iti 23 April 2025
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Welder (Integrated Steel Plant) Apprenticeship Course Syllabus

Course Title

Welder (Integrated Steel Plant) Apprenticeship Course

Course Code

FMOWISP101

Description

This course, under the Flexible Memorandum of Understanding (Flexi-MoU) Scheme within the Apprenticeship Training Scheme (ATS), provides specialized training for welders in integrated steel plants. It focuses on applying welding techniques, including Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW), and Shielded Metal Arc Welding (SMAW), to fabricate and repair structural components, pipes, and machinery used in steel production. Apprentices will gain hands-on experience using welding equipment, performing quality inspections, and ensuring safety, preparing them for roles in steel manufacturing facilities. The course emphasizes precision and safety in high-risk environments and aligns with the National Apprenticeship Promotion Scheme (NAPS) and the Apprentices Act, 1961.

Objectives

  • Perform GMAW, GTAW, and SMAW to weld structural components and pipes for steel plant applications.
  • Repair and maintain heavy machinery and equipment through welding techniques.
  • Inspect welds using visual and non-destructive testing (NDT) methods to meet BIS and ASME standards.
  • Adhere to safety, environmental, and BIS regulations in welding 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 welders in integrated steel plants. Below is the detailed breakdown:

Weeks 1-2: Basic Training

Introduction to welding in steel plants, workplace safety, and trade practices. Overview of welding processes (GMAW, GTAW, SMAW), materials (carbon steel, stainless steel), and equipment (MIG/TIG welders, plasma cutters). Training on personal protective equipment (PPE), hazard identification, and safety regulations for high-temperature and heavy-traffic areas.

Months 1-3: SMAW and Structural Welding

Performing Shielded Metal Arc Welding (SMAW) to join structural components like beams and columns. Training on electrode selection, weld positions (flat, horizontal, vertical), and fabricating steel frameworks for plant infrastructure.

Months 4-6: GMAW and Pipe Welding

Applying Gas Metal Arc Welding (GMAW) for pipe welding and structural repairs. Training on welding pipes for cooling systems and gas lines, including root pass and filler techniques, with emphasis on high-pressure applications.

Months 7-9: GTAW and Precision Welding

Using Gas Tungsten Arc Welding (GTAW) for precision welding of stainless steel and thin materials used in steel plant equipment. Training on achieving high-quality welds for critical components like furnace parts.

Months 10-11: Weld Inspection and Maintenance

Inspecting welds using visual inspection and basic NDT methods (e.g., dye penetrant, magnetic particle testing). Training on repairing welds, maintaining welding equipment, and documenting weld quality reports.

Month 12: Final Project and Assessment

Completion of a comprehensive welding project (e.g., fabricating a structural component or repairing a pipeline section) 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% (welding tasks, weld quality)
  • Project Work: 30% (complete welding fabrication or repair)
  • Theoretical Tests: 15% (welding principles, safety regulations)
  • Attendance and Participation: 5%

Instructor

Industry Expert (designated by ITP, e.g., steel plant welding supervisor or quality control engineer)

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 an ITI Welder 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, ASME, and steel industry standards, addressing the demand for skilled welders 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, Technician - Plant Maintenance, Turner (Integrated Steel Plant/OF)) and your focus on enhancing MM Private ITI’s offerings in Kasganj. The inclusion of calculations for welding parameters (e.g., welding current, arc voltage, heat input) aligns with your earlier request for "Workshop Calculation and Science" content on March 25, 2025, ensuring technical depth suitable for your audience. Your prior request for Welder (GMAW & GTAW) and Welder (Pipe) syllabi on April 19, 2025, informs the welding techniques emphasized here, tailored to steel plant needs. 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.