iti 25 April 2025

CITS Chemical Plant Technology 

Overview

The CITS Chemical Plant Technology trade is a one-year program aimed at training instructors to teach chemical plant operation skills in ITIs. The course is divided into two semesters and covers Trade Technology (theory and practical), Training Methodology, Engineering Drawing, Workshop Calculation & Science, and Soft Skills. It adheres to NSQF Level 5 standards, emphasizing advanced chemical process techniques, safety management, equipment maintenance, and instructional methods.

Semester 1 Syllabus

Trade Technology - Theory

  • Introduction to CITS and Chemical Plant Technology: Role of instructors, scope of the chemical industry, and emerging trends (e.g., green chemistry, automation).

  • Safety and Environmental Standards:

    • Advanced safety protocols: Hazard identification, risk assessment, and HAZOP studies.

    • Personal protective equipment (PPE), fire safety, and emergency response.

    • Environmental regulations: Effluent treatment, emission control, and waste management.

  • Chemical Plant Equipment:

    • Types and functions: Reactors, distillation columns, heat exchangers, pumps, and compressors.

    • Maintenance and calibration of equipment.

  • Process Fundamentals:

    • Material and energy balances in chemical processes.

    • Fluid flow, heat transfer, and mass transfer principles.

    • Unit operations: Distillation, absorption, extraction, and filtration.

  • Instrumentation and Control:

    • Basics of process instrumentation: Sensors, transmitters, and controllers.

    • Introduction to Distributed Control Systems (DCS) and Programmable Logic Controllers (PLC).

  • Chemical Plant Operations:

    • Start-up, shutdown, and troubleshooting of chemical processes.

    • Batch and continuous process operations.

  • Quality Control: Sampling techniques, laboratory analysis, and quality assurance standards.

  • Industrial Chemistry: Properties of chemicals, reaction kinetics, and catalysis basics.

Trade Technology - Practical

  • Demonstrate advanced safety practices, including PPE usage and emergency drills.

  • Identify and operate chemical plant equipment (e.g., pumps, heat exchangers).

  • Perform material and energy balance calculations for a given process.

  • Conduct unit operations: Distillation, filtration, and absorption in a lab setup.

  • Use process instrumentation tools (e.g., pressure gauges, temperature sensors).

  • Simulate start-up and shutdown procedures for a chemical process.

  • Perform basic laboratory analysis (e.g., pH, titration) for quality control.

  • Practice troubleshooting common process issues in a simulated environment.

  • Prepare reports on plant operations and safety audits.

Training Methodology

  • Role of an Instructor: Teaching techniques, lesson planning, and student assessment methods.

  • Communication Skills: Effective verbal and non-verbal communication for training.

  • Classroom Management: Engaging diverse learners and maintaining discipline.

  • Instructional Aids: Use of projectors, digital boards, and e-learning platforms.

  • Practical Training Techniques: Demonstrating tasks, supervising practice, and providing constructive feedback.

Semester 2 Syllabus

Trade Technology - Theory

  • Advanced Chemical Processes:

    • Petrochemical processes, polymerization, and fertilizer production.

    • Process optimization and energy efficiency techniques.

  • Process Safety Management:

    • Safety audits, incident investigation, and root cause analysis.

    • Management of change (MOC) and process safety information (PSI).

  • Maintenance and Repair:

    • Preventive and predictive maintenance of chemical plant equipment.

    • Repair techniques for pipelines, valves, and reactors.

  • Automation in Chemical Plants:

    • Advanced DCS and PLC applications.

    • Introduction to Industry 4.0: IoT, data analytics, and smart sensors in chemical processes.

  • Sustainable Chemical Operations:

    • Green chemistry principles and cleaner production techniques.

    • Waste minimization and recycling in chemical plants.

  • Quality Management Systems:

    • ISO standards (e.g., ISO 9001, ISO 14001) for chemical industries.

    • Statistical process control (SPC) and Six Sigma basics.

  • Entrepreneurship in Chemical Industry:

    • Setting up a small-scale chemical unit.

    • Costing, budgeting, and marketing strategies.

  • Legal and Ethical Aspects: Chemical safety laws, labor regulations, and ethical practices.

Trade Technology - Practical

  • Simulate advanced chemical processes (e.g., distillation column operation) in a lab or pilot plant.

  • Conduct safety audits and prepare HAZOP study reports.

  • Perform preventive maintenance on equipment like pumps and compressors.

  • Program and operate PLC-based control systems for a simple process (if available).

  • Implement green chemistry techniques in a lab experiment (e.g., solvent-free reactions).

  • Apply statistical process control tools to analyze process data.

  • Develop a business plan for a small chemical processing unit.

  • Demonstrate troubleshooting of automated systems using DCS/PLC.

  • Prepare documentation for compliance with ISO standards.

Training Methodology

  • Advanced Teaching Techniques: Micro-teaching, flipped classroom, and blended learning approaches.

  • Assessment and Evaluation: Designing tests, practical assessments, and grading systems.

  • Digital Tools for Training: Use of Learning Management Systems (LMS), virtual labs, and e-learning modules.

  • Mentoring and Guidance: Supporting trainees in skill development and career planning.

  • Project-Based Learning: Guiding trainees to complete chemical plant-related projects.

Additional Components

Workshop Calculation & Science

  • Calculations: Flow rate calculations, heat transfer coefficients, and process yield estimations.

  • Science: Chemical thermodynamics, reaction kinetics, and properties of industrial chemicals.

Engineering Drawing

  • Drawing Basics: Piping and instrumentation diagrams (P&ID) and process flow diagrams (PFD).

  • Plant Layouts: Sketches of chemical plant layouts and equipment arrangements.

Soft Skills & Employability Skills

  • Communication: Report writing, presentation skills, and team coordination.

  • Leadership: Supervising teams and managing plant operations.

  • Time Management: Prioritizing tasks and meeting operational deadlines.

Assessment

  • Internal Assessment: Continuous evaluation through assignments, practicals, and tests.

  • Final Examination: Theory and practical exams conducted by NCVT at the end of the year.

  • Project Work: Trainees must complete a chemical plant-related project (e.g., process optimization study) and a teaching demonstration.

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