ITI Attendant Operator (Chemical Plant) Syllabus: Course Structure, Detailed Syllabus

• SAFETY:
• Introduction & Importance of safety, general precautions about safety. PPEs used in chemical industries. Safety slogan. First aid in workshop & industry.

• BASIC FITTING: Safety precautions to be followed in the fitting workshop.
• Introduction to different hand tools such as files, chisels, hacksaw & hammers, etc., and their uses.
• Description, construction, and uses of different marking tools such as steel rule, caliper, punches, v-block, scribing block, etc.

• JOB HOLDING DEVICES:
• Description, construction, and uses of different job-holding devices. Such as vice, VBlock.

• Description, construction, calculation, and uses of different Linear Measuring Instruments – VernierCalliper, Vernier Depth gauge, Height gauge, Outside Micrometre, Bevel protector.

• Drilling, Countersinking, counter boring.
• Reaming and tapping.
• Nomenclature and uses of Drill, Reamer

• Description, nomenclature, and uses of different types of threads – Metric, BSW, BSF, BSP, etc.
• Calculation of tap drill size.

• Introduction to Physics, Units, dimensions, and physical quantities.
• Vernier caliper – parts of a Vernier caliper, principle, and uses of a Vernier caliper.
• Least count and measurement with Vernier caliper.
• Outside micrometer – parts of an outside micrometer, working principle, least count, and measurement with outside micrometer.

• Velocity, its unit, average velocity, speed, average speed, acceleration, Acceleration due to gravity, Newton’s laws of motion.
• Force, unit of force, Effect of force.
• Representation of forces resultant. triangle and parallelogram laws of forces.

• Friction-definition, unit, types of friction, laws of friction, advantages, and disadvantages of friction.

• Inclined plane.
• Simple machines- types of simple machines-pulley, inclined plane, lever, wheel and axle, screw jack.
• Mechanical advantage, velocity ratio, the efficiency of the machine.

• Current electricity, Ohm’s law, Kirchhoff’s law.
• Resistances in series and parallel.
• Electrolysis, Faraday's laws of electrolysis.
• Energy and power, forms of energy- potential, kinetic, heat, light. Mechanical equivalent of heat (‘J’ by electric method).

• Modes of heat transfer – conduction, convection, and radiation.
• Determination of thermal conductivity.
• Temperature & expansion of solid, and liquid.
• Coefficient of linear and cubical expansion.

• Introduction to Chemistry, branches of chemistry
• Importance of chemistry.
• Safety precautions are to be taken in the Chemistry Laboratory.
• Different equipment and apparatus are used in the Chemistry Laboratory.

• Acids, bases, and salts-their properties and uses. Element, atom, and molecule.
• Compound, mixture, Physical change, chemical change, Molecular weight, equivalent weight, atomic weight, Normality, molarity, and molality.
• Volumetric analysis- titrimetric analysis- determination of the amount of substance in solution. Detection of endpoint.
• Types of Titrimetric analysis.

• ATOMIC STRUCTURE:
• Electrons, protons, neutrons.
• Electronic theory of valency.
• Classification of elements, Modern periodic law, table, Groups, periods, and periodic properties.
• Allotropy of hydrogen, carbon, phosphorus, and sulfur.
• Allotropic forms of sulfur – monoclinic, amorphous, and rhombic sulfur.

• WATER:
• Sources, hard and soft water, causes and removal of hardness, water for industrial purposes. Corrosion- causes, effects, and prevention.
• Catalyst definition types of catalysts, characteristics of catalysts, and use of catalyst.
• Introduction to Effluent treatment plant (ETP)

• Definition of pH, pH scale, measurement of pH.
• ORGANIC CHEMISTRY:
• Introduction, purification processes, organic reactions- substitution, addition, Elimination, rearrangement reactions, examples.
• Nomenclature-Basic rules for Common name & IUPAC name system for alkanes, alkenes & alkynes, their examples.
• The boiling point and melting point of organic compounds.

• Definition of fire, chemistry of fire, fire triangle classification of fire.
• Causes of fire in chemical industries.
• Different types of fire Extinguishers
• Accident - causes and effects of accident
• Prevention of accidents.

• Different terms such as Hazard, risk, LEL, VEL, TWA, STEL.
• Flash point, fire point auto ignition temp.
• Material safety data sheet.
• Housekeeping – the importance of housekeeping in chemical industries.
• Pollution and its controls
• Concept of 5S.

• Pressure: Definition, unit’s conversion of units.
• Classification of pressure measuring instruments
• Bourdon type, capsule type helical type, bellows type diaphragm type pressure
• gauges.

• Temperature: Definition, units, conversation of units. Classification of temperature measuring
• Instruments: Mercury in glass thermometer, bimetallic thermometer, RTD thermometer & Thermocouple.

• Flow Measurement. -
• Classification of flow measuring instruments.
• Construction, workings & uses of orifice meter, venturi meter, and turbine-type flow meters.

• Level Measurement –
• Classification of level measuring instruments – simple float type level indicator, sight glass level indicator, air purge level indicator, Capacitance type level indicator.

• Definition and measurement of specific gravity.
• Working principle of Hydrometer.
• Construction of final control element (control valve).

• Standard pipe threads, nominal diameter, wall thickness, schedule number, die & diestock, tubing.

• Different types of pipe joints – flanged and threaded. Straight connections, bedsore, elbows, tees, screwed fittings, coupling, flanges, bush & caller, plug, stop cock, binding material.
• Tools for fitting.

• Thermal insulation – Lagging of utilities in chemical industries.
• Types & uses of lagging materials. Properties of lagging materials.
• Gasket materials for particular applications cork sheet, oilproof paper, PTFE rubber & graphite.

• Locking devices- use of correct material and locking devices – locknut castle nut, saw nut, locking pin, spring lock water.
• Construction, working & use of gate valve.

• Construction, working & use of Globe valve & check valve.

• Construction, working & use of needle valve, diaphragm & ball valve.

• Construction, working & use of stop cock & butterfly valve
• Maintenance of valve
• Selection of appropriate type of valve for given service.

• PUMP Classification of pumps
• Construction, working & use of centrifugal pump
• Starting & Shutting down the procedure for the centrifugal pump
• Troubleshooting in centrifugal pump.

• Construction, working & use of Gear pump
• Troubleshooting in Gear pump.

• Construction, working & use of Screw pump & metering pump.

• Construction, working & uses of fans, blowers & compressors.

• Types, construction & uses of bearings such as ball, roller, bush, etc. their care & maintenance.

• Types of gears - Spur gear, Helical gear, Bevel gear.Their uses & care.

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1st Year

2nd Year

1.

Professional Skill (Trade Practical)

1000

1000

2.

Professional Knowledge (Trade Theory)

280

360

3.

Workshop Calculation and Science

80

80

4.

Engineering Drawing

80

80

5.

Employability Skills

160

80

Total

1600

1600