Instrument Mechanic (Chemical Plant)

ITI Instrument Mechanic (Chemical Plant) Syllabus (English)

Course Overview

• Trade Name: Instrument 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 installing, calibrating, testing, and maintaining instrumentation systems for chemical plants, preparing them for roles as instrumentation technicians, process technicians, or maintenance mechanics in chemical, petrochemical, or pharmaceutical industries, or for self-employment in calibration services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Instrumentation: Role of instrumentation in chemical plants, types of instruments, process control basics.
• Safety and Environment: Fire extinguishers, PPE (gloves, goggles), chemical hazards, first aid, environmental regulations.
• Trade Tools: Multimeters, oscilloscopes, calibrators, pressure gauges; standardization and maintenance.
• Basic Chemistry and Physics: pH, conductivity, titration methods, properties of gases and liquids.
• Workshop Practices: Precision measurements, fitting, drilling, threading, use of vernier calipers and micrometers.
• Electrical Fundamentals: Ohm’s Law, series/parallel circuits, AC/DC basics, earthing systems.
• Process Parameters: Pressure, temperature, flow, level; principles and measurement techniques.

Trade Practical

• Safety Training: Using fire extinguishers, wearing PPE, handling chemical spills.
• Tool Handling: Operating multimeters, calibrators; maintaining tools.
• Chemistry Lab: Performing titration (acid-base, redox), preparing standard solutions, measuring pH/conductivity.
• Workshop Jobs: Filing, drilling, pipe threading; achieving dimensional accuracy (±0.25mm).
• Electrical Practice: Measuring voltage/current, assembling simple circuits, testing earthing.
• Instrument Familiarization: Identifying pressure gauges, thermometers, flowmeters; recording readings.
• Project Work: Preparing a report on chemical plant safety protocols and basic instrument setup.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Pressure Measurement: Bourdon tubes, diaphragm gauges, manometers; calibration techniques.
• Temperature Measurement: Thermocouples, RTDs, thermistors; principles and applications.
• Flow Measurement: Orifice plates, venturi meters, rotameters; installation and calibration.
• Level Measurement: Sight glass, float, capacitance type; selection criteria.
• Transmitters: Pneumatic and electronic transmitters; 4-20 mA signal systems.
• Valves and Actuators: Control valves, solenoid valves, actuators; operation and maintenance.
• Engineering Drawing: Reading P&ID diagrams, instrument loop diagrams, block diagrams.

Trade Practical

• Pressure Calibration: Calibrating Bourdon gauges, testing pressure transmitters.
• Temperature Calibration: Setting up thermocouples/RTDs, verifying readings with calibrators.
• Flow Experiments: Installing orifice meters, measuring flow rates, troubleshooting errors.
• Level Setup: Configuring float-type level indicators, testing capacitance sensors.
• Transmitter Testing: Connecting and calibrating 4-20 mA transmitters.
• Valve Maintenance: Dismantling and assembling control valves, checking actuator response.
• Project Work: Assembling a basic process loop (pressure or temperature) with calibration and testing.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Recorders and Controllers: Strip chart, circular chart recorders; PID controller basics.
• PLC Basics: Programmable Logic Controllers, ladder logic, input/output modules.
• Process Control Systems: Feedback, feedforward control; tuning controllers.
• Final Control Elements: Pneumatic/hydraulic actuators, positioners; maintenance procedures.
• Chemical Plant Equipment: Distillation columns, heat exchangers, evaporators; instrumentation roles.
• Troubleshooting: Identifying faults in sensors, transmitters, and controllers.
• Quality Standards: BIS guidelines, calibration traceability, documentation.

Trade Practical

• Recorder Setup: Installing and calibrating chart recorders for process parameters.
• PLC Programming: Writing simple ladder logic programs, testing I/O operations.
• Controller Tuning: Adjusting PID settings for stable control in a simulated loop.
• Actuator Maintenance: Overhauling pneumatic actuators, aligning positioners.
• Equipment Handling: Operating a packed distillation column, maintaining heat exchangers.
• Troubleshooting: Diagnosing faults in transmitters, rectifying wiring errors.
• Project Work: Designing and testing a control loop with PLC integration for a chemical process.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Advanced Control Systems: SCADA, DCS; architecture and applications in chemical plants.
• Fieldbus Systems: Profibus, Foundation Fieldbus; communication protocols.
• Erection and Commissioning: Planning instrument installation, loop checking, startup procedures.
• Maintenance Practices: Preventive maintenance, overhauling, failure analysis.
• Entrepreneurship: Starting a calibration lab, cost estimation, market trends in instrumentation.
• Environmental Control: Instrumentation for pollution control, waste treatment systems.
• Industry Trends: IoT in instrumentation, smart sensors, Industry 4.0 basics.

Trade Practical

• SCADA/DCS Operation: Configuring a basic SCADA interface, monitoring process variables.
• Fieldbus Setup: Connecting instruments via Profibus, testing communication.
• Commissioning Tasks: Performing loop checks, simulating plant startup with instruments.
• Maintenance Work: Overhauling transmitters, replacing faulty sensors, maintaining logs.
• Field Exposure: Hands-on training in chemical plants or instrumentation labs (4-6 weeks).
• Environmental Monitoring: Setting up instruments for pH or emission control systems.
• Project Work: Developing a complete process control system (e.g., level control) with SCADA/DCS integration.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Process calculations (flow rates, pressure drops), calibration formulas, scaling signals.
  • Science: Thermodynamics, fluid mechanics, electrical properties of materials.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: P&ID diagrams, instrument layouts, control loop schematics.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Technical report writing, client interaction, teamwork.
  • IT Literacy: Using software for calibration, basics of PLC programming.
  • 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 calibrating instruments, troubleshooting loops, commissioning setups.
• Evaluation Criteria: Calibration accuracy, troubleshooting skills, safety adherence, system integration.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Instrumentation technician, process technician, maintenance mechanic in chemical, petrochemical, or pharmaceutical industries.
• Self-Employment: Calibration lab, instrumentation consultancy, annual maintenance contracts for SCADA/DCS.
• Further Studies: Diploma in Instrumentation Engineering, certifications in PLC/SCADA programming, or IoT applications.