indian iron & steel sector skill council · understand slurry pumping system & receiving...

Contents

1. Introduction and Contacts..….……….…….P.1

2. Qualifications Pack……….………………........P.2

3. Glossary of Key Terms …..…………...........P.4

4. NOS Units……………………..……….……..……..P.6Ø OS describe what

individuals needto do, know andunderstand inorder to carry outa particular jobrole or function

Ø OS areperformancestandards thatindividuals mustachieve whencarrying outfunctions in theworkplace,together withspecifications ofthe underpinningknowledge andunderstanding

Qualifications Pack – Iron & Steel - Control RoomOperator for Agglomeration

SECTOR: Iron and Steel

SUB-SECTOR: Steel

REFERENCE ID: ISC/Q0301

ALIGNED TO: NCO-2004/NIL

Title of Job: This job is all about control/operate plant (Sinter & Pellet) from DCS

(Distribution Control system) to ensure quality, quantity of agglomerate produced in the

shift and also analyse deviations if any.

Personal Attributes: This job requires the individual to work independently as

well as in teams. He should be physically fit, not having colour blindness , having analytical skills,

problem solving attitude, high concentration levels and willingness to work in a factory

environment.

Introduction

Indian Iron & Steel SectorSkill Council

QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR IRON & STEEL INDUSTRY

Qualifications Pack forIron & Steel - Control Room Operator for Agglomeration

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Job Role Iron & Steel - Control Room Operator for Agglomeration

Role Description

Control room Operator is responsible to operate the plantfrom DCS to control different sub processes. This involvesraw material receiving, preparation, mixing & nodulizing, charging ofgreen mix on bed, ignition & sintering, crushing & cooling, sizing andfinal screening, storage & dispatch, sampling & testing for sinteringoperation. This also involves palletizing operations e.g. raw materialstorage and additive crushing, drying & grinding, green ballformation, ignition, pellet induration, sintering & product handlingand sampling & testing.

NSQF level

Minimum Educational Qualifications

Maximum Educational Qualifications

5

Diploma (Metallurgical / Mechanical) Pass

BE (Metallurgical / Mechanical) Pass

Training(Suggested but not mandatory)

· Knowledge on iron ore beneficiation and pelletization byprofessional organization like IMMT

· Knowledge on Raw Materials and additives that are used· Basic concepts on DCS operation· Training on Statistical tools· Safety practices

Minimum Job Entry Age 18 years

Experience · 2-3 year in 4 MTPA Pellet plant Control room operations

Qualifications Pack CodeISC/Q0301

Job Role Iron & Steel - Control Room Operator for Agglomeration

Credits(NSQF) TBD Version number 1.0

Industry Iron & Steel Drafted on 15/12/2014

Sub-sector Steel Last reviewed on 25/03/2015

Occupation Agglomeration Next review date 25/03/2016

NSQC Clearance on 20/07/2015

Job

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· In lieu of minimum qualification the incumbent shouldhave minimum 5 to 6 years’ experience working under asupervisor in the similar operation

Occupational Standards (OS)

Compulsory:

ISC/N0301: Carry out control room operationISC/N0302: Problem identification & reportingISC/N0008: Use basic health and safety practices at workplaceISC/N0096: Work effectively with others and manage teammembers

Optional:

N/A

Performance Criteria As described in the relevant OS unit


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Keywords /Terms Description

Core Skills/GenericSkills

Core Skills or Generic Skills are a group of skills that are key to learningand working in today's world. These skills are typically needed in anywork environment. In the context of the NOS, these includecommunication related skills that are applicable to most job roles.

Function Function is an activity necessary for achieving the key purpose of thesector, occupation, or area of work, which can be carried out by a personor a group of persons. Functions are identified through functionalanalysis and form the basis of NOS.

Job role Job role defines a unique set of functions that together form a uniqueemployment opportunity in an organization.

Knowledge andUnderstanding

Knowledge and Understanding are statements which together specify thetechnical, generic, professional and organizational specific knowledgethat an individual needs in order to perform to the required standard.

National OccupationalStandards (NOS)

NOS are Occupational Standards which apply uniquely in the Indiancontext

Occupation Occupation is a set of job roles, which perform similar/related set offunctions in an industry.

Organisational Context Organisational Context includes the way the organization is structuredand how it operates, including the extent of operative knowledgemanagers have of their relevant areas of responsibility.

Performance Criteria Performance Criteria are statements that together specify the standardof performance required when carrying out a task.

Qualifications Pack(QP) Qualifications Pack comprises the set of NOS, together with theeducational, training and other criteria required to perform a job role. AQualifications Pack is assigned a unique qualification pack code.

Qualifications PackCode

Qualifications Pack Code is a unique reference code that identifies aqualifications pack.

Scope Scope is the set of statements specifying the range of variables that anindividual may have to deal with in carrying out the function which havea critical impact on the quality of performance required.

Sector Sector is a conglomeration of different business operations having similarbusinesses and interests. It may also be defined as a distinct subset of theeconomy whose components share similar characteristics and interests.

Def

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Sub-Sector Sub-sector is derived from a further breakdown based on thecharacteristics and interests of its components.

Sub-functions Sub-functions are sub-activities essential to fulfil the achieving theobjectives of the function.

Technical Knowledge Technical Knowledge is the specific knowledge needed to accomplishspecific designated responsibilities.

Unit Code Unit Code is a unique identifier for a NOS unit, which can be denotedwith an ‘N’

Unit Title Unit Title gives a clear overall statement about what the incumbentshould be able to do.

Vertical Vertical may exist within a sub-sector representing different domainareas or the client industries served by the industry.

Keywords /Terms Description

NOS National Occupational Standard(s)

NSQF National Skills Qualifications Framework

OEM Original Equipment Manufacturer

OS Occupational Standard(s)

QP Qualifications Pack

5 S Technique of maintaining orderliness –Japanese terminology

CP Control Plan

WI Work Instructions

Acr

onym

s

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ISC/N0301: Carry out control room operation----------------------------------------------------------------------------------------------------------------------------- ---------------------------

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Overview

The unit is about understanding control room operation and is responsible for DCS (Distributed ControlSystem) Operation, control of induration furnace , operation of additive grinding plant, filtration plant ,mixing & balling unit.

National OccupationalStandards

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Unit Code ISC/N0301Unit Title(Task)

Carry out control room operation

Description The unit is about understanding and operating all control parameters related toinduration furnace, additives grinding plant, filtration plant, mixing & balling unit. Thisunit also involves understanding of DCS systems related to entire pellet plantoperations.

Scope This OS unit/task covers the following:

· Understand all operating parameters, all equipment in pellet / sinter plant andDCS operation, logics and Interlocks

· Production of pellet / sinter with good quality and low cost & power consumption· Operation of Grinding plant, Filtration plant, Mixing & balling units and controlling

process parameters· Operation of Raw material Bedding & Blending, Homogenous mixing and Micro

pelletizing and controlling process parameters· Communicate with operators and carry out documentation

Performance Criteria (PC) w.r.t. the Scope

Element Performance CriteriaUnderstand alloperatingparameters, allequipment in pellet /Sinter plant and DCSoperation, logics andInterlocks

To be competent, the user/individual on the job must be able to:

PC 1. Understand DCS architecture, key facilities like trends, graphs, alarms, face platereadingPC 2. Understand the quality requirements of iron ore slurry, filter cake, additives &pelletsPC 3. Understand the characteristics of raw material, additives analysis and effect ofchange in production & qualityPC 4. Understand control of process parameters and capable handling processdeviationsPC 5. Understand product knowledge , environment standards.

Production of pellet /sinter with goodquality and low cost& powerconsumption


PC 6. Understand Importance of close monitoring and control of furnace parametersPC 7. Adjust temperatures ,process fan flows to get good quality of pellets / sinterPC 8. Ensure Proper control of balling feed to maximum productionPC 9. Ensure proper control & nodulizing to maximise sinter productionPC 10. Maintain documentation of process parameters, run hours, productiontotalizersPC 11. Alert operators for proper inspection of equipment, machinery

Operation of Grindingplant, Filtration plant,Mixing & balling unitsand controlling


PC 12. Understand functioning of equipment involved in AGP, Filtration, slurryhandling & storage, mixing and balling units

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process parameters PC 13. Understand slurry pumping system & receiving station / storage & feeding ofpressure filters.PC 14. Ensure Control of grinding parameters to get desired fineness of additives;PC 15. Maintain Log sheetsPC 16. Maintain de dusting systems , ESPs, recovery of fines to process scrubbersystem and thickener.PC 17. Inspect of Critical equipment, monitoring of alarms and taking correctivemeasures

Operation of Rawmaterial Bedding &Blending,Homogenous mixingand Micro pelletizingand controllingProcess parameters


PC 18. Understand functioning of equipment involved in addition, crushing rawmaterial, bedding and blending of all heterogeneous raw materials and convert asingle raw material (base mix) for Sinter making.PC 19. Carry out reclamation of base mix, its dispatch to sinter making unit and itsstoragePC 20. Ensure control of accurate proportioning and micro pellet formationPC 21. Understand implication of quality deviation of base material and otheradditives on sinter making process w.r.t production rate and qualityPC 22. Monitor all dispatches and communicate with Bedding Blending plantPC 23. Ensure required ignition for temperature and pressure control from DCS /control deskPC 24. Understand start, progress and completion of sintering process and how totake care of any process parameters deviations as and when it arisesPC 25. Understand all de-dusting system (Process and plant de-dusting ESP and Bagfilters) and re-circulation of micro fine dustPC 26. Inspect of critical equipment, monitoring of alarms, its analysis and takingcorrective measures

Communicate withoperators and carryout documentation


PC 27. Acknowledge process alarms and caution field operatorsPC 28. Document process parameters, quality figures, log sheetsPC 29. Generate of daily production report & special reportsPC 30. Develop important logics for higher operation efficiency and process safety

Element Knowledge and Understanding

A. OrganisationalContext(Knowledge of theCompany/Organisation andits processes)

The user/individual on the job needs to know and understand:

KA1. Implications of changes in slurry granulometry , effect on filtration and ballingand hence production rateKA2. Risk and impact of not following defined procedures/ process parametersKA3. Escalation and reporting identified problems to shift In chargeKA4. Maintaining log sheets and documentationKA5. Records to be maintained and implications of non-maintenance of the sameKA6. Importance of effective communication & good data analysisKA7. Health, Safety and Environment guidelines, legislation and regulations applicableKA8. Personal protection (Which protective equipment to be used and how)KA9. Potential hazards and actions to minimize the same

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B. Technical Knowledge


KB 1. Pelletization process and straight grate furnace operation.KB 2. Parameters involved in achieving set quality targetsKB 3. Calculations involved in calculating fixed carbon addition, tonnage w.r.t densityof slurry, LOI of additives used in pellet makingKB 4. Procedure to handle power failure, power dip & accretion of pelletsKB 5. Steps required for starting cold furnace, restarting of pellet plantKB 6. Steps required for shutting down the pellet plant and induration furnaceKB 7. Implications of not adhering to organizational SOPKB 8. Raw material sufficiency in Day Bins and reporting to Shift In ChargeKB 9. Use of different type of binders, coke, limestoneKB 10. Material flow sheet and the equipment involved in the process

Skills (S) w.r.t. the scope

Element Skills

A. Core Skills/Generic Skills

Writing SkillsThe user/ individual on the job needs to know and understand how to:

SA1. Maintain Log Sheets and Log Books and express clearly through writtencommunication.

SA2. To understand and activity logs which are maintainedSA3. Communicate to his immediate supervisor (Shift In Charge / Engineer), field

operators on process changes and steps to take by them.SA4. Carry out various calculations involved in pelletization process / units of

measurement.

Reading & Understanding

The user/ individual on the job needs to know and understand how to:

SA5. Read and understand SOPs, manuals, specific standards, health and safetyinstructions, memos, reports, etc.

SA6. Read and interpret instructions received.

Oral Skills


SA7. Express statements, opinions or information clearly.SA8. Respond appropriately to any queries.SA9. Communicate with down the line workmen & his supervisor and close co-

ordination with shift maintenance departments.SA10. Work in a team and other behavioral skills required to support the small group

activities (Quality Circle, Cross Functional Team, Suggestion Scheme).

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B. Professional Skills Analytical Thinking


SB1: Understand the behavior of the induration furnace.SB2: Understand the concentrate size distribution, moisture & LOI.SB3: Carry out simple corrections / additions, in consultation with his superiors

Time Management


SB4. Carry out proper planning of slurry volume to run pellet plant continuously without production loss.SB5. Feed timely raw material to furnace

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NOS Version Control

NOS Code ISC/N0301

Credits(NSQF) TBD Version number 1.0Industry Iron and Steel Drafted on 21/11/2014Industry Sub-sector Steel Last reviewed on 25/03/2015

Occupation Agglomeration Next review date 25/03/20161/04/2017

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ISC/N0302: Problem identification & reporting-------------------------------------------------------------------------------------------------------------------------------

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Overview

This unit is about problem identification and reporting.


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Problem identification & reporting

Description This unit is about problem identification and reporting.

Scope This unit/task covers the following:

· Identify problems across:o Materialso Productso Equipmento Others

· Identify solutions to problems· Take corrective action· Report / escalate unresolved identified problems


Element Performance CriteriaIdentify problemsacross:· Materials· Products· Equipment· Others


PC1. Identify defects/indicators of problemsPC2. Identify any wrong practices that may lead to problemsPC3. Identify practices that may impact the final product qualityPC4. Identify if the problem has occurred beforePC5. Identify other operations that might be impacted by the problemPC6. Ensure that no delays are caused as a result of failure to escalate problems

Identify solutions toproblems


PC7. Take appropriate materials and sample to conduct testsPC8. Evaluate results to confirm suspected reasons for non-conformance (whererequired)PC9. Consider possible reasons for identification of problems

Take correctiveaction


PC10. Consider applicable corrections and formulate corrective actionPC11. Formulate action in a timely mannerPC12. Communicate problem/remedial action to appropriate authoritiesPC13. Take corrective action in a timely mannerPC14. Monitor corrective actionPC15. Evaluate implementation of corrective action taken to determine if theproblem has been resolvedPC16. Ensure that corrective action selected is viable and practicalPC17. Ensure that correct solution is identified to an identified problem

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PC18. Take corrective action for problems identified according to the companyproceduresPC19. Ensure that no delays are caused as a result of failure to take necessary action

Report / escalateunresolved identifiedproblems


PC20. Report/document problem and corrective action in an appropriate mannerPC21. Escalate problem as per laid down escalation matrixPC22. Escalate the problem within stipulated timePC23. Escalate the problem in an appropriate mannerPC24. Ensure that no delays are caused as a result of failure to escalate problems


A. OrganisationalContext (Knowledge ofthe Company/Organisation and itsprocesses)


KA1. Implications of changes in slurry granulometry , effect on filtration and ballingand hence production rateKA2. Risk and impact of not following defined procedures/ process parametersKA3. Escalation and reporting identified problems to shift In chargeKA4. Maintaining log sheets and documentationKA5. Records to be maintained and implications of non-maintenance of the sameKA6. Importance of effective communication & good data analysisKA7. Health, Safety and Environment guidelines, legislation and regulations applicableKA8. Personal protection (Which protective equipment to be used and how)KA9. Potential hazards and actions to minimize the same

B. TechnicalKnowledge


KB1. Indicators of problemsKB2. The working of the equipment and accessories( if applicable)KB3. The impact of operations on the user and equipment( if applicable)KB4. The impact of operations on the final product ( if applicable)KB5. The effect of not rectifying the problems identifiedKB6. The reason for the occurrence of previous problemsKB7. Measures and steps that have been taken to address the previous problemsKB8. Possible solutions for various problemsKB9. The correct method for carrying out corrective actions outlined for eachproblemKB10. The impact of not carrying out the corrective actionsKB11. The documentation procedure for recording such problems, as per companynormsKB12. Escalation matrix for reporting unresolved problemsKB13. The time frame within which in which each problem needs to be escalated


Element Skills

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Writing SkillsThe user/ individual on the job needs to know and understand how to:

SA1. Maintain Log Sheets and Log Books and express clearly through writtencommunication.

SA2. Understand and activity logs which are maintainedSA3. Communicate to his immediate supervisor (Shift In Charge / Engineer), field

operators on process changes and steps to take by them.SA4. Various calculations involved in pelletization process / Units of measurement.

Reading & Understanding


SA5. Read and understand SOPs, manuals, specific standards, health and safetyinstructions, memos, reports, etc.

SA6. Read and interpret instructions received.

Oral Skills


SA7. Express statements, opinions or information clearly.SA8. Respond appropriately to any queries.SA9. Communicate with down the line workmen & his supervisor and close co-

ordination with shift maintenance departments.SA10. Work in a team and other behavioral skills required to support the small group

activities (Quality Circle, Cross Functional Team, Suggestion Scheme).

B. Professional Skills Analytical Thinking


SB1: Understand the behavior of the induration furnaceSB2: Understand the concentrate size distribution, moisture & LOISB3: Simple corrections of the additions ,in consultation with his superiors

Time Management


SB4. Properly plan for slurry volume to run pellet plant continuously withoutproduction lossSB5. Feed timely raw material to furnace

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NOS Version Control

NOS Code ISC/N0302

Credits(NSQF) TBD Version number 1.0Industry Iron and Steel Drafted on 21/11/2014Industry Sub-sector Steel Last reviewed on 25/03/2015


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ISC/N0008: Use basic health and safety practices at the workplace---------------------------------------------------------------------------------------------------------------------------------------


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Overview

This unit covers health, safety and security at the workplace. This includes procedures and practices thatcandidates need to follow to help maintain a healthy, safe and secure work environment.

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Use basic health and safety practices at the work place

Description This OS unit is about knowledge and practices relating to health, safety and securitythat candidates need to use in the workplace. It covers responsibilities towards self,others, assets and the environment.

It includes understanding of risks and hazards in the workplace, along with commontechniques to minimize risk, deal with accidents, emergencies, etc.


• Health and safety procedures• Fire safety procedures• Emergencies, rescue and first aid procedures


Element Performance CriteriaHealth and safetyprocedures

The user/individual on the job should be able to:

PC1. Use protective clothing/equipment for specific tasks and work conditions

Protective clothing includes:• Leather or asbestos gloves• Flame proof aprons• Flame proof overalls buttoned to neck• Cuff less (without folds) trousers• Reinforced footwear• Helmets/hard hats• Cap and shoulder covers• Ear defenders/plugs• Safety boots• Knee pads• Particle masks• Glasses/gloves/visors

Equipment includes:• Hand shields• Machine guards• Residual current devices• Shields• Dust sheets• Respirator

PC2. State the name and location of people responsible for health and safety in the

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workplace

Various areas are listed below:• On chemical containers• Equipment• Packages• Inside buildings• Open areas, public places etc.

PC3. State the names and location of documents that refer to health and safety in theworkplacePC4. Identify job-site hazardous work and state possible causes of risk or accident inthe workplaceHazards include:

• Working with electrical and thermal tools and equipment• Sharp edged and heavy tools• Heated metals• Oxyfuel and gas cylinders• Welding radiation• Surfaces: sharp, slippery, uneven, chipped, broken, etc.• Substances: chemicals, gas, oxy-fuel, fumes, dust, etc.• Physical: working at heights, large and heavy objects and machines, sharp

and piercing objects, tolls and machines, intense light, load noise,obstructions in corridors, by doors, blind turns, noise, over stackedshelves and packages, etc.

• Electrical: power supply and points, loose and naked cables and wires,electrical machines and appliances, etc.

PC5. Carry out safe working practices while dealing with hazards to ensure the safetyof self and others state methods of accident prevention in the work environment ofthe job role

Safe working practices include:• Using protective clothing and equipment• Putting up and reading safety signs• Handle tools in the correct manner and store and maintain them properly• Keep work area clear of clutter, spillage and unsafe object lying casually• While working with electricity take all electrical precautions like insulated

clothing, adequate equipment insulation, use of control equipment, drywork area, switch off the power supply when not required, etc.

• Safe lifting and carrying practices• Use equipment that is working properly and is well maintained• Take due measures for safety while working in confined places, trenches

or at heights, etc. Including safety harness, fall arrestors etc.Methods are:

• Training in health and safety procedures• Using health and safety procedures• Use of equipment and working practices (such as safe carrying

procedures)• Safety notices, advice

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• Instruction from colleagues and supervisorsPC6. State location of general health and safety equipment in the workplacePC7. Inspect for faults, set up and safely use steps and ladders in general use

Faults :• Corrosion of metal components• Deterioration• Splits and cracks timber components• Imbalance• Loose rungs• Nuts or bolts, etc.

Set up:• Firm/level base• Clip/lash down• Leaning at the correct angle, etc.

PC8. Work safely in and around trenches, elevated places and confined areasPC9. Lift heavy objects safely using correct proceduresPC10. Apply good housekeeping practices at all times. Good housekeeping practices:

• Clean/tidy work areas• Removal/disposal of waste products• Protect surfaces

PC11. Identify common hazard signs displayed in various areasPC12. Retrieve and/or point out documents that refer to health and safety in theworkplace

Fire safetyprocedures


PC13. Use the various appropriate fire extinguishers on different types of firescorrectly.Fire extinguishers:

• Sand• Water• Foam• Co2• Dry powder

Fires:• Class A: Ordinary solid combustibles, e.g. wood, paper, cloth, plastic,

charcoal etc.• Class B: Flammable liquids and gases, e.g. gasoline, propane, diesel fuel,

tar, cooking oil and similar substances• Class C: Electrical equipment e.g. appliances, wiring, breaker panels etc.

(these categories of fires become Class A, B, and D fires when theelectrical equipment that initiated the fire is no longer receivingelectricity)

• Class D: Combustible metals such as magnesium, titanium, and sodium(these fires burn at extremely high temperatures and require specialsuppression agents)

Causes of fires:

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• Heating of metal• Spontaneous ignition• Sparking,• Electrical heating• Loose fires (e.g. Smoking, welding, etc.)• Chemical fires, etc.

PC14. Demonstrate rescue techniques applied during fire hazardPC15. Demonstrate good housekeeping in order to prevent fire hazardsPC16. Demonstrate the correct use of a fire extinguisher

Emergencies, rescueand first-aidprocedures


PC17. Demonstrate how to free a person from electrocutionPC18. Administer appropriate first aid to victims as required e.g. in case of bleeding,burns, choking, electric shock, poisoning etc.PC19. Demonstrate basic techniques of bandagingPC20. Respond promptly and appropriately to an accident situation or medicalemergency in real or simulated environments. few General health and safetyequipment are mentioned below :

• Fire extinguishers• First aid equipment• Safety instruments and clothing• Safety installations, e.g. Fire exits, exhaust fans etc.

PC21. Perform and organize loss minimization or rescue activity during an accident inreal or simulated environmentsPC22. Administer first aid to victims in case of a heart attack or cardiac arrest due toelectric shock, before the arrival of emergency services in real or simulated casesPC23. Demonstrate the artificial respiration and the CPR ProcessPC24. Participate in emergency procedures. Emergency procedures are:

• Raising alarm• Safe/efficient evacuation• Correct means of escape• Correct assembly point• Roll call• Correct return to work

PC25. Complete a written accident/incident report or dictate a report to anotherperson, and send report to person responsibleIncident Report should capture:

• Name• Date/time of incident• Date/time of report,• Location• Environment conditions• Persons involved• Sequence of events• Injuries sustained• Damage sustained• Actions taken

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• Witnesses• Supervisor/manager notified

Documents:• Fire notices• Accident reports• Safety instructions for equipment and procedures• Company notices and documents• Legal documents (e.g. Government notices)

Job titles:• Health and safety officer• First aid officer• Fire officer

PC26. Demonstrate correct method to move injured people and others during anemergency




KA1. State the names (and job titles if applicable), and describe where to find, all thepeople responsible for health and safety in a workplaceKA2. State the names and location of documents that refer to health and safety in theworkplace



KB3. Meaning of “hazards” and “risks”KB4. Health and safety hazards commonly present in the work environment andrelated precautionsKB5. Possible causes of risk, hazard or accident in the workplace and why risk and/oraccidents are possibleKB6. Activities and causes of risk and accidentKB7. Methods of accident preventionKB8. Safe working practices when working with tools and machinesKB9. Safe working practices while working at various hazardous sitesKB10. Where to find all the general health and safety equipment in the workplaceKB11. Various dangers associated with the use of electrical equipmentKB12. Preventative and remedial actions to be taken in the case of exposure to toxicmaterials.

• Exposure: ingested, contact with skin, inhaled• Preventative action: ventilation, masks, protective clothing/equipment• Remedial action: immediate first aid, report to supervisor• Materials: solvents, flux, lead

KB13. Importance of using protective clothing/equipment while workingKB14. Precautionary activities to prevent the fire accidentActivities and causes:

• Physical actions• Reading

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• Listening to and giving instructions• Inattention• Sickness and incapacity (e.g. Drunkenness)• Health hazards (e.g. Untreated injuries and contagious illness)

KB15. Various causes of fireKB16. Techniques of using the different fire extinguishersKB17. Different methods of extinguishing fireKB18. Rescue techniques applied during a fire hazardKB19. Various types of safety signs and what they meanKB20. Appropriate basic first aid treatment relevant to the condition e.g. Shock,electrical shock, bleeding, breaks to bones, minor burns, resuscitation, poisoning, eyeinjuriesKB21. Content of written accident reportKB22. Potential injuries and ill health associated with incorrect manual handingKB23. Safe lifting and carrying practicesKB24. Personal safety, health and dignity issues relating to the movement of a personby othersKB25. Potential impact to a person who is moved incorrectly


Element Skills


Reading and Writing SkillsThe user/individual on the job needs to know and understand how to:

SA1. Read and comprehend basic content to read labels, charts, signage’sSA2. Read and comprehend basic English to read manuals of operationsSA3. Read and write an accident/incident report in local language or English

Oral Communication (Listening and Speaking skills)The user/individual on the job needs to know and understand how to:

SA4. Question co-workers appropriately in order to clarify instructions and otherissuesSA5. Give clear instructions to co-workers, subordinates others

Decision MakingThe user/individual on the job needs to know and understand how to:

SA6. Make appropriate decisions pertaining to the concerned area of work withrespect to intended work objective, span of authority, responsibility, laid downprocedure and guidelines

B. Professional Skills Plan and Organize


SB1. Plan and organize their own work schedule, work area, tools, equipment and

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materials to maintain decorum and for improved productivity

Working with othersThe user/individual on the job needs to know and understand how to:

SB2. Remain congenial while discussing and debating issues with co-workersSB3. Follow appropriate protocols for communication based on situation, hierarchy,organizational culture and practiceSB4. Ask for, provide and receive required assistance where possible to ensureachievement of work related objectivesSB5. Thank co-workers for any assistance receivedSB6. Offer appropriate respect based on mutuality and respect for fellowworkmanship and authority

Problem SolvingThe user/individual on the job needs to know and understand how to:

SB7. Think through the problem, evaluate the possible solution(s) and suggest anoptimum /best possible solution(s)SB8. Identify immediate or temporary solutions to resolve delaysSB9. Identify sources of support that can be availed of for problem solving for variouskind of problemsSB10. Seek appropriate assistance from other sources to resolve problemsSB11. Report problems that you cannot resolve to appropriate authority

Analytical ThinkingThe user/individual on the job needs to know and understand how to:

SB12. Identify cause and effect relations in their area of workSB13. Use cause and effect relations to anticipate potential problems and theirsolution

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NOS Version Control

NOS Code ISC/N0008

Credits(NSQF) TBD Version number 1.0Industry Iron and Steel Drafted on 23/07/2014Industry Sub-sector All Departments Last reviewed on 30/12/2014

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ISC/N0096: Work effectively with others and manage team members

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Occupation Agglomeration Next review date 30/12/2015

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Overview

This unit covers basic practices that improve effectiveness of working with others in an organisationalset-up and managing team members


Work effectively with others and manage team members

Description This unit covers basic etiquettes and competencies that a candidate is required topossess and demonstrate in their behaviour and interactions with others at theworkplace.

These cover areas such as communication etiquette, discipline, listening, handlingconflict and grievances.


· Communicate effectively with team members, co-workers and supervisors• Encourage friendly working environment• Use appropriate titles and terms of respect• Follow code of conduct and ethics as applicable• Follow organisation specific policies

· Demonstrate effective behaviours for team work· Ensure engagement of team members through on-the job handholding & support


Element Performance CriteriaCommunicateeffectively with co-workers andsupervisors


PC1. Accurately receive, absorb and share information and instructions from thesupervisor and fellow workers, getting clarification where requiredPC2. Display appropriate communication etiquette while workingPC3. Display active listening skills while interacting with others at workPC4. Use appropriate tone, pitch and language to convey politeness, assertiveness,care and professionalism

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Demonstrateeffective behavioursfor team work


PC5. Display helpful behaviour by assisting others in performing tasks in effectivemannerPC6. Consult with and assist others to maximize effectiveness and efficiency incarrying out tasksPC7. Demonstrate responsible and disciplined behaviours at the workplacePC8. Escalate grievances and problems to superiors

Ensure engagementof team membersthrough on-the jobhandholding &support


PC9. Communicate day-to-day objectives, instructions etc. to team membersPC10. Guide the team members to manage day-to-day issues at workPC11. Gather concerns, feedback from team members and convey them toappropriate authoritiesPC12. Escalate grievances and problems to superiors




KA1. Legislation, standards, policies, and procedures followed in the company relevantto own employment and performance conditionsKA2. Reporting structure, inter-dependent functions, lines and procedures in thework areaKA3. Relevant people and their responsibilities within the work areaKA4. Escalation matrix and procedures for reporting work and employment relatedissues



KB1. Various categories of people that one is required to communicate and co-ordinate with in the organizationKB2. Importance of teamwork in organizational and individual successKB3. Various components of effective communication and importance of effectivecommunication while communicating professional circlesKB4. Key elements of active listening and importance of active listeningKB5. Importance of ethics for professional successKB6. Importance of discipline and disciplined behaviour for professional successKB7. Common reasons, importance and ways of managing interpersonal conflicteffectivelyKB8. Expressing and addressing grievances appropriately and effectively


Element Skills


Writing skills and reading skillsThe user/individual on the job needs to know and understand how to:

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SA1. Read and comprehend basic content to read instructions, labels, charts, signage’sSA2. Write notes in log books etc.SA3. Prepare incident reports, as appropriate

Oral Communication (Listening and Speaking skills)The user/individual on the job needs to know and understand how to:

SA4. Question co-workers appropriately in order to clarify instructions and otherissuesSA5. Communicate with co-workersSA6. Share information with Supervisors

Decision MakingThe user/individual on the job needs to know and understand how to:

SA7. Make appropriate decisions pertaining to the concerned area of work withrespect to safely achieving work objective following the laid down procedure andguidelines

B. Professional SkillsPlan and OrganizeThe user/individual on the job needs to know and understand:

SB1. Plan and organize their own work schedule, work area, tools, equipment andmaterials to maintain decorum and for improved productivity

Problem SolvingThe user/individual on the job needs to know and understand how to:

SB2. Identify sources of support that can be availed of for problem solving for variouskind of problemsSB3. Seek appropriate assistance from other sources to resolve problemsSB4. Report problems that cannot be resolved to appropriate authority

Analytical ThinkingThe user/individual on the job needs to know and understand how to:

SB5. Identify cause and effect relations in own area of workSB6. Use cause and effect relations to anticipate potential problems and their solution

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NOS Version Control

NOS Code ISC/N0096

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CRITERIA FOR ASSESSMENT OF TRAINEES

Job Role: Iron & Steel - Control Room Operator for AgglomerationQualification Pack: ISC/Q0301Sector Skill Council: Indian Iron & Steel Sector Skill Council

Guidelines for Assessment:

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. EachPerformance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will alsolay down proportion of marks for Theory and Skills Practical for each PC.2. The assessment for the theory part will be based on knowledge bank of questions created by theSSC.3. Individual assessment agencies will create unique question papers for theory part for eachcandidate at each examination/training center (as per assessment criteria below)4. Individual assessment agencies will create unique evaluations for skill practical for every studentat each examination/training center based on this criteria.5. To pass the Qualification Pack , every trainee should score a minimum of 60% in every NOS.6. In case of successfully passing only certain number of NOS's, the trainee is eligible to takesubsequent assessment on the balance NOS's to pass the Qualification Pack.

Marks AllocatedNOSs PCs Total

Marks1000

Out Of Theory Practical

ISC/N0301:Carry outcontrol room

PC 1. Understand DCS architecture, keyfacilities like trends, graphs, alarms, faceplate reading

55015 5 10

Credits(NSQF) TBD Version number 1.0Industry Iron and Steel Drafted on 23/07/2014

Industry Sub-sector All Departments Last reviewed on 30/12/2014


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operation PC 2. Understand the qualityrequirements of iron ore slurry, filtercake, additives & pellets

20 5 15

PC 3. Understand the characteristics ofraw material, additives analysis and effectof change in production & quality

20 5 15

PC 4. Understand Control of processparameters and capable handling processdeviations

20 5 15

PC 5. Understand Product knowledge ,environment standards

20 5 15

PC 6. Understand Importance of closemonitoring and control of furnaceparameters

20 5 15

PC 7. Adjust temperatures, process fanflows to get good quality of pellets / sinter

15 0 15

PC 8. Ensure Proper control of balling feedto maximum production

15 0 15

PC 9. Ensure proper control & nodulizingto maximise sinter production

15 0 15

PC 10. Maintain documentation ofprocess parameters, run hours,production totalizers

20 5 15

PC 11. Alert operators for properinspection of equipment, machinery.

15 0 15

PC 12. Understand functioning ofequipment involved in AGP, Filtration,slurry handling & storage, mixing andballing units.

20 5 15

PC 13. Understand slurry pumping system& receiving station / storage & feeding ofpressure filters

20 5 15

PC 14. Ensure Control of grindingparameters to get desired fineness ofadditives

20 5 15

PC 15. Maintain Log sheets 10 5 5PC 16. Maintain de dusting systems , ESPs,recovery of fines to process scrubbersystem and thickener

20 5 15

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PC 17. Inspect critical equipment,monitoring of alarms and takingcorrective measures

20 5 15

PC 18. Understand functioning ofequipment involved in addition, crushingraw material, bedding and blending of allheterogeneous raw materials and converta single raw material (base mix) for Sintermaking

20 5 15

PC 19. Reclamation of base mix, itsdispatch to sinter making unit and itsstorage

20 5 15

PC 20. Ensure control of accurateproportioning and micro pellet formation

20 5 15

PC 21. Understand implication of qualitydeviation of base material and otheradditives on sinter making process w.r.tproduction rate and quality

20 5 15

PC 22. Monitor all dispatches andcommunicate with Bedding Blending plant

20 5 15

PC 23. Ensure required ignition fortemperature and pressure control fromDCS / control desk

20 5 15

PC 24. Understand start, progress andcompletion of sintering process and howto take care of any process parametersdeviations as and when it arises

20 5 15

PC 25. Understand all de-dusting system(Process and plant de-dusting ESP and Bagfilters) and re-circulation of micr0 finedust

20 5 15

PC 26. Inspect critical equipment,monitoring of alarms, its analysis andtaking corrective measures

20 5 15

PC 27. Regular acknowledgement ofprocess alarms and cautioning fieldoperators

15 5 10

PC 28. Document of process parameters,quality figures, log sheets

15 5 10

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PC 29. Generate of daily productionreport & special reports

15 5 10

PC 30. Develop important logics for higheroperation efficiency and process safety

20 5 15

Total 550 130 420ISC/N0302:Problemidentification& reporting

PC1. Identify defects/indicators ofproblems

200

8 3 5

PC2. Identify any wrong practices thatmay lead to problems

8 3 5

PC3. Identify practices that may impactthe final product quality

8 3 5

PC4. Identify if the problem has occurredbefore

8 3 5

PC5. Identify other operations that mightbe impacted by the problem

8 3 5

PC6. Ensure that no delays are caused as aresult of failure to escalate problems

8 3 5

PC7. Take appropriate materials andsample to conduct tests

8 3 5

PC8. Evaluate results to confirm suspectedreasons for non-conformance (whererequired)

10 3 7

PC9. Consider possible reasons foridentification of problems

8 3 5

PC10. Consider applicable corrections andformulate corrective action

8 3 5

PC11. Formulate action in a timelymanner

8 3 5

PC12. Communicate problem/remedialaction to appropriate authorities

8 3 5

PC13. Take corrective action in a timelymanner

10 3 7

PC14. Monitor corrective action 10 3 7PC15. Evaluate implementation ofcorrective action taken to determine if theproblem has been resolved

8 3 5

PC16. Ensure that corrective actionselected is viable and practical

8 3 5

PC17. Ensure that correct solution isidentified to an identified problem

8 3 5

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PC18. Take corrective action for problemsidentified according to the companyprocedures

8 3 5

PC19. Ensure that no delays are caused asa result of failure to take necessary action

8 3 5

PC20. Report/document problem andcorrective action in an appropriatemanner

10 5 5

PC21. Escalate problem as per laid downescalation matrix

8 3 5

PC22. Escalate the problem withinstipulated time

8 3 5

PC23. Escalate the problem in anappropriate manner

8 3 5

PC24. Ensure that no delays are caused asa result of failure to escalate problems

8 3 5

Total 200 74 126ISC/N0008:Use basichealth andsafetypractices attheworkplace

PC1. Use protective clothing/equipmentfor specific tasks and work conditions

150

10 5 5

PC2. State the name and location ofpeople responsible for health and safetyin the workplace

5 0 5

PC3. State the names and location ofdocuments that refer to health and safetyin the workplace

1 0 1

PC4. Identify job-site hazardous work andstate possible causes of risk or accident inthe workplace

9 5 4

PC5. Carry out safe working practiceswhile dealing with hazards to ensure thesafety of self and others state methods ofaccident prevention in the workenvironment of the job role

10 5 5

PC6. State location of general health andsafety equipment in the workplace

5 0 5

PC7. Inspect for faults, set up and safelyuse steps and ladders in general use

5 0 5

PC8. Work safely in and around trenches,elevated places and confined areas

5 0 5

PC9. Lift heavy objects safely using correctprocedures

5 0 5

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PC10. Apply good housekeeping practicesat all times

1 0 1

PC11. Identify common hazard signsdisplayed in various areas

6 5 1

PC12. Retrieve and/or point outdocuments that refer to health and safetyin the workplace

4 0 4

PC13. Use the various appropriate fireextinguishers on different types of firescorrectly

9 5 4

PC14. Demonstrate rescue techniquesapplied during fire hazard

10 5 5

PC15. Demonstrate good housekeeping inorder to prevent fire hazards

1 0 1

PC16. Demonstrate the correct use of afire extinguisher

4 0 4

PC17. Demonstrate how to free a personfrom electrocution

5 0 5

PC18. Administer appropriate first aid tovictims as required e.g. in case ofbleeding, burns, choking, electric shock,poisoning etc.

10 5 5

PC19. Demonstrate basic techniques ofbandaging

5 0 5

PC20. Respond promptly andappropriately to an accident situation ormedical emergency in real or simulatedenvironments

10 5 5

PC21. Perform and organize lossminimization or rescue activity during anaccident in real or simulatedenvironments

5 0 5

PC22. Administer first aid to victims incase of a heart attack or cardiac arrestdue to electric shock, before the arrival ofemergency services in real or simulatedcases

5 0 5

PC23. Demonstrate the artificialrespiration and the CPR Process

5 0 5

PC24. Participate in emergencyprocedures

5 0 5

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PC25. Complete a writtenaccident/incident report or dictate areport to another person, and send reportto person responsible

9 5 4

PC26. Demonstrate correct method tomove injured people and others during anemergency

1 0 1

Total 150 45 105ISC/N0096:Workeffectivelywith othersand manageteammembers

PC1. Accurately receive, absorb and shareinformation and instructions from thesupervisor and fellow workers, gettingclarification where required

100

5 0 5

PC2. Display appropriate communicationetiquette while working

10 0 10

PC3. Display active listening skills whileinteracting with others at work

10 0 10

PC4. Use appropriate tone, pitch andlanguage to convey politeness,assertiveness, care and professionalism

5 0 5

PC5. Display helpful behaviour by assistingothers in performing tasks in effectivemanner

10 0 10

PC6. Consult with and assist others tomaximize effectiveness and efficiency incarrying out tasks

10 0 10

PC7. Demonstrate responsible anddisciplined behaviours at the workplace

5 0 5

PC8. Escalate grievances and problems tosuperiors

5 0 5

PC9. Communicate day-to-day objectives,instructions etc. to team members

15 5 10

PC10. Guide the team members tomanage day-to-day issues at work

5 0 5

PC11. Gather concerns, feedback fromteam members and convey them toappropriate authorities

15 5 10

PC12. Escalate grievances and problemsto superiors

5 0 5

Total 100 10 90