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ADVANCED WELDING TRAINING INSTITUTE

ICF, CHENNAI - 38.

Training Calendar

2019-2020

KNOWLEDGE CENTRE ON WELDING TECHNOLOGY

ADVANCED WELDING TRAINING INSTITUTE

ICF, CHENNAI – 38.

General Information Name of the Principal K.Thiyagan

AME/Training Milind Mahadeo Rao Chimurkar Phone No. 044-26147672

Fax No. 044-26281227 Email-ID ptc@icf.railnet.gov.in

Vision Innovate, Indigenize, Inculcate & Integrate Mission Qualifying welders as per standards through quality training

Training Timings Monday to Friday: 0830 to 1230 Hrs & 1300 to 1730 Hrs Saturday : 0830 to 1330 Hrs

Hostel facilities ICF Subordinate Rest house for Supervisors &

Apprentice Hostel for Artisan Trainees Classroom Facilities Equipped with LCD projector & Smart Board

Contact Numbers of faculty members of AWTI

Name of Faculty Rly. Phone Mobile Number BSNL

T.S.Ravichandran 47211 9003149549 044-261 47211

S.Annadurai 47210 9003149500 044-261 47210

M.Selvamani 47210 9003149476 044-261 47210

D.Selvakumaran 47212 9003149538 044-261 47212

N.Harihara Swaminathan 47220 9003149410 044-261 47220

V.Gnanamoorthy 47222 9003149623 044-261 47222

Abdul Razaack(SSE-Hostel) - 9003149716 - Apprentice Hostel 47757 - 044-261 47757

Subordinate Rest House 47756 - 044-261 47756

List of Holidays for the year 2019

Date Occasion Date Occasion Date Occasion

01-01-19 New Year’s Day 01-05-19 May Day 07-10-19 AyudhaPooja

15-01-19 Pongal 05-06-19 Ramzan 08-10-19 Vijayadasami 16-01-19 Thiruvalluvar Day 12-08-19 Bakrid 25-12-19 Christmas

17-01-19 Uzhavar Thirunal 15-08-19 Independence Day 26-12-19

to 31-12-19

Factory Holidays

26-01-19 Republic Day 02-09-19 Vinayagar Chaturthi

06-04-19

Telugu New Year Day

11-09-19 Onam

19-04-19 Good Friday 02-10-19 Gandhi Jayanthi

About the training centre Established in the year 2010 as per Railway Board guidelines

Provided with state of the art training facilities

Offers welding training for processes like MMAW, GMAW, TIG, SAW &RSW

Caters to the welding training needs of Zonal Railways like SR, SCR, SWR,CR,WR in addition to ICF

Assists to prepare Welding Procedure Specification (WPS) for all types of joints .

Conducts welder certification programs as per ISO: 9606 / IS: 7310 / IS: 817 Provides training and consultancy for ISO:3834 & ISO:15085 certifications

Organizes welding seminars

SCHEDULE FOR REGULAR TRAINING MODULES

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TM010 BASIC COURSE FOR BEGINNERS& ICF PQ 4 wk 20 01 06 10 08 05 09 14 18 06 10 09 MSM

TM020 REFRESHER COURSE FOR WELDERS 3 wk 20 08 17 19 28 02 17 NHS

TM030 TIG WELDING FOR ARTISANS 1 wk 10 13 22 23 18 20 16 SA

EM040 WELDING COURSE FOR SUPERVISORS,

INSPECTORS AND CMT STAFF 3 wk 20 24 11 TSR

TM080 STAINLESS STEEL WELDING FOR

WELDERS 1 wk 20 20 29 30 04 27 23 PVK

EM090 STAINLESS STEEL WELDING FOR SUPERVISORS

1 wk 30 15 03 05 14 09 24 DSK

TM110 SHORT REFRESHER COURSE FOR WELDERS

1 wk 20 15 03 05 14 09 24 NHS

EM150 COST REDUCTION METHODS IN FABRICATION

3D 30 06 19 18 17 KCS

EM230 FABRICATION OF LHB SHELL & FIAT BOGIE FOR SUPERVISORS

3D 30 22 15 21 20 PVK

TM240 TROUBLE SHOOTING OF MIG / MAG

WELDING PLANT 3D 15 18 04 SA

TM250 LHB FABRICATION FOR ARTISANS OF ALL TRADES

3D 30 29 10 18 06 08 11 MSM

EM340 WELDING COURSE FOR DESIGN & PLG. ENGINEERS

3D 30 06 11 STR

EM350 SELECTION OF WELDING CONSUMABLES 3D 30 10 29 KCS

EM370 HEAT TREATMENT OPEARTIONS BEFORE AND AFTER WELDING.

3D 30 27 RN

EM380 WELDING POWER SOURCES AND ITS

SELECTION 3D 30

19 09 KCS

EM390 ALUMINIUM WELDING FOR

SUPERVIOSRS 3D 30 28 TSR

SPECIAL TRAINING COURSES

VM120 TRAINING OF RLY VENDORS ON QAP PREPARATION AS PER ISO: 3834

3D Programme to be finalized in consultation with PTC/AWTI/ICF SA

TM160 WELDER QUALIFICATION AS PER ISO: 9606 (WORKSHOPS AND ZONAL RLYS)

2D Programme to be finalized in consultation with PTC/AWTI/ICF

(Eligibility: Welders should have qualified in IS 7310 standard) STR

EM180 PROGRAMME ON WELDING

STANDARDS ISO:3834 & EN:15085 3D 30 03 17 16 22 MSH

EM190

NON- DESTRUCTIVE TESTING OF WELDS

FOR CMT STAFF AS PER ISO-3834 & EN-15085 REQUIREMENTS

3D 20

01 21 VGM

EM290 WPS PREPARATION AS PER ISO: 3834

REQUIREMENTS 3D 15 04 18 SA

EM360 CERTIFICATION COURSE ON VISUAL INSPECTION AS PER ISO : 3834 REQUIREMENTS

4D 30 10 08 12 03 21 25 23 06 04 08 05 04 MSH

EM900 WELDING COORDINATORS FOR RAILWAY APPLICATIONS

6D 15

26 DSK

OTHER PROGRAMS OFFERED AGAINST SPECIFIC DEMAND FROM THE CUSTOMERS

MOD. No.

COURSE TITLE DURATION CAPACITY Course

incharge

EM050 WELDING COURSE FOR NEW RECRUIT JEs & SSEs [As per Rly Bd:MRT-10 for STCs / Zonal Rlys]

1 Week 30 KCS

TM130 TRAINING PROGRAMME FOR ASSEMBLY FITTERS 3 Days 30 MSH

VM200 WELDER QUALIFICATION FOR VENDORS AS PER IS:7310&ISO:9606 3 Days 12 MSH

TM320 OXY-FUEL GAS CUTTING AND PLASMA CUTTING PROCESSES 1 Week 10 NHS

TM300 SELF INSPECTION COURSE FOR WELDERS 1D 10 KCS

TM330 TRAINING ON GMAW WELDING PROCESS 1 Week 10 NHS

COURSE CONTENTS

Module No.

Course Title Target Audience Topics Covered

TM010

Basic Course in welding for Beginners

New recruits / Technicians redeployed as welders from other trades.

Introduction to different welding processes. Weld defects causes and remedies. Introduction to Oxy-acetylene gas cutting. Practical in MMAW. Test for IS: 817 standard.

(About 30 Hours Theory & 100 Hours of Practical)

TM020

On the Job Continuous Improvement Training(Refresher Course)

Welders who have completed Basic Welding course (TM010)/ welders of all grades.

Principles and techniques of welding (MMAW, GMAW & SAW). FCAW with CO2 gas shielding. Weld defects causes and remedies. Distortion and its control. Different positions welding in GMAW. Introduction to ISO 9606 standards(About 25 Hours Theory & 75 Hours of Practical)

TM030 TIG Welding for artisans

Welders who have completed TM010 or TM020 OR welding technicians with 2 yrs

experience.

Introduction to TIG welding process. TIG welding accessories, consumables and techniques. TIG Welding defects causes and remedies. Practical training on TIG welding. Introduction to ISO: 9606 / IS: 7310 testing standards(About 8 Hours Theory & 28

Hours of Practical)

TM080 Stainless Steel Welding for Welder

Technicians

Welders who have completed Basic Welding course / welders of all grades

Introduction to stainless steel welding techniques. Defects causes and remedies. Distortion control. Practical in MMAW, FCAW & MIG welding for stainless steel. Introduction to ISO

9606 / IS 7310 testing standards(About 8 Hours Theory & 28 Hours of Practical)

TM110 Refresher course for welders

Welders of all Grades with minimum 2 years of experience.

Principles of Carbon steel & Stainless Steel Welding (MMAW,

SAW, GMAW, FCAW & TIG). Weld Joint Preparation. Weld defects causes and Remedies. Distortion Control. Critical Weld Joints in ICF coaches. Introduction to ISO 9606 / IS 7310 testing standards. (About 8 Hours Theory & 28 Hours of Practical)

TM130 Training Program for Assembly Fitters.

All fitters involved in fabrication of details, assemblies, including millwright & tool room fitters involved in welding.

Weld Joints &symbols. Edge preparation. Effects of assembly deviation. Acceptance criteria for gap, mismatch and other fitment deviations. Assembly techniques and tack welding method for Stainless Steel. Understanding of ICF, RCF & LHB drawings (About 12 Hours Theory & 6 Hours Practical)

TM160 Certification for welders as per ISO 9606-1

IS: 7318/IS: 7310 qualified welders with two year experience

Introduction to ISO 9606-1 and its need in the present scenario. Explaining welders about the evaluation procedure followed by test(2 hrs briefing followed by practice and test)

TM240

Troubleshooting of MIG / MAG welding plants

Welders of IR having minimum 2yrs of experience or who have completed TM020 module .

Setting up MIG welding plant & wire feeder. Understanding recommended parameters for welding. Good maintenance practices in welding plant and wire feeder. Usage of different shielding gases. Trouble shooting in MIG torch. (About 6 Hours Theory & 12 Hours of Practical)

TM250 LHB fabrication for artisans of all

trades

Technicians of all trades and grades

Introduction to LHB. Various Materials Used.Fabrication aspects of FIAT bogie & LHB coach. Interpretation of LHB&FIAT bogie drawings with ISO 3834 requirements. (About 12 Hours Theory & 6 Hrs of Field visit)

TM300 Self inspection course for welders welders of all grades

Points to be checked before, during & after welding. Types of defects and their identification. Corrective and preventive actions to be followed (About 6 Hours Theory & 12 Hours of Practical)

TM320

Oxy-fuel gas cutting and plasma cutting process

Welders, fitters and helpers

Introduction to oxy-gas cutting principles. Plasma cutting of stainless steel. Safety precautions to be followed. (About 8 Hours Theory & 28 Hours of Practical)

TM330

Training on MIG welding

Welders who have completed Basic Welding course / welders of all grades.

Introduction to MIG welding process. MIG power source, accessories, consumables and techniques. MIG Welding defects causes and remedies. Practical training on MIG welding. Introduction to ISO 9606 testing standards. (About 8 Hours Theory & 28 Hours of Practical)

TRAINING MODULES FOR ENGINEERS, SUPERVIOSRS & CMT STAFF

Module No.

Course Title Target Audience Topics Covered

EM040

Training for welding supervisors, Welding inspectors and CMT staff in

service

Supervisors, Inspectors and CMT staff.

Introduction to various welding processes. Welding metallurgy. Inspection and testing of welding. Welding defects causes and remedies. WPS & PQR preparation as per ISO: 15609, ISO: 15614 & ISO: 9606 requirements. EN 15085 & ISO 3834

standards, Welding economics. Objective Test

EM050

Training for Newly Recruited Supervisors in

Welding and NDT [As per Rly. Board guidelines MRT-10]

Apprentice JEs and SSEs (Direct recruits

from RRB and promotees).

Introduction to welding processes and metallurgy. Introduction to SS welding. Inspection and testing of welding. Welding defects causes and remedies. Introduction to Oxy- acetylene

gas cutting and plasma cutting. Resistance welding, LASER welding, Introduction to ISO 3834standards.Objective type Test. (About 24 Hours Theory &12 Hours of Practical)

EM090 Stainless Steel Welding Course for Supervisors

The supervisors engaged in fabrication / repair of coach and wagon using Stainless Steel welding-

Introduction to SS welding. Application of TIG, MIG, Pulse MIG.

Dissimilar metal welding. Welding defects causes and remedies. Welding codes and practices. WPS&PQR preparation as per ASME Section IX. EN 287, EN 15085 & ISO 3834 standards. Distortion control. Post weld surface treatment for SS. Welding practice. Objective Test. (About 24 Hours Theory & 12 Hours of Practical)

EM150

Cost reduction methods in fabrication for JEs & SSEs

All SSE, JE, & CMT staff

of Indian Railways including Design staff.

Productivity improvement, automation and robotics, Time study methods, Lean Manufacturing, 5S principles, 6 sigma & 7 QC tools as applicable to fabrication. Welding economics. Welder qualification, WPS &PQR, welding repairs and re-works and awareness of ISO 3834 & EN 15085 standards. Objective Test. (About 15 Hours Theory & 3 Hours G D)

EM180

Awareness program on welding standards ISO 3834 & EN15085.

All SSE, JE, & CMT staff of ICF including Design staff.

Introduction to EN 15085 & ISO 3834, its significance in the present design. Introduction to stress category, safety category, weld performance class, quality levels for imperfections, inspection class and testing and their relationship. Design requirements as per EN 15085 PART-3. Recommendation for joint preparation as per ISO 9692. WPS & PQR as per ISO 15614.

Welder Qualification as per ISO-9606. (About 18 Hours Theory )

EM190

Non- destructive tests of welds for CMT staff as per ISO-3834 & EN-

15085requirements

CMT staff of ICF and other workshops & zonal railways

Introduction to EN 15085 & ISO 3834, and their significance. Introduction to NDT techniques like VT, DPT, MPT, UT & RT. Practical demonstrations. Practical usage of gauges for weld measurements. Acceptance criteria as per ISO 5817.

EM230

Fabrication of LHB shell & FIAT bogie

All SSE, JE, & CMT staff of ICF including Design

staff.

Introduction to LHB. Materials Used and its specification. Design Features. Fabrication aspects of FIAT BOGIE. Fabrication aspects of LHB coach. Interpretation of LHB&FIAT bogie

drawings with ISO 3834 requirements. (About 12 Hours Theory & 6 Hrs of Field visit)

EM290

Welding procedure specification as per ISO 3834 requirements.

Supervisors of Mechanical & CMT department of Indian Railways

Process Parameters and their influence on weld quality,

Importance of Procedure qualification, Preparation and Evaluation of test coupons, Preparation of WPS, Welders Performance Qualification Record and its purpose, Referring International standards for welding. ISO- 15614

EM340

Welding course for design & planning engineers.

Design and planning engineers of Production Units, Workshops, Zonal Railways of IR.

Introduction to various welding processes. Design of weld joints. Design requirement as per EN 15085, welding symbols as per ISO- 2553. Weld defects, causes and remedies. WPS as per ISO 15609. Pre and Post weld heat treatments. Failure analysis. Cost saving ideas for design engineers. Checklist for prototype inspection including usage of gauges and other instrument s.

Module No.

Course Title Target Audience Topics Covered and mode of evaluation

EM350

Selection of welding

consumables

All SSE, JE, & CMT staff of Indian

Railways including Design staff.

Introduction to weldability of materials. Selection & classification of consumables for MMAW, GMAW & TIG welding. Classification of fluxes & wire flux combinations for SAW. Shielding gas selection & economics. Inspection of electrodes as per various standards.

EM360

Certification course on Visual inspection as per ISO 3834 requirements

Inspection and

Production Personnel of Indian Railways engaged for rolling stock fabrication & maintenance.

Introduction to ISO 3834&EN 15085 standards. Visual inspection as per ISO 17637.welding defects causes and remedies. Material grouping as per ISO/TR 15608.WPS preparation as per ISO 15609.Welder qualification as per ISO 9606.Practical usage of gauges for weld measurements. Acceptance criteria as per ISO 5817.Examination(both theory and practical)

(About 16 Hours Theory & 8 Hours of Practical)

EM370

Heat treatment operations before and after welding

All SSE, JE, & CMT staff of Indian Railways including

Design staff.

Basics of heat treatment, thermal stresses and distortion due to welding, Preheating, Post weld heat treatment, temperature calculations.

EM380

Welding Power source and its selection

SSEs & JEs of ICF and other Railway workshops

Types of power sources, Thyrister, MOSFET & IGBT controlled, elementary level trouble shooting

EM390

Aluminium welding for supervisors

SSEs & JEs of ICF & other Railway workshops

Introduction to different grades in aluminium, weldability of aluminium, challenges faced, MIG & TIG for aluminium welding, shielding gases.

TRAINING MODULES FOR ENGINEERS & SUPERVIOSRS OF VENDORS OF INDIAN RAILWAYS

VM120

Training of managers and engineers from vendors of Indian Railways on QAP preparation

Engineers, managers of firms involved in planning, design, production &quality

Understanding Drawings of ICF, RCF & LHB Systems.

Acceptance Criteria as per ICF standards. Welding Symbols, Welding defects, causes and Remedies. Welding Distortion and Control measures. Introduction to ISO: 15609, ISO: 15614, ISO: 9606, EN: 15085 & ISO 3834, their significance in the present design, inspection clause and testing and their relationship.

VM200 Welder certification programs as per ISO :7310 &ISO:9606

Welders from vendors of ICF/ other Railways having sufficient experience.

Introduction to the standard to be tested. Testing both theory and practical.

FACULTY PROFILE

NAME OF FACULTY QUALIFICATION PROFESSIONAL QUALIFICATION IN WELDING

T.S.Ravichandran (TSR) M.Sc, AMIE. IWE, CWI

S.Annadurai (SA) M.Tech. IWT,CWI,SNT-TC-IALevel II (UT,RT) ,ISO9712 Level-II(VT)

M.Selvamani (MSM) AMIE, MBA IWT, ISO9712 Level-II(VT)

D. Selvakumaran (DSK) BE IWT,CWI,SNT-TC-IALevel II (VT,MPT,DPT)

K.Chandrasekaran (KCS) AMIE, ME, MBA IWT, CWI,SNT-TC-IALevel-II (VT,MPT,DPT), ISO9712 Level-II (VT)

M. Sreehari (MSH) AMIE, ME, MBA IWT, SNT-TC-IA Level II (VT,MPT,DPT),ISO9712 Level-II (VT)

P.Vijayakumar(PVK) AMIE. IWT, SNT-TC-IA Level-II(VT)

S.TirupatiRao(STR) AMIE IWT, ISO9712 Level-II(VT)

N.HariharaSwaminathan(NHS) AMIE, BBA, PGDCA IWS, SNT-TC-IA Level II (VT), ISO9712 Level-II (VT)

V.Gnanamurthy (VGM) M.Sc., AIIM. SNT-TC-IALevel II (VT,MPT,UT,RT,DPT) , ISO9712 Level-II (VT,MPT,DPT)

A. Ganesh (AG) B.Tech., MS SNT-TC-IA Level II (VT,MPT,UT,RT,DPT) , ISO9712 Level-II (VT,UT)

R.Niranjan(RN) B.E ISO9712 Level-II (MPT,DPT), SNT-TC-IALevel II (UT)

G.Sugumar(GS) DME Workshop practical trainer

PHOTO GALLERY

Welding Workshop Centralized fume extraction system

PPEs Display Board Library

Yoga for Trainees Smart class room

Visual inspection area Wels sample cut section

Route map to AWTI

How to Reach

By train: From Chennai Central- Catch suburban train towards AVADI direction and alight at Loco Works / Villivakkam Railway station then by walk /Auto rickshaw

By Bus :Bus No.20,20A,20B,20C &120 from Chennai Central & 22B,27D&27K from Chennai Egmore Bus Stop –Kambar Arangam on Konnur High road.

IMPORTANT INSTRUCTIONS

All trainees coming for training at AWTI shall adhere to following instructions

1. Discipline, sincerity and punctuality are the foremost qualities expected from the trainees.

2. Trainees shall bring their own safety shoes and working dress for doing welding practice.

3. Trainees having corrected vision must wear their spectacles during welding.

4. Trainees shall report with Photo ID card and relieving letter.

5. Trainees shall bring two passport size photographs.

6. Hostel accommodation is available.

7. At present, no mess facility is available in the hostel.

8. No cooking is allowed in the hostel.

For additional information please contact: Principal: (BSNL) 044-26147612, Mobile: 09003141417, Tele Fax:044-26281227, Railway Phone: 47612

Chief Course Coordinator:(BSNL) 044-26147211, Mobile: 09003149549 Railway Phone: 47211

Email: ptc@icf.railnet.gov.in