central staff training and research institute ministry of labour and employment govt...

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SYLLABUS FOR

Electrician (Steel Plant)

Under

APPRENTICESHIP TRAINING SCHEME

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE

MINISTRY OF LABOUR AND EMPLOYMENT

GOVT. OF INDIA

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GENERAL INFORMATION

Name of Designated Trade : Electrician (Steel Plant) N.C.O. Code No. : 7137.10 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 to work

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List of members attended the Workshop to finalize the Trade Syllabus for the trade of Electrician (Steel Plant)

Under Apprenticeship Training Scheme

on 12th and 13th July, 2010 at SNTI, Jamshedpur, Jharkhand

Shri S.D. Lahiri, Director, CSTARI – Chairman

Sl.No. Name of Member & Designation Organization

1 R.K. Mohanty, Sr. DGM (E&I) Jindal Steel & Power Ltd. 2 S.K. Mishra, DGM/ETL SAIL, Bokaro

3 H. Singh Usha Martin Ltd., Jamshedpur

4 Subhash Kumar Usha Martin Ltd., Jamshedpur 5 P.K. Mohanta Tata Steel Ltd.

6 Sanjay Kr. Sinha Adhunik Alloy & Power Ltd. 7 Shankar Banerjee Tata Steel Ltd.

8 Satyajit Pal Tata Steel Ltd.

9 Tapas Kumar Dhar Tata Steel Ltd. 10 S.C. Jha Tata Steel Ltd.

11 M. Mitra Tata Steel Ltd. 12 S. Bhowmik Tata Steel Ltd.

13 U.K. Choudhary Tata Steel Ltd.

14 K.N. Choubey Tata Steel Ltd.

15 Amit Kumar Tata Steel Ltd.

16 Sanjeev Kumar SAIL, Bokaro 17 S.N. Dutta, DGM (Gl.Maint.) SAIL, Bokaro

18 B.N. Prasad, DGM(HRD) SAIL Bokaro

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43 R.K. Mishra Tata Steel Ltd.

44 S.P. Sharma Tata Steel Ltd. 45 J. Sarkar SAIL, Rourkela

46 A.K. Mallick SAIL, Rourkela

Sl.No. Name of Member & Designation Organization with address 19 B. Bushan Tata Steel

20 A. Nandi, Dy. Director CSTARI, Kolkata 21 N. Pandit Tata Steel Ltd.

22 A.K. Neogy, Trg. Officer CSTARI, Kolkata 23 M.K. Verma Tata Steel Ltd.

24 A.K. Bhattacharjee, JTA RDAT, Kokata

25 Anil Kumar, Jt. Director RDAT, Kolkata 26 Dr. Binod Kumar FTI, Jamshedpur

27 N.R. Arvindam, Dy. Director FTI, Jamshedpur 28 R.K. Sharma TCIL, Jamshedpur

29 Sandeep Dhir Tata Steel 30 Vijay Kumar Singh Adhunik Alloy & Power Ltd.

31 V.K. Sinha Tata Steel Ltd.

32 Biswanath Roy Tata Steel Ltd. 33 S.K. Singh Tata Steel Ltd.

34 D.M. Chowdhury Tata Steel Ltd. 35 Suresh Kumar Tata Steel Ltd.

36 Surendra Kumar Tata Steel Ltd.

37 B.B. Das Tata Steel Ltd. 38 A. Ranjan Tata Steel Ltd.

39 Sanjay Kedia Tata Steel Ltd. 40 S.B. Choudhary Tata Steel Ltd.

41 A.K. Karn Tata Steel Ltd. 42 C.K. Goswami TCIL, Jamshedpur

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47 S.K. Gupta Jindal Steel & Power Ltd. 48 S.N. Rana Jindal Steel & Power Ltd.

49 Major K. Satyanarayan Tata Steel Ltd.

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SYLLABUS FOR THE TRADE OF

Electrician (Steel Plant)

UNDER

APPRENTICESHIP TRAINING SCHEME PERIOD OF TRAINING: TWO YEARS

NOTE: The period of training for the trade is two years and this consists of A) Basic Training and B) Shop floor

(In-plant) training. During the basic training, the trainee is exposed to fundamental of workshop practices in various shops/trade in order to prepare him/her for the trade in which he/she will be trained as an apprentice.

Out line of Training Programme: A. Basic Training in Training Institute: 78 weeks (One and half Year) B. Shop Floor (Plant) Training: 26 weeks (Six month including revision and project work of 2 weeks)

C. Related Instruction (Throughout the training period, 1 day/week)

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Trade- Electrician (Steel Plant) Training Structure

Sl.No. Module

No Modules/ Subject

Duration in weeks

1st Year

1 A.1 Introduction, general & behavioral safety 01

2 A.2 Industrial safety & Quality 01

3 A.3 Bench-fitting Skills 08

4 A.4 Electrical Fundamentals and circuit 08

5 A.5 Electrical machines 08

6 A.6 Electrical Measuring Instruments 02

7 A.7 Electronics and communication 08

8 A.8 Power Electronics & Drives 06

9 A.9 Electrical Power System 04

10 A.10 Instrumentation & Control 04

11 Revision & Test 02

2nd Year

12 A.11 PLC & DCS 02

13 A.12 Fluid Power (Industrial hydraulics & pneumatics) 02

14 A.13 Welding 01

15 A.14 Advanced Electrical Machine 08

16 A.15 Industrial wiring 05

17 A.16 Computer and IT 01

18 A.17 Iron & Steel making technology 02

19 A.18 Quality Management and Improvement Techniques 01

20 A.19 Rigging 02

21 A.20 Environment Control and Occupational Health 01

22 Revision & Test 01

23 B.1 Shop floor (In-plant) training 24

24 B.2 Industrial visits, project work, Revision & Test 02

25 C Related instruction class (1 day/week) Syllabus to be covered within 2 years of training period

Total 104

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SYLLABUS FOR THE TRADE OF ELECTRICIAN (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)

Terminal Competencies:

After completion of this module the trainee will be aware of

Trade apprenticeship training scheme, general and behavioral safety

Overview of steel manufacturing process and machinery

Week No.

Trade Theory Trade Practical Engineering Drawing Workshop Calculation & Science

1 2 3 4 5

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Familiarization with the Institute & steel industry. Machinery used in the trade and type of work done by the trainees in the trade. Importance of safety, general safety precautions observed in the Institute and in the section. Importance of the trade & trade training, Related instructions & subjects to be taught. Salient features of Apprentices’ Act. Introduction to general , behavioral and road safety Overview of steel manufacturing process.

Plant visit to observe steel making process and machineries used in steel plant. Use of Personal Protective Equipment. Rules & regulation of the institute

Introduction to Engineering drawing, its importance and uses in engineering fields.

Applied workshop problems involving common fractions. Science – Definition, Nomenclature, Various branches, significance and definitions of important terms.

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2.Industrial Safety & Quality (1 week)


After completion of this module the trainee will be aware of

Industrial Safety and first aid techniques

Quality Circle

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Introduction of first aid. Causes and type of fires, fire precautions, precautions against outbreak of fire, different type of fire extinguishers and their uses. Precautions while working at height. Gas safety Electrical safety Quality- brief introduction of improvement techniques followed in the organization- Small group activities (SGA), Quality Circle (QC) and its tools.

Usage of First aid box and practice of Cardiopulmonary Resuscitation (CPR) Usage of

- Fire extinguishers - Safety appliances- personal

protective equipment (PPEs), gas detector, gas mask, oxygen pack etc. (specific to steel industries)

Geometrical construction of Square, Rectangle, Triangle, Circle, Ellipse, Polygons, etc. Drawing different types of lines.

Rounding of decimal values, use of approximation Units – definition, Fundamental and derived units, system of units- FPS, CGS, MKS and SI. Unit of some important parameters – length, mass, time, density, current, voltage, pressure etc. Unit Conversion.

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3. Bench-fitting Skills (8 weeks)


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.

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 Safety precaution to be observed in the workshop. Classification, constructional and functional details of different type of bench and machine vices. Care of vices. Classification, construction and functional detail of Hammers.

Classification, construction and functional detail of following cutting tools: Chisels, Hacksaw, Files, Drills, Reamers, Scrapers, Taps & Dies. Classification, construction and functional detail of following bench tools: Steel rule, Try square, Calipers, Divider, Centre punch, Surface plate, V-Block and Trammel etc.

Hacksawing- Marking lines, Cut metals pieces of different profiles & sections by hack-sawing (straight, inclined & curved line) up to an accuracy of 0.5 mm. Filing - Parallel filing practice on flat surface. Marking practice of straight, parallel and curved lines with odd leg calipers, steel rule, dividers, Scriber. Filing flat, square, steps and contour surfaces up to an accuracy of 0.2 mm. Marking - Transfer of dimensions from drawing to work pieces. Finding center of a round bar with the help of ‘V’ block and marking block.

Chipping - Chipping practice on flat surface, slots & oils grooves, and chamfer at different angle on MS plate.

Difference between the orthographic and oblique projection. Concept of planes of Projection and Quadrants. Convention of their rotation and the concept of FIRST ANGLE and THIRD ANGLE Projection and difference between them. Concept of three views. Drawing of three views from pictorial and isometric views. Letter writing: Types of Letters viz. Normal condensed and extended (theoretical aspects). Writing of Single Stroke Vertical and inclined letters only. Writing of numerals in the same specification. Dimensioning practice.

Workshop problems related to average, percentage and ratio and proportion. Workshop problems related on time and work. Scalar and vector quantities, definition and units of terms related to motion- speed, displacement, velocity, acceleration and retardation. Equations of motion with acceleration and retardation on earth surface or parallel to it and vertical motion under gravity. Related problems. Newton’s Laws of Motion with proper examples, Concept of Force, Concept of

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Marking media, marking blue, Prussian blue, red lead, chalk and their special application, description. Measuring Instruments: Vernier calipers, principle, graduations, reading, use and care. Micrometer (outside and inside) – working principle, use and care, Calculation of least count.

Elements of mechanical components: bearing, coupling and keys

Basic knowledge of gear and gear boxes

Leveling and alignment of electrical machine

Lubrication related to electrical machines

Drilling & Reaming - Use of drilling machine for drilling through & blind holes, Reaming of drilled hole by hand reamer.

Internal & external threading by Taps & Die

Dismantling, inspection and re-assembly of bearings, coupling and keys Practice on leveling, alignment, static balancing and plumbing related to electrical machines including Laser alignment.

Practice on lubrication related to electrical machines

Inertia i.e. inertia of motion and inertia of rest.

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4. Electrical Fundamentals and circuit (8 weeks)

Terminal competencies:

After completion of this module the trainee should be able to

Understand the basic principles of electricity, 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.

11 Fundamentals of electricity, electron theory, concept of free electrons and difference between conductor, insulator and semi-conductor.

Definition and units of voltage, current, resistance, power and energy

Ohm’s law, simple electrical circuits and problems, Resistance- series and parallel, laws of resistance, temperature co-efficient of resistance, work, power and energy.

Kirchhoff’s current & voltage laws and application, Wheatstone bridge and its application, Simple problems

Use of common electrical measuring instruments and related safety aspects

Demonstration and use of electrical measuring instruments with safety aspects Verification of Ohm’s law Verification of law of series and parallel circuits Verification of Kirchhoff’s law Measure resistance by using voltmeter and ammeter, post-office box, AVO meter, Standard resistance comparison, bridge, megger and potentiometer

Dimensioned Drawing: - Method of dimensioning according to BIS specifications. Art of Spacing the views. Drawing three views of simple machine parts using all the instruments with dimensioning.

Workshop problem on time and distance. Workshop problem on mixture. Measurement of force, i.e. P = ma where P is the force, ‘m’ is the mass and ‘a’ is the acceleration. Units of force. Momentum – definition and its significance. Problems. Nature of forces – composition and resolution of forces. Resultant of a number of coplanar forces acting at a point. Problems.

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12 Types of wire and cables, their specification, insulation and voltage grade, Standard wire gauge, Common electrical accessories, their functions and specifications viz. switches, plugs, lamp holders, sockets. Development of electrical circuits used in workshop. Related Safety aspects

Demonstration and identification of different types of cables, wires Examination and checking of cables and conductors Practice on using tools like cutting pliers, screw drivers, skinning the cable, joint practice on single strand. Demonstration and practice on bare conductor joints. Practice on making simple electrical circuits on wooden board Practice on installation and overhauling common electrical accessories, fixing of switches, holders, plugs etc.

Do Profit and Loss and problems concerning to workshop practice. The law of parallelogram of forces, Triangle of forces. Lami’s Theorem, Polygon of forces and problems

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Magnetism- classification of magnets, methods of magnetizing, magnetic material, Coulomb’s law, permeability, ferro, para and diamagnetic materials

Electromagnetism- Solenoid, field around conductors carrying current, polarity, screw-rule, right-hand grip rule, advantages and application of electromagnet. Magnetic series and parallel circuits, B-H curves, hysteresis loop, hysteresis loss, eddy current, eddy current loss, equations and problems. Principles of electromagnetic induction, Faraday’s laws, Lenz’s law, Fleming’s Rules,

Perform experiments to draw B-H curve. Prepare simple electromagnet and find the polarity Experimenting faraday’s laws, Lenz’s law, Fleming’s rules, self and mutual inductance Determining hysteresis loss and eddy current loss.

Do

Do

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Related safety aspects

14 Self-inductance, mutual-inductance, their co-efficient, equations and problems Joule’s law of heating, Joule’s equivalent, heating appliances and elements. Electrostatics- terms and definitions, coulomb’s law, capacitors, charging and discharging of capacitors, energy stored. Chemical effect of electricity – principle of electrolysis, Faraday’s laws. Applications of electrolysis, Basic principles of electroplating Principle and construction of simple voltaic cell, Leclanche cell, dry cell, standard cells, their uses, care, maintenance and grouping. Secondary cells principle, types, lead-acid cells, description of parts, chemical action, method of charging, rate of charging, testing equipment, hydrometer, high rate of discharge tester, capacity, general defects and their remedies. Re-chargeable dry cells Related safety aspects

Connect the capacitors in series and parallel and measure different values. Observation of charging and discharging of capacitors, its testing. Grouping of dry cells for a specific voltage and current Battery charging- Prepare electrolyte for lead- acid storage battery; charge the battery using different methods, Check for battery condition. Routine care and maintenance of batteries

Do

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15 Alternating Current- comparison between DC and AC, its related terms, waveform, frequency and phase, instantaneous, RMS, average values Resistance, inductance and capacitance in AC circuits, reactance and impedance, power factor, vector diagram, active and reactive power. Simple problems Related safety aspects

Use of CRO Observation of different types of AC waves and measurement of their different parameters by oscilloscope

Do Simple equations and its application in solving workshop related problems. Newton’s Law of Gravitation – its statement and explanation. Centre of Gravity – C.G. of regular and irregular bodies. Position of C.G by calculation. Problems.

16 AC series and parallel circuits – RL, RC and RLC. Power factor and resonance Poly phase systems, its advantages over single-phase system. Star and delta connections in 3-phase system, relationship of VL, VP, IL, IP, formulae and calculations Related safety aspects

AC series and parallel circuits Determining L for a coil and choke and C for a capacitor Observation of 3-phase voltages and measurement of voltage, connections in star & delta

Do Do

17-18

Power and power factor in 3-phase circuits, active and reactive power, methods of improvement of power factor. Balanced and unbalanced loads Measurement of power and energy in 3-phase, 3-wire and 3-phase-4 wire circuits Related safety aspects

Demonstration of three-phase load and measurement of voltage, current power & power factor in 3-phase circuit

Do Simultaneous Equations and its application in solving workshop related problems. Work, Power and Energy- definition and units, Potential and Kinetic Energy, related problems.

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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.

Draw circuit diagrams and wiring diagrams of DC motor control system and AC induction motor control system.

Specify correctly (frame size, insulation class, cooling etc), inspect, test and detect faults and carry out simple repair on AC and DC machines.

Test the transformer and determine losses and efficiency

Connect and operate single phase transformers in parallel and three-phase transformers in parallel.

Carry out preventive and routine maintenance on AC/DC machines including the protective devices.

Practice safe working on electrical equipment

19 Types of electrical machines. DC generator- working principle, EMF equation, electromagnetic drag, types, and parts, Self and separately excited generators, practical uses Explanation of armature reaction and commutation, interpoles and their uses, connections and polarity

Characteristics of series, shunt, compound and separately excited generators, critical resistance and critical speed, application of DC generators, Losses and efficiency

Familiarization with safe working practice with electrical equipment Identification and study of parts of a DC Machine Identifying terminals of DC machine by measuring resistance of shunt field, series field and armature Connecting, running and studying the characteristics of DC series, Shunt, and compound generators. Study of No-load and load characteristics Finding critical resistance and critical speed of DC generators

Drawing of few more exercises on Orthographic Projection using all instruments and dimensioning the views.

Geometry:- Simple definitions of points, lines, parallel straight lines, triangle and rectangular figures - their properties and problems concerning workshop practice. Friction – Types of friction and laws of limiting friction. Co-efficient of friction, angle of friction, angle of repose. Advantages and disadvantage of friction. Related Problems. Lubricants – types, viscosity and effect of temperature on viscosity.

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20-21 DC motor- working principle, torque, speed, back emf, their relations. Types of DC motors- series, shunt, compound and separately excited their characteristics and applications. Starting and speed control of DC motors. Related safety aspects

Testing DC motors, identifying terminals, connecting, running and reversing direction of rotation of DC motors. Studying characteristics and drawing characteristic curves of DC motors of all types.

Do Do

22-23 Transformers- working principle, transformation ratio, no-load and on-load phasors, classification, types of core, EMF equation, equivalent resistance, reactance and impedance; equivalent circuits. Open and short-circuit tests, regulation, losses and efficiency of transformers. Three-phase transformers- types, construction, applications, advantages and connections, Protective devices and cooling systems of transformers Auto-transformers, Instrument transformers - CT, PT, Tong-tester and their applications Related safety aspects

Identification of types of transformers and its parts Verification of transformation ratio, loading secondary, finding relation between primary and secondary currents, voltages and no. of turns Measurement of iron and copper losses, determination of regulation, efficiency etc., polarity marking of single-phase and three-phase transformers Testing of single and three phase transformers, cleaning and maintenance, oil testing. Study of Instrument transformers - CT, PT and Tong-tester

Interpretation of Orthographic Projection: - Important Points and significance of projection lines. Techniques to draw the missing views and various types of possibilities of elevations with a single plan.

Moment of a force-meaning and its importance. Varignon’s Theorem and problems on it The circle – its various properties like angle and tangent properties. Problems on the above topics concerning to the workshop practice.

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24-25 Induction motors- Rotating magnetic field, and working of 3-phase induction motors, production of torque. Construction of SC and SR motors, slip, rotor emf, current, frequency, p0wer factor, Cu loss, Slip torque characteristics Double-cage rotor, comparison of SC and SR motors. Starters of induction motors and its necessity, types-DOL, star-delta, auto-transformer, soft-starters and rotor resistance starters of wound-rotor induction motors Use of motor Checker Protective devices in AC motor circuits – Principle and setting of over-current relays- thermal, magnetic, EOCR and numerical relays. Single-phasing-its effects and prevention, NVR and its function Single-phase induction motors - theory of rotation and self-starting, types, reversal and speed control. Related safety aspects

Dismantling, inspection of parts, cleaning and testing of windings, lubricating bearings and assembling of 3-phase SC and SR motors Polarity marking (phase-sequence test) of a 3-phase induction motor and connection in star and delta Testing induction motor by megger, and Motor Checker Starting the motor using different starters, running and reversing the motor, measuring the starting and no-load currents, measuring speeds at different loads, calculating speed etc Dismantling, studying and re-assembling the electromagnetic AC contactors of different voltages, types, makes and categories. Settings of different types of motor protection relays Doing panel wiring by using contactors relays etc. for automatic star-delta, autotransformer, rotor-resistance, and forward-reverse D.O.L. starters. Studying, overhauling of fan motors, connecting, running and reversing of single-phase motors.

Simple exercises on Interpretation of Orthographic Projections.

Do

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26 Synchronous machines Alternator- parts, types of poles- salient pole and smooth-cylindrical type, rotating-field and rotating armature type etc Prime movers for alternators, turbo-alternator, engine-driven alternators, EMF equation, pitch-factor, breadth-factor Alternator characteristics, OCC, SCC, Exciter, Excitation, and voltage regulation, cooling of alternators and rating Synchronous motors: operation, types, characteristics, application. Related safety aspects

Identification of terminals of alternator, connecting, starting, running, loading and plotting characteristic curves

Starting synchronous motors by different methods

Do Do

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6. Electrical Measuring Instruments (2 weeks)

Terminal Competencies :

After completion of this module trainees will be able to

Know the working principles, construction and uses of different electrical measuring instruments

27-28 Electrical Instruments- Classification, types, methods of achieving deflecting, controlling and damping torque, their advantage and limitations.

Constructional details of moving coil and moving iron instruments. Extension of range, use of shunt and multiplier

Description, construction, working principle and use of:

a) Electro-dynamic instruments single-phase and three-phase watt meters.

b) Thermocouple and hot-wire meter

c) Power factor meters d) Frequency meter e) KVAR, tri-vector and maximum

demand indicator f) Ferranti-type DC energy meter

i.e., Ampere-hour meter. g) AC energy meter, 1-phase, 3-

phase 3-wire, 3-phase-4-wire. h) Megger- insulation testing and

Earth testing i) Ohmmeter and multimeter j) Precaution while using

electrical instruments k) DC tongue tester

Related safety aspects and applicable IP class

Calibration of ammeter, voltmeter, wattmeter and energy meters Preparing correction curves/ calibration records Connections of ammeters through CTs, Voltmeters through PTs Connections of watt meters and energy meters through CTs and PTs Changing CTs for higher rating

Different types of simple and intricate exercises on interpretation of orthographic projections with proper dimensioning (6 classes)

Mensuration:- Plane figures – Triangle, Square, Rectangle, Parallelogram, Trapezium, Regular Polygons, Circle, Hollow Circle, sector and segment of circle, fillets etc. Simple machines – what is a machine, its advantage and utility. Important definitions concerning to machines – Mechanical Advantage, Velocity Ratio and Efficiency of the Machine.

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7. Electronics and communication (8 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

Make simple electronic circuits on bread-board and PCB

Understand the principle of digital electronics, digital 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

Understand working of industrial weighing system and communication system

Use various electronic instruments

29-30 Basic Analog Electronics – Introduction to Electronics and its application, difference between analog and digital electronics.

Atomic theory, energy band diagram, classification of matter based on energy band diagram.

Active and passive circuit elements: Resistors- fixed and variable, carbon and wire wound, metal film and metal oxide, colour coding, power rating, accuracy and effect of temperature, uses of resistors.

Fuses and their specifications

Inductors- types: ferrite core, air core fixed, tapped and variable inductors, Factors affecting inductance and use of inductors. Capacitors: Mica, ceramic, paper, electrolytic, tantalum, silvered mica, variable capacitors, colour

Electronic Component identification and testing, reading and interpretation of colour codes

Use of digital multimeters

Connecting function generator with oscilloscope, study of wave forms, measurement of voltage and frequency.

Diode characteristic, Zener diode characteristics, testing, and identification

Making half wave and full wave rectifiers: Study of different wave shapes and their values on oscilloscope, calculation of different parameters

Hands on practice on soldering / de-soldering

Assembly and testing of power supply with filter and regulators on PCB by soldering the components.

Do

Do

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coding, rating and uses.

Semiconductor theory: intrinsic and extrinsic, P and N type, development of P-N junction, barrier potential.

Diodes: working, classification, characteristics, coding, specification, identification and applications. Half wave and full wave rectifiers, Zener diodes: characteristics, types and application.

Power supply with filter and regulators for different applications, Introduction to SMPS and UPS

Related safety aspects

31-32 Transistors: working, classification, VI characteristics (static and dynamic), CE, CB, CC configuration and their difference, current, voltage gains and their relationship. Biasing and thermal stabilization circuits, heat sink. Packaging, coding, specification, identification and applications Field effect transistors: construction, operation and VI characteristics of JFET, Enhancement and depletion type MOSFET, concepts of CMOS and its handling. Difference with bipolar junction transistors Uses UJT- Construction, operation VI characteristics and uses

Transistors: identification and testing, finding static and dynamic characteristics of transistors in different modes using training kits. Biasing circuits FET and MOSFET: identification, drawing of characteristic curves. Assembly and testing of amplifier circuits: RC coupled amplifiers. Study of waves on oscilloscope Drawing the frequency response curve of amplifiers Demonstration on various types of oscillators

Do The Laws of Indices and problems, Power and Exponent, laws of exponent Levers – Classification of Levers and problems

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Amplifiers: working principle, classification, circuits and applications. Oscillators: working principle, classification, circuits and applications. Related safety aspects

33 Linear ICs and OP-AMPs: working, characteristic, pin diagram, applications as inverting and non-inverting amplifier, calculation of gain, comparator, unity gain buffer and scale changer, adder, subtractor, differentiator, integrator. Switching and timer circuits: classification of multi-vibrators, astable, monostable and bi-stable. Internal block diagram, operating of 555 timers and its applications Opto-electronics- elementary idea of LED, LCD, photo diodes, photo transistors, solar cells and their applications Related safety aspects

OPAMPS pins identification, assembly of inverting and non-inverting amplifiers, calculation of voltage gain, assembly of comparator, adder, subtractors, differentiator, integrator circuit and its testing using training kit. Construction of multivibrators using 555 timers, Calculation of frequency

Concepts of Sectioning, necessity, significance, conventions and characteristics Practice on different types of sectioning – (a) Full section (b) Half section (c) Off-set section (d) Partial or logical section (e) Revolved section and (f) Removed section. Exercises on sectioning from isometric view

Do

34-35 Digital Electronics Number systems: Introduction to number system and conversion Basic logic gates: Symbolic representation and truth tables for logic gates: Buffer, NOT, OR, AND, NAND, NOR, XOR, XNOR. Different logic families and their characteristics, Electrical

Verification of truth tables of different logic gates Demo on adders and subtractors Construct and verify truth tables of flip flops Demo on counters and registers

Do Logarithms – Types of logarithms e.g. Naperian and Common Meaning of logarithms its elements i.e. characteristics and mantissa. Problems on Positive Characteristics Wheel and Axle, Screw

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equivalent of gates Combinational and sequential circuits: Brief introduction of

Half and full adder and subtractors, Flip-flops: RS, JK, D, T type Memory and its types: RAM, ROM, PROM. EPROM, EEPROM, CD-ROM, and IC chips Related safety aspects

Jack, Inclined plane and related problems

36 Hardware of a personal computer (PC) –CPU, ALU, Registers, counters, data and address bus, memory, I/O devices, Microprocessors and Microcontrollers Data communication: serial and parallel communication, MODEMS, Interfaces - RS-232, RS-485. Related safety aspects

Demo on Microprocessor programming Identification of different parts of a personal computer Demo on industrial weighing system

Do Do

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8. Power Electronics and 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 Thyristor circuits: Converter, AC voltage Regulator, Chopper, Inverter, IGBT circuit, PWM and their use

Observation of different types of power electronic components Drawing the V-I characteristic of a thyristor Study of different firing circuits of thyristors (RC, UJT, Ramp and Cosine firing circuits) Study of 1 ph and 3 ph converter - half wave, full wave, half controlled etc Study of inverter circuit and waveforms Checking of power MOSFET, thyristors, IGBT, GTO, IGCT etc

Exercise on sectioning from isometric view.

Logarithms - Problems on Negative Characteristics.

Hydrostatics – Nature and pressure of liquid inside a vessel at different positions. Unit of pressure, Pascal’s Law, simple problems. Types of pressure- atmospheric, absolute and gauge.

39 Electric Drives: Concept of modern electric drives, Classification of load and motor according to their speed/torque characteristics and drive performance characteristics. Behavior of drive system during change of state Control system - concept of open and closed loop system. DC drives: concept of speed control of DC motor. Block diagram

Testing of thyristor and Ramp firing circuit, study of waveform on different test points of ramp firing circuits Study of the effect of KP, KI, KD in relation to close loop DC drive kits Demo of a real time microprocessor based DC drive used in industries. Exercise on configuration and parameterization of DC drives.

Do Do

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of close loop unidirectional DC drive, four quadrant operation of DC drive, concept of dual converter, block diagram of close loop reversible DC drive, field weakening control and spill over control, Electronic modules used in DC drives. Parameters and concept of parameterization of DC drives Maintenance and trouble shooting of DC drive. Related safety aspects

Exercise on maintenance and trouble shooting of DC drive.

40- 41 AC drives: concept of speed control of AC motors, principle of V/f control of drives, block diagram of close loop AC drive, principle and operation of inverters (1 ph and 3 ph)- concept of PWM inverter. Principles of speed control of SCIM and SRIM in AC drives. Block diagram of Close loop control, power circuit, control circuit, electronic control modules of AC drive. Parameter and Concept of parameterization of AC drives, Maintenance and trouble shooting of AC drive Related safety aspects

Testing and study of IGBT, power plate Study of inverter voltage waveforms Demo of a real time microprocessor based AC drive used in different processes in industries. Demonstration on parameterization of AC drives Exercise on maintenance and trouble shooting of AC drive.

Free hand sketch of tools and tackles used in electrical trade

Factors and Different types of factorization Density and Specific Gravity – its importance and significance, Archimedes’ principle, Law of floating bodies, Condition of equilibrium of a floating body

42 UPS - Understanding of float charger, off-line UPS and On-line redundant UPS, Different type of controls, circuit and maintenance of UPS and battery. Related safety aspects

Study of a UPS and its circuit and controls Trouble shooting and rectification.

Do Do

27

9. 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

Working of LT and HT Switch- gears and protective relays

Power factor improvement methods

Monitoring system for power generation and utilization

43 Power Generation, Transmission and distribution System Introductory concepts - generating stations: Hydel, Thermal, Nuclear, Gas turbine, IC engine etc. High voltage safety, use of safety devices like HV tester, discharge rod, cool coat Earthing, system and equipment, neutral earthing, maintenance of earth pits Related IE rules and safety aspects

Measurement of pit resistance. Demonstration of HV safety devices Use of HV tester, cool coat, discharge rod

Draw the typical symbols used in electrical circuits. Graphical symbols used in electrical technology, circuit elements, types of distribution system and method of connection. (As per BIS code and IEEE, IES rules)

Do

44 Transmission O/H line, conductor, support, insulators, their merit and demerit, sag, span, joints, guard, binding of insulators, stay, damper jumpers, erection of line, maintenance and inspection of transmission lines.

Cables- construction, classification of cables, property of XLPE, paper, PVC, insulation, jointing and laying of cable, testing and fault

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

Do Do

28

localization

Indoor and outdoor substation, layout, single line diagram, CT& PT, isolators, earth switch, transformer, lightening arrestor, reactor, breaker, bus and its protection.

Energy management, maximum demand, load factor, connected load, diversity load curve, tariff. LDC- monitoring system for power generation and utilization.

Indian electricity rules pertaining to safety of supply system, LT and HT equipment, O/H transmission.

Related IE rules and safety aspects

Polarity marking of CT Connection of CT and PT Connection of lightening arrestors

45 Power system protection

Switch gear- arcing phenomena, ACB parts and their function, maintenance of arc chute, contacts, limitation and tightening, testing and calibration of releases, trouble shooting.

Construction, working and maintenance of OCB, VCB and SF6, GIS, their merit and demerit

Protection relay: classification, terms and definitions, comparison of mechanical, solid state, digital

Connection of relays, Maintenance and adjustment of arc chute, and contact Opening and assembling - pole assembly, trip assembly and hand assembly Maintenance of ACB, OCB, VCB, and SF6 breakers Demo on parameterization of digital relay and numerical relay

Screw Threads – Forms of various screw threads, Nomenclature, convention and drawing of various thread profile

Quadratic equations and practical problems concerning to workshop practice Specific Gravity of:- a) Solids heavier than water. b) Solids lighter than water. c) Solids soluble in water. Related Problems

29

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

46 Fuse- terms and definitions, selection and characteristic of HRC fuse Power factor- effect of low power factor, cause of low PF, power factor improvement, use of static VAR compensation Energy management- maximum demand, load factor, connected load, diversity load curve, tariff. Related IE rules and safety aspects

Demonstration of different types of fuses Demonstration of different types of power factor improvement and compensation equipment Visit to Energy Management Centre such as Load Despatch Centre (LDC), Sub-stations.

Do Do

30

10. Instrumentation & Control (4 weeks)


System and equipment used for the measurement of various process parameters related to steel plant

Process control system and PID controllers

Different control strategies used in steel plant

47-48 Introduction- Objective of the Instrumentation & control, elements of measurement systems, instrument terminology, Sensors and transducers – definition and types Load cell and its application in industrial weighing Encoders and its applications Introduction to process parameter measurement: Temperature measurement- Principles, types and working of mechanical, electrical and radiation temperature sensors, relative advantages and limitations Temperature switches: constructional details and maintenance. Temperature transmitters: types, working, calibration and maintenance. Hot metal detectors, Molten metal (Bath) temperature measurement.

Verification of working principle and characteristic of different sensors and transducers covered in theory class viz. LVDT, strain gauge, capacitive gauges, thermocouples, RTDs, thermistors etc. Dismantling, assembly, overhauling and calibration of transmitters, indicators, gauges, regulators and switches used for pressure, temperature, flow, level and other measurement Configuration of smart transmitters using HART and other configurators

Fastening Devices – Temporary and Permanent, meaning and difference. Temporary Device – Hexagonal Bolt, Nut, Check Nut, Washer. To draw the three views of individual devices and the assembly.

Principle of Similarity:- Properties of similar triangle and their application to day to day workshop problems. Properties of Matter – Different types of Properties of Matter e.g. Mechanical, Electrical, Chemical, Magnetic etc Properties of Matter (Electrical):- resistivity, permittivity, permeability, resistance temp. Co-efficient etc Insulating materials. Brief description and properties of electrical materials such as silicon, nichrome, silver, copper, aluminum, transformer oil.

31

Pressure measurement- Types and units of pressure and differential pressure. Manometers: principles, types and working. Pressures sensors and transducers: working principle and construction of elastic and electrical pressure and DP sensors. Pressure gauges: constructional details, calibration and maintenance. Pressure switches: constructional details and maintenance. Transmitters: Smart P/DP transmitters and its configuration. Flow measurement: Definition, units and types. Restriction method: principles, types and installation of orifice plate, venturi tube, flow nozzle and others sensors. Variable area method: principles, types, and working. Mass flow meters, magnetic, turbine and vortex flowmeters Flow switches: constructional details and maintenance. Level measurement - definition, units and types of liquid and solid level measurement using direct and indirect methods: hydro-static pressure, capacitive ultrasonic, air bubbler Thickness measurement: types of methods, working principle, construction, calibration and maintenance. Related safety aspects

32

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 Final control elements: types, working principle, construction, calibration and maintenance of I/P converters, Control valves & actuators, Valve positioned, power cylinders. Reading and interpretation of PI diagrams, instrument manuals and part list, panel wiring diagram etc. Related safety aspects

Operation of a controller, setting of its PID values, controller tuning. Testing of a control valve, I/P converter and valve positioners

Different methods of preventions of rotation of Bolts - Check nut, Square headed bolt, Square headed bolt with square neck, Cup headed bolt, eye bolt, Counter sunk headed bolt and Rag bolt

Trigonometric ratios and simple problems connected to workshop practice Properties of Matter (mechanical):- Tenacity, Toughness, Malleability, Ductility, Elasticity, Plasticity, Brittleness and Hardness.

Properties and uses of copper, zinc, lead, tin, aluminum brass, bronze, solder, bearing metals, timber and rubber.

51 Revision/ Plant visit/ Industrial visit

52 Examination

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2nd Year 11. PLC & DCS (2 weeks)


Need and working principle of PLC

Hardware of PLC

Programming of PLC

Hardware of DCS

Communication with different field and control devices

53-54 Programmable Logic Controller (PLC)- Need and working principle, hard ware details. Function and connections of different cards Program techniques of PLC, inputs, outputs, timer and counter instructions, data manipulation Development of simple programs Documentation, different functional blocks & mathematical instructions Communication system used in networking of PLC Data Acquisition System (DAS) & Supervisory Control And Data Acquisition (SCADA) System- Basic structure, software and applications, introduction to HMI packages. Distributed Control System (DCS)- basic concepts, architecture advantages. Level of automation in steel industry Related safety aspects

Familiarization with different I/O modules of PLC Development of simple programmes involving bit level instructions, timers and counters, simple data manipulation instructions. 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

Different methods of locking of nuts- Lock nuts, Split pin , Slotted nut, Symonds nut, Castle nut, Wings nut etc.

Do

34

12. Industrial hydraulics and pneumatics (2 weeks)


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

55-56 Industrial hydraulics and pneumatics

Basic principles of hydraulic and pneumatics, characteristic of fluid media, safety aspects

Operational details of fluid power control element.

Energy converter, Fluid conditioner, Control valves

Symbols of basic hydraulic and pneumatic components

Basics of proportional and servo valves, its electrical and electronic circuitry, control and feedback systems

Concepts of interfacing of hydraulic and pneumatic components with PLC

Identify components such as reservoir, filter, pumps, float switch, valves, actuators etc. Operation of proportional and servo valves, functions of control and feedback components Demonstration of simple hydraulic devices and circuits Demonstration of simple pneumatic devices and circuits Hydraulic and pneumatic circuits, reading and interpretation Development of simple logic circuits in PLC and its testing

Permanent Fastening Devices- Rivets – different parts and their types Different types of rivet heads

Trigonometric ratios and practice on solving problems related to workshop practice. Engineering Material – Introduction classification, metallic and non-metallic material, physical and mechanical properties, testing of metal and hardness testing. .

35

13. Welding (1 weeks)

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, electrodes and their selection, various joints and joint preparation, their suitability for various applications. Related safety aspects

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- chain, zig – zag Butt Joint – a) Single plate or strap b) Double plate or strap

Angle of Elevation and Angle of Depression, Problems on Height and Distances taking the help of Trigonometric Ratios Heat treatment of steel – Hardening, annealing, tempering, normalizing and case hardening

36

14. Advanced Electrical machine (8 weeks)


After completion of this module the trainee will become familiar with

Specifying correctly, inspect, test, detect faults and carryout simple repair on AC/DC machines (Generator, motors, transformers)

Connect and operate single phase and three phase transformers in parallel

Dismantle, overhaul, diagnose and rectify faults of commonly used transformers

Synchronize alternators using different methods

58-59 Advanced Electrical machine Generators: Parallel operation of series, shunt and compound generators. Motors - classifications of motors based on BIS and other standards for protection, insulation, frame size, enclosures etc. DC Machine- Distinguish various frequently used DC motors according to type and construction, their control and protective devices. Data sheet and name-plate data of DC machines. Reading of schematic and wiring diagrams of DC machine control. Installing and commissioning of DC motors and generators.

Safety precautions related to electric machines Safely connecting DC generators in parallel and load sharing Testing DC generators, doing general upkeep and maintenance; preparing maintenance schedule. Studying and drawing internal connections of all types of DC motor-starters and controllers, testing and connecting them with motors, running, reversing and controlling speed. Testing, locating, rectifying faults in DC motors, motor-starters and controllers. Maintenance of DC motors and their connected accessories, motor check chart, preparing maintenance schedule for DC motors.

Isometric Projection:- Difference between isometric and actual scale, construction of isometric scale and simple exercises

Solution of Triangles: - Meaning and its use, The Sine rule and the Cosine Rule. Problems related to Workshop practice. Effect of force on Materials in Expanding, Bending, twisting and shearing

37

60-61 Transformers Constructional details of power transformers, cooling methods-AN, AF, ONAN, ONAF etc. Transformer connections-star/star, delta/delta, star/delta, delta/star, V/V, T/T etc. and their applications. Tap-changer: OFF-load and ON-load, voltage stabilizer and voltage regulators. Parallel operation of single-phase and three-phase transformers, phasor groups. Testing and maintenance of transformers. Related safety aspects

Identification of parts of power transformers, Parallel operation of single phase as well as three phase transformers. Connections of CTs and PTs for single phase and three phase circuits V and Scott connections of transformers.

Drawing the typical diagram of D-type cartridge fuse, H.R.C. type fuse. Fuse curves Graphics as per relevant IS standard. Symbols indicating the method of operation of the instrument and accessories as per relevant IS: Standard

Solid Mensuration:- Prism, Cylinder, Pyramid, Cone, Frustum of Pyramid and of Cone, Problems concerning to workshop practice. Relation between load and extension – Graph – meaning of Yield Point – 1st & 2nd Ultimate tensile Stress, Breaking Stress and factor of safety

38

62-64 AC motor control - basic methods, slip-control, voltage control, rotor resistance control, cascading, pole changing, frequency control etc. Motor classification, duty cycle, protection class, insulation class, frame sizes etc. Troubleshooting and maintenance of induction motors, motor check chart. Related safety aspects

Connecting reversible D.O.L. starter with induction motor and studying operation at under voltage, no-voltage, overload, short circuit and braking in motor control circuit. Regulating the speed of AC motors by conventional controllers. Running induction motor at no load, connecting with 2-wattmeters, measuring power and calculating power factor, loading the motor and finding the change in power factor. Measuring rotor frequency of slip ring induction motor, calculating the speed, slip and rotor copper loss, measuring rotor PF at various loads. Rewinding and overhauling fan motors. Preparing maintenance schedule, carrying out routine maintenance, attending to faults and rectifying.

Sketching of brush and brush gear of D.C. machines Lay out D.C. Panel board arrangement. Lettering-Numbers, Alphabets. Sketching of D.C. 3 point face plate starter top scale.

Solid Mensuration: - practice problems. Stress, Strain – Definitions, different types of Strain, Hook’s Law, Modulus of Elasticity – Young’s Modulus, Bulk Modulus – Modules of Rigidity, Poisson’s Ratio and Problems.

65 Synchronizing of alternators: bright-lamp, dark-lamp, synchroscope methods, phase sequence, sharing of loads by alternators in parallel. Related safety aspects

Synchronizing of alternators by lamp methods and synchroscope method, sharing of loads. Load behavior of synchronous motor with change of excitation etc

Drawing of sine wave (single phase and three phase AC system wave forms)

Solid Mensuration: - Sphere, Spherical segment, material weight and cost problems on above topics concerning workshop practice. Heat – Definition and its importance. Temperature – Definition and significance. Difference between heat and temperature Scales of Temperature e.g. Fahrenheit, Centigrade, Kelvin- relationship between them, Lower and Upper fixed points, Fundamental Interval. Reasons for the selection of Mercury as thermometric substance

39

15. Industrial wiring (5 weeks)


Use different types of tools and measuring instruments, equipment and accessories used in electrical wiring.

Prepare layout, circuit and wiring diagrams for different types of wiring systems used in industries

Laying, work on and fixing up the wiring materials and accessories for various industrial wiring installations as per IE rules and BIS code of practice.

Testing and Inspection of wiring

66-67 Knowledge of tools required for marking, punching, cutting, drilling, filing, stripping, crimping, socketing and fixing glands & screws etc.

Wiring diagram and symbols- Knowledge of different electrical wiring systems-lighting, industrial control and O.H. Lines. IE rules for different wiring systems.

Different types of wires, conductors, cables and insulators and their load carrying capacity. Their specification, identification and selection as per given parameter and standard. Wiring material and accessories, its selection and estimation. Knowledge of different types of trays, junction boxes, panels and terminal blocks. Related safety aspects

Stair case, godown and tunnel wiring including bill of materials. Cutting, finishing and mounting of rigid/flexible pipes and fittings frequently used in low voltage installations Laying, fastening, cutting, finishing, gland preparation and mounting the cables in low voltage installations Drawing wires, cutting, crimping and soldering of wires.

Exercise on electrical drawing reading of connections to motors through ammeter, voltmeter and KW meters. Exercise on reading and tracing wiring diagram of an alternator and reproducing it in proper sequence .

Do

40

68-69 Different types of DC/AC machines and methods of their starting and control. Connections lay out and earthing as per standard code of practice for industrial wiring. Types of common faults and method of fault findings and remedies thereof. Related safety aspects

Assembling, placing and wiring switch gear and distribution devices. Placing and connecting according to drawing and diagrams the commonly used single-phase and three-phase ac motors including their manual and automatic switching, protecting and signaling devices

Graphic symbols for Rotating m/cs and Transformers Diagram of connection to a squirrel cage induction motor. Sketching the connection diagram of controlling and protective devices for induction motor.

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 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

70 Knowledge of Quality assurance required in Electrical works. Energy saving concept

Tracking down and localizing by measurements the faults in wiring Connections of voltmeters, ammeters, watt meters, energy meters, PF meter, KVAR meter etc. Preparing correction curves for ammeter, voltmeter, energy meter etc.

Reading of simple blue prints and electrical power/ control diagrams. Sketching of D.C. machine starters to scale.

Do

41

16. Computer & IT (1 week)


Hardware of PC

Common software used in PC

Use of Intranet, Internet, E-mail 71

Computer & IT Basics of computer hardware and software MS office: Word, Excel and power point Use of Intranet, Internet, E-mail

Preparation of a word document (eg. Project report) Preparation of an excel file and make graphical representation of data obtained during practical sessions on electricity

Layout arrangement of D.C. Generators, motors and the control panel

Statistics – Mean, Median, Mode, Variance, Frequency distribution , Cumulative frequency, Pie-Chart Expansion of Liquids – it has only one type of expansion e.g. Cubical expansion. Two forms - Real and Apparent – the relation between them ,coefficient of apparent and real expansion. Problems.

42

17. Iron & Steel making technology (2 weeks)


Different types of raw material used for iron making and their sources

Iron and steel making processes

Hot and cold rolling process 72-73 Different types of raw material

used for iron making and their sources Details of Blast furnace reactions, Cooling system, Cast House practices. Gas cleaning system. Hot metal Desulphurisaion. Complete Heat cycle in LD vessel. Secondary Steel Making. Casting of Steel. Theory of Rolling. Rolling of long products & flat products in hot and cold rolling.

Guided visit of different plants of the organization and familiarization with the process.

Layout arrangement of AC Generators, motors and the control panel

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

43

18. Quality Management & Improvement Technique (1 week)


QMS and its important provisions

Concept and application of TPM

Quality Control tools and systems practiced in industries

74 Introduction to TQM, Quality management standards, its importance and important provisions. TPM- Concept, different pillars, its implementation in an organization Problem solving technique used in industry - QC and SPC tools

Familiarization with Quality Management System, TPM, Small Group Activity (SGA) and Quality Circles as being practice in the industry.

Drawing of circuit of an instrumentation amplifier with labeling and waveform

Set Theory – Introduction and problem. Mechanical Equivalent of Heat-problems. Transmission of heat – Conduction, Convection and Radiation. Examples from industries.

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

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

Drawing of flow sheet symbols different process control instruments.

Problems related to set theory. Transmission of Power and motion of Belt and Pulleys: - Driver and Follower – Open and Cross belt system of belt

44

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.

Inspection of tools and tackles Loading, unloading and shifting of common and uncommon shapes of material. Hand signal used in rigging.

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

20. Environment Control and Occupational Health (1 week)

Terminal Competencies: After completion of this module the trainee will be able to appreciate the following

Major emission source and their effect on global environment.

Problems and attention needed to overcome and minimize emission.

Permissible extent as per Factory Act and rules thereof.

Occupational Hazards and ergonomical issues.

77 Awareness on environment pollution and effects. Basic knowledge of air pollution control equipment. (ESP, Bag house, cyclone separators etc) Major emission and pollution source and their effect on environment. Control of NOX and SOX and SPM to permissible level. Standard of ambient air quality, work environment, effluent discharge. Dust handling and disposal system. Control of water pollution- effluent treatment plants Occupational health and ergonomics

Observation of - emission and pollution

control equipment - dust handling & disposal

system - effluent treatment plants - emission monitoring

equipment

Do Do

78 Revision/ Plant visit/ Industrial visit

45

Part B: Shop Floor (In- plant) Training- Duration- Half ( ½ ) Year

B.1 Shop Floor (In- plant) training

Terminal Competencies: This is on-the-job and observational training module which will enable trainees to relate and learn the practical applications of contents covered during the basic training.

79-102 The content of this module will be developed by the organization based on the existing Electrical, Electronics and Instrumentation maintenance practice which may include the following Electrical repair shop 1. Maintenance and repairing of

electrical machines 2. Calibration and testing of

electrical instruments 3. Testing and setting of electrical

protective devices 4. Dismantling, assembly and

testing of electrical motors Electronic repair shop 5. Maintenance and repairing of

electronic cards 6. Calibration and testing of

electronic instruments

Instrument Repair Shop 1. Maintenance and repairing of

instruments 2. Calibration and testing of

sensors, transmitters, control valves etc.

On the job training – Safety pre-cautions to be followed in the section/plant including need of special protective equipment, if any. Study of working of different equipment used in plant/section visited. Carry-out repair/ test/ calibration of instruments/ equipment under the guidance of competent person Carry-out minor maintenance job under guidance of competent person Working with skilled supervisors/ workmen/ operators. Preparing report on the job done/ observations made.

Reading and interpretation of electrical diagram used in the plant. Reading & interpretation of P&I diagram related to process plants (Blast Furnace, Coke Plant, Sinter Plant, Steel Melting Shops, Rolling mills etc.

Peak , RMS and average value of AC supply. Relationship between them. Peak , RMS and average value of current in Rectifiers. Calculation of form factor, ripple factor, transformation ratio. Estimation of PIV of a diode in different types of rectifiers. Number system- decimal, binary, octal, hex. BCD code, conversion from decimal to binary, octal and hex and vice-versa. Applied problems on Electrical trade. Simple estimation of the requirements of materials as applicable to the trade. Problems on estimation and costing. Meaning of HP and BHP. Problems on work, power and energy related to

46

Power Houses and sub-stations 1. Power plant equipment &

Control 2. Distribution of electrical power

and SLD. 3. Substation equipment 4. 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

electrical area. Magnet and magnetism. Simple workshop problems.

47

B.2 Industrial Visit/ Project work/ Revision & Test (2 weeks)


Functioning of local industries

Preparing project report and presentation

103-104 Revision of theory covered during the training. Presentation skills

Revision of practical conducted during training. Visit to local industries(optional) Preparation of project/ training report and presentation to experts

Revision. Revision.

48

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 connect an induction motor with DOL starter and run it 2. Able to perform straight married joint 3. Able to do stair case wiring 4. Able to do godown wiring 5. Able to wire-up contactors to form auto star delta starter 6. Able to connect all the accessories to glow a tube-light 7. Able to find out efficiency of a given single phase transformer. 8. Able to find out efficiency of a DC shunt motor 9. Able to measure energy using 2/3 watt meter method 10. Able to synchronise 3 phase alternator with the existing 3 ph power supply.

49

LIST OF TOOLS & EQUIPMENT FOR THE TRADE OF ELECTRICIAN (Steel Plant) TOOL KIT

Sl.No Description Quantity

1 Steel rule , 150 mm Quantity to be sufficient as per seats surveyed & allocated

2 Pliers insulated 150 mm

3 Pliers side cutting 150 mm

4 Screw driver 100 mm

5 Screw driver 150 mm

6 Electrician connector, screw driver 100 mm insulated handle thin stem

7 Heavy duty screw driver 200 mm

8 Electrician screw driver 250 mm thin stem insulated handle

9 Punch centre 150 mm X 9 mm

10 Double bladed electrician knife

11 Neon Tester

12 Rule steel 300 mm

13 Saw tenon 250 mm

14 Hammer, cross peen 115 grams with handle

15 Hammer ball peen 0.75 kg. With handle

16 Firmer chisel wood 12 mm

17 Gimlet 6 mm.

18 Bradwal

19 Scriber 150 mm X Ø 4 mm (Knurled centre position )

20 Pincer 150 mm

50

SHOP TOOLS, INSTRUMENTS & MACHINERY

SL.No. Specification Quantity

1 C. Clamp 200 mm, 150 mm and 100 mm. each Quantity to be sufficient as per seats surveyed & allocated

2 Spanner 150 mm adjustable 15 degree

3 Blow lamp 0.5 litre

4 Melting pot

5 Ladle

6 Chisel cold firmer 25 mm X 200 mm

7 Chisel 25 mm & 6 mm

8 Drill Machine hand 0 to 6 mm capacity

9 Electric drill machine portable 6 mm capacity

10 Pillar electric drill machine 12 mm capacity

11 Allen key

12 Oil can 0.12 litre

13 Grease gun

14 Out side micrometer 0 to 25 mm

15 Bench grinder motorised

16 Rawl plug tool & bit

17 Pulley puller

18 Bearing puller

19 Hygrometer

20 Thermometer 0 to 100 deg. centigrade

21 Scissors blade 150 mm

22 Crimping tool

23 Wire stripper 20 cm

24 Chisel cold flat 12 mm

25 Mallet hard wood 0.50 kg..

26 Hammer Exeter type 0. 40 kg.

27 Hacksaw frame 200 mm, 300 mm adjustable

28 Square try 150 mm blade .

29 Divider 150 mm, outside & inside calliper

30 Pliers flat nose 100 mm

31 Pliers gas round nose 100 mm

32 Pliers Gas 150 mm

33 Tweezers 100 mm

34 Snip straight 150 mm

51


35 Snip bent 150 mm Quantity to be sufficient as per seats surveyed & allocated

36 Spanner D.E. metric standard set

37 Drill hand brace 0 to 100 mm

38 Drill S.S. Twist block 2 mm, 5 mm 6 mm set of 3

39 Plane, smoothing cutters, 50 mm

40 Gauge, wire imperial

41 File flat 200 mm 2nd cut

42 File half round 200 mm 2nd cut

43 File round 200 mm 2nd cut

44 File flat 150 rough 4 nos.

45 File flat 250 mm bastard

46 File flat 250 mm smooth

47 Rasp, half round 200 bastard

48 Iron, soldering 25 watt, 65 watt, 125 watt

49 Copper bit soldering iron 0.25 kg.

50 Desoldering gun

51 Vice hand 50mm jaw

52 Vice Table jaw 100 mm

53 Vice Hand 150 mm jaw

54 Pipe cutter to cut pipes upto 5 cm. dia

55 Pipe cutter to cut pipes above 5 cm dia

56 Stock and die set for 20 mm to 50 mm G.I. pipe

57 Stock and dies conduit.

58 Digital Multi meter ( 3 ½ digits )

59 Digital Multi meter ( 4 ½ digits )

60 A.C. Voltmeter M.I. 0 –500V A.C.

61 Milli-Voltmeter centre zero 100 – 0 – 100 m volt

62 D.C. Milli ammeter 0 – 500 mA

63 D.C. Ammeter MC 0-1 A

64 Ammeter MC 0-5 A

65 Ammeter MC 0-15-25 A

66 A.C. Ammeter M.I.. 0-5A

67 A.C. Ammeter M.I.. 0-15-25A

68 K.W. Meter 0-1-3Kw

69 A.C. Energy meter (single phase 5 amp. 230 V)

52


70 Single phase power factor meter Quantity to be sufficient as per seats surveyed & allocated

71 Frequency meter

72 Tacho meter with stop watch

73 Current transformer

74 Potential transformer

75 Growler

76 Tong tester / Clamp meter 0 – 100 Amp. AC.

77 Megger 500volts

78 Wheat stone bridge complete with galvanometer and battery

79 Relays – Over current, under voltage, etc. 3 volt, 100 amp.

80 Contactor 3phase,440volt,16amp.2 NO &2 NC auxiliary contacts

81 Contactor3 phase, 440 volt, 32 amp.2NO&2NCauxiliary contacts

82 Limit Switch

83 Rotary Switch 16A

84 Load bank- 5 KW( Lamp / heater Type)

85 Brake test arrangement with two spring balance of 0 to 25 kg rating

86 Knife switch DPDT fitted with fuse terminals 16 amp

87 Knife switch TPDT fitted with fuse terminals 16 amp

88 DC power supply 0 - 100 volt, 5 amp

89 Inverter 1 KVA Input 12 volt DC, Output 220 volt AC with 12 battery

90 Voltage stabiliser- Input 150 – 230 volt AC, Output 220 volt AC

91 Rheostat 0 – 1 Ohm, 5 Amps. 0 – 10 Ohm, 5 Amps. ; 0 – 25 Ohm, 1 Amp; 0 – 300 Ohm. 1 Amp.

92 Resistance Temperature Detector (Pt-100)

93 Digital Temperature Indicator (with RTD input)

94 Laboratory type induction coil 6 volt to 800-10,000 volt

95 3-point D.C. starters

96 4-point D.C. starters

97 Cut out, reverse current, over load, under voltage relays.

98 Starters for 3-phase, 400 V, 50 cycles, 2 to 5 H.P. A.C. motors a) Direct on line starter b) Star delta starter with manual, semi-auto and automatic c) Auto transformer type starter

99 Electrical machine trainer: -Suitable for demonstrating the construction. and functioning of different types of DC machines and AC machines (single phase and three phase). Should be completed with friction brake, dynamo meter, instrument panel and power supply units

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100 Motor generator (AC to DC) set consisting of - Motor induction squirrel cage, 7 HP 400 Volts, 50-cycles, 3-phase with star delta starter and switch directly coupled to DC shunt generator 5 KW 440 volts, and switch board mounted with regulator, air circuit breaker, ammeter, voltmeter knife blade switches and fuses, set complete with case iron and plate, fixing bolts, foundation bolts and flexible coupling.

Quantity to be sufficient as per seats surveyed & allocated

101 Motor generator(DC to AC) set consisting of - Motor shunt 5 HP, 440 Volts with starting compensator and switch directly coupled to generator AC. 3.5 KVA, 400/230 Volts, 3-Phase, 4 wire, 0.8 PF 50cyccles with exciter and 1 switch board mounted with regulator, circuit breaker, ammeter, voltmeter frequency meter, knife blade switch and fuses etc. Set complete with cast iron bed plate, fixing bolts, foundation bolts and flexible coupling.

102 Used DC generators-series, shunt and compound type for overhauling practice

103 D.C. shunt generator, 2.5 KW, 220 V with control panel

104 D.C. compound generator, 2.5 K.W. 250 V, with control panel including filed rheostat, voltmeter, ammeter and circuit breaker

105 Diesel generator set, 5 KVA, 44 volt, AC 3 phase with change over switch, over current circuit breaker and water-cooled with armature, star-delta connections.

106 Motor series DC, 220 Volt, 0.5 to 2 HP, coupled with mechanical load

107 Motor shunt DC 220 volt, 2 to 3 HP

108 Motor DC compound wound 220 volt 2 to 3 :HP with starter and switch

109 Motor AC squirrel cage, 3-phase 400 volt, 50 cycles, 2 to 3 HP with star delta starter and triple pole iron clad switch fuse.

110 Motor AC phase-wound slip ring type 5 HP 400 volts, 3-phase, 50 cycles with starter and switch.

111 Motor A.C. series type 230V, 50 cycles, ¼ HP with mechanical load

112 Motor AC single phase 230 volt 50 cycles 1 HP capacitor type with starter switch 1 HP

113 Motor universal 230 volt, 50 cycles ¼ HP with starter/switch

114 Stepper motor with digital controller

115 Fan A..C. 230 volt 1200 mm

116 Transformer single phase, 1 K.V.A., 230 / 115-50-24-12 volts, 50 cycles core type, air cooled.

117 Transformer three phase, 5 K...V...A., 440/230 volts, 50 cycles, delta / star, shell type oil cooled.

118 Variable auto transformer 0-250 V, 8 amps.

119 Oscilloscope –Dual Trace,30 MHZ

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120 Function Generator

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121 Discrete component trainer Quantity to be sufficient as per seats surveyed & allocated

122 Linear I.C.Trainer

123 Digital I.C.Trainer

124 Bath impregnating

125 Oven stoving

126 Oil testing Kit

127 Battery charger with variable output 1 KW

128 Hydrometer

129 A.C.B. 5 KVA

130 M.C.B. 16 amp.

131 Thyristor controlled D.C. motor drive 1 HP with tacho-generator feedback arrangement.

132 IGBT controlled A.C. motor drive with VVVF control ,3 Phase 1 HP

133 Lockers with 2 drawers (standard size)

134 Bench working 2.5 x 1.20 x 0.75 meters

135 Almirah 2.5 x 1.20 x 0.5 meter

136 Instructor’s table

137 Instructor’s chair

138 Fire extinguisher

139 Fire buckets

140 Metal rack 100 x 150 x 45 cm

141 VCB – HT

142 Numerical relays

143 Portable temperature indicator (0-200 Deg C)

144 Motor Checker

145* PLC with processor and I/O cards along with programming unit

146* Instrumentation tutor (LVDT, Strain gauge, RTD, Thermocouple, Thermistor)

Note:

1. For each unit a Trainee’s Tool Kit from Sl. No. 1 to 20 of the “Tool Kit” and locker is required. 2. If the two units are working simultaneously in any shift, additional Shop’s general outfit from Sl. No. 1 to 98 of “Shop Tools,

Instrument & Machinery” is required for the second shift. 3. For each two units in a shift, one set of Machinery and equipment from Sl. No. 99 to 146 are required. 4. *Some tools, instrument and equipment may be shared with other trades also.

central staff training and research institute ministry of labour and employment govt...

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