ITI Course: Chemical Plant Operator / Process Plant Operator
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Course Overview
During the two-year duration of this ITI course, candidates receive comprehensive training in:
- Professional Skill
- Professional Knowledge
- Engineering Drawing
- Workshop Science & Calculation
- Employability Skills
Additionally, candidates engage in Project Work and Extra-Curricular Activities to enhance confidence and employability.
Practical skills are introduced progressively, from simple to complex concepts, while theoretical knowledge complements hands-on practice. The course covers Allied Trades, Basic Physics and Chemistry, and focuses on Unit Operations such as Fluid Flow, Heat Transfer, Mass Transfer, and Mechanical Operations.
Year-wise Course Content
First Year: Foundational Skills & Allied Trades
Allied Trades (Basic Fitting)
- Hack-sawing
- Marking, Punching
- Chiseling, Filing
- Drilling, Countersinking, Counter Boring
- Reaming, Tapping
- Mandatory focus on Safety Aspects
Basic Physics & Chemistry Practicals
- Determination of Physical Constants
- Verification of Laws of Physics
- Determining Concentration of Solutions, pH, Melting & Boiling Points
- Comparison of Properties of Metals & Alloys
- Preparation of Basic Chemicals
Safety Training
- Personal Protective Equipment (PPE)
- Fire Extinguishers & First Aid
- Safety and General Awareness in the Chemical Industry
Instrumentation & Equipment
- Identification, Installation & Connection of devices for:
- Pressure
- Temperature
- Flow
- Level
- Density
- Pipe Joints, Fittings & Valves on Pipes
- Dismantling, Overhauling, Cleaning & Assembling:
- Centrifugal Pumps
- Gear Pumps
- Metering Pumps
- Screw Pumps
- Multistage Compressors
- Dismantling, Repairing & Assembling:
- Gearboxes
- Bearings
Second Year: Advanced Unit Operations & Processes
Unit Operations
- Fluid Flow Operations
- Heat Transfer Operations
- Mass Transfer Operations
Machine Operations
- Shell and Tube Heat Exchangers
- Evaporators
- Distillation Columns
Processes & Plants
- Pressure Vessels
- Petroleum Refining
- Chemical Reactors
- Pollution Control in Chemical Industry
Mass Transfer Techniques
- Solvent Extraction
- Leaching
- Absorption
- Crystallization
- Drying
Mechanical Operations
- Size Reduction
- Mixing
- Conveying
- Filtration
Utilities & Plant Systems
- Steam Generation (Boilers)
- Cooling Towers
- Chilled Water Systems
- Instrument Air Systems
Skills Acquired
Laboratory Assistant - Physical/Chemical
- Conduct routine laboratory experiments
- Set up apparatus & instruments (balances, heaters)
- Prepare chemical solutions & reagents
- Record observations & perform calculations
Process Operator - Chemical
- Mix, heat, distill, cool, filter, and blend materials
- Monitor gauges, temperature, and pressure instruments
- Perform simple chemical tests & adjustments
Reactor/Converter Operator
- Operate equipment for complex chemical reactions
- Regulate material feed (gaseous, liquid, solid)
Pump Operator (Petroleum Refining)
- Control pumps & manifold systems for circulation of materials
- Ensure continuous flow & synchronize pump house operations
Evaporator Operator / Vacuum Pan Operator
- Operate evaporators to concentrate solutions
- Test concentration levels & regulate steam flow
Still Operator (Petroleum/Chemical)
- Distill crude oil or chemicals to obtain various fuels and by-products
- Monitor operations & adjust equipment controls
Crusher Operator
- Operate crushing machines for size reduction
- Regulate machine speed and ensure proper material output
Autoclave Operator
- Operate high-pressure vessels (autoclaves) for processing chemicals
- Perform sterilization of bottles, ampoules, etc.
Ammonia Plant Operator
- Control converters in ammonia plants
- Operate pumps, compressors, and monitor process instruments
Acid Plant Operator
- Manufacture acids (Sulphuric, Hydrochloric, Nitric)
- Operate treatment units and manage raw materials
Digester Operator (Paper Pulp)
- Convert raw materials into paper pulp
- Manage cooker operations and chemical treatments
Mixing Attendant (Chemical)
- Operate mixing machines for blending ingredients
- Maintain accurate proportions and mixing standards
Filter Press Operator
- Operate filter press to separate impurities from liquids
- Replace and maintain filtering media
Hydro Extractor/Centrifuge Operator
- Operate centrifuge machines for liquid-solid separation
- Control speeds and maintain equipment cleanliness
Dryer Operator / Drying Chamber Attendant
- Dry materials like tablets, crystals, powders in drying chambers
- Monitor moisture content and ensure quality standards
Extraction Attendant - Chemical
- Operate extractor machines for solvent extraction and separation
- Regulate flow rates, collect extracts, and check concentrations
Employment Opportunities
Graduates of this course are qualified for employment in:
- Chemical Industries
- Fertilizer Industries
- Pharmaceutical Industries
- Petroleum (Oil and Gas) Refineries
- Power Plants
- Water Treatment Plants