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									        SYLLABUS OF SEMESTER SYSTEM
               FOR THE TRADE
                     OF




    WELDER (GAS & ELECTRIC)

                  UNDER
      CRAFTSMEN TRAINING SCHEME (CTS)
             (TWO SEMESTER)




                    Designed By
                Government of India
           Ministry of Labour (D.G.E.&T.)
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
            EN-Block, Sector-V, Salt Lake
                  Kolkata-700 091

                     [1]
                             List of trade committee members approved the syllabus of semester system for the
                          trade of “WELDER (Gas & Electric)” held at Foremen Training Institute, Bangalore -22


Sl. Name                            Name of the Organization      Remarks
No
1   Shri. B.S aviprasath,                   FTI, Bangalore.       Chairman
    Joint Director/ Director I/c,
2   M.Kumaravel,                         FTI, Bangalore           Convener
    Deputy Director of
    Training
3   M.Thamizharasan,                      ATI, Chennai             Member
    Deputy Director of
    Training
4   C.H.Subbarao                            ATI, Hyderabad.        Member
    Deputy Director of
    Training
5   J.D.Masilamani,                      FTI, Bangalore            Member
    Deputy Director of
    Training
6   B.V.S.Seshachari,                    FTI, Bangalore            Member
    Deputy Director of
    Training
7   D.N.Sharma,                          FTI, Bangalore            Member
    Training Officer
8   V.L.Ponmozhi                          CTI, Chennai             Member
    Training Officer,
9   Pazhanimurugan                  Govt. ITI, KGF, Bangalore      Member
    Junior Training Officer
10 D.Ravichandar                       Govt. ITI, Peenya,          Member
    Junior Training Officer                 Bangalore
11 M.S.Hanumantharayappa              Govt. ITI, Hosur road,       Member

                                                                  [2]
     Junior Training Officer            Bangalore
12   V.Venugopala,                Govt. ITI, Hosur road,    Member
     Junior Training Officer            Bangalore
13   V.Muralidharan,                 IIW, Chennai.          Member
     Regional Director
14   Martindoss,                TuV Rheindland, Bangalore   Member
     Manager
15   Balasubramanya,               Wipro Infrastructure     Member
     Consultant                   Engineering, Bangalore
16   V.Muralidharan, Regional      IIW-india, Chennai.      Member
     Director- South
17   Kishan Cariappa,             Volvo Construction        Member
     Senior Manger               Equipments, Bangalore.

18   K.Vijayakumar, AGM,          Volvo Construction        Member
                                 Equipments, Bangalore.

     G.Sundarraj, AGM,            Volvo Construction        Member
                                 Equipments, Bangalore.

     D.B.Anandkuma,                ACE Designers Ltd.,      Member
     Senior Engineer,                 Bangalore.

     M.Puttaraju,                 HAL Engine Division,      Member
     Chief Manager                    Bangalore.

     A.Chakravorty                  Weldcraft(P) Ltd.,      Member
     Chief Executive,                 Bangalore.

     C.Ramnath,                 GTRE,DRDO, Bangalore.       Member

     Group Director(Retd),
     Trimal,                       Fouress Engineering,     Member
                                       Bangalore.
     Asst. Manager,


                                                            [3]
                                          GENERAL INFORMATION


1.   Name of the Trade              : WELDER (GENERAL)

2. N.C.O. Code No.                 :

3. Duration of Craftsmen Training : 06 months

4. Entry Qualification             : Pass in 8th Class


5. Unit strength                   : 20

6. Space norms                         : a) Workshop:96 Sqr meter.
                                         b) Class room: 30 sq.meter.

7. Power norms                         : 15.4 KW

8. Trainers qualification        : (i) National Trade Certificate in welder trade with five years
                                       Experience with relevant field.
                                 (ii) Diploma in Mechanical with two years experience in relevant field.
                                 (iii) Degree Mechanical engineering with one year experience in relevant
                                       field.
9. Desirable qualification     : Preference will be given to a candidate with CITS.
                                                                       (If not done CITS than must be
trained within 02yrs on joining)


                                                     [4]
                Syllabus for the Trade of “WELDER (GENERAL)” under C.T.S.
                                     Duration : 6 MONTHS

                                                         First Semester

Week   Ex.No                  Practical                                  Theory                   Engg. Drawing               Vocational Science and
No.                                                                                                                           Calculation
1              Induction training:                      - General discipline in the Institute     - Importance of             - Importance of Science
               - Familiarisation with the Institute.    - OSH                                       Engineering Drawing and     and Calculation to the
               - Importance of trade Training           - Elementary First Aid.                     its Knowledge.              Trade skill and
               - Machinery used in the trade.           - Importance of Welding in Industry                                     fundamental Arithmetical
               - Introduction to safety equipment and   - Safety in Manual                                                      operations Addition,
                 their use etc.                         - Metal Arc Welding,Oxy-Acetylene Welding                               Subtraction,
               - Setting up of Arc and gas Apparatus.      and Cutting.                                                         Multiplication and
               - Lighting and setting of flame.                                                                                 Division.
               - Striking an arc

2              - Hack sawing, filing square to          - Arc and Gas Welding Equipments, tools   - Use of Drawing              General simplifications
                 dimensions.                              and accessories .                         Instruments. T- Square    - Fraction-Addition,
               - Marking out on MS plate and punching   - Various Welding Processes and its         Drawing Board etc.          Subtraction,
                                                          applications .                                                        multiplication and
                                                        - Arc and Gas Welding terms and                                         Division-Problems
                                                          definitions.




                                                                   [5]
3   OAW-1    - Fusion run with and without              - Different process of metal joining            - Letters, Numbers and          - Fraction-Addition,
               filler rod on M.S. sheet 1.6 mm thick in   bolting, riveting, soldering, brazing,          Alphabets as per BIS            Subtraction,
               flat position.                             seaming etc.                                                                    Multiplication and
    OAW-2    - Edge joint on M.S sheet 1.6 mm thick     - Types of welding joints and its                                                 Division-Problems.
               in flat position without filler rod        applications. Edge preparation and fit up
                                                          for different thickness.
4   MMAW-1     Straight line beads on M.S. 10 mm        - Oxy-Acetylene Cutting Equipment               - Letters, Numbers and          - Decimal-Addition,
               thick in flat position by 3.15 mm φ        principle and application.                      Alphabets as per BIS            Subtraction,
               electrode                                - Basic electricity applicable to arc welding                                     Multiplication, and
    MMAW-2   - Weaved bead on M. S 10mm in flat           and related electrical terms & definitions.                                     Division-Problems.
               position by 4 mm Ø electrode - D/H       - Principle of arc welding.
               position.
5   OAW-3    - Square butt joint on M.S. sheet. 2 mm    - Common gases used for welding, their          - Freehand Sketching of         - Conversion of Fraction
               thick in flat Position by gas.             flame temperatures and uses.                    straight lines, rectangles,     to Decimal
    MMAW-3   - Fillet Tee joint on M.S.10 mm in flat    - Chemistry of oxy-acetylene flame.               Circles, Polygons etc.          and vice-versa.
               position by Arc.                         - Types of oxy-acetylene flames and
                                                          uses.

6   OAW-4    - Outside corner joint on MS 2 mm in       - Arc welding power sources- Transformer, - Use of different types of           - Decimal-Addition,
               flat Position by gas.                      Motor Generator set, Rectifier and Inverter     line and symbols for            Subtraction,
    MMAW-4   - Fillet lap joint on M.S. 10 mm in flat     type welding machines.                          drawing.                        Multiplication, and
               position by Arc.                         - Advantages and disadvantages of A.C.          - Importance of putting           Division-Problems.
                                                          and D.C. welding machines                       dimension on the
                                                                                                          drawing as per BIS.
7   OAW-5    - Fillet Tee joint on MS 2 mm in flat      - Welding positions – flat-horizontal- vertical - Freehand sketching with       - Decimal-Addition,
               position by gas.                           and over head position. Weld slope and          dimension scale and             Subtraction,
    MMAW-5   - Outside Corner joint on MS 10 mm in        rotation.                                       proportionate sketching,        Multiplication, and
               flat position by arc.                    .                                                                                 Division-Problems.

8   OAW-6    - Fillet Lap joint on MS 2 mm in flat      - Arc length – types – effects of arc length.   - Reading of simple blue          Metals:
               position by gas.                         - Polarity and its uses.                          print.                        - Properties and uses of
    MMAW-6   - Single Vee Butt joint on MS 12 mm in                                                                                       cast iron, wrought iron,
               flat position by arc.                                                                                                      plain carbon steels and
                                                                                                                                          alloy steels

9   OAW-7    - Square Butt joint on M.S. sheet. 3 mm    - Calcium carbide properties and uses.      - Isometric views and               - Properties and uses of
               in Horizontal vertical position by gas   - Manufacture of calcium carbide. Acetylene   oblique views with                  Cast iron, Plain carbon
             - Straight line beads on M.S. 10 mm in       gas Generators and manufacturing            dimensions of such as               steels and alloy steels
    MMAW-7     Horizontal vertical position by arc        methods and properties.                     Cube, Rectangular,

                                                                    [6]
               - Fillet Tee joint on M.S. 6 mm in                                                             Block, Cylinder etc
                 Horizontal vertical position by Arc.


10   OAW-8     - Outside Corner joint on MS 2 mm in          - Acetylene gas Purifier, Hydraulic back       - Explanation of simple       - Properties and uses of
                 horizontal position by gas.                   pressure valve. Charging methods of            Orthographic                  Copper, Zinc, Lead, Tin
     MMAW-8    - Fillet Lap joint on M.S. 10 mm in             oxygen and acetylene gases                     Projection 1st angle,as       and Aluminum
                 horizontal position by arc.                                                                  per BIS

11   OAW-9     - Fillet Tee joint on MS 2 mm in              - Oxygen and Acetylene gas cylinders and       - Explanation of simple       - Properties and uses of
                 horizontal position by gas.                   color coding for different gas cylinders.      Orthographic projection       Brass, Bronze, Solder,
               - Outside Corner joint on MS 10 mm in                                                          3rd angle, as per BIS         Rubber and Timber.
     MMAW-9      horizontal position by arc.




12   OAW-10    - Fillet Lap joint on MS 2 mm in              - Gas regulators, types and uses. Welding      - Sketching the views solid   - System of Units -
                 horizontal position by gas.                   and gas cutting torches and types.             bodies when viewed            British, Metric and S. l.
     MMAW-10   - Single Vee Butt joint on MS 12 mm in                                                         perpendicular to their        Units for Length, Mass,
                 horizontal position by arc                                                                   surfaces and axes.            Area, Volume, Capacity,
                                                                                                                                            time.


13   OAW-11    - Square Butt joint on M.S. sheet. 3 mm       - Arc blow – causes and methods to control     - Sketching the views solid   - Conversions between
                 in vertical position by gas                   arc blow.                                      bodies when viewed            British and Metric
               - Straight line Beads on M.S. 10 mm in        - Distortion in welding and methods              perpendicular to their        Systems.
     MMAW-11     vertical position by arc                      employed to minimize distortion                surfaces and axes.
               - Fillet Tee joint on M.S. 6 mm in vertical
                 position by Arc
               -
14   OAW-12    - Outside Corner joint on MS sheet 2          - Electrode – types – functions of flux,       - Freehand Sketching of         Square roots:
                 mm in vertical position by gas.               coating factor, sizes of electrode. Coding     plan and elevation of       - The Square and Square
     MMAW-12   - Fillet Lap joint on M.S. 10 mm in             of electrode as per BIS, AWS, and BS.          simple objects like           root of a Whole Number
                 vertical position by arc.                   - Effects of moisture pick up on electrodes      Hexagonal bar, square         and Decimal,
                                                               and backing.                                   bar, Circular bar,          - Shop Problems.
                                                                                                              tapered bar and Hollow      - Pythagoras Theorem-
                                                                                                              bar etc.                    - Shop Problems.



                                                                         [7]
15    OAW-13    - Fillet Tee joint on MS sheet 2 mm in      - Gas welding filler rods, specifications and   - Freehand Sketching of      - Effects of Heat,
                  vertical position by gas.                   sizes. Welding techniques – right and           plan and elevation of        Thermometric Scales
      MMAW-13   - Outside Corner joint on MS plate 10         leftward methods.                               simple objects like          such as a Celsius,
                  mm in vertical position by arc.                                                             Hexagonal bar, square        Fahrenheit and Kelvin-
                                                                                                              bar, Circular bar,           Temperature measuring
                                                                                                              tapered bar and Hollow       Instruments
                                                                                                              bar etc.
16    OAW-14    - Fillet lap joint on MS sheet 2 mm in      - Resistance welding- principle of              - Views of simple Hollow     - Conversions between
                  vertical position by gas.                   resistance welding – types and                  and solid Bodies with        the above Scales of
      MMAW-14   - Single Vee Butt joint on MS plate12         applications.                                   Dimensions.                  Temperature.
                  mm in vertical position by arc                                                                                         - Units of Heat-Calorie,
                                                                                                                                           Specific Heat, Latent
                                                                                                                                           Heat, Heat Loss and
                                                                                                                                           Heat Gain-Simple -
                                                                                                                                           Problems.


17    OAW-15    - Square Butt joint on M.S. sheet. 3 mm     - Welding symbols as per BIS.                   - Views of simple Hollow     - Changing Percent to
                  in over head position by gas              - Weld defects, causes and corrections.           and Solid Bodies with        Decimal and Fraction
      MMAW-15   - Fillet Tee joint on M.S. 6 mm in over     - Inspections of weld –before – during and        Dimensions.                  and vice versa- Problems
                  head position by Arc                        after welding.                                                               on Percentages related
                                                                                                                                           to The Trade.

18    OAW-16    - Outside Corner joint on MS sheet 2        - Non-destructive testing’s like visual,     - Construction of          - Percentage-Changing
                  mm in over head position by gas.            sound, magnetic, liquid and dye penetrant,   Orthographic Projection    Percent to Decimal and
      MMAW-16   - Fillet Lap joint on M.S. plate 10 mm in     radiographic and ultrasonic tests.           from the given Isometric   Fraction and vice versa-
                  over head position by arc.                                                               view of shaped Blocks in
                                                                                                           First angle method.

19    OAW-17    - Fillet Tee joint on MS sheet2 mm in       - Destructive test such as nick break, free     - Construct an               - Problems on
                  over head position by gas                   and guided bend, tensile and impact tests       orthographic                 Percentages related to
      MMAW-17   - Single Vee Butt joint on MS plate           etc.                                            Projection from the          the Trade
                  10mm in over head position by arc                                                           given Isometric view of
                                                                                                              shaped Blocks in First
                                                                                                              angle method.
20.   OAW-18    - Square Butt joint on Brass sheet.         - Brass – types – properties- uses.             - Construct an               - Newton's Laws of
                  Sheet 2 mm in flat position by gas        - Copper – types – properties and uses.           Orthographic Projection      Motion-Definite of Force-
      MMAW-18   - Square Butt joint on M.S. sheet                                                             from the given Isometric     Units of Force in M.K.S.
                  1.6mm by brazing.                                                                           view of shaped Blocks        Systems and S .l. Unit

                                                                        [8]
               - Tee joint on M.S.sheet 1.6mm by                                                         in 3rd angle method.         of force.
                 brazing.

21   OAW-19    - Square Butt joint on Aluminium sheet.   - Aluminium - properties- weld ability of     - Construct an               - Ratio-Simple Problems in
                 3 mm in flat position by gas.             aluminium by different welding process.       orthographic Projection      Ratios.
     MMAW-19   - Bronze welding on cast iron (Single     - Cast iron- types and fusion welding of cast   from the given Isometric
                 vee butt joint) 6mm by oxy-acetylene      iron and bronze welding of cast iron.         view of shaped Blocks
                 process.                                                                                In 3rd angle method.
22   OAW-20    - Square Butt joint on S.S. sheet. 1.6    - Stainless steel – types- uses – weld decay - Construct an                - Proportion-Direct and
                 mm in flat position by gas                and stainless steel welding by gas.          orthographic Projection       Inverse Proportion
                                                         - Welding Technique-Right Hand-Left            from the given Isometric    - Shops Problems.
                                                           Hand - Explanation                           view of shaped Blocks
                                                                                                        in 3rd angle method.

23             Revision                                  Revision                                      Revision                     Revision
24             Test                                      Test                                          Test                         Test




                                                                     [9]
                  LIST OF TOOLS & EQUIPMNT FOR SEMESTER-I
                    FOR THE TRADE OF “WELDER (GENERAL)”

                                                        (Unit Size : 20)


TRAINEES KIT
S. Name of the Tools              Qty
No
1  Hand Gloves                    20+1
2   Apron leather                 20+1
3  Welding helmet                 20+1
4  Welding hand shield            20+1
5  Gas welding Goggles with       20+1
   Colour glass
6  Chipping hammer                20+1
7  Chisel cold flat 19 mm x 150   20+1
   mm
8  Centre punch 9 mm x 127 mm     20+1
9  Dividers 20 mm                 20+1
10 Caliper outside 15 mm          20+1
11 Stainless steel rule 300mm     20+1
12 Wire brush 5 rows and 3 rows   20+1
13 Leather sleeves 16”            20+1pairs
14 Safety boots for welders       20+1pairs
15 Safety goggles                 20+1
                                          [10]
16 Scriber 15 mm                     20+1
17 Tongs holding 350mm               20+1
SHOP OUTFIT
18 Stainless steel rule 600mm        2
19 Hammer ball pen 1.5 kg with       4
   handle
20 Spark lighter                     4
21 Spindle key                       2
22 Screw Driver 30 0mm blade         1 each
   and 250 mm blade
23 Tip cleaner set                   2
24 Number bunch 6 mm and 1 set       1 set each
   letter punch 6 mm
25 Hacksaw frame fixed 300 mm        8
26 Arc welding coloured glasses      17 nos
   108 mm x 82 mm x 3 mm.
   DIN 11 A &12 A
27 Magnifying glass 100 mm . dia     2
28 Weld measuring gauge fillet and   1 each
   butt
29 File half round bastard 350 mm.   6
30 File flat 350 mm rough            6
31 Earth clamp                       6
32 Spanner D.E. 6 mm to 32mm         2 sets
33 Clamps 10 cm and 15 cm            4 each
34 Hammer sledge double faced 4      1
                                              [11]
   kg
35 Pipe wrench 25 cm and 35 cm        1 each
36 Steel tape 5 meters flexible in    1
   case
37 Electrode holder 400 amps          6
38 H.P. Welding torch No. 2 with      2 sets
   nozzle nos. 1,2,3, 5 & 7
39 Rubber hose clips ¾”               10
40 Welding rubber hose, oxygen        2
   8mm. dia x 5mts.long
41 Welding rubber hose Acetylene      2
   8mm. dia x 5mts.long
42 Gas Pressure regulator oxygen      2
   double stage
43 Gas Pressure regulator acetylene   2
   double stage
GENERAL INSTALLATION
44 Welding Transformer with all       4 sets
   accessories ( 400A , OCV 60
   – 100 V, 60% duty cycle)
45 D.C Arc welding rectifiers set     4 sets
   with all accessories     (400 A.
   OCV 60 – 100 V, 60% duty
   cycle )
46 Suitable gas welding table with    2 sets
   fire bricks
                                               [12]
47 Suitable Arc welding table         4
   with positioner
48 Trolley for cylinder (H.P. Unit)   2
49 Bench shear capacity up to 5       1
   mm
50 Pedestal grinder fitted with       2
   coarse and medium grain size
   grinding wheels dia. 300 mm
51 Work bench 340x120x75 cm           2 sets
   with 4 bench vices of 125 mm
   jaw opening
52 Power hacksaw machine              1
53 AG 7 Grinder                       1
54 AG 4 Grinder .                     2 nos
55 Portable drilling machine (Cap.    1
   6 mm)
56 Fire extinguishers (foam type      1
   and CO2 type)
57 Metal rack 182 cm x 152 cm x       1
   45 cm
58 Instructor’s table and Chair       1 set
   (Steel)
59 Blackboard or white board          I
60 First Aid box                      1
61 Fire buckets with stand            4
62 Steel lockers with 8 Pigeon        2
                                               [13]
     holes
63   Oven, electrode drying 0 to 250   1
     ⁰c, 10 kg capacity
64   Oxy Acetylene Gas cutting         2 sets
     blow pipe
65   Oxygen, Acetylene Cylinders       1 each


     NOTE: 1. No additional items are required to be provided for unit or batch
              working in the Second shift except the items under trainee's tool
             kit lockers.

           2. Provision of cleaning of periodically welding helmets and goggles
              with antiseptic solution should be made as these are likely to be
              used by more than one trainee.




                                                [14]
                                  GENERAL INFORMATION


1. Name of the Trade              : WELDER (TIG/MIG)
2. N.C.O. Code No.                :

3. Duration of Craftsmen Training : 06 months

4. Entry Qualification           : Pass in 8th Class and completion of I semester welder
                                   (General)
5. Unit strength                 : 20

6. Space norms                        : a) Workshop:96 Sqr meter.
                                        b) Class room: 30 sq.meter.

7. Power norms                        : 15.4 KW

8. Trainers qualification        : (i) National Trade Certificate in welder trade with five years
                                       Experience with relevant field.
                                 (ii) Diploma in Mechanical with two years experience in relevant
                                       field.
                                 (iii) Degree Mechanical engineering with one year experience in
                                        relevant field.
9. Desirable qualification     : Preference will be given to a candidate with CITS.
                                                       (If not done CITS than must be trained within 02yrs
                                                       on joining)

                                                [15]
                     Syllabus for the Trade of “WELDER (TIG/MIG)” under C.T.S.
                                         Duration : 6 MONTHS

                                                                Second Semester
Week   EX. No                    Practical                                          Theory                         Engg. Drawing               Vocational Science and
No.                                                                                                                                            Calculation
1      MAG-1    - Depositing bead on M.S (10mm thick) in        - Brief introduction about the course and   - Print Reading related            - Electricity, Current, Power,
                  flat position                                   objectives                                  to missing lines and               resistance, Conductors,
       MAG-2    - Fillet weld – Lap joint on M.S (10mm          - Introduction to CO2 welding – equipment –   missing views.                     insulators, Ohm′s law,
                  thick) in flat position (1.2mm wire and Dip     accessories.                                Exercise on Blue print             Faraday′s laws of
                  transfer).                                    - Description of CO2 welding set with                                            Electromagnetic induction,
       MAG-3    - Fillet weld – Tee joint on M.S (10mm            diagram.
                  thick ) in flat position (1.2mm wire and
                  Dip transfer).
       MAG-4    - Fillet weld – corner joint on M.S (10mm
                  thick ) in flat position (1.2mm wire and
                  Dip transfer).
2      MAG-5    - Fillet weld – Lap joint on M.S. (3mm          - Advantages of CO2 welding over MMAW ,            - Simple Isometric          - Types of Current, Effects of
                  thick) in flat position (0.8 mm wire and        limitations and applications                       drawing- from the given     current and related
                  Dip transfer).                                - Process variables and modes of metal               orthographic                problems.
       MAG-6    - Fillet weld – Tee joint on M.S. (3mm            transfer – dip or short circuiting transfer,       views of simple objects
                  thick) in flat position (0.8 mm wire and        spray transfer (free flight transfer) and        - Welding Symbols as per
                  Dip transfer).                                  globular transfer (intermittent transfer) etc.     BIS.
       MAG-7    - Fillet weld – corner joint on M.S. (3mm
                  thick) in flat position (0.8 mm wire and
                  Dip transfer).

3      MAG-8    - Butt weld – Single Vee butt joint on M.S      - Welding wires used in CO2 welding ,              - Freehand Sketching        - Units of work in M.K.S,
                  (10mm thick) in flat position.                  diameter , designation as per                      on rivets and washers       System and S .l. Unit of
       MAG-9    - Butt weld – Square butt joint on M.S            specification.                                     with dimensions from        Work-
                  (3mm thick) in flat position.                                                                      samples as per BIS        - Simple Problems.
       MAG-10   - Butt weld – Double Vee butt joint on M.S      - Various gases and gas mixtures used in           - Freehand Sketching
                  (16 mm thick) in flat position                  MIG/MAG welding and its applications.              of Riveted joints.
                                                                           [16]
               (1.6mm wire and Spray transfer).

4   MAG-11   - Fillet weld – Lap joint on M.S (10mm         - Wire feed system – types – applications    - Freehand Sketching of      - Practical Units of Power
               thick) in Horizontal position (1.2mm wire      limitations care and maintenance.            Riveted joints.              such as Watt and Horse
               and Dip transfer).                                                                        - Exercise on Blue Print.      Power,
    MAG-12   - Fillet weld – Tee joint on M.S (10mm         - Flux cored arc welding – description,        reading related to         - Definition of I.H.P., B.H.P.
               thick ) in Horizontal position (1.2mm          advantage, welding wires, diameters and      missing dimensions and       and Efficiency.
               wire and Dip transfer).                        specification                                missing section.
    MAG-13   - Fillet weld – corner joint on M.S (10mm
               thick ) in Horizontal position (1.2mm
               wire and Dip transfer).

5   MAG-14   - Fillet weld – Lap joint on M.S. (3mm         - Edge preparation and fit up for CO2        - Freehand sketching of      - Definition of Energy,
               thick)in Horizontal position (0.8 mm wire      welding various thickness of metals          nuts and bolts with        - Potential Energy.
               and Dip transfer).                           - CO2 Welding defects, causes and              dimensions from               Kinetic Energy
    MAG-15   - Fillet weld – Tee joint on M.S. (3mm           remedies                                     Samples.                   - Law of Conservation of
               thick) in Horizontal position (0.8 mm wire                                                - Freehand sketching of        Energy, S.I. Unit of Energy
               and Dip transfer).                                                                          hand tools of the Trade.   - Simple Problems in P.E.
    MAG-16   - Fillet weld – corner joint on M.S. (3mm                                                                                  and K.E.
               thick) in Horizontal position (0.8 mm wire
               and Dip transfer).

6   MAG-17   - Fillet weld – Lap joint on M.S (10mm         - Classification of steel.                   - Freehand sketching of-     - Algebraic Symbols and
               thick) in vertical position (1.2mm wire      - Welding of low, medium and high carbon       hand tools of the trade.     Fundamentals Addition,
               and Dip transfer).                             steel and alloy steels.                                                   Subtraction, Multiplication
    MAG-18   - Fillet weld – Tee joint on M.S (10mm         - Weldability of metals, importance of pre                                  and Division-Problems
               thick ) in vertical position (1.2mm wire       heating, post heating and maintenance
               and Dip transfer).                             of interpass temperature.
    MAG-19   - Fillet weld – corner joint on M.S (10mm
               thick ) in vertical position (1.2mm wire
               and Dip transfer).

7   MAG-20   - Fillet weld – Lap joint on M.S. (3mm         - Effects of alloying elements on steel      - Freehand sketching of      - Algebraic Symbols and
               thick) in vertical position (0.8 mm wire     - Pipe welding – specification of pipes,       hand tools of the trade.     Fundamentals Addition,
               and Dip transfer).                             various types of pipe joints and welding                                  subtraction,
    MAG-21   - Fillet weld – Tee joint on M.S. (3mm           procedure such as up-hill and downhill                                    multiplication and Division-
               thick) in vertical position (0.8 mm wire       method                                                                    Problems
               and Dip transfer).

                                                                       [17]
     MAG-22   - Fillet weld – corner joint on M.S. (3mm
                thick) in vertical position (0.8 mm wire
                and Dip transfer).

8    MAG-23   - Fillet weld – Lap and Tee joint on M.S         - Submerged arc welding process –            - Freehand sketching of      - Algebra-Simple Equations
                (10mm thick) in over head position by            principles, equipments advantages and        keys and cotters with        - Problems.
     MAG-24     Argoshield gas(1.2mm wire and Dip                limitations                                  their dimensions from
                transfer).                                                                                    samples as per BIS
              - Fillet weld – Lap and Tee joint on M.S
                (3mm thick) in over head position
                (0.8mm wire and Dip transfer).
9    MAG-25   - Single Vee butt joint on M.S pipe (100         - Electro slag and Electro gas welding       - Freehand sketching of      - Levers : Types of
                mm OD x 6mm WT) 1.2 mm wire                      processes–principles, equipments,            screw threads with their     Levers with their
                Position .Arc constant (Rolling)                 advantages and limitations                   dimensions from              examples.
     MAG-26   - Elbow Joint on MS Pipe( 60 mm OD x 3                                                          samples as per BIS
                mm WT) position – Arc constant (Rolling)
     MAG-27   - Tee Joints on MS Pipe ( 60 mm OD x 3
                mm WT) position – Arc constant (Rolling)
              -
10   MIG-1    - Fillet weld – Lap, Tee and corner joint on     - Thermit welding process- equipments,       - Geometrical                - Simple problems on
                Stainless steel (2 mm thick sheet) in flat       thermit mixture types and applications       Development of Prism.        straight and ball
                position (0.8 mm wire and Dip transfer).                                                      Pyramid and Isometrics.      cranked levers
                                                                                                                                         - Density &specific gravity :
     MIG-2    - Fillet weld – Tee a joint on Aluminium (6                                                                                - Mass, weight, Archimedes
                mm thick) in flat position (1.2 mm wire                                                                                    principle & related
                and Dip transfer).                                                                                                         problems.
11   TIG-1    - Depositing bead on Aluminium (2 mm             - TIG welding process -Difference between - Exercise on Blue Print        - Mensuration :
                thick) in flat position.                         AC and DC TIG welding, brief description,  reading related              - Areas - Square, Rectangle,
     TIG-2    - Butt weld - Square butt joint on                 equipments ,types of polarities and        identification of welding      Equilateral Triangle,
                Aluminium (1.6mm thick ) in flat position.       applications.                              symbols.                       Isosceles Triangle, Right
     TIG-3    - Fillet weld – Tee joint on Aluminium (1.6      - Power sources for TIG welding AC & DC                                     Angled
                mm thick) in flat position.                      - high frequency unit, D.C.suppressor unit                                Triangle, Scalene
     TIG-4    - Fillet weld – Outside corner joint on            and uses.                                                                 Triangle-Problems
                Aluminium (2 mm thick ) in flat position
              -
12   TIG-5    - Butt weld - Square butt joint on Stainless     - Tungsten electrodes –types & uses, sizes   - Triangular Prism and       - Areas-
                steel sheet (1.6 mm thick) in flat position.     and preparation                              Hexagonal Prism -            Square, Rectangle,
     TIG-6    - Fillet weld – Tee joint on Stainless steel     - TIG welding Torches- types, parts and        Projection and               Equilateral Triangle,

                                                                         [18]
                 sheet (1.6 mm thick) in flat position         their functions                            Development                  Isosceles Triangle,
     TIG-7     - Fillet weld – Outside corner joint on       - TIG welding filler rods and selection                                   Right Angled
                 Stainless steel sheet (1.6 mm thick) in       criteria                                                                Triangle, Scalene
                 flat position.                              - Edge preparation and fit up.                                            Triangle-Problems.
                                                             - TIG welding parameters for welding
                                                               different thickness of metals
                                                             -
13   TIG-8     - Pipe butt joint on Aluminium pipe dia. 50   - Pulsed TIG welding- brief description,   - Cylinder Projection        - Areas
                 mmx 3 mm wall thickness in Flat               pulse parameters slope up and slope        and Development,           - Hexagon, Circle, Circular
                 position.                                     down                                       Cone Projection              ring, Sector Ellipse-
     TIG-9     - Root pass welding on M.S pipe (100mm        - Argon / Helium gas properties – uses.      and Development.             Problems.
                 ODX 6 mm WT) in Flat position                 Defects, causes and remedy               - Examples based on
                                                                                                          right cones.
14   MMAW-1 - Square butt joint on M.S pipe (50 mm OD - Friction welding process- equipment and         - Cylinder Projection        - Volume and Weight of
              x 3 mm WT) Position – Flat                application                                       and Development,             Simple Solid bodies such
     MMAW-2 - Elbow Joint on MS Pipe( 50 mm OD x 3 - Friction stir welding process- description           Cone Projection              as Cube, Square Prism,
              mm WT) position – Flat                    and advantage                                     and Development.             Rectangular Prism,
     MMAW-3
            - Tee Joints on MS Pipe ( 50 mm OD x 3                                                      - Examples based on            Hexagonal Prism,
              mm WT) position – Flat                                                                      right cones.
15   OAW-1 - Square butt joint on M.S pipe (50 mm     - Laser beam welding (LBW)and Electron            - Views of simple'           - Triangular Prism, Cone,
              OD x 3 mm WT) ,Position – 1G              beam welding(EBW)                                 solid bodies cut by          Cylinder, Hollow
            - Elbow Joint on MS Pipe( 50 mm OD x 3                                                        section plane on             Cylinder-
              mm WT), position – Flat                                                                     drawing standard           - Shop Problems.
     OAW-2 - Tee Joints on MS Pipe ( 50 mm OD x 3                                                         methods. (Full and
              mm WT), position – Flat                                                                     Half Sections) BIS.

16   OAW-3     - Pipe flange joint on M.S sheet to M.S       - Plasma Arc Welding (PAW) process –       - Views of simple solid      - Volume and Weight of
                 pipe ( 50 mm OD x 3 mm WT) –                  principles of operation, equipment,        bodies cut by section        Simple Solid bodies such
                 position – Flat                               difference between TIG welding and         plane on drawing             as Cube, Square Prism,
                                                               Plasma Arc welding, types of arc,          standard methods             Rectangular Prism,
     OAW-4     - Pipe branch joint 45⁰ on M.S pipe ( 50        advantages and applications.               (Full and Half Sections)     Hexagonal Prism,
                 mm OD x 3 mm WT) - position – Flat                                                       BIS                          Triangular Prism, - Shop
                                                                                                                                       Problems.
17   MMAW-4    - Pipe flange joint on M.S sheet to M.S       - Surfacing /metal buildup- Purpose,       - Exercise on Blue           - Volume and Weight of
                 pipe ( 50 mm OD x 3 mm WT)                    applications and different surfacing     - Print Reading.               Simple Solid bodies such
                 position – Flat                               methods                                    Sketching of finished        as, Cone, Cylinder,
                                                                                                          articles from drawing        Hollow Cylinder- Shop
               - Pipe branch joint 45⁰ on M.S pipe ( 50                                                   and preparation of           Problems.

                                                                        [19]
     MMAW-5     mm OD x 3 mm WT) - position – Flat                                                           sequence of operations.
18   OAW-5    - Single Vee butt joint on Cast Iron (10mm    - Hard facing – necessity, method of           - Exercise on Blue         - Finding the capacity in
                thick) by fusion welding in flat position     preparation, various hard facing alloys and - Print Reading.              Liters of Square,
                                                              advantages of hard facing                      Sketching of finished      Rectangular, Hexagon,
     ERSW     - Lap joint on Stainless steel and MS                                                          articles from drawing      Cone and Cylinder Shaped
     (Spot)     sheets by Resistance Spot welding                                                            and preparation of         Vessels
                                                                                                             sequence of operations.
19   OAW-6    - Square butt joint on Copper                 - Metalizing – types of metalizing principles, - Free sketching of simple - Finding the lateral Surface
                (2mm thick) in flat position                  equipments, advantages and applications        objects related to the     Area and Total Surface
     OAW-7    - Tee joint on Copper to MS                                                                    trade and preparation of   Area of Square,
                (2mm thick) in flat position by Brazing     - Manual Oxy – acetylene powder process          simple working drawing     Rectangular, Hexagon,
     OAW-8    - Silver brazing on S.S Sheet with copper       (hot and cold) principles of operation and     from the Sketches.         Cone and Cylinder Shaped
                sheet (Tee joint)                             applications



20   MMAW-6   - Hard surfacing practice on M.S round        - Types of welding defects.                   - Free sketching of simple - Meaning of Stress, Strain-
                rod φ 25 mm by using Hard facing            - Identification, causes and remedy             objects related to the     Simple Problems.
                electrode                                                                                   trade and preparation of
              - Testing of weld joints by visual                                                            simple working drawing
     I &T-1     inspection ,Dye penetrant test, Nick-                                                       from the Sketches.
                break test, and Magnetic particle test
21            - Producing jobs as per Drawings.             - Types of Inspection methods                 - Conventional              - Meaning of Stress, Strain-
                (Jobs involving all position Welding)       - Classification of destructive and NDT         representation of           Simple Problems.
                                                              methods                                       Materials by I.S.I.

22            - Producing jobs as per Drawings.             - Welding codes and standards            - Conventional                   - Types of Current, Effects of
                                                            - Reading of assembly drawing              representation of                current and related
                                                                                                       Materials by I.S.I.              problems.
23                                                Industrial training OR Project work preferably in cross sectoral trades

24                                                                                Revision & Test




                                                                       [20]
    LIST OF TOOLS & EQUIPMENT FOR THE TRADE OF WELDER (TIG/MIG)
                         (For a Unit of 20 trainees)


TRAINEES KIT                                     8    Centre punch 9 mm x 127 mm     20+
S. Name of the Tools               Qty                                               1
No                                               9    Dividers 20 mm                 20+
1  Hand Gloves                      20+                                              1
                                    1            10   Caliper outside 15 mm          20+
2   Apron leather                   20+                                              1
                                    1            11   Stainless steel rule 300mm     20+
3   Welding helmet                  20+                                              1
                                    1            12   Wire brush 5 rows and 3 rows   20+
4   Welding hand shield             20+                                              1
                                    1            13   Leather sleeves 16”            20+
5   Gas welding Goggles with        20+                                              1pai
    Colour glass                    1                                                rs
6   Chipping hammer                 20+          14   Safety boots for welders       20+
                                    1                                                1pai
7   Chisel cold flat 19 mm x 150 mm 20+                                              rs
                                    1            15   Safety goggles                 20+

                                          [21]
                                       1             30   File flat 350 mm rough           6
16   Scriber 15 mm                     20+           31   Earth clamp                      6
                                       1             32   Spanner D.E. 6 mm to 32mm        2
17   Tongs holding 350mm               20+                                                 sets
                                       1             33   Clamps 10 cm and 15 cm           4
SHOP OUTFIT                                                                                each
18 Stainless steel rule 600mm          2             34   Hammer sledge double faced 4     1
19 Hammer ball pen 1.5 kg with         4                  kg
   handle                                            35   Pipe wrench 25 cm and 35 cm      1
20 Spark lighter                       4                                                   each
21 Spindle key                         2             36 Steel tape 5 meters flexible in    1
22 Screw Driver 30 0mm blade and       1                case
   250 mm blade                        each          37 Electrode holder 400 amps          6
23 Tip cleaner set                     2             38 H.P. Welding torch No. 2 with      2
24 Number bunch 6 mm and 1 set         1                nozzle nos. 1,2,3, 5 & 7           sets
   letter punch 6 mm                   set           39 Rubber hose clips ¾”               10
                                       each          40 Welding rubber hose, oxygen        2
25   Hacksaw frame fixed 300 mm        8                8mm. dia x 5mts.long
26   Arc welding coloured glasses      17            41 Welding rubber hose Acetylene      2
     108 mm x 82 mm x 3 mm. DIN        nos              8mm. dia x 5mts.long
     11 A &12 A                                      42 Gas Pressure regulator oxygen      2
27   Magnifying glass 100 mm . dia     2                double stage
28   Weld measuring gauge fillet and   1             43 Gas Pressure regulator acetylene   2
     butt                              each             double stage
29   File half round bastard 350 mm.   6             GENERAL INSTALLATION
                                              [22]
44   D.C Arc welding rectifiers set     4                  cm
     with all accessories     (400 A.   sets          57   Instructor’s table and Chair        1
     OCV 60 – 100 V, 60% duty                              (Steel)                             set
     cycle )                                          58    Blackboard or white board          I
45   Suitable gas welding table with    2             59   First Aid box                       1
     fire bricks                        sets          60   Fire buckets with stand             4
46   Suitable Arc welding table with    4             61   Steel lockers with 8 Pigeon holes   2
     positioner                                       62   Oven, electrode drying 0 to 250     1
47   Trolley for cylinder (H.P. Unit)   2                  ⁰c, 10 kg capacity
48   Bench shear capacity up to 5 mm    1             63   Oxy Acetylene Gas cutting blow      2
49   Pedestal grinder fitted with       2                  pipe                                sets
     coarse and medium grain size                     64   Oxygen, Acetylene Cylinders         1
     grinding wheels dia. 300 mm                                                               each
50   Work bench 340x120x75 cm with      2             65  Air plasma cutting equipment         1
     4 bench vices of 125 mm jaw        sets          *   with standard accessories and        set
     opening                                              compressor
51   Power hacksaw machine              1             66* CO₂ Arc welding machine 400A         2
52   AG 7 Grinder                       1                 capacity with air cooled torch,      set
53   AG 4 Grinder .                     2                 regulator, gas preheater, Gas hose
                                        nos               and standard accessories
54   Portable drilling machine (Cap. 6  1             67* AC/DC TIG welding machine            2
     mm)                                                  with water cooled torch 300 A,       set
55   Fire extinguishers (foam type and 1                  Argon regulator, gas hose, water
     CO2 type)                                            circulating pump and standard
56   Metal rack 182 cm x 152 cm x 45 1                    accessories
                                               [23]
68* Bench grinder fitted with fine       1             70* Spot welding machine               1
    grain size silicon carbide green
    grinding wheeldia. 150 mm
69* CO₂ , Argon and Argoshield           1
    Cylinders                            each


NOTE:
       1. * Additional items S. Nos 65 to 70 are only required to be provided for this semester if
first semester T/E list fulfilled.
       2. No additional items are required to be provided for unit or batch working in the Second
shift except the items under trainee's tool kit and lockers.
       3. Provision of cleaning of periodically the helmets and goggles with antiseptic solution
should be made available as these are likely to be used by more
          than one trainee.
       4. Minimum width and length of plates/sheets for practical and tests should be 50 x 150 mm




                                                [24]
                                  GENERAL INFORMATION


1. Name of the Trade              : WELDER (PIPE)
2. N.C.O. Code No.                :

3. Duration of Craftsmen Training : 06 months

4. Entry Qualification           : Pass in 8th Class and completion of I semester welder
                                   (General)
5. Unit strength                 : 20

6. Space norms                        : a) Workshop:96 Sqr meter.
                                        b) Class room: 30 sq.meter.

7. Power norms                        : 15.4 KW

8. Trainers qualification        : (i) National Trade Certificate in welder trade with five years
                                       Experience with relevant field.
                                 (ii) Diploma in Mechanical with two years experience in relevant
                                       field.
                                 (iii) Degree Mechanical engineering with one year experience in
                                        relevant field

9. Desirable qualification     : Preference will be given to a candidate with CITS.
                                      (If not done CITS than must be trained within 02yrs on joining)

                                                [25]
                       Syllabus for the Trade of “WELDER (PIPE)” under C.T.S.
                                         Duration : 6 MONTHS

                                                         Second Semester
Week   EX. No                  Practical                                    Theory                       Engg. Drawing               Vocational Science and
No.                                                                                                                                  Calculation
1               Induction training:                      - General safety in Arc welding and             - Print Reading related     - Electricity, Current, Power,
                - Importance of trade Training             gas cutting                                     to missing lines and        resistance, Conductors,
                - Machinery used in the trade.           - Importance of pressure vessel and pipe        - Missing views.              insulators, Ohm′s law,
                - Introduction to safety equipment and     welding                                         Exercise on Blue print      Faraday′s laws of
                   their use etc.                        - Safety in pressure welding                                                  Electromagnetic induction,

2      MMAW1
           -    - Single Vee Butt joint on M.S 10 mm     - Essentials of MMAW technology                 - Simple Isometric          - Types of Current, Effects of
            -     thickness by MMAW. (Position–          - Elements of flux coating and their function     drawing- from the given     current and related
            -     Flat)                                  - Shielding gases produced during welding         orthographic views of       problems.
       MMAW 2                                              and its importance for welding                  simple objects
                - Single Vee Butt joint on M.S 10 mm
                  thickness by MMAW. (Position –         - Forces acting for metal transfer              - Welding Symbols as per
                  Horizontal)                            - Slag and its characteristics and functions      BIS.
                                                         - Technique of striking and maintaining
                                                           arc, manipulation of weld puddle and
                                                           prevention of weld defects
                                                         - Arc length and its effect on variation
3      MMAW-3  - Single Vee Butt joint on M.S10 mm       - MMAW power sources and polarity used          - Freehand Sketching        - Units of work in M.K.S,
                 thickness MMAW - Position -               for welding pipes and pressure vessels.         on rivets and washers       System and S .l. Unit of
                 Vertical                                - Welding positions and weld symbols as           with dimensions from        Work-
       MMAW-4 - Single Vee Butt joint on M.S 10 mm         per BIS and AWS                                 samples as per BIS        - Simple Problems.
                 thickness by MMAW (Position - O/H)      - MMAW electrodes classification and            - Freehand Sketching
                                                           coding as per IS and AWS, coating factor        of Riveted joints.
                                                           and selection criteria


                                                                     [26]
4   MMAW-5   - Roll Welding single Vee but joint on    - Preparation of pipe joints for thin wall        - Freehand Sketching of      - Practical Units of Power
               8” schedule 60 pipe by MMAW.              pipe and thick wall pipes, cleaning of joints     Riveted joints.              such as Watt and Horse
               (Position - Flat)                         and fit-up                                      - Exercise on Blue Print.      Power,
                                                       - Tack welding procedure, maintaining               reading related to         - Definition of I.H.P., B.H.P.
                                                         length of tack, pitch of tack and feathering      missing dimensions and       and Efficiency.
                                                         the edges of tack welds                           missing section.
                                                       - Heat input and techniques of controlling
                                                         heat input during welding.
                                                       - Heat distribution and effect of faster
                                                         cooling of pipe joints
                                                       - Necessity of pre heating and maintaining
                                                         inter pass temperature during welding
5   MMAW-6   - Welding single Vee butt joint on 8”     - Weld quality inspection, common welding         - Freehand sketching of      - Definition of Energy,
               schedule 60 pipe by MMAW.                 mistakes and appearance of good and               nuts and bolts with        - Potential Energy.
               (Position - vertical - Pipe axis          defective welds                                   dimensions from               Kinetic Energy
               vertically fixed)                                                                           Samples.                   - Law of Conservation of
                                                                                                         - Freehand sketching of        Energy, S.I. Unit of Energy
                                                                                                           hand tools of the Trade.   - Simple Problems in P.E. and
                                                                                                                                        K.E.
                                                                                                                                      -
6   MMAW-7   - Welding single Vee butt joint on 8”     - Uphill welding of root bead on heavy wall       - Freehand sketching of-     - Algebraic Symbols and
               schedule 60 pipe by MMAW. (Position       pipes by MMAW                                     hand tools of the trade.     Fundamentals Addition,
               - horizontal - Pipe axis horizontally   - Starting ending position of weld (clock                                        Subtraction, Multiplication
               fixed)                                    positions)                                                                     and Division-Problems
                                                       - Maintaining key hole-
                                                       - Cleaning and feathering & making a tie-in.
                                                       - Welding the root bead by Low hydrogen
                                                         electrode by V – wave.
                                                       - Welding Hot pass, intermediate and cover
                                                         passes on heavy wall pipes by MMAW
                                                       -
7   MMAW-8   - Welding single Vee butt joint on 8”     - Techniques of root bead welding of heavy        - Freehand sketching of      - Algebraic Symbols and
               schedule 60 pipe by MMAW.(Position        wall pipes in inclined position                   hand tools of the trade.     Fundamentals Addition,
               - Inclined - Pipe axis 45⁰ fixed)       - Techniques of making intermediate and                                          subtraction,
                                                         cover pass welding of heavy wall pipes in                                      multiplication and Division-
                                                         inclined position                                                              Problems

8   MMAW-9   - Welding single Vee butt joint on thin   - Techniques of root bead welding of thin         - Freehand sketching of      - Algebra-Simple Equations -
               wall pipe by MMAW. (Position -            wall pipes in inclined position (vertical         keys and cotters with        Problems.
                                                                   [27]
                horizontal - vertical downward)              downward)                                           their dimensions from
                                                                                                                 samples as per BIS
9    MMAw10   - Welding single Vee but joint on            - Techniques of making intermediate and             - Freehand sketching of       - Levers : Types of
                thin wall pipe by MMAW. (Position –          cover pass welding of thin wall pipes in 6G         screw threads with their      Levers with their
                inclined - vertical downward)                position(vertical downward)                         dimensions from               examples.
                                                                                                                 samples as per BIS
10   TIG-1    - Depositing beads on M.S (2 mm) by          - Advantages of root bead welding of pipes          - Geometrical                 - Simple problems on
                TIG welding (Position - Flat)                 and pressure vessels                               Development of Prism.         straight and ball
     TIG-2    - Root bead welding single Vee Butt           - TIG welding principles and equipment               Pyramid and Isometrics.       cranked levers
                joint on M.S (10mm) by TIG welding -                                                                                         - Density &specific gravity :
                Position - Flat                                                                                                              - Mass, weight, Archimedes
                                                                                                                                               principle & related problems.
11   TIG-3    - Depositing beads on M.S (2 mm) by          - TIG welding Torches-types –parts and              - Exercise on Blue Print      - Mensuration :
                TIG welding ( Position - Horizontal)         functions                                           reading related             - Areas - Square, Rectangle,
     TIG-4    - Root bead welding single Vee Butt          - Gas nozzle types and nozzle preparation             identification of welding     Equilateral Triangle,
                joint on M.S (10 mm) by TIG welding        - TIG welding electrodes –types, applications         symbols.                      Isosceles Triangle, Right
                (Position – Vertical)                        and preparation                                                                   Angled
                                                                                                                                               Triangle, Scalene
                                                                                                                                               Triangle-Problems
12   TIG-5    - Depositing beads on M.S (2 mm) by          - Current range for TIG welding with different      - Triangular Prism and        - Areas-
                TIG welding ( Position - Vertical)            diameter electrodes.                               Hexagonal Prism -             Square, Rectangle,
     TIG-6    - Root bead welding single Vee Butt           - Filler wire specifications for welding various     Projection and                Equilateral Triangle,
                joint on M.S (10 mm) by TIG welding           materials                                          Development                   Isosceles Triangle,
                (Position - Vertical)                                                                                                          Right Angled
                                                                                                                                               Triangle, Scalene
                                                                                                                                               Triangle-Problems.


13   TIG-7    - Depositing beads on M.S (2 mm) by          - Edge preparation and fit up, selection of         - Cylinder Projection         - Areas
                TIG welding (Position - Overhead)            gas nozzle size , tungsten electrode, filler        and Development,            - Hexagon, Circle, Circular
     TIG-8    - Root bead welding single Vee Butt            wire and welding current                            Cone Projection               ring, Sector Ellipse-
                joint on M.S (10 mm) by TIG welding        - TIG welding defects causes and remedy               and Development.              Problems.
                (Position - Overhead)                      - Pressure vessel welder qualification test -       - Examples based on
                                                             codes and standards and welder                      right cones.
                                                             qualification record
14   TIG-9    - Root bead welding single Vee but joint     - Welding procedure and techniques for root         - Cylinder Projection         - Volume and Weight of
                on 8” schedule 60 pipe by TIG                bead welding of heavy wall pipe by TIG              and Development,              Simple Solid bodies such as
                welding - Position - Flat (roll welding)     welding and tie- in                                 Cone Projection               Cube, Square Prism,
                                                           - Application of pulse TIG welding for root           and Development.              Rectangular Prism,
                                                                         [28]
                                                           bead welding of heavy wall pipe by TIG          - Examples based on            Hexagonal Prism,
                                                           welding                                           right cones.
15   TIG-10   - Root bead welding single Vee but joint   - Material used for pies and pressure vessels     - Views of simple'           - Triangular Prism, Cone,
                on 8” schedule 60 pipe by TIG              and pipe schedules                                solid bodies cut by          Cylinder, Hollow Cylinder-
                welding- Position - Vertical             - Welding procedure qualification as per            section plane on           - Shop Problems.
                                                           different codes and standards                     drawing standard
                                                                                                             methods. (Full and
                                                                                                             Half Sections) BIS.
16   TIG-11   - Root bead welding single Vee but joint   - Classification of pressure piping               - Views of simple solid      - Volume and Weight of
                8” schedule 80 pipe by TIG welding       - Welders responsibility on high pressure           bodies cut by section        Simple Solid bodies such as
                Position - horizontal                      pipes and pressure welding                        plane on drawing             Cube, Square Prism,
                                                                                                             standard methods             Rectangular Prism,
     TIG-12   - Root bead welding single Vee but joint   - Suggestions to pressure vessel welders            (Full and Half Sections)     Hexagonal Prism, Triangular
                on 8” schedule 60 pipe by TIG              Inspection of pressure piping                     BIS.                         Prism, - Shop Problems.
                welding Position - Inclined
17   TIG-13   - Root bead welding Tee joint on 8”        - Pipe development and preparation of             - Exercise on Blue           - Volume and Weight of
                schedule 60 pipe by TIG welding            templates for marking Tee and Y joints          - Print Reading.               Simple Solid bodies such as,
                in fixed Position                        - Summary of points on welding procedure of         Sketching of finished        Cone, Cylinder, Hollow
              - Root bead welding Y joint on 8”            pressure vessels and piping                       articles from drawing        Cylinder- Shop Problems.
                schedule 60 pipe by TIG welding in                                                           and preparation of
                fixed Position                                                                               sequence of operations.
18   MAG-1    - Depositing beads on M.S10 mm             - Introduction to CO2 welding                     - Exercise on Blue           - Finding the capacity in Liters
                thickness by CO₂ Arc welding -           - Equipment & accessories.                        - Print Reading.               of Square, Rectangular,
                Position - Flat                          - Description of CO2 welding set with               Sketching of finished        Hexagon, Cone and Cylinder
     MAG-2    - Single Vee Butt joint on M.S 10 mm         diagram.                                          articles from drawing        Shaped Vessels
                thickness by CO₂ Arc welding -                                                               and preparation of
                Position - Flat                                                                              sequence of operations.



19   MAG-3    - Depositing beads on M.S 10 mm            - Advantages of CO2 welding over MMAW,            - Free sketching of simple - Finding the lateral Surface
                thickness by CO₂ Arc welding                limitations and applications                     objects related to the     Area and Total Surface Area
                (Position - Horizontal)                   - Process variables and modes of metal             trade and preparation of   of Square, Rectangular,
     MAG-4    - Single Vee Butt joint on M.S 10 mm          transfer – dip or short circuiting transfer,     simple working drawing     Hexagon, Cone and Cylinder
                thickness by CO₂ Arc welding.               spray transfer (free transfer) and globular      from the Sketches.         Shaped
                (Position - Vertical)                       transfer (intermittent transfer) etc.


20   MAG-5    - Depositing beads on M.S10 mm             - Welding wires used in CO2 welding,              - Free sketching of simple - Meaning of Stress, Strain-
                                                                      [29]
               thickness by CO ₂ Arc welding -           diameter , designation as per AWS and         objects related to the       Simple Problems.
     MAG-6     Position - vertical                       applications.                                 trade and preparation of
             - Single Vee Butt joint on M.S 10 mm      - Various gases and gas mixtures used in        simple working drawing
               thickness by CO ₂ Arc welding -           MIG/MAG welding and its applications.         from the Sketches.
               Position - Vertical

21   MAG-7   - Depositing beads on M.S10 mm              - Wire feed system – types – applications     - Conventional             - Meaning of Stress, Strain-
               thickness by Argoshield Arc welding - - limitations care and maintenance.                 representation of          Simple Problems.
               Position - over head                      - Flux cored arc welding – description,         Materials by I.S.I.
     MAG-8   - Single Vee Butt joint on M.S 10 mm          advantage, welding wires, diameters and
               thickness by Argoshield Arc welding         specification as per AWS
               - Position - over head
22   MAG-9   - Making intermediate and cover pass        - Edge preparation and fit up for CO2 welding - Conventional             - Types of Current, Effects of
               on root pass welded pipes by CO ₂ Arc       various thickness of metals                   representation of          current and related
               welding – Position -Horizontal            - CO2 Welding defects, causes and               Materials by I.S.I.        problems.
             - Making intermediate and cover pass          remedies
               on root pass welded pipes by CO ₂         - Destructive and nondestructive
               Arc welding – Position Inclined             testing of weld ments
             - Preparation of test specimens and
               making Nick break test and fillet weld
               fracture test
             - Die penetrant & MP test on welds
23                                                 Industrial training OR Project work preferably in cross sectoral trades
24                                                                            Revision & Test




                                                                  [30]
       LIST OF TOOLS & EQUIPMENT FOR THE TRADE OF WELDER (PIPE)
                          (For a Unit of 20 trainees)
TRAINEES KIT                                                                                 1pai
S.  Name of the Tools                  Qty                                                   rs
No                                                  14   Safety boots for welders            20+
1   Hand Gloves                        20+                                                   1pai
                                       1                                                     rs
2    Apron leather                     20+          15   Safety goggles                      20+
                                       1                                                     1
3    Welding helmet                    20+          16   Scriber 15 mm                       20+
                                       1                                                     1
4    Welding hand shield               20+          17   Tongs holding 350mm                 20+
                                       1                                                     1
5    Gas welding Goggles with Colour   20+          SHOP OUTFIT
     glass                             1            18  Stainless steel rule 600mm           2
6    Chipping hammer                   20+          19  Hammer ball pen 1.5 kg with handle   4
                                       1            20  Spark lighter                        4
7    Chisel cold flat 19 mm x 150 mm   20+          21  Spindle key                          2
                                       1            22  Screw Driver 30 0mm blade and 250    1
8    Centre punch 9 mm x 127 mm        20+              mm blade                             eac
                                       1                                                     h
9    Dividers 20 mm                    20+          23   Tip cleaner set                     2
                                       1            24   Number bunch 6 mm and 1 set         1
10   Caliper outside 15 mm             20+               letter punch 6 mm                   set
                                       1                                                     eac
11   Stainless steel rule 300mm        20+                                                   h
                                       1            25   Hacksaw frame fixed 300 mm          8
12   Wire brush 5 rows and 3 rows      20+          26   Arc welding coloured glasses 108    17
                                       1                 mm x 82 mm x 3 mm. DIN 11 A         nos
13   Leather sleeves 16”               20+               &12 A
                                             [31]
27   Magnifying glass 100 mm . dia          2             GENERAL INSTALLATION
28   Weld measuring gauge fillet and butt   1
                                            eac           44   D.C Arc welding rectifiers set with all   4
                                            h                  accessories      (400 A. OCV 60 –         sets
29   File half round bastard 350 mm.        6                  100 V, 60% duty cycle )
30   File flat 350 mm rough                 6             45   Suitable gas welding table with fire      2
31   Earth clamp                            6                  bricks                                    sets
32   Spanner D.E. 6 mm to 32mm              2             46   Suitable Arc welding table with           4
                                            sets               positioner
33   Clamps 10 cm and 15 cm                 4             47   Trolley for cylinder (H.P. Unit)          2
                                            eac           48   Bench shear capacity up to 5 mm           1
                                            h             49   Pedestal grinder fitted with coarse       2
34   Hammer sledge double faced 4 kg        1                  and medium grain size grinding
35   Pipe wrench 25 cm and 35 cm            1                  wheels dia. 300 mm
                                            eac           50   Work bench 340x120x75 cm with 4       2
                                            h                  bench vices of 125 mm jaw opening     sets
36   Steel tape 5 meters flexible in case   1             51   Power hacksaw machine                 1
37   Electrode holder 400 amps              6             52   AG 7 Grinder                          1
38   H.P. Welding torch No. 2 with          2             53   AG 4 Grinder .                        2
     nozzle nos. 1,2,3, 5 & 7               sets                                                     nos
39   Rubber hose clips ¾”                   10            54   Portable drilling machine (Cap. 6 mm) 1
40    Welding rubber hose, oxygen 8mm.      2             55   Fire extinguishers (foam type and     1
     dia x 5mts.long                                           CO2 type)
41    Welding rubber hose Acetylene 8mm. 2                56   Metal rack 182 cm x 152 cm x 45 cm 1
     dia x 5mts.long                                      57   Instructor’s table and Chair (Steel)  1
42   Gas Pressure regulator oxygen double 2                                                          set
     stage                                                58    Blackboard or white board            I
43   Gas Pressure regulator acetylene     2               59   First Aid box                         1
     double stage                                         60   Fire buckets with stand               4
                                                          61   Steel lockers with 8 Pigeon holes     2
                                                   [32]
62      Oven, electrode drying 0 to 250 ⁰c, 10   1                   water cooled torch 300 A, Argon          set
        kg capacity                                                  regulator, gas hose, water circulating
63      Oxy Acetylene Gas cutting blow pipe      2                   pump and standard accessories
                                                 sets          68*   Bench grinder fitted with fine grain     1
64      Oxygen, Acetylene Cylinders              1                   size silicon carbide green grinding
                                                 eac                 wheeldia. 150 mm
                                                 h             69*   CO₂ , Argon and Argoshield               1
65 * Air plasma cutting equipment with           1                   Cylinders                                eac
     standard accessories and compressor         set                                                          h
66* CO₂ Arc welding machine 400A                 2             70*   Pipe beveling machine Dia 2 to 8”        1
     capacity with air                           set           71*   Die penetrant testing kit                1
     cooled torch, regulator, gas preheater,                                                                  set
     Gas hose and standard accessories                         72*   Magnetic particle testing Kit            1
67* AC/DC TIG welding machine with               2                                                            set

NOTE:

       1. * Additional items S. Nos 65 to 71 are only required to be provided for this semester if
first semester T/E list fulfilled.
       2. No additional items are required to be provided for unit or batch working in the Second
shift except the items under trainee's tool kit and lockers.
       3. Provision of cleaning of periodically the helmets and goggles with antiseptic solution
should be made available as these are likely to be used by more
          than one trainee.
       4. Minimum width and length of plates/sheets for practical and tests should be 50 x 150 mm
       5. Minimum length of pipes for practical and tests should be 50 x 150 mm



                                                        [33]

								
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