Course Content: During the two-year duration a candidate is trained on subjects Professional Skill, Professional Knowledge, Engineering Drawing, Workshop Science & Calculation and Employability Skills. In addition to this a candidate is entrusted to make/do project work and Extra Curricular Activities to build up confidence. The practical skills are imparted in simple to complex manner & simultaneously theory subject is taught in the same fashion to apply cognitive knowledge while executing task. The practical part starts with allied trade training viz basic fitting and laboratory experiments in basic physics and chemistry. Practical skills related to unit operations comprising of Fluid flow, Heat transfer, and Mass transfer, Mechanical operations are covered in period of two years.

In the first year -The practical part starts with allied trades viz., basic fitting- In the basic fitting the skills imparted are Hack-sawing, marking, punching, Chiseling, Filing, Drilling, countersinking,counter boring, reaming, Taping and observation of all safety aspects is mandatory. Basic physics and chemistry practical covers conducting experiments in laboratory to determine physical constants, verification of laws, to determine concentration of solutions, PH, melting point, boiling point, compare properties of metals & alloys, prepare chemicals. The safety aspect covers components like PPE, Fire extinguisher, First Aid. performing different operations or experiments related to safety and general awareness in chemical industry. Identification, installation /connection of instrument/devices to measure pressure, temperature, flow, level and density are covered. Skills to execute pipe joints, fittings valves on pipes, dismantling, overhauling, cleaning & assembling valves, different machines & components used for fluid transportation such as centrifugal pump, gear pump, metering pump, screw pump, multistage compressor are achieved in this year. Dismantling, repairing and assembling of different damaged mechanical components used for power transmission such as Gearbox, bearings are also covered.

In the second year – This Year covers Unit operations i.e. fluid flow, heat transfer and mass transfer operations. Skills to operate different machines/equipment such as Shell and tube Heat exchangers, evaporators, Distillation columns are gained in this section. Study of pressure vessels, petroleum refining is covered in this section. Mass transfer operations such as Solvent extraction, Leaching, Absorption, Crystallization, and Drying are taught. Mechanical operations such as Size reduction, mixing, conveying, and filtration are also covered in this year. Study of chemical reactor, plant utilities like steam, Boilers, cooling towers, chilled water, instrument air are covered in this section. Pollution in chemical industry and manufacturing processes are also taught

Skills acquired: Laboratory Assistant- Physical/chemical, assists and carries out routine duties in laboratory as directed in conducting experiments. Sets up required apparatus and instruments in position as directed for conducting experiments such as balances, heaters, arrange chemicals such as salts, acids, Makes necessary electrical connection to equipment and instruments as required. Records routine and other observations as indicated by instruments and makes necessary calculations.

Process Operator - Chemical, Process chemical ingredients by mixing in specific proportions, heating, distilling, cooling, filtering, blending, percolating, refining, pulverising, etc. for causing chemical reactions for research or production. Regulates feed of gaseous, liquid or solid materials into equipment. Checks progress of process by looking through peep holes, observing temperature readings, pressure gauges and other instruments and making simple chemical tests; regulates material feed, and heating and cooling devices and makes other adjustments necessary to ensure that processes are correctly carried out

Reactor / Converter Operator , Reactor Operator (Chemical Process, except Petroleum) operates number of pieces of equipment, other than those used for treating petroleum, which perform sequence of complex operations in chemical reaction process. Regulates feed of gaseous, liquid or solid material into equipment.

Pump Operator (Petroleum Refining), controls pumps and manifold systems to circulate crude, semi compressed and finished petroleum products, water and chemical solutions through processing and storage departments of refinery according to schedules or instructions. Synchronizes activities with other pump houses to assure continuous flow of product. Records operating data.

Evaporator Operator: Pan Operator; Vacuum Pan Operator charges and operates evaporating tank, vacuum-pan or similar device to concentrate solutions by driving off excess water contents. regulates flow of steam into heater coils of evaporator; periodically tests concentrations of solution by making simple chemical tests

Still Operator- Petroleum/chemical, still operator (Distillation operator) operates one or more batch/ continuous stills for distilling or refining Chemicals and crude oil to obtain fuel gas, gasoline, kerosene, diesel oil, lubricating oil, wax, bitumen, etc. Reads processing schedules, writing log books, test results of oil samples, and laboratory recommendations to determine changes in equipment controls required to produce specified quantity and quality of product

Crusher Operator, Crusher Operator operates power driven crushing machine to break solid lumps of chemicals or other materials into smaller size for further processing. Collects material to be crushed; fills hopper of machine, regulate speed of machine, May weigh the material before and after crushing to know loss in crushing.

Autoclave Operator, Autoclave Operator; Sterilization Attendant charges, operates and unloads an autoclave (high-pressure vessel) for processing chemicals, oils, or sterilizing bottles, ampoules, etc. Checks valves for operation; raises temperature of autoclave by increasing steam pressure

Ammonia Plant Operator, Ammonia Plant Operator controls converter and auxiliary equipment that combine hydrogen and nitrogen to produce anhydrous ammonia, Lights burner and start pumps, compressors etc. Reads instruments such as temperature indicators, pressure gauges etc.

Acid Plant Operator Acid Plant Operator maintains and operates acid plant for manufacturing sulphuric, hydrochloric, nitric or other acids by treating raw materials (Sculpture, salts, etc.)

Digester Operator, Paper Pulp Digester Operator operates (cooker) to convert raw materials into paper pulp. Supervises charging of cooker with ingredients such as wood chips, rags, straw and waste paper shreds.Directs adding of chemicals and admission of steam to raise temperature.

Mixing Attendant (Chemical) feeds and tends machine to mix and blend different solid or liquid ingredients in required proportions. starts machine agitators to mix materials thoroughly

Filter Press Operator operates filter press machine to filter impurities or other insoluble materials from slurries, chemical solutions or other liquids. Opens filter press and covers filter plates with canvas or other filtering media; closes press, pumps slurry till specified pressure is reached. Removes impurities and sludge in between plates. Replaces damaged filter media.

Hydro Extractor Operator /Centrifuge operator operates centrifuge machine that separates solids from liquids, Fills drum of machine with liquid material. Starts machine and adjusts drum speed to obtain efficient separation of substances, May clean and fix filtering media.

Drying Chamber Attendant (Drugs)/Dryer Operator dries tablets, wet seeds, wet crystals and powder in drying chamber. loads tablets and powder trays on racks and shelves in drying chamber, loads seeds and crystals in rotary dryers, Closes chamber and applies heat for fixed period of time; checks at frequent intervals to ensure that products are properly dried and test products for moisture content

Extraction Attendant-Chemical, Extraction Battery Attendant, Extractor Operator, feeds necessary chemicals and solvents in Mixer settlers, spray towers and regulates flow, pressure etc. as directed by Process man to effect desired chemical separation. Collects Extract, Raffinate separately, and checks their concentration separately.

Options for employment: All Chemical, Fertilizer, Pharmaceutical and Petroleum (Oil and Gas) and Power Plants (Water treatment) will be able to recruit these trainees.

ITI trade Maintenance Mechanic (Chemical Plant) is powered by NCVT.  ITI trade Maintenance Mechanic (Chemical Plant)  is a job oriented trade ITI trade Maintenance Mechanic (Chemical Plant) is suitable for government job and private job. This ITI trade Maintenance Mechanic (Chemical Plant) is very powerful for self-empowerment. This ITI trade Maintenance Mechanic (Chemical Plant) is perfectly design to fulfill industrial requirement of Indian Industries as well as International industries.

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

The person should be able to perform preventive, periodical, breakdown, online routine, daily maintenance of chemical plant equipment and machineries. Should be prompt in record maintaining. Should be highly skilled in use of hand/machine tools & work permit system. Should be good in housekeeping and self-dependent. Able to perform failure analysis of machine for leading to corrective action. 

“Maintenance Mechanic (Chemical Plant)” has a wide scope of Employability ranging from self-employment, contractual employment to Industrial jobs. On successful completion of this course, the candidates shall be gainfully employed in the industries for following occupations: Maintenance Mechanic (Chemical Plant)

Job roles of “Maintenance Mechanic (Chemical Plant)”

Mechanic Maintenance (Chemical Plant); repairs and overhauls chemical plant, machinery and equipment periodically and on break downs to maintain them in efficient operating condition. Studies methods of processing of raw material to finished products. Examines plant and equipment to locate faults and removes minor defects on spot. Reports major defects and break downs to Chemical Engineer and dismantles defective unit as directed with necessary precaution, using hand tools, adopter, twists etc. as necessary. Replaces or repairs defective parts and components by re-metalling, filling, drilling, grinding, scraping, soldering, brazing, etc. as required and reassembles unit according to specifications with prescribed precautions particularly for explosive, gas acid and other chemical plants, ensuring correct alignment clearance, valve operations, adjustments, flow of material operational functions and other necessary details. Tests assembled unit for proper performance, makes further adjustments, if necessary and gets assembled if examined by appropriate authority before handing over to production. Checks, adjusts and lubricates equipment periodically or gets it done and performs other tasks to maintain plan in proper working order. May maintain records of parts examined, repairs done, replacements made and plant performance. May erect and install equipment under the guidance of Chemical Engineer.