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SYLLABUS FOR
Electronics Mechanic (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 designated trade : Electronics Mechanic (Steel Plant) N.C.O. Code No. : 7243 Duration of Apprenticeship Training : Two Years Entry Qualification : Passed 10th class examination under 10+2 system of education or its equivalent Ratio of Apprentice to Workers : 1: 5
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List of members attended the Workshop to finalize trade syllabus of ‘Electronic Mechanic (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 Shri/
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
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
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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
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
Electronics Mechanic (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 and B) Shop floor (In-
plant) training. During the basic training, the trainee is exposed to fundamental of workshop practices in various shops/trade in order to prepare him/her for the trade in which he/she will be trained as an apprentice.
Out line of Training Programme: A. Basic Training in Training Institute: 78 weeks ( One and half Year) B. Shop Floor (Plant) Training : 26 weeks (Six month including revision and project work of 2 weeks)
C. Related Instruction ( Throughout the training period, 1 day/week )
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Trade- Electronics Mechanic (Steel Plant) Training Structure
Sl.No. Module No Modules/ Subject Duration in weeks
1st Year
Basic Trade Training
1 A.1 Introduction, general & behavioral safety 01
2 A.2 Industrial safety & Quality 01
3 A.3 Bench-fitting Skills 08
4 A.4 Electrical Fundamentals and circuit 08
5 A.5 Electrical machines 08
6 A.6 Basic Electronics 10
7 A.7 Power Electronics & Drives 06
8 A.8 Analog & Digital Communication 04
9 A.09 Instrumentation & Control 04
10 Revision & Test 02
2nd Year
11 A.10 PLC & DCS 02
12 A-11 Fluid Power (Industrial hydraulics & pneumatics) 02
13 A.12 Welding 01
14 A.13 Advanced Industrial Electronics 04
15 A.14 Repair & maintenance of electronic equipment 05
16 A.15 Electrical Power System 04
17 A.16 Computer and IT 01
18 A.17 Iron & Steel making technology 02
19 A.18 Quality Management and Improvement Techniques 01
20 A.19 Rigging 02
21 A-20 Environment Control and Occupational Health 01
22 Revision & Test 01
23 B.1 Shop floor (In-plant) training 24
24 B.2 Industrial visits, project work, Revision & Test 02
25 C Related instruction class (1 day/week) Syllabus to be covered within 2 years
of training period
Total 104
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SYLLABUS FOR THE TRADE OF ELECRONIC MECHANIC (STEEL PLANT) UNDER ATS
DURATION- 2 YEARS
Part A: Basic Trade Training- Duration- One and Half ( 1 ½ ) Year
1st Year 1. Introduction, general & behavioral safety (1 week)
Week No.
Trade Theory Trade Practical Engineering Drawing Workshop Calculation & Science
Terminal Competencies:
After completion of this module the trainee will be aware of
Trade apprenticeship training scheme, general and behavioral safety
Overview of steel manufacturing process and machinery
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
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.
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2. Industrial Safety & Quality (1 week)
Terminal Competencies:
After completion of this module the trainee will be aware of
Industrial Safety and first aid techniques
Quality Circle
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) and its tools.
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)
Geometrical construction of Square, Rectangle, Triangle, Circle, Ellipse, Polygons, etc. Drawing different types of lines.
Rounding of decimal values, use of approximation Units – definition, Fundamental and 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.
3. Bench-fitting Skills (8 weeks)
Terminal Competencies:
After completion of this module the trainee should be able to
Chip flat surface to an accuracy of 1.0 mm
Cut metal pieces of different profiles by hand hack-sawing to an accuracy of 0.5mm
Produce flat, angular and contour surfaces by filing to a dimensional accuracy of 0.20mm.
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Transfer dimensions from drawing to work piece.
Drill, ream and threading by hand/machine
Level and align mechanical components to ensure proper functioning
Dismantle bearing and coupling
Lubricate electrical machines
Understand gear box mechanism
3-10 Classification, constructional and functional details of different type of bench and machine vices. Care of vices. Classification, construction and functional detail of Hammers.
Classification, construction and functional detail of following cutting tools: Chisels, Hacksaw, Files, Drills, Reamers, Scrapers, Taps & Dies. Classification, construction and functional detail of following bench tools : Steel rule, Try square, Calipers, Divider, Centre punch, Surface plate, V-Block and Trammel etc. Marking media, marking
Hacksawing - Marking lines, Cut metals pieces of different profiles & sections by hack-sawing (straight, inclined & curved line) to an accuracy of 0.5 mm. Filing - Parallel filing practice on flat surface Marking practice of straight, parallel and curved lines with odd leg calipers, steel rule, dividers, Scriber. Filing flat, square, steps and contour surfaces to an accuracy of 0.2 mm. Marking - Transfer of dimensions from drawing to work pieces. Finding center of a round bar with the help of „V‟ block and marking block.
Chipping - Chipping practice on flat surface, slots & oils grooves, and chamfer at different angle on MS plate.
Difference between the orthographic and oblique projection. Concept of planes of Projection and Quadrants. Convention of their rotation and the concept of FIRST ANGLE and THIRD ANGLE Projection and difference between them. Concept of THREE VIEWS. Drawing of THREE views from pictorial and isometric views. Letter writing:- Types of Letters viz. normal condensed and extended (theoretical aspects). Writing of Single Stroke Vertical and inclined letters only. Writing of Numerals in the same specification.
Workshop problems related to average, percentage and ratio and proportion. Workshop problems related on time and work. Scalar and vector quantities, definition and units of terms related to motion- speed, displacement, velocity, acceleration and retardation. Equations of motion with acceleration and retardation on earth‟s surface or parallel to it and vertical motion under gravity. Related problems. Newton‟s Laws of
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blue, Prussian blue, red lead, chalk and their special application, description. Measuring Instruments: Micrometer (outside and inside) – working principle, use and care, Calculation of least count. Vernier calipers, principle, graduations, reading, use and care.
Elements of mechanical components: bearing, coupling and keys
Basic knowledge of gear and gear boxes
Leveling and alignment of electrical machine
Lubrication related to electrical machines
Drilling & Reaming - Use of drilling machine for drilling through & blind holes, Reaming of drilled hole by hand reamer.
Internal & external threading by Taps & Die
Dismantling, inspection and re-assembly of bearings, coupling and keys
Practice on leveling, alignment, static balancing and plumbing related to electrical machines including Laser alignment.
Practice on lubrication related to electrical machines
Dimensioning practice. Motion with proper examples, Concept of Force, Concept of Inertia i.e. inertia of motion and inertia of rest.
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4. Electrical Fundamentals and circuit (8 weeks)
Terminal Competencies: After completion of this module the trainee should be able to
Understand the basic principles of electricity, its various effects, types and functions of electrical components.
Know about network theorem and apply it in solving simple numerical problems.
Make simple electrical circuits and joints
Know about various chemical effect of electricity,
Charge batteries and test its conditions.
Know about magnetism, electromagnetic induction, capacitance and carry out simple experiments.
Understand AC circuits, terms used, single and poly phase circuits, series and parallel RLC circuits. Carry out simple experiments.
Identify, connect and use common electrical measuring instruments, tools and appliances. Find out faults and trouble shoot simple electrical circuits and appliances used in workshop.
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Fundamentals of electricity, electron theory, concept of free electrons and difference between conductor, insulator and semi-conductor.
Definition and units of voltage, current, resistance, power and energy Ohm’s law, simple electrical circuits and problems. Resistance- series and parallel, laws of resistance, temperature co-efficient of resistance, work, power and energy. Kirchhoff‟s current & voltage
Demonstration and use of electrical measuring instruments with safety aspects Verification of Ohm‟s law Verification of law of series and parallel circuits Verification of Kirchhoff‟s law Measure resistance by using voltmeter and ammeter, post-office box, AVO meter, Standard resistance comparison, bridge, megger and potentiometer
Dimensioned Drawing:- Method of dimensioning according to BIS 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. Workshop problem on mixture. Measurement of force, i.e. P = ma where P is the force, m is the mass and a is the acceleration. Units of force. Momentum – definition and its significance. Problems. Nature of forces – composition and resolution of forces. Resultant of a number of coplaner forces acting at a point. Problems.
12
laws and application, Wheatstone bridge and its application, Simple problems Use of common electrical measuring instruments and related safety aspects
12
Types of wire and cables, their specification, insulation and voltage grade, Standard wire gauge, Common electrical accessories, their functions and specifications viz. switches, plugs, lamp holders, sockets. Development of electrical circuits used in workshop. Related Safety aspects
Demonstration and identification of different types of cables, wires Examination and checking of cables and conductors Practice on using tools like cutting pliers, screw drivers, skinning the cable, joint practice on single strand. Demonstration and practice on bare conductor joints. Practice on making simple electrical circuits on wooden board Practice on installation and overhauling common electrical accessories, fixing of switches, holders, plugs etc.
Do Profit and Loss and problems concerning to workshop practice. The law of parallelogram of forces, Triangle of forces. Lami‟s Theorem, Polygon of forces and problems
13
Magnetism- classification of magnets, methods of magnetizing, magnetic material, Coulomb‟s law, permeability, ferro, para and diamagnetic materials
Electromagnetism- Solenoid, field around
Perform experiments to draw B-H curve. Prepare simple electromagnet and find the polarity Experimenting faraday‟s laws, Lenz‟s law, Fleming‟s rules, self and mutual inductance Determining hysteresis loss and eddy current loss.
Do
Do
13
conductors carrying current, polarity, screw-rule, right-hand grip rule, advantages and application of electromagnet. Magnetic series and parallel circuits, B-H curves, hysteresis loop, hysteresis loss, eddy current, eddy current loss, equations and problems. Principles of electromagnetic induction, Faraday‟s laws, Lenz‟s law, Fleming‟s Rules, Related safety aspects
14 Self-inductance, mutual-inductance, their co-efficient, equations and problems Joule’s law of heating, Joule‟s equivalent, heating appliances and elements. Electrostatics- terms and definitions, coulomb‟s law, capacitors, charging and discharging of capacitors, energy stored. Chemical effect of electricity – principle of electrolysis, Faraday‟s laws. Applications of electrolysis,
Connect the capacitors in series and parallel and measure different values. Observation of charging and discharging of capacitors, its testing. Grouping of dry cells for a specific voltage and current Battery charging- Prepare electrolyte for lead- acid storage battery; charge the battery using different methods, Check for battery condition.
Do Do
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Basic principles of electroplating Principle and construction of simple voltaic cell, Leclanche cell, dry cell, standard cells, their uses, care, maintenance and grouping. Secondary cells principle, types, lead-acid cells, description of parts, chemical action, method of charging, rate of charging, testing equipment, hydrometer, high rate of discharge tester, capacity, general defects and their remedies. Re-chargeable dry cells Related safety aspects
Routine care and maintenance of batteries
15 Alternating Current- comparison between DC and AC, its related terms, waveform, frequency and phase, instantaneous, RMS, average values Resistance, inductance and capacitance in AC circuits, reactance and impedance, power factor, vector diagram, active and reactive power. Simple problems Related safety aspects
Use of CRO Observation of different types of AC waves and measurement of their different parameters by oscilloscope
Do Simple equations and its application in solving workshop related problems. 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. Problems.
15
16 AC series and parallel circuits – RL, RC and RLC. Power factor and resonance Poly phase systems, its advantages over single-phase system. Star and delta connections in 3-phase system, relationship of VL, VP, IL, IP, formulae and calculations Related safety aspects
AC series and parallel circuits Determining L for a coil and choke and C for a capacitor Observation of 3-phase voltages and measurement of voltage, connections in star & delta
Do Do
17-18 Power and power factor in 3-phase circuits, active and reactive power, methods of improvement of power factor. Balanced and unbalanced loads Measurement of power and energy in 3-phase, 3-wire and 3-phase-4 wire circuits Related safety aspects
Demonstration of three-phase load and measurement of voltage, current power & power factor in 3-phase circuit
Do Simultaneous Equations and its application in solving workshop related problems. Work, Power and Energy-definition and units, Potential and Kinetic energy, related problems.
5. Electrical machines (8 weeks)
Terminal Competencies :
After completion of this module trainees will be able to
Identify parts, mark terminals, connect, adjust voltage and apply load on AC and DC machines including transformers.
Test, connect with devices, start, control and reverse the direction of rotation of DC motors AC single phase and three phase induction motors, synchronous motors.
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Draw circuit diagrams and wiring diagrams of DC motor control system and AC induction motor control system.
Specify correctly (frame size, insulation class, cooling etc), inspect, test and detect faults and carry out simple repair on AC and DC machines.
Test the transformer and determine losses and efficiency
Connect and operate single phase transformers in parallel and three-phase transformers in parallel.
Carry out preventive and routine maintenance on AC/DC machines including the protective devices.
Practice safe working on electrical equipment
19 Types of electrical machines. DC generator- working principle, EMF equation, electromagnetic drag, types, and parts, Self and separately excited generators, practical uses Explanation of armature reaction and commutation, interpoles and their uses, connections and polarity
Characteristics of series, shunt, compound and separately excited generators, critical resistance and critical speed, application of DC generators, Losses and efficiency
Familiarization with safe working practice with electrical equipment
Identification and study of parts of a DC Machine
Identifying terminals of DC machine by measuring resistance of shunt field, series field and armature
Connecting, running and studying the characteristics of DC series, Shunt, and compound generators. Study of No-load and load characteristics
Finding critical resistance and critical speed of DC generators
Drawing of few more exercises on Orthographic Projection using all instruments and dimensioning the views.
Geometry:- Simple definitions of points, lines, parallel straight lines, triangle and rectangular figures - their properties and problems concerning workshop practice. Friction – Types of friction and laws of limiting friction. Co-efficient of friction, angle of friction, angle of repose. Advantages and disadvantage of friction. Related Problems. Lubricants – types, viscosity and effect of temperature on viscosity.
20-21 DC motor- working principle, torque, speed, back emf, their relations. Types of DC
Testing DC motors, identifying terminals, connecting, running and reversing direction of
Do Do
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motors- series, shunt, compound and separately excited their characteristics and applications. Starting and speed control of DC motors. Related safety aspects
rotation of DC motors. Studying characteristics and drawing characteristic curves of DC motors of all types.
22-23 Transformers- working principle, transformation ratio, no-load and on-load phasors, classification, types of core, EMF equation, equivalent resistance, reactance and impedance; equivalent circuits. Open and short-circuit tests, regulation, losses and efficiency of transformers. Three-phase transformers- types, construction, applications, advantages and connections, Protective devices and cooling systems of transformers Auto-transformers, Instrument transformers - CT, PT, Tong-tester and their applications Related safety aspects
Identification of types of transformers and its parts Verification of transformation ratio, loading secondary, finding relation between primary and secondary currents, voltages and no. of turns Measurement of iron and copper losses, determination of regulation, efficiency etc., polarity marking of single-phase and three-phase transformers Testing of single and three phase transformers, cleaning and maintenance, oil testing. Study of Instrument transformers - CT, PT and Tong-tester
Interpretation of Orthographic Projection:- Important points and significance of projection lines. Techniques to draw the missing views and various types of possibilities of elevations with a single plan.
Moment of a force-meaning and its importance. Varignon‟s Theorem and problems on it. The circle – its various properties like angle and tangent properties. Problems on the above topics concerning to the workshop practice.
24-25 Induction motors- Rotating magnetic field, and working of 3-phase induction motors, production of torque.
Dismantling, inspection of parts, cleaning and testing of windings, lubricating bearings and assembling of 3-phase SC
Simple exercises on Interpretation of Orthographic Projections.
Do
18
Construction of SC and SR motors, slip, rotor emf, current, frequency, pf, Cu loss, Slip torque characteristics. Double-cage rotor, comparison of SC and SR motors. Starters of induction motors and its necessity, types-DOL, star-delta, auto-transformer, soft-starters and rotor resistance starters of wound-rotor induction motors Use of motor Checker Protective devices in AC motor circuits – Principle and setting of over-current relays- thermal, magnetic, EOCR and numerical relays. Single-phasing-its effects and prevention, NVR and its function Single-phase induction motors - theory of rotation and self-starting, types, reversal and speed control. Related safety aspects
and SR motors Polarity marking (phase-sequence test) of a 3-phase induction motor and connection in star and delta Testing induction motor by megger, and Motor Checker Starting the motor using different starters, running and reversing the motor, measuring the starting and no-load currents, measuring speeds at different loads, calculating speed etc Dismantling, studying and re-assembling the electromagnetic AC contactors of different voltages, types, makes and categories. Settings of different types of motor protection relays Doing panel wiring by using contactors relays etc. for automatic star-delta, autotransformer, rotor-resistance, and forward-reverse D.O.L. starters. Studying, overhauling of fan motors, connecting, running and reversing of single-phase motors.
19
26 Synchronous machines Alternator- parts, types of poles- salient pole and smooth-cylindrical type, rotating-field and rotating armature type etc Prime movers for alternators, turbo-alternator, engine-driven alternators, EMF equation, pitch-factor, breadth-factor Alternator characteristics, OCC, SCC, Exciter, Excitation, and voltage regulation, cooling of alternators and rating Synchronous motors: operation, types, characteristics, application. Related safety aspects
Identification of terminals of alternator, connecting, starting, running, loading and plotting characteristic curves
Starting synchronous motors by different methods
Do Do
6. Basic Electronics (10 weeks)
Terminal Competencies : After completion of this module trainees will be able to
Understand the principle of Electronics and its application in industry and society.
Know the principle and characteristic of different active and passive components of electronics.
Know the principle, working, characteristics and applications of semi conductor devices and circuits
20
Make simple electronic circuits on bread-board and PCB
Understand the principle of digital electronics, IC chips, sequential and combinational digital devices and circuits.
Understand the principle of working of micro-processor, memory, micro-controller, interfacing and do simple programming.
Read and understand electronic circuits and drawings
27-28 Basic Analog Electronics – Introduction to Electronics and its application, difference between analog and digital electronics. Atomic theory, energy band diagram, classification of matter based on energy band diagram. Active and passive circuit elements: Resistors and their rating - fixed and variable, carbon and wire wound, metal film and metal oxide, colour coding, power rating, accuracy and effect of temperature, uses of resistors. Fuses and their rating- Slow blow and fast blow, semiconductor fuse Inductors and their rating - types: ferrite core, air core, tapped and variable inductors. Factors affecting inductance and use of inductors Capacitors and their rating: Mica, ceramic, paper,
Electronic Component identification and testing, Reading and interpretation of colour codes of components Use of digital multimeters Connecting function generator with oscilloscope, study of wave forms, measurement of voltage and frequency. Diode characteristic, Zener diode characteristics, testing, and identification Making half wave and full wave rectifiers using training kits, study of different wave shapes and their values on oscilloscope Soldering and desoldering practice
Different types of simple and intricate exercises on interpretation of orthographic projections with proper dimensioning
Mensuration:- Plane figures – Triangle, Square, Rectangle, Parallelogram, Trapezium, Regular Polygons, Circle, Hollow Circle, sector and segment of circle, fillets etc. Simple machines – what is a machine, its advantage and utility. Important definitions concerning to machines – Mechanical Advantage, Velocity Ratio and Efficiency of the Machine
21
electrolytic, tantalum, silvered mica, variable capacitors, colour coding and uses. Voltage and current sources- Ideal and practical, AC and DC signal and its source. Semiconductor theory: intrinsic and extrinsic, P and N type, development of P-N junction, drift and diffusion currents, barrier potential, biasing arrangement. Effect of temperature Diodes: working, classification, characteristics, coding, specification, identification and testing. Half wave and full wave rectifiers, PIV. Zener diodes: characteristics, types and application. Calculation of series resistance for varying inputs and load currents, Voltage regulator using zener LED, varactor and photo diodes- working principle and applications.
29 Transistors: working, classification, VI characteristics (static and dynamic), CE, CB,
Transistors: identification and testing finding static and dynamic characteristics of
Do Do
22
CC configuration and their difference, current, voltage gains and their relationship. Biasing and thermal stabilization circuits, heat sink. Packaging, coding, specification, identification and applications in detail DC and AC load lines. H parameters
transistors in different modes using training kits, calculation of gains. Biasing circuits
30 Field effect transistors: construction, operation and VI characteristics of JFET, Enhancement and deletion type MOSFET, concepts of CMOS, Difference with bipolar junction transistors, uses. UJT- Construction, operation VI characteristics and application
Identify, test and draw the VI characteristic of FET, MOSFET and UJT.
Do Do
31 Amplifiers: working principle, classification and circuits. Small signal single stage AF/RF amplifiers: different circuits, load line, voltage, current and power gain, waveforms, frequency response Multistage amplifiers- need and types of coupling. RC, transformer and direct couple amplifier circuits, voltage and
Assembly and testing of amplifier circuits on PCB: Single stage CE,CB,CC amplifiers, RC, Transformer and direct couple amplifiers. Study of input and output wave forms on oscilloscope. Calculation of gain and bandwidth. Drawing the frequency response curve
Do Do
23
power gain, frequency response, bandwidth, comparison between different types. Power amplifier- voltage and power amplifier, classification Class A, B.C and AB amplifier circuits Push-pull amplifier, Use of heat sink., harmonic distortion and its control. Feedback amplifiers- circuit and applications
32 Oscillators: working principle, classification, circuits and applications. Factors controlling oscillation. Different types of oscillators, their characteristics and applications, crystal oscillators.
Assembly of oscillator circuits using transistor and measuring the output frequency and waveform.
Do The Laws of Indices and problems. Power and Exponent, laws of exponent Levers – Classification of Levers and problems
33 Linear ICs and OP-AMPs: working, characteristic, pin diagram, applications as inverting and non-inverting amplifier, calculation of gain, comparator, unity gain buffer and scale changer, adder, subtractor, differentiator, integrator, V/I and I/V converter. Differential and Instrumentation amplifier Switching and timer circuits: classification of multi-vibrators,
OPAMPS pins identification, assembly of inverting and non-inverting amplifiers, calculation of voltage gain, assembly of comparator, adder, subtractors, differentiator, integrator, V/I and I/V circuit and its testing. Study of Differential and Instrumentation amplifier Construction of multivibrators using 555
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
Do
24
astable, monostable and bi-stable. Internal block diagram, operating of 555 timers and its applications Opto-electronics- elementary idea of LED, LCD, photo diodes, photo transistors, solar cells and their applications
timers, Calculation of frequency
34-35 Digital Electronics Number systems: binary, octal, hex, 1's and 2's complements, conversion from one system to other, Boolean algebra: De Morgan theorem and its applications Basic logic gates: Symbolic representation and truth tables for logic gates: Buffer, NOT, OR, AND, NAND, NOR, XOR, XNOR. Different logic families and their characteristics, Electrical equivalent of gates, Negative and positive logic gates Boolean algebra- Karnaugh map technique, simplification of Boolean expressions, realization of Boolean expression with logic gates
Verification of truth tables of different gates Realization of different Boolean expression with logic gates Realization of adders and subtractors Construct and verify truth tables of flip flops Construct synchronous and asynchronous counters and study its functions Construct controlled shift register and study their functions Practice on reading and interpretation of IC data sheets.
Do Logarithms – Types of logarithms eg. Naperian and Common. Meaning of logarithms its elements i.e. characteristics and mantissa. Problems on Positive Characteristics Wheel and Axle, Screw Jack, Inclined plane and problems.
25
Combinational logic circuits: Half and full adder and subtractors. Encoders, decoders, multiplexer, de-multiplexers, parity generators and checker Sequential logic circuits: Difference between sequential and combinational circuits, triggering of sequential circuits. Flip-flops: RS, JK, D, T type, preset and clear signals, timing diagrams. Counters, Registers and its applications Memory devices: types, memory cells: RAM, ROM, PROM. EPROM, EEPROM, CD-ROM, memory addressing and IC chips, Static and dynamic RAM, latest developments Data converters: Digital to analog converters, simple circuits, and applications. Analog to digital converters Multivibrators: Types, characteristics and circuits, Schmidt trigger
36 Microprocessor and computer: Organization in general: CPU, ALU, resistors, counters, data and address
Programming practice on Microprocessor Identification of different
Do Do
26
process, memory and I/O devices. Instruction set, Simple programming. Introduction to other processors Hardware of a personal computer (PC) Microcontrollers: basic principle, architecture, types, programming concepts, interfacing.
parts of a personal computer.
Programming practice on Microprocessor
7. Power Electronics & Drives (6 weeks)
Terminal Competencies: After completion of this module the trainee will be able to
Understand the concept of modern electric drive
Identify and test power electronics components and devices and know its characteristics and mounting.
Understand the working of power electronic circuits
Understand the application of above devices in modern control system
Understand the functioning of DC and AC drives and UPS.
37-38 Power electronic devices: Thyristor, its construction, characteristics and family. Turn “ON” & turn “OFF” behavior of thyristors Firing and commutation circuits,, role of snubber circuit. Rating & protection of thyristors, Power diodes and power transistors, power MOSFET, IGBT, GTO, IGCT and their applications
Observation of different types of power electronic components Drawing the V-I characteristic of a thyristor Study of different firing circuits of thyristors (RC, UJT, Ramp and Cosine firing circuits) Study of 1 ph and 3 ph converter - half wave, full wave, half controlled etc Study of inverter circuit and waveforms
Exercise on sectioning from isometric view.
Logarithms - Problems on Negative Characteristics. Hydrostatics – Nature of liquids and Pressure of liquid inside a vessel at different positions. Unit of pressure, Pascal‟s Law, simple problems.
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Thyristor circuits: Converter, AC voltage Regulator, Chopper, Inverter, IGBT circuit, PWM and their use
Checking of power MOSFET, thyristors, IGBT, GTO, IGCT etc
Types of pressure- atmospheric , absolute and gauge.
39 Electric Drives: Concept of modern electric drives, Classification of load and motor according to their speed/torque characteristics and drive performance characteristics. Behavior of drive system during change of state Control system - concept of open and closed loop system. DC drives: concept of speed control of DC motor. Block diagram of close loop unidirectional DC drive, four quadrant operation of DC drive, concept of dual converter, block diagram of close loop reversible DC drive, field weakening control and spill over control, Electronic modules used in DC drives. Parameters and concept of parameterization of DC drives Maintenance and trouble shooting of DC drive. Related safety aspects
Testing of thyristor and Ramp firing circuit, study of waveform on different test points of ramp firing circuits Study of the effect of KP, KI, KD in relation to close loop DC drive kits Demo of a real time microprocessor based DC drive used in industries. Exercise on configuration and parameterization of DC drives. Exercise on maintenance and trouble shooting of DC drive.
Free hand sketch of tools and tackles used in electronics trade- soldering iron, plier, screw drivers, desoldering pump
Do
28
40-41 AC drives: concept of speed control of AC motors, principle of V/f control of drives, block diagram of close loop AC drive, principle and operation of inverters (1 ph and 3 ph)- concept of PWM inverter. Principles of speed control of SCIM and SRIM in AC drives. Block diagram of Close loop control, power circuit, control circuit, electronic control modules of AC drive. Parameter and Concept of parameterization of AC drives, Maintenance and trouble shooting of AC drive Related safety aspects
Testing and study of IGBT, power plate Study of inverter voltage waveforms Demo of a real time microprocessor based AC drive used in different processes in industries. Demonstration on parameterization of AC drives Exercise on maintenance and trouble shooting of AC drive.
Free hand sketch of tools and instruments used in electronics trade- multimeters, power supply, function generators and CRO etc.
Factors and different types of factorization Density and Specific Gravity – its importance and significance, Archimedes‟ principle, Law of floating bodies, Condition of equilibrium of a floating body.
42 UPS - Understanding of float charger, off-line UPS and On-line redundant UPS, Different type of controls, circuit and maintenance of UPS and battery. Related safety aspects
Study of a UPS and its circuit and controls Trouble shooting and rectification.
Drawing symbols of electronics components- resistors, diode, transistors, FET, MOSFET, UJT etc.
Do
8. Analog & Digital Communication (4 weeks)
Terminal Competencies: After completion of this module the trainee will become familiar with
Principle and types of Electronic communication system (analog and digital)
Devices used in electronic communication
29
Working principle and circuit details of Television, Telephone (fixed and mobile), GPS, DA and PA system
Communication media
Fiber-optics communication
43 Communication system- Elements of communication system, principle of analog communication, , basic terminology used, bandwidth of signal and channel, propagation of electromagnetic wave, modulation and its necessity, antenna and types Modulation – methods of modulation- AM, FM, PM. Amplitude modulation- methods, modulation index, generation of side bands, block diagram of AM transmitters. Demodulation- AM radio receiver circuits, super heterodyne receiver Frequency modulation- methods, modulation index and number of side bands, FM transmitter and receiver circuits Other modulation schemes and their comparison
Lab work on AM and FM communication. Calculation of modulation index.
Screw Threads – Forms of various screw threads, nomenclature, convention and drawing of various thread profile.
Quadratic Equations and practical problems concerning to workshop practice Specific Gravity of:- a) Solids heavier than water. b) Solids lighter than water. c) Solids soluble in water. Related Problems.
44 Familiarization with TV circuits and its working- block diagram of different sections of TV, its circuit
Demonstration of TV circuits, identification and use of different controls.
Do Do
30
details, tuner, test points, VIF, AGC, Video amplifier, synchronization and sweep circuit, matrix, display screen, sound section, power supply, advancement in TV- flat screen, LCD and LED display.
45 Digital communication- principle of digital communication, methods and industrial application. Data communication: serial and parallel communication, MODEMS, Interfaces-RS-232, 422, 485, Ethernet. Industrial communication protocols- MODBUS, FIELDBUS, CONTROLNET and Interface buses Communication media Computer networking fundamentals
Demonstration of RS-232, RS 485, Ethernet and other communication standards. Familiarization with different communication equipment and media- Coaxial, UTP, Fibre Optic cable etc.
Do Do
46 Simple concepts of communication devices (block diagram only): Telephone (fixed and mobile), wireless, satellite, GPS, DA and PA system Fibre optics- structure, classification, characteristics,
Familiarization with FO communication
Do Do
31
losses, choice of wave-length, FO cable, splicing and connectors, applications and maintenance.
9. Instrumentation & Control (4 weeks)
Terminal Competencies: After completion of this module the trainee will become familiar with
System and equipment used for the measurement of various process parameters related to steel plant
Process control system and PID controllers
Different control strategies used in steel plant
47-48 Introduction- Objective of the Instrumentation & control, elements of measurement systems, instrument terminology Sensors and transducers– definition and types Load cell and its application in industrial weighing Encoders and its applications Introduction to process parameter measurement:
Verification of working principle and characteristic of different sensors and transducers covered in theory class viz. LVDT, strain gauge, capacitive gauges, thermocouples, RTDs, thermistors etc. Dismantling, assembly, overhauling and calibration of transmitters, indicators, gauges, regulators and switches used for pressure, temperature, flow, level and other measurement Configuration of smart transmitters using HART and other configurations.
Fastening Devices – Temporary and Permanent. meaning and difference. Temporary device – Hexagonal Bolt, Nut, Check Nut, Washer. To draw the three views of individual and the assembly.
Principle of Similarity:- Properties of similar triangle and their application to day to day workshop problems. Properties of Matter – Different types of Properties of Matter eg. Mechanical, Electrical, Chemical, Magnetic etc. Properties of Matter (Electrical):- resistivity, permittivity, permeability, resistance temp.
32
Temperature measurement- Principles, types and working of mechanical, electrical and radiation temperature sensors, relative advantages and limitations. Temperature switches: constructional details and maintenance. Temperature transmitters: types, working, calibration and maintenance. Hot metal detectors, Molten metal (Bath) temperature measurement. Pressure measurement- types and units of pressure and differential pressure. Manometers: principles, types and working. Pressures sensors and transducers: working principle and construction of elastic and electrical pressure and DP sensors. Pressure gauges: constructional details, calibration and maintenance. Pressure switches: constructional details and maintenance. Transmitters: Smart P/DP transmitters and its configuration. Flow measurement : Definition, units and types.
coefficient etc. Insulating materials. Brief description and properties of electrical materials such as silicon, nichrome, silver, copper, aluminum, transformer oil.
33
Restriction method: principles, types and installation of orifice plate, venturi tube, flow nozzle and others sensors. Variable area method: principles, types, and working. Mass flowmeters, magnetic, turbine and vortex flowmeters Flow switches.: constructional details and maintenance. Level measurement - definition, units and types of liquid and solid level measurement using direct and indirect methods: hydro-static pressure, capacitive ultrasonic, air bubbler Thickness measurement: types of methods, working principle, construction, calibration and maintenance. Related safety aspects
49-50 Process Control System Introduction, process variables, manual and automatic, close loop and open loop process control systems, process disturbances. Controller – types, P, D & I control actions. Tuning of a controller.
Operation of a controller, setting of its PID values, controller tuning. Testing of a control valve, I/P converter and valve positioners.
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. Properties of Matter (mechanical):- Tenacity, Toughness, Malleability, Ductility, Elasticity, Plasticity Brittleness and Hardness
34
Final control elements: types, working principle, construction, calibration and maintenance of I/P converters, Control valves & actuators, Valve positioned, power cylinders. Reading and interpretation of PI diagrams, instrument manuals and part list, panel wiring diagram etc. Related safety aspects
51 Revision/ Plant visit/ Industrial visit
52 Examination
Part B- Advance Trade training in Training Institute/ Industry & In-plant training Duration- 52 Weeks
10. PLC & DCS (2 weeks)
Terminal Competencies: After completion of this module the trainee will become familiar with
Need and working principle of PLC
Hardware of PLC
Programming of PLC
Hardware of DCS
Communication with different field and control devices.
53-54 Programmable Logic Controller (PLC)- Need and working principle, hard ware details. Function and connections of different cards. Program techniques of
Familiarization with different I/O modules of PLC Development of simple programmes involving bit level instructions, timers and counters, simple data manipulation instructions.
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
Properties and uses of copper, zinc, lead, tin, aluminium brass, bronze, solder, bearing metals, timber, rubber.
35
PLC, inputs, outputs, timer and counter instructions, data manipulation Development of simple programs Documentation, different functional blocks & mathematical instructions Communication system used in networking of PLC Data Acquisition System (DAS) & Supervisory Control And Data Acquisition (SCADA) System- Basic structure, software and applications, introduction to HMI packages. Distributed Control System (DCS)- basic concepts, architecture advantages. Level of automation in steel industry. Related safety aspects
Feeding and running the programmes in PLC, I/O forcing Documentation and editing of programmes. Simple fault finding and trouble shooting Demonstration of different communication system used in networking of PLC. DCS Familiarization with hardware of DCS, Process operation using DCS .
11. Industrial hydraulics and pneumatics (2 weeks)
Terminal Competencies: After completion of this module the trainee will become familiar with
Principle of working of hydraulic & Pneumatic components and circuits
Proportional and servo hydraulics and its applications
Symbols of basic hydraulic and pneumatic components
Interfacing of fluid power devices with electrical controller
36
55-56 Industrial hydraulics and pneumatics Basic principles of hydraulics and pneumatics, characteristic of fluid media, safety aspects Operational details of fluid power control element. Energy converter, Fluid conditioner, Control valves Symbols of basic hydraulic and pneumatic components Basics of proportional and servo valves, its electrical and electronic circuitry, control and feedback systems Concepts of interfacing of hydraulic and pneumatic components with PLC
Identify components such as reservoir, filter, pumps, float switch, valves, actuators etc. Operation of proportional and servo valves, functions of control and feedback components Demonstration of simple hydraulic devices and circuits. Demonstration of simple pneumatic devices and circuits. Hydraulic and pneumatic circuits, reading and interpretation. Development of simple logic circuits in PLC and its testing
Permanent Fastening Devices- Rivets – different parts and their types Different types of rivet heads
The Trigonometrical ratios and simple problems connected to workshop practice. Engineering Material – Introduction, classification, metallic and non-metallic material, physical and mechanical properties, testing of metal and hardness testing. .
12. Welding
Terminal Competencies: After completion of this module the trainee will become familiar with basic principle, devices and techniques used for welding
57 Arc welding and gas cutting tools and equipment. Different gases used in gas cutting. Regulators and blow pipes, filler rods and fluxes. Flame characteristics and uses, arc welding machines,
Familiarization with tools and accessories. Arc welding on mild steel (down hand) Making welding joints. Gas cutting on mild steel. Brazing of two similar metals
Rivets Joints – Lap joint and Butt or Strap joint. Lap Joint – a) Single Riveted b) Double riveted i) Chain ii) zig – zag Butt Joint –
Angle of Elevation and Angle of Depression, Problems on Height and Distances taking the help of Trigonometrical Ratios
37
electrodes and their selection, various joints and joint preparation, their suitability for various applications. Related safety aspects
a) Single plate or strap b) Double plate or strap
Heat treatment of steel – Hardening, annealing, tempering, normalizing and case hardening
13. Advanced Industrial Electronics ( 04 weeks)
Terminal Competencies: After completion of this module the trainee will become familiar with
Techniques of electronic circuit fabrication
Circuit details of electronic equipment – SMPS, UPS, Inverter, PC, Industrial camera, CCTV etc.
Industrial weighing system
58 Different techniques of electronic circuit fabrication Surface mounted devices technology, micro-electronics
Fabrication of electronic circuits on Assembly and testing of power supply with filter and regulators on PCB by soldering the components. Demonstration on soldering and de-soldering SMDs
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. Effect of force on Materials in Expanding, Bending, twisting and shearing.
59 Regulated power supply. Introduction to SMPS and UPS. Understanding of specification. PC hardware including I/O devices, memories
Study of SMPS, UPS and Inverter circuits and its testing Study of PC hardware and peripheral devices Study of industrial camera and CCTV used in steel plants
Drawing the symbols of electrical instruments- ammeter, voltmeter, watt meters, ohmmeter, energy meters etc. as per BIS practice.
Solid Mensuration:- Prism, Cylinder, Pyramid, Cone, Frustum of Pyramid and of Cone, Problems concerning to workshop practice.
38
Working principle and types of industrial camera and CCTV
Relation between load and extension – Graph – meaning of Yield Point – 1st & 2nd Ultimate tensile Stress, Breaking Stress and factor of safety.
60-61 Welding machine and its control CNC machines- basic idea. Sensors and switches- Proximity switch, Micro switch, limit switch, photo switch, encoder and other types of electronic sensors and their application Industrial weighing system- types, different types of load cell and processing units, configuration, maintenance and trouble shooting.
Study of welding machine and CNC control circuit Study and testing of different types of sensors, transducer and switches Demonstration of different units of an industrial weighing system.
Drawing the symbols of electrical components and devices- push buttons, switches, fuse, motor, generators, transformers, relays and contractors etc.
Solid Mensuration:- practice problems. Stress, Strain – Definitions, different types of Strain, Hook‟s Law, Modulus of Elasticity – Young‟s Modulus, Bulk Modulus – Modules of Rigidity, Poisson‟s Ratio and Problems.
14. Repair and maintenance of electronic equipment ( 5 weeks)
Terminal Competencies: After completion of this module the trainee will become familiar with
Repair and maintenance of electronic equipment.
Use of different electronic test and measuring instruments
62-66 Safety precautions. Requirement of grounding of self and equipment. Working principles, block
Testing and maintenance of electronic modules such as rectifiers, amplifiers, oscillators, logic circuits,
Drawing of various wave shapes- sine , square, triangular, saw tooth etc.
Solid Mensuration:- Sphere, Spherical segment, material weight and cost
39
diagram, circuit diagram and applications of following electronic test & measuring instruments-
a. Multimeter b. CRO- conventional and
storage type c. Scope meter d. DC power supplies e. Function generators f. Pulse generators g. Temperature controlled
soldering and de-soldering stations etc.
h. IC tester Modern trouble shooting techniques and use of electronic test equipment for service and repairing of electronic cards and equipment, use of test rigs and jigs, component substitution in handling of PCB and hybrid circuits.
multivibrator, multiplexer, timers, voltage regulators, ADC, DAC etc Repair and maintenance practices on defective electronic equipment such as power supplies, PC, microprocessor based circuits, CCTV, industrial camera, weighing system, PA system, modem etc. Repair and maintenance of communication equipment including fibre optic communication modules. (Note- Trainees should be given defective electronic equipment for repair)
Drawing the circuit of a DC power supply with rectifier, filter and regulator with labeling and waveforms. Drawing the circuit diagram of a UPS and SMPS with labeling and waveforms. Drawing the circuit diagram of a Signal generator with labeling and waveforms.
problems on above topics concerning workshop practice. Heat – Definition and its importance. Temperature – Definition and significance. Difference between heat and temperature. 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.
15. Electrical Power System (4 weeks)
Terminal Competencies: After completion of this module the trainee will become familiar with
Know how electrical power is generated and distributed
High voltage safety equipment and safe working procedures, Earthing system, IE rules
40
Working of LT and HT Switch- gears and protective relays
Power factor improvement methods
Monitoring system for power generation and utilization
67 Power Generation, Transmission and distribution System Introductory concepts - generating stations: Hydel, Thermal, Nuclear, Gas turbine, IC engine etc. High voltage safety, use of safety devices like HV tester, discharge rod, cool coat Earthing, system and equipment, neutral earthing, maintenance of earth pits Related IE rules and safety aspects
Measurement of pit resistance. Demonstration of HV safety devices Use of HV tester, cool coat, discharge rod
Drawing the block diagram of an oscilloscope with labeling and waveform.
Do
68 Transmission O/H line, conductor, support, insulators, their merit and demerit, sag, span, joints, guard, binding of insulators, stay, damper jumpers, erection of line, maintenance and inspection of transmission lines. Cables- construction, classification of cables, property of XLPE, paper, PVC, insulation, jointing and
Study of various types of power transmission equipment/ devices – conductors, support, insulators and cables. Cable jointing practices Study of single line diagram of interconnected industrial power supply system Polarity marking of CT Connection of CT and PT
Drawing the block diagram of an RC couple amplifier with labeling and waveform.
Graphs:-Dependent and Independent variable. Concept of Quadrants. Plotting of Points and other types of curves e.g. Straight line curve, Parabolic and Hyperbolic curves. To solve Equations of two and three unknown with the help of Graphs.
41
laying of cable, testing and fault localization Indoor and outdoor substation, layout, single line diagram, CT& PT, isolators, earth switch, transformer, lightening arrestor, reactor, breaker, bus and its protection. Energy management, maximum demand, load factor, connected load, diversity load curve, tariff. LDC- monitoring system for power generation and utilization. Indian electricity rules pertaining to safety of supply system, LT and HT equipment, O/H transmission. Related IE rules and safety aspects
Connection of lightening arrestors
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.
69 Power system protection Switch gear- arcing phenomena, ACB parts and their function, maintenance of arc chute, contacts, limitation and tightening, testing and calibration of releases, trouble shooting.
Connection of relays, Maintenance and adjustment of arc chute, and contact Opening and assembling - pole assembly, trip assembly and hand assembly Maintenance of ACB, OCB,
Drawing of control circuit of a motor starter
Do
42
Construction, working and maintenance of OCB, VCB and SF6, GIS, their merit and demerit Protection relay: classification, terms and definitions, comparison of mechanical, solid state, digital and numerical relays. O/C relay- its testing and calibration, E/F relay - its testing and calibration. Different types of E/F relays, reverse power relay, differential relay, restricted E/F relay, feeder protection relay, directional earth fault relays. Digital motor protection relay, numerical relays used with power system. Related IE rules and safety aspects
VCB, and SF6 breakers Demo on parameterization of digital relay and numerical relay
43
70 Fuse- terms and definitions, selection and characteristic of HRC fuse Power factor- effect of low power factor, cause of low PF, power factor improvement, use of static VAR compensation Energy management- maximum demand, load factor, connected load, diversity load curve, tariff. Related IE rules and safety aspects
Demonstration of different types of fuses Demonstration of different types of power factor improvement and compensation equipment Visit to Energy Management Centre such as Load Despatch Centre (LDC), Sub-stations.
Drawing the block diagram of a TV set with different sections and its labelling.
Do
16. Computer & IT (1 week)
Terminal Competencies: After completion of this module the trainee will become familiar with
Hardware of PC
Common software used in PC
Use of Intranet, Internet, E-mail
71
Computer & IT Basics of computer hardware and software MS office: Word, Excel and power point Use of Intranet, Internet, E-mail
Preparation of a word document (eg. Project report) Preparation of an excel file and make graphical representation of data obtained during practical sessions on electricity
Drawing of symbols of different digital electronic circuit and components- gates, flip-flop, register, counter with timing diagrams.
Statistics – Mean, Median, Mode, Variance, Frequency distribution , Cumulative frequency, Pie-Chart Expansion of Liquids – it has only one type of expansion e.g.
44
Cubical expansion. Two forms - Real and Apparent – the relation between them, coefficient of apparent and real expansion. Related problems.
17. Iron & Steel making technology (2 weeks)
Terminal Competencies: After completion of this module the trainee will become familiar with
Different types of raw material used for iron making and their sources
Iron and steel making processes
Hot and cold rolling process
72-73 Different types of raw material used for iron making and their sources Details of Blast furnace reactions, Cooling system, Cast House practices. Gas cleaning system. Hot metal Desulphurization Complete Heat cycle in LD vessel. Secondary Steel Making. Casting of Steel. Theory of Rolling. Rolling of long products & flat products in hot and cold rolling.
Guided visit of different plants of the organization and familiarization with the process.
Drawing of opamp based circuits- adder, subtractor, integrator, differentiators, V/I and I/V converters.
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 and related problems
45
18. Quality Management & Improvement Techniques (1 week)
Terminal Competencies: After completion of this module the trainee will become familiar with
QMS and its important provisions
Concept and application of TPM
Quality Control tools and systems practiced in industries
74 Introduction to TQM, Quality management standards, its importance and important provisions. TPM- Concept, different pillars, its implementation in an organization Problem solving technique used in industry - QC and SPC tools
Familiarization with Quality Management System, TPM, Small Group Activity (SGA) and Quality Circles as being practice in the industry.
Drawing of circuit of an instrumentation amplifier with labeling and waveform.
Set Theory – Introduction and problem. Mechanical Equivalent of Heat-problems. Transmission of heat – Conduction, Convection and Radiation. Examples from industries.
46
19. Rigging (2 weeks)
Terminal Competencies: After completion of this module the trainee will be able to do the following.
Loading, unloading and shifting of common and uncommon shapes of material with the help of different lifting tools and tackles.
Working at height.
Reaving pulley block in different part.
Able to communicate with crane operator through signals.
75-76 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. 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.
Practice of different type of knots & hitches used in material handling Reaving sets of pulley block. Splicing of manila rope. Inspection of wire rope. 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.
Drawing of circuit of an different types of multi-vibrators using 555 timer with labeling and waveform
Problems related to set theory. 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
47
20. Environment Control and Occupational Health (1 week)
Terminal Competencies: After completion of this module the trainee will be able to appreciate 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.
77 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
Do Do
78 Revision/ Plant visit/ Industrial visit
48
Part B: Shop Floor (In- plant) Training- Duration- Half ( ½ ) Year
B.1 Shop Floor (In- plant) training (24 weeks)
Terminal Competencies:
This is on-the-job and observational training module which will enable trainees to relate and learn the practical applications of contents covered during the basic training.
79-102
The content of this module will be developed by the organization based on the existing Electrical, Electronics and Instrumentation maintenance practices which may include the following Electronic repair shop 1. Maintenance and repairing
of electronic cards 2. Calibration and testing of
electronic instruments
Instrument Repair Shop 1. Maintenance and repairing
of instruments 2. Calibration and testing of
sensors, transmitters, control valves etc.
Electrical repair and testing section 1. Observation of
maintenance and repairing of electrical machines
2. Calibration and testing of electrical instruments
On the job training – Safety pre-cautions to be followed in the section/plant including need of special protective equipment, if any. Study of working of different equipment used in plant/section visited. Carry-out repair/ test/ calibration of instruments/ equipment under the guidance of competent person Carry-out minor maintenance job under guidance of competent person Working with skilled supervisors/ workmen/ operators. Preparing report on the job done
Drawing of AM and FM modulated waveform at different modulation index. Drawing of a radio receiver circuit Practice on Free hand sketching of electronic tools and instruments. Drawing of block diagram of a microprocessor, microcontroller and Personal Computer. Drawing of flow sheet symbols of sensors, transmitter, controller, recorder, control valve etc. Drawing of symbols of power electronic components and circuits- SCR, firing circuit of SCR, thyristorised
Peak , RMS and average value of AC supply. Relationship between them. Peak , RMS and average value of current in Rectifiers. Calculation of form factor, ripple factor, transformation ratio. Estimation of PIV of a diode in different types of rectifiers. Number system- decimal, binary, octal, hex. BCD code, conversion from decimal to binary, octal and hex and vice-versa. De-Morgan theorem. Introduction to Boolean algebra. Simple estimation of the requirements of
49
Power Houses and sub-stations 1. Power plant equipment &
Control system, P& I diagram of plant.
2. Distribution of electrical power, SLD.
3. Protection schemes and protective devices
Production Departments a) Plant process + Plant process control electrics. b) Power source + S.L.D c) Equipment layout, PCC/ MCC locations. d) PCC/ MCC details, different protection levels of equipment. e) Faults finding and rectification in electrical , electronic and process control equipment/ instruments f) Maintenance/ Inspection practices. g) Document management systems. h) Spares management. i) Use of MIS, computer based maintenance management
converters, inverters, chopper, cyclo-converter etc. (1ph & 3 ph) Drawing of block diagram of a feedback control system.
materials as applicable to the trade. Problems on estimation and costing. Meaning of HP and BHP. Problems on work, power and energy related to electrical area. Magnet and magnetism. Simple workshop problems.
50
B.2 Industrial Visit, Project work, Revision & Test (2 weeks)
Terminal Competencies:
Functioning of local industries
Making the project report and its presentations to the experts.
103-104
Revision of theory covered during the training. Effective Presentation skills
Revision of practical conducted during training. Visit to local industries Preparation of project/ training report and presentation to experts
Revision. Revision.
51
Evaluation: AITT – Evaluation on practical to be based on following combined skill area: (Total three skills need to be judged. Sl.No. 1 is compulsory and any other two skills to be chosen from the list given)
1. To make a regulated DC power supply on a PCB and test the % regulation
2. Able find out input and output characteristics of diode
3. Able to find out input and output characteristics of a transistor
4. Able to find out input and output characteristics of a transistor (FET)
5. Able to find out the characteristics of UJT
6. Able to check truth table of logic gates
7. Able to repair defective electronic instrument/ equipment
8. Able to check truth table of flip flops
9. Able to make an RC coupled amplifier/ FET amplifier
10. Able to make an LC/RC oscillator
52
List of tools and equipment required for Trade- Electronics Mechanic (Steel Plant) Trainees kit:
Sl. No.
Description Quantity
1 Connecting screwdriver 100 mm Quantity to be sufficient as per seats surveyed & allocated
2 Neon tester 500 v
3 Screwdriver set (set of 5 bits) - plane and diamond ended
4 Insulated combination pliers 150 mm
5 Insulated side cutting pliers 150 mm
6 Long nose pliers 150mm
7 Soldering iron 25 w, 240 v
8 Electrician knife D.B
9 Digital multimeter portable
10 Soldering iron 15 W/25 W/ 65 W
11 Desoldering pumps
List of equipments required
Sl. No. Description Quantity
1 First aid kit Quantity to be sufficient as per seats surveyed & allocated
2 Fire extinguisher
3 Bench vice
4 Steel rule
5 Digital multimeter
6 30-0-30 V, 2A D.C regulated power supply
7 0-300V, 500mA DC regulated power supply
8 LCR bridge( digital)
9 Signal generator 100 kHz
10 Digital storage oscilloscope, 100MHz with probe
11 Wattmeter
53
12 Megger (insulation tester)
12 a Megger (earth testing)
13 Battery charger
14 Digital IC tester
15 Pulse generator
16 Logic probes
17 DOL starter
18 DOL starter with forward/reverse control
19 Automatic sequencing control
20 Overload relays (Thermal, magnetic, electronic)
21 On delay timer, off delay timer
22 Earth leakage circuit breaker
23 Dimmerstat, 8 Amps
24 Counters
25 Temp. controller
26 DC motor control training kit (Electronic)
27 Level detector
28 Output power meter
29 Distortion factor meter
30 EPROM programmer
31 Microprocessor trainer kit alongwith ADC/DAC with stepper motor controller
32 Proximity switches
33 Photo tachometer
34 Burglar alarm
35 Smoke detector
36 Emergency tubelight
37 Single phase preventer
38 Servomotor
39 Servo controller
40 Absolute encoder
41 Rotary encoder (incremental)
42 DC tong tester
43 Weighing system (load cell based)
44* Programmable logic controller(PLC) with programming
54
unit
45 Personal computer with latest configuration with printer
46 High voltage testing kit
47 Surge generator
48 Instrument training kit (LVDT, Strain gauge, Thermocouple etc)
49 Electronic voltmeter
50 DC generator
51 DC motor
52 Single phase alternator
53 SMPS
54 Induction motor( single phase)
55 Stroboscope
56 Synchronous motor
57 Transformer (1 ph/ 3 ph), 1 KVA
58 Motorized control valve
59 Solenoid valve
60 Strain gauge
61 Load cell
62 LVDT
63 Dual trace CRO 100 Mhz
64 Analog IC trainer kit and Discrete component training kit
65 Linear amplifier trainer
66 Digital IC trainer kit
67 Magnifying glass for IC no. reading
68 Microprocessor 8085 trainer kit
69 Digital trainer A/D ,D/A convertor, Mux, Demux, display devices, etc
70 Motor trainer with dummy loads
71 Three phase motor speed controller/ trainer kit
72 Soldering station
73 De-soldering station
74 Hot air soldering station- cum –de soldering station for SMD devices
75 PLC training kit
56
List of consumable materials
Sl. No. Description Quantity
1 Maintenance free batteries Quantity to be sufficient as per seats surveyed & allocated
2 Re-chargeable cells-dry cells
3 Power diodes
4 Heat sinks, heat sinks compounds
5 LED‟s
6 Switches
7 Relays (AC/DC), contactors(AC/DC),
8 Push button switches
9 Lamps
10 IC‟s such as -7400,4001,4011,4017,4007,4033,74159,74154,etc
11 OPAMP IC 741 wave form generator IC 8035
12 IC DAC 0808, IC ACD 0801
13 Transistors , JFET, MOSFET, UJT
14 Various diodes
15 Various transistors
16 Microphone
17 Speaker 4”, 8 ohm
18 Various capacitors
19 Various resistors
20 Various transformers
21 SCR,DIAC,TRIAC, GTO, IGBT, IGCT
22 7-segment display (both common cathode and anode)
23 J & T type thermo couple
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