BANGLADESH TECHNICAL EDUCATION BOARD

Transcription

1 BANGLADESH TECHNICAL EDUCATION BOARD SYLLABUS FOR THE NSS (BASIC) TRADE COURSE ON WELDING & FABRICATION (Effect from July 2012) Total Duration: 360 Hours/6 Months

2 Course Title: WELDING & FABRICATION Index: Sl. No. Subject Page No. 01 Introduction 2 02 Objectives 2 03 Course outline 2 04 Competencies 2 05 Contents 3 06 Entry Qualification List of Tools and Equipment Raw materials 13 1

3 Course Name: WELDING & FABRICATION Introduction: This course is designed to covers the knowledge, skill and attitude required for welding in different industrial sector.. This course has three competencies such as Basic, Common and Core competencies. The core competency covers skills and attitudes required to Perform Arc Welding, Arc cutting.oxy-acetylene gas Welding & cutting, Metal Inert Gas (MIG) Welding &Tungsten Inert Gas (TIG) Welding. Objectives: 1. To develop skill manpower 2. To develop socio-economic condition of the people 3. To create employment opportunities. 4. To earn foreign currency 5. To provide basic knowledge, skills & attitude on welding & fabrication. 6. To develop skills to perform arc welding & cutting,oxy-acetylene gas welding & cutting, metal inert gas (MIG) & tungsten inert gas (TIG) welding Course Outline: Name of Course Duration of Course Entry Welding &Fabrication List of Competency Qualification Total 360 hrs 6 days week, per day 3hrs Minimum Theory=1 hrs, per lesson Class Practical=2 hrs, per lesson Eight/J.S.C/JDC Total=3 hrs, per working day Pass Theory=60hrs Practical=240hrs Basic & Common Competency =60hrs Basic Competencies: 1. Receive and Respond, Participate and Lead to workplace communication 2. Work with others, Team Environment and Lead small Teams. 3. Demonstrate work values, Practice career professionalism and Develop & Practice Negotiation skills. 4. Practice workplace Occupational safety and health(osh) procedures. 5. Use basic mathematical concept. 6. Use English in work place. Common Competencies: 1. Know & understand welding codes, standards, and specifications 2. Read & interpret working drawing & blueprint. 3. Basic measurement and calculation. 4. Identify & Prepare raw materials. 5. Perform Layout on different metal sheet, plate, angle, channel & pipes 6. Understand & practice finishing operation. 2

4 Core Competencies: 1. Perform Arc Welding(AC& DC supply) & Arc cutting. 2. Perform Oxy-Acetylene gas Welding & cutting. 3. Perform Metal Inert Gas (MIG) Welding &Tungsten Inert Gas (MIG) Welding. 4. Perform Metal Active Gas-CO 2 (MAG) Welding. 5. Identify welding defects & Understand remedial steps needed to remove welding defects. Basic Competencies: Contents: (i) Basic Competencies - 30 hours SL.NO. Topics hours i). Receive and respond, participate and lead to workplace communication: 1 a) Explain & follow routinary speaking & messages in a 1 workplace. 2 b) Follow routinary speaking & message. 1 3 c) Perform work duties following written notices. 1 ii). Work with others, Team Environment and Lead small Teams: 4 a) Develop effective workplace relationship b) Show good Manner 1 6 c) Respect honorable person (Sir, Trainer, Senior, Trainees) 1 7 d) Describe team role and scope c) Contribute to work group activities d) Work as a team member e) Identify own role and responsibility within team 1.5 iii). Demonstrate work values, practice career professionalism and develop & practice negotiation skills 11 a) Define the purpose of works b) Apply work values/ethics c) Deal with ethical problems d) Integrate personal objectives with organizational goal e) Maintain professional growth and development 2 iv). Practice workplace Occupational health and safety procedure 16 a) Workplace maintained as per required standards b) Arrange items c) Maintain work areas, Tools and Equipment d) Follow standardizes work process and procedures e) perform work spontaneously f) Occupational safety and health procedure 2 v). Use Mathematical Concepts & Techniques and Use Relevant Technologies: 22 a) Identify calculation requirements in the workplace b) Appropriate method is selected to carry out the 2 calculation. 24 c) Calculations are completed using appropriate method 2 such as addition, subtraction, multiplication and division. 3

5 a) (ii) Use English in work place - 30 hours Related Subject-10 hours and General Subject- 20 hours 1 hour/period On the completion of this course trainees will be able to: 1. Communicate with target persons effectively. 2. Understand the speech of English users. 3. Achieve better professional performance. 4. Speak in English with confidence Sl. No. Tropics- Conversational Situation hours 01 Speaking English Getting Information & Finding one s way 1 02 Speaking English About Tools and Equipments 1 03 Speaking English About meeting some one & participating in class Speaking English Daily Activities & Asking About Activities 1 05 Speaking English Evening Activities and about theoretical contents Speaking English Meeting at the Train station & Asking Question at the 1 Train station. 07 Speaking English Meeting at the Airport & Getting information at the 1 Airport s 08 Speaking English About different type of Measuring Tools and Cutting 1 Tools 09 Speaking English Getting to the Hotel & Asking direction Speaking English Asking about Buses & Traveling by bus Speaking English - About Practical Class Speaking English Going by Taxi and Asking the time Speaking English Arriving early or late and Time and the calendar Speaking English Living in an Apartment Speaking English Using the Telephone Speaking English Getting help in stores and talking about shopping Speaking English Sending and Receiving Letters Speaking English Talking about the Weather & Trips and sight seeing Speaking English Talking about Eating & Dinner Conversation Speaking English About Machines and Materials Speaking English Common Health problem and Quitting & Finding 1 Jobs. 22 Speaking English Office Details and Office Conversation Speaking English About Practical Job Speaking English On a specific situation & Public speaking Speaking English About Exchanging view with a Persons & Introducing oneself Speaking English Describing and Narrating events, place, Objects etc Speaking English About different type of computer, operating system, system and operating software, add remove software, DBM, and internet. 4 4

6 Practical: 1. Speaking on a specific Situation. 2. Public Speaking. 3. Exchanging views with target persons. 4. Introducing one self. 5. Describing & Narrating events, places, objects etc. 6. Producing the meaning of given words (by the teachers)-vocabulary. 7. Prepared speech. c) Theoretical: Common Competencies Si. Topics No. 1 Introduction to personal protective Equipments (PPE) 2 Introduction of welding shop safety. 3 Understand about First aid box. 4 Know the measuring tools and equipment needed for welding trade. 5 Understand Linear, Angular and Circular measurement systems. Understand the using technique of measuring tools ( Steel rule, 6 Slide Calipers, Micrometer, Bevel protector, Surface gauge and Dial indicator gauge). 7 Estimate amount of raw materials required for a particular job. Know common symbols & standard code use in working drawing 8 of Welding & Fabrication. 9 Read & Interpret working Drawing of Welding & Fabrication. 10 Understand Lay-out tools-equipments for welding. Understand Lay-out of working drawing for Welding & 11 Fabrication. Understand cutting techniques of Cutting tools & machines( Hack- Saw, Power- Saw, File, Chisel, Snip, Hand Shearing & Power 12 Shearing m/c, Drill m/c & Grinding m/c) for preparation of raw materials for welding & fabrication. 13 Understand common defects in different Arc welded joints. 14 Understand causes of the defects in different welded joints. 15 Understand the effects of quick & slow cooling of welded joints. 16 Understand surface finishing of welded joints. Use of surface finishing tools- equipments & materials (File, 17 Portable grinding m/c, Emery Cloth etc.) Understand the physical testing techniques of welded & fabricated 18 job. Period 5

7 d) Theoretical: Common Competencies (Arc Welding) Sl. Topics Hour No. 1 Understand safety measures required to work in Arc welding shop. 1 2 Understand use of personnel protective equipments (PPE) for Arc 1 welding & Arc cutting. 3 Know the name & use of Arc welding m/c, tools-equipments & 1 accessories. 4 Understand Arc welding terminology. 1 5 Understand Lay-out & preparation of raw materials 1 6 Understand the concept of working principle of welding m/c & 1 power supply ( AC & DC supply ). 7 Set- up welding m/c (Adjust range of voltage & current for the 1 job). 8 Know the types & use of consumable & non consumable 1 electrodes. 9 Understand the criteria of Electrode selection Understand the techniques of Electrode & job holding Describe the techniques of Arc creation & Arc maintain Understand remedy of Arc-blow 1 13 Understand the concepts of Running welding beads 1 14 State short Arc &Long Arc and understand about padding Classify welded joints (Lap, Butt, Tee, Corner, Edge etc ) Classify welding position 17 Understand welding Grooves 1 18 Understand the concept of Weld & Tag-Weld Describe the slag & impurities removing procedure Understand finishing activities of Arc welded joints. 1 6

8 e) Theoretical: Common Competencies (Gas Welding ) Sl. Topics No. 1 Understand safety measures required to work in Gas welding shop Understand use of personnel protective equipments (PPE) for Gas 1 welding &Gas cutting. 3 List & state use of Gas welding and Gas cutting tools-equipments 1 & accessories. 4 Understand Gas welding terminology. 1 5 Classify filler metals used in Gas welding. 1 6 List the fluxes used in Gas welding. 1 7 Understand Lay-out & preparation of raw materials for Gas 1 welding 8 Identify Gas Cylinder and list common Gases used in Gas Welding 1 & Gas cutting. 9 Describe the safe handling procedure of Gas cylinder. 10 Describe different types of welding & cutting torch Describe the feature & functions of different flames Understand the ratio of different gas needed for different flames 1 13 State gas cutting nozzle and cleaning process Understand the assembling techniques of Welding & Cutting 1 Torch, pressure regulator & Hose pipe. 15 Understand Gas pressure control techniques Understand Gas welding procedure 1 17 State the position for Gas welding 1 18 Describe the Handling process of gas cutter hose 19 Understand gas cutting position 1 20 Understand the gas cutting procedure Understand common defects in different Gas welded joints Understand causes of the defects in different Gas welded joints State the remedial preventive measures needed for defect less Gas 1 welded joints. 24 Understand physical testing techniques of Gas welded joints Understand surface finishing techniques for Gas welded joints. 1 7

9 F ) Theoretical: Common Competencies (TIG & MIG Welding ) Sl. Topics No. 1. List personnel safety measures needed for operating TIG & MIG welding 1 2. List PPEs for TIG & MIG welding List the tools, equipment & accessories required for TIG & MIG welding Understand the preparation of raw material for TIG &MIG welding Identify the filler metals used in TIG & MIG welding Prepare & set- up TIG & MIG welding m/c Understand principle of TIG welding Understand principle of MIG welding Understand the feed mechanisms used for filler metals List gases used in TIG & MIG welding Understand gas flow control mechanism. 12. Understand current & voltage setting for particular job Understand the operational procedure of TIG & MIG welding m/c List the name of common defects of TIG & MIG welding Understand Soldering and brazing 1 g) Practical: Arc Welding Sl. No. Jobs 1. Identify & use personnel protective equipment 1 2. Cut a piece of MS flat bar by hacksaw Clean the flat bar Identify arc welding m/c, tools, equipment and accessories Set-up current & voltage of arc welding m/c according to the job requirement Select & hold the electrode in to the electrode holder & connect the ground 1 clamp with the bar. 7. Make straight bead on the MS flat bar in flat position Cut sheet by shear machine Cut MS. plate as per dimension Prepare edges Single-V, Double-V Prepare edges by Single bevel & Double bevel Prepare edges Single U & Double U Prepare edges for Single J & Double J Make straight bead on MS plate in horizontal position Make straight bead on MS. plate in vertical up position Make straight bead on MS. plate overhead position Make tack welding on butt joint on MS Plate Make single -V butt joint welding on MS. plate - Flat position (1G) Make single -V butt joint welding on MS. plate - Horizontal position (2G) Make single -V butt joint welding on MS. plate -Vertical position (3G) 3 8

10 21. Make single -V butt joint welding on MS. plate Overhead position(4g) Weld Corner joint on MS. Plate Weld T-joint on MS. Plate Straight bead on pipe (Rolled position) Make straight bead on pipe (Fixed position) Perform weaving bead on pipe (Rolled position) Perform weaving bead on pipe (Fixed position) Perform padding/build up on pipe (Fixed position) Weld single -V butt joint on pipe 1 G (Rolled position) Weld single -V butt joint on pipe 2 G (Fixed position) Weld single -V butt joint on pipe 3G (overhead position) Weld single -V butt joint on pipe 4G (overhead position) 6 h) Practical :Gas welding& Gas Cutting Sl. Hours Jobs No. 1. Set gas welding tools, equipment & accessories 1 2. Make & adjust flame 3 3. Perform gas welding on Flat position 6 4. Perform gas welding on horizontal position 6 5. Perform brazing and soldering 3 6. Identify and set-up the gas cutter sets Perform straight gas cutting on MS. Plate 6 8. Perform zig - zag gas cutting on MS. Plate 6 9. Perform Curve gas cutting on MS. Plate Perform Circular gas cutting practice on MS. Plate Perform Free bevel cutting on MS. Plate Perform Practice 30 Bevel cutting on MS. Plate Perform Bevel cutting on MS. Plate Perform Bevel cutting on MS. Plate Perform Sheet cutting by automatic machine Perform MS. Plate bending by using hammer Perform MS. Plate bending by bending machine. 3 9

11 i ) Practical : TIG & MIG WELDING Sl. No. Jobs 1. Setup the TIG welding machine and equipment 3 2. Make bead weld (flat position) 6 3. Perform welding of stainless steel (but joint flat position) 3 4. Perform welding of stainless steel (lap joint flat position) 3 5. Perform welding of stainless steel (fillet joint flat position) 6 6. Perform welding of aluminum (but joint flat position) 6 7. Perform welding of aluminum (lap joint flat position) 6 8. Setup the MIG machine and equipment Make bead weld (flat Position ) Perform the single-v butt joint (flat position) Perform the welding fillet (flat position) 6 Job List: Sl. No. Jobs 1 MS. L-section fabrication 2 MS. T-section fabrication 3 MS. Box/chute fabrication 4 MS. Pipe fabrication 5 Reducer (200 Â200=400 Â400. H= 500 mm) fabrication 6 Reducer (<1>200-<1>400.h=500mm) fabrication 7 Reducer (<1> Â200.h=500mm) fabrication 8 Wind crawl fabrication 9 Oil tank/water tank fabrication 10 Manhole/deck opening fabrication 11 Railing/bulwark fabrication 12 Tool box fabrication 13 Single V Butt joint by TIG welding 14 Flange joint by MIG welding 15 Plate joint with pipe by MIG welding 16 Plate joint with 45 section of pipe by TIG welding 10

12 Entry Qualification: Class Eight,JSC,JDC or equivalent Employment Opportunity: 1. NGO s 2. Abroad 3. Public & Private Training Institute and industry 4. Self Employment Materials Welding Electrode Filler metal Work piece metal Emery clothes Oxygen gas Acetylene gas Flux Argon gas Co 2 gas Filler metal coil Tungsten electrode MS plate Stainless steel sheet Aluminum sheet Brass sheet Cast iron plate GI pipe Lime Machine and Equipment: Arc Welding Machine(AC & DC) TIG Welding Machine MIG Welding Machine Gas Welding Set Oxygen gas cylinder Acetylene gas cylinder Hand Grinder Power saw machine Welding table Electrode drying oven 11

13 Tools Disc Cutter Shear Machine Grinding Machine Gas Welding set Pipe cutter Soldering iron C-Clamp Chipping Hammer Tongs Welding positioned\ C-Clamp Chipping Hammer Tongs Welding positioners Ball peen hammer Sledge hammer Chisel Shearing machine Bench vice Hacksaw. Try square Steel rule Anvil Combination square Scriber Steel tape Chain tongs Flat file Triangular file Half round file Round file Pipe Vice 12

14 Training Materials Whiteboard Marker Learning Guides Handouts Charts Whiteboard Learning Guides Handouts Charts PPEs Welding Goggles Hand Shield Fire Extinguisher Hand gloves Safety Goggles Welding Helmet Musk Ear Plug Boiler Suit Safety shoes First aid box 13