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

Transcription

1 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 & 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 Locomotive and Rail Cranes in Steel Plant under Apprenticeship Training Scheme (ATS) at Central Staff Training & Research Institute (CSTARI), Kolkata. Sl. NAME & DESIGNATION S/Shri ORGANISATION REMARKS No. 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 Tata Steel Ltd., Jamshedpur Member (O&P) 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. AJC Bose Polytechnic, 24 Paraganas Member Engg.) (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 Bengal Engineering & Science University, Member Metallurgy Shibpur 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, Durgapur Steel Plant, Durgapur Member SAIL 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 Locomotive and Rail Crane in Steel Plants 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 Locomotive and Rail Cranes in Steel Plant UNDER APPRENTICESHIP TRAINING SCHEME PERIOD OF TRAINING: TWO YEARS Course Contents 1. Introduction & safety 4 weeks 2. Introduction to Locomotive Operation & Traffic Layout 8 weeks 3. Operation in Blast Furnace Hot Metal and Slag Zone 20 weeks 4. SMS and Ingot Movement Zone 20 weeks 5. Rolling Mills Zone 20 weeks 6. Iron Ore, Coal Tippler & High Line Zone 20 weeks 7. Mobile Rail Crane Operation 8 weeks 8. Tests & 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 Loco Operation and Traffic Layout: 8 Weeks Theory Practical General awareness and Traffic Management, Rail Network and Logistics, Familiarization with rail networks Personal Safety and Housekeeping Use of Personal Protective Equipments, House keeping practice Derailment and Demurrage Practical tips on how to avoid derailments, Familiarization with derailment prone areas. Introduction to Locomotives, Construction of Locomotives, Operation of Locomotives in Steel Plants, Pre-start Checks, Fire Precautions Shift Takeover, General Precautions during Loco Operation, Types of Emergency situations Types of Locomotives, Operation of Locomotives, Pre-start checks, Slips and Skid management, Adjustment of Brakes Precautions during Shunting and Coupling, Precautions during movements in Curvatures and Elevated areas Handling Emergency situations 3. Operation in Blast Furnace Hot Metal and Slag Zone : 20 Weeks THEORY PRACTICAL 1. Introduction to Point Lever, parts of 1. How to take personal safety before and during Loco operation

6 Locomotives, Types of Rolling Stocks. 2. Personal safety before start & during Loco operation - a) Use of PPEs (Personal Protective Equipments), b)fitted clothes c) House Keeping. Types, uses of rolling stocks used in this zone Procedure of drawing out loaded ladle from furnace. Procedure of Placement of Empty ladle to furnace Procedure of drawing out loaded Dump Car from furnace 2. Operation of Lever Points, Couplings /De- Couplings. 3. Use of PPEs 4. Suitable clothes for Loco & Shunting operation 1. Study and use various types of rolling stocks in this zone 2. Study various parts of the same and application Steps to follow a) Coupling and de-coupling with loco & wagon b) Blowing Sharp Horn c)checking point lever & tongue rail function d) Taking clearance from concerned agency Steps to follow a)coupling and de-coupling with loco & wagon b)blowing sharp horn c)checking point lever & tongue rail function d) Taking clearance from concerned agency Steps to follow a) coupling and de-coupling with loco & wagon b)blowing sharp horn c)checking point lever & tongue rail function d) Taking clearance from concerned agency 4. SMS and Ingot Movement Zone: 20 Weeks THEORY 1. Introduction to various track lines in this zone. 2. Functions and role of Shunting Porter, Loco operator & Ground Man. 3. Different rolling stocks and PRACTICAL 1. Use of Safety Helmet, Shoes, Fitted Cloths etc. 2. Use of Hand gloves. 3. Inspection & Stair case / Walk way cleaning 5. Operation of Ready Train, Heat, Spl.

7 their movements. 4. Steps of heat withdrawal, Stripping 5. Steps of Ready Train placement. 6. Procedure for taking out of Wheel Heats and Ready Train placement. 7. Special attention during Ingot & Crop movements 8. Safety precautions Quality Heat, Crop and Ingot movement in different routes. 6. Special precautions during coupling and de-coupling Ingot carrier cars. 5. Rolling Mills Area Movements : 20 Weeks THEORY 1. Safety precautions on equipments, Points and at Yards, 2. Introduction to various Yards. 3. Introduction to different Mills Track Lines. 4. Functions of different types of Wagons and their uses. 5. Systematic approach to collection of Wagons and empty placement to Mills. 6. Loco Operation during weighment of Wagons. 7. Steps to follow during adjustment and final weighment. 8. Procedure of Rake formation and line up. PRACTICAL 1. Checking of personal safety and equipment safety. 2. Operation of Point Lever. Loco at different lines. 3. Inspection of Track and Mill Bay before placement of wagons and drawing of loads from mills. 4. Actions during derailment of wagon. 5. Inspection of internal Wagon fitness 6. Checking of Coupling, Coupling pin, Yard illumination. 7. Housekeeping activities of equipment and Yards on regular basis. 8. Operation during conditions of Overload, Track Jamming etc. 9. Coupling and Decoupling of Loco and Wagon. 10. Actions and Precautions to be taken during Push Back inside.

8 6. Operation in Iron Ore, Coal Tippler and High Line Zone: 20 Weeks THEORY 1. Awareness to Safety on equipments and rolling stocks in this zone. 2. Check up procedure before start up The locomotive. 3. Introduction to iron ore, coal tippler, high line Angadpur, MMBL, SGP and other yards layout. 4. Procedure of Dressing of load wagons to tipplers. 5. Operational parameters in push back mode movement. 6. Following instructions and sequence of high line operation. 7. Operation procedure at Steel Exchange Yard movements. 8. Inspection and operation procedure at Slag Granulation Plant yards. 9. Movement restrictions at weigh bridges. 10. Safety precautions during point lever operation. PRACTICAL 1. Checking of personal safety, equipment health, yard condition, illumination. 2. Movement with locomotive and pointing to get acquainted with different routes of control-ii and high line. 3. Checking of track position and communication with shunting porter and ground man before placement of load wagons to the tipplers. 4. Actions during placement of wagons in push back mode at Slag Granulation Plant yards. 5. Inspection of internal wagon fitness before high line movement. 6. Checking of coupling, coupling pin, during empty wagon rake formation & make over. 7. Housekeeping activities of equipment and yards on regular basis. 8. Operation during conditions of overload, track jam etc at Slag Granulation Plant yards 7. Mobile Rail Crane Operation: 8 Weeks THEORY 1. Awareness to Safety on equipment. 2. Pre start Check up procedure without actual PRACTICAL 1. Checking of personal safety, equipment health, Yard condition, Illumination before Crane operation.

9 load condition. Operation of the Locomotive. 3. Starting Operation of the engine 4. Procedure of Post Start Checking without load. 5. Operational parameters with load condition. 2. Steps to Understand movement and work restrictions at special areas. 3. Checking of track positions and communication with Shunting Porters and concerned Agencies during actual work. 4. Checking of Slinging, Jacking before any operation. 5. Operation of Crane at different working condition and areas. 8. Tests and Evaluation 4 weeks

10 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) 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

11 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.