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
Ph: (07) 5472 8285
Fax: (07) 5472 8286
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
• 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
• 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
TOPIC ONE MAINMAIN 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
The Principles of Assessment
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
Outline the uses of assessment in the RPL/ RPL/RCC proc-
RCC process. esses
Explain the five principles of RPL which Principles of RPL
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
• 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
• 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
• 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
• 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
• 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
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
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
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
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,
• 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
• 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
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.
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
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
• safety lanyard
• drift switches
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
• 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
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%)
• DCS Thickener Panel (Density) • DCS Thickener Panel (Density)
• Marcy scale readings • Marcy scale readings
• Laboratory analysis • Laboratory analysis
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
N/A Excessive Solids
• Overflow excessively dirty.
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
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
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?
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?
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