FITTER (STEEL PLANT)

COMPETENCY BASED CURRICULUM

(Duration: 2 Yrs.)

APPRENTICESHIP TRAINING SCHEME (ATS)

NSQF LEVEL- 5

SECTOR – PRODUCTION & MANUFACTURING

GOVERNMENT OF INDIA
MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
DIRECTORATE GENERAL OF TRAINING

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FITTER (STEEL PLANT)

FITTER (STEEL PLANT)

(Revised in 2018)

APPRENTICESHIP TRAINING SCHEME (ATS)

NSQF LEVEL - 5

Developed By

Ministry of Skill Development and Entrepreneurship

Directorate General of Training
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
EN-81, Sector-V, Salt Lake City,
Kolkata – 700 091
 FITTER (STEEL PLANT) ACKNOWLEDGEMENT

The DGT sincerely expresses appreciation for the contribution of the Industry, State
Directorate, Trade Experts and all others who contributed in revising the curriculum. Special
acknowledgement to the following industries/organizations who have contributed valuable inputs
in revising the curricula through their expert members:

Special acknowledgement is extended by DGT to the following expert members who

had contributed immensely in this curriculum.

Co-ordinator for the course: Sh. N. Nath, ADT, CSTARI- Kolkata

Sl. Name & Designation Mentor Council

Organization
No. Shri/Mr./Ms. Designation

Expert group on restructuring of Apprenticeship Training Modules

1. PRAKASH SINGH, Capability Development TATA Steel Chairman
Chief Capability Development LTD, Jamshedpur- 831001
2. B.N. CHOWDHURY, -Do- Member
Head-Cadre and special training.
3. PAWAN KUMAR DAS, -Do- Member
SR. Manager, Training
4. MANU KUMAR VARMA -Do- Member
SR. Manager, Training
5. AKHILESH KUMARKARN, -Do- Member
SR. Manager, Training
6. SAKET KUMAR, -Do- Member
Manager
7. S.K. MAKUR, -Do- Member
SR. Manager
8. RABINDRA K. SINGH -Do- Member
Manager, Training
9. SATRUGHNA NAYAK, -Do- Member
JE-II
10. RAHUL SHARMA, -Do- Member
SR. Manager
11. JAI KISHORE, -Do- Member
Assistant Manager
12. SUNIL KUMAR, -Do- Member
Manager
13. TRIBENI PRASAD, -Do- Member
SR. Instructor
14. BINU SHARKAR ROY, -Do- Member
Assistant Manager
15. TAPAS KR. DHAR, Manager -Do- Member
16. L. K. Mukherjee, DDT CSTARI, Kolkata Member
17. N. Nath, ADT CSTARI, Kolkata Member
 FITTER (STEEL PLANT)
CONTENTS

Sl.
Topics Page No.
No.

1. Background 1

2. Training System 3

3. Job Role 8

4. NSQF Level Compliance 9

5. General Information 10

6. Learning Outcome 11

7. Learning Outcome with Assessment Criteria 13

8. Syllabus

9. Syllabus - Core Skill 16

9.1 Core Skill – Workshop Calculation & Science and 24

Engineering Drawing

9.2 Core Skill – Employability Skill 27

10. Details of Competencies (On-Job Training) 31

11. List of Trade Tools & Equipment Basic Training - Annexure I 33

12. Format for Internal Assessment -Annexure II 40

FITTER (STEEL PLANT)
1. BACKGROUND

1.1 Apprenticeship Training Scheme under Apprentice Act 1961

The Apprentices Act, 1961 was enacted with the objective of regulating the
programme of training of apprentices in the industry by utilizing the facilities
available therein for imparting on-the-job training. The Act makes it obligatory for
employers in specified industries to engage apprentices in designated trades to impart
Apprenticeship Training on the job in industry to school leavers and person having
National Trade Certificate(ITI pass-outs) issued by National Council for Vocational
Training (NCVT) to develop skilled manpower for the industry. There are four
categories of apprentices namely; trade apprentice, graduate, technician and
technician (vocational) apprentices.
Qualifications and period of apprenticeship training of trade apprentices vary from
trade to trade. The apprenticeship training for trade apprentices consists of basic
training followed by practical training. At the end of the training, the apprentices are
required to appear in a trade test conducted by NCVT and those successful in the
trade tests are awarded the National Apprenticeship Certificate.

The period of apprenticeship training for graduate (engineers), technician (diploma

holders and technician (vocational) apprentices is one year. Certificates are awarded
on completion of training by the Department of Education, Ministry of Human
Resource Development.

1.2 Changes in Industrial Scenario

Recently we have seen huge changes in the Indian industry. The Indian Industry
registered an impressive growth during the last decade and half. The number of
industries in India have increased manifold in the last fifteen years especially in
services and manufacturing sectors. It has been realized that India would become a
prosperous and a modern state by raising skill levels, including by engaging a larger
proportion of apprentices, will be critical to success; as will stronger collaboration
between industry and the trainees to ensure the supply of skilled workforce and drive
development through employment. Various initiatives to build up an adequate
infrastructure for rapid industrialization and improve the industrial scenario in India
have been taken.

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1.3 Reformation
The Apprentices Act, 1961 has been amended and brought into effect from 22nd
December, 2014 to make it more responsive to industry and youth. Key amendments
are as given below:

 Prescription of number of apprentices to be engaged at establishment level instead

of trade-wise.

 Establishment can also engage apprentices in optional trades which are not
designated, with the discretion of entry level qualification and syllabus.

 Scope has been extended also to non-engineering occupations.

 Establishments have been permitted to outsource basic training in an institute of

their choice.

 The burden of compliance on industry has been reduced significantly.

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2. TRAINING SYSTEM

2.1 GENERAL

Directorate General of Training (DGT) under Ministry of Skill Development &

Entrepreneurship offers range of vocational training courses catering to the need of different
sectors of economy/ Labour market. The vocational training programmes are delivered under
aegis of National Council of Vocational Training (NCVT). Craftsman Training Scheme (CTS)
and Apprenticeship Training Scheme (ATS) are two pioneer programmes of NCVT for
propagating vocational training.

Fitter (Steel Plant) trade under ATS is one of the courses delivered nationwide through
different industries. The course is of two years (02 Blocks) duration. It mainly consists of
Domain area and Core area. In the Domain area Trade Theory & Practical impart professional -
skills and knowledge, while Core area - Workshop Calculation and science, Engineering
Drawing and Employability Skills imparts requisite core skills & knowledge and life skills. After
passing out the training programme, the trainee is being awarded National Apprenticeship
Certificate (NAC) by NCVT having worldwide recognition.

Broadly candidates need to demonstrate that they are able to:

 Read & interpret technical parameters/document, plan and organize work processes,
identify necessary materials and tools;
 Perform task with due consideration to safety rules, accident prevention regulations and
environmental protection stipulations;
 Apply professional skill, knowledge, core skills & employability skills while performing
jobs and solve problem during execution.
 Check the job/assembly as per drawing for functioning, identify and rectify errors in
job/assembly.
 Document the technical parameters related to the task undertaken.

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2.2 CAREER PROGRESSION PATHWAYS:

 Indicative pathways for vertical mobility.

2.3 COURSE STRUCTURE:

Table below depicts the distribution of training hours across various course elements
during a period of two years (Basic Training and On-Job Training): -

Total training duration details: -

Time 1-3 4-12 13-15 16-24

(in months)
Basic Training Block– II ----- Block – II ------
Practical Training ---- Block – II ------ Block – II
(On - job training)

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A. Basic Training
For 02 yrs. course (Engg.) :-(Total 06 months: 03 months in 1styr. + 03 months in 2nd yr.)
For 01 yr. course (Engg.) :-(Total 03 months: 03 months in 1st yr.)

S No. Course Element Total Notional Training Hours

For 02 Yrs. For 01 Yr.

course course
1. Professional Skill (Trade Practical) 550 275
2. Professional Knowledge (Trade Theory) 240 120
3. Workshop Calculation & Science 40 20
4. Engineering Drawing 60 30
5. Employability Skills 110 55

Total (Including internal assessment) 1000 500

B. On-Job Training:-

For 02 yrs. Course (Engg.) :-( Total 18 months: 09 months in 1st yr. + 09 months in 2nd yr.)

Notional Training Hours for On-Job Training: 3120 Hrs.

For 01 yr. course (Engg.) :-( Total 12 months)

Notional Training Hours for On-Job Training: 2080 Hrs.

C. Total training hours:-

Duration Basic Training On-Job Training Total

For 02 yrs. 1000 hrs. 3120 hrs. 4120 hrs.

course (Engg.)
For 01 yr. 500 hrs. 2080 hrs. 2580 hrs.
course (Engg.)

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2.4 ASSESSMENT & CERTIFICATION:

The trainee will be tested for his skill, knowledge and attitude during the period of course
and at the end of the training programme as notified by Govt of India from time to time. The
Employability skills will be tested in first two semesters only.

a) The Internal assessment during the period of training will be done by Formative assessment
method by testing for assessment criteria listed against learning outcomes. The training institute
have to maintain individual trainee portfolio as detailed in assessment guideline (section-2.4.2).
The marks of internal assessment will be as per the template (Annexure – II).

b) The final assessment will be in the form of summative assessment method. The All India
Trade Test for awarding NAC will be conducted by NCVT on completion of course as per
guideline of Govt of India. The pattern and marking structure is being notified by govt of India
from time to time. The learning outcome and assessment criteria will be basis for setting
question papers for final assessment. The examiner during final examination will also
check individual trainee‟s profile as detailed in assessment guideline (section-2.4.2) before
giving marks for practical examination.

2.4.1 PASS REGULATION

The minimum pass percent for Practical is 60% & minimum pass percent for Theory
subjects 40%. The candidate pass in each subject conducted under all India trade test.

2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial

barriers to assessment. The nature of special needs should be taken into account while
undertaking assessment. Due consideration should be given while assessing for team work,
avoidance/reduction of scrap/wastage and disposal of scarp/wastage as per procedure, behavioral
attitude, sensitivity to environment and regularity in training. The sensitivity towards OSHE and
self-learning attitude are to be considered while assessing competency.

Assessment will be evidence based comprising the following:

 Job carried out in labs/workshop

 Record book/ daily diary
 Answer sheet of assessment
 Viva-voce
 Progress chart
 Attendance and punctuality
 Assignment
 Project work

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Evidences of internal assessments are to be preserved until forthcoming semester
examination for audit and verification by examination body. The following marking pattern to be
adopted while assessing:

Performance Level Evidence

(a) Weightage in the range of 60 -75% to be allotted during assessment
For performance in this grade, the  Demonstration of good skill in the use of
candidate with occasional guidance and hand tools, machine tools and workshop
showing due regard for safety procedures equipment
and practices, has produced work which  Below 70% tolerance dimension/accuracy
demonstrates attainment of an acceptable achieved while undertaking different work
standard of craftsmanship. with those demanded by the
component/job/set standards.
 A fairly good level of neatness and
consistency in the finish
 Occasional support in completing the
project/job.

(b) Weightage in the range of above75% - 90% to be allotted during assessment

For this grade, the candidate, with little  Good skill levels in the use of hand tools,
guidance and showing due regard for safety machine tools and workshop equipment
procedures and practices, has produced  70-80% tolerance dimension/accuracy
work which demonstrates attainment of a achieved while undertaking different work
reasonable standard of craftsmanship. with those demanded by the
component/job/set standards.
 A good level of neatness and consistency in
the finish
 Little support in completing the project/job

(c) Weightage in the range of above 90% to be allotted during assessment

For performance in this grade, the  High skill levels in the use of hand tools,
candidate, with minimal or no support in machine tools and workshop equipment
organization and execution and with due  Above 80% tolerance dimension/accuracy
regard for safety procedures and practices, achieved while undertaking different work
has produced work which demonstrates with those demanded by the
attainment of a high standard of component/job/set standards.
craftsmanship.  A high level of neatness and consistency in
the finish.
 Minimal or no support in completing the
project.

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3. JOB ROLE

Brief description of Job roles:

Fitter Steel Plant identifies metals, tools; carrying out fitting and fabrication operations like
measuring, marking out, sawing, grinding, drilling, chiseling, threading, tapping, scraping,
manual lapping and inspecting of components in order to fit a component as per specifications. It
also involves basic oxy-fuel gas cutting and basic manual arc welding as per given instructions
and under supervision. He dismantles, removes and replaces faulty equipment at component or
unit level on a variety of different types of mechanical assemblies and sub-assemblies and
diagnosing, locating faults, overhauling, fitting and adjusting mechanical systems and
equipment, checking vibration etc. to ensure fitness of equipment prior to hand over and
informing supervisor, operations, etc

He does Leveling, Alignment and Balancing ensures alignment of moving parts (e.g. Pumps,
blowers, fans etc.). He does regular upkeep of Hydraulic/Pneumatic equipment/system,
checking of hydraulic medium (hydraulic mineral oil), air pressure, identifying problem and
rectifying breakdowns in hydraulic and pneumatic system.

Plan and organize assigned work and detect & resolve issues during execution. Demonstrate
possible solutions and agree tasks within the team. Communicate with required clarity and
understand technical English. Sensitive to environment, self-learning and productivity.

Perform TPM (Total Production Management), TQM (Total Quality Management) and record
keeping system.

Reference NCO:
1. 7126.0301, - Pipe Fitter
2. 7126.9900, - Plumbers and Pipe Fitters, Other
3. 7224.0102, - Fitter – Fabrication
4. 7233.0101, - Maintenance Fitter –Mechanical
5. 7233.0121, - Fitter Levelling, Alignment & Balancing
6. 7233.2901, - Fitter: Hydraulic and Pneumatic System
7. 7233.9900, - Machinery Mechanics and Fitters, Other
8. 7412.0202 - Mechanical Fitter

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4. NSQF LEVEL COMPLIANCE

NSQF level for Fitter (Steel Plant) trade under ATS: Level 5

As per notification issued by Govt. of India dated- 27.12.2013 on National Skill

Qualification Framework total 10 (Ten) Levels are defined.

Each level of the NSQF is associated with a set of descriptors made up of five outcome
statements, which describe in general terms, the minimum knowledge, skills and attributes that a
learner needs to acquire in order to be certified for that level.

Each level of the NSQF is described by a statement of learning outcomes in five

domains, known as level descriptors. These five domains are:

a) Process
b) professional knowledge,
c) professional skill,
d) core skill and
e) Responsibility.

The Broad Learning outcome of Fitter (Steel Plant) trade under ATS mostly matches with
the Level descriptor at Level- 5.

The NSQF level-5 descriptor is given below:

LEVEL Process required Professional Professional Core skill Responsibility

knowledge skill
Level 5 Job that requires knowledge a range of Desired Responsibility for
well developed of facts, cognitive and mathematical own work and
skill, with clear principles, practical skills skill, Learning and some
choice of processes and required to understanding of responsibility for
procedures in general accomplish social, political other‟s works and
familiar context. concepts, in a tasks and solve and some skill of learning.
field of problem by collecting and
work selecting and organizing
or study applying basic information,
methods, tools, communication.
materials and
information.

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5. GENERAL INFORMATION

Name of the Trade

FITTER (STEEL PLANT)
NCO-2015 7126.0301, 7126.9900, 7224.0102, 7233.0101, 7233.0121,
7233.2901, 7233.9900, 7412.0202
NSQF Level Level – 5
Duration of Apprenticeship
Training Two years (02 Blocks each of one year duration).
(Basic Training + On-Job Training)

Duration of Basic Training a) Block –I : 3 months

b) Block – II : 3 months
Total duration of Basic Training: 6 months
Duration of On-Job Training a) Block–I: 9 months
b) Block–II : 9 months
Total duration of Practical Training: 18 months
Entry Qualification Passed 10th Class with Science and Mathematics under 10+2
system of Education or its equivalent
Selection of Apprentices The apprentices will be selected as per Apprenticeship Act
amended time to time.
Instructors Qualification for As per ITI instructors qualifications as amended time to time for
Basic Training the specific trade.
Infrastructure for Basic As per related trade of ITI
Training
Examination The internal examination/ assessment will be held on completion
of each block.
Final examination for all subjects will be held at the end of course
and same will be conducted by NCVT.
Rebate to Ex-ITI Trainees 02 years
CTS trades eligible for Fitter Fitter (Steel Plant)
(Steel Plant) Apprenticeship

Note:
 Industry may impart training as per above time schedule for different block, however this is not fixed. The
industry may adjust the duration of training considering the fact that all the components under the syllabus
must be covered. However the flexibility should be given keeping in view that no safety aspects is
compromised.
 For imparting Basic Training the industry to tie-up with ITIs having such specific trade and affiliated to NCVT.

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6. LEARNING OUTCOME

6.1 GENERIC LEARNING OUTCOME

The following are minimum broad Common Occupational Skills/ Generic Learning Outcome
after completion of the Fitter (Steel Plant) course of 02 years duration under ATS.

Block I & II:-

1. Recognize & comply safe working practices, environment regulation and housekeeping.

2. Understand and explain different mathematical calculation & science in the field of study
including basic electrical. [Different mathematical calculation & science -Work, Power
& Energy, Algebra, Geometry & Mensuration, Trigonometry, Heat & Temperature,
Levers & Simple machine, graph, Statistics, Centre of gravity, Power transmission,
Pressure]

3. Interpret specifications, different engineering drawing and apply for different application
in the field of work. [Different engineering drawing-Geometrical construction,
Dimensioning, Layout, Method of representation, Symbol, scales, Different Projections,
Machined components & different thread forms, Assembly drawing, Sectional views,
Estimation of material, Electrical & electronic symbol]

4. Select and ascertain measuring instrument and measure dimension of components and
record data.

5. Explain the concept in productivity, quality tools, and labour welfare legislation and
apply such in day to day work to improve productivity & quality.

6. Explain energy conservation, global warming and pollution and contribute in day to day
work by optimally using available resources.

7. Explain personnel finance, entrepreneurship and manage/organize related task in day to

day work for personal & societal growth.

8. Plan and organize the work related to the occupation.

6.2 SPECIFIC LEARNING OUTCOME

Block – I
1. Filing & fitting of mating components within an accuracy
2. Dismounting and Mounting of pedestal & hand grinding wheel
3. Performance of common jigs and Fixture for drilling.

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4. Installation & Alignment of belts, Chain, Sprockets

5. Mounting of split bush bearing, Roller contact bearing, Taper roller bearing with proper
clearance
6. Inspection and mounting of ball bearing on shaft with proper fit.
7. Plummer blocks Mounting methods
8. Checking size of solid bush bearing, journal and housing for proper fit.
9. Checking split bush bearing for proper contact on journal and housing
10. Overhauling of gear box (Pre cleaning, dismantling, clearing, inspection,
repair/replacement, assemble).
11. Checking of backlash and root clearance with feeler gauge, Dial Test Indicator and lead
wire.
12. Shaft alignment
13. Method of levelling, Preparation of packing and shim.
14. Checking misalignment with the help of Taper gauge, Feeler gauge and Dial test.
15. Checking the verticality of a pole with the help of plum bob
16. Locking static unbalance in a rotor, finding the correction weight.
17. Cutting, Threading and fitting of pipe.
18. Method of static balancing and correction.

Block – II
1. Bending of pipes and making pipe joint as per drawing.
2. Assembly, disassembly and overhauling of valves.
3. Preventive & Schedule maintenance of pumps and overhauling of pump.
4. Dismantling, cleaning assembly of fans, Blowers, their parts.
5. Preventive & schedule maintenance.
6. Measurement current, voltage, resistance and power using appropriate measuring
equipments
7. Measurement of displacement, pressure, temperature, flow, level and speed
8. Testing of power supply (AC & DC)
9. Overhauling of Valves, Hydraulic pumps and hydraulic actuators.
10. Preparing inspection check-list, taking measurement with the help of industrial
thermometer and temperature gun.
11. Overhauling/ Assembly practice of Bearing assembly, Gear/Pulley mounting
12. Overhauling/ Assembly practice of Gear box, Pump and Valve
13. Overhauling/ Assembly practice of Jack, Hydraulic cylinder, Lifting hoist and Belts
14. Joining of metals using welding methods.
15. Inspection of plant machinery and system
16. Maintenance of Fans, Blowers and compressor
NOTE: Learning outcomes are reflection of total competencies of a trainee and assessment
will be carried out as per assessment criteria.

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7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

GENERIC LEARNING OUTCOME

LEARNING ASSESSMENT CRITERIA
OUTCOMES
1. Recognize & comply safe 1. 1. Follow and maintain procedures to achieve a safe
working practices, environment working environment in line with occupational health
regulation and housekeeping. and safety regulations and requirements.
1. 2. Recognize and report all unsafe situations according to
site policy.
1. 3. Identify and take necessary precautions on fire and
safety hazards and report according to site policy and
procedures.
1. 4. Identify, handle and store / dispose off
dangerous/unsalvageable goods and substances
according to site policy and procedures following
safety regulations and requirements.
1. 5. Identify and observe site policies and procedures in
regard to illness or accident.
1. 6. Identify safety alarms accurately.
1. 7. Report supervisor/ Competent of authority in the event of
accident or sickness of any staff and record accident
details correctly according to site accident/injury
procedures.
1. 8. Identify and observe site evacuation procedures
according to site policy.
1. 9. Identify Personal Productive Equipment (PPE) and use
the same as per related working environment.
1. 10. Identify basic first aid and use them under different
circumstances.
1. 11. Identify different fire extinguisher and use the same as
per requirement.
1. 12. Identify environmental pollution & contribute to
avoidance of same.
1. 13. Take opportunities to use energy and materials in an
environmentally friendly manner
1. 14. Avoid waste and dispose waste as per procedure
1. 15. Recognize different components of 5S and apply the
same in the working environment.

2. Understand, explain different 2.1 Explain concept of basic science related to the field such as
mathematical calculation & Material science, Mass, weight, density, speed, velocity,
science in the field of study heat & temperature, force, motion, pressure, heat treatment,

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including basic electrical and centre of gravity, friction.

apply in day to day 2.2 Measure dimensions as per drawing

work.[Different mathematical 2.3 Use scale/ tapes to measure for fitting to specification.
calculation & science -Work,
2.4 Comply given tolerance.
Power & Energy, Algebra,
Geometry & Mensuration, 2.5 Prepare list of appropriate materials by interpreting detail
Trigonometry, Heat & drawings and determine quantities of such materials.
Temperature, Levers & Simple 2.6 Ensure dimensional accuracy of assembly by using
machine, graph, Statistics, different instruments/gauges.
Centre of gravity, Power 2.7 Explain basic electricity, insulation &earthing.
transmission, Pressure]

3. Interpret specifications, 3. 1. Read & interpret the information on drawings and apply in
different engineering drawing executing practical work.
and apply for different 3. 2. Read & analyse the specification to ascertain the material
application in the field of work. requirement, tools, and machining /assembly /maintenance
[Different engineering drawing- parameters.
Geometrical construction, 3. 3. Encounter drawings with missing/unspecified key
Dimensioning, Layout, Method information and make own calculations to fill in missing
of representation, Symbol, dimension/parameters to carry out the work.
scales, Different Projections,
Machined components &
different thread forms, Assembly
drawing, Sectional views,
Estimation of material,
Electrical & electronic symbol]

4. Select and ascertain measuring 4.1 Select appropriate measuring instruments such as
instrument and measure micrometers, vernier calipers, dial gauge, bevel protector
dimension of components and and height gauge (as per tool list).
record data. 4.2 Ascertain the functionality & correctness of the instrument.
4.3 Measure dimension of the components & record data to
analyse the with given drawing/measurement.

5. Explain the concept in 5.1 Explain the concept of productivity and quality tools and
productivity, quality tools, and apply during execution of job.
labour welfare legislation and 5.2 Understand the basic concept of labour welfare legislation
apply such in day to day work to and adhere to responsibilities and remain sensitive towards
improve productivity & quality. such laws.
5.3 Knows benefits guaranteed under various acts

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6. Explain energy conservation, 6.1 Explain the concept of energy conservation, global
global warming and pollution warming, pollution and utilize the available recourses
and contribute in day to day optimally & remain sensitive to avoid environment
work by optimally using pollution.
available resources. 6.2 Dispose waste following standard procedure.

7. Explain personnel finance, 7. 1. Explain personnel finance and entrepreneurship.

entrepreneurship and 7. 2. Explain role of Various Schemes and Institutes for self-
manage/organize related task in employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for
day to day work for personal & financing/ non financing support agencies to familiarizes
societal growth. with the Policies /Programmes & procedure & the available
scheme.
7. 3. Prepare Project report to become an entrepreneur for
submission to financial institutions.

8. Plan and organize the work 8. 1. Use documents, drawings and recognize hazards in the
related to the occupation. work site.
8. 2. Plan workplace/ assembly location with due consideration
to operational stipulation
8. 3. Communicate effectively with others and plan project tasks
8. 4. Assign roles and responsibilities of the co-trainees for
execution of the task effectively and monitor the same.
SPECIFIC OUTCOME
Block- I & II (Section:10)
Assessment Criteria i.e. the standard of performance, for each specific learning
outcome mentioned under block – I & II (section: 10) must ensure that the trainee
achieves well developed skill with clear choice of procedure in familiar context.
Assessment criteria should broadly cover the aspect of Planning (Identify, ascertain,
estimate etc.); Execution (perform, illustration, demonstration etc. by applying 1) a
range of cognitive and practical skills required to accomplish tasks and solve
problems by selecting and applying basic methods, tools, materials and information
2) Knowledge of facts, principles, processes, and general concepts, in a field of work
or study 3)Desired Mathematical Skills and some skill of collecting and organizing
information, communication) and Checking/ Testing to ensure functionality during
the assessment of each outcome. The assessments parameters must also ascertain that
the candidate is responsible for own work and learning and some responsibility for
other’s work and learning.

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8. SYLLABUS

BASIC TRAINING (Block – I)

Duration: (03) Three Months

Week Professional Skills Professional Knowledge

No.
1. Cardiopulmonary Usage of Familiarization with the Institute & steel industry.
Resuscitation (CPR) Machinery used in the trade and type of work done by the
trainees in the trade.
Importance of safety, general safety precautions observed in
the Institute and in the section.
Importance of the trade & trade training,
Related instructions & subjects to be taught. Salient features
of Apprentices‟ Act. Introduction to general, behavioural
and Road safety Overview of steel manufacturing process.

2. Marking lines, Cut metals pieces of Introduction of first aid. Causes and type of fires, fire
different profiles & selections by precautions against outbreak of fire, different type of fire
hack-sawing (straight, inclined & extinguishers and their uses. Precautions while working at
curved line) to an accuracy of height. Gas safety Electrical safety Quality-brief
0.5mm introduction of improvement techniques followed in the
Filling flat, square and steps to an organization-Small group activities (SGA), Quality Circle
accuracy of 0.5mm (Measurement (QC) Importance of house keeping
by Precision Instrument).
3. Checking and setting of Linear measurements & its units. Classification and
micrometer, Vernier calipers. functional detail of following basic measuring and marking
Filling flat, square, steps and tools:-
contour surfaces to an accuracy of  Steel Rule
0.4mm.  Calipers,
 Divider, Trammel
 Try Square
 Marking Punch
Classification and functional detail of Files. Filling
technique. Precision Measuring Instruments: Concept of
precision & accuracy Micrometer (outside, inside and
depth) – working principle, use & care, calculation of least
count. Vernier calipers, principle, calculation of least count,
use and care.

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 FITTER (STEEL PLANT)
4. Transfer of dimensions from Classification and functional detail of following marking
drawing to work pieces. Finding devices:
center of a round bar with the help Surface plate, angle plate, marking block and V-Block.
of „V‟ block and marking block. Chipping technique.
Filling flat, square, steps and Introduction and care of pedestal grinding machine. Related
contour surfaces to an accuracy of hazards, risk and precautions.
0.3mm Interchangeability-Definition and its necessity, basic size,
Chipping practice on flat surface, actual size, limits, deviation, Tolerance, allowance,
slots & oils grooves, and chamfer at clearance, interference, Fits-Definition, types, description
different angle on MS plate. with sketches. Method of expressing Tolerance as per BIS,
Hole and Shaft basis (BIS standard) Related calculation on
Limit, Fit and Tolerance.
Surface finish – importance, symbol, measuring techniques.
Lapping & horning process
Jigs & fixtures-type & uses
5. Use of drilling machine for drilling Classification and functional detail of Drill, tap, dies &
through & blind holes, counter Reamer. Drilling machines:
sinking on MS flat. Drilling on -Bench, pillar & radial
cylindrical surface. Reaming of -Drilling operation
drilled hole by hand reamer. Filling -Cutting speed, feed & depth of cut. Related hazards, risk
flat, square, steps and contour and precautions.
surface to an accuracy of 0.2mm. Grinding wheel specification Bond, structure, grade,
Internal & external threading by abrasives, Types and their applications, care during
Taps & Die Making internal threads mounting and operation. Related hazards, risk and
with taps (through holes and blind precautions.
holes).
6. Scraping practice on flat & curved Scrapers:
surfaces Filing practice on internal Types and use
and external profiles to an accuracy Marking media, Prussian blue, red lead, chalk and their
of 0.2mm. special application and description. Precision measuring
instruments: Classification, use, least count Vernier height
gauge, Dial test indicator, Digital Micrometer, Vernier
Bevel protractor Gauges- Classification and uses of Sine
bar, Slip gauge, Limit gauge, Feeler gauge, thread gauge,
screw pitch gauge, taper gauge. Brief Introduction to ferrous
metals used for hand tools. Concept of normalizing,
annealing, tempering, case hardening. Related hazards, risk
and precautions.

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 FITTER (STEEL PLANT)
7. Identification of various types of Introduction to fasteners, screw threads, related terminology
fasteners & locking devices, and specification.
checking threads, use of various Keys-types & use,(parallel, sunk, tangential, gib head,
type of spanners, Use of circlip and woodruff, key ways.)
circlip plier. Related hazards, risk and precautions
Filling & fitting mating Types of nuts, bolt, studs, locking devices for nut, wrench
components within an accuracy of and spanner, pliers, screw drivers, Circlip, split pin,
± 0.10mm & angular 30 minutes. Concept of torque & torque wrench.
Tightening of nut with the help of
torque wrench Different types of rivets and their application.

8. Identification of various Elements of mechanical power transmission, type of

components of mechanical power spindles and shafts (Universal spindle, Plain shaft, Hollow
transmission system- Shafts, shaft, crank shaft, cam shaft).
coupling, keys, gears, bearing, Positive and Non-positive driver, Friction drive, Gear drive,
belts, chains pulley, rope. Belt drive, Chain drive and Rope drive.
Measuring shaft and coupling bore Basic concept of Clutches
for finding out taper & ovality and Couplings:
to determine the type of fit. Concept of coupling and its type viz. Rigid coupling- Muff
Finding out the size of key for a coupling, Flange coupling, Flexible coupling, Pin-bush
given set of shaft & bore. Key coupling, Chain coupling, Gear coupling, Spider coupling,
making, mounting of coupling on Tyre coupling, Grid coupling, Oldham-coupling, Fluid
shaft with key. coupling, Universal coupling.
Belts-
Belt specification (Flat and V)
Pulley used for belts driver.

9. Identification of various types of Bearing:

bearings. Type, description and function of sliding and rolling
Identification of various types of contact bearings-
rolling contact bearing and Tools- Solid bush, Split bush, Collar and Pivot bearing.
tackles used for mounting and Type of Rolling contact bearings-Bell bearings-Deep
dismounting. groove, Angular contact, magneto bearing, Self aligning and
Ball thrust bearing.
Roller bearing-Cylindrical-Needle roller, Taper roller,
Spherical roller, self aligning and Spherical roller thrust
bearing. ISO bearing designation code.
10. Filing & fitting mating components Gear:
within an accuracy of ± 0.12 mm & Type, description and function of gears-Spur, Single helical,
angular within 30 minutes. Double helical, Spiral, Bevel, Straight and Spiral bevel,

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 FITTER (STEEL PLANT)
Worm gears, Rack and pinion. Gear terminology.
Gear train- simple, compound, reverted and epicyclic.
Types of Gear box Gear meshing
Lubrication (oil and Grease)
Concept of lubrication Types and properties of Oil and
Grease. Methods of oil lubrication- Once through and
centralized system-grease guns, centralized system.
11. Plane and Step turning up to an Introduction to lathe machines and lathe operations.
accuracy of 0.1 mm Cutting tools.
Removal of broken studs from an Speed, feed & depth of cut
assembly. Lathe accessories and attachment.
Related hazards, risk and precautions.
Type of taper and methods of taper turning.
Introduction to Shaper machine and shaper operations.
Quick return mechanism of shaper. Speed, feed & depth of
cut. Types of pipe, tubes and different fittings. Tools used
in pipe work.
12. Making key in a shaper machine up Leveling
to an accuracy of 0.1mm. Definition and importance of leveling, Concept of Soft foot,
Methods of checking and correcting soft foot.
Lap and finish flat surfaces by hand Types of levels-Sprit level, Water level, Dumpy level.
only Alignment:
Tool grinding. Definition and importance of alignment, Type of
misalignment, Shaft vs. coupling alignment, Concept of
Soft foot, Concept of axial float, Concept of indicator sag,
Dial Test Indicator, Plumbing
Understanding plumbing, method of checking the verticality
of pole or structure, Calculation of packing required to
make corrections.
Balancing
Understanding importance of balancing and reasons of
unbalancing. Types of unbalancing
13. Revision & Internal Assessment

NOTE: -

More emphasis to be given on video/real-life pictures during theoretical classes. Some real-life
pictures/videos of related industry operations may be shown to the trainees to give a feel of
Industry and their future assignment.

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 FITTER (STEEL PLANT)
BASIC TRAINING (Block – II)
Duration: (03) Three Months

Week Professional Skills Professional Knowledge

No.
1. Use of different type of valve like: Pipe bending and jointing methods. Different types of
Gate, Globe, butterfly, Diaphragm. expansions joints and their application in steel industry.
Supports and hangers. Pipe colour code.
Safety precaution to be observed while working at pipeline.
Constructional detail of different type of valve & their uses
like: Gate, Globe, butterfly, Diaphragm.
2. Identification of various types of Pump
centrifugal pumps, their parts. Function of pump.
Identification of various types of Types and working principle of centrifugal pump.
fans, Blowers, their parts. Vertical turbine pump. Constructional detail of pump.
Identification of various types of Starting and stopping Series & parallel operation of pump.
compressors, their parts. Pump performance and characteristics. Cavitations &
aeration
Fan & Blowers
Types and working principle Constructional detail of Fans
& Blowers.
Compressors
Compression theory Types of compressors Constructional
detail of compressors, working mechanism , loading
unloading.

3. Electrical: Safety in electrical shop

Safety precautions to be observed Passive circuit elements-resistors, capacitors and inductors.
while working in electric shop. Its identification and testing. Colour code.
Identification of electrical Ohm‟ law and its applications. Energy sources. Series and
accessories. parallel connections.
Making simple wiring circuits and Basic principle of DC generators and motors, alternators
measurement of current and and AC motors and transformers.
voltage. Introduction to electronics and its industrial applications.
Identification of passive and active Diodes and transistors.
electronic components. Introduction to digital electronics- numbers system and
Observation of waveforms in a logic gates Programmable logic controller (PLC)-General
power Verification of logic gate concept of working, Relay Logic Control vs PLC, Block
operations. diagram, applications.

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 FITTER (STEEL PLANT)
4. Identification and familiarization Basic principles of Hydraulic- Advantage & limitation of
of various types of hydraulic hydraulic system, hydrostatic transmission, Pascal‟s law,
elements such as pumps, valves, Brahma‟s press, pressure & flow, speed of an actuator.
actuators and oil filters. Function and construction of gear pump, vane pump and
piston pump, cylindrical & hydraulic motor.

5. Simulation of hydraulic circuits. Auxiliary & fluid conditioner: Reservoir, filter, strainer,
-Simple hydraulic circuits. pressure gauge, pipe & pipe fitting, accumulator, seal &
Practical on hydraulic circuits. packing.
Simple hydraulic circuits:
- Hydraulic symbols
- Study of different hyd. Circuits
Related hazards, risk and precautions.
Electro hydraulic circuit, Electrical components
- Switches, Solenoid, Relay
6. Identification of various types of Basic principle of pneumatic system.
pneumatic elements such as: Advantages & limitation.
control valves, actuators, filter, Air preparation.
pressure regulator and lubricator. Functional details of pneumatic cylinder, motor, control
Overhauling of pneumatic valves and FRL unit.
cylinders Introduction to Pneumatic actuators Pneumatic Symbols
- Practice on Pneumatic circuit Pneumatic circuit Electrical control components
- Switches , Solenoid, Relay
7. Video demo of awareness on Awareness on environment pollution and effects.
environment pollution. Basic knowledge of air pollution control equipment. (ESP,
Use of vibration meter to take Bag house, cyclone separators etc.) Major emission and
measurement. pollution source and their effect on environment.
Control of NOx and SOx and SPM to permissible level.
Practice on accuracy testing of Standard of ambient air quality, work environment, effluent
machine tools. discharge.
Dust handling and disposal system. Control of water
pollution- effluent treatment plans Occupational health and
ergonomics.

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 FITTER (STEEL PLANT)
8. Setting up of an arc welding Metal joining Method & its advantages Welding (Fusion,
machine, Straight bead practice. Non-fusion & Pressure)
Edge preparation for same Common tools used in welding, Classification of welding
thickness of plate for arc welding. processes.
Laying straight-line bead on 12mm Arc Welding accessories.
M.S. Plate in flat position and Electric Arc Welding – Manual Metal Arc Welding - effect
Horizontal position. of variations in welding procedure on weldments during
Making butt, lap, tee and corner manual metal Arc Welding.
joint by arc on 12 mm M.S. Plate Basic Welding joints & Positions:-
on Flat, Horizontal position. Purpose of root gap, tacking & key hole in the job pieces
during welding.
Arc Welding Machine:- AC & DC Welding Machine
advantages & disadvantages of AC & DC Welding. Safety
Precautions: Related to Arc welding m/c & accessories.
Manual Metal Arc Welding Electrodes:- Sizes & Coding
Edge Preparation:- Necessity of edge preparation,
Nomenclature of butt & fillet weld.
Welding Symbols. Weld defects.
9. Setting up of a gas welding set. High Pressure Oxy-Acetylene Welding equipments &
Making different types of flames Accessories Safety precautions in handling Oxy-Acetylene
with gas welding equipment. Gas welding set.
Making straight beads with and Systems of Oxy-Acetylene Welding-Flashback & backfire
without filler rod. Types of Oxy-Acetylene flames:-
Making square butt joint using Gases used in welding & Gas flame combination.
plates / sheets of up to 3mm Filler Rods for Gas Welding Safety in gas cutting process.
thickness. Setting up to gas cutting Principle of gas cutting.
set. Setting up & adjustment of Oxy-Acetylene-Oxy L.P.G. cutting equipments.
flame. Gas cut plates and sheets Name and application of other metal joining methods.
for the required dimensions –
Straight cut, bevel cut, piercing
hole and profile cutting.

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 FITTER (STEEL PLANT)
10. Dismantle, inspect and do minor Knowledge of different tools & tackles used in rigging.
repairs and assemble machine Construction and capacity of wire rope. Capacity of ropes
tools such as drill, shaper, lathe (other than wire rope). Application of knots and hitches.
and power saw machines. Care and maintenance of wire rope. Different type of jacks,
chain block and pull lift. Knowledge of different types of
scaffolding. Material movement by using different rigging
tools and techniques. Safety appliances & precautions in
rigging. Maintenance of tools and tackles. Principle & mode
of material handling. Various components used in belt
conveyor system & their functions.(Pulleys, idlers, scrapers,
skirts, belt, take up unit system and safety devices)
Vibratory screen- working mechanism.
Feeders:- types, working, mechanism.

11. Practice of different type of knots Different types of raw materials used for Iron making.
& hitches used in material Process of sinter, coke, iron and
handling Reaving sets of pulley steel making.
block. Awareness of rolling process. Rolling of long & flat
Splicing of manila rope. product,- Hot & cold rolling.
Inspection of wire rope. Sources of water, Various types of impurities in water
(Total suspended, dissolved solids and dissolved gases) Soft
& hard water, filtration. Awareness of water quality
parameters.
Introduction to cooling circuits- open/close
Introduction to Cooling Towers, Heat Exchangers
12. Identification of different Power transmission and lubrication system in machine
components of machine tools. tools. Accuracy testing of machine tools.
Inspection of machine tool Various maintenance practices. Maintenance strategy-
components. Demo on Reactive, Preventive, Predictive and proactive Importance
maintenance tools. of inspection. Chain and Pulley Blocks-
Demonstration on belt joining Uses and working principle -Cranes and Hoists
-Crab and winch, slings, rollers, bars and levers.
Engineering material and their properties Heat and
temperature

13. Assessment / Examination (03 days)

NOTE: -

 More emphasis to be given on video/real-life pictures during theoretical classes. Some

real-life pictures/videos of related industry operations may be shown to the trainees to
give a feel of Industry and their future assignment.

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 FITTER (STEEL PLANT)
9. SYLLABUS - CORE SKILLS

9.1 WORKSHOP CALCULATION SCIENCE & ENGINEERING DRAWING

BLOCK I

Topic a) Engineering Drawing Duration b) Workshop Science & Duration

No. (in hours) Calculation (in
hours)
30 20
1 Engineering Drawing: Unit: Systems of unit- FPS,
Introduction and its importance CGS, MKS/SI unit, unit of
length, Mass and time,
-Viewing of engineering drawing Conversion of units.
sheets.
Method of Folding of printed
Drawing Sheet as per BIS SP:46-
2003
Drawing Instruments : their
Standard and uses
- Drawing board, T-Square,
Drafter (Drafting M/c), Set
Squares, Protractor, Drawing
Instrument Box (Compass,
Dividers, Scale, Diagonal Scales
etc.), Pencils of different Grades,
Drawing pins / Clips.
2 Lines : Fractions & Simplification:
- Definition, types and Fractions, Decimal fraction,
applications in Drawing as per Multiplication and Division of
BIS SP:46-2003 Fractions and Decimals,
- Classification of lines (Hidden, conversion of Fraction to
centre, construction, Extension, Decimal and vice versa. Simple
Dimension, Section) problems
- Drawing lines of given length Simplification using BODMAS.
(Straight, curved)
- Drawing of parallel lines,
perpendicular line
- Methods of Division of line
segment

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 FITTER (STEEL PLANT)
3 Drawing of Geometrical Square Root : Square and
Figures: Definition, nomenclature Square Root, method of finding
and practice of - out square roots, Simple
- Angle: Measurement and its problem using calculator
types, method of bisecting.
- Triangle -different types
- Rectangle, Square, Rhombus,
Parallelogram.
- Circle and its elements.
4 Lettering and Numbering as per Ratio &Proportion: Simple
BIS SP46-2003: calculation on related problems.
- Single Stroke, Double Stroke,
inclined, Upper case and Lower
case.
5 Free Hand sketch: Hand tools Percentage: Introduction,
and measuring instruments used Simple calculation. Changing
in electronics mechanics Trades percentage to decimal and
fraction and vice-versa.
6 Free hand drawing : Material Science : Properties -
- Lines, polygons, ellipse, etc. Physical & Mechanical, Types
- Geometrical figures and blocks –Ferrous & Non-Ferrous,
with dimension. difference between Ferrous and
-Transferring measurement from Non-Ferrous metals,
the given object to the free hand introduction of Iron, Cast Iron,
sketches. Wrought Iron, Steel, difference
between Iron and Steel, Alloy
steel, carbon steel, stainless
steel, Non-Ferrous metals, Non-
Ferrous Alloys.

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 FITTER (STEEL PLANT)
B. Block- II

Topic a) Engineering Drawing Duration b) Workshop Science & Durati

No. (in Calculation on
hours) (in
hours)
30 20
1 Symbolic Representation (as per Mass ,Weight and Density :
BIS SP:46-2003) of : Mass, Unit of Mass, Weight,
- Fastener (Rivets, Bolts and difference between mass and
Nuts) weight, Density, unit of density,
- Bars and profile sections specific gravity of metals
- Weld, brazed and soldered
joints. - Electrical and electronics
element
- Piping joints and fittings
2 Construction of Scales and Work, Power and Energy: work,
diagonal scale unit of work, power, unit of
power, Horse power of engines,
3 LED, IRLED, photo diode, photo mechanical efficiency, energy, use
transistor, opto-coupler symbols of energy, potential and kinetic
symbol of Logic gates energy, examples of potential
energy and kinetic energy.
4 Half adder, full adder, Algebra: Addition, Subtraction,
multiplexer and de-multiplexer Multiplication, Division,
Algebraic formula, Linear
equations (with two variables).

5 UJT, FET, MOSFET, DIAC, Mensuration: Area and perimeter

TRIC, SCR, IGBT symbols and of square, rectangle,
circuits of FET Amplifier, SCR parallelogram, triangle, circle,
using UJT triggering, snubber semi circle.
circuit, light dimmer circuit using Volume of solids – cube, cuboid,
TRIAC, UJT based free running cylinder and Sphere.
oscillator. Surface area of solids – cube,
cuboid, cylinder and Sphere.
Trigonometry: Trigonometrical
ratios, measurement of angles.
Trigonometric tables.
Finding height and distance by
trigonometry.

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 FITTER (STEEL PLANT)
9.2 EMPLOYABILITY SKILLS

(DURATION: - 110 HRS.)

Block – I
(Duration – 55 hrs.)
1. English Literacy
Duration : 20 Hrs. Marks : 09
Pronunciation Accentuation (mode of pronunciation) on simple words, Diction
(use of word and speech)

Functional Grammar Transformation of sentences, Voice change, Change of tense,

Spellings.

Reading Reading and understanding simple sentences about self, work and
environment

Writing Construction of simple sentences Writing

simple English

Speaking / Spoken Speaking with preparation on self, on family, on friends/ classmates,

English on know, picture reading gain confidence through role-playing and
discussions on current happening job description, asking about
someone's job habitual actions. Cardinal (fundamental) numbers
ordinal numbers. Taking messages, passing messages on and filling in
message forms Greeting and introductions office hospitality, Resumes
or curriculum vita essential parts, letters of application reference to
previous communication.

2. I.T. Literacy
Duration : 20 Hrs. Marks : 09
Basics of Computer Introduction, Computer and its applications, Hardware and peripherals,
Switching on-Starting and shutting down of computer.

Computer Operating Basics of Operating System, WINDOWS, The user interface of

System Windows OS, Create, Copy, Move and delete Files and Folders, Use of
External memory like pen drive, CD, DVD etc, Use of Common
applications.

Word processing and Basic operating of Word Processing, Creating, opening and closing
Worksheet Documents, use of shortcuts, Creating and Editing of Text, Formatting
the Text, Insertion & creation of Tables. Printing document.
Basics of Excel worksheet, understanding basic commands, creating
simple worksheets, understanding sample worksheets, use of simple
formulas and functions, Printing of simple excel sheets.

Computer Networking Basic of computer Networks (using real life examples), Definitions of

27
 FITTER (STEEL PLANT)
and Internet Local Area Network (LAN), Wide Area Network (WAN), Internet,
Concept of Internet (Network of Networks),
Meaning of World Wide Web (WWW), Web Browser, Web Site, Web
page and Search Engines. Accessing the Internet using Web Browser,
Downloading and Printing Web Pages, Opening an email account and
use of email. Social media sites and its implication.
Information Security and antivirus tools, Do's and Don'ts in
Information Security, Awareness of IT - ACT, types of cyber crimes.

3. Communication Skills
Duration : 15 Hrs. Marks : 07
Introduction to Communication and its importance
Communication Skills Principles of Effective communication
Types of communication - verbal, non verbal, written, email, talking on
phone.
Non verbal communication -characteristics, components-Para-language
Body language
Barriers to communication and dealing with barriers.
Handling nervousness/ discomfort.

Listening Skills Listening-hearing and listening, effective listening, barriers to

effective listening guidelines for effective listening.
Triple- A Listening - Attitude, Attention & Adjustment.
Active Listening Skills.

Motivational Training Characteristics Essential to Achieving Success.

The Power of Positive Attitude.
Self awareness
Importance of Commitment
Ethics and Values
Ways to Motivate Oneself
Personal Goal setting and Employability Planning.

Facing Interviews Manners, Etiquettes, Dress code for an interview

Do's & Don'ts for an interview.

Behavioral Skills Problem Solving

Confidence Building
Attitude

Block – II
Duration – 55 hrs.
4. Entrepreneurship Skills
Duration : 15 Hrs. Marks : 06
Concept of Entrepreneur - Entrepreneurship - Enterprises:-Conceptual issue
Entrepreneurship Entrepreneurship vs. Management, Entrepreneurial motivation.
Performance & Record, Role & Function of entrepreneurs in relation to
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 FITTER (STEEL PLANT)
the enterprise & relation to the economy, Source of business ideas,
Entrepreneurial opportunities, The process of setting up a business.

Project Preparation & Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept
Marketing analysis & application of PLC, Sales & distribution Management. Different
Between Small Scale & Large Scale Business, Market Survey,
Method of marketing, Publicity and advertisement, Marketing Mix.
Institutions Support Preparation of Project. Role of Various Schemes and Institutes for self-
employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/
non financing support agencies to familiarizes with the Policies
/Programmes & procedure & the available scheme.

Investment Project formation, Feasibility, Legal formalities i.e., Shop Act,

Procurement Estimation & Costing, Investment procedure - Loan procurement -
Banking Processes.

5. Productivity
Duration : 10 Hrs. Marks : 05
Benefits Personal / Workman - Incentive, Production linked Bonus,
Improvement in living standard.

Affecting Factors Skills, Working Aids, Automation, Environment, Motivation - How

improves or slows down.

Comparison with Comparative productivity in developed countries (viz. Germany,

developed countries Japan and Australia) in selected industries e.g. Manufacturing, Steel,
Mining, Construction etc. Living standards of those countries, wages.

Personal Finance Banking processes, Handling ATM, KYC registration, safe cash
Management handling, Personal risk and Insurance.

6. Occupational Safety, Health and Environment Education

Duration : 15 Hrs. Marks : 06
Safety & Health Introduction to Occupational Safety and Health importance of safety
and health at workplace.

Occupational Hazards Basic Hazards, Chemical Hazards, Vibroacoustic Hazards, Mechanical

Hazards, Electrical Hazards, Thermal Hazards. Occupational health,
Occupational hygienic, Occupational Diseases/ Disorders & its
prevention.

Accident & safety Basic principles for protective equipment.

Accident Prevention techniques - control of accidents and safety
measures.

First Aid Care of injured & Sick at the workplaces, First-Aid & Transportation

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 FITTER (STEEL PLANT)
of sick person.

Basic Provisions Idea of basic provision legislation of India.

safety, health, welfare under legislative of India.

Ecosystem Introduction to Environment. Relationship between Society and

Environment, Ecosystem and Factors causing imbalance.

Pollution Pollution and pollutants including liquid, gaseous, solid and hazardous
waste.

Energy Conservation Conservation of Energy, re-use and recycle.

Global warming Global warming, climate change and Ozone layer depletion.
Ground Water Hydrological cycle, ground and surface water, Conservation and
Harvesting of water.

Environment Right attitude towards environment, Maintenance of in -house

environment.

7. Labour Welfare Legislation

Duration : 05 Hrs. Marks : 03
Welfare Acts Benefits guaranteed under various acts- Factories Act, Apprenticeship
Act, Employees State Insurance Act (ESI), Payment Wages Act,
Employees Provident Fund Act, The Workmen's compensation Act.

8. Quality Tools
Duration : 10 Hrs. Marks : 05
Quality Consciousness Meaning of quality, Quality characteristic.

Quality Circles Definition, Advantage of small group activity, objectives of quality

Circle, Roles and function of Quality Circles in Organization,
Operation of Quality circle. Approaches to starting Quality Circles,
Steps for continuation Quality Circles.

Quality Management Idea of ISO 9000 and BIS systems and its importance in maintaining
System qualities.

House Keeping Purpose of House-keeping, Practice of good Housekeeping.

Quality Tools Basic quality tools with a few examples.

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 FITTER (STEEL PLANT)

10. DETAILS OF COMPETENCIES (ON-JOB TRAINING)

BROAD LEARNING TO BE COVERED IN INDUSTRY FOR FITTER (STEEL PLANT)

TRADE:

1. Safety and best practices /Basic Industrial Culture (5S, KAIZEN, etc.)
2. Record keeping and documentation
3. Fitting components using different metal fitting procedure and perform testing of the
assembly.
4. Assembling of different components as per requirement and check functionality.
5. Carryout maintenance of different systems .
6. Note: Actual training will depend on the existing facilities available in the
establishments.
The competencies/ specific outcomes on completion of On-Job Training are detailed
below: -

Block – I

1. Practice and understand precautions to be followed while working in fitting jobs.

2. Prepare different types of documentation as per industrial need by different methods of
recording information
3. Demonstration of common jigs and Fixture for drilling.
4. Dismounting and Mounting of pedestal & hand grinding wheel
5. Filing & fitting of mating components within an accuracy
6. Installation & Alignment of belts, Chain, Sprockets
7. Mounting of split bush bearing, Roller contact bearing, Taper roller bearing with proper
clearance
8. Inspection and mounting of ball bearing on shaft with proper fit.
9. Plummer blocks Mounting methods
10. Checking size of solid bush bearing, journal and housing for proper fit.
11. Checking split bush bearing for proper contact on journal and housing
12. Overhauling of gear box (Pre cleaning, dismantling, clearing, inspection,
repair/replacement, assemble).
13. Checking of backlash and root clearance with feeler gauge, Dial Test Indicator and lead
wire.
14. Shaft alignment
15. Method of levelling, Preparation of packing and shim.
16. Checking misalignment with the help of Taper gauge, Feeler gauge and Dial test.
17. Checking the verticality of a pole with the help of plum bob
18. Locking static unbalance in a rotor, finding the correction weight.
19. Cutting, Threading and fitting of pipe.
20. Method of static balancing and correction.

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 FITTER (STEEL PLANT)

Block – II
1. Bending of pipes and making pipe joint as per drawing.
2. Assembly, disassembly and overhauling of valves.
3. Preventive & Schedule maintenance of pumps and overhauling of pump.
4. Dismantling, cleaning assembly of fans, Blowers, their parts.
5. Preventive & schedule maintenance.
6. Measurement current, voltage, resistance and power using appropriate measuring
equipments
7. Measurement of displacement, pressure, temperature, flow, level and speed
8. Testing of power supply (AC & DC)
9. Overhauling of Valves, Hydraulic pumps and Hydraulic actuators.
10. Preparing inspection check-list, taking measurement with the help of industrial
thermometer and temperature gun.
11. Overhauling/ Assembly practice of Bearing assembly, Gear/Pulley mounting
12. Overhauling/ Assembly practice of Gear box, Pump and Valve
13. Overhauling/ Assembly practice of Jack, Hydraulic cylinder, Lifting hoist and Belts.
14. Joining of metals using welding methods.
15. Inspection of plant machinery and system
16. Maintenance of Fans, Blowers and compressor

Note:
1. Industry must ensure that above mentioned competencies are achieved by the trainees
during their on job training.
2. In addition to above competencies/ outcomes industry may impart additional training
relevant to the specific industry.

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FITTER ((STEEL PLANT)
ANNEXURE – I

INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL

KNOWLEDGE

FITTER (STEEL PLANT)

LIST OF TOOLS AND EQUIPMENT for Basic Training (For 20 Apprentices)
Sl. No. Item Qty
1. Steel Rule 15cm with metric graduation As required.
2. Try Square 10cm blade.
3. Caliper outside 15cm spring
4. Caliper inside 15cm spring.
5. Caliper 15cm hermaphrodite
6. Divider 15cm spring
7. Straight Scriber 15cm.
8. Centre Punch 10cm.
9. Screw driver 15cm
10. Chisel cold flat 10cm
11. Hammer ball peen 0.45 kg. With handle
12. Hammer ball peen 0.22 kg. With handle
13. File flat 25cm. second cut
14. File flat 25 cm. smooth
15. File half round second cut 15cm.
16. Hacksaw frame fixed 30cm.
17. Safety goggles.
18. Dot slot punch 10 cm.
19. Steel Rule 30cm to read metric.
20. Steel Rile 60cm.
21. Straight edge 45cm steel
22. Surface plate 45x45 cm Cl/Granite.
23. Marking table 91x91x122 cm.
24. Universal scribing block 22cm.
25. V-Block pair 7cm and 15cm with clamps
26. Square adjustable 15cm blade.
27. Angle plate 10 x 20 cm.
28. Spirit Level 15cm metal
29. Punch letter 3mm set.
30. Punch number set 3mm
31. Punch hollow 6mm to 19 set of 5
32. Punch round 3mm x 4mm set of 2.
33. Portable hand drill (Electric)0 to 6mm

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FITTER ((STEEL PLANT)
34. Drill twist s/s 1.5 to 12mm by 0.5 mm
35. Drill twist S/S 8mm to 15mm by ½ mm
36. Taps and dies complete set in box B.A
37. Taps and dies complete set in box with-worth.
38. Taps and dies complete set in box 3-18mm set of 10
39. File warding 15cm smooth
40. File knife edge 15cm smooth
41. File cut saw 15cm smooth
42. File feather edge 15cm smooth
43. File triangular 15cm smooth
44. File round 20 cm second cut
45. File square 15cm second cut
46. File square 25cm second cut
47. Feeler gauge 10 blades
48. File triangular 20cm second cut
49. File flat 30cm second cut
50. File flat 20cm bastard
51. File flat 30cm bastard.
52. File Swiss type needle set of 12.
53. File half round 25cm second cut.
54. File half round 25cm bastard
55. File round 30cm bastard
56. File hand 15cm second cut.
57. Card file.
58. Oil Stone 15cm x 5cm x 2.5cm
59. Stone carborandum 15cm x 5cm x 5cm x 4cm.
60. Oil Can 0.25 litres.
61. Pliers Combination 15 cm
62. Soldering Iron 350 gm.
63. Blow lamp 0.50 litres.
64. Spanner D.E. 6-25mm set of 10 pcs.
65. Spanner adjustable 15cm
66. Interchangeable ratchet socket set with a 12mm driver, sized 10-
32mm set of 18 socket & attachments.
67. Box spanner set 6-25mm set of 8 with Tommy bar.
68. Glass magnifying 7cm
69. Clamp toolmaker 5cm and 7.5cm set of 2.
70. Clamp “C” 5cm
71. Clamp “C” 10cm
72. Hand Reamer adjustable cover max 9,12,18mm-set of 3
73. Hand Reamer taper 4-9mm set of 6 OR 4-7mm set of 4.
74. Reamer parallel 12-16mm set of 5.

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FITTER ((STEEL PLANT)
75. Scraper flat 15cm
76. Scraper triangular 15cm
77. Scraper half round 15cm
78. Chisel cold 9mm cross cut 9mm diamond.
79. Chisel cold 19mm flat
80. Chisel cold 9mm flat
81. Stud Extractor EZY-out
82. Combination Set 30cm.
83. Micrometer 0-25 mm outside.
84. Micrometer 25-50mm outside.
85. Micrometer 50-75mm outside.
86. Micrometer inside 25-50 mm with extension rods.
87. Vernier calliper 15cm
88. Vernier height gauges 30cm.
89. Vernier bevel protractor.
90. Screw pitch gauge.
91. Wire gauge, metric standard.
92. Drill twist Taper Shank 12mm to 25mm x 1.5.
93. Drill chunk 12mm.
94. Pipe wrench 40cm
95. Pipe wrench 30cm
96. Pipe vice 100mm
97. Adjustable pipe tap set BSP with die set cover pipe size 15,
20,25,32,38,50mm.
98. Wheel dresser (One for 4 units).
99. Machine vice 10 cm
100. Machine vice 15 cm
101. Sleeve drill Morse 0-1,1-2,2-3.
102. Vice bench 12cm jaws.
103. Vice leg 10cm jaw.
104. Bench working 240 x 120 x 90 cm.
105. Almirah 180 x 90 x 45cm
106. Lockers with 8 drawers (standard size).
107. Metal rack 182 x 182 x 45 cm
108. Instructor Table
109. Instructor Chair
110. Black Board with eraser.
111. Fire extinguisher (For 4 units)
112. Fire Buckets
113. Wing compass 25.4cm or 30cm.
114. Hand hammer 1kg. with handle
115. Slip Gauge as Johnson metric set.

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 FITTER ((STEEL PLANT)
116. Carbide Wear Block 1mm-2mm.
117. Gauge snap Go and Not Go 25 to 50mm by 5mm.Set of 6pcs.
118. Gauge plug single 3 ended 5 to 55 by 5mm. Set of 11 pcs.
119. Gauge telescopic upto 150mm.
120. Dial test indicator. 01mm on stand.
121. Sine bar 125mm.
122. Sine bar 250mm.
123. Lathe tools H.S.S. tipped set.
124. Lathe tools bit 6mm x 75mm.
125. Lathe tools bit 8mm x 75mm.
126. Lathe tools bit 10mm x 85mm.
127. Arm strong type tool bit holder R.H.
128. Arm strong type tool bit holder L.H.
129. Arm strong type tool bit holder straight.
130. Stilson wrenches 25cm.
131. Pipe cutter 6mm to 50mm wheel type.
132. Pipe bender spool type up to 25mm. with stand manually operated.
133. Adjustable pipe chain tonge to take pipes up to 300mm.
134. Adjustable spanner 38 cm long.
135. Dial vernier caliper 0-200 mm LCO 0.05mm.(Universal type)
136. Screw thread micrometer with interchangeable 0-25mm. Pitch
anvils
137. for checking metric threads 60.
138. Depth micrometer 0-25mm. 0.01mm.
139. Vernier caliper 0-150mm. L.C. 0.02mm.
140. Comparators stand with dial indicator LC 0.01mm.
141. Engineer‟s try square (knife-wedge) 150mm blade.
LIST OF ADDITIONAL TOOLS FOR ALLIED TRADE IN WELDING
142. Transformer welding set 150 amps.-continuous welding current, As required
with all accessories and electrode holder.
143. Welder cable to carry 200 amps. With flexible rubber cover
144. Lungs for cable
145. Earth clamps.
146. Arc welding table (all metal top) 122cm x 12cm x 60mm with
positioner.
147. Oxy-acetylene gas welding set equipment with hoses, regulator
and other accessories.
148. Gas welding table with positioner
149. Welding torch tips of different sizes
150. Gas lighter.
151. Trolley for gas cylinders.
152. Chipping hammer.
153. Gloves (Leather)

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 FITTER ((STEEL PLANT)
154. Leather apron.
155. Spindle key for cylinder valve.
156. Welding torches 5 to 10 nozzles.
157. Welding goggles.
158. Welding helmet with coloured glass.
159. Tip cleaner

The specifications of the items in the above list have been given in Metric Units. The items which are
available in the market nearest of the specification as mentioned above, if not available as prescribed
should be procured Measuring instruments such as steel rule which are graduated both English and
Metric Units may be procured, if available.

General Machinery Installation

1. Drilling machine pillar sensitive 0-20 mm cap with chuck & key
2. Drilling machine pillar sensitive 0-12 mm cap motorized with chuck and key.
3. Grinding machine (general purpose) D.E. pedestal with 20 cm dia. wheels rough and
smooth with twist drill grinding- attachment.

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 FITTER ((STEEL PLANT)
INFRASTRUCTURE FOR WORKSHOP CALCULATION & SCIENCE AND
ENGINEERING DRAWING

TRADE: Fitter (Steel Plant)

LIST OF TOOLS& EQUIPMENTS FOR -20APPRENTICES

1) Space Norms : 45 Sq. m.(For Engineering Drawing)

2) Infrastructure:

A : TRAINEES TOOL KIT:-

Sl.
Name of the items Specification Quantity
No.
1. Draughtsman drawing instrument box 20+1 set
2. Set square celluloid 45⁰ (250 X 1.5 mm) 20+1 set
3. Set square celluloid 30⁰-60⁰ (250 X 1.5 20+1 set
mm)
4. Mini drafter 20+1 set
5. Drawing board (700mm x500 mm) IS: 1444 20+1 set
B : Furniture Required
Sl.
Name of the items Specification Quantity
No.
1 Drawing Board 20
2 Models : Solid & cut section as required
3 Drawing Table for trainees as required
4 Stool for trainees as required
5 Cupboard (big) 01
6 White Board (size: 8ft. x 4ft.) 01
7 Trainer‟s Table 01
8 Trainer‟s Chair 01

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 FITTER ((STEEL PLANT)

TOOLS & EQUIPMENTS FOR EMPLOYABILITY SKILLS

Sl. No. Name of the Equipment Quantity
1. Computer (PC) with latest configurations and Internet connection with 10 Nos.
standard operating system and standard word processor and worksheet
software
2. UPS - 500VA 10 Nos.
3. Scanner cum Printer 1 No.
4. Computer Tables 10 Nos.
5. Computer Chairs 20 Nos.
6. LCD Projector 1 No.
7. White Board 1200mm x 900mm 1 No.

Note: - Above Tools & Equipments not required, if Computer LAB is available in the institute.

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 ANNEXURE-II

FORMAT FOR INTERNAL ASSESSMENT

Name & Address of the Assessor : Year of Enrollment :

Name & Address of ITI (Govt./Pvt.) : Date of Assessment :

Name & Address of the Industry : Assessment location: Industry / ITI

Trade Name : Semester: Duration of the Trade/course:

Learning Outcome:

Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15

assessment Marks
Quality in workmanship
Attendance/ Punctuality

Skills to handle tools &

Safety consciousness

Speed in doing work

Total internal
Workplace hygiene

Result (Y/N)
Economical use of
Manuals/ Written
Ability to follow

Application of
instructions

Knowledge
Sl. No

equipment

materials

VIVA
Father's/Mother’s
Candidate Name
Name

40