Instrument Mechanic - IM
Week No. Practical Theory Engineering Drawing Workshop Calculation & Science
1
  • 2
3 4 5
1. Introduction to Training. Familiarization with the Institute.
Layout of shop equipment and
machineries. Syllabus, system of Training, Examination, Types of work done by the trainees. Introduction to safety. To observe the Institutional Rules,
discipline, Cleaning and forming
those habits.
Introduction to the trade
importance, safety precautions, First Aid, Importance of the Trade in the development of industrial economy, syllabus topics and course. Introduction to chemical handling, safety and hazards.
__ __
2. Bench Work. Filing practice,
Balance of Pressure, Filling
surface & sides and checking 90. by try square ( simple exercises involving filing & saving use of vice.)
Basic hand tools, Types, Classification use & metal cutting fundamentals. Familiarization with the drawing equipment, Free
hand sketching.
Basic Mathematics
related to Workshop problems.
3. Simple filing exercises as per
dimension up to an accuracy of ± 0.5 mm. Marking Block, Out sidec & Inside Caliper, Try square, Surface Plate, Angle plate, “ V ” Block.
Measurements & measuring Instruments. Marking tools,
Fasteners & Fastening devices.
Types of lines & its use
Dimensioning Method,
Geometrical drawing,
angles,triangles, circle, square, Rectangle, Rhombus, Parallelogram, Pentagon, Hexagon, Heptagon, Regular Polygon.
Review of
Fundamentals of Algebra & trigonometry.
4. Filing exercises involving “V”
groove, square groove,
radius(inside & outside) up to an accuracy of ± 0.2 mm. Marking & Measuring with the help of Vernier Caliper, Vernier Height Gauge, depth gauge, Micrometers & Radius Gauge.
Precision Measuring
Instruments.
-- Do -- Properties & use of cast iron, wrought iron,
plain carbon steel, high
carbon steel and alloy steel.
5. Simple fitting exercises involving angular, curved and regular surfaces up to an accuracy of ± 0.1 mm. Marking & measurement with combination set, Vernier Bevel Protractor and other precision Instruments. Template filing. Use sine bar. Elements & types of screw threads used in Instruments, Calculation of drill size for tapping. Geometrical drawing of
ellipse, oval etc. Free hand sketch of hand tools.
Applied work shop problems.
6. Drilling precision holes with
bench/pillar drilling Machines
and reaming. External & Internal
Thread cutting with the help of
Taps & Dies.
Drills & drilling, Taps &Tappings, dies & Dieing, Lubricants.
Basic Hand Tools such as screw drivers, Pliers, spanners.
Lettering both capital & small letters. Logarithms, use of logarithmetic tables for
multiplication and division.
7. Straightening of tube, bending
and flaring of tube connection of
tube with straight & other
couplers. Flare & Ferrule fittings. Checking leakage , Use of Jigs & fixture etc.
Types of pipes used for
instrumentation. Tube cutter, flaring tools, swedging tools,
equipments & fixtures required for pipe bending, straightening,
thread cutting, method of Installation.
Lettering numbers. Mensuration –area of
rectangle, square, triangle,
circle, regular polygons etc.
8. to
10.
Lathe Work. Familiarization with
the lathe & its accessories, chuck mounting, fixing lathe tools. Plain turning holding the job on lathe chuck step turning, grooving, knurling and taper turning, thread cutting & drilling. Holding work between centres & turning with an accuracy of ± 0.04 mm. Grinding of Lathe tools
Introduction & function of lathe. Main accessories. Fixing of
lathe tools & precautions. Fixing chuck. Taper turning & its calculation. Cutting fluids, cutting speed & feed etc. Introduction of thread cutting on lathe. Calculation of gear train
for thread cutting. Drilling on Lathemethod & precautions
tobe taken. Method to grind lathe tools & precautions to be taken.
Isometric & oblique view of
various jobs. Simple orthographic projection of 1st angle and 3rd
angle.
Calculation on volume &
weights of solid & hollow bodies. C.G.S. & M.K.S.
system of units of force, weight etc. Defining work,
power energy, torque. Laws of conservation of
energy, Forms of energy,
Kinetic energy & Potential
energy.
11 to
15.
Mechanical Measuring (Metrology). Practice on using
specific purpose gauges such as Plug, Ring, Snap, Feeler, Screw pitch, go & no go, Dial indicators, Measuring Microscope. Use gauge block directly or with the assistance of some form of comparator, such as Mechanical, electrical, pneumatic and optical flats, monochromatic light sources. Making small instrument parts with an accuracy of =0.02 mm.
Fundamental methods of measurement, Direct comparison, using a calibrated system Generalized measuring
system. Stages of the generalized measuring system. Calibration standards, dimensions and units of
measurements.
Certainty uncertainty, validity of result. Measuring System
Response. Introduction, amplitude response, frequency
response, Phase response, Delay, rise time and slew rate.
Damping and its importance.
Standards of Measurements. The Metric system, Base &
supplementary units, Derived Units, Multiplying factors
standards of lengths, mass, time and frequency. Electronic
oscillators, Temperature and electrical units. Treatment of
Uncertainties. Introduction,
Nomenclature such as data, error, accuracy precision, resolution, sensitivity, uncertainty dead band, dead zone, deviation etc.
classification of errors, systematic errors, systematic errors, systematic, random and
illegitimate errors. Displacement and Dimensional
Measurement. Introduction,
Classification of displacement.
Measuring devices, low, medium and high resolution devices, gauge blocks, surface
plate, use of comparators, pneumatic comparators, optical
methods, monochromatic light,
optical flats, the interfero meter,
measuring microscopes, feeler microscopes, fixed scale microscopes, traveling microscopes, draw-tube microscopes.
Orthographic
projection, 1st
angle & 3rd angle.
Forces &
motion,
Sources of
forces, applied
to stationary
objects.
Acceleration,
Newton’s laws
of motion.
Lever, classes
of lever, Wheel
& Axle, Gear
train, Inclined
plane the
wedge,
Mechanical
advantages.
Cam &
follower
device, Sector
& Pinion, Race
Pinion, Screw
Jack, Pulley &
Pulley system.
Various motion
transfer
mechanisms.
Problems on
measurements,
power, energy,
force.
Problems on
Moments. Problems on
acceleration
speed.
  Practice on making unbounded
wire type strain gauges and
measuring strain in terms of
resistances.
Stress and strain Measurement.
Introduction, strain measurement, electrical type strain gauge, electrical resistance type strain gauge bonded wire strain gauge, load
   
  Dismantling assembling,
repairing and testing of
Vibrometer & Accelerometer.
Study of Seismic Instruments.
Constructional details, repairing
and testing of microphones.
cell unbonded resistance type gauge, foil strain gauge, semi-conductor gauge, metallic
resistance gauge and its application. Measurement of
Motion. Sensing element of vibrometers and accelerometers, seismic instrument, measurement of velocity with seismic instrument, vibration & shock
testing. Measurement of Sound.
Basic acoustical parameters, sound pressure, sound pressure level, microphones,
sound level meter.
   
16 to
18
Optical Instruments.
Introduction to optical
instruments. Dismantling,
assembling, cleaning, fault
finding, repairing, checking &
testing of Monocular, Telescope, Microscope, Theodolite, Dumpy Level, Camera.
Optics, Various Laws, formation of image, lenses & prism.
Description, working principle and use of the instruments mentioned in practical. Testing & correct functioning of
the Instruments.
--- do --- Non ferrous metals manufacturing processes,
properties, application and
selection criterion.
19. Basic Electricity. Introduction to
fundamental of electricity,
Generation of electricity by
friction, Identifying +ve & -ve
polarities. Identifying and use of
various electrical components,
their symbols. Measuring current voltage & resistance. Resistance measurement by colour code. Resistance in series & parallel.
Introduction to electricity. Static
electricity and current electricity. Magnetism, current, voltage, P.D., E.M.F., resistance,
electrical components, conductors & conductors & insulators. Electrical circuits. D.C. and A.C. circuits.
Importance of earth and grounding.
Blue print reading. Problems on friction.
20. Tracing of magnetic fild. making
series & parallel ckts. Veri
fication of ohm’s law. verification of kirchhoff’s law. Cells in series & parallel & mixed combination.
Electromagnets & its
polarity. Solenoid series
& parallel ckts. Ohm’s law & kirchhoff`s law calculation. Primary and secondary cells (liquid
Sectional views. Electrical units in M.K.S.
system . calculation of
specific resistance.
21. Measuring capacitance with test
bridge. (L.C.R. bridge)
Capacitors in series & parallel.
Verification of R-L-C ckts.
Resonance effect.
Experiments
& dry) their connections. D.C.
circuits. Various types of
capacitors, principles of alternating current, AC & DC electricity, wave forms, frequency, peak values, average values, effective values,
impedance, capacitive reactance, inductive reactance, Faraday’s law.
---do--- Problems on kirchhoff’s law.
---do---
22. Experiments on electro magnetic induction. Static testing of electrical components. Voltage divider ckts. A.C. circuits, resistance
in A.C. ckts. Induction
& inductance. Self and
mutual induction.
Electrical symbols and
drawing electrical circuits as IS :
1248.
Composition, properties &
uses of nonferrous alloys.
23. Experiments on transformers.
Measuring current & voltage in
primary and secondary winding.
Testing auto transformers in its
various tappings. Care and
maintenance & connection of auto transformer.
Transformers, its cores,
transformation ratio. Auto transformer. Current measurement. Instrument transformer. Demagnetizing current & potential
transformers.
---do--- ---do---
24. Simple exercises on soldering.
Soldering by temperature
controlled soldering station.
Soldering of various components in vero boards.
Definition and purpose of soldering. Soft soldering . types of soldering irons. Solder
& flux. Care & precaution of soldering.
---do--- Simple problems based
on AC fundamentals,
calculation of periodic time,
frequency, wave length,
average value, RMS value.
25.
to
32.
Electrical measurement &
measuring instruments.
Familiarisation with the
construction of M.I. &
M.C.(PMMC) instruments.
Overhauling & testing of
voltmeters & ammeters.
Testing & calibration of ammeters & voltmeters of various types. Making shunt of various ranges of ammeters. Making multipliers for different ranges of instrument range.
Familiarization with the
construction of M.C. (dynamometer type) instruments, overhauling and
calibration of dynamometer
Type instruments. Measurement
of power by wattmeter &
calibration of wattmeter.
Use of ohm meter ,calibration of
ohm meter , use of megger.
Familiarisation with the
construction of ampere hour
meter overhauling and calibration of ampere hour meter. Measurement of three phase and single phase power by voltmeter & ammeter.
Overhauling and calibration of
KWH meter (energy meter)
Practical on frequency meter and power factor meters.
R,L,C measurement.

Using phase sequence meter & synchroscope.

Using oscilloscope for voltage & wave form measurement
Principal of “D” Arsonval meter. The “D” Arsonval
movement, working methods, moving coil damping, magnetic
shielding, parallax error, measurement value, shunt construction & connections, voltage measurements,
instrument sensitivity, meter accuracy, changing meter range.
D.C. instrument. Using a DC ammeter, extending the DC meter range. Selecting a
meter, accuracy, sensitivity, connection of voltmeter. Using DC voltmeter. Measuring electrical resistance. Ohm meter, operating principles,
calibration, using ohm meter, details of megger. AC instruments. Principal of moving iron meters, damping methods, application of moving iron meters, uses of electro
dynamometers, AC meters rectifiers, instruments etc.
Power measuring Instruments. Electro dynamometer, watt
meter, thermal watt meters, Wattmeter rating, measuring three phase power, Watt Hour
meter, reading a Wattmeter, demand meter, power factor
meter, operating factors. Ampere hour meter & energy meter. Special instruments.
The multimeter, bridge circuits, wheat stone bridge, inductance
bridge, voltage tester , continuity tester, Rotation tester, phase sequence in dicator, synchronizing, the
synchroscope, frequency meter. Indicating Instruments. of terms, the voltmeter, the
oscilloscope, connection of electronic Instruments.
Diagram &
sketches of
electrical
measuring
instruments, viz, all types of
moving coil
instruments.

Calculations on
extension of
instrument
range.

Problems on
cells in series,
parallel and
mixed
combinations.
RLC
calculations,
capacitors in
series and
parallel.


Calculations on
the cost of
repairing/recon
ditioning of
electrical
instruments.
Problems on
electro
magnetic
induction,
transformers.

33 to
45.
Industrial Electronics.
Identification of various types of
diodes (solid state) ,checking of
diodes. Verification the
characteristic of diode, use of
LEDs & seven segment displays. Identification of transistors, checking of transistors, Verification the characteristic of transistor for all three configuration, I .e., common base, common emitter, common collector.
Layout of component and preparation of P.C.B.’s surface
mounting device(smd) soldering and desoldering practice.
Semiconductors . introduction to semiconductor,
semiconductor diodes , semi conductor, materials, doping
semiconductor, junction diodes biasing diodes , diode characteristic, power dissipation , special semiconductor diodes.
TRANSISTOR. Defining transistor,
NPN&PNP transistor, bipolar transistor, operation current gain , voltage gain, and power
gain field effect transistor comparison transistor and triodes. Printed circuit board.
Definition ,materials for board and conductor, single sided pc boards mounting components,
conformal coatings, pc board connector ,pc mounting assemblies, tools for repairing pc
  Problem of
transistor
  Making half-wave & full-wave
rectifiers, center tap & bridge
type. Study of ripple factor in
half wave &full wave rectifier
with various filter circuits.
assemblies, exposer to multilayer PCBs. Integrated circuit. Development of IC s.
how ICS are made , types of ICS, linear ICS digital ICS, family of
digital ICS, combining analog and digital. How to re Recognise &
Replace semiconductor
packages. Semiconductor
packaging identifying leads, manufactures , data sheet substituting components, chasis mounted component, sockets, tools techniques.
Rectifiers .Diode rectifiers, Half wave rectifier, full rectifiers
Bridge rectifiers , three phase Y full wave and half wave rectifiers, Voltage multiplier
circuits diodes rating , parallel and series diodes silicon controlled rectifiers, Diac, Triac, Triggering. Filters. Introduction,
purpose and use ripple, filter circuit components, capacitance filter, Inductance filters, RC
filters, LC filters, voltage dividers and by pass filters.
Voltage Regulators. Introduction & purpose, shunt regulators, series regulators, IC regulators, switching regulators.
Drawing circuit diagrams
of various transistors.
Drawing of circuit diagram of rectifier circuit .
Batteries, types construction & applications.
Types of fuses, selection and application .
  Assembling of a power supply
unit. Trouble shooting of power
supply units. To hook up transistor amplifiers & determine their characteristics.
Study of FET amplifier. Study of
class “A”. class “B” and class
“AB” amplifiers. Amplifier performance and multistage amplifiers. Trouble shooting of amplifiers. Use of differential amplifier. Operational amplifier. Study of operational integrator.
Power supplies. Introduction, purpose & use. Types of power
suppliers, Galvanic cells, DC to AC, DC to DC, AC to AC, AC to
DC, UPS and SMPS, battery backup application.
Amplifier. Introduction, amplifier, characteristics,
transistor amplifiers, characteristics curves, output –input characteristics curves,
effect of temperature, operational amplifier and switching amplifiers.
Single Stage Amplifiers. Allowing operating region,
operating points and load lines, operating points stability, biasing circuit, biasing
amplifier. FET amplifiers, classifying amplifiers and their
operation. Multistage amplifiers.
Amplifier performance, power gain ,current gain, voltage gain ,
amplifier efficiency, distortion, maximum power transfer,
multistage amplifier couplings, capacitance coupling, transformer coupling and direct
coupling amplifier. Operational
Amplifier. Differential amplifier,
differential amplifier
Sketching of different power supply units.
Drawing circuit diagram of
various types of amplifier.
Drawing characteristic
curves of single stage amplifier. Drawing
multistage amplifiers.
Connectors, sockets, cables, signal connectors, power supply cables.
Problems on half wave and
full wave rectifiers.
Problems on voltage gain
power gain of various
amplifiers. Examples on
voltage gain of RC coupled and transformer coupled
amplifier.
  Study of oscillator as mentioned
in theory column. Study of invertors and convertors. Study of multivibrator. Verification of gates, flip-floops etc. study logic ckts. Of all types (address, subtractor, multiplexer,
demultiplexer etc.) perform
practical on trainers kit or trainer.
with feed back , and ideal opamp, inverting amplifier, virtual ground and summing junction , operational summer,
non-in- verting amplifier, operational in tegrators, and special operational circuits.
Oscillators and Multivibrators.
Oscillators, Oscillators, Oscillators and amplifiers, oscillation and amplifiers.
Frequency talk circuits, crystal controlled, armstrong oscillators, RC phase shift
oscillators, colpitt, clap, hartely, and IC oscillators.
Invertors and Convertors. Types of power conversion system, invertor and convertor application, static invertor and
convertor, basic magnetic, single transformer invertors,
dual transformer invertors, driven invertors, SCR invertor
and converters. Multivibratiors.
Switching curcit, types of mulivibrators, astable & monostable, bistable multivibrator, dual trigger flipflop. Logic circuits. basic
digital ICs, digital logic,
Boolean algebra, logical AND, OR , NOT function ,digital
application logic state logic switches, positive
Drawing circuit diagram of
operational amplifiers.
Drawing circuit diagram of
various oscillators. Drawing the sketches of differents types of gates & logic symbols. Drawing the circuit converntions.
Calculation on negative feed amplifier, zero
decibels and reference level. Problems on oscillators. Simple
calculation on multivibrator.
 

Study of signal and control
cables, screen cables shield.

Microprocessors. Practical on
microprocessor training kits and trainers applicable to process control instrumentation.

and negative logic, logic symbol conversions, NAND, NOR, Ex-OR,
Ex-NOR logic, combining logic
circuits, IC logic devices, numeration system, binary coded decimal(BAD), ASCII,
grey code, Boolean logic and algerbra. Logical building bloks.
Sequential logic, flipflops,
clocked flip-flops, clock circuits, Schmitt triggers, frequency
divider, pules , counter number system. Functional counting
system. General logic system and subsystems ROM logic, logic subsystem, microprocessors, I/O subsystem, multiple bit devices, data transfer. Introduction to
explosion proof, intrinsically safe, zener barriers, weather
profners, junction boxes, cable glands, terminators etc.
Introduction to computers & micro controllers, purpose and
use.
Drawing the block diagram of different microprocessor & computer system. Conversion of binary to
decimal and decimal to
binary, octal to decimal and
decimal to octal, binary to
hexadecimal & hexadecimal to binary. Boolean algebra.
Karnaugh
    Computer Hardware. Computer systems, computer hardware,
CPU , CPU operations, fast memory, core memory, ROMs and RAMs, characteristic of
ROMs and RAMs. I/P and O/P and peripheral equipments, mass
memory, terminals, operator console, printers, MODEMs,
Data interface, ADC and DAC. Exposer to EPROM, EPROM and
Bipolar PROM. Introduction to
languages.
  maps, addition, subtraction.
Preparation of truth table.
Calculation on the to
repair/reconditi on of Electronic Instruments &
Microprocessors.
    Computers and Microprocessors.
Microprocessors define.
Microprocessor characteristics, Physical properties, Instructions
set, Microprocessors types, Micro computers. Microprocessors Applications.
Microprocessor revolution, categories of applications, logic
replacement systems, Industrial applications.
   
    How Microprocessor Functions.
Microprocessor structure, BUS
structure, Memory device, Input out devices, computer languages, Examining application input out put devices, Digital I/O devices,
Analog I/O device-s, Analog I/O devices, data acquisition system.
Drawing the block diagram of data acquisition system.  
54. Fundamentals of Measuring
Instruments & Systems.
Practical on Instrumentation
Trainer/simulator (real type) and
also computerized
Instrumentation simulator
(package type, Real system and
computerized system can be
interfaced).
Introduction to Process Measurement. The purpose of process measurement,
measurement requirement, uses of measurement, Display
requirement, Remote vs. local display, Errors in measurement systems, calibration, noise,
response time, measurement system, deterioration, Errors of
observation, transmitters, prproportionality
Drawing the block diagram.
Diagrams of process
instrumentation systems.
Calculation on the cost to
repair/reconditi on process
control systems with field
mounted, panel mounted and control room mounted.
    Basic Process Measurement systems. System elements
interact, translating the measurement, communication,
electrical vs. pneumatic output from analog to digital and back,
interpreting the output, typical application. Principle of
Transducer operation. Signal
measurement and transmission, matching the transducer to the application, kids of output, transducer
elements, mechanical and electrical element, the nature of pneumatic response, relating
distorstion to pressure, the nature of electrical response, combining effects.
Free and sketches of the elements of measuring devices.  
  Speed and R.P.M. Measurement.Overhauling and Testing of Speedometers and
Techometers. Pressure Measurement. Practical on various Pressure sensors and
pressure gauges. Repairing, fault finding, Testing &
calibration with dead weight tester and manometers.
Perform practical on pressure simulator or experimental setup (real & Package type). Pressure
transmitters (SMART & INTELLIGENT TYPE)
System Standards and
Instruments Calibration.
Interpreting specifications
accuracy the importance of
precision, resolution, transfer
function and sensitivity, ant,
nits of measure, SI uits,
nglish unit, alibration laboratory.
Introduction to computer in
Instrumentation. Fundamentals and use of computerized
Instrumentation simulator.
Speedo Meters &Tachometers. Description, working principle,use,calibration and
testing of various types of
speedo meters & Tachometers.
Principle of Pressure in
Liquids & Gases. Properties
of matter,Principles of liquid
pressure,units of pressure
Liquids pressure and volume, density and specific gravity. Factors affecting liquid pressure.Guage pressure and absolute pressure, liquid pressure measurements,gas pressure and temperature
relation, temperature & volume relation. Atmospheric pressure, pressure and flow, using pressure to measure flow, Manometers. Pressure Sensors. Function
Free hand sketches of the
parts of Tachometers &
Speedometers. Free hand
sketches of pressure sensors & transmitters.
Schematic diagrams of
Calculation on the cost to
repair/reconditi oning
Speedomaters & Tachometers. Problems on
liquid pressure and gas
pressure. Bending,Twisting and shearing
    of measuring
instruments, Bourdon tube
sensors, other Bourdon tube
shapes, Bourdon tube metals, diaphragm pressure sensors, Capsule diaphragm element, Bellows pressure sensors, Dead weight tester, Pressure switch transducers and its
calibration. Pressure
Transducers.Introduction to pr. Sensing instruments,method of
conversion,potentiometric pr.
Transducers,Capacitive pr.
Transducers,reluctance,servo
pressure transducers, strain guage pressure transducers,piezo-electric
pressure transducer.SMART
& INTELLIGENT type pressure transducer. Low Pressure
Measurement.Vaccum, low
pressure,units of low pr.
Measurement,method of
conversion,gauges,thermal
conductivity gauges,pirani
gauges,t hermocouple gauge, slack diaphragm gauge, ionization gauge,Mcleod gauge, capacitance manometer.
Pressure Instrument Installation & servicing. Elements of pressure transmitters, Installation components, pressure taps,isolation valve, instrument piping,connections and fittings blow down
valve,instrument valve,pulsation
damper(snubber),diaphragm
seal,pressure transmitter, Installation,proce
transducers. moments.Stress, Strain and Young modulus.Calcul
ation on the cost of repair/reconditi oning pressure measuring
instruments.
    dure,locating and mounting, piping, electrical wiring placing into service, guidelines for
periodic maintenance, trouble shooting and repair, instrument shop safety.
   
68 to 73. Flow Measurement. Checking
various types of flow
restrictors (oifice, ventury, flow
nozzle and use.) Dismantling, checking overhauling and
calibration of D.P. cell/transmitter. Rotameter : Fitting of tapered glass tube,checking & testing.
Properties of Fluid Flow. Basic properties of fluids, fluids in
motion, getting fluids to flow, way of indicating fluid flow rate, factors affectinf flow rate, Reynolds number. Primary Measuring Devices. Flow
classification, flow measurement methods,flow
measurement in completely
filled pipes,restricting the
flow,the orifice plate,orifice
plate design features,special
features of orifice plates,orifice plate fittings,the flow nozzle,the
ventury location pipe taps, straight pipe requirement.
Secondary Measuring Devices. Secondary Measuring devices, basic manometer design, reading the meniscus accuracy ,float type mercury manometer. Target meter,the elbow mounted measuring devices,the pitot tube devices. Variable Area Instruments. The rotameter, reading a rotameter, factors affecting rotameter performance, measuring gas
and liquid flow,specific
gravity, pressure and temperature, liquid-to-gas
conversions, float shapes, special use of
Free hand
sketches of the
parts of flow
measuring
instruments.
Drawing of
various
symbols,notations
,colour
coding,used in
instrumentation.
 
  Practical on open channel
flow device. Practical on piston meter. Practical on turbine flow
meter, quality type flow meter, impeller type flow meter,magnetic flow meter.
Fitting & Testing of correct functioning on vortex meter and mass flow meter. Perform practical on Flow simulator (transparent double tank type).
Installation and
rotameter. Open Channel flow
Devices. Principle of open
channel flow,the weir,shapes
of notches,choice of notch shape, design of a weir, weir
plate,precautions,weir
maintenance, calculating flow
rates,rectangular notch,still
water, moving water, cippoletti notch, using nomo-graphs to calculate flow,flumes(parshall
flame),flume terminology,flume
uses,flume maintenance. Flow Measurement-II Positive Displacement Meters. Advantages and disadvantages of positive displacement meters,the piston meter,the
reciprocating piston meter,the oscillating piston meter,the rotating vane mater, nutating disk mater,lobed impeller and
oval flow meters,the dry gas
bellows meter,calibrating positive displacement meters
the target flowmeter.
Turbine and Magnetic Flow Meters. Turbine flow
meters- components and
operating principles,turbine flow meter construction, magnetic pick ups and readout
instruments,types of turbine
flow meters,installation of turbine flow meters, Advantages and disadvantages of turbine meters.Magnetic flow
meters,principle of operation, construction of magnetic flow meter, output installation tips, advantages and disadvantages.
Other Fluid Flow Meters.
Drawing of
various flow
restrictors.
 
  Maintenance of Flow Instruments. Components
for flow measurement system, primary flow elements, pressure taps, piping and fitting
valve, DP transmitter, miscellaneous items. Installation of the flow measurement system,pressure taps installation, Instrument
piping installation, electrical
hookup,the final step,level
measurement installation, maintenance, precautions, preventive maintenance, calibration, a DP instrument calibration procedure. as mentioned in the theory.
Vortex precision
meters, output systems for
vortex precision meters, feature of vortex precision meter,vortex
shedding meters, Coriolismass flow meter, thermal flow
meters,summary basics of
ultrasonic flowmeters.The
Dopplershift method.The
beam deflection method, the
frequency difference method, characteristics of ultrasonic flow meters. Metering the flow of solid particles. Measuring
voluvetric and mass flow rate
of solids, volumetric solids
flowmeter, mass flowmeter
for solids, belt- trpe solid
meters belt speed sensing
and signal processing ,
slurries, constant weight feeders.
   
74.
to
77
Measurement of level.
Performing practical onf level measuem ents, i.e,
ezperimental set up for level
measurements/process
simulator of level measure
ment (real type, transparent double tank type, computerized
package type). Calibration of level transmitters.
Level instrument servicing. Introduction to instrument servicing. Maintenance, repairiong and control.
Serving level instruments,
Principle of level measurement. Measuring liquid level, surfacesensing gauges, storage tank gauges, sight glasses, magnetic gauges, buoyancy,
displacement gauges, level
switches, mercury level switches, level switches in
high pressure tank, level
detectors, magnetic reed
switches. Pressure head instruments. Hydrostatic pressure, specific gravity, pressuried fluids, pressure head instrumentation, air bellows, U-tube manometers, air purge systems, liquid purge
systems, force balance diaphragm system. Electrical method.
Drawing free hand sketches of the parts of level measuring instruments. Drawing the  
  in the field, gauge glasses,
float actuated instruments,
displacer level gauges,
pressure head instruments,
servicing level instruments, in the shop. Shop repairing and
calibration facilities, trouble shooting, reading flow diagram.
Conductivity and capacitance
method for measuring the liquid level, capacitance probes, zero and span adjustments, sonic level detectors, radiation level
detectors, point level detection.
Solid level measurement. Using weight to determine level, sonic solid level measurement with
microwaves, using capacitance probes to measure solid level,
diaphragm switches, automatic bin fillers, tilt switches, rotating paddle detector, nuclear gauges, sonic and micro wave solid level detectors.
circuit diagram of various level measuring systems.  
78
to
81
Temperature measurement.
Performing practical on
temperature measurement
with different sensors as in the theory part, in the temperature controlled oil bath/muffle
furnace/electrical furnace.
Practical on various thermocouples, RTDs and
pyrometers. Temperature instrument maintenance and
calibration. Primary calibration standards, primary standard
instruments, secondary
standard instruments, instrument inspection, controlled temperature
environments,using triplepoint
baths,other fixed points, temperature
Temperature Measurement.
Temperature, heat, specific
heat, changing physical state,
Fahrenheit and Celsius
temperature scales, Ranking
and Kelvin scales, calibration
of temperature scales, primary & secondary standards. Industrial applications of temperature measuring instruments with cpmpensation link & precautions to be taken.
Bimetallic and Fluid-filled Temperature Instruments.
Bimetallic thermonerors, liquid-in- glass thermomerter, filled system thermomerers, thermomerter bulbs, types of thermometer bulbs, capillary & Bourdon tubes, temp. transmitters for filled system, advantages & disadvantages of filles systems. Electrical Temperature
Drawing the sketches of
various types of filled system thermometers.
Drawing the sketches of
various temperature
sensors and compensating
systems.
Problems on temperature.
Calculation on
  references,calibration and
testing methods. Perform
practical on experimental
setup/temperature simulator (real type and package type) for
temperature measurements and controls.

Recorders and Servicing. Overhauling, checking, fault finding, repairing, testing of
pneumatic, electrical/electronic
recorders, (single point & multipoints). Controllers. Practical on PID controller trainer.
Instrument. Resistance
thermometer, how it works,
RTD bridge circuits, lead wire error, RTD elements
protecting wells for RTDs, advantages and
disadvantages of RTDs,
Thermistors, thermocouples,
Extension wires, cpmpensationg for changes in reference juncrion remperature, construction of thermocouple junctions, advantages and disadvantages of thermocouples. Pyrometry. Molecular activity and electromagnetic radiation, definging pyrometry, effects of
emittance, effects of temperature, wave length and
radiated energy, pyrometers
and wavelengths, narrow band pyrometers, using of optical pyrometer, automatic optical pyrometer, broadband pyrometers, using broadband
pyrometers, band pass
pyrometers. Recorders. Introduction to recorders. Construction, wording pricviple, various parts, installation and use of pneumatioc and electronic recorders. Quality of ink marding mechanism, types of charts chart mounting
technique, chart driving system, signals and signal conditioning.
Introduction to controllers.
Process varrable and
setpoint, analog controllers,
digital controllers, control
ranges and limits, controllers, control ranges and limits, control loop, measuring PV, amplifying signals, final control elements, current proportioning, Huntiong & its effect on the product.
Drawing the sketches of the optical and radiation pyrometers. Drawing the free hand sketches of the parts of recorders. Drawing schematic diagram of open
loop and closed loop system.
the cost of repairing/recon
ditioning temp. measuring
instruments. Calculation on
the cost of repairing/recon
ditioning recorders.
Calculation on the cost of
repairing/recon ditioning of
controllers.
  Controller Features and
Installation.Optional controller
feature,remote SP selection, Alarm reset control, dead band
adjustments, Indicators, control
installation,manuals, electrical
noise,electrical noise sources, inadequate primary
power, regulating primary power, electrical coupling, temperature effects.
Study and use of DCS & SCADA complete with communication
system on process trainer.
Exposures to distributed control system.
Types of Controllers and Their
Operation. Types of controller,
range limit of controllers, on/off
controllers, direct and reverse
acting controllers, proportional
controllers, current proportioning control, time
proportioning control, position
proportioning control, automatic/manual split control, pneumatic control. Adaptive, limiting and batch control, ratio control system and cascade control system.
Scanning, (scannucators) and
annuntiators. Basic knowledge
and communication protocol.
Controller Models and Tuning.
Controller tuning, setting, controller modes, proportional mode, offset, integral mode, reset mode, desivative mode(rate), single
mode controller, two mode
controller, three mode controller, tuning the control loop, stepchange-response method.
   
89
to
92.
Basic Industrial Programmable
Controllers. Practical on programmable logic controller trainer.
Introduction to Programmable
Controllers. History of
programmable controllers, general characteristics of programmable controllers, some limitation of PLCs, Methods of developing PLC Programmings. Input/Output Devices. Definition
Drawing the schematic
diagrams of programmable
controllers.
Calculation on the cost to
repair/recondition
Programmable Controller
  Documentation, Start
up & Trouble Shooting.
Documentation, system start up. Routine and preventive maintenance, trouble shooting,
debugging a problem areas, unreadable signals. Redundancy concept, application of PC & PLC.
of input/output devices, I/O
interface, input modules, output
modules, input devices,
Encoders, output devices, the
opto-isolator, safety. Processing and Programming Functions. The processor unit, the memory, memory organization, ledder diagrams, data logger, most used programming symbols , start, stop, station example, other programming symbol timers and counters, data manipulation instructions, alternate PLC symbols.
   
93
to
95.
Final Control Elements. Study of
control valves/finsl control elements, with VVVM, dyno type etc. Dismantling, fault
finding, repairing, cleaning, reassembling and testing of control valves. Assembly of Control Valves. Piping tubing
and fitting.
Final Control Elements in
Process Loops. Final control
element, Actuators, load set
point compensation, feed back
loops, control variables, effects
of disturbances on performance, parts of a final control subsystem, control signal, electric control signals, fluidic control signals.
Electric Actuators. Solenoids,
solenoid operated valves, electric motors, DC motors, universal motors, three phase induction motors, single phase induction motors, stepper motors, relay system.
Pneumatic and Hydraulic
Actuators. Pneumatic principles, effects of changing pressure,
pressure/volume/temperarture
relationship, effects of changing
temp. pneumatic actuators,
diaphragm actuator, spring and
springless actuators, direct and
reverse acting actuator, piston
actuator, positioners, hydraulic
principles, effect of temperature, mechanical advantages, one way
Drawing the
various parts
of control
valves and
actuators.
Control valve
terminology
with simple
calculations.
Calculation
on the cost to
repair/recondi
tion control
valves.
    hydraulic system, two way
hydrauliv system, hydraulic
fluid, Hydraulic maintenance.
Control Valves. Control valves
functions and components.
Types of control valves, globe
valves, cage valves, butterfly
valves, bsll valves, sliding gate
valves, diaphragm valves, split
body valves, capacitive,
inductive type valve, proximity
switch, I/R switch, micro switch,
limit switch, other control
valves, control valve flow
characteristics, inherent
characteristics, mechanical
considerations, selecting control valves, valve actuators, valve positioners. Control Elements Applications. Feed water control system, How the feed water control system works, sequential valve control, conteol and block valves, applying relays in final control elements, relay logic in operation, automatic valve control, furnace control system, controllers and activators, turbine control system, throttle and governor valves and activators. Explain to CV accessories like I/P convertors, valve positioners, air lockup, relay, quick exhaust valves basten relay, air filter regulator, different types of gland packings. Electrical actuators, pneumatic actuators and hydraulic actuators.
   
96
to
97.
Basic hydraulics and pneumatics. Practical on Hydraulic trainer. Basic Hydraulics :
Principles of Hydraulics. Fluid
power and hydraulics, force,
weight and mass, pressure, work, power, energy, in compressibility and non-diffusion, hydrostatic pressure, Pascal’s law, transmission of fluid power, fluid flow in pipes, Bernoulli’s principle, the effect of hest on
Drawing the sketches of
the components of hydraulic systems.
Block diagram of hydraulic systems.
Simple calculation on
hydraulics. Calculation of
the cost of repairing/reco
nditioning hydraulic
systems.
  Continue practical on trainer.
Dismantling and assembling of various valves.
liquids. A typical hydraulic power system. Hydraulic Fluids. Functions of hydraulic fluids, physical properties, viscosity, viscosity index, viscosity and pressure, power point, fluid selection, component protection, chemical properties, system contamination, water, dissolve air, foaming, corrosion and rusting, types of hydraulic fluids. Directional Control Valves. Directional control valves. classification, review of two way valves, globe, gage, plug, needle, ball, automatic two-way valves, check valves, pilot operated check valves, spool valves, twoway spool valves, three-way spool valves, controlling hydraulic motors, NO and Nc valves, holding valves, four and five way valves, rotary spool valves, schematicsymbols, flow ratings, accessories. Drawing the sketches of
valves and their parts.
 
98
to
100.
Basic pneumatics. Pneumatic systems, forces, weight and
pressure. Practical on pneumatic training kits. Practical on air filter regulator.
Pneumatic Principles. Mass,
pressure, work and energy,
compressibility, law of
pneumatics, transmission of
pneumatic fluid power,
pneumatic leverage, air
properties, air flow in pipe lines,
viscosity of air pressure,
Bernoulli’s law, components of
pneumatic power system.
Primary Air Treatment. Air
treatment, preliminary filtering,
relarive humidity, effects of
moisture, water removal, dew
point, moisture separators, oil
scrubbers, air dryers, (
deliaquescent and absorption
types ) air receivers, using a
nomograph to size a receiver.
Secondary Air Treatment.
Drawing sketches of
the components
of pneumatic systems.
Block diagram of pneumatic
systems.
Simple calculation on
pneumatics. Calculation of
the cost of repairing/reco
nditioning pneumatic
systems.
  Instrument pipes, schedules, pipe fittings, union, elbow, sockets, reducing sockets,
straight coupling, instrument tube and tube fittings, copper
tube and its fittings, air net fittings. Practical on pneumatic
trainer.
Methods of treatment,
contaminate separation,
contaminate filtration, filter
classification and rating, types of media, surface filters, depth
filters, absorption filters,
lubricating the air. Piping, Hoses and Fitting. Requirement of piping, air flow, piping dimensions and safety
factors, piping connections,
compressed air piping applications, metallic tubing,
tube bending and tube fittings,
tube installation, non-metallic
tubing hoses, hose fittings and
couplings, hose installation.
Pneumatic Cylinders. Descriptions, double scting
cylinders, single acting
cylinders, two-piston cylinders,
cylinder construction, variations
in cylinder mounting, pneumatic
cylinder selection, reading the
performance charts, cushioning
devices.
   
101. Analytical Instruments. Exercises on pH meter, conductivity meter, gas
chromatograph & GLCs.
Analytical Instruments. Exposure to basic analytical
instruments. Types of electrodes used for pH
measurements.Relation of pH &
mV. pH indicator and controllers.
Analysis & analysers. Gas
analysers. Conductivity &
conductivity meters. Application
of analyzer in industry. GLCs.
Revision Revision
102. Quality control & Ecological
Considerations. Practicals for assurinf quality products
avoiding environmental pollution, preventing wastage of energy.
Quality Control. Methods to be followed for assuming quality products, conservation of energy & preventing pollution. -- do -- -- do --
103. Industrial visit / Tour. Ecological consideration. Methods to be followed to avoid
environmental pollution.
   
104. Examination Achievements. Trainees will be able to
1. Make small instrument parts within an accuracy of ± 0.02 mm.
2. Recondition pressure , temperature, level and flow measuring instruments.
3. Recondition monocular, binocular, prismetic, compass, telescope, microscope, theodolite, dumpy level & single lens with view finder camera.
4. Recondition ammeter, voltmeter, wattmeter and energymeter.
5. Maintain process control instrumentation.
6. Handle analytical instruments.
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