Fitter (Integrated Steel Plant) Apprenticeship Course Syllabus

Course Title

Fitter (Integrated Steel Plant) Apprenticeship Course

Course Code

FMOFISP101

Description

This course, under the Flexible Memorandum of Understanding (Flexi-MoU) Scheme within the Apprenticeship Training Scheme (ATS), provides specialized training for fitters in integrated steel plants. It focuses on assembling, maintaining, and repairing mechanical systems and equipment, including blast furnaces, rolling mills, conveyors, and hydraulic systems, to ensure operational efficiency. Apprentices will gain hands-on experience using precision tools, performing equipment overhauls, and troubleshooting mechanical faults, 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

• Assemble and align mechanical components for steel plant machinery with precision.
• Perform maintenance and repair on equipment like rolling mills, furnaces, and conveyors.
• Troubleshoot and overhaul hydraulic and pneumatic systems in steel plant operations.
• Adhere to safety, environmental, and BIS (Bureau of Indian Standards) regulations in mechanical fitting 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 fitters in integrated steel plants. Below is the detailed breakdown:

Weeks 1-2: Basic Training

Introduction to mechanical fitting in steel plants, workplace safety, and trade practices. Overview of steel plant equipment (blast furnaces, rolling mills, conveyors), materials (steel alloys, bearings), and precision tools (vernier calipers, micrometers, torque wrenches). Training on personal protective equipment (PPE) and hazard identification in high-temperature environments.

Months 1-3: Mechanical Assembly and Alignment

Assembling mechanical components, including gearboxes, shafts, and couplings, for steel plant machinery. Training on alignment techniques using dial indicators and laser alignment tools to ensure precision in high-load systems.

Months 4-6: Equipment Maintenance and Repair

Performing preventive maintenance on rolling mills, conveyors, and furnace components. Training on dismantling, repairing, and reassembling equipment, including bearing replacement and lubrication systems.

Months 7-9: Hydraulic and Pneumatic Systems

Troubleshooting and repairing hydraulic and pneumatic systems used in steel plant cranes, presses, and rolling mills. Training on hydraulic pumps, valves, and actuators, including seal replacement and pressure testing.

Months 10-11: Fault Diagnosis and Overhaul

Diagnosing mechanical faults using vibration analysis, thermal imaging, and root cause analysis. Training on overhauling major equipment, such as conveyor drives and furnace rollers, and documenting repair procedures.

Month 12: Final Project and Assessment

Completion of a comprehensive mechanical fitting project (e.g., overhauling a conveyor drive system or aligning a rolling mill component) 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% (assembly, repair, alignment tasks)
• Project Work: 30% (complete equipment overhaul or repair)
• Theoretical Tests: 15% (mechanical principles, safety regulations)
• Attendance and Participation: 5%

Instructor

Industry Expert (designated by ITP, e.g., steel plant mechanical engineer or maintenance 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 Fitter certificate, 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 precision, safety, and compliance with BIS and steel industry standards, addressing the demand for skilled fitters 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, Automotive trades, Crane Operator, Electrician (Integrated Steel Plant)) and your focus on enhancing MM Private ITI’s offerings in Kasganj. The inclusion of mechanical calculations (e.g., tolerances, gear ratios) aligns with your earlier request for "Workshop Calculation and Science" content, ensuring technical depth suitable for your audience. Note that, based on your mention of Pacific Private ITI on March 22, 2025, which offers the Fitter trade but may lack official NCVT recognition, this syllabus is designed for verified Flexi-MoU programs to ensure credibility for MM Private ITI.