Maintenance Mechanic (Chemical Plant)

ITI Maintenance Mechanic (Chemical Plant) Syllabus (English)

Course Overview

• Trade Name: Maintenance Mechanic (Chemical Plant)
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in maintaining, repairing, and troubleshooting machinery and equipment in chemical plants, equipping them for roles as maintenance mechanics, plant technicians, or equipment supervisors in chemical manufacturing, petrochemical industries, or fertilizer plants, or for self-employment in industrial maintenance services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Chemical Plants: Role of maintenance mechanics, types of chemical plants (fertilizer, petrochemical, pharmaceutical), safety overview.
• Safety Practices: PPE (helmets, gloves, respirators), handling chemicals, fire hazards, confined space safety, first aid.
• Workshop Tools: Wrenches, screwdrivers, vernier calipers, micrometers, torque wrenches; usage and maintenance.
• Materials: Properties of steel, stainless steel, alloys; corrosion resistance in chemical environments.
• Mechanical Systems: Basics of pumps, compressors, valves, bearings; functions in chemical plants.
• Fitting Techniques: Filing, drilling, tapping, reaming; precision fitting for machine parts.
• Engineering Drawing: Reading blueprints, equipment layouts, piping and instrumentation diagrams (P&ID).

Trade Practical

• Safety Drills: Using PPE, handling chemical spills, operating fire extinguishers, practicing confined space protocols.
• Tool Handling: Measuring with vernier calipers/micrometers, filing surfaces, drilling holes accurately.
• Fitting Practice: Tapping threads, reaming bores, assembling mechanical components with tolerances (±0.02mm).
• Pump Maintenance: Dismantling centrifugal pumps, identifying parts (impeller, shaft), checking alignments.
• Valve Handling: Servicing gate and globe valves, replacing gaskets, testing for leaks.
• Drawing Interpretation: Reading P&ID for chemical plant equipment, marking components for maintenance.
• Project Work: Overhauling a small pump assembly with proper fittings and alignments.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Pumps and Compressors: Types (centrifugal, reciprocating), working principles, maintenance schedules.
• Piping Systems: Pipe materials (carbon steel, PVC), fittings, flanges, welding techniques for chemical plants.
• Lubrication Systems: Types of lubricants, grease vs. oil, lubrication schedules for rotating equipment.
• Heat Exchangers: Shell-and-tube, plate types; cleaning and maintenance procedures.
• Welding Basics: Arc welding, TIG welding; applications in chemical plant repairs.
• Instrumentation Basics: Pressure gauges, flow meters, temperature sensors; calibration principles.
• Quality Control: Inspection of equipment, BIS standards, tolerances in maintenance tasks.

Trade Practical

• Pump Servicing: Aligning centrifugal pumps, replacing seals, testing performance.
• Piping Tasks: Cutting and joining pipes, installing flanges, leak testing pipe joints.
• Lubrication Practice: Applying lubricants to bearings, setting up centralized lubrication systems.
• Heat Exchanger Maintenance: Cleaning tubes, replacing gaskets, checking for corrosion.
• Welding Practice: Performing arc welds on steel pipes, ensuring joint integrity.
• Instrumentation Checks: Calibrating pressure gauges, testing flow meters for accuracy.
• Project Work: Servicing a heat exchanger or compressor with full maintenance and testing.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Advanced Equipment: Reactors, distillation columns, agitators; maintenance challenges in chemical processes.
• Troubleshooting: Diagnosing faults in pumps, valves, compressors; root cause analysis.
• Preventive Maintenance: Maintenance schedules, condition monitoring, vibration analysis.
• Hydraulic and Pneumatic Systems: Cylinders, actuators, control valves; maintenance procedures.
• Electrical Basics: Motors, starters, circuit breakers; safe handling during maintenance.
• Corrosion Control: Anti-corrosion coatings, cathodic protection, material selection for chemical plants.
• Safety Standards: OSHA, HAZOP studies, chemical plant safety audits.

Trade Practical

• Equipment Servicing: Maintaining agitators, inspecting reactor linings, testing distillation column components.
• Troubleshooting Tasks: Identifying pump cavitation, fixing valve leaks, analyzing compressor noise.
• Preventive Maintenance: Setting up vibration monitoring, scheduling equipment checks, logging data.
• Hydraulic/Pneumatic Work: Servicing actuators, replacing seals in control valves, pressure testing.
• Electrical Handling: Checking motor windings, replacing circuit breakers, ensuring electrical safety.
• Corrosion Tasks: Applying anti-corrosion coatings, inspecting pipelines for rust.
• Project Work: Performing preventive maintenance on a chemical plant pump-compressor system.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Automation in Maintenance: PLC basics, SCADA systems, IoT for predictive maintenance.
• Advanced Troubleshooting: Vibration analysis, thermal imaging, fault diagnosis in complex systems.
• Energy Efficiency: Optimizing equipment for energy savings, leak detection in chemical plants.
• Environmental Practices: Handling chemical waste, complying with pollution norms, effluent treatment basics.
• Entrepreneurship: Starting a maintenance service business, costing, market trends in chemical industries.
• Project Management: Planning maintenance shutdowns, resource allocation, safety audits.
• Quality Standards: ISO 9001, Six Sigma; ensuring defect-free maintenance output.

Trade Practical

• Automation Tasks: Interfacing with PLCs for equipment control, monitoring via SCADA.
• Advanced Diagnostics: Using vibration analyzers, thermal cameras for fault detection.
• Energy Optimization: Detecting leaks in pipelines, tuning pumps for efficiency.
• Environmental Work: Managing chemical waste safely, inspecting effluent treatment systems.
• Field Exposure: Hands-on training in chemical plants or maintenance workshops (4-6 weeks).
• Shutdown Practice: Planning and executing a mock maintenance shutdown, documenting tasks.
• Project Work: Comprehensive maintenance of a chemical plant equipment setup (e.g., reactor system) with diagnostics and reporting.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Pump flow rates, heat exchanger efficiency, pipe pressure drops, maintenance cost estimation.
  • Science: Fluid mechanics, thermodynamics, corrosion chemistry, material strength.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Equipment assemblies, P&ID, sectional views of pumps and reactors.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Technical reporting, client interaction, teamwork.
  • IT Literacy: Using maintenance software, PLC programming basics, online technical resources.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like pump servicing, troubleshooting, welding, instrumentation checks.
• Evaluation Criteria: Maintenance accuracy, fault diagnosis, safety adherence, equipment uptime.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Maintenance mechanic, plant technician, equipment supervisor in chemical manufacturing, petrochemical industries, or fertilizer plants.
• Self-Employment: Industrial maintenance services, consultancy for plant upkeep, spare parts supply.
• Further Studies: Diploma in Chemical Engineering, certifications in PLC automation or corrosion control.