Electronic Mechanic (Steel Plant)

SYLLABUS FOR
Electronics Mechanic (Steel Plant)

Under
APPRENTICESHIP TRAINING SCHEME
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE

MINISTRY OF LABOUR AND EMPLOYMENT
GOVERNMENT OF INDIA
GENERAL INFORMATION
Name of designated trade
N.C.O. Code No.
7243
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
List of members attended the Workshop to finalize trade syllabus of

Electronic Mechanic (Steel Plant)
Under
Apprenticeship Training Scheme
on 12th and 13th July, 2010 at SNTI, Jamshedpur, Jharkhand
Shri S.D. Lahiri, Director, CSTARI Chairman
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Name of Member & Designation

Shri/
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
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
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Anil Kumar, Jt. Director

Dr. Binod Kumar
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
RDAT, Kolkata
FTI, Jamshedpur
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
Tata Steel Ltd.
SYLLABUS FOR THE TRADE

of
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 )
Trade- Electronics Mechanic (Steel Plant)

Training Structure
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2nd Year
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Module No
A.1
A.2
A.3
A.4
A.5
A.6
A.7
A.8
A.09
A.10
A-11
A.12
A.13
A.14
A.15
A.16
A.17
A.18
A.19
A-20
B.1
B.2
C
Modules/ Subject
1st Year
Basic Trade Training
Introduction, general & behavioral safety
Industrial safety & Quality
Bench-fitting Skills
Electrical Fundamentals and circuit
Electrical machines
Basic Electronics
Power Electronics & Drives
Analog & Digital Communication
Instrumentation & Control
Revision & Test
PLC & DCS
Fluid Power (Industrial hydraulics & pneumatics)
Welding
Advanced Industrial Electronics
Repair & maintenance of electronic equipment
Electrical Power System
Computer and IT
Iron & Steel making technology
Quality Management and Improvement Techniques
Rigging
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
Duration in weeks
01
01
08
08
08
10
06
04
04
02
02
02
01
04
05
04
01
02
01
02
01
01
24
02
Syllabus to be
covered within 2 years
of training period
104
6
SYLLABUS FOR THE TRADE OF ELECRONIC MECHANIC (STEEL PLANT) UNDER ATS
DURATION- 2 YEARS
Part A: Basic Trade Training- Duration- One and Half ( 1 ) Year
1st Year
1. Introduction, general & behavioral safety (1 week)
Week
Trade Theory
No.
Terminal Competencies:
Trade Practical
Engineering Drawing
Workshop Calculation
& Science
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

Familiarization
with
the Plant visit to observe steel
Institute & steel industry.
making process & machineries
Machinery used in the trade used in steel plant.
and type of work done by the Use of Personal Protective
trainees in the trade.
Equipment.
Importance of safety, general Rules & regulation of the
safety precautions observed institute
in the Institute and in the
section.
Importance of the trade &
trade training,
Related
instructions
&
subjects to be taught.
Salient
features
of
Apprentices Act.
Introduction to general ,
behavioral and road safety
Overview
of
steel
manufacturing process.
Introduction
to Applied
workshop
Engineering drawing, its problems
involving
importance and uses in common fractions.
engineering fields.
Science Definition,
Nomenclature, Various
branches , significance
and
definitions
of
important terms.
2. Industrial Safety & Quality (1 week)
After completion of this module the trainee will be aware of
Industrial Safety and first aid techniques
Quality Circle
Introduction of first aid.
Causes and type of fires, fire
precautions,
precautions
against outbreak of fire,
different
type
of
fire
extinguishers and their uses.
Precautions while working at
height.
Gas safety
Electrical safety
Quality- brief introduction of
improvement
techniques
followed in the organizationSmall group activities (SGA),
Quality Circle(QC) and its
tools.
Usage of First aid box and

Geometrical construction
practice of Cardiopulmonary of Square, Rectangle,
Resuscitation (CPR)
Triangle, Circle, Ellipse,
Polygons, etc.
Usage of
Drawing different types of
- Fire extinguishers
- Safety
appliances- lines.
personal
protective
equipment (PPEs), gas
detector, gas mask,
oxygen
pack
etc.
(specific
to
steel
industries)
Rounding of decimal
values,
use
of
approximation
Units
definition,
Fundamental
and
derived units, system of
units- FPS, CGS, MKS
and SI. Unit of some
important parameters
length,
mass,
time,
density, current, voltage,
pressure
etc.
Unit
Conversion.
3. Bench-fitting Skills (8 weeks)

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.
8
Transfer dimensions from drawing to work piece.

Drill, ream and threading by hand/machine
Level and align mechanical components to ensure proper functioning
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.
Hacksawing - Marking lines,

Cut metals pieces of different
profiles & sections by hacksawing (straight, inclined &
curved line) to an accuracy of
0.5 mm.
Classification,
construction
and functional detail of Filing - Parallel filing practice
Hammers.
on flat surface
Marking
practice of straight, parallel
Classification,
construction and curved lines with odd leg
and functional detail of calipers, steel rule, dividers,
following
cutting
tools: Scriber. Filing flat, square,
Chisels, Hacksaw,
Files, steps and contour surfaces to
Drills, Reamers, Scrapers, an accuracy of 0.2 mm.
Taps & Dies.
Marking
Transfer
of
Classification,
construction dimensions from drawing to
and functional detail of work pieces. Finding center of
following bench tools : Steel a round bar with the help of V
rule, Try square, Calipers, block and marking block.
Divider,
Centre
punch,
Surface plate, V-Block and Chipping - Chipping practice
Trammel etc.
on flat surface, slots & oils
grooves, and chamfer at
Marking media, marking different angle on MS plate.
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
Projection and difference
between them. Concept
of THREE VIEWS.
Drawing of THREE views
from
pictorial
and
isometric views.
Letter writing:- Types of
Letters
viz.
normal
condensed and extended
(theoretical
aspects).
Writing of Single Stroke
Vertical
and
inclined
letters only. Writing of
Numerals in the same
specification.
Workshop
problems
related to average,
percentage and ratio
and proportion.
Workshop
related on
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 earths
surface or parallel to it
and vertical motion
under gravity. Related
problems.
Newtons
Laws
9
of
blue, Prussian blue, red lead,

Dimensioning practice.
chalk and their special Drilling & Reaming - Use of
application, description.
drilling machine for drilling
through
&
blind
holes,
Measuring
Instruments: Reaming of drilled hole by
Micrometer
(outside
and hand reamer.
inside) working principle,
use and care, Calculation of Internal & external threading
least count. Vernier calipers, by Taps & Die
principle,
graduations,
reading, use and care.
Dismantling, inspection and reassembly of bearings, coupling
Elements of mechanical and keys
components:
bearing,
coupling and keys
Practice on leveling, alignment,
static balancing and plumbing
Basic knowledge of gear related to electrical machines
and gear boxes
including Laser alignment.
Motion
with
proper
examples, Concept of
Force,
Concept
of
Inertia i.e. inertia of
motion and inertia of
rest.
Leveling and alignment of Practice on lubrication related

electrical machine
to electrical machines
Lubrication
related
electrical machines
to
10
4. Electrical Fundamentals and circuit (8 weeks)
After completion of this module the trainee should be able to
Understand the basic principles of electricity, its 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
Know about various chemical effect of electricity,
Charge batteries and test its conditions.
Know about magnetism, electromagnetic induction, 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.
Find out faults and trouble shoot simple electrical circuits and appliances used in workshop.
Dimensioned Drawing:- Workshop problem on
11
Fundamentals of electricity, Demonstration and use of Method of dimensioning time and distance.
electron theory, concept of electrical
measuring according
to
BIS Workshop problem on
free electrons and difference instruments
with
safety specifications.
Art
of mixture.
between conductor, insulator aspects
Spacing
the
views.
and semi-conductor.
Drawing three views of Measurement of force,
Verification of Ohms law
simple machine parts i.e. P = ma where P is
Definition and units of
using all the instruments the force, m is the mass
voltage, current, resistance, Verification of law of series and with dimensioning.
and
a
is
the
power and energy
parallel circuits
acceleration. Units of
force. Momentum
Ohms law, simple electrical Verification of Kirchhoffs law
definition
and
its
circuits
and
problems.
significance. Problems.
Resistanceseries
and Measure resistance by using
parallel, laws of resistance, voltmeter and ammeter, postNature of forces
temperature co-efficient of office
box,
AVO
meter,
composition
and
resistance, work, power and Standard
resistance
resolution of forces.
energy.
comparison, bridge, megger
Resultant of a number
and potentiometer
of coplaner forces acting
Kirchhoffs current & voltage
at a point. Problems.
11
laws
and
application,
Wheatstone bridge and its
application, Simple problems
12
Use of common electrical

measuring instruments and
related safety aspects
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.
Related Safety aspects
13
Magnetism- classification of
magnets,
methods
of
magnetizing,
magnetic
material, Coulombs law,
permeability, ferro, para and
diamagnetic materials
ElectromagnetismSolenoid,
field
around
Demonstration
and
identification of different types
of cables, wires
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.
Lamis
Theorem,
Polygon of forces and
problems
Demonstration and practice on

bare conductor joints.
Practice on making simple
electrical circuits on wooden
board
Practice on installation and
overhauling common electrical
accessories, fixing of switches,
holders, plugs etc.
Perform experiments to draw Do
B-H curve.
Prepare simple electromagnet
and find the polarity
Experimenting faradays laws,
Lenzs law, Flemings rules,
self and mutual inductance
Determining hysteresis loss
and eddy current loss.
Do
12
conductors carrying current,

polarity, screw-rule, righthand grip rule, advantages
and
application
of
electromagnet.
Magnetic
series
and
parallel circuits, B-H curves,
hysteresis loop, hysteresis
loss, eddy current, eddy
current loss, equations and
problems.
14
Principles
of
electromagnetic induction,
Faradays laws, Lenzs law,
Flemings Rules,
Related safety aspects
Self-inductance,
mutual- Connect the capacitors in Do
inductance, their co-efficient, series
and
parallel
and
equations and problems
measure different values.
Do
Joules law of heating, Observation of charging and

Joules equivalent, heating discharging of capacitors, its
appliances and elements.
testing.
Electrostatics- terms and
definitions, coulombs law,
capacitors, charging and
discharging of capacitors,
energy stored.
Grouping of dry cells for a

specific voltage and current
Battery charging- Prepare

electrolyte for lead- acid
storage battery; charge the
Chemical
effect
of battery
using
different
electricity principle of methods, Check for battery
electrolysis, Faradays laws. condition.
Applications of electrolysis,
13
Basic
principles
electroplating
of Routine care and maintenance

of batteries
Principle and construction of

simple voltaic cell, Leclanche
cell, dry cell, standard cells,
their
uses,
care,
maintenance and grouping.
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
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 equations and its

application in solving
workshop
related
problems.
Newtons
Law
of
Gravitation
its
statement
and
explanation. Centre of
Gravity C.G. of regular
and irregular bodies.
Position of C.G by
calculation. Problems.

14
16
17-18
AC series and parallel AC series and parallel

circuits RL, RC and RLC. circuits
Power factor and resonance
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
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
Do
Demonstration of three-phase Do
load and measurement of
voltage, current power & power
factor in 3-phase circuit
Do
Simultaneous Equations
and its application in
solving
workshop
related problems.
Work,
Power
and
Energy-definition
and
units, Potential and
Kinetic energy, related
problems.
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, control and reverse the direction of rotation of DC motors AC single phase and three
phase induction motors, synchronous motors.
15
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.
19
20-21
Practice safe working on electrical equipment

Types
of
electrical Familiarization
with
safe
machines.
working practice with electrical
DC
generatorworking equipment
principle,
EMF
equation,
electromagnetic drag, types, Identification and study of parts
and
parts,
Self
and of a DC Machine
separately
excited
generators, practical uses
Identifying terminals of DC
Explanation
of
armature machine
by
measuring
reaction and commutation, resistance of shunt field, series
interpoles and their uses, field and armature
connections and polarity
Connecting,
running
and
Characteristics of series, studying the characteristics of
shunt,
compound
and DC
series,
Shunt,
and
separately
excited compound generators. Study of
generators, critical resistance No-load
and
load
and critical speed, application characteristics
of DC generators, Losses
and efficiency
Finding critical resistance and
critical speed of DC generators
DC motor- working principle, Testing DC motors, identifying

torque, speed, back emf, their terminals, connecting, running
relations. Types of DC and reversing direction of
Drawing of few more

exercises
on
Orthographic Projection
using all instruments and
dimensioning the views.
Geometry:Simple
definitions of points,
lines, parallel straight
lines,
triangle
and
rectangular figures their properties and
problems
concerning
workshop practice.
Friction Types of
friction and laws of
limiting friction. Coefficient of friction, angle
of friction, angle of
repose. Advantages and
disadvantage of friction.
Related Problems.
Lubricants
types,
viscosity and effect of
temperature
on
viscosity.
Do
Do
16
22-23
motorsseries,
shunt,
compound and separately
excited their characteristics
and applications. Starting and
speed control of DC motors.
rotation of DC motors.
Transformersworking
principle, transformation ratio,
no-load and on-load phasors,
classification, types of core,
EMF equation, equivalent
resistance, reactance and
impedance;
equivalent
circuits.
Open and short-circuit tests,
regulation,
losses
and
efficiency of transformers.
Three-phase transformerstypes,
construction,
applications, advantages and
connections,
Protective
devices and cooling systems
of transformers
Identification of types
transformers and its parts
Studying characteristics and

drawing characteristic curves of
DC motors of all types.
of Interpretation
of
Orthographic Projection:Important points and
Verification of transformation significance of projection
ratio,
loading
secondary, lines. Techniques to draw
finding
relation
between the missing views and
primary
and
secondary various
types
of
currents, voltages and no. of possibilities of elevations
turns
with a single plan.
Measurement of iron and
copper losses, determination of
regulation,
efficiency
etc.,
polarity marking of singlephase
and
three-phase
transformers
Moment
of a forcemeaning
and
its
importance. Varignons
Theorem and problems
on it.
The circle its various
properties like angle and
tangent
properties.
Problems on the above
topics concerning to the
workshop practice.
Testing of single and three

Auto-transformers,
phase transformers, cleaning
Instrument transformers - CT, and maintenance, oil testing.
PT, Tong-tester and their
applications
Study
of
Instrument
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
Do
17
Construction of SC and SR
motors, slip, rotor emf,
current, frequency, pf, Cu
loss,
Slip
torque
characteristics.
Double-cage
rotor,
comparison of SC and SR
motors.
Starters of induction motors
and its necessity, types-DOL,
star-delta, auto-transformer,
soft-starters
and
rotor
resistance starters of woundrotor induction motors
and SR motors
Polarity
marking
(phasesequence test) of a 3-phase
induction motor and connection
in star and delta
Testing induction motor by
megger, and Motor Checker
Starting the motor using
different starters, running and
reversing the motor, measuring
the starting and no-load
currents, measuring speeds at
different
loads,
calculating
speed etc
Use of motor Checker
Dismantling, studying and reassembling

the
Protective devices in AC electromagnetic AC contactors
motor circuits Principle and of different voltages, types,
setting of over-current relays- makes and categories.
thermal, 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.
Studying, overhauling of fan

motors, connecting, running
and reversing of single-phase
motors.
18
26
Synchronous machines
Do
Do
Identification of terminals of
Alternator- parts, types of alternator, connecting, starting,
poles- salient pole and running, loading and plotting
smooth-cylindrical
type, characteristic curves
rotating-field and rotating
armature type etc
Starting synchronous motors
by different methods
Prime movers for alternators,
turbo-alternator,
enginedriven
alternators,
EMF
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.
6. Basic Electronics (10 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
19
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
programming.
Read and understand electronic circuits and drawings
27-28 Basic Analog Electronics Electronic
Component Different types of simple Mensuration:- Plane
Introduction to Electronics and identification and testing,
and intricate exercises on figures Triangle,
its
application,
difference Reading and interpretation of interpretation
of Square, Rectangle,
between analog and digital colour codes of components
orthographic projections Parallelogram,
electronics.
with proper dimensioning Trapezium, Regular
Use of digital multimeters
Polygons,
Circle,
Atomic theory, energy band
Hollow Circle, sector
diagram,
classification
of Connecting
function
and
segment
of
matter based on energy band generator with oscilloscope,
circle, fillets etc.
diagram.
study
of
wave
forms,
measurement of voltage and
Simple machines
Active and passive circuit frequency.
what is a machine, its
elements:
Diode characteristic, Zener
advantage and utility.
Resistors and their rating - diode characteristics, testing,
Important definitions
fixed and variable, carbon and and identification
concerning
to
wire wound, metal film and
machines
metal oxide, colour coding, Making half wave and full

Mechanical
power rating, accuracy and wave rectifiers using training
Advantage, Velocity
effect of temperature, uses of kits, study of different wave
Ratio and Efficiency
resistors.
shapes and their values on
of the Machine
Fuses and their rating- Slow oscilloscope
blow
and
fast
blow,
semiconductor fuse
Soldering and desoldering
practice
Inductors and their rating types: ferrite core, air core,
tapped and variable inductors.
Factors affecting inductance
and use of inductors
Capacitors and their rating:
Mica,
ceramic,
paper,
20
electrolytic, tantalum, silvered

mica,
variable
capacitors,
colour coding and uses.
Voltage and current sourcesIdeal 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.
Zener diodes: characteristics,
types
and
application.
Calculation of series resistance
for varying inputs and load
currents, Voltage regulator
using zener
29
LED, varactor and photo

diodes- working principle and
applications.
Transistors:
working, Transistors: identification Do
classification, VI characteristics and testing finding static and
(static and dynamic), CE, CB, dynamic characteristics of
Do
21
CC configuration and their transistors in different modes

difference, current, voltage using training kits, calculation
gains and their relationship. of gains. Biasing circuits
Biasing
and
thermal
stabilization circuits, heat sink.
Packaging,
coding,
specification, identification and
applications in detail
DC and AC load lines. H
parameters
30
Field
effect
transistors: Identify, test and draw the VI Do
construction, operation and VI characteristic
of
FET,
characteristics
of
JFET, MOSFET and UJT.
Enhancement and deletion
type MOSFET, concepts of
CMOS, Difference with bipolar
junction transistors, uses.
Do
UJT- Construction, operation

VI
characteristics
and
application
31
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
Multistage amplifiers- need frequency response curve
and types of coupling. RC,
transformer and direct couple
amplifier circuits, voltage and
Do
22
power
gain,
frequency
response,
bandwidth,
comparison between different
types.
32
33
Power amplifier- voltage and

power amplifier, classification
Class A, B.C and AB amplifier
circuits
Push-pull amplifier, Use of
heat sink., harmonic distortion
and its control. Feedback
amplifierscircuit
and
applications
Oscillators: working principle,
classification,
circuits
and
applications.
Factors
controlling oscillation. Different
types of oscillators, their
characteristics
and
applications,
crystal
oscillators.
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
Assembly of oscillator circuits Do

using
transistor
and
measuring
the
output
frequency and waveform.
OPAMPS pins identification,

assembly of inverting and
non-inverting
amplifiers,
calculation of voltage gain,
assembly of comparator,
adder,
subtractors,
differentiator, integrator, V/I
and I/V circuit and its testing.
Study of Differential and
Instrumentation amplifier
Switching and timer circuits: Construction

classification of multi-vibrators, multivibrators
using
of
555
The Laws of Indices

and problems. Power
and Exponent, laws
of exponent
Levers
Classification
of
Levers and problems
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
(f) Removed section.
Exercises on sectioning
from isometric view
23
astable, monostable and bi- timers,

stable. Internal block diagram, frequency
operating of 555 timers and its
applications
Calculation
of
Opto-electronics- elementary
idea of LED, LCD, photo
diodes, photo transistors, solar
cells and their applications
34-35
Digital Electronics
Number systems: binary,
octal, hex, 1's and 2's
complements, conversion from
one system to other, Boolean
algebra: De Morgan theorem
and its applications
Verification of truth tables of Do

different gates
Realization
of
different
Boolean expression with logic
gates
Realization of adders
Basic logic gates: Symbolic subtractors
representation and truth tables
for logic gates: Buffer, NOT, Construct and verify
OR, AND, NAND, NOR, XOR, tables of flip flops
XNOR. Different logic families
and
their
characteristics, Construct synchronous
Electrical equivalent of gates, asynchronous counters
Negative and positive logic study its functions
gates
Construct controlled
Boolean algebra- Karnaugh register and study
map technique, simplification functions
of
Boolean
expressions,
realization
of
Boolean Practice on reading
expression with logic gates
interpretation of IC
sheets.
and
Logarithms Types
of logarithms eg.
Naperian
and
Common. Meaning of
logarithms
its
elements
i.e.
characteristics
and
mantissa. Problems
on
Positive
Characteristics
truth
and
and
Wheel and
Axle,
Screw Jack, Inclined
plane and problems.
shift
their
and
data
24
Combinational logic circuits:

Half and full adder 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:
characteristics and
Schmidt trigger
36
Types,
circuits,
Microprocessor
and Programming practice on
computer:
Organization in Microprocessor
general: CPU, ALU, resistors,
counters, data and address Identification of different
Do
Do
25
process, memory and I/O

devices. Instruction set, Simple
programming. Introduction to
other processors
Hardware of a personal
computer (PC)
Microcontrollers:
basic
principle, architecture, types,
programming
concepts,
interfacing.
parts of
computer.
personal
Programming practice on
Microprocessor
7. Power Electronics & Drives (6 weeks)
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.
37-38
Power electronic devices:

Thyristor, its construction,
characteristics and family.
Turn ON & turn OFF
behavior of thyristors
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
Observation of different types Exercise on sectioning

of
power
electronic from isometric view.
components
Drawing the V-I characteristic
of a thyristor
Study of different firing circuits
of thyristors (RC, UJT, Ramp
and Cosine firing circuits)
Study of 1 ph and 3 ph
converter - half wave, full
wave, half controlled etc
Study of inverter circuit and
waveforms
Logarithms
Problems
Negative
Characteristics.
on
Hydrostatics Nature
of
liquids
and
Pressure of liquid
inside a vessel at
different
positions.
Unit of
pressure,
Pascals Law, simple
problems.
26
Thyristor
circuits: Checking of power MOSFET,
Converter,
AC
voltage thyristors, IGBT, GTO, IGCT
Regulator, Chopper, Inverter, etc
IGBT circuit, PWM and their
use
39
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
Control system - concept of
open and closed loop system.
Testing of thyristor and Ramp

firing circuit, study of waveform
on different test points of ramp
firing circuits
Study of the effect of KP, KI, KD
in relation to close loop DC
drive kits
Types of pressureatmospheric
,
absolute and gauge.
Free hand sketch of tools Do

and tackles used in
electronics
tradesoldering
iron,
plier,
screw
drivers,
desoldering pump
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 Exercise on maintenance and
quadrant operation of DC trouble shooting of DC drive.
drive,
concept
of
dual
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.
27
40-41
42
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 trouble
shooting of AC drive
UPS - Understanding of float
charger, off-line UPS and Online redundant UPS, Different
type of controls, circuit and
maintenance of UPS and
battery.
Testing and study of IGBT, Free hand sketch of tools

power plate
and instruments used in
electronics
tradeStudy of inverter voltage multimeters,
power
waveforms
supply,
function
generators and CRO etc.
Demo
of
a
real
time
microprocessor based AC
drive
used
in
different
processes in industries.
Demonstration
on
parameterization of AC drives
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.
Exercise on maintenance and

trouble shooting of AC drive.
Study of a UPS and its circuit Drawing

symbols
of Do
and controls
electronics componentsresistors,
diode,
Trouble
shooting
and transistors,
FET,
rectification.
MOSFET, UJT etc.
8. Analog & Digital Communication (4 weeks)

After completion of this module the trainee will become familiar with
Principle and types of Electronic communication system (analog and digital)
Devices used in electronic communication
28
43
44
Working principle and circuit details of Television, Telephone (fixed and mobile), GPS, DA and PA system
Communication media
Fiber-optics communication
Communication systemLab work on AM and FM Screw Threads Forms Quadratic Equations
Elements of communication communication. Calculation of of various screw threads, and
practical
system, principle of analog modulation index.
nomenclature, convention problems concerning
communication,
,
basic
and drawing of various to workshop practice
terminology used, bandwidth
thread profile.
of signal and channel,
Specific Gravity of:propagation
of
a) Solids heavier than
electromagnetic
wave,
water.
b)
Solids
modulation and its necessity,
lighter than water. c)
antenna and types
Solids
soluble
in
water.
Related
Modulation methods of
Problems.
modulation- AM, FM, PM.
Amplitude
modulationmethods, modulation index,
generation of side bands,
block
diagram
of
AM
transmitters.
Demodulation- AM radio
receiver
circuits,
super
heterodyne receiver
Frequency
modulationmethods, modulation index
and number of side bands,
FM transmitter and receiver
circuits
Other modulation schemes
and their comparison
Familiarization with TV Demonstration of TV circuits, Do
circuits and its working- identification and use of
block diagram of different different controls.
sections of TV, its circuit
Do
29
45
details, tuner, test points, VIF,

AGC,
Video
amplifier,
synchronization and sweep
circuit, matrix, display screen,
sound section, power supply,
advancement in TV- flat
screen, LCD and LED
display.
Digital
communication- Demonstration of RS-232, RS Do
principle
of
digital 485, Ethernet and other
communication, methods and communication standards.
industrial application.
Familiarization with different
Data communication: serial communication equipment and
and parallel communication, media- Coaxial, UTP, Fibre
MODEMS,
Interfaces-RS- Optic cable etc.
232, 422, 485, Ethernet.
Industrial communication
protocolsMODBUS,
FIELDBUS, CONTROLNET
and Interface buses
Do
Communication media
Computer
fundamentals
46
networking
Simple
concepts
of Familiarization
communication
devices communication
(block
diagram
only):
Telephone (fixed and mobile),
wireless, satellite, GPS, DA
and PA system
with
FO Do
Do
Fibre
opticsstructure,
classification, characteristics,
30
losses, choice of wavelength, FO cable, splicing and

connectors, applications and
maintenance.
9. Instrumentation & Control (4 weeks)
47-48
System and equipment used for the measurement of various process parameters related to steel plant
Process control system and PID controllers
Different control strategies used in steel plant
Introduction- Objective of Verification of working principle Fastening Devices
Principle
of
the Instrumentation & control, and characteristic of different Temporary
and Similarity:- Properties
elements of measurement sensors
and
transducers Permanent.
meaning of similar triangle
systems,
instrument covered in theory class viz. and
difference. and their application
terminology
LVDT, strain gauge, capacitive Temporary
device
to
day
to
day
gauges, thermocouples, RTDs, Hexagonal Bolt, Nut, workshop problems.
Sensors and transducers thermistors etc.
Check Nut, Washer. To
definition and types
draw the three views of Properties of Matter
Dismantling,
assembly, individual
and the Different types of
Load cell and its application overhauling and calibration of assembly.
Properties of Matter
in
transmitters,
indicators,
eg.
Mechanical,
industrial weighing
gauges,
regulators
and
Electrical, Chemical,
switches used for pressure,
Magnetic etc.
Encoders and its applications temperature, flow, level and
other measurement
Introduction to process Configuration
of
smart
(Electrical):parameter measurement:
transmitters using HART and
resistivity, permittivity,
other configurations.
permeability,
resistance
temp.
31
Temperature measurementPrinciples, types and working

of mechanical, electrical and
radiation
temperature
sensors, relative advantages
and limitations. Temperature
switches:
constructional
details and maintenance.
Temperature transmitters:
types, working, calibration
and maintenance. Hot metal
detectors,
Molten
metal
(Bath)
temperature
measurement.
coefficient etc.
Insulating materials.
Brief description and
properties
of
electrical
materials
such
as
silicon,
nichrome,
silver,
copper,
aluminum,
transformer oil.
Pressure
measurementtypes and units of pressure
and differential pressure.
Manometers:
principles,
types
and
working.
Pressures sensors and
transducers:
working
principle and construction of
elastic and electrical pressure
and DP sensors. Pressure
gauges:
constructional
details,
calibration
and
maintenance.
Pressure
switches:
constructional
Transmitters: Smart P/DP
transmitters
and
its
configuration.
Flow
measurement
:
Definition, units and types.
32
Restriction
method:
principles,
types
and
installation of orifice plate,
venturi tube, flow nozzle and
others sensors. Variable
area method: principles,
types, and working. Mass
flowmeters, magnetic, turbine
and vortex flowmeters Flow
switches.:
constructional
Level
measurement
definition, units and types of
liquid
and
solid
level
measurement using direct
and indirect methods: hydrostatic pressure, capacitive
ultrasonic, air bubbler
Thickness
measurement:
types of methods, working
principle,
construction,
calibration and maintenance.
49-50
Process Control System

Introduction,
process
variables,
manual
and
automatic, close loop and
open loop process control
systems,
process
disturbances.
Controller types, P, D & I
control actions. Tuning of a
controller.
Operation of a controller, Different

methods
of
setting of its PID values, preventions of rotation of
controller tuning.
Bolts - Check nut, Square
headed bolt,
Square
Testing of a control valve, I/P headed bolt with square
converter
and
valve neck, cup headed bolt,
positioners.
eye bolt, counter sunk
headed bolt, rag bolt
Trigonometrical ratios
and simple problems
connected
to
workshop practice.
(mechanical):Tenacity, Toughness,
Malleability, Ductility,
Elasticity, Plasticity
Brittleness
and
Hardness
33
Final control elements:

types,
working
principle,
construction, calibration and
maintenance
of
I/P
converters, Control valves &
actuators, Valve positioned,
power cylinders.
Reading and interpretation
of PI diagrams, instrument
manuals and part list, panel
wiring diagram etc.
51
52

Revision/
Plant
visit/
Industrial visit
Examination
Part B- Advance Trade training in Training Institute/ Industry & In-plant training Duration- 52 Weeks
10. PLC & DCS (2 weeks)
Need and working principle of PLC
Hardware of PLC
Programming of PLC
Hardware of DCS
Communication with different field and control devices.
53-54 Programmable
Logic Familiarization with different Different methods
Controller (PLC)- Need and I/O modules of PLC
locking of nuts:working principle, hard ware Development
of
simple
a) Lock nuts
details.
Function
and programmes involving bit level
b) Slotted nut
connections
of different instructions,
timers
and
c) Castle nut
cards.
counters,
simple
data
d) Wings nut etc
Program
techniques
of manipulation instructions.
of
Properties and uses

of copper, zinc, lead,
tin, aluminium
b) Split
brass,
pin
bronze,
d) solder,
Symmonds nu
bearing
metals,
timber, rubber.
34
PLC, inputs, outputs, timer

and counter instructions, data
manipulation
Development of simple
programs
Documentation,
different
functional
blocks
&
mathematical instructions
Communication
system
used in networking of PLC
Data Acquisition System
(DAS) &
Supervisory
Control
And
Data
Acquisition
(SCADA)
System- Basic structure,
software and applications,
introduction to HMI packages.
Distributed Control System
(DCS)basic
concepts,
architecture advantages.
Level of automation in steel
industry.
Feeding and running the

programmes in PLC, I/O
forcing
Documentation and editing of
programmes.
Simple fault finding and trouble
shooting
Demonstration of different
communication system used in
networking of PLC.
DCS
Familiarization
with
hardware of DCS, Process
operation using DCS .

11. Industrial hydraulics and pneumatics (2 weeks)
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
35
55-56
Industrial hydraulics and

pneumatics
Basic principles of hydraulics
and
pneumatics,
characteristic of fluid media,
safety aspects
Operational details of fluid
power control element.
Energy
converter,
Fluid
conditioner, Control valves
Symbols of basic hydraulic
and pneumatic components
Basics of proportional and
servo valves, its electrical
and
electronic
circuitry,
control and feedback systems
Concepts of interfacing of
hydraulic and pneumatic
components with PLC
Identify components such as

reservoir, filter, pumps, float
switch, valves, actuators etc.
Operation of proportional and
servo valves, functions of
control
and
feedback
components
Demonstration
of simple
hydraulic devices and circuits.
Demonstration of
simple
pneumatic
devices
and
circuits.
Hydraulic
and
pneumatic
circuits,
reading
and
interpretation.
Development of simple logic
circuits in PLC and its testing
Permanent Fastening
DevicesRivets
different parts and their

types Different types of
rivet heads
The 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.
.
12. Welding
After completion of this module the trainee will become familiar with basic principle, devices and techniques used for welding
57
Arc welding and gas cutting

tools
and
equipment.
Different gases used in gas
cutting.
Regulators and blow pipes,
filler rods and fluxes.
Flame characteristics and
uses, arc welding machines,
Familiarization with tools and

accessories.
Arc welding on mild steel
(down hand)
Making welding joints.
Gas cutting on mild steel.
Brazing of two similar metals
Rivets Joints Lap joint

and Butt or Strap joint.
Lap Joint
a) Single Riveted
b) Double riveted
i) Chain
ii) zig zag
Butt Joint
Angle of Elevation
and
Angle
of
Depression,
Problems on Height
and Distances taking
the
help
of
Trigonometrical
Ratios
36
electrodes
and
their
selection, various joints and
joint
preparation,
their
suitability
for
various
applications.
a) Single plate or strap

b) Double plate or strap
Heat treatment of
steel Hardening,
annealing, tempering,
normalizing and case
hardening
13. Advanced Industrial Electronics ( 04 weeks)

Techniques of electronic circuit fabrication
Circuit details of electronic equipment SMPS, UPS, Inverter, PC, Industrial camera, CCTV etc.
Industrial weighing system
58
59
Different techniques of Fabrication

of
electronic
electronic
circuit circuits on Assembly and
fabrication
testing of power supply with
filter and regulators on PCB by
Surface mounted devices soldering the components.
technology, micro-electronics
Demonstration on soldering
and de-soldering SMDs
Isometric Projection:Difference
between
isometric
and
actual
scale, construction of
isometric
scale
and
simple exercises
Regulated power supply.

Introduction to SMPS and
UPS.
Understanding
of
specification.
Drawing the symbols of

electrical
instrumentsammeter, voltmeter, watt
meters,
ohmmeter,
energy meters etc. as per
BIS practice.
Study of SMPS, UPS and

Inverter circuits and its testing
Study of PC hardware and
peripheral devices
Study of industrial camera and
PC hardware including I/O CCTV used in steel plants
devices, memories
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.
Solid Mensuration:Prism,
Cylinder,
Pyramid,
Cone,
Frustum of Pyramid
and
of
Cone,
Problems concerning
to workshop practice.
37
Working principle and types

of industrial camera and
CCTV
60-61
Welding machine and its

control
CNC machines- basic idea.
Sensors and switchesProximity
switch,
Micro
switch, limit switch, photo
switch, encoder and other
types of electronic sensors
and their application
Industrial weighing systemtypes, different types of load
cell and processing units,
configuration,
maintenance
and trouble shooting.
Study of welding machine and

CNC control circuit
Study and testing of different
types of sensors, transducer
and switches
units of an industrial weighing
system.
Relation
between
load and extension
Graph meaning of
Yield Point 1st & 2nd
Ultimate
tensile
Stress,
Breaking
Stress and factor of
safety.
Drawing the symbols of Solid Mensuration:electrical components practice problems.
and
devicespush
buttons, switches, fuse, Stress,
Strain
motor,
generators, Definitions, different
transformers,
relays types
of
Strain,
and contractors etc.
Hooks Law, Modulus
of
Elasticity
Youngs
Modulus,
Bulk
Modulus
Modules of Rigidity,
Poissons Ratio and
Problems.
14. Repair and maintenance of electronic equipment ( 5 weeks)

Repair and maintenance of electronic equipment.
Use of different electronic test and measuring instruments
62-66
Safety
precautions.
Requirement of grounding of
self and equipment.
Working principles, block
Testing and maintenance of Drawing of various wave

electronic modules such as shapes- sine , square,
rectifiers,
amplifiers, triangular, saw tooth etc.
oscillators,
logic
circuits,
Solid Mensuration:Sphere,
Spherical
segment,
material
weight
and
cost
38
diagram, circuit diagram and

applications
of
following
electronic test & measuring
instrumentsa. Multimeter
b. CRO- conventional and
storage type
c. Scope meter
d. DC power supplies
e. Function generators
f. Pulse generators
g. Temperature controlled
soldering
and
desoldering stations etc.
h. IC tester
Modern trouble shooting
techniques and use of
electronic test equipment
for service and repairing of
electronic
cards
and
equipment, use of test rigs
and
jigs,
component
substitution in handling of
PCB and hybrid circuits.
multivibrator,
timers, voltage
ADC, DAC etc
multiplexer, Drawing the circuit of a

regulators, DC power supply with
rectifier,
filter
and
regulator with labeling
Repair
and
maintenance and waveforms.
practices on
defective
electronic equipment such as Drawing
the
circuit
power
supplies,
PC, diagram of a UPS and
microprocessor based circuits, SMPS with labeling and
CCTV,
industrial
camera, waveforms.
weighing system, PA system,
modem etc.
Drawing
the
circuit
diagram of a Signal
Repair and maintenance of generator with labeling
communication
equipment and waveforms.
including
fibre
optic
communication modules.
(Note- Trainees should be
given defective electronic
equipment for repair)
problems on above
topics
concerning
workshop practice.
Heat Definition and
its importance.
Temperature
Definition
and
significance.
Difference between
heat
and
temperature.
Scales
of
Temperature
eg.
Fahrenheit
,
Centigrade,
Kelvinrelationship between
them. Lower and
Upper fixed points,
Fundamental Interval.
Reasons
for
the
selection of Mercury
as
thermometric
substance.
15. Electrical Power System (4 weeks)

Know how electrical power is generated and distributed
High voltage safety equipment and safe working procedures, Earthing system, IE rules
39
67
Working of LT and HT Switch- gears and protective relays

Power factor improvement methods
Monitoring system for power generation and utilization
Power
Generation, Measurement
of
pit
Transmission
and resistance.
distribution System
Demonstration of HV safety
devices
Introductory
concepts
- Use of HV tester, cool coat,
generating stations: Hydel, discharge rod
Thermal,
Nuclear,
Gas
turbine, IC engine etc.
Drawing
the
block Do
diagram
of
an
oscilloscope
with
labeling and waveform.
High voltage safety, use of

safety devices like HV tester,
discharge rod, cool coat
Earthing,
system
and
equipment, neutral earthing,
maintenance of earth pits
Related IE rules and safety
aspects
68
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.
Cablesconstruction,
classification
of
cables,
property of XLPE, paper,
PVC, insulation, jointing and
Study of various types of

power transmission equipment/
devices conductors, support,
insulators and cables.
Cable jointing practices
Study of single line diagram of
interconnected industrial power
supply system
Polarity marking of CT
Connection of CT and PT
Drawing
the
block
diagram of an RC
couple amplifier with
labeling and waveform.
Graphs:-Dependent
and
Independent
variable. Concept of
Quadrants. Plotting of
Points and
other
types of curves e.g.
Straight line curve,
Parabolic
and
Hyperbolic curves. To
solve Equations of
two
and
three
unknown with the
help of Graphs.
40
laying of cable, testing and Connection

fault localization
arrestors
Indoor
and
outdoor
substation, layout, single
line diagram, CT& PT,
isolators,
earth
switch,
transformer,
lightening
arrestor, reactor, breaker, bus
and its protection.
of
lightening
Energy
management,
maximum
demand,
load
factor,
connected
load,
diversity load curve, tariff.
LDC- monitoring system for
power
generation
and
utilization.
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.
Indian
electricity
rules
pertaining to safety of supply
system,
LT
and
HT
equipment, O/H transmission.

aspects
69
Power system protection

Switch
geararcing
phenomena, ACB parts and
their function, maintenance of
arc chute, contacts, limitation
and tightening, testing and
calibration
of
releases,
trouble shooting.
Drawing of control circuit Do

Connection
of
relays, of a motor starter
Maintenance and adjustment
of arc chute, and contact
Opening and assembling - pole
assembly, trip assembly and
hand assembly
Maintenance of ACB, OCB,
41
Construction, working and

maintenance of OCB, VCB
and SF6, GIS, their merit and
demerit
VCB, and SF6 breakers

Demo on parameterization of
digital relay and numerical
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.
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.
aspects
42
70
Fuse- terms and definitions,

selection and characteristic of
HRC fuse
Power factor- effect of low
power factor, cause of low
PF,
power
factor
improvement, use of static
VAR compensation
Energy
managementmaximum
demand,
load
factor,
connected
load,
diversity load curve, tariff.
aspects
types of fuses
types
of
power
factor
improvement
and
compensation equipment
Visit to Energy Management
Centre such as Load Despatch
Centre (LDC), Sub-stations.
Drawing
the
block Do
diagram of a TV set with
different sections and its
labelling.
16. Computer & IT (1 week)

71
Hardware of PC
Common software used in PC
Use of Intranet, Internet, E-mail
Computer & IT
Drawing of symbols of
Basics of computer hardware Preparation
of
a
word different digital electronic
and software
document (eg. Project report)
circuit and componentsgates, flip-flop, register,
MS office: Word, Excel and Preparation of an excel file and counter
with
timing
power point
make graphical representation diagrams.
of
data obtained during
Use of Intranet, Internet, E- practical sessions on electricity
mail
Statistics Mean,
Median,
Mode,
Variance, Frequency
distribution
,
Cumulative
frequency, Pie-Chart
Expansion of Liquids
it has only one type
of expansion e.g.
43
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)
72-73
Different types of raw material used for iron making and their sources
Iron and steel making processes
Hot and cold rolling process
Different
types
of
raw Guided visit of different plants Drawing of opamp based
material used for iron making of
the
organization
and circuitsadder,
and their sources
familiarization
with
the subtractor,
integrator,
Details of Blast furnace process.
differentiators, V/I and
reactions, Cooling system,
I/V converters.
Cast House practices.
Gas cleaning system.
Hot metal Desulphurization
Complete Heat cycle in LD
vessel.
Secondary Steel Making.
Casting of Steel.
Theory of Rolling.
Rolling of long products & flat
products in hot and cold
rolling.
Problems on statistics
Expansion of Gases
Boyles
Law,
Charles law and
Combined gas law.
Absolute
Zero
Meaning of N.T.P.
Thermal conductivity
and related problems
44
18. Quality Management & Improvement Techniques (1 week)
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, its
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 Set

Theory
instrumentation amplifier Introduction

and
with
labeling
and problem.
waveform.
Mechanical
Equivalent of Heatproblems.
Transmission of heat
Conduction,
Convection
and
Radiation. Examples
from industries.
45
19. Rigging (2 weeks)

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

& tackles used in rigging.
Construction and capacity of
wire rope.
Capacity of ropes (other than
wire rope).
Application of knots and
hitches.
Care and maintenance of
wire rope.
Different type of jacks, chain
block and pull lift.
Knowledge of different types
of scaffolding.
Material movement by using
different rigging tools and
techniques.
Safety
appliances
&
precautions in rigging.
Maintenance of tools and
tackles.
Practice of different type of

knots & hitches used in
material handling
Reaving sets of pulley block.
Splicing of manila rope.
Inspection of wire rope.
Use of mechanical & hydraulic
jack, rope puller, chain puller,
chain block, winch
Inspection of tools and tackles
Loading, unloading and shifting
of common and uncommon
shapes of material.
Hand signal used in rigging.
Drawing of circuit of an
different types of multivibrators using 555 timer
with
labeling
and
waveform
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
46
20. Environment Control and Occupational Health (1 week)

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
78
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.
Standard of ambient air
quality, work environment,
effluent discharge.
Dust handling and disposal
system.
Control of water pollutioneffluent treatment plants
Occupational
health
and
ergonomics
Revision/
Plant
visit/
Industrial visit
Do
47
Part B: Shop Floor (In- plant) Training- Duration- Half ( ) Year

B.1 Shop Floor (In- plant) training (24 weeks)
This is on-the-job and observational training module which will enable trainees to relate and learn the practical
applications of contents covered during the basic training.
79The content of this module On the job training
Drawing of AM and FM Peak , RMS and
will be developed
1
by the
modulated waveform at average value of AC
organization based
0
on the Safety pre-cautions to be different
modulation supply. Relationship
existing Electrical,2Electronics followed in the section/plant index.
between them. Peak ,
and
Instrumentation including need of special
RMS and average
maintenance practices which protective equipment, if any.
Drawing of a radio value of current in
may include the following
receiver circuit
Rectifiers. Calculation
Study of working of different
of form factor, ripple
Electronic repair shop
equipment
used
in Practice on Free hand factor, transformation
1. Maintenance and repairing plant/section visited.
sketching of electronic ratio. Estimation of
of electronic cards
tools and instruments.
PIV of a diode in
2. Calibration and testing of Carry-out
repair/
test/
different types of
electronic instruments
calibration
of
instruments/ Drawing of block diagram rectifiers.
equipment under the guidance of
a microprocessor,
Instrument Repair Shop
of competent person
microcontroller
and Number
system1. Maintenance and repairing
Personal Computer.
decimal, binary, octal,
of instruments
Carry-out minor maintenance
hex.
BCD
code,
2. Calibration and testing of job
under
guidance
of Drawing of flow sheet conversion
from
sensors,
transmitters, competent person
symbols
of
sensors, decimal to binary,
control valves etc.
transmitter,
controller, octal and hex and
Working
with
skilled recorder, control valve vice-versa.
Electrical
repair and supervisors/
workmen/ etc.
testing section
operators.
De-Morgan theorem.
1. Observation
of
Drawing of symbols of Introduction
to
maintenance and repairing Preparing report on the job power
electronic Boolean algebra.
of electrical machines
done
components and circuits2. Calibration and testing of
SCR, firing circuit of Simple estimation of
electrical instruments
SCR,
thyristorised the requirements of
48
Power Houses and substations

1. Power plant equipment &
Control system, P& I
diagram of plant.
2. Distribution of electrical
power, SLD.
3. Protection schemes and
protective devices
Production Departments
a) Plant process + Plant
process control electrics.
b) Power source + S.L.D
c) Equipment layout, PCC/
MCC locations.
d)
PCC/
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
converters,
inverters, materials
chopper, cyclo-converter applicable
to
etc. (1ph & 3 ph)
trade. Problems
estimation
Drawing of block diagram costing.
of a feedback control
system.
Meaning of HP
BHP. Problems
work, power
energy related
electrical area.
as
the
on
and
and
on
and
to
Magnet
and
magnetism.
Simple
workshop problems.
49
B.2 Industrial Visit, Project work, Revision & Test (2 weeks)

Functioning of local industries
Making the project report and its presentations to the experts.
103Revision of theory covered Revision of practical conducted Revision.
during the training.
1
during training.
0
Visit to local industries
Effective Presentation
4
skills
Preparation of project/ training
report and presentation to
experts
Revision.
50
Evaluation:
AITT Evaluation on practical to be based on following combined skill area:
(Total three skills need to be judged. Sl.No. 1 is compulsory and any other two skills to be chosen from the
list given)
1. To make a regulated DC power supply on a PCB and test the % regulation
2. Able find out input and output characteristics of diode
3. Able to find out input and output characteristics of a transistor
4. Able to find out input and output characteristics of a transistor (FET)
5. Able to find out the characteristics of UJT
6. Able to check truth table of logic gates
7. Able to repair defective electronic instrument/ equipment
8. Able to check truth table of flip flops
9. Able to make an RC coupled amplifier/ FET amplifier
10. Able to make an LC/RC oscillator
51
List of tools and equipment required for Trade- Electronics Mechanic (Steel Plant)
Trainees kit:
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
Description
Quantity
Connecting screwdriver 100 mm

Neon tester 500 v
Screwdriver set (set of 5 bits) - plane and diamond ended
Insulated combination pliers 150 mm
Insulated side cutting pliers 150 mm
Long nose pliers 150mm
Soldering iron 25 w, 240 v
Electrician knife D.B
Digital multimeter portable
Soldering iron 15 W/25 W/ 65 W
Desoldering pumps
Quantity to be
sufficient as per
seats surveyed &
allocated
List of equipments required

Sl. No.
1
2
3
4
5
6
7
8
9
10
11
Description
First aid kit
Fire extinguisher
Bench vice
Steel rule
Digital multimeter
30-0-30 V, 2A D.C regulated power supply
0-300V, 500mA DC regulated power supply
LCR bridge( digital)
Signal generator 100 kHz
Digital storage oscilloscope, 100MHz with probe
Wattmeter
Quantity
Quantity to be
sufficient as per
seats surveyed &
allocated
52
12
12 a
13
14
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*
Megger (insulation tester)

Megger (earth testing)
Battery charger
Digital IC tester
Pulse generator
Logic probes
DOL starter
DOL starter with forward/reverse control
Automatic sequencing control
Overload relays (Thermal, magnetic, electronic)
On delay timer, off delay timer
Earth leakage circuit breaker
Dimmerstat, 8 Amps
Counters
Temp. controller
DC motor control training kit (Electronic)
Level detector
Output power meter
Distortion factor meter
EPROM programmer
Microprocessor trainer kit alongwith ADC/DAC with
stepper motor controller
Proximity switches
Photo tachometer
Burglar alarm
Smoke detector
Emergency tubelight
Single phase preventer
Servomotor
Servo controller
Absolute encoder
Rotary encoder (incremental)
DC tong tester
Weighing system (load cell based)
Programmable logic controller(PLC) with programming
53
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
unit
Personal computer with latest configuration with printer
High voltage testing kit
Surge generator
Instrument
training
kit
(LVDT,
Strain
gauge,
Thermocouple etc)
Electronic voltmeter
DC generator
DC motor
Single phase alternator
SMPS
Induction motor( single phase)
Stroboscope
Synchronous motor
Transformer (1 ph/ 3 ph), 1 KVA
Motorized control valve
Solenoid valve
Strain gauge
Load cell
LVDT
Dual trace CRO 100 Mhz
Analog IC trainer kit and Discrete component training kit
Linear amplifier trainer
Digital IC trainer kit
Magnifying glass for IC no. reading
Microprocessor 8085 trainer kit
Digital trainer A/D ,D/A convertor, Mux, Demux, display
devices, etc
Motor trainer with dummy loads
Three phase motor speed controller/ trainer kit
Soldering station
De-soldering station
Hot air soldering station- cum de soldering station for
SMD devices
PLC training kit
54
76
77
CNC training kit

3 ph alternator
55
List of consumable materials

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
Description
Maintenance free batteries
Re-chargeable cells-dry cells
Power diodes
Heat sinks, heat sinks compounds
LEDs
Switches
Relays (AC/DC), contactors(AC/DC),
Push button switches
Lamps
ICs
such
as
7400,4001,4011,4017,4007,4033,74159,74154,etc
OPAMP IC 741 wave form generator IC 8035
IC DAC 0808, IC ACD 0801
Transistors , JFET, MOSFET, UJT
Various diodes
Various transistors
Microphone
Speaker 4, 8 ohm
Various capacitors
Various resistors
Various transformers
SCR,DIAC,TRIAC, GTO, IGBT, IGCT
7-segment display (both common cathode and anode)
J & T type thermo couple
Quantity
Quantity
to
be
sufficient as per seats
surveyed & allocated
56

Electronic Mechanic (Steel Plant)

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SYLLABUS FOR

Electronics Mechanic (Steel Plant)

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE

Name of designated trade

Electronics Mechanic (Steel Plant)

N.C.O. Code No.

Duration of Apprenticeship Training

Passed 10th class examination under 10+2 system of education or

Ratio of Apprentice to Workers

List of members attended the Workshop to finalize trade syllabus of

Name of Member & Designation

Anil Kumar, Jt. Director

SYLLABUS FOR THE TRADE

Trade- Electronics Mechanic (Steel Plant)

After completion of this module the trainee will be aware of

Overview of steel manufacturing process and machinery

2. Industrial Safety & Quality (1 week)

Usage of First aid box and

3. Bench-fitting Skills (8 weeks)

Transfer dimensions from drawing to work piece.

Hacksawing - Marking lines,

Difference between the

blue, Prussian blue, red lead,

Leveling and alignment of Practice on lubrication related

4. Electrical Fundamentals and circuit (8 weeks)

Use of common electrical

Profit and Loss and

Demonstration and practice on

conductors carrying current,

Joules law of heating, Observation of charging and

Grouping of dry cells for a

Battery charging- Prepare

of Routine care and maintenance

Principle and construction of

Related safety aspects

Simple equations and its

Related safety aspects

AC series and parallel AC series and parallel

Related safety aspects

5. Electrical machines (8 weeks)

Practice safe working on electrical equipment

DC motor- working principle, Testing DC motors, identifying

Drawing of few more

Studying characteristics and

Testing of single and three

Induction motors- Rotating

Use of motor Checker

Dismantling, studying and reassembling

Studying, overhauling of fan

6. Basic Electronics (10 weeks)

Make simple electronic circuits on bread-board and PCB

metal oxide, colour coding, Making half wave and full

electrolytic, tantalum, silvered

LED, varactor and photo

CC configuration and their transistors in different modes

UJT- Construction, operation

Amplifiers: working principle,

Assembly and testing of Do

Power amplifier- voltage and

Assembly of oscillator circuits Do

OPAMPS pins identification,

Switching and timer circuits: Construction

The Laws of Indices

astable, monostable and bi- timers,