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SYLLABUS FOR

Electronics Mechanic (Steel Plant)

Under

APPRENTICESHIP TRAINING SCHEME

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE

MINISTRY OF LABOUR AND EMPLOYMENT

GOVERNMENT OF INDIA

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GENERAL INFORMATION

Name of designated trade : Electronics Mechanic (Steel Plant) N.C.O. Code No. : 7243 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

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List of members attended the Workshop to finalize trade syllabus of ‘Electronic Mechanic (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 Shri/

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

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

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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

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

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

Electronics Mechanic (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- Electronics Mechanic (Steel Plant) Training Structure

Sl.No. Module No Modules/ Subject Duration in weeks

1st Year

Basic Trade Training

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 Basic Electronics 10

7 A.7 Power Electronics & Drives 06

8 A.8 Analog & Digital Communication 04

9 A.09 Instrumentation & Control 04

10 Revision & Test 02

2nd Year

11 A.10 PLC & DCS 02

12 A-11 Fluid Power (Industrial hydraulics & pneumatics) 02

13 A.12 Welding 01

14 A.13 Advanced Industrial Electronics 04

15 A.14 Repair & maintenance of electronic equipment 05

16 A.15 Electrical Power System 04

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 ELECRONIC MECHANIC (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)

Week No.

Trade Theory Trade Practical Engineering Drawing Workshop Calculation & Science

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

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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 & 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)

Terminal Competencies:

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.

3. Bench-fitting Skills (8 weeks)

Terminal Competencies:

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.

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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 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. Marking media, marking

Hacksawing - Marking lines, Cut metals pieces of different profiles & sections by hack-sawing (straight, inclined & curved line) 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 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.

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‟s surface or parallel to it and vertical motion under gravity. Related problems. Newton‟s Laws of

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

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

Dimensioning practice. Motion with proper examples, Concept of Force, Concept of 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, its 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.

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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

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 coplaner forces acting at a point. Problems.

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laws and application, Wheatstone bridge and its application, Simple problems Use of common electrical measuring instruments and related safety aspects

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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

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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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, 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,

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.

Do Do

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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

Routine care and maintenance of batteries

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.

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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.

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.

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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.

20-21 DC motor- working principle, torque, speed, back emf, their relations. Types of DC

Testing DC motors, identifying terminals, connecting, running and reversing direction of

Do Do

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motors- series, shunt, compound and separately excited their characteristics and applications. Starting and speed control of DC motors. Related safety aspects

rotation of DC motors. Studying characteristics and drawing characteristic curves of DC motors of all types.

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.

24-25 Induction motors- Rotating magnetic field, and working of 3-phase induction motors, production of torque.

Dismantling, inspection of parts, cleaning and testing of windings, lubricating bearings and assembling of 3-phase SC

Simple exercises on Interpretation of Orthographic Projections.

Do

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Construction of SC and SR motors, slip, rotor emf, current, frequency, pf, 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

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.

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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

6. Basic Electronics (10 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

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Make simple electronic circuits on bread-board and PCB

Understand the principle of digital electronics, 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

27-28 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 and their rating - 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 rating- Slow blow and fast blow, semiconductor fuse Inductors and their rating - types: ferrite core, air core, tapped and variable inductors. Factors affecting inductance and use of inductors Capacitors and their rating: Mica, ceramic, paper,

Electronic Component identification and testing, Reading and interpretation of colour codes of components 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 using training kits, study of different wave shapes and their values on oscilloscope Soldering and desoldering practice

Different types of simple and intricate exercises on interpretation of orthographic projections with proper dimensioning

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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electrolytic, tantalum, silvered mica, variable capacitors, colour coding and uses. Voltage and current sources- Ideal and practical, AC and DC signal and its source. Semiconductor theory: intrinsic and extrinsic, P and N type, development of P-N junction, drift and diffusion currents, barrier potential, biasing arrangement. Effect of temperature Diodes: working, classification, characteristics, coding, specification, identification and testing. Half wave and full wave rectifiers, PIV. Zener diodes: characteristics, types and application. Calculation of series resistance for varying inputs and load currents, Voltage regulator using zener LED, varactor and photo diodes- working principle and applications.

29 Transistors: working, classification, VI characteristics (static and dynamic), CE, CB,

Transistors: identification and testing finding static and dynamic characteristics of

Do Do

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CC configuration and their difference, current, voltage gains and their relationship. Biasing and thermal stabilization circuits, heat sink. Packaging, coding, specification, identification and applications in detail DC and AC load lines. H parameters

transistors in different modes using training kits, calculation of gains. Biasing circuits

30 Field effect transistors: construction, operation and VI characteristics of JFET, Enhancement and deletion type MOSFET, concepts of CMOS, Difference with bipolar junction transistors, uses. UJT- Construction, operation VI characteristics and application

Identify, test and draw the VI characteristic of FET, MOSFET and UJT.

Do Do

31 Amplifiers: working principle, classification and circuits. Small signal single stage AF/RF amplifiers: different circuits, load line, voltage, current and power gain, waveforms, frequency response Multistage amplifiers- need and types of coupling. RC, transformer and direct couple amplifier circuits, voltage and

Assembly and testing of amplifier circuits on PCB: Single stage CE,CB,CC amplifiers, RC, Transformer and direct couple amplifiers. Study of input and output wave forms on oscilloscope. Calculation of gain and bandwidth. Drawing the frequency response curve

Do Do

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power gain, frequency response, bandwidth, comparison between different types. Power amplifier- voltage and power amplifier, classification Class A, B.C and AB amplifier circuits Push-pull amplifier, Use of heat sink., harmonic distortion and its control. Feedback amplifiers- circuit and applications

32 Oscillators: working principle, classification, circuits and applications. Factors controlling oscillation. Different types of oscillators, their characteristics and applications, crystal oscillators.

Assembly of oscillator circuits using transistor and measuring the output frequency and waveform.

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

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, V/I and I/V converter. Differential and Instrumentation amplifier Switching and timer circuits: classification of multi-vibrators,

OPAMPS pins identification, assembly of inverting and non-inverting amplifiers, calculation of voltage gain, assembly of comparator, adder, subtractors, differentiator, integrator, V/I and I/V circuit and its testing. Study of Differential and Instrumentation amplifier Construction of multivibrators using 555

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

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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

timers, Calculation of frequency

34-35 Digital Electronics Number systems: binary, octal, hex, 1's and 2's complements, conversion from one system to other, Boolean algebra: De Morgan theorem and its applications 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 equivalent of gates, Negative and positive logic gates Boolean algebra- Karnaugh map technique, simplification of Boolean expressions, realization of Boolean expression with logic gates

Verification of truth tables of different gates Realization of different Boolean expression with logic gates Realization of adders and subtractors Construct and verify truth tables of flip flops Construct synchronous and asynchronous counters and study its functions Construct controlled shift register and study their functions Practice on reading and interpretation of IC data sheets.

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

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Combinational logic circuits: Half and full adder and subtractors. Encoders, decoders, multiplexer, de-multiplexers, parity generators and checker Sequential logic circuits: Difference between sequential and combinational circuits, triggering of sequential circuits. Flip-flops: RS, JK, D, T type, preset and clear signals, timing diagrams. Counters, Registers and its applications Memory devices: types, memory cells: RAM, ROM, PROM. EPROM, EEPROM, CD-ROM, memory addressing and IC chips, Static and dynamic RAM, latest developments Data converters: Digital to analog converters, simple circuits, and applications. Analog to digital converters Multivibrators: Types, characteristics and circuits, Schmidt trigger

36 Microprocessor and computer: Organization in general: CPU, ALU, resistors, counters, data and address

Programming practice on Microprocessor Identification of different

Do Do

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process, memory and I/O devices. Instruction set, Simple programming. Introduction to other processors Hardware of a personal computer (PC) Microcontrollers: basic principle, architecture, types, programming concepts, interfacing.

parts of a personal computer.

Programming practice on Microprocessor

7. Power Electronics & 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

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

Exercise on sectioning from isometric view.

Logarithms - Problems on Negative Characteristics. Hydrostatics – Nature of liquids and Pressure of liquid inside a vessel at different positions. Unit of pressure, Pascal‟s Law, simple problems.

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

Checking of power MOSFET, thyristors, IGBT, GTO, IGCT etc

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 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

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. Exercise on maintenance and trouble shooting of DC drive.

Free hand sketch of tools and tackles used in electronics trade- soldering iron, plier, screw drivers, desoldering pump

Do

28

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 instruments used in electronics trade- multimeters, power supply, function generators and CRO etc.

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.

Drawing symbols of electronics components- resistors, diode, transistors, FET, MOSFET, UJT etc.

Do

8. Analog & Digital Communication (4 weeks)

Terminal Competencies: After completion of this module the trainee will become familiar with

Principle and types of Electronic communication system (analog and digital)

Devices used in electronic communication

29

Working principle and circuit details of Television, Telephone (fixed and mobile), GPS, DA and PA system

Communication media

Fiber-optics communication

43 Communication system- Elements of communication system, principle of analog communication, , basic terminology used, bandwidth of signal and channel, propagation of electromagnetic wave, modulation and its necessity, antenna and types Modulation – methods of modulation- AM, FM, PM. Amplitude modulation- methods, modulation index, generation of side bands, block diagram of AM transmitters. Demodulation- AM radio receiver circuits, super heterodyne receiver Frequency modulation- methods, modulation index and number of side bands, FM transmitter and receiver circuits Other modulation schemes and their comparison

Lab work on AM and FM communication. Calculation of modulation index.

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.

44 Familiarization with TV circuits and its working- block diagram of different sections of TV, its circuit

Demonstration of TV circuits, identification and use of different controls.

Do Do

30

details, tuner, test points, VIF, AGC, Video amplifier, synchronization and sweep circuit, matrix, display screen, sound section, power supply, advancement in TV- flat screen, LCD and LED display.

45 Digital communication- principle of digital communication, methods and industrial application. Data communication: serial and parallel communication, MODEMS, Interfaces-RS-232, 422, 485, Ethernet. Industrial communication protocols- MODBUS, FIELDBUS, CONTROLNET and Interface buses Communication media Computer networking fundamentals

Demonstration of RS-232, RS 485, Ethernet and other communication standards. Familiarization with different communication equipment and media- Coaxial, UTP, Fibre Optic cable etc.

Do Do

46 Simple concepts of communication devices (block diagram only): Telephone (fixed and mobile), wireless, satellite, GPS, DA and PA system Fibre optics- structure, classification, characteristics,

Familiarization with FO communication

Do Do

31

losses, choice of wave-length, FO cable, splicing and connectors, applications and maintenance.

9. Instrumentation & Control (4 weeks)

Terminal Competencies: After completion of this module the trainee will become familiar with

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:

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 configurations.

Fastening Devices – Temporary and Permanent. meaning and difference. Temporary device – Hexagonal Bolt, Nut, Check Nut, Washer. To draw the three views of individual 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 eg. Mechanical, Electrical, Chemical, Magnetic etc. Properties of Matter (Electrical):- resistivity, permittivity, permeability, resistance temp.

32

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. 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.

coefficient etc. Insulating materials. Brief description and properties of electrical materials such as silicon, nichrome, silver, copper, aluminum, transformer oil.

33

Restriction method: principles, types and installation of orifice plate, venturi tube, flow nozzle and others sensors. Variable area method: principles, types, and working. Mass flowmeters, 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

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.

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, rag bolt

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

34

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

51 Revision/ Plant visit/ Industrial visit

52 Examination

Part B- Advance Trade training in Training Institute/ Industry & In-plant training Duration- 52 Weeks

10. PLC & DCS (2 weeks)

Terminal Competencies: After completion of this module the trainee will become familiar with

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

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

Different methods of locking of nuts:-

a) Lock nuts b) Split pin b) Slotted nut d) Symmonds nut. c) Castle nut d) Wings nut etc

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

35

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

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 .

11. Industrial hydraulics and pneumatics (2 weeks)

Terminal Competencies: After completion of this module the trainee will become familiar with

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

36

55-56 Industrial hydraulics and pneumatics Basic principles of hydraulics 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

The Trigonometrical ratios and simple problems connected to workshop practice. Engineering Material – Introduction, classification, metallic and non-metallic material, physical and mechanical properties, testing of metal and hardness testing. .

12. Welding

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,

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 i) Chain ii) zig – zag Butt Joint –

Angle of Elevation and Angle of Depression, Problems on Height and Distances taking the help of Trigonometrical Ratios

37

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

a) Single plate or strap b) Double plate or strap

Heat treatment of steel – Hardening, annealing, tempering, normalizing and case hardening

13. Advanced Industrial Electronics ( 04 weeks)

Terminal Competencies: After completion of this module the trainee will become familiar with

Techniques of electronic circuit fabrication

Circuit details of electronic equipment – SMPS, UPS, Inverter, PC, Industrial camera, CCTV etc.

Industrial weighing system

58 Different techniques of electronic circuit fabrication Surface mounted devices technology, micro-electronics

Fabrication of electronic circuits on Assembly and testing of power supply with filter and regulators on PCB by soldering the components. Demonstration on soldering and de-soldering SMDs

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.

59 Regulated power supply. Introduction to SMPS and UPS. Understanding of specification. PC hardware including I/O devices, memories

Study of SMPS, UPS and Inverter circuits and its testing Study of PC hardware and peripheral devices Study of industrial camera and CCTV used in steel plants

Drawing the symbols of electrical instruments- ammeter, voltmeter, watt meters, ohmmeter, energy meters etc. as per BIS practice.

Solid Mensuration:- Prism, Cylinder, Pyramid, Cone, Frustum of Pyramid and of Cone, Problems concerning to workshop practice.

38

Working principle and types of industrial camera and CCTV

Relation between load and extension – Graph – meaning of Yield Point – 1st & 2nd Ultimate tensile Stress, Breaking Stress and factor of safety.

60-61 Welding machine and its control CNC machines- basic idea. Sensors and switches- Proximity switch, Micro switch, limit switch, photo switch, encoder and other types of electronic sensors and their application Industrial weighing system- types, different types of load cell and processing units, configuration, maintenance and trouble shooting.

Study of welding machine and CNC control circuit Study and testing of different types of sensors, transducer and switches Demonstration of different units of an industrial weighing system.

Drawing the symbols of electrical components and devices- push buttons, switches, fuse, motor, generators, transformers, relays and contractors etc.

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.

14. Repair and maintenance of electronic equipment ( 5 weeks)

Terminal Competencies: After completion of this module the trainee will become familiar with

Repair and maintenance of electronic equipment.

Use of different electronic test and measuring instruments

62-66 Safety precautions. Requirement of grounding of self and equipment. Working principles, block

Testing and maintenance of electronic modules such as rectifiers, amplifiers, oscillators, logic circuits,

Drawing of various wave shapes- sine , square, triangular, saw tooth etc.

Solid Mensuration:- Sphere, Spherical segment, material weight and cost

39

diagram, circuit diagram and applications of following electronic test & measuring instruments-

a. Multimeter b. CRO- conventional and

storage type c. Scope meter d. DC power supplies e. Function generators f. Pulse generators g. Temperature controlled

soldering and de-soldering stations etc.

h. IC tester Modern trouble shooting techniques and use of electronic test equipment for service and repairing of electronic cards and equipment, use of test rigs and jigs, component substitution in handling of PCB and hybrid circuits.

multivibrator, multiplexer, timers, voltage regulators, ADC, DAC etc Repair and maintenance practices on defective electronic equipment such as power supplies, PC, microprocessor based circuits, CCTV, industrial camera, weighing system, PA system, modem etc. Repair and maintenance of communication equipment including fibre optic communication modules. (Note- Trainees should be given defective electronic equipment for repair)

Drawing the circuit of a DC power supply with rectifier, filter and regulator with labeling and waveforms. Drawing the circuit diagram of a UPS and SMPS with labeling and waveforms. Drawing the circuit diagram of a Signal generator with labeling and waveforms.

problems on above topics concerning workshop practice. Heat – Definition and its importance. Temperature – Definition and significance. Difference between heat and temperature. Scales of Temperature eg. Fahrenheit , Centigrade, Kelvin- relationship between them. Lower and Upper fixed points, Fundamental Interval. Reasons for the selection of Mercury as thermometric substance.

15. 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

40

Working of LT and HT Switch- gears and protective relays

Power factor improvement methods

Monitoring system for power generation and utilization

67 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

Drawing the block diagram of an oscilloscope with labeling and waveform.

Do

68 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

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 Polarity marking of CT Connection of CT and PT

Drawing the block diagram of an RC couple amplifier with labeling and waveform.

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.

41

laying of cable, testing and fault 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

Connection of lightening arrestors

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.

69 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.

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,

Drawing of control circuit of a motor starter

Do

42

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 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

VCB, and SF6 breakers Demo on parameterization of digital relay and numerical relay

43

70 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.

Drawing the block diagram of a TV set with different sections and its labelling.

Do

16. Computer & IT (1 week)

Terminal Competencies: After completion of this module the trainee will become familiar with

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

Drawing of symbols of different digital electronic circuit and components- gates, flip-flop, register, counter with timing diagrams.

Statistics – Mean, Median, Mode, Variance, Frequency distribution , Cumulative frequency, Pie-Chart Expansion of Liquids – it has only one type of expansion e.g.

44

Cubical expansion. Two forms - Real and Apparent – the relation between them, coefficient of apparent and real expansion. Related problems.

17. Iron & Steel making technology (2 weeks)

Terminal Competencies: After completion of this module the trainee will become familiar with

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 Desulphurization 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.

Drawing of opamp based circuits- adder, subtractor, integrator, differentiators, V/I and I/V converters.

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

45

18. Quality Management & Improvement Techniques (1 week)

Terminal Competencies: After completion of this module the trainee will become familiar with

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.

46

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 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.

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

Drawing of circuit of an different types of multi-vibrators using 555 timer with labeling and waveform

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

47

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

48

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

B.1 Shop Floor (In- plant) training (24 weeks)

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 practices which may include the following Electronic repair shop 1. Maintenance and repairing

of electronic cards 2. 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.

Electrical repair and testing section 1. Observation of

maintenance and repairing of electrical machines

2. Calibration and testing of electrical instruments

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

Drawing of AM and FM modulated waveform at different modulation index. Drawing of a radio receiver circuit Practice on Free hand sketching of electronic tools and instruments. Drawing of block diagram of a microprocessor, microcontroller and Personal Computer. Drawing of flow sheet symbols of sensors, transmitter, controller, recorder, control valve etc. Drawing of symbols of power electronic components and circuits- SCR, firing circuit of SCR, thyristorised

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. De-Morgan theorem. Introduction to Boolean algebra. Simple estimation of the requirements of

49

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

Control system, P& I diagram of plant.

2. Distribution of electrical power, SLD.

3. Protection schemes and 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

converters, inverters, chopper, cyclo-converter etc. (1ph & 3 ph) Drawing of block diagram of a feedback control system.

materials as applicable to the trade. Problems on estimation and costing. Meaning of HP and BHP. Problems on work, power and energy related to electrical area. Magnet and magnetism. Simple workshop problems.

50

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

Terminal Competencies:

Functioning of local industries

Making the project report and its presentations to the experts.

103-104

Revision of theory covered during the training. Effective Presentation skills

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

Revision. Revision.

51

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 make a regulated DC power supply on a PCB and test the % regulation

2. Able find out input and output characteristics of diode

3. Able to find out input and output characteristics of a transistor

4. Able to find out input and output characteristics of a transistor (FET)

5. Able to find out the characteristics of UJT

6. Able to check truth table of logic gates

7. Able to repair defective electronic instrument/ equipment

8. Able to check truth table of flip flops

9. Able to make an RC coupled amplifier/ FET amplifier

10. Able to make an LC/RC oscillator

52

List of tools and equipment required for Trade- Electronics Mechanic (Steel Plant) Trainees kit:

Sl. No.

Description Quantity

1 Connecting screwdriver 100 mm Quantity to be sufficient as per seats surveyed & allocated

2 Neon tester 500 v

3 Screwdriver set (set of 5 bits) - plane and diamond ended

4 Insulated combination pliers 150 mm

5 Insulated side cutting pliers 150 mm

6 Long nose pliers 150mm

7 Soldering iron 25 w, 240 v

8 Electrician knife D.B

9 Digital multimeter portable

10 Soldering iron 15 W/25 W/ 65 W

11 Desoldering pumps

List of equipments required

Sl. No. Description Quantity

1 First aid kit Quantity to be sufficient as per seats surveyed & allocated

2 Fire extinguisher

3 Bench vice

4 Steel rule

5 Digital multimeter

6 30-0-30 V, 2A D.C regulated power supply

7 0-300V, 500mA DC regulated power supply

8 LCR bridge( digital)

9 Signal generator 100 kHz

10 Digital storage oscilloscope, 100MHz with probe

11 Wattmeter

53

12 Megger (insulation tester)

12 a Megger (earth testing)

13 Battery charger

14 Digital IC tester

15 Pulse generator

16 Logic probes

17 DOL starter

18 DOL starter with forward/reverse control

19 Automatic sequencing control

20 Overload relays (Thermal, magnetic, electronic)

21 On delay timer, off delay timer

22 Earth leakage circuit breaker

23 Dimmerstat, 8 Amps

24 Counters

25 Temp. controller

26 DC motor control training kit (Electronic)

27 Level detector

28 Output power meter

29 Distortion factor meter

30 EPROM programmer

31 Microprocessor trainer kit alongwith ADC/DAC with stepper motor controller

32 Proximity switches

33 Photo tachometer

34 Burglar alarm

35 Smoke detector

36 Emergency tubelight

37 Single phase preventer

38 Servomotor

39 Servo controller

40 Absolute encoder

41 Rotary encoder (incremental)

42 DC tong tester

43 Weighing system (load cell based)

44* Programmable logic controller(PLC) with programming

54

unit

45 Personal computer with latest configuration with printer

46 High voltage testing kit

47 Surge generator

48 Instrument training kit (LVDT, Strain gauge, Thermocouple etc)

49 Electronic voltmeter

50 DC generator

51 DC motor

52 Single phase alternator

53 SMPS

54 Induction motor( single phase)

55 Stroboscope

56 Synchronous motor

57 Transformer (1 ph/ 3 ph), 1 KVA

58 Motorized control valve

59 Solenoid valve

60 Strain gauge

61 Load cell

62 LVDT

63 Dual trace CRO 100 Mhz

64 Analog IC trainer kit and Discrete component training kit

65 Linear amplifier trainer

66 Digital IC trainer kit

67 Magnifying glass for IC no. reading

68 Microprocessor 8085 trainer kit

69 Digital trainer A/D ,D/A convertor, Mux, Demux, display devices, etc

70 Motor trainer with dummy loads

71 Three phase motor speed controller/ trainer kit

72 Soldering station

73 De-soldering station

74 Hot air soldering station- cum –de soldering station for SMD devices

75 PLC training kit

55

76 CNC training kit

77 3 ph alternator

56

List of consumable materials

Sl. No. Description Quantity

1 Maintenance free batteries Quantity to be sufficient as per seats surveyed & allocated

2 Re-chargeable cells-dry cells

3 Power diodes

4 Heat sinks, heat sinks compounds

5 LED‟s

6 Switches

7 Relays (AC/DC), contactors(AC/DC),

8 Push button switches

9 Lamps

10 IC‟s such as -7400,4001,4011,4017,4007,4033,74159,74154,etc

11 OPAMP IC 741 wave form generator IC 8035

12 IC DAC 0808, IC ACD 0801

13 Transistors , JFET, MOSFET, UJT

14 Various diodes

15 Various transistors

16 Microphone

17 Speaker 4”, 8 ohm

18 Various capacitors

19 Various resistors

20 Various transformers

21 SCR,DIAC,TRIAC, GTO, IGBT, IGCT

22 7-segment display (both common cathode and anode)

23 J & T type thermo couple