SYLLABUS

For the trade of

ADVANCE MECHANIC (INSTRUMENTS)

UNDER

Apprenticeship Training Scheme

Government of India
Ministry of Labour & Employment
Directorate General of Employment & Training
New Delhi-110001
 GENERAL INFORMATION

Name of the Trade : Advance Mechanic (Instruments)

N.C.O. Code No. : 73111.10, 7311.30, 7241.10

Entry Qualification : Passed 10th class examination

under 10+2 system of education
or its equivalent.

Duration of the Apprenticeship Training : 02 years

Rebate allowed in Apprenticeship Training : One year and six months for
trainees completed Broad
Based Basic Training in
Chemical Sector under Centre
of Excellence Scheme and
Advanced module of Centre of
Excellence Scheme in
Instruments Mechanic.

Ratio of apprentices to workers other than : 1:2

Terminal Behavior : On completion of the training

the trainee is able to work as
Mechanic Instruments in
Chemical Plant.

Course Outline:

The training shall comprise of-

(a) On the job training
The actual training shall be depended on the facilities available in the
establishment, with an idea to expose the trainees to as many activities as
possible, The trainees shall maintain a daily work diary for the on job
training, which shall be periodically authenticated by the supervisor.

(b) Project
Each apprentice shall under take a project in any of the areas
depending on his/her interest and facilities available in the establishment.
The duration of the project shall be two weeks.
 Syllabus for the trade of

ADVANCE MECHANIC (INSTRUMENTS)

Under Apprentice Training Scheme

List of the members participated in design of the curriculum

Sr Name & Designation Organization
1 Shri.S.S. Bhonsle General Manager Sandoz Pvt.Ltd. Mahad
2 Shri. K.Narsappa General Manager Vinyl Chemical(1)Ltd.
Mahad
3 Shri. M.R. Ramukka General Manager Shrihari Chemical(1)Ltd.
Mahad
4 Shri. A.G. Chandlekar Sr. Manager Vinyl Chemical(1)Ltd.
Mahad
5 Shri. V.S. Deshmukh Manager Laxmi Organic Ltd. Mahad
6 Shri S.L. Gole Manager (Maintenance) Hikal Ltd. Mahad.
7 Shri. Prasad Limaye Work manager Sudarshan Chemical Ltd.
Mahad
8 Shri. V.G. Dhupkar General Manager Kopran Ltd. Mahad
9 Shri . S.V. Aherrao Personal manager E.B.P.L. Mahad
10 Shri Tambe Sr. Manager( Inst.) Vinyl Organic ltd Mahad
11 Shri. Sadamate S.M. Principal I.T.I. Mahad – Raigad
12 Shri Deshmukh S.E. Science Instructor I.T.I. Mahad – Raigad

List of the members present in trade committee meeting held on 13th January 2007 for
the above trade at Industrial Training Institute, Aundh, Pune,

Sr Name & Designation Organization

01 Bhonsle S.S. General Manager Sandoz Pvt.Ltd. Mahad
 Syllabus for the trade of
Advance Mechanic (Instruments)
Under the Apprenticeship Training

Sr.No. Shop Floor - Skills Related Instructions

1 Measuring system's 1)Study of all latest instruments
Handling of all latest instruments volume, pressure, level
volume, pressure, level instruments, instruments,

2 Handling of product catalog, slide 2)Study of product catalog, slide

shows, transfer sheet shows, transfer sheet

3 Handling of control system and final 3) Study of control system and

control system final control system

4 Application of measuring system 4)Application of measuring

system
5 Supervisory control of data
acquisition system 1) Communication protocol
Overview of DCS, Architecture- Overview of SCADA System
block diagram, field control station,
operator station, Features of
operator station, Networking with
different control stations and
operator station,
Communication protocol Overview
of SCADA
System , component of system ,
2) Programmable logic controller
6 PLC (Programmable logic , Programming with PLC , HMI-
controller) (Human machine meter face)
Programming with PLC , HMI- feature of HMI
(Human machine meter face) (Human machine meter face)
feature of HMI , communication of feature of HMI ,
PLC with HMI , 3) communication of PLC with
HMI ,

4) Use of desktop PCs with

Use of desktop PCs with windows
operating system , DCS & SCADA
System
windows
(Human machine meter face)
feature meter face) feature of
HMI ,3) communication of PLC
with HMI
4) Use of desktop PCs with
windows operating system , DCS
& SCADA System
Sr.No. Shop Floor - Skills
.
7 1) Calibration of pressure gauge ,
vacuum gauge , Temp indicator -
RTD i/p & Thermocouple i/p ,
Universal controller , D.P.
Transmitter , Control valves - PID
ON-OFF with positioned.
8
Process indicator - Level ,
Pressure, pH indicator,
Conductivity indicator , weight
balance . Study of Solenoid Valve .
Timers , Dial thermometer I/P
Converter Flow meter - Water
meter , Voltmeter ,Rota meter.
9 meter.
Understanding Sensor traducer
,signal conditioning.
10 Master instruments
1) Dead weight tester
2) Universal calibration
3) Monometer
11
4) Master Flow meter
5) Timer
12
6) Conductivity simulation
7) pH-buffer
8) Standard weight
9) Multi meter analog digital
Related Instructions
1) Introduction to calibration
pressure gauge calibration
vacuum gauge , Temp
indicator -RTD i/p &
Thermocouple i/p ,
2) Universal controller , D.P.
Transmitter , Control valves -
PID ON-OFF with positioned
3) Process indicator - Level,
Pressure, pH indicator,
Conductivity indicator , weight
balance .
Study of Solenoid Valve
4) Timers, Dial thermometer
I/P Converter Flow meter -
Water meter, Voltmeter, Rota
Introduction Sensor traducer
,signal conditioning.
Dead weight tester Universal
calibration Monometer
Master Flow meter
2) Conductivity simulation PH-
buffer
simulation PH-buffer Standard
weight Multi meter analog
digital
Sr.No. . Shop Floor - Skills Related Instructions
13 1) Understanding basic primary 1) Introduction to basic primary
element Each type of process element Each type of process
parameters (Flow, temp, pressure, parameters (Flow, temp,
level) pressure, level) 2) Brief theory
2) Brief theory of each primary of each primary element Flow -
element Flow - orifice , Rota orifice , Rota meters level -D.P.
meters level -D.P. instrument , instrument, displayer type
displayer type measurement , measurement , ultrasonic level
ultrasonic level measurement , measurement , Non contact
Non contact type Ruder & type Ruder & Radioactive type
Radioactive type 3) Pressure -Bourdon tube
3)Pressure -Bourdon tube type , type, capacitance type, strain
capacitance type, strain gauge gauge type . Temp -
type . Temp -thermostats, thermostats, thermocouple
thermocouple RTD, Field system, RTD, Field system, bimetallic.
bimetallic.
14 4)Introduction to final control
element, control valves
4)Understanding final control 5) Automation of control valve
element, control valves operation
5) Selection of proper control 6) Actuators and valve
valve. positioners, IP Converters.
6) Sizing of control valves
7) Automation of control valve
operation
15 8) Actuators and valve petitioners, 7) Control loop - close loop and
IP Converters. open loop system
8)Solenoid /Remote operated
9) Control loop - close loop and ON-OFF valve
open loop system 9)Safety valve
10) Solenoid /Remote operated 10)Pressure regulating valve
ON-OFF valve
11) Safety valve
12) Pressure regulating valve
Sr.No. Shop Floor - Skills Related Instructions
.
16 1) Basic control theory and 1)Basic control theory and
applications applications
2) Industrial applications of each type 2)Industrial applications of
of controls each type of controls
3) Introduction to advance control 3)Introduction to advance
devices control devices
4) Digital Microprocessor 4)Digital Microprocessor
base control and monitoring base control and monitoring
devices – devices –recorders and
recorders and scanners scanners
17
5)ON -OFF Controller
5) ON -OFF Controller 6)Single loop controller and
6) Single loop controller and multi multi loop controller
loop controller 7)Configuration and
7) Configuration and programming of programming of above devices
above devices 8)Tuning of controllers
18 8) Tuning of controllers
9) Introduction to DCS and
9) Understanding DCS and PLC PLC
10) PC interface of 10)PC interface of intelligent
intelligent device device

19 1) Process and industrial safety 1) Hazards to various

Hazards to various chemical chemical process and nature
process and nature of process of process

20 2) Legal provisions 2)Legal provisions

21 3) Safety devices - safety 3)Safety devices - safety valves

valves , safety relief , safety relief valves ( thermal &
valves ( thermal & pressure ) rapture disk
pressure ) rapture disk
4) Nitrogen blanketing 4)Nitrogen blanketing system,
system, self regulation, self regulation, pressure control
pressure control valve valve safety vacuum relief
safety vacuum relief
5) Fire alarm and smoke 5) Fire alarm and smoke
detection system detection system
6) Hydrogen gasses 6)Hydrogen gasses
7) Safety interlock and trip 7)Safety interlock and trip
/systematic shut down system /systematic shut down system
Sr.N Shop Floor - Skills Related Instructions

22 Overview of DCS, Architecture-block 1) Overview of DCS,

diagram, field control station, operator Architecture-block diagram,
station, Features of operator satin, field control station, operator
station,
23 Networking with different control
stations and operator station, 2) Features of operator satin,
Networking with different
control stations and operator
24 Communication protocol conventional station,
system, protocol conventional system
profibus P.A. foundation field bus. 3) Communication protocol
conventional system,
4) Profibus P.A. foundation field
bus.
25 1) Handling of traffic control system 1) Handling of traffic control
2) purpose of traffic control system system
3) Use of photo cells, different types of 2)purpose of traffic control
material used. Wiring diagram system
3)Use of photo cells, different
types of material used. Wiring
diagram
26 4) Benefits of traffic control system
5) Practice about electrical logic 4)Benefits of traffic control
6) Understanding of EPABX system system
7) Variable frequency device(in plant) 5) Study of electrical logic
(paint , packing industry, detergent 6)Introduction to EPABX
industry) system
7)Variable frequency device(in
plant) (paint , packing industry,
detergent industry)
 General Installation
List of Accessories & Machines Advance mechanic Instrument Must be available with
Industry

1) Distributed control system(D.C.S.)

2) Super visor control of data actuation system (SCADA)
3) Calibration of pressure gauge, vacuum gauge, temps. indicator , RTD ,
Thermocouple, O.P. Transmitter PID Controller, pH Indicator, Solenoid valve,
Water Meter, Rota meter & transducer
4) Dead Wt tester,
Universal calibrator
Manometer
Master flow meter
Multi meter
5) Primary element like orifice
6) Diff. types of level indicator’s like capacitance type level indicator
7) ON-OFF controller, single loop controller & multi loop controller & tuning of
controller
8) Safety devices-safety valves, safety relief valves, self regulation pressure
control valve
9) Fire alarm & smoke detection system
10) Use of photo cell, study of electrical logic
 Examination of Scheme for the trade of Advance Mechanic (Instruments)

Sr.No Title Total Marks Minimum Marks

Marks Obtained

1 Project work based on 200 120

Practical Training in
respective Industry

2 Practical Test /Viva 100 60

based on Practical
training in Respective
Industry

Total 300 180