SYLLABUS

FOR THE TRADE OF

OPERATOR ( STEEL PLANT )

UNDER

APPRENTICESHIP TRAINING SCHEME

DESIGNED IN 2007

GOVERNMENT OF INIDA MINISTRY OF LABOUR & EMPLOYMENT DIRECTORATE GENERAL OF EMPLOYMENT & TRAINING

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE

EN BLOCK, SECTOR V, SALT LAKE CITY KOLKATA 700 091

List of members attended the Trade Committee Meeting for designing the syllabus for the Trade of Operator( Steel Plant) under ATS on 12. 04.2007
Sl.No.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Name
Shri Ashok Kumar Shri G.B.Pradhan Shri Pradip Sett Shri Gautam Ghosh Shri K.N.Choubey Shri M.K.Verma Shri Harcharan Singh Shri A.K.Kundu Shri A.K.Pal Shri S.R.Mazumder Shri A.K.Mukherjee Shri G.Bhowmik Dr. Samiran Mondal Shri P.K.Roy Shri M.Sridhar Shri M.M.Gera Shri T.Mukhopadhyay Shri R.R.Mannewar Shri A.K.Mitra Shri Sanjay Kumar Shri V.Babu Shri A.Chakraborty Shri P.K.Roy Shri R.N.Manna Shri A.K.Karmi

Designation/Representing Org.
Dy. Director General, D.G.E & T, New Delhi Dy. General Manager, Bokaro Steel Plant Senior Manager(HRD), Durgapur Steel Plant Tata Sponge Iron Ltd. Kolkata Group Head, SNTI,Tata Steel Manager, SNTI,Tata Steel Chairman Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member

Dy. General Manager, Usha Martin Ltd Dy. General Manager, MECON Ltd. General Manager(P&A), WBSEDCL Ex- Director, C.S.T.A.R.I. Ex. Senior Manager, IISCO, Burnpur Ex- Director, C.S.T.A.R.I. Professor (Mech.Engg.), NITTTR(ER) Sr.Environment Officer, Deptt. Of Environment Director, ATI, Kolkata Dy. Director of Trg., CSTARI, Kolkata Dy. Director of Trg., CSTARI, Kolkata Dy. Director of Trg., CSTARI, Kolkata Ex- Director, ATI,Kolkata Dy. Director of Trg., RDAT, Kolkata Astt. Director of Trg., CSTARI,Kolkata Astt. Director of Trg., CSTARI,Kolkata Astt. Director of Trg., ATI,Kolkata Training Officer, CSTARI,Kolkata Training Officer, RDAT, Kolkata

GENERAL INFORMATION 1. 2. Name of Trade N.C.O. Code No. : Operator (Steel Plant) : 8121.15, 8121.55, 8121.60 8122.50,8122.52, 8159.10 8159.12, 8161.45

3. 4.

Duration of Apprenticeship Training : Two Years Entry Qualification : Pass 10th class Examination under 10+2 system of education with physics, chemistry & mathematics or its equivalent. : 1: 7

5. Ratio of Apprentices to workers

SYLLABUS FOR THE TRADE OF OPERATOR (STEEL PLANT) UNDER APPRENTICESHIP TRAINING SCHEME PERIOD OF TRAINING: TWO YEARS NOTE: The period of training for the trade is two years and this consists of a Basic Training of one year and the remaining one year is for shop floor training. During the basic training, the trainee is exposed to fundamental of workshop practice in various shops/trade in order to prepare him for the trade in which he will be trained as an apprentice. Out line of Training Programme: A. Basic Training in Training Institute: 52 weeks ( One Year) i. Basic Fitting Skill & Mech Assembly ii. Refractory iii. Fuel and Combustion control iv. Process Measurement and control v. Basic Electrical & Electronics vi. Hydraulics & Pneumatics vii. Pump and Valve Operation viii. Safety, quality & improvement techniques x. Computer x. Industrial Piping System xi. Emission and Pollution Control 8 weeks 6 weeks 3 weeks 10 weeks 6 weeks 5 weeks 4 weeks 2 weeks 3 weeks

- 3 weeks - 2 weeks

B. Shop Floor Training : 52 weeks

A. BASIC TRAINING (Duration one year) A i. Basic Fitting Skill & Mech.Assembly a) (8 weeks) a) b) Theory Units of measurement in SI Construction, use, function and type of marking, measuring, testing and cutting tools such as vices, hammers, hacksaw, chisels, files, drill, tap, die, Steel rule, callipers, punches, reamer, scarpers etc Types, uses and working principle of precision instruments like micrometers, vernier callipers, depth gauge, dial indicators etc.. Introduction to various power transmission systems. Different types of bearings and their use. Various types of gears, their use. Introduction to lubrication system. Safety precautions to observed while working on bench.

b) c) d) e) f) g) h) i)

j) k) l) A ii.

Practical Use of simple measuring and marking instruments. Use of steel rule, callipers, micrometers in measuring lengths. Marking of lines and curves. Flat chipping practice on mild steel. Hacksawing practice. Sharpening of chisel. Filing of flat surface up to an accuracy of 0.2mm. Marking out positions of holes, drilling and counter sinking. Internal and external threading. Dismantling and assembly of mechanical components using mechanical and hydraulic puller and press. Dismantle gear boxes, fans, blowers and identify various parts. Do levelling, alignment and balancing. Use of Lubrication equipments. Refractory (6 weeks)

c)

d) e) f) g) h)

Practical a) Simple testing of refractory bricks like hardness, specific gravity and porosity. b) Cutting bricks to different shape and size. c) Mortars preparation methods, proportion of different ingredient of mortar. d) Laying bricks for straight wall, arches etc. by using common masonry tools and by using different joining methods e) Levelling jointing and plastering operation. f) Making of expansion joints in brick wall. g) Stamping material application along with expansion joints h) Application of castable i) Pitching, gunning, fettling etc and other temporary repairs of refractory work. j) Drying & heating of refractory after application k) Practice of simple drawing related to refractory work.

a)

b) c) d) e) f) g)

h) i) j) k)

Theory Introduction to refractories. Acid, basic, neutral and special refractories (stamping, LC castable, normal castable) Importance of refractories in Iron & Steel industry Different shape, size and quality of refractory bricks. Introduction to common masonry tools. Stamping material application along with expansion joints Knowledge of castable Use of refractories in coke-oven battery, L D Vessel, re-heating furnaces, blast furnace cast house Furnace operation for longer life of refractory lining. Reading simple drawing related to mason work. Cost of refractories & prevention of wastage. Safety precautions related to job.

A iii. Fuel and Combustion control (3 weeks) Practical a) Study of various types of fuels (Coal, Oil, Gases) b) Sample study of pit, lignite, bituminus coal and anthrasite c) Proximate & ultimate analysis of fuel d) Determination of flash and fire point of fuels, viscosity of furnace oils. e) Determination of composition and calorific values of fuels (oils, natural gas, BF gas, Coke Ovens gas etc.) f) Study of various zones of burner and control of flame length and flame temperature of a burner. Self sustaining flames, supported flames, flame sensors. g) Air & fuel ratio for complete combustion and analysis of the flue gas for un-burnt combustion and applying corrective measures. Theory Type of furnaces Introduction to fuel and combustion. Coal and types of coal. Natural and prepared fuel, non renewable (fossil fuels) and renewable fuel. e) Flash and fire point of fuel, viscosity of furnace of oils. f) Types of gaseous fuel available in a Steel plant & their uses. g) Composition and calorific values of fuel oils, natural gas, BF gas, Coke Ovens gas etc. h) Various conditions necessary to obtain maximum heat from the fuel burned concept of air to fuel ratio i) Various zones of burner and control of flame length and flame temperature of a burner. Pilot burners. j) Self sustaining flames, supported flames, flame sensors. k) Methods of analysing the fuel gas for unburnt combustion and corrective measures l) Safety precautions to be observed

a) b) c) d)

A iv.

Process Measurement and control ( 10 weeks) Theory a) Units of measurements for various parameters like pressure, temperature, level and flow. b) Mechanical and electrical means of measuring temperature. c) Construction & types of pressure gauges, vacuum gauges, level gauges, flow gauges and rota meters d) Introduction & application of recorder, manometers and radiation pyrometers & thermocouple. e) Introduction to conductivity meter, pH meter, hardness meter and f) Type of gas analyzer NDIR,UV, Chemilumiscent g) Concept of calibration of instruments. h) Introduction to process control &

Practical a) Measurement of pressure, temperature, level and flow. b) Use of recorder and manometers. c) Application of radiation pyrometers. d) Use of pressure gauges and vacuum gauges. Level gauges, flow gauges and rota meters. e) Use of Conductivity meter, pH meter, hardness meter and f) Use of gas analyzer. g) Calibration practice of instruments. h) Practice on setting & tuning of different controller- ON/OFF, P,I,PI,PD and PID controllers (electronic/pneumatic types) i) Study of Transducers, Sensors, Recorders) j) Practice on controlling of pressure, temperature, level & flow using demonstration kits. 5

k) Practice on simple programming of PLC. l) Interfacing of PLC with system. m) Upkeep of PLC.

instrumentation. Principle of controlling different process control parameters i) Types of Sensor, Transducers, controllerON/OFF, P, I, PI, PD and PID. j) Introduction to PLC and its architecture. Programming concept of PLC, Uses of PLC in automation of industrial process k) Safety precaution to be observed

A v.

Basic Electrical & Electronics (6 weeks) Practical Practical application of safety in electrical shop Measurement current, voltage, resistance, Power, Power factor; Testing of capacitors, frequency Making simple AC, DC circuits- Series, parallel and mixed circuits. Electric wiring practice. Earthing. Application of various types of switches, fuses, lamps, proximity switches, contactor, relays, lamps and MCB in electrical circuits. Use of test lamps, multi-meters, etc. Insulation testing Installation, running care & maintenance of electric meters. Testing and identification of leads of diodes, bipolar transistors, Practice on Soldering Study of gates, logic circuits Demonstration on various weighing system Theory Safety precautions to be observed while working on electrical shop Current, voltage, resistance, inductance, capacitance & Ohms Law. Work, power and energy; their units, measurements. Construction , types & use of switches, fuses, lamps, proximity switches, capacitors, relays, and MCB Function of test lamps, multi-meters, ammeter, volt meter, megger, watt meter, energy meter. Simple AC, DC circuits. Series, parallel and mixed circuits. Earthing & its purpose. Introduction to Electrical motors and starters. Speed control Function to multi-meters. Semiconductor diodes, constructions and lead identification DC power supply, rectifier, voltage regulator using ICs. SMPS,INVERTER,UPS, Bipolar transistors, construction, parameters, uses, testing and identification of leads. Solder, flux, soldering techniques Digital electronic- basic idea, gates, logic circuits Concept of various electronic weighing systems.

a) b)

a) b)

c)

c)

d)

d)

e) f) g) h) i) j) k)

e) f) g) h) i)

j)

k) l) m)

A vi.

Hydraulics & Pneumatics (5weeks) Theory a) Basic principles of Hydraulic Power Transmission. b) Introduction to various types of Pumps, valves, actuators, hydraulic fluid and fluid filtration. c) Different types of pneumatic control valves, actuators, FRL unit. d) Symbols of hydraulic & pneumatic components. e) Simple hydraulic and pneumatic circuits. f) Safety precautions to be observed while working with hydraulic and pneumatic equipments. g) Study of simple Electro-hydraulic and electro-pneumatic circuit. h) Maintenance & trouble shooting of hydraulic and pneumatic system

Practical a) Familiarisation of various type of hydraulic elements such as: valves, actuators and fluid filters, b) Study of various types of pumps used in hydraulic system c) Familiarisation of various type of pneumatic elements such as: control valves, actuators, filter, pressure regulator and lubricator, their symbol . d) Making & study of simple hydraulic and pneumatic circuits. e) Study of simple Electro-hydraulic and electro-pneumatic circuit. f) Maintenance & trouble shooting of hydraulic and pneumatic system

A vii.

Pump and Valve Operation (4 weeks) Theory a) Constructional detail of pumps, types, working mechanism b) Different parts of pump and their function. c) Priming of pump, air locking d) Series & parallel operation of pump e) Preventive & schedule maintenance of pumps, Trouble shooting in pump operation, Gland packing changing procedure f) Constructional detail of different type of valve & their uses like: Gate, Globe, butterfly, Diaphragm g) Symbols of valves h) Concept of Cavitations, & aeration.

Practical a) Identification of various types of pumps, their parts and their functions b) Dismantling, cleaning of parts and assembly of parts for different types of pumps c) Priming of pump, fitting gland packing. d) Starting and stopping of pumps. e) Preventive & schedule maintenance of pumps, Trouble shooting in pump operation. f) Use of different type of valve like: Gate, Globe, butterfly, Diaphragm g) Assembly and disassembly of valves h) Demonstration on cavitations & aeration

A viii.

Safety, quality & improvement techniques ( 2 weeks) Theory Various hazard involve in different section steel plant OSHAS, Safety standard & slogan Safety symbols & chart Various protective devices used in steel plant Gas safety Fire fighting Quality management system TPM and TOC. Bench Marking, Suggestion management. Problem solving technique, control chart & their uses Attitude development Communication and presentation skill

a) b) c) d)

Practical Use of protective devices Use of gas safety devices Use of fire fighting equipment Use of problem solving techniques, control chart

a) b) c) d) e) f) g) h) i) j) k) l)

A. ix. Computer Practical a) Familiarisation with computer b) Application of MS Office c) Practice on networking and internet & email Theory a) Basics of computer hardware and software. b) MS Office. c) Concepts of computer networking and Internet and email.

A. X. Industrial Piping System (3 weeks) Practical a) Identification of different type of pipe b) Application of different colour codes, pipe symbols and circuits. c) Pipe threading. d) Mark, cut and prepare different pipe joints. e) Develop, mark, cut and prepare pipe bending. f) Use of tubes, hoses, different fittings and assembly, quick connecting couplings g) Practice coal injection lance assembly (including NRV) and its changing online Theory a) Types of pipe b) Concept of different colour codes, symbols and circuits. c) Tubes, hoses, different fittings and assembly, Quick couplings d) Repair techniques of pipe joints e) Safety precautions to be observed while working at pipeline carrying different materials.

A xi. Emission, Pollution Control and immission monitoring: (2 week) Practical a) Use of emission and pollution control devices. b) Study on dust handling & disposal system c) Study on effluent treatment plants d) Study of immission monitoring Theory Awareness of environment pollution and health effect. Basic knowledge of air pollution control equipment. Major emission and pollution source and their effect on global environment. Control of NO2 and SO2 and SPM to permissible level. NOX & SOX with respect to coke plant & BF stoves Dust handling and disposal system. Effluent treatment plants Control of water pollution Standard of ambient air quality, work environment, effluent discharge.

a) b) c) d) e) f) g) h) i)

B. SHOP FLOOR TRAINING (ONE Year) Note: The trainees will undergo shop floor training in the second year only after completion of Basic training in first year. B.i. Process Technology (Iron & Steel making) a) Coke Making: Operation of Oven M/c, charging, pushing, isolation, heating, Operation of Gas handling plant (BPP) & Gas Exhauster booster, Coke property testing & Quality, Coke handling b) Sinter Making: Sintering, Sinter quality control, c) Iron Making: Cast house operation:- Basics of Cast house, Tap hole face maint., clay preparation, clay leakage control, trough & runners repair maintenance, mud gun and drill machine operation and maintenance, trough discharge, handling of hot-metal & slag under normal & viscous conditions. Furnace operation:blowing, burdening, backdrafting, stopping and starting. Stoves: manual heating & auto operation. Operation of stock house, coal injection, tar injection. d) Steel Making: Study & practice on primary & secondary steel making (including tapping control, deviation & chemical control), continuous casting, Billet caster Slab caster. e) Rolling technology.: Operation of hot rolling Operation of cold rolling, Processing lines (Annealing, skin passing, pickling, Galvanising, tinning) Re-Heating Furnaces: Charging & discharging of Furnace Judging & noting the temperature of material inside the furnace Controlling the air and fuel ratio to maintain temperature inside the furnace Control of furnace atmosphere Cleaning of burners Water Treatment & cooling water systems: a) Operation of water treatment plant b) Operation of waste disposal plant c) Testing of water quality like pH value etc Power Plant Operation: In-plant Observation on a) Operation of boiler and its accessories b) Operation of Turbine & its control c) Fuel and ash handling system Rigging & crane operation Use of rigging tools and tackles. Making knots and hitches, reaving pulley block and scaffolding. Use of crane signals. Loading, unloading and shifting common and uncommon shaped materials. Basic operation of EOT crane. 10

a) b) c) d) e)

a) b) c) d) e)

Trade Theory for Second year Process Technology: Orientation on Steel manufacturing process a) Coke Making: Construction, type and use of crusher, feeder, screening Detail of Oven M/c, charging, pushing, isolation, heating techniques, Details of gas handling plant, Coke ovens biproduct plant & gas Exhauster booster, Safety involved in handling Explosive & Poisonous Gas , Gas Holder b) Coke property testing & Quality, Coke handling c) Sinter Making: Raw Material for Sinter, Sinter Making Theory, Detail of base mix preparation, Sinter quality control, effect of bad sinter on Blast furnace d) Iron Making: Basics of Cast house, Tap hole face maint., clay leakage control, trough & runners repair maintenance, mud gun and drill machine operation and maintenance, trough discharge, knowledge of furnace operation: blowing, burdening, backdrafting, stopping and starting procedure. Construction of stoves, heating operation. Stock house, cooling system, coal injection, tar injection. Safety in Cast house. e) Steel Making: Primary & secondary steel making (including tapping control, deviation & chemical control ), continuous casting, Safety in Steel making f) Rolling technology: Hot & cold rolling theory & process, Continuous & tandem mill, rolling defect etc. Processing line: pickling, galvanising, annealing, tinning etc. g) Elementary knowledge of heat treatment processes Reheating furnace: Furnace types and their classification, like, re-heating furnaces, walking beam furnace, refining furnace. Furnace atmosphere and its control, Function of recuperator, regenerator. Drafts: forced and induced draft. Burners: Types and applications. Safety precaution and hazards Water treatment & cooling water system Source of water, water impurities. Cause of water pollution and environmental norms. Problem related to impurities of water. pH value of water, Soft water, DM water, Identification of cat-ion and an-ion resins. Scale formation, corrosion, priming and foaming of boiler. water treatment for condenser. Power plant operation Types of boiler and its application. Principle of heat transfer and heat transfer zones. Sensible heat, latent heat and super heat, application of steam table. Boiler mounting and accessories. Fuel and ash handling. Safety precautions Rigging and crane operation: Introduction to various tools and tackles used in rigging, their safe load capacity. Different types of knots and hitches and their use, reaving pulley block, Safety while moving materials from one place to another and operating crane.

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Workshop calculation & Science (for 2 year) Physics: Different states of matter Newtons law of motion Equation of Motion Density & Specific gravity Archimedes Principle Pressure & Its measurement Heat & temperature measurement a) Methods of heat transfer b) Thermal expansion of matter Electricity & its uses Methods of Heat transfer Units & measurement Work, Power & Energy Composition & Resolution of Force Properties of Liquid Gas Laws Friction Magnetism

Chemistry: Mathematics: -

Chemical Formulae & Symbols Matter & Its Properties Periodic Classification of Elements Acid, Base & Salts Atoms, Molecules & Its weights Laws of Chemical combination / Conservation of mass Coal & its compounds Gay Lucass Law of Gaseous volume Properties of metal, heat treatment Mensuration (Calculation of Area, volume & weight of simple & hollow solids Ratio, proportion & Percentage Simple Algebra Trigonometry (Use of trig. Tables, applied problems, trig. Function & sine bar principle) Plotting of Graphs for given data, reading of graphs. Trade calculation such as capacity & volume of the furnace, weight & volume of stock. Binary number, logic gates Estimation & costing

Engineering Drawing: a) Introduction to engineering drawing. b) Geometrical Drawing, Orthographic projection (first angle and third angle), dimensioning, Introduction to geometrical tolerance, Sectional drawing, Isometric projection, Structural Drawing,. c) Blue print reading. SOCIAL STUDIES The syllabus has already been approved is the same for all trades.

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