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Transcript of lfR(I'-~Ril' lfR(I' Lab...
Sk II India .Ril' lfR(I'-~Ril' lfR(I'
Lab Specifications Welding
An initiative of Ministry of Skill Development & Entrepreneurship, Govt. of India and National Skill Development Corporation
LAB SPECIFICATIONS WELDING
Shri Narendra Modi Honourable Prime Minister
~f we have to promote the
development of our country
then our mission has to be
'skill development' and
'skilled India'. '
LAB SPECIFICAllONS WELDING
OVERVIEW
The lab standardization guidelines envisions to standardize the lab infrastructure for welding trades across sectors. The document intends to ensure industry linked training with state-of-art infrastructure.
IILAB SPECIFICATIONS WELDING
WELDING SECTOR 1. Description of Lab
2. List of Tools & Equipment Welding
3. 3D Representation of Welding Lab
4. Illustrative Architectural Layout of Lab
5. Illustrative Pricing of Tools & Equipment
6. Safety Instructions
LAB SPECIFICATIONS WELDING II
DESCRIPTION OF LAB
Lab Specifications for the Listed Sectors I Job Roles
1. Capital Goods Sector Skill Council
a GMAW
b SMAW (Level 2 &3) c Fitter Fabrication
2. Indian Iron & Steel Sector Skill Council a GTAW
b Plasma Cutter
3. Mining Sector Skill Council
a Mining Welder
4. Automotive Sector Skill Council
a Welding Technician Level 2 - 4
Proposed Batch Size
25
Machine - Man Ratio
1 :4 for Level 1-3 Job Roles 1:3 for Level4 Job Roles 1 :2 for GMAW International Models
IILAB SPECIFICATIONS WELDING
LIST OF TOOLS &EQUIPMENT -WELDING
s. No.
Equipment Nama Qty MMAW/Minlng Walder L2-1..3
GMAW/ FCAW
GTAW WTLaval2· Laval3
WT· Laval4
Plama Cutter
Machines
1 Arc Welding Machines (Inverter Based Welding
Rectifiers Min 250 V) 5 5 2 2 3 3
2 Gas Cutting 2 2 2 2 1 1 2
3 Plasma Cutter, 3 Phase, Capacity Upto 15 mm MAX 1 1
4 Regulator for any Gas (CO/Argon/Helium/Nitrogen/Hydrogen) 4 2 4 4 2 2 4
5 Hand Grinders (AG 4) 5 5 5 5 2 2 2
6 Hand Grinders (AG 7) 5 5 5 5 2 2 2
7 Fume Extractors (1 Set for 7 Machines/Booths) 1 1 1 1 1 1 1
8 Electrode Driving Over Thermostatically Controlled Temperature 0-250 Celcius, 1 Okg CAP 2 2 2 2 1 1 1
9 Power Saw 1 1 1 1 1 1
10 Scrap Box (3 x 3 x 1.5) 2 2 2 2 2 2 2
11 Power Backup 125KVA (Diesel Generator) 1 1 1 1 1 1 1
12 Equipment for Destructive & Non Destructive Tests 1 1 1 1 1 1
13 Welding Simulator (Indicative) 1 1 1 1 1 1
Tools
14 Benchwise 8 8 8 8 8 8 15 Anvil 1 1 1 1 1 1
16 D.E. Grinder 30 em, Wheel Motorised Pedestal Type 1 1 1 1 1 1
17 Spindle Key (For Opening Cylinder Valve) 4 2 4 4 2 2 4
18 Tip Cleaner 4 2 4 4 2 2 4
19 Pipe Wrench 25 em and 35 em 4 4 4 4 4 4
20 Steel Tape 182 em Flexible in Case 10 10 10 10 10 10 10
LAB SPECIFICATIONS WELDING
LIST OF TOOLS & EQUIPMENT -WELDING
s. No.
Equipment Name Qty MMAWIMinlng WelderL2-1..3
GMAW/ FCAW
GTAW WT Leve12Level3
WTLevel4
Plasma Cutter
21 GTAW Machines with Water Cooling Unit 300 ampsAC/DC 5 5
22 GMAW /FCAW Complete Unit with Gas Stands and Trolley 300amps
5 5
Hand Tools
23 Number Punch (For Iron Use) 4 4 4 4 4 4 4
24 Chisel 6 6 6 6 6 6
25 File Set 6 6 6 6 6 6
26 Center Punch 6 6 6 6 6 6
27 Try Square 6 6 6 6 6 6 6
28 Scriber 6 6 6 6 6 6 6
29 Dot Punch 6 6 6 6 6 6
30 Hacksaw Frame 10 8 8 8 8 8
31 Flat Tongs 8 8 8 8 8 8 8
32 Steel Rule 10 10 10 10 10 10 10
33 Divider 6 6 6 6 6 6 6
Personal Protective Equipment
34 Hand Shield 15 15 15 15 15 15 15
35 Head Shield 10 10 10 10 10 10 10
36 Grinding Helmet 15 15 15 15 15 15 15
37 Leather Apron 25 25 25 25 25 25 25
38 Goggles 25 25 25 25 25 25 25
39 Leg Guard 25 25 25 25 25 25 25
40 Hand Guard 25 25 25 25 25 25 25
IILAB SPECIFICATIONS WELDING
LIST OF TOOLS &EQUIPMENT -WELDING
s. No.
Equipment Name Qty MMAWIMinlng Welder L2-L3
GMAW/ FCAW
GTAW WT Leve12Level3
WTLevel4
Plasma Cutter
41 GTAW Welding Gloves 25 25 25 25
42 MMAWGioves 25 25 25 25 25 25 25
43 Safety Shoes 25 25 25 25 25 25 25
Supporting Infrastructure
44 Fitting Tables for Bench Vices Made of MS 4 x 4 x 2.5 4 4 4 4 4 4 2
45 Welding Booths with Size 6 X 4 8 5 5 3 5 5 3
IILAB SPECIFICATIONS WELDING
3D REPRESENTATION OF WELDING LAB
List of Equipment
SMAW Machines
GTAW Machines
Fume Evacuation System
Trainee Job Display Units
Hand Tools
Scrap and Waste Disposal
Fire and Helmet Stands
GMAW Machines
Incubators
Fitting Tables
Tool Display Units
Work Benches
Raw Material Stands
IILAB SPECIFICATIONS WELDING
ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB
17075
~~ 3000
' Student Entry Student Entry ~
~
;::~
g ~
'<-----
I Store 2400 X 3000 r
IL 8 ~
CLASSROOM 4500x6500
bQQ?QibQQI Qi lifQ;l~Qi bQQ?QibQQI bQQ?QibQbQ kQkQQikQkQ
4500
List of Items in the Above Figure
1. Gas Cylinder
2. Welding Machine
3. Welding Jig
4 Grinding Machine
5. Fitting Table with Bench Vice
and Tools Storage
~ ~ n n n
F~ & Extinguisher
RAW MATERIAL STORE
u Oven / Incubator
Grinder Scrap Box Machine DrillingDisplay I Pow~[] D
Dc=J Machin Hacksa
900 1()00 1' 900 r1' 10- Welding Booth1-WeldlngBooth ~·
0 ~rn WorkTable WorkTable
900 ,. 1000 900
0 ~ru ,~~CJ O ~J1 1'
2- Welding Booth 9- Welding BoothDemonstration Table
Work Table
, ~
3- Welding Booth
8- Welding Booth~ 4- Welding Booth 7- Welding Booth5- Welding Booth 6- Welding Booth
1900 12000
6. Raw Material Stand
7. Demonstrator Table
8. Classroom with 25 Capacity
9. Trainee Display Unit
10. Store Room
11. Scrap Box
12. Entry
13. Fire Exit
14. Oven /Incubator
IILAB SPECIFICATIONS WELDING
ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB
Welding Booth
16 o. me aheel
40x40x5 mm oroa
35x35x5 mm argll b BB8B
TOP VIEW INSIDE VIEW TABLEVIEW
WELDING 80011-1 WELDING BOOlH WELDING 800 11-1
Fitting Table
151D, ' I
I • •
, 151D , ' ~~====~=========~==~~ .......... .........
' I] ' ' TOP VIEW SIDE VIEW
FmtNGTABLE FITTlNG TABLE
LAB SPECIFICATIONS WELDING
ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB
Helmets Stand & Fire Bucket
450
FRONT VIEW
40 x410 mm hollow eactton
18mm aq. bBI hookfcrhelm81
HELMETS STAND & ARE BUCKET
/
1500
g g
~ ~ ~ "' D
~ .
~ =
40 x 40 mm hollow 1118tltion = .... ~
SIDE VIEW
HELMETS STAND & ARE BUCKET
Raw Material Stand
401D
40 .w mm oollow 118C11onj' ,_X
!:!
SIDE VIEW
RAW MATERIAL STAND RAW MATERIAL STAND
FRONT VIEW
LAB SPECIFICATIONS WELDING
ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT
S.No. Equipment Name Qty UnH Price• (INR) Amount (INR) Brand•"
Machin•
1 Arc Welding Machines(Mmaw AC I DC) 300 amps 5 65,000 3,25,000 Ador Welding, ESAB,
Panasonic, Kempi, Riland, Rilan, Miller or Equivalent
2 Gas Cutting 2 3,500 7,000 Ador Welding, ESAB, Messer or Equivalent
3 Plasma Cutter 1 1,50,000 1,50,000 Ador Welding, ESAB, Messer or Equivalent
4 Regulator (2 Sets of Oxygen &Acetylene) 4 2,500 10,000 CE/BIS/ISI Marked and
Ador Welding, ESAB, Messer or Equivalent
5 Hand Grinders (AG 4) 5 3,500 35,000 Bosch, Dewalt or Equivalent
6 Hand Grinders (AG 7) 5 3,500 35,000 Bosch, Dewalt or Equivalent
7 Fume Extractors (1 set for 7 Machines I Booths) 1 2,00,000 2,00,000 Customised/Non Branded
8 Electrode Driving Over Thermostatically Controlled Temperature 0-250 C 1 Okg I CAP 2 25,000 50,000 CEIBIS/ISI Marked
9 Power Saw 1 15,000 15,000 Bosch, Dewalt or Equivalent
10 Scrap Box (3 x 3x 1.5) 2 7,500 15,000 Customised/Non Branded
11 Power Backup 125KVA (Diesel Generator) 1 3,25,000 3,25,000 Kirloskar or Equivalent
12 Equipment For Destructive & Non Destructive Tests 1 15,000 15,000 Non Branded
13 Welding Simulator (Indicative) 1 10,00,000 10,00,000
Tools
14 Bench Wise 8 3,500 28,000 Non Branded
15 Anvil 1 3,000 3,000 Non Branded
"Price is indicative for the majorbrands, similar tools/equipment may be used "*Brands are illustrative, other brands with same specifications may be used
IllLAB SPECIFICATIONS WELDING
ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT
S.No. Equipment Name Qty UnH Price• (INR) Amount (INR) Brand•"
16 D.E. Grinder 30 em, Wheel Motorised Pedestial Type 1 5,000 5,000 Non Branded
17 Spindle Key (For Opening Cylinder Valve) 4 1,500 6,000 Non Branded
18 Tip Cleaner 4 280 1,120 Non Branded
19 Pipe Wrench 25 em and 35 em 4 350 1,400 Non Branded
20 Steel Tape 182 em Flexible in Case 10 300 3,000 Non Branded
21 GTAW Machines with Water Cooling Unit 300amps AC/DC 5 1,50,000 7,50,000 Ador Welding, ESAB,
Panasonic, Kempi, Riland, Rilan, Miller or Equivalent
22 GMAW/FCAW Complete Unit with Gas Stands and Trolley 5 1,50,000 7,50,000 Ador Welding, ESAB,
Panasonic, Kempi, Riland, Rilan, Miller or Equivalent
Hand Tom.
23 Number Punch (For Iron Use) 4 200 800 Non Branded
24 Chisel 6 220 1,320 Non Branded
25 File Set 6 500 3,000 Non Branded
26 Center Punch 6 220 1,320 Non Branded
27 Try Square 6 300 1,800 Non Branded
28 Scriber 6 320 1,920 Non Branded
29 Dot Punch 6 300 1,800 Non Branded
30 Hacksaw Frame 10 500 5,000 Non Branded
31 Flat Tongs 7 300 2,100 Non Branded
32 Steel Rule 10 30 300 Non Branded
33 Divider 6 100 600 Non Branded
"Price is indicative for the majorbrands, similar tools/equipment may be used ..Brands are illustrative, other brands with same specifications may be used
LAB SPECIFICATIONS WELDING
ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT
S.No. Equipment Name Qty UnH Price• (INR) Amount (INR) Brand•"
Personal Protac:tlve Equipment
34 Hand Shield 15 300 4,500 Ador Welding, ESAB/ Welspring or Equivalent
35 Head Shield 10 650 6,500 Ador Welding, ESAB/ Welspring or Equivalent
36 Grinding Helmet 15 350 5,250 Ador Welding, ESAB/ Welspring or Equivalent
37 Leather Apron 25 300 7,500 Ador Welding, ESAB/ Welspring or Equivalent
38 Goggles 25 225 5,625 Ador Welding, ESAB/ Welspring or Equivalent
39 Leg Guard 25 220 5,500 Ador Welding, ESAB/ Welspring or Equivalent
40 Hand Guard 25 150 3,750 Ador Welding, ESAB/ Welspring or Equivalent
41 GTAW Welding Gloves 25 500 12,500 Ador Welding, ESAB/ Welspring or Equivalent
42 MMAWGioves 25 350 8,750 Ador Welding, ESAB/ Welspring or Equivalent
43 Safety Shoes 25 400 10,000 Ador Welding, ESAB/ Welspring or Equivalent
Supporting lnfrutrurctuN
44 Fitting Tables for Bench Vices Made of MS 4 x 4 x 2.5 4 8,000 32,000 Customised/Non Branded
45 Welding Booths with Size 6 x 4 6 20,000 1,20,000 Customised/Non Branded
Total 39,71,355
"Price is indicative for the majorbrands, similar tools/equipment may be used "*Brands are illustrative, other brands with same specifications may be used
LAB SPECIFICATIONS WELDING
SAFETY INSTRUCTIONS
Given below Safety Instruction posters should be placed at appropriate places in the lab. The posters should be digitally printed and pasted on sun board.
Welding Personal Protective Equipment
CI)~-Safety Glasses Safety Shoes Hearing Protection
cro@®Respirator Full Face Shield Gloves
@(j)(j) Welding Shirts/Arm Bands Harness Apron/Chaps
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Weld Geometry ASME 9 Welding Positions
~8 :::~ :=.:: . , ..~-"""'G ~::::"'!""~:--=,::....6G • Pipe lncl"** U" (60) Downwards
SG • P .... Wekled~Up )G • .._Waldedv..tka!Down lF• FIIIMw.ldv.rtlci!I Up
() ~ l ) IPipe Fixed Horizontal I
IILAB SPECIFICATIONS WELDING
SAFETY INSTRUCTIONS
Basic Safety Rules for Welding I Fabrication:
Following safety rules should be followed:
1. Ensure that adjusting screws on regulators are released before opening valves
2. When opening a valve, stand on the opposite side ofthe regulator
3. The cylinder valve has to be opened slowly, releasing the oxygen initially. After the oxygen has been released, turn the valve by a quarter ofa tum to release acetylene
4. Set working pressure as prescribed fora specific welding process
5. Do notuse oxygen as a substitute for compressed air
6. Keep heat, flames and sparks away from combustibles
LAB SPECIFICATIONS WELDING
SAFETY INSTRUCTIONS
Electrical Hazards - Follow the Listed Precautions to Avoid Electric Shock
Welding generally uses low voltage, however, there is still a dangerofelectric shock
• Do not work in wet orcramped up work spaces
• Ensure no naked or loose wires are present in the lab
Electrical exposure can lead to falls, fractures and brain damage. Heavy shocks may also lead to death
Electrical Safety
• Use dry gloves
• Wear rubber soled shoes
• Use insulating layers
• Protectyourselffrom surfaces that conduct electricity
• When working on electrically powered machinery, make sure the frame is grounded
• Keep insulation on all welding equipment and components dry and in working condition
• Do not change electrodes with bare hands, wet gloves orwhile standing on wet or ungrounded surfaces
LAB SPECIFICATIONS WELDING
' We are a youthful nation.
Our youth is our
strength.The world and
India need a skilled
workforce and we are
committed to achieve this
mission.''
-Shri Rajiv Pratap Rudy Minister of State (1/C) for Skill Development & Entrepreneurship Govt. of India
-
LAB SPECIFICATIONS WELDING
LAB SPECIFICATIONS WELDING
~"GI'>ffi MINISTRY OF SKILL DEVELOPMENT
& ENTREPRENEURSHIP GOVERNMENT OF INDIA
Sk It India .R'I1!Ril·f'R'11!Ril
N S · D· C National Skill Development Corporation
Transforming the skill landscape