welding technician level 3 syllabus - welcome...
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PCFCT Ver.1.0 1/17
Annexure 1
WELDING TECHNICIAN
LEVEL 3
SYLLABUS
Submitted by
PREMIER CENTER FOR COMPETENCY
TRAINING (PCFCT)
PCFCT Ver.1.0 2/17
Contents 1. Introduction to the Course ......................................................................................3
2. Synopsis of Course Duration ..................................................................................5
3. Detailed Syllabus ....................................................................................................5
4. Minimum General Requirements to conduct practical .........................................14
5. Internship ..............................................................................................................15
6. Qualification and Experience of Skill Development Executive (Trainer) ............15
7. Training Calendars(Not Applicable now) ............................................................15
PCFCT Ver.1.0 3/17
1. Introduction to the Course
Course Specifications
Welding Technician Level 3 Qualification Pack & NOS : ASC/Q3102
Automotive Premier Center For Competency Training
On completion of the course the candidates will have skills and competencies to work as
a assistant welding technician in automotive industry.
The course lays foundation for diverse kinds of skills and competencies relevant for the
specific job-role. The course is designed as per standards set by industry National Skill
Development Corporation (NSDC) / Sector Skill Council / ASAP (Tick as applicable).
Key Objectives of the Course:
Is to make the participant to know, 1. How to prepare welding machine before welding
2. How to read and understand work order, job card, control plan and machine manual by
self
3. How to perform welding as per requirement
4. How to conduct pre-inspection, process monitoring & post inspection.
5. Know how to maintain the environment clean and safe working area, tools & machinery
ready.
Key competencies to be developed 1.Gas welding
Particulars Description
Course name as assigned by
ASAP
Code of course assigned by
ASAP
Duration of the course
160 hrs
QP reference
ASC/Q3102
Level of the Course
[as per National Skill
Qualification Framework
(NSQF)]
Level 3
PCFCT Ver.1.0 4/17
Particulars Description
Job role after training
[as per NOS]
1.Responsible for supporting operator during welding
process
2.Loading and unloading welding components
3.Recoring and maintaining documentation
Eligibility criteria for
admission
1.Minimum Educational Qualification: class 10
2.Minimum age: 18
Training delivery model
1.Activity based model (practical)
Assessment of trainees
[to be in conformity with
quality framework of ASAP]
Please refer annexure no. II
for quality framework of
ASAP
1. Theory test
2. Practical test
3. weightage
Internal Assessment (please
refer annexure V)
External (please refer
annexure v)
Further learning opportunities
List of courses which the students may be able to join after successful completion of
the present training:
After successful completion of course the candidate is eligible for following further
learning opportunities:
1. Can join Welder level 4
2. Can join under water welding course
3. Can join non-destructive testing course level 2
4. Can join advanced welding courses.
5. This, course further develops the necessary knowledge to produce Welding
Procedure Specification's (WPS) and welder qualifications to the mentioned
standards.
Further Job opportunities / Occupations
PCFCT Ver.1.0 5/17
List the existing and emerging job opportunities / occupations which students will be
able to join:
After successful completion of course the candidate can avail following job
opportunities:
1.Assistant welder in automotive industry
2. Assistant Gas welder
3. Assistant Arc welder
4. Assistant Mig/Mag welder
2. Synopsis of Course Duration
Particulars Duration (hrs)
Institution-based training:
1. Theory Sessions 70 hrs
2. Practical Sessions 90 hrs
Industry-based training:
3. Internship 150 hrs
Total 310 hrs
3. Detailed Syllabus
The syllabus is to be provided in detail in the table given below.
Sl.
No.
Module
and Units
Theory /
Practical
Content in terms of
Key Learning
Outcomes*
The
ory
[hrs
]
Pract
ical
[hrs]
Total
durat
ion
[hrs]
NOS
code
1 Module :
Basics of
metal
joining
process
Basics of
engineering
drawing
Theory Define Fundamentals
of engineering drawing
Describe Projections
of solids & Isometric
views
3 hrs 3 hrs ASC/N
3103
2 Module :
Basics of
metal
joining
process
Theory Describe symbols used
in drawing
Define Measurements
and
Tolerance
Reading product
3 hrs 3 hrs ASC/N
3104
PCFCT Ver.1.0 6/17
Product
drawing
drawing &
understanding the
requirements
3 Module :
Basics of
metal
joining
process
Introduction
to metals
Theory List out Properties of
Metals
Define Impact of Heat,
Pressure in metals
List out Common
ferrous and non
ferrous metal alloys
and their melting point
Define State of matter
1 hrs 1 hrs ASC/N
3103
4 Module :
Industrial
orientation
First Aid
Theory Define what is first aid
List out procedure for
first aid
1 hr 1hr ASC/N
0006
5 Module :
Industrial
orientation
Fire Safety
Theory List out types of fire
Describe the procedure
for Evacuating fire
1 hr 1 hr ASC/N
0006
6 Module :
Basics of
metal
joining
process
Introduction
to welding
Theory List out the Safety in
welding and welding
shop
Describe Safety
equipments used in
welding
Safety in (GAS and
ARC welding)
1 hr 1 hr ASC/N
0006
7 Module :
Basics of
metal
joining
process
Workshop
calculations
Theory/Practic
al Various types and
standards of
measurements
Conversion of units
Pythagoras theorem
and its application
Algebra
4 hrs 4 hrs
8 Module :
Basics of
metal
joining
process
Basics of
Theory Describe OHM'S law
Define source of
electricity
AC & DC current
Generators &
Transformers
2 hrs 2 hrs ASC/N
3104
PCFCT Ver.1.0 7/17
Electricity
9 Module :
Basics of
metal
joining
process
Uses of
Hand tools
Theory To know how to use
the following tools,
Bench vice, Scriber,
Try square, Calipers,
Dividers, Punches,
Files, Hacksaw,
Hammers, Chisels,
Clamps, Bench
Grinder, chisel, etc.
2 hrs 2 hrs ASC/N
3105
ASC/N
0007
ASC/N
0007
10 Module :
Basics of
metal
joining
process
Gas welding
Theory Describe Gas welding
equipments
The basic setting of
flames
Operation and pressure
setting
Techniques used in gas
welding
Selection of filler
metals and fluxes used
in brazing
Difference between
brazing and fusion
welding
Process of welding
dissimilar metals
Care and maintenance
of cylinders
Advantages of non-
fusion welding
Safety to be followed
during gas welding
4 hrs 4 hrs ASC/N
3104
11 Module :
Basics of
metal
joining
process
Manual
Shielded
Arc
Welding
Theory Principle of arc
welding
Electric arc theory
Power source
AC & DC welding
Machines
List out Welding
Accessories
Describe Operating
procedure
Arc length and its
Effects
Classification of Arc
length
Effects of Arc length
Safety in Arc welding
4 hrs 4 hrs ASC/N
3105
PCFCT Ver.1.0 8/17
12 Module :
Basics of
metal
joining
process
Selection of
Electrodes
Theory List out types of
electrodes
Define Specification of
electrodes
Electrode
classification - Carbon
steel
2 hrs 2 hrs ASC/N
3105
13 Module :
Basics of
metal
joining
process
Welding
Defects
Manual Arc
Welding
Theory Describe Arc length
and its Effects
Define Classification
of Arc length
Effects of Arc length
Causes of welding
defects
List out remedies of
welding defects
2 hrs 2 hrs ASC/N
3104
ASC/N
007
14 Module :
Basics of
metal
joining
process
Lifting
Tools
Theory List out Clamping
device
Describing Various
lifting tools
Functioning of Hoist
Crane &Pulley
Operation Fork lift
Safety to be followed
in using lifting tools
2 hrs 2 hrs ASC/3
106
15 Module :
Basics of
quality
Gauges
Theory Describe the functions
of each gauge
Define the importance
of calibration of
gauges
2 hrs 2 hrs ASC/N
3105
ASC/N
0007
16 Module :
Basics of
quality
Inspection
of Weld
Theory Define Visual
inspection
Distinguish between
Destructive testing &
Non Destructive
testing
4 hrs 4 hrs ASC/N
3105
ASC/N
0007
17 Module :
Basics of
quality
Standard
Operating
Procedure-
Theory Explain the importance
of SOP
Describe the procedure
for the preparation of
SOP
1 hr 1 hr ASC/N
0006
PCFCT Ver.1.0 9/17
SOP
18 Module :
Basics of
quality
Calibration
Theory Define frequency of
calibration
List the importance of
calibration
1 hr 1 hr ASC/N
3106
19 Module :
Basics of
quality
Distortion
and its
Control
Theory List out types of
distortion
Define causes for
distortion
Factors affecting
Distortion
Prevention of
distortion
2 hrs 2 hrs ASC/3
105
20 Module :
Basics of
quality
Measuring
Instruments
Theory/Practical Define how to use
Vernier caliper
Micro meter
Steel rule
Calipers
Welding templates &
Weld gauges
Understand the
calibration of
measuring instruments
4 hrs 4 hrs ASC/N
3104
ASC/N
3105
ASC/N
0007
21 Module :
Industrial
orientation
Factory Act
and
Discipline
Theory Explain Factory Act
and the disciplines
should be followed in
an organization
1 hr 1 hr ASC/N
0006
22 Module :
Industrial
orientation
Safety
Theory Describe personal,
industrial and social
safety
List out Why PPE is
essential
2 hrs 2 hrs ASC/N
0006
23 Module :
Industrial
orientation
5S
Theory Define purpose of 5S
Benefits of 5S
2 hrs 2 hrs ASC/N
0008
ASC/N
0006
24 Module :
Industrial
orientation
Environmen
t
Managemen
Theory Describe what is
environmental hazard
and its types
How to deal in hazard
the responsibilities in
handling environment
1 hr 1 hr ASC/N
0006
PCFCT Ver.1.0 10/17
t System -
EMS How to report in
hazard
State common causes
for accidents
25 Module :
Basics of
metal
joining
process Manual
Titanium
inactive Gas
welding-
TIG
Theory List out TIG welding
equipments and
identification
Describe Preparation
of TIG welding
machine
Advantages of TIG
welding
List out Operating
procedure
List out Safety in TIG
welding
Power source in TIG
welding
List out Maintenance
and care of
TIG welding machine
List out Causes of
Defects and Remedies
in TIG welding
4 hrs 4 hrs ASC/N
3104
ASC/N
3105
ASC/N
0008
26 Module :
Basics of
metal
joining
process Manual
Metal active
Gas
welding-
MAG/MIG
Theory Principle of
MAG/MIG welding
List out MAG/MIG
welding equipments
and identification
Define Functions of
Shielding gases
Distinguish
Advantages &
Disadvantages of
MAG /MIG welding
List out safety in
MAG/MIG welding
Define Electrode
Position
Welding Positions
Safety in MAG/MIG
welding
Welding Process and
Parameter
Filler rods in
4 hrs 4 hrs ASC/N
3104
ASC/N
3105
PCFCT Ver.1.0 11/17
MAG/MIG Welding
Causes of Defects and
Remedies in
MAG/MIG welding
27 Module :
Basics of
metal
joining
process Spot
Welding
Theory Describe
Fundamentals of Spot
welding process
List out Characteristic
of Spot welding
Define Surface
preparation
Application of Spot
welding
2 hrs 2 hrs ASC/3
105
28 Module :
Basics of
metal
joining
process Projection
Welding
Theory Describe
Fundamentals of
Projection welding
process
List out Techniques in
projection welding
2 hrs 2 hrs ASC/3
105
29 Module :
Basics of
quality
Quality
tools
Theory Describe the various
types of 7QC tools
Understand the
importance of each
tool
Describe how to draw
the QC tools
1hr 1 hr
30 Module :
Behaviour
skills
Communica
tion and
Listening
Skills
Theory Describe the
importance of body
language
Define the process of
communication
Channels of
communication
Understand the active
listening process
1hr 1 hr ASC/N
3103
ASC/N
3104
31 Module :
Behaviour
skills
Positive
thinking
Theory To become spirited
and spunky to handle
situations effectively
1hr 1 hr ASC/N
3105
32 Module :
Behaviour
skills
Theory To promote team for
increasing synergy
1hr 1 hr ASC/N
0007
PCFCT Ver.1.0 12/17
Team Work
33 Module :
Behaviour
skills
Writing,
reading and
oral
communicat
ion
Theory Describe how to
complete accurate,
well written work
Read instructions,
guidelines, procedures,
rules and service level
agreements
Listen effectively and
orally communicate
information accurately
1hr 1 hr ASC/3
104
34 Module :
Behaviour
skills
Personal
Health and
Hygiene
Theory Describe how to keep
the health in good
condition and practice
the habits of being
hygiene
1hr 1 hr ASC/N
0006
35 Module :
Basics of
metal
joining
process
Gas welding
Practical
EX.name
1. Setting of
oxy- acetylene
flames
2. Straight line
bead Fusion
weld with
filler rod (flat
3. Square butt
joint (flat
position)
4. Fillet weld in
lap joint (flat
position)
5. Fillet weld in
T joint
(flat position)
6. Square butt
joint (flat
position)
7. Fillet weld in
lap joint (flat
position)
8. Fillet weld in
T joint
(flat position)
9. Brazing lap
fillet in
(flat position)
10. Fillet weld
To know how to do
List out safe handling
of oxy-acetylene plant,
distinguish between
oxygen and acetylene
fittings
List out types of flames
Starting, re starting and
finishing techniques
Selection of nozzle and
filler rod, Surface
preparation of work
piece
Selection of correct
nozzle and filler rod,
job setting with correct
lapping distance
Selection of correct
nozzle and filler rod
and flux, brazing
techniques
Surface preparation of
work piece and job
setting with correct
corner position
30 hrs 30 hrs ASC/N
3104
PCFCT Ver.1.0 13/17
outside corner
joint
( flat position)
11. Butt weld
single v butt
joint
(flat position)
12. Fillet weld
inside corner
joint
(flat position)
36 Module :
Basics of
metal
joining
process Arc
Welding
Practical Eg.
Name
1. Setting up of
Arc welding
machines
2. Straight line
beading (flat
position)
3. Square butt
joint
(flat position)
4. Fillet weld in
lap joint (flat
position)
5. Fillet weld in
T joint
(flat position)
6. Fillet weld
outside corner
joint
(flat position)
7. Fillet weld
inside corner
joint
(flat position)
8. Fillet weld in
T joint
(Horizontal
position)
9. Butt weld
single V butt
joint
(Horizontal
position)
To know how to conduct
welding and
Safe handling of Arc
welding machines and
accessories, necessity
of cleaning.
Selection of electrode
and effect of low
current and high
current,
Tools used in welding,
Common welding
symbols,
Importance of root gap
Use of chipping
hammer, wire brush
and cleaning slag
,spatter from the weld
Arc length and its
effects, coding of
standard electrodes as
per IS.
Identification of
different types of
electrodes and function
of flux coating on
electrodes.
30 hrs 30 hrs ASC/N
3105
37 Module :
Basics of
metal
joining
Practical
Ex. Name
1. Setting up of
MIG welding
Safe handling of MIG
welding machines and
accessories, necessity
of cleaning.
30 hrs 30 hrs ASC/N
3104
PCFCT Ver.1.0 14/17
process MIG
Welding
machines
2. Straight line
beading (flat
position)
3. Square butt
joint
(flat position)
4. Fillet weld in
lap joint (flat
position)
5. Fillet weld in
T joint
(flat position)
6. Fillet weld
outside corner
joint
(flat position)
7. Fillet weld T
and Lap joint
(flat position)
8. Butt weld
single V
butt joint
(Vertical
position
upward)
9. Butt weld
single V
butt joint
(Horizontal
Selection of filler rod
and effect of low
voltage and high
voltage, effect of wire
speed, tools used in
welding, common
welding symbols,
cleaning spatter from
the weld
Selection of gas flow
rate, selection of wire
feed rate, angle of the
welding torch.
Importance of root gap,
Selection of wire
diameter, voltage and
wire speed setting and
necessity of tacking.
Position of welding
torch
Lapping distance for
thin and thick plate.
Method of presenting
upper plate edge
melting off.
4. Minimum General Requirements to conduct practical
Category Description
Infrastructure
1. Classroom with white board,marker,projector,screen,etc
2. Laboratory to inspect weld
3. Workshop fully equipped to conduct welding practical
Equipment
1. Gas welding machine
2. Arc welding machine
3. Mig welding machine
4. Welding accessories
5. Safety devices like PPE, Fire extinguishers
PCFCT Ver.1.0 15/17
Teaching-
learning
material
Welding technician practical guide
5. Internship
Particulars Description
Duration of internship 30 days (150 hrs)
Prospective
organizations
Sn. Organisation Product / Service
1 Automotive
manufacturing
industries
Auto components
Job roles to be
included
1.Responsible for supporting operator during welding process
2.Loading and unloading welding components
3.Recoring and maintaining documentation
Specific skills to be
focused
1.Various Welding techniques used in industries
Mode of placement Full Day
Time of placement After completion of internship
6. Qualification and Experience of Skill Development Executive (Trainer)
Sl.
No. Qualification
Experience [ years]
Total Industry Teaching / Training
1. B tech 6 years Automotive 3 years
2. DME 3 years Automotive 3 years
3. DME( Marine ) 3 years Automotive 3 years
7. Training Calendars (Not Applicable now)
Illustrative formats for the calendars are provided below. The TSP may modify the
same as required.
Format for Training Calendar:
PCFCT Ver.1.0 16/17
Day Module / Unit Theory / Practical Time [From – To]
1
2
3
4
5
Rows to be added as required
Format for Calendar of Internship: (Not Applicable now)
Dates / Month
[From - To]
Industry Tasks assigned by the industry
Rows to be added as required
Format for Calendar of Tests / Examination (Not Applicable now)
Day Modules Theory /
Practical
Time
[From – To]
1
2
3
4
5
Rows to be added as required