training objectives - punjab

Welder (ARC & GAS) – 1 Year Course

Developed by Curr icu lum Sect ion, Academics Department TEVTA.

1

TRAINING OBJECTIVES: Technological development has encouraged replacing the old / obsolete methods

and techniques being used in the industry New machines & skill have come into

existence by covering all the relevant factors / areas to meet the need of the

market.

This curriculum of one year duration consisting two semesters is revised /

updated keeping in view the local job market and modern industrial requirements

by more emphasizing on practical along with essential theoretical knowledge

along with ethical values for producing the capable & skillful workforce to meet

market demand.

This curriculum covers Basic Metal Work, Soldering & Brazing, Gas Welding &

Cutting, Arc Welding, Mathematics, Drawing, Functional English and Work

Ethics.

CURRICULUM SALIENTS:

Entry level: Middle / Matric

Duration of course: One year

Total training hours: 1600 hours

800 hours per semester

40 Hours per week

7 hours per day (Friday 5 Hours)

Training methodology: Practical 80%

Theory 20%

Medium of Instruction: Urdu / English



2

SKILL PROFICIENCY DETAILS:

On successful completion of this course, the trainee should be able to:

1. File, Mark, Measure, Drill, Threading, Sawing, Cutting.

2. Surface preparation and bevel cutting

3. Solder the joints

4. Tacking and leveling the pipe line piece during project execution.

5. Braze the joints

6. Gas weld of common welding joints for pipe and plate in flat, horizontal,

vertical & overhead positions.

7. Arc weld of common welding joints in flat, horizontal, vertical & overhead

positions.

8. Braze on different metals i.e. Mild steel (MS), Cost Iron (CI), Aluminum (Al),

Copper and Brass.

9. Inspect and test of welding joints



3

KNOWLEDGE PROFICIENCY DETAILS:

On successful completion of this course, the trainee should be able to:

1. Describe the measuring, Marking, Drilling, Filing, Threading, Sawing,

Cutting tools & Instruments their uses & safety.

2. Describe the basic arithmetic & geometric terminologies calculate &

solve the problems.

3. Explain the soldering brazing process & their use on common metals.

4. Explain the Gas Welding, Gas cutting tools & equipment, their use &

safety.

5. Express the Arc welding joints, positions their use & selection

6. Express the inspection & testing of welded joints to ensure weld quality.



4

CCUURRRRIICCUULLUUMM DDEELLIIVVEERRYY SSTTRRUUCCTTUURREE

1ST SEMESTER

Week

1-20 21-25 26

26 20 5 1

2ND SEMESTER

Week

1-20 21-25 26

26 20 5 1

Course Delivery

Co Curricula Activities / Vacations

Test Total

Course Delivery

Co Curricula Activities / Vacations

Final Test

Total



5

SCHEME OF STUDIES Welder (ARC & Gas)

(1-Year Course)

1ST SEMESTER

Sr. No.

Subjects/ Main Topics Theory Hours

Practical Hours

Total Hours

1 Workshop practice-II 70 300 370

2 Soldering & Brazing 10 64 74

3 Gas welding & cutting - I 26 230 256

4 Math – I 20 - 20

Drawing – I 20 - 20

6 Work Ethics 20 - 20

7 Functional English 20 20 40

Total 186 614 800

2ND SEMESTER

Sr. No.

Subjects Theory Hours

Practical Hours

Total Hours

1 Gas welding & cutting - II 30 154 184

2 Arc welding 76 440 516

3 Math – II 20 - 20

4 Drawing – II 20 - 20

5 Work ethics 20 - 20

6 Functional English 20 20 40

Total 186 614 800



6

DETAIL OF COURSE CONTENTS Welding (Arc & Gas)

(1-Year Course)

Sr. No

Detail of Topics Theory

Hrs. Practical

Hrs.

1 Workshop practice-II

70

300

2 1. Soldering and Brazing

2.1. Introduction of soldering

2.1.1. Soldering Process

2.1.2. Type of soldering iron

2.1.3. Kinds of solders

2.1.4. Soldering fluxe

2.2. Lap joint soldering

2.2.1. Tool safety

2.2.2. Practice

2.2.3. Personal safety

2.3. Butt joint soldering

2.3.1. Preparation

2.3.2. Practice

2.3.3. Safety

2.4. Soldering of angle

2.4.1. Preparation of job

2.4.2. Practice

2.4.3. Job safety

2.5. Brazing

2.5.1. Brazing process

2.5.2. Tool and equipment

2.5.3. Type of splatter

2.5.4. Type of flux

2.6. Lap joint brazing

2.6.1. Preparation

4

-

-

-

2

-

-

10

09

9

-

06



7

2.6.2. Practice

2.6.3. Job safety

2.7. Butt joint

2.7.1. Preparation

2.7.2. Practice

2.7.3. Safety

2.8. Double lap joint

2.8.1. Preparation practice safety

2.9. Soldering / brazing

2.9.1. Temperature of different metal

2.9.2. Melting temperature of spatter

2.9.3. Silver soldering process

2.10. Pipe joint brazing

2.10.1. Pipe forming (Bevel cutting)

2.10.2. Pipe over lapping

2.10.3. Flow of spatter metal

2.11. Brazing of dissimilar metal in different

shape


2.11.2. Practice on different metal

2.11.3. Job safety


-

-

2

-

2

6

6

-

8

10

3 3. Gas Welding & Cutting – I

3.1. Introduction of welding

3.1.1. Definition

3.1.2. Kinds of welding

3.2. Oxyacetylene equipment & tools

3.2.1. Oxyacetylene cylinders

3.2.2. Oxyacetylene gauges

3.2.3. Rubber hose pipe

3.2.4. Welding torch

1

1

1

1

1

-



8

3.2.5. Spark lighter

3.2.6. Welding goggle

3.2.7. Welding pliers

3.3. Gas welding blind weld flat


3.3.2. Marking

3.3.3. Center punching

3.3.4. Gas welding

3.4. Double flanged butt weld

3.4.1. Mark & cut the pieces

3.4.2. Flanging

3.4.3. Tacking

3.4.4. Fusion of flange without filler metal

safety

3.5. Welding joint

3.5.1. Square butt joint

3.5.2. Single vee butt joint

3.5.3. Edge joint

3.5.4. Bevel joint

3.5.5. Tee joint

3.5.6. Flange joint

3.5.7. Lap joint

3.6. Square butt joint(Flat)

3.6.1. Preparation

3.6.2. Tacking

3.6.3. Weld the pieces with left ward

technique

3.7. Corner weld outside (Horizontal)

3.7.1. Tack the pieces 90 degree

3.7.2. Torch angle 45 degree

3.7.3. Welding position (H)

1

-

-

3

-

-

16

16

-

16

16



9

3.8. Welding Types & Their Application

3.9. Fillet weld T-Joint

3.9.1. Preparation

3.9.2. Tacking

3.9.3. Practice

3.9.4. Safety

3.10. Pipe butt welding (Horizontal)

3.10.1. Preparation

3.10.2. Tacking with space

3.10.3. Practice

3.11. Preparation of gases

3.11.1. From air

3.11.2. From Calcium carbide

3.12. Square butt weld horizontal

3.12.1. Preparation

3.12.2. Welding with preparation

3.12.3. Safety factors

3.13. Square butt weld (over head)

3.13.1. Preparation

3.13.2. Fix the job at over head

position

3.13.3. Proper penetration safety

3.14. Square butt weld (Vertical up)

3.14.1. Preparation

3.14.2. Position vertical up

3.14.3. Penetration equal

3.14.4. Seam height equal

3.15. Acetylene generator

3.15.1. Type of generator

3.15.2. Function of generator

3.15.3. Safety of generator

3

-

-

3

-

-

-

3

-

16

16

-

16

16

16

-



10

3.15.4. Back fire chamber

3.16. Square butt weld on pipe(fix)

3.16.1. Preparation

3.16.2. Tacking

3.16.3. Fix the pipe

3.16.4. Weld in Over head/Vertical/Flat

3.16.5. Position

3.16.6. Keep proper penetration safety

3.17. Drawing

3.17.1. Development of pipe

3.17.2. Form the cone

3.17.3. Flat surface pyramid

3.17.4. Square pipe

3.18. Branch pipe

3.18.1. Development of pipes

3.18.2. Tacking L-Shape

3.18.3. Good ripples T-Shape

3.18.4. Finishing Y-Shape

3.19. Gas Cylinders

3.19.1. Oxygen cylinder

3.19.2. Acetylene cylinder

3.19.3. Low pressure system

3.19.4. High pressure system

3.19.5. Safety rules

3.20. Square butt weld flat

3.20.1. Preparation

3.20.2. Tacking

3.20.3. Right ward welding

3.20.4. Proper penetration

3.20.5. Safety

3.21. Single v butt weld

-

½

½

1

1

2

-

-

18

-

18

-

16

16



11

3.21.1. Preparation

3.21.2. Tacking

3.21.3. Practice


3.21.5. Pressure Proper fusion

3.22. Pressure Regulator

3.22.1. Single stage

3.22.2. Double stage

3.23. Corner weld (outside)

3.23.1. Preparation

3.23.2. Tacking

3.23.3. Practice

3.23.4. Penetration

3.23.5. Ripples control

3

-

-

18

4 4. Math – I

4.1. Addition & Subtraction

4.2. Multiplication & Division

4.3. Fraction Addition & Subtraction

4.4. Metric System and Measurements

4.5. Diameter / Circumference finding

4.6. Percentage

4.6.1. Meaning of Percentage

4.6.2. Changing Number to Percentage

4.6.3. Changing Percentage to Fraction

4.7. Conversion of inch to metric

4.8. Conversion of metric to SI

4.9. Changing Percentage Decimal and Common

Fraction

4.10. Finding rate base and percentage.

2

2

2

2

2

2

2

2

2

2

5 5. Drawing- I

5.1. Kinds of Line

2



12

5.2. Letter Practice

5.3. Division of Cavalier Projection

5.4. Corner Finding from Isometric Views.

5.5. Views finding and matching of views.

5.6. Assembling bodies according to views.

5.7. completion of view & view edges

5.8. Finding covered edges

5.9. Drawing according to scale and entry of

dimension.

5.10. Drawing of radius.

2

2

2

2

2

2

2

2

2

TOTAL 146 594



13

2ND SEMESTER

Sr. No

Detail of Topics Theory

Hrs. Practical

Hrs.

1 Gas Welding & Cutting – II

1.1. Single v butt weld on pipe

1.1.1. Preparation

1.1.2. Rolling position

1.1.3. Penetration

1.1.4. Practice

1.2. Oxyacetylene flame

1.2.1. Torch

1.2.2. Flame structure

1.2.3. Various flame preparing

1.2.4. Use of flames


1.3.1. Preparation

1.3.2. Tacking

1.3.3. Position Vertical up

1.3.4. Practice

1.3.5. Safety


1.4.1. Preparation

1.4.2. Tacking

1.4.3. Welding position Over head

1.4.4. Practice

1.5. Back fire

1.5.1. Definition

1.5.2. Cause

1.5.3. Protection and use of flash back

arrestor


4

3

-

-

5

-

20

-

20

18

-

14



14

1.6.1. Preparation

1.6.2. OH/V flat position

1.6.3. Practice


1.7.1. Preparation

1.7.2. Horizontal position

1.7.3. Practice

1.8. Welding direction

1.8.1. Left ward welding



1.9.1. Preparation cast iron pieces in

(60 degree) vee

1.9.2. Preheat the pieces by flame

1.9.3. Prevention of welding defect

1.10. Gas cutting

1.10.1. Equipment

1.10.2. Principal of cutting


1.11.1. Preparation different metals

1.11.2. Practice

1.11.3. Job safety

1.12. Gas cutting

1.12.1. Preparation

1.12.2. Marking

1.12.3. Punching

1.12.4. Cutting at 90 degree

1.13. Gas cutting EX2

1.13.1. Preparation

1.13.2. Marking

1.13.3. Center punching

-

6

-

5

-

-

-

14

-

14

-

18

14

14



15

1.13.4. Cutting at 30 degree

1.14. Welding defect

1.14.1. Gas pocket

1.14.2. Poor penetration

1.14.3. Under cuts

1.14.4. Improper speed

1.14.5. Crack

1.15. Gas Welding off shape pieces

5

2

-

8

2 Arc Welding

2.1. Introduction of arc welding tool /

Equipment and use of personnel

protective equipment

2.1.1. Welding screen/helmet

2.1.2. Leather apron

2.1.3. Leather gloves

2.1.4. Chipping hammer

2.1.5. Goggles

2.1.6. Sleeves

2.1.7. Tong

2.1.8. Wire brush

2.2. Safety and handling welding tools

machine


2.2.2. Tool safety

2.2.3. Machine safety

2.3. Blind weld flat

2.3.1. Preparation

2.3.2. Selection of current / striking

2.3.3. Angle of electrode

2.4. Electricity Circuit

2.4.1. Volt ampere resistance welding joints

3

5

-

6

-

-

25

-

25



16


2.5.1. Preparation

2.5.2. Tacking distance and length

2.5.3. Space in pieces

2.6. Electric Circuit

2.6.1. Series circuit parallel circuit

connection

2.7. Single v butt joint

2.7.1. Preparation

2.7.2. Tacking

2.7.3. Penetration

2.7.4. Distortion control


2.8. Exercise (Circuit)

2.8.1. Exercise

2.9. Fillet weld flat

2.9.1. Preparation

2.9.2. Equal layers

2.9.3. Multi layers

2.9.4. Under cut control

2.10. Transformer

2.10.1. Primary winding

2.10.2. Secondary winding

2.11. Corner weld (Horizontal)

2.11.1. Preparation

2.11.2. Role edge

2.11.3. Convex control


2.12. Arc Welding Processes / position

2.12.1. TIG Welding

2.12.2. Mag/ MIG welding

-

5

-

5

-

6

-

6

-

25

-

25

-

25

-



17

2.12.3. Flat, vertical, overhead,

Horizontal



2.13.1. Preparation

2.13.2. Speed control

2.13.3. Proper fusion

2.13.4. Convex contour

2.14. Welding Power Source

2.14.1. Welding machine

2.14.2. Transformer

2.14.3. Rectifier

2.14.4. Generator


2.15. Single v butt weld vertical up

2.15.1. Preparation movement of root

pass

2.15.2. Movement of filling pass

2.15.3. Movement of capping pass

2.16. Electrode

2.16.1. Arc welding rods

2.16.2. Type of flux

2.17. Fillet weld vertical up

2.17.1. Preparation

2.17.2. Undercut control

2.17.3. Slag inclusion


2.18. Proprieties of Electrode

2.18.1. Classification of electrode

2.18.2. Preparation of electrode

2.19. Fillet vertical down ward

-

6

-

4

-

5

-

25

-

25

-

25

-

25



18

2.19.1. Preparation

2.19.2. Selection of electrode

2.19.3. Current down ward

2.19.4. Undercut (welding defects and

corrective measures)

2.19.5. Electrode angle

2.20. Arc Welding

2.20.1. Welding current

2.20.2. Electric arc

2.20.3. Arc blow


2.21.1. Vertical up

2.21.2. Preparation

2.21.3. Puddle control

2.21.4. Movement first bead

2.21.5. Movement of electrode

2.21.6. Filling bead

2.22. Polarity

2.22.1. Straight polarity

2.22.2. Reverse polarity

2.23. Single v butt weld (Horizontal)

2.23.1. Preparation

2.23.2. Movement of electrode


2.24. Fillet weld (Horizontal)


2.24.2. Clamping of job

2.24.3. Distance of arc

2.25. Care of Electrodes

2.25.1. Packing of electrode

2.25.2. Storage of electrode

6

-

4

-

-

6

-

25

-

25

25

-



19

2.25.3. Protection of electrode

2.26. Tube on plate (Horizontal)

2.26.1. Preparation

2.26.2. Position of electrode

2.26.3. Thin pipe with thick plate

2.26.4. Control under cut

2.27. Resistance welding process

2.27.1. Spot welding

2.27.2. Unit of volume and conical

2.27.3. Paramedical work pieces

2.28. Build up weld (Flat)

2.28.1. Preparation

2.28.2. Parallel bead

2.28.3. Reinforcement

2.29. Welding Positions

2.29.1. Welding position

2.29.2. Flat/vertical/horizontal/over

head

2.30. Single v butt weld on tube (Flat)

2.30.1. Preparation

2.30.2. Rolling position

2.30.3. Convex contour

2.30.4. Penetration

2.31. Welding Joints

2.31.1. Welding joint

2.31.2. Square/butt/fillet/all round

2.32. Single v butt weld on tube

(Flat/Vertical/Over head)

2.32.1. Preparation


2.32.3. Starting

-

3

-

3

-

3

-

25

-

25

-

25

-

25



20

2.32.4. Ending


2.33.1. Horizontal fillet

2.33.2. Preparation


2.33.4. First bead

2.33.5. Second bead

2.33.6. Third bead

2.34. Welding test

2.34.1. Angle sport & angle checking

2.34.2. Handling of tool

2.34.3. Welding position

2.34.4. Shearing

2.34.5. Shearing tools & Exercise

2.34.6. Welding qualification test

through radiographic technique

-

-

25

15

3 Math – II

3.1. Angle and its Units

3.2. Types of Angles

3.3. Calculation of Angles Addition and

Subtraction

3.4. Cutting Methods Angles Calculation by

Multiplication and Division

3.5. Expression in Values of Angle in Decimal

Form.

3.6. Conversion from degree, minute & second

into decimal.

3.7. Surface of square rectangle.

3.8. Surface area of parallelogram & circle.

3.9. Practice of use of tables.

3.10. Surface of assembled part.

1

1

2

2

2

2

2

2

2

2



21

3.11. Calculating area of composed surface &

volume.

2

4 Drawing - II

4.1. Drawing of Radial.

4.2. Dimensions of inclined surface.

4.3. Cylindrical work piece & central line

dimension.

4.4. Drawing less than two views.

4.5. Drawing three views (basic) + Drawing three

views (advance)

4.6. Purpose of symbol entry.

4.7. Assembly of 2 parts & repetition of respective

exercise.

4.8. Nominal, Minimum & maximum size objects

drawing.

4.9. Assembly of 3 parts

4.10. Drawing of

4.10.1. Reference edge and faces.

4.10.2. Dimension according to

sequence.

4.11. Drawing from model exercise.

4.12. Pyramidical and conical work piece

representation.

4.13. Full section drawing.

1

1

1

1

2

1

2

2

1

2

2

2

2

TOTAL 146 594



22

LIST OF TOOLS / EQUIPMENT / LAB. OR WORKSHOP Welder (Arc & Gas)

1 – Year Course (For the class of 25 Students)

Name of Trade Welder (ARC & Gas)

Duration of Course 1 – Year

LAB / WORKSHOP ONE

Sr. No. Name of Items Quantity

1. Oxygen Cylinder 6 Nos.

2. Acetylene Cylinder 4 Nos.

3. Oxygen Hose pipe

12 Sets

4. Acetylene Hose pipe

5. Oxy-Acetylene Manifold

6. Backfire Arrestor

7. Nozzles size 0,2,3,5,6

8. Cutting Tips, 25/50

9. Cutting Torch

10. Tip cleaner

11. Gas welding Goggle

12. Tong 25 Nos.

13. Steel Wire Brush 25 Nos.

14. Gas Welding Table 12 Nos.

15. Gas Cutting Table 1 No.

16. Welding Stools 25 Nos.

17. Electric Soldering Iron 200 up to 300 watt 10 Nos.

Machines:

18. Pillar Drill Machine 3mm to 13mm 1 No.

19. Hand Drill Machine (Electric) 01mm to 13mm 1 No.

20. Padestal Grinder 1 No.

21. Hand Grinder (Electric) (4” x 7”) 1 No.

22. Bench Shearing Machine 1 No.



23

23. Lever Shearing Machine 1 No.

24. Surface Plate 1 X 1m X 100mm 1 No.

25. Anvil with stands 300 kg. 2 Nos.

TOOLS:

26. Work Bench 13 Nos.

27. Bench vice (size 5”) 25 Nos.

28. Flat File 300 X 1 25 Nos.

29. Round File 250 X 1 25 Nos.

30. Half Round File 250 X 1 25 Nos.

31. Tri-angular File 200 X 1 25 Nos.

32. Steel Foot Rule 25 Nos.

33. Flat Chisel 25 Nos.

34. Cross Cut Chisel 25 Nos.

35. Center Punch 25 Nos.

36. Hammer 500/1000 g.m. 25 Nos.

37. Try – square 8” / 6” 25 Nos.

38. Hand Vice 4 Nos.

39. Twist Drill Set (3-13mm) 2 set (set of 25 piece).

40. Hand Hacksaw frame (Blade size 12”) 25 Nos.

41. Tap and Dia set (6-12mm) 2 set

42. Line Scriber 25 Nos.

43. Vernier Caliper 6” 6 Nos.

44. Safety goggle 6 Nos.

45. Vernier height gauge 2 Nos.

46. Angle Plate 2 Nos.

47. Welding Transformer (50-450amp.) Complete with lead & holders

6 Nos.

48. Welding rectifier (400 Amps.) 4 Nos.

49. Welding Generator 2 Nos.

50. Welding Face shield 12 Nos.

51. Welding Helmet 12 Nos.



24

52. Safety Helmet 6 Nos.

53. Arc Welding Table 12 Nos.

54. Chipping Hammer 12 Nos.

55. Leather Gloves (Left & Right) 12 Set

56. Leather Apron 12 Nos.

57. Oven for welding rods 300 Co 1 No.

58. Desiccators (100 – 120 Co) 10 Nos.

Welding Quality Test

59. Inspection Torch (Pencil) 5 Nos.

60. Inspection Mirror 5 Nos.

61. Welding Gloves 5 Nos.

62. X-Ray Monitor Lamp 2 Nos.

63. White Paint Markers 5 Nos.

64. Spirit Level 45” 5 Nos.

65. Inspection Gauges 5 Nos.



25

EMPLOYABILITY OF PASS-OUTS:

The pass-outs of this course may find job / employment opportunities in the

following sectors / areas:

1. Packages

2. Pakistan Ordinance Factory Wah

3. Heavy Mechanical Complex /Heavy .Forge & Foundry, Taxila

4. PECO, Kot Lakhpat

5. DESCON Engineering

6. Pakistan Railways Workshops

7. Tractor Manufacturing Firms

8. Welding Workshop

9. Construction Industry

10. Auto Mobile Industry



26

Reference Books

Sr. No

Book Name Author Name Publisher

1. ARC WELDING (basic fundamentals)

JOHN R.WALKER South Holland, Illions

The Good Heart-Will Cox (Company) INC

2. OXYACETYLENE WELDING (basic fundamentals)

RONALD J.BAIRD South Holland, Illions


3. MODREN WELDING Althose Turnguist Bowditch

South Holland, Illions


4. OXYACETYLENE HAND BOOK

LINDE, Linde Company

5. WELDING SKILLS

JOSEPH W.GIACHINO Pub. American Technical Publisher

6. GAS WELDING AND CUTTING

YENSEXER Mosco – Pease Bublisher



27

MINIMUM QUALIFICATION OF INSTRUCTOR

DAE with five years relevant experience

OR

Two Year Proficiency Certificate of Welding Trade with 6 years relevant

experience

training objectives - punjab

Documents