central staff training and research institute

SYLLABUS FOR

FITTER (STEEL PLANT)

Under

APPRENTICESHIP TRAINING SCHEME

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE

MINISTRY OF LABOUR AND EMPLOYMENT

GOVERNMENT OF INDIA

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GENERAL INFORMATION

Name of the designated trade : Fitter (Steel Plant) N.C.O. Code No. : 7233.10 Duration of Apprenticeship Training : Two Years Entry Qualification : Passed 10th class examination under 10+2 system of education or its equivalent Ratio of Apprentices to Workers : 1 : 5

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List of members attended the Workshop to finalize Trade Syllabus for the trade of ‘Fitter (Steel Plant)’ under

Apprenticeship Training Scheme on 12th and 13th July, 2010 at SNTI, Jamshedpur, Jharkhand Shri S.D. Lahiri, Director, CSTARI – Chairman

Sl.No. Name of Member & Designation Organization

1 R.K. Mohanty, Sr. DGM (E&I) Jindal Steel & Power Ltd.

2 S.K. Mishra, DGM/ETL SAIL, Bokaro

3 H. Singh Usha Martin Ltd., Jamshedpur

4 Subhash Kumar Usha Martin Ltd., Jamshedpur

5 P.K. Mohanta Tata Steel Ltd.

6 Sanjay Kr. Sinha Adhunik Alloy & Power Ltd.

7 Shankar Banerjee Tata Steel Ltd.

8 Satyajit Pal Tata Steel Ltd.

9 Tapas Kumar Dhar Tata Steel Ltd.

10 S.C. Jha Tata Steel Ltd.

11 M. Mitra Tata Steel Ltd.

12 S. Bhowmik Tata Steel Ltd.

13 U.K. Choudhary Tata Steel Ltd.

14 K.N. Choubey Tata Steel Ltd.

15 Amit Kumar Tata Steel Ltd.

16 Sanjeev Kumar SAIL, Bokaro

17 S.N. Dutta, DGM (Gl.Maint.) SAIL, Bokaro

18 B.N. Prasad, DGM(HRD) SAIL Bokaro

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Sl.No. Name of Member & Designation Organization with address

19 B. Bushan Tata Steel

20 A. Nandi, Dy. Director CSTARI, Kolkata

21 N. Pandit Tata Steel Ltd.

22 A.K. Neogy, Trg. Officer CSTARI, Kolkata

23 M.K. Verma Tata Steel Ltd.

24 A.K. Bhattacharjee, JTA RDAT, Kokata

25 Anil Kumar, Jt. Director RDAT, Kolkata

26 Dr. Binod Kumar FTI, Jamshedpur

27 N.R. Arvindam, Dy. Director FTI, Jamshedpur

28 R.K. Sharma TCIL, Jamshedpur

29 Sandeep Dhir Tata Steel

30 Vijay Kumar Singh Adhunik Alloy & Power Ltd.

31 V.K. Sinha Tata Steel Ltd.

32 Biswanath Roy Tata Steel Ltd.

33 S.K. Singh Tata Steel Ltd.

34 D.M. Chowdhury Tata Steel Ltd.

35 Suresh Kumar Tata Steel Ltd.

36 Surendra Kumar Tata Steel Ltd.

37 B.B. Das Tata Steel Ltd.

38 A. Ranjan Tata Steel Ltd.

39 Sanjay Kedia Tata Steel Ltd.

40 S.B. Choudhary Tata Steel Ltd.

41 A.K. Karn Tata Steel Ltd.

42 C.K. Goswami TCIL, Jamshedpur

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Sl.No. Name of Member & Designation Organization with address

43 R.K. Mishra Tata Steel Ltd.

44 S.P. Sharma Tata Steel Ltd.

45 J. Sarkar SAIL, Rourkela

46 A.K. Mallick SAIL, Rourkela

47 S.K. Gupta Jindal Steel & Power Ltd.

48 S.N. Rana Jindal Steel & Power Ltd.

49 Major K. Satyanarayan Tata Steel Ltd.

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SYLLABUS FOR THE TRADE OF

FITTER (STEEL PLANT) UNDER

APPRENTICESHIP TRAINING SCHEME PERIOD OF TRAINING: TWO YEARS

NOTE: The period of training for the trade is two years and this consists of A) Basic Training of one and half year and B) the remaining

half year is for shop floor training. During the basic training, the trainee is exposed to fundamental of workshop practice in various shops/trade in order to prepare him/her for the trade in which he/she will be trained as an apprentice.

Outline of Training Programme: A. Basic Training in Training Institute: 80 weeks ( One and half Year) B. Shop Floor (Plant)Training : 24 weeks

C. Related Instruction (All along the training period)

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Training Structure

Sl.No. Module No. Name of Modules Duration in week

01 A.i. Introduction, general & behavioral safety 01

02 A.ii. Industrial Safety & Quality 01

03 A.iii. Basic Bench Fitting Skill 12

04 A.iv. Precision Bench Fitting Skill 12

05 A.v. Mechanical Assembly and Maintenance Practices 12

06 A.vi. Metal Cutting 04

07 A.vii. Pipe fitting & Valves 03

08 A.viii. Pump, Fan, Blower & Compressors 04

09 A.ix. Basic Electrical, Electronics, PLC & Instrumentation 04

10 A.x. Hydraulics & Pneumatics 06

11 A.xi. Environment Control and Occupational Health 01

12 A.xii. Welding & Gas Cutting 04

13 A.xiii. Rigging 02

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14 A.xiv. Bulk Material Handling (Conveyor belt, Vibratory screen, Feeders) 03

15 A.xv. Water treatment and cooling water system 01

16 A.xvi. Machine Tool Maintenance 04

17 A.xvii. Inspection, Condition Monitoring & NDT 02

18 B.i. Shop floor (Plant) training 24

19 B.ii. Revision skill 04

20 C Related Instruction Classes (Engineering Drawing, Workshop Science &

Calculation and Social Study)

Syllabus to be covered

within 2 years of training

period

Total 104

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A. BASIC TRADE TRAINING (Duration one and half year) A.i. Introduction, general & behavioral safety (1 week)

TERMINAL COMPETENCY:

After completion of this module the trainee will be aware about

Trade apprenticeship training scheme, general and behavioral safety

Overview of steel manufacturing process & machinery

Week No.

Trade Theory Trade Practical Engineering Drawing Workshop Calculation & Science

1. Familiarization with the Institute & steel industry. Machinery used in the trade and type of work done by the trainees in the trade. Importance of safety, general safety precautions observed in the Institute and in the section. Importance of the trade & trade training, Related instructions & subjects to be taught. Salient features of Apprentices‟ Act. Introduction to general, behavioral and Road safety Overview of steel manufacturing process.

Plant visit to observe steel making process & machineries used in steel plant. Use of Personal Protective Equipment. Rules & regulation of the institute

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A.ii. Industrial Safety & Quality (1 week)

TERMINAL COMPETENCY: After completion of this module the trainee will be aware of

Industrial Safety and first aid techniques

Introduction to Quality Circle

Week No.


2. Introduction of first aid. Causes and type of fires, fire precautions, precautions against outbreak of fire, different type of fire extinguishers and their uses. Precautions while working at height. Gas safety Electrical safety Quality- brief introduction of improvement techniques followed in the organization- Small group activities (SGA), Quality Circle(QC) Importance of house keeping

Usage of First aid box and practice of Cardiopulmonary Resuscitation (CPR) Usage of

- Fire extinguishers - Safety appliances- personal

protective equipment (PPEs), gas detector, gas mask, oxygen pack etc. (specific to steel industries)

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A iii. Basic Fitting Skill (12 weeks)

TERMINAL COMPETENCY: After completion of this module the trainee will be able to do the following:

Chip flat surface

Cut metal pieces of different profiles by hand hack-sawing to an accuracy of 0.5mm

Produce flat, angular and contour surfaces by filling to a dimensional accuracy of 0.20mm.

Transfer dimensions from drawing to work piece.

Drill by machine & ream by hand .

Internal & external threading by hand.

Grind the hand cutting tools used by the bench fitters to correct profile and angle.

Week No.


3. Classification, constructional and functional details of different type of vices (bench & machine), Care of vices Hacksaw, its classification, saw setting, selection of blades. Bench work safety- related hazards, risk and precautions.

Marking lines, Cut metals pieces of different profiles & sections by hack-sawing (straight, inclined & curved line) to an accuracy of 0.5 mm.

Introduction to Engineering drawing, its importance and uses in engineering fields.

Applied workshop problems involving common fractions. Science – Definition, Nomenclature, Various branches , significance and definitions of important terms.

4. Linear measurements & its units Classification, construction and functional detail of following basic measuring and marking tools : -

Steel Rule

Marking practice of straight, parallel and curved lines with odd leg calipers, steel rule, dividers, Scriber

Geometrical construction of Square, Rectangle, Triangle, Circle, Ellipse, Polygons, etc. Drawing different types of

Rounding of decimal values, use of approximation. Units – definition, Fundamental and

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Calipers,

Divider, Trammel

Try Square

Marking Punch

lines. .

derived units, system of units- FPS, CGS, MKS and SI. Unit of some important parameters – length, mass, time, density, current, voltage, pressure etc. Unit Conversion.

5. Classification, construction and functional detail of Files Filing technique

Breaking of new file teeth(on Brass) Parallel filing practice on flat surface.

Difference between the orthographic and oblique projection. Concept of planes of Projection and Quadrants. Convention of their rotation

Workshop problems related to average.

6. Precision Measuring Instruments: Concept of precision & accuracy Micrometer (outside, inside and depth) – working principle, construction, use & care, calculation of least count.

Checking and setting of micrometer Filing- flat, square and steps surfaces to an accuracy of 1.00mm (Measurement by caliper and steel rule). Adjustment of zero error.

Concept of first angle and third angle projection, difference between them. Concept of three views.

Workshop problems related to percentage.

7. -Do- Filing flat, square and steps to an accuracy of 0.5mm (Measurement by Precision Instrument).

Drawing of three views from pictorial and isometric views.

Workshop problems related to ratio and proportion.

8. Vernier calipers, principle, construction, calculation of least count, use and care.

Checking and setting of Vernier calipers Filing flat, square, steps and contour surfaces to an accuracy of 0.4mm

Letter writing:- Types of Letters viz. Normal condensed and extended (theoretical aspects). Writing of Single Stroke Vertical and Inclined letters only.

Workshop problems related to ratio and proportion.

9. Classification, construction and Transfer of dimensions from Writing of Numerals with the Workshop problems

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functional detail of following marking devices Surface plate, angle plate, marking block and V-Block.

drawing to work pieces. Finding center of a round bar with the help of „V‟ block and marking block. Filing flat, square, steps and contour surfaces to an accuracy of 0.3mm.

same specification.

related on time and work.

10. Classification, construction and functional detail of Chisel & Hammer. Chipping technique Introduction and care of pedestal grinding machine. Related hazards, risk and precautions.

Fixing of hammer handle Grinding of chisel and centre punch Chipping practice on flat surface, slots & oils grooves, and chamfer at different angle on MS plate.

Dimensioning practice. Workshop problems related on time and work.

11. Classification, construction and functional detail of Drill & Reamer. Drilling machines: -Bench, pillar & radial - Drilling operation - Cutting speed, feed & depth of cut. Related hazards, risk and precautions.

Use of drilling machine for drilling through & blind holes, counter boring and counter sinking on MS flat. Drilling on cylindrical surface. Reaming of drilled hole by hand reamer. Filing flat, square, steps and contour surfaces to an accuracy of 0.2mm.

Drawing of THREE views from pictorial and isometric views.

Scalar and vector quantities.

12. Classification, construction and functional detail of Taps & Dies

Internal & external threading by Taps & Die Making internal threads with taps (through holes and blind holes). Making external threads with dies. Prepare studs and bolt.

Drawing of three views from pictorial and isometric views.

Definition and units of terms related to motion- speed, displacement, velocity, acceleration and retardation.

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Prepare nuts and match with bolts

13. Scrapers: Types and use Marking media, Prussian blue, red lead, chalk and their special application and description.

Scraping practice on flat & curved surfaces Repair and maintain ordinary fitters tools such chisel, Hammer, Screw driver, Scriber, Centre punches, dividers, trammel and scrapers.

Drawing of three views from pictorial and isometric views

Equations of motion with acceleration and retardation on earth‟s surface. or parallel to it and vertical motion .

14. Revision & Test ( Practical & Theory)

Do Equations of motion with acceleration and retardation in vertical motion under gravity. Related problems.

A iv. Precision Fitting Skill (12 weeks)

TERMINAL COMPETENCY: After completion of this module the trainee will be able to do the following

Make male & female mating components within the dimensional accuracy of 0.10 mm.

Measure components with precision instruments.

Mark the job as per given drawing.

Use fasteners

Lap of flat surface.

Dismount and mount grinding wheel.

Week No.


15. Precision measuring instruments Classification, use , least count Vernier height gauge, Dial test indicator, Digital Micrometer, Vernier Bevel protractor

Filing practice internal and external profiles to an accuracy of 0.2mm.

Drawing of three views from pictorial and isometric views

Newton‟s Laws of Motion with proper examples, Concept of Force, Concept of Inertia i.e. inertia of motion and inertia of rest

16. Gauges- Classification and uses of Sine bar, Slip gauge, Limit gauge, Feeler gauge, thread gauge, screw pitch gauge, taper gauge.

Making square, Triangular, hexagon on MS flat to an accuracy of 0.2mm.

Drawing:- Method of dimensioning according to B.I.S. specifications. Art of Spacing the views. Drawing three views of simple machine parts using all the instruments with dimensioning.

Workshop problem on time and distance.

17. Brief Introduction to ferrous metals used for hand tools. Concept of Heat treatment of

Filing & fitting mating components within an accuracy of ± 0.15 mm & angular 45 minutes

Do Workshop problem on mixture

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ferrous metals- normalizing, annealing, tempering, case hardening. Related hazards, risk and precautions.

18. Interchangeability-Definition and its necessity, basic size, actual size, limits, deviation, Tolerance, allowance, clearance, interference, Fits-Definition, types, description with sketches. Method of expressing Tolerance as per BIS, Hole and Shaft basis (BIS standard) Related calculation on Limit, Fit and Tolerance.

Filing & fitting mating components within an accuracy of ± 0.14 mm & angular within 45 minutes

Do Measurement of force, i.e. P = ma where P is the force, m is the mass and a is the acceleration. Units of force.

19. Filing & fitting mating components within an accuracy of ± 0.13 mm & angular within 30 minutes

Do Momentum – definition and its significance. Problems.

20. Surface finish - importance, symbol, measuring techniques. Lapping & honing process

Lap and finish flat surfaces by hand only. Filing & fitting mating components within an accuracy of ± 0.12 mm & angular within 30 minutes

Do Nature of forces – composition and resolution of forces.

21. Jigs & fixtures- type & uses

Demonstration of common Jigs and Fixtures for drilling. Filing & fitting mating components within an accuracy of ± 0.12 mm & angular within 30 minutes

Do Resultant of a number of coplaner forces acting at a point. Problems.

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22. Introduction to fasteners, screw threads, related terminology and specification. Keys- types & use, (parallel, sunk, tangential, gib head, woodruff, key ways.) Related hazards, risk and precautions

Identification of various types of fasteners & locking devices, checking threads, use of various type of spanners,. Use of circlip and circlip plier. Filing & fitting mating components within an accuracy of ± 0.10mm & angular 30 minutes.

Do Profit and Loss and problems concerning to workshop practice.

23. Types of nuts, bolts, studs, locking devices for nut, wrench and spanner, pliers, screw drivers, Circlip, split pin, Concept of torque & torque wrench.

Removal of broken studs from an assembly. Tightening of nut with the help of torque wrench. Filing & fitting mating components within an accuracy of ± 0.10 mm & angular within 30 minutes.

Do Do

24. Different types of rivets and their application.

Do The law of parallelogram of forces. Triangle of forces.

25. Grinding wheel specification Bond, structure, grade, abrasives. Types and their applications, care during mounting and operation. Related hazards, risk and precautions.

Dismounting and Mounting of pedestal & hand grinding wheel Filing & fitting mating components within an accuracy of ± 0.10 mm & angular within 30 minutes.

Do Lami‟s Theorem, Polygon of forces and problems.

26. Revision & Test ( Practical & Theory)

Do Do

A. v. Mechanical Assembly and Maintenance Practice (12weeks)


Dismantle and assemble of mechanical components like bearing and couplings.

Level, align & able to static balance

Understanding lubrication system

Detect fault and undertake repair of gear boxes and other mechanical equipment

Week No.


27. Elements of mechanical power transmission, type of spindles and shafts(Universal spindle, Plain shaft, Hollow shaft, crank shaft, cam shaft). Positive and Non-positive drive, Friction drive, Gear drive, Belt drive, Chain drive and Rope drive. Basic concept of Clutches

Identification of various components of mechanical power transmission system - Shafts, couplings, keys, gears, bearings, belts, chains, pulley, rope.

Simple Exercises on Interpretation of Orthographic Projections.

Simple equations and its application to workshop practice.

28. Couplings: Concept of coupling and its type viz. Rigid coupling- Muff coupling, Flange coupling, Flexible coupling, Pin-bush coupling, Chain coupling, Gear coupling, Spider coupling, Tyre coupling, Grid coupling, Oldham-coupling, Fluid coupling, Universal coupling. Belts- Belt specification(Flat and V ) Pulleys used for belt drive. Installation of belts. Alignments of belts. Problems related to belts(Creep and slip)

Measuring shaft and coupling bore for finding out taper & ovality and to determine the type of fit. Finding out the size of key for a given set of shaft & bore. Key making, mounting of coupling on shaft with key. Installing drive belts, Measuring and adjusting the belt tension.

Do

Newton‟s Law of Gravitation – its statement and explanation. Centre of Gravity – C.G. of regular and irregular bodies. Position of C.G by calculation.

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Belt maintenance. Sheave alignment, Chain drive- Roller chain, Silent chain, alignment of sprockets, maintenance of chain drive.

29. Bearing:

Type, description and function of sliding and rolling contact bearings- Solid bush, Split bush, Collar and Pivot bearing. Plummer blocks Mounting of sliding contact bearings, measurement and adjustment of clearances in bearings.

Identification of various type of bearings. Checking size of solid bush bearing, journal and housing for proper fit. Checking split bush bearing for proper contact on journal and housing by impression testing. Mounting of split bush bearing with proper clearance, measuring clearance with the help of lead wires.

Do

Simultaneous Equations and its application to practical problems.

30. Type of Rolling contact bearings- Ball bearings- Deep groove, Angular contact, Four point contact, magneto bearing, Self aligning and Ball thrust bearing. Roller bearing- Cylindrical, Needle roller, Taper roller, Spherical roller, self aligning and Spherical roller thrust bearing . ISO bearing designation code Methods of Mounting and dismounting of rolling contact bearing. Checking and adjustment of bearing clearance.

Identification of various types of rolling contact bearing and Tools- tackles used for mounting and dismounting. Inspection and mounting of ball bearing on shaft with proper fit by i) Impact sleeve ii) hydraulic or mechanical press iii)heating – in oil bath & induction heater. Mounting of ball & roller

Do Work, Power and Energy –their units, Potential and Kinetic Energy, related problems.

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bearing in a gear box housing. Dismounting of rolling contact bearing by using i) Hydraulic puller ii) Hydraulic press and iii) Mechanical pullers.

31. Mounting-dismounting and adjustment of taper roller bearing. (Back to back, Face to face and tandem) Mounting of taper bore bearings with adopter and withdrawal sleeve. Handling and storage of bearings. Related hazards, risk and precautions.

Mounting of taper roller bearing, clearance adjustment i) back to back and ii) face to face position. Mounting of taper bore bearing with adopter sleeve. Mounting of taper bore bearing with withdrawal sleeve.

Different types of simple and intricate exercises on interpretation of orthographic projections with proper dimensioning.

Geometry:- Simple definitions of Points, Lines, Parallel straight lines. Triangle and Rectangular figures - their properties and problems concerning workshop practice.

32. Gear:

Type, description and function of gears- Spur, Single helical, Double helical, Spiral, Bevel, Straight and Spiral bevel, Worm gears, Rack and pinion. Gear terminology. Gear train- simple, compound, reverted and epicyclic. Types of Gear box Gear meshing Checking of backlash and root clearances with feeler gauge, Dial Test Indicator and lead wire. Impression testing of gear mesh with Prussian blue. Running maintenance Related hazards, risk and precautions

Overhauling of gear box (Pre cleaning, dismantling, cleaning, inspection, repair/replacement, assembly).

Do

Friction – Types of Friction and Laws of Limiting friction. Co-efficient of friction, Angle of friction, Angle of repose. Advantages and Disadvantage of friction and Problems.

33. Lubrication (Oil and Grease)

Concept of lubrication Types and properties of Oil and Grease. Methods of oil lubrication- Once through and centralized system. Methods of grease lubrication system- grease guns, centralized system. Warning & protective devices used in centralized lubrication system (Pressure switch, temperature gauge, level indicator and relief valve.) Lubrication fittings. Storage and handling Contamination control Leakage prevention- Shaft seals, sealing devices and O rings.

Identification of lubricators. Demo on centralized lubrication system(plant) Demonstration on various lubrication fittings. Making lubrication fittings Cleaning/Changing filters Identification & Fitting of different type of seals Preparation & Fitting gasket for different joint surfaces.

Do

Moment of a force-meaning and its importance. Varignon‟s Theorem and problems on it.

34. Leveling

Definition and importance of leveling, Concept of Soft foot, Methods of checking and correcting soft foot. Types of levels- Spirit level, Water level, Dumpy level, Method of leveling. Preparation of packing and shim.

Checking for soft foot, checking for leveling, calculation of required amount of packing and shim for 4 legged bed, putting shim and do final check.

Do

The circle – its various properties like angle and tangent properties. Problems on the above topics concerning to the workshop practice.

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35. Alignment:

Definition and importance of alignment, Types of misalignment, Planes of misalignment, Shaft vs. coupling alignment, Actions to be taken before alignment, Concept of Soft foot, Methods of checking and correcting soft foot, Concept of axial float, Concept of Indicator sag, Dial Test Indicator, Methods of alignment- Rim and Face readings on Stationary Machine, Rim and Face reading on machine to be seamed.

Shaft alignment, Doing the pre-check: coupling fit, eccentricity, perpendicularity, finding soft-foot with feeler, dial gauge and making corrections. Checking misalignment with the help of Taper gauge, Feeler gauge and Dial test indicator for i) Rim and Face readings on stationary machine (SM) ii)-Rim and Face reading on machine to be seamed (MTBS) Doing the related calculations to find out the rectification value adjusting for indicator sag. Preparing the appropriate shims, Correcting misalignment in vertical plane by providing calculated thickness of shim and in horizontal plane by shifting to required distance. Checking and correcting alignment with straight edge and thread: V-pulley and sprocket.

Do Do

36. Plumbing

Understanding plumbing, method of checking the verticality of a pole or structure, Calculation of packing required to make corrections.

Checking the verticality of a pole with the help of plumb bob, calculating the amount of packing required and making the corrections

Do Do

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37. Balancing

Understanding importance of balancing and reasons of unbalance. Type of unbalance. Method of static balancing. Method of correction -Adding and removing mass -Mass centering.

Locating static unbalance in a rotor, finding the correction weight.

Do Do

38. Revision & Test ( Practical)

A. vi. Metal Cutting (4 weeks)


Plain and step turning to an accuracy of 0.1 mm.

Make key in a shaper machine

Week No.


39. Introduction to lathe machines and lathe operations. Cutting tools Speed, feed & depth of cut Lathe accessories and attachment. Related hazards, risk and precautions.

Tool grinding Use of power saw Plain turning up to an accuracy of 0.1 mm.

Concepts of Sectioning, necessity, significance, conventions and characteristics. Practice on different types of sectioning – (a) Full section (b) Half section (c) Off-set section (d) Partial or logical section (e) Revolved section and (f) Removed section. Exercises on sectioning from isometric view

Logarithms – Types of logarithms eg. Naperian and Common. Meaning of logarithms its elements i.e. characteristics and mantissa. Problems on Positive Characteristics.

40. Type of taper and methods of taper turning.

Step turning up to an accuracy of 0.1 mm

Do Wheel and Axle, Screw Jack.

41.

Introduction to Shaper machine and shaper operations. Quick return mechanism of shaper. Speed, feed & depth of cut.

Making key in a shaper machine. up to an accuracy of 0.1 mm

Do

Inclined plane and problems.

42. Revision & Test Do

Do

A.vii. Pipe Fitting and Valves (3 weeks)


Internal & external threading. in pipe

Interprète different pipe symbols & circuits.

Develop, mark, cut & make fabricated bend up to tolerance 3.0mm.

Identify all types of tubes, hose and their fittings and should have idea of their assembly.

Plan, layout and execute the pipe line erection as per plant need.

Assemble and disassemble water, stream and gas line valves and do routine maintenance.

Use compression fittings.

Week No.


43. Types of pipe, tubes and different fittings. Tools used in pipe work.

Cutting & Threading of pipe. Fitting of pipes as per sketch.

Exercise on sectioning from isometric view.

Logarithms - Problems on Negative Characteristics.

44. Pipe bending and jointing methods. Different types of expansions joints and their application in steel industry. Supports and hangers.

Bending of pipes as per drawing. Making pipe joint (flaring and ferrule).

Do Nature of Liquids and Pressure of liquid inside a vessel at different positions.

45. Pipe colour code. Safety precautions to be observed while working at pipeline. Constructional detail of different type of valve & their uses like: Gate, Globe, butterfly, Diaphragm. Revision & Test

Use of different type of valve like: Gate, Globe, butterfly, Diaphragm. Assembly and disassembly of valves. Making and replacement of gaskets. Overhauling of valves applicable to steel industry.

Do Unit of pressure. Pascal‟s Law and simple problems. Types of pressure- atmospheric , absolute and gauge pressure.

A. viii. Centrifugal Pump, Fan, Blower and Compressor (4 weeks)


Start and stop of pump, Fan, Blower and compressor with proper sequence.

Dismantle, clean and assemble of pump, fan, Blower and compressor

Carry out routine inspection and maintenance of pump, fan, Blower and compressor

Week No.


46. Pump Function of pump. Types and working principle of centrifugal pump. Vertical turbine pump. Constructional detail of pump Starting and stopping Series & parallel operation of pump. Pump performance and characteristics. Cavitation, & aeration Preventive & schedule maintenance of pumps. Gland packing changing procedure. Concept of Mechanical seal Trouble shooting in pump.

Identification of various types of centrifugal pumps, their parts. Overhauling of pump. Priming of pump, Fitting gland packing. Starting and stopping of pumps. Trouble shooting in pump operation.

Free hand sketch of tools and tackles used in Fitter trade.

Factors and Different types of factorization.

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47. Fan & Blowers

Types and working principle Constructional detail of Fans & Blowers. Starting and stopping of Fans and Blowers Different parts of Fans & Blowers Concept of surge Preventive & scheduled

maintenance.

Identification of various type of fans, Blowers, their parts. Dismantling, cleaning and assembly of parts.

Do Density and Specific Gravity – its importance and significance

48. Compressors

Compression theory Types of compressors

A. Constructional detail of compressors, working mechanism

Different parts and their function. Loading unloading system Concept of air dryer Preventive & schedule maintenance.

Identification of various types of compressors, their parts. Starting and stopping of compressors Cleaning and changing of filters.

Do

Archimedes‟ principle, Law of floating bodies, Condition of equilibrium of a floating body.

49. Revision & Test

A.ix. Basic Electrical, Electronics, PLC & Instrumentation (4 weeks)

TERMINAL COMPETENCY: After completion of this module the trainee will be aware and able to do the following

Identify common electrical accessories

Test presence of power supply, AC or DC

Test and replace fuses.

Fundamental of electronics

Working principles of basic process control instruments.

Basic concept of PLC & UPS

Week No.


50. Safety in electrical shop Passive circuit elements – resistors, capacitors and inductors. Its identification and testing. Colour code. Ohm‟ law and its applications. Energy sources. Series and parallel connections.

Electrical

Safety precautions to be observed

while working in electrical shop.

Identification of electrical accessories. Making simple wiring circuits and measurement of current and voltage.

Screw Threads – Forms of Various Screw threads – Nomenclature, convention and drawing of various thread profile.

Quadratic Equations and Practical problems concerning to workshop practice.

51. Measurement current, voltage, resistance and power. Use of multimeters. Basic principle of DC generators and motors, alternators and AC motors and transformers. Various types of switches, breakers, fuses, lamps, proximity switches, relays and contactor in electrical circuits.

Testing of power supply (AC & DC) Demonstration of use of test lamp and megger. Connections of DC/AC motors and its speed control. (Demonstration only)

Do Specific Gravity of:- a) Solids heavier than water. b) Solids lighter than water. c) Solids soluble in water. Related Problems.

52. Introduction to electronics and its industrial applications. Diodes and transistors. Introduction to digital electronics – numbers system and logic gates

Identification of passive and active electronic components. Observation of waveforms in a power supply using oscilloscope. Verification of logic gate operations.

Fastening Devices – Temporary and Permanent. Meaning and difference. Temporary Device – Hexagonal Bolt, Nut, Check Nut, Washer. To draw the three views of individuals and the assembly

The Principle of Similarity:- Properties of similar triangle and their application to day to day workshop problems.

53. Introduction to industrial process control system and equipment - sensors, transmitters, and final control elements. Measurement of displacement, pressure, temperature, flow, level and speed. Application of encoders. Programmable logic controller (PLC) – General concept of working, Relay Logic Control vs PLC, Block diagram, applications.

Instrumentation Demonstration on various measuring devices Demonstration of PLC

Do Do

A. x. Hydraulics & Pneumatics (6 weeks)


Identify various types of basic hydraulic & Pneumatic components.

Dismantle, inspect and assemble various components.

Routine maintenance of hydraulic & Pneumatic system.

Week No.


54. Basic principles of Hydraulic - Advantages & limitation of hydraulic system, hydrostatic transmission, Pascal‟s law, Brahma‟s press, pressure & flow, speed of an actuator. Control valves: Different type of control valves used in hydraulic System Function of pressure control valve, directional control valve, check valve, flow control valve.

Identification and familiarisation of various types of hydraulic elements such as pumps, valves, actuators and oil filters. Overhauling of valves

Do Do

55. Function and construction of gear pump, vane pump and piston pump, cylinder & hydraulic motor.

Overhauling of - Hydraulic pumps - Hydraulic actuators.

Do Properties of Matter – Different types of Properties of Matter eg. Mechanical, Electrical, Chemical, Magnetic.

56. Auxiliary & fluid conditioner: Reservoir, filter, strainer, pressure gauge, pipe & pipe fitting, accumulator, seals & packing Simple hydraulic circuits :

Simulation of hydraulic circuits. - Simple hydraulic circuits.

Do Do

31

- Hydraulic symbols - Study of different hyd. Circuits Related hazards, risk and precautions.

57. Electro hydraulic circuit, Electrical components

- Switches - Solenoid - Relay

Practical on hydraulic circuits.

Do Do

58. Basic principle of pneumatic system. Advantages & limitation. Air preparation. Constructional & functional details of pneumatic cylinder, motor, control valves and FRL unit.

Identification of various types of pneumatic elements such as: control valves, actuators, filter, pressure regulator and lubricator.

Do Properties of Matter (Electrical):- resistivity, permittivity, permeability, resistance temp. coefficient etc.

59. Introduction to Pneumatic actuators Pneumatic Symbols Pneumatic circuit Electrical control components

- Switches - Solenoid - Relay

Overhauling of pneumatic cylinders - Practice on Pneumatic circuit

Do Do

A.xi. Environment Control and Occupational Health (1 week)

TERMINAL COMPETENCY: After completion of this module the trainee will be sensitized about the following

Major emission source and their effect on global environment.

Problems and attention needed to overcome and minimize emission.

Permissible extent as per Factory Act and rules thereof.

Occupational Hazards and ergonomical issues.

Week No.


60. Awareness on environment pollution and effects. Basic knowledge of air pollution control equipment. (ESP, Bag house, cyclone separators etc) Major emission and pollution source and their effect on environment. Control of NOX and SOX and SPM to permissible level. Standard of ambient air quality, work environment, effluent discharge. Dust handling and disposal system. Control of water pollution- effluent treatment plants Occupational health and ergonomics

Observation of - Emission and pollution control

equipment. - dust handling & disposal

system - effluent treatment plants - emission monitoring equipment

Different Methods of Preventions of rotation of Bolts - Check nut, Square headed bolt, Square headed bolt with square neck, cup headed bolt, Eye bolt, counter sunk headed bolt, rag bolt

Trigonometrical ratios and simple problems connected to workshop practice

A.xii. Welding & Gas Cutting (4 weeks)


Gas cut different profiles on mild steel plate to an accuracy of ± 1mm.

Perform arc and gas welding in flat positions on mild steel plates of different thickness.

Identify different types of welding joints.

Week No.


61. Metal Joining Methods & its advantages Welding (Fusion, Non-fusion & Pressure) Common tools used in welding Classification of welding processes Arc Welding accessories. Basic Electricity as applied to Welding Arc Length & its effects Electric Arc Welding – Manual Metal Arc Welding – effect of variations in welding procedure on weldments during manual metal Arc Welding. Basic Welding Joints & Positions: - Purpose of root gap, tacking & key hole in the job pieces during welding. Arc Welding Machines: - AC & DC Arc Welding Machine

Setting up of an arc welding machine, Straight bead practice. Edge preparation for same thickness of plate for arc welding.

Do Properties of Matter (mechanical):- Tenacity, Toughness, Malleability, Ductility, Elasticity, Plasticity Brittleness, hardness Properties and uses of copper, zinc, lead, tin, aluminum brass, bronze, solder, bearing metals, timber, rubber.

34

advantages & disadvantages of AC & DC Welding. Safety Precautions: Related to Arc welding m/c & accessories.

62. Manual Metal Arc Welding Electrodes :- Sizes & Coding Edge Preparation: - Necessity of edge preparation, Nomenclature of butt & fillet weld. Welding Symbols. Weld defects .

Laying straight-line bead on 12mm M.S. Plate in flat position and Horizontal position. Making butt , lap, tee and corner joint by arc on 12 mm M.S. Plate in Flat, Horizontal position.

Different Methods of locking of nuts:-

a) Lock nuts b) Split pin b) Slotted nut d) Symmonds nut. c) Castle nut d) Wings nut etc

Do

63. High Pressure Oxy-Acetylene Welding equipments & Accessories Safety precautions in handling Oxy-Acetylene Gas welding set. Systems of Oxy-Acetylene Welding- Flashback & backfire Types of Oxy-Acetylene flames: - Gases used in welding & Gas flame combination. Filler Rods for Gas Welding Safety in gas cutting process.

Setting up of a gas welding set. Making different types of flames with gas welding equipment. Making straight beads with and without filler rod. Making square butt joint using plates / sheets of up to 3 mm thickness.

Do Trigonometrical ratios and simple problems connected to workshop practice.

64. Principle of gas cutting. Oxy-Acetylene- Oxy L.P.G. cutting equipments. Name and application of other metal joining methods.

Setting up of gas cutting set. Setting up & adjustment of flame. Gas cut plates and sheets for the required dimensions – Straight cut, bevel cut, piercing hole and profile cutting.

Do Do

A.xiii. Rigging (2 weeks)


Load, unload and shift common and uncommon shapes of material with the help of different lifting tools and tackles.

Work at height.

Reave pulley block in different part.

Communicate with crane operator through signals.

Week No.


65. Knowledge of different tools & tackles used in rigging. Construction and capacity of wire rope. Capacity of ropes (other than wire rope). Application of knots and hitches. Care and maintenance of wire rope.

Practice of different type of knots & hitches used in material handling Reaving sets of pulley block. Splicing of manila rope. Inspection of wire rope.

Permanent Fastening Devices- Rivets – different parts and their types Different types of rivet heads.

Engineering Material – Introduction, classification, metallic and non-metallic material, physical and mechanical properties, testing of metal and hardness testing.

66. Different type of jacks, chain block and pull lift. Knowledge of different types of scaffolding. Material movement by using different rigging tools and techniques. Safety appliances & precautions in rigging. Maintenance of tools and tackles.

Use of mechanical & hydraulic jack, rope puller, chain puller, chain block, winch Inspection of tools and tackles Loading, unloading and shifting of common and uncommon shapes of material. Hand signal used in rigging.

Do Do

36

A.xiv. Bulk Material Handling (Conveyor belt, Vibratory screen, Feeders) (3 weeks)

TERMINAL COMPETENCY: After completion of this module the trainee will be aware and able to do the following

Know the conveyor system & their accessories.

Operate and maintain the material handling system effectively.

Maintain belt conveyor system.

Week No.


67. Principle & mode of material handling. Various components used in belt conveyor system & their functions. (Pulleys, idlers, scrapers, skirts, belt, take up unit system and safety devices)

Demonstration on Belt conveyor system, Vibratory screen & feeder

Rivets Joints – Lap joint and Butt or Strap joint. Lap Joint – a) Single Riveted b) Double riveted i) Chain, ii) zig – zag Butt Joint – a) Single plate or strap b) Double plate or strap

Angle of Elevation and Angle of Depression, Problems on Height and Distances taking the help of Trigonometrical Ratios Heat treatment of steel – Hardening, annealing, tempering, normalizing and case hardening

68 Vibratory screen- working mechanism. Feeders- types, working mechanism.

-Do- -Do-

69. Maintenance practice- Pulley lagging, belt sway control belt joining methods. Revision & Test

Demonstration on belt jointing

Isometric Projection:- Difference between isometric and actual scale, construction of isometric scale and simple exercises.

Solution of Triangles:- Meaning and its use, The Sine rule and the Cosine Rule. Problems related to Workshop practice.

A.xv. Water Treatment and Cooling Water System (1 week)

TERMINAL COMPETENCY: After completion of this module the trainee will be able to know the following

Awareness about equipment and operational failures due to improperly treated water.

Week No.


70.

Sources of water, Various types of impurities in water (Total suspended, dissolved solids and dissolved gases ) Soft & hard water, filtration. Awareness of water quality parameters. Introduction to cooling circuits – open /close Introduction to Cooling Towers, Heat Exchangers Revision & Test

Demonstration of water treatment plant Operation of water treatment plant Observation of Cooling Tower, Heat Exchanger

Keys and Cotter Joints Difference between Keys and Cotters Different types of Keys

Effect of force on Materials in Expanding, Bending, twisting and shearing. Solid Mensuration:- Prism, Cylinder, Pyramid, Cone, Frustum of Pyramid and of Cone, Problems concerning to workshop practice.

A.xvi. Machine Tool Maintenance (4 weeks)

TERMINAL COMPETENCY: After completion of this module, trainees will be able to inspect and do minor repairing in Lathe, Shaper, Grinder and Drilling machines

Week No.


71.

Introduction, parts & constructional details of drill, shaper, lathe, power saw and grinding machines.

Identification of different components of machine tools. Inspection of machine tool components. Demo on maintenance tools.

Gib and Cotter Joints

Relation between Load and extension – Graph – meaning of Yield Point – 1st & 2nd Ultimate tensile Stress, Breaking Stress and factor of safety.

72. Power transmission and lubrication system in machine tools.

Dismantle, inspect and do minor repairs and assemble machine tools such as drill, shaper, lathe and power saw machines.

Socket and spigot Joint

Solid Mensuration:- practice problems.

73. Accuracy testing of machine tools.

Practice on accuracy testing of machine tools.

Cotter Joint with sleeve

Stress, Strain – Different types of Strain, Hook‟s Law, Modulus of Elasticity – Young‟s Modulus, Bulk Modulus – Modules of Rigidity, Poisson‟s Ratio and Problems.

74. Various maintenance practices.

Logging checklist for machine tools. Revision & Test ( Practical

Knuckle Joint

Do

A.xvii. Inspection & Condition Monitoring (2 weeks)

TERMINAL COMPETENCY: After completion of this module the trainee will be able to do the following:

Inspect as per the check-list,

Week No.


75. Maintenance strategy – Reactive, Preventive, Predictive and proactive Importance of inspection. Type/methods of inspection-shutdown inspection, Inspection of running equipments and inspection of spare parts. Commonly used gadgets for inspection. Concept of inspection check-list.

Preparing inspection check-list, taking measurement with the help of industrial thermometer and temperature gun.

Shaft Coupling Box and Muff coupling Flanged Coupling Protected Type Solid

Do

76. Importance of condition monitoring. Various techniques used for condition monitoring. (vibration, temperature, sound and lubricant condition) Revision & Test

Use of vibration meter to take measurement.

Do Solid Mensuration:- Sphere, Spherical segment, material weight and cost problems on above topics concerning workshop practice. Heat – Definition and its importance. Temperature – Definition and its importance.

40

B. i. Shop floor(Plant) training ( 24 weeks)

TERMINAL COMPETENCY: After completion of this module the trainee will be able to

Know Iron making, Steel making and Rolling process

Overhaul the main mechanical equipments.

Maintain material handling system

Week No.


77. Note: Theoritical classes to be planned at respective Institute during 77th to 100th week. Safety at work. Accidents-their causes, General safety rules, Protective devices and guard, action taken in emergencies, Associated Safety Hazards & Risk, Occupational Health Hazards and associated environment related issues (Pollution, waste management, resource handling, its preventions, avoidance and minimization measures) during on job training.

Orientation training on Iron and Steel manufacturing Identification and recognition of equipment in the plant for iron making, steel making and rolling Overhauling / Assembly practice:

1. Bearing assembly 2. Gear / Pulley mounting 3. Seals, packing and

gasket fitting 4. Gear box overhauling 5. Pump overhauling 6. Valve overhauling 7. Jack overhauling 8. Hydraulic cylinder and

valves overhauling 9. Lifting hoist overhauling

Do Difference between heat and temperature.

78. Scales of Temperature eg. Fahrenheit , Centigrade, Kelvin- relationship between them. Lower and Upper fixed points, Fundamental Interval. Reasons for the selection of Mercury as thermometric substance.

79. Do Do

80. Do Graphs:-Dependent and Independent variable. Concept of Quadrants. Plotting of Points and other types of curves eg.

41

Different types of raw materials used for Iron making. Process of sinter, coke, iron and steel making. Awareness of rolling process. Rolling of long & flat product, - Hot & cold rolling. Material Handling-different types of appliances and tackles used for shifting, loading and unloading of machine and equipment. Chain and Pulley Blocks- Uses and working principle - Cranes and Hoists - Crab and winch, slings, rollers, bars and levers. Special precautions in the handling of heavy equipments, removal and replacement of heavy parts. Maintenance – Its importance in productivity, types and preventive maintenance. Engineering materials and their properties Heat and temperature

10. Belt jointing Maintenance welding techniques Overview of lubrication systems. Maintenance of machine tools such as drill, shaper, planner, lathe and power saw. Alignment of machines. Maintenance of conveyor belt system Maintenance of Fans , Blowers and compressor. Use and application of pneumatic tools – (i) Grinder (ii) Torque Wrench and (iii) Drill. Application of hydraulic / pneumatic systems Application of PLC, Control systems (Hydraulics, Pneumatics etc.) Changing of hydraulic / pneumatic components in the system. Changing of hoses. Observation of pressure testing of cylinders . Concept of hoseveyors. Observation on energy isolation systems (Positive Isolation). Inspection of plant machinery and system. Condition based maintenance of running equipment. Observation of Water Treatment and Cooling Water System.

Straight line curve, Parabolic and Hyperbolic curves. To solve Equations of two and three unknown with the help of Graphs.

81. Assembly Drawing of Pin Type Flexible Coupling, Oldham‟s Coupling, Universal Coupling, Claw Coupling.

Do

82. Do Units of heat – calorie. BTU and CHU and their relation. Method used for the measurement of heat i.e. Heat gained = Heat lost. Calorimetry. Specific heat, Water Equivalent of a calorimeter, Thermal Capacity – Latent heat of Fusion and latent heat of Vaporization. Related problems.

83. Do Do

84. Do Statistics – Mean, Median, Mode, Variance, Frequency

42

measurement

Use of emission and pollution control devices.

distribution , Cumulative frequency, Pie-Chart Expansion of Liquids – it has only one type of expansion e.g. Cubical expansion. Two forms - Real and Apparent – the relation between them ,Coefficient of apparent and real expansion. Problems.

85. Do Problems on statistics Expansion of Gases – Boyle‟s Law, Charle‟s law and Combined gas law. Absolute Zero - Meaning of N.T.P. Thermal conductivity & Problems.

86. Assembly Drawing of Bearings Bush Bearing.

Do

87. Assembly Drawing of Bearings Pedestal bearing in Half Section.

Set Theory – Introduction and problem related to set theory.

88. Assembly Drawing of Bearings. Plummer Block assembly.

Do

43

89. Assembly Drawing of Bearings Screw jack assembly.

Mechanical Equivalent of Heat-problems. Transmission of heat – Conduction, Convection and Radiation. Examples from industries.

90. Assembly Drawing of Bearings Wall bracket .

Do

91. Assembly Drawing of Bearings Pillar bracket .

Do

92. Assembly Drawing of Bearings Stuffing box.

Do

93. Assembly Drawing of Bearings Lathe tail stock.

Transmission of Power and motion of Belt and Pulleys:- Driver and Follower – Open and Cross belt system of belt drives. Velocity ratio. Effect of thickness of belt & slip on Velocity Ratio. Compound belt drive. Power Transmission by belt – Problems Gear, Cam and Follower, Sector & Pinion.

94. Assembly Drawing of Bearings Engine block and connecting rod assembly.

Do

44

95. Development of some common Geometrical Objects Prism

Do

96. Development of some common Geometrical Objects Cube

Do

97. Development of some common Geometrical Objects Cuboid

Do

98. Development of some common Geometrical Objects Pyramid

Do

99. Development of some common Geometrical Objects Cylinder

Do

100. Development of some common Geometrical Objects Cone

Do

B.ii. Revision Skill (4 weeks)

Week No.


101. The theory, practical, Engineering Drawing , Workshop Calculation & Science and Social Study Skill & knowledge learnt should be repeated as crash course to brush up their knowledge and hone their skill.

102.

103.

104.

46

Evaluation: A.I.T.T. evaluation on practical to be based on following combined skill area: (Total three skills needs to be judged. Sr. No. 1 is compulsory and any two other skills to be chosen from the list given)

1. Male female fitting job accuracy up to +/- 0.10mm 2. Able to make different types of knots and hitches as required by a rigger. 3. Able to make simple ( lap/ butt) welding joints by Arc. 4. Able to do mounting and dismounting of bearing 5. Able to do level. 6. Able to balance wheel. 7. Able to make pipe joints. 8. Able to prepare gaskets for flanges. 9. Able to change gland packing of pump/ valve. 10. Able to change seal of hydraulic and pneumatic cylinder.

47

LIST OF TOOLS AND EQUIPMENT FOR THE FIRST 52 WEEKS (1 YEAR) FOR A BATCH OF 16 TRAINEES.

Sl. No. Name of the Tools& Equipment Quantity

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Steel Rule 15 cm with metric graduation Try Square 10 cm blade. Caliper outside 15 cm spring Caliper inside 15 cm spring. Caliper 15 cm hermaphrodite Divider 15 cm spring Straight Scriber 15 cm. Centre Punch 10 cm Screw driver 15 cm Chisel cold flat 10 cm Hammer ball peen 0.45 kg. With handle Hammer ball peen 0.22 kg. With handle. File flat 25 cm. second cut File flat 25 cm. smooth File half round second cut 15 cm. Hacksaw frame fixed 30 cm. Safety goggles. Dot slot punch 10 cm. Tools – Instruments & General Shop Outfit per Unit. Steel Rule 30 cm to read metric. Steel Rule 60 cm. Straight edge 45 cm steel Surface plate 45 x 45 cm CI / Granite. Marking table 91 x 91 x 122 cm. Universal scribing block 22 cm.

Quantity should be sufficient as per seat surveyed and located.

48

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56.

V-Block pair 7 cm and 15 cm with clamps Square adjustable 15 cm blade. Angle plate 10 x 20 cm. Spirit Level 15 cm metal Punch letter 3 mm set. Punch number set 3 mm. Punch hollow 6 mm to 19 set of 5 Punch round 3mm x 4 mm set of 2. Portable hand drill (Electric) 0 to 6 mm Drill twist s/s 1.5 to 12 mm by 0.5 mm Drill twist S/S 8 mm to 15 mm by ½ mm Taps and dies complete set in box B.A Taps and dies complete set in box with-worth. Taps and dies complete set in box 3-18 mm set of 10 File warding 15 cm smooth File knife edge 15 cm smooth File cut saw 15 cm smooth File feather edge 15 cm smooth File triangular 15 cm smooth File round 20 cm second cut File square 15 cm second cut File square 25 cm second cut Feeler gauge 10 blades File triangular 20 cm second cut. File flat 30 cm second cut. File flat 20 cm bastard File flat 30 cm bastard. File Swiss type needle set of 12. File half round 25 cm second cut. File half round 25 cm bastard. File round 30 cm bastard. File hand 15 cm second cut.

49

57. 58 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87.

Card file. Oil Stone 15 cm x 5 cm x 2.5 cm Stone carborandum 15 cm x 5 cm x 5 cm x 4 cm. Oil Can 0.25 liters. Pliers combination 15 cm Soldering Iron 350 gm. Blow Lamp 0.50 liters. Spanner D.E. 6 -26 mm set of 10 pcs. Spanner adjustable 15 cm Interchangeable ratchet socket set with a 12 mm driver, sized 10-32 mm set of 18 socket & attachments. Box spanner set 6-25 mm set of 8 with Tommy bar. Glass magnifying 7 cm Clamp toolmaker 5 cm and 7.5 cm set of 2. Clamp “C” 5 cm Clamp “C” 10 cm Hand Reamer adjustable cover max 9 ,12,18mm – set of 3 Hand Reamer taper 4 -9mm set of 6 OR 4 -7 mm set of 4. Reamer parallel 12 - 16mm set of 5. Scraper flat 15 cm. Scraper triangular 15 cm Scraper half round 15cm Chisel cold 9 mm cross cut 9 mm diamond. Chisel cold 19 mm flat Chisel cold 9 mm round noze. Stud Extractor EZY – out Combination Set 30 cm. Micrometer 0 – 25 mm outside. Micrometer 25 – 50 mm outside. Micrometer 50 –75 mm outside. Micrometer inside 25 - 50 mm with extension rods. Vernier caliper 15 cm

50

88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98 99. 100. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110 111 112 113. 114. 115 116 117 118

Vernier height gauges 30 cm. Vernier bevel protractor. Screw pitch gauge. Wire gauge, metric standard. Drill twist Taper Shank 12 mm to 25 mm x 1.5. Drill chuck 12 mm. Pipe wrench 40 cm Pipe wrench 30 cm Pipe vice 100mm Adjustable pipe tap set BSP with die set cover pipe size 15, 20, 25,32,38,50 mm. Wheel dresser (One for 4 units). Machine vice 10 cm Machine vice 15 cm Sleeve drill Morse 0 – 1, 1 – 2, 2 – 3. Vice bench 12 cm jaws. Vice leg 10 cm jaw. Bench working 240 x 120 x 90 cm. Almirah 180 x 90 x 45 cm. Lockers with 8 drawers (standard size). Metal rack 182 x 182 x 45 cm Instructor Table Instructor Chair Black board with eraser. Fire extinguisher (For 4 Units) Fire buckets. Wing compass 25.4 cm or 30 cm. Hand hammer 1 kg. with handle. Slip Gauge as Johnson metric set. Carbide Wear Block 1 mm – 2 mm. Gauge snap Go and Not Go 25 to 50 mm by 5mm. Set of 6 pcs. Gauge plug single 3 ended 5 to 55 by 5 mm. Set of 11 pcs.

51

119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141

Gauge telescopic upto 150 mm. Dial test indicator .01 mm on stand Sine bar 125 mm. Sine bar 250 mm. Lathe tools H.S.S. tipped set. Lathe tools bit 6 mm x 75 mm. Lathe tools bit 8 mm x 75 mm. Lathe tools bit 10 mm x 85mm. Arm strong type tool bit holder R.H. Arm strong type tool bit holder L.H. Arm strong type tool bit holder straight. Stilson wrenches 25 cm Pipe cutter 6 mm to 50 mm wheel type. Pipe bender spool type up to 25 mm. with stand manually operated. Adjustable pipe chain tonge to take pipes up to 300 mm. Adjustable spanner 38 cm long. Dial vernier caliper 0 – 200 mm LCO 0.05 mm. (Universal type). Screw thread micrometer with interchangeable 0-25mm. Pitch anvils for checking metric threads 60. Depth micrometer 0-25 mm. 0.01 mm. Vernier caliper 0-150 mm. L.C. 0.02 mm. Comparators stand with dial indicator LC 0.01mm. Engineer‟s try square (knife-wedge) 150 mm blade.

52

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

. LIST OF ADDITIONAL TOOLS FOR ALLIED TRADE IN WELDING Transformer welding set 150 amps. – continuous welding current, with all accessories and electrode holder Welder cable to carry 200 amps. With flexible rubber cover Lungs for cable Earth clamps. Arc welding table (all metal top) 122 cm X 12 cm X 60 cm with positioner. Oxy – acetylene gas welding set equipment with hoses, regulator and other accessories. Gas welding table with positioner Welding torch tips of different sizes Gas lighter. Trolley for gas cylinders. Chipping hammer. Gloves (Leather) Leather apron. Spindle key for cylinder valve. Welding torches 5 to 10 nozzles. Welding goggles. Welding helmet with coloured glass Tip cleaner

53

The specifications of the items in the above list have been given in Metric Units. The items which are available in the market nearest of the specification as mentioned above, if not available as prescribed should be procured Measuring instruments such as steel rule which are graduated both English and Metric Units may be procured, if available. General Machinery Installation Drilling machine pillar sensitive 0-20 mm cap with swivel table motorised with chuck & key. Drilling machine bench sensitive 0-12 mm cap motorised with chuck and key. Grinding machine (General purpose) D.E. pedestal with 20 cm dia wheels rough and smooth with twist drill grinding – attachment. LIST OF REFERENCE :

SL.No. Titles Code

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Spring calipers. Punches Matric steel scales for Engineers. Engineers square. V-Block. Steel straight edges. Hacksaw blades. Bench vices. Chisels (Cold) Engineer‟s file. Surface plates (C.I.) Twist drill Vernier depth gauges. External micrometers. A dimension for counter – sinks & counter bores. Internal micrometers. Vernier calipers. Vernier height gauges. Gib – head keys and key ways. Taper keys and key ways.

IS : 4052 – 1967 IS : 413 – 1974 IS : 1481 - 1970 IS : 2013 – 1972 IS : 2049 – 1974 IS : 2220 – 1962 IS : 2504 - 1977 IS : 2586 - 1975 IS : 402 - 1974 IS : 1931 - 1972

IS IS : 2285 – 1974 ISIS : 5100 – 1960 to 5106

IS : 4213 – 1967 IS : 2967 – 1964 IS : 3406 – 1975 IS : 2966 – 1964 IS : 3651 – 1974 IS : 2021 – 1964 IS : 2203 – 1974

54

21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45.

Screw driver. Bevel protractors. Reamers. Thread cutting dies. Metric screw threads (Metric thread pitch-gauges) Dial gauges. Hexagonal bolts and nuts. Feeler gauges (m.m. ranges). Spanners, open jaw. Thickness of sheet & diameters of wire Centre drills. Lathe, sizes for general purpose. Recommendations for tapping drill sizes. Needle files. Plain plug gauges. Plain ring gauges (Go) Snap gauges (Go & No Go) Slip gauges. Ball & roller Bearings gauging practice for. V-belt for Industrial purposes. Limits & fits for engineering, recommendations for Plain limit gauges tolerances for. Rivets for general purposes. Tapers for general engineering purposes. General Engineering drawing.

IS : 2292 – 1974 IS : 884 – 1972 IS : 4229 – 1970 IS : 1836 – 1961 IS : 1859 – 1961 IS : 4211 – 1967 IS : 2092 – 1962 IS : 2038 – 1968 IS : 3179 – 1976 IS : 2028 – 1968 IS : 1137 – 1950 IS : 6703 – 1977 IS : 2392 – 1963 IS : 3230 – 1970 IS : 3152 – 1965 IS : 6137 – 1871 IS : 3435 – 1972 IS : 3477 – 1973 IS : 2984 – 1966 IS : 4025 – 1967 IS : 2404 – 1974 IS : 919 – 1963 IS : 3455 – 1971 IS : 2155 – 1961 IS : 3458 – 1966 IS : 696 –

Note: - Those additional items are to be provided for the Allied Trade Training where the welding trade does not exist.

central staff training and research institute

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