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SAFETY:
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Introduction & Importance of safety, general precautions about safety. PPEs used in chemical industries. Safety slogan. First aid in workshop & industry.
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BASIC FITTING: Safety precautions to be followed in the fitting workshop.
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Introduction to different hand tools such as files, chisels, hacksaw & hammers, etc., and their uses.
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Description, construction, and uses of different marking tools such as steel rule, caliper, punches, v-block, scribing block, etc.
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JOB HOLDING DEVICES:
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Description, construction, and uses of different job-holding devices. Such as vice, VBlock.
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Description, construction, calculation, and uses of different Linear Measuring Instruments – VernierCalliper, Vernier Depth gauge, Height gauge, Outside Micrometre, Bevel protector.
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Drilling, Countersinking, counter boring.
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Reaming and tapping.
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Nomenclature and uses of Drill, Reamer
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Description, nomenclature, and uses of different types of threads – Metric, BSW, BSF, BSP, etc.
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Calculation of tap drill size.
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Introduction to Physics, Units, dimensions, and physical quantities.
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Vernier caliper – parts of a Vernier caliper, principle, and uses of a Vernier caliper.
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Least count and measurement with Vernier caliper.
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Outside micrometer – parts of an outside micrometer, working principle, least count, and measurement with outside micrometer.
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Velocity, its unit, average velocity, speed, average speed, acceleration, Acceleration due to gravity, Newton’s laws of motion.
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Force, unit of force, Effect of force.
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Representation of forces resultant. triangle and parallelogram laws of forces.
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Friction-definition, unit, types of friction, laws of friction, advantages, and disadvantages of friction.
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Inclined plane.
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Simple machines- types of simple machines-pulley, inclined plane, lever, wheel and axle, screw jack.
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Mechanical advantage, velocity ratio, the efficiency of the machine.
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Current electricity, Ohm’s law, Kirchhoff’s law.
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Resistances in series and parallel.
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Electrolysis, Faraday's laws of electrolysis.
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Energy and power, forms of energy- potential, kinetic, heat, light. Mechanical equivalent of heat (‘J’ by electric method).
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Modes of heat transfer – conduction, convection, and radiation.
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Determination of thermal conductivity.
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Temperature & expansion of solid, and liquid.
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Coefficient of linear and cubical expansion.
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Introduction to Chemistry, branches of chemistry
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Importance of chemistry.
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Safety precautions are to be taken in the Chemistry Laboratory.
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Different equipment and apparatus are used in the Chemistry Laboratory.
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Acids, bases, and salts-their properties and uses. Element, atom, and molecule.
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Compound, mixture, Physical change, chemical change, Molecular weight, equivalent weight, atomic weight, Normality, molarity, and molality.
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Volumetric analysis- titrimetric analysis- determination of the amount of substance in solution. Detection of endpoint.
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Types of Titrimetric analysis.
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ATOMIC STRUCTURE:
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Electrons, protons, neutrons.
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Electronic theory of valency.
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Classification of elements, Modern periodic law, table, Groups, periods, and periodic properties.
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Allotropy of hydrogen, carbon, phosphorus, and sulfur.
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Allotropic forms of sulfur – monoclinic, amorphous, and rhombic sulfur.
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WATER:
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Sources, hard and soft water, causes and removal of hardness, water for industrial purposes. Corrosion- causes, effects, and prevention.
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Catalyst definition types of catalysts, characteristics of catalysts, and use of catalyst.
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Introduction to Effluent treatment plant (ETP)
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Definition of pH, pH scale, measurement of pH.
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ORGANIC CHEMISTRY:
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Introduction, purification processes, organic reactions- substitution, addition, Elimination, rearrangement reactions, examples.
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Nomenclature-Basic rules for Common name & IUPAC name system for alkanes, alkenes & alkynes, their examples.
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The boiling point and melting point of organic compounds.
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Definition of fire, chemistry of fire, fire triangle classification of fire.
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Causes of fire in chemical industries.
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Different types of fire Extinguishers
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Accident - causes and effects of accident
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Prevention of accidents.
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Different terms such as Hazard, risk, LEL, VEL, TWA, STEL.
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Flash point, fire point auto ignition temp.
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Material safety data sheet.
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Housekeeping – the importance of housekeeping in chemical industries.
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Pollution and its controls
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Concept of 5S.
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Pressure: Definition, unit’s conversion of units.
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Classification of pressure measuring instruments
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Bourdon type, capsule type helical type, bellows type diaphragm type pressure
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gauges.
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Temperature: Definition, units, conversation of units. Classification of temperature measuring
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Instruments: Mercury in glass thermometer, bimetallic thermometer, RTD thermometer & Thermocouple.
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Flow Measurement. -
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Classification of flow measuring instruments.
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Construction, workings & uses of orifice meter, venturi meter, and turbine-type flow meters.
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Level Measurement –
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Classification of level measuring instruments – simple float type level indicator, sight glass level indicator, air purge level indicator, Capacitance type level indicator.
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Definition and measurement of specific gravity.
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Working principle of Hydrometer.
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Construction of final control element (control valve).
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Standard pipe threads, nominal diameter, wall thickness, schedule number, die & diestock, tubing.
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Different types of pipe joints – flanged and threaded. Straight connections, bedsore, elbows, tees, screwed fittings, coupling, flanges, bush & caller, plug, stop cock, binding material.
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Tools for fitting.
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Thermal insulation – Lagging of utilities in chemical industries.
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Types & uses of lagging materials. Properties of lagging materials.
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Gasket materials for particular applications cork sheet, oilproof paper, PTFE rubber & graphite.
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Locking devices- use of correct material and locking devices – locknut castle nut, saw nut, locking pin, spring lock water.
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Construction, working & use of gate valve.
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Construction, working & use of Globe valve & check valve.
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Construction, working & use of needle valve, diaphragm & ball valve.
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Construction, working & use of stop cock & butterfly valve
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Maintenance of valve
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Selection of appropriate type of valve for given service.
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PUMP Classification of pumps
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Construction, working & use of centrifugal pump
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Starting & Shutting down the procedure for the centrifugal pump
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Troubleshooting in centrifugal pump.
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Construction, working & use of Gear pump
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Troubleshooting in Gear pump.
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Construction, working & use of Screw pump & metering pump.
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Construction, working & uses of fans, blowers & compressors.
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Types, construction & uses of bearings such as ball, roller, bush, etc. their care & maintenance.
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Types of gears - Spur gear, Helical gear, Bevel gear.Their uses & care.
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