PRACTICAL- 150HRS

Module III Peripheral Devices

1) Chain surveying –Offsetting Triangulation

2) Compass survey—setting out instruments Taking bearings

Traverse plotting 3) Plane tabling ----Radiation,

Intersection Traversing 4) Levelling: fly levelling

Rise and fall method

Height of instrument method 5) Theodolite: Measurement of horizontal angle

Measurement of vertical angle 6) Total station: Measurement of area

Contour map of an area Remote height

Finding heights of building

Finding horizontal distance between points (tie distance) Free station surveys (resection method)

Stake out (setting out)

Alignment surveys for roads, railways canals Software training

Data down loading

Implementing in AutoCad Data processing

Preparation of drawings Apprenticeship:

During the apprenticeship the candidate should be imparted training using Total Station in the following areas.Should undergo training in re-survey wing of revenue department and should be capable of preparing a topographic sheet.They should be imparted training in preparing a contour map of large extent of land.Candidate should be trained on setting out of pile or column positions of a building.Should betrained on aligning a road or canal or railway line or pipe line.Should betrained on computer interfacing options of Total Station.

Course Title : PLUMBING AND SANITARY Course Code : KGTE – STEP 06

Duration : 1 Year Total Hrs. : 250 Hrs Total Marks : 200

TIME SCHEDULE

Module Topic Hrs.

I Importance of Plumbing works 20

II Familiarization Of Different Types Of Pipes 20 III Joining/ assembling and laying of GI, PVC and

CPVC pipes

IV Importance of Sanitary Works 20

V Uses, Types, Position And Method of Fitting Various Sanitary Fittings

Practical 150

Total 250

COURSE CONTENTS

(Duration – 6 months -Theory – 100hrs – Practical -150hrs) Module-I

Importance of plumbing works in water distribution system – Familiarization and use of the following - Tools used in plumbing – measuring tools, cutting tools, fitting tools - Fixtures and fastenings for pipes

Module-II

Familiarization of different types of pipes based on material and their suitability -– Pipe joints – Different types of joints (Pasted, Treaded, flanged and spigot joints) – Special fittings used in pipe joints. Bending of pipes - control devices (Taps and valves).

Module-III

Joining/ assembling and laying of GI, PVC and CPVC pipes – Preparation of layout plan for storage and distribution system – Fitting of water pumps

Module-IV

Importance of sanitary works - Systems of sanitary plumbing (single stack system, one pipe system partially ventilated and two pipe system) – Different types water traps (P-Q and S-trap, Bottle trap, floor traps, Gully trap and intercepting trap – Manhole and septic tank connection.

Module-V

Uses, types, position and method of fitting various sanitary fittings – washbasin – Sink – Urinals – Water closets – flushing cistern - Traps – Bath tub – Water heater.

Practical (150 Hours) 1. Measuring practice 2. Marking practice 3. Punching practice

4. Handling of tools and equipments 5. Cutting practice on GI and PVC pipes 6. Threading practice on GI and PVC pipe 7. Fixtures and fastening work for pipes 8. Bending practice on GI pipe

9. Bending practice on PVC pipe

10. Pipe joining practice (Threading type, flagged joint, Spigot and Socket, PVC pipe joint)

11. Pump fitting.

12. Connections to OH – tank man hole – septic tank 13. Practice on different trap fitting

14. Fitting water meter and taking domestic service connection

15. Fitting of all sanitary appliances (Water taps, different types of valves, Sink, wash basin, urinal, closets, flushing cistern, shower, bath tub, water heater.

16. Repair and maintenance of sanitary and water supply system

17. Preparation of layout and service plan for water supply and sanitary systems in multi-storeyed buildings.

APPRENTICESHIP:

Programme should cover plumbing and sanitary works in multi story building fitted with all modern water supply and sanitary fittings and their service connections – maintenance of these fittings, service connection from street main, fitting of submersible pump, bore well pump, and other types of pumps fitted with non return valves.

Course Title : REPAIR AND MAINTENANCE OF TWO, THREE AND

II Fuel system Cooling system Lubrication system Exhaust system & Emission control

III Transmission Wheels and tyres 81

IV Chassis/Frame suspension system Steering system Brake system

Safety precautions, safety equipments and purposes, first-aid. Study off engines, single/multi cylinder, two/four stroke engines( petrol & diesel ), difference between petrol and diesel engines, working principle, major engine components/materials, valve function and mechanism , valve timing, running and stopping of engines

PRACTICALS: Safety precautions, Tools, automobile special tools, overhauling of petrol and diesel engines (engines of two, three and four wheelers) Dismantling & assembling of valve mechanism, clearance adjustment and setting of valve timing

Module – II

Purpose of fuel supply system, types & functions of carburettor. Types of fuel pump-AC mechanical fuel pump and electrical fuel pump. Force feed system, fuel filter. Function and working of fuel injection system, performance of engine. Description of spark ignition system.

Distributor, spark plug- types and construction, spark advance mechanism, condenser, C.B Point. Electronic Ignition System, Purpose of cooling system. Types of cooling system, water cooling system and its parts. Radiator, water pump, Thermostat valve.Antifreezers, coolants, radiator pressure cap. Types of Lubricating system and is parts, Oil classification, types of oil pumps its drive, oil filter, oil cooling in engines. Major elements in exhaust gas, Emission control system.

PRACTICALS: Engine oil and filter change , oil pump overhauling, carburettor removing , Dismantling and resetting . Fuel injection pump and feed pump dismantling and assembling, fuel injector dismantling and assembling, Overhauling of cooling system.

Module – III

Requirement of a clutch , types of clutch, main parts & its function, clutch pedal, clutch release bearing, fork, purpose of gearbox, types of gear box , parts of gearbox, types of gear , gear lever, gear shifter fork. Description & purpose of different types of propeller shaft, universal joint, slip joint or sliding joints. Differential & rear axles, front wheel drive and rear wheel drive. Differential lock. Different types of bearings.-roller type, ball bearing, taper roller bearings, Description of wheels and tyres- types, Selection of tyres, ply rating, inflation pressure and carrying capacity

PRACTICALS: Clutch dismantling and assembling (both single and multiple), Clutch plate replacement, finger adjustment and pedal adjustment, Gear box overhauling (two three and four wheelers) Propeller shaft and universal joint overhauling. . Dismantling and assembling of both three and four wheelers. Dismantling and assembling of front and rear axles.

Module – IV

Frames-description and function common troubles, Location of each components. Types of frame of two- wheeler. Types of frames in three &four wheelers. Conventional suspension caster , camber,, Toe- in , Toe- out, toe-out on turn, king pin inclination- purpose and effect of these angles Steering linkage system. Need of front wheel alignment. Functions of different types of brakes and its parts. Description and advantages of vacuum assisted hydraulic brakes, common troubles in vacuum assisted brakes and air brake,

PRACTICALS: Chain and sprocket setting of two wheelers, Dismantling and assembling of shock absorber, coil spring and leaf spring, Dismantling and assembling of brake drum. Shoe adjustment and bleeding of brakes. Dismantling and assembling of master cylinder and wheel cylinder. Removal and refitting of tyre and tube.

Module – V

Methods of generating voltage-through electro chemical process, battery constructions and working principle.Battery rating, testing and maintenance.Description of different electrical circuits.Description of charging circuits- operation of alternator.Parts and working principle.Symbols,colour codes and cable specifications used in wiring diagram, Method of circuit tracing. Types of relays , solenoids , transformers. Components of starting system.

Different starter motor drives , Starter construction and operation.

PRACTICALS: Overhauling of dynamo, alternator and starter motor. Tracing and connection of circuits of head lights and other accessories.Battery testing, charging and topping – up.

Driving Practice: Motor vehicle Act, Driving road rules, road signals, Overtaking, Parking procedure, Driving through curves and slops.

Apprenticeship: (Two Three & Four wheeler)

Student should undergo apprenticeship in any of the dealer workshops of Two, Three or Four wheeler. After completion of apprenticeship student should understand the weekly and monthly maintenance tips and usual checkups. He should be able to do oil changing of units like engine, gear

Course Title : ALUMINIUM FABRICATION AND GLASS CUTTING Course Code : KGTE – STEP 08

Duration : 1 Year Total Hrs. : 250 Total Marks : 200

TIME SCHEDULE

Module Topic Hrs.

I Safety 50

II Measurements 50

III Study of available accessories 50

IV Fabricating scale model of sliding window 50

V Ceiling work with PVC panel 50

Total 250

Theory : 100 hours Practical : 150 hours

COURSE CONTENTS MODULE I

Theory: 15 Hrs. Practical: 35 Hrs.

Safety: personal safety- safety precautions to be followed in fabrication shops-familiarization of fire safety equipments- buckets extinguishers- its practice. Introduction to aluminum fabrication and glass cutting- field of application-scope-advantages over other fabrication.

Study of measuring and marking tools used in aluminum fabrication and carpentry.

Blade - protractor-scriber- mortise gauge- marking gauges-punches- centre and dot- combination set- verniercaliper-hack saw- handsaw-tenon saw-application of these items as practical.

Study of striking tools-hammer- ball peen- cross peen- straight peen etc.- claw hammer- soft hammer- mallet- rubber-nylon/fiber. its parts name –use- material-specification- precautions to be followed during working- application of these items as practical. Study of files and chisel- parts-use-material-classification-specification. Fitting and cutting as practical.

Study of screw drivers- flat and Philips head- parts-use-material-classification-specification.

Tightening and loosening various screws on aluminum sections and wooden pieces. as practical Study of holding devices- bench vice-hand vice-carpentry vice-- parts-use-material-classification-specification. Hold the work piece and file or cut as practical.

Study of glass cutter-identification of various types of glass-how to perform the cutting action-cut various thickness glass.

Study of level checking devices-straight-spirit level-water level- usage of these devices.

Study of hand drills-manual and electrical- parts-use-working-classification –specification- precaution to be followed. Types of drill bits- make holes with various drill sizes on aluminium and wooden pieces.

Study of pope rivet and gun-size of rivet and gun- join two pieces of channel with pope rivet.

Study of power tools-angle grinder-power screw fastener - miter saw –uses classifications etc.

Grinding- cutting- fastening on various works.

MODULE II

Theory: 15 Hrs. Practical: 35 Hrs

Measurements- MKS-FPS-CGS and SI system conversion of different systems.

Elementary engineering drawing-introduction- instruments-lines-dimensioning and free hand sketching- isometric view of simple engineering objects. Draw aluminum sections used for ordinary and special work as per BIS norms. Measurement done on various section in both standards and their conversions.

Draw various joints used in aluminum fabrication work and dimension it.- Draw isometric view of doors, windows hand rail etc.

Mensuration: find area, volume, density, mass of given figures.

Estimating and costing- preparation of detailed estimate for aluminum fabrication work-preparing quotation as per drawing.

Familiarization of various surface finishing used for aluminum sections-buffing –anodizing-electro coloring, coating etc. Material used along with fabrication.

MODULE III

Theory: 15 Hrs. Practical: 35 Hrs

Study of available accessories such as rubber beading, roller, hinches, locks etc.

Cutting and filing practice-straight and angular cutting using hacksaw-filing and leveling a work piece-cutting various sections using saber saw and compound miter saw and glass cutting practice. Drilling practice-using hand drill and power drill with various drill bits in all direction as required for the work. Measuring, marking, cutting in fiber sheet, Navopan, aluminum composite panel etc.

Preparing various joints such as flat cut, angle cut 450 and 600 ,miter etc. step cut joint, lap joint, drilling and making slots and key holes.

MODULE IV

Theory: 15 Hrs. Practical: 35 Hrs

Fabricating scale model of sliding window. Prepare drawing and fabricate scale model of super sliding window. Prepare drawing and fabricate scale model of open window, hinged window, door-site outer railing and lowers.

Prepare drawing- fabrication of open window- rack of different size and patterns.

Prepare drawing-make a wooden frame for racks. Fabricate kitchen cabinet-using hinged door with lock.

MODULE V

Theory: 15 Hrs. Practical: 35 Hrs

Ceiling work with PVC panel - ceiling work with thermo coal sheet 10mm-show case with wooden frame and glass sliding door. Small type display schedule with aluminum frame and hinged door with lock.

Prepare a drawing – make estimation and costing- fabricate a shelve with two level-one door is pivoted and the other sliding.

Make hinged door- hand rails of stair case and sit out.

Apprenticeship:

All the students may be given on the job training for six months in reputed organizations. The apprenticeship training will be focused mainly on area where they need more expertise. The selected firm should have the machineries tools and tackles which is essential for an aluminium fabricator.

The students may be given hands on training in fabricating windows, doors, hand rails and all types of rack works using aluminium sheets and frames.

Course Title : ADVANCED WELDING Course Code : KGTE – STEP 09

Duration : 1 Year Total Hrs. : 250 Total Marks : 200

TIME SCHEDULE

Module Topic Hrs.

I General safety precautions 50

II Arc welding 50

III TIG welding 50

IV MIG welding 50

V Advanced welding process 50

Total 250

Theory : 100 hours Practical : 150 hours COURSE CONTENTS

MODULE I

Theory: 15 Hrs.

General safety precautions to be maintained in works shops. Safety recommendations in welding and cutting. Introduction to Welding-classifications of welding-advantages of welding over other joining process- Welding symbols- Welding tools and equipments-hand tools and safety equipments.

Practical: 35 Hrs.

Identification of tools- cutting and filing practice-edge preparation - single V- Double V, J, U and Bevel etc. Basic welding joints- butt, lap, corner, T and angle joint.

Welding positions: 1F, 2F, 3F, 4F, 1G, 2G, 3G, 4G, 5G, 6G, 6GR MODULE II

Theory: 15 Hrs.

Arc welding - introduction – principle - application and methods. Arc welding equipments-transformer and generator. Welding polarity- types- arc length- welding electrodes- types- description. Functions of flux- coated electrodes-electrode specification. Gas welding introduction –types of flames - welding torch - regulators-types-identification of the plant.

Practical: 35 Hrs.

Straight line practice on MS plate- weaved bead on MS plate- square butt joint on MS plate with down hand position.-Fillet weld on MS plate- down hand welding-T joint and lap joint-Single V butt joint. Butt joint in all positions-1F to 4F on MS plate.

Pipe joint- joint preparation- 1G to 6G on MS pipe and CS pipes.

Gas welding- straight line bead on MS sheet-weaved bead on MS sheet.

MODULE III

Theory: 15 Hrs.

TIG welding: Introduction- TIG welding equipments-Accessories- high frequency (HF) unit- DC suppressor- Tungsten electrode- types- sizes- uses. Types of shielding gases used in TIG welding- advantages and applications if TIG welding. Purging methods.

Practical: 35 Hrs.

Setting up of TIG welding plant – straight line beading on MS sheet- pipe welding in various positions from 1G to 6G- square butt joint- welding in aluminum sheet- welding in SS.

MODULE IV

Theory: 15 Hrs.

MIG welding- Introduction- MIG welding power source and accessories- wire feed unit- standard tables and data- welding parameters – current-voltage-feed and speed etc.-gases used in MIG welding

Practical: 35 Hrs.

Setting up of MIG welding plant- straight line bead on MS plate by CO2 welding- welding of T joint on MS plate- single V joint by CO2 welding- square butt joint on plate. Pipe welding by MIG welding in various positions.

MODULE V

Theory: 15 Hrs.

Advanced welding process, Inspection and testing methods.

Submerged arc welding - plasma welding- micro-plasma welding- electro slag welding- laser beam welding - electron beam welding-friction welding.

Nondestructive testing methods-RT, UT, MPT etc. Destructive testing-tensile-compression- bend testing etc. welding procedure specification (WPS) – procedure qualification record (PQR). Familiarization of piping isometric drawing.

Practical: 35 Hrs.

Conduct study about various types of advanced welding process-practice various NDT

techniques-familiarize tensile, compression and bend tests etc in UTM-Preparation of WPS and PQR.

Course Title : CARPENTRY AND POWER TOOLS

Theory: 15 Hrs. Practical : 35 Hrs.

Introduction of carpentry and its scope

Safety precautions- Personal, hand tools, electric tools, machineries, shop floor.

Hand Tools Familiarization of hand tools Marking Tools-Pencil, marking

knife, cribber, wing compasses, trammel points etc. Measuring Tools; Measuring tape,, steel rule, folding rule, zig- zag rule/carpenters rule, calipers etc.

Testing Tools: Try-square, sliding/bevel square, miter square, combination set, winding sticks, sprit level etc. Holding and supporting tools: Bench and its appliances, carpenters bench vice, bench stop, bench hold fast, bench hook, G-cramp, sash cramp etc. Cutting tools ; planes, bench planes, curve planes, special purpose planes, Cutting blade setting and operations.

cutting tools: saws, straight cutting saw, curve cutting saws, reconditioning- cure and maintenance. Cutting tools; chisels-types-sharpening and reconditioning.

Percussion tools; braces- bits, sharpening, care and maintenance. impelling tools;

Mallet- hammers- ball peen hammer, straight peen hammer, cross peen hammer, claw hammer, soft faced hammer etc

MODULE II

Theory: 15 Hrs. Practical: 35 Hrs.

Carpenter joints: classification- lengthening – widening – angle joints, framing joints etc.

Lengthening joints-fished joints – sear fed joints etc.

Widening/broadening joints- simple butt joints, tong and groove, screwed joint. Dowelled joint etc.

Angle joint: corner angle joint and angle joints other than corner angle joints.

Corner angle joints; butt joint- dado joint, miter joint- mortise tenon joints dove tailed joints etc.

Angle joint other than corner angle joints: horsed joints, carcase pinned joint etc.

Framing joints: halving joints mortise and tenon joints etc.

Hardwires: Glues, nails, screws, hinges

Glues: verities – natural glues – other protein glues, synthetic resin glues, epoxy resin glues- preparation and use.

Nails; verities- use, screws- verities- use, hinges- types, use.

MODULE III

Theory: 15 Hrs. Practical: 35 Hrs.

Commercial wood- veneer- manufacturing process, Plywood- manufacturing process Sift and hand boards- particle board-block board.

Wood working lathe- parts- operations- practice plain turning, chamfering, moulding, taper turning, face plate work polishing tools etc.

Drilling machine – types- parts- operation- sander machine- types – parts- setting operation.

MODULE IV

Theory: 15 Hrs. Practical: 35 Hrs.

Planer machine- parts and function- practice- surfacer- table adjustments- fence adjustments.

Thicknesses- table adjustments for height and width.

Portable planer- use – checking for trueness and squreness.

Router machine- portable router machine. Moulding machines- spindle moulder- automatic moulding machine- setting care and maintenance- safety precautions.

MODULE V

Theory: 15 Hrs. Practical: 35 Hrs.

Sawing practice- sawing machine – types –parts- functions. Circular sawing - parts- saw blade setting-operations. Band sawing machine- parts- functions – blade setting- safety precautions. Portable cutter- use safety precautions

Polishing- stages of applying polishing.

Apprenticeship:

Training may be given for all students for six months. The industry selected may have wood working equipments-accessories etc. The students may given on job training in the application of all the power tools related to the trade.

Course Title : Repair and Maintenance of Electronic Equipments

I Introduction to basic Electronics 40

II Study of Power supply 25

III Study of TV Transmission 25

IV Study of Integrated Circuits 50

V Study the working of Equipments 30

Total 250

Theory : 100 hours Practical : 150 hours COURSE CONTENTS

Module I

Introduction to basic electronics -Identification of Electronic Components-Passive and Active, Study of different types of resistors, capacitors, inductors, colour coding and standard values.

Study of differ types of transformers.

Study of semiconductors

Study of Intrinsic / Extrinsic Semiconductors, P-type, N-type semiconductor, PN junction, Forward bias, Reverse bias, PIV. Working Principle of Diode, Transistor PNP & NPN , SCRs, TRIAC, DIAC, Zener diode, FET,MOSFET,IGBT etc. Study the symbols of the above

In document step4u-syllabus (1) (Page 30-49)