ITI's which provides courses for Pump Operator and Mechanic

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Familiarisation with institute, Job opportunities in the automobile sector, Machinery used in Trade. Types of work done by the students in the shop floor.

Admission & introduction to the trade: Introduction to the Course duration, course content, study of the syllabus. General rule pertaining to the Institute, facilities available–Hostel, Recreation, Medical and Library working hours and time table

2

Practical related to Safety and Health, Importance of maintenance and cleanliness of Workshop. Interaction with health centre and fire service station to provide demo on First aid and Fire safety, Use of fire extinguishers.

Occupational Safety & Health Importance of Safety and general Precautions to be observed in the shop. Basic first aid, safety signs - for Danger, Warning, caution & personal safety message. Safe handling of Fuel Spillage, Fire extinguishers used for different types of fire. Safe disposal of toxic dust, safe handling and Periodic testing of lifting equipment, Authorization of Moving & road testing vehicles.

3

Practice using all marking aids, like steel rule with spring calipers, dividers, scriber, punches, Chisel etc., Layout a work piece- for line, circle, arcs and circles. Practice to measure a wheel base of a vehicle with measuring tape.

Hand & Power Tools: Marking scheme, Marking material-chalk, Prussian blue. Cleaning tools- Scraper, wire brush, Emery paper, Description, care and use of Surface plates, steel rule, measuring tape, try square. Calipers-inside and outside. Dividers, surface gauges, scriber, punches-prick punch, center punch, pin punch, hollow punch, number and letter punch. Chisel-flat, cross-cut. Hammer- ball pein, lump, mallet.

4

Measuring practice on Cam height, Camshaft Journal dia, crankshaft journal dia, Valve stem dia, piston diameter, and piston pin dia with outside Micrometers.

Systems of measurement, Description, care & use of - Micrometers- Outside and depth mirometer, Micrometer adjustments, Vernier calipers, Telescope gauges, Dial bore gauges, Dial indicators, straightedge, feeler gauge, thread pitch gauge, vacuum gauge, tire pressure gauge.

5

Practice on General cleaning, checking and use of nut, bolts, & studs etc., Removal of stud/bolt from blind hole.

Fasteners- Study of different types of screws, nuts, studs & bolts, locking devices, Such as lock nuts, cotter, split pins, keys, circlips, lock rings, lock washers and locating where they are used. Washers & chemical compounds can be used to help secure these fasteners.

6

Practice on Marking and Drilling clear and Blind Holes, Sharpening of Twist Drills Safety precautions to be observed while using a drilling machine. Practice on Tapping a Clear and Blind Hole, Selection of tape drill Size, use of Lubrication, Use of stud extractor.

Drilling machine - Description and study of Bench type Drilling machine, Portable electrical Drilling machine, drill holding devices, Work Holding devices, Drill bits. Taps and Dies: Hand Taps and wrenches, Calculation of Tap drill sizes for metric and inch taps. Different type of Die and Die stock. Screw extractors. Hand Reamers – Different Type of hand reamers, Drill size for reaming, Lapping, Lapping abrasives, type of Laps.

7

Practice on making Rectangular Tray. Pipe bending, Fitting nipples unions in pipes. Soldering and Brazing of Pipes.

Sheet metal - State the various common metal Sheets used in Sheet Metal shop Sheet metal operations - Shearing, bending, Drawing, Squeezing Sheet metal joints - Hem & Seam Joints Fastening Methods - Riveting, soldering, Brazing. Fluxes used on common joints. Sheet and wire-gauges. The blow lamp- its uses and pipe fittings.

8

Practice in joining wires using soldering Iron, Construction of simple electrical circuits, Measuring of current, voltage and resistance using digital multimeter, practice continuity test for fuses, jumper wires, fusible links, circuit breakers.

Basic electricity, Electricity principles, Ground connections, Ohm's law, Voltage, Current, Resistance, Power, Energy. Voltmeter, ammeter, Ohmmeter Mulitmeter, Conductors & insulators, Wires, Shielding, Length vs. resistance, Resistor ratings.

9

Diagnose series, parallel, series parallel circuits using Ohm’s law, Check electrical circuit with a test lamp, perform voltage drop test in circuits using multimeter, measure current flow using multimeter /ammeter, use of service manual wiring diagram for troubleshooting

Fuses & circuit breakers, Ballast resistor, Stripping wire insulation, cable colour codes and sizes, Resistors in Series circuits , Parallel circuits and Series-parallel circuits, Electrostatic effects, Capacitors and its applications, Capacitors in series and parallel.

10

Cleaning and topping up of a lead Acid battery, Testing battery with hydrometer, Connecting battery to a charger for battery charging, Inspecting & testing a battery after charging, Measure and Diagnose the cause(s) of excessive Key-off battery drain (parasitic draw) and do corrective action.

Description of Chemical effects, Batteries & cells, Lead acid batteries & Stay Maintenance Free (SMF) batteries, Magnetic effects, Heating effects, Thermo-electric energy, Thermisters, Thermo couples, Electrochemical energy, Photovoltaic energy, Piezo-electric energy, Electromagnetic induction, Relays, Solenoids, Primary & Secondary windings, Transformers, stator and rotor coils.

11

Identify and test power and signal connectors for continuity, Identify and test different type of Diodes, NPN & PNP Transistors for its functionality, Construct and test simple logic circuits OR, AND & NOT and Logic gates using switches

Basic electronics: Description of Semi conductors, Solid state devices- Diodes, Transistors, Thyristors, Uni Junction Transistors (UJT), Metal Oxide Field Effect Transistors (MOSFETs), Logic gates-OR, AND & NOT and Logic gates using switches.

12

Practice to make straight beads and Butt, Lap & T joints Manual Metal Arc Welding. Setting of Gas welding flames, practice to make a straight beads and joints Oxy – Acetylene welding Film on Heat treatment process.

Introduction to welding and Heat Treatment Welding processes –Principles of Arc welding, brief description, classification and applications. Manual Metal Arc welding -principles, power sources, electrodes, welding parameters, edge preparation & fit up and welding techniques; Oxy – Acetylene welding - principles, equipment, welding parameters, edge preparation & fit up and welding techniques.

13

Practice on Liquid penetrant testing method and Magnetic particle testing method. Identification of Hydraulic and pneumatic components used in vehicle.

Non-destructive Testing Methods- Importance of Non-Destructive Testing In Automotive Industry, Definition of NDT, Liquid penetrant and Magnetic particle testing method – Portable Yoke method

14

Identification of different type of Vehicle. Demonstration of vehicle specification data; Identification of vehicle information Number (VIN).

Auto Industry - History, leading manufacturers, development in automobile industry, trends, new product. Brief about Ministry of Road transport & Highways, The Automotive Research Association of India (ARAI), National Automotive Testing and R&D Infrastructure Project (NATRIP), & Automobile Association.

Sem. II

Trade Practical

Trade Theory

1

Identification of different type of stationary Engine and their applications. Familiarisation with diesel engines, tools and equipment required for maintenance, engine parts and their handling technique. Starting and stopping of engines. Running of engines and checking temperatures, fuel oil pressure and consumption on load and engine speed.

Pump Industry in India - leading manufacturers, development in Pump Industry, trends, new product. Principle of Compression-ignition engine, Spark Ignition Engine, differentiate between 4-stroke and 2 stroke, C.I engine and S.I Engine, Otto cycle and Diesel cycle.

2

Cleaning of fuel tank, checking leaks in the fuel lines. Cutting, flaring of tubes to make T & Elbow fitting using unions. Fitting of lubrication pump oil filters, air filters, checking and adjusting of oil pressure. Preventive maintenance & repairing.

Procedure to clean fuel tank & check leak in the fuel line. Lubrication system – types, description and advantages of each over others. Filters and oil coolers – their description functions and method to overhaul for efficient functioning.

3

Practice on troubleshooting in for Engine Not starting – Mechanical & Electrical causes, High fuel consumption, Engine overheating, Low Power Generation, Excessive oil consumption, Low/High Engine Oil Pressure, Engine Noise.

Troubleshooting : Causes and remedy for Engine Not starting – Mechanical & Electrical causes, High fuel consumption, Engine overheating, Low Power Generation, Excessive oil consumption, Low/High Engine Oil Pressure, Engine Noise.

4

Familiarization with plain/journal bearings, anti-friction bearings used on machine assembly. Specification Mounting of bearing on shafts and in housing with proper fit & axis alignment. Use of proper tools.

Types of belt drives, velocity ratio of belt drive. Horse Power transmitted by belt. Ratio & driving tension in a belt. Parallel & cross belt drive, open & cross belt drive, angular belt drive. Methods of fixing and uses.

5

Identification of different pumps, its components, prime movers. Practice on operational safety Dismantling of reciprocating pumps- valves, pistons, cranks, seals etc. for inspection, repair & replacement.

Pumps-its importance for agricultural & industrial applications. Classification of pumps, its prime movers, parts and operation safety. Classification of reciprocating pump, construction and operation. Installation technique of reciprocating pump.

6

Dismantling of rotary pumps- impeller, shaft, bearing etc, for inspection, Repair & replacement. Cleaning of parts and assembling.

Classification of rotary pumps- Construction and operation- repairing procedure. Brief description of turbine & stage pumps, positive displacements and their advantages.

7

Servicing of pumps and valves of general purpose and of corrosive fluids. Selection of gasket, packing & gland materials, marking & cutting off gasket as per shape & profile.

Different types of valves-their description, advantages & use. Special pumps & glands used for corrosive fluids. Different gasket cement used to prevent leakage and advantages of each over the other.

8

Installation of seals leather polythene, asbestos, rope rubber and mechanical seals. Maintenance of lubrication systems.

Various seals- their use and places of application with advantages. Lubrication types of lubricant use & methods of lubrication.

9

Installation of stationary & coupled pumps, checking and correcting of alignment of pump with its prime movers and its serviceability test.

Method of install, align and testing of pumps for their serviceability. Concept of lightening torque for different sizes of bolts.

10

Reconditioning of centrifugal pumps.

Principle of centrifugal pump. Construction and operation of centrifugal pump in series and parallel.

11

Dismantling identifying of parts, finding out defects, repairing, and replacement of components, cleaning, assembling, installing and testing of submersible pumps.

Submersible pump- construction, operation and selection of appropriate type. Procedure to recondition, install and test of submersible pumps.

12

Identifying and rectifying defects of pump sets. Practice on preventive & scheduled maintenance of pump sets.

Defects in pump sets- procedure for detection of causes & rectification. Purpose and procedure for balancing of rotor.

13

Familiarization with the safety precautions to be followed for electrical work. Treatment for electrical shock.

Safety rules to be followed in connection with electrical work. First aid when affected by electrical shock.

14

Verification of Ohm’s law. Building up of electrical series, parallel and combination of series & parallel circuits. Measurement of current, voltage resistance.

Description and method to use current, voltage and resistance measuring instruments and precaution to be taken. Insulation Tester description, method to use and precautions to be taken.

15

Identifying of A.C motors, their testing, identifying terminals, connecting running & reversing.

AC Motors – related terminology. Purpose, type, construction, operation, testing for correct functioning, maintenance and industrial applications.

16

Practice on making out key as per shaft, hub, keyways, preparing keys to fit into keyways.

Types of key and key ways, their uses and applications. Preparation of keys, allowable tolerance, clearances.

17

Identifying, selecting, use of different types of ropes such as hemp, manila, nylon, wire etc. Practicing different types of knots and its applications.

Specification and use of different types of ropes such as hemp, manila, nylon, wire etc. Practicing different types of knots and its applications.

18

Use of different types lifting tackles both mechanical and hydraulic such as – Screw jacks, chain pulley block, crabs and winches, rollers and bars, levers, lashing and packing.

Description, operation, purpose, application, care and use of Different types of lifting tackles for components of pump set. Precaution to be observed while using lifting tackles.

19

Making different types of keys for fitting pulleys, Assembling and dismantling of bushes, bearings and couplings maintaining safety.

Types of pulleys solid, split, “V” groove, step, cone, taper, guided and jockey or rider pulleys, their functions and uses. Procedure to assemble and dismantle pulleys and impellers from shafts following safety precautions.

Project Work