COURSE INFORMATION :-
- During the one year duration a candidate is trained on subjects Professional Skill, Professional Knowledge, Engineering Drawing, Workshop Science & Calculation and Employability Skills related to job role. In addition to this a candidate is entrusted to undertake project work and extracurricular activities to build up confidence. The broad components covered under Professional Skill subject are as below: The practical skills are imparted in simple to complex manner & simultaneously theory subject is taught in the same fashion to apply cognitive knowledge while executing task. The safety aspects covers components like OSH & E, PPE, Fire extinguisher, First Aid and in addition 5S being taught. The practical part starts with edge preparation by hacksawing, filing and fitting followed by Oxy Acetylene Welding & Brazing, Oxy Acetylene Cutting, Shielded Metal Arc Welding, Gas Metal Arc Welding, Gas Tungsten Arc Welding and Spot Welding, Plasma Cutting and Arc Gouging. These processes are widely used in Industries. During the practice on Welding / Brazing process, the trainees will learn to read the job drawing, select the required base metal and filler metals, cut the metals by appropriate process, carry out edge preparation, setup the plant and do welding/Brazing on M.S, SS, Aluminium and Copper in different positions. On completion of each 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. The professional knowledge taught will be useful in understanding the principles of Welding, Brazing and Cutting process, use of jigs and Fixtures, distortion and methods of control, selection of consumables and to take precautionary measures for storage and handling and apply the same for executing the Cutting, Welding and Brazing. The knowledge and practice imparted on Destructive and Non-destructive testing will be use in understanding the standard quality of welds and to carry out shop floor Inspection and test in laboratories. One project need to be completed by the candidates in a group. 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.
2. TRAINING SYSTEM :-
- 2.1 GENERAL The Directorate General of Training (DGT) under Ministry of Skill Development & Entrepreneurship offers a range of vocational training courses catering to the need of different sectors of economy/ Labour market. The vocational training programmes are delivered under the aegis of Directorate General of Training (DGT). Craftsman Training Scheme (CTS) with variants and Apprenticeship Training Scheme (ATS) are two pioneer schemes of DGT for strengthening vocational training. Welder trade under CTS is one of the most popular courses delivered nationwide through a network of ITIs. The course is of one-year duration. It mainly consists of Domain area and Core area. In the Domain area (Trade Theory & Practical) imparts professional skills and knowledge, while the core area (Workshop calculation & Science, Engg. Drawing and Employability Skill) imparts requisite core skills, knowledge, and life skills. After passing out the training program, the trainee is awarded National Trade Certificate (NTC) by DGT which is recognized worldwide. Trainee broadly needs to demonstrate that they are able to:
- Read & interpret technical parameters/documentation, plan and organize work processes, identify necessary materials and tools;
- Perform tasks with due consideration to safety rules, accident prevention regulations and environmental protection stipulations;
- Apply professional knowledge, core skills & employability skills while performing the job, and repair & maintenance work.
- Check the job/ assembly as per drawing for functioning identify and rectify errors in job/ assembly.
- Document the technical parameters in tabulation sheet related to the task undertaken. 2.2 PROGRESSION PATHWAYS
- Can join industry as Technician and will progress further as Senior Technician, Supervisor and can rise up to the level of Manager.
- Can become Entrepreneur in the related field.
- 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.
- Can join Advanced Diploma (Vocational) courses under DGT as applicable.
2.3 COURSE STRUCTURE :- Table below depicts the distribution of training hours across various course elements during a period of one year: –
- 2.4 ASSESSMENT &CERTIFICATION :-
- The trainee will be tested for his skill, knowledge and attitude during the period of course through formative assessment and at the end of the training programme through summative assessment as notified by the DGT from time to time. a) The Continuous Assessment (Internal) during the period of training will be done by Formative assessment method by testing for assessment criteria listed against learning outcomes. The training institute have to maintain individual trainee portfolio as detailed in assessment guideline. The marks of internal assessment will be as per the formative assessment template provided on www.bharatskills.gov.in b) The final assessment will be in the form of summative assessment. The All India Trade Test for awarding NTC will be conducted by Controller of examinations, DGT as per the guidelines. The pattern and marking structure is being notified by DGT from time to time. The learning outcome and assessment criteria will be basis for setting question papers for final assessment. The examiner during final examination will also check 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 Trade Practical and Formative assessment is 60% & for all other subjects is 33%. There will be no Grace marks.
- 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 assessment. Due consideration should be given while assessing for team work, avoidance/reduction of scrap/wastage and disposal of scarp/wastage as per procedure, behavioral attitude, sensitivity to 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
- Progress chart
- Attendance and punctuality
- Project work Evidences and records of internal (Formative) assessments are to be preserved until forthcoming examination for audit and verification by examination body.
3. 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 heat it to melting point, simultaneously melting welding rod and spreading molten metal along joint shape, size etc. and rectifies defects if any. Welder, Electric; fuses metals using arc-welding power source and electrodes. Examines parts to be welded, cleans them and sets joints together with clamps or any other suitable device. Starts welding power source and regulates current according to material and thickness of welding. Connect one lead to part to be welded, selects required type of electrode and clamps other lead to electrode holder. May join parts first at various points for holding at specified angles, shape, form and dimension by tack welding. Establish arc between electrode and joint and maintain it throughout the length of the joint. Welder, Resistance; sets up and operates resistance welding machine to join metal parts, according to blueprints, work orders, or oral instructions. Turns machine dials to set air and hydraulic pressure, amperage, and joining time, according to specified type of metal, weld, and assembly. May select, install, and adjust electrodes. Aligns work pieces, using square and rule. May hold pieces together manually, fasten into jigs, or secure with clamps to align in specified assembly position. Holds part between electrodes or positions on machine worktable. Depresses pedal or pulls trigger to close electrodes and form weld at point of contact. Releases pedal or trigger after specified welding time. Cleans electrodes, using file, tip dresser, emery cloth. May operate machine which automatically releases electrodes from metal after welding cycle. May devise and build fixtures to hold pieces. May inspect finished work. May operate machine equipped with two or more electrodes which weld at several points simultaneously. Important variations include types of joints welded (seam, spot, butt) and types of materials welded (aluminium, steel). Gas Cutting; cuts metal to require shape and size by gas flame either manually or by machine. Examines material to be cut and marks it according to instruction of specification. Makes necessary connections and fits required size of nozzle in welding torch. Releases and regulates flow of gas in nozzle, ignites and adjusts flame. Guides flame by hand or machine along cutting line at required speed and cuts metal to required size.
- Brazer; joints metal parts by heating using flux and filler rods. Cleans and fastens parts to be joined face to face by wire brush. Apply flux on the joint and heats by torch to melt filler rods into joint. Allows it to cool down. Clean and examines the joint. Tungsten Inert Gas (TIG) welder; reads fabrication drawing, examines parts to be welded, cleans them and sets joints with clamps or any other suitable device. Selects suitable tungsten electrode, grinds the edges and fit in to the GTA welding torch. Selects gas nozzle and fit in to the GTA welding torch. Selects suitable filler rods and cleans them. Connects work piece with earth cable, Connects the machine with Inert gas Cylinder, regulator and flow meter. Starts the Constant current GTA welding machine, sets suitable welding current & polarity and inert gas flow. Establish arc through across a column of highly ionized inert gas between work piece and Tungsten electrode. Melts the metal and deposit weld beads on metal surfaces by passing the suitable filler rod in to the weld puddle. Joins metal pieces such as Steel, Stainless steel and Aluminium metals. Gas Metal Arc Welder/ Metal Inert Gas/ Metal Active Gas/ Gas Metal Welder (MIG/MAG/GMAW); reads fabrication drawing, examines parts to be welded, cleans them and sets joints with clamps or any other suitable device. Connects work piece with earth cable. Connects the machine with suitable gas Cylinder, regulator and flow meter. Connects pre-heater when CO2 is used as shielding gas. Selects suitable wire electrode, feed it to welding GMA Welding torch through wire feeder. Selects contact tip gas nozzle and fit in to the GMA welding torch. Preheats joints as required. Starts the Constant Voltage GMA welding machine, sets suitable welding voltage & wire feed speed and shielding gas flow, produces arc between work piece and continuously fed wire electrode. Melts the metal and deposit weld beads on the surface of metals or joins metal pieces such as Steel, and Stainless-steel metals. Iron and Steel Plasma Cutter- Manual; cuts different materials (mild carbon steel, stainless steel, aluminium, high tensile and special steels, and other materials) in various profiles. This involve setting-up and preparing operations interpreting the right information from the specification documents, obtaining the right consumables and other materials, etc. Plan and organize assigned work and detect & resolve issues during execution in his own work area within defined limit. Demonstrate possible solutions and agree tasks within the team. Communicate with required clarity and understand technical English. Sensitive to environment, self-learning and productivity. Reference NCO 2015: (i) 7212.0100 – Welder, Gas (ii) 7212.0200 – Welder, Electric (iii) 7212.0700 – Welder, Resistance