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SYLLABUS OF SEMESTER SYSTEM FOR THE TRADE OF “INSTRUMENT MECHANIC’’ UNDER CRAFTMAN TRAINING SCHEME (CTS) (FOUR Semesters) Designed in – 2012 By Government of India Ministry of Labour & Employment (DGE&T) CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN-81,Sector -V, Salt Lake, Kolkata – 700 091 List of the trade committee members approved the syllabus of Semester System for the trade of “INSTRUMENT MECHANIC” under Craftsmen Training Scheme (CTS) held on 13th & 14th Sep.2011 at ATI, Mumbai – 22, Maharashtra. Shri S.J.Amalan, Director, C.S.T.A.R.I, kolkata Sl. No. 1. Organization ATI, Mumbai Remarks Chairman ATI, Mumbai Member ATI, Mumbai Member 4. Name and Designation ,Shri S/Shri R. K. Pathak Director In Charge/HOD Ujjwal Biswas Dy. Director of Trg Abhinoy Nandi Dy. Director of Trg P.S. More, Training Officer ATI, Mumbai Member 5. S. J. Wakde, Training Officer ATI, Mumbai Member 6. Smt. Kavita K. Phadnis, Training Officer A.R.H. Shaikh, Training Officer N.V.Nare, Training Officer J.H.Suryawanshi, Training Officer D. N. More, Training Officer A. N. Mancharkar, Instructor S. Z. Rajput, Instructor P.R.Patil, Instructor S.S.Barve, Instructor R.S.Wagh, Instructor D. M. Basha, Instructor ATI, Mumbai Member ATI, Mumbai ITI, Mahad ITI, Mahad Member Member Member ITI, Mahad IT I Ambarnath IT I Ambarnath ITI, Nagathane, Roha ITI, Mahad ATI, Mumbai ATI, Mumbai Member Member Member Member Member Member Member 2. 3. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. GENERAL INFORMATION 1. Name of the Trade : 2. NCO Code : 3. Duration of Craftsman Training : Instrument Mechanic Two Year(Four semesters having duration of six months each). 4. Entry Qualification : pass 10th under 10+2 scheme. 5. Space Norms : Workshop: 100 Sq. M. 6. Power Norms : 8.07 KW. 7. Trainees per unit : 8. Qualification for Instructor : 20 Degree Engineering in Instrumentation /Instrumentation and control /Electronic Instrumentation/ Process Control Instrumentation with one year post qualification experience in relevant field. OR Diploma Engineering in Instrumentation /Instrumentation and Control /Electronic Instrumentation/ Process Control Instrumentation with two year post qualification experience in relevant field OR National Trade Apprentice Certificate with 4 years post qualification experience in relevant trade. OR National Trade Certificate with 5 years post qualification experience in relevant trade. 9.Desirable Qualification : Preference will be given to a candidate having Craft instructor Training Certificate. (If not done CITS than must be trained within 02yrs on joining) Syllabus for the trade of “INSTRUMENT MECHANIC (GENERAL)” under Craftsmen Training Scheme (CTS) Based on Semester System Week. No. 1 2 Trade practical FIRST SEMESTER (Basic electricity and electrical measuring instruments) Trade Theory Engineering drawing Vocational science & Calculation Introduction to General simplifications Engineering - introduction, fraction, Drawing. Importance, decimal fraction, LCM, familiarization of multiplication of drawing equipment decimal, division of decimals etc. Organization of the Institute, Departments various trades & functions. Types of work, responsibility to be undertaken, incentives and future planning of profession. OSH:Safety precautions to be observed in the trade both during ‘theoretical Periods’ and ‘Practical hours/workshop hours’ Elementary First Aid. Safety and hazards. Sign boards and types. Hazardous and non-hazardous . environmental pollution related to the trade caused, consequences , mitigation and control. Bench Work. Filing practice, Basic hand tools, types, classification Sheet layout Balance of Pressure, Filing surface & use. basic file, hack saw, vice, screw sketching. side & checking 90 degree by the try drivers, spanners, chisel, pliers square (simple exercises involving filing & use of vice) Introduction to the training. Familiarization with the institute. Layout of shop equipment & machineries. Syllabus, system of training, Examination, Types of work done by the trainees. Familiarization with the institutional Rules, discipline, cleaning & forming those habits. ‘Elementary First Aid’ practice, Artificial respiration practice. Occupational health hazard related to the trade its causes consequences, mitigation and control. and -Do- 3 4 5 6 Simple filing exercises as per dimension up to an accuracy of +/0.5mm. Measuring with the help of Vernier Caliper, Micrometer Measurement & measuring instruments. Marking tools steel rule, try square, hammer, punch, chisels, scriber. Precision Measuring Instruments. dial indicators, surface plate, calipers, micrometers, bevel protractor. gauges Lettering, Numbering Drilling small holes with help of bench drill machine. Tapping holes Checking hole size with gauges. Straightening of tube, bending of tube with straight & other couplers. Checking leakage etc. Element & types of screw threads used in instruments, drilling and tapping, taps and dies. tube fitting:Types of tubes used for instrumentation. Tube cutter, Flaring tools, equipments & fixture required for pipe bending, straightening, thread cutting, method of installation. Geometrical drawing angles, triangles, circle, square, Rectangle -Do- Basic electricity: Electrical componentsconductor, semiconductor & insulators. Standard wire gauge (SWG). Introduction of electricitystatic electricity. Current, voltage, P.D, E.M.F, resistance. Electrical circuit – D.C & A.C circuit differences. Importance of grounding. Geometrical drawing Logarithms- definition, refer to the log table , Rhombus, log and antilog Parallelogram, Pentagon, Hexagon, Heptagon, Regular Polygon 7 Identification +Ve –Ve polarities. Identifying and use of various electrical components, their symbols. Wire size measurement technique. Measuring current voltage & resistance. 8 Resistance measured by the colour code. Simple exercise on soldering. By temperature controlled soldering station. Uses of multimeter. Resistor, Resistivity and colour code. Types of resistors used in instrumentation. Definition and purpose of soldering and Types of lines & its use Dimensioning Method. -Do- Square roots – square and square root, symbol of root, theorem of Pythagoras. -Do- Percentageintroduction examples Basic units electricity conversion and of and 9 10 11 12 Soldering and desoldering of various de-soldering. Soft soldering. Types of components in verso boards. soldering irons. Solder & flux. Care & precaution of soldering Desoldering tools and method of use. Verification of ohm’s law. Cells and batteries: Ohm’s law & Resistor in series and parallel Kirchhoff’s laws. circuits. Series & parallel circuits. Primary & Measurement of voltage in series secondary cells and batteries. (Liquid & and parallel circuits. dry). Maintenance free batteries - constructioncharging, efficiency-use, advantage. Familiarize with various types of Switches: Switches and types. switches; construct circuits with Magnet and magnetism, magnetic SPST, SPDT, DPDT switches. properties. Magnetic campus and its uses. Operating and installation of relays. Explanation of Electromagnetism. Use of magnetic campus. Study Advantages, disadvantages-applicationvarious types of applications like types E.M. relays. Types- uses of buzzers, solenoid valves. Solenoids. Circuit breakers and their working. Testing of inductor. Measure the Inductor and capacitor: Inductor and values of inductor by inductance Inductance, types of inductors, Factors (LCR) meter. affecting the value of inductance, self Measuring Q- factor of inductor. inductance (L), Mutual inductance (M), Demonstration on self and mutual Inductors in series and parallel, Q factor induction. of the coil. Testing of capacitor. Measure the Capacitance, types of capacitor, unit of values of capacitor by capacitance capacitance, factors affecting the value of (LCR) meter. capacitors, charge, energy stored in Identifying capacitor value using capacitors. Capacitors in series and various techniques parallel. Capacitors in DC circuit, RC -Do- Simple problems on ohms law and Kirchhoff’s laws. Geometrical drawing of Simple problems on ellipse, oval etc. series and parallel circuits. -Do- Simple problems on inductor series and parallel Isometric & oblique Simple problems on view of various jobs. capacitor series and Simple orthographic parallel projection of 1st angle & 3 rd angle 13 14 & 15 16 Verification of RC time constant. time constant. Study the characteristics of series and A.C.-impedance, Inductive reactance, parallel resonance circuits. capacitive reactance. AC current through – R,L,C circuits. Resonance in RLC circuit. Importance – of series and parallel resonance, properties. Impedance, Admittance, Qfactor. Study working of AC and DC Generator and motors: Principles of motors. alternating current , A.C & DC electricity Identification, testing & running of Introduction of AC and DC generators Motors and generators. working principles, construction, operation, field magnets, armature windings, commutator and brushes. EMF equation. Faraday’s Law, Lenz’s Law, Fleming’s left Hand and right hand rules. DC motors working principles, construction, operation, types. AC motors, induction motors, three phase motors, stepper motors. Experiments on transformer. Transformers: Transformer, types, Measuring current & voltage in transformation ratio. Open circuit test primary & secondary windings. and short circuit test. Regulation auto Testing auto transformer in its transformer Current measurement. various tapping Care & maintenance Instrument transformer. Potential & connection of auto transformer and transformer and current transformer. instrument transformer. -Do- -Do- -Do- -Do- Simple sectional views. Problems transformer ratio. on 17 18 Familiarization with the construction Electrical measuring instruments: Free hand sketching of -Doof (PMMC) instruments. testing Basics of electrical measuring hand tools instruments- types – absolute and Testing & calibration of ammeters secondary instruments. and voltmeter of various types. Types of secondary instruments. Finding meter FSD full scale Essential of electrical measuring deflection reading, measurement instruments-deflecting torque, controlling value, meter sensitivity, accuracy. torque, damping torque etc Meter resistance, maximum power DC instruments - ‘D’ Arsonval meter, capability etc. PMMC meter- working principle, method of working, moving coil operation. Terminology -parallax error, FSD full scale deflection reading, measurement value, meter sensitivity, accuracy. Meter resistance, maximum power capability etc. Ideal and practical characteristics of ammeter, voltmeter. Making shunt and series resistances Meter range extension – converting -DoProblems on meter of various ranges of ammeters. galvanometer in to ammeter, voltmeter. range extension. Making multipliers for different Range extension of voltmeter, ammeter. ranges of voltmeter and ammeter. Shunt resistance and series resistance making extension of instrument value calculation. range. Meter resistance, meter FSD Finding meter resistance. identification techniques. Use of Ohm meter. Calibration of Ohm meters- measuring electrical ohm meter, use of megger & earth resistance. Basic construction of Ohm meter, tester. working method of ohm meter. 19 Familiarization with the construction of dynamometer type instruments and MI, overhauling and calibration of dynamometer type instruments. Measurement of power by wattmeter & calibration of wattmeter. 20 Familiarization with the construction of ampere hour meter . calibration of ampere hour meter. Measurement of three phase and single phase power. calibration of Energy meter Types of Ohm meter – series and shunt type of ohm meters. Megger/insulation tester, earth tester – construction working advantages and disadvantages of various types of ohm meter. AC instruments – types of AC measuring instruments – MI , electro dynamometer type. Working principle, construction, advantages and disadvantages of MI instruments and electro dynamometer instruments. Various applications. Electro dynamometer applications – as voltmeter, ammeter, power measuring instrument, energy measuring instrument, power factor meter etc. AC voltage and current measurement using PMMC meter(rectifier type ). Induction type meters – working principle construction and operation of induction type instruments . Construction and Applications – single phase and three phase energy meter, watt meter. Watt hour meter, Ampere Hour meter, power factor meter etc. -Do- -Do- -Do- -Do- 21 to 26 Revision And Test Syllabus for the Trade of “INSTRUMENT MECHANIC Duration : Six Month (GENERAL)” under C.T.S. Second Semester SECOND SEMISTER (BASIC ELECTRONICS) Week. No. 27 28 29 Trade Practical Trade Theory Identification of various types of diodes Electronics basics: Semi conductor, (solid state), checking of diodes. Covalent bond, Doping, Intrinsic and Verification the characteristics of diode. extrinsic semiconductor. PN junction diode, Forward and Reverse bias characteristics. Specification of diodes. Applications of diode. Special semiconductor diode- Zener diode, tunnel diode, Photo diode. LED, 7 segment display, LCD Identification of transistors, FET, Transistors: Defining transistors, checking of transistors, FET NPN & PNP transistor, Symbol, operation, Biasing of Transistor & mode of Application. Transistor CB, CC, CE Amplification. Current gain, voltage gain, and power gain. Introduction to FET, MOSFET. Making half wave & full wave rectifiers, Power supply unit: Engineering Drawing Symbols electricity. in Vocational science & Calculation basic Ratio and proportionsimple examples and problems Symbols of switches and relays. Symbols of various types of transformers. -Do- Diagram and sketches of . Graph – roles for 30 31 32 33 center tape & bridge full wave rectifiers. Rectifiers: half wave rectifier, full Study the function of filters. wave (bridge & center tapped) rectifier. Voltage multipliers. Filters: Introduction, purpose and use of ripple filter. Types of filters. Capacitance filter, inductance filters, RC filters, LC filters, voltage dividers and bypass filters. Hooking up a various types of fixed and Voltage regulators. Introduction & variable voltage regulators & determine purpose Zener regulators, shunt its characteristics. regulators, series regulators, IC regulators, variable IC regulators. Study the power supply units. Power Supply units. Introduction, Testing of SCR, TRIAC, DIAC and study purpose & use. UPS and SMPS, the characteristics of SCR, TRIAC, inverters and converters. and their DIAC. applications Thyristor devices : basic description and applications of SCR, TRAIAC, DIAC. Layout of components and preparation of General characteristics of an PCB’s. soldering and disordering amplifier, Concept of amplification. practice. Types of Amplifiers. DC load line and AC load line. PCB basic construction, applications. Lay outing circuit on PCB. Study CE and FET amplifiers. Amplifiers: Single Stage Finding the gain and phase relation of Amplifiers. amplifiers. Classifying amplifiers and their operation. Single stage voltage electrical measuring drawing graph, drawing instruments. and reading simple graphs Symbols of electronics. basic Simple problems on transistor voltage gain, current gain, and power gain Circuit diagram of Simple Problems on rectifiers. rectifiers.-efficiency, output voltage. -Do- -Do- Circuit diagram of single stage transistor amplifier and multistage transistor amplifier -Do- 34 Study of various types of Oscillator as mentioned theory. 35 Study various op- amp applications – inverting amplifier, summer, and differencial amplifier. V to I and I to V, Instrumentation amplifier 36 Astable and monostable multivibrator using IC 555 timer 37 -Do- divider biased CE amplifier Allowing operating region, operating point, and load lines, FET amplifiers. Advantages and disadvantages. Oscillators:oscillations, oscillation frequency, basic working principle and working of Tank circuit, Crystal controlled oscillators, Phase shift oscillators, RC phase shift oscillators, Colpitt, Clapp, Hartely, and IC oscillators. Operational Amplifier: Differencetial amplifier, ideal opamp. Op-amp with feed back, advantages of feed back. Inverting and Non inverting and inverting amplifier, Op-amp as summer, differential amplifier. V to I converter and I to V converter, Instrumentation amplifier Basics of op- amp applications integrator, differentiator. Mulivibrator- astable, monostable, and bistable multivibrator. Introduction of timers (555) and its applications. Digital electronics: Number systems: binary, octal, Circuit diagram oscillators of Problems on oscillators – output frequency. op-amp applications Problems on Op- amp circuits- inverting and gain, summer, non-inverting amplifier, subractor. summer, instrumentation amplifier Circuit diagram of astable and monostable multivibrator using IC 555 -Do- -Do- Number convertions. systems, 38 Verification of truth tables of various logic gates. 39 Verification of truth tables for adders and subtractors. RS and JK Fillip flops. 40 Introduction of Counters. Study function of BCD to decimal decoder, BCD to 7 segment display circuits 41 Study various types of bridge circuits. 42 Study function of D/A and A/D circuits. decimal and hexadecimal number system. Conversion of number systems. Boolean algebra, binary addition, subtraction, 1’s and 2’s compliment. BCD code, ASCII code, greys code. Logic Circuits. Basic gates- AND, OR and NOT gates. De-Morgan’s Theorem. Universal gates – NAND and NOR gates. Special gates – Ex-OR, Ex – NOR gates and Buffer and its applications. Basic digital ICs, function, digital application, logic symbols. Adders – Half adder, full adder Subractor – Half subtractor, full subtractor. Flip flops – RS flip flop, clocked RS flip flop, JK flip flop,. Basics of Counters and registers. Multiplexer and de-multiplexer. Encoder and decoder. BCD display, BCD to decimal decoder. BCD to 7 segment display circuits. Bridge circuits: need of bridges, types of AC and DC bridges, Wheatstone bridge. A/D and D/A converters. Introduction, weighted register D / A Symbols in electronics. digital -Do- Block diagram of adder and subtractors. -Do- Block diagram of 1’s and counters and registers. compliment. Free hand sketches of bridges. 2’s -Do- Simple circuit diagram Binary of A/D and D/A subtraction, addition, 43 Measurement voltage, frequency using CRO. Study method of operating storage oscilloscope. Method of using CRO probes. 44 Identification of PC components and devices. 45 and 46 To familiarize with 8085 Microprocessor kit. converter, binary(R-2R) ladder D / A converter, specification for D / A converter, Ramp and successive type A/D converter, Digital voltmeter CRO: introduction and applications of CRO, functional block diagram of CRO, CRT power supply. Various types of probes. Applications of various types of CROs like dual beam CRO, Dual trace CRO, storage oscilloscope. Computer fundamentals: Introduction to Computer, Block diagram of PC, I/P and O/P and peripheral equipm ents, terminals, printers, MODEMS programming languages, software, Familiarization of Multi Media System consisting of CD ROMS, DVD ROMS, Microprocessors: Introduction to microprocessor micro computers, Memories Intel 8085. Architecture , Microprocessor applications. Instruction set of 8085, Microprocessor. 1. Data transfer group. 2. Arithmetic group. converters. multiplication divisions Block diagram of CRO -Do- Computer diagram. -Do- block and Simple block diagram of Calculations on finding 8085 microprocessor. unknown resistance using bridges 3. Logic group. Basic Programming of 8085 Revision And Test 47 to 52 Syllabus for the Trade of “INSTRUMENT MECHANIC Duration : Six Month (GENERAL)” under C.T.S. Third Semester THIRD SEMISTER (INSTUMENTATION AND MEASUREMENTS) Week No. 53 54 Trade Practical Trade Theory Study various types of instruments Instrumentation fundamentals: constructions and identifying various Scope and necessity of parts and section. instrumentation. Fundamentals of measurement systems- functional block diagram of measurement system . calibration and calibration standards – basic standards, secondary standards, working standards. Fundamental units The metric system, Base & supplementary units, Derived Units, Multiplying factors and standards of length, mass, time, & frequency. Temperature & electrical units. -DoInstrument characteristics Static characteristics – accuracy, Engineering Drawing Drawing various types of lines using in instrumentation field as per ISA (International society for automation). Simple block diagram of measuring instruments. Vocational Science and Calculation Force- Newton’s law of motion, unit of force, resultant force, space and vector diagrams, parallelogram law of forces, condition of equilibrium, triangle of force, Lami’s theorems, moment of inertia, centripetal and centrifugal force. -Do- 55 Measuring strain in terms of resistances. Operating load cells, LVDT and capacitive transducer. 56 Measuring speed and velocity using various tachometers. Operating stroboscope 57 Pressure Measurement. Practical on various Pressure sensors and pressure gauges. Measuring gauge, absolute and vacume pressure using manometer. precision, sensitivity, resolution dead zone, repeatability, reproducibility, drift, Dead band, backlash, hysteresis. Dynamic characteristics – speed response, fidelity, lag. Error, deviation, true value, data. Types of errors- systematic, random & illegitimate error. Motion measurement: Stress & Strain Measurement. Introduction to Strain gauges, types of strain gauges and differences. Applications of strain gauges , load cells. LVDT, RVDT, capacitive and inductive transducers advantages and limitations. Measurement of motion, velocity/ vibro-meters and acceleration. Difference between tachometer and speedometers. Types of tachometers - Eddy current type, AC and DC tachometer. Stroboscope and its applications. Pressure Measurement: Principle of Pressure in Liquids& Gases. Properties of matter Principles of liquid pressure, units of pressure Liquids pressure and volume, density and specific gravity. Factors Symbols of transmitter and sensors indication as per ISA block diagram of Velocity and speedLVDT, capacitive, definition, vector inductive transducer quantity, scalar quantity, difference between speed and velocity, acceleration. Symbols of displacement devices, tachometers. block diagram of tachometer. Symbols of various pressure sensors. block diagram of pressure indicator and transmitter. -Do- Method of using barometer 58 Testing and installation of bourdon tube, diaphragm type, capsule type pressure gauges and pressure switches. 59 Operating and calibrating Pressure transmitters, DP transmitters practical on I to P and P to I converters. 60 Measuring low pressure affecting liquid pressure. Pressure relation with volume, temperature and flow. Units of pressure and unit conversions. Types of pressure: absolute, gauge, atmospheric and vacuum pressures and their relation ships. Barometers, Aneroid barometer, manometers types and applications. Types of pressure sensing elementsbourdon tube, diaphragms, capsules, and bellows. Each on types, shapes, material used for various applications, ranges advantages and limitations. Pressure switches types and applications. Electrical pressure transducers. method of conversion, primary and secondary pressure transducers. potentio metric pr. transducers, Capacitive pr. transducers, reluctance pressure transducers, strain gauge pressure transducers, piezoelectric pressure transducer. Differentials pressure transducers. P to I and I to P converter Low Pressure Measurement. Vacuum, gauges, thermal conductivity gauges, pirani gauges, -Do- Stress and straindefinition, simple stress, strain, hooks law, young’s modulus or modulus of elasticity , factor of safety Free hand sketches of bourdon tube/diaphragm gauges and various pressure measuring devices. -Do- -Do- Unit of pressure and unit conversions. 61 Repairing, fault finding, Testing & calibration of various types of pressure measuring instruments. Calibration with dead weight tester and comparator. 62 Flow Measurement Checking various types of flow restrictors (orifice, venturi, flow nozzle) and use. 63 Dismantling, checking overhauling and calibration of D.P. cell/ transmitter in the flow line. 64 Installation and testing of variable area type flow meters study the construction of weirs and flumes. thermocouple gauges, McLeod gauge. Method of pressure instrument calibration. Dead weight tester and comparators/manifolds. Maintenance and servicing of various pressure measuring instruments. Flow measurement: Properties of Fluid Flow. Basic properties of fluids, fluids in motion, getting fluids to flow, units of flow rate and quantity flow, factors affecting flow rate, Reynolds number, relation between flow rate and pressure, area, quantity. Types of flow meters – head type, variable area type, quantitative flow meters. Mass flow meters. Head type of flow meters: working principle, types- venturi tube, orifice plates and it’s shapes. Pitot tube, flow nozzles, constructions, tapings, advantages, limitations, applications, materials used for various flows. Types of secondary devices used to measure for flow rates. Open channel flow meters- principle of open channel flow, weirs and flumes. Various shapes and their -Do- -Do- block diagram of flow Density and relative meters. density- mass, unit of mass, weight, difference between mass and weight, density, unit of density, relative density, Archimedes principle, law of floatation, buoyancy, hydrometer Free hand sketches of head type flow meters. -Do- Free hand sketches of Rotameter. -Do- 67 65 Study construction, repairing various types of positive displacement flow meters- rotating vane. Calibration of positive displacement flow meters. 66 Calibrating and installing turbine flow meter, vertex flow meters Installation maintance of flow instruments. (Components for flow measurement system, primary flow elements, pressure taps, piping and fitting valve, DP transmitter, miscellaneous items.). applications, maintenance. Variable area type flow meterRotameter, constructions, working principle, applications. Various shapes of float, type of materials used to body and float, applications. Positive Displacement Meters. Symbols of various flow Unit of flow and flow Advantages and disadvantages of sensors, indicators and rate, unit conversion positive displacement meters, transmitters. piston meter, oscillating piston meter, rotating vane meter, notating disk meter, lobed impeller and oval flow meter, calibrating positive displacement meters. Electronic flow meters-Target flow -Do-Dometers, turbine flow meter, magnetic flow meters, vertex flow meter. Construction, working principle, advantages and disadvantage, applications.. Carioles mass flow meter, thermal flow meters, summary basics of ultra sonic flow meters. Metering the flow of solid particles. Measuring volumetric and mass flow rate of solids. Free hand sketches of Installation and measurement of liquid Level measurement: various level measuring level using sight glass, float type, static Principles of level measurement types of level measurementssolid system. pressure type and air purge liquid -Do- measurement setup. 68 69 Calibration and measurement using DP and capacitance type level transducer/ transmitters Temperature measurement. Performing practical on temperature measurement with different sensors as in the theory part, in the temperature controlled oil bath/ furnace for low and high temperature . and liquid, volume and mass, mechanical and electrical type. Sight glass type, float type, static pressure type Differential pressure type, and air purge type liquid level measurement systems. Factors need to consider for open and closed channel level measurements level switches, mercury level switches, level detectors, magnetic reed switches. Electrical method- capacitance type liquid level Measurement, radiation type, sonic level detectors. Solid level measurement. Using weight to determine level, sonic, radiation type solid level measurement. micro wave solid level detectors Temperature measurement: Temperature measurement. Temperature, heat, specific heat, temperature. properties of liquid, solids and gases. Temperature scales Fahrenheit and Celsius, Rankin and Kelvin scales primary and secondary standards. Bimetallic and filled systems temperature instruments/ thermometers Basic symbols of various level sensors, transmitters and indicators. -Do- -Do- Free hand sketches of various types of filled system thermometers. Free hand sketches of various temperature sensors Heat – unit of heat, temperature, differec between heat and temperature, boiling point, melting point, scale of temperature, specific heat, thermal capacity, water equivalent o heat advantages & disadvantages 70 Practical on various thermocouples, Electrical temperature instrument. and RTDs and pyrometers. RTD, thermocouple, thermistor71 principle, working types, advantages, disadvantages, applications. thermopiles 72 Calibration of RTD and thermocouple Optical and radiation type pyrometers. transmitters and measuring instruments. Introduction to the thermal imagers. Thermo-wells and calibration methods of electrical pressure transmitters. 73 to Revision And Test 78 Syllabus for the Trade of “INSTRUMENT MECHANIC Duration : Six Month Symbols of temperature indicators transmitters. various sensors, and -Do- Free hand sketches of Units of temperature optical and radiation and unit conversion pyrometers. (GENERAL)” under C.T.S. Fourth Semester Week. No. 79 FOURTH SEMISTER (Process Instrumentation and Control) Trade Practical Trade Theory Engineering Drawing Recorders and servicing. Overhauling, checking, fault finding, repairing, testing of electrical/ electronic recorders.(single point & multipoint). Coping and editing on digital storage recorders 80 Dismantling, fault finding, repairing, cleaning, reassembling and testing of Vocational science & calculation Recorders: Introduction to Symbols of various Fundamental of recorders. Construction, working types of recorders. Algebra- introduction, principle, various parts installation addition, subtraction, and use of pneumatic and Block diagram of strip multiplication and electronic recorders. Strip chart chart recorder. division, algebra and circular and XY charts. formula, factorization, Introduction to the Digital equations recorders and types Symbol of different -DoFinal control elements: Pneumatic and Hydraulic types of valves. control valves. 81 82 Actuators. Pneumatic principles pneumatic actuators, diaphragm actuator, spring and springless actuators, direct and reserve acting actuator, piston actuator, positioner,. Electrical actuators and their advantages. Study the cut sections of various types of Control valves. Control valves control valves. functions and components, types of control valves, based on valve flow characteristics – liner, equal percentage, quick opening valves, by shape of plug- globe valves, , butterfly valves, ball valves, gate valves, diaphragm valves, split body valves, proximity switch, IR switch, micro switch, limit switch, other control valves, control valve mechanical considerations, selecting control valves, valve positioner. Controllers. Practical on PID controller Process control systems: trainer on various process parameters. Introduction to controllers. Basic block diagram of control systems. Advantages Process variable and set point, analog controllers, digital controllers, control ranges and limits, control loop, measuring PV, final control elements Free hand sketches of control valve- gate valve, butterfly valve, single seated and double seated valves -Do- Simple block diagrams of various types of control systems like feed back, feed forward, ratio, cascade control systems etc. Mensuration-1rectangle, square, parallelogram, rombus, trapezium, triangles 83 84 85 -Do- Types of controller and their -Do-Dooperation. Types of controller, range limit of controllers, ON/OFF controllers, direct and reverse acting controllers, proportional controllers, automatic/manual, split control, pneumatic control. Adaptive, limiting and batch control, ratio control system, feed forward, feed back control systems and cascade control system. Comparison between pneumatic and electronic control systems. Basic knowledge on communication protocol. Study operation on cascade, ratio, feed Controller models and tuning. -Do-Doforward control trainer. Controller tuning, setting, controller modes, proportional mode, off-set, integral mode, reset mode, derivative mode(rate), single mode controller, multi mode controller, tuning the control loop, step-change- response method. Basics industrial programmable controllers. PLC basics: Basic block diagram of Mensuration 2 – Practical on programmable logic controller Introduction to programmable PLC. pentagon, hexagon, trainer. controllers. History of circle, segment of programmable controllers, general circle, ellipse characteristics of programmable controllers, some limitation of PLCs, method of developing PLC 86 87 88 and 89 programming. Basic simple programs on PLC – logic gates Input/output devices. Definition of preparation, input/output devices, I/O interface, input modules, output modules, input devices encoders, output devices, the Op-to-isolators, safety. Small programs on timers and counters. Processing and programming functions. The processor unit, the memory, memory organization, ladder diagrams, most used programming symbols, other programming symbol timers and counters, data manipulation instructions, alternate PLC symbols. Installing & Operating HART HART devices: transmitters/devices (I/O). Digital control systems: need of Calibration of HART devices. smart devices, HART transmitters futures, advantages, applications. Working method of HART devices, HART protocol. HART communicators and PC based HART device configuration. Steps in calibration of HART devices. Communication fundamentals: modulation and demodulation, signal to noise ratio, digital communication basics – PWM, Symbols devices -Do- -Do- -Do- Mensuration 3 Volumes of solids cube, rectangle block, cylinders, sphere frustum of cone. of HART Basic block diagram of HART devices. -Do- 90 91 and 92 PCM, FSK Study various network lines. Networking: Preparation network cables and connectors. Net working: types of networks Testing network cables. used in digital instrument systems. LAN, WAN , Ethernet. Point to point and multipoint networking. Ring, delta, star connections. Redundant Net. TCP/IP addresses and descriptions. Types of Cable categories(CAT), and their descriptions. Various types of Cable connectors. Advantages and disadvantages of co-axial cable and fiber optic cables. Various tools used in networkingwire cutter, crimp tool, memory blade holder, memory blade cartridge, cable strip tool with blade cassettle. Terminators and extra connectors, taps, calibration tool etc. Study and use of DCS & SCADA complete Fundamentals of SCADA and with communication system through DCS. History of DCS industrial visit. development. Basic architecture, block diagram description advantages and disadvantages, applications. TerminologyRTU(remote transmitting unit, central Simple block/schematic diagrams of various network systems in instrumentation field. Trigonometry – definition, formulas, measurement of angles, area of triangle, sin bar, angle of elevation and depression. Solution of triangle using sine and cosine rules Simple block diagram of DCS and SCADA -Do- 93 and 94 95 monitoring station, types of communications, field instruments and types Study various field bus/ profibus based Fundamentals field control system through industrial visit. bus/profibus: Introduction field bus/profibus : futures, advantages, architecture, basic block diagram, working. Work station, Human Machine interface(HMI). Controller(with basic types), filed bus/profibus interfacing modules, gateway, network manager, I/O modules, field bus devices(I/O), remote transmission panel(RTP), ethernet. Electronic device description language (EDDL) and device description(DD). Centralized control system power supply and its function. Introduction of digital and multi drop communication protocol. Vendors. Need and advantages of redundancy. Futures- library, call up, various visualized futures, reports(alarms, events), history, trading etc. Basic pneumatics. Pneumatic systems, Basic pneumatics: forces, weight and pressure. Pneumatic principles, mass, Simple block diagram of Work power and field bus/ profibus energy- work, unit of system. work power, unit of power, hourse power, hourse power of engine, mechanical efficiency energy, usage of energy, potential and kinetic energy. Drawing the sketches of the components of -Do- Practical on pneumatic training kits . 96 Practical on pneumatic trainer. 97 Analytical Instruments. Exercises on PH meter, conductivity meter Through industrial visitOnline measurement of pH, conductivity and dissolved oxygen . pressure, work and energy, pneumatic system. compressibility, law of Block diagram of pneumatics, transmission of pneumatic systems. pneumatic fluid power, pneumatic leverage, air properties, air flow in pipe lines, viscosity of air pressure, Bernoulli’s law, components of pneumatic power system. Pneumatic Cylinders. -DoDescriptions, single and double acting cylinders, two-position cylinders, cylinder construction, variations in cylinder mounting, pneumatic cylinder selection, reading the performance charts, cushioning devices. Analytical instruments: Analytical Instruments. Exposure to basic analytical instruments. Types of electrodes used for PH measurements. Relation of PH & mV. PH indicator and controllers. -Do- -Do- -Do- 98 99 100104 Quality Control &Ecological Considerations. Practical for assuring quantity products avoiding environmental pollution, preventing wastage of energy. Industrial visit/tour Quality Control. Methods to be followed for assuming quality products, conservation of energy & preventing pollution. Ecological Consideration. Methods to be followed to avoid environmental pollution. -Do- Industrial training OR Project work preferably in cross sectoral trades Revision and Test -Do- Tools are specified for batch 20 Nos of students. I. Trainee’s Tool Kit (Required for all Four Semester) S.No. Name of instrument/tools/item For Instructor 1. Screw driver set (5 bit minimum) 1 No. 2. Combination Pliers (150 mm) 1 No. 3. Soldering Iron with stand (25watt) 1 No. 4. Adjustable spanner 1 No. 5. Wire cutter 1 No. 6. Hammer 1 No. 7. Desoldering pumps 1 No. 8. Twizer 1 No. 9. Electrician knife 1 No. 10. watchmaker screw driver set 1 No. 11. Steel Rule 150 mm (metric and 1 No. English Marking) 12. File hand smooth 200 mm 1 No. nd 13. File Flat 2 cut 200 mm 1 No. For Trainees 20 Nos. 20 Nos. 20 Nos. 20 Nos. 20 Nos. 20 Nos. 20 Nos. 20 Nos. 20 Nos. 20 Nos. 20 Nos. 21 Nos. 21 Nos. 21 Nos. 21 Nos. 21 Nos. 21 Nos. 21 Nos. 21 Nos. 21 Nos. 21 Nos. 21 Nos. 20 Nos. 20 Nos. 21 Nos. 21 Nos. II. Tools and Equipment (Required for all Four Semester) S.No. Name of instrument/tools/item 1. Hand drill machine (electrical) 2. Long nose pliers 3. Round nose pliers 4. Standard wire gauge (SWG) 5. IC pullers 6. Pipe wrench 7. Spanner set 8. Pipe wice 9. Pipe die set 10. Allen key 11. Fire extinguishers 12. Digital Multimeter (auto ranging) 13. Digital Multimeter (manual ranging) 14. Analog Multimeter 15. Temperature controlled soldering station 16. DC regulated power supply ( 0- 30 V) 17. Dual trace CRO III. IT Equipments and Software (Required for all Four Semester) S.No. Name of instrument/tools/item 1. Computers ( latest configuration) with tables (For operating various control system trainers for mentioned above ) 2. Lap top (for convenient to control system ) 3. Licensed/free operating system (latest version) 4. Latest Office (licensed(MS office)/free version like open office oracle) Total quantity 1 No. 2 Nos. 2 Nos. 2 Nos. 4 Nos. 2 Nos. 2 Nos. 1 No. 1 No. 2 Nos. 3 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 4 Nos. 4 Nos. quantity 02 No. 02 Nos. 04 Nos. 1 No. 5. 6. 7. 8. LCD multimedia projector with trolley/installation arrangement Broad band internet connection Printer (Scan/copy) Networking tool kit 01 No. 01 No. 01 No. 02 Nos. General Installation (Required for all Four Semester) S.No. Name of instrument/tools/item quantity 1. Work benches (240 cm x 120 cm x 75 cm ) 4 Nos. 2. Instrument test bench with cup boards 4 Nos. 3. Steel cup boards with eight lockers for trainees 2 nos. 4. Steel cup boards/ alminrah (6 x 2 x 1feet or above) (with five 3 Nos. shelves) 5. Student chairs 20 Nos. 6. Instructor chair and table 1 No. each 7. Fire buckets 4 no. FIRST SEMESTER Tools And Equipment For First semester (S.No.1 to 19 Not required, if fitter/machinist/ turner/ Tool and Die trades are available in the Institute) S.No. Name of instrument/tools/item quantity 1. * triangle file 4 Nos. 2. *Square file 4 Nos. 3. *Round file 4 Nos. 4. * Chisel 1 No. 5. *Try square hardened blade 100 mm 4 Nos. 6. * Surface plate 400×400 mm 1 No. 7. *Universal scribing block 250 mm 2 Nos. 8. *Angle plate 2 Nos. 9. *Hacksaw frame adjustable 8 Nos. 10. *Vice bench jaw 100 mm 20 Nos. 11. *Punch center 100×10 mm 2 nos. 12. * Micrometer outside 0 to 25 mm 2 nos. 13. *Vernier height gauge 300 mm 2 nos. 14. * Combination set 300 mm 1 no. 15. *Vernier caliper 150 mm 2 nos. 16. *bevel protractor 2 Nos. 17. * Dial test indicator in mm with accessories. 1 No. 18. *Tube cutter 1 no. 19. *Tube bender 1 no. Electrical tools and Equipments 1. LCR meters 2. Standard wire gauge (SWG) 3. Magnetic campus 4. Buzzers and solenoid valve 5. Simple generator and motor trainer 6. Current transformers 7. Variac (variable transformers/auto transformer) 2 Nos. 2 Nos. 2 Nos. 2 Nos. each 2 Nos. 2 Nos. 2 Nos. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. DC ammeter (PMMC type) various range DC voltmeter (PMMC type) various range AC ammeter (MI/ electro dynamometer) various range AC voltmeter (MI/ electro dynamometer) various range Energy meter (single phase) Energy meter (3 phase) Watt meters Ampere Hour meter Frequency meter Power factor meter Megger Earth tester Electrical trainer (consisting ohms law ,series & parallel circuits, krichoff’s law, bridge circuits, switches, solenoid testing, resonance circuits, capacitor and inductor series parallel properties etc) SECOND SEMISTER Tools and Equipments 1. Function generator 2. Frequency counter 3. Storage oscilloscope 4. Digital panel meters (current measurement) various range 5. Digital panel meters (voltage measurement) various range 6. 7. Digital IC tester Rheostat 50 ohm, 500 ohm, 1 k ohm, 10 k ohm 8. 9. 10. 11. CRO trainer Computer trainer Multiplexer and demultiplexer trainer Liner IC trainer ( consisting OP-AMP experiments, instrumentation amplifier,555 timer practical, A/D and D/A converter Electronic trainers (consisting diode and Zener diode characteristic, rectifiers, IC regulators various types of diodes & transistors, CE amplifier, cascade amplifiers, FET amplifiers, oscillators , multivibrators , class B and C power amplifiers, SCR, TRIAC and DIAC characteristics etc ) Digital Trainers (consisting basic gates, universal gates, adders, subtractors, flip flops, counters, registers, 7 segment display, BCD display etc) 8085 micro processor trainer instrumentation application modules For 8085 kit 12. 13. 14. 15. THIRD SEMESTER Displacement Measurement 2 Nos. each 2 Nos. each 2 Nos. each 2 Nos. each 4 Nos. 2 Nos. 2 Nos. 1 No. 1 No. 1 No. 2 Nos. 2 Nos. 2 Nos. 4 Nos. 1 No. 1 No. 2 Nos. each 2 Nos. each 2 Nos. 2 Nos. each 1 No. 1 No. 1 No. 1 No. 2 Nos. 2 Nos. 2 Nos. 1 No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Stain gauge/load cell trainer LVDT trainer Capacitive and inductive displacement trainer Tachometer (contact type) Tachometer (non contact type) Speedo meter Stroboscope Acceleration meter Bridge circuit trainer Pressure Measurement 1. Bourdon tube pressure gauges (C and spiral type ) various range 2. Diaphragm pressure gauges various range(6 inch dial minimum) 3. Capsule pressure gauges various range(6 inch dial minimum) 4. Pressure switches 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 2 Nos. each 2 Nos. each 2 Nos. each 2 Nos. 5. Vaccume pressure gauge (6 inch dial minimum) 2 Nos. 6. Absolute pressure gauge (6 inch dial minimum) 2 Nos. 7. U tube manometer 2 Nos. 8. Well type manometer 2 Nos. 9. Inclined manometer 2 Nos. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Aneroid barometer Electronic pressure transmitter Pneumatic pressure transmitter DP transmitter (electronic) DP transmitter(pneumatic) I to P converter P to I converter Pressure comparator/ manifold Dead weight tester Electronic pressure calibrator Pneumatic pressure calibrator FLR (filter +Lubricator+ regulator ) Unit Air compressor (0 – 10 Kg/cm2, 500 liters tank capacity or above) Vaccume pump with gauge Very low pressure measuring gauges (any two types) 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 1 No. 1 No. 1 Nos. 4 Nos. 1 No. 23. 24. Flow measurement 1. Venturi tube 1 No. 1 No. each. 1 No. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Orifice plates Pitot tube Oscillation piston flow meter Rotating van flow meter Turbine flow meter Magnetic flow meter Vertex flow meter Ultrasonic flow meter Mass flow meter Flow calibration setup(using venture, orifice, flow nozzle, PD meter, Rotameter, DP transmitter ) Level measurement 1. Sight glass level indicator 2. Float type level indicator 3. Air purge type level indicator/transmitter 4. Static pressure level indicator (for closed channel and open channel) 5. Electronic static pressure level transmitter/indicator (for closed channel and open channel) 6. Capacitive type level transmitter/ indicator 7. Resistive type level transmitter 8. Non contact type level transmitter 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 2 Nos. 2 Nos. 1 No. 1 No. each 1 No. each 2 Nos. 1 No. 1 No. Temperature measurement 1. Mercury glass thermometer (consumable) various range and sizes 2. Alcoholic glass thermometer (consumable) various range and sizes 3. Bimetallic thermometer 4. Mercury in steel thermometer 5. Thermocouples (minimum 4 types) 6. RTD ( minimum 2 types) 7. RTD temperature transmitter/ indicator 8. Thermocouple temperature transmitter/ indicator 9. Thermocouple welder 10. Thermistor temperature indicator / transmitter 11. Pyrometer 12. Thermal imager 13. Temperature calibrator 14. Electric Furnace (600 C or above) 2 Nos. 1 No. 1 No. each 1 No. each 2 Nos. 2 Nos. 1 No. 1 No. 1 No. 1 No. 1 No. 2 Nos. FOURTH SEMESTER Recorders 1. Single point recorder (electrical and pneumatic) 2. Multipoint recorder (electrical) 3. Digital recorder setup 1 No. each 1 No. 1 No. 2 Nos. each 2 Nos. Final Control Elements 1. Different type of control valves such as gate valves, globe valves, Ball valves, diaphragm valves, butterfly valves etc. (with at least one with eclectically actuated, pneumatic actuated and hydraulic actuated) 2. Valve positioner, booster relays etc. 3. Cut section models of various type of control valve 4. Liner, equal percentage, ratio type control valve 5. HART/ FIELD BUS/PROFIBUS final control element 6. Proximity sensor trainer (inductive, capacitive, resistive etc) Control systems 1. Electronic Pressure control trainer (complete unit consisting PID controller, HART transmitter, final control element and process, computer inter face and software) 2. Pneumatic pressure control trainer (complete unit consisting PID controller, transmitter, final control element and process) 3. Flow and level control trainer (complete unit consisting PID controller, HART Transmitters, final control element and process, feed forward, feedback, Ratio and cascade control loop arrangement with computer inter face and software) 4. Temperature control trainer (complete unit consisting PID controller, HART transmitter, final control element and process, computer inter face and software) 5. PLC (programmable logic controller ) with SCADA development software for process control 6. Universal process calibrator and communicator 7. HART device communicator and calibrator Analytical and Pneumatic Instruments 8. Pneumatic trainer 9. pH meter 10. Conductivity meter 11. Hygrometer 1 no. each. 1 no. each. 1 no. each. 1 no. each. 1 no. each 1 no. each 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No.