SYLLABUS For the trade of

OPERATOR SINTER PLANT EQUIPMENTS

Under Apprenticeship Training Scheme (ATS)

GOVERNMENT OF INDIA MINISTRY OF LABOUR & EMPLOYMENT DIRECTORATE GENERAL OF EMPLOYMENT & TRAINING

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN-81, SECTOR-V, SALT LAKE CITY KOLKATA – 700 091

List of members attended the Trade Committee meeting for designing of syllabus for the trade of “Operator Sinter Plant Equipment” under Apprenticeship Training Scheme (ATS) at Central Staff Training & Research Institute (CSTARI), Kolkata. Sl. No.

NAME & DESIGNATION S/Shri 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Sanjay Kant, Joint Director K.L.Kuli, O.P.Gupta, DGM (HRD), SAIL S.Nair, AGM (HRD), SAIL N.N.Tiwari, Programme Director (O&P) P.Debnath, Manager Personnel, SAIL K. Srinivasa Rao, AGM (Training) Pradip Sett, AGM (HRD), SAIL R. Choudhury, DGM (Roll Shop), SAIL Amitava Roy, Sr. Lecturer (Elect. Engg.) A.N.Mishra, AGM (SMS), SAIL Major K.Satyanarayana Prof. P.Sadhu Khan, Deptt. Of Metallurgy I. Mukherjee, AGM (RMHP), SAIL Bhaskar Prasad , AGM (COCC), SAIL M.Pramanik, AGM (CHP-OP), SAIL Dr. D.Basu

18. Sameer Jain, AGM (O), Sinter Plant , SAIL 19. L.K. Mukherjee, Dy. Director of Trg. 20. K.N.Halder, Dy. Director of Trg. 21. N. Nath, Asst. Director Trg. 22. A.K.Bhattacharya, Training Officer 23. Mr. Muktanand, Training Officer

ORGANISATION RDAT, Kolkata CSTARI, Kolkata Bokaro Steel Plant, Bokaro Bhilai Steel Plant , Bhilai Tata Steel Ltd. , Jamshedpur

REMARKS Chairman Member Member Member Member

Durgapur Steel Plant, Durgapur

Member

Visakhapatnam Steel Plant, Visakhapatnam Durgapur Steel Plant, Durgapur Durgapur Steel Plant, Durgapur

Member Member Member

AJC Bose Polytechnic, 24 Paraganas (North) Durgapur Steel Plant, Durgapur Tata Steel Ltd. , Jamshedpur Bengal Engineering & Science University, Shibpur Durgapur Steel Plant, Durgapur

Member Member Member Member

Durgapur Steel Plant, Durgapur

Member

Durgapur Steel Plant, Durgapur

Member

Directorate Of Industrial Training, West Bengal Durgapur Steel Plant, Durgapur

Member Member

CSTARI, Kolkata

Member

CSTARI, Kolkata CSTARI, Kolkata RDAT (ER), Kolkata

Member Member Member

RDAT (ER), Kolkata

Member

Member

GENERAL INFORMATION

1. Name of trade

: Operator Sinter Plant Equipments

2. NCO Code

: 8121.90

3. Duration of apprenticeship training

: 02 Years

4. Entry Qualification

: Passed 8th class examination from a recognized school or its equivalent.

5. Ratio of apprentices to Worker

: 1:5

SYLLABUS FOR THE TRADE OF

Operator Sinter Plant Equipment

UNDER APPRENTICESHIP TRAINING SCHEME PERIOD OF TRAINING: TWO YEARS

Course Contents 1. Induction and Safety Training 2. Overview of Sinter Plant & Related Safety Aspects 3. Material handling equipments 4. Material receiving and proportioning 5. Nodulising drum operation 6. Compressor operation 7. Pump house operation 8. Exhauster operation 9. Gas mixing and boosting station 10. Sinter Dispatch operation 11. Pollution control equipments operation Air conditioning and ventilation 12. Technical cell 13. Sinter Machine operation 14. Sinter screening system 15. Lime dosing system 16. Tests & Evaluations Total

: 4 weeks : 1 week : 8 weeks : 10 weeks : 4 weeks : 8 weeks : 6 weeks : 4 weeks : 6 weeks : 6 weeks : 10 weeks : 7 weeks : 12 weeks : 6 weeks : 8 weeks : 4 weeks : 104 weeks

1. Induction & Safety Training:

Syllabus 4 weeks

Company Profile, Significance of Steel Business Plant familiarization, Layout, Product Mix, Objectives. Safety, Health & Environment Awareness Basic skill development training on Use of Tools, Basic Measuring Instruments, Coupling & Alignment, Welding, Gas Cutting.

2. Introduction to Sinter Plant: 1 week Practical 1. Use of protective devices like helmet, gloves, safety belts 2. Use of gas safety devices 3. Use of fire fighting equipments 4. Layout of sintering plant, assembly point, emergency exits 5. Visit to Hazardous areas of sintering plant

4 weeks

Theory 1. Introduction to sintering, equipment details, flow process, organization structure, working of sinter plant, 2. Safety instruction for Sinter plant 3. Hazards of sinter plant 4. Material handling equipment safety 5. System of permits and shutdown

3. Sinter plant equipments: 8 weeks Practical Theory 1. Operation of various material 1. Introduction to various material handling equipments with handling equipments at sinter plant monitoring and logging of 2. Layout and capacity, 3. Operational parameters of operational parameters equipments 2. Schedule and critical check up 4. Maintenance schedule and before start up identification of trouble 3. Inspection during running of 5. Safety devices on equipments and equipments their functions 4. Housekeeping activities of 6. Lubrication system equipment 5. Operation during conditions of 7. Identification of troubles and overload, jam, drive failure proper reporting. 6. Actions during emergency conditions 7. Logging of parameters 8. Procedure for shut down 9. Inspection of side skirts, return idlers, back plate rubber, chute liners, CCD etc. 10. Identification of troubles

4. Material receiving and proportioning: Practical 1. Operation of weigh feeders/ receiving conveyors 2. Operational aspects for material receiving like sequence of bunker filling, level of filling , withdrawal sequence etc. 3. Calibration of weigh feeders 4. Online cleaning during shutdown 5. Inspection of equipments and log book recording 6. Inspection of running equipments 7. Housekeeping activities of equipment and grill at bunker top including boulder removal and disposal 8. Operation during conditions of overload, jam, drive failure 9. Actions during emergency conditions 10. Logging of parameters 11. Procedure for shut down of equipment

10 weeks Theory 1. Introduction to various material received at sinter plant 2. Functions and role of material receiving 3. Layout and capacity 4. Operational parameters of equipments 5. Identification of trouble 6. Safety devices on equipments and its functions 7. Calculation of material received and sinter production based on yield and blend mix consumption

5. Balling and Nodulising Drum Operation: Practical 1. Operation in local and auto mode 1. 2. Online inspection of Drum Lubrication and greasing of tyres 2. 3. Inspection of water spray nozzles 3. 4. Discharge chute and inlet chute inspection and cleaning activity 4. 5. Housekeeping activities of equipment 5. 6. Operation during conditions of overload, jam, drive failure 6. 7. Actions during emergency conditions

4 weeks Theory Introduction to Nodulising drum and its functions Layout and details Operational parameters of Nodulising Drum Maintenance schedule and trouble shooting Safety devices on equipments and its functions Air blaster

8. Procedure for shut down equipment 9. Air blaster operation 10. Operation of jack hammer 11. Flushing of lines water and air

of

6. Compressor Operation: 8 weeks Practical Theory 1. Operation of Compressor both in 1. Introduction to Compressor and local and auto mode its functions 2. Online inspection of Compressor 2. Pre and Post Start Checks Lubrication 3. Layout details 3. Check up procedure before start 4. Operational parameters of up equipments 4. Cleaning of filters 5. Maintenance schedule and trouble 5. Housekeeping activities of shooting equipment 6. Safety devices on equipments and 6. Operation during conditions of its functions overload, jam, drive failure 7. Screw compressor 7. Actions during emergency 8. Air filters and driers conditions 9. Air tanks and piping networks 8. Procedure for shut down of 10. Nitrogen change over equipment 11. Handling Emergency situations. 9. Operation of air drier 10. Air tank operation 11. Different valves, coolers, gauges, instruments operation 12. Starting and stopping of compressor

7. Pump House Operation: 6 weeks Practical 1. Operation of Pumps both in local 1. and auto mode 2. Online inspection of pump and glands 2. 3. Check up procedure before start 3. up 4. Gland packing 4. 5. Housekeeping activities of 5. equipment 6. Operation during conditions of 6. overload, jam, drive failure 7. 7. Actions during emergency conditions 8. 8. Procedure for shut down of 9. equipment 9. Diesel pump operation 10. Fire fighting pump operation 11. Different valves gauges, instruments operation 12. Operation in Auto and manual mode

8. Exhauster Operation: 4 weeks Practical 1. Operation of exhauster in local mode 2. Online inspection of exhauster 3. Check up procedure before start up 4. Housekeeping activities of equipment 5. Actions during emergency conditions 6. Procedure for shut down of exhauster 7. Operation in Auto and manual mode r 8. Oil pump change over

Theory Introduction to pumps like cold circulating , drinking water, make up water pumps, booster pumps Layout and capacity Operational parameters of pumps and pump house Identification of troubles Safety devices on equipments and its functions Pipe line network details Types of valves manual and motorized Level sensors and calibration Interlock arrangements

Theory 1. Introduction to exhauster operation 2. Layout and capacity 3. Operational parameters of exhauster 4. Identification of troubles 5. Safety devices on equipments and its functions 6. Lubrication pump and pipe line details 7. Damper control 8. Interlock scheme 9. Precautions during start up and shut down

9. Temperature and pressure gauges, scanners reading and reporting 10. Oil cooler and water circuit operation

9. Gas Mixing and Boosting Station: 6 weeks Practical Theory 1. Operation of gas boosters in local 1. Introduction to gas booster gas lines mode and Auto mode 2. Check up procedure before start 2. Layout and capacity 3. Operational parameters of up 3. Housekeeping activities of booster 4. Identification of troubles equipment 4. Actions during emergency 5. Safety devices on equipments its functions conditions 5. Procedure for shut down of gas 6. Gas valves and functions 7. Interlock scheme booster 8. Precautions during start up 6. Running checkups for booster 7. Oil pump change over shut down 8. Water seal operation, bleeder 9. Steps for shutdown operation 9. Operation of Nitrogen purging 10. Gas sample and analysis 11. Booster balancing 12. Inverter operation for booster 13. Interlock arrangement

and

gas

and

and

10. Sinter machine operation:

12 weeks

Practical 1. Upkeep of segregation plate & Deflector plate. 2. Raw mix bin level control 3. Control of moisture, temperature, machine speed 4. Loading of sinter machine. 5. Bed height adjustment 6. Start and stop of machine 7. Operation of equipment through Digital display & control system. 8. Operation of various equipment through PLC terminals. 9. Understanding of various groups of equipments. 10. Interlock arrangement. 11. Recording of data. 12. Grate bar changing. 13. Emergency situation handling

11. Sinter Dispatch operation:

Theory 1. Introduction to sintering. 2. Quality parameters. 3. Details of equipments, capacity and design features. 4. Sinter cooling and normalizing.

6 weeks

Practical Operation of disposal route Check up procedure before start up Housekeeping activities of equipment Actions during emergency conditions Cleaning of chutes Running checkups for conveyors Surge bin operation Vibro feeder interlocks Operation of Nut coke addition system Interlock schemes Control desk operation Coordination with high lines

Theory Introduction sinter disposal route Layout and capacity Operational parameters of conveyors of disposal route Identification of troubles Safety devices on equipments and its functions Control desk operation Interlock system Precautions during start up and shut down Liners for chutes Flap gate

12. Pollution Control Equipments Operation: Practical 1. Operation of Electro Static Precipitator (ESP), flight conveyors, sluice feeders, DDGV (Double Dust Gate Valve), Flap gates 2. Check up procedure before start up 3. Housekeeping activities of equipment 4. Actions during emergency conditions 5. Cleaning of chutes 6. Running checkups for ESP 7. Monitoring of current and voltage of ESP 8. Interlock arrangement 9. Steps for Shut down 10. Operation of air conditioning system 11. Pipe line network, valve operation and booster pump operation and inspection of ESP ducts.

13. Technical Cell:

10 weeks 1. 2. 3. 4. 5. 6. 7. 8.

Theory Working of ESP, Multicellar, heat recovery, cyclones Design layout and Capacity. Operational parameters Maintenance schedule and trouble shooting Safety devices on equipments and its functions Dust disposal scheme Air conditioning system Water cooling network and booster pump

7 weeks

Practical 1. Data entry in Computers. 2. Operation of Management information system 3. Record keeping & back up taking 4. Preparation of daily, monthly and yearly report 5. Data exchange with concerned departments

Theory 1. Working of technical cell

14. Sinter Screening System:

6 weeks

Practical 1. Operation of screens in auto and local mode. 2. Oil cellar operation. 3. Checking and upkeep of mats. 4. Cleaning of screen chutes. 5. Housekeeping activities of equipment 6. Actions during emergency conditions

15. Lime Dosing System:

Theory 1. Introduction sinter screens 2. Capacity and layout 3. Operational parameters of screens 4. Identification of troubles 5. Safety devices on equipments and its functions 6. Auto and manual operation 7. Interlock scheme 8. Precautions during start up and shut down 9. Liners for chutes 10. Changeover chutes

8 weeks

Practical 1. Operation of lime dozing equipments from control panel. 2. Lime tanker operation. 3. Operation of compressed air tanks. 4. Operation of safety devices installed in lime tankers.

16. Tests and Evaluation – 4 weeks

Theory 1. Introduction lime dozing system. 2. Layout and capacity 3. Operational parameters of lime dozing system. 4. Identification of troubles 5. Safety devices on equipments and its functions 6. Interlock scheme 7. Precautions during start up and shut down

Workshop Calculations & Science 1.

Applied workshop problems involving simple addition, subtraction, multiplication, division and common fractions.

2.

Science- Definition, Nomenclature, various branches, significance and definitions of important terms.

3.

Rounding of decimal values, use of approximation.

4.

Units – Definition, fundamental & derived units, system of units- FPS, CGS, MKS and SI units of some important parameters- Length , mass, time, density, current, voltage, pressure etc. Unit conversion.

5.

Workshop problems related to average.

6.

Workshop problems related to percentage.

7.

Workshop problems related to ratio and proportion.

8.

Workshop problems related on time & work.

9.

Profit & Loss and problems concerning to workshop practices.

10.

Properties of Matter- Different types of Properties of Matter e.g. Mechanical, Electrical, Chemical, Magnetic.

11.

Properties of Matter (Mechanical) - Tenacity, Toughness, Malleability, Ductility, Elasticity, Plasticity, Brittleness, Hardness (concept & definition)

12.

Properties and uses of copper, zinc, lead, tin, aluminum, brass, bronze, solder, bearing metals, timber, and rubber.

13.

Engineering Material- Introduction, classification, Metallic- Non metallic material, physical and mechanical properties,

14.

Heat & temperature- Definition and its importance. Scales of Temperature, e.g. Fahrenheit, Centigrade, Kelvin- relationship between them.

15.

Transmission of heat- Conduction, Convection and Radiation. Examples from Industries (concept & definition)

16.

Transmission of Power and motion of Belt and Pulleys:- Driver and Follower – Open and Cross belt system of belt drives. Velocity ratio. Power Transmission by belt – Problems

Engineering Drawing : 1. 2. 3. 4. 5. 6. 7. 8.

Introduction to Engineering drawing, its importance and uses in engineering fields. Simple definitions of Points, Lines, Parallel straight lines. Geometrical construction of Square, Rectangle, Triangle, Circle, Polygons, etc. Drawing different types of lines. Free hand sketch of Hand tools used in the trade. Lettering and dimensioning practice. Reading and Interpretation of Charts, Posters, Figures, Layout diagrams, etc. Simple drawing of Charts, Posters, Figures, Layout diagrams, etc. Use of different signals and colour codes in the trade as well as in steel industry.