iti 4 April 2025
Pump Operator-cum-Mechanic

ITI Pump Operator-cum-Mechanic Syllabus (English)

Course Overview

  • Trade Name: Pump Operator-cum-Mechanic

  • Duration: 1 Year (2 Semesters)

  • NSQF Level: Level 4

  • Eligibility: 10th Grade Pass with Science and Mathematics

  • Objective: To train candidates in installing, operating, maintaining, and repairing pumps (centrifugal, reciprocating, rotary), preparing them for roles as pump operators, mechanics, or self-employed technicians in industries like water treatment, oil and gas, and manufacturing.

  • Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

  • Introduction to Pumps: Types (centrifugal, reciprocating, rotary), applications in waterworks, refineries, and industries.

  • Safety Practices: PPE (gloves, safety glasses, boots), electrical safety, handling hazardous fluids, fire prevention.

  • Pump Components: Impellers, shafts, bearings, seals, valves; functions and materials (carbon steel, stainless steel).

  • Basic Mechanics: Principles of fluid flow, pressure, head, cavitation, priming, and pump efficiency.

  • Tools and Instruments: Hand tools (wrenches, pliers), measuring tools (vernier caliper, micrometer ±0.01 mm), torque wrenches.

  • Fasteners and Bearings: Types (bolts, nuts, lock washers), plain/journal bearings, anti-friction bearings; fitting and alignment.

  • Basic Electricity: Single-phase/three-phase motors, wiring, earthing, circuit protection.

Trade Practical

  • Safety Drills: Wearing PPE, practicing lockout-tagout procedures, handling chemical spills.

  • Tool Usage: Using hand tools for assembly, measuring dimensions (±0.1 mm accuracy).

  • Pump Dismantling: Disassembling centrifugal pumps, identifying components (impeller, casing, shaft).

  • Bearing Maintenance: Removing and fitting bearings, checking alignment, lubricating with grease/oil.

  • Fastener Practice: Tightening bolts with torque wrench, using locking devices (spring washers, lock nuts).

  • Electrical Testing: Checking motor continuity, testing insulation resistance with multimeter.

  • Project Work: Dismantle and reassemble a 1 HP centrifugal pump, ensuring leak-free operation.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

  • Advanced Pump Systems: Reciprocating pumps, rotary pumps (gear, vane), submersible pumps; performance curves.

  • Pump Maintenance: Troubleshooting (misalignment, cavitation, leaks), bearing replacement, seal maintenance.

  • Hydraulics and Pneumatics: Hydraulic actuators, pneumatic valves, their role in pump systems.

  • Welding and Fabrication: Basic arc welding, gas cutting for pump repairs, non-destructive testing (dye penetrant).

  • Pump Installation: Site preparation, foundation alignment, pipe connections, priming procedures.

  • Quality Control: Testing pump performance (flow rate, pressure), adherence to standards (ISO, BIS).

  • Entrepreneurship: Starting a pump repair shop, market trends (e.g., energy-efficient pumps).

Trade Practical

  • Pump Troubleshooting: Diagnosing issues (low flow, high vibration), correcting shaft misalignment (±0.05 mm).

  • Reciprocating Pump Maintenance: Servicing pistons, valves, and seals; reassembling with proper gasket selection.

  • Rotary Pump Repair: Inspecting gear/vane pumps, replacing worn components, testing for leaks.

  • Welding Tasks: Performing arc welds on pump casings, ensuring defect-free joints.

  • Installation Practice: Installing a submersible pump, connecting pipes, and testing output (flow rate ±5 L/min).

  • NDT Testing: Conducting dye penetrant tests on welds, identifying surface cracks.

  • Project Work: Overhaul a 2 HP reciprocating pump, test performance, and document flow rate and pressure.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

  • Workshop Calculation and Science

    • Calculations: Pump power, flow rate, head loss, efficiency; unit conversions (liters/min to m³/hr).

    • Science: Fluid mechanics, pressure dynamics, thermal effects on bearings, motor torque.

    • Hours: 80 hours/year

  • Engineering Drawing

    • Drawings: Pump assembly diagrams, piping layouts, sectional views of impellers and casings.

    • Hours: 80 hours/year

  • Employability Skills

    • Communication: Reading technical manuals, reporting maintenance issues, client interaction.

    • IT Literacy: Using pump design software, inventory systems, online spare parts catalogs.

    • Soft Skills: Time management, teamwork, resume writing, interview preparation.

    • Hours: 60 hours/year

Assessment and Certification

  • Exams:

    • Theory: Written exams per semester (MCQs, descriptive questions).

    • Practical: Pump assembly, repair, troubleshooting, performance testing, safety compliance.

  • Evaluation Criteria: Accuracy in repairs, pump performance, adherence to safety and standards.

  • Certification: NCVT National Trade Certificate (NTC), globally recognized.

Career Opportunities

  • Employment: Pump operator, mechanic, or service technician in water treatment plants, oil refineries, manufacturing units, or construction.

  • Self-Employment: Pump repair shop, spare parts dealership, freelance maintenance services.

  • Further Studies: Diploma in Mechanical Engineering (lateral entry), certifications in pump technology or hydraulics.

Trade Type

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