related services in a process plant.

Be Able to:1. Conduct pre-use inspection of all the size reduction equipment.2. Check the settings of the equipment and take action to correct the settings where required.3. Check the operational readiness and availability of all required auxiliary equipment4. Check the environment to ensure compliance with all health safety and environmental requirements5.


Applied Knowledge1. Various techniques for checking the settings of the size reduction equipment



2. Techniques and documentation to conduct pre-use inspections on equipment

Internal Assessment:1. Observe the extent to which the learners follow all required steps to conduct safe and effective pre use inspections on the equipment and identify all current and potential defects.2. Observe that learners comply with all safety and lock out procedures when checking equipment conditions and settings.3. Evaluate that all checklists and documentation is correctly and accurately completed.

313912-001-PM-07-PS02 Start up the size reduction equipment and machines (Credits: 3)


Given:Given a simulated or controlled work environment where learners have access to a control room and physical access to the equipment in the plant.

Be Able to:1. Communicate the intention to start up and obtain clearance for startup.2. Follow the required control sequence for the remote startup of the size reduction plant.3. Follow the manual start up process and sequence to start up the plant manually.4. Check the functionality of all the equipment on the computer based control system5. Physically observe and check the effective operation of the plant6. Identify and deal with alarm conditions during the startup process.7. Initiate the feed of material into the size reduction plant using the computer based control system8. Initiate the feed manually into the size reduction process.


Applied Knowledge1. Techniques for starting up a size reduction process using a computer based control system2. Techniques and processes for starting up a size reduction process manually

Internal Assessment:1. Test understanding of the full range of possible alarm conditions - Learners must describe all alarm conditions explaining the possible causes and the required action to deal with each of the conditions.2. Observe the extent to which learners follow the laid down start up procedures on the computer and manually. All procedures must be complied with.3. Evaluate the achievement of the appropriate flow of material through the process within a stipulated time period.



313912-001-PM-07-PS03 Monitor the operating efficiency of all size reduction equipment and machines Identify potential equipment problems by checking the parameters of the discharged product (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-07-PS04 Identify substandard conditions and take corrective action (Ensure that maintenance is done) (Credits: )


Given:

Be Able to:


Applied Knowledge






Legal Requirements:

Exemptions:

313912-001-PM-08-Start, monitor, control and stop all Separation, de-watering and classification equipment (NQF Level: )




313912-001-PM-08-PS01 Access and operate desktop computer systems313912-001-PM-08-PS02 Check the availability of the relevant processing media313912-001-PM-08-PS03 Identify and take corrective action to correct deviations and

breakdowns in the Separation, de-watering and classification processes

313912-001-PM-08-PS04 Start up the Separation, de-watering and classification equipment and machines

313912-001-PM-08-PS05 Monitor the operating efficiency of all Separation, de-watering and classification equipment and machines and make required changes to settings

313912-001-PM-08-PS06 Identify sub standard conditions and take corrective action in the Gravity/centrifugal Separation, de-watering and classification process (Ensure that maintenance is done)

313912-001-PM-08-PS07 Inspect all Gravity Separation, de-watering and classification equipment for defects prior to start up.

313912-001-PM-08-PS08 Access and do basic work on word processing and spreadsheet software

313912-001-PM-08-PS01 Access and operate desktop computer systems (Credits: )


Given:

Be Able to:




Applied Knowledge


313912-001-PM-08-PS02 Check the availability of the relevant processing media (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-08-PS03 Identify and take corrective action to correct deviations and breakdowns in the Separation, de- watering and classification processes (Credits: )


Given:

Be Able to:


Applied Knowledge




313912-001-PM-08-PS04 Start up the Separation, de-watering and classification equipment and machines (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-08-PS05 Monitor the operating efficiency of all Separation, de-watering and classification equipment and machines and make required changes to settings (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-08-PS06 Identify substandard conditions and take corrective action in the Gravity/centrifugal Separation, de- watering and classification process (Ensure that maintenance is done) (Credits: )




Given:

Be Able to:


Applied Knowledge


313912-001-PM-08-PS07 Inspect all Gravity Separation, de- watering and classification equipment for defects prior to start up. (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-08-PS08 Access and do basic work on word processing and spreadsheet software (Credits: )


Given:

Be Able to:




Applied Knowledge






Legal Requirements:

Exemptions:

313912-001-PM-09-Report operating conditions of size reduction equipment (NQF Level: )




313912-001-PM-09-PS01 Communicate using a range of electronic communication media313912-001-PM-09-PS02 Complete logbooks and reports

313912-001-PM-09-PS01 Communicate using a range of electronic communication media (Credits: )


Given:

Be Able to:


Applied Knowledge




313912-001-PM-09-PS02 Complete logbooks and reports(Credits: )


Given:

Be Able to:


Applied Knowledge




Legal Requirements:

Exemptions:



313912-001-PM-10-Monitoring and controlling the handling and storage of the processed product (1st stage beneficiation) (NQF Level: )




313912-001-PM-10-PS01 Identify and co-ordinate the availability of appropriate storage facilities (Stockpiles, silos etc)

313912-001-PM-10-PS02 Check the readiness and availability of mobile material handling machinery (NOT APPLICABLE TO DIAMONDS)(FEL, BOBCAT, etc)

313912-001-PM-10-PS03 Inspect the readiness and availability of conveyance systems(NOT APPLICABLE TO DIAMONDS)

313912-001-PM-10-PS04 Ensure the correct grading and labeling of the products (COAL DO NOT GRADE)

313912-001-PM-10-PS05 Start and monitor the conveyance systems (NOT APPLICABLE TO DIAMONDS)

313912-001-PM-10-PS06 Complete all the required storage/dispatch documentation313912-001-PM-10-PS07 Ensure the effective containment and clean up of spillages

313912-001-PM-10-PS01 Identify and co-ordinate the availability of appropriate storage facilities (Stockpiles, silos etc) (Credits: )


Given:

Be Able to:


Applied Knowledge




313912-001-PM-10-PS02 Check the readiness and availability of mobile material handling machinery (NOT APPLICABLE TO DIAMONDS)(FEL, BOBCAT, etc) (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-10-PS03 Inspect the readiness and availability of conveyance systems (NOT APPLICABLE TO DIAMONDS) (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-10-PS04 Ensure the correct grading and labeling of the products (COAL DO NOT GRADE) (Credits: )




Given:

Be Able to:


Applied Knowledge


313912-001-PM-10-PS05 Start and monitor the conveyance systems (NOT APPLICABLE TO DIAMONDS) (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-10-PS06 Complete all the required storage/dispatch documentation (Credits: )


Given:

Be Able to:




Applied Knowledge


313912-001-PM-10-PS07 Ensure the effective containment an clean-up of spillages (Credits: )


Given:

Be Able to:


Applied Knowledge




Legal Requirements:

Exemptions:



313912-001-PM-11-Monitoring and controlling the dispatch of the processed

product (NOT APPLICABLE TO DIAMONDS) (NQF Level: )




313912-001-PM-11-PS01 Interpret the dispatch schedules and liaise with the various logistics stakeholders (ONLY APPLICABLE TO COAL)

313912-001-PM-11-PS02 Check and ensure that the required product is available - calculate the required tonnage in storage facilities to meet specified dispatch requirements

313912-001-PM-11-PS03 Check and ensure that the loading and sampling equipment is available and ready for use

313912-001-PM-11-PS04 Monitor the availability and utilisation of the required mobile machinery

313912-001-PM-11-PS05 Monitor and control the effective operation of weighbridges313912-001-PM-11-PS06 Ensure that all required dispatch documentation is completed.

313912-001-PM-11-PS01 Interpret the dispatch schedules and liaise with the various logistics stakeholders (ONLY APPLICABLE TO COAL) (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-11-PS02 Check and ensure that the required product is available - calculate the required tonnage in storage facilities to meet specified dispatch requirements (Credits: )




Given:

Be Able to:


Applied Knowledge


313912-001-PM-11-PS03 Check and ensure that the loading and sampling equipment is available and ready for use (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-11-PS04 Monitor the availability and utilisation of the required mobile machinery (Credits: )


Given:



Be Able to:


Applied Knowledge


313912-001-PM-11-PS05 Monitor and control the effective operation of weighbridges (Credits: )


Given:

Be Able to:


Applied Knowledge


313912-001-PM-11-PS06 Ensure that all required dispatch documentation is completed. (Credits: )


Given:

Be Able to:


Applied Knowledge






Legal Requirements:

Exemptions:

313912-001-PM-12-Monitor and control the removal and disposal of waste products. (NQF Level: )





Legal Requirements:

Exemptions:



SECTION 3C: WORK EXPERIENCE MODULE SPECIFICATIONS

List of Work Experience Module Specifications


313912-001-WM-01 Exposed to risk management processes for all areas of the plant 0313912-001-WM-02 Exposure to the full raw material handling processes for the

specific site0

313912-001-WM-03 Exposure to the full range of raw materials in the site specific processes

0

313912-001-WM-04 EXPOSURE to the raw material reduction processes 0313912-001-WM-05 EXPOSURE to the separation, de-watering and classification

processes0

313912-001-WM-06 EXPOSURE to the final product handling, storage and dispatch processes

0

Total Work Experience Credits: 0

313912-001-WM-01 - Exposed to risk management processes for all areas of the plant

Purpose of the Module

List of Experiences included in this module


313912-001-WM-01-01 Participate in the completion two continuous risk assessments per shift for a period of four weeks.

313912-001-WM-01-02 Participate in daily safety/start up meetings for a period of four weeks313912-001-WM-01-03 Conduct planned inspections in all areas of the plant for a four week shift

period313912-001-WM-01-04 Participate in the conducting of planned task observations for designated

tasks in the plant313912-001-WM-01-05 Participate in different types of emergency drills at least one.313912-001-WM-01-06 Meet company requirements regarding first aid certificate313912-001-WM-01-07 Identify and report incidents, sub standard acts and sub standard

conditions (At least one in a four week shift cycle)313912-001-WM-01-08 Perform lockout procedures according to the site specific standards (At

least one per shift cycle)313912-001-WM-01-09 Participate in incident/accident investigations (At least one in a four week

shift cycle)313912-001-WM-01-10 Successful completion of the company specific induction



313912-001-WM-01-01 Participate in the completion two continuous risk assessments per shift for a period of four weeks.

Guidelines for Work Experience

Contextual Workplace Knowledge

Supporting Evidence

313912-001-WM-01-02 Participate in daily safety/start up meetings for a period of four weeks



Supporting Evidence

313912-001-WM-01-03 Conduct planned inspections in all areas of the plant for a four week shift period



Supporting Evidence

313912-001-WM-01-04 Participate in the conducting of planned task observations for designated tasks in the plant



Supporting Evidence



313912-001-WM-01-05 Participate in different types of emergency drills at least one.



Supporting Evidence

313912-001-WM-01-06 Meet company requirements regarding first aid certificate



Supporting Evidence

313912-001-WM-01-07 Identify and report incidents, substandard acts and substandard conditions (At least one in a four week shift cycle)



Supporting Evidence

313912-001-WM-01-08 Perform lockout procedures according to the site specific standards (At least one per shift cycle)



Supporting Evidence



313912-001-WM-01-09 Participate in incident/accident investigations (At least one in a four week shift cycle)



Supporting Evidence

313912-001-WM-01-10 Successful completion of the company specific induction



Supporting Evidence

Criteria for Workplace Approval:



Legal Requirements:

Exemptions:



313912-001-WM-02 - Exposure to the full raw material handling processes for the specific site




313912-001-WM-02-01 Inspect and confirm the availability and running condition of raw material handling and transporting equipment (TWO FOUR WEEK SHIFT CYCLES)

313912-001-WM-02-01 Inspect and confirm the availability and running condition of raw material handling and transporting equipment (TWO FOUR WEEK SHIFT CYCLES)



Supporting Evidence




Legal Requirements:

Exemptions:



313912-001-WM-03 - Exposure to the full range of raw materials in the site specific processes




313912-001-WM-03-01 Determine the levels of raw material in the storage facilities on the control system (Two four week shift cycles)

313912-001-WM-03-02 Physically inspect levels of raw material in storage facilities/stockpiles(Two four week shift cycles)

313912-001-WM-03-01 Determine the levels of raw material in the storage facilities on the control system (Two four week shift cycles)



Supporting Evidence

313912-001-WM-03-02 Physically inspect levels of raw material in storage facilities/stockpiles (Two four week shift cycles)



Supporting Evidence






Legal Requirements:

Exemptions:

313912-001-WM-04 - EXPOSURE to the raw material reduction processes




313912-001-WM-04-01 Achieve the production targets (volume and quality) for a reduction section for a two four week shift cycle. (Over a period of six months)

313912-001-WM-04-01 Achieve the production targets (volume and quality) for a reduction section for a two four week shift cycle. (Over a period of six months)



Supporting Evidence




Legal Requirements:

Exemptions:



313912-001-WM-05 - EXPOSURE to the separation, de-watering and classification processes






Legal Requirements:

Exemptions:



313912-001-WM-06 - EXPOSURE to the final product handling, storage and dispatch processes






Legal Requirements:

Exemptions:

Documents

benvanas.co.zabenvanas.co.za/downloads/MQA/pages/CONTROLLERS/… · Web viewTOTAL TOPIC CREDITS: 66. 313912-001-KS-02:01 -Principles for determining the quality specifications for