iti 23 April 2025

Technician - Plant Maintenance Apprenticeship Course Syllabus

Course Title

Technician - Plant Maintenance Apprenticeship Course

Course Code

FMOTPM101

Description

This course, under the Flexible Memorandum of Understanding (Flexi-MoU) Scheme within the Apprenticeship Training Scheme (ATS), provides specialized training for plant maintenance technicians in integrated steel plants. It focuses on maintaining and repairing mechanical, electrical, and automation systems, including conveyors, rolling mills, pumps, motors, and PLC-based control systems, to ensure operational continuity. Apprentices will gain hands-on experience using diagnostic tools, maintenance equipment, and software, preparing them for roles in steel manufacturing facilities. The course emphasizes safety in high-risk environments and aligns with the National Apprenticeship Promotion Scheme (NAPS) and the Apprentices Act, 1961.

Objectives

  • Perform preventive and corrective maintenance on mechanical systems like conveyors, pumps, and rolling mills.
  • Troubleshoot and repair electrical systems, including motors, switchgear, and control circuits.
  • Maintain and program PLC-based automation systems for steel plant operations.
  • Adhere to safety, environmental, and BIS (Bureau of Indian Standards) regulations in maintenance operations.

Duration

12 months (2 weeks basic training, 11 months on-the-job training)

Schedule

The course spans 12 months, combining basic training and on-the-job practical training as per Flexi-MoU guidelines. Each phase focuses on specific skills essential for plant maintenance technicians in integrated steel plants. Below is the detailed breakdown:

Weeks 1-2: Basic Training

Introduction to plant maintenance in steel plants, workplace safety, and trade practices. Overview of steel plant systems (mechanical, electrical, automation), equipment (conveyors, furnaces, motors), and tools (multimeters, torque wrenches, PLC software). Training on personal protective equipment (PPE) and hazard identification in high-temperature and electrical environments.

Months 1-3: Mechanical Maintenance

Performing preventive maintenance on mechanical systems, including conveyors, pumps, and rolling mill components. Training on dismantling, repairing, and reassembling equipment, using tools like vernier calipers, hydraulic presses, and alignment devices.

Months 4-6: Electrical Maintenance

Troubleshooting and repairing electrical systems, including motors, switchgear, and control circuits. Training on wiring, earthing, and testing high-voltage systems (up to 33 kV) using multimeters and insulation testers.

Months 7-9: Automation and PLC Systems

Maintaining and programming PLCs (e.g., Siemens, Allen-Bradley) for automation of steel plant processes. Training on SCADA systems, variable frequency drives (VFDs), and sensor calibration for production equipment.

Months 10-11: Fault Diagnosis and System Integration

Diagnosing faults using vibration analysis, thermal imaging, and electrical diagnostics. Training on integrating mechanical, electrical, and automation systems for seamless plant operations, including documentation of maintenance logs.

Month 12: Final Project and Assessment

Completion of a comprehensive maintenance project (e.g., overhauling a conveyor system or troubleshooting a PLC-controlled rolling mill circuit) 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% (maintenance tasks, troubleshooting)
  • Project Work: 30% (complete system maintenance or repair)
  • Theoretical Tests: 15% (mechanical/electrical principles, safety regulations)
  • Attendance and Participation: 5%

Instructor

Industry Expert (designated by ITP, e.g., steel plant maintenance engineer or 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 with science and mathematics or equivalent, preferably with an ITI certificate in Electrician, Fitter, or Mechanic Machine Tool Maintenance, 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 multidisciplinary maintenance, safety, and compliance with BIS and Indian Electricity Rules, addressing the demand for skilled plant maintenance technicians in India’s integrated steel plants, with the steel industry producing 128.85 million tonnes of crude steel 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 (e.g., Electrician, Fitter, Machinist (Integrated Steel Plant/OF), Office Management) and your focus on enhancing MM Private ITI’s offerings in Kasganj. The inclusion of calculations for maintenance tasks (e.g., motor load, gear ratios, electrical power) aligns with your earlier request for "Workshop Calculation and Science" content on March 25, 2025, ensuring technical depth suitable for your audience. Note that, based on your mention of Pacific Private ITI on March 22, 2025, which may lack official NCVT recognition, this syllabus is designed for verified Flexi-MoU programs to ensure credibility for MM Private ITI.