WELDER (WELDING & INSPECTION) - Directorate General of ...

Welder (Welding & Inspection)

GOVERNMENT OF INDIA MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP

DIRECTORATE GENERAL OF TRAINING

COMPETENCY BASED CURRICULUM

WELDER (WELDING & INSPECTION)

(Duration: One Year)

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL- 3

SECTOR – CAPITAL GOODS AND MANUFACTURING


WELDER (WELDING & INSPECTION)

(Engineering Trade)

(Revised in 2015)

Version: 1.1

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL- 3

Developed By

Ministry of Skill Development and Entrepreneurship Directorate General of Training

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN-81, Sector-V, Salt Lake City,

Kolkata – 700 091


The DGT sincerely acknowledges contributions of the Industries, State Directorates, Trade

Experts, Domain Experts and all others who contributed in revising the curriculum. Special

acknowledgement is extended by DGT to the following expert members who had contributed

immensely in this curriculum.

List of Expert members participated in preparation of course curriculum of Welder (Welding & Inspection) trade

S No. Name & Designation

Shri/Mr./Ms. Organization Remarks

MEMBERS OF SECTOR MENTOR COUNCIL

1. Dr.G. Buvanashekaran, AGM WRI, Trichy - Chairman Chairman

2. Dr.K. Ashok Kumar, AGM BHEL, Trichy Member

3. Prof. Jyothi Mukhopadhya IIT, Ahmedabad Member

4. B. Pattabhiraman, MD GB Engineering, Tricgy Member

5. Dr. Rajeev Kumar IIT, Mandi Member

6. Dr. Vishalchauhan IIT, Mandi Member

7. D.K. Singh IIT, Kanpur Member

8. Navneet Arora IIT, Roorkee Member

9. R. K. Sharma, Head SDC, JBM Group, Faridabad Member

10. Puneet Sinha, Deputy Director MSME, New Delhi Member

MENTOR

11. Deepankar Mallick, DDG (C&P) DGT HQ Mentor

MEMBERS OF CORE GROUP

12. M Thamizharasan, JDT CSTARI, Kolkata Member

13. M Kumaravel, DDT FTI , Bangalore Team Leader

14. Sushil Kumar, DDT DGTHq, Member

15. S.P. Khatokar, T.O. ATI, Mumbai Member

16. V.L. Ponmozhi, TO CTI, Chennai Member

17. D. Pani, TO ATI, Howrah Member

18. Amar Singh, TO ATI, Ludhiyana Member

19. Gopalakrishnan, TO NIMI, Chennai Member

20. Manjunatha B.S., JTO GITI, K.G.F. Karnataka Member

21. Venugopal PC ITI Chalakudi, Kerala Member

ACKNOWLEDGEMENT


S No. Topics Page No.

1. Course Information 1

2. Training System 2-5

3. Job Role 6-7

4. General Information 8-9

5. NSQF Level Compliance 10

6. Learning Outcome 11-12

7. Learning Outcome with Assessment Criteria 13 - 18

8. Syllabus 19-26

9. Syllabus - Core Skill

9.1 Core Skill – Workshop Calculation & Science and Engineering Drawing

27-29

9.2 Core Skill – Employability Skill 30-33

10. Annexure I

List of Trade Tools & Equipment 34-36

List of Tools & Equipment for Employability Skill 37

11. Annexure II - Format for Formative Assessment 38

CONTENTS

1


During the one-year duration a candidate is trained on subjects Professional Skill,

Professional Knowledge, Engineering Drawing, Workshop Science & Calculation and

Employability Skills. In addition to this a candidate is entrusted to make/do project work and

Extra Curricular Activities to build up confidence. The practical skills are imparted in simple

to complex manner & simultaneously theory subject is taught in the same fashion to apply

cognitive knowledge while executing task. The practical part starts with basic welding work

viz. gas welding, arc gauging etc. and performing different testing methods viz. bend test,

tensile test, impact test, dye penetrant inspection etc. The broad components covered

under Professional Skill subject are as below:

The practical part starts with basic welding and the candidate is imparted training on

viz., Welding (Gas & Arc), pipe joints, MS sheet / plate joints which leads to multi-skilling.

The safety aspects cover components like OSH&E, PPE, Fire extinguisher, First Aid etc.

Perform visual inspection of metal by using different methods like bend test, tensile test,

hardness test, impact test etc. The learner does practical of surface defects inspection by

dye penetrant inspection, sub surface inspection by magnetic particle testing method,

interprets radiographic films of weldments and prepares reports after welding inspection.

Professional Knowledge subject is simultaneously taught in the same fashion to

apply cognitive knowledge while executing task. In addition, components like Physical

properties of engineering materials, different types of iron, properties and uses, Heat &

Temperature are also covered under theory part.

Projects need to be completed by the candidates in a group. In addition to above

components the core skills components viz., Workshop calculation & science, Engineering

drawing, employability skills are also covered. These core skills are essential skills which are

necessary to perform the job in any given situation.

1. COURSE INFORMATION

2


2.1 GENERAL

Directorate General of Training (DGT) under Ministry of Skill Development &

Entrepreneurship offers range of vocational training courses catering to the need of

different sectors of economy/ Labour market. The vocational training programmes are

delivered under aegis of National Council of Vocational Training (NCVT). Craftsman Training

Scheme (CTS) and Apprenticeship Training Scheme (ATS) are two pioneer programmes of

NCVT for propagating vocational training.

Welder (Welding & Inspection) trade under CTS is delivered nationwide through

network of ITIs. The course is of one year duration. It mainly consists of Domain area and

Core area. The Domain area (Trade Theory & Practical) imparts professional skills and

knowledge, while Core area (Workshop Calculation science, Engineering Drawing and

Employability Skills) imparts requisite core skills, knowledge and life skills. After passing out

of the training program, the trainee is awarded National Trade Certificate (NTC) by NCVT

which is recognized worldwide.

Broadly candidates need to demonstrate that they are able to:

Read & interpret technical parameters/document, plan and organize work

processes, identify necessary materials and tools;

Perform task with due consideration to safety rules, accident prevention regulations

and environmental protection stipulations;

Apply professional skill, knowledge, core skills & employability skills while

performing jobs.

Check the job/assembly as per drawing for functioning, identify and rectify errors in

job/assembly.

Document the technical parameters related to the task undertaken.

2.2 CAREER PROGRESSION PATHWAYS

Can take admission in diploma course in notified branches of Engineering by lateral

entry.

Can join Apprenticeship programme in different types of industries leading to

National Apprenticeship certificate (NAC).

Can join Crafts Instructor Training Scheme (CITS) in the trade for becoming instructor

in ITIs.

2. TRAINING SYSTEM

3


2.3 COURSE STRUCTURE

Table below depicts the distribution of training hours across various course elements

during a period of one year:-

S No. Course Element Notional Training

Hours

1 Professional Skill (Trade Practical) 1050

2 Professional Knowledge (Trade Theory) 252

3 Workshop Calculation & Science 84

4 Engineering Drawing 126

5 Employability Skills 110

6 Library & Extracurricular activities 58

7 Project work 160

8 Revision & Examination 240

Total 2080

2.4 ASSESSMENT & CERTIFICATION

The trainee will be tested for his skill, knowledge and attitude during the period of the

course and at the end of the training program as notified by the Government of India (GoI)

from time to time. The employability skills will be tested in the first year itself.

a) The Formative Assessment during the period of training will be done by Formative

Assessment Method by testing for assessment criteria listed against learning outcomes. The

training institute has to maintain an individual trainee portfolio as detailed in assessment

guideline. The marks of Formative Assessment will be as per the template (Annexure – II).

b) The final assessment will be in the form of summative assessment method. The All India

Trade Test for awarding NTC will be conducted by NCVT as per the guideline of Government

of India. The pattern and marking structure is being notified by Govt. of India from time to

time. The learning outcome and assessment criteria will be the basis for setting question

papers for final assessment. The examiner during final examination will also check the

individual trainee’s profile as detailed in assessment guideline before giving marks for

practical examination.

2.4.1 PASS REGULATION

For the purposes of determining the overall result, weightage of 100% is applied for

six months and one year duration courses and 50% weightage is applied to each

examination for two years courses. The minimum pass percent for Practical is 60% &

minimum pass percent for Theory subjects is 33%.

4


2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial

barriers to assessment. The nature of special needs should be taken into account while

undertaking the assessment. Due consideration should be given while assessing for

teamwork, avoidance/reduction of scrap/wastage and disposal of scrap/waste as per

procedure, behavioral attitude, sensitivity to the environment and regularity in training. The

sensitivity towards OSHE and self-learning attitude are to be considered while assessing

competency.

Assessment will be evidence based comprising the following:

Job carried out in labs/workshop

Record book/ daily diary

Answer sheet of assessment

Viva-voce

Progress chart

Attendance and punctuality

Assignment

Project work

Evidences of formative assessments are to be preserved until forthcoming

examination for audit and verification by examining body. The following marking pattern to

be adopted while assessing:

Performance Level Evidence

(a) Weightage in the range of 60%-75% to be allotted during assessment

For performance in this grade, the candidate should produce work which demonstrates attainment of an acceptable standard of craftsmanship with occasional guidance, and due regard for safety procedures and practices

Demonstration of good skill in the use of hand tools, machine tools and workshop equipment.

60-70% accuracy achieved while undertaking different work with those demanded by the component/job.

A fairly good level of neatness and consistency in the finish.

Occasional support in completing the project/job.

(b) Weightage in the range of 75%-90% to be allotted during assessment

For this grade, a candidate should produce work which demonstrates attainment of a reasonable standard of craftsmanship, with

Good skill levels in the use of hand tools, machine tools and workshop equipment.

5


little guidance, and regard for safety procedures and practices

70-80% accuracyachieved while undertaking different work with those demanded by the component/job.

A good level of neatness and consistency in the finish.

Little support in completing the project/job.

(c) Weightage in the range of more than 90% to be allotted during assessment

For performance in this grade, the candidate, with minimal or no support in organization and execution and with due regard for safety procedures and practices, has produced work which demonstrates attainment of a high standard of craftsmanship.

High skill levels in the use of hand tools, machine tools and workshop equipment.

Above 80% accuracy achieved while undertaking different work with those demanded by the component/job.

A high level of neatness and consistency in the finish.

Minimal or no support in completing the project.

6


Brief description of Job Role: Welder, Gas; fuses metal parts together using welding rod and oxygen acetylene flame.

Examines parts to be welded, cleans portion to be joined, holds them together by some suitable

device and if necessary makes narrow groove to direct flow of molten metal to strengthen joint.

Selects correct type and size of welding rod, nozzle etc. and tests welding, torch. Wears dark

glasses and other protective devices while welding. Releases and regulates valves of oxygen and

acetylene cylinders to control their flow into torch. Ignites torch and regulates flame gradually.

Guides flame along joint and heats it to melting point, simultaneously melting welding rod and

spreading molten metal along joint shape, size etc. and rectifies defects if any. May join part at

various spots to prevent distortion of shape, form dimension etc. May preheat materials like cast

iron prior to welding.May also weld by other gases such as argon coal etc.

Welder, Electric; Arc Welder fuses metals using arc-welding apparatus and electrodes (welding

material). Examines parts to be welded, cleans them and sets joints together with clamps or any

other suitable device. Starts generator or transformer (welding apparatus and regulates current

according to material and thickness of welding. Clamps one lead (insulated wire carrying current

from generator) to part to be welded, selects required type of electrode and clamps it to holder

connected with other lead). Generates sparks between electrode and joint, simultaneously

guiding and depositing melting electrode uniformly for welding. Takes precautionary measures

such as wearing rubber gloves, holding welding screen of dark glass etc. May join parts first at

various points for holding at specified angles, shape, form and dimension.

Welder, Machine; operates gas or electric welding machine to joint metal parts by fusion. Sets

machine for operation by igniting burners and adjusting flames or by switching on current.

Regulates flow of gas or current and adjusts machine according to material to be welded. Checks

cooling system and adjusts movement of conveyor, if any. Feeds material to be welded with

either one by one or in batch according to type of machine and welds them by pressing paddle,

or by automatic arrangements. May use fixtures or other suitable devices for mass production

work. Is designated as SPOT WELDER, FLASH WELDER, etc. according to machine and type of

work done.

Gas Cutter; Flame Cutter cuts metal to required shape and size by gas flame either manually or

by machine. Examines material to be cut and marks it according to instruction of specification.

Mounts template and sets machine to cut to specifications. Makes necessary connections and

fits required size of nozzle or burner in welding torch. Releases and regulates flow of gas in

nozzle or burner, ignites and adjusts flame. Guides flame by hand or machine along cutting line

at required speed and cuts metal to required size. May use oxyacetylene or any other

appropriate gas flame.

Brazer; fuses metal parts by heating using flux and fillings. Cleans and fastens parts to be joined

face to face by wire, by seaming or by any other suitable means and prepares paste of flux and

3. JOB ROLE

7


fillings. Applies it to joint and hearts in furnace or by torch to melt filling into joint.Allows it to

cool down. Examines joint and cleans them by filing, buffing etc.

Reference NCO-2015:

(i) 7212.0100 – Welder, Gas

(ii) 7212.0200 – Welder, Electric

(iii) 7212.0300 – Welder, Machine

(iv) 7212.0400 – Gas Cutter

(v) 7212.0500 – Brazer

8


Name of the Trade Welder (Welding & Inspection)

NCO - 2015 7212.0100, 7212.0200, 7212.0300, 7212.0400, 7212.0500

NSQF Level Level-3

Duration of Craftsmen Training

One year

Entry Qualification Passed 8thclass examination

Unit Strength (No. Of Student)

20

Space Norms 80 sq. m

Power Norms 16 KW

Instructors Qualification for

1. Welder (Welding & Inspection) Trade

Degree in Mechanical/ Metallurgy/ Production Engineering/

Mechatronics from recognized university with one year experience

in relevant field.

OR

Diploma in Mechanical and allied from recognized technical board

of education with two years experience in relevant field.

NTC/ NAC passed in “Welder” Trade or relevant trade with 3 years' post qualification experience. Essential Qualification: Craft Instructor Certificate in relevant trade under NCVT.

Note:

1. Out of two Instructors required for the unit of 1+1, one

must have Degree/Diploma and other must have NTC/NAC

qualifications.

2. Instructor qualification for W/shop Calculation, Engg

Drawing & Employability Skill would be as per the training

manual.

2. Workshop Calculation & Science

Degree in Engineering with one year experience. OR

Diploma in Engineering with two years experience. Essential Qualification: Craft Instructor Certificate in RoD& a course under NCVT.

3. Engineering Drawing Degree in Engineering with one year experience. OR

4. GENERAL INFORMATION

9


Diploma in Engineering with two years experience. OR

NTC/ NAC in the Draughtsman (Mechanical) with three years experience. Essential Qualification: Craft Instructor Certificate in RoD& A course under NCVT.

4. Employability Skill MBA OR BBA with two years experience OR Graduate in Sociology/ Social Welfare/ Economics with Two years experience OR Graduate/ Diploma with Two years experience and trained in Employability Skills from DGT institutes.

AND Must have studied English/ Communication Skills and Basic Computer at 12th / Diploma level and above.

OR Existing Social Studies Instructors duly trained in Employability Skills from DGT institutes.

List of Tools and Equipment

As per Annexure – I

Distribution of training on Hourly basis: (Indicative only)

Total hours /week

Trade practical

Trade theory

Workshop Cal. &Sc.

Engg. Drawing

Employability skills

Extra-curricular

activity

40 Hours 25 Hours 6 Hours 2 Hours 3 Hours 2 Hours 2 Hours

10


NSQF level for Welder (Welding & Inspection) trade under CTS: Level - 3

As per notification issued by Govt. of India dated- 27.12.2013 on National Skill

Qualification Framework total 10 (Ten) Levels are defined. Each level of the NSQF is associated with a set of descriptors made up of five outcome statements, which describe in general terms, the minimum knowledge, skills and attributes that a learner needs to acquire in order to be certified for that level. Each level of the NSQF is described by a statement of learning outcomes in five domains, known as level descriptors. These five domains are:

a. Process b. professional knowledge c. professional skill d. Core skill and e. Responsibility

The Broad Learning outcome of Welder (Welding & Inspection) trade under CTS mostly

matches with the Level descriptor at Level- 3.

The NSQF level-3 descriptor is given below:

Level Process Required Professional Knowledge

Professional Skill Core Skill Responsibility

Level 3 Person may carry out a job which may require limited range of activities routine and predictable

Basic facts, process and principle applied in trade of employment

recall and demonstrate practical skill, routine and repetitive in narrow range of application

Communication written and oral, with minimum required clarity, skill of basic arithmetic and algebraic principles, personal banking, basic understanding of social and natural environment

Under close supervision Some Responsibility for own work within defined limit.

5. NSQF LEVEL COMPLIANCE

11


Learning outcomes are a reflection of total competencies of a trainee and assessment will be carried out as per the assessment criteria.

6.1 GENERIC LEARNING OUTCOME

1. Apply safe working practices.

2. Comply with environment regulation and housekeeping

3. Interpret & use Company terminology and technical communication

4. Demonstrate knowledge of concept and principles of basic arithmetic, algebraic

calculations and apply knowledge of specific area to perform practical operations.

5. Understand and explain basic science in the field of study including basic electrical.

6. Read and apply engineering drawing for different application in the field of work.

7. Understand and explain the concept in productivity, quality tools, and labour welfare

legislation and apply such in day to day work to improve productivity & quality.

8. Explain energy conservation, global warming and pollution and contribute in day to

day work by optimally using available resources.

9. Explain personnel finance, entrepreneurship and manage/organize related task in

day to day work for personal & societal growth.

10. Understand and apply basic computer working, basic operating system and uses

internet services to get accustomed& take benefit of IT developments in the

industry.

6.2 SPECIFIC LEARNING OUTCOME

11. Join MS sheet by Gas welding in different positions.

12. Join MS plate by SMAW in different positions.

13. Perform straight, bevel & circular cutting on MS plate by Oxy-acetylene cutting

process.

14. Perform different types of MS pipe joints by Gas welding (OAW).

15. Weld different types of MS pipe joints by SMAW.

16. Join Aluminium & Stainless Steel sheets by GTAW in different position.

17. Perform Arc gauging on MS plate.

18. Join MS sheets/ plates by GMAW in various positions using different modes of metal

transfer.

19. Perform visual inspection / testing of welded joint.

20. Perform destructive Inspection of metal by using different methods like, Bend test,

tensile test, hardness test and Impact test etc.

6. LEARNING OUTCOME

12


21. Perform surface defects inspection by Dye penetrant Inspection.

22. Perform sub surface inspection by Magnetic particle testing method.

23. Perform sub surface inspection by Ultrasonic Flaw detector of weldments.

24. Perform Interpretation of Radiographic films of weldments.

13


GENERIC LEARNING OUTCOME

LEARNING OUTCOME ASSESSMENT CRITERIA

1. Apply safe working practices. 1.1 Follow and maintain procedures to achieve a safe working environment in line with occupational health and safety regulations and requirements and according to site policy.

1.2 Recognize and report all unsafe situations according to site policy.

1.3 Identify and take necessary precautions on fire and safety hazards and report according to site policy and procedures.

1.4 Identify, handle and store / dispose off dangerous goods and substances according to site policy and procedures following safety regulations and requirements.

1.5 Identify and observe site policies and procedures in regard to illness or accident.

1.6 Identify safety alarms accurately.

1.7 Report supervisor/ Competent of authority in the event of accident or sickness of any staff and record accident details correctly according to site accident/injury procedures.

1.8 Identify and observe site evacuation procedures according to site policy.

1.9 Identify Personal Productive Equipment (PPE) and use the same as per related working environment.

1.10 Identify basic first aid and use them under different circumstances.

1.11 Identify different fire extinguisher and use the same as per requirement.

2. Comply with environment

regulation and

housekeeping.

2.1 Identify environmental pollution & contribute to the avoidance of instances of environmental pollution.

2.2 Deploy environmental protection legislation & regulations

2.3 Take opportunities to use energy and materials in an environmentally friendly manner

2.4 Avoid waste and dispose waste as per procedure

2.5 Recognize different components of 5S and apply the same in the working environment.

3. Interpret & use Company

terminology and technical

3.1 Obtain sources of information and recognize information.

3.2 Use and draw up technical drawings and documents.

7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

14


communication. 3.3 Use documents and technical regulations and occupationally related provisions.

3.4 Conduct appropriate and target oriented discussions with higher authority and within the team.

3.5 Present facts and circumstances, possible solutions &use English special terminology.

3.6 Resolve disputes within the team.

3.7 Conduct written communication.

4. Demonstrate knowledge of

concept and principles of

basic arithmetic, algebraic

calculations and apply

knowledge of specific area to

perform practical operations.

4.1 Final examination to test basic skills on arithmetic, and algebra.

4.2 Their applications will also be assessed during execution of assessable outcome and also tested during theory and practical examination.

5. Understand and explain

basic science in the field of

study including basic

electrical.

5.1 Final examination to test basic skills on science in the field of study including basic electrical


6. Read and apply engineering

drawing for different

application in the field of

work.

6.1 Final examination to test basic skills on engineering drawing.


7. Understand and explain the

concept in productivity,

quality tools, and labour

welfare legislation and apply

such in day to day work to

improve productivity &

quality.

7.1 Final examination to test the concept in productivity, quality tools and labour welfare legislation.

7.2 Their applications will also be assessed during execution of assessable outcome.

8. Explain energy conservation,

global warming and pollution

and contribute in day to day

work by optimally using

available resources.

8.1 Final examination to test knowledge on energy conservation, global warming and pollution.


9. Explain personnel finance,

entrepreneurship and

manage/organize related

9.1 Final examination to test knowledge on personnel finance, entrepreneurship.


15


task in day to day work for

personal & societal growth.

10. Understand and apply basic

computer working, basic

operating system and uses

internet services to get

accustomed & take benefit

of IT developments in the

industry.

10.1 Final examination to test knowledge on basic computer working, basic operating system and uses internet services.


16


SPECIFIC LEARNING OUTCOME

LEARNING OUTCOME ASSESSMENT CRITERIA

11. Join MS sheets by Gas

welding in different

positions.

11.1 Plan and select the nozzle size, working pressure type of flame, filler rod as per requirement.

11.2 Prepare, set and tack the pieces as per drawing.

11.3 Setting up the tacked joint in specific position.

11.4 Deposit the weld following proper welding technique and safety aspect.

11.5 Carry out visual inspection to ascertain quality weld joint.

12. Join MS plates by SMAW

in different positions.

12.1 Plan and select the type & size of electrode, welding current, type of edge preparation etc. as per requirement.


12.3 Set up the tacked pieces in specific position.

12.4 Deposit the weld maintaining appropriate arc length, electrode angle, welding speed, weaving technique and safety aspects.

12.5 Clean the welded joint thoroughly.

12.6 Carry out visual inspection for appropriate weld joint.

12.7 Inspect the weld using DPT/MPT.

13. Perform straight, bevel &

circular cutting on MS

plate by Oxy-acetylene

cutting process.

13.1 Plan and mark on MS plate surface for straight/bevel/circular cutting.

13.2 Select the nozzle size and working pressure of gases as per requirement.

13.3 Set the marked plate properly on cutting table.

13.4 Perform the straight and bevel cutting operation maintaining proper techniques and all safety aspects.

13.5 Perform the circular cutting operation by using profile cutting machine maintaining proper techniques and all safety aspects.

13.6 Clean the cutting burrs and inspect the cut surface for soundness of cutting.

14. Perform different types of

MS pipe joints by Gas

welding (OAW).

14.1 Plan and prepare the development for a specific type of pipe joint.

14.2 Mark and cut the MS pipe as per development.

14.3 Select the size of filler rod, size of nozzle, working pressure etc.

14.4 Set and tack the pieces as per drawing.

14.5 Deposit the weld bead maintaining proper technique and safety aspects.

14.6 Inspect the welded joint visually for poor penetration, uniformity of bead and surface defects.

17


15. Weld different types of

MS pipe joints by SMAW.

15.1 Plan and prepare the development for a specific type of pipe joint.

15.2 Mark and cut the MS pipe as per development.

15.3 Select the electrode size and welding current for welding.

15.4 Set and tack the pieces as per drawing.

15.5 Deposit the weld bead maintaining proper technique and safety aspects.

15.6 Insect the welded joint visually for root penetration, uniformity of bead and surface defects.

16. Join Aluminum &

Stainless Steel sheets by

GTAW in different

position.

16.1 Select power source as per material, size and type of Tungsten electrode, welding current, gas nozzle size, gas flow rate and filler rod size as per requirement.


16.3 Set up the tacked joint in specific position.

16.4 Deposit the weld by adapting proper welding technique and safety aspects.

16.5 Carry out visual inspection to ensure quality of welded joint.

16.6 Inspect the weld using Dye-penetration Test (DPT)/Magnetic particle Test (MPT).

16.7 Identify the materials and measuring instruments.

16.8 Carry out butt & fillet welds on sheet metals.

16.9 Mark on plates on structural sections- I, L, C etc.

16.10 Perform gas cutting of MS plate, I section and channels profile cutting.

16.11 Perform root run welding by using backing strip.

16.12 Install GTAW welding plant.

16.13 Carry out beading by TIG.

16.14 Carry out square butt and corner joint on MS by TIG.

16.15 Perform butt, T and corner joint on SS sheet.

16.16 Carry out straight line beads on MS plate by CO2 welding.

16.17 Carry out lap T and corner joint on MS plate by CO2 16.18 welding.

16.19 Carry out single V –butt joint by CO2 welding.

16.20 Develop pipe weld joint and fit up on elbow and T-joint.

16.21 Perform pipe joint root welding by TIG.

17. Perform Arc gauging on

MS plate.

17.1 Plan and select the size of electrode for Arc gouging.

17.2 Select the polarity and current as per requirement.

17.3 Perform gouging adapting proper gouging technique.

17.4 Clean and check to ascertain the required stock removed.

18. Join MS sheets/ plates by

GMAW in various

positions using different

18.1 Select size of electrode wire, welding voltage, gas flow rate, wire feed rate as per requirement.


18.3 Set up the tacked joint in specific position.

18


modes of metal transfer. 18.4 Deposit the weld adapting proper welding technique and safety aspects.

18.5 Carry out visual inspection to ensure quality of welded joint.

18.6 Inspect the weld using Dye-penetration (DPT)/Magnetic particle Test (MPT).

19. Perform visual inspection

of welded joint.


19.2 Carry out visual inspection to ascertain quality of weld joint.

19.3 Locate and mark out visual defects if any for repair.

19.4 Record the observation in the Inspection report.

20. Perform destructive

Inspection of metal by using

different methods like,

Bend test, tensile test,

hardness test and Impact

test etc.

20.1 Cut the welded joint to the required size.

20.2 Prepare the specimen according to the testing method.

20.3 Test with the DT method.


21. Perform surface defects

inspection by Dye

penetrantInspection.


21.2 Carry out visual inspection to ascertain quality of weld joint.

21.3 Locate and mark out visual defects if any for repair.


22. Perform sub surface

inspection by Magnetic

particle testing method.



22.3 Select the appropriate testing methods.

22.4 Perform testing of welded joints adapting standard operating procedure.

22.5 Accept/reject the job based on test result.

23. Perform sub surface

inspection by Ultrasonic

Flaw detector of

weldments.




23.4 Perform testing of welded joints adapting standard operating procedure.

23.5 Use correct angle probes as per metals and its density.

23.6 Save the graph image for reference.


24. Interpret Radio graphic

films of weldment.





19


SYLLABUS - WELDER (WELDING & INSPECTION)

DURATION: ONE YEAR

Week No.

Reference Learning Outcome

Professional Skills (Trade Practical)

With Indicative Hours

Professional Knowledge (Trade Theory)

1 Apply safe working

practices.

Induction training: 1. Familiarization with the

Institute. (2hrs.) 2. Importance of trade

Training.(2hrs.) 3. Machinery used in the trade.

(3hrs.) 4. Introduction to safety

equipment and their use etc. (6hrs.)

5. Hack sawing, filing square to dimensions. (6hrs.)

6. Marking out on MS plate and punching. (6hrs.)

General discipline in the Institute. Elementary First Aid. Importance of Welding in Industry. Safety precautions in Shielded Metal Arc Welding, and Oxy-Acetylene Welding and Cutting.

2 Join MS sheet by

Gas welding in

different positions.

7. Setting up of Arc welding machine & accessories and striking an arc. (10hrs.)

8. Setting of oxy-acetylene welding equipment, Lighting and setting of flame. (15hrs.)

Introduction and definition of welding. Arc and Gas Welding Equipments, tools and accessories. Various Welding Processes and its applications. Arc and Gas Welding terms and definitions.

3 -do- 9. Fusion run without and with filler rod on M.S. sheet 2 mm thick in flat position. (15hrs.)

10. Edge joint on MS sheet 2 mm thick in flat position without filler rod. (5hrs.)

11. Marking and straight line cutting of MS plate. 10 mm thick by gas. (5hrs.)

Different process of metal joining methods: Bolting, riveting, soldering, brazing, seaming etc. Types of welding joints and its applications. Edge preparation and fit up for different thickness. Surface Cleaning

4 Join MS plate by

SMAW in different

positions.

12. Straight line beads on M.S. plate 10 mm thick in flat position. (15hrs.)

13. Weaved bead on M.S. plate 10mm thick in flat position. (10hrs.)

Basic electricity applicable to arc welding and related electrical terms & definitions. Heat and temperature and its terms related to welding. Principle of arc welding. And characteristics of arc.

5 -do- 14. Square butt joint on M.S. Common gases used for welding

8. SYLLABUS

20


sheet 2 mm thick in flat Position. (10hrs.)

15. Fillet "T" j oint on M.S. Plate 10 mm thick in flat position. (15hrs.)

&cutting, flame temperatures and uses. Chemistry of oxy-acetylene flame. Types of oxy-acetylene flames and uses. Oxy-Acetylene Cutting Equipment principle,parameters and application.

6 -do- 16. Beveling of MS plates 10 mm thick. By gas cutting. (10hrs.)

17. Open corner joint on MS sheet 2 mm thick in flat Position. (9hrs.)

18. Fillet lap joint on M.S. plate 10 mm thick in flat position. (6hrs.)

Arc welding power sources: Transformer, Motor Generator set, Rectifier and Inverter type welding machines and its care & maintenance. Advantages and disadvantages of A.C. and D.C. welding machines.

7 -do- 19. Circular gas cutting on MS plate 10 mm thick by profile cutting machine. (9hrs.)

20. Fillet "T" joint on M S she et 2 mm thick in flat position. (8hrs.)

21. Open Corner joint on MS plate 10 mm thick in flat position. (8hrs.)

Welding positions as per EN &ASME: flat, horizontal, vertical and over head position. Weld slope and rotation. Welding symbols as per BIS & AWS.

8 -do- 22. Fillet Lap joint on MS sheet 2 mm thick in flat position. (12hrs.)

23. Single "V" Butt joint on M S plate 12 mm thick in flat position (1G). (13hrs.)

Arc length - types - effects of arc length. Polarity: Types and applications.

9 -do- 24. Square Butt joint on M.S. sheet. 2 mm thick in Horizontal position. (8hrs.)

25. Straight line beads and multi layer practice on M.S. Plate 10 mm thick in Horizontal position. (8hrs.)

26. F "T" 10 mm thick in Horizontal position. (9hrs.)

Calcium carbide properties and uses. Acetylene gas properties and generating methods. Acetylene gas Purifier, Hydraulic back pressure valve and Flash back arrestor.

10 Perform straight,

bevel & circular

cutting on MS plate

by Oxy-acetylene

cutting process.

27. Fillet Lap joint on M.S. sheet 2 mm thick in horizontal position. (10hrs.)

28. Fillet Lap joint on M.S. plate 10 mm thick in horizontal position. (15hrs.)

Oxygen gas and its properties Production of oxygen by Air liquefaction. Charging process of oxygen and acetylene gases. Oxygen and Dissolved Acetylene gas cylinders and Color coding for different gas cylinders.

21


Gas regulators, types and uses.

11 -do- 29. Fusion run with filler rod in vertical position on 2mm thick M.S sheet. (8hrs.)

30. Square Butt joint on M.S. sheet. 2 mm thick in vertical position. (8hrs.)

31. Single Vee Butt joint on M.S. plate 12 mm thick in horizontal position (2G). (9hrs.)

Oxy acetylene gas welding Systems (Low pressure and High pressure). Difference between gas welding blow pipe(LP & HP) and gas cutting blowpipe. Gas welding techniques. Rightward and Leftward techniques.

12 -do- 32. Weaved bead on M.S Plate 10mm in vertical position. (8hrs.)

33. Fillet "T" joint on M.S sheet 2 mm thick in vertical position. (8hrs.)

34. F "T" 10 mmthick in vertical position. (9hrs.)

Arc blow - causes and methods of controlling. Distortion in arc & gas welding and methods employed to minimize distortion. Arc Welding defects, causes and Remedies.

13 Perform different

types of MS pipe

joints by Gas

welding (OAW).

35. Structural pipe welding butt joint on MS pipe 0 50 and 3mm WT in 1G position. (15hrs.)

36. Fillet Lap joint on M.S. Plate 10 mm in vertical position. (10hrs.)

Specification of pipes, various types of pipe joints, pipe welding positions, and procedure. Difference between pipe welding and plate welding.

14 -do- 37. Open Corner joint on MS plate 10 mmthick in vertical position. (10hrs.)

38. Pipe welding - Elbow joint on MS pipe 0 -50 and 3mm WT. (15hrs.)

Pipe development for Elbow joint, "T" joint, Y joint and branch joint. Manifold system.

15 -do- 39. Pip e welding "T" joint on MS pipe 0 5 0 and 3mm WT. (10hrs.)

40. Single "V" Butt joint on M S p late 12 mm thick in vertical position (3G). (15hrs.)

Gas welding filler rods, specifications and sizes. Gas welding fluxes - types and functions. Gas Brazing & Soldering: principles, types fluxes & uses. Gas welding defects, causes and remedies.

16 Weld different

types of MS pipe

joints by SMAW.

41. Pipe welding 45 ° angle joint on MS pipe 0 50 and 3mm WT. (15hrs.)

42. Straight line beads on M.S. plate 10mm thick in over head position.(10hrs.)

Electrode: types, functions of flux, coating factor, sizes of electrode Coding of electrode as per BIS, AWS. Effects of moisture pick up. Storage and baking of electrodes. Special purpose electrodes and their applications.

22


17 -do- 43. Pipe Flange joint on M.S plate with MS pipe 0 50 mm X 3mm WT.(10hrs.)

44. F "T"10 mmthick in over head position.(15hrs.)

Weldability of metals, importance of pre heating, post heating and maintenance of inter pass temperature.

18 -do- 45. Pipe welding butt joint on MS pipe 0 50 and 5 mm WT. in 1G position.(15hrs.)

46. Fillet Lap joint on M.S. plate 10 mm thick in over head position.(10hrs.)

Classification of steel. Welding of low, medium and high carbon steel and alloy steels.

19 -do- 47. Single "V" Butt joint on MS plate 10mm thick in over head position(4G).(10hrs.)

48. Pipe butt joint on MS pipe 0 50mm WT 6mm (1G Rolled).(15hrs.)

Effects of alloying elements on steel. Stainless steel: types- weld decay and weldability.

20 Join Aluminium &

Stainless Steel

sheets by GTAW in

different position.

Perform Arc gauging

on MS plate.

49. Square Butt joint on S.S. sheet. 2 mm thick in flat position.(9hrs.)

50. Square Butt joint on S.S. Sheet 2 mm thick in flat position.(8hrs.)

51. Square Butt joint on Brass sheet 2 mm thick in flat position.(8hrs.)

Brass - types - properties and welding methods. Copper - types - properties and welding methods.

21 -do- 52. Square Butt & Lap joint on M.S. sheet 2 mm thick by brazing.(9hrs.)

53. Single "V" butt joint C.I. plate 6mm thick in flat position.(8hrs.)

54. Arc gouging on MS plate 10 mm thick.(8hrs.)

Aluminium and its alloys, properties and weldability, welding methods. Arc cutting & gouging.

22 -do- 55. Square Butt joint on Aluminium sheet. 3 mm thick in flat position.(10hrs.)

56. Bronze welding of cast iron (Single "V" butt joint) 6mm thick plate. (15hrs.)

Cast iron and its properties types. Welding methods of cast iron.

23-24 Industrial Training / Project Work

25-26 Revision

27 Join MS sheets/ plates by GMAW in various positions using different

57. Handling of measuring instruments - Steel tape, Vernier Caliper, spirit level, micrometer, Try square,

Outline of various subjects to be covered Quality and its definition Inspection methods Measuring Instruments and least

23


modes of metal transfer.

Plum drop etc. (15hrs.) 58. Simple dimensional

measurements using the appropriate instruments. (10hrs.)

count Dimension report preparation Types of metals & characteristics Classification of steels

28 Join Aluminium &

Stainless Steel

sheets by GTAW in

different position.

59. Identification of materials. (25hrs.)

Types of welding process Advantages & limitations Various types of welding power sources.

29 -do- 60. Simple gas welding exercises on sheet metals (Butt & Fillet welds). (25hrs.)

Welding parameters Different types of weld joints Gas welding principle and application Safety in welding and cutting.

30 -do- 61. Lay out marking on plates.(5hrs.)

62. Marking on structural sections - I, L, C etc.(12hrs.)

63. Development marking for cylinders.(8hrs.)

Marking with pantograph Gas cutting principles, basic CNC profile cutting. Different size and shape of rolled sections.

31 -do- 64. Gas cutting of MS plate, I section and channels Profile cutting.(25hrs.)

Basic welding metallurgy (pre heating, post heating etc.) Welding symbol and its nomenclatures Effects of heat.

32 -do- 65. Making square butt joint on MS sheet in down hand position by SMAW.(10hrs.)

66. Making single V - Butt joint on MS sheet in down hand position by SMAW.(9hrs.)

67. Use of backing strip for root runs welding.(6hrs.)

Principle of Shielded metal Arc welding (SMAW) Function of flux and baking requirements Selection of electrodes and coating factors Different type of edge preparation. Welding procedure - Edge preparation and fit up, use of backing strips and bars, root run welding and cover pass welding.

33 -do- 68. Setting up GTAW welding plant. Beading practicing by TIG Square butt and corner joint on M.S by TIG Butt, T and Corner joint on S.S sheet.(25hrs.)

Introduction to GTAW welding TIG welding equipments Advantages of TIG welding process Accessories - HF unit and DC suppressor. Tungsten electrode, Types, sizes, and uses. Type of shielding gases Purging Methods Parameter setting.

34 -do- 69. Setting up GMAW welding plant Straight line beads on MS plate by CO2 welding Lap T & corner joint on MS plate by CO2 welding Single V - Butt joint by CO2

GMAW welding process Power source & accessories Wire Feed unit Modes of metal transfer - Dip, Globular, spray &pulsed transfer and its significance Welding wire

24


welding.(25hrs.) types and specification & Parameter setting.

35 -do- 70. Pipe weld joint development &fit up on elbow and T- joint.(25hrs.)

Classifications of pipes and tubes Various types of pipe joints Development of pipe - elbow and T- joint.

36 -do- 71. Pipe joint root welding by TIG.(25hrs.)

Various equipments used for root pass cleaning Pipe bending Pipe welding procedure.

37 Perform visual inspection / testing of welded joint.

72. Visual Inspection of welds. (15hrs.)

73. Application of weld gauge. (10hrs.)

Types of Welding defects (Cracks, Inclusions, Incomplete penetration, Lack of fusion, Under cut, Burn through, Overlap etc.)

38 Perform destructive

Inspection of metal

by using different

methods like, Bend

test, tensile test,

hardness test and

Impact test etc.

74. Dimensional inspection of weldments using weld measuring gauges.(25hrs.)

Causes for defects. Remedial measures Inspection methods.

39 -do- 75. Hardness Testing.(5hrs.) 76. Bend Testing of

Weldments.(10hrs.) 77. Tensile testing.(10hrs.)

Mechanical Testing of Metals. Principles, Applications of - Hardness testing ( Rockwell and Brinell ) - Impact testing ( Izod and Charpy ) - Tensile testing and Bend Test.

40 Perform surface

defects inspection

by Dye penetrant

Inspection.

78. Evaluation of welding defects using Dye penetrant testing method on plate. (25hrs.)

Non destructive Testing of Metals. Visual inspection Dye penetrant test - Principles - Advantages -Limitations - Types of Penetrants - Cleaners -Dwelling time.

41 -do- 79. Evaluation of welding defects using Dye penetrant testing method on pipe.(25hrs.)

Dye penetrant test (DPT) - Types of Penetrants -Cleaners - Dwelling time

42 Perform sub surface inspection by Magnetic particle testing method.

80. Evaluation of welding defects using Magnetic Particle Testing method.(25hrs.)

Magnetic Particle Test (MPT)- Principles - Advantages - Limitations -Types of Magnetation - Current requirements -Testing equipments - Indication and Interpretations.

43 Perform sub surface

inspection by

81. Ultrasonic Flaw detector- Setting & calibration.(25hrs.)

Ultrasonic Testing (UT)- Principles - Advantage -Limitation

25


Ultrasonic Flaw

detector of

weldments.

44 -do- 82. Ultrasonic Flaw detector- probe identification & application on pipes & plates. (25hrs.)

Types of UT Waves - Attenuation - Types of Transducers - Couplants - Equipments and controls - Type of scans.

45 -do- 83. Ultrasonic Flaw detector- application on weldments of various metals. (25hrs.)

Measuring Techniques - Standard reference blocks. - Contact Testing procedure - Indications and interpretations.

46 Perform

Interpretation of

Radiographic films

of weldments.

84. Study of IIW / ASTM reference Radiograph.(25hrs.)

Radiographic testing (RT) - Principles – Advantages. - Limitations - Basic Radiation Physics - X-Rays -Gama Rays - Radiation Sources - Types of Films -Film Processing.

47 -do- 85. Interpretation of Radiographic films.(25hrs.)

Radiographic Sensitivity - Image Quality indicators- Radiographic Techniques – Radiographic Interpretation and Evaluation - Radiation Hazard and Control.

48 -do- 86. Preparation of welding inspection reports. (25hrs.)

Certification methods for welding inspectors. Codes and standards for welding inspection. Welding procedure specifications (WPS) Procedure qualification Record (PQR).

49-50 Industrial training / Project work

51 Revision

52 Examination

Note: -

1. The instructor may design their own project and also inputs from local industry may

be taken in designing such new project.

2. The project should broadly cover maximum skills in the particular trade and must

involve some problem solving skill. Emphasis should be on Teamwork: Knowing the

power of synergy/ collaboration, work to be assigned to a group (Group of at least 4

trainees). The group should demonstrate Planning, Execution, Contribution and

Application of Learning. They need to submit a project report.

26


3. If the instructor feels that for execution of specific project more time is required then

he may plan accordingly in appropriate time during the execution of normal trade

practical.

4. Abbreviations:

OAW - Oxy-Acetylene gas Welding

OAGC - Oxy-Acetylene Gas Cutting

F - Fitting

WT - Wall Thickness.

SMAW - Shielded Metal Arc welding

GTAW - Gas Tungsten Arc Welding

SAW - Submerged Arc Welding

GMAW - Gas Metal Arc Welding

MIG - Metal Inert Gas

27


9.1 WORKSHOP CALCULATION SCIENCE & ENGINEERING DRAWING

DURATION: ONE YEAR

S No. Workshop Calculation and Science Engineering Drawing

1. General simplifications - BODMAS rule Fraction-Addition, Subtraction, multiplication and Division-Problems. Decimal-Addition, Subtraction, Multiplication, and Division-Problems

Importance of Engineering Drawing and its Knowledge. Use of Drawing Instruments.

2. Conversion of Fraction to Decimal and vice-versa.

Letters, Numbers and Alphabets as per BIS Layout of Drawing Sheet & Title Block.

3. Square roots: The Square and Square root of a Whole Number and Decimal

Drawing of straight lines, Geometrical constructions, rectangles, Circles, Polygons etc.

4. Percentage - Changing Percent to Decimal and Fraction and vice - versa - applied problem

Use of different types of line and symbols for drawing. Importance & dimensioning techniques as per BIS.

5. Concept on Ratio and Proportion-Direct and Inverse Proportion, simple applied problems

Isometric views with dimensions such as Cube, Rectangular Block, Cylinder, etc

6. Algebraic Symbols and Fundamentals Addition, Subtraction, Multiplication and Division-Problems.

Orthographic Projection in 3rd angle, as per BIS. Orthographic Projection in 1st angle, as per BIS (Concept only).

7. Introduction and Importance of Science and Calculation to the Trade skill

Plan and elevation of simple objects like Hexagonal Block, square Block, Circular Block, tapered Block, etc.

8. - System of Units - British, Metric and S. I. Units for Length, Mass, Area, Volume, Capacity and time. Conversions between British and Metric Systems.

Views of simple Hollow and Solid Blocks with Dimensions.

9. Density & Specific gravity Mass, weight. Definition and units

Construction of Orthographic Projection from the given Isometric view of simple shaped Blocks in 3rd angle method.

10. Metals: Properties and uses of cast iron, wrought iron, plain carbon steels and alloy steels. Difference between metals, non-metals and alloys.

Construct an Orthographic Projection from the given Isometric view of shaped Blocks in 1st angle method.

11. Properties and uses of Copper, Zinc, Lead, Tin and Aluminum.

Reading of simple Engineering drawing.

9. SYLLABUS - CORE SKILLS

28


12. Properties and uses of Brass, Bronze, Rubber, Timber and insulating materials.

Reading of Engineering drawing related to missing lines and missing views.

13. Concept of heat and temperature. Difference between heat and temperature. Effects of Heat, Thermometric Scales such as a Celsius, Fahrenheit and Kelvin, Temperature measuring Instruments -types of thermometers and pyrometers

Simple orthographic drawing- from the given Isometric views of simple objects.

14. Conversions between the above Scales of Temperature. Units of Heat-Calorie, B.Th.U& C.H.U., joule. Concept of Specific Heat, Latent Heat, problems on Heat Loss and Heat Gain.

Conventional representation of Materials as per BIS. Views of simple solid bodies cut by section plane on drawing standard methods. (Full and Half Sections) BIS.

15. Definition of Force - Units of Force in M.K.S.& S.I. Systems . Concept of Pressure and its Units in different systems

Surface Development of Prism, Pyramid.

16. Fundamental algebraic formulae viz. (a+b)2, (a-b)2, etc. Simple Equations - related problems.

Cylinder Projection and Development, Cone Projection and Development. Examples based on right cones.

17. Menstruation- Concept of 2D figures and 3D object. Definition of perimeter, area and volume : related units - perimeter and area of plain figures like Square, Rectangle, Equilateral Triangle, Isosceles Triangle, Right Angled Triangle, Scalene Triangle-simple applied Problems

Types of rivets with dimensions as per BIS.

18. Perimeter and area: Hexagon, Circle, Circular ring, Sector & Ellipse- Problems.

Types of Riveted joints.

19. Volume and Weight of Simple Solid bodies such as Cube, Cuboids, Cone, Cylinder and Hollow Cylinder- applied Problems.

Hexagonal nuts and bolts with dimensions.

20. Finding the capacity in Litres of Square, Rectangular, Hexagonal, Conical and Cylindrical Shaped Vessels

Screw threads with their dimensions as per BIS.

21. Finding the lateral Surface Area and Total Surface Area of Square, Rectangular, Hexagonal, Conical and Cylindrical Shaped Vessels by using simple calculator

Different symbols used in related trade.

22. Trigonometrical ratios. Trigonometrical tables. Basic trigonometrical calculations by using scientific calculator

Exercises on application of Trade related symbols.

23. Electricity, Current, voltage, Power, resistance, Conductors, insulators, Ohm's law, Types of Current, Effects of current and related problems. Watt, kW, Electrical

Freehand sketching of hand tools of the trade.

29


energy - watt-hour, kWH& Board of trade unit.

24. Concept of fuse. Concept of open circuit, closed circuit, Short circuit. Concept of earthing.

Free hand sketching of simple objects related to trade.

25. Units of work in M.K.S, System and S .l. Unit of Work- Simple Problems.

Reading of fabricated engineering drawing

26. Units of Power such as Watt and Horse Power. Definition of I.H.P., B.H.P. and Efficiency.

------------------------

27. Definition of Energy: Potential Energy and Kinetic Energy. Law of Conservation of Energy, S.I. Unit of Energy. Simple Problems in P.E. and K.E.

------------------------

28. Linear motion - Speed, velocity, acceleration, retardation

------------------------

29. Definition and units of Stress, Strain. Ultimate stress & breaking stress. Explanation of terms shear force and bending moment. Simple problems on stress & strain

------------------------

30


9.2 EMPLOYABILITY SKILLS

DURATION: 110 Hours

1. English Literacy Duration: 20 Hrs. Marks : 09

Pronunciation Accentuation (mode of pronunciation) on simple words, Diction (use of word and speech)

Functional Grammar

Transformation of sentences, Voice change, Change of tense, Spellings.

Reading Reading and understanding simple sentences about self, work and environment

Writing Construction of simple sentences Writing simple English

Speaking / Spoken English

Speaking with preparation on self, on family, on friends/ classmates, on know, picture reading gain confidence through role-playing and discussions on current happening job description, asking about someone's job habitual actions. Cardinal (fundamental) numbers ordinal numbers. Taking messages, passing messages on and filling in message forms Greeting and introductions office hospitality, Resumes or curriculum vita essential parts, letters of application reference to previous communication.

2. I.T. Literacy Duration: 20 Hrs. Marks : 09

Basics of Computer Introduction, Computer and its applications, Hardware and peripherals, Switching on-Starting and shutting down of computer.

Computer Operating System

Basics of Operating System, WINDOWS, The user interface of Windows OS, Create, Copy, Move and delete Files and Folders, Use of External memory like pen drive, CD, DVD etc, Use of Common applications.

Word processing and Worksheet

Basic operating of Word Processing, Creating, opening and closing Documents, use of shortcuts, Creating and Editing of Text, Formatting the Text, Insertion & creation of Tables. Printing document. Basics of Excel worksheet, understanding basic commands, creating simple worksheets, understanding sample worksheets, use of simple formulas and functions, Printing of simple excel sheets.

Computer Networking and Internet

Basic of computer Networks (using real life examples), Definitions of Local Area Network (LAN), Wide Area Network (WAN), Internet, Concept of Internet (Network of Networks), Meaning of World Wide Web (WWW), Web Browser, Web Site, Web page and Search Engines. Accessing the Internet using Web Browser, Downloading and Printing Web Pages, Opening an email account and use of email. Social media sites and its implication.

Information Security and antivirus tools, Do's and Don'ts in Information Security, Awareness of IT - ACT, types of cyber crimes.

31


3. Communication Skills Duration: 15 Hrs. Marks : 07

Introduction to Communication Skills

Communication and its importance Principles of Effective communication Types of communication - verbal, non verbal, written, email, talking on phone. Non verbal communication -characteristics, components-Para-language Body language Barriers to communication and dealing with barriers. Handling nervousness/ discomfort.

Listening Skills Listening-hearing and listening, effective listening, barriers to effective listening guidelines for effective listening. Triple- A Listening - Attitude, Attention & Adjustment. Active Listening Skills.

Motivational Training

Characteristics Essential to Achieving Success. The Power of Positive Attitude. Self awareness Importance of Commitment Ethics and Values Ways to Motivate Oneself Personal Goal setting and Employability Planning.

Facing Interviews

Manners, Etiquettes, Dress code for an interview Do's & Don'ts for an interview.

Behavioral Skills Problem Solving Confidence Building Attitude

4. Entrepreneurship Skills Duration: 15 Hrs. Marks : 06

Concept of Entrepreneurship

Entrepreneur - Entrepreneurship - Enterprises:-Conceptual issue Entrepreneurship vs. management, Entrepreneurial motivation. Performance & Record, Role & Function of entrepreneurs in relation to the enterprise & relation to the economy, Source of business ideas, Entrepreneurial opportunities, The process of setting up a business.

Project Preparation & Marketing analysis

Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept & application of PLC, Sales & distribution Management. Different Between Small Scale & Large Scale Business, Market Survey, Method of marketing, Publicity and advertisement, Marketing Mix.

Institutions Support

Preparation of Project. Role of Various Schemes and Institutes for self-employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non financing support agencies to familiarizes with the Policies /Programmes& procedure & the available scheme.

Investment Project formation, Feasibility, Legal formalities i.e., Shop Act, Estimation

32


Procurement &Costing, Investment procedure - Loan procurement - Banking Processes.

5. Productivity Duration: 10 Hrs. Marks : 05

Benefits Personal / Workman - Incentive, Production linked Bonus, Improvement in living standard.

Affecting Factors Skills, Working Aids, Automation, Environment, Motivation - How improves or slows down.

Comparison with developed countries

Comparative productivity in developed countries (viz. Germany, Japan and Australia) in selected industries e.g. Manufacturing, Steel, Mining, Construction etc. Living standards of those countries, wages.

Personal Finance Management

Banking processes, Handling ATM, KYC registration, safe cash handling, Personal risk and Insurance.

6. Occupational Safety, Health and Environment Education Duration: 15 Hrs. Marks : 06

Safety & Health Introduction to Occupational Safety and Health importance of safety and health at workplace.

Occupational Hazards

Basic Hazards, Chemical Hazards, Vibroacoustic Hazards, Mechanical Hazards, Electrical Hazards, Thermal Hazards. Occupational health, Occupational hygienic, Occupational Diseases/ Disorders & its prevention.

Accident & safety Basic principles for protective equipment. Accident Prevention techniques - control of accidents and safety measures.

First Aid Care of injured & Sick at the workplaces, First-Aid & Transportation of sick person.

Basic Provisions

Idea of basic provision legislation of India.

safety, health, welfare under legislative of India.

Ecosystem Introduction to Environment. Relationship between Society and Environment, Ecosystem and Factors causing imbalance.

Pollution Pollution and pollutants including liquid, gaseous, solid and hazardous waste.

Energy Conservation

Conservation of Energy, re-use and recycle.

Global warming Global warming, climate change and Ozone layer depletion.

Ground Water Hydrological cycle, ground and surface water, Conservation and Harvesting of water.

Environment Right attitude towards environment, Maintenance of in -house environment.

33


7. Labour Welfare Legislation Duration: 05 Hrs. Marks : 03

Welfare Acts Benefits guaranteed under various acts- Factories Act, Apprenticeship Act, Employees State Insurance Act (ESI), Payment Wages Act, Employees Provident Fund Act, The Workmen's compensation Act.

8. Quality Tools Duration: 10 Hrs. Marks : 05

Quality Consciousness

Meaning of quality, Quality characteristic.

Quality Circles Definition, Advantage of small group activity, objectives of quality Circle, Roles and function of Quality Circles in Organization, Operation of Quality circle. Approaches to starting Quality Circles, Steps for continuation Quality Circles.

Quality Management System

Idea of ISO 9000 and BIS systems and its importance in maintaining qualities.

House Keeping Purpose of House-keeping, Practice of good Housekeeping.

Quality Tools Basic quality tools with a few examples.

34


LIST OF TOOLS AND EQUIPMENT

WELDER (WELDING & INSPECTION) (For Batch of 20 Candidates)

S No. Name of the Tool & Equipment Specification Quantity

A. TRAINEES TOOLS KIT

1. Welding helmet fiber #21 nos.

2. Welding hand shield fiber #21 nos.

3. Chipping hammer with metal handle 250 Grams #21 nos.

4. Chisel cold flat 19 mm x 150 mm #21 nos.

5. Centre punch 9 mm x 127 mm #21 nos.

6. Dividers 200 mm #21 nos.

7. Stainless steel rule 300mm #21 nos.

8. Scriber 150 mm double point #21 nos.

9. Flat Tongs 350mm long #21 nos.

10. Hack saw frame fixed 300 mm #21 nos.

11. File half round bastard 300 mm #21 nos.

12. File flat 350 mm bastard #21 nos.

13. Hammer ball pane 1 kg with handle #21 nos.

14. Tip Cleaner #21 nos.

15. Try square 6" #21 nos.

B. GENERAL MACHINERY SHOP OUTFIT

16. Spindle key 4 Nos.

17. Screw Driver 300mm blade and 250 mm blade

1 No. each

18. Number punch 6 mm 2 set

19. Letter punch 6 mm 2 set

20. Magnifying glass 100 mm. dia 2 nos.

21. Universal Weld measuring gauge 2 nos.

22. Earth clamp 600A 6 nos.

23. Spanner D.E. 6 mm to 32mm 2 nos. sets

24. C-Clamps 10 cm and 15 cm 2 each

25. Hammer sledge double faced 4 kg 1 No.

26. S.S tape 5 meters flexible in case 1 No.

27. Electrode holder 600 amps #7 Nos.

28. H.P. Welding torch with 5 nozzles 2 sets

29. Oxygen Gas Pressure regulator double stage 2 nos.

30. Acetylene Gas Pressure regulator double stage

2 nos.

31. CO2 Gas pressure regulator, with flow meter 1 set

32. Argon Gas pressure regulator with flow meter

2 set

ANNEXURE-I

35


33. Metal rack 182 cm x 152 cm x 45 cm 1 No.

34. First Aid box 1 No.

35. Steel lockers with 8 Pigeon holes 2 nos.

36. Steel almirah / cupboard 2 nos.

37. Black board and easel with stand 1 No.

38. Flash back arrester (torch mounted) 4 pairs

39. Flash back arrester (cylinder mounted) 4 pairs

40. Auto Darkening Welding Helmet 2 nos.

C. GENERAL INSTALLATION

41. Welding Transformer with all accessories 400A , OCV 60 - 100 V, 60% duty cycle

1 sets

42. Welding Transformer or Inverter based welding machine with all accessories

300A , OCV 60 - 100 V, 60% duty cycle

1 sets

43. D.C Arc welding rectifiers set with all accessories

400 A. OCV 60 -100 V, 60% duty cycle

1 sets

44. GMAW welding machine 400A capacity with air cooled torch, Regulator, Gas preheater, Gas hose and Standard accessories

1 set

45. AC/DC GTAW welding machine with water cooled torch 300 A, Argon regulator, Gas hose, water circulating system and standard accessories.

1set

46. Air Plasma cutting equipment with all accessories

capacity to cut 12 mm clear cut

01 set

47. Air compressor suitable for air plasma cutting system

01 no.

48. Fillet weld gauge 8 Nos.

49. Welding Simulators for SMAW/ GTAW/ GMAW

1 each (Optional)

50. Pug cutting machine Capable of cutting Straight & Circular with all accessories

1 set

51. Pedestal grinder fitted with coarse and medium grain size grinding wheels

dia. 300 mm 01 no.

52. Bench grinder fitted with fine grain size silicon carbide green grinding wheel

dia. 150 mm 01 no.

53. AG 4 Grinder 2 Nos.

54. Suitable gas welding table with fire bricks 2 Nos.

55. Suitable Arc welding table with positioner 6 Nos.

56. Trolley for cylinder (H.P. Unit) 2 nos.

57. Hand shearing machine capacity to cut 6 mm sheets and flats

01 no.

58. Power saw machine 18'' 01 no.

59. Portable drilling machine (Cap. 6 mm) 01 no.

60. Oven, electrode drying 0 to 250°C, 10 kg capacity 01 no.

61. Work bench 340x120x75 cm with 4 bench vices of 150 mm jaw opening

4 sets

36


62. Oxy Acetylene Gas cutting blow pipe 2 sets

63. Oxygen, Acetylene Cylinders 2 each*

64. CO2 cylinder 1 No *

65. Argon gas cylinder 1 No *

66. Anvil 12 sq. inches working area with stand 01 no.

67. Swage block 01 no.

68. Die penetrant testing kit 1 set

69. Magnetic particle testing Kit 1 set

70. Fire extinguishers foam type and CO2 type 01 no.

71. Fire buckets with stand 4 nos.

72. Portable abrasive cut-off machine 01 no.

73. IIW/ASTM reference radiographic standard for steel fusion welds

1 set

74. Ultrasonic Flaw detector with accessories 1 set

75. Rockwell hardness testing machine 1 set

76. Universal Testing machine Optional

77. Suitable gas cutting table 1 No.

D. LIST OF CONSUMABLE

78. Leather Hand Gloves 14 " #21 pairs.

79. Cotton hand Gloves 8" #21 pairs.

80. Leather Apron leather #21 pairs.

81. S.S Wire brush 5 rows and 3 rows #21 nos. each

82. Leather hand sleeves 16" #21 pairs.

83. Safety boots for welders #21 pairs.

84. Leg guards leather #21 pairs.

85. Rubber hose clips 1/2" #21 nos.

86. Rubber hose oxygen 8 mm dia X 10 Mts long as per BIS

2 nos.

87. Rubber hose acetylene 8 mm dia X 10 Mts long as per BIS

2 nos.

88. Arc welding cables multi cored copper 400/ 600 amp as per BIS 45 mts. each

89. Arc welding single coloured glasses 108 mm x 82 mm x 3 mm. DIN 11A &12 A

#42 nos.

90. Arc welding plain glass 108 mm x 82 mm x 3 mm. 68 nos.

91. Gas welding Goggles with Colour glass 3 or 4A DIN #42 nos.

92. Safety goggles plain #42 nos.

93. Spark lighter 6 nos.

94. AG 4 Grinding wheels 10 nos.

Note: - 1. Quantity marked with # has been increased as per the batch size. 2. * Optionally Gas cylinders can also be hired as and when required 3. No additional items are required to be provided for unit or batch working in the Second shift

except the items under trainee's tool kit and steel lockers. 4. Internet facility is desired to be provided in the class room.

37


Tools & Equipment for Employability Skills

S No. Name of the Equipment Quantity

1. Computer (PC) with latest configurations and Internet connection with standard operating system and standard word processor and worksheet software

10 Nos.

2. UPS - 500VA 10 Nos.

3. Scanner cum Printer 1 No.

4. Computer Tables 10 Nos.

5. Computer Chairs 20 Nos.

6. LCD Projector 1 No.

7. White Board 1200mm x 900mm 1 No.

Note: - Above Tools & Equipment not required, if Computer LAB is available in the institute.

38


Name & Address of the Assessor: Year of Enrollment:

Name & Address of ITI (Govt./Pvt.): Date of Assessment:

Name & Address of the Industry: Assessment location: Industry / ITI

Trade Name: Examination: Duration of the Trade/course:

Learning Outcome:

S N

o.

Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15

Tota

l In

tern

al

Ass

essm

ent

Ma

rks

Res

ult

(Y

/N)

Candidate Name Father's/Moth

er’s Name

Saf

ety

Co

nsc

iou

snes

s

Wo

rkpla

ce H

ygie

ne

&

Eco

no

mic

al u

se o

f

mat

eria

ls

Att

endan

ce/

Pun

ctual

ity

Ab

ilit

y t

o f

oll

ow

Man

ual

s/ W

ritt

en

inst

ruct

ion

s

Ap

pli

cati

on

of

Kn

ow

led

ge

Sk

ills

to

Han

dle

Tools

/

Eq

uip

men

t/ I

nst

rum

ents

/

Dev

ices

Eco

no

mic

al u

se o

f

Mat

eria

ls

Wo

rkin

g S

trat

egy

Qu

alit

y i

n

Wo

rkm

ansh

ip/

Per

form

ance

VIV

A

1

2

ANNEXURE-II

FORMAT FOR FORMATIVE ASSESSMENT

WELDER (WELDING & INSPECTION) - Directorate General of ...

Documents

Transcript of WELDER (WELDING & INSPECTION) - Directorate General of ...