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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 1 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 2 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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Name of Member & Designation Shri/ R.K. Mohanty, Sr. DGM (E&I) S.K. Mishra, DGM/ETL H. Singh Subhash Kumar P.K. Mohanta Sanjay Kr. Sinha Shankar Banerjee Satyajit Pal Tapas Kumar Dhar S.C. Jha M. Mitra S. Bhowmik U.K. Choudhary K.N. Choubey Amit Kumar Sanjeev Kumar S.N. Dutta, DGM (Gl.Maint.) B.N. Prasad, DGM(HRD) B. Bushan A. Nandi, Dy. Director N. Pandit A.K. Neogy, Trg. Officer M.K. Verma A.K. Bhattacharjee, JTA Organization Jindal Steel & Power Ltd. SAIL, Bokaro Usha Martin Ltd., Jamshedpur Usha Martin Ltd., Jamshedpur Tata Steel Ltd. Adhunik Alloy & Power Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. SAIL, Bokaro SAIL, Bokaro SAIL Bokaro Tata Steel CSTARI, Kolkata Tata Steel Ltd. CSTARI, Kolkata Tata Steel Ltd. RDAT, Kokata 3 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Anil Kumar, Jt. Director Dr. Binod Kumar N.R. Arvindam, Dy. Director R.K. Sharma Sandeep Dhir Vijay Kumar Singh V.K. Sinha Biswanath Roy S.K. Singh D.M. Chowdhury Suresh Kumar Surendra Kumar B.B. Das A. Ranjan Sanjay Kedia S.B. Choudhary A.K. Karn C.K. Goswami R.K. Mishra S.P. Sharma J. Sarkar A.K. Mallick S.K. Gupta S.N. Rana Major K. Satyanarayan RDAT, Kolkata FTI, Jamshedpur FTI, Jamshedpur TCIL, Jamshedpur Tata Steel Adhunik Alloy & Power Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. Tata Steel Ltd. TCIL, Jamshedpur Tata Steel Ltd. Tata Steel Ltd. SAIL, Rourkela SAIL, Rourkela Jindal Steel & Power Ltd. Jindal Steel & Power Ltd. Tata Steel Ltd. 4 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 (Inplant) 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 ) 5 Trade- Electronics Mechanic (Steel Plant) Training Structure Sl.No. 1 2 3 4 5 6 7 8 9 10 2nd Year 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Module No A.1 A.2 A.3 A.4 A.5 A.6 A.7 A.8 A.09 A.10 A-11 A.12 A.13 A.14 A.15 A.16 A.17 A.18 A.19 A-20 B.1 B.2 C Modules/ Subject 1st Year Basic Trade Training Introduction, general & behavioral safety Industrial safety & Quality Bench-fitting Skills Electrical Fundamentals and circuit Electrical machines Basic Electronics Power Electronics & Drives Analog & Digital Communication Instrumentation & Control Revision & Test PLC & DCS Fluid Power (Industrial hydraulics & pneumatics) Welding Advanced Industrial Electronics Repair & maintenance of electronic equipment Electrical Power System Computer and IT Iron & Steel making technology Quality Management and Improvement Techniques Rigging Environment Control and Occupational Health Revision & Test Shop floor (In-plant) training Industrial visits, project work, Revision & Test Related instruction class (1 day/week) Total Duration in weeks 01 01 08 08 08 10 06 04 04 02 02 02 01 04 05 04 01 02 01 02 01 01 24 02 Syllabus to be covered within 2 years of training period 104 6 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 Trade Theory No. Terminal Competencies: Trade Practical Engineering Drawing Workshop Calculation & Science After completion of this module the trainee will be aware of Trade apprenticeship training scheme, general and behavioral safety 1 Overview of steel manufacturing process and machinery Familiarization with the Plant visit to observe steel Institute & steel industry. making process & machineries Machinery used in the trade used in steel plant. and type of work done by the Use of Personal Protective trainees in the trade. Equipment. Importance of safety, general Rules & regulation of the safety precautions observed institute 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. Introduction to Applied workshop Engineering drawing, its problems involving importance and uses in common fractions. engineering fields. Science – Definition, Nomenclature, Various branches , significance and definitions of important terms. 7 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 2 Quality Circle 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 organizationSmall group activities (SGA), Quality Circle(QC) and its tools. Usage of First aid box and Geometrical construction practice of Cardiopulmonary of Square, Rectangle, Resuscitation (CPR) Triangle, Circle, Ellipse, Polygons, etc. Usage of Drawing different types of - Fire extinguishers - Safety appliances- lines. personal protective equipment (PPEs), gas detector, gas mask, oxygen pack etc. (specific to steel industries) 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. 8 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. Hacksawing - Marking lines, Cut metals pieces of different profiles & sections by hacksawing (straight, inclined & curved line) to an accuracy of 0.5 mm. Classification, construction and functional detail of Filing - Parallel filing practice Hammers. on flat surface Marking practice of straight, parallel Classification, construction and curved lines with odd leg and functional detail of calipers, steel rule, dividers, following cutting tools: Scriber. Filing flat, square, Chisels, Hacksaw, Files, steps and contour surfaces to Drills, Reamers, Scrapers, an accuracy of 0.2 mm. Taps & Dies. Marking Transfer of Classification, construction dimensions from drawing to and functional detail of work pieces. Finding center of following bench tools : Steel a round bar with the help of „V‟ rule, Try square, Calipers, block and marking block. Divider, Centre punch, Surface plate, V-Block and Chipping - Chipping practice Trammel etc. on flat surface, slots & oils grooves, and chamfer at Marking media, marking 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 related on work. problems time and Scalar and vector quantities, definition and units of terms related to motionspeed, 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 9 of blue, Prussian blue, red lead, Dimensioning practice. chalk and their special Drilling & Reaming - Use of application, description. drilling machine for drilling through & blind holes, Measuring Instruments: Reaming of drilled hole by Micrometer (outside and hand reamer. inside) – working principle, use and care, Calculation of Internal & external threading least count. Vernier calipers, by Taps & Die principle, graduations, reading, use and care. Dismantling, inspection and reassembly of bearings, coupling Elements of mechanical and keys components: bearing, coupling and keys Practice on leveling, alignment, static balancing and plumbing Basic knowledge of gear related to electrical machines and gear boxes including Laser alignment. Motion with proper examples, Concept of Force, Concept of Inertia i.e. inertia of motion and inertia of rest. Leveling and alignment of Practice on lubrication related electrical machine to electrical machines Lubrication related electrical machines to 10 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. Dimensioned Drawing:- Workshop problem on 11 Fundamentals of electricity, Demonstration and use of Method of dimensioning time and distance. electron theory, concept of electrical measuring according to BIS Workshop problem on free electrons and difference instruments with safety specifications. Art of mixture. between conductor, insulator aspects Spacing the views. and semi-conductor. Drawing three views of Measurement of force, Verification of Ohm‟s law simple machine parts i.e. P = ma where P is Definition and units of using all the instruments the force, m is the mass voltage, current, resistance, Verification of law of series and with dimensioning. and a is the power and energy parallel circuits acceleration. Units of force. Momentum – Ohm’s law, simple electrical Verification of Kirchhoff‟s law definition and its circuits and problems. significance. Problems. Resistanceseries and Measure resistance by using parallel, laws of resistance, voltmeter and ammeter, postNature of forces – temperature co-efficient of office box, AVO meter, composition and resistance, work, power and Standard resistance resolution of forces. energy. comparison, bridge, megger Resultant of a number and potentiometer of coplaner forces acting Kirchhoff‟s current & voltage at a point. Problems. 11 laws and application, Wheatstone bridge and its application, Simple problems 12 Use of common electrical measuring instruments and related safety aspects 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 13 Magnetism- classification of magnets, methods of magnetizing, magnetic material, Coulomb‟s law, permeability, ferro, para and diamagnetic materials ElectromagnetismSolenoid, field around 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. 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 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. Perform experiments to draw Do 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 12 conductors carrying current, polarity, screw-rule, righthand 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. 14 Principles of electromagnetic induction, Faraday‟s laws, Lenz‟s law, Fleming‟s Rules, Related safety aspects Self-inductance, mutual- Connect the capacitors in Do inductance, their co-efficient, series and parallel and equations and problems measure different values. Do Joule’s law of heating, Observation of charging and Joule‟s equivalent, heating discharging of capacitors, its appliances and elements. testing. Electrostatics- terms and definitions, coulomb‟s law, capacitors, charging and discharging of capacitors, energy stored. Grouping of dry cells for a specific voltage and current Battery charging- Prepare electrolyte for lead- acid storage battery; charge the Chemical effect of battery using different electricity – principle of methods, Check for battery electrolysis, Faraday‟s laws. condition. Applications of electrolysis, 13 Basic principles electroplating of Routine care and maintenance of batteries 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. Rechargeable dry cells 15 Related safety aspects Alternating Currentcomparison 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 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. Related safety aspects 14 16 17-18 AC series and parallel AC series and parallel circuits – RL, RC and RLC. circuits Power factor and resonance Determining L for a coil and Poly phase systems, its choke and C for a capacitor advantages over singlephase system. Observation of 3-phase voltages and measurement of Star and delta connections in voltage, connections in star & 3-phase system, relationship delta of VL, VP, IL, IP, formulae and calculations Related safety aspects 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 Do Demonstration of three-phase Do 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. Related safety aspects 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. 15 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. 19 20-21 Practice safe working on electrical equipment Types of electrical Familiarization with safe machines. working practice with electrical DC generatorworking equipment principle, EMF equation, electromagnetic drag, types, Identification and study of parts and parts, Self and of a DC Machine separately excited generators, practical uses Identifying terminals of DC Explanation of armature machine by measuring reaction and commutation, resistance of shunt field, series interpoles and their uses, field and armature connections and polarity Connecting, running and Characteristics of series, studying the characteristics of shunt, compound and DC series, Shunt, and separately excited compound generators. Study of generators, critical resistance No-load and load and critical speed, application characteristics of DC generators, Losses and efficiency Finding critical resistance and critical speed of DC generators DC motor- working principle, Testing DC motors, identifying torque, speed, back emf, their terminals, connecting, running relations. Types of DC and reversing direction of 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. Coefficient of friction, angle of friction, angle of repose. Advantages and disadvantage of friction. Related Problems. Lubricants – types, viscosity and effect of temperature on viscosity. Do Do 16 22-23 motorsseries, shunt, compound and separately excited their characteristics and applications. Starting and speed control of DC motors. Related safety aspects rotation of DC motors. Transformersworking 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 transformerstypes, construction, applications, advantages and connections, Protective devices and cooling systems of transformers Identification of types transformers and its parts Studying characteristics and drawing characteristic curves of DC motors of all types. of Interpretation of Orthographic Projection:Important points and Verification of transformation significance of projection ratio, loading secondary, lines. Techniques to draw finding relation between the missing views and primary and secondary various types of currents, voltages and no. of possibilities of elevations turns with a single plan. Measurement of iron and copper losses, determination of regulation, efficiency etc., polarity marking of singlephase and three-phase transformers Moment of a forcemeaning 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. Testing of single and three Auto-transformers, phase transformers, cleaning Instrument transformers - CT, and maintenance, oil testing. PT, Tong-tester and their applications Study of Instrument transformers - CT, PT and Related safety aspects Tong-tester 24-25 Induction motors- Rotating magnetic field, and working of 3-phase induction motors, production of torque. Dismantling, inspection of Simple exercises on parts, cleaning and testing of Interpretation of windings, lubricating bearings Orthographic Projections. and assembling of 3-phase SC Do 17 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 woundrotor induction motors and SR motors Polarity marking (phasesequence 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 Use of motor Checker Dismantling, studying and reassembling the Protective devices in AC electromagnetic AC contactors motor circuits – Principle and of different voltages, types, setting of over-current relays- makes and categories. thermal, magnetic, EOCR and numerical relays. Single- Settings of different types of phasing-its effects and motor protection relays prevention, NVR and its function Doing panel wiring by using contactors relays etc. for Single-phase induction automatic star-delta, motors - theory of rotation autotransformer, rotorand self-starting, types, resistance, and forwardreversal and speed control. reverse D.O.L. starters. Related safety aspects Studying, overhauling of fan motors, connecting, running and reversing of single-phase motors. 18 26 Synchronous machines Do Do Identification of terminals of Alternator- parts, types of alternator, connecting, starting, poles- salient pole and running, loading and plotting smooth-cylindrical type, characteristic curves rotating-field and rotating armature type etc Starting synchronous motors by different methods Prime movers for alternators, turbo-alternator, enginedriven 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 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 19 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 – Electronic Component Different types of simple Mensuration:- Plane Introduction to Electronics and identification and testing, and intricate exercises on figures – Triangle, its application, difference Reading and interpretation of interpretation of Square, Rectangle, between analog and digital colour codes of components orthographic projections Parallelogram, electronics. with proper dimensioning Trapezium, Regular Use of digital multimeters Polygons, Circle, Atomic theory, energy band Hollow Circle, sector diagram, classification of Connecting function and segment of matter based on energy band generator with oscilloscope, circle, fillets etc. diagram. study of wave forms, measurement of voltage and Simple machines – Active and passive circuit frequency. what is a machine, its elements: Diode characteristic, Zener advantage and utility. Resistors and their rating - diode characteristics, testing, Important definitions fixed and variable, carbon and and identification concerning to wire wound, metal film and machines – metal oxide, colour coding, Making half wave and full Mechanical power rating, accuracy and wave rectifiers using training Advantage, Velocity effect of temperature, uses of kits, study of different wave Ratio and Efficiency resistors. shapes and their values on of the Machine Fuses and their rating- Slow oscilloscope blow and fast blow, semiconductor fuse Soldering and desoldering practice 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, 20 electrolytic, tantalum, silvered mica, variable capacitors, colour coding and uses. Voltage and current sourcesIdeal 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 29 LED, varactor and photo diodes- working principle and applications. Transistors: working, Transistors: identification Do classification, VI characteristics and testing finding static and (static and dynamic), CE, CB, dynamic characteristics of Do 21 CC configuration and their transistors in different modes difference, current, voltage using training kits, calculation gains and their relationship. of gains. Biasing circuits Biasing and thermal stabilization circuits, heat sink. Packaging, coding, specification, identification and applications in detail DC and AC load lines. H parameters 30 Field effect transistors: Identify, test and draw the VI Do construction, operation and VI characteristic of FET, characteristics of JFET, MOSFET and UJT. Enhancement and deletion type MOSFET, concepts of CMOS, Difference with bipolar junction transistors, uses. Do UJT- Construction, operation VI characteristics and application 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 Assembly and testing of Do 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 Multistage amplifiers- need frequency response curve and types of coupling. RC, transformer and direct couple amplifier circuits, voltage and Do 22 power gain, frequency response, bandwidth, comparison between different types. 32 33 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 amplifierscircuit and applications Oscillators: working principle, classification, circuits and applications. Factors controlling oscillation. Different types of oscillators, their characteristics and applications, crystal oscillators. 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 Assembly of oscillator circuits Do using transistor and measuring the output frequency and waveform. 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 Switching and timer circuits: Construction classification of multi-vibrators, multivibrators using of 555 The Laws of Indices and problems. Power and Exponent, laws of exponent Levers – Classification of Levers and problems Concepts of Sectioning, Do 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 23 astable, monostable and bi- timers, stable. Internal block diagram, frequency operating of 555 timers and its applications Calculation of Opto-electronics- elementary idea of LED, LCD, photo diodes, photo transistors, solar cells and their applications 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 Verification of truth tables of Do different gates Realization of different Boolean expression with logic gates Realization of adders Basic logic gates: Symbolic subtractors representation and truth tables for logic gates: Buffer, NOT, Construct and verify OR, AND, NAND, NOR, XOR, tables of flip flops XNOR. Different logic families and their characteristics, Construct synchronous Electrical equivalent of gates, asynchronous counters Negative and positive logic study its functions gates Construct controlled Boolean algebra- Karnaugh register and study map technique, simplification functions of Boolean expressions, realization of Boolean Practice on reading expression with logic gates interpretation of IC sheets. and Logarithms – Types of logarithms eg. Naperian and Common. Meaning of logarithms its elements i.e. characteristics and mantissa. Problems on Positive Characteristics truth and and Wheel and Axle, Screw Jack, Inclined plane and problems. shift their and data 24 Combinational logic circuits: Half and full adder and subtractors. Encoders, decoders, multiplexer, demultiplexers, 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: characteristics and Schmidt trigger 36 Types, circuits, Microprocessor and Programming practice on computer: Organization in Microprocessor general: CPU, ALU, resistors, counters, data and address Identification of different Do Do 25 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 computer. a personal 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 Exercise on sectioning of power electronic from isometric view. 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 Logarithms Problems Negative Characteristics. on Hydrostatics – Nature of liquids and Pressure of liquid inside a vessel at different positions. Unit of pressure, Pascal‟s Law, simple problems. 26 Thyristor circuits: Checking of power MOSFET, Converter, AC voltage thyristors, IGBT, GTO, IGCT Regulator, Chopper, Inverter, etc IGBT circuit, PWM and their use 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. 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 Types of pressureatmospheric , absolute and gauge. Free hand sketch of tools Do and tackles used in electronics tradesoldering iron, plier, screw drivers, desoldering pump Demo of a real time microprocessor based DC drive used in industries. DC drives: concept of speed Exercise on configuration and control of DC motor. Block parameterization of DC drives. diagram of close loop unidirectional DC drive, four Exercise on maintenance and quadrant operation of DC trouble shooting of DC drive. 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 27 40-41 42 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 UPS - Understanding of float charger, off-line UPS and Online redundant UPS, Different type of controls, circuit and maintenance of UPS and battery. Related safety aspects Testing and study of IGBT, Free hand sketch of tools power plate and instruments used in electronics tradeStudy of inverter voltage multimeters, power waveforms supply, function generators and CRO etc. Demo of a real time microprocessor based AC drive used in different processes in industries. Demonstration on parameterization of AC drives 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. Exercise on maintenance and trouble shooting of AC drive. Study of a UPS and its circuit Drawing symbols of Do and controls electronics componentsresistors, diode, Trouble shooting and transistors, FET, rectification. MOSFET, UJT etc. 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 28 43 44 Working principle and circuit details of Television, Telephone (fixed and mobile), GPS, DA and PA system Communication media Fiber-optics communication Communication systemLab work on AM and FM Screw Threads – Forms Quadratic Equations Elements of communication communication. Calculation of of various screw threads, and practical system, principle of analog modulation index. nomenclature, convention problems concerning communication, , basic and drawing of various to workshop practice terminology used, bandwidth thread profile. of signal and channel, Specific Gravity of:propagation of a) Solids heavier than electromagnetic wave, water. b) Solids modulation and its necessity, lighter than water. c) antenna and types Solids soluble in water. Related Modulation – methods of Problems. modulation- AM, FM, PM. Amplitude modulationmethods, modulation index, generation of side bands, block diagram of AM transmitters. Demodulation- AM radio receiver circuits, super heterodyne receiver Frequency modulationmethods, modulation index and number of side bands, FM transmitter and receiver circuits Other modulation schemes and their comparison Familiarization with TV Demonstration of TV circuits, Do circuits and its working- identification and use of block diagram of different different controls. sections of TV, its circuit Do 29 45 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. Digital communication- Demonstration of RS-232, RS Do principle of digital 485, Ethernet and other communication, methods and communication standards. industrial application. Familiarization with different Data communication: serial communication equipment and and parallel communication, media- Coaxial, UTP, Fibre MODEMS, Interfaces-RS- Optic cable etc. 232, 422, 485, Ethernet. Industrial communication protocolsMODBUS, FIELDBUS, CONTROLNET and Interface buses Do Communication media Computer fundamentals 46 networking Simple concepts of Familiarization communication devices communication (block diagram only): Telephone (fixed and mobile), wireless, satellite, GPS, DA and PA system with FO Do Do Fibre opticsstructure, classification, characteristics, 30 losses, choice of wavelength, 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 47-48 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 Introduction- Objective of Verification of working principle Fastening Devices – Principle of the Instrumentation & control, and characteristic of different Temporary and Similarity:- Properties elements of measurement sensors and transducers Permanent. meaning of similar triangle systems, instrument covered in theory class viz. and difference. and their application terminology LVDT, strain gauge, capacitive Temporary device – to day to day gauges, thermocouples, RTDs, Hexagonal Bolt, Nut, workshop problems. Sensors and transducers– thermistors etc. Check Nut, Washer. To definition and types draw the three views of Properties of Matter – Dismantling, assembly, individual and the Different types of Load cell and its application overhauling and calibration of assembly. Properties of Matter in transmitters, indicators, eg. Mechanical, industrial weighing gauges, regulators and Electrical, Chemical, switches used for pressure, Magnetic etc. Encoders and its applications temperature, flow, level and other measurement Properties of Matter Introduction to process Configuration of smart (Electrical):parameter measurement: transmitters using HART and resistivity, permittivity, other configurations. permeability, resistance temp. 31 Temperature measurementPrinciples, 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. coefficient etc. Insulating materials. Brief description and properties of electrical materials such as silicon, nichrome, silver, copper, aluminum, transformer oil. Pressure measurementtypes 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. 32 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: hydrostatic 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, Different methods of setting of its PID values, preventions of rotation of controller tuning. Bolts - Check nut, Square headed bolt, Square Testing of a control valve, I/P headed bolt with square converter and valve neck, cup headed bolt, positioners. 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 33 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. 51 52 Related safety aspects Revision/ Plant visit/ Industrial visit 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 Familiarization with different Different methods Controller (PLC)- Need and I/O modules of PLC locking of nuts:working principle, hard ware Development of simple a) Lock nuts details. Function and programmes involving bit level b) Slotted nut connections of different instructions, timers and c) Castle nut cards. counters, simple data d) Wings nut etc Program techniques of manipulation instructions. of Properties and uses of copper, zinc, lead, tin, aluminium b) Split brass, pin bronze, d) solder, Symmonds nu bearing metals, timber, rubber. 34 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. 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 . Related safety aspects 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 35 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 DevicesRivets – 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 36 electrodes and their selection, various joints and joint preparation, their suitability for various applications. a) Single plate or strap b) Double plate or strap Heat treatment of steel – Hardening, annealing, tempering, normalizing and case hardening Related safety aspects 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 59 Different techniques of Fabrication of electronic electronic circuit circuits on Assembly and fabrication testing of power supply with filter and regulators on PCB by Surface mounted devices soldering the components. technology, micro-electronics Demonstration on soldering and de-soldering SMDs Isometric Projection:Difference between isometric and actual scale, construction of isometric scale and simple exercises Regulated power supply. Introduction to SMPS and UPS. Understanding of specification. Drawing the symbols of electrical instrumentsammeter, voltmeter, watt meters, ohmmeter, energy meters etc. as per BIS practice. Study of SMPS, UPS and Inverter circuits and its testing Study of PC hardware and peripheral devices Study of industrial camera and PC hardware including I/O CCTV used in steel plants devices, memories 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. Solid Mensuration:Prism, Cylinder, Pyramid, Cone, Frustum of Pyramid and of Cone, Problems concerning to workshop practice. 37 Working principle and types of industrial camera and CCTV 60-61 Welding machine and its control CNC machines- basic idea. Sensors and switchesProximity switch, Micro switch, limit switch, photo switch, encoder and other types of electronic sensors and their application Industrial weighing systemtypes, 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. Relation between load and extension – Graph – meaning of Yield Point – 1st & 2nd Ultimate tensile Stress, Breaking Stress and factor of safety. Drawing the symbols of Solid Mensuration:electrical components practice problems. and devicespush buttons, switches, fuse, Stress, Strain – motor, generators, Definitions, different transformers, relays types of Strain, and contractors etc. 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 Drawing of various wave electronic modules such as shapes- sine , square, rectifiers, amplifiers, triangular, saw tooth etc. oscillators, logic circuits, Solid Mensuration:Sphere, Spherical segment, material weight and cost 38 diagram, circuit diagram and applications of following electronic test & measuring instrumentsa. 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 desoldering 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, timers, voltage ADC, DAC etc multiplexer, Drawing the circuit of a regulators, DC power supply with rectifier, filter and regulator with labeling Repair and maintenance and waveforms. practices on defective electronic equipment such as Drawing the circuit power supplies, PC, diagram of a UPS and microprocessor based circuits, SMPS with labeling and CCTV, industrial camera, waveforms. weighing system, PA system, modem etc. Drawing the circuit diagram of a Signal Repair and maintenance of generator with labeling communication equipment and waveforms. including fibre optic communication modules. (Note- Trainees should be given defective electronic equipment for repair) 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, Kelvinrelationship 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 39 67 Working of LT and HT Switch- gears and protective relays Power factor improvement methods Monitoring system for power generation and utilization Power Generation, Measurement of pit Transmission and resistance. distribution System Demonstration of HV safety devices Introductory concepts - Use of HV tester, cool coat, generating stations: Hydel, discharge rod Thermal, Nuclear, Gas turbine, IC engine etc. Drawing the block Do diagram of an oscilloscope with labeling and waveform. 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 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. Cablesconstruction, 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. 40 laying of cable, testing and Connection fault localization arrestors Indoor and outdoor substation, layout, single line diagram, CT& PT, isolators, earth switch, transformer, lightening arrestor, reactor, breaker, bus and its protection. of lightening Energy management, maximum demand, load factor, connected load, diversity load curve, tariff. LDC- monitoring system for power generation and utilization. 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. Indian electricity rules pertaining to safety of supply system, LT and HT equipment, O/H transmission. Related IE rules and safety aspects 69 Power system protection Switch geararcing phenomena, ACB parts and their function, maintenance of arc chute, contacts, limitation and tightening, testing and calibration of releases, trouble shooting. Drawing of control circuit Do Connection of relays, of a motor starter Maintenance and adjustment of arc chute, and contact Opening and assembling - pole assembly, trip assembly and hand assembly Maintenance of ACB, OCB, 41 Construction, working and maintenance of OCB, VCB and SF6, GIS, their merit and demerit VCB, and SF6 breakers Demo on parameterization of digital relay and numerical relay 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 42 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 managementmaximum 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 Do diagram of a TV set with different sections and its labelling. 16. Computer & IT (1 week) Terminal Competencies: After completion of this module the trainee will become familiar with 71 Hardware of PC Common software used in PC Use of Intranet, Internet, E-mail Computer & IT Drawing of symbols of Basics of computer hardware Preparation of a word different digital electronic and software document (eg. Project report) circuit and componentsgates, flip-flop, register, MS office: Word, Excel and Preparation of an excel file and counter with timing power point make graphical representation diagrams. of data obtained during Use of Intranet, Internet, E- practical sessions on electricity mail Statistics – Mean, Median, Mode, Variance, Frequency distribution , Cumulative frequency, Pie-Chart Expansion of Liquids – it has only one type of expansion e.g. 43 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 72-73 Different types of raw material used for iron making and their sources Iron and steel making processes Hot and cold rolling process Different types of raw Guided visit of different plants Drawing of opamp based material used for iron making of the organization and circuitsadder, and their sources familiarization with the subtractor, integrator, Details of Blast furnace process. differentiators, V/I and reactions, Cooling system, I/V converters. 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. 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 44 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. TPMConcept, 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 Set Theory – instrumentation amplifier Introduction and with labeling and problem. waveform. Mechanical Equivalent of Heatproblems. Transmission of heat – Conduction, Convection and Radiation. Examples from industries. 45 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 multivibrators 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 46 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 78 Awareness on environment Observation of Do pollution and effects. - Emission and pollution Basic knowledge of air control equipment. pollution control equipment. - dust handling & disposal (ESP, Bag house, cyclone system separators etc) - effluent treatment Major emission and pollution plants source and their effect on - emission monitoring environment. equipment 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 pollutioneffluent treatment plants Occupational health and ergonomics Revision/ Plant visit/ Industrial visit Do 47 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. 79The content of this module On the job training – Drawing of AM and FM Peak , RMS and will be developed 1 by the modulated waveform at average value of AC organization based 0 on the Safety pre-cautions to be different modulation supply. Relationship existing Electrical,2Electronics followed in the section/plant index. between them. Peak , and Instrumentation including need of special RMS and average maintenance practices which protective equipment, if any. Drawing of a radio value of current in may include the following receiver circuit Rectifiers. Calculation Study of working of different of form factor, ripple Electronic repair shop equipment used in Practice on Free hand factor, transformation 1. Maintenance and repairing plant/section visited. sketching of electronic ratio. Estimation of of electronic cards tools and instruments. PIV of a diode in 2. Calibration and testing of Carry-out repair/ test/ different types of electronic instruments calibration of instruments/ Drawing of block diagram rectifiers. equipment under the guidance of a microprocessor, Instrument Repair Shop of competent person microcontroller and Number system1. Maintenance and repairing Personal Computer. decimal, binary, octal, of instruments Carry-out minor maintenance hex. BCD code, 2. Calibration and testing of job under guidance of Drawing of flow sheet conversion from sensors, transmitters, competent person symbols of sensors, decimal to binary, control valves etc. transmitter, controller, octal and hex and Working with skilled recorder, control valve vice-versa. Electrical repair and supervisors/ workmen/ etc. testing section operators. De-Morgan theorem. 1. Observation of Drawing of symbols of Introduction to maintenance and repairing Preparing report on the job power electronic Boolean algebra. of electrical machines done components and circuits2. Calibration and testing of SCR, firing circuit of Simple estimation of electrical instruments SCR, thyristorised the requirements of 48 Power Houses and substations 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, materials chopper, cyclo-converter applicable to etc. (1ph & 3 ph) trade. Problems estimation Drawing of block diagram costing. of a feedback control system. Meaning of HP BHP. Problems work, power energy related electrical area. as the on and and on and to Magnet and magnetism. Simple workshop problems. 49 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. 103Revision of theory covered Revision of practical conducted Revision. during the training. 1 during training. 0 Visit to local industries Effective Presentation 4 skills Preparation of project/ training report and presentation to experts Revision. 50 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 51 List of tools and equipment required for Trade- Electronics Mechanic (Steel Plant) Trainees kit: Sl. No. 1 2 3 4 5 6 7 8 9 10 11 Description Quantity Connecting screwdriver 100 mm Neon tester 500 v Screwdriver set (set of 5 bits) - plane and diamond ended Insulated combination pliers 150 mm Insulated side cutting pliers 150 mm Long nose pliers 150mm Soldering iron 25 w, 240 v Electrician knife D.B Digital multimeter portable Soldering iron 15 W/25 W/ 65 W Desoldering pumps Quantity to be sufficient as per seats surveyed & allocated List of equipments required Sl. No. 1 2 3 4 5 6 7 8 9 10 11 Description First aid kit Fire extinguisher Bench vice Steel rule Digital multimeter 30-0-30 V, 2A D.C regulated power supply 0-300V, 500mA DC regulated power supply LCR bridge( digital) Signal generator 100 kHz Digital storage oscilloscope, 100MHz with probe Wattmeter Quantity Quantity to be sufficient as per seats surveyed & allocated 52 12 12 a 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44* Megger (insulation tester) Megger (earth testing) Battery charger Digital IC tester Pulse generator Logic probes DOL starter DOL starter with forward/reverse control Automatic sequencing control Overload relays (Thermal, magnetic, electronic) On delay timer, off delay timer Earth leakage circuit breaker Dimmerstat, 8 Amps Counters Temp. controller DC motor control training kit (Electronic) Level detector Output power meter Distortion factor meter EPROM programmer Microprocessor trainer kit alongwith ADC/DAC with stepper motor controller Proximity switches Photo tachometer Burglar alarm Smoke detector Emergency tubelight Single phase preventer Servomotor Servo controller Absolute encoder Rotary encoder (incremental) DC tong tester Weighing system (load cell based) Programmable logic controller(PLC) with programming 53 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 unit Personal computer with latest configuration with printer High voltage testing kit Surge generator Instrument training kit (LVDT, Strain gauge, Thermocouple etc) Electronic voltmeter DC generator DC motor Single phase alternator SMPS Induction motor( single phase) Stroboscope Synchronous motor Transformer (1 ph/ 3 ph), 1 KVA Motorized control valve Solenoid valve Strain gauge Load cell LVDT Dual trace CRO 100 Mhz Analog IC trainer kit and Discrete component training kit Linear amplifier trainer Digital IC trainer kit Magnifying glass for IC no. reading Microprocessor 8085 trainer kit Digital trainer A/D ,D/A convertor, Mux, Demux, display devices, etc Motor trainer with dummy loads Three phase motor speed controller/ trainer kit Soldering station De-soldering station Hot air soldering station- cum –de soldering station for SMD devices PLC training kit 54 76 77 CNC training kit 3 ph alternator 55 List of consumable materials Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Description Maintenance free batteries Re-chargeable cells-dry cells Power diodes Heat sinks, heat sinks compounds LED‟s Switches Relays (AC/DC), contactors(AC/DC), Push button switches Lamps IC‟s such as 7400,4001,4011,4017,4007,4033,74159,74154,etc OPAMP IC 741 wave form generator IC 8035 IC DAC 0808, IC ACD 0801 Transistors , JFET, MOSFET, UJT Various diodes Various transistors Microphone Speaker 4”, 8 ohm Various capacitors Various resistors Various transformers SCR,DIAC,TRIAC, GTO, IGBT, IGCT 7-segment display (both common cathode and anode) J & T type thermo couple Quantity Quantity to be sufficient as per seats surveyed & allocated 56