ATP_sample - ATP - Advanced Technical Publications

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This sample package has been designed to provide an introduction to the
types of documentation that Advanced Technical Publications
produces. We develop all types of site-specific documentation including:

       • Training Programs for Fixed Plant and Mobile Equipment

       • Induction Programs

       • Supervisory Skills Training Programs

       • Safe Work Procedures

       • Control Plans

       • Assessment Instruments

       • Wall Charts

We strive to achieve the highest quality in all the material we develop and
we believe this results in the absolute best documentation that is currently
available to industry.

We invite you to browse through this sample package. If you find there are
areas where Advanced Technical Publications could be of use to your
organisation, please feel free to give us a call. We are happy to provide a
proposal on any aspect of the documentation that you require for your

For more information on Advanced Technical Publications,
please contact us at:

Advanced Technical Publications

PO Box 579
Queensland 4558

Ph:     (07) 5472 8285
Fax:    (07) 5472 8286
                             Training Programs

We develop and produce high quality training programs for all aspects of
industry. These include:
      • Training modules for all types of fixed process plant
      • Training modules for computerised plant control systems
      • Training modules for all types of mobile equipment
      • Training modules for inductions, environmental policy and EEO
      • Supervisory skills training modules.
The aim of every training program that we produce is to set high levels of
safety-consciousness within the workforce and to help to raise efficiency and
productivity for the organisation.

Each of our training programs is developed in ready-to-train format. Each
module is supplied as comprehensive, self-contained program which contains:
      • Descriptor — this provides all the administrative information for
         the program
      • Lesson plans — these provide the instructor with step-by-step
         instructions for the delivery of the program
      • Trainee booklet — this provides all the information in easy-to-read
         text which is illustrated in colour with high-quality graphics and
      • Theoretical and practical assessment instruments — which
         ensure that all the key elements of the program are tested to the
         required standard
      • PowerPoint or overhead transparency presentation — which
         can be used by the instructor to ensure that the training sessions are
         delivered in a smooth, professional manner.
All of our training programs, are carefully developed to suit the audience. We
include the target workforce in the planning, design and research phases of
development in order to instill confidence in the product and to ensure on-site
‘ownership’ of the completed training program. We ensure that the text is
structured and written in such a way that it will be easily understood and
remembered by the people who are required to undertake the training

By using Advanced Technical Publications to develop your site-specific
training programs, you can guarantee that your training system will achieve its
goals by developing a workforce that conducts all of its tasks safely and

The following pages provide a small sample of the lesson plans, text and
assessment instruments that Advanced Technical Publications has devel-
oped in the past.
Sample — Lesson Plan                                                              Page 4

                               LEARNING POINTS
                       Topic Two Outline
                       The Purpose of Assessment
                           •   What is Assessment?
                           •   What is Competence?
                           •   Practical Uses for Assessment
                                −     Assessing in the Recruitment Process
                                −   Assessing for Recognition of Prior Learning
                                −     Assessing to Identify Training Needs
                                −     Assessing for Skill-Based Classification
                                −     Assessing to Improve Production
                                −     Assessing to Determine Progress
                       The Assessor’s Role
                           •   Functions of an Assessor
                                −     Manager
                                −     Coordinator
                                −     Evaluator
                                −     Designer
                                −     Counsellor
                                −     Administrator
                       The Principles of Assessment
                           •   Validity
                           •   Reliability
                           •   Flexibility
                           •   Fairness
                       Types of Assessment
                           •   Initial/Diagnostic Assessment
                           •   Formative Assessment
                           •   Summative Assessment
Sample — Lesson Plan                                                                         Page 5

             Trainer Activities                   Trainee Activities            Key Points

                                     Topic Two Outline

Introduce the topic.

Discuss the learning outcomes.                Discuss learning outcomes.     Learning outcomes

Provide an overview of the topic.

Discuss the topic assessment.                 Discuss assessment             Topic assessment

                                  Purpose of Assessment

This section outlines the purpose of
assessment and provides its practical uses.

 What is Assessment?

Define assessment, ie, ‘A process in which    Discuss the various types of   Assessment
evidence about performance is collected       evidence that would be         definition
and evaluated’.                               available in a typical
Explain that the assessor will be required                                   Sufficient evidence
to collect sufficient evidence to establish
that a candidate meets the requirements
specified in a unit standard.

 What is Competence?

Define competence, ie, ‘The specification                                    Competence
of the knowledge and skill and the appli-                                    definition
cation of that knowledge and skill across
industries or within an industry, to the
standard of performance required in

Explain that competence does not              Discuss the meaning of the
necessarily mean expertise.                   term ‘Competence and
Explain that competence implies                                              Repeatability
Sample — Lesson Plan                                                                    Page 6

             Trainer Activities                  Trainee Activities           Key Points

                            Practical Uses for Assessment

Lead the trainees through exercise one       Exercise One —
which asks them to list as many possible     Trainees to list as many
uses as they can for competency-based        uses as they can for compe-
assessment.                                  tency-based assessment.

Outline the uses of assessment in the
recruitment process.

Outline the uses of assessment in the RPL/                                 RPL/RCC proc-
RCC process.                                                               esses
Explain the five principles of RPL which                                   Principles of RPL

   •   competence
   •   commitment
   •   access
   •   fairness
   •   support.

Outline the use of assessment to identify                                  Using assessment to
training needs.                                                            identify training

Discuss the benefits that a training needs                                 Performance gaps
assessment provides to employees and
employers, including:

   •   eliminate unnecessary training        Allow the trainees to dis-
   •   defining career paths                 cuss how a training needs
   •   raising employer confidence           assessment could be used in
                                             their own workplaces.
   •   raising employee confidence
   •   identifying gaps in employee
   •   improving employee awareness in
       critical areas
   •   determining the difference between
       current and desired performance.
Training Module for Gypsum Handling Operations                                                   Page 15 of 27

  9 DIESEL COMPRESSOR INSPECTION, START-UP                                   AND     SHUTDOWN

This section provides basic information on the portable
diesel air compressor that will be used in the Gypsum
Handling and Stacking Plant when there is a
requirement to use the air sparges in the reslurry tank.

        The type of compressor you use may be
          different to the one described in this
         module. Ensure that you access and
         read the instructions for the model of
       compressor that you are intending to use.                Compair — 400 Diesel Air Compressor

  9.1 Compressor Set Up
When setting up the compressor, ensure that you observe the following points:
   •     Set the compressor up on a flat, level surface — level the compressor using its jockey wheel.
   •     Ensure that it will not obstruct other equipment and traffic.
   •     Ensure that it is located in a position where it can be refuelled and where the oil and water can be
         easily checked.
   •     Do not locate the compressor where exhaust fumes can collect
   •     Ensure the location of the compressor is such that the air hoses will not cause trip hazards and
         will not be in the path of traffic.
   •     Do not place the compressor in a hollow where rainwater can rise and flood it.

  9.2 Compressor Pre-Start Inspection
Once the compressor is set up, you must carry out a pre-start inspection.

Lift the side panels of the compressor and check the following:
   •     Coolant level in the radiator

                  Check the radiator coolant level when the engine is cold. If the
             engine has been running, ensure that the radiator is de-pressurised before
                                     opening the radiator cap.
Training Module for Gypsum Handling Operations                                                     Page 16 of 27

  •     That the engine oil level is correct — the
        dipstick is located on the left-hand side of the
  •     That the fuel tank is full — the filler is located
        on the left-hand side of the engine and a fuel
        gauge is located in the control panel at the front
        of the compressor.


      Ensure that no dirt is allowed to enter the                        Diesel and Engine Oil Fillers
         fuel tank when refilling with diesel.

  •     Check the compressor oil level in the oil
        reclaimer — the reclaimer is located on the
        right-hand side of the compressor. The sight
        glass levels must be read with the engine
        stopped and they indicate the following:
  •     MAXIMUM is when the upper sight glass
        registers half
  •     MINIMUM is when the lower sight glass
        registers three quarters full.

                                                                         Oil Reclaimer Sight Glasses
          Operate the compressor with the
       reclaimer oil level at but not exceeding
       maximum. Do not allow the oil level to
                fall below minimum.

  •     Ensure that all filler caps and drain plugs are firmly secured
        in place
  •     Check that there no oil or fuel leaks around the engine or
  •     Release any residual air pressure from the compressor’s air
        receiver — ensure the release valve is re-tightened once the
        pressure is released.
  •     Ensure that the ends of all air hoses are properly secured —
        ‘snaking’ or flailing hoses can cause personal injury and
        equipment damage.
Training Module for Mine Operations Induction                                                    Page 6 of 24

Traffic cones are used to create a temporary
barrier to traffic. No vehicle is permitted to
pass through any line of traffic cones of any
colour. If you encounter a line of cones that
is in place for no apparent reason, do not
pass through the line — contact your
supervisor for clarification.

The placement of cones should be in line
with the following considerations:
   •   cones should be placed to make the
       limit of traffic access obvious
   •   spacing between cones should be less
       than the width of a light vehicle
   •   cones should not be used as a means of restricting access to pedestrians — bunting and/or signage
       is better suited for this purpose.

The removal of cones must be in line with the following considerations:
   •   do not remove cones unless you were the person who placed them and you have confirmed that
       the reason for restricting/blocking traffic no longer exists; or
   •   your supervisor has confirmed that the reason for restricting/blocking traffic no longer exists and
       has instructed you to remove the cones.

  1.1 Seat Belts
All persons (drivers and passengers) travelling in either light or heavy vehicles must be seated on a seat
designed for the purpose and must be wearing a functional and correctly adjusted seat belt.

Persons travelling in buses must wear a correctly adjusted seat belt where these are fitted.
Training Module for Mine Operations Induction                                              Page 7 of 24

  1.2 Pedestrians
Pedestrians will be wearing high visibility clothing.
However, all drivers/operators should remain
alert for pedestrians in the mine operations
area and exercise consideration for persons on
foot (see the earlier section on heavy vehicle
operations for details of vehicle visibility
restrictions and procedures for approaching
heavy vehicles).

  1.3 Mine Speed Limits
Unless otherwise sign-posted, the speed limits within the mine
operations area are as follows:

   •   main haul roads — 60 kph
   •   secondary and other light vehicle roads — 40 kph
   •   active mining areas — 20 kph
   •   workshop vicinity — 20 kph

  1.4 Overtaking
Generally you are not permitted overtake vehicles within the mine operations area. However, you may
overtake slow-moving tracked vehicles or working graders under the following circumstances:
   •   you have ample clear vision of the road ahead
   •   there are no intersections in the vicinity of the manoeuvre
   •   you contact the operator of the slow-moving machine by radio and advise him/her of your
       intention to pass.

  1.5 Clearance Between Vehicles
All vehicle drivers and operators must maintain adequate clearance between vehicles. Clearance between
vehicles is dictated by the stopping distance of the following vehicle. You should maintain greater
distance than is needed to stop safely should it be required. The distance between vehicles should be
increased in wet conditions or conditions of poor visibility.
Training Module for Mine Operations Induction                                                     Page 8 of 24

            Maintain a distance of at least 50 metres when following other vehicles —
            particularly loaded haul trucks. Rocks will fall from loaded trucks and you
                                 will need time to respond safely.

  1.6 Right of Way
Unless otherwise specified by traffic signage, the following right of way priority is to be observed in all
areas of the mine:

                           Priority       Vehicle Type
                               1.         Emergency vehicles attending an emergency
                               2.         Haul trucks
                               3.         Water trucks
                               4.         Working dozers or graders
                               5.         Other heavy equipment
                               6.         Light vehicles

  1.7 Adverse Conditions
From time-to-time, adverse conditions for vehicle operations will occur in the mine. These, for example,
can include:
   •   wet and/or muddy conditions
   •   dusty conditions
   •   uneven or rocky road surfaces
   •   steep slopes.
                  Safe Work Procedures

Safe Work Procedures (SWPs) are the simplest way to provide step-by-step
instructions for any frequently repeated task. The staff at Advanced
Technical Publications possess a wealth of experience in the research and
development of SWPs. The SWPs that we develop are deliberately struc-
tured to be used by either experienced operators or inexperienced opera-
tors. This is achieved by providing three columns in the SWP. The three
columns are:

      • Task Step — In this column, we number and detail each step of the
            task in the order in which it should be done. An operator who
            was experienced at the task would only need to read this column
            as a ‘reminder’ of each of the steps that need to be undertaken.

      • Explanation — This column is provided for those operators who
           possess less experience in the task. Where appropriate, an
           explanation of the step is provided so that an inexperienced
           operator immediately understands why or how the step identi-
           fied in the first column is provided. As well as a written explana-
           tion, photographs can also be used in the explanation column to
           ensure that the requirements of the task step are clear.

      • Critical Comment — The comments in this column highlight the
            hazards that may be encountered in this step of the task. This
            helps to ensure that the task will be carried out with due regard
            for the potential hazards so that the job can be completed in
Procedure for Beneficiation Plant Start-up                                                         Page 13

         Task Step                             Explanation                     Critical Comment

Before Start-up:

1. Liaise with maintenance            DCS Tech to liaise with
   personnel regarding plant hand-    Maintenance Supervisor to ensure
   back.                              that all plant items are available

2. Contact ESI and Mining in          DCS Tech to contact ESI (channel
   advance to advise                  42) and Mining
   approximate start up time.         Supervisor (channel 33)

3. Ensure all relevant                DCS Tech to contact all
   personnel are aware of the start   relevant personnel in the
   up and can be                      Beneficiation Plant                    Ensure your two-way radio
   contacted by radio.                                                       batteries are fully charged.

4. Check process water and raw        Field Tech to check actual levels
   water tank levels are above        and report to the DCS Tech who
   setpoint.                          checks them against setpoints
                                      shown on the DCS

5. Check status of the plant air,     Check on the DCS to ensure at
   borefield pumps and raw water      least 2 bore pumps are on auto.
   dam level.

6. Check the drive status for each    Check drive status by                        REMEMBER
   area on the DCS for equipment      accessing the area panel on the
                                                                               It is more efficient to
   availability. Write down all       DCS and then calling up the
                                                                              thoroughly check drive
   faults. Have these actioned by     Drives status for that area (see
                                                                           statuses before attempting a
   the appropriate personnel as       DCS Training Module, Doc No:
                                                                            start than it is to discover a
   soon as possible.                  18462)
                                                                            fault during actual start up.

7. Ensure all other automated         Check the:
   valves are in the AUTO mode
                                       • thickener underflow valves
   on the DCS.
                                       • deslimes cyclones valves
                                       • water addition valves

8. Ensure all the equipment under
   group starts has been put into                                                      NOTE
   the AUTO mode on the DCS.                                                This includes the crusher
                                                                              lubrication systems.
Procedure for Beneficiation Plant Start-up                                                       Page 14

         Task Step                              Explanation                    Critical Comment

9. Inspect conveyors and             Field Tech/s to walk the length of
                                     each conveyor and check:                       IMPORTANT
   report back to the DCS Tech
   on status                         • guards                               Inspect all equipment items in
                                                                                 accordance with the
                                     • belting material                      relevant procedure/s and/or
                                                                                  training module/s:
                                     • safety lanyard
                                     • drift switches
                                     • idlers
                                     • framework
                                     • weightometers

10. Inspect chutes and report back   Field Tech/s to check each chute to
    to the DCS Tech on status        ensure:
                                     • chutes are clear
                                     • chute probes are OK
                                     • hatches are securely closed

11. Inspect pumps and report back    Field Tech/s to check each pump
    to the DCS Tech on status        for the following:
                                     • scuttles closed
                                     • gland water valves open
                                     • inlet and discharge valves
                                       correctly set
                                     • guards in place

12. Inspect valves and report back   Field Tech/s to check all valves:
    to the DCS Tech on status        • are set to correct positions
                                     • have air turned on to all auto

13. Inspect screens and report       Field Tech/s to check all screens to
    back to the DCS Tech on          ensure they:
    status                           • are clean
                                     • have all guards in place
                                     • are ready to run
                                           Control Plans

We structure control plans to assist those people whose job is to control or
monitor a given process or plant. The introduction and use of control plans
provides a set of approved actions for operators to take when the process or
plant they are monitoring goes outside of specification.

In each control plan we identify the potential changes in the process and then
provide a step-by-step guide for the operator to adjust operational settings to
bring the system back into specification. This type of documentation is very
useful where a plant or process is computer-controlled from a central loca-
tion (control room). The control plan format can also be developed for
individual items of equipment.

By developing and using control plans for your plant, you remove the possibil-
ity of operators setting plant parameters based on subjective analysis. This
leads to uniformity of plant operation across shifts and, in turn, greater plant
efficiency and safety.
Control Plan for the Thickener and Slurry Storage Tanks                                            Page 9 of 16

  3.1           CONTROL PLAN           FOR THE      PRODUCT THICKENER

                            UNDERFLOW PERCENTAGE SOLIDS
 Too High (Above 68%)                                     Too Low (Below 63%)
 Indicators:                                              Indicators:

 • DCS Thickener Panel (Density)                          • DCS Thickener Panel (Density)

 • Marcy scale readings                                   • Marcy scale readings

 • Laboratory analysis                                    • Laboratory analysis

                      NOTE                                                     NOTE
 Laboratory analysis results will be up to 16 hours       Laboratory analysis results will be up to 16 hours
 behind actual plant processes.                           behind actual plant processes.

 Operator Actions:                                        Operator Actions:

 1. Check if the recirculation circuit is in operation    Density will take up to two hours to reach
    — shut down the recirculation circuit                 specification following start up. A significant
                                                          increase should be noticed after 30 minutes’
 2. Check the deslimes underflow valves — these           operation.
    may be set to deliver deslimes underflow to the
    thickener — manually switch valves as                 1. Check the thickener DCS panel and trend
    appropriate.                                             screens to determine if density is trending
                                                             towards specification — if density is trending
 3. Check that the underflow pump is set to                  towards specification, monitor the DCS until
    AUTO.                                                    specification is reached
 4. Check the underflow with the Marcy scale —            2. Check that all flushing water is turned off
    the in-line density gauge may require
    calibration.                                          3. Check that the underflow pump is set to AUTO
                                                             — speed may be too high and require
 5. Increase the speed of the underflow pump.                adjustment of setpoints .
 6. Ore type settling too quickly — consider              4. Check the underflow with the Marcy scale —
    reducing tonnage in up-stream processes.                 the in-line density gauge may require calibration.

                                                          5. Check the ball mill feed weightometer — the
                                                             weightometer may be reading
                                                             incorrectly due to material build-up on the
                                                             weighframe — clean as necessary.
                                                             Check tonnage in up-stream circuits — consider
                                                             increasing tonnage in up-stream processes.
Control Plan for the Thickener and Slurry Storage Tanks                                       Page 10 of 16

                                       OVERFLOW CLARITY
 N/A                                                      Excessive Solids
                                                          • Overflow excessively dirty.
                                                          Operator Actions:
                                                          1. Check the underflow density.
                                                          2. Check the bed pressure.
                                                          3. Check the torque readings.
                                                          4. Check up-stream processes:
                                                             • thickener load may be increasing —
                                                               consider increasing the underflow flow-rate
                                                             • mill grind may be too fine (see control plan
                                                               for milling, Doc No: 25797)
                                                             • ore type may be creating excessive slimes
                                                             • drum scrubber and deslimes circuit may not
                                                               be removing sufficient slimes (see control
                                                               plan for drum scrubber and deslimes, Doc
                                                               No: 25798).

                                            RAKE TORQUE
 Too High
 Indicators:                                              General Points:
 • DCS thickener panel torque readings                                        WARNING
 • DCS thickener panel current draw readings                  An inadequate underflow flow-rate will
 • Trips on torque or current                               cause a build-up of solids in the thickener
                                                             which will result in a greater load on the
 Operator Actions:                                                  rakes and higher torque.

   Do not re-start the thickener rakes after a                              IMPORTANT
   torque trip without first checking that it is             If you want to reduce rakes torque, bed
     safe to do so. Serious damage to the                   pressure or bed levels, it is more effective
   rakes and torque tube can be caused by                     to make a large increase in underflow
        operating at excessive torques.                       flow-rates for a short time than it is to
                                                             make several small changes over a long
                      CAUTION                                                   time.
    Incorrect use of the recirculate facility
     can cause the rakes to be ‘buried’ by
  returned material which in turn will cause
           high torque conditions.

 1. Check that the thickener has not been
    switched to recirculate — if set to recirculate,
    switch to normal operation.
Competency Assessment for Mine Operations Induction

 Trainee’s Name:                               Area & Position:

 Assessment Date:           /    /             Venue:

 Time Allowed for Assessment:          •       15 Minutes
 Assessment Materials Permitted:       •       Mine Induction Handout Notes

 Answer the following questions (100% accuracy required):                               Correct Incorrect

 1. Name the three requirements for unaccompanied access to the mine operations area.

 2. If you have been absent from the mine for _________ days you must be
     refamiliarised with the mine operations area.

 3. What are the following contact details:
 a) The Emergency Response radio channel:_______________________
 b) The Emergency Response extension No:_______________________
 c) The Mine Operations radio channel:___________________________

 4. If you need to broadcast a call for emergency assistance over the two-way
 radio, you should begin the call with which words?

 5. List the minimum PPE requirements for entry to the mine operations area

 6. A mandatory sign displays an instruction that you _________________

 7. A prohibitory sign displays an activity or action that is _____________

 8. A danger sign indicates a hazard that is likely to be _______________

 9. An area barricaded with red and white barrier tape may be which?
 a) Not entered                         ____
 b) Entered by authorised personnel     ____
Competency Assessment for Mine Operations Induction

      Questions (continued)                                                                    Correct Incorrect

 10. In addition to meeting the Major Hazard Standards, what other requirements must
     light vehicles meet to enter the mine:

 11. A light vehicle must not be parked within ____ metres of working heavy vehicles.

 12. When a light vehicle is travelling in the mine operations area, what lights must be on?

 13. Who must you notify when entering a haul road in a light vehicle?

 14. The horn signals for heavy vehicles are:
 a)    Start up:              _____ blasts
 b)    Moving off forwards:   _____ blasts
 c)    Moving off in reverse: _____ blasts

 15. Who must you contact if you need to approach an operating heavy vehicle?
 Answer: __________________________________________________

 16. All passengers in all vehicles must be seated in a seat designed for the purpose and
 must be wearing a_______________________________ .

 17. The speed limits in the mine operations are:
 a)    Main haul roads:                         _____ kph
 b)    Secondary and other light vehicle roads: _____ kph
 c)    Active mining areas:                     _____ kph
 d)    Workshop area:                           _____ kph

 18. You may overtake slow-moving tracked vehicles or graders under what conditions?
 a) ________________________________________________________
 b) ________________________________________________________
 c) ________________________________________________________

19. What is the minimum distance that must be maintained between vehicles?
    Answer:     ____ metres

All of the training programs that we develop use graphics and cartoons to
illustrate the text. The addition of illustrations and cartoons ensures that
complex information is easier to understand and easily remembered. It
also helps to overcome the reluctance that some people have when they
are asked to read technical literature. By breaking up the page with mean-
ingful illustrations, we can present technical information in a way that invites
the audience to read and study the subject at hand.

All of our illustrations are designed specifically for each document. As well
as reflecting the content of the manual, they also reflect the culture of the
organisation. This is important because it reinforces organisation regula-
tions and procedures as well as helping to identify the document as being

Technical diagrams can be either two or three dimensional and can be
rendered in either black & white or colour depending on the requirements
of the situation. All illustrations and cartoons are as informative as possible
and each helps to give the document a professional appearance.

When there is a concern within the training system that large amounts of
written text are clouding the main issues, the best way to overcome the
problem is to use the high quality illustrations and cartoons — that is
exactly the approach that we take at Advanced Technical Publications.

The following pages provide a small sample of the graphic illustrations and
cartoons that we use in the development of our documents.
Technical Illustrations 2D
Technical Illustrations 3D

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