Welding Operator (CAPITAL GOODS)

Transcription

1 SYLLABUS OF SEMESTER SYSTEM FOR THE ROLE OF Welding Operator (CAPITAL GOODS) Under High Employment Potential Courses through Flexi MOUs (One Year/Two Semesters) Designed in 2014 By Government of India Ministry of Labour & Employment (DGE&T)

2 FORMAT 1. Cover Page 2. Title 3. General Information 4. Week wise contents of TT and TP (In tabular form) 5. Tools and Equipment list- broad specification 6. List of the consumable 7. Trade testing and certification 8. Further learning options 9. List of Trade Committee Members

3 GENERAL INFORMATION 1.Name of the Course Certificate Course in Welding Technology 2.N.C.O.Code No. NCO-2004 / Qualification Pack Code No. CSC/ Q Duration of Training One Year (Two semesters) 5.Entry Qualification 6.Unit Strength 7.Space Norms 8.PowerNorms 9.Job Role: 10 th Pass 20 Trainees (Two Batches of 10 Trainees each) a) Class room: 30sqm. b) Workshop: 80sqm. a) Class room: 1kw (6000lumen) b) Workshop: 2kw (30,000lumen) By the end of course the trainee will be able to:- Plan and prepare the work area for welding Set the machine parameters and carry out welding as per work instructions and manufacture defect free components Perform welding operation Manufacture parts by welding at the required rate of production Perform post - welding operation activities Carry out reporting and documentation Perform quality checks Identify problems and escalate as per the defined procedure Conduct himself as per the guidelines related to behaviour and attitude for the industrial environment Communicate effectively as per organisational hierarchy Follow the safety regulations without any deviation Apply the principles of 5S in the work area along with housekeeping Study the drawings of incoming components and finished parts for identification of welded areas and carry out visual inspection 10. Instructor s Plan and Qualification prepare the work area for welding Training officer/instructor 1 no Workshop attendant 1 no Graduate Degree holders in Mechanical Engineering at least2years post qualification experience in Manufacturing (Welding).

4 11. Trainer Qualifications (a) Academic Qualification: (i) Graduate Degree in Mechanical Engineering Or (ii) Diploma in Mechanical Engineering (b) Technical Qualification: (i) For Graduate Degree holders in Mechanical Engineering at least 2 years post qualification experience in Manufacturing (Welding). OR (ii) For Diploma holders in Mechanical Engineering at least 4 years post qualification experience in Manufacturing (Welding). (c) Desirable Qualification: N/A

5 Syllabus for the role of Welding Operator (Capital Goods) First Semester (Semester Code No WEL: SEM-I) Duration: Six Months Syllabus for TP01 and TT01 Week wise content Index of First Semester Sl. No. Week No. Practical Contents Heading Theory Duration 1. 1,2 Introduction to Manufacturing Industry, Overview of the job role of welder, Engineering work place skills WEL-100 Introduction 2 Weeks 2. 3 Safety, health and environment WEL-200 SHE 3. 4 Basics of metallurgy WEL-300 WEL BM 4. 5 Welding consumables WEL-400 WEL CON 5. 6, 7 Welding machines WEL-500 WEL MAC 2 Weeks 6. 8 Reading of drawings WEL-600 WEL DRA 7. 9 Material handling WEL-700 WEL MAT Part preparation WEL-800 WEL PRE

6 9. 11 Welding fixtures WEL-900 WEL WFA to 23 OJT /Project work/site Visit 12+11Weeks Revision ,26 Examination 2 Weeks

7 Syllabus for the role of Welder (Manufacturing) First Semester (Semester Code No WEL: SEM-I) Duration: Six Months Syllabus for TP01 and TT01 Week No. 1, 2 Trade Practical Activities pertaining to the following: communication, writing skill, listening skills, presentation skills, time management, grooming, team work, work ethics, identification of safe areas with respect to floor marking, emergency response procedures Trade Theory Introduction to Manufacturing Industry, Overview of the job role of welder, Engineering work place skills 3 Study of work place to identify the hazards and suggest mitigation, application of first aid, Activities pertaining to health awareness, identification of hazardous wastes and disposal as per the norms, activities pertaining to electrical safety, lock out and tag out procedures Safety, health and environment Hazard identification and avoidance of accident, Electrical safety Preventive measures for electrical accidents, Disposal procedure of waste materials, 4 Study of welding characteristics of Cast iron, Steels, Aluminium alloy and Copper based alloy. Activities pertaining to controlling of residual stresses Basics of metallurgy Metallurgical aspects of welding Solidification and structure of welds Heat affected zone Effects of residual stresses Control of residual stresses Welding characteristics of metals

8 5 Study of selection of electrodes depending on factors such as Base metal, Thickness of metal, Diameter of electrode, Surface finish, Mechanical properties and cost of electrode. Welding consumables Consumable electrode Manufacture of electrodes Non-Consumables electrodes Selection of Electrodes Indian standard (IS) designation of welding electrodes Filler Rod Use of Fluxes Types of Fluxes 6, 7 Identification of welding machine, operations of various types of welding machine 8 Study and interpretation of engineering drawings, preparation of engineering drawings Welding machines Classification of welding machines Welding Principle Welding power sources Steps involved in the preparation of base metal for welding Reading of drawings, types and formats of engineering drawings, graphic language and welding symbols of engineering drawing, dimensioning, isometric and orthographic projections, sectional views and shop floor drawings 9 Activities pertaining to manual handling and material handling equipment viz hydraulic trolley, forklift etc,. Material handling, manual handling, material handling equipment, loading and unloading practices, safe operations in shop environment 10 Activities pertaining to preparation of Part Part preparation 11 Selection of proper fixture for the job Welding fixtures Uses of fixture Different types of welding fixtures 12 to 23 Site visit/ojt /Practical s 24 Revision 25, 26 Examination

9 Syllabus for the role of Welding Operator (Capital Goods) Second Semester (Semester Code No WEL: SEM-II) Duration: Six Months Syllabus for TP02 and TT02 Week wise content Index of Second Semester Sl. No. Week No. Practical Contents Heading Theory Duration 1. 1 Welding process WEL-1000 WEL PRO 2. 2, 3 Arc welding WEL-1100 WEL ARC 2 Weeks 3. 4 Basics of gas welding WEL-1200 WEL GAS 4. 5, 6, 7 MIG welding WEL-1300 WEL MIG 3 Weeks 5. 8, 9, 10 TIG welding WEL-1400 WEL TIG 3 Weeks Stud welding WEL-1500 WEL STD Spot and projection welding Quality inspection 9 14 Productivity WEL-1600 WEL SPT WEL-1700 WEL QUT WEL-1800 WEL PRO

10 Reporting and documentation WEL-1900 WEL DOC to 23 OJT /Project work/site Visit 20+4 Weeks Revision ,26 Examination 2 Weeks

11 Syllabus for the role of Welding Operator (Capital Goods) First Semester (Semester Code No WEL: SEM-II) Duration: Six Months Syllabus for TP02 and TT02 Week No. 1 Trade Practical Study of classification of welding processes Trade Theory Welding process Classification of welding processes Oxyfuel gas welding Arc welding Resistance welding Thermit welding 2, 3 Setting up of Arc Apparatus Straight line beads on M.S 10mm thick in flat position by 3.15mm 9 electrode by arc welding Fillet Tee joint on M.S 10 mm in flat position by Arc welding Arc welding Component of Arc welding Arc welding accessories Arc welding principle Advantages and disadvantages of arc welding Straight polarity D.C Arc welding Reversed polarity D.C. Arc welding Direct Arc welding Indirect Arc Welding 4 Study of Gas welding parameters Basics of gas welding Gas welding Equipment tools and accessories Gas welding terms and definition Gas welding filler rods, specification and sizes 5, 6, 7 Activities pertaining to MIG welding. Fillet weld lap joint on M.S (3mm thick) in flat position (0.8mm wire) Fillet weld Corner joint on M.S (3mm thick) in flat position (0.8mm wire) Butt weld Single Vee butt joint on M.S (10mm thick) in flat position (1.2mm wire) MIG welding Component of MIG welding MIG welding accessories MIG welding principle Various gases and gas mixture used in MIG Wire feed system, Types Applications limitations care and maintenance Advantages and disadvantages of MIG welding MIG welding application

12 8, 9, 10 Activities pertaining to TIG Welding Butt weld Square butt joint on Aluminium (1.6mm thick) in flat position by TIG welding Fillet weld Tee joint on Aluminium (1.6mm) in flat position by TIG welding Fillet weld Outside corner joint on stainless steel sheet (1.6mm thick) in falt position by TIG welding TIG welding Components of TIG welding TIG welding processes Difference between AC and DC TIG welding Tungsten electrodes Types, uses, sizes and preparation TIG welding torches Types, Parts and their functions TIG welding filler rods and selection criteria TIG welding parameters for welding different thickness of metals 11 Activities pertaining to Stud Welding Stud welding Components of Stud welding Stud welding processes Stud welding accessories Advantages and disadvantages of Stud welding Stud welding application 12 Activities pertaining to Spot/Projection Welding Lap joint on stainless steel and MS sheets by spot welding 13 Use of measuring instruments, equipment and gauges, practice visual inspection, follow the quality working instruction manuals, 14 List hourly production rate of presses in the shop, list factors affecting productivity along with suggestions to improve productivity, follow the SOP to ensure productivity, calculation of scrap wastage Spot and projection welding Components of spot welding Spot welding processes Spot welding accessories Spot welding parameters for welding different thickness of metals Spot welding applications Quality, importance of quality, defects in components, root cause analysis, quality management system, quality working instructions, quality circles, measuring instruments,equipment and gauges, calibration of instruments Productivity, factors effecting productivity, production norms, components of cycle time, machine utilization, standard operating procedures

13 15 Study of all the reports pertaining to production and quality, practice filling up the documents related to shop floor operations, maintain the documents, as per the industry norms Reporting and documentation, reporting on production status, quality of inputs, error messages during the operation of the machines, conditions of machine and accessories,defects in finished parts etc; and documentation as per the company norms 16 to 23 Site visit/ojt /Practical s 24 Revision 25, 26 Examination

14 LIST OF TOOLS & EQUIPMENT SL. No. Name of items Quantity 1. PPE 5 Sets 2. Basic tool kit 5 Sets 3. Fire extinguisher 1 4. First aid kit 1 5. Measuring tool set 5 6. Inspection mirror 5 7. Cold Chisel 5 8. MIG welding equipment* 1 9. TIG welding equipment* Spot and projection welding equipment* 1 Stud welding machine* 1 * * Will be provided as part of OJT along with materials and consumables

15 Trade Testing and Certification As per the NCVT norms Further Learning Options Upon successful completion of this Course the candidate will be eligible for attending the advanced Courses in Welding. List of Trade Committee Members Sl.No NAME & DESIGNATIONS/SHRI REPRESENTING ORGANIZATION REMARKS