SYLLABUS. Apprenticeship Training Scheme

Transcription

1 SYLLABUS For the trade of WELDER (PIPE & PRESSURE VESSELS) UNDER Apprenticeship Training Scheme Government of India Ministry of Labour & Employment Directorate General of Employment & Training New Delhi

2 GENERAL INFORMATION Name of the Trade : Welder (Pipe & Pressure Vessels) N.C.O. Code No. : , , , Entry Qualification : Passed 10 th class examination under 10+2 system of education or its equivalent. Duration of the Apprenticeship Training : 02 years Rebate allowed in Apprenticeship Training : One year and six months for trainees completed Broad Based Basic Training in Fabrication (Fitting and Welding) Sector under Centre of Excellence Scheme and Advanced module of Centre of Excellence Scheme in Pressure vessels & pipe welding. Ratio of apprentices to workers other than : 1:2 Terminal Behavior : On completion of the training the trainee should be able to do Pipe & Pressure Vessels welding in various positions on different metals. Course Outline: The training shall comprise of- a) On the job training The actual training shall be depended on the facilities available in the establishment, with an idea to expose the trainees to as many activities as possible; the trainees shall maintain a daily work diary for on the job training, which shall be periodically authenticated by the supervisor. b) Project Each apprentice shall under take a project in any of the areas depending on his/her interest and facilities available in the establishment. The duration of the project shall be two weeks.

3 Syllabus for the trade of : WELDER & PRESSURE VESSEL Under Apprenticeship Training Scheme List of the members participated in design of the curriculum Sr Name & Designation Organization 1 Shri.R.S. Korpe, Director Spark Engineering Pvt. Ltd. Satara 2 Shri. U.L.Jadhav, Production Manager Kirloskar Copland Ltd., Satara 3 Shri. S.Joshi Kay Iron Works Pvt. Ltd., Satara 4 Shri. D.D.Lad Consolidated Hoist Pvt. Ltd., Satara 5 Shri. D.D.Chavan G.M.Bartakke, Electrofab Pvt. Ltd. Satara 6 Shri R.P.Shinde, Tech. Director Cyclo Transmission Ltd.,Satara 7 Shri. W.V.Kothekar, I/C Principal ITI Satara

4 Syllabus for the trade of WELDER (PIPE & PRESSURE VESSELS) Week No. Shop Floor Practice Skill to be covered 1 & 2 Familiarization with machinery in shop & safety equipments and their use. Setting of welding plant, Arc, Gas Gas and plasma cutting 3 & 4 Welding in different position. Grove welding in plate 1G, 2G positions 5 & 6 Track welding using simple fixture and LPI testing 7 & 8 Grove welding 3G, 4G, position and root pass and cover pass welding and LPI testing. 9 & 10 Pipe welding with schedule 60/80 and fit up pipe. Related Instructions Importance or pressure vessel and pipe weld. Advantages of limitation of different types of weld process. Safety in pressure vessel welding Principles of SMAW, polarity and its effect. Welding fixture and its clamp. Electrode specifications, selection BIAS, AWS. Electrode selection and coating factors. Different metals and their characteristics. Introduction of different type of welding procedure schedule. 11 & 12 Root weld of pipes in 1G, 2G, 5G position and testing by using PLI test 13 & 14 Root welding of pipe in 1G, 2G and position cover pass welding in 5G position. Heavy wall pipe welding in 5G position. Selection of electrode. Welding heavy wall pipe in 6 G position and different welding symbol. 15 & 16 Flange welding and T.Y. pipe joint Complicated pipe welding joint T joint, Y joint procedure 17 & 18 Setting of TIG welding machinery and equipment for beading practice. Root passes TIG welding Procedure for thin wall pipe in Downhill position. Gas shielding and introduction TIG electrodes. TIG welding, orbital pipe welding.

5 19 & 20 Setting of Co 2 plant for welding and practice on automatic submerged arc welding. 21 & 22 Inspection of elements and non destructive test. 23 & 24 Testing of specimen with codes and standards, weld test on plates and pipe. Preparation of WPS and PQR. Welding inspection and test. 25 & 26 Review and Test. Project work. Introduction of MIG types of electrodes. Shielding gases introduction welding parameters Different welding defects. Their causes and remedies. Stress relieving process and welding metallurgy and weld heat treatment. Different types of pressure welding codes and standards as per IBR and A.S.M.E. Qualifying procedure for various codes. Grouping of metals and filler rod (P & F No.). Different inspection methods of welds.

6 Tools & equipments for the trade of WELDER (PIPE & PRESSURE VESSELS) General installation 1. Transformer welding set with all accessories 300A 2. Arc welding set rectifier type 400 Amp with all accessories 3. TIG welding set complete 300 amps AC/DC with water cooled torch 4. Co 2 welding machine complete 400 amps with gas cooled goose necked torch 300 A 5. Welding cables to carry 400 amps with flexible rubber 6. Lugs for cables 7. PUG cutting machine 8. Gas welding table 822x92 cm+60 cm fire bricks on stand 9. Arc welding table all metal with positioner 10. Trolley for cylinder (HP Unit) 11. Gullitine shearing machine 12. D.E. grinder 30 cm wheel motorized pedestal type 13. Vice bench 10 cm 14. Power hacksaw 15. Electrode drying oven temp. range degree, 10 kg. cap 16. AG7 grinder & AF Portable drilling machine (cap. 5mm) 18. Welding helmets 19. Dye penetrant testing kit 20. Magnetic particle testing machine 21. Ultrasonic flaw detector 22. IIW/ASTM reference radiographic standard 23. Submerged arc welding machine 600 amps 24. Micro plasma welding machine 25 amps 25. Impact testing machine 26. Air plasma cutting system with standard accessories & compressor 27. Universal testing machine 28. Fibre welding booth & welding screen 29. Fume extractors 30. Oxygen, acetylene, argon & Co 2 cylinders 31. Fire fighting equipments & first aid box 32. Centre lathe swing over dia. 10