CURRICULUM

FOR THE TRADE OF

STEAM TURBINE-CUM-AUXILIARY
PLANT OPERATOR

UNDER

APPRENTICESHIP TRAINING SCHEME

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

1
 CONTENTS

Sl. No. Topics Page No.

1. Acknowledgement 3
2. Background 4-5
2. 1. Apprenticeship Training under Apprentice Act 1961
2. 2. Changes in Industrial Scenario
2. 3. Reformation

3. Rationale 6
4. Job roles: reference NCO 7
5. General Information 8
6. Course structure 9-10
Syllabus 11-33
7.1 Basic Training
7.1.1 Detail syllabus of Core Skill
A. Block-I (Engg. drawing & W/ Cal. & Sc.)
B. Block-II (Engg. drawing & W/ Cal. & Sc.)
7.1.2 Detail syllabus of Professional Skill & Professional
Knowledge
A. Block – I
B. Block – II
7.
7.1.3 Employability Skill
7.1.3.1 Syllabus of Employability skill
A. Block – I
B. Block – II
7.2 Practical Training (On-Job Training)
7.2.1 Broad Skill Component to be covered during on-job
training.
A. Block – I
B. Block – II
Assessment Standard 34-36
8.1 Assessment Guideline
8.
8.2 Final assessment-All India trade Test (Summative
assessment)
9. Further Learning Pathways 37
10. Annexure-I – Tools & Equipment for Basic Training 38-47
11. Annexure-II – Infrastructure for On-Job Training 48
12. Annexure-III - Guidelines for Instructors & Paper setter 49

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

1. TATA Steel, Jamshedpur

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

Co-ordinator for the course: Sh. Nirmalya Nath., ADT

Sl. Name & Designation Organization Expert Group

No. Sh./Mr./Ms. Designation
1. Anand Kumar Singh, Manager SNTI, TATA Steel Ltd. Expert
2. N. Nath, ADT CSTARI, Kolkata Expert

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 2. BACKGROUND

2. 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.

2. 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.

2. 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.

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 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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 3. RATIONALE
(Need for Apprenticeship in Steam Turbine cum Auxiliary Plant Operator trade)

1. It will enhance the ability to understand importance of housekeeping, disposal

procedure of waste material, health and safety. Preventive measure for electrical
accident and fire hazards and actions to be taken after such accidents.
2. It will enhance the ability to fit, repair/replace the machine elements used in the
boiler plant.
3. It will help the trainees to understand overview, components and auxiliaries of
various power plants.
4. It will enhance the ability to operate, fault diagnosis, carry out
preventive/breakdown maintenance and test various parts of the power plant e.g.
pumps, blowers, various valves, compressors, pneumatic tools and hydraulic
driven machines etc.
5. It will enhance the ability to assemble/dissemble, erection and alignment of
machines and accessories.
6. It will enhance the ability to handle machines for transportation purpose involving
the use of screw jacks, pulley blocks, cranes, hoists & slings, roller, bars and wire
ropes etc.
7. It will enhance the ability to use the precision measuring instruments and batteries.
Maintenance of small AC/DC motors.

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 4. JOB ROLES: REFERENCE NCO

Brief description of Job roles:

Turbine Operator, Steam; Turbo generator Operator, Steam operates steam powered
turbine which drives generators for producing electricity. Starts of turbine by opening
valve for supply of steam into turbine to rotate turbine wheels; runs turbine at low speed
for pre-determined length of time and notifies switch-board operator when ready to run
turbine at full working speed; increases speed of turbine and ensures that automatic
regulator maintains correct working speed; notifies switch-board operator that turbine
can be synchronized with other power units in plant. Observes gauges and meters to
ensure proper handling of load by turbine and its proper functioning; alters power output
of turbine and makes other adjustments as necessary. Cuts out unit evaporator to conduct
blow down of turbine for periodic overhauling. May keep records of instrument
readings. May repair and overhaul equipment and other auxiliaries.

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

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

Reference NCO:
i) NCO-2004: 8161.30

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 5. GENERAL INFORMATION

1. Name of the Trade : STEAM TURBINE CUM AUXILIARY

PLANT OPERATOR
2. N.C.O. Code No. : NCO-2004: 8161.30

3. Duration of Apprenticeship Training (Basic Training + Practical Training):2years

3.1 For Freshers: - Duration of Basic Training: -
a) Block –I : 3 months
b) Block – II : 3 months
Total duration of Basic Training: 6 months
Duration of Practical Training (On -job Training): -
a) Block–I: 9 months
b) Block–II : 9 months
Total duration of Practical Training: 18 months

3.2 For ITI Passed: - Duration of Basic Training: - NIL

Duration of Practical Training (On -job Training): 12 months

4. Entry Qualification : Passed 10th Class under 10+2 system of Education or its
equivalent

5. Selection of Apprentices: The apprentices will be selected as per Apprentices Act

amended time to time.

6. Rebate for ITI passed trainees : NIL

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 .

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 6. COURSE STRUCTURE

Training duration details: -

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

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

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 Duration of Training in Months
Components of Training
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4
Basic Training Block - I
Practical Training Block - I
Basic Training Block - II
Practical Training Block - II

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 7. SYLLABUS
7.1 BASIC TRAINING
(BLOCK – I & II)
DURATION: 06 MONTHS

GENERAL INFORMATION

1) Name of the Trade : STEAM TURBINE CUM AUXILIARY

PLANT OPERATOR
2) Hours of Instruction : 1000 Hrs. (500 hrs. in each block)
3) Batch size : 20
4) Power Norms : 17 KW for Workshop
5) Space Norms : 192 Sq. m.
6) Examination : The internal assessment will be held on
completion of each Block.
7) Instructor Qualification :

i) Degree/Diploma in Mechanical Engg. from recognized university/Board

with one/two year post qualification experience respectively in the relevant
field.
OR

ii) NTC/NAC in the trade of Steam Turbine cum Auxiliary Plant

Operator/MMTM with three year post qualification experience in the
relevant field.

Preference will be given to a candidate with Craft Instructor Certificate (CIC)

8) Tools, Equipments & Machinery required: - As per Annexure – I

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 7.1.1 DETAIL SYLLABUS OF CORE SKILL

A. Block– I
Basic Training

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

No. (in hours) Calculation (in hours)

1. Engineering Drawing: 30 Units & Measurements- FPS, 20

Introduction and its importance CGS, MKS/SI unit, unit of
Different types of standards used length, Mass and time.
in engineering drawing. Fundamentals and derived units
Drawing Instruments: their uses Conversion of units and applied
Drawing board, T-Square, Drafter problems.
(Drafting M/c), Set Squares,
Protractor, Drawing Instrument
Box (Compass, Dividers, Scale,
Diagonal
Scales etc.), Pencils of different
Grades, Drawing pins / Clips.
2. Lines : Material Science : properties -
types and applications in Drawing Physical & Mechanical, Types -
as per BIS SP:46-2003 Ferrous & Non-Ferrous,
Drawing geometrical object using difference between Ferrous and
all types of lines. Non-Ferrous metals
Drawing of Geometrical
Figures: Angle, Triangle, Square,
Rectangle and Circle.
Letters: - Lettering styles, Single
stroke letters and numbers as per
IS standard. Lettering practice
3. Dimensioning- Types of Mass .Weight and Density :
dimension, elements of Mass, Unit of Mass, Weight,
dimensions, Methods of difference between mass and
indicating Values, Arrangement, weight, Density, unit of density,
Alignment and indication of
dimensions.
Scales:-Types use and
construction. Representative
factor of scale.
4. Method of presentation of Speed and Velocity: Rest and
Engineering Drawing motion, speed, velocity,
- Pictorial View difference between speed and
- Orthogonal View velocity, acceleration,
- Isometric view retardation.
Average Velocity, Acceleration
& Retardation. Related
problems.
Circular Motion: Relation
between circular motion and
Linear motion, Centrifugal

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 force, Centripetal force

5. Constructions: - Draw Ratio & Proportion :

proportionate free hand sketches Simple calculation on related
of plane figures. Sketch problems.
horizontal, vertical and inclined Percentage: Introduction,
line by free hand, Draw circles by Simple calculation.
free hand using square and radial
line method, Draw arcs and
ellipse by free hand
6. Projections: Work, Power and Energy:
Concept of axes plane and work, unit of work, power, unit
quadrant. of power, Horse power of
Orthographic projections engines, mechanical efficiency,
Method of first angle and third energy, use of energy, potential
angle projections (definition and and kinetic energy, examples of
difference) potential energy and kinetic
Symbol of 1st angle and 3rd angle energy.
projection as per IS specification. Meaning of H.P., I.H.P.,
Free hand Drawing of B.H.P., and F.H.P. and CC
Orthographic projection from and Torque.
isometric/3D view of geometrical
blocks

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 B. Block- II
Basic Training

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

No. (in hours) Calculation (in hours)

1. Screw :- 30 Algebra: 20
Its Types and Sizes, Screw thread, Addition, Subtraction,
their standard forms as per BIS, Multiplication, Division,
external and internal thread. Algebraic formula, Linear
equations (with two variables).
2. Rivets and Joints:- Heat & Temperature:
Prepare a drawing sheet on rivets Heat and temperature, their
nomenclature and Joints. units, difference between heat
and temperature, boiling point,
melting point, scale of
temperature, relation between
different scale of temperature,
Thermometer, pyrometer,
transmission of heat,
conduction, convection,
radiation.
3. Free hand Sketches for simple Mensuration: Area and
pipe line with general fittings. perimeter of square, rectangle,
parallelogram, triangle, circle,
semi circle, Volume of solids -
cube, cuboid, cylinder and
Sphere.
Surface area of solids -cube,
cuboid, cylinder and Sphere.
Volume of cut-out solids:
hollow cylinders, frustum of
cone, block section. Volume
of simple solid blocks.
4. Reading of drawing. Simple Basic Electricity: Introduction,
exercises related to missing lines, use of electricity, how
dimensions. How to make queries. electricity is produced, Types
of current_ AC, DC, their
comparison, voltage, resistance,
their units. Conductor,
insulator, Types of connections
- series, parallel, electric power,
Horse power, energy, unit of
electrical energy. Concept of
earthling.
5. Simple exercises related to trade Simple machines
related symbols. Transmission of power: -
Basic electrical and electronic Transmission of power by belt,
symbols pulleys & gear drive.
Heat treatment process: -
Heat treatment and advantages.

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 Annealing, Normalizing,
Hardening, Tempering.

6. Free hand sketch of trade related Trigonometry:

components / parts /cutting tool Trigonometrical ratios,
indicating angles. measurement of angles.
Trigonometric tables.
Finding the value of unknown
sides and angles of a triangle by
Trigonometrical method.
Finding height and distance by
trigonometry.
Application of trigonometry in
shop problems. (viz. taper angle
calculation).
Calculate the area of triangle by
using trigonometry and
application of Pythagoras
theorem.
7. Concept of pressure -
Definition:-Force, Pressure,
and their units, atmospheric
pressure, gauges used for
measuring pressure, problems.
Introduction to pneumatics &
hydraulics systems.
8.
Simple exercises related to trade related Test Papers. Solution of NCVT test papers.

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 7.1.2 DETAIL SYLLABUS OF PROFESSIONAL SKILLS & PROFESSIONAL
KNOWLEDGE
A. Block –I
Basic Training

Week Professional Skills Professional Knowledge

No.
1. Safety: - its importance, classification, Importance of safety and general
personal, general, workshop and job safety. precautions observed in the in the
Occupational health and safety. industry/shop floor. All necessary guidance
Basic injury prevention, Basic first aid, Hazard to be provided to the new comers to
identification and avoidance, safety signs for become familiar with the working of
Danger, Warning, caution & personal safety Institute system including stores
message. procedures.
Preventive measures for electrical accidents &
steps to be taken in such accidents. Introduction of First aid. Safety attitude
development of the trainee by educating
Importance of housekeeping & good shop him to use Personal Protective Equipment
floor practices. (PPE).
Disposal procedure of waste materials like Response to emergencies e.g.; power
cotton waste, metal chips/burrs etc. failure, fire, and system failure.
Fire& safety: Use of Fire extinguishers. Accidents- Definition types and causes.
First-Aid, nature and causes of injury and
Safety regarding working with different types utilization of first-aid.
of steam and its First-Aid.
Introduction to 5S concept & its
application.
Fire: - Types, causes and prevention
methods. 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. Identification of tools & equipments as per Hand tools and its importance, steel rule,
desired specifications for marking & sawing( Try square, chisel, surface gauge and care
Hand tools , Fitting tools & Measuring tools) & maintenance, Hacksaw frame, blades.
Selection of material as per application Visual Classification and types of chisels, files &
inspection of raw material for rusting, scaling, uses, vices - its constructions and uses.
corrosion etc. Hammers and its types. Related safety.

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 Uses of marking tools, Punch, Try square & Marking block, Steel rule, and calipers-
basic measuring tools, caliper, steel rule. different types and uses. Combination set-
Marking out lines, gripping suitably in vice its components and uses.
jaws, hacksawing to given dimensions, sawing Hacksaw blade, Hacksaw frame and its
different types of metals of different sections.
types. Drill bits- parts, Types & uses.
3. Understand and usage of different measuring Linear measurements & its units
instruments e.g. bore gauge, dial indicator, Classification, construction, materials and
edge finder. functional detail of following basic
Checking and setting of Vernier calipers, measuring and marking tools : -
vernier height gauge &vernier bevel protractor.  Steel Rule
Filing flat, square, steps and contour surfaces  Calipers(Inside & outside),
to an accuracy of 0.4 mm  Divider, Trammel
 Try Square
 Marking Punch
Measuring Instruments.
Vernier calipers, vernier height gauge
&vernier bevel protractor - principle,
construction, calculation of least count and
its use and care.
4. Chipping practice on flat surface, slots & oil Precision Measuring Instruments:
grooves, and chamfer at different angle on MS Concept of precision & accuracy
plate. Micrometer (outside, inside and depth) –
Scraping practice on curved surfaces. use & care, calculation of least count.
Preparation of flat surfaces and scraping Limits, fits and tolerances:
practice on flat surface taking impression on
Different system of limit and tolerances -
face high spots using prussian blue sharpening
Newall, BIS, British, DIN, ISO.
by diamond dresser & wheel and lapping
stone. Details of BIS system.

Interchangeability and standardization.

Use of templates, jigs and fixtures, gauges

for manufacturing of interchangeable parts.

Scrapers: Introduction, its types, material

and use.
5. Hand grinding of different types of tools, e.g. Joining & Fastening Devices
chisel, drill, etc.

Reaming with hand reamers. Permanent, semi-permanent & temporary

fastening devices.
Threading by hand using taps and dies.
Different types of fasteners and their
Cold riveting of two components with different functions like bolts, nuts, washers, rivets,
studs,pins cotter, keys, machine screws,
types of rivets. Philip screws etc.

Pipe cutting, pipe threading, pipe fitting etc. Rivets and riveting - types, sizes, riveting

17
 tools, etc.
Punching of holes with hollow punches on
leather gaskets and other packing materials. Pipes and pipe fitting - tools, fixtures,
threads etc.
Screws and screwing - different type of
threads function etc.
Taper and tapering - devices with the use
of tapers.

6. Skills involving in repairing on machine Boiler Plant Operation

e1ements:
Boiler light-up and shutdown procedure,
Removing of broken studs from machine parts. boiler emergency and normal operations,
boiler protections.
Removal and mounting of pulleys, gears in
General Terms of Boilers
the shaft.

Replacement of /repairing of bolts. Familiarization with different types of

boiler and its mounting and accessories.
Removal and mounting of antifriction
Familiarisation with Indian Boiler Act,
bearings. Boiler Protects, Hydraulic test, different
boiler losses.
Practice of scraping on machine slides,
machine beds, plain bearings etc.

Checking and repairing of broken and worn-

out gears, shafts, pulleys, clutches, flanges,
etc.

7-8.
Diagnosis of faults in machines. Steam Turbines
Identify various types of boiler and its Fundamental principles of turbine-impu1se
mounting and accessories by using charts, and reaction, condensing and non-
posters and models. condensing turbines, turbine compounding.
Nomenclature and parts of a turbine,
simples features & construction and
functions of nozzles, blades, rotors, discs,
cylinders, Steam Chest, diaphragm, gland,
couplings, bearings, thrust block, thrust
balancing. Concept of turbine critical
speed.

Turbine Plant Auxi1iaries

Condenser, its classification, function and
its construction. Circulating water pumps,
Condensate & feed water system extraction
pumps, drain cooler, feed heaters, steam
traps de-aerator.
Air evacuation system, turbine gland
sealing system, Air compressors – it
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 working, types and Air drivers.
Gas Turbine Power Plant
Introduction, advantages and limitations of
gas turbine power plant, cycles for gas
turbine - open & close cycle gas turbine
power plants. Methods used for improving
of gas turbine power plant, fuel system of
gas turbine plant, combustion chamber,
essential auxiliaries of gas turbine power
plant, governing system of gas turbine
plant, starting and stopping procedures.

9-10. Identify various pressure, temperature, flows, Diesel Engine Power Plant
current and voltage measuring instruments and
Working of diesel engine, advantages and
its use. Filling log sheets & record keeping.
disadvantages of diesel engine power plant,
Identify and use of various types of valves like essential components of diesel engine
gate valve, globe valve, flap valve, butter fly power plant. Air intake system, fuel supply
valve, needle valve, disk valve, hydraulic system, Cooling system, Exhaust system,
valves, pneumatic valves, motor operated lubricating system, starting and stopping
valves, non return valves, cocks etc. operation, governing system.
Nuclear Power PI ant: Fundamentals,
Identify and understanding operation of basic elements of power plant, reactors.
different types of pumps like centrifugal Hyde1 Power Plant
pumps - single stage & multistage, gear
pumps, screw pumps, reciprocating pumps, Water turbine working principles, basic
etc. Priming the pumps, starting, elements of hydro power plant,
stopping isolating them . classification, its auxiliaries, speed controls
of water turbines, operation of hydro power
station.

11. Identification of various types of centrifugal Centrifugal Pump, Fan, Blower and
pumps, their parts. Overhauling of pump. Compressor: - Function of pump. Types
Priming of pump, Fitting gland packing. and working principle of centrifugal pump.
Starting and stopping of pumps. Trouble Constructional detail of pump Starting and
shooting in pump operation. stopping Pump performance and
characteristics. Capitation & aeration.
Preventive & schedule maintenance of
pumps. Gland packing changing procedure.
Concept of Mechanical seal Trouble
shooting in pump.
Air compressors - cooling system, inter &
after coolers, storage devices, Air dryers,
compressor on load - off load regulation
etc.
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12. Identification of various types of fans, Fan & Blowers: Types and working
Blowers, their parts. Dismantling, cleaning principle Constructional detail of Fans &
and assembly of parts. Identification of Blowers. Starting and stopping of Fans and
various types of compressors, their parts. Blowers Different parts of Fans & Blowers
Starting and stopping of compressors CleaningConcept of surge. Preventive & scheduled
and changing of filters Preventive & schedulemaintenance.
maintenance of Blower & Compressor Compressors: Compression theory, Types
of compressors Constructional detail of
compressors, working mechanism
Different parts and their function. Loading
unloading system Concept of air dryer.
Preventive & schedule maintenance.
13. Revision &Internal Assessment

20
 B. Block –II
Basic Training

Week Professional Skills Professional Knowledge

No.
1-2. General Maintenance:
Repair of machines including preventive

1. Standard pipe thread, join pipes and make maintenance: Importance of maintenance work,
pipe assemb1y. Different types of maintenance.
2. Scrap angular matching and sliding
surfaces& originate flat surface without Methods of maintenance and overhauling of
machines and tools. Basic concepts on
master. preventive maintenance.
3. Assemble components accurately using
dowel pins and screw.
4. Lap and finish flat surfaces.
5. Make oil grooves on bearing with chisel.
6. Assemble parts by riveting, screwing,
pinning, so as to make complete unit
according to drawing.
7. Dismantle or remove worn out broken or
defective parts using hand tools and replace
them by repaired or new one test completed
article to ensure correct performance.
8. Fit parts together in set order using nuts,
bolts, screws and pins etc. with necessary
wrenches, spanners and other special tools.
9. Mechanical handling of machines for
transportation purpose involving the use of
screw jacks, pulley blocks, cranes, hoists
&slings, roller, bars and wire ropes etc.
10. Alignment of brackets and shafts.
11. Remove and fit antifriction bearings.
12. Maintenance of pneumatic tools &
hydraulic driven machines.
13. Recondition thread by tap.
14. Use of precision measuring instruments.
15. Reaming holes for proper assembly.

3-4 Basic skills involved in breakdown Power Transmission and Driver :

maintenance, preventive maintenance and
overhauling of machine: 1. Common methods of power transmission and
drives.

21
 1. Diagnosis of faults in machines. 2. Belts and belting - types, sizes and use of
2. Breakdown maintenance of general belts, fasteners, belt speeds, parallel and
machine tools (lathe, drilling machine, etc.) crossed belt drives.
3. Practice in carrying out preventive 3. Types and uses of keys and keyways -
maintenance work (the jobs involve 4. Tooth gears and gearing - types and uses of
inspection and lubrication of the machine gears, conversion of rotary motion into
as per instructions). Painting and use of reciprocating motion, pinning and racks, etc.
surface protective coatings under 5. Chain and sprockets - types and uses, solid,
preventive maintenance programme. flexible, friction, universal etc.
4. Overhauling of Bench Drilling Machine, 6. Coupling and sprockets - types and uses,
Pedestal Grinding Machine, coolant pump, solid, flexible, friction, universal etc.
and machine accessories e.g. chucks vice, 7. Mechanical, hydraulic and pneumatic drives -
steadies, tai1 stock, etc. basic principles and uses.
8. Prime movers, line shafts and drive system,
individual drive system, reciprocating drive,
reverse drive, eccentric drive, crank drive,
cam drive, rotary to linear drive and vice
versa.
9. Systems of speed, variation using stepped
pulleys, gear box, disc-contact, etc.

5. Making of different types of keys, keyways on Friction and Lubrication:

pulleys, gears, etc. by hand.
Friction - its effect, methods of reducing friction,
Practice on exercise involving making of use of bearings.
simple machine parts which have certain
functional relationship to other parts.
Coolants - different types and uses, cooling
system.
Make oil grooves on bearing with chisel.
Lubrication and Lubricants - methods of
lubrication, need and use, qualities of good
lubricants, viscosity, techniques of selection,
type of lubrication oil and greases - their rating,
commercial names and uses.

6. Hydraulic &pneumatic circuit reading Basic principle of Hydraulic& pneumatic system.

practice & constructing hydraulic circuits for Advantages & limitation.
single & double acting cylinders, meter in, Constructional & functional details of Hydraulic
meter out circuit, pressure control circuits & pneumatic cylinder, motor, control valves and
&regenerating circuit. FRL unit.

7. Fit parts together in set order using nuts, bolts, Bearings:

screws and pins etc. with necessary wrenches,
spanners and other special tools. Different types, their application and
Mounting and dismounting of pulleys and dimensional relationship with shafts, methods of
gears on shaft. clamping and fitting lubrication of bearings,
methods of mounting and dismounting, care
maintenance, inspection of bearings.

22
 Basic working principal of water flowmeter,
steam flowmeter, CO2, indicator and reactors,
Electro static pacificator, smoke density meter,
types of draughts.

8. a) Use of basic hand tools for electrical Basic Electricity: -

work. Fundamental of electricity
b) Making of points in single and multi- Definition and properties of conductors,
strand cables and wires. insulators and semi-conductors. Voltage grading
c) Wiring and use of electrical accessories, of different types of Insulators, Temp.
such as switches, plugs, cut-outs, fuese, Familiarization with the units and its measuring
regulators, fluorescent lights, etc. indoor instruments - Volts, Amp., Ohm’s, watt., B.O.T.,
and outdoor wiring. H.P. etc.
d) Making simple electrical circuits on Capacitor, resistance, reluctance,
wooden boards. Colour code of resistance.
Types of wires & cables standard wire gauge
Specification of wires & Cables-insulation &
voltage grades
-Low , medium & high voltage
Precautions in using various types of cables /
Ferrules
Ohm’s Law, Flemings rules.
Simple electrical circuits and problems (series
and parallel)
9. a) Use of primary and secondary batteries. Different types of Batteries.
b) Use of electrical measuring instruments.
c) Verification of Ohm's Law. Types of Voltage (A.C. and D.C.)
d) Dismantling, cleaning and assembling of
A.C. and D.C. motors upto one H. P., Principal of Motor and generator (A.C. and D.C.)
detection of failures of these motors and
remedy thereof.

10. Identification by Flow chart of a thermal Coal Pulverisers

power plant.
Types of pulverisers, -working principles.
Importance of fineness of pulverised fuel and
methods of controlling it, Coal feeders
emergency operation during fire.

Ash Handling System

Handling bottom ash and fly ash in boilers.

Description and use of cyclone type of
mechanical dust collectors, Principle and
function of electrostatic precipitator.

Water Treatment Plant

Impurities in water and their harmful effects.

23
 Priming, foaming, scale formation and corrosion,
softening and de-mineraling plant, boiler internal
chemical treatment of feed water. Familiarisation
with TDS & PH value of water & their effects.
11- Detect faults, Inspect, align and test machine Familiarization of air-preheaters, Seal setting of
12. for accurate functioning. air-preheaters, Inspection of Tabular air-heater,
S C A P H cleaning, Knowledge of International
Boiler Regulation. Pu1verisers and Feeders,
Fans: Fan lubrication system, Ash & Dust
Collect ion System of dust collection ash
handling system, Ash disposal line. Air
Compressors: Trouble shooting, Pump
Maintenance:
Steam Turbine Generator Overhauling:
Maintenance of Heat Exchangers Ejector
maintenance.
Cooling Tower: Components, Specific problems,
Major modifications, I D fan gear box
overhauling. Types of faults, Types of joints,
gland packing & gaskets.
13. Revision & Internal Assessment

24
 7.1.3 EMPLOYABILITY SKILLS
GENERAL INFORMATION

1) Name of the subject : EMPLOYABILITY SKILLS

2) Applicability : ATS- Mandatory for fresher only

3) Hours of Instruction : 110 Hrs. (55 hrs. in each block)

4) Examination : The examination will be held at the end of

two years Training by NCVT.

5) Instructor Qualification :

i) MBA/BBA with two years experience or graduate in sociology/social

welfare/Economics with two years experience and trained in Employability skill from
DGET Institute.
And
Must have studied in English/Communication Skill and Basic Computer at 12th
/diploma level
OR
ii) Existing Social Study Instructor duly trained in Employability Skill from DGET
Institute.

25
 7.1.3.1 SYLLABUS OF EMPLOYABILITY SKILLS
A. Block – I
Basic Training

Topic Topic Duration

No. (in hours)

English Literacy 15
1 Pronunciation :
Accentuation (mode of pronunciation) on simple words, Diction (use of word
and speech)
2 Functional Grammar
Transformation of sentences, Voice change, Change of tense, Spellings.

3 Reading
Reading and understanding simple sentences about self, work and
environment
4 Writing
Construction of simple sentences Writing simple English

5 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. Cardinal (fundamental) numbers ordinal numbers. Taking messages,
passing messages on and filling in message forms Greeting and introductions
office hospitality, Resumes or curriculum vita essential parts, letters of
application reference to previous communication.
I.T. Literacy 15

1 Basics of Computer
Introduction, Computer and its applications, Hardware and peripherals,
Switching on-Starting and shutting down of computer.
2 Computer Operating System
Basics of Operating System, WINDOWS, The user interface of Windows OS,
Create, Copy, Move and delete Files and Folders, Use of External memory
like pen drive, CD, DVD etc, Use of Common applications.
3 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
4. Computer Networking and INTERNET
Basic of computer Networks (using real life examples), Definitions of Local
Area Network (LAN), Wide Area Network (WAN), Internet, Concept of
Internet (Network of Networks),
Meaning of World Wide Web (WWW), Web Browser, Web Site, Web page

26
 and Search Engines. Accessing the Internet using Web Browser, Downloading
and Printing Web Pages, Opening an email account and use of email. Social
media sites and its implication.
Information Security and antivirus tools, Do's and Don'ts in
Information Security, Awareness of IT - ACT, types of cyber crimes.
Communication Skill 25

1 Introduction to Communication Skills

Communication and its importance
Principles of Effective communication
Types of communication - verbal, non verbal, written, email, talking on
phone.
Non verbal communication -characteristics, components-Para-language
Body - language
Barriers to communication and dealing with barriers.
Handling nervousness/ discomfort.
Case study/Exercise
2 Listening Skills
Listening-hearing and listening, effective listening, barriers to effective
listening guidelines for effective listening.
Triple- A Listening - Attitude, Attention & Adjustment.
Active Listening Skills.
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.
Case study/Exercise
4 Facing Interviews
Manners, Etiquettes, Dress code for an interview
Do's & Don'ts for an interview
5 Behavioral Skills
Organizational Behavior
Problem Solving
Confidence Building
Attitude
Decision making
Case study/Exercise

27
 B. Block– II
Basic Training

Topic Topic Duration

No. (in hours)

Entrepreneurship skill 15

1 Concept of Entrepreneurship
Entrepreneurship- Entrepreneurship - Enterprises:-Conceptual issue
Entrepreneurship vs. Management, Entrepreneurial motivation. Performance &
Record, Role & Function of entrepreneurs in relation to the enterprise & relation to
the economy, Source of business ideas, Entrepreneurial opportunities, The process of
setting up a business.
2 Project Preparation & Marketing analysis
Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept & application
of Product Life Cycle (PLC), Sales & distribution Management. Different Between
Small Scale & Large Scale Business, Market Survey, Method of marketing, Publicity
and advertisement, Marketing Mix.
3 Institutions Support
Preparation of Project. Role of Various Schemes and Institutes for self-employment
i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non financing support
agencies to familiarizes with the Policies /Programmes & procedure & the available
scheme.
4 Investment Procurement
Project formation, Feasibility, Legal formalities i.e., Shop Act, Estimation & Costing,
Investment procedure - Loan procurement - Banking Processes.
Productivity 10

1 Productivity
Definition, Necessity, Meaning of GDP.

2 Affecting Factors
Skills, Working Aids, Automation, Environment, Motivation
How improves or slows down.
3 Comparison with developed countries
Comparative productivity in developed countries (viz. Germany, Japan and Australia)
in selected industries e.g. Manufacturing, Steel, Mining, Construction etc. Living
standards of those countries, wages.
4 Personal Finance Management
Banking processes, Handling ATM, KYC registration, safe cash handling, Personal
risk and Insurance.
Occupational Safety, Health & Environment Education 15
1 Safety & Health
Introduction to Occupational Safety and Health importance of safety and health at
workplace.

28
 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 and safety measures.
4 First Aid
Care of injured & Sick at the workplaces, First-Aid & Transportation of sick person
5 Basic Provisions
Idea of basic provision of safety, health, welfare under legislation of India.

6 Ecosystem
Introduction to Environment. Relationship between Society and Environment,
Ecosystem and Factors causing imbalance.
7 Pollution
Pollution and pollutants including liquid, gaseous, solid and hazardous waste.
8 Energy Conservation
Conservation of Energy, re-use and recycle.
9 Global warming
Global warming, climate change and Ozone layer depletion.
10 Ground Water
Hydrological cycle, ground and surface water, Conservation and Harvesting of water
11 Environment
Right attitude towards environment, Maintenance of in -house environment
Labour Welfare Legislation 5

1 Welfare Acts
Benefits guaranteed under various acts- Factories Act, Apprenticeship Act,
Employees State Insurance Act (ESI), Payment Wages Act, Employees Provident
Fund Act, The Workmen's compensation Act.
Quality Tools 10

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 Quality Management System :
Idea of ISO 9000 and BIS systems and its importance in maintaining qualities.
4 House Keeping :
Purpose of Housekeeping, Practice of good Housekeeping.
5 Quality Tools
Basic quality tools with a few examples

29
 7.2 PRACTICAL TRAINING (ON-JOB TRAINING)
(BLOCK – I & II)
DURATION: 18 MONTHS (9 months in each block)

GENERAL INFORMATION

1) Name of the Trade : STEAM TURBINE CUM AUXILIARY

PLANT OPERATOR
2) Batch size : a) Apprentice selection as per Apprenticeship
guidelines.
b) Maximum 20 candidates in a group.
3) Examination : i) The internal assessment will be held on
completion of each block
ii) NCVT exam will be conducted at the end of
2nd year.
4) Instructor Qualification :

i) Degree/Diploma in Mechanical Engg. from recognized university/Board

With one/two year post qualification experience in the relevant field.
OR

ii) NTC/NAC in the trade of Steam Turbine cum Auxiliary Plant Operator with
three year post qualification experience in the relevant field.

Preference will be given to a candidate with Craft Instructor Certificate (CIC)

5) Infrastructure for On-Job Training : - As per Annexure – II

30
7.2.1 BROAD SKILL COMPONENT TO BE COVERED DURING ON-
JOB TRAINING

A. BLOCK – I (09 months)

1. Safety and best practices/Basic Industrial Culture (5S, KAIZEN, etc.)
2. Prepare different types of documentation as per industrial need by different methods of recording
information.
3. Introduction to elementary knowledge of feed water system and boiler feed pump, draught system
of boilers, fuel system, steam network and turbine and visit at site.
4. Study of different parts & fittings of a boiler such as steam and water drums, stoker gauge, water
tubes and flow tubes, high and low water level alarm, gauge glasses, soot blowers, safety valves
etc. Forced draught, induced draught, balanced draught and secondary draught fans, Air pre-heater,
chimney, water walls, water wall tubes, boiler bank tubes, primary and secondary super heaters,
Attemperator, down comer and riser tubes, de-aerator, LP and HP dosing pumps, DM water plant
and water chemistry, coal mills and coal handling plats, cooling towers & economizer, boiler
controls, etc.
5. Measurement of temperature, pressure, vacuum, draught, flow using appropriate instruments for
different system.
6. Uses, methods of jointing, checking of joints for leakage and remedy thereof.
7. Study of different parts of turbine; study the features of construction of blades, nozzles, governor
parts, condensers, ejectors, etc. Study of different types of pumps, compressors and their parts.
Different types of valves.
8. Boiler & their Auxiliaries:

i. Working and management of steam boilers; economizers and air heater.

ii. Correct use of various types of cocks, mounting and fittings used in boilers.
iii. Functions of feed pumps.
iv. Operation of fans, blowers, feed pumps including starting and stopping.
v. Operation of fuel preparation equipment, fuel feeding indicators and recorders orsat apparatus,
smoke density drive and draft regulation of proper combustion.
vi. Operation of ash discharge disposal system in boiler.
vii. Water level control in boiler operation, blow-down of boiler.
viii. Control of steam pressure and steam flow.
ix. Operation of super heater and control of super heated steam temperature.
x. Starting and commissioning of boilers, banking and shutting down.
xi. Periodical cleaning and inspection of boilers.
xii. Preparation of boiler for testing, inspection, hydraulic, and steam test.
xiii. Draining of steam lines - the danger of water logging and precautions to be observed in starting
of steam lines.
xiv. Testing the correctness of water gauges - replacement of gauge glass.
xv. Detection of false water level and knowledge of alarm device.
xvi. Use of safety valve, easing operation, use of blow down cock or valve, and adjustment of high
steams and low water safety alarm.
xvii. Checking and renewal of gland packings and mechanical seals of pumps, valve chest and
working knowledge of feed pumps and/or injectors.

31
xviii. Use of thermometers and pressure gauges, vacuum gauges steam and water flow meters,
pyrometers, fuel meters, CO2 indicators and recorders, orsat apparatus, smoke-density meter.
xix. Boiler safety precautions.

9. CONTROL ROOM & ELECTRICAL SYSTEMS:

i. Starting of power plant equipment, such as fans, pumps, compressors, etc. Control room
operations, such as operation of switch gear, control of turbo alternator load, excitation etc.
ii. Building up of voltage and synchronizing, alternator with operation of field rheostat,
voltage regulator, governor control, synchroscope etc.
iii. Alternator cooling system air cooling, hot air stator water cooling and cold air temperature,
air cooler, hydrogen cooling system (if available) normal pressures and temperature control
and changing of hydrogen cylinders, method of regenerating hydrogen drier (if available) ,
safety precautions, (if hydrogen cooling exists).
iv. Study of methods of boiler control and turbine control. Method of loading an alternator,
meger power factor control of machines running in parallel.
v. Use of emergency lighting, fire protection, handling of power failure and breakdown.

10. PERFORMANCE IMPROVEMENT IN OPERATION

Losses in boiler and turbine, Insulation of boiler, turbine and pipelines, Insulation in penthouse
of boiler.

11. RELIABILTY OF BOILER OPERATION

Creep in boiler tube materials, boiler tube failures, Safety valve floating of boiler, Know-how of
Remaining Life Assessment of boiler.

B. BLOCK – II (09 months)

1. Turbine and Auxiliaries:

i. Explanation on Turbine & construction of different parts, back-pressure turbine. PRDS

operation, Advantage of back pressure turbine over pressure reducing station for process
steam.
ii. Study of steam cylinder, steam chest, diaphragms rotor blades, discs, glands, coupling,
bearing etc.
iii. Method of gland sealing - steam seals, water seals, clearances, sealing pressure regulators
and controls.
iv. Lubrication system - oil tank, oil strainers, centrifugal filters and oil coolers, cleaning of oil
coolers and oil strainers, oil piping, method of jointing -oil pumps, jack-oil pump, gear
pumps, reciprocating pumps and centrifugal pumps, main oil pumps and auxiliary oil
pumps, methods of dismantling & assembling. Contamination control of lubricating oil.
v. Turbine bearings, bearing clearances and blue matching, monitoring of parameters of
bearing.

2. Turbine auxiliaries such as condensers, ejectors, extraction pumps, C.W. pumps etc.
i. Condensers - water flow, steam flow, constant water level control starting a condensing
plant or stopping it. Care and precautions to prevent loss of vacuum, causes of loss of
vacuum, remedies, air leakages, condenser cleaning methods.

32
 ii. Pumps - centrifugal and reciprocating, starting a centrifugal pump. Different methods of
priming, putting the pumps on load, starting a reciprocating pump, care and maintenance of
running pumps.
iii. Air ejectors - different types, steam, hydraulic, starting ejectors, sequence of operation,
stopping it, starting an ejector in conjunction with a condensing plant,
iv. Function and use of evaporators, drain collers and feed heaters, putting them into operation
and taking them out of operation, maintenance of proper feed water temperature.
v. Atmospheric relief valve and other safety devices.
vi. Compressors, operation, care and maintenance.
vii. Cooling water system.
viii. Reheat and regenerative system.

3. Study, operation and adjustment of turbine governor, different types, method of working of
synchronizing governor, over speed governor, speed limit governor and emergency shut-off
devices, Electro-hydraulic governer. The trainee must get a thorough practical idea of manual
remote control of governors.

4. Turbine plant operation - starting an condensing plant, starting a steam turbine from cold
condition, method of running up to speed necessity of slow and uniform heating, critical speed
avoiding, vibration at critical speeds, care to be taken when removing and applying load on turbo-
alternators, stopping a turbine, sequence of operations, stopping the condensing plant and other
auxiliaries. Study of feed water and steam: cycle. Turning gear.

5. Turbine troubles and remedies - study of abnormalities during operation and remedial measures.
Troubles, such as loss of vacuum, air leakage, low oil pressure, hot bearings, etc. vibration - their
causes and remedies.

6. Instrumentation and control - necessity of different instruments for measuring and recording
temperature, pressure, flow etc. Co-relation of different date as recorded by various instruments.
Study of these in relation to load. Turbine supervisory instrumentation.

7. Importance of maintenance of daily log sheets and records, delay register, defect register.

8. Operation of steam pressure reducing station and H. P., L. P. by pass station.

33
 8. ASSESSMENT STANDARD
8.1 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 to be given while assessing for team work,
avoidance/reduction of scrape/wastage and disposal of scarp/wastage as per procedure,
behavioral attitude and regularity in training.

The following marking pattern to be adopted while assessing:

a) Weightage in the range of 60-75% to be allotted during assessment under following

performance level:

For this grade, the candidate with occasional guidance and showing due regard for safety
procedures and practices, has produced work which demonstrates attainment of an
acceptable standard of craftsmanship.

In this work there is evidence of:

 good skill levels in the use of hand tools, machine tools and workshop equipment
 many tolerances while undertaking different work are in line with those demanded
by the component/job.
 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 under

following performance level:

For this grade, the candidate, with little guidance and showing due regard for safety
procedures and practices, has produced work which demonstrates attainment of a
reasonable standard of craftsmanship.

In this work there is evidence of:

 good skill levels in the use of hand tools, machine tools and workshop equipment
 the majority of tolerances while undertaking different work are in line with those
demanded by the component/job.
 a good level of neatness and consistency in the finish
 little support in completing the project/job

34
c) Weightage in the range of above 90% to be allotted during assessment under
following performance level:

For performance in this grade, the candidate, with minimal or no support in organization
and execution and with due regard for safety procedures and practices, has produced
work which demonstrates attainment of a high standard of craftsmanship.

In this work there is evidence of:

 high skill levels in the use of hand tools, machine tools and workshop equipment
 tolerances while undertaking different work being substantially in line with those
demanded by the component/job.
 a high level of neatness and consistency in the finish.
 minimal or no support in completing the project

35
 8.2 FINAL ASSESSMENT- ALL INDIA TRADE TEST

(SUMMATIVE ASSESSMENT FOR TWO YEARS TRADE)

SUBJECTS Marks Sessional Full Pass Marks Duration of
Marks Marks Exam.

Practical 300 100 400 240 08 hrs.

Trade Theory 100 20 120 48 3 hrs.
Workshop Cal. & Sc. 50 10 60 24 3 hrs.
Engineering Drawing 50 20 70 28 4 hrs.
Employability Skill 50 50 17 2 hrs.
Grand Total 550 150 700 -

Note: - The candidate pass in each subject conducted under all India trade test.

36
 9. FURTHER LEARNING PATHWAYS

 On successful completion of the course trainees can opt for Diploma course
(Lateral entry). [Applicable for candidates only who undergone ATS after CTS]
 On successful completion of the course trainees can opt for CITS course.

Employment opportunities:

On successful completion of this course, the candidates may be gainfully

employed in the following industries:

1. Production & Manufacturing industries like steel plant.

2. Power plant industries or other related industries where steam based power
generation are involved.

37
 ANNEXURE – I

TOOLS & EQUIPMENT FOR BASIC TRAINING

INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL

KNOWLEDGE

TRADE: STEAM TURBINE CUM AUXILIARY PLANT OPERATOR

LIST OF TOOLS & EQUIPMENTS FOR 20 APPRENTICES

A : TRAINEES TOOL KIT:-

Quantity
Sl. No. Name of the items
(indicative)
1. Scale BB 20 20 Nos.
2. Inside Spring Caliper 150 mm. 20 Nos.
3. Outside Spring Caliper 150 mm 20 Nos.
4. Spring Divider 150 mm 20 Nos.
5. Engineers Square 150 mm. 20 Nos.
6. Hacksaw Frame AB 250,300. 20 Nos.
7. Engineer Ball Pein Hammer 400 complete with handle. 20 Nos.
8. Engineer Ball Pein Hammer 800 Complete with handle. 20 Nos.
9. Flat Chisel 20x200 H 20 Nos.
10. Cross cut Chisel 10x150 20 Nos.
11. Half round Chisel 10x250 20 Nos.
12. Diamond Point Chisel 9.5 mm. 20 Nos.
13. Centre Punch 5 20 Nos.
14. Prick Punch 150 mm. 20 Nos.
15. Engineers File Flat Bastard 300mm 20 Nos.
16. Engineers File Flat 2nd cut250 with two sq. edges 20 Nos.
17. Engineers File Flat Bastard 350mm 20 Nos.
18. Engineers File Flat smooth 200 mm. two safe edges. 20 Nos.
19. Flat/Round Nose Piier 20 Nos.

38
 20. Combination Plier 20 Nos.
21. Engg. Half Round File 2nd cut 250 mm. 20 Nos.
22. Engg. Three sq. File Smooth 20 Nos.
23. Engg. Round File Smooth 200 20 Nos.
24. Engg. Square File Smooth 200 mm. 20 Nos.
25. Engg. Needle Set of 12 20 Nos.
26. File Handle 20 Nos.
27. Caliper Hermaphrodite 150 20 Nos.
28. Scraper A 250 mm. 20 Nos.
29. Scraper D 160 20 Nos.
30. Scraper B 160 20 Nos.
31. Spindle Blade Screw Driver 20 Nos.
32. Keys Allen Hexagonal 2.5 to 12 20 Nos.
33. Tap Wrench (adj.) and fixed 20 Nos.
34. Die Ho 1der s 20 Nos.
35. Card File 20 Nos.
36. Scriber 300 mm. 20 Nos.

B : TOOLS INSTRUMENTS AND GENERAL SHOP OUTFITS

Sl. Quantity
Name of the items
No. (indicative)
1. Master Bar 45 Degree scraping Bar 600 mm. width of bar 75 mm.,
1 No.
thickness25 mm., all sider an accuracy of 0.02 mm seasoned
2. --Do- 1 No.
3. Master F1 at-scraping test bar 600 mm, length 7 5x7 5 mm sq. in cross
section all sizes scraped to an accuracy of 0.02 mm. per 300 mm. 1 No.
seasoned.
4. Hand tap M-6 to 12 each size set of 3 with tap wrench thread cutting
1 each
die MM6 to HS.
5. Spaner Socket set of 8 with Ratchet 8, 12,20 1 each
6. Hexagonal Key 1.5 to 12. 1 Set
7. Hammer Soft (faced 30 mm dia. Plastic tipped). 4 Nos.
8. Pipe Wrench 450 2 Nos.
9. Chain Pipe Wrench 650 1 No
10. Flat Nose Plier AI 80 1 No.
11. Spindle Blade Screw Driver 150 mm. 1 No.
12. Scriber Block Universal 300 mm 4 Nos.
13. Bench Vice 100 8 Nos.
14. Bench Vice 150 8 Nos.
39
15. Ring Spanner set of 6 S.A.E. 1 No.
16. Double Ended Open Spanner 5.5 to 50 mm. 1 Set
17. Double Ended Off-set Ring spanner 5.5 to 50 1 Set
18. Gear Puller 150 mm.dia. capacity three leg type 1 No
19. 'C'Spanner CxlO 1 Set
20. Scale BB 80 8 Nos.
21. Scale BB 20 1 No
22. Metric Steel Tape measure 1 No
23. Thread Pitch Gauge 0-25,6-00,150-60 deg 1 No
24. Thread Pitch Gauge metric screw threads 1 No
25. 2/3 Cells Torch 2 Nos.
26. Grease Gum 1 No
27. Level 1 P 300-0.05/metre 1 No
28. Engineer Square 400 blade 1 Set.
29. Feeler Gauge(0.03 to 1 mm). 1 No
30. Magnetic Basic Off-on Type 1 No
31. Detachable Spout Oil Can 250 1 No
32. Single Ended Open Jaw adj. Wrench A-200 1 No
33. Stationery Scissors Type-II 65 1 No
34. Gasket Hollow Punches 5,6,8,10,12, 19,25 mm. dia. 1 Each
35. Bar Type Torque Wrench 1 No
36. Hand operated Socket Wrench 1 Set
37. Taps & Dies Complete Set. 1 No
38. Cam Lock Type Screw Driver 1 No
39. Dial Indicator Type Torque 1 No
40. Propane Torch 1 No
41. Ring Spanner SE of 8-25 mm. 1 Set
42. Box Spanner SE Hexagonal 1 Set
43. Heavy Duty Screw Driver 1 No.
44. Spindle Blade Screw Driver (Engg. 200 mm). 1 No.
45. Hammer Soft 1 No.
46. Pipe Cutter 19 mm dia. capacity 1 No.
47. Flaring Tool 1 No.
48. Tube Expander upto 62 mm. 1 Set
49. Cranked Double ended Ring Spanner 1 No
50. Box Spanner DE 8 to 20 1 Set
51. Gear Box Unit (For Trg.) 1 No
52. Bearing Housing Unit (for trg.) 1 No
53. Shafting Unit with Pulleys as available (for trg.) 1 No
54. Horizontal Centrifugal Pumps (Gear and Spindle) 1 No
55. Air Compressor 1 Se t .
56. Key Alien Hex
57. Circiip P1iers(inside and outside) 1 Set .
58. Right angle drill attachment 6 mm. capacity. 1 No .
59. SRDG Bal1 Bearing 1 No.
60. DRDG Bal1 Bearing 1 No.
61. Self aligning Bali Bearing 1 No.

40
62. SRAC Bal1 Bearing 1 No.
63. Ball Bearing Thrust Type 1 No.
64. Needle Bearing 1 No.
65. Single Row Cylindrical Roller Bearing 1 No.
66. Tapered Roller Bearing 1 No.
67. Barrel Type Bearing 1 No.
68. Plain Bush Bearing 1 No.
69. Thin Walled Bearing 1 No.
70. Thrust Roller Bearing 1 No.
71. Se1f-alignment Roller Ball Bearings 1 No.
72. Telescopic Gauges 1 No.
73. Arbour Press Bench Type 1 No.
74. Lubricant Tro11ey-2409x 1 200x1200 mm (8 mm chamber). 1 No.
75. Compressor Sprayer Machine 1 No.
76. Tap Extractor 1 No.
77. Gear Pump 1 No.
78. Vane Pump (fixed and variable delivery). 1 Each
79. Piston Pump (radial and axial) 1 Each
80. Re 1i ef Valve 1 No.
81. Sequence Valve 1 No.
82. Un-loading Valve 1 No.
83. Pressure Reducing Valve 1 No.
84. Check Valve 1 No.
85. Directional Control Valve(rotary spool and sliding spool) 1 Each
86. Flow Control Valve 1 No.
87. Pressure Gauge 1 No.
88. Reservoir 1 No.
89. Linear Actuator (differential and non-differential) 1 Each
90. Hydromotor 1 No.
91. Accumulator (spring and gas) 1 Each
92. Pneumatic too1s(portable nut runner, pneumatic chise1,pneumatic ram etc.)
1 Each
for demonstration purpose.
93. Pneumatic Valves and Actuators 1 Each
94. Hydraulic and Pneumatic Board with necessary aggreagates for different
1 Set
machine circuits.
95. Double Face Sledge Hammer 1600 1 No.
96. Wooden Straight Edge 300,600,900,1200. 1No.
97. Man-on-chise1 1Each
98. Tasla 1 No.
99. Pick Axes. 2 Nos.
100. Bar Bending Tools and Cutting Tools 1 No.
101. Spirit Leve1 1 No.

102. Pocket Steel Tape 150 mm 1 No.

103. Four Fold Foot Rule 1 No.

104. Crow Bar 2 Nos.

105. Plumb Bob 1 No
106. Masons Tool for Plaster Work 1 No.

41
107. Drill Chuck 13 1 No.
108. Reduction Sleeve and Extension Sockets 1 Each
109. Centre Drill A-4 1 Each
110. Revolving Centres 1 No
111. Knurling Too 1(straight, cross &diamond) 1 Set
112. Lathe Carriers up to 75 mm 1 Set
113. Centre Gauge 1 Set
114. Oil Stone 10x100 1 No.
115. Emmery Cloth No.00, 0, & 1. 1 Pkt
116. Engg. File 50 length 1 No.
117. H.S.S Tool Bits 8 & 10sq.x75 16 Nos.
118. Boring Tool Holder 10 mm sq9 Bit Size x Length 200 mm. 2 Nos.
119. Cylindrical Milling Cutter 1 No.
120. Side and Face Milling Cutter 150x10x271 1 No.
121. Side and Face Cutter 100x6x27 1 No.
122. Equal Angle Milling Cutter 45~ox27 mm bore 60x27 mm bore 1 Each
123. Single Angle Milling Cutter 45~ox27 mm bore(LH) and (RH) 1 Each
124. Single Angle Milling Cutter 60~ox27 mm bore(LH) and (RH) 1 Each
125. Slot Milling Cutter with Parallel Shank 1 No.
126. Slot Milling Cutter with Parallel Shank 10x27 mm. 1 No.
127. Slitting Saw 3 mm Thick x 2 7 mm. 1 No.
128. Slitting Saw 4 mm Thick x 27 mm. 1 No.
129. Key Way Milling Cutter 1 Set
130. T - Slot Mi 11ing Cutter 1 Set
131. Convex Milling Cutter 1 Set
132. Concave Milling Cutter 1 Set
133. Single Corner Rounding Milling Cutter 1 Set
134. Milling Cutter No.8,9,10, 12 , 16,20, D.P.No. 1 to 8 1 Set
135. Rotary Gear Cutters for Spur and Helical Gear . 1 Set
136. Fly Cutter Holder 1 No.
137. Hexagonal Bolt and Nut M 60 x 150 1 Set
138. Plain Washers 1 Set
139. Plain Clamps 1 Set
140. Engineers Parallel 1 Set
141. Spanner D.E.G.P 1 Set
142. Hexagon Socket Screw Keys 1 Set
143. Engineers File 1 No.
144. Single Ended Open Jaw adjustable Wrench A150 1 No.
145. Table Chuck 3 Jaw with tightening arrangement and graduated in degrees. 1 No.
146. Machine Vice 200 mm Swivel Base 1 No.
147. Machine Vice Swivel Base 160 1 No.
148. Tool Holder L.H,R.H & Straight 1 No.

PRECISION INSTRUMENT
1. Vernier height Gauge 500 mm. 1 No.
2. Mechanical Bevel Protractor A 150 1 No.
3. Vernier Caliper A 200 1 No.

42
 4. Vernier Caliper A 300 1 No.
5. External Micrometer Gr.1 1 No.
6. External Micrometer Gr.I I 1 No.
7. External Micrometer Gr.I I I 1 No.
8. External Micrometer Gr.IV . 1 No.
9. External Micrometer Gr.V 1 No.
10. Combination Set with 300 mm Scale, 1 No.
11. Centre Head sq. head & Protractor head. 1 No.
12. Telescopic Gauge 12 mm to 150 mm Set. 1 Set
13. Vernier Depth Gauge 200 with fine adjustment. 1 No.
14. Sine Bar 200 mm. 1 No.
15. Sine gauge (in sets) 1 Set
16. Engineers Square 450 B 1 No.
17. V - Block, Grade A & B 1 Each.
18. V - Block 50/5 -40 A 1 No
19. Precision Angle Plate 250x150 1 No.
20. Precision Angle Plate 19195x75 1 No.
21. Micrometer Internal 1 No.
22. Micrometer External 1 No.
23. Vernier Gear Tooth Caliper 1 No.
24. Bevel Gauge 200 1 No.
25. Dial Gauge Type 1 Gr. A (complete with clamping devices and stand). 2 Nos.
26. Feeler Gauge (0.03 to 1) 1 No.
27. Radius Gauge 1 No.
28. Radius Gauge 1 No.
29. Thread Pitch Gauge 0.25 to 6.15 degree x60 degree 1 No.
30. Thread Gauge 55 deg.x47 1/2 degree 1 No.
31. Thread Gauge 60 degree 1 No.
32. Plug Gauge Plain(designation of tape as per tab 1e 1) 1 No.
33. Ring Gauge Morse Taper No.1,2,3,4. 1 Set.
34. Ring Gauge 5 to 25 by 2.5 mm. 1 No.
35. Wire Gauge 1 No.
36. Bore Dial Gauge(01 mm dial) 1 No.
37. Indicator with Magnetic Base 1 No.
38. Dial Gauge Tupe1, Gr. A complete with clamping devices 1 No.
39. Straight Edge 485mm to 1445mm 1 Set
40. Hand Techometer for checking the R.P.M. 0-10,000 1 No.
41. Mandrels 1 Set

C : GENERAL MACHINERY INSTALLATIONS:-

Sl. Name & Description of Machines Quantity
No. (indicative)
1. Centre Lathe with all accessories 1 No.
43
2. Mi11ing Machine, Universal motorized No.1 with all access.
1 No.
3. Pedestal Grinder 1 No.
4. Drilling Machine Pillar Type Sensitive 0-20 mm Cap. with Swivel Table
1 No.
Motorized with chuck and key
5. Drilling Machine Bench Sensitive 0-12.5 Cap. motorized with Chuck and
1 No.
Key and other access.
6. Portable Hand Grinder 150 mm.dia. motorized 1 No.
7. Flexible Hand Grinder 100 mm. dia. ( lighter Type) 1 No.
8. Portable Drilling Machine 6 mm. capacity 1 No.
MACHINE FOR REPAIR AND RECONDITIONING
1. Old Lathe 2 Nos.
2. Old Milling Machine 1 No.
3. Old Grinding Machine 1 No.
4. Old Shaper Machine 1 No.
5. Old Press (power) 1 No.
ARC WELDING

1. DC Welding Generator 150-300 amps. Complete to AC Induction with all

accessories. 1 No.
2. Arc Welding Transformer Single operator type 380, 440 Volts up to 350 1No.
amps maximum continuous low welding current
3. Rectifier Type D.C. Arc Welder (Manual Metal Arc)300.400 amps.
1 No.
4. Insulated cable 2 length with links fitted 1 Set
5. Electrode Holder the preferred rated current should be 200,400 amps. 1Set

6. Welding Helmet Screen 1 No.

7. Welders Chipping Hammer 1 No.
8. Chipping Screen 1 No.
9. Brush, Welders 40 mm wide 1 No.
HOISTING EQUIPMENT
1. Portable Jacks 1 No.
2. Cargo Winches 3,5 & 8 Tonnes. 1 No.
3. Wall Hosts 1 No.
4. Travelling & Gantry cranes 1 No.
5. Shear Legs (tripod) 1 No.
6. Flat Pulley 1 No.
7. Hand Operated Chain Pulley block. 1 No.
8. Mobi1e Crane, 1 No.
9. Conveyor 1 No.
10. Elevators 1 No.
11. Fibre Rope Sling 1 No.
12. Stee1 Wire S1ing 1 No.
13. Steel Chain Slings from 6.3.to 45 mm. 1 No.

44
14. For fan, light catch 2 Nos.
15. Ramps and its fittings 4 Nos.
16. Crow Bar 4 Nos.
17. Cut sizes of Timber 3 Sets
18. Rollers (steel tubes) from 38 to6 3.5 mm dia. 10 nos.
19. Block of Timber (various sizes) 10 Nos.
20. Steel Skids or Wood Skids 1 Set
21. Steel Wedges 1 Each
22. Manilor Rope 12 Ø 20 Ø 30 Ø 1 Each
23. Eye Bolt with Collars range M 10 to M 36 2 Nos.
24. Channel 1 No.
25. Rails 1 No.
26. Ratchet chain Pulley 2 Nos.
27. Shack 1e s 1 No.
EQUIPMENT FOR ELECTRICAL MAINTENANCE.
1. Combination side cutting pliers with insulated. 1 No.
2. Handle 180 mm. 1 No.
3. Spindle blade screw driver 150 mm 1 No.
4. Double bladed electrician knife 1 No.
5. Engineer's cross pein hammer 200 gm. with handle. 1 No.
6. Spindle blade screw driver(electricians) 100 mm. 1 No.
7. Neon tester 500 V double prove type 1 No.
8. Spindle blade screw driver engineer's 200 1 No.
9. Scale AA 300 1 No.
10. Diagonal Cutting nippers 125 1 No.
11. Hand drilling machine 6 mm capacity 1 No.
12. Engineer's square 150 B 1 No.
13. Hammer plastic faced 1 No.
14. Test lamp 200 V, 25 W. 1 No.
15. Hacksaw frame AB 250-300 1 No.
16. Tachometer 1 No.
17. Flat file rough, 250 mm with two square edges. 1 No.
18. Moving iron voltmeter portable type class 1.0, 0-500 V. 1 No.
19. Moving Iron Ammeter portable type 1.0, 0-25 Amp. 1 No.
20. Wattmeter Ironless electro dynamo meter type, portable class 1.0, 0- 1 No.
3000 W, voltage range:150 V,300 V, 600 V. Current range 2.5 A and 5 A
21. Wire stripping pliers 150 A 1 No.
22. Insulation resistance tester500 V, 100 M-2 1 No.
23. Reverse current cut out
over lead relay 1 Each
) no voltage relay
24. Starters for 3phase 415 V, 50 Hz 3.7 to 7.5 KW,AC. Motor.
(a)Auto-transformer type (f1oormounted, manually operated) 1 Each
(b)Star-de1ta type with O/L and N.V protection floor mounted and manually
operated.

45
 25. A.C Motor 3 phase, 50 HZ,415 V (Induction mo tor) 1 No.
ERECTION TOOLS
1. Foundation Bo 11 8 Each
2. Threaded fastner type-B
3. Threaded fastner type-C 1 No.
4. Threaded fastner type-F 1 No.
5. Plum bob 1 No.
6. Square box wrenches 1 No.
7. Square Tee wrenches 1 No.
8. Pipe wrenches 1 No.
9. Chain pipe wrenches 1 No.
10. Single ended open jaw adjustable wrench A 150 Gr.I I. 1 No.
11. Slide wrenches 1 No.
12. Pulley and tackle 1 No.
13. Crow bar 1 No.
14. Straight edges 500 B 1 No.
15. Engineers square 700 mm. 1 No.
16. Excavation tools 1 No.
17. Spirit 1 eve 1 1 No.
FURNITURE’S
1. Metal lockers 8 lockers type with individual locks 1980x910x480mm. 2 Nos.
2. Metal office chair with arm, cane sit and back. 1 No.
3. Metal shelving cabinet with 4 adjustable shelves 180x60x40 cm. 6 Nos.
4. Metal office table with 3 drawers. 3 Nos.
5. Work bench 4 Nos.
6. Metal shelving rack open type 1800x900x500 with adjustable shelves.
4 Nos.
7. Desk 1 No.
8. Stool 1 No.
9. Black Board with easel 2 Nos.
10. Portable fire extinguisher water type (constant ) 2 Nos.
11. Galvanised mild steel fire bucket 4 liters.
4 Nos.

Note: In case of basic training setup by the industry the tools, equipment and
machinery available in the industry may also be used for imparting basic training.

46
 INFRASTRUCTURE FOR WORKSHOP CALCULATION & SCIENCE AND
ENGINEERING DRAWING

TRADE: STEAM TURBINE CUM AUXILIARY PLANT OPERATOR

LIST OF TOOLS & EQUIPMENTS FOR 20 APPRENTICES

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

2) Infrastructure:

A : TRAINEES TOOL KIT:-

Sl. Quantity
Name of the items
No. (indicative)
1. Draughtsman drawing instrument box 20 Nos.
2. Set square celluloid 45⁰ (250 X 1.5 mm) 20 Nos.
3. Set square celluloid 30⁰-60⁰ (250 X 1.5 mm) 20 Nos.
4. Mini drafter 20 Nos.
5. Drawing board (700mm x500 mm) IS: 1444 20 Nos.

B : FURNITURE REQUIRED
Sl. Quantity
Name of the items
No. (indicative)
1 Drawing Board 20 Nos.
2 Models : Solid & cut section as required
3 Drawing Table for trainees as required
4 Stool for trainees as required
5 Cupboard (big) 01
6 White Board (size: 8ft. x 4ft.) 01
7 Trainer’s Table 01
8 Trainer’s Chair 01

47
 ANNEXURE – II

INFRASTRUCTURE FOR ON-JOB TRAINING

TRADE: STEAM TURBINE CUM AUXILIARY PLANT OPERATOR

For Batch of 20 APPRENTICES

Actual training will depend on the existing facilities available in the

establishments. However, the industry should ensure that the broad skills defined against
On-Job Training part (i.e. 9 months + 9 months) are imparted. In case of any short fall
the concern industry may impart the training in cluster mode/ any other industry/ at ITI.

48
 ANNEXURE-III

GUIDELINES FOR INSTRUCTORS AND PAPER SETTERS

1. Due care to be taken for proper & inclusive delivery among the batch. Some of the
following some method of delivery may be adopted:

A) LECTURE
B) LESSON
C) DEMONSTRATION
D) PRACTICE
E) GROUP DISCUSSION
F) DISCUSSION WITH PEER GROUP
G) PROJECT WORK
H) INDUSTRIAL VISIT

2. Maximum utilization of latest form of training viz., audio visual aids, integration of
IT, etc. may be adopted.

3. The total hours to be devoted against each topic may be decided with due diligence to
safety & with prioritizing transfer of required skills.

49