Welder (Fabrication & Fitting)

GOVERNMENT OF INDIA
MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
DIRECTORATE GENERAL OF TRAINING

COMPETENCY BASED CURRICULUM

WELDER (FABRICATION &

FITTING)
(Duration: One Year)

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL- 3

SECTOR – CAPITAL GOODS AND MANUFACTURING

Welder (Fabrication & Fitting)

WELDER (FABRICATION &

FITTING)
(Engineering Trade)

(Revised in 2015)

Version: 1.1

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL- 3

Developed By

Ministry of Skill Development and Entrepreneurship

Directorate General of Training
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
EN-81, Sector-V, Salt Lake City,
Kolkata – 700 091
Welder (Fabrication & Fitting)
ACKNOWLEDGEMENT

The DGT sincerely acknowledges contributions of the Industries, State Directorates, Trade
Experts, Domain Experts and all others who contributed in revising the curriculum. Special
acknowledgement is extended by DGT to the following expert members who had contributed
immensely in this curriculum.

List of Expert members participated in preparation of course curriculum of Welder (Fabrication

& Fitting) trade
Name & Designation
S No. Organization Remarks
Shri/Mr./Ms.
MEMBERS OF SECTOR MENTOR COUNCIL
1. Dr. G. Buvanashekaran, AGM WRI, Trichy - Chairman Chairman
2. Dr. K. Ashokkumar, AGM BHEL, Trichy Member
3. Prof. Jyothi Mukhopadhya IIT, Ahmedabad Member
4. B. Pattabhiraman, MD GB Engineering, Tricgy Member
5. Dr. Rajeev kumar IIT, Mandi Member
6. Dr. Vishalchauhan IIT, Mandi Member
7. D.K. Singh IIT, Kanpur Member
8. Navneet Arora IIT, Roorkee Member
9. R. K. Sharma,Head SDC, JBM Group, Faridabad Member
10. Puneet Sinha, Deputy Director MSME, New Delhi Member
MENTOR
11. Deepankar Mallick, DDG (C&P) DGT Hq, Mentor
MEMBERS OF CORE GROUP
12. M Thamizharasan, JDT CSTARI, Kolkata Member
13. M Kumaravel, DDT FTI , Bangalore Team Leader
14. SushilKumar, DDT DGTHq, Member
15. S.P.Khatokar, T.O. ATI, Mumbai Member
16. V.L. Ponmozhi, TO CTI, Chennai Member
17. D.Pani, TO ATI, Howrah Member
18. Amar Singh, TO ATI, Ludhiyana Member
19. Gopalakrishnan, TO NIMI, Chennai Member
20. Manjunatha B.S, JTO GITI, K.G.F. Karnataka Member
21. Venugopal PC ITI Chalakudi, Kerala Member
Welder (Fabrication & Fitting)
CONTENTS

S No. Topics Page No.

1. Course Information 1
2. Training System 2-5
3. Job Role 6-7
4. General Information 8-9
5. NSQF Level Compliance 10
6. Learning Outcome 11-12
7. Learning Outcome with Assessment Criteria 13 - 19
8. Syllabus 20-28
9. Syllabus - Core Skill
9.1 Core Skill – Workshop Calculation & Science and 29-31
Engineering Drawing
9.2 Core Skill – Employability Skill 32-35
10. Annexure I
List of Trade Tools & Equipment 36-39
List of Tools & Equipment for Employability Skill 40
11. Annexure II - Format for Internal Assessment 41
Welder (Fabrication & Fitting)

1. COURSE INFORMATION

During the one-year duration of “Welder (Fabrication & Fitting)” trade, a candidate
is trained on Professional Skill, Professional Knowledge, Engineering Drawing, Workshop
Science & Calculation and Employability Skill. In addition to this, a candidate is entrusted to
undertake project work, extracurricular activities and on-the-job training to build up
confidence. The broad components covered under Professional Skill subject are as below:-

In the one-year duration, the trainee learns about elementary first aid, firefighting,
environment regulation and housekeeping etc. The practical part starts with basic welding
work on stainless steel, cast iron, aluminium and brass viz. cutting of pipes, brazing, arc
gauging etc. Cutting of MS sheets & plates in different angles as per drawing, related to
structural and pressure parts. Joining of pipes of different diameter and angles by gas
welding, thread cutting on different types of pipes & fitting accessories and carry out drilling
machine operations to steel structures for fabrication of structures. On completion of each
welding job the trainees will also evaluate their jobs by visual inspection and identify the
defects for further correction/improvement. They learn to adapt precautionary measures
such as preheating; maintaining inter-pass temperature and post weld heat treatment for
Welding Alloy steel, Cast Iron etc. The Work Shop calculation taught will help them to plan
and cut the required jobs economically without wasting the material and also used in
estimating the Electrodes, filler metals etc. The Workshop Science taught will help them to
understand the materials and properties, effect of alloying elements etc. Engineering
Drawing taught will be applied while reading the job drawings and will be useful in
understanding the location, type and size of weld to be carried out.

Professional Knowledge subject is simultaneously taught in the same fashion to

apply cognitive knowledge while executing task. In addition components like Physical
properties of engineering materials, different types of iron, properties and uses,
introduction to GTAW & GMAW, Heat & Temperature are also covered under theory part. In
addition to above components the core skills components viz., Workshop calculation &
science, Engineering drawing, employability skills are also covered. These core skills are
essential skills which are necessary to perform the job in any given situation.

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Welder (Fabrication & Fitting)
2. TRAINING SYSTEM

2.1 GENERAL

Directorate General of Training (DGT) under Ministry of Skill Development &

Entrepreneurship offers range of vocational training courses catering to the need of
different sectors of economy/ Labour market. The vocational training programmes are
delivered under aegis of National Council of Vocational Training (NCVT). Craftsman Training
Scheme (CTS) and Apprenticeship Training Scheme (ATS) are two pioneer programmes of
NCVT for propagating vocational training.

Welder (Fabrication & Fitting) trade under CTS is one of the courses delivered
nationwide through network of ITIs. The course is of one year duration. It mainly consists of
Domain area and Core area. The Domain area (Trade Theory & Practical) imparts
professional - skills and knowledge, while Core area (Workshop Calculation science,
Engineering Drawing and Employability Skills) imparts requisite core skills, knowledge and
life skills. After passing out of the training program, the trainee is awarded National Trade
Certificate (NTC) by NCVT which is recognized worldwide.

Broadly candidates need to demonstrate that they are able to:

 Read & interpret technical parameters/document, plan and organize work

processes, identify necessary materials and tools;
 Perform task with due consideration to safety rules, accident prevention regulations
and environmental protection stipulations;
 Apply professional skill, knowledge, core skills & employability skills while
performing jobs.
 Check the job/assembly as per drawing for functioning, identify and rectify errors in
job/assembly.
 Document the technical parameters related to the task undertaken.

2.2 CAREER PROGRESSION PATHWAYS

 Can take admission in diploma course in notified branches of Engineering by lateral

entry.

 Can join Apprenticeship programme in different types of industries leading to

National Apprenticeship certificate (NAC).

 Can join Crafts Instructor Training Scheme (CITS) in the trade for becoming instructor
in ITIs.

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Welder (Fabrication & Fitting)

2.3 COURSE STRUCTURE

Table below depicts the distribution of training hours across various course elements
during a period of one year:-

Notional Training
S No. Course Element
Hours
1 Professional Skill (Trade Practical) 1050
2 Professional Knowledge (Trade Theory) 252
3 Workshop Calculation & Science 84
4 Engineering Drawing 126
5 Employability Skills 110
6 Library & Extracurricular activities 58
7 Project work 160
8 Revision & Examination 240
Total 2080

2.4 ASSESSMENT & CERTIFICATION

The trainee will be tested for his skill, knowledge and attitude during the period of the
course and at the end of the training program as notified by the Government of India (GoI)
from time to time. The employability skills will be tested in the first year itself.

a) The Internal Assessment during the period of training will be done by Formative
Assessment Method by testing for assessment criteria listed against learning outcomes. The
training institute has to maintain an individual trainee portfolio as detailed in assessment
guideline. The marks of internal assessment will be as per the template (Annexure – II).

b) The final assessment will be in the form of summative assessment method. The All India
Trade Test for awarding NTC will be conducted by NCVT as per the guideline of Government
of India. The pattern and marking structure is being notified by Govt. of India from time to
time. The learning outcome and assessment criteria will be the basis for setting question
papers for final assessment. The examiner during final examination will also check the
individual trainee’s profile as detailed in assessment guideline before giving marks for
practical examination.

2.4.1 PASS REGULATION

For the purposes of determining the overall result, weightage of 100% is applied for
six months and one year duration courses and 50% weightage is applied to each
examination for two years courses. The minimum pass percent for Practical is 60% &
minimum pass percent for Theory subjects is 33%.

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Welder (Fabrication & Fitting)

2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial

barriers to assessment. The nature of special needs should be taken into account while
undertaking the assessment. Due consideration should be given while assessing for
teamwork, avoidance/reduction of scrap/wastage and disposal of scrap/waste as per
procedure, behavioral attitude, sensitivity to the environment and regularity in training. The
sensitivity towards OSHE and self-learning attitude are to be considered while assessing
competency.

Assessment will be evidence based comprising the following:

 Job carried out in labs/workshop

 Record book/ daily diary
 Answer sheet of assessment
 Viva-voce
 Progress chart
 Attendance and punctuality
 Assignment
 Project work

Evidences of internal assessments are to be preserved until forthcoming examination

for audit and verification by examining body. The following marking pattern to be adopted
while assessing:

Performance Level Evidence

(a) Weightage in the range of 60%-75% to be allotted during assessment
For performance in this grade, the candidate
should produce work which demonstrates
attainment of an acceptable standard of
craftsmanship with occasional guidance, and
due regard for safety procedures and
practices
 Demonstration of good skill in the use of
hand tools, machine tools and workshop
equipment.
 60-70% accuracy achieved while
undertaking different work with those
demanded by the component/job.
 A fairly good level of neatness and
consistency in the finish.
 Occasional support in completing the
project/job.

(b) Weightage in the range of 75%-90% to be allotted during assessment

For this grade, a candidate should produce  Good skill levels in the use of hand tools,
work which demonstrates attainment of a machine tools and workshop
reasonable standard of craftsmanship, with equipment.
little guidance, and regard for safety  70-80% accuracy achieved while
procedures and practices undertaking different work with those
demanded by the component/job.

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Welder (Fabrication & Fitting)

 A good level of neatness and

consistency in the finish.
 Little support in completing the
project/job.

(c) Weightage in the range of more than 90% to be allotted during assessment
For performance in this grade, the  High skill levels in the use of hand tools,
candidate, with minimal or no support in machine tools and workshop
organization and execution and with due equipment.
regard for safety procedures and practices,  Above 80% accuracy achieved while
has produced work which demonstrates undertaking different work with those
attainment of a high standard of demanded by the component/job.
craftsmanship.  A high level of neatness and consistency
in the finish.
 Minimal or no support in completing the
project.

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Welder (Fabrication & Fitting)
3. JOB ROLE

Brief description of Job Role:

Welder, Gas fuses metal parts together using welding rod and oxygen acetylene flame. Examines
parts to be welded, cleans portion to be joined, holds them together by some suitable device
and if necessary makes narrow groove to direct flow of molten metal to strengthen joint. Selects
correct type and size of welding rod, nozzle etc. and tests welding, torch. Wears dark glasses and
other protective devices while welding. Releases and regulates valves of oxygen and acetylene
cylinders to control their flow into torch. Ignites torch and regulates flame gradually. Guides
flame along joint and heats it to melting point, simultaneously melting welding rod and
spreading molten metal along joint shape, size etc. and rectifies defects if any. May join part at
various spots to prevent distortion of shape, form dimension etc. May preheat materials like cast
iron prior to welding. May also weld by other gases such as argon coal etc.

Welder, Electric; Arc Welder fuses metals using arc-welding apparatus and electrodes (welding
material). Examines parts to be welded, cleans them and sets joints together with clamps or any
other suitable device. Starts generator or transformer (welding apparatus and regulates current
according to material and thickness of welding. Clamps one lead (insulated wire carrying current
from generator) to part to be welded, selects required type of electrode and clamps it to holder
connected with other lead). Generates sparks between electrode and joint, simultaneously
guiding and depositing melting electrode uniformly for welding. Takes precautionary measures
such as wearing rubber gloves, holding welding screen of dark glass etc. May join parts first at
various points for holding at specified angles, shape, form and dimension.

Welder, Machine; operates gas or electric welding machine to joint metal parts by fusion. Sets
machine for operation by igniting burners and adjusting flames or by switching on current.
Regulates flow of gas or current and adjusts machine according to material to be welded. Checks
cooling system and adjusts movement of conveyor, if any. Feeds material to be welded with
either one by one or in batch according to type of machine and welds them by pressing paddle,
or by automatic arrangements. May use fixtures or other suitable devices for mass production
work. Is designated as SPOT WELDER, FLASH WELDER, etc. according to machine and type of
work done.

Gas Cutter; Flame Cutter cuts metal to required shape and size by gas flame either manually or
by machine. Examines material to be cut and marks it according to instruction of specification.
Mounts template and sets machine to cut to specifications. Makes necessary connections and
fits required size of nozzle or burner in welding torch. Releases and regulates flow of gas in
nozzle or burner, ignites and adjusts flame. Guides flame by hand or machine along cutting line
at required speed and cuts metal to required size. May use oxyacetylene or any other
appropriate gas flame.

Brazer; fuses metal parts by heating using flux and fillings. Cleans and fastens parts to be joined
face to face by wire, by seaming or by any other suitable means and prepares paste of flux and

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Welder (Fabrication & Fitting)

fillings. Applies it to joint and hearts in furnace or by torch to melt filling into joint. Allows it to
cool down. Examines joint and cleans them by filing, buffing etc.

Reference NCO-2015:

(i) 7212.0100 – Welder, Gas

(ii) 7212.0200 – Welder, Electric
(iii) 7212.0300 – Welder, Machine
(iv) 7212.0400 – Gas Cutter
(v) 7212.0500 – Brazer

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Welder (Fabrication & Fitting)
4. GENERAL INFORMATION

Name of the Trade Welder (Fabrication & Fitting)

NCO - 2015 7212.0100, 7212.0200, 7212.0300, 7212.0400, 7212.0500

NSQF Level Level-3
Duration of Craftsmen
One year
Training

Entry Qualification Passed 8th class examination

Unit Strength (No. Of

20
Student)

Space Norms 80 Sq. m

Power Norms 16 KW
Instructors Qualification for
1. Welder (Fabrication & Degree in Mechanical / Metallurgy / Production Engineering/
Fitting) Trade Mechatronics from recognized university/ college with one year
experience in the relevant field.
OR
Diploma in Mechanical and allied from recognized board of
technical education with two years experience in relevant field.
OR
NTC / NAC passed in “Welder” Trade or relevant trade with 3
years' post qualification experience.

Essential Qualification:
Craft Instructor Certificate in relevant trade under NCVT.

Note:
1. Out of two Instructors required for the unit of 1+1, one
must have Degree/Diploma and other must have NTC/NAC
qualifications.
2. Instructor qualification for W/shop Calculation, Engg
Drawing & Employability Skill would be as per the training
manual.
2. Workshop Calculation Degree in Engineering with one year experience.
& Science OR
Diploma in Engineering with two years experience.

Essential Qualification:
Craft Instructor Certificate in RoD& a course under NCVT.
3. Engineering Drawing Degree in Engineering with one year experience.
OR
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Welder (Fabrication & Fitting)

Diploma in Engineering with two years experience.

OR
NTC/ NAC in the Draughtsman (Mechanical) with three years
experience.

Essential Qualification:
Craft Instructor Certificate in RoD& A course under NCVT.

4. Employability Skill MBA OR BBA with two years experience OR Graduate in Sociology/
Social Welfare/ Economics with Two years experience OR
Graduate/ Diploma with Two years experience and trained in
Employability Skills from DGT institutes.
AND
Must have studied English/ Communication Skills and Basic
Computer at 12th / Diploma level and above.
OR
Existing Social Studies Instructors duly trained in Employability
Skills from DGT institutes.

List of Tools and

As per Annexure – I
Equipment
Distribution of training on Hourly basis: (Indicative only)

Total Work Extra-

Trade Trade Engg. Employability
hours shop Cal. curricular
practical theory Drawing skills
/week &Sc. activity

40 Hours 25 Hours 6 Hours 2 Hours 3 Hours 2 Hours 2 Hours

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Welder (Fabrication & Fitting)
5. NSQF LEVEL COMPLIANCE

NSQF level for Welder (Fabrication & Fitting) trade under CTS: Level - 3

As per notification issued by Govt. of India dated- 27.12.2013 on National Skill

Qualification Framework total 10 (Ten) Levels are defined.

Each level of the NSQF is associated with a set of descriptors made up of five
outcome statements, which describe in general terms, the minimum knowledge, skills and
attributes that a learner needs to acquire in order to be certified for that level.

Each level of the NSQF is described by a statement of learning outcomes in five

domains, known as level descriptors. These five domains are:

a. Process
b. professional knowledge
c. professional skill
d. Core skill and
e. Responsibility

The Broad Learning outcome of Welder (Fabrication & Fitting) trade under CTS mostly
matches with the Level descriptor at Level- 3.

The NSQF level-3 descriptor is given below:

Professional
Level Process Required Professional Skill Core Skill Responsibility
Knowledge
Level 3 Person may carry Basic facts, recall and Communication Under close
put a job which process and demonstrate written and oral, supervision
may require principle practical with minimum Some
limited range of applied in skill, routine required clarity, Responsibility
activities routine trade of and skill of basic for own
and predictable employment repetitive in arithmetic and work within
narrow algebraic defined limit.
range of principles,
application personal
banking, basic
understanding of
social and natural
environment

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Welder (Fabrication & Fitting)
6. LEARNING OUTCOME

Learning outcomes are a reflection of total competencies of a trainee and assessment

will be carried out as per the assessment criteria.

6.1 GENERIC LEARNING OUTCOME

1. Recognize & comply safe working practices, environment regulation and housekeeping.
2. Work in a team, understand and practice soft skills, technical English to communicate
with required clarity.
3. Demonstrate knowledge of concept and principles of basic arithmetic &algebraic and
apply knowledge of specific area to perform practical operations.
4. Understand basic science in the field of study including.
5. Read and understand engineering drawing for different application in the field of work
6. Understand the concept in productivity, quality tools, and labour welfare legislation.
7. Explain energy conservation, global warming and pollution.
8. Explain time management, entrepreneurship and manage/organize related task in day
to day work for personal & societal growth.
9. Understand and apply basic computer working, basic operating system and uses
internet services to get accustomed & take benefit of IT developments in the
industry.

6.2 SPECIFIC LEARNING OUTCOME

10. Join MS sheets by Gas welding in different positions.

11. Join MS plates by SMAW in different positions.
12. Perform straight, bevel & circular cutting on MS plate by Oxy-acetylene cutting process.
13. Perform different type of MS pipe joints by Gas welding (OAW).
14. Weld different types of MS pipe joints by SMAW.
15. Weld Stainless steel, Cast iron, Brass & Aluminum by OAW.
16. Perform Arc gauging on MS plate.
17. Perform linear and angular measurement and check surface level using specified gauges
and carry out marking using marking block.
18. Perform drilling machine operations to steel structures for fabrication of structures.
19. Mark, cut and bevel the parts and prepare edges by Oxy acetylene Gas cutting for
fabrication of structures.
20. Develop and make different geometrical shapes.

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Welder (Fabrication & Fitting)

21. Study the design drawing related to structural and pressure parts and identify of
metals, bars, plates, flats, channels, I section, T section, and box /hollow section etc for
the purpose of fabricating structure.
22. Mark and cut sheet metals to required size using guillotine shearing machine.
23. Perform bending, straightening and edge planning for fabrication of structures.
24. Make fit up and carry out tack welding to fabricate structures as per the standard tack
welding procedure.
25. Mark and prepare riveted joints.
26. Mark and prepare edges for different types of pipe joints viz T, Y & K joints and Tack
welding Pipes.
27. Make templates for simple objects and fixtures.
28. Perform Marking on Girder and Trusses and make a simple lattice structure.
29. Make pipeline Assembly, welded section and cylindrical Tanks by SMAW.
30. Rectify distorted welded structure by flame straightening.
31. Carry out dimensional inspection of fit ups, Perform Cleaning & Painting on fitted
structures.

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Welder (Fabrication & Fitting)
7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

GENERIC LEARNING OUTCOME

LEARNING OUTCOME ASSESSMENT CRITERIA
1. Apply safe working practices. 1.1 Follow and maintain procedures to achieve a safe
working environment in line with occupational health
and safety regulations and requirements and according
to site policy.
1.2 Recognize and report all unsafe situations according to
site policy.
1.3 Identify and take necessary precautions on fire and
safety hazards and report according to site policy and
procedures.
1.4 Identify, handle and store / dispose off dangerous goods
and substances according to site policy and procedures
following safety regulations and requirements.
1.5 Identify and observe site policies and procedures in
regard to illness or accident.
1.6 Identify safety alarms accurately.
1.7 Report supervisor/ Competent of authority in the event
of accident or sickness of any staff and record accident
details correctly according to site accident/injury
procedures.
1.8 Identify and observe site evacuation procedures
according to site policy.
1.9 Identify Personal Productive Equipment (PPE) and use
the same as per related working environment.
1.10 Identify basic first aid and use them under different
circumstances.
1.11 Identify different fire extinguisher and use the same as
per requirement.

2. Comply environment 2.1 Identify environmental pollution & contribute to the

regulation and avoidance of instances of environmental pollution.
housekeeping. 2.2 Deploy environmental protection legislation &
regulations
2.3 Take opportunities to use energy and materials in an
environmentally friendly manner
2.4 Avoid waste and dispose waste as per procedure
2.5 Recognize different components of 5S and apply the
same in the working environment.

3. Interpret & use company 3.1 Obtain sources of information and recognize
and technical information.
3.2 Use and draw up technical drawings and documents.

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Welder (Fabrication & Fitting)
communication. 3.3
3.4
3.5
3.6
3.7
4. Demonstrate knowledge of 4.1
concept and principles of
basic arithmetic, algebraic 4.2
calculations and apply
knowledge of specific area to
perform practical operations.
5. Understand and explain 5.1
basic science in the field of
study including basic 5.2
electrical.
6. Read and apply engineering 6.1
drawing for different
application in the field of 6.2
work.
7. Understand and explain the 7.1
concept in productivity,
quality tools, and labour 7.2
welfare legislation and apply
such in day to day work to
improve productivity &
quality.
8. Explain energy conservation, 8.1
global warming and pollution
and contribute in day to day 8.2
work by optimally using
available resources.
9. Explain personnel finance, 9.1
entrepreneurship and
manage/organize related 9.2
task in day to day work for
Use documents and technical regulations and
occupationally related provisions.
Conduct appropriate and target oriented discussions
with higher authority and within the team.
Present facts and circumstances, possible solutions &use
English special terminology.
Resolve disputes within the team.
Conduct written communication.
Final examination to test basic skills on arithmetic,
and algebra.
Their applications will also be assessed during
execution of assessable outcome and also tested during
theory and practical examination.
Final examination to test basic skills on science in the
field of study including basic electrical
Their applications will also be assessed during execution
of assessable outcome and also tested during theory and
practical examination.
Final examination to test basic skills on engineering
drawing.
Their applications will also be assessed during execution
of assessable outcome and also tested during theory and
practical examination.
Final examination to test the concept in productivity,
quality tools and labour welfare legislation.
Their applications will also be assessed during execution
of assessable outcome.
Final examination to test knowledge on energy
conservation, global warming and pollution.
Their applications will also be assessed during
execution of assessable outcome.
Final examination to test knowledge on personnel
finance, entrepreneurship.
Their applications will also be assessed during
execution of assessable outcome.
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Welder (Fabrication & Fitting)
personal & societal growth.
10. Understand and apply basic 10.1
computer working, basic
operating system and uses
internet services to get 10.2
accustomed & take benefit
of IT developments in the
industry.
Final examination to test knowledge on basic computer
working, basic operating system and uses internet
services.
Their applications will also be assessed during
execution of assessable outcome.
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Welder (Fabrication & Fitting)

SPECIFIC LEARNING OUTCOME

LEARNING OUTCOME ASSESSMENT CRITERIA

11. Join MS sheets by Gas 11.1 Plan and select the nozzle size, working pressure type of
welding in different flame, filler rod as per requirement.
positions. 11.2 Prepare, set and tack the pieces as per drawing.
11.3 Setting up the tacked joint in specific position.
11.4 Deposit the weld following proper welding technique and
safety aspect.
11.5 Carry out visual inspection to ascertain quality weld joint.

12. Join MS plates by SMAW
in different positions.
12.1 Plan and select the type & size of electrode, welding
current, type of edge preparation etc. as per requirement.
12.2 Prepare, set and tack the pieces as per drawing.
12.3 Set up the tacked pieces in specific position.
12.4 Deposit the weld maintaining appropriate arc length,
electrode angle, welding speed, weaving technique and
safety aspects.
12.5 Clean the welded joint thoroughly.
12.6 Carry out visual inspection for appropriate weld joint.
12.7 Inspect the weld using DPT/MPT.

13. Perform straight, bevel & 13.1 Plan and mark on MS plate surface for
circular cutting on MS straight/bevel/circular cutting.
plate by Oxy-acetylene 13.2 Select the nozzle size and working pressure of gases as per
cutting process. requirement.
13.3 Set the marked plate properly on cutting table.
13.4 Perform the straight and bevel cutting operation
maintaining proper techniques and all safety aspects.
13.5 Perform the circular cutting operation by using profile
cutting machine maintaining proper techniques and all
safety aspects
13.6 Clean the cutting burrs and inspect the cut surface for
soundness of cutting.

14. Perform different type of 14.1 Plan and prepare the development for a specific type of pipe
MS pipe joints by Gas joint.
welding (OAW). 14.2 Mark and cut the MS pipe as per development.
14.3 Select the size of filler rod, size of nozzle, working pressure
etc.
14.4 Set and tack the pieces as per drawing.

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Welder (Fabrication & Fitting)

14.5 Deposit the weld bead maintaining proper technique and

safety aspects.
14.6 Inspect the welded joint visually for poor penetration,
uniformity of bead and surface defects.

15. Weld different types of
MS pipe joints by SMAW.
15.1 Plan and prepare the development for a specific type of pipe
joint.
15.2 Mark and cut the MS pipe as per development.
15.3 Select the electrode size and welding current for welding.
15.4 Set and tack the pieces as per drawing.
15.5 Deposit the weld bead maintaining proper technique and
safety aspects.
15.6 Insect the welded joint visually for root penetration,
uniformity of bead and surface defects.

16. Weld Stainless steel, Cast 16.1 Plan and prepare the pieces for welding.
iron, Brass & Aluminum
16.2 Select the type and size of filler rod and flux, size of nozzle,
by OAW. gas pressure, preheating method and temperature as per
requirement.
16.3 Set and tack plates as per drawing.
16.4 Deposit the weld maintaining appropriate technique and
safety aspects.
16.5 Cool the welded joint by observing appropriate cooling
method. Use post heating as per requirement.
16.6 Clean the joint and inspect the weld for its uniformity and
different types of surface defects.

17. Perform Arc gauging on
MS plate.
17.1 Plan and select the size of electrode for Arc gouging.
17.2 Select the polarity and current as per requirement.
17.3 Perform gouging adapting proper gouging technique.
17.4 Clean and check to ascertain the required stock removed.

18. Perform linear and 18.1 Measure inside & outside dimensions using Vrenier caliper.
angular measurement and 18.2 Check surface Level using sprit level.
check surface level using 18.3 Measure heights using Vernier height gauge.
specified gauges and carry 18.4 Measure angle using Bevel protractor.
out marking using 18.5 Mark dimensions using marking block.
marking block.

19. Perform drilling machine 19.1 Drill different diameter of through holes by drilling.
operations to steel 19.2 Drill Blind holes.
structures for fabrication 19.3 Perform Countersinking.

17
Welder (Fabrication & Fitting)
of structures.
20. Mark, cut and bevel the
parts and prepare edges
by Oxy acetylene Gas
cutting for fabrication of
structures.
21. Develop and make
different geometrical
shapes.
22. Study the design drawing 22.1 Read fabrication drawings and identify the metal bars,
related to structural and
pressure parts and
identify of metals, bars, 22.2 Identify metal by colour code and measure dimension of
plates, flats, channels, I
section, T section, and box
/hollow section etc for the
purpose of fabricating
structure.
23. Mark and cut sheet
metals to required size
using guillotine shearing
machine.
24. Perform bending,
straightening and edge
planning for fabrication of
structures.
25. Make fit up and carry out
tack welding to fabricate
structures as per the
standard tack welding
procedure.
26. Mark and prepare riveted
20.1 Clean surface of plate by grinding and filing.
20.2 Mark on plates for bevelling and chamfering.
20.3 Prepare edge for Single "V" butt joint, Single bevel butt joint
and Double V butt joint by Oxy acetylene Gas cutting.
20.4 Grind and file for maintaining root face.
21.1 Develop Prism to the given dimensions out of sheet
metal.
21.2 Develop Cylinder to the given dimensions out of
sheet metal.
21.3 Develop Cylinder to the given dimensions out of sheet metal.
21.4 Develop Cone to the given dimensions out of sheet metal.
plates, flats, channels, I section, T section, and box /hollow
section etc. Identify specification of metals.
Bars, Plates, Flats, Channels, I section, T' section, L section
and Box section.
23.1 Identify the safety Precautions, and operate power Shearing
machine.
23.2 Mark on sheets to the require Size.
23.3 Shear different sizes of sheets by adapting safety
precaution.
24.1 Bend plates & pipe by using plate/pipe bending machine.
24.2 Bend pipes to different angles and shapes by using Pipe
bending machine.
24.3 Straighten plates by hammering (cold straightening)
24.4 Straighten plates by heating and hammering (hot
straightening.
25.1 Cut high pressure pipe to required size by Gas cutting.
25.2 Mark and bevel the pipes to required bevel angle and root
face size by Gas cutting.
25.3 Grind and file pipe edges pipes to required bevel angle and root
face and clean the pipe surface.
25.4 Tack weld the pipes together by SMAW.
26.1 Prepare single riveted lap joint.
18
Welder (Fabrication & Fitting)
joints.
27. Mark and prepare edges
for different types of pipe
joints viz T, Y & K joints
and Tack welding Pipes.
28. Make templates for
simple objects and
fixtures.
29. Perform Marking on
Girder and Trusses and
make a simple lattice
structure.
30. Make pipeline Assembly,
welded section and
cylindrical Tanks by
SMAW.
31. Rectify distorted welded
structure by flame
straightening.
32. Carry out dimensional
inspection of fit ups,
Perform Cleaning &
Painting on fitted
structures.
26.2 Prepare Double riveted lap joint.
26.3 Single cover plate riveted butt joint.
26.4 Bolted joints.
27.1 Develop templates for Gas cutting Pipes for „T' „Y' and „K'
joint.
27.2 Fit up the Pipes and tack weld the pipes as per the
standard procedure for „T' „Y' and „K' joint.
27.3 Mark for assembly and tack welding of gusset plates using
height gauge.
27.4 Mark on joint section beam using height gauge.
27.5 Mark on joint column using height gauge.
27.6 Mark on curved and bend plates and sections using
measuring and marking tools.
27.7 Mark on build up sections using measuring and marking
tools.
27.8 Mark using pantograph.
28.1 Make templates for marking on Simple objects.
28.2 Make templates for Gussets and joint sections.
28.3 Make simple fixtures.
29.1 Making simple riveted plate assembly - Girder , trusses.
29.2 Make Girder and trusses.
29.3 Make a simple lattice structure.
30.1 Make pressure pipe line assembly by SMAW.
30.2 Make welded section assembly by SMAW
30.3 Make cylindrical tanks by SMAW
31.1 Rectify distorted welded structure by flame straightening
with the use of oxy-acetylene flame heating, hammer and
pull rod.
32.1 Check dimensions of welded structures using measuring
tape, try square, Levelling instruments etc.
32.2 Clean the structures properly using chipping hammer, wire
brush etc.
32.3 Perform Painting.
19
Welder (Fabrication & Fitting)
8. SYLLABUS

SYLLABUS - WELDER (FABRICATION & FITTING)

DURATION: ONE YEAR

Professional Skills
Week Reference Learning Professional Knowledge
(Trade Practical)
No. Outcome (Trade Theory)
With Indicative Hours
1 Apply safe working Induction training: - General discipline in the
practices. 1. Familiarization with the Institute
Institute. - Elementary First Aid.
2. Importance of trade Training - Importance of Welding in
3. Machinery used in the trade. Industry
4. Introduction to safety - Safety precautions in
equipment and their use etc. Shielded Metal Arc Welding,
5. Hack sawing, filing square to and Oxy-Acetylene Welding
dimensions. and Cutting.
6. Marking out on MS plate and
punching.
2 Join MS sheet by Gas 7. Setting up of Arc welding - Introduction and definition of
welding in different machine & accessories and welding.
positions. Striking an arc - Arc and Gas Welding
8. Setting of oxy-acetylene Equipments, tools and
welding equipment, Lighting accessories.
and setting of flame. - Various Welding Processes
and its applications.
- Arc and Gas Welding terms
and definitions.
3 Join MS plates by 9. Fusion run without and with - Different process of metal
SMAW in different filler rod on M.S. sheet 2 mm joining methods: Bolting,
thick in flat position. riveting, soldering, brazing,
positions.
10. Edge joint on MS sheet 2 mm seaming etc.
thick in flat position without - Types of welding joints and
filler rod. its applications. Edge
11. Marking and straight line preparation and fit up for
cutting of MS plate. 10 mm different thickness.
thick by gas. - Surface Cleaning
4 Perform straight, 12. Straight line beads on M.S. - Basic electricity applicable to
bevel & circular plate 10 mm thick in flat arc welding and related
position. electrical terms & definitions.
cutting on MS plate
13. Weaved bead on M. S plate - Heat and temperature and its
by Oxy-acetylene
10mm thick in flat position. terms related to welding
20
Welder (Fabrication & Fitting)

cutting process. - Principle of arc welding. And

characteristics of arc.
5 -do- 14. Square butt joint on M.S. sheet - Common gases used for
2 mm thick in flat Position. welding & cutting, flame
15. Fillet "T" j oint on M.S. Plate 10 temperatures and uses.
mm thick in flat position. - Chemistry of oxy-acetylene
flame.
- Types of oxy-acetylene
flames and uses.
- Oxy-Acetylene Cutting
Equipment principle,
parameters and application.
6 -do- 16. Bevelling of MS plates 10 mm - Arc welding power sources:
thick. By gas cutting. Transformer, Motor
17. Open corner joint on MS sheet Generator set, Rectifier and
2 mm thick in flat Position Inverter type welding
18. Fillet lap joint on M.S. plate 10 machines and its care &
mm thick in flat position. maintenance.
- Advantages and
disadvantages of A.C. and
D.C. welding machines.
7 -do- 19. Circular gas cutting on MS - Welding positions as per EN
plate 10 mm thick by profile & ASME: flat, horizontal,
cutting machine. vertical and over head
20. Fillet "T" joint on M S she et 2 position.
mm thick in flat position - Weld slope and rotation.
21. Open Corner joint on MS plate - Welding symbols as per BIS &
10 mm thick in flat position. AWS.
8 -do- 22. Fillet Lap joint on MS sheet 2 - Arc length - types - effects of
mm thick in flat position. arc length.
23. Single "V" Butt joint on M S - Polarity: Types and
plate 12 mm thick in flat applications.
position (1G).
9 -do- 24. Square Butt joint on M.S. - Calcium carbide properties
sheet. 2 mm thick in and uses.
Horizontal position. - Acetylene gas properties and
25. Straight line beads and multi generating methods.
layer practice on M.S. Plate 10 - Acetylene gas Purifier,
mm thick in Horizontal Hydraulic back pressure valve
position. and Flash back arrestor
26. F "T" 10 mm thick in Horizontal
position.
21
Welder (Fabrication & Fitting)
10 -do- 27. Fillet Lap joint on M.S. sheet 2
mm thick in horizontal
position.
28. Fillet Lap joint on M.S. plate 10
mm thick in horizontal
position.
11 -do- 29. Fusion run with filler rod in
vertical position on 2mm thick
M.S. sheet
30. Square Butt joint on M.S.
sheet. 2 mm thick in vertical
position.
31. Single Vee Butt joint on M.S.
plate 12 mm thick in horizontal
position (2G).
12 -do- 32. Weaved bead on M.S Plate
10mm in vertical position.
33. Fillet "T" j oint on M.S sheet 2
mm thick in vertical position.
34. F "T" 10 mm thick in vertical
position.
13 Perform different 35. Structural pipe welding butt -
type of MS pipe joint on MS pipe 0 50 and
3mm WT in 1G position.
joints by Gas
36. Fillet Lap joint on M.S. Plate 10
welding (OAW).
mm in vertical position.
14 -do- 37. Open Corner joint on MS plate -
10 mm thick in vertical
position.
38. Pipe welding - Elbow joint on -
MS pipe 0 -50 and 3mm WT.
15 -do- 39. Pip e we l ding "T" joint on MS -
pipe 0 5 0 and 3mm WT.
22
- Oxygen gas and its properties
- Production of oxygen by Air
liquefaction.
- Charging process of oxygen
and acetylene gases
- Oxygen and Dissolved
Acetylene gas cylinders and
Color coding for different gas
cylinders.
- Gas regulators, types and
uses.
- Oxy acetylene gas welding
Systems (Low pressure and
High pressure). Difference
between gas welding blow
pipe(LP & HP) and gas cutting
blow pipe
- Gas welding techniques.
Rightward and Leftward
techniques.
- Arc blow - causes and
methods of controlling.
- Distortion in arc & gas
welding and methods
employed to minimize
distortion
- Arc Welding defects, causes
and Remedies.
Specification of pipes, various
types of pipe joints, pipe
welding positions, and
procedure.
- Difference between pipe
welding and plate welding.
Pipe development for Elbow
joint, "T" joint, Y joint and
branch joint
Manifold system
Gas welding filler rods,
specifications and sizes.
Welder (Fabrication & Fitting)
40. Single "V" Butt joint on M S p -
late 12 mm thick in vertical
position (3G). - Gas Brazing & Soldering :
16 Weld different types 41. Pipe welding 45 ° angle joint -
of MS pipe joints by on MS pipe 0 50 and 3mm WT.
SMAW. 42. Straight line beads on M.S.
plate 10mm thick in over head
position. - Effects of moisture pick up.
- Storage and baking of
17 -do- 43. Pipe Flange joint on M.S plate
with MS pipe 0 50 mm X 3mm
WT
44. F "T" 10 mm thick in over head
position.
18 -do- 45. Pipe welding butt joint on MS
pipe 0 50 and 5 mm WT. in 1G
position.
46. Fillet Lap joint on M.S. plate 10
mm thick in over head
position.
19 -do- 47. Single "V" Butt joint on MS
plate 10mm thick in over head
position(4G)
48. Pipe butt joint on M. S. pipe 0
50mm WT 6mm (1G Rolled).
20 Perform welding of 49. Square Butt joint on S.S. sheet.
Stainless steel, Cast 2 mm thick in flat position.
iron, Aluminium and 50. Square Butt joint on S.S. Sheet
Brass by OAW. 2 mm thick in flat position.
51. Square Butt joint on Brass
sheet 2 mm thick in flat
position.
21 Perform Arc gauging 52. Square Butt & Lap joint on
on MS plate. M.S. sheet 2 mm thick by
brazing.
23
Gas welding fluxes - types
and functions.
principles, types fluxes &
uses
- Gas welding defects, causes
and remedies.
Electrode : types, functions of
flux, coating factor, sizes of
electrode Coding of electrode
as per BIS, AWS,
electrodes.
- Special purpose electrodes
and their applications.
- Weldability of metals,
importance of pre heating,
post heating and
maintenance of inter pass
temperature.
- Classification of steel.
- Welding of low, medium and
high carbon steel and alloy
steels.
- Effects of alloying elements
on steel
- Stainless steel: types- weld
decay and weldability.
- Brass - types - properties and
welding methods.
- Copper - types - properties
and welding methods.
- Aluminium and its alloys,
properties and weldability,
Welding methods
Welder (Fabrication & Fitting)

53. Single "V" butt joint C.I. plate - Arc cutting & gouging,
6mm thick in flat position.
54. Arc gouging on MS plate 10
mm thick.
22 -do- 55. Square Butt joint on - Cast iron and its properties
Aluminium sheet. 3 mm thick types.
in flat position. - Welding methods of cast
56. Bronze welding of cast iron iron.
(Single "V" butt joint) 6mm
thick plate
23-24 Industrial Training / Project Work
25-26 Revision
27 Perform linear and 57. Familiarisation with the - Outline of the subjects to be
angular machinery Hand tools used in covered.
the trade. - Role of fabrication in industry
measurement and
58. Introduction to safety - Basic Trigonometric
check surface level
equipment and their use. calculations.
using specified
59. Handling of measuring - Marking of Angles, Triangles,
gauges and carry out instruments - Steel tape, Square, Rectangle,
marking using Vernier caliper, Spirit level, Parallelogram, Hexagon,
marking block. Micrometer, Try square, Octagon and Circles.
Height gauge, Marking blocks,
Bevel protractor etc.
28 -do- 60. Development practice of - Calculation of volume and
surface of prism, cylinder, surface area of rectangular
pyramids, cones, etc. prism, cubes and cylinders.
- Development of right solids,
prisms, cylinders, pyramids,
cones, frustum of pyramid,
cone etc.
29 Perform drilling 61. Marking on plates for drilling - Workshop practice - Hack
machine operations practice. sawing, Filing, Chipping, Hand
62. Drilling required diameter grinding, Marking, Punching,
to steel structures
hole. Drilling, Tapping, Die-passing,
for fabrication of
etc.
structures.
- Drilling machine -
construction and operation
feature
30 Mark, cut and bevel 63. Marking on plates for beveling - Machine shop practice -
the parts and and chamfering. Milling machine construction
64. Beveling and chamfering to and operation - Milling cutter
prepare edges by
required Angle. -Types of Milling etc.
24
Welder (Fabrication & Fitting)

Oxy acetylene Gas - Lathe - construction and

cutting for operation.
- Turning - Facing - Taper
fabrication of
Turning - Threading etc.
structures

31 Develop and make 65. Straight line beads on M S - Principles of Shielded metal
different plate by SMAW Arc welding (SMAW)
66. Tack welding on M S plate & - Basic Electricity of welding
Geometrical shapes.
channels by SMAW in different power source
position. - AC / DC power source
67. Square butt joint weld on M S advantages and
plate in down hand position by disadvantages.
SMAW. - Polarity types & Arc length.
32 Study the design 68. Fillet, Tee and Lap joint weld in - Electrode - Types, description
drawing related to down hand position by SMAW. & Specification - BIS, AWS,
structural and 69. Fillet weld open corner joint etc..
pressure parts and on MS plate in down hand - Functions of flux &
identify of metals, position by SMAW. Characteristics of flux & arc
bars, plates, flats, 70. Single V butt joint on MS flat in - Selection of electrodes and
channels, I section, T down hand position by SMAW. coating factors
section, and box - Tack welding procedure on
/hollow section etc plate , channels & pipe:
for the purpose of Length & pitch
fabricating structure.
33 -do- 71. Identification of metals, bars, - Metals used in fabrication
plates, flats, channels, I - Types of fabrication joints
section, T section, and box - Types and classification of
section etc. steel and application
- Framed structures - shell
structure - Rolled sections, I
section, channel section,
angle section, T-section
34 -do- 72. Study of design drawing - Welding symbols
related to structural and - Structural/ Pressure vessel
pressure parts and preparation design drawing reading and
of fitting square. understanding the concepts
35 Mark and cut sheet 73. Using guillotine shearing - Description and operation of
metals to required machine, marking and cutting croppers, shearing machine,
of sheet metals to required Guillotine shears, punching
size using guillotine
size. machines, Edge planning
shearing machine.
machine and nibbling

25
Welder (Fabrication & Fitting)

machine etc.
- Description and operation of
straightening machines.
36 Perform bending, 74. Practice on bending of plates - Methods of bending plates,
straightening and and pipes to required shape. angle iron etc.
edge planning for 75. Straightening plates and - Cold bending and hot
fabrication of section. bending etc.
structures. 76. Edge planning as per - Bending of angles and
requirement. channels.
- Press work.
- Flame straightening
methods.
37 -do- 77. Preparation of pipe joint for - Pipes and pipe fitting - Pipe
high pressure pipe welding. schedule - types - methods of
78. Pipe Welding - preparation of bending - use of bending
edges – cleaning the joint fixture - pipe bending
surface - Fit up the pipes machine - use of pipe cutter,
pipe wrenches - pipe vices -
pipe threads - pipe dies
and taps etc.
38 Make fit up and 79. Tack weld two pipes together - Edge preparation for
carry out tack 80. Pipe work - cutting - bending - pressure line pipes
threading -joining and - Fit up procedure
welding to fabricate
assembly.
structures as per the
standard tack
welding procedure.
39 Mark and prepare 81. Preparation of single riveted - Hand riveting, cold and hot -
riveted joints. lap joint. methods of riveting - use of
82. Double riveted lap joint. pneumatic riveting, hydraulic
riveting - checking rivets -
removing of bad rivets
40 -do- 83. Single cover plate riveted butt - Types of bolts - black bolt,
joint. turned bolt, high strength
84. Double cover plate riveted bolt etc. and their
butt joint. application.
85. Bolted joints. - Development of pipe
templates for T,Y,K joints.
41 Mark and prepare 86. Preparation of pipes for T, Y, K - Kind of structures - Column
edges for different joints. base, plate girders, Gantry
types of pipe joints 87. Marking gusset plates. girders, Root trusses -
viz T,Y&K joints and 88. Marking joint section beam. description, types and use -

26
Welder (Fabrication & Fitting)

Tack welding Pipes. 89. Marking joint column using Beam connection, beam to
height gauge. column connection - framed
connection and seated
connection.
42 -do- 90. Marking on curved and bend - Type of pressure vessels -
plates and section. Boilers, Heat exchangers,
91. Marking on built up section. High pressure pipe lines etc. -
92. Usage of pantograph for Marking for cutting to size,
marking. marking for beveling and
chamfering and marking for
pipes and intersection
43 Make templates for 93. Making templates for cutting - Jigs and Template making -
simple objects and to size and simple objects. Design and description of
fixtures. templates for cutting -
templates of gussets -
templates for marking angle
44 -do- 94. Making templates for Gussets - Template for marking joint
and joint sections. section
95. Making simple fixtures. - Design and development of
jigs for drilling and angles
- Design of simple fixture and
clamping devices
45 Perform Marking on 96. Making simple riveted plate - Assembly: Procedure and
Girder and Trusses assembly - Girder , trusses. technique for assembly
97. Making a simple lattice - Assembling of riveted plates,
and make a simple
structure. girders and trusses
lattice structure.
46 Make pipeline 98. Making pressure pipe line - Assembly of welded section
Assembly, welded assembly. - Assembly of cylindrical tanks
99. Making welded section including fitting and lining of
section and
assembly. vessels
cylindrical Tanks by
100. Making cylindrical tanks.
SMAW.
47 Rectify distorted 101. Rectification of distorted - Distortion & methods of
welded structure by welded structure by flame control
flame straightening. straightening. - Preventing and allowing for
weld distortion
- Common welding defects
- Inspection and testing
- Non destructive method of
flaw detection -PT, MPT,
Ultrasonic & Radiographic
inspection
27
Welder (Fabrication & Fitting)

48 Carry out 102. Dimensional inspection of fit - Chipping & Grinding : Chisels
dimensional ups Cleaning & Painting. & pneumatic chisels used for
chipping- Method of chipping
inspection of fit ups,
and cutting - Types of
perform Cleaning &
grinding machines -Grinding
Painting on fitted
wheels - Method of removing
structures. welds and rivets by chipping
and grinding.
- Finishing & Painting:
Common types of painting.
Stenciling, marking and
colour marking
49-50 Industrial training / Project work
51 Revision
52 Examination

Note: -

1. The instructor may design their own project and also inputs from local industry may
be taken in designing such new project.
2. The project should broadly cover maximum skills in the particular trade and must
involve some problem solving skill. Emphasis should be on Teamwork: Knowing the
power of synergy/ collaboration, work to be assigned to a group (Group of at least 4
trainees). The group should demonstrate Planning, Execution, Contribution and
Application of Learning. They need to submit a project report.
3. If the instructor feels that for execution of specific project more time is required then
he may plan accordingly in appropriate time during the execution of normal trade
practical.
4. Abbreviations:

OAW - Oxy-Acetylene gas Welding

OAGC - Oxy-Acetylene Gas Cutting
F - Fitting
WT - Wall Thickness.
SMAW - Shielded Metal Arc welding
GTAW - Gas Tungsten Arc Welding
SAW - Submerged Arc Welding
GMAW - Gas Metal Arc Welding

28
Welder (Fabrication & Fitting)
9. SYLLABUS - CORE SKILLS

9.1 WORKSHOP CALCULATION SCIENCE & ENGINEERING DRAWING

DURATION: ONE YEAR

S No. Workshop Calculation and Science Engineering Drawing

1. General simplifications - BODMAS rule Importance of Engineering Drawing and its
Fraction-Addition, Subtraction, Knowledge.
multiplication and Division-Problems. Use of Drawing Instruments.
Decimal-Addition, Subtraction,
Multiplication, and Division-Problems
2. Conversion of Fraction to Decimal and vice- Letters, Numbers and Alphabets as per BIS
versa. Layout of Drawing Sheet & Title Block.
3. Square roots: Drawing of straight lines,
The Square and Square root of a Whole Geometrical constructions,
Number and Decimal rectangles, Circles, Polygons etc.
4. Percentage - Changing Percent to Decimal Use of different types of line and symbols for
and Fraction and vice -versa - applied drawing.
problem Importance & dimensioning techniques as
per BIS.
5. Concept on Ratio and Proportion-Direct and Isometric views with dimensions such as
Inverse Proportion, simple applied Cube, Rectangular Block, Cylinder, etc
problems
6. Algebraic Symbols and Fundamentals Orthographic Projection in 3rd angle, as per
Addition, Subtraction, Multiplication and BIS
Division-Problems. Orthographic Projection in 1st angle, as per
BIS (Concept only)
7. Introduction and Importance of Science and Plan and elevation of simple objects like
Calculation to the Trade Hexagonal Block, square Block, Circular
skill Block, tapered Block, etc.
8. System of Units - British, Metric and S. I. Views of simple Hollow and Solid Blocks with
Units for Length, Mass, Area, Volume, Dimensions.
Capacity and time.
Conversions between British and
Metric Systems.
9. - Density & Specific gravity Construction of Orthographic Projection
- Mass, weight. Definition and units from the given Isometric view of simple
shaped Blocks in 3rd angle method.
10. - Metals: Properties and uses of cast Construct an Orthographic Projection
iron, wrought iron, plain carbon steels and from the given Isometric view of

29
Welder (Fabrication & Fitting)

alloy steels shaped Blocks in 1st angle method.

- Difference between metals, non-
metals and alloys.
11. - Properties and uses of Copper, Zinc, Lead, Reading of simple Engineering drawing.
Tin and Aluminum
12. - Properties and uses of Brass, Bronze, Reading of Engineering drawing related to
Rubber ,Timber and insulating materials. missing lines and missing views.
13. - Concept of heat and temperature. Simple orthographic drawing- from the given
Difference between heat and Isometric views of simple objects.
temperature. Effects of Heat,
Thermometric Scales such as a Celsius,
Fahrenheit and Kelvin, Temperature
measuring Instruments -types of
thermometers and pyrometers
14. -Conversions between the above Scales Conventional representation of Materials as
of Temperature. per BIS.
-Units of Heat-Calorie, B.Th.U & C.H.U., Views of simple solid bodies cut by section
joule. plane on drawing standard methods.
(Full and Half Sections) BIS.
15. - Concept of Specific Heat, Latent Heat, Surface Development of Prism, Pyramid.
problems on Heat Loss and Heat Gain.
16. -Definition of Force - Units of Force in Cylinder Projection and
M.K.S. & S.I. Systems. Development, Cone Projection
-Concept of Pressure and its Units in and
different systems Development.
Examples based on right cones.
17. Fundamental algebraic formulae viz. Types of rivets with dimensions as per BIS.
(a+b)2, (a-b)2, etc. Simple Equations -
related problems.
18. • Menstruation- Concept of 2D Types of Riveted joints.
figures and 3D object,
• Definition of perimeter, area and
volume : related units -perimeter and area
of plain figures like Square, Rectangle,
Equilateral Triangle, Isosceles Triangle,
Right Angled Triangle, Scalene Triangle-
simple applied Problems
19. • Perimeter and area: Hexagon, Circle, Hexagonal nuts and bolts with dimensions.
Circular ring, Sector & Ellipse- Problems.
20. • Volume and Weight of Simple Solid Screw threads with their dimensions as per
bodies such as Cube, Cuboids, Cone, BIS.

30
Welder (Fabrication & Fitting)

Cylinder and Hollow Cylinder- applied

Problems.
21. • Finding the capacity in Litres of Square, Different symbols used in related trade.
Rectangular, Hexagonal, Conical and
Cylindrical Shaped Vessels
22. •Finding the lateral Surface Area and Total Exercises on application of Trade related
Surface Area of Square, Rectangular, symbols.
Hexagonal, Conical and Cylindrical Shaped
Vessels by using simple calculator
23. •Trigonometrical ratios. Freehand sketching of hand tools of the
Trigonometrical tables. Basic trade.
trigonometrical calculations by using
scientific calculator
24. Electricity, Current, voltage, Power, Free hand sketching of simple objects
resistance, Conductors, insulators, Ohm's related to trade.
law, Types of Current, Effects of current
and related problems. Watt, kW, Electrical
energy - watt-hour, kWH & Board of trade
unit.
25. - Concept of fuse Reading of fabricated engineering drawing
- Concept of open circuit, closed circuit,
Short circuit
- Concept of earthing
26. - Units of work in M.K.S, System and S .l.
-------------------
Unit of Work- Simple Problems.
27. - Units of Power such as Watt and Horse
Power -------------------
- Definition of I.H.P., B.H.P. and Efficiency.
28. - Definition of Energy: Potential Energy
and Kinetic Energy
- Law of Conservation of Energy, S.I. Unit -------------------
of Energy
- Simple Problems in P.E. and K.E.
29. - Linear motion - Speed, velocity,
-------------------
acceleration, retardation
30. - Definition and units of Stress, Strain.
Ultimate stress & breaking stress.
- Explanation of terms shear force and -------------------
bending moment.
- Simple problems on stress & strain

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Welder (Fabrication & Fitting)

9.2 EMPLOYABILITY SKILLS

DURATION: 110 HRS

Duration: 20 Hrs.
1. English Literacy
Marks : 09
Pronunciation Accentuation (mode of pronunciation) on simple words, Diction (use
of word and speech)

Functional Grammar Transformation of sentences, Voice change, Change of tense, Spellings.

Reading Reading and understanding simple sentences about self, work and
environment

Writing Construction of simple sentences Writing

simple English

Speaking / Spoken Speaking with preparation on self, on family, on friends/ classmates, on

English know, picture reading gain confidence through role-playing and discussions
on current happening job description, asking about someone's job habitual
actions. Cardinal (fundamental) numbers ordinal numbers. Taking
messages, passing messages on and filling in message forms Greeting and
introductions office hospitality, Resumes or curriculum vita essential parts,
letters of application reference to previous communication.

Duration: 20 Hrs.
2. I.T. Literacy
Marks : 09
Basics of Computer Introduction, Computer and its applications, Hardware and peripherals,
Switching on-Starting and shutting down of computer.

Computer Operating Basics of Operating System, WINDOWS, The user interface of Windows OS,
System Create, Copy, Move and delete Files and Folders, Use of External memory
like pen drive, CD, DVD etc, Use of Common applications.

Word processing and Basic operating of Word Processing, Creating, opening and closing
Worksheet Documents, use of shortcuts, Creating and Editing of Text, Formatting the
Text, Insertion & creation of Tables. Printing document.
Basics of Excel worksheet, understanding basic commands, creating simple
worksheets, understanding sample worksheets, use of simple formulas and
functions, Printing of simple excel sheets.

Computer Networking Basic of computer Networks (using real life examples), Definitions of Local
and Internet Area Network (LAN), Wide Area Network (WAN), Internet, Concept of
Internet (Network of Networks),
Meaning of World Wide Web (WWW), Web Browser, Web Site, Web page
and Search Engines. Accessing the Internet using Web Browser,
Downloading and Printing Web Pages, Opening an email account and use of
email. Social media sites and its implication.
Information Security and antivirus tools, Do's and Don'ts in Information
Security, Awareness of IT - ACT, types of cyber crimes.

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Welder (Fabrication & Fitting)

Duration: 15 Hrs.
3. Communication Skills
Marks : 07
Introduction to Communication and its importance
Communication Skills Principles of Effective communication
Types of communication - verbal, non verbal, written, email, talking on
phone.
Non verbal communication -characteristics, components-Para-language
Body language
Barriers to communication and dealing with barriers.
Handling nervousness/ discomfort.

Listening Skills Listening-hearing and listening, effective listening, barriers to effective

listening guidelines for effective listening.
Triple- A Listening - Attitude, Attention & Adjustment.
Active Listening Skills.

Motivational Training Characteristics Essential to Achieving Success.

The Power of Positive Attitude.
Self awareness
Importance of Commitment
Ethics and Values
Ways to Motivate Oneself
Personal Goal setting and Employability Planning.

Manners, Etiquettes, Dress code for an interview

Do's & Don'ts for an interview.
Facing Interviews
Behavioral Skills Problem Solving
Confidence Building
Attitude

Duration: 15 Hrs.
4. Entrepreneurship Skills
Marks : 06
Concept of Entrepreneur - Entrepreneurship - Enterprises:-Conceptual issue
Entrepreneurship Entrepreneurship vs. management, Entrepreneurial motivation.
Performance & Record, Role & Function of entrepreneurs in relation to the
enterprise & relation to the economy, Source of business ideas,
Entrepreneurial opportunities, The process of setting up a business.

Project Preparation & Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept &
Marketing analysis application of PLC, Sales & distribution Management. Different Between
Small Scale & Large Scale Business, Market Survey, Method of marketing,
Publicity and advertisement, Marketing Mix.
Institutions Support Preparation of Project. Role of Various Schemes and Institutes for self-
employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non
financing support agencies to familiarizes with the Policies /Programmes &
procedure & the available scheme.

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Welder (Fabrication & Fitting)

Investment Procurement Project formation, Feasibility, Legal formalities i.e., Shop Act, Estimation &
Costing, Investment procedure - Loan procurement - Banking Processes.

Duration: 10 Hrs.
5. Productivity
Marks : 05
Benefits Personal / Workman - Incentive, Production linked Bonus,
Improvement in living standard.

Affecting Factors Skills, Working Aids, Automation, Environment, Motivation - How

improves or slows down.

Comparison with Comparative productivity in developed countries (viz. Germany, Japan

developed countries and Australia) in selected industries e.g. Manufacturing, Steel, Mining,
Construction etc. Living standards of those countries, wages.

Personal Finance Banking processes, Handling ATM, KYC registration, safe cash handling,
Management Personal risk and Insurance.

Duration: 15 Hrs.
6. Occupational Safety, Health and Environment Education
Marks : 06
Safety & Health Introduction to Occupational Safety and Health importance of safety and
health at workplace.

Occupational Hazards Basic Hazards, Chemical Hazards, Vibroacoustic Hazards, Mechanical

Hazards, Electrical Hazards, Thermal Hazards. Occupational health,
Occupational hygienic, Occupational Diseases/ Disorders & its prevention.

Accident & safety Basic principles for protective equipment.

Accident Prevention techniques - control of accidents and safety measures.

First Aid Care of injured & Sick at the workplaces, First-Aid & Transportation of sick
person.

Basic Provisions Idea of basic provision legislation of India.

safety, health, welfare under legislative of India.

Ecosystem Introduction to Environment. Relationship between Society and

Environment, Ecosystem and Factors causing imbalance.

Pollution Pollution and pollutants including liquid, gaseous, solid and hazardous
waste.

Energy Conservation Conservation of Energy, re-use and recycle.

Global warming Global warming, climate change and Ozone layer depletion.
Ground Water Hydrological cycle, ground and surface water, Conservation and Harvesting
of water.

Environment Right attitude towards environment, Maintenance of in -house

34
Welder (Fabrication & Fitting)

environment.

Duration: 05 Hrs.
7. Labour Welfare Legislation
Marks : 03
Welfare Acts Benefits guaranteed under various acts- Factories Act, Apprenticeship Act,
Employees State Insurance Act (ESI), Payment Wages Act, Employees
Provident Fund Act, The Workmen's compensation Act.

Duration: 10 Hrs.
8. Quality Tools
Marks : 05
Quality Consciousness Meaning of quality, Quality characteristic.

Quality Circles Definition, Advantage of small group activity, objectives of quality Circle,
Roles and function of Quality Circles in Organization, Operation of Quality
circle. Approaches to starting Quality Circles, Steps for continuation Quality
Circles.

Quality Management Idea of ISO 9000 and BIS systems and its importance in maintaining
System qualities.

House Keeping Purpose of House-keeping, Practice of good Housekeeping.

Quality Tools Basic quality tools with a few examples.

35
Welder (Fabrication & Fitting)

ANNEXURE-I

LIST OF TOOLS AND EQUIPMENT

WELDER (FABRICATION & FITTING) (For Batch of 20 Candidates)

S No. Name of the Tool & Equipment Specification Quantity

A. TRAINEES TOOLS KIT

1. Welding helmet fibre *21 Nos.
2. Welding hand shield fibre *21 Nos.
3. Chipping Hammer with metal handle 250 grams *21 Nos.
4. Chisel cold flat 19 mmx 150 mm *21 Nos.
5. Centre punch 9mm x 127 mm *21 Nos.
6. Dividers 200 mm *21 Nos.
7. Stainless steel Rule 300 mm *21 Nos.
8. Scriber 150 mm *21 Nos.
9. Tongs flat 300 mm *21 Nos.
10. Hacksaw frame adjustable / fixed 30 cm *21 Nos.
11. File half round bastard 30 cm *21 Nos.
12. File flat 35 cm rough/bastard *21 Nos.
13. Hammer ball peen 1 Kg with handle *21 Nos.
14. Try square 150 mm *21 Nos.
15. Protractor with blade 150 mm *21 Nos.
16. Steel Tape 2 meters *21 Nos.
B. GENERAL MACHINERY SHOP OUTFIT
17. Steel Square 450mm x 600 mm x 50 mm 4 Nos.
thick
18. Sheet Metal Gauge 2 Nos.
19. Stake Round and Bottom 4 Nos.
20. Tinmans 300 mm 8 Nos.
21. Snips straight 250 mm 8 Nos.
22. Right cut snips 250 mm 4 Nos.
23. Left cut Snips 250 mm 4 Nos.
24. Hand Shear Universal 250 mm 4 Nos.
25. Punch Round 3 mm dia 4 Nos
26. Rivet set and snap and dolly combined 3 mm ,4 mm, 6mm 4 Nos each
27. Chisel cold flat 25 mm x 250 mm 4 Nos
28. Punch Letter 4mm 1 set
29. Punch Number 4 mm 1 set
30. Hand Groover 3 mm, 4mm, 5mm 4 Nos. each
31. Plier Combination 150 mm 2 Nos
32. Grip Wrench 200mm 2 Nos
33. H.S.S. Twist Drill (Parallel Shank) 3 mm, 4mm & 6 mm 3 Nos each
34. Hand Drill 0 to 6 mm, 8mm, 10mm & 2 Nos. each
12mm
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Welder (Fabrication & Fitting)

35. Pneumatic rivet gun 2 Nos.

36. Trammel Point with beam 600 mm 1 No.
37. Vernier caliper 0mm -150mm 1 No.
38. Micrometer outside 0 to 25mm 1 No.
39. Raspcut file 250 mm 4 Nos.
40. D.E.Spanner G.P 6mmto32mm 2set
(Setof12spanner
41. Hand vice 50mm *20 Nos.
42. Raising Hammer with handle 4 Nos
43. Rawl Punch holder and bits No.8,10, 12,14 2 sets
44. Hollowing Hammer with handle 4 Nos
45. Tripaning tool 70mm 1 No.
46. Crow bar 910 x 25mm 2 Nos.
47. Trowel Medium 1 No.
48. Crow bar 910 x 25mm 2 Nos.
49. Trowel Medium 1 No.
50. Pop rivet gun 2 Nos.
51. Screw Driver 250mm 2 Nos.
52. C Clamp 6" 6 Nos
53. Bench lever shears 250mm Blade x 3 mm 1 No.
Capacity
54. Air Compressor ( Pressure and 1 No.
displacement of air)
55. Circle Cutting Machine 300 mm Dia 1 No
56. Pillar type drilling machine 12mm 1 No.
57. Slip roll former 1.6mm x 1000 mm 1 No.
58. D.E. Grinder Pedestal motorized 200 mm 1 No.
59. Anvil 50 Kgs with Stand 1 No.
60. Bench vice 120mm, 150mm 2 each
61. Fly press Ball press No.4 single body 1 No.
62. Pipe Bending Machine ( Hydraulic type) 12mm to 30mm 1 No.
63. Hand Press Brake Capacity 0.8mm 1 No.
64. Tin smiths bench folder 600 x 1.6mm 1 No.
65. Pipe bend machine Manual with Dies 1 No
66. Plate bending machine (Roller type) 1 No
capacity upto 8 mm thickness
67. Pneumatic Screw Driver with 6 mm, 8mm, 10mm, 16 mm 1 No
68. Pneumatic Rivetting machine depth of 50 mm 1 No
69. Pneumatic Drilling machine with bits 1 No
4,5,6,8 & 12 mm capacity
70. Pneumatic Chips 50mm 1 No
71. Pentagrap machine for marking 1 mt 1 No
72. Vernier Height gauge range 500 mm 1 No
73. Surface plate with cover 100cm x 100 cm 1 No
74. Plums 4 Nos.
75. Hydraulic Jack 250 mm Capacity 1ton 2 Nos.
76. Air compressor capacity 10 bar 1 No.
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Welder (Fabrication & Fitting)

77. Earth clamps 400A 6

78. Pipe Cutting machine 1
79. Oxy Acetylene Gas Welding Torch (H.P) 5 nozzles 2 sets
with
80. Oxy-Acetylene gas cutting torch with 0.8 mm and 1.2 mm 2 set
cutting nozzle
81. Electrode holder 400 amps 6
82. Spindle key 2
83. Pressure regulator oxygen double stage 2
84. Pressure regulator acetylene double stage 2
85. Tip cleaner 2
86. Outfit spanner for Oxy Acetylene 2
87. Metal Rack 182 cmx152 cmx45 cm 1 no
88. Trainees locker (with 8 pigeon holes) 3 nos
89. Storage shelf/Steel Almirah 2 no
90. Chalk board 1 no
91. Flash back arrester (torch mounted) 2 pairs
92. Flash back arrester (cylinder mounted) 2 pairs
93. Fire fighting equipment As required
94. First aid box 1 no
C. GENERAL INSTALLATION
95. Welding Transformer with all accessories 400A , OCV 60 - 100 V, 60% 2 sets
duty cycle
96. Welding Transformer or Invertors with all 300A , OCV 60 - 100 V, 60% 2 sets
accessories duty cycle
97. D.C .Arc welding rectifiers set with all 400A,OCV 60-100V,60% duty 1 set
accessories cycle
98. Welding cables to carry 400 A with flexible 30 mtr
rubber as per BIS
99. Lugs for Cables 20 nos
100. Trolley for cylinders 2 nos
101. Suitable Gas welding table 2 nos
102. Arc welding table/post all metal with 5 nos
positioner
103. Hand shearing machine capacity to cut 6 mm on sheet and flat 1 No.
104. Power hacksaw 1 No.
105. Angle Grinder AG4 2 nos
106. Electrode drying oven Temp. Range 0-2500C, 10Kg cap. 1 No.
107. Dye penetrant Testing kit 2 set
108. Power shearing machine cutting capacity 4 1 No.
mm on S.S
109. Work bench approx. size 340x120x75 cm *5 No.
with 4 bench vices of 150
m
110. nvil 12 square inch working area 1
111. Portable abrasive cut-off machine 1 No.
112. Oxygen and D.A cylinders (may be hired) #2 each

38
Welder (Fabrication & Fitting)

113. Pantograph 600mm with 30 adjustments 1 No.

D. LIST OF CONSUMABLE
114. Leather Hand Gloves 14 " *21 Pairs
115. Cotton hand gloves 8" *21 pairs
116. Leather hand sleeves 16 " *21 pairs
117. Leg guards leather *21 pairs
118. Leather Apron *21 Nos.
119. Gas welding Goggles with filter glass 3A or *21 Nos.
4A DIN
120. Wire brush (M.S & SS) 5 rows and 3 rows *21 Nos. each
121. Spark lighter 6 Nos.
122. Safety boots for welders *21 pairs
123. Safety goggles with plain glass *21 Nos.
124. AG 4 Grinding wheels 10 nos.
125. Welding rubber hose, oxygen and 30 mtr each
acetylene 8 mm dia. As per BIS
126. Rubber hose clips / " *20 nos
127. Arc welding filter glasses DIN 9A 11 A & 13 108 mm x 82 mm x 3 mm *20 each
A
128. Plain glasses for helmets 108 mm x 82 mm x 3 mm 32 nos

Note:
1. Quantity marked with * has been increased as per the batch size.
2. Internet facility is desired to be provided in the class room.
3. # Optionally Gas cylinders can also be hired as and when required.
4. No additional items are required to be provided for unit or batch working in the Second shift
except the items under trainee's tool kit and steel lockers.

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Welder (Fabrication & Fitting)

Tools & Equipment for Employability Skills

S No. Name of the Equipment Quantity

1. Computer (PC) with latest configurations and Internet connection with 10 Nos.
standard operating system and standard word processor and
worksheet software

2. UPS - 500VA 10 Nos.

3. Scanner cum Printer 1 No.
4. Computer Tables 10 Nos.
5. Computer Chairs 20 Nos.
6. LCD Projector 1 No.
7. White Board 1200mm x 900mm 1 No.

Note: - Above Tools &Equipments not required, if Computer LAB is available in the institute.

40
Welder (Fabrication & Fitting)

ANNEXURE-II

FORMAT FOR INTERNAL ASSESSMENT

Name & Address of the Assessor: Year of Enrollment:

Name & Address of ITI (Govt./Pvt.): Date of Assessment:

Name & Address of the Industry: Assessment location: Industry / ITI

Trade Name: Examination: Duration of the Trade/course:

Learning Outcome:

Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15

Assessment Marks
Equipment/ Instruments/
Attendance/ Punctuality

Skills to Handle Tools/

Workplace Hygiene &
Safety Consciousness

Total Internal

Result (Y/N)
Economical use of

Economical use of

Working Strategy
Manuals/ Written
Ability to follow

Workmanship/
Application of

Performance
instructions

Knowledge
S No.

Quality in
Materials
materials

Devices

VIVA
Father's/Moth
Candidate Name
er’s Name

41