Crane Operator (Integrated Steel Plant) Apprenticeship Course Syllabus

Course Title

Crane Operator (Integrated Steel Plant) Apprenticeship Course

Course Code

FMOCR101

Description

This course, under the Flexible Memorandum of Understanding (Flexi-MoU) Scheme within the Apprenticeship Training Scheme (ATS), provides specialized training for crane operators in integrated steel plants. It focuses on operating overhead cranes, gantry cranes, and other lifting equipment to handle heavy materials such as steel slabs, coils, and molten metal ladles. Apprentices will gain hands-on experience in safe crane operation, load rigging, and maintenance checks, preparing them for roles in steel manufacturing facilities. The course emphasizes safety due to the high-risk environment of steel plants and aligns with the National Apprenticeship Promotion Scheme (NAPS) and the Apprentices Act, 1961.

Objectives

• Operate overhead and gantry cranes safely to lift and position heavy steel materials and molten metal ladles.
• Perform rigging and signaling for precise load handling in steel plant operations.
• Conduct pre-operational inspections and basic maintenance on cranes to ensure reliability.
• Adhere to safety, environmental, and BIS (Bureau of Indian Standards) regulations specific to steel plant crane operations.

Duration

6 months (2 weeks basic training, 5 months on-the-job training)

Schedule

The course spans 6 months, combining basic training and on-the-job practical training as per Flexi-MoU guidelines. Each phase focuses on specific skills essential for crane operators in integrated steel plants. Below is the detailed breakdown:

Weeks 1-2: Basic Training

Introduction to crane operations in steel plants, workplace safety, and trade practices. Overview of crane types (overhead, gantry), steel plant materials (slabs, coils, molten metal), and safety regulations. Training on personal protective equipment (PPE) and hazard identification.

Month 1: Crane Operation Fundamentals

Learning to operate overhead cranes, including control systems, load charts, and lifting capacities. Training on basic maneuvers and load positioning in simulated steel plant environments.

Month 2: Rigging and Signaling

Mastering rigging techniques for steel slabs, coils, and ladles. Training on hand signals, radio communication, and coordination with ground crews (riggers and signalers).

Month 3: Advanced Crane Operations

Operating cranes in high-risk steel plant scenarios, such as handling molten metal ladles and hot rolled coils. Training on precise load placement and emergency procedures.

Month 4: Maintenance and Inspections

Conducting pre-operational inspections, identifying wear in crane components (e.g., cables, hooks), and performing basic maintenance tasks. Training on logging inspection reports.

Month 5: Safety and Quality Control

Implementing safety protocols for high-temperature environments, ensuring compliance with BIS and OSHA-equivalent standards, and conducting quality checks on load handling accuracy.

Month 6: Final Project and Assessment

Completion of a comprehensive crane operation project (e.g., handling a steel slab from furnace to rolling mill) and preparation for joint ITP-DGT assessment.

Assessment Methods

Apprentice performance is evaluated through a combination of practical, theoretical, and participatory components, preparing them for the Certificate of Proficiency:

• Practical Assessments: 50% (crane operation, rigging, load handling)
• Project Work: 30% (complete steel plant lifting task)
• Theoretical Tests: 15% (crane mechanics, safety regulations)
• Attendance and Participation: 5%

Instructor

Industry Expert (designated by ITP, e.g., steel plant safety officer or crane supervisor)

Language

Available in: English

Status

Published

Additional Notes

Apprentices must be at least 18 years old (due to hazardous environments) and meet the minimum educational qualification (typically 10th grade passed or equivalent, preferably with a technical or science background, as per ITP requirements). The course includes 20-25% basic training and 75-80% on-the-job training, with a stipend as per NAPS guidelines (e.g., Rs. 7700 per month for one-year ITI trade passed apprentices, as per Gazette notification dated 25th September 2019). The government reimburses 25% of the stipend (up to Rs. 1500/month) to the ITP. Successful completion leads to a Certificate of Proficiency, recognized for employment in steel manufacturing and related industries. The training emphasizes safety, precision, and compliance with BIS and steel industry standards, addressing the demand for skilled crane operators in India’s integrated steel plants, with the steel industry contributing significantly to industrial growth (e.g., 128.85 million tonnes of crude steel production in FY24). For specific ITP curriculum details, contact the Apprenticeship Training Portal (www.apprenticeshipindia.gov.in). This syllabus can be adapted for posting on vocational training websites like https://mmiti.in or https://iti.today, aligning with your previous requests for trade syllabi.

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