professional diploma in industrial...

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SYLLABUS

FOR

PROFESSIONAL DIPLOMA IN INDUSTRIAL INSTRUMENTATION AND

FIRE & SAFTEY (PDIFS)

CCEK – NSDC SKILL DEVELOPMENT TRAINING PROGRAM

SYLLABUS

FOR

PROFESSIONAL DIPLOMA IN INDUSTRIAL INSTRUMENTATION AND FIRE & SAFETY

(PDIFS)

CENTRE FOR CONTINUING EDUCATION KERALA

Anathara Lane, Charachira, Kowdiar PO, Thiruvananthapuram Kerala, PIN– 695 003

CCEK - NSDC SKILL DEVELOPMENT TRAINING

PROGRAM

PROFESSIONAL DIPLOMA IN INDUSTRIAL INSTRUMENTATION AND FIRE &

SAFETY (PDIFS) CCEK – NSDC course package covers the following Qualification

Packs and leads to the following NSDC certifications. The students who successfully

completed the course programs are entitled to get NSDC certification after

undergoing the assessment process of NSDC as per the rules and regulations

stipulated by NSDC from time to time.

Sl. Qualifications Pack Qualifications No Pack Code

1 Assistant Electrician

Brief Job Description: Assistant Electrician will be

CON/Q0602 assisting level -4 electrician or superior in electrical work

for the installation, repair, and maintenance of temporary

LV electrical connections at the construction sites and

permanent connections at residential and commercial

buildings. The individual will be engaged in laying conduits

for LV single phase wiring with appropriate selection and

use of hand and power tools efficiently.

PROFESSIONAL DIPLOMA IN INDUSTRIAL

INSTRUMENTATION AND FIRE & SAFTEY

OBJECTIVE AND SCOPE OF THE COURSE

An Instrument Technician repairs, calibrates, Adjusts and

installs Industrial measuring and Controlling instrumentation.

This instrumentation makes sure that all machines in a Plant are

safe and running correctly. They may regulant the fluid flow in

equipment or Check the quality of a product.

The operation and safety of the plant relies on these

Instruments so the instrumentation technician is very

important as they constantly Monitor and calibrate

these instruments.

An Instrument Fitter performs maintenance, installation and

integrations of various types of process control instrumentation

such as transmitters, controllers, integrator, recorders, square

root extractors and final control elements. Day to day tasks

include fitting and assembling instrument parts, installing

industrial instruments and tubing’s, dismantling and

reassembling delicate mechanisms or electronic circuits,

overhauling instrument systems, use of common test,

equipment’s etc.

Ability to lay out, fabricate, installs and perform leak testing on instrument tubing and piping systems.

Make cut-outs on instrument panel and install instruments

Under the supervision of instrument technician.

Ability to read and interpret instrumentation drawings documents

And specifications

Select and use proper fasteners, gaskets, packing and O-rings

Exhibit basic mechanical and mathematical skills

Demonstrate good safety practice especially electrical safety.

Test and calibrate different types of process control instruments.

Demonstrate basic programming abilities of PLC and SCADA.

Read and interpret ladder logic diagrams.

TYPICAL DUTIES INCLUDED



COURSE DETAILS

SL. NO.

EXAM EXAM CODE

MAX. MARK

INTERNAL TOTAL MARK

THEORY PAPERS

1 Industrial Instrumentation

PDIFS

T001

100

50

150

2 Fire & Safety PDIFS T001

100 50 150

PRACTICAL PAPERS

1 Industrial Instrumentation lab

PDIFS

L001

100 50 150

2 Fire & Safety lab PDIFS L002

100 50 150

TOTAL MARKS

1

Total Examination Marks ( Theory Online + Practical Examination )

400

2

Total Internal Marks

200

3

Total Marks( Total Internal Marks + Total Examination Marks ) 600

COURSE NAME

COURSE

CODE ELIGIBILITY FEES DURATION

PROFESSIONAL DIPLOMA IN INDUSTRIAL INSTRUMENTION AND FIRE & SAFTEY

PDIFS

SSLC And above

28000+ GST 480 Hrs.

COURSE DETAILS

ONLINE EXAMINATION NAME : PROFESSIONAL DIPLOMA IN INSTRUMENTATION AND FIRE AND SAFETY

ONLINE EXAMINATION CODE : PDIFS T001

SL SUBJECT SUB. CODE

NO. OF QUESTIONS

MARKS FOR EACH

QUESTION

MAXIMUM MARK

INTERNAL MARK

TOTAL MARK

1

Industrial Instrumentation

S001

50

2

100

50

150

2

Fire & Safety

S002

50

2

100

50

150

TOTAL 100 200 100 300

EXAMINATION MARK CRITERIA FOR PRACTICAL EXAMINATION

PROCEDURE RESULT/OUTPUT VIVA VOCE TOTAL MARKS

40 40 20 100

INTERNAL MARK CRITERIA FOR EACH SUBJECT

ATTENDANCE

GENERAL

PROJECTS/ASSIGNMENTS

TOTAL MARKS

PERFORMANCE

5 5 40 50

INTERNAL MARK CRITERIA FOR PRACTICAL EXAMINATION

ATTENDANCE

GENERAL

LAB

TOTAL MARKS

PERFORMANCE

RECORDS/ASSIGNMENTS

5 5 40 50

SUBJECT WISE EXAMINATION DETAILS

PROGRAM DETAILS

1. Application form

Application form and Prospectus can be had from the office of the respective

CCEK Sub Centre.

2. How to apply

Completed application along with pass port size photograph and two attested copies

of SSLC certificate should reach the CCEK sub Centres on or before the last date

prescribed.

3. Basis of Selection

Selection will be done on the basis of first come first serve basis. In the case of

reservation the selection will be based on the aggregate percentage of marks secured in

the SSLC Examination. (Each training centre will be treated as separate unit for

selection of candidates).

4. Medium of Instruction

The medium of instruction in all the theory and practical subjects shall be English &

Malayalam.

5. Expected Intake

Minimum 25 students per Institute (There will not be any maximum limit provided the

Implementing Agency should ensure that sufficient infrastructure is made available for

the effective conduct of the training to the students)

6. Examination Fee

There is no separate examination fee. It is included in the course fee.

7. Examination

The final Examination will be conducted by CCEK, immediately after the completion

of the course. There will be examination for theory and practical subjects as per the

notification of the Director, CCEK.

8. The mode of Examination

There will be theory online and practical examination. The Theory Online examination

will be multiple choice on-line examination. Before doing the Theory Online

Examination, the marks of practical and internal marks should be entered to on-line

portal. Then only the exam is available to conduct. After the submission of on-line

examination, the result will be automatically appeared.

9. Rules And Regulations For Examination And Promotion

a) Duration of the course is 12 month

b) The minimum qualification prescribed for admission is SSLC.

c) The examinations will be conducted by CCEK.

d) Minimum attendance required for a candidate to register for the examination is 70%.

e) Shortage of attendance up to 15% can be condoned in deserving cases on payment of

prescribed condensation fee of Rs.200/- on the recommendation of the course

coordinator of the respective centre. Condensation fee from the students will be

collected by the sub-centre concerned and forwarded to the Director, CCEK by DD

payable at Thiruvananthapuram in lump sum with the details of the candidates

registered for the examination.

f) A minimum of 35% marks in theory and practical is required to pass in each subject

g) There will be 5 classifications of passed candidates in the following grading system.

Total Mark >= 35 and <51% C

Total Mark >= 51 and <66% B

Total Mark >= 66 and < 81% B+

Total Mark >= 81 and <91% A

Total Mark >= 91% A+

h) The total marks obtained in theory and practical examinations and internal marks

shall be counted for the grading system.

i) There will be no revaluation for theory or practical examinations.

j) Any other details not specifically mentioned herein will be decided by The

Director, CCEK and decision will be final.

COURSE SYLLABUS

FOR

PROFESSIONAL DIPLOMA IN INDUSTRIAL INSTRUMENTAION AND

FIRE & SAFTEY (PDIFS)



SUBJECT – 1 ‘INDUSTRIAL INSTRUMENTATION’

SUBJECT – 1 “INDUSTRIAL INSTRUMENTATION

After Completing This Subject The Candidate Will Able To:

Carryout installation of instruments, instrument stands and support.

Ability to lay out, fabricate, installs and perform leak testing on instrument tubing and piping systems.

Make cut-outs on instrument panel and install

instruments under the supervision of

instrument technician.

Ability to read and interpret instrumentation

drawings documents and specifications

Select and use proper fasteners, gaskets, packing and O-rings.

Exhibit basic mechanical and mathematical skills

Demonstrate good safety practice especially electrical safety.

Test and calibrate different types of process control instruments.

Demonstrate basic programming abilities of PLC

and SCADA.

Read and interpret ladder logic diagrams

Estimated Hours: 165 hrs

SUBJECT TITLE INDUSTRIAL INSTRUMENTATION

TOTAL HOURS Subject Mark : 100 Internal Mark : 50

TOTAL MARKS 165 hours ( Theory Session + Lab Session )

MODULE 1 HAND TOOLS & POWER TOOLS

BASIC HAND TOOLS

Screw drivers

Spanner

Hammer

Hacksaw

Pliers

Chisel

Files

Hand Drills

Punches

Wood saw

Tube cutter

Tube bender

Tube bending tools

Pipe bender

POWER TOOLS

Drilling Machine

Cutting Machine

Welding

MODULE – 2 PRESSURE, TEMPERATURE, LEVEL & FLOW MEASUREMENTS

PRESSURE MEASUREMENT

What is pressure

Types of pressure

Units of pressure

Liquid & Gas pressure

Pascal's law

Boyel's law

Charles law

Methods of pressure measurements

Manometer

Mechanical sensors

Electric & Electronic pressure sensors

Pneumatic instruments

Pressure switches

TEMPERATURE MEASUREMENT

Heat & Temperature

Conduction, Convection, Radiation

Temperature scales

Temperature measuring devices

Liquid in glass thermometer

Bimetal thermometer

Filled System thermometer

Temperature switches

Thermocouple

RTD

Two wire, three wire & four wire methods

Thermo well

Thermistors

Pyrometers

LEVEL MEASUREMENT

Introduction

Continues level measurements

Point to point level measurements

Direct & Indirect level measurements

Visual level sensors

Float devices

Magnetic float level gauge

Pressure operated type sensors

Differential pressure methods

Dry leg & Wet leg

Level Compensation

Air bubbler purges system

Displacement type level sensors

Level troll calibration

Interface level measurement

Capacitance type

Ultrasonic type

Radar type

Conductivity type

Nuclear radiation type

FLOW MEASUREMENT

Properties of flow

Density, specific gravity, viscosity

Laminar flow & Turbulent flow

Bernoulli's theorem

Reynolds's Number

Units of flow

Flow measuring instrument

Volumetric flow meters and mass flow meters

Differential flow meter

Orifice plate

Differential pressure tapping options

Rota meter

Venturi tube, flow nozzle, Dahl tube, Annu bar

Positive displacement meter

Magnetic flow meter

Turbine flow meter

Vortex flow meter

Flow switches

PRESSURE,TEMPERATURE,LEVEL&FLOW MEASUREMENTS

LAB LAB PRESSURE,TEMPERATURE,LEVEL&FLOW MEASUREMENTS

PRESSURE

Mechanical pressure sensor

U-Tube Manometer

Bourdon Tube pressure gauge

Dead Weight tester

Calibration of a pressure gauge

Pressure Switch

Servicing of Pressure Regulator

Pressure Gauge Installation

Pressure Safety Valve

Pressure Scale

TEMPERATURE

Measure the temperature using mercury in glass thermometer

Calibration of filled system thermometer

Calibration of Bimetalic thermometer

RTD (Resistance Temperature Detector)

Thermocouple

Thermowell

LEVEL

Float level switch

Sight Glass

Conductivity type level switch

Capacitance type level sensor

Vibration type level sensor

FLOW

Familiarization of Orifice plate

Installation of Orifice plate

Flow measurement using Orifice plate

Flow measurement using rotameter

Familiarization of magnetic flow meter

MODULE 3 TRANSMITTER & CONTROL VALVE

PROCESS TRANSMITTERS

Types of signals

Pneumatic - Analog - Digital signal

Pneumatic transmitter

Electronic transmitter

Digital transmitter

CONTROL VALVE

Globe Valve

Gate Valve

Butterfly valve

Ball Valve

Needle Valve

Angle valve

Three way valve

Saunders valve

Pinch valve

Single seated & double seated valve

Control valve

Valve flow characteristics

Types of actuator

LAB

TRANSMITTER & CONTROL VALVE

TRANSMITTERS

Pneumatic transmitter

Electrical wiring connection for temperature and differential pressure transmitter

Temperature transmitter calibration

Calibration of differential pressure transmitter

Familiarization of HART Communicator

Familiarization of Manifold Valve

Transmitter Mounting

CONTROL VALVE

Familiarization of Control Valve

Control valve Overhauling

Control valve stroke checking

Familiarization of Solenoid valve

Operation of control valve using solenoid valve

MODULE 4 INSTRUMENT INSTALLATION AND ERECTION HARDWARE

TUBES AND TUBE FITTINGS

Difference between pipe and tube

Types of tubes

Different sizes of tubes

Design of tubing and tubing systems

Pressure testing of instrument tubing

Different types of tube fittings

ELECTRICAL HARDWARES

Cables

Cable tray

Junction box

Conduct

Cable glands

Terminal lugs

PNEUMATIC SUPPLY SYSTEMS

Compressor

Relays

Regulator

Instrument air

Service air

LAB INSTRUMENT INSTALLATION AND ERECTION HARDWARE

IDENTIFY TYPES OF TUBING AND DESCRIBE THEIR APPLICATION

Identify types of tube and tube fittings

Describe procedure used to select and install tubing systems

Measure, mark and cut tube

Bend tubing based on instructors template

Fabricate support for tubing systems

Select and terminate armored cable

Dress a cable with proper glanding

MODULE 5 INDUSTRIAL AUTOMATION

CONTROL ENGINEERING

Opened and closed loop

Analog and digital control devices

Pneumatic controllers

Proportional Controller

Proportional-plus-derivative controllers

Pneumatic Auxiliary Devices Pneumatic computing elements

Electric and Electronic Controllers, On-Off controller

Three-Mode Controller

Feed back Control

Feed forward controller

Ratio Control

Cascade Control

PROGRAMMABLE LOGIC CONTROLLERS

Principle of operation

PLC vs Other types of controllers

PLC vs Computer Control

PLC vs Personal computers

PLC vs Dedicated controllers

Advantage of using PLC

Ladder logic concepts

Devices, processors, programming devices

PLC architecture and programming

PLC architecture Organization

Replacing relays

Ladder diagram

Function blocks

Simulations

Verifications

Installation

SCADA

Introduction to SCADA systems

SCADA architecture

Communication protocols

Introduction to DCS

ABSTRIAL AUTOMATION

LAB INDUSTRIAL AUTOMATION

PLC

Realization of logic gates in ladder logic

Latching

Control of Motors

Interlocking

Bottling Plant

Temperature Control using PLC

SCADA

Familiarization of different symbols and its usage

Introduction to scripting

Develop a time delay programme in SCADA environment

PLC to SCADA communication

Historical trend

Real time trend

Alarms

MODULE - 6

ELECTRICAL INSTALLATIONS

IE rules

Installation plan

Load calculation

Selection of switch gears and principle of operation.

Circuit breakers

MCCBs

Switch

Fuse unit

MCB

ELCB

Wiring systems

Selection wire size

Calculation of length of wire

Light sources

Incandescent lamps

Fluorescent lamps

Compact fluorescent

lamps

Vapor lamps

LED Preparation of material list

Earthing of systems

Standard schematic drawing Symbols

Types of wiring systems

Electrical and electronic connectors

Cables

Type of Cable

Cable Glands

Cable termination

Tools used for termination,

Types of terminal blocks

Soldering and desoldering

Inverters & UPS

Principle of operation

Type of UPS

Characteristics

Cells and batteries

Primary Cells

Lead-acid batteries

Nickel-Cadmium battery

Lithium battery

Testing and commissioning of installation

Continuity test

Polarity test in single phase wiring

Insulation resistance

Earth resistance tests.

submission of completion test reports

Safety measures

Personal protection equipment

Safety symbols

Colour codes

LAB ELECTRICAL INSTALLATIONS

To study about IE Rules

Familiarize Methods of Wiring

One Lamp Controlled by One Switch wiring

Fluorescent Lamp wiring

Staircase Wiring

Two Lamp Controlled by Two Switch wiring

Godown Wiring

Residential House Wiring

Single Phase DB setting

Three Phase DB setting

Insulation Test using Megger

Earth leakage Test using Megger

Familiarize Types of cables

Fault finding of the Underground cable

Fixing the gland to the cable.


INSTRUMENTATION AND FIRE & SAFETY

SUBJECT – 2 FIRE & SAFETY

SUBJECT – 2 “FIRE & SAFETY”

After Completing This Subject The Candidate Will Able To:

Apply basic emergency incident management strategies

Define the basic concepts of fire as a chemical

reaction, the major phases the main factors

that influence fire spread and fire behaviour.

Identify the types of common fire department

apparatus equipment and safety equipment used for

fire fighting.

Define fire fighting’s strategy and tactics.

Describe the elements of fire fighter safety and survival.

Demonstrate knowledge in the spectrum of fire

prevention functions and their relationship to

fire suppression efforts.

Identify five different types of non-water based fire

suppression systems and how these systems

extinguish fire.

Explain the operation and application of portable

fire extinguishing system.

Estimated Hours: 150 hrs

SUBJECT TITLE

FIRE & SAFETY.

TOTAL MARKS Subject Mark : 100 Internal Mark : 50

TOTAL HOURS 150 hours ( Theory Session + Practical Session )

MODULE 1 FIRE & SFAETY.

BASIC PHYSICS AND CHEMISTRY RELATED TO FIRE

Definition of Matter and energy

Physical properties of matter like Density specific gravity, Relative density, Vapour density, Melting & Boiling point, flammable limits, latent heat

Effects of density on behaviour of gases,

Basics of oxidizing and reducing agents, Acids.

Flammable liquids- classification and types of tanks, Dust and

Explosion, Liquid and Gas Fires, LPG.

ANATOMY OF FIRE

Definition of Combustion

Elements of Combustion

Products of Combustion

Heat of reaction and calorific value

Flash point, Fire point, Ignition temperature and spontaneous combustion.

CLASSIFICATION OF FIRE & EXTINGUISHERS

Classification of Fire and types of extinguishers

Maintenance, method of operation.

Techniques of fire extinction-Smothering cooling and starvation.

Halon and its detrimental effect on environment.

Alternatives of Halon.

HOSE AND HOSE FITTINGS

Types of Suction and Delivery Hoses, Hose-reel, causes of decay

Care and Maintenance, Marking of Hose, Repair of hose, Standard tests of

Delivery Hoses

Definition and different groups of Hose Fittings.

Types and Construction of Suction; Monitors, Water-cum-foam Monitor, Nozzles &

branch holders, collecting head and suction hose

Fittings; frost valve, Deep lift suction fittings, Breechings, Adaptors and Blank

cap suction reduction piece, Hose Ramps, Care & Maintenance of Hose Fittings.

HYDRANT & FITTINGS

Introduction of Hydrant and Water supplies, Hydrant Gears and Equipment.

Marking, Testing, cares maintenance Operation.

FOAM & FOAM MAKING EQUIPMENT

Water as an extinguishant- it merits, demerits and modification.

Introduction to all types of foam concentrate, properties of foams and techniques of

extinguishment by foam, types of foams, Characteristics of good foam, foam making

Equipment- Mechanical.

High Expansion and Low Expansion Foam. Storage of foam Compound. Dry Chemical

Powder- Types and application. Carbon dioxide as extinguishant.

LADDERS

Introduction, Types of Ladders

Construction features of conventional Ladders

Operational use, Elementary Knowledge of T.T.L. & Snorkel (As per Bureau of I.S.).

BREATHING APPARATUS

Introduction of Types of B.A. Sets in use, Working principles

Care and maintenance of breathing apparatus

FIRST AID, RESUSCITATION

Definition of First-Aid

Qualities of first aider

Shock-Signs and Symptoms, Asphyxia-Signs and Symptoms

Wounds and Hemorrhage -Classification of injuries, Signs, Symptoms and management.

Burns, Scalds and frost Bits signs and symptoms and management.

Causes and types of fractures Sprain & Dislocation-Signs and symptoms

Snake Bite-Treatment.

AUTOMATIC FIRE DETECTION CUM ALARM SYSTEM

Introduction of Types of Detectors

Smoke, Heat, Flame/Gas Detectors

Operating principles, Control Panel.

HAZARD AND RISK

Causes, Identification, Evaluation & Control.

HAZOP, Sources for Information on Hazard Evaluation.

Risk and Risk Analysis.

ACCIDENT

Industrial Accidents

Classification of Accidents

Need for the Analysis of Accidents, Accidents Reports

Methods Adopted for Reducing Accidents, Investigation of Accidents

Safety Slogans, Safety Precautions adopted in the Plant.

SAFETY CONCEPT

Introduction to Safety Management Safety Policy, Safety Committee

Responsibility of Management, Safety Officers Duties & Responsibilities, Safety Targets,

Objectives, Standards, Practices and Performances.

FACTORIES ACT 1948 (AMENDED)

Health

Safety

Welfare

Lighting, Ventilation & Work related stress

Construction Industry

FIRE FIGHTING

Fixed Fire Fighting Installations

Introduction of Sprinkler System and their care and maintenance and

operational Procedure

Elementary requirements of Drenchers, Rising Mains, Hose Reels And Down-comer

Automatic Fire Alarms system.

PERSONAL PROTECTIVE EQUIPMENT

Need for Personal Protection Equipment, Selection, Use, Care & Maintenance

Respiratory and Non-respiratory Personal Protective Equipment.

Head Protection, Ear Protection, Face and Eye Protection, Hand Protection, Foot

Protection, Body Protection.

VARIOUS RESCUE TECHNIQUES

Rescue technique from lift, Sewer, Collapsed building, motor vehicle accident.

Working at Height, Confined Space: Safety precautions related to Scaffolds, Ladders,

Work at height including Roof Work, fall arrestors, Confined Space,

Work Permit System, Excavation.

MATERIAL HANDLING

Safety related to Mechanical and Manual Material Handling, Lifting Appliances, Transport

Earthmoving & Material Handling Equipment – Cranes, Forklift

Truck, Hoists, Conveyors.

HOUSE KEEPING AND WASTE DISPOSAL

Introduction of Good House Keeping & Maintenance, Introduction of Disposal of Waste Material.

Hazardous Chemicals

Safety in Engineering Industries.

LAB FIRE & SAFETY

Demonstration of :

Various acids.

Alkalis & Gases

Organic flammable liquids and commonly used industrial chemical-

Fire-fighting technique.

Drill I : Water CO2 Extinguisher Drill

Drill II :Chemical Foam Extinguishing

Drill VI : Dry Chemical Powder

Drill VII : ABC Extinguisher

Drill VIII : CO2 Extinguisher

Familiarization and demonstration of Hose and Hose fittings

Drill – I : Hose pick up Drill

Drill – II : Hose Running Drill with one hose

Demonstration and Familiarization of Extension Ladder

Introduction of parts of extension ladder

Rescue Operation from buildings.

Drill I : Pitching of ladder

Drill II : Climbing the ladder

Drill III : Use leg Lock

Drill IV : Ladder Drill with Fireman Lift

Techniques of CPR

One Sitter

Two Sitter

Three Sitter

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