20 - Week Modular Course on Basic Electronics & Repair and Maintenance of Inverter, UPS & Stabilizer

Total Credits – 18

Eligibility VIII^th Pass

TheoryContent                   

• Electrical and personal safety, dangers and preventions

• Multimeter and its various applications

• Basics of electricity – define DC, AC, practical measuring units of voltage, current, resistance. Types of transformers – its construction, testing

• Testing of proper earth using test lamp

• Testing of earth using multimeter

• Fuse – types, use of fuses and its rating

• Basic Electronics – passive and active components – testing of components, MOSFET –   precautions when   handling.

• Applications of transistor – its uses

• Op-Amp – Introduction, applications, construction, comparators

• Voltage Regulator and their types

• DIAC, SCR, TRIAC – application

• Digital electronics – gates and its application, multiplexers, de-multiplexers, counter

• Electrical load their VA and watts. Various types of batteries used in UPS and Inverters and their maintenance.

• Single phase and three phase system, different types of inverter, UPS, working principle, specifications, explanation with the help of block diagram, basic principle of working of power switches, testing methods, discussions of various faults, diagnosing methods, rectifying common faults.

Practical Content

•Practice procedure for electrical and personal safety measures

• Use of multimeter

• Testing of active and passive Components

• Testing of transformers

• Testing of semiconductor components

• Testing of unregulated and regulated Voltages

• Soldering and de-soldering techniques

• Assemble and test rectifier circuits – half wave, full wave & bridge rectifier

• Assemble a power amplifier circuit (ce,emitter follower)

• Assemble and test an audio power amplifier (buzzer)

• Construct a RC- oscillator and test it.

• Find the total load and select a suitable UPS/Inverter (rating factor)

• Installation of UPS and Inverters

• Maintenance of battery.

• Opening & dismantling an equipment and identifying the major parts, testing of major components, identifying transformers and checking, checking of power modules, charging, discharging and testing of batteries, repairing of SMPS, simulating various faults diagnosing and rectifying it.

The modular course is of 9 credits and is upon to candidates who have either completed or are enrolled in a certificate level vocational course in any Engg. trade.

The theory and practical content of the course is given below:

Theory Content

Unit 1

- Types of welding processes and application - Nomenclature of Fillet and groove welds - Welding terms and definitions - Oxy-Acetylene welding plant – description operating procedures, safety etc. - Types of metals and characteristics- Principles of shielded Metal Arc welding its advantages and limitations. - Tools, accessories and equipment for SMAW - Types of welding joints and edge preparation - Safety precaution in Arc welding

Unit 2

- Types of Oxy-Acetylene flames and their uses. - Chemistry of Oxy-Acetylene and flame temperatures - Oxy-Acetylene regulators – description and safe operating procedures - Oxy Acetylene welding blow pipes types description care and maintenance - Oxy Acetylene welding parameters – Blow pipe size, pressure setting and filler rod size for different sheet thickness- Principles of Oxy Acetylene cutting process - Selection of blow pipe size, pressure setting for various thickness of MS       plates - Types & function of flux of shielded Metal Arc Welding electrodes and coating factor - Coding of SMAW electrodes as per BIS/AWS - Selection criteria of electrode types and diameter - Principle of welding Arc, its characteristics and Arc length - Arc welding procedure and technique

Unit 3

- Welding positions and their significance - Filler rods and fluxes for brazing and soldering Gas Welding Techniques - Distortion and methods of control- Inside corner joint on MS by SMAW in flat positions - Outside corner joint on MS by SMAW in flat position - Single ‘V’ but joint on MS by SMAW in flat position - Basic Electricity applicable to welding - Arc welding power source, AC Transformers, DC welding rectifier, Dc welding generator and their features - Care and maintenance of welding power source - Polarity – types and application

Unit 4

- Arc blow and its control - Metals and their Weldability - Necessity of pre-heating and post heating while wel- Welding defects causes and remedy - Inspection and testing of welding ding alloy steels

Unit 5

-TIG & MIG- Definition, Working Process, Advantage, Disadvantage & Application- Defects and their remedies-Resistance welding-Types of resistance welding- Spot & Seam RW- Definition, working process, Advantage, Disadvantage & Application

Practical Content

Unit 1

-Safety in Shop floor - Identification of tools and accessories used for Gas and Arc welding - Setting up of Gas Welding Plant - Opening and closing procedure of gas welding plant - Lighting and adjustment of Oxy-Acetylene flame - Beading practice on MS sheet with and without filler rod- Setting up Arc Welding pl- Striking an Arc and depositing straight and wearing beads on MS in Flat position

Unit 2

- Close square butt joint – on M.S. Sheet by gas welding in flat position - Open square butt join on M.S. sheet by gas welding in flat position

- Fillet T joint on M.S. Sheet by gas welding in flat position - Setting up Oxy Acetylene cutting plant and practicing gas cutting on M.S. plate

- Filler ‘T’ joint on M.S. flat by SMAW in flat position - Fillet lap joint on M.S. by SMAW in flat position

Unit 3

- Outside and Inside corner joint – on M.S sheet by gas welding in flat position - Brazing with Oxy-Acetylene flame - Silver soldering and Oxy-Acetylene flame- Inside corner joint on MS by SMAW in flat positions - Outside corner joint on MS by SMAW in flat position - Single ‘V’ but joint on MS by SMAW in flat position

Unit 4

- Pipe butt joint on MS pipe by Oxy-Acetylene welding in 1G position - Pipe to Sheet flange joint on MS by Oxy – Acetylene welding in horizontal – vertical position- Pipe butt joint on MS pipe by SMAW in 1 G position - Pipe to plate flange joint on MS by SMAW in horizontal – vertical position

Unit 5

-Lap joint on MS in flat position-Butt joint on MS in vertical position-V- joint on MS in horizontal position-Lap joint on GI sheet -Butt joint on GI sheet.

10-Week Modular Course on “Industrial Painting”

The Modular course is of 9 credits and is open to candidates who have either completed or are enrolled in a certificate level vocational course in any Engg. trade.

The theory and practical contents of this course are given below:

Theory Content

UNIT-I

Paint Industry in India.• Importance of painting, painter & related works.• Health and safety precautions, safe working    practices.• Tools & Equipment used in painting technique, their specifications & quality. • Various types of Putty, primer, paints, varnishes generally used for painting applications and their quality.• Importance of using proper tools & equipments.• Systematic use of various types of painting tools & equipment, spray guns, ford cup sets.• Necessity and type of help to Painter by Helper.• Waste disposal at work places.• Behavior at work place. Customer & their expectations while painting•Health and safety precautions, safe working practices and waste disposal at work place.• Corrosion: Causes of Corrosion. Types of Corrosion, its effect on metallic surfaces, purpose of Metal pretreatment.•Corrosion on different Metals both Ferrous and non ferrous. Factors affecting corrosion.• Economical loss due to corrosion.

UNIT-II

Methods for the protection of Metal from corrosion.• Various methods of spray applications.• Adhesives like putties, Filler and metal cement for metallic paintings• Brushes, Description, sizes & uses.

UNIT-III

Colour and tone perception. Effect of light on colour, warm/cold colours. Special considerations of colour scheme selection.• Quality & Finishing of Work: Importance of quality & finish of job at all stages. Protection of finish surfaces.• Economical use of material, calculation for quantity of paint required, costing & evaluation.• Behavioral etiquette• Health and safety precautions, safe working Practices and waste disposal at work   place.• Spray Painting Equipments – different types of Spray Guns.• Method of spraying techniques on various  surfaces.• Precautions in holding of Spray Guns &   spraying stroke.• Maintenance of Spray Guns.

UNIT-IV

Method and application process of metal   surface painting & finishing.• Various types of system of spray painting and their effect on metal surfaces.• Synthetic, Cellulose & Acrylic paints and  finishing on metal surfaces.• Use of higher performance coating like  Chlorinated rubber & Epoxy paints.

UNIT-V

Treatment of various defects arising    while spray painting and their remedies such as lifting, checking, craking wrinkling.• Airless & Electrostatic spraying: Description and safety precautions.• Handling of paints for Electrostatic spraying.• Paint used in Electrostatic spraying.  Behavioral etiquette• Calculation for quantity of paint required, costing & evaluation. • Health and safety precautions, safe working practices and waste disposal at work place.• Basics of MSDX• Theory related to methods of testing paints and varnishes• Material Safety Data Sheets• Processes of pretreatment of metals, wood and  wall surfaces. Pre treatment processes on ferrous  and non ferrous metals, casting and sheet metal• Processes of painting different types of   machines, tools and equipments.• Various colour codes and identification of pipe   lines as per international & industrial standards.• Standard colour code practices.• Spray painting on Machines Automobiles & Domestic appliances.• Use of high performance coatings.• Painting problems and their resolutions• System of storage of paints & lacquers,  solvents, thinners, painters tools.• Maintenance of store records, quality   assessments of materials and man power requirements for painting jobs. Preparing cost estimates.

Practical Content

UNIT-I

Use of protective clothing and equipment and carry out safe working practices • Apply good housekeeping practices, proper    handling of materials and waste disposal.• Identify and familiarize with tools & equipments    used in painting.• Identify and familiarize with various types of raw materials used in painting e.g. paints, Putty, Varnishes • Use of tools, equipments used for painting.• Upkeep, care & maintenance of tools & equipments.• Familiarization with various types and conditions  of painting surfaces e.g. wall, wood & metal etc.• Prepare basic surfaces: wall, metal and wood for good painting work.• Apply putty, paint varnishes and polish to the  different surfaces by using proper application   sequence.• Field visits to locations where painting is going on.• Use of protective clothing and equipment and   carry out safe working practices.• Apply good housekeeping practices, proper   handling of materials and waste disposal.• Demonstration and practical on Metal • Pretreatment such as Scraping, Rubbing by Emery   cloth, Wire brushes, buffing, pickling, phosphating, and Blasting etc.• Practical on Metal surface preparation for painting by rubbing with emery scraping, wire brushing, Manual chipping & by portable Grinder.• Descaling of Metal surfaces and flame cleaning of rusted surfaces.

UNIT-II

• Demonstration and Practical on Pretreatment of Ferrous & nonferrous surfaces by degreasing, etching, pickling & solvent wiping• Preparing surface for primary coat of different metals. Practicing by brushes of various sizes • Cleaning & wiping of different surfaces to be painted to the required standard.

• Practical on Preparation of Adhesive Compound like putties, filler and Metal, Cement and applying them on as metal surfaces.• Primary painting & finishing painting by Brushes of Metal surfaces.

UNIT-III

• Practical on Selecting, Mixing, Tinting & preparing of all types of oil paints/water paints synthetic paints & other paints to obtain specific colours.• Practical on Rectifying the Common Coating Failures & repairing of various painting defects.• Use of protective clothing and equipment and carry out safe working practices.• Apply good housekeeping practices, proper handling of materials and waste disposal.• Demonstration on Handling of different types of spray painting machines in different types of painting booths

UNIT-IV

• Practicals on Pretreatment, applying of primer coats & spray painting on metal surfaces & finishing work• Practicals as Spray painting on different surfaces like corners, round, parallel, curved surfaces angles, rectangular, cone, cylinder, square.• Adjustment of spray gun stroke and holding spray gun for multipurpose work.

UNIT-V

• Spray painting with Compressed Air Atomisation.• Practice on different types of Spray Guns.• Practice of Airless & Electrostatic spraying by using different types of Electrostatic Spray Guns.• Practical on Testing of different paints and varnishes in respect of specific gravity, viscosity, hardness gloss, finish, adhesion, flexibility and drying time etc.• Practice on different types of spray booths.

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