OPERATOR COAL HANDLING EQUIPMENTS. Under Apprenticeship Training Scheme (ATS)

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SYLLABUS For the trade of OPERATOR COAL HANDLING EQUIPMENTS Under Apprenticeship Training Scheme (ATS) GOVERNMENT OF INDIA MINISTRY OF LABOUR &

1 SYLLABUS For the trade of OPERATOR COAL HANDLING EQUIPMENTS Under Apprenticeship Training Scheme (ATS) GOVERNMENT OF INDIA MINISTRY OF LABOUR & EMPLOYMENT DIRECTORATE GENERAL OF EMPLOYMENT & TRAINING CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN 81, SECTOR V, SALT LAKE CITY KOLKATA

2 List of members attended the Trade Committee meeting for designing of syllabus for the trade of Operator Coal Handling Equipment under Apprenticeship Training Scheme (ATS) at Central Staff Training & Research Institute (CSTARI), Kolkata on 18 th December, Sl. No. NAME & DESIGNATION S/Shri ORGANISATION REMARKS 1. Sanjay Kant, Joint Director RDAT, Kolkata Chairman 2. K.L.Kuli, CSTARI, Kolkata Member 3. O.P.Gupta, DGM (HRD), SAIL Bokaro Steel Plant, Bokaro Member 4. S.Nair, AGM (HRD), SAIL Bhilai Steel Plant, Bhilai Member 5. N.N.Tiwari, Programme Director (O&P) Tata Steel Ltd., Jamshedpur Member 6. P.Debnath, Manager Personnel, SAIL Durgapur Steel Plant, Durgapur Member 7. K. Srinivasa Rao, AGM (Training) Visakhapatnam Steel Plant, Member Visakhapatnam 8. Pradip Sett, AGM (HRD), SAIL Durgapur Steel Plant, Durgapur Member 9. R. Choudhury, DGM (Roll Shop), SAIL Durgapur Steel Plant, Durgapur Member 10. Amitava Roy, Sr. Lecturer (Elect. Engg.) AJC Bose Polytechnic, 24 Paraganas Member (North) 11. A.N.Mishra, AGM (SMS), SAIL Durgapur Steel Plant, Durgapur Member 12. Major K.Satyanarayana Tata Steel Ltd., Jamshedpur Member 13. Prof. P.Sadhu Khan, Deptt. Of Metallurgy Bengal Engineering & Science University, Shibpur Member 14. I. Mukherjee, AGM (RMHP), SAIL Durgapur Steel Plant, Durgapur Member 15. Bhaskar Prasad, AGM (COCC), SAIL Durgapur Steel Plant, Durgapur Member 16. M.Pramanik, AGM (CHP OP), SAIL Durgapur Steel Plant, Durgapur Member 17. Dr. D.Basu Directorate Of Industrial Training, West Member Bengal 18. Sameer Jain, AGM (O), Sinter Plant, SAIL Durgapur Steel Plant, Durgapur Member 19. L.K. Mukherjee, Dy. Director of Trg. CSTARI, Kolkata Member 20. K.N.Halder, Dy. Director of Trg. CSTARI, Kolkata Member 21. N. Nath, Asst. Director Trg. CSTARI, Kolkata Member 22. A.K.Bhattacharya, Training Officer RDAT (ER), Kolkata Member 23. Mr. Muktanand, Training Officer RDAT (ER), Kolkata Member

3 GENERAL INFORMATION 1. Name of trade : Operator Coal Handling Equipments 2. NCO Code : Duration of apprenticeship training : 02 Years 4. Entry Qualification : Passed 8 th class examination from a recognized school or its equivalent. 5. Ratio of apprentices to Worker : 1 : 5

4 SYLLABUS FOR THE TRADE OF Operator Coal Handling Equipment UNDER APPRENTICESHIP TRAINING SCHEME PERIOD OF TRAINING: TWO YEARS Training Syllabus 1. Induction and Safety Training : 4 weeks 2. Introduction to Coal Handling : 1 week 3. Unloading of Coal Wagons by Tippler Operation : 21 weeks 4. Stacking and averaging of Coal by Stacker Operation : 15 weeks 5. Retrieving of stacked coal by Reclaimer Operation : 17 weeks 6. Crushing of Coal by Selective Crushing Unit Operation : 25 weeks 7. Operation of Conveyors : 12 weeks 8. Fire fighting network & pump operation : 5 weeks 9. Tests and Evaluations : 4 weeks Total : 104 weeks

5 Syllabus 1. Induction & Safety Training 4 weeks Company Profile, Significance of Steel Business Plant familiarization, Layout, Product Mix, Objectives. Safety, Health & Environment Awareness Basic skill development training on Use of Tools, Basic Measuring Instruments, Coupling & Alignment, Welding, Gas Cutting. 2. Introduction to Coal Handling 1 week a. Coke making process, Cost & sensitivity analysis, Pollution control equipments & norms b. Familiarization with different equipment of Coal Handling Plant(CHP) c. General safety d. Function of different equipment in CHP e. Study of material flow diagram of CHP f. Safety in material handling g. Financial impact of coal on steel making, Concept of Demurrage h. Concept of Blending and Averaging i. Monsoon Preparations a. Preparation of major equipment list b. Dos and don ts c. Utility & potential of major equipments d. Material flow diagram for CHP e. Safety precaution during handling of coal & use of PPEs. f. Cost of different types of coal & wastage control. 3. Unloading of Coal Wagons by Tippler 21 weeks a. Operation of Wagon Tippler ii) Types of Wagon Tipplers iii) Safety to man & machines iv) Importance of load setting b. Operation of Wagon Chargers ii) Types of Wagon Chargers iii) Safety to man & machines iv) Importance of smooth running of wagon Chargers c. Introduction to Drives of Tipplers, Side Arm Charger, Beetle Chargers & Feed Belts d. Introduction to function of different limit switches & other safety devices e. Log Book entry a) Familiarization with different parts of Wagon tippler, dos and don ts, Pre start checks, shift take over, feed belt / conveyor operation, chute cleaning, post job checks, housekeeping, adherence to Standard Operating Procedures (SOPs) b) Familiarization with different parts of Wagon Chargers, dos and don ts, Prestart checks, shift take over, operation of wagon charger & feed belts, post job checks, housekeeping. c) Stopping & starting of drives, check points, Emergency stoppage, and power failure. d) Identification & utility of limit switches of Tipplers, Side Arm Chargers, Beetles, Chute Jam Sensors, pull chords.

6 4. Stacking and averaging of Coal by Stacker Operation : 15 weeks Operation of Stackers i)technical data ii) Quality Parameters iii) Types of Stackers iv) Safety to man & machines while operating Stackers v) Importance of averaging vi) Factor affecting averaging vii) Functions of different limit and safety switches. viii) Introduction to Material Conveying system. ix) Log book entry i) Familiarization with different parts of Stackers, dos and don ts, Pre start checks, shift take over. ii) Post job checks, Control Desk Operation, chute cleaning, housekeeping, adhere to SOP iii) Stopping & starting of drives, check points, Emergency stoppage, and power failure. iv) Stacker operation in monsoon. v) Identification & utility of limit and safety switches of stackers and conveyors, inspection of trolley wire, Power Collectors, reeling drums & belt joints. 5. Retrieving of stacked coal by Reclaimer : 17 weeks Operation of Reclaimer i) Familiarization with different parts of Reclaimers, dos and don ts, Pre start ii) Types of Reclaimers checks, shift take over. iii) Safety to man & machines during ii) Post job checks, Control Desk equipment operation. Operation, housekeeping, adhere to SOP iv) Importance of proper loading of iii) Stopping & starting of drives, check conveyor & spillage control. points, Emergency stoppage, and power v) Importance of adherence to SOP failure and spillage control vi) Functions of different limit iv) Reclaimer operation in monsoon. switches, safety switches & drives v) Identification & utility of limit and vii) Introduction to Material safety switches of Reclaimer and Conveying system. conveyors, inspection of trolley wire, viii) Log book entry Power Collectors, reeling drums & belt joints. 6. Crushing of Coal by Selective Crushing Unit Operation : 25 weeks a. Operation of Hammer Crusher a) Familiarization with different parts of Hammer Crusher, dos and don ts, Prestart checks, shift take over, feed ii) Types of Crushers iii) Types of Hammers conveyor operation, chute cleaning, post iv) Safety to man & machines while job checks, housekeeping, adherence to operating Crushers. SOP, adjustment of Grate Bar assembly & v) Milling indices & desired Crushing Breaker plate of crusher

7 b. Importance of Blending of coal & Operation of Pneumatic Classifiers ii) Parts of Pneumatic Classifiers iii) Quality of input coal and its blending iv) Quality of blended coal v)parameters of Classifier iv) Safety to man & machines in case of classifiers Operations c. Introduction to Drives of Crushers, Classifiers, Conveyors, quality control system d. Log book entry b) Familiarization with different parts of Pneumatic Classifiers, Weigh Feeders, Dos and Don ts, Pre start Checks, shift take over, sequential starts of equipments, post job checks, housekeeping. Eye estimation of coal crushing. Water addition to coal blend. c) Stopping & Starting of drives, Emergency stoppage and power failure. d) Identification & utility of limit switches 7. Operation of Conveyors 12 weeks a. Introduction to Conveying Systems i. Types of conveyors ii. Design features iii. Weigh Feeders b. Drives of conveyors c. Transfer of material from one conveyor to another d. General layout of conveyors e. Various parts of a conveyor f. Conveyor related safety aspects g. Monsoon Hazards & Preparations h. General safety a. Shift take over b. Pre start checks c. Running checks i. Feed adjustments ii. Tracking of conveyors iii. Spillage prevention d. Closing down e. Shutdown preparations f. Equipment safety g. Stoppage on emergency / power failure h. House keeping 8. Fire fighting system & pump operation 5 weeks a. Concept of Self combustion b. Operation of Fire Pump ii) Types of Pumps & Fire Extinguishers iii) Parts of Pump attachments iv) Loading of Centrifugal Pump c. Introduction to fire fighting network ii) Types fittings in fire fighting network. iii) Safety to man, machines and a) Familiarization with different parts of Centrifugal Pump, Dos and Don ts, Pre Start Checks, Post Job checks, b) Familiarization with different types of Fire Extinguishers & parts of fire fighting network, Dos and Don ts, Mock Drills.

8 importance of fire fighting system. iv) Fire Extinguisher Operation & Valve operation. v) Log book entry 9. Tests and Evaluation 4 weeks Workshop Calculations & Science 1. Applied workshop problems involving simple addition, subtraction, multiplication, division and common fractions. 2. Science Definition, Nomenclature, various branches, significance and definitions of important terms. 3. Rounding of decimal values, use of approximation. 4. Units Definition, fundamental & derived units, system of units FPS, CGS, MKS and SI units of some important parameters Length, mass, time, density, current, voltage, pressure etc. Unit conversion. 5. Workshop problems related to average. 6. Workshop problems related to percentage. 7. Workshop problems related to ratio and proportion. 8. Workshop problems related on time & work. 9. Profit & Loss and problems concerning to workshop practices. 10. Properties of Matter Different types of Properties of Matter e.g. Mechanical, Electrical, Chemical, Magnetic. 11. Properties of Matter (Mechanical) Tenacity, Toughness, Malleability, Ductility, Elasticity, Plasticity, Brittleness, Hardness (concept & definition) 12. Properties and uses of copper, zinc, lead, tin, aluminum, brass, bronze, solder, bearing metals, timber, and rubber. 13. Engineering Material Introduction, classification, Metallic Non metallic material, physical and mechanical properties, 14. Heat & temperature Definition and its importance. Scales of Temperature, e.g. Fahrenheit, Centigrade, Kelvin relationship between them. 15. Transmission of heat Conduction, Convection and Radiation. Examples from Industries (concept & definition)

9 16. Transmission of Power and motion of Belt and Pulleys: Driver and Follower Open and Cross belt system of belt drives. Velocity ratio. Power Transmission by belt Problems Engineering Drawing : 1. Introduction to Engineering drawing, its importance and uses in engineering fields. Simple definitions of Points, Lines, Parallel straight lines. 2. Geometrical construction of Square, Rectangle, Triangle, Circle, Polygons, etc. 3. Drawing different types of lines. 4. Free hand sketch of Hand tools used in the trade. 5. Lettering and dimensioning practice. 6. Reading and Interpretation of Charts, Posters, Figures, Layout diagrams, etc. 7. Simple drawing of Charts, Posters, Figures, Layout diagrams, etc. 8. Use of different signals and colour codes in the trade as well as in steel industry.

OPERATOR LOCOMOTIVE AND RAIL CRANES IN STEEL PLANT Under Apprenticeship Training Scheme (ATS)

SYLLABUS for the trade of OPERATOR LOCOMOTIVE AND RAIL CRANES IN STEEL PLANT Under Apprenticeship Training Scheme (ATS) GOVERNMENT OF INDIA MINISTRY OF LABOUR & EMPLOYMENT DIRECTORATE GENERAL OF EMPLOYMENT