ITI Trade: Maintenance Mechanic (Chemical Plant)
Powered by NCVT, the ITI trade Maintenance Mechanic (Chemical Plant) is a highly job-oriented course designed to meet the manpower requirements of both Indian and international industries. This trade is suitable for government and private sector jobs and offers strong potential for self-employment. The curriculum has been meticulously crafted to fulfill industrial requirements with a focus on skill development and self-empowerment.
About the Course
The Maintenance Mechanic (Chemical Plant) trade under the Apprenticeship Training Scheme (ATS) is one of the most popular and in-demand courses, delivered nationwide through various industries. The course duration is two years (02 Blocks), covering both Domain and Core areas.
- Domain Area: Trade Theory & Practical for professional skills and technical knowledge.
- Core Area: Workshop Calculation & Science, Engineering Drawing, and Employability Skills for core competencies and life skills.
Upon successful completion of the program, trainees are awarded the National Apprenticeship Certificate (NAC) by NCVT, which is recognized worldwide.
Job Role
As a Maintenance Mechanic (Chemical Plant), the professional is expected to:
- Perform preventive, periodical, breakdown, online routine, and daily maintenance of chemical plant equipment and machinery.
- Maintain accurate records and documentation.
- Be skilled in using hand and machine tools along with an understanding of the work permit system.
- Ensure excellent housekeeping standards and be self-reliant.
- Conduct failure analysis of machinery and recommend corrective actions.
Scope of Employment
The trade offers a wide range of employability options, including:
- Self-employment
- Contractual employment
- Industrial jobs in both public and private sectors
Job Opportunities:
- Mechanic Maintenance (Chemical Plant)
- Operator/Maintenance Technician in chemical plants
- Opportunities in India and abroad
Job Description
The Maintenance Mechanic (Chemical Plant):
- Repairs and overhauls chemical plant machinery and equipment.
- Identifies processing methods from raw materials to finished products.
- Locates faults in machinery and addresses minor defects on-site.
- Reports major breakdowns, dismantles units, and repairs/replaces defective components.
- Reassembles units with precision, ensuring operational safety, particularly in plants handling explosive, gaseous, or corrosive substances.
- Performs periodic checks, adjustments, and lubrication of machinery.
- Maintains records of inspections, repairs, replacements, and plant performance.
- May assist in equipment erection and installation under supervision.
Key Responsibilities
- Ensure safety while working with machinery in chemical process plants.
- Prepare industrial documentation and reports.
- Familiarize with different sections of a chemical plant, raw materials, production capacities, and flow sheets.
- Understand Safety, Health & Environment (SHE) guidelines.
- Handle plant utilities and follow proper pipe color coding.
- Perform basic fitting operations with high accuracy.
- Install and maintain instruments for measuring pressure, temperature, flow, and level.
- Install and maintain equipment like flow meters, pumps, compressors, fans, blowers, heat exchangers, reactors, and drying equipment.
- Overhaul and troubleshoot vacuum pumps and various types of valves.
- Maintain and repair pumps and machines for liquid transportation.
- Perform quality control tests.
- Carry out routine tasks like startup and shutdown of plants, recording data, and maintaining seals and gaskets.
- Understand different maintenance types: Online, Predictive, Preventive, and Breakdown maintenance.
- Handle cooling towers, refrigeration units, crystallizers, filtration units, and size reduction equipment.
- Plan and implement machinery handling and installation.
- Operate and maintain pressure vessels and boilers.
- Perform size reduction and analysis.
- Handle mixing and agitation equipment.
- Maintain conveyor systems and elevators.
Specific Learning Outcomes
- Understand the role and duties of a Maintenance Mechanic in the chemical process industry.
- Apply safety precautions and emergency procedures.
- Prepare documentation as per industry standards.
- Familiarize with plant layout, raw materials, products, and flow sheets.
- Understand SHE practices in chemical plants.
- Perform precise fitting operations (accuracy ±0.25mm).
- Assemble components within close tolerances (±0.04mm).
- Perform safety experiments (fire extinguisher use, hazard identification, PPE handling).
- Install and record readings from pressure, temperature, flow, and level measuring devices.
- Install and maintain plant equipment (pumps, compressors, blowers, heat exchangers, reactors, etc.).
- Understand and apply vacuum systems in chemical processes.
- Overhaul and maintain valves and pumps.
- Perform quality control and ensure machinery functionality.
- Start up and shut down chemical plants, maintain logs, and replace mechanical parts.
- Execute different types of maintenance and record-keeping.
- Maintain cooling towers, absorption towers, refrigeration units, and crystallizers.
- Work with power transmission devices (belts, pulleys).
- Handle installation and functioning of pressure vessels.
- Manage steam systems and boiler maintenance.
- Operate size reduction machines and perform screening analysis.
- Understand mixing/agitation processes and equipment maintenance.
- Operate and maintain conveyors and elevators.
- Perform repair and maintenance work on all plant machinery and equipment.
Why Choose This Course?
✅ High Demand: In both Indian and international industries
✅ Versatile Employment: Government jobs, private sector roles, and self-employment
✅ Worldwide Recognition: NAC certification is globally recognized
✅ Hands-on Learning: Strong focus on practical knowledge and industrial application
✅ Career Progression: Opportunities for higher education, diplomas, and instructor training