OPERATOR BLAST FURNACE IRON

MAKING EQUIPMENTS
COMPETENCY BASED CURRICULUM
(Duration: 1 Year 3 Months)

APPRENTICESHIP TRAINING
SCHEME (ATS)
NSQF LEVEL- 4

SECTOR – PRODUCTION & MANUFACTURING

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

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Operator blast furnace iron making equipments

OPERATOR BLAST
FURNACE IRON MAKING
EQUIPMENTS
(Revised in 2018)
APPRENTICESHIP TRAINING SCHEME (ATS)

NSQF LEVEL - 4

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
 Operator blast furnace iron making equipments

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 is extended by DGT to the following expert members who had
contributed immensely in this curriculum.

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 LTD, Jamshedpur- 831001
Capability Development
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, -Do- Member
Manager
16. L. K. Mukherjee, DDT CSTARI, Kolkata Member
17. N. Nath, ADT CSTARI, Kolkata Member
 Operator blast furnace iron making equipments
CONTENTS

Sl.
Topics Page No.
No.

1. Background 1-2

2. Training System 3-7

3. Job Role 8

4. NSQF Level Compliance 9

5. General Information 10

6. Learning Outcome 11-13

7. Learning Outcome with Assessment Criteria 14-16

8. Syllabus 17-22

9. Syllabus - Core Skill 23-27

9.1 Core Skill – Workshop Calculation & Science and 23-24

Engineering Drawing

9.2 Core Skill – Employability Skill 25-27

10. Details of Competencies (On-Job Training) 28-29

11. List of Trade Tools & Equipment Basic Training - Annexure I 30-31

12. Format for Internal Assessment -Annexure II 32

 Operator blast furnace iron making equipments
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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 Operator blast furnace iron making equipments
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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 Operator blast furnace iron making equipments
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.

Operator blast furnace iron making equipments trade under ATS is one of the most
popular courses delivered nationwide through different industries. The course is of one year
three months (01 Block of 15months including basic training) 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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 Operator blast furnace iron making equipments
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 one year (Basic Training and On-Job Training) : -

Total training duration details: -

Time 1-3 4 - 15
(in months)
Basic Training Block– I -----
Practical Training ---- Block – I
(On - job training)

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 Operator blast furnace iron making equipments
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.)

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
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 Operator blast furnace iron making equipments
have to maintain individual trainee portfolio as detailed in assessment guideline. 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 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

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:

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 Operator blast furnace iron making equipments
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 for “Operator blast furnace iron making equipments.”

Operate and maintain the iron making (Blast Furnace) equipment efficiently and safely.
The main jobs are follows:
 Stock house operation, batching & screening, charging
 Control room operation
 Cast house preparation & operation
 Tapping & closing of tap hole i.e., tapping practice.
 Slag granulation.
 G.C.P equipment & operation.
 Safe working practice etc.

Reference NCO Code -2015:

3131.0500 Power Plant Operator
3133.0200 Furnace Operator (Chemical)
3135.1300 Furnace Operator (Smelting and Refining)
3135.2600 Furnace Man, Reverberatory, Pulverised Coal Fired

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 Operator blast furnace iron making equipments

4. NSQF LEVEL COMPLIANCE

NSQF level for Operator blast furnace iron making equipments trade under ATS: Level 4

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 Operator (Steel Plant) trade under ATS mostly matches
with the Level descriptor at Level- 4.

The NSQF level-4 descriptor is given below:

LEVEL Process required Professional Professional Core skill Responsibility

knowledge skill
Level 4 work in familiar, factual recall and language to Responsibility for
predictable, knowledge demonstrate communicate own work and
routine, situation of field of practical skill, written or oral, learning.
of clear choice. knowledge routine and with required
or study repetitive in clarity, skill to
narrow range of basic Arithmetic
application, and algebraic
using principles, basic
appropriate rule understanding of
and social political
tool, using and natural
quality environment.
concepts

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5. GENERAL INFORMATION
Name of the Trade
Operator Blast Furnace Iron Making Equipments
NCO - 2015 3131.0500, 3133.0200, 3135.1300, 3135.2600
NSQF Level Level – 4
Duration of Apprenticeship
Training 3 months + One year (15 months duration where 01 Block of 12
(Basic Training + On-Job Training) months duration).
Duration of Basic Training a) Block –I : 3 months
Total duration of Basic Training: 3 months
Duration of On-Job Training a) Block–I: 12 months
Total duration of Practical Training: 12 months
Entry Qualification Passed 10th Class with Science and Mathematics under 10+2
system of Education or its equivalent
Selection of Apprenticeship 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.
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 Nil

CTS trades eligible for 1. Operator Blast Furnace Iron Making Equipments
Operator Blast Furnace Iron
Making Equipments
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 operator blast furnace iron making equipments course of 01 years
duration under ATS.

Block I:-

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, Heat & Temperature, Levers & Simple
machine, 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, 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.

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6.2 SPECIFIC LEARNING OUTCOME

Block – I
DURATION: 12 MONTHS

 Perform safety appliances such as general safety appliances i.e. helmet, hand gloves etc, Cast
house safety appliances i.e. apron, ankle guard etc, gas safety appliances & devices i.e. Gas
masks, gas monitors etc.
 Orient the different sections of Blast Furnace.
 Perform the Housekeeping practices in various sections of Blast Furnace.
 Perform the Regular & scheduled check up of all important check points
 Operate various equipments in stock house & high line i.e. Belt conveyors, screens, weighing
system, skip car operation etc.
 Monitor the bunker position, belt condition, highline condition etc.
 Monitor the process flow & filling of log books
 Operate the various equipment i.e. charging equipment, Stoves, septum valve, bleeder valve,
Primary Dust Catcher valve, hot blast valve, Snort valve etc.
 Monitor all operational parameters & filling of log sheets.
 Perform Visual inspection of Tuyeres, valve condition & other check points.
 Perform OFF blast & ON blast operation
 Submit Report of abnormalities
 Perform Handling of emergency situations i.e. Power failure, cooling water line failure etc.
 Check the oil levels in mud gun& drill machine, availability of sufficient clay for mud gun,
checking of Tap hole face condition, filling of mud gun clay, cleaning of metal –slag runner,
runner preparation, sample taking, poking, lancing, Rocking Runner operation etc.
 Operate equipment i.e. Drums, Conveyors, recovery pumps, granulation pumps, Lubrication
pumps etc.
 Monitor operational parameters & filling log sheet/Log book.
 Operate various pumps & valves in GCP pump houses – Isolation, pump changing etc.
 Operate Electrostatic precipitators ( Isolation, charging, flushing)
 Operate slurry disposal system – thickeners, agitators & slurry disposal pumps, flushing &
hosing
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 Operate various gas valves for gas line isolation & charging
 Monitor water levels in Cooling Tower, Scrubber, hot sump and overflow control
 Operate various pumps, cooling tower fans, valves – Isolation & changing
 Monitor various parameters i.e. Pump bearing temp, amps, Emergency tank level, water flow
rate, line pressure etc. & filling logbooks.
 Operate major equipment i.e. centrifugal compressor, Screw compressor, Grinding Mill, Hot gas
generator, conveyors, bag filters & Tar injection system.
 Monitor various parameters and their control
 Operate equipment & pouring of hot metal in pig casting machines.
 Dismantle the boulders, positioning of ladles, heating of ladles.
 Operate compressors, cooling water recirculation systems etc.
 Operate Power Plant, Blower etc.
 Distribution of clay mass to various furnaces

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 OUTCOMES ASSESSMENT CRITERIA
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,
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.

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calculation & science -Work, 2.4 Comply given tolerance.
Power & Energy, Algebra, 2.5 Prepare list of appropriate materials by interpreting detail
Geometry & Mensuration, Heat drawings and determine quantities of such materials.
& Temperature, Levers & Simple 2.6 Ensure dimensional accuracy of assembly by using
machine, Centre of gravity, different instruments/gauges.
Power transmission, Pressure] 2.7 Explain basic electricity, insulation & earthing.

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 callipers, 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

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.

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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
Assessment Criteria i.e. the standard of performance, for each specific learning
outcome mentioned under Block – I(section: 10) must ensure that the trainee works in
familiar, predictable, routine, situation of clear choice. Assessment criteria should
broadly cover the aspect of Planning (Identify, ascertain, etc.); Execution apply
factual knowledge of field of knowledge, recall and demonstrate practical skill during
performing the work in routine and repetitive in narrow range of application, using
appropriate rule and tool, complying with basic arithmetic and algebraic principles
and language to communicate in written or oral with required clarity; Checking/
Testing to ensure functionality during the assessment of each outcome. The
assessments parameters must also ascertain that the candidate is responsible for
his/her own work and learning.

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8. SYLLABUS

BASIC TRAINING (Block – I)

Duration: (03) Three Months

Week
No. Professional Skills (Trade Practical) Professional Knowledge (Trade Theory)
1. Safety: - its importance, classification, Importance of safety and general precautions
personal, general, workshop and job safety. obsed in the in the industry/shop floor. All
Occupational health and safety. necessary guidance to be provided to the new
Basic injury prevention, Basic first aid, comers to become familiar with the working of
Hazard identification and avoidance, safety Institute system including stores procedures.
signs for Danger, Warning, caution &
personal safety message. Introduction of First aid. Safety attitude
Preventive measures for electrical accidents development of the trainee by educating him to
& steps to be taken in such accidents. use Personal Protective Equipment (PPE).
Response to emergencies e.g.; power failure,
Importance of housekeeping & good shop fire, and system failure.
floor practices. Accidents- Definition types and causes.
Disposal procedure of waste materials like First-Aid, nature and causes of injury and
cotton waste, metal chips/burrs etc. utilization of first-aid.
Fire& safety: Use of Fire extinguishers.
Introduction to 5S concept & its application.
Safety regarding working with different Fire: - Types, causes and prevention methods.
types of steam and its First-Aid. Fire Extinguisher, its types.
Define environment, environment Pollution,
Pollutants, type of Pollution (Air pollution,
water pollution, soil pollution noise pollution,
thermal pollution, radiation.
Global warming its causes and remedies.
Industrial Waste its types, sources and waste
Management.
2. Induction & Safety Training
- 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.

3. Video demo of Blast furnace & related Overview of Blast Furnace & Related Safety
Aspects

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safety process. - Overview of Blast Furnace i.e. Blast
Furnace Iron making process flow, technical
details of Blast Furnaces, important
operating parameters etc.
- Different sections of Blast Furnace & their
functions
- General safety & Gas safety
- Fire fighting system
- Hazards in Blast Furnace
- Shut down procedures
- Handling of emergency situations
- Role of Refractory Bricks
4. Video demo of housekeeping and HOUSE KEEPING & ENVIRONMENTAL
environmental pollution control process. POLLUTION CONTROL
- Importance of housekeeping &
environmental pollution control
- Factors affecting environment
- Opportunities to control
STOCK HOUSE & HIGHLINE
- Introduction to various equipments in Stock
House & Highline i.e. Bunker, Belt
Conveyors, Screens, Weigh Hoppers, Skip
Car etc.
- Process flow & technical details
- Important operational parameters & check
points
- Safety aspects
- (Personal & equipment)
- Various Standard Operating Practices to be
followed
- Communication system
- Handling of emergency situations i.e.
Failure of belt conveyors, Break down of
Sinter Fines Belts, PLC system failure,
Break down of Coke screen etc
5 Video demo of furnace proper process. FURNACE PROPER
Practice on Furnace process flow & - Overview of Blast Furnace process flow &
technical details.(Involving different stoves, technical details
- Important equipment & their functions i.e.
top charging equipment, hot blast etc.)
Stoves, Top charging equipment, Hot blast
valves, bleeder valve, septum valve, snort
valves, Tuyeres, back draft valves etc.
- Important operational parameters & their
control
- Important check points
- Safety aspects (Personal & equipment)
- Various Standard Operating Practices to be

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 Operator blast furnace iron making equipments
followed especially OFF blast & ON blast
activities
- Co-ordination with concerned sections &
departments
- Handling of emergency situations
- i.e. Power failure, blower failure, cooling
water line failure, equipment failure etc.
6. Video demo of cast house process. CAST HOUSE
- Introduction to important equipment in cast
house -their function and technical details
i.e. Mud gun, Drill Machine, Cast House
crane, Rocking runner, Pusher car, skimmer
plate etc.
- Major activities to be done i.e. Inspection &
filling of mud gun, cleaning & preparation
of metal runner, slag runner etc
- Safety aspects ( Personal & Equipment)
- Various Standard Operating Practices to be
followed
- Communication system
- Handling of emergency situation i.e. Cast
opening problem, Rocking runner tripping,
Pusher car failure, Auto by-pass cut,
cleaning & preparation of slag runners etc.
7. Practice on cast house slag granulation CAST HOUSE SLAG GRANULATION
process.(Involving different flow slag, PROCESS
granulation process etc.) - Overview & process flow Slag Granulation
Process
- Major equipment & technical details i.e.
Granulation Mechanism, Granulation tank,
Dewatering system, Pumps, conveyors,
screens, feeders etc.
- Important operational parameters & their
control
- Important check points
- Major operational activities to be done i.e.
Cleaning & inspection
- Safety aspects
- (Personal & Equipment)
- Various Standard Operating Practices to be
followed
- Communication system
- Handling of emergency situations i.e. Power
failure, major equipment failure due to
Mechanical problem, belt conveyor failure,
pump failure etc.

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 Operator blast furnace iron making equipments
8. Practice on Gas cleaning plant. GAS CLEANING PLANT
- Overview of Gas Cleaning system – Process
flow & technical details
- Overview of GCP water recirculation
system & slurry disposal system
- Important equipment in Gas Cleaning plant
and their function i.e. Primary Dust Catcher,
Secondary dust catcher, Scrubber, Demister,
Semi Clean gas line, Electro Static
Precipitators, GCP Pumps etc.
- Important parameters & check points
- Major operational activities done in shop
floor & control room
- Safety aspects ( Personal & Equipment)
- Gas Safety devices & their application
- Various Standard Operating Practices to be
followed
- Communication system
- Handling of emergency situations i.e.
Power failure, water line leakages, Pump
Failure, Gas line leakages etc.
9. Video demo of BF-cooling water BF –COOLING WATER
recirculation system process. RECIRCULATION SYSTEM
1. Process flow & technical details of
water recirculation system
2. Various pumps, valves & their functions
3. Important parameters & check points
4. Major operational activities done
5. Safety aspects ( Personal & Equipment)
6. Various Standard Operating Practices to
be followed
7. Communication system
8. Handling of emergency situations i.e.
Power failure, water line leakages,
Pump Failure etc.
10. Video demo of coal dust/ tar injection COAL DUST/ TAR INJECTION SYSTEM
system process. 1. Overview of Coal Dust/ Tar Injection
system- Process flow & technical details
2. Major equipment in Coal Dust/Tar
Injection system & their functions i.e.
centrifugal compressor, Screw
compressor, high rise conveyor, hot gas
generator, grinding mill, distributor, bag
filter, Tar injection system Pumps etc.
3. Important operational parameters &
check point
4. Major operational activities done

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 Operator blast furnace iron making equipments
5. Safety aspects ( Personal & Equipment)
6. Various Standard Operating Practices to
be followed
7. Communication system
8. Handling of emergency situation i.e.
Power failure, equipment failure etc.
11. Video demo of PIG casting machine PIG CASTING MACHINE
process. 1. Overview of Pig casting process-process
Practice on PIG casting machine flow & technical details
2. Major equipment and their functions i.e.
process.(Involving different pig moulds,
Ladle Tilters, Pouring house, Pig
conveyor chain, lime spray equipment etc.) moulds, conveyor chain, Lime spray
equipment, wagon winch, storage yard
etc.
3. Important tools & tackles required in
operation i.e. Hammers, hooks, shovels,
lancing pipes etc.
4. Important parameters & check points
5. Safety aspects
( Personal & Equipment)
6. Various Standard Operating Practices to
be followed
7. Communication system
8. Handling of emergency situations i.e.
Equipment failure & Power failure
during operation
9. Handling of emergency situation
LADLE REPAIR SHOP
1. Function of Ladle repair shop
2. Major equipment & their functions
3. Important tools & tackles required
4. Safety aspects
( Personal & Equipment)
5. Various Standard Operating Practices to
be followed
6. Communication system

12. Video demo of centralized compressed CENTRALISED COMPRESSED AIR

air station & power plant (turbo blower) STATION
process. 1. Overview & process flow of
Compressed air station- technical details
2. Major equipment & their functions in
Compressed air station i.e.
Compressors, cooling water
recirculation system, receivers, Nitrogen
manifolds, pipe lines etc.
3. Important parameters & their control

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 Operator blast furnace iron making equipments
4. Important check points
5. Safety aspects
( Personal & Equipment)
6. Various Standard Operating Practices to
be followed
7. Communication systems
8. Handling of emergency situations i.e.
Power failure, equipment failure etc.
POWERPLANT ( TURBO BLOWER)
OVERVIEW
1. Overview & Process flow
2. Important operating parameters
3. Relation with Blast Furnace operation
4. Communication system
5. Handling of emergency situations i.e.
Power failure, Equipment failure etc.
TECHNICAL CELL
1. Function of Technical cell
2. Overview of Quality parameters
3. Availability & storage of tools & tackles
4. Communication system

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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 Operator blast furnace iron making equipments
9. SYLLABUS - CORE SKILLS

9.1 WORKSHOP CALCULATION SCIENCE & ENGINEERING DRAWING

Block – I

Sl. Workshop Calculation and Science Engineering Drawing

No. (Duration: - 20 hrs.) (Duration : - 30 hrs.)
1. Applied workshop problems involving Introduction to Engineering drawing, its
simple addition, subtraction, importance and uses in engineering fields. Simple
multiplication, division and common definitions of Points, Lines, Parallel straight lines.
fractions.
2. Science- Definition, Nomenclature, Geometrical construction of Square, Rectangle,
various branches, significance and Triangle, Circle, Polygons, etc.
definitions of important terms.
3. Rounding of decimal values, use of Drawing different types of lines.
approximation.
4. Units – Definition, fundamental & Free hand sketch of Hand tools used in the trade.
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. Screw Threads – Forms of Various Screw threads
used in general in the industry – Nomenclature,
convention
6. Workshop problems related to Fastening Devices – Temporary and Permanent.
percentage. Meaning and difference. Temporary Device –
Hexagonal Bolt, Nut, Check Nut, Washer.
7. Workshop problems related to ratio and Different Methods of Preventions of rotation of
proportion. Bolts - Check nut, Square headed bolt, Square
headed bolt with square neck, cup headed bolt,
Eye bolt, counter sunk headed bolt, rag bolt, etc.

8. Workshop problems related on time & Different Methods of locking of nuts :- a) Lock
work. nuts, b) Split pin, c) Slotted nut , d)
Symmonds nut, e) Castle nut, f) Wings nut,
etc.

9. Profit & Loss and problems concerning Permanent Fastening Devices- Rivets – different
to workshop practices. parts and their types Different types of rivet heads.

10. Properties of Matter- Different types of Rivets Joints – Lap joint and Butt or Strap joint.
Properties of Matter e.g. Mechanical, Lap Joint – a) Single Riveted, b) Double riveted, i)
Chain, ii) zig – zag

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 Operator blast furnace iron making equipments
Electrical, Chemical, Magnetic. Butt Joint – a) Single plate or strap, b) Double
plate or strap

11. Properties of Matter (Mechanical) - Keys and Cotter Joints, Difference between Keys
Tenacity, Toughness, Malleability, and Cotters, Different types of Keys.
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

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 Operator blast furnace iron making equipments
9.2 EMPLOYABILITY SKILLS
Duration: 55 HRS

SL. Topic Duration

NO. (in hours)
English Literacy 7
1. Reading
Reading and understanding simple sentences about self, work and environment

2. Writing
Construction of simple sentences Writing simple English

3. Speaking / Spoken English

Speaking with preparation on self, on family, on friends/ classmates, on know,
picture reading gain confidence through role-playing and discussions on current
happening job description, asking about someone's job habitual actions. 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.
I.T. Literacy 10
1. Basics of Computer
Introduction, Computer and its applications, Hardware and peripherals,
Switching on-Starting and shutting down of computer.
2. Word processing and Worksheet
Basic operating of Word Processing, Creating, opening and closing 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.
Use of External memory like pen drive, CD, DVD etc,
3. Computer Networking and INTERNET
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.
Communication Skill 18
1 Introduction to Communication Skills
Communication and its importance
Principles of Effective communication
Types of communication - verbal, nonverbal, written, email, talking on
phone.
Nonverbal communication - components-Para-language
Body - language
Barriers to communication and dealing with barriers.

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 Operator blast furnace iron making equipments
2 Listening Skills
Listening-hearing and listening, effective listening, barriers to effective
listening guidelines for effective listening.
3 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.
4 Facing Interviews
Manners, Etiquettes, Dress code for an interview
Do's & Don'ts for an interview
Entrepreneurship skill 8

1. Concept of Entrepreneurship
Entrepreneurship- Entrepreneurship - Enterprises:-Conceptual issue.
Source of business ideas, Entrepreneurial opportunities, The process of setting
up a business.
2. Institutions Support
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.
Productivity
1. Productivity
Definition, Necessity.

2. Affecting Factors
Skills, Working Aids, Automation, Environment, Motivation
How improves or slows down.
3. Personal Finance Management
Banking processes, Handling ATM, KYC registration, safe cash handling,
Personal risk and Insurance.
Occupational Safety, Health & Environment Education 6
1 Safety & Health
Introduction to Occupational Safety and Health importance of safety and health
at workplace.
2 Occupational Hazards
Basic Hazards, Chemical Hazards, Vibro-acoustic Hazards, Mechanical
Hazards, Electrical Hazards, Thermal Hazards. Occupational health,
Occupational hygienic, Occupational Diseases/ Disorders & its prevention.
3 Accident & safety
Basic principles for protective equipment.
Accident Prevention techniques - control of accidents andsafety measures.

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 Operator blast furnace iron making equipments
4 First Aid
Care of injured & Sick at the workplaces, First-Aid & Transportation of sick
person
Labour Welfare Legislation

1 Welfare Acts
Benefits guaranteed under various acts- Factories Act, Apprenticeship Act,
Employees State Insurance Act (ESI), Employees Provident Fund Act.
Quality Tools 6

1. Quality Consciousness :
Meaning of quality, Quality Characteristic
2. 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.
3. House Keeping :
Purpose of Housekeeping, Practice of good Housekeeping.
4. Quality Tools
Basic quality tools with a few examples

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 Operator blast furnace iron making equipments

10. DETAILS OF COMPETENCIES (ON-JOB TRAINING)

The competencies/ specific outcomes on completion of On-Job Training are

detailed below: -
BLOCK – I
DURATION: 12 MONTHS

 Practice to use safety appliances.

 Operate the arious equipment in stock house & high line i.e. Belt conveyors, screens,
weighing system, skip car operation etc.
 Monitor the bunker position, belt condition, highline condition, process flow & filling of log
books.
 Operate various equipments i.e. charging equipment, Stoves, septum valve, bleeder valve,
Primary Dust Catcher valve, hot blast valve, Snort valve etc.
 Perform Visual inspection of Tuyeres, valve condition & other check points. And perform
OFF blast & ON blast operation.
 Perform Handling of emergency situations i.e. Power failure, cooling water line failure etc.
 Check the oil levels in mud gun& drill machine, availability of sufficient clay for mud gun,
checking of Tap hole face condition, filling of mud gun clay, cleaning of metal –slag runner,
runner preparation, sample taking, poking, lancing, Rocking Runner operation etc.
 Operate equipment i.e. Drums, Conveyors, recovery pumps, granulation pumps, Lubrication
pumps etc.
 Operate various pumps & valves in GCP pump houses – Isolation, pump changing etc.
 Operate Electrostatic precipitators ( Isolation, charging, flushing),slurry disposal system
thickeners, agitators & slurry disposal pumps, flushing & hosing.
 Operate various gas valves for gas line isolation & charging,monitor water levels in Cooling
Tower, Scrubber, hot sump and overflow control
 Operate various pumps, cooling tower fans, valves, and monitor various parameters for Pump
bearing temp, amps, Emergency tank level, water flow rate, line pressure etc.

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 Operator blast furnace iron making equipments
 Operate major equipment i.e. centrifugal compressor, Screw compressor, Grinding Mill, Hot
gas generator, conveyors, bag filters & Tar injection system.
 Operate equipment & pouring of hot metal in pig casting machines, compressors, cooling
water recirculation systems, Power Plant, Blower etc.
 Practice to dismantle the boulders, positioning of ladles, heating of ladles,

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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 Operator blast furnace iron making equipments
ANNEXURE – I

INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL

KNOWLEDGE

TRADE: OPERATOR BLAST FURNACE IRON MAKING EQUIPMENTS

LIST OF TOOLS & EQUIPMENTS FOR 20 APPRENTICES

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.
6. Drawing Board 20
7. Models : Solid & cut section as required
8. Drawing Table for trainees as required
9. Stool for trainees as required
10. Cupboard (big) 01
11. White Board (size: 8ft. x 4ft.) 01
12. Trainer’s Table 01
13. Trainer’s Chair 01

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 Operator blast furnace iron making equipments

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.

31
 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

32