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CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE MINISTRY OF LABOUR AND EMPLOYMENT

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CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE MINISTRY OF LABOUR AND EMPLOYMENT
SYLLABUS FOR
Instrument Mechanic (Steel Plant)
Under
APPRENTICESHIP TRAINING SCHEME
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
MINISTRY OF LABOUR AND EMPLOYMENT
GOVERNMENT OF INDIA
1
Instrument Mechanic (Steel Plant)
GENERAL INFORMATION
Name of designated trade
:
Instrument Mechanic (Steel Plant)
N.C.O. Code No.
:
7311.10
Duration of Apprenticeship Training
:
Two Years
Entry Qualification
:
Passed 10th class examination under 10+2 system of
education or its equivalent
Ratio of Apprentice to Workers
:
1: 5
2
Instrument Mechanic (Steel Plant)
List of members attended the Workshop to finalize the trade syllabus for the trade of ‘Instrument
Mechanic (Steel Plant)’ under Apprenticeship Training Scheme
on 12th and 13th July, 2010 at SNTI, Jamshedpur, Jharkhand
Shri S.D. Lahiri, Director, CSTARI – Chairman
Sl.No.
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Name of Member & Designation
R.K. Mohanty, Sr. DGM (E&I)
S.K. Mishra, DGM/ETL
H. Singh
Subhash Kumar
P.K. Mohanta
Sanjay Kr. Sinha
Shankar Banerjee
Satyajit Pal
Tapas Kumar Dhar
S.C. Jha
M. Mitra
S. Bhowmik
U.K. Choudhary
K.N. Choubey
Amit Kumar
Sanjeev Kumar
S.N. Dutta, DGM (Gl.Maint.)
B.N. Prasad, DGM(HRD)
B. Bushan
A. Nandi, Dy. Director
N. Pandit
A.K. Neogy, Trg. Officer
M.K. Verma
A.K. Bhattacharjee, JTA
Anil Kumar, Jt. Director
Dr. Binod Kumar
Organization
Jindal Steel & Power Ltd.
SAIL, Bokaro
Usha Martin Ltd., Jamshedpur
Usha Martin Ltd., Jamshedpur
Tata Steel Ltd.
Adhunik Alloy & Power Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
SAIL, Bokaro
SAIL, Bokaro
SAIL Bokaro
Tata Steel
CSTARI, Kolkata
Tata Steel Ltd.
CSTARI, Kolkata
Tata Steel Ltd.
RDAT, Kokata
RDAT, Kolkata
FTI, Jamshedpur
Instrument Mechanic (Steel Plant)
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N.R. Arvindam, Dy. Director
R.K. Sharma
Sandeep Dhir
Vijay Kumar Singh
V.K. Sinha
Biswanath Roy
S.K. Singh
D.M. Chowdhury
Suresh Kumar
Surendra Kumar
B.B. Das
A. Ranjan
Sanjay Kedia
S.B. Choudhary
A.K. Karn
C.K. Goswami
R.K. Mishra
S.P. Sharma
J. Sarkar
A.K. Mallick
S.K. Gupta
S.N. Rana
Major K. Satyanarayan
FTI, Jamshedpur
TCIL, Jamshedpur
Tata Steel
Adhunik Alloy & Power Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
Tata Steel Ltd.
TCIL, Jamshedpur
Tata Steel Ltd.
Tata Steel Ltd.
SAIL, Rourkela
SAIL, Rourkela
Jindal Steel & Power Ltd.
Jindal Steel & Power Ltd.
Tata Steel Ltd.
Instrument Mechanic (Steel Plant)
SYLLABUS FOR THE TRADE
OF
‘INSTRUMENT MECHANIC (STEEL PLANT)’
UNDER
APPRENTICESHIP TRAINING SCHEME
PERIOD OF TRAINING: TWO YEARS
NOTE: The period of training for the trade is two years and this consists of A) Basic Training and B) Shop floor (Inplant) training. During the basic training, the trainee is exposed to fundamental of workshop practices in various
shops/trade in order to prepare him/her for the trade in which he/she will be trained as an apprentice.
Out line of Training Programme:
A. Basic Training in Training Institute: 78 weeks (One and half Year)
B. Shop Floor (Plant) Training: 26 weeks (Six month including revision and project work of 2 weeks)
C. Related Instruction (Throughout the training period, 1 day/week)
5
Instrument Mechanic (Steel Plant)
Trade- Instrument Mechanic (Steel Plant)
Training Structure
Sl.No.
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4
5
6
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2nd Year
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20
6
Module
No
A.1
A.2
A.3
A.4
A.5
A.6
A.7
A.8
A.9
A.10
A.11
A-12
A.13
A.14
A.15
A.16
A.17
A.18
A.19
Modules/ Subject
Duration in weeks
1st Year
Basic Trade Training
Introduction, general & behavioral safety
Industrial safety & Quality
Bench-fitting Skills
Electrical Fundamentals and circuit
Electrical machines
Basic Electronics
Instrumentation & Control
PLC & DCS
Power Electronics & Drives
Revision & Test
01
01
08
08
08
08
08
02
06
02
Electrical Power System
Fluid Power (Industrial hydraulics & pneumatics)
Welding
Advanced Instrumentation
Instrument calibration & maintenance
Electrical Instruments
Computer and IT
Iron & Steel making technology
Quality Management and Improvement Techniques
Rigging
04
02
01
06
03
02
01
02
01
02
Instrument Mechanic (Steel Plant)
21
22
23
24
25
A-20
B.1
B.2
C
Environment Control and Occupational Health
Revision & Test
Shop floor (In-plant) training
Industrial visits, project work, Revision & Test
Related instruction class (1 day/week)
Total
7
01
01
24
02
Syllabus to be
covered within 2
years of training
period
104
Instrument Mechanic (Steel Plant)
SYLLABUS FOR THE TRADE OF INSTRUMENT MECHANIC (STEEL PLANT) UNDER ATS
DURATION- 2 YEARS
Part A: Basic Trade Training
Duration- One and Half ( 1 ½ ) Year
1st Year
1. Introduction, general & behavioral safety (1 week)
Week
No.
Trade Theory
Trade Practical
Engineering Drawing
Workshop Calculation
& Science
Terminal Competencies:
After completion of this module the trainee will be aware of
Trade apprenticeship training scheme, general and behavioral safety
Overview of steel manufacturing process and machinery
1
Familiarization
with
Institute & steel industry.
the Plant visit to observe steel Introduction
to Applied
workshop
making
process
and Engineering drawing, its problems
involving
Machinery used in the trade machineries used in steel importance and uses in common fractions.
engineering fields.
and type of work done by the plant.
trainees in the trade.
Use of Personal Protective
Importance of safety, general Equipment.
safety precautions observed Rules & regulation of the
in the Institute and in the institute
section.
Science – Definition,
Nomenclature, Various
branches, significance
and
definitions
of
important terms.
Importance of the trade &
trade training,
8
Instrument Mechanic (Steel Plant)
Related
instructions
subjects to be taught.
&
Salient
features
Apprentices‟ Act.
of
Introduction to general
behavioral and road safety
,
Overview
of
steel
manufacturing process.
2. Industrial Safety & Quality (1 week)
Terminal Competencies:
After completion of this module the trainee will be aware of
Industrial Safety and first aid techniques
Quality Circle
9
Instrument Mechanic (Steel Plant)
Introduction of first aid.
2
Usage of First aid box and
Geometrical construction Rounding of decimal
use
of
Causes and type of fires, fire practice of Cardiopulmonary of Square, Rectangle, values,
Triangle,
Circle,
Ellipse,
approximation
precautions,
precautions Resuscitation (CPR)
Polygons, etc.
against outbreak of fire,
different
type
of
fire
Units
–
definition,
extinguishers and their uses. Usage of
Drawing different types of Fundamental
and
Precautions while working at
- Fire extinguishers
lines.
derived units, system of
height.
units- FPS, CGS, MKS
- Safety
appliancesGas safety
and SI. Unit of some
personal
protective
important parameters –
equipment (PPEs), gas
Electrical safety
length,
mass,
time,
detector, gas mask,
Quality- brief introduction of
density,
current,
voltage,
oxygen
pack
etc.
improvement
techniques
pressure
etc.
Unit
(specific
to
steel
followed in the organizationConversion.
industries)
Small group activities (SGA),
Quality Circle (QC) and its
tools.
3. Bench-fitting Skills (8 weeks)
Terminal Competencies:
After completion of this module the trainee should be able to
Chip flat surface to an accuracy of 1.0 mm
Cut metal pieces of different profiles by hand hack-sawing to an accuracy of 0.5mm
Produce flat, angular and contour surfaces by filing to a dimensional accuracy of 0.20mm.
Transfer dimensions from drawing to work piece.
Drill, ream and threading by hand/machine
Level and align mechanical components to ensure proper functioning
10
Instrument Mechanic (Steel Plant)
Dismantle bearing and coupling
Lubricate electrical machines
Understand gear box mechanism
3-10
Classification, constructional
and functional details of
different type of bench and
machine vices. Care of vices.
Classification,
construction
and functional detail of
hammers.
Classification,
construction
and functional detail of
following
cutting
tools:
Chisels, Hacksaw,
Files,
Drills, Reamers, Scrapers,
Taps & Dies.
11
Hacksawing - Marking lines,
cut metals pieces of different
profiles and sections by hacksawing (straight, inclined &
curved line) to an accuracy of
0.5 mm.
Difference between the
orthographic and oblique
projection. Concept of
planes of Projection and
Quadrants. Convention of
their rotation and the
concept of FIRST ANGLE
and
THIRD
ANGLE
Filing - Parallel filing practice Projection and difference
on flat surface, Marking between them. Concept
practice of straight, and of THREE VIEWS.
parallel and curved lines with
odd leg calipers, steel rule,
dividers, Scriber. Filing flat, Drawing of three views
square, steps and contour from
pictorial
and
surfaces to an accuracy of 0.2 isometric views.
mm.
Classification,
construction
and functional detail of
following bench tools: Steel
rule, Try square, Calipers,
Divider,
Centre
punch,
Surface plate, V-Block and
Trammel
Marking
Transfer
of
dimensions from drawing to
work pieces. Finding center of
a round bar with the help of „V‟
block and marking block.
Marking media, marking blue,
Prussian blue, red lead, chalk
and their special application,
description.
Chipping - Chipping practice
on flat surface, slots & oils
grooves, and chamfer at Dimensioning practice.
different angle on MS plate.
Letter writing: - Types of
Letters
viz.
normal
condensed and extended
(theoretical
aspects).
Writing of single stroke
vertical
and
inclined
letters.
Writing
of
numerals in the same
specification.
Workshop
problems
related to average,
percentage and ratio
and proportion.
Workshop
related to
work.
problems
time and
Scalar
and
vector
quantities,
definition
and units of terms
related
to
motionspeed,
displacement,
velocity,
acceleration
and retardation.
Equations of motion
with acceleration and
retardation on earth
surface or parallel to it
and vertical motion
under gravity. Related
problems.
Newton‟s
Laws
of
Motion
with
proper
Instrument Mechanic (Steel Plant)
Measuring
Instruments:
Micrometer
(outside
and
inside) – working principle,
use and care, Calculation of
least count. Vernier calipers,
principle,
graduations,
reading, use and care.
Drilling & Reaming - Use of
drilling machine for drilling
through
&
blind
holes,
Reaming of drilled hole by
hand reamer.
examples, Concept
Force,
Concept
Inertia i.e. inertia
motion and inertia
rest.
Internal & external threading
Elements
of
mechanical
by Taps & Die
components:
bearing,
Dismantling, inspection and recoupling and keys
assembly of bearings, coupling
Basic knowledge of gear and and keys
gear boxes
Practice on leveling, alignment,
Leveling and alignment of static balancing and plumbing
electrical machine
related to electrical machines
including Laser alignment.
Lubrication
related
electrical machines
12
to Practice on lubrication related
to electrical machines
Instrument Mechanic (Steel Plant)
of
of
of
of
4. Electrical Fundamentals and circuit (8 weeks)
Terminal Competencies:
After completion of this module the trainee should be able to
Understand the basic principles of electricity, various effects, types and functions of electrical components.
Know about network theorem and apply it in solving simple numerical problems.
Make simple electrical circuits and joints
Understand various chemical effect of electricity.
Charge batteries and test its conditions.
Know magnetism, electromagnetic induction, and capacitance and carry out simple experiments.
Understand AC circuits, terms used, single and poly phase circuits, series and parallel RLC circuits. Carry out
simple experiments.
Identify, connect and use common electrical measuring instruments, tools and appliances.
Finding faults and trouble shoot simple electrical circuits and appliances used in workshop.
11
Fundamentals of electricity,
electron theory, concept of
free electrons and difference
between conductor, insulator
and semi-conductor.
Demonstration and use of
electrical
measuring
instruments
with
safety
aspects
Verification of Ohm‟s law
Definition and units of
voltage, current, resistance,
Verification of law of series and
power and energy
parallel circuits
13
Dimensioned Drawing:Method of dimensioning
according
to
BIS
specifications.
Art
of
spacing
the
views.
Drawing three views of
simple machine parts
using all the instruments
with dimensioning.
Workshop problem on
time and distance.
Workshop problem on
mixture
Measurement of force,
i.e. P = ma where P is
the force, m is the mass
and
a
is
the
acceleration. Units of
force. Momentum –
definition
and
its
Instrument Mechanic (Steel Plant)
Ohm’s law, simple electrical
circuits
and
problems.
Resistanceseries
and
parallel, laws of resistance,
temperature co-efficient of
resistance, work, power and
energy.
Verification of Kirchhoff‟s law
significance.
Problems.
Measure resistance by using
voltmeter and ammeter, postoffice
box,
AVO
meter,
Standard
resistance
comparison, bridge, megger
and potentiometer.
Related
Nature of forces –
composition
and
resolution of forces.
Resultant of a number
of coplaner forces acting
at a point. Problems.
Kirchhoff‟s current & voltage
laws
and
application,
Wheatstone bridge and its
application, Simple problems
Use of common electrical
measuring instruments and
related safety aspects.
12
14
Types of wire and cables,
their specification, insulation
and voltage grade, Standard
wire
gauge,
Common
electrical accessories, their
functions and specifications
viz. switches, plugs, lamp
holders,
sockets.
Development of electrical
circuits used in workshop.
Demonstration
and
identification of different types
of cables, wires
Related Safety aspects
Demonstration and practice on
bare conductor joints.
Examination and checking of
cables and conductors
Practice on using tools like
cutting pliers, screw drivers,
skinning the cable, joint
practice on single strand.
Do
Profit and Loss and
problems concerning to
workshop practice.
The
law
of
parallelogram of forces,
Triangle of forces.
Lami‟s
Theorem,
Polygon of forces and
problems
Instrument Mechanic (Steel Plant)
Practice on making simple
electrical circuits on wooden
board
Practice on installation and
overhauling common electrical
accessories, fixing of switches,
holders, plugs etc.
13
Magnetism- classification of
magnets,
methods
of
magnetizing,
magnetic
material, Coulomb‟s law,
permeability, Ferro, Para and
diamagnetic materials
Perform experiments to draw Do
B-H curve.
Do
Prepare simple electromagnet
and find the polarity
Experimenting faraday‟s laws,
Lenz‟s law, Fleming‟s rules,
self and mutual inductance
ElectromagnetismDetermining hysteresis
Solenoid,
field
around and eddy current loss.
conductors carrying current,
polarity, screw-rule, righthand grip rule, advantages
and
application
of
electromagnet.
loss
Magnetic
series
and
parallel circuits, B-H curves,
hysteresis loop, hysteresis
loss, eddy current, eddy
current loss, equations and
problems.
15
Instrument Mechanic (Steel Plant)
Principles
of
electromagnetic induction,
Faraday‟s laws, Lenz‟s law,
Fleming‟s Rules,
Related safety aspects
14
Self-inductance,
mutual- Connect the capacitors in Do
inductance, their co-efficient, series
and
parallel
and
equations and problems
measure different values.
Do
Joule’s law of heating, Observation of charging and
Joule‟s equivalent, heating discharging of capacitors, its
appliances and elements.
testing.
Electrostatics- terms and Grouping of dry cells for a
definitions, coulomb‟s law, specific voltage and current
capacitors, charging and
discharging of capacitors,
Battery charging- Prepare
energy stored.
electrolyte for lead- acid
storage battery; charge the
Chemical
effect
of battery
using
different
electricity – principle of methods, Check for battery
electrolysis, Faraday‟s laws. condition.
Applications of electrolysis,
Basic
principles
of
Routine care and maintenance
electroplating
of batteries
Principle and construction of
simple voltaic cell, Leclanche
cell, dry cell, standard cells,
their
uses,
care,
maintenance and grouping.
16
Instrument Mechanic (Steel Plant)
Secondary cells principle,
types,
lead-acid
cells,
description of parts, chemical
action, method of charging,
rate of charging, testing
equipment, hydrometer, high
rate of discharge tester,
capacity, general defects and
their
remedies.
Rechargeable dry cells
Related safety aspects
15
Alternating
Currentcomparison between DC and
AC,
its
related
terms,
waveform, frequency and
phase, instantaneous, RMS,
average values
Resistance, inductance and
capacitance in AC circuits,
reactance and impedance,
power factor, vector diagram,
active and reactive power.
Simple problems
Use of CRO
Observation of different types
of
AC
waves
and
measurement of their different
parameters by oscilloscope
Do
Simple
algebraic
equations
and
its
application in solving
workshop problems.
Newton‟s
Law
of
Gravitation
–
its
statement
and
explanation. Centre of
Gravity – C.G. of regular
and irregular bodies.
Position of C.G by
calculation. Problems.
Related safety aspects
17
Instrument Mechanic (Steel Plant)
16
AC series and parallel AC series
circuits – RL, RC and RLC. circuits
Power factor and resonance
and
parallel
Do
Do
Determining L for a coil and
Poly phase systems, its choke and C for a capacitor
advantages
over
singlephase system.
Observation
of
3-phase
voltages and measurement of
Star and delta connections in voltage, connections in star &
3-phase system, relationship delta
of VL, VP, IL, IP, formulae and
calculations
Related safety aspects
17
Power and power factor in
3-phase circuits, active and
reactive power, methods of
improvement of power factor.
Balanced and unbalanced
loads
Measurement of power and
energy in 3-phase, 3-wire
and 3-phase-4 wire circuits
Demonstration of three-phase Do
load and measurement of
voltage, current power & power
factor in 3-phase circuit
Simultaneous Equations
and its application in
solving
workshop
related problems.
Work,
Power
and
Energy-definition
and
units, Potential and
Kinetic energy, related
problems.
Related safety aspects
18
Instrument Mechanic (Steel Plant)
5. Electrical machines (8 weeks)
Terminal Competencies :
After completion of this module trainees will be able to
Identify parts, mark terminals, connect, adjust voltage and apply load on AC and DC machines including transformers.
Test, connect with devices, start and control and reverse the direction of rotation of DC motors AC single phase and
three phase induction motors, synchronous motors.
Draw circuit diagrams and wiring diagrams of DC motor control system and AC induction motor control system.
Specify correctly (frame size, insulation class, cooling etc), inspect, test and detect faults and carry out simple repair on
AC and DC machines.
Test the transformer and determine losses and efficiency
Connect and operate single phase transformers in parallel and three-phase transformers in parallel.
Carry out preventive and routine maintenance on AC/DC machines including the protective devices.
Practice safe working on electrical equipment
19
Types
of
machines
electrical
DC
generatorworking
principle,
EMF
equation,
electromagnetic drag, types,
and
parts,
Self
and
separately
excited
generators, practical uses
Explanation
of
armature
reaction and commutation,
interpoles and their uses,
connections and polarity
19
Familiarization with
working
practice
electrical equipment
safe Drawing of few more
with exercises
on
Orthographic Projection
using all instruments and
dimensioning the views.
Identification and study of
parts of a DC Machine
Geometry:Simple
definitions of points,
lines, parallel straight
lines,
triangle
and
rectangular figures their properties and
problems
concerning
workshop practice.
Identifying terminals of DC
machine
by measuring
resistance of shunt field,
series field and armature
Friction – Types of
friction and laws of
limiting friction. Coefficient of friction, angle
of friction, angle of
Instrument Mechanic (Steel Plant)
Characteristics of series,
shunt,
compound
and
separately
excited
generators, critical resistance
and critical speed, application
of DC generators, Losses
and efficiency
repose. Advantages and
disadvantage of friction.
Related Problems.
Connecting, running and
studying the characteristics
of DC series, Shunt, and
compound
generators.
Study of No-load and load
characteristics
Lubricants
–
types,
viscosity and effect of
temperature
on
viscosity.
Finding critical resistance
and critical speed of DC
generators
20-21
DC motor- working principle,
torque, speed, back emf, their
relations. Types of DC
motorsseries,
shunt,
compound and separately
excited their characteristics
and applications. Starting and
speed control of DC motors.
Related safety aspects
22-23
20
Transformersworking
principle, transformation ratio,
no-load and on-load phasors,
classification, types of core,
EMF equation, equivalent
resistance, reactance and
impedance;
equivalent
circuits.
Testing DC motors, identifying
terminals, connecting, running
and reversing direction of
rotation of DC motors.
Do
Do
Studying characteristics and
drawing characteristic curves of
DC motors of all types.
Identification of types
transformers and its parts
of Interpretation
of
Orthographic Projection:Important points and
significance of projection
Verification of transformation lines. Techniques to draw
ratio,
loading
secondary, the missing views and
finding
relation
between various
types
of
primary
and
secondary possibilities of elevations
currents, voltages and no. of with a single plan.
Open and short-circuit tests, turns
regulation,
losses
and
efficiency of transformers.
Moment
of
forcemeaning
and
its
importance Varignon‟s
Theorem and problems
on it
Circle – its various
properties like angle and
tangent
properties.
Problems on the above
topics concerning to the
workshop practice.
Instrument Mechanic (Steel Plant)
Three-phase transformerstypes,
construction,
applications, advantages and
connections,
Protective
devices and cooling systems
of transformers
Measurement of iron and
copper losses, determination of
regulation,
efficiency
etc.,
polarity marking of singlephase
and
three-phase
transformers
Auto-transformers,
Testing of single and three
Instrument transformers - CT, phase transformers, cleaning
PT, Tong-tester and their and maintenance, oil testing.
applications
Study
of
Instrument
Related safety aspects
transformers - CT, PT and
Tong-tester
24-25
Induction motors- Rotating
magnetic field, and working of
3-phase induction motors,
production of torque.
Dismantling,
inspection
of Simple
exercises
on
parts, cleaning and testing of Interpretation
of
windings, lubricating bearings Orthographic Projections.
and assembling of 3-phase SC
Construction of SC and SR and SR motors
motors, slip, rotor emf, Polarity
marking
(phasecurrent, frequency, pf, Cu sequence test) of a 3-phase
loss,
Slip
torque induction motor and connection
characteristics.
in star and delta
Do
Double-cage
rotor, Testing induction motor by
comparison of SC and SR megger, and Motor Checker
motors.
Starting the motor using
Starters of induction motors different starters, running and
and its necessity, types-DOL, reversing the motor, measuring
star-delta, auto-transformer, the starting and no-load
soft-starters
and
rotor currents, measuring speeds at
resistance starters of wound- different
loads,
calculating
rotor induction motors
speed etc
21
Instrument Mechanic (Steel Plant)
Use of motor Checker
Dismantling, studying and reassembling
the
electromagnetic AC contactors
Protective devices in AC of different voltages, types,
motor circuits – Principle and makes and categories.
setting of over-current relaysthermal, magnetic, EOCR
and numerical relays. Single- Settings of different types of
phasing-its
effects
and motor protection relays
prevention, NVR and its
function
Doing panel wiring by using
contactors relays etc. for
Single-phase
induction automatic
star-delta,
motors - theory of rotation autotransformer,
rotorand
self-starting,
types, resistance,
and
forwardreversal and speed control.
reverse D.O.L. starters.
Related safety aspects
26
Studying, overhauling of fan
motors, connecting, running
and reversing of single-phase
motors.
Synchronous machines
Alternator- parts, types of
poles- salient pole and
smooth-cylindrical
type,
rotating-field and rotating
armature type etc
Do
Do
Identification of terminals of
alternator, connecting, starting,
running, loading and plotting
characteristic curves
Prime movers for alternators, Starting synchronous motors
turbo-alternator,
engine-
22
Instrument Mechanic (Steel Plant)
driven
alternators,
EMF by different methods
equation,
pitch-factor,
breadth-factor
Alternator
characteristics,
OCC,
SCC,
Exciter,
Excitation,
and
voltage
regulation,
cooling
of
alternators and rating
Synchronous
motors:
operation,
types,
characteristics, application.
Related safety aspects
5. Basic Electronics (8 weeks)
Terminal Competencies :
After completion of this module trainees will be able to
Understand the principle of Electronics and its application in industry and society.
Know the principle and characteristic of different active and passive components of electronics.
Know the principle, working, characteristics and applications of semi conductor devices and circuits
Make simple electronic circuits on bread-board and PCB
Understand the principle of digital electronics, IC chips, sequential and combinational digital devices and circuits.
Understand the principle of working of micro-processor, memory, micro-controller, interfacing and do simple
23
Instrument Mechanic (Steel Plant)
programming.
Read and understand electronic circuits and drawings
27
Basic Analog Electronics –
Introduction to Electronics
and its application, difference
between analog and digital
electronics.
Electronic
Component Different types of simple
identification and testing,
and intricate exercises on
of
Reading and interpretation of interpretation
orthographic
projections
colour codes of components
with proper dimensioning
Use of digital multimeters
Atomic theory, energy band
diagram, classification of
matter based on energy band Connecting function generator
diagram.
with oscilloscope, study of
wave forms, measurement of
voltage and frequency.
Active and passive circuit
Diode characteristic, Zener
elements:
diode characteristics, testing,
Resistors and their rating - and identification
fixed and variable, carbon
and wire wound, metal film
and metal oxide, colour Making half wave and full
coding,
power
rating, wave rectifiers using training
accuracy and effect of kits, study of different wave
temperature,
uses
of shapes and their values on
resistors.
oscilloscope
Fuses and their rating- Slow
blow
and
fast
blow,
Soldering and desoldering
semiconductor fuse
practice
Mensuration:- Plane
figures – Triangle,
Square, Rectangle,
Parallelogram,
Trapezium, Regular
Polygons,
Circle,
Hollow Circle, sector
and
segment
of
circle, fillets etc.
Simple machines –
what is a machine, its
advantage and utility.
Important definitions
concerning
to
machines
–
Mechanical
Advantage, Velocity
Ratio and Efficiency
of the Machine
Inductors and their rating types: ferrite core, air core,
tapped
and
variable
24
Instrument Mechanic (Steel Plant)
inductors. Factors affecting
inductance and use of
inductors
Capacitors
and
their
rating: Mica, ceramic, paper,
electrolytic, tantalum, silvered
mica, variable capacitors,
colour coding and uses.
Voltage
and
current
sources- Ideal and practical,
AC and DC signal and its
source.
Semiconductor
theory:
intrinsic and extrinsic, P and
N type, development of P-N
junction, drift and diffusion
currents, barrier potential,
biasing arrangement. Effect
of temperature
Diodes:
working,
classification, characteristics,
coding,
specification,
identification and testing. Half
wave and full wave rectifiers,
PIV.
25
Instrument Mechanic (Steel Plant)
Zener
diodes:
characteristics, types and
application. Calculation of
series resistance for varying
inputs and load currents,
Voltage regulator using zener
LED, varactor and photo
diodes- working principle and
applications.
28
Transistors:
working,
classification,
VI
characteristics (static and
dynamic), CE, CB, CC
configuration
and
their
difference, current, voltage
gains and their relationship.
Biasing
and
thermal
stabilization circuits, heat
sink.
Packaging,
coding,
specification,
identification
and applications in detail
Transistors:
identification Do
and testing finding static and
dynamic characteristics of
transistors in different modes
using training kits, calculation
of gains. Biasing circuits
Do
Field effect transistors: Identify, test and draw the VI Do
construction, operation and characteristic
of
FET,
VI characteristics of JFET, MOSFET and UJT.
Enhancement and deletion
Do
DC and AC load lines. H
parameters
29
26
Instrument Mechanic (Steel Plant)
type MOSFET, concepts of
CMOS,
Difference
with
bipolar junction transistors,
uses.
UJT- Construction, operation
VI
characteristics
and
application
30
Amplifiers: working principle,
classification and circuits.
Small signal single stage
AF/RF amplifiers: different
circuits, load line, voltage,
current and power gain,
waveforms,
frequency
response
Assembly and testing of Do
amplifier circuits on PCB:
Single
stage
CE,CB,CC
amplifiers, RC, Transformer
and direct couple amplifiers.
Study of input and output wave
forms
on
oscilloscope.
Calculation
of
gain
and
bandwidth.
Drawing
the
frequency response curve
Do
Multistage amplifiers- need
and types of coupling. RC,
transformer and direct couple
amplifier circuits, voltage and
power
gain,
frequency
response,
bandwidth,
comparison between different
types.
Power amplifier- voltage and
power amplifier, classification
Class A, B.C and AB
amplifier circuits
27
Instrument Mechanic (Steel Plant)
Push-pull amplifier, Use of
heat
sink.,
harmonic
distortion and its control.
Feedback amplifiers- circuit
and applications
31
32
Oscillators:
working
principle,
classification,
circuits and applications.
Factors controlling oscillation.
Different types of oscillators,
their
characteristics
and
applications,
crystal
oscillators.
Assembly of oscillator circuits Do
using transistor and measuring
the output frequency and
waveform.
Linear ICs and OP-AMPs:
working, characteristic, pin
diagram,
applications
as
inverting and non-inverting
amplifier, calculation of gain,
comparator, unity gain buffer
and scale changer, adder,
subtractor,
differentiator,
integrator,
V/I
and
I/V
converter. Differential and
Instrumentation amplifier
OPAMPS pins identification,
assembly of inverting and noninverting amplifiers, calculation
of voltage gain, assembly of
comparator,
adder,
subtractors,
differentiator,
integrator, V/I and I/V circuit
and its testing.
Switching
and
timer
circuits: classification of
multi-vibrators,
astable,
monostable and bi-stable.
Internal
block
diagram,
operating of 555 timers and
its applications
28
The Laws of Indices
and problems. Power
and Exponent, laws
of exponent
Levers
–
Classification
of
Levers and problems
Study of Differential
Instrumentation amplifier
Construction
multivibrators using
timers,
Calculation
frequency
Concepts of Sectioning, Do
necessity,
significance,
conventions
and
characteristics. Practice
on different types of
sectioning – (a) Full
section (b) Half section
(c) Off-set section (d)
Partial or logical section
(e) Revolved section and
and (f) Removed section.
Exercises on sectioning
from isometric view
of
555
of
Instrument Mechanic (Steel Plant)
Opto-electronicselementary idea of LED,
LCD, photo diodes, photo
transistors, solar cells and
their applications
33
Digital Electronics
Verification of truth tables of Do
Number systems: binary, different gates
octal, hex, 1's and 2's
complements,
conversion Realization
of
different
from one system to other, Boolean expression with logic
Boolean algebra: De Morgan gates
theorem and its applications
Basic logic gates: Symbolic
representation
and
truth
tables for logic gates: Buffer,
NOT, OR, AND, NAND,
NOR, XOR, XNOR. Different
logic families and their
characteristics,
Electrical
equivalent of gates, Negative
and positive logic gates
Realization
subtractors
of
adders
Construct and verify
tables of flip flops
truth
Construct synchronous
asynchronous counters
study its functions
and
and
Boolean algebra- Karnaugh
map technique, simplification Construct
controlled
of
Boolean
expressions, register
and
study
realization
of
Boolean functions
expression with logic gates
Practice on reading
Combinational
logic interpretation of IC
29
and
Logarithms – Types
of logarithms eg.
Naperian
and
Common. Meaning of
logarithms
its
elements
i.e.
characteristics
and
mantissa. Problems
on
Positive
Characteristics
Wheel and
Axle,
Screw Jack, Inclined
plane and problems.
shift
their
and
data
Instrument Mechanic (Steel Plant)
circuits: Half and full adder sheets.
and subtractors. Encoders,
decoders, multiplexer, demultiplexers,
parity
generators and checker
Sequential logic circuits:
Difference
between
sequential and combinational
circuits,
triggering
of
sequential circuits. Flip-flops:
RS, JK, D, T type, preset and
clear
signals,
timing
diagrams.
Counters,
Registers and its applications
Memory devices: types,
memory cells: RAM, ROM,
PROM. EPROM, EEPROM,
CD-ROM,
memory
addressing and IC chips,
Static and dynamic RAM,
latest developments
Data converters: Digital to
analog converters, simple
circuits, and applications.
Analog to digital converters
Multivibrators:
Types,
characteristics and circuits,
Schmidt trigger
30
Instrument Mechanic (Steel Plant)
34
Microprocessor
and
computer: Organization in
general: CPU, ALU, resistors,
counters, data and address
process, memory and I/O
devices.
Instruction
set,
Simple
programming.
Introduction
to
other
processors
Hardware of
computer (PC)
a
Programming practice
Microprocessor
Identification of
parts
of
a
computer.
on
Do
Do
different
personal
Programming practice
Microprocessor
on
personal
Microcontrollers:
basic
principle, architecture, types,
programming
concepts,
interfacing.
A.7 Basic Instrumentation & Control (8 weeks)
Terminal Competencies:
After completion of this module the trainee will be able to
Understand the function of elements of measurement systems viz. sensor, signal conditioner and display
elements, static & dynamic characteristics of instruments, specifications of the instruments.
Know the working principles of different pressure, temperature, flow, level, thickness and other
transducers, transmitters, switches etc. Carry out maintenance and calibration related to these devices.
sensors,
Understand the working principles of gas analysers, pH and conductivity analysers, CV analysers, HMD and
31
Instrument Mechanic (Steel Plant)
encoders.
Understand the requirement of industrial process control, elements of basic process system, adjust the various
control modes of a controller connected in feed back or feed forward control loop.
35-39
Process measurement
Verification of working principle Exercise on sectioning
Objectives
of
the and characteristic of different from isometric view.
and
transducers
instrumentation, system of sensors
covered
in
theory
class
viz.
units and standards of
measurement.
LVDT,
Instrument terminology –
accuracy,
precision,
resolution, sensitivity, span,
range, error, uncertainty,
dead band, dead zone,
classification of error.
Elements of measurement
systems and their functions.
Sensors and transducersclassification
and
characteristics.
Signal
conditionersneed
and
circuits.
Display
and
recording instruments.
Common
sensors
and
transducersWorking
principle, characteristic and
application of
resistive,
inductive, capacitive, thermal,
optical and other sensors and
transducers viz. strain gauge,
LVDT,
Piezo-electrical,
capacitive and Hall effect.
32
Strain gauge,
Capacitive gauges,
Thermocouples,
RTDs,
Thermistors etc.
Familiarization with working of
dead weight tester, pneumatic
calibrator,
temperature
calibrator
and
other
.
calibrators.
Logarithms
Problems
Negative
Characteristics
Hydrostatics – Nature
of
Liquids
and
Pressure of liquid
inside a vessel at
different
positions,
unit
of
pressure.
Pascal‟s
Law
,
simple problems.
Types of pressureatmospheric
,
absolute and gauge.
Dismantling,
assembly,
overhauling and calibration of
transmitters,
indicators,
gauges,
regulators
and
switches used for pressure,
temperature, flow, level and
other measurement
Configuration
of
on
smart
Instrument Mechanic (Steel Plant)
Test and calibration of these transmitters using HART and
sensors.
other configurators.
Encoders- types,
and applications.
working
Pressure and differential
pressure
measurementDefinition, types and units,
requirements
of
measurement. Manometers:
principles, types and working.
Working
principle
and
constructional
details
of
elastic and electrical pressure
and DP sensors, Pressure
gauges:
constructional
details,
calibration
and
maintenance.
Pressure
switches:
constructional
details and maintenance.
Dead weight testers and
other pressure calibrators.
Pressure/DP
transmitters:
types, working, calibration
and maintenance. Smart
P/DP transmitters : working
principles, configuration and
maintenance. HART and
other protocols.
Pressure
recorders.
Temperature measurement
- Definition, types, units and
requirements
of
33
Instrument Mechanic (Steel Plant)
measurement.
Principles,
types
and
working
of
mechanical,
electrical,
radiation
and
other
temperature
sensors,
its
constructional
details,
calibration and maintenance,
relative
advantages
and
limitations.
Temperature
switches:
constructional
details and maintenance.
Temperature
calibrators.
Temperature
transmitters:
types, working, calibration
and maintenance. Smart
temperature transmitters :
working
principles,
configuration
and
maintenance.
Temperature
recorders.
Hot metal detectors, molten
Metal (bath) temperature
measurement, Celox principle
of temperature, oxygen and
carbon measurement.
Flow
measurement
definition, types, units and
requirements
of
measurement. Classification
of
methods. Restriction
method:
principles,
mathematical derivation of
relationship between flow and
differential
pressure.
34
Instrument Mechanic (Steel Plant)
Constructional details, types
and installation of orifice
plate, ventuti tube, flow
nozzle, anubar and others.
Variable
area
method:
principles,
types,
constructional
details,
calibration and maintenance.
Special flow meters – positive
displacement flow meters,
magnetic, turbine, vortex and
other flow meters. Mass flow
meter and its advantages.
Flow switches: constructional
details and maintenance.
Open
channel
flow
measurement methods.
Liquid and solid level
measurementdefinition,
types, units and requirements
of measurement. Direct and
indirect methods: hydro-static
pressure,
capacitive,
ultrasonic,
radioactive,
microwave, air bubbler and
other methods, its working,
advantages and limitations.
Thickness
and
profile
measurement:
types
of
methods, working principle,
construction, calibration and
maintenance.
35
Instrument Mechanic (Steel Plant)
Radiation
Hazards
precautions
and
Measurement
of
displacement,
vibration,
speed, and acceleration –
different techniques.
40-42
Process Control
Operate a controller in different Free hand sketch of tools
Introduction
to
process modes, setting of its PID and tackles used in the
trademulti-meters,
control,
elements
of
a values (controller tuning).
power
supply,
CRO,
process control system, block
pneumatic
calibrator,
diagram. Variables involved Configuration
of
different
screw-drivers,
viz.
process variables, blocks of a PID digital pliers,
spanner, pointer puller
manipulated variable and controllers.
etc.
disturbances. Basic types of
controlmanual
and
automatic, close loop and Connecting I/Os with a digital
open loop, feedback and controllers )on- off & PID) and
feed-forward.
making it operation.
Controller- basic building
blocks of analog and digital
controllers, P, D & I control
modes
and
their
characteristics. Tuning of a
controller
Factors and different
types of factorization
Density and Specific
Gravity
–
its
importance
and
significance,
Archimedes‟
principle,
Law
of
floating
bodies,
Condition
of
equilibrium
of
a
floating body.
Calibration and testing of a
control valve, I/P converter and
valve positioners.
Determination
of
process
characteristics of a process on
simulator / instrumentation
Final control elements: I/P tutors.
converters: types, working
principle,
construction,
calibration and maintenance.
36
Instrument Mechanic (Steel Plant)
Control valves & actuators:
types,
working
principle,
construction, characteristic,
calibration and maintenance.
Valve
positioner:
types,
working
principle,
construction, calibration and
maintenance.
Process Characteristic and
Control
Process characteristic and
parameters- lead, lag and
regulation, cycling, dead time,
stability
PID controllers- controller
tuning, auto tuning, stability
Advanced control strategies:
Cascade and ratio control
system, lead/lag adjustment,
multivariable control system,
introduction
to
adaptive
control, model based control
Reading and interpretation
of P&I diagrams- flow sheet
symbols,
reading
and
interpretation
of
P&I
diagrams.
37
Instrument Mechanic (Steel Plant)
8. PLC & DCS (2 weeks)
Terminal Competencies:
After completion of this module the trainee will become familiar with
Need and working principle of PLC
Hardware details of PLC
Programming of a PLC
Architecture, hardware and software details of DCS used in the plant
Communication with different field and control devices
43-44
Introduction to PLC & DCS
Familiarization with different
Introduction to PLC, its hard I/O modules of PLC
ware details, Function and Development
of
simple
working of different cards
programmes involving bit level
timers
and
Program techniques of PLC, instructions,
simple
data
inputs, outputs, timer and counters,
manipulation
instructions.
counter instructions, data
manipulation
Drawing
flow
sheet Do
symbols
of
process
control instruments viz.
sensors,
transmitters,
controllers, control valves
etc.
Feeding and running
simple programmes in PLC,
forcing
the Drawing block diagram of
I/O a process control system
Development
of
and labeling its various
programs
parts.
Documentation,
different Documentation and editing of
functional
blocks
& programmes
mathematical instructions
Simple fault finding and
DAS
and
SCADA, trouble- shooting related to
Introduction
to
MMI PLC.
packages, applications.
Demonstration
of
SCADA
Study
of
DCS:
basic
concepts, system,
communication
system
used
in
architecture, advantages.
networking of PLC: DH,
38
Instrument Mechanic (Steel Plant)
Controlnet,
PROFIBUS
MODBUS,
DCS
Familiarization with hardware
of DCS
Process operation practice on
DCS (On DCS used in the
plant,
9. Power electronics & Drives (6 weeks)
Terminal Competencies:
After completion of this module the trainee will be able to
Understand the concept of modern electric drive
Identify and test power electronics components and devices and know its characteristics and mounting.
Understand the working of power electronic circuits
Understand the application of above devices in modern control system
Understand the functioning of DC and AC drives and UPS.
45-46
39
Power electronic devices: Observation of different types Screw Threads – Forms Quadratic equations
Thyristor, its construction, of
power
electronic of various screw threads , and
practical
characteristics and family. components
nomenclature, convention problems concerning
Instrument Mechanic (Steel Plant)
Turn “ON” & turn “OFF” Drawing the V-I characteristic and drawing of various to workshop practice
behavior of thyristors
of a thyristor
thread profile.
Firing
and
commutation
circuits,, role of snubber
circuit. Rating & protection of
thyristors, Power diodes and
power transistors, power
MOSFET, IGBT, GTO, IGCT
and their applications
Study of different firing circuits
of thyristors (RC, UJT, Ramp
and Cosine firing circuits)
Specific Gravity of:a) Solids heavier than
water.
b)
Solids
lighter than water. c)
Solids
soluble
in
water.
Related
Problems.
Study of 1 ph and 3 ph
converter - half wave, full
wave, half controlled etc
Study of inverter circuit and
waveforms
Thyristor
circuits: Checking of power MOSFET,
Converter,
AC
voltage thyristors, IGBT, GTO, IGCT
Regulator, Chopper, Inverter, etc
IGBT circuit, PWM and their
use
47
Electric Drives: Concept of
modern
electric
drives,
Classification of load and
motor according to their
speed/torque characteristics
and
drive
performance
characteristics. Behavior of
drive system during change
of state
Fastening Devices
–
temporary
and
permanent.
Temporary
Device – Hexagonal Bolt,
Nut, Check Nut, Washer.
To draw the three views
Study of the effect of KP, KI, KD of individual and the
in relation to close loop DC assembly.
drive kits
Testing of thyristor and Ramp
firing circuit, study of waveform
on different test points of ramp
firing circuits
Control system - concept of
open and closed loop system. Demo
of
a
real
time
microprocessor based DC
drive used in industries.
DC drives: concept of speed Exercise on configuration and
control of DC motor. Block parameterization of DC drives.
diagram
of
close
loop
unidirectional DC drive, four
quadrant operation of DC Exercise on maintenance and
40
Principle of Similarity:
Properties of similar
triangle
and their
application to day to
day
workshop
problems.
Properties of Matter –
Different types of
Properties of Matter
eg.
Mechanical,
Electrical, Chemical,
Magnetic etc.
Properties of Matter
(Electrical):-
Instrument Mechanic (Steel Plant)
drive,
concept
of
dual trouble shooting of DC drive.
converter, block diagram of
close loop reversible DC
drive, field weakening control
and
spill
over
control,
Electronic modules used in
DC drives. Parameters and
concept of parameterization
of DC drives
Maintenance and trouble
shooting of DC drive.
Related safety aspects
48
AC drives: concept of speed
control
of
AC
motors,
principle of V/f control of
drives, block diagram of close
loop AC drive, principle and
operation of inverters (1 ph
and 3 ph)- concept of PWM
inverter. Principles of speed
control of SCIM and SRIM in
AC drives. Block diagram of
Close loop control, power
circuit,
control
circuit,
electronic control modules of
AC drive. Parameter and
Concept of parameterization
of AC drives,
Maintenance and
shooting of AC drive
41
Testing and study of IGBT, Do
power plate
Study of
waveforms
inverter
resistivity, permittivity,
permeability,
resistance
temp.
coefficient etc.
Insulating materials.
Brief description and
properties
of
electrical
materials
such
as
silicon,
nichrome,
silver,
copper,
aluminum,
transformer oil.
Do
voltage
Demo
of
a
real
time
microprocessor based AC
drive
used
in
different
processes in industries.
Demonstration
on
parameterization of AC drives
trouble
Exercise on maintenance and
trouble shooting of AC drive.
Instrument Mechanic (Steel Plant)
Related safety aspects
50
UPS - Understanding of float
charger, off-line UPS and Online redundant UPS, Different
type of controls, circuit and
maintenance of UPS and
battery.
Study of a UPS and its circuit Do
and controls
Trouble
shooting
rectification.
Do
and
Related safety aspects
51
Revision/
Plant
Industrial visit
52
Examination
42
visit/
Instrument Mechanic (Steel Plant)
2nd Year
10. Electrical Power System (4 weeks)
Terminal Competencies:
After completion of this module the trainee will become familiar with
Know how electrical power is generated and distributed
High voltage safety equipment and safe working procedures, Earthing system, IE rules
Working of LT and HT Switch- gears and protective relays
Power factor improvement methods
Monitoring system for power generation and utilization
53
Power
Generation, Measurement
of
pit
Transmission
and resistance.
distribution System
Demonstration of HV safety
Introductory
concepts
- devices
generating stations: Hydel, Use of HV tester, cool coat,
Thermal,
Nuclear,
Gas discharge rod
turbine, IC engine etc.
High voltage safety, use of
safety devices like HV tester,
discharge rod, cool coat
Earthing,
system
and
equipment, neutral earthing,
43
Different
Methods
of
Preventions of rotation of
Bolts - Check nut, Square
headed bolt,
Square
headed bolt with square
neck, cup headed bolt,
eye bolt, counter sunk
headed bolt, rag bolt
Trigonometrical ratios
and simple problems
connected
to
workshop practice
Properties of Matter
(mechanical):Tenacity, Toughness,
Malleability, Ductility,
Elasticity,
Brittleness
Hardness.
Plasticity
and
Properties and uses
of copper, zinc, lead,
Instrument Mechanic (Steel Plant)
maintenance of earth pits.
tin, aluminum brass,
bronze,
solder,
bearing
metals,
timber, rubber.
Related IE rules and safety
aspects
54
Transmission
O/H
line,
conductor,
support,
insulators, their merit and
demerit, sag, span, joints,
guard, binding of insulators,
stay,
damper
jumpers,
erection of line, maintenance
and
inspection
of
transmission lines.
Study of various types of Do
power transmission equipment/
devices – conductors, support,
insulators and cables.
Do
Cable jointing practices
Study of single line diagram of
Cablesconstruction, interconnected industrial power
classification
of
cables, supply system.
property of XLPE, paper,
PVC, insulation, jointing and
laying of cable, testing and Polarity marking of CT
fault localization
Connection of CT and PT.
Indoor
and
outdoor
of
lightening
substation, layout, single line Connection
arrestors
diagram, CT& PT, isolators,
earth switch, transformer,
lightening arrestor, reactor,
breaker,
bus
and
its
protection.
Energy
maximum
44
management,
demand,
load
Instrument Mechanic (Steel Plant)
factor,
connected
load,
diversity load curve, tariff.
LDC- monitoring system for
power
generation
and
utilization.
Indian
electricity
rules
pertaining to safety of supply
system,
LT
and
HT
equipment, O/H transmission.
Related IE rules and safety
aspects
55
45
Power system protection
Connection
of
relays. Do
Maintenance
and
adjustment
Switch
geararcing
phenomena, ACB parts and of arc chute, and contact.
their function, maintenance of
arc chute, contacts, limitation Opening and assembling - pole
and tightening, testing and assembly, trip assembly and
calibration
of
releases, hand assembly
trouble shooting.
Maintenance of OCB, VCB,
and SF6
Construction, working and breakers
maintenance of OCB, VCB
and SF6, GIS, their merit and Demo on parameterization of
digital relay and numerical
demerit
relay.
Protection
relay:
classification,
terms
and
definitions, comparison of
mechanical,
solid
state,
digital and numerical relays.
O/C relay- its testing and
calibration, E/F relay - its
testing
and
calibration.
Do
Instrument Mechanic (Steel Plant)
Different types of E/F relays,
reverse
power
relay,
differential relay, restricted
E/F relay, feeder protection
relay, directional earth fault
relays.
Digital motor protection relay
, numerical relays used with
power system.
Related IE rules and safety
aspects.
56
Fuse- terms and definitions, Demonstration of different Different Methods
selection and characteristic of types of fuses.
locking of nuts:HRC fuse
Demonstration of different
a) Lock nuts
Power factor- effect of low types of
power factor
b) Slotted nut
power factor, cause of low improvement
and
c) Castle nut
PF,
power
factor compensation equipment
improvement, use of static Visit to Energy Management
d) Wings nut etc
VAR compensation
Centre
such
as
Load
of
Do
b) Split pin
d) Symmonds nu
Energy
management- Despatch Centre (LDC), Submaximum
demand,
load stations.
factor,
connected
load,
diversity load curve, tariff.
Related IE rules and safety
aspects.
46
Instrument Mechanic (Steel Plant)
11. Industrial hydraulics and pneumatics (2 weeks)
Terminal Competencies:
After completion of this module the trainee will become familiar with
Principle of working of hydraulic & Pneumatic components and circuits
Proportional and servo hydraulics and its applications
Symbols of basic hydraulic and pneumatic components
Interfacing of fluid power devices with electrical controller
57-58
Basic principles of hydraulic Identify components such as
and
pneumatics, reservoir, filter, pumps, float
characteristic of fluid media, switch, valves, actuators etc.
safety aspects.
Operation of proportional and
Operational details of fluid servo valves, functions of
power control element.
control
and
feedback
components
Energy
converter,
Fluid
conditioner, Control valves
Symbols of basic hydraulic
and pneumatic components.
Demonstration
of simple
Basics of proportional and hydraulic devices and circuits.
servo valves, its electrical Demonstration of
simple
and
electronic
circuitry, pneumatic
devices
and
control and feedback systems circuits.
Permanent Fastening
DevicesRivets
–
different parts and their
types Different types of
rivet heads
Trigonometrical ratios
and simple problems
connected
to
workshop practice.
Engineering Material
–
Introduction,
classification, metallic
and
non-metallic
material, physical and
mechanical
properties, testing of
metal and hardness
testing.
.
Concepts of interfacing of Hydraulic
and
pneumatic
hydraulic and pneumatic circuits,
reading
and
components with PLC
interpretation.
Development of simple logic
47
Instrument Mechanic (Steel Plant)
circuits in PLC and its testing
12. Welding (1 week)
Terminal Competencies:
After completion of this module the trainee will become familiar with basic principle, devices and techniques used for welding
57
Familiarization with tools and Rivets Joints – Lap joint Angle of Elevation
accessories.
and Butt or Strap joint.
and
Angle
of
Depression,
Arc welding on mild steel Lap Joint –
Problems on Height
(down hand)
a) Single Riveted
and Distances taking
Regulators and blow pipes, Making welding joints.
the
help
of
b) Double rivetedfiller rods and fluxes.
Trigonometrical
Gas cutting on mild steel.
i) Chain
ii) zig – zag Ratios
Flame characteristics and
Brazing
of
two
similar
metals
uses, arc welding machines,
electrodes
and
their
Butt Joint –
selection, various joints and
Heat treatment of
joint
preparation,
their
steel – Hardening,
a) Single plate or strap
suitability
for
various
annealing, tempering,
b)
Double
plate
or
strap
applications.
normalizing and case
hardening
Arc welding and gas cutting
tools
and
equipment.
Different gases used in gas
cutting.
Related safety aspects
13. Advanced Instrumentation (6 weeks)
48
Instrument Mechanic (Steel Plant)
Terminal Competencies:
After completion of this module the trainee will become familiar with
Working of hydraulic and pneumatic instruments
Types and working of different types of indicators and recorders
Process characteristics and parameters
Digital control system, types and applications.
Steel plant instrumentation and control system
60
Pneumatic
InstrumentsNeed
and
principle
of
pneumatic
instruments.
Quality of air supply required
in pneumatic system and its
sources.
Parts
of
an
pneumatic
instrumentFlapper nozzle mechanism,
null
balance,
pneumatic
relays etc. Working principle,
construction , calibration and
maintenance of pneumatic
instruments.
Pneumatic
calibrators.
Dismantling, assembly, test
and calibration checking of
pneumatic PT/DPT, indicator,
recorder controller and control
valves..
Isometric Projection:Difference
between
isometric
and
actual
scale, construction of
isometric
scale
and
simple exercises
Solution of Triangles:Meaning and its use,
The Sine rule and the
Cosine
Rule.
Problems related to
Workshop practice.
Effect of force on
Materials
in
Expanding, Bending,
twisting and shearing.
Hydraulic
instrumentsprinciple
of
measuring,
transmitting and controlling
instrument
based
on
hydraulic principle and uses.
61
49
Indicators and recorders- Dismantling, assembly, test Drawing the symbols of Solid Mensuration:working
of
industrial and calibration checking of electrical
instruments- Prism,
Cylinder,
Instrument Mechanic (Steel Plant)
indicators and recorder, its indicators and recorders.
types,
working
principle,
calibration and maintenance.
ammeter, voltmeter, watt
meters,
ohmmeter,
energy meters etc. as per
BIS practice.
Pyramid,
Cone,
Frustum of Pyramid
and
of
Cone,
Problems concerning
to workshop practice.
Relation
between
Load and Extension –
Graph – meaning of
Yield Point – 1st & 2nd
Ultimate
tensile
Stress,
Breaking
Stress and factor of
safety.
62
Gas analyzers: requirement
of
gas
analyzers,
components
of
a
gas
analyzer system, sampling
system, working of Oxygen,
CO, CO2 and Hydrogen
analyzers. Calibration of gas
analyzers.
Demonstrations of
gas Drawing the symbols of
analyzers and CV analysers
electrical
components
and
devicespush
buttons, switches, fuse,
Demonstrations
of
liquid motor,
generators,
analyzers – pH & conductivity. transformers, relays and
contractors etc.
Demonstrations of humidity
CV analyzers: requirements, and moisture gauges.
working principle, type and
construction.
Conductivity and
pH
analyzers:
requirements,
working principle, type and
construction. Calibration.
Solid Mensuration:practice problems.
Stress,
Strain
–
Definitions, different
types
of
Strain,
Hook‟s Law, Modulus
of
Elasticity
–
Young‟s
Modulus,
Bulk
Modulus
–
Modules of Rigidity,
Poisson‟s Ratio and
Problems.
Humidity and moisture
gauges:
principle
and
applications.
50
Instrument Mechanic (Steel Plant)
63-64
Programming of DCS, its
maintenance
and
Principle of digital control, troubleshooting
difference between analog
Programming of PLC, setting
and digital control, advantage
communication
link,
and limitation.
debugging,
forcing.,
Microprocessor
based maintenance
and
controllerInput
unit, troubleshooting.
processor, output devices,
Development
of
simple
memory.
projects
using
SCADA
software.
Digital Controllers
Computer based controlgeneral architecture, typedirect
digital
control,
supervisory
control,
distributed control.
Digital
communicationprinciple,
methods
and
industrial application
Data communication - serial
and parallel communication RS-232,
RS-485
and
Ethernet standards. Different
industrial
communication
protocolsMODBUS,
FIELDBUS, CONTROLNET,
DEVICENET
etc.
Communication
mediacopper, FO and wireless.
(Brief description only)
Drawing of various wave Solid Mensuration:shapes- sine , square, Sphere,
Spherical
triangular, saw tooth etc.
segment,
material
weight
and
cost
problems on above
Drawing the circuit of a topics
concerning
DC power supply with workshop practice.
rectifier,
filter
and
regulator with labeling
and waveforms.
Heat – Definition and
its importance.
–
Drawing
the
circuit Temperature
and
diagram of a UPS and Definition
significance.
SMPS with labeling and
Difference between
waveforms.
heat
and
temperature.
Drawing
the
circuit
diagram of a Signal
of
generator with labeling Scales
Temperature
eg.
and waveforms.
Fahrenheit
,
Centigrade,
Kelvinrelationship between
them. Lower and
Upper fixed points,
Fundamental Interval.
Reasons
for
the
selection of Mercury
as
thermometric
substance.
Computer networking- OSI
51
Instrument Mechanic (Steel Plant)
model, network architecture
and devices, topologies;
Distributed control system –
Study
of
architecture,
hardware
and
software
organization of common DCS
used in steel plants. Fault
finding and trouble shooting
of DCS.
PLC- Advanced programming
,
debugging
and
documentation of PLCs used
in the plant. Inter PLC
communication. Fault finding
trouble shooting of PLCs.
Programmable
Automation
Controller (PAC) and its
application.
SCADA system- development
of projects using SCADA
system used in the plant
65
Steel plant instrumentation
and control system
a. Fuel and furnaces used
in steel plant, water,
oxygen, nitrogen and
other utilities network
b. Level of automation in
steel plant
c.
52
Study of various control
loops used in Blast
Furnaces, Steel Melting
Drawing diagram of dead Do
weight tester.
Drawing block diagram of
various control loops
used in steel plant viz.
furnace
temperature
control,
air
pressure
control, air flow control,
tank level control etc.
Instrument Mechanic (Steel Plant)
Shops, Mills and power
plant.
14. Instrument Calibration and maintenance (3 weeks)
Terminal Competencies:
After completion of this module the trainee will become familiar with
Importance of calibration and its methods
Calibration of different types of instruments
Interconnection of instruments and devices used
Faultfinding and troubleshooting of instruments
66-68
53
Calibrationneed
of
calibration,
types
of
calibration,
calibration
standards- working, reference
and international standards.
Calibration record, Error and
Familiarization with different Drawing
the
block
types of electronic, pneumatic diagram of single stage
and hydraulic calibrators
and an RC couple
amplifier with labeling
and waveform.
Calibration of all types of
Graphs:-Dependent
and
Independent
variable. Concept of
Quadrants. Plotting of
Points and
other
types of curves eg.
Instrument Mechanic (Steel Plant)
uncertainty
instruments and preparing its
calibration report
Working of electronic and
pneumatic calibrators
Impulse
line
laying
and
connection with transmitters
and control valves
Instrument sub-systemsPanels, relays, terminals,
interconnection
fuse
terminals,
junction Instrument
using
cable,
JBs
and terminals
boxes, MCBs, cable gland,
pipe and its colour code, air
filter regulators.
Practice on different types of
terminations.
Instrument cabling, Earthing
and grounding of instruments
Trouble
shooting
and
and its importance
rectification of instrumentation
Elimination of ground loops.
system
P&I diagram – flow sheet
symbols,
reading
and
interpretation of GA, SLD and
P&I diagrams.
Trouble
shooting
rectification
instrumentation system
54
Straight line curve,
Parabolic
and
Hyperbolic curves. To
solve Equations of
two
and
three
unknown with the
help of Graphs.
Units of heat –
calorie. BTU and
CHU
and
their
relation. Method used
for the measurement
of heat i.e. Heat
gained = Heat lost.
Calorimetry. Specific
heat,
Water
Equivalent
of
a
calorimeter, Thermal
Capacity – Latent
heat of Fusion and
latent
heat
of
Vaporization. Related
problems.
and
of
Instrument Mechanic (Steel Plant)
15. Electrical Measuring Instruments ( 2 weeks)
Terminal Competencies :
After completion of this module trainees will be able to
Know the working principles, construction and uses of different electrical measuring instruments
69-70
Electrical
InstrumentsClassification, types, methods
of
achieving
deflecting,
controlling
and
damping
torque, their advantage and
limitations.
Calibration
of
ammeter,
voltmeter,
wattmeter
and
energy
meters.
Preparing
correction curves/ calibration
records.
Drawing the symbols of Do
electrical
instrumentsammeter, voltmeter, watt
meters,
ohmmeter,
energy meters etc. as per
BIS practice.
Connections
of
ammeters
Constructional details of through
CTs,
Voltmeters
moving coil and moving through PTs.
iron instruments. Extension
of range, use of shunt and
Connections of watt meters
multiplier.
and energy meters through
CTs and PTs.
Description, construction,
working principle and use
Changing CTs for higher rating
of:
a) Electro-dynamic
instruments
singlephase
and
threephase watt meters.
b) Thermocouple
hot-wire meter
55
and
Instrument Mechanic (Steel Plant)
c) Power factor meters
d) Frequency meter
e) KVAR, tri-vector and
maximum
demand
indicator
f) Ferranti-type
DC
energy
meter
i.e.,
Ampere-hour meter.
g) AC energy meter, 1phase, 3-phase 3-wire,
3-phase-4-wire.
h) Meggerinsulation
testing
and
Earth
testing
i) Ohmmeter
multimeter
and
j) Precaution while using
electrical instruments
k) DC tong tester
Related safety aspects
16. Computer & IT
Terminal Competencies:
56
Instrument Mechanic (Steel Plant)
After completion of this module the trainee will become familiar with
Hardware of PC
Common software used in PC
Use of Intranet, Internet, E-mail
71
Computer & IT
Drawing of symbols of
Basics of computer hardware Preparation
of
a
word different digital electronic
circuit and componentsand software
document (eg. Project report)
gates, flip-flop, register,
counter
with
timing
diagrams.
MS office: Word, Excel and Preparation of an excel file and
power point
make graphical representation
of
data obtained during
practical sessions on electricity
Use of Intranet, Internet, Email
Statistics – Mean,
Median,
Mode,
Variance, Frequency
distribution
,
Cumulative
frequency, Pie-Chart
Expansion of Liquids
– it has only one type
of expansion e.g.
Cubical
expansion.
Two forms - Real and
Apparent
–
the
relation
between
them ,coefficient of
apparent and real
expansion. Related
problems.
17 Iron & Steel making technology (2 weeks)
57
Instrument Mechanic (Steel Plant)
Terminal Competencies:
After completion of this module the trainee will become familiar with
Different types of raw material used for iron making and their sources
Iron and steel making processes
Hot and cold rolling process
72-73
Different
types
of
raw Guided visit of different plants Drawing
of
OPAMP Problems on statistics
material used for iron making of
the
organization
and based circuits- adder,
and their sources
familiarization
with
the subtractor,
integrator,
process.
differentiators
V/I, I/V Expansion of Gases
Details of Blast furnace
–
Boyle‟s
Law,
converters.
reactions, Cooling system,
Charle‟s law and
Cast House practices.
Combined gas law.
Gas cleaning system.
Drawing of block diagram Absolute
Zero
of
a
microprocessor,
Meaning
of
N.T.P.
Hot metal Desulphurisaion.
microcontroller
and Thermal conductivity
Complete Heat cycle in LD
Personal Computer.
and related problems
vessel.
Secondary Steel Making.
Casting of Steel.
Theory of Rolling.
Rolling of long products & flat
products in hot and cold
rolling.
58
Instrument Mechanic (Steel Plant)
18. Quality Management & Improvement techniques (1 week)
Terminal Competencies:
After completion of this module the trainee will become familiar with
QMS and its important provisions
Concept and application of TPM
Quality Control tools and systems practiced in industries
74
Introduction to TQM, Quality
management standards, their
importance and important
provisions.
TPMConcept,
different
pillars, its implementation in
an organization
Problem solving technique
used in industry - QC and
SPC tools
Familiarization with Quality
Management System, TPM,
Small Group Activity (SGA)
and Quality Circles as being
practice in the industry.
Drawing of circuit of an
instrumentation amplifier
with
labeling
and
waveform
Set
Theory
Introduction
problem
Mechanical
Equivalent of Heatproblems.
Transmission of heat
–
Conduction,
Convection
and
Radiation. Examples
from industries.
19. Rigging (2 weeks)
59
–
and
Instrument Mechanic (Steel Plant)
Terminal Competencies:
After completion of this module the trainee will be able to do the following.
Loading, unloading and shifting of common and uncommon shapes of material with the help of different lifting tools
and tackles.
Working at height.
Reaving pulley block in different part.
Able to communicate with crane operator through signals.
75-76
Knowledge of different tools Practice of different type of Drawing of circuit of an
& tackles used in rigging.
knots & hitches used in different types of multivibrators using 555 timer
Construction and capacity of material handling
with
labeling
and
wire rope.
Reaving sets of pulley block.
waveform
Capacity of ropes (other than Splicing of manila rope.
wire rope).
Inspection of wire rope.
Application
hitches.
of
knots
and Use of mechanical & hydraulic
jack, rope puller, chain puller,
Care and maintenance of chain block, winch
wire rope.
Inspection of tools and tackles
Different type of jacks, chain Loading, unloading and shifting
block and pull lift.
of common and uncommon
Knowledge of different types shapes of material.
of scaffolding.
Hand signal used in rigging.
Material movement by using
different rigging tools and
techniques.
Safety
appliances
precautions in rigging.
Problems related to
set theory.
Transmission
of
Power and motion of
Belt and Pulleys:Driver and Follower –
Open and Cross belt
system of belt drives.
Velocity ratio. Effect
of thickness of belt &
slip on Velocity Ratio.
Compound belt drive.
Power Transmission
by belt – Problems
Gear,
Cam
and
Follower, Sector &
Pinion.
&
Maintenance of tools and
tackles.
60
Instrument Mechanic (Steel Plant)
20. Environment Control and Occupational Health (1 week)
Terminal Competencies:
After completion of this module the trainee will be able to appreciate the following
Major emission source and their effect on global environment.
Problems and attention needed to overcome and minimize emission.
Permissible extent as per Factory Act and rules thereof.
Occupational Hazards and ergonomical issues.
77
Awareness on environment Observation of
Do
pollution and effects.
- Emission and pollution
Basic knowledge of air
control equipment.
pollution control equipment.
- dust handling & disposal
(ESP, Bag house, cyclone
system
separators etc)
- effluent
treatment
Major emission and pollution
plants
source and their effect on
- emission
monitoring
environment.
equipment
Control of NOX and SOX and
SPM to permissible level.
Do
Standard of ambient air
quality, work environment,
effluent discharge.
Dust handling and disposal
system.
61
Instrument Mechanic (Steel Plant)
Control of water pollutioneffluent treatment plants
Occupational
ergonomics
78
62
health
Revision/
Plant
Industrial visit
and
visit/
Instrument Mechanic (Steel Plant)
Part B: Shop Floor (In- plant) Training- Duration- Half ( ½ ) Year
B.1 Shop Floor (In- plant) training (24 weeks)
Terminal Competencies:
This is on-the-job and observational training module which will enable trainees to relate and
applications of contents covered during the basic training.
79-
The content of this module
will be developed
1
by the
organization based
0
on the
existing Electrical,2Electronics
and
Instrumentation
maintenance practices which
may include the following
On the job training –
Safety pre-cautions to be
followed in the section/plant
including need of special
protective equipment, if any.
Study of working of different
equipment
used
in
1. Maintenance and repairing plant/section visited.
of instruments
Instrument Repair Shop
2. Calibration and testing of
repair/
test/
sensors,
transmitters, Carry-out
of
instruments/
indicators,
recorders, calibration
equipment under the guidance
controllers etc.
of competent person
3. Overhauling
and
calibration
of
control
valves, I/P converters, Carry-out minor maintenance
Valve positioners etc.
job
under
guidance
of
competent person
63
learn the practical
Free hand sketches of Peak , RMS and
the
elements
of average value of AC
measuring devices.
supply. Relationship
Free hand sketching of between them. Peak ,
the
temperature RMS and average
value of current in
measuring instrumentsthermocouple (complete Rectifiers. Calculation
assembly),
RTD, of form factor, ripple
Thermistor,
radiation factor, transformation
pyrometers, filled thermal ratio. Estimation of
PIV of a diode in
system.
different types of
Free hand sketch of rectifiers.
pressure
gauge,
pressure/DP transmitters
etc.
Number
systemdecimal,
binary,
octal,
Free hand sketching of
BCD
code,
flow measuring devices- hex.
conversion
from
orifice plate (all types),
venture tube , rotameter decimal to binary,
octal and hex and
etc.
vice-versa.
Drawing
of
various
symbols,
notations,
Instrument Mechanic (Steel Plant)
Electronic repair shop
1. Maintenance and repairing
of electronic cards
2. Calibration and testing of
electronic instruments
Electrical repair shop
1. Observation
of
maintenance and repairing
of electrical machines
2. Calibration and testing of
electrical instruments
Power Houses and substations
1. Power plant equipment &
Control system, P& I
diagram of plant.
2. Distribution of
power, SLD.
colour coding used in
skilled instrumentation.
workmen/ Free hand sketch of level
measuring instruments
Simple estimation of
the requirements of
Working
with
materials
as
supervisors/
applicable
to
the
operators.
trade. Problems on
.Drawing the schematic estimation
and
diagram
of
open
loop
and
costing.
Preparing report on the job
closed
loop
control
done
system.
Drawing various parts of Meaning of HP and
control
valve
and BHP. Problems on
work, power and
actuators.
energy related to
Drawing sketches of the electrical area.
components of pneumatic
system.
and
Drawing of flow sheet Magnet
magnetism.
Simple
symbols
of
sensors,
transmitter,
controller, workshop problems.
recorder,
etc.
control
valve
electrical
3. Protection schemes and
protective devices
Production Departments
a) Plant process + Plant
process control electrics.
b) Power source + S.L.D
c)
64
Equipment layout, MCC
Instrument Mechanic (Steel Plant)
locations.
d)
MCC details, different
protection
levels
of
equipment.
e)
Faults finding and
rectification
in electrical ,
electronic
and
process
control
equipment/
instruments
f) Maintenance/ Inspection
practices.
g) Document management
systems.
h) Spares management.
i)
Use of MIS, computer
based
maintenance
management
B.2 Industrial Visit, Project work, Revision & Test (2 weeks)
Terminal Competencies:
Functioning of local industries
Making the project report and its presentations to the experts.
103-
65
Revision of theory covered Revision of practical conducted Revision.
during the training.
1
during training.
0
Revision.
Instrument Mechanic (Steel Plant)
4
Effective Presentation skills
Visit to local industries
Preparation of project/ training
report and presentation to
experts
66
Instrument Mechanic (Steel Plant)
Evaluation:
AITT evaluation on practical to be based on following combined skill areas :
(Total thee skills need to be judged. Serial No. 1 is compulsory and any two other skills to be chosen from the
list given)
Instrument Mechanic (Steel Plant)
1.
2.
3.
4.
5.
6.
7.
8.
Able to dismantle, inspect, calibrate and assemble Pressure gauge
Able to calibrate Pressure Transmitter/Differential Pressure Transmitter
Able to calibrate Temperature Transmitter
Able to dismantle, inspect, calibrate and assemble Control Valves
Able to dismantle, inspect, calibrate and assemble Valves Positioner
Able to calibrate I/P Convertors
Able to calibrate Pressure/Level/Temperature Switch
Able to dismantle, inspect, assemble and connect Volt meter, Ammeter, Watt meter, Energy meter and
measure different parameters
9. Able to dismantle, inspect, calibrate, assemble and tune PID Controllers
10. Able to find out iron and copper loss of transformer
11. Able to make rectifier and amplifier circuits
12. Able to draw the characteristic curve of diode and transistors
67
Instrument Mechanic (Steel Plant)
LIST OF TOOLS & EQUIPMENTS FOR THE TRADE:-INSTRUMENT MECHANIC (STEEL PLANT)
SL.NO.
1
2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
Steel rule 150 mm
Caliper outside 100 mm
Watch maker screw driver(set of 6)
Pliers flat nose 100mm
Hammer ball pain 250gm with handle
Twiser fine point 125mm
Twiser ordinary 125 mm
File hand smooth 200mm
File half round 2nd cut 250mm
File triangular 2nd cut 200mm
File square 2nd cut 150mm
Screw driver set of 5 pieces
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
TOOL,MEASURING INSTRUMENTS & GENERAL SHOP OUTFIT FOR UNIT
SL.NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
68
DESCRIPTION
Try square hardened blade 100mm
Spring divider 100mm
Neon (phase) tester 230 v
Swiss file, set of 12 nos
Eye glass 3 “ focus watch maker
Goggles safety
Oil can
Surface plate 400x400mm
Universal scribing block 250mm pillar
Vee block with clamp pair
Angle plate 150x100
Punch letter set 2mm
Punch figures set 2mm
Hacksaw frame adjustable 200-300mm
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
Instrument Mechanic (Steel Plant)
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
69
Hand drill machine 6mm cap
Chisel cold flat 12mm
Drill twist S.S. 1mm-12mm
Taps & dyes B.A set
Taps & dies B.S.F set
Hammer ball pain 450 gm with handle
Spirit level metal 100mm
Electric soldiering iron 15 watt pencil tip
De-soldering pump
Temperature controlled soldering station
Single hot plate 1000watts
File flat 2nd cut 250mm
File flat smooth 150 mm
File warding 2nd cut 100mm
File warding smooth 100mm
vice swiveled base jaw 100mm
Vice bench jaw 100mm
Vice pipe 100 mm
Pointer extractors(puller)
Screw pitch gauge B.A.& metric each
Reamer parallel 1 mm to 6 mm
Punch centre 100x10mm
Tool makers clamps 65x12x25mm
Plier side cutting 150 mm
Sine bar 125 mm plate
Spanner adjustable 200 mm
Flaring tool set
Micrometer outside 0-25 mm
Micrometer outside 25-50mm
Vernier height gauge 300mm
Combination set 300mm
Vernier caliper 150 mm
Standard wire gauge
Feeler gauge leaf type,26 blades,eng & metric
Instrument Mechanic (Steel Plant)
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
Radius gauge leaf type1-15mm
Dial test indicator in mm with accessories
Spanner set 1 mm to 25mm
Taps set metric
Micrometer inside 25 mm with extension upto 150mm
Combination plier heavy duty 150mm
Fire buckets
Glazed with felt cloth & marking pen sets (blue, black. Red & green)
Tube cutter
Tube bender
Pinching tool
Combinational plier 200mm
Allen key set(metric)
Allen key set (English)
Soldering station (temp controlled)
Screw driver 200mm
Screw driver 400mm
Philips screw driver 200mm
Outside micrometer, 0-25mm, LED/LCD display
Round nose plier 150mm
Machine vice 150mm
Magnifying glass 75mm
LIST OF INSTRUMENTS
MECHANICAL PRECISION INSTRUMENTS
SL.NO.
1
2
3
4
5
70
DESCRIPTION
Vernier micrometer (0-25mm),outside
Vernier micrometer (25-50mm),outside
Vernier caliper(0-300mm)
Plug gauge
Ring gauge
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
Instrument Mechanic (Steel Plant)
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Snap gauge
Dial test indicator, metric with all accessories
Surface gauge
Telescopic gauge
Vernier bevel protector
Dividers,250mm
Gauge blocks
Comparators
Monochromatic light source
Optical flat
Wire type strain gauge (bonded & unbounded)
Bonded & unbounded type microphone
Vibration sensing elements.
Accelerometer
Seismic instruments
Load cells of various ranges
Measuring microscope &travelling microscope.
ROTATIONAL OR VELOCITY INSTRUMENTS
SL.NO.
DESCRIPTION
1
Speedometers (at least 4 diff popular make) with adopters of various Quantity to
sizes.
be sufficient
as per seats
Centrifugal type tachometer.
surveyed &
Drag cup type tachometer.
allocated
Electrical tachometer.
Chronometric type tachometer.
Digital type tachometer.
Stroboscope
2
3
4
5
6
7
71
QUANTITY
Instrument Mechanic (Steel Plant)
PRECISION INSTRUMENTS
SL.NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
72
DESCRIPTION
Digital panel meter,3.5 digit
Digital panel meters,4.5 digits
Digital line frequency indicator
D.C .regulated power supplies
a) low tension series (single)
b) low tension series (dual)
c) high tension series
d) multi output series
e) fixed output series
Digital sign or square generator(1Mhz) with frequency counter(8
digit/10 Mhz)
Digital function generator
Pulse generator
Digital frequency counter
Digital insulation tester
Digital multimeter
Analog multimeter
Digital ph meter
Digital L.C.R bridge
Digital IC tester
Digital storage oscilloscope (100 mHz)
Decade voltage dividers
Decade attenuators
Decade resistance boxes
Decade capacitance boxes
Decade inductance boxes
Transistor curve tracer
Transistor tester
Electronic timers
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
Instrument Mechanic (Steel Plant)
GENERAL EQUIPMENT TRAINERS FOR INSTRUMENTATION
SL.NO.
1
2
3.
DESCRIPTION
Instrumentation amplifier trainer.
Voltage controlled oscillator trainer.
Frequency to voltage converter trainer
4.
5.
Voltage to frequency converter trainer.
8 channel analog multiplexer trainer.
6.
7.
8.
8 channel analog demultiplexer trainer.
FET voltmeter trainer
Measurement of RMS voltage trainer.
9.
Measurement of average voltage trainer.
10.
Wheatstone`s bridge trainer.
11.
Kelvin`s bridge trainer.
12.
13.
Trainer on C.R.O.
Trainers on transistor of all types
14.
Trainers on microphone
15.
Trainers on network circuits i.e. Kirchhoff‟s law etc.
16.
Trainers on linear ICs - operational amplifiers and 555 timers
17.
Discreet component trainer.
18.
Trainers on power suppliers-Half wave rectifier, full wave rectifier, ridge
rectifier and power supply, regulated power supply.
Trainers on basic digital electronics, i.e. logic
gates, Boolean expression, adder, subtracter, flip-flop, counter,
register, converter etc.
Trainers on transistor amplifier circuits at least
one each for all types of amplifiers.
19.
20.
73
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
Instrument Mechanic (Steel Plant)
21
22.
23.
24.
25.
Trainers on oscillators and multivibrators, signal
integrators, triggers and other wave shaping ckts.
Trainers on firing circuits, converters and invertors
generators,
Trainers on stepper motor, SCR motor, serve motor, UJT trigger, circuit
breaker, timer and alarm.
SCR driven/controlled power supply trainer
Instrumentation training kits for following sensors- Strain gauge, LVDT,
RTD, TC, Thermistors, Capacitive transducers, inductive transducers,
hall effect transducers, optical encoders, magnetic encoder
ELECTRICAL INSTRUMENTS
SL.NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
74
DESCRIPTION
DC moving coil voltmeters. (various ranges)
DC moving coil ammeters. (various ranges)
DC moving coil miliammeters (various ranges)
Centre zero galvanometers
AC moving iron type voltmeter (various ranges)
AC moving iron type ammeters (various ranges)
Wattmeter dynamometer.
Voltmeter dynamometer type AC & DC.
Voltmeter induction type
Power factor meter
Vibrating reed frequency meter
KWh meter induction type 1 ph
Ampere hour meter
Ohm`s meter
Multimeter (analog)
Multimeter (digital)
Potentiometer / Thermocouple test set
Earth Insulation Tester (Megger)
Autotransformer.
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
Instrument Mechanic (Steel Plant)
PRESSURE INSTRUMENTS
SL.NO.
DESCRIPTION
QUANTITY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
“U” tube manometers
Well type manometer
Inclined limp manometers
Ring balance type manometer
Bourdon tube type gauges of various ranges
Capsule type pressure gauges
Aneroid barometers
Dead weight tester
Pressure regulators with filter and input & output gauges
Differential pressure transmitter (pneumatic).
Differential pressure transmitter (electronic/ Smart) with configurator
(HART)
Diaphragm type pressure gauges of various ranges
Pressure Transmitters- Resistive and Capacitive type, 4-20 mA output,
24 V DC Power Supply
Smart Pressure Transmitters with configurators (HART)
Pneumatic indicating controller (PID)
Electronic pressure controller (PID)
Pressure control training simulators consisting of (a) process
(pressurised vessel) and (b) control equipment to establish closed loop
automatic control system using pressure transmitter, indicator, PID
controller, recorder and final control element. A small PLC/DCS can
also be used as controller.
DC Power supply unit (0-24 V DC)
Pressure calibrator (Pneumatic/ electronic)
Pressure switches of various ranges
Other miscellaneous fittings, pipes, tubes, etc.
Low pressure measuring gauges such as thermal conductivity gauges,
pirani gauges and mcleod gauge
I to P converters
Quantity to
be sufficient
as per seats
surveyed &
allocated
12.
13.
14
15.
16.
17.
18.
19.
20.
21.
22.
23.
75
Instrument Mechanic (Steel Plant)
24.
25.
26.
27.
28.
Vacuum tester with pump and gauge
Vacuum gauge, 100 mm dial, Bourdon tube type
Pneumatic regulator with filter and input & output gauges
Diaphragm type pressure gauge
Stop watch
FLOW METERS / INSTRUMENTS
SL.NO.
DESCRIPTION
QUANTITY
1.
2.
3.
4
5.
6.
7.
8.
9.
10.
11.
12
14
15
Simple tank type quantity meter 2 nos.
Reciprocating piston type flow meter
Impeller type flow meter
Bellows and liquid seal drum type flow meter
Deflecting and rotating vane flow meter
Helical and turbine flow meter
Pitot tube flow meter.
Orifice type flow meter
Venturi tube flow meter
Tapered tube flow meter
Rotameter with needle valve
Magnetic Flow meter
Vortex flow meter
Flow control training simulators consisting of (a) process (Water flowing
in a pipe ) and (b) control instruments to establish automatic feedback
water flow control loop using flow element, transmitter, indicator,
controller, recorder and final control element. A small PLC/DCS can
also be used as controller.
Coriolis mass flow meter
Ultrasonic flow meter
Flow switches
Quantity to
be sufficient
as per seats
surveyed &
allocated
16
17
18
76
Instrument Mechanic (Steel Plant)
LEVEL INSTRUMENT
SL.NO.
1.
2.
3
4.
5.
6.
7.
8.
9
DESCRIPTION
Hook type level indicator
Sight glass level indicator
Float type level indicator with potentiometer
Air purge (bubbler) type level indicator
Level transmitters (float with potentiometer)
Level control training simulators consisting of (a) process (a tank being
filled in with water by a pump) and (b) control instruments to establish
automatic feedback water level control loop using level transmitter,
indicator, controller, recorder and final control element. A small
PLC/DCS can also be used as controller.
Level measurement equipment by electrical method i.e.
conductivity, capacitance, ultrasonic, radar, hydrostatic pressure type
and point level detectors/transmitter with configurator.
Level measurement equipments for solid – ultrasonic, Microwave,
Capacitance probes and Diaphragm switches
Level switches of different type
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
TEMPERATURE INSTRUMENTS
SL.NO.
1.
2.
3.
4.
5.
6.
7.
8.
7.
8.
77
DESCRIPTION
Mercury in glass thermometer (various ranges)
Alcohol or other liquid in glass thermometers
Stem and dial type bimetallic thermometer (various ranges).
Mercury in steel remote indicating thermometers
Resistance temperature detector- Pt, Cu and Ni
Thermocouples – J,K,T and N type
Thermocouples – R, S and B type
Temp. Indicator (RTD & TC input)
Radiation (IR) pyrometer with all accessories
Vapour pressure thermometer.
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
Instrument Mechanic (Steel Plant)
9.
10.
11.
12.
13.
14 .
15.
16.
17.
Immersion pyrometers with bath temp. indicators
Thermocouple type indicator with millivolt potentiometer for
testing pyrometer
Temperature transmitter- RTD & TC input, 4-20 mA output, 24 V DC
power supply
Smart Temperature transmitter with configurators
Experimental setup for measuring and controlling of temperature,
consisting of measuring, controlling, indicating, recording and final
control elements, complete closed loop system.
Thermistor training kit
Digital calibrator with adjustable mV/mA source and indicator injector
Electric furnace, twin chambers (300*200*1200) with standard
temperature indicator
Compensating lead with for various thermocouples
RECORDERS
SL.NO.
1
2
78
DESCRIPTION
QUANTITY
Electronic recorders(single point & multi point) both circular & strip Quantity to
chart types , analog and digital type
be sufficient
as per seats
Pneumatic recorders (single point) circular chart types
surveyed &
allocated
Instrument Mechanic (Steel Plant)
CONTROLLER
SL.NO.
1
2
3
4
5
6
7
DESCRIPTION
QUANTITY
PID controller trainer consisting of instrument panel, digital computer& Quantity to
interface system
be sufficient
as per seats
Real PID controller-training kit
surveyed &
Process simulator based on distributed control system
allocated
PLC trainer with simulated process
Precision air filter regulator with input & output gauges
Pneumatic PID controller trainers
PID controller
FINAL CONTROLLING ELEMENTS
SL.NO.
1
2
3
4
5
DESCRIPTION
Different types of control valves such as gate valves, globe valves, ball
valves, diaphragm valves and butterfly valves- Electrically actuated,
pneumatic actuated & hydraulic actuated
Valve positioners, booster relays, gland packing etc.
Motorized control valve
I/P converter
Test jig for control valve testing
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
EQUIPMENT FOR MICROPROCESSOR
SL.NO.
1
2
3
4
5
DESCRIPTION
QUANTITY
Training kits/ trainers as available on microprocessors applicable to Quantity to
process control & instrumentation
be sufficient
as per seats
Training kits on introduction to computers & computers hardware
surveyed &
Training kits on how microprocessor function
allocated
Digital to analog converter (DAC) kit
Analog to digital converter kit
EQUIPMENTS ON HYDRAULICS AND PNUEMATICS
79
Instrument Mechanic (Steel Plant)
SL.NO
1
2
3
4
DESCRIPTION
Hydraulic trainer
Hydraulic training kits
Pneumatic trainer
Pneumatic training kits
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
ANALYTICAL INSTRUMENTS
SL.NO
1
2
3
4
5
6
DESCRIPTION
Conductivity meter (probe and transmitter with indicator) with water
sampling system
pH meter (probe and transmitter with indicator) with water sampling
system
Gas analyzers for O2, CO, CO2 and H2 along with sampling system
and calibration gas
CV analyzers with calibration gas
Humidity detector
Moisture detector
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
GENERAL INSTALLATIONS (MACHINES)
SL.NO
1
2
3
4
5
6
7
8
9
10
80
DESCRIPTION
Drill power, bench type, precision, motorized with chuck 0 to 12 mm
capacity
Grinder, double ended, bench, high revolutions motorized
Bench lathe, motorized with all accessories
Buffing machine, 900 mm spindle
Electric furnace, twin chambers (275*150*150)
Bench working 1800*900*900 mm
Instrument testing bench with cup boards
Steel cup boards/steel almirah 1800*1200*450 mm (with five shelves)
Steel cup boards with eight lockers for trainees (1800*1200*450 mm)
LCD projector with PC/ Laptop
QUANTITY
Quantity to
be sufficient
as per seats
surveyed &
allocated
Instrument Mechanic (Steel Plant)
11
12
13
14
15
Hydrometers (lab. & storage battery testing type)
Hair hydrometer
Wet & dry bulb thermometer
Sling Psychrometer hydrometer
Fire extinguishers
Note – Some tool, equipment and instrument can be used for other trades/sections of the institute/centre
81
Instrument Mechanic (Steel Plant)
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