ITI's which provides courses for Mechanic Maintenance (Chemical Plant)

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Induction Training – Familiarization with Institute. Importance of trade training. Introduction out machineries & equipments used in chemical trade work done by trainee. Introduction to safety equipment, first aid & fire lighting equipments and their uses in the section.     

Introduction & importance of safety &. General precautions observed in the Workshop.  Fire prevention fire control in chemical industries. Study of personal protective equipments used in chemical plant. First aid in chemical plant. Environmental pollution, sources, causes, consequences and controls. Role of maintenance mechanic in the Chemical Industries.

2

Filing flat surface and checking the flatness and squareness with engineers‟ try square. Filing four edges, checking all dimensions with outside calliper and steel rule. Filing adjoining sides/surfaces maintain the right angle between the sides. Marking of parallel lines using dot punch. Chiselling practice as per marking lines.

Description, construction and uses of different hand tools such as files, chisels, hacksaw & hammer etc. Description, construction and uses of different marking tools such   as steel rule, calliper, punches, v-block, scribing block etc. Description construction and uses of different job holding devices.

3

Making a job on step fitting (Male & female). Marking out the position of holes for drilling. Use of centre drill for drilling operations.

Description, construction, calculation and uses of different linear measuring Instruments such as –vernier calliper, micrometer, bevel protractor, height gauge.

4

Marking the job using height gauge.  Practice of through & blind hole drilling to a specific depth. Practice of enlargement of drill holes, countersinking, counter boring, spot facing and reaming etc. tapping and  dieing  of BSW, and metric  threads  of  various sizes.

Description, nomenclature and uses of different types of threads – metric, BSW, BSF, BSP etc. Calculation of tap drill size. Description and uses of drill chuck, drill drifts & sleeves etc.

5

Practice of angular filling (male & female part) and fitting of both the parts, checking angle with bevel protector.

Introduction of drilling  machine  its–  types, parts & specifications

6

Practice on combination fitting consisting of step, radius and angle.

--

Practice on dismantling & assembling different types of bearing & bushes.

--

7

Demonstrate about shop safety, safety precaution as applied to section. Introduction, types of work done in the section, lathes its parts and functions. Check it for proper running, cleaning and oiling of various parts.

Shop safety, safety precaution as applied to section, Lathe – its construction, cleaning and oiling. Independent chucks different types and construction, uses. Common lathe cutting tools, type, shapes, different angles.

8

Setting tools in tool post. Facing operation, centre drilling. Grinding of lathe tools. Plain turning by holding  job  in  the chuck turning to specified dia.

Lathe accessories, such as centre, mandrel, catch plate, face plate, lathe steady etc. Common lathe cutting tools, roughing and finishing tools, knife tool, recessing tool etc. Lathe tool material.

9

Drilling on lathe – through and   step boring tool in tool post. Plain Boring.

Drills – construction, types uses of sleeves. Boring tool types. Setting of boring tool.

10

Exercise on knurling, practice on form turning.

Screw thread purpose and forms. Screw thread terminology.

11

Thread cutting (BSW), thread cutting (Metric).

Calculation  of Calculation of pitch, depth, core dia, pitch dia etc.

Sem. II

Trade Practical

Trade Theory

1

Introduction-importance of trade, types of work done. Demonstrate about general safety, personal safety, & precaution observed during gas welding. Procedure of fire prevention and fire control in gas welding workshop. Safety equipment's and their uses. Lighting and adjustments of flame. Fusion runs with and without filler rod-D.

Safety and general precautions observed in workshop. Importance of welding in maintenance of chemical plant and equipment. Safety precautions in gas welding. Description and uses of tool and equipment used. Welding terms and their definitions.

2

Practice of edge joint with or without filler rod -D. Square butt joint-D.

Welding methods and groups of welding, welding terms and definitions. Common gases used in welding- Oxygen, hydrogen acetylene, CO2 gas etc. Chemistry and types of flame.

3

Practice on outside corner Joints-D. Fillet weld-D. Inside corner joint.

Oxy-acetylene welding, equipment such as regulator, blow pipes etc. Assembling, care and maintenance.

4

Practice on Pipe butt joint-D & Pipe T-joint-D.

Oxygen cylinder, DA cylinders, Description methods of charging and care. 

5

Practice of hard surface stilting. Brazing of similar metals. Straight cutting by gas. P.V.C. Welding, all types joints  on  sheets 3mm,  4 mm, 6 mm. P.V.C. Welding pipe, Flange, elbow and T etc.

Hard facing-necessity, types, methods application. Destructive test, stilting-necessity, type flame adjustment- methods and applications.  Methods Employed to control distortion and stress relieving.

6

Determination of co-efficient of expansion of solid and liquid. Measurement of specific heat by calorimeter. Determination of coefficient of thermal conductivity of metal rod.

Objective, procedure, apparatus explanation and calculations involved in the experiments.

7

To study the allotropic forms of sulphur. To study the properties of mixtures (FeS) and compound (FeS). To study action of pure salt water on metals and alloys. To study action of acids and bases on metals and alloys. To study corrosion of metals. Volumetric analysis: Qualitative analysis (Inorganic) (Simple without interfering radicals.

Objective, procedure, apparatus required explanation and calculations involved in the experiments. Objective, procedure, apparatus required explanation and calculations involved  in  the experiments

Project work

Sem. III

Trade Practical

Trade Theory

1

Introduction to safety equipments and their uses. Awareness of first aid, fire fighting equipments and hydrant system, material safety data sheet (MSDS), Personal protective equipments (PPEs). Marking out key ways in shafts, using cross out chisel for key ways. Fitting key into the grooves.

Introduction & importance of safety & general precautions observed in the workshop. Fire prevention and fire control in chemical industries. Study of personal protective equipments (PPEs) used in chemical plant. First aid in chemical plant. Introduction to occupational health hazard.

2

Filling for smoothness of machined surface. Use of Prussian blue for high spots & scrapping.

Scrapers, their uses, type method of scrapping. Tolerance and limits, types of its allowance definition.    

3

Cutting, threading, bending and fitting of pipes as per drawing. Making different types joints  such  as  screwed  & flanged etc.

Pipes and pipe joints, pipe bending fixtures, standard pipe threads, taps and dies used for pipe threading.                              

4

Use  and  maintenance  of lagging material, such as glass-wool, asbestos, magnesia, thermocole, aeroflex etc.

Lagging material, types, uses. How to use high, medium slow  pressure pipe  lines,  testing leakage etc.

5

Preparing pipe lines, using various  pipe  fittings  for metals such as – Aluminium, copper, G.I. Steel, PVC pipes etc.

Standard pipe fittings method. Methods of fitting or replacing them.

6

Dismantling, overhauling & assembling of globe valves, gate valves, stop cocks, non  return valves, ball valves, needle valves etc.

Construction

7

Fitting  and  assembling  of different gears  and  gear boxes, reduction gear etc.

Types of gears such as Spur, Helical, bevel, worm & worm wheel etc. – their uses.

8

Dismantling, overhauling and assembling of different type of pump such as positive displacement pumps (reciprocating pump, gear Pumps, plunger pumps), centrifugal pumps and vacuum pumps.

Types of pumps, their construction details and uses.

9

Checking the alignment of shaft and of motors, correcting alignment by using of spirit level & dial gauges.

Causes of mis-alignment, different methods of checking alignment.  Effect  of  mis-alignment on shafts and couplings

10

Fitting and maintenance of compressors blowers, fan, crushers, mixer, pulverisers.      

Compressors, blowers, fans, crushers, mixers, pulveriser-their types, construction and uses.

11

Fitting of bearings, such as ball bearing, roller bearing, bush bearing etc.  –  their care, lubrication and maintenance

Bearing –their types, construction, uses.

12

Fitting of oil seals, checking and replacing of oil seals, removing bearings using bearing pullers.                                               

Different types of lubricating oils their grades and uses. Bearing puller types, and their use.

13

Dismantling, cleaning, repairing and reassembling machinery using chain pulley, blocks, jack      etc. Safe handling and operation of the same

Installation, maintenance and overhauling of machinery and levelling, equipment and alignment of machines

14

Importance of preventive and routine maintenance, log cards, records of maintenance schedules etc.                

Types of maintenance, keeping various records of preventive maintenance, log cards, repair schedules.

15

Maintenance of pressure vessel fittings, making of packing, gaskets.                         

Different types of pressure vessels, their care and maintenance. Different  types  of  packing materials gaskets etc.

16

Use of correct materials and locking devices, such as split pin, locknut, pring washer, etc

Purpose of locking devices, locking nuts, types their application. Washers, types, use.

17

Trouble shooting and maintenance of various equipments like compressors, pumps, valves, blowers, fans etc.                   

Various types of lifting appliances, extractors’ pressure, and their uses. Different methods of getting mechanical advantages

18

Trouble shooting

Handling of heavy machinery precaution to be taken etc.

19

Machinist General introduction to the shaping machine

Shaping machine: Working principle, purpose, size and specification

20

Setting tool in the holder, shaping plain surface by roughing too.

Different part and their functions, shaping machine safety

Project Work

Sem. IV

Trade Practical

Trade Theory

Shaping of rectangular block to size and checking up with steel rule, calliper and try square. Marking out for shaping steels, slots etc.   

Use  of  machine  vice  in  shaping machine, methods of holding work in the vice, method of adjusting length and position of strokes.

General introduction to slotting machines, setting up job on the table. Setting up tool adjustment of stroke slotting rectangular block to size.

Use of  slotting machine, different parts  and working principles, specification,  different method of setting tool, safety in slotting.

Marking out for slotting, cutting slot, and grooves.

Driving machine in the slotting machine, common method of holding jobs for slotting.

General introduction to milling machines, setting of vice on the table, plain milling practice.

Milling Machine: Purpose, types and classification, constructional features of milling machine, controls etc. Use of graduated dial

Setting work in the vice fixing plain milling cutter on the arbour. Milling rectangular blades to dimensions.

Milling cutters, types, uses of various milling operation, various common holding device used in milling machines                    

Making rectangular clocks and straight            slot cutting according to dimensions with cylindrical cutters and side and face cutters.

Driving and feeding mechanism of milling machine. Various common milling operations various common holding devices used in milling machine.                                             

Making rectangular clocks and straight slot cutting according to dimensions with cylindrical cutters and side and face cutters.

Driving and feeding mechanism of milling machine. Various common milling operations various holding machine.

Welding (ARC) Straight line beads on M.S. Plate.                             

Different process of metal joining, bolting, revetting, soldering, brazing etc.

Open corner joint M.S. Plate.

Types of joints, classifications, Elementary electricity. Applied to welding.

Fillet weld (M.S. Plate)          

Description and use of tools and equipment used in Arc welding.

Outside and inside joints. Single ‘V’ Butt joint.

Types of electric welding metallic, carbon, resistance etc. & application arc length etc.             

Fillet lap joint and T joint.

Principle of arc welding types of welding and their advantages.

Pipe joints, T-butt joints (Square butt)

Electrodes, types, method  of coating,  flux, characteristic I.S.I. specification

Advanced welding (TIG & MIG) with all types of joints

Arc welding defects, causes and effects, how to overcome etc. Distortion and its control

Practice of different PVC welding process.

Simple estimating involving fabrication, consumption of gas, electrode, length of weld use of hand book and relief tables.            

Installation of orifice meter, venture meter  and rota-meter

Orifice taps, construction of orifice meter, venuri-meter and rota-meter, precaution to be taken during their installation.                 

Making head vs. capacity curve for centrifugal and gear pumps.

Construction of centrifugal and gear pumps, characteristics curves, trouble shooting.

Determination of rate of evaporation of a vertical tube evaporator. Separation of   a binary liquid mixture in a packed distillation tower.

Construction of vertical tube evaporator.     

Operation of-
(a) Plate and frame filter press,
(b) Top driven  centrifuge,  and
(c) Rotary vacuum filter.

Construction, trouble shooting and applications.

Operation of –
a) hammer mill
b) ball mill
c) Blake jaw crusher

Construction, trouble shooting and applications.   

Study of multi-stage compressor. Study of three phase, electrical motors, starters.

Theory of compression, Related electrical technology. 

Instrumentation–Calibration of –
a) Bimetallic thermometer
b) Thermocouple
c) Resistance thermometer
d ) Mercury in glass thermometer. Calibration of Bourden’s tube pressure gauges –
a) C-type
b) Spiral
c) Helix Calibration of vacuum gauge, pressure switch, Study of pneumatic control valve, pressure, level, flow, temperature transmitter/controller, recorders.

Heat - its mode of transfer, temperature scale, different methods of temperature measurement. Pressure: Definition, its units, different methods of pressure Measurement. Study of vacuum gauge, pressure switch, pneumatic control valve, level controller, flow controller, temperature transmitter / controller, recorders.