apprenticeship curriculum for process operator rolling
TRANSCRIPT
APPRENTICESHIP CURRICULUM
For
Process Operator Rolling Mills
Under
Indian Iron & Steel Sector Skill Council
For
NSQF compliance
National Apprenticeship Promotion Scheme
1 Program Title Process Operator Rolling Mills
2 Program Code, if any ISC/Q0701
3 Any related NSQF approved QP/Course/NOS and code
Process Operator Rolling Mills ,ISC/Q0701
4 Hours and months for Basic Training (Block I) 350 Hours(2 Months)
5 Hours and months for On the Job Training (Block II)
3528Hours (21 Months)
6 Certifying body for Basic Training Program Indian Iron & Steel Sector Skill Council
7 Certifying Body for On the Job training Industry Body
8 Any Licensing requirements, wherever applicable NA
9 Minimum eligibility criteria (Educational and/ or technical Qualification) Exemptions, if any
ITI(Mechanical/Electrical/Electronic)) Graduates-B.E (Mechanical/Electrical/ Electronics), BSC (Electronics)
10 Trainer’s Qualification and Experience (BT and OJT)
B.E Mechanical /Electrical with 4-5 years of relevant work experience under an experienced Process Operator
11 NCO code and occupation NCO-2004/NIL
12 Proposed NSQF level 5
13 Indicative list of training tools required to deliver this qualification (may be attached)
Refer Annexure A
14 Formal structure of the curriculum
Modules Notional hours- Theory
Notional hours- Practical
Total duration
Basic Training Program
1 Introduction to Steel industry , Rules & Regulation 2.Industrial safety & Maintain 5s at workplace 3. Team work management.
25
25
40
20
40
60
45
65
100
4 Basic of Metallurgy & process
50
90
140
Total duration of BT
140 3
Week
210 5
Week
350 8
Week
On the Job Training Program
1. Operation of rolling Mills 2.Control System 3.Rolling & coil Method 4.Operations of Control Room 5.Manufacturing Process 6.Loading & Unloading of coils 7.Stripping & testing method 8.Operation of command & specification
40
40
35
35
40
40
40
38
470
300
500
400
450
500
300
300
510
340
535
435
490
540
340
338
Total duration of OJT
308 7.4
Week
3220 76.6
Week
3528 84
Week
15 Total Pass marks
Total and Pass Marks- Theory
Total and Pass Marks- Practical
Basic Training Program
70 70
On the Job Training Program
70 70
16 Job description- This job role involves keeping the different process lines (viz. Pickling, Rolling, Annealing, Galvanising, Utilities etc.) Functional by ensuring continuity of process. This includes providing the actual commands for different operations, as needed and Monitors the operations for any deviations. This also involves inspection of the material between the workstations of the processes to ensure alignment to specifications.
17 Progression from the qualification (Please show Professional and academic progression)
The Apprentices after completion of this course can work in rolling department, can handle the different process of rolling mills and to monitor the operation
18 Employment avenues/opportunities
The Apprentices after completion of this course can find opportunities as Process operator, Control room operator
19 Assessment strategy (Basic training and On the Job)
The assessment for the Basic Training and for On the Job Training will be conducted toward the end of the OJT duration
20 Curriculum update version and date 10 Feb-2021
21 Curriculum revision date 31 March-2021
Curriculum
Module Name with duration Key Learning outcomes
Theory/Basic Training Program- Block I
1. Introduction to Steel industry , Rules & Regulation Theory Duration 25:00 hr. Practical duration 20:00 hr. Corresponding NOS:ISC/N0008
Identify and observe evacuation procedures
according to site Policy
Follow the rules and regulations of steel industry
Know the overview of steel industry
Read and apply the knowledge of data sheet of raw
material
Identify the steel industry and its sub-sectors
Know the basic Processes are used in steel
industry
To know the equipment and machinery used in
steel industry
To know the safety code of iron and steel sector
industry & apply practical knowledge on shop floor
To know the Iron and steel manufacturing
processes.
Identify the role and responsibility of a furnace technician in steel industry
Acquire the knowledge of organizational structure and employment benefits in iron and steel industry
Creating of products of Iron & Steel industry
Activities in Iron & Steel Industry323311
2.Industrial safety & Maintain 5s at workplace Theory Duration 25:00 hr. Practical duration 40:00 hr. Corresponding NOS:ISC/N0008
Identify individual responsibilities in relation to maintaining workplace health safety and security requirements.
Follow the organisation’s emergency procedures.
Identify and recommend opportunities for improving health, safety, and security.
Know the requirements of health, safety and security in workplace.
Use fire extinguishers.
Identify and Report unsafe working conditions to seniors
Observe Safety related to Mechanical and Manual Material Handling, Lifting Appliances, Transport / Earthmoving& Material Handling Equipment’s.
Apply fire safety concepts in case of fire emergency in industry
Report supervisor/ Competent of authority in the event of accident or sickness of any staff and
record accident
Follow safe working practices when working with tools and machinery
Follow and apply PPE & 5 S guidelines
Various dangers associated with the use of electrical equipment
3. Team work management. Theory Duration 40:00 hr. Practical duration 60:00 hr. Corresponding NOS:ISC/N0096
Accurately receive information and instructions from the supervisor and fellow workers, getting clarification where required
Importance of teamwork in organizational and individual success
Importance of discipline and disciplined behaviour for professional success
Maintain competence within one’s role and field of practice
Importance of effective communication in the workplace
Promote and demonstrate good practice as an individual and as a team member at all times
Identify and manage potential and actual risks to the quality and safety of practice
Know the boundaries of one’s role and responsibilities and other team members
Communicate with other people clearly and effectively & integrate one’s work with other people’s work effectively.
Know how to deal with difficult working relationships with other people to sort out problems.
Identify the types of working relationships that help people to work well together and the types of relationships that need to be avoided.
4.Basic of Metallurgy & process Theory Duration 50:00 hr. Practical duration 90:00 hr. Corresponding NOS: ISC/N0706
Basic knowledge on processes related to Milling mills
To understand deeper issues regarding material behaviour
To know the Knowledge of rolling, pickling, annealing, galvanizing
To know the different processes of metallurgy
To know the properties of ferrous metal and their alloys ,material of rolling mills
To know the mechanical & physical properties of metal
Apply knowledge for production of alloys, their shaping extremes
Know the production processes of steel and casting alloy & material property of rolling sheets
To Monitor the process parameters during operation
To Understand the basic parameter like RPM, temperature, linetension,pressure, concentration, line-speed, fillage, coating thickness
To know different process lines functional by ensuring Continuity of process.
To know the characteristic of acid
concentration, bath characteristics, alkali
solution etc. on the coils as applicable in the
different processing lines.
To know the Corrosion of metal components
Understand the characteristic of chemicals,
gas, oxy-fuel, fumes, and dust.
Knowledge on OIL properties
On the Job Training Program- Block II
1.Operation of rolling Mills Theory Duration 40:00 hr. Practical duration 470:00 hr. Corresponding NOS: ISC/N0706
Apply Iron and steel manufacturing processes
Know the Rolling mills operation & processes
Understand how the pickling/ rolling/annealing/ electrolytic cleaning/galvanising
To Analyse systems work and the essential associated parts/machines for the specific process
Use of different interlocks and operation sequence
To understand the types and application of rolling mills
Understand hot & cold working process of rolling mills
Understanding Steel rolling & passing the material, rolling stock.
To produce a product which is having constant cross section throughout its length
To know the product rolling mill comprised of equipment for reheating, rolling and cooling.
To know the mechanical properties and microstructure of the product.
To know the process of reheating, rolling, cooling.
To use of series of rolling stands in tandem to obtain high production rates
Identify job requirements for performing heat treatment operations as per instructions given from valid sources.
2.Control System Theory Duration 40:00 hr. Practical duration 300:00 hr. Corresponding NOS: ISC/N0707
To Inspect the incoming coil according to
specifications
To Read and understand the specifications of
the job to be carried out
Inspect the incoming coil for dimensions,
telescopicity, quality/ physical defect according
to the process chart and ensure they tally with
PDI (Primary Data Input)
To Take necessary actions to get any
deviations from specifications corrected
To load the coil on the rolling system correctly
Apply and understand PLC systems / Micro-
processor operations
Understand Load or stack the coil(s) for
conducting the operation, as appropriate control
system
To arrange the coil as per diameter and width to
ensure correct placement with controlling
parameter
Understand the physical properties and the
features of coils.
To know the effect f temperature, time, line-
speed, burner flames, molten zinc as per
parameter
Apply Working knowledge of the Entry, Process
and Exit parameters of the continuous process .
Apply and understand relation between Voltage / Currents / Power Factor
To Read & understand control parameters on
computer screen
Give appropriate commands for operation
3.Rolling & coil Method Theory Duration 35:00 hr. Practical duration 500:00 hr. Corresponding NOS: ISC/N0707
To understand the method of rolling
To understand the method of coil system
Apply necessary commands for the next operation (coil cooling, skin-passing, drying, side trimming, chromatin, logo printing, oiling etc. as appropriate)
To know the coil specifications and give command for carrying out the operation
To Check and compare the specifications of the coil with those in system/record and ensure correctness of the requirement
Apply the importance of parameters for rolling in the roughing, intermediate, and finishing group of stands in the rolling mill are temperature,
percentage of reduction in area, inter-pass time and strain rate.
The input material usually billet is heated in the reheating furnace to the rolling temperature.
Apply the importance of parameters are heating rate, time of heating, and temperature of reheating.
Understand the physical properties and the features of coils.
Inspect the incoming coil for dimensions, telescopicity, quality/ physical defect according to the process chart
4.Operations of Control Room Theory Duration 35:00 hr. Practical duration 400:00 hr. Corresponding NOS ISC/N0706
To Load or stack the coil(s) for conducting the operation, as appropriate
To Maintain the continuity of operation by welding the forward coil with the trailing coil, where appropriate
Check that the strip matches planned/designed specifications
To Set appropriate parameters (like pressure, current, speed, time-temperature cycle, fillage, concentration, tension etc.)
Monitor the process parameters during operation
Identify different parameters & defects to be segregated and noted before passing material
Apply and understand relation between Voltage / Currents / Power Factor
Apply and understand PLC systems / Micro-
processor operations
Ensure transformer parameters monitoring Maintaining log sheets and documentation
Parameters involved in Primary & Secondary
Voltages & Currents
Calculations involved in maintaining current
densities on Electrodes
Steps required for starting up SAF and shutting
down the SAF
Response to emergencies e.g. Power failures
,fire and system failures
5.Manufacturing Process Theory Duration 40:00 hr. Practical duration
Response to emergencies e.g. Power failures ,fire and system failures
Understand how the pickling/ rolling/annealing/ electrolytic cleaning/galvanising systems work and the essential associated parts/machines for the specific process
450:00 hr. Corresponding NOS:ISC/N0706
Use of different interlocks and operation sequence
To follow SOP of machine as per given process
Apply various types of heat treatment processes during heat treatment for ex-Annealing, Normalizing Tempering, Quenching, Carburizing, Induction etc.
Identify job requirements for performing heat treatment operations as per instructions given from valid sources.
Verify the components safely and correctly from the heat source and solutions
To apply Hot-dip galvanizing process of immersing iron or steel in a bath of molten zinc to produce a corrosion resistant, multi-layered coating of zinc-iron alloy and zinc metal
To know a metallurgical reaction occurs between the iron in the steel and the molten zinc.
Apply Electrolytic cleaning method of removing soil, scale or corrosion products from a metal surface by subjecting it as an electrode to an electric current in an electrolytic bath
To Apply roll stands holding pairs of rolls are grouped together into rolling mills that can quickly process metal, typically steel, into products such as structural steel (I-beams, angle stock, channel stock), bar stock, and rails
6.Loading & Unloading of coils Theory Duration 40:00 hr. Practical duration 500:00 hr. Corresponding NOS: ISC/N0707
To know the function types & uses of coils
Understand the physical properties and the features of coils
To know the effect of temperature, time, line-speed, burner flames, molten zinc & acid concentration
Understand the coils as applicable in the different processing lines.
Monitor the process parameters during operation
Give necessary commands for the operation
To know the function of coil cooling, skin-passing, drying, side trimming, chromatin, logo printing, oiling etc.
Unload the coil, recoil, weigh, strap, label and dispatch to the next station
Identify Material Handling equipment which is required for loading & unloading process
Use properly Material handling equipment
Analyse the MHS equipment system
To know the function of a soft iron core placed within a coil produces an electromagnet.
Apply cylindrical coil that moves a plunger within it
by variations in the current through the coil .
To Apply Coil, in an electric circuit, one or more turns, roughly circular or cylindrical, of current-carrying wire designed to produce a magnetic field or to provide electrical resistance or inductance; in the latter case
7.Stripping & testing method Theory Duration 40:00 hr. Practical duration 300:00 hr. Corresponding NOS: ISC/N0707
Check that the strip matches planned/designed specifications
To prepare the strip for the next process
Apply Stripping separation process where one or more components are removed from a liquid stream by a vapour stream
Apply batch process steel strip coils are stacked on top of each other in the bell type furnace
To know the Temper rolling (skin pass rolling) - final cold rolling operation with low thickness reduction conducted in order to impart to the steel required levels of hardness, evenness and surface finish.
To know the function of hot stripping & cold stripping method
Read control parameters on computer screen & take appropriate operating decision accordingly
To operate desktop computer & be conversant with the latest software in use
To proper testing of equipment’s with specific limit
Identify different parameters & defects to be segregated
Testing of electrical and thermal tools and equipment
Testing of ox fuel and gas cylinders
Use equipment that is working properly and is well maintained
To safe way to test for spark is to use a spark plug tester tool.
To test coil problem suspected & to measure the coil's primary and secondary resistance with an ohmmeter with specifications.
8.Operation of command & specification Theory Duration 38:00 hr. Practical duration 300:00 hr.
Give necessary commands for the operation
To apply proper command operation on coil cooling, skin-passing, drying, side trimming, chromatin, logo printing, oiling etc.
To Monitor the process parameters during operation with specification of Machine
Check and compare the specifications of the coil with those in system
To know the authority granted to a commander to
Corresponding NOS: ISC/N0707 assign missions or tasks to subordinate commanders.
To deploy units, to reassign forces, and to retain or delegate operational and/or tactical control
To Set appropriate parameters of Machine
To Maintain the coil specifications and give command for carrying out the operation
Proper testing power supply and points, loose and naked cables and wires, electrical machines and appliances, etc.
Proper Use of Combustible metals such as magnesium, titanium, and sodium(these fires burn at extremely high temperatures and require special suppression agents) with specification
List of Assessable outcomes/assessment criteria
CRITERIA FOR ASSESSMENT OF TRAINEES
Job Role: Process Operator Rolling Mills
Qualification Pack: ISC/Q0701
Sector Skill Council: Indian Iron & Steel Sector Skill Council
Guidelines for Assessment:
1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill
Council. Each Performance Criteria (PC) will be assigned marks proportional to its
importance in NOS. SSC will also lay down proportion of marks for Theory and Skills
Practical for each PC.
2. The assessment for the theory part will be based on knowledge bank of questions
created by the SSC.
3. Individual assessment agencies will create unique question papers for theory part
for each candidate at each examination/training center (as per assessment
criteria below)
4. Individual assessment agencies will create unique evaluations for skill practical for
every student at each examination/training center based on this criteria.
5. To pass the Qualification Pack , every trainee should score a minimum of 70 % in every NOS.
6. In case of successfully passing only certain number of NOS's, the trainee is
eligible to take subsequent assessment on the balance NOS's to pass the
Qualification Pack.
Marks Allocated
NOSs PCs Total
Mark
1000
Out of Theory Practical
ISC/N0706:
Prepare for
operation of
control
systems
PC1. Read and understand the
specifications of the job to be carried
out
200
20 5 15
PC2. Inspect the incoming coil for
dimensions, telescopicity, quality/
physical defect according to the
process chart and ensure they
tally with PDI (Primary Data Input)
30 5 25
PC3. Take necessary actions to get
any deviations from specifications
corrected
20 5 15
PC4. Report any issues that may be out
of his/her scope to supervisor
15 0 15
PC5. Understand how to load the coil
on the rolling system correctly
25 5 20
PC6. Load or stack the coil(s) for
conducting the operation, as
appropriate
20 0 20
PC7. Arrange the coil as per diameter
and width to ensure correct
placement
25 5 20
PC8: Maintain the continuity of
operation by welding the forward
coil with the trailing coil, where
appropriate
45 5 40
Total 200 30 170
ISC/N0707:
Perform
operation of
control
systems
PC 1. Check and compare the
specifications of the coil with those
in system/record and ensure
correctness of the requirement
550
70 20 50
PC2. Set appropriate parameters
(like pressure, current, speed,
time- temperature cycle, fillage,
concentration, tension etc.) as
applicable for welding / pickling/
rolling/ annealing/ electrolytic
cleaning/galvanising according to
coil specifications and give
command for carrying out the
operation
250 50 200
PC3. Monitor the process
parameters during operation e.g.
RPM, temperature, line- tension,
pressure, concentration, line-speed,
fillage, coating thickness, etc.
120 20 100
PC4. Give necessary commands for
the next operation (coil cooling, skin-
passing, drying, side trimming,
chromating, logo printing, oiling etc.
as appropriate)
60 10 50
PC5. Unload the coil, recoil, weigh,
strap, label and dispatch to the next
station
30 0 30
PC6. Report any issues to the
supervisor that may be beyond
his/her scope
20 5 15
Total 550 105 445
PC1. Use protective
clothing/equipment for specific tasks
9 4 5
ISC/N0008:
Use basic
health and
safety
practices at
the
workplace
and work conditions 150
PC2. State the name and location
of people responsible for health and
safety in the workplace
6 1 5
PC3. State the names and location
of documents that refer to health and
safety in the workplace
2 1 1
PC4. Identify job-site hazardous work
and state possible causes of risk or
accident in the workplace
8 4 4
PC5. Carry out safe working
practices while dealing with hazards
to ensure the safety of self and others
state methods of accident prevention
in the work environment of the job
role
6 1 5
PC6. State location of general health
and safety equipment in the
workplace
6 1 5
PC7. Inspect for faults, set up and
safely use steps and ladders in
general use
6 1 5
PC8. Work safely in and around
trenches, elevated places and
confined areas
6 1 5
PC9. Lift heavy objects safely using
correct procedures
6 1 5
PC10. Apply good housekeeping
practices at all times
2 1 1
PC11. Identify common hazard signs
displayed in various areas
6 5 1
PC12. Retrieve and/or point out
documents that refer to health and
safety in the workplace
5 1 4
PC13. Use the various appropriate
fire extinguishers on different types
of fires correctly
9 4 5
PC14. Demonstrate rescue techniques
applied during fire hazard
8 4 4
PC15. Demonstrate good housekeeping
in order to prevent fire hazards
2 1 1
PC16. Demonstrate the correct use
of a fire extinguisher
6 1 5
PC17. Demonstrate how to free a
person from electrocution
6 1 5
PC18. Administer appropriate first aid
to victims as required e.g. in case
of bleeding, burns, choking, electric
shock, poisoning etc.
8 3 5
PC19. Demonstrate basic techniques
of bandaging
6 1 5
PC20. Respond promptly and
appropriately to an accident situation
or medical emergency in real or
simulated environments
7 2 5
PC21. Perform and organize loss
minimization or rescue activity during
an accident in real or simulated
environments
6 1 5
PC22. Administer first aid to victims
in case of a heart attack or cardiac
arrest due to electric shock, before the
arrival of emergency services in real
or simulated cases
6 1 5
PC23. Demonstrate the
artificial respiration and the
CPR Process
6 1 5
PC24. Participate in emergency
procedures
6 1 5
PC25. Complete a written
accident/incident report or dictate a
report to another person, and send
report to person responsible
4 1 3
PC26. Demonstrate correct method
to move injured people and others
during an emergency
2 1 1
Total 150 45 105
ISC/N0096:
Works
effectively
with
others and
manage
team
members
PC1. Accurately receive, absorb and
share information and instructions
from the supervisor and fellow
workers, getting clarification where
required
100
5 0 5
PC2. Display appropriate
communication etiquette while
working
10 0 10
PC3. Display active listening skills
while interacting with others at
10 0 10
work
PC4. Use appropriate tone, pitch and
language to convey politeness,
assertiveness, care and
professionalism
5 0 5
PC5. Display helpful behavior by
assisting others in performing tasks in
effective manner
10 0 10
PC6. Consult with and assist others to
maximize effectiveness and efficiency in
carrying out tasks
10 0 10
PC7. Demonstrate responsible and
disciplined behaviors at the workplace
5 0 5
PC8. Escalate grievances and problems to
superiors
5 0 5
PC9. Communicate day-to-day objectives,
instructions etc. to team members
15 5 10
PC10. Guide the team members to
manage day-to-day issues at work
5 0 5
PC11. Gather concerns, feedback from
team members and convey them to
appropriate authorities
15 5 10
PC12. Escalate grievances and problems
to superiors
5 0 5
Total 100 10 90
Annexure A:
List of Tools and Equipments to be attached
S. No.
Equipment Name Number required
Unit type Dimension / Specification
1 CO2 type Fire Extinguisher 10 each Nos --
2 ABC Type Fire Extinguisher 10 each Nos --
8 First Aid Box 5 Nos --
11 PVC Apron 10 Nos --
12 Safety Goggles 10 Nos --
13 Safety Shoes 10 Nos --
14 Ear plug
10 Nos --
15 Helmet
10 Nos --
16 Vernier caliper, Micrometer 4 Nos As per required specification
17 Measuring gauges 10 Nos As per required
specification
18
Apparatus for measurement of thermal heat co-efficient of expansion of solid (plunger’s apparatus)
10 Set
--
19 Multi meter(digital)
05 Nos --
20 Milli voltmeter
10 Nos --
21 Digital Stop Watch
10 Nos --
22 Heating coil
30 Nos --
23 Cooling coil
5 Nos As per
Specification
24 Heat exchanger
5 Nos As per
Specification
25 Electric heating coil
10 Nos --
26 Heating furnace
15 Nos As per Specification
27 Critical heat flux
2 Nos --
28 Heating chamber
10 Nos As per
Specification
29 Surface Flux
10 Nos As per
Specification
30 Electric resistance
10 Nos As per
Specification
31 Vacuum furnace
10 Nos As per
Specification
32
Gas detector with air tight chamber
10 Nos
As per Specification
33 pressure gauge
05 Nos
As per Specification
34 Electrical Winding 1 Nos
--
35 Hand Gloves 10 Nos --
36 LV/HV Transformer 02 Nos --
37 Oil & Water circulation system 1 Nos --
38 Hand tools 10 Nos --
39 Assembling tools 10 Nos --
40 Power tools 10 Nos --
41 Hand tools for Electrician 05 Nos --
42 Soldering gun 10 Nos --
43 Funnel Equipment 10 Nos --
44 Electrodes 05 Nos --
45 Lubricants and grease 500 ML --
46 Pumps, motors, compressors, generators,
02 Nos As per required
Specification
47 Water tank for quenching capacity about 50 liters.
01 Nos 50 liters
48 chemical containers 02 Nos --
49 Oxyfuel and gas cylinders 02 Nos --
50 Machine guards 05 Nos --
51 Cap and shoulder covers 05 Nos --
52 Reinforced footwear 03 Nos --
53 Flame proof overalls buttoned to neck
03 Nos --
54 Nuts or bolts, 05 Nos ---
55 Raising alarm 04 Nos --
56 Digital Millimeter 05 Nos --
57 Speedometer 02 Nos --
58 Roller Belt 10 Nos --
59 Oil Quenching tank 50 liters capacity
1
Nos 50 liters
60 Surface furnace 300Kw
1
Nos As per
Specification
61 Heating chamber
1
Nos As per
Specification
62 Vacuum furnace 180 Kw
1
Nos As per
Specification
63 Salt Bath 24Kw
1
Nos As per
Specification