CURRICULUM

FOR THE TRADE OF

OPERATOR COAL HANDLING

EQUIPMENTS

UNDER

APPRENTICESHIP TRAINING SCHEME

2017

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
Syllabus 10-23
7.1 Basic Training
7.1.1 Detail syllabus of Core Skill
A. Block-I (Engg. drawing & W/ Cal. & Sc.)
7.1.2 Detail syllabus of Professional Skill & Professional
Knowledge
A. Block – I
7.
7.1.3 Employability Skill
7.1.3.1 Syllabus of Employability skill
A. Block – I
7.2 Practical Training (On-Job Training)
7.2.1 Broad Skill Component to be covered during on-job
training.
A. Block – I
Assessment Standard 24-26
8.1 Assessment Guideline
8.
8.2 Final assessment-All India trade Test (Summative
assessment)
9. Further Learning Pathways 27
10. Annexure-I – Tools & Equipment for Basic Training 28-29
11. Annexure-II – Infrastructure for On-Job Training 30
12. Annexure-III - Guidelines for Instructors & Paper setter 31

2
 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. 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

3
 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.

4
 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.

5
 3. RATIONALE
(Need for Apprenticeship in Operator Coal Handling Equipments trade)

1. Perform preventive maintenance and repairs to the coal handling and conveying equipment at
the CHPP.
2. Operate the ash unloading equipment and drive the hauling trucks to dispose of the coal.
3. Ensure the coal conveying equipment including the unloader, crusher, elevators, coal car
shakers, coal pullers and coal storage area are properly maintained and available for plant
operations.
4. Incumbent must be able operate a coal car mover into position over a grizzly by means of an
electrically operated capstan and continuous car puller cable.
5. Capable of releasing locking devices on hopper doors of cars to allow coal to fall into grizzly.
6. Frequently during winter months, hand shovels coal that has stuck to the sides and bottoms of
cars, and uses picks or heavy bars to break up oversize lumps of frozen coal.
7. Starts and operates boiler bunker conveyors, belt conveyors, elevator conveyors, crusher
magnetic separator and pan feeder conveyor in sequence of local controls on each individual
piece of equipment and/or panel board controls. Operates by-pass gates on bins, under-bunker
reclaiming conveyor, railroad car loader or outside storage area.
8. Incumbent must know and understand the entire coal/ash handling systems in the plant.
9. Continuously monitor and inspect coal/ash handling equipment before and during operations to
assure adequate coal supply for boilers and prevent spill over of coal inside plant.
10. Constantly monitor bunkers and storage bins for sign of overheated coal so that it can be
removed before spontaneous combustion occurs. Participate in cleaning and washing of plant
areas and equipment to prevent fires or explosions from coal dust accumulations.
11. Maintain accurate daily records of coal received and unloaded.
12. Collect gross samples of incoming coal shipments for analysis.
13. Serve as a member of a coal handling crew.

6
 4. JOB ROLES: REFERENCE NCO

Brief description of Job roles:

Washing Plant Operator, Coal operates different machines and equipment for sizing,
cleaning, washing and preparing coal for sale or further processing. Checks operating
condition of plant, machines and equipment, such as conveyor, crusher, agitator,
elevator, wash box, blower, pump, feeder screen, core and refuse gate. Sets and adjusts
them as necessary to have desired pulsation, correct performance, proper control of air,
water and coal, etc. by observing readings on different meters and gauges and by
regulating values on control panel. Adjusts flow of raw coal through them to separate
slate rock and other impurities. Operates cone to mix sand and water in proper
proportions to ensure correct specific gravity and observes operation. Tests sample of
processed coal by weighing and simple physical and chemical tests to ensure correct
percentage of ash content, and minimum rejection of usable coal. May conduct repairs of
machinery. May perform only a portion of above duties and be designated as RAW
COAL SECTION OPERATOR, FEED OPERATOR, CONE OPERATOR, REFUSE,
GATE OPERATOR, etc. according to operation performed or machine handled.

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

Reference NCO:
i) NCO-2015: -- 8112.0600

7
 5. GENERAL INFORMATION

1. Name of the Trade : OPERATOR COAL HANDLING EQUIPMENTS

2. N.C.O. Code No. : NCO-2015: --8112.0600

3. Duration of Apprenticeship Training (Basic Training + Practical Training): 15

Months
4. Duration of Basic Training: -
a) Block –I : 3 months
Total duration of Basic Training: 3 months
5. Duration of Practical Training (On -job Training): -
a) Block–I: 12 months
Total duration of Practical Training: 12 months

6. Entry Qualification : Passed 10th Class Exam.

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

amended time to time.

8. 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.

8
 6. COURSE STRUCTURE

Training duration details: -

Time 1-3 4-15

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

Components of Training Duration of Training in Months

1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5
Basic Training Block - I
Practical Training Block - I

9
 7. SYLLABUS
7.1 BASIC TRAINING
(BLOCK – I)
DURATION: 03 MONTHS

GENERAL INFORMATION

1) Name of the Trade : OPERATOR COAL HANDLING EQUIPMENTS

2) Hours of Instruction : 500 Hrs.
3) Batch size : 20
4) Power Norms : 3 KW for Workshop
5) Space Norms : -- 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 Operator Coal Handling Equipments 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

10
 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)
30 20
1. Introduction to Engineering drawing, Applied workshop problems
its importance and uses in involving simple addition,
engineering fields. Simple subtraction, multiplication,
definitions of Points, Lines, Parallel division and common fractions.
straight lines.

2. Geometrical construction of Square, Science- Definition,

Rectangle, Triangle, Circle, Nomenclature, various branches,
Polygons, etc. significance and definitions of
important terms.

3. Drawing different types of lines. Rounding of decimal values, use

of approximation.

4. Free hand sketch of Hand tools used Units – Definition, fundamental

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. Screw Threads – Forms of Various Workshop problems related to

Screw threads used in general in the average.
industry – Nomenclature, convention

6. Fastening Devices – Temporary and Workshop problems related to

Permanent. Meaning and difference. percentage.
Temporary Device – Hexagonal
Bolt, Nut, Check Nut, Washer.

7. Different Methods of Preventions of Workshop problems related to

rotation of Bolts - Check nut, Square ratio and proportion.
headed bolt, Square headed bolt
with square neck, cup headed bolt,
Eye bolt, counter sunk headed bolt,
rag bolt, etc.

8. Different Methods of locking of nuts Workshop problems related on

:- a) Lock nuts, b) Split pin, c) time & work.
Slotted nut , d) Symmonds
nut, e) Castle nut, f) Wings nut, etc.

11
9. Permanent Fastening Devices- Rivets Profit & Loss and problems
– different parts and their types concerning to workshop practices.
Different types of rivet heads.

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

11. Keys and Cotter Joints, Difference Properties of Matter (Mechanical)

between Keys and Cotters, Different - Tenacity, Toughness,
types of Keys. Malleability, Ductility, Elasticity,
Plasticity, Brittleness, Hardness
(concept & definition)

12. --- Properties and uses of copper,

zinc, lead, tin, aluminum, brass,
bronze, solder, bearing metals,
timber, and rubber.

13. --- Engineering Material-

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

14. --- Heat & temperature- Definition

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

15. --- Transmission of heat-

Conduction, Convection and
Radiation. Examples from
Industries (concept & definition)

16. --- Transmission of Power and motion

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

12
 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, Safety Precautions to be followed at site. Fire
personal, general, workshop and job safety. precautions causes and types of fire, precaution
Occupational health and safety. against outbreak of fire. Fire extinguisher types
Basic injury prevention, Basic first aid, and uses. Proper centering erection, proper
Hazard identification and avoidance, safety scaffolding making & precautions to be taken
signs for Danger, Warning, caution & while working at higher attitudes and during hot
personal safety message. repair. Precautions to be followed in Gas
Preventive measures for electrical accidents hazardous area. Precaution during dismantling.
& steps to be taken in such accidents.

Importance of housekeeping & good shop

floor practices.
Disposal procedure of waste materials like
cotton waste, metal chips/burrs etc.
Fire& safety: Use of Fire extinguishers.

Safety regarding working with different

types of steam and its First-Aid.

Drill on fire fighting & safety

2. a. Preparation of major equipment list a. Coke making process, Cost & sensitivity
b. Dos and don’ts analysis, Pollution control equipments &
c. Utility & potential of major equipments norms
d. Material flow diagram for CHP b. Familiarization with different
e. Safety precaution during handling of coal equipment of Coal Handling Plant(CHP)
& use of PPEs. c. General safety
f. Cost of different types of coal & wastage d. All safety devices in CHP.
control.
3. -Do- e. Function of different equipment in CHP
f. Study of material flow diagram of CHP
g. Safety in material handling
h. Financial impact of coal on steel making,
Concept of Demurrage
i. Concept of Blending and Averaging
j. Monsoon Preparations

13
4. Video demo of the Operation of Wagon a. Operation of Wagon Tippler
Tippler process. i) Technical data (Specification)
ii) Types of Wagon Tipplers
iii) Safety to man & machines
iv) Importance of load setting
b. Operation of Wagon Chargers
i) Technical data
ii) Types of Wagon Chargers
iii) Safety to man & machines
iv) Importance of smooth running of wagon
Chargers
5. Practice on Drives of Tipplers, side arm c. Introduction to Drives of Tipplers, Side Arm
charger, beetle chargers and feed Charger, Beetle Chargers & Feed Belts
belts.(Involving different switches & safety d. Introduction to function of different limit
devices) switches & other safety devices
e. Log Book entry
6. Video demo of the Operation of Stackers Operation of Stackers
process. i)Technical data
ii) Quality Parameters
iii) Types of Stackers
iv) Safety to man & machines while operating
Stackers
v) Importance of averaging
vi) Factor affecting averaging
vii) Functions of different limit and safety
switches.
viii) Introduction to Material Conveying
system.
ix) Log book entry
7. Video demo of the Operation of Reclaimer Operation of Reclaimer
process. i) Technical data
ii) Types of Reclaimers
iii) Safety to man & machines during
equipment operation.
iv) Importance of proper loading of conveyor
& spillage control.
v) Importance of adherence to SOP
vi) Functions of different limit switches,
safety switches & drives
vii) Introduction to Material Conveying
system.
viii) Log book entry

14
 8. Practice on Hammer crushers.(Involving a. Operation of Hammer Crusher
different types of crusher, hammer, machines i) Technical data
etc.) ii) Types of Crushers
iii) Types of Hammers
iv) Safety to man & machines while operating
Crushers.
v) Milling indices & desired Crushing
9. Video demo of blending of coal & b. Importance of Blending of coal & Operation
operation of pneumatic classifiers process. of Pneumatic Classifiers
i) Technical data
ii) Parts of Pneumatic Classifiers
iii) Quality of input coal and its blending
iv) Quality of blended coal v)Parameters of
Classifier
iv) Safety to man & machines in case of
classifiers Operations
c. Introduction to Drives of Crushers,
Classifiers, Conveyors, quality control system
d. Log book entry
10. Video demo of related process. a. Introduction to Conveying Systems
Practice on Conveying system.(Involving i. Types of conveyors
different types of conveying) ii. Design features
iii. Weigh Feeders
b. Drives of conveyors
c. Transfer of material from one conveyor to
another
d. General layout of conveyors
e. Various parts of a conveyor
f. Conveyor related safety aspects
g. Monsoon Hazards & Preparations
h. General safety
11-12 Video demo of self-combustion process. a. Concept of Self-combustion
b. Operation of Fire Pump
Video demo of safety devices in conveyor i) Technical data
system (flow accidents can happen) ii) Types of Pumps & Fire Extinguishers
iii) Parts of Pump attachments
Video demo of belt joints (cold patching, iv) Loading of Centrifugal Pump
hot vulcanizing & mechanical fastening.) c. Introduction to fire fighting network
i) Technical data
Basic of screens & feeders (operation & ii) Types fittings in fire fighting network.
maintenance) iii) Safety to man, machines and importance
V-belt adjustment & tension checking. of fire fighting system.
iv) Fire Extinguisher Operation & Valve
operation.
v) Log book entry
13 Revision & Internal Assessment

15
 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.

16
 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

17
 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
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.

18
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.
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.

19
 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

20
 7.2 PRACTICAL TRAINING (ON-JOB TRAINING)
(BLOCK – I)
DURATION: 12 MONTHS

GENERAL INFORMATION

1) Name of the Trade : OPERATOR COAL HANDLING EQUIPMENTS

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 Operator Coal Handling Equipments 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

21
7.2.1 BROAD SKILL COMPONENT TO BE COVERED DURING ON-
JOB TRAINING

A. BLOCK – I
DURATION: 12 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. Unloading of Coal Wagons by Tippler :Familiarization with different parts of Wagon tippler,
dos and don’ts, Pre-start checks, shift take over, feed belt / conveyor operation, chute cleaning,
post job checks, housekeeping, adherence to Standard Operating Procedures (SOPs)
4. Familiarization with different parts of Wagon Chargers, dos and don’ts, Pre-start checks, shift
take over, operation of wagon charger & feed belts, post job checks, housekeeping.
5. Stopping & starting of drives, check points, Emergency stoppage, and power failure.
6. Identification & utility of limit switches of Tipplers, Side Arm Chargers, Beetles, Chute Jam
Sensors, pull chords.
7. Stacking and averaging of Coal by Stacker Operation: Familiarization with different parts of
Stackers, dos and don’ts, Pre-start checks, shift take over.
8. Post job checks, Control Desk Operation, chute cleaning, housekeeping, adhere to SOP.
9. Stopping & starting of drives, check points, Emergency stoppage, and power failure.
10. Stacker operation in monsoon.
11. Identification & utility of limit and safety switches of stackers and conveyors, inspection of
trolley wire, Power Collectors, reeling drums & belt joints.
12. Retrieving of stacked coal by Reclaimer: Familiarization with different parts of Re-claimers,
dos and don’ts, Pre-start checks, shift take over.
13. Post job checks, Control Desk Operation, housekeeping, adhere to SOP.
14. Stopping & starting of drives, check points, Emergency stoppage, and power failure and spillage
control.
15. Reclaimer operation in monsoon.
16. Identification & utility of limit and safety switches of Reclaimer and conveyors, inspection of
trolley wire, Power Collectors, reeling drums & belt joints.
17. Crushing of Coal by Selective Crushing Unit Operation: Familiarization with different parts
of Hammer Crusher, dos and don’ts, Pre-start checks, shift take over, feed conveyor operation,
chute cleaning, post job checks, housekeeping, adherence to SOP, adjustment of Grate Bar
assembly & Breaker plate of crusher.
18. Familiarization with different parts of Pneumatic Classifiers, Weigh Feeders, Dos and Don’ts,
Pre-start Checks, shift take over, sequential starts of equipments, post job checks, housekeeping.
Eye estimation of coal crushing. Water addition to coal blend.
19. Stopping & Starting of drives, Emergency stoppage and power failure.
20. Identification & utility of limit switches.
21. Operation of Conveyors: Shift take-over
22. Pre-start checks
i. Running checks : Feed adjustments
ii. Tracking of conveyors
22
 iii. Spillage prevention
23. Shutdown preparations
24. Equipment safety & daily check list
25. Stoppage on emergency / power failure
26. House-keeping
27. Fire fighting system & pump operation: Familiarization with different parts of Centrifugal
Pump , Dos and Don’ts, Pre-Start Checks, Post Job checks.
28. Familiarization with different types of Fire Extinguishers & parts of fire fighting network, Dos
and Don’ts, Mock Drills.

23
 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:

 demonstration of good operational skills while executing the assigned job.
 different accuracy achieved while undertaking different skills demanded by the
job.
 a fairly good level of neatness and consistency in handling controls.
 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 operation while executing the assigned job.
 the majority of the accuracy achieved while undertaking different skills demanded
by the job.
 a good level of neatness and consistency in handling controls.
 little support in completing the job.

24
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 operation while executing the assigned job.

 accuracy while undertaking different work being substantially in line with those
demanded by the job.
 a high level of neatness and consistency in the finish.
 minimal or no support in completing the project

25
 8.2 FINAL ASSESSMENT- ALL INDIA TRADE TEST FOR APPRENTICE

SUBJECTS Marks Sessional Full Marks Pass 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 50 20 70 28 4 hrs.
Drawing
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.

26
 8. FURTHER LEARNING PATHWAYS

Employment opportunities:

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

in the following industries:

1. Manufacturing & Process industries like steel plant and other related industries etc.

27
 ANNEXURE – I

TOOLS & EQUIPMENT FOR BASIC TRAINING

INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL

KNOWLEDGE

TRADE: OPERATOR COAL HANDLING EQUIPMENTS

LIST OF TOOLS & EQUIPMENTS FOR 20 APPRENTICES

As per training need the tools & equipment may be procured.

28
 INFRASTRUCTURE FOR WORKSHOP CALCULATION & SCIENCE AND
ENGINEERING DRAWING

TRADE: OPERATOR COAL HANDLING EQUIPMENTS

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

29
 ANNEXURE – II

INFRASTRUCTURE FOR ON-JOB TRAINING

TRADE: OPERATOR COAL HANDLING EQUIPMENTS

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. 12 months) are imparted. In case of any short fall the concern
industry may impart the training in cluster mode/ any other industry/ at ITI.

30
 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.

31