Syllabus for the trade of INSTRUMENT CONTROLLER Under Apprenticeship Training Scheme By Government of India Ministry of Labour & Employment (D.G.E.&T.) CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN Block, Sector V, Salt Lake City Kolkata-700091. 1
List of the Trade Committee Members designed and approved the syllabus for the trade of INSTRUMENT CONTROLLER under Apprenticeship Training Scheme Shri S.D. Lahiri Director C.S.T.A.R.I., Kolkata Sr Name & Designation Address Remarks 1 Mr. Haritash Gulshan, Director Training & Employment, Chairman Uttrakhand, Haldwani (Nainital) 2 Mr L.K. Mukherjee, Deputy Director CSTARI, Kolkata Member 3 Mr A Rarhi, Deputy Director CSTARI, Kolkata Member 4 Mr Mayank Agrawal, Principal Govt. I.T.I. (B), Kashipur Member 5 Mr S. Devrajan India Glycols Ltd., Kashipur Member Asst. General Manager 6 Mr J. Khuntia India Glycols Ltd., Kashipur Member Deputy General Manager 7 Mr R. J. Singh Govt. Polytechnic, Kashipur Member Workshop Supdt. 8 Mr P.C. Navani, Foreman Govt. I.T.I. (B), Kashipur Member 9 Mr Vinod Kumar, Engineer Kashipur Sugar Mill, Kashipur Member 10 Mr Rohan Pathak, Off. ERD Mahindra & Mahindra Ltd. Lalpur Member 11 Mr Ankur Agrawal Mahindra & Mahindra Ltd. Lalpur Member Deputy manager 12 Mr Himanshu Marwat Naini Tissues Ltd., Kashipur Member Manager (Elec) 13 Mr N.C. Pant, Sr. Manager Naini Tissues Ltd., Kashipur Member 14 Mr Vivek Varshney, GM (Maint) Banwari Paper Mill, Kashipur Member 15 Mr Anil Kumar Banwari Paper Mill, Kashipur Member Incharge Technician 16 Mr Romesh Sharma Nestle India Ltd., Pantnagar Member Executive 17 Mr R.N. Pande Tata Motors Ltd., Pantnagar Member Divisional Manager 18 Mr Praguman Verma Tata Motors Ltd., Pantnagar Member Asstt. Manager 19 Mr Raj Deep Sharma Govt. I.T.I. (B), Kashipur Member Instructor 20 Mr G.D. Sharma, Instructor Govt. I.T.I. (B), Kashipur Member 21 Mr Anurodh Sharma Dabur India Ltd., Pantnagar Member Executive 22 Mr S.K. Singh Alps Industries Ltd., Kashipur Member General Manager 23 Mr S. Nagar, Manager (HR) Pepsico India Holdings Pvt. Ltd., Bazpur Member 2
General information 1. Name of the designated trade : Instrument Controller 2. N.C.O. Code No. : 7241.10 3. Educational Qualification : Passed 10 th class examination under 10+2 system of education or its equivalent. 4. Duration of Apprenticeship Training : Two years 5. Rebate : One year & six months Broad Based Basic Training in Process Plant Maintenance Sector under Centre of Excellence Scheme and Advanced module of Centre of Excellence Scheme in Instrument Maintenance of Process Plant. 6. Ratio of Apprentice to Workers : 1:3 7. Terminal Behavior : On completion of the training the trainee Will be able to work as an Instrument Controller in any Process Plant. Course Outline The training shall comprise of- a) On the job training The actual training shall be depended on the facilities available in the establishment, with an idea to expose the trainees to as many activities as possible. The trainees shall maintain a daily work diary for the on job training, which shall be periodically authenticated by the supervisor. b) Project Group / Individual apprentice shall under take a project in any of the areas depending on his/her interest and facilities available in the establishment. The duration of the project shall be four weeks. 3
Syllabus for the trade of Instrument Controller under Apprenticeship Training Scheme Shop Floor Training: 6 months The syllabus of this trade should be considered as a guide for imparting apprenticeship training according to the facilities available in the industry. (list of operations in Petro-Chemicals, Heavy Chemicals, Fire Chemicals, Paper & Pulp, Cement, Fertilizer and allied industries where electrical equipments and gadgets are install & function) Orientation i) The plant and its products, raw materials used for production ii) Different sections of the plant iii) Different instruments used in different section and its function. iv) Instrument in Control panel and its lay out Safety: i. Cause and prevention of accidents first aid to the injured ii. Electrical safety and hazards iii. Industrial safety and personnel safety and its protection iv. Fire prevention and fighting Practical Training: i. Familiarization with instruments used in industries and its function. ii. Fittings, calibration and maintenance of pressure gauge iii. Maintenance, reconditioning & calibration of thermocouple iv. RTD, Thermostat & thermister application & function v. Maintenance of flow switch, different type of flow-meter, electromagnet flow meter etc. vi. Maintenance of different type of level indicator, level switch and magnetic level gauge. 4
vii. Maintenance and calibration of flue gas analyzer, SOx & NOx analyzer, photo meter, colorimeter, potentiometer, viscometer and conductivity meter etc. viii. Maintenance and calibration of different electrical measuring instrument digital and analog (Ammeter, Voltmeter, Wattmeter, AVO meter, PF meter etc.) ix. Maintenance & calibration of different type of transmitters, converter and recorder (pneumatic & electronic) x. Working on different controllers and identification of its component and calibration (ON-OFF & PID controller) xi. Working and maintenance on solenoid control valve, control valve with potentiometer etc. xii. Working and maintenance temperature scanners. xiii. Working on micro processor kit, flow charts and making programme. xiv. Working on logic relay control, programmable logic controller and digital controller system. xv. Troubleshooting of controllers and identification of its parts. xvi. Working on different type of transducers, application and its measurement procedure. The practical training programme of the apprentices under ATS should be as per the facilities available in the industry / Establishment. SYLLABUS FOR RELATED INSTRUCTIONS The syllabus for related instructions should be considered as guide. The subjects to be taught to the apprentices in related instruction. 1. Trade theory 2. Industrial entrepreneurship. 5
Examination Scheme for the trade of Instrument Controller S.No Title Total Marks Minimum Marks Marks Obtained 1 PRACTICAL Project work based on Practical Training in respective Industry 200 120 Practical Test /Viva based on Practical training in Respective Industry 100 60 2 Theory 100 40 Total 400 220 6