CURRICULUM

FOR THE TRADE OF

WELDER (GAS &ELECTRIC)

UNDER

APPRENTICESHIP TRAINING SCHEME

GOVERNMENT OF INDIA
MINISTRY OF SKILL DEVELOPMENT& ENTREPRENURESHIP
DIRECTORATE GENERAL OF TRAINING

1
 CONTENTS

Sl. No. Topics Page No.

1. Acknowledgement 3
2. Background 4
2. 1. Apprenticeship Training under Apprentice Act
1961
2. 2. Changes in Industrial Scenario
2. 3. Reformation

3. Rationale 5
4. Job roles: reference NCO 6-7
5. General Information 8
6. Course structure 9
Syllabus 10-24
7.1 Basic Training
7.1.1 Detail syllabus of Core Skill - Block-I (Engg. drawing
& W/ Cal. & Sc.)
7.1.2 Detail syllabus of Professional Skill & Professional
7. Knowledge - Block – I
7.1.3 Employability Skill
7.1.3.1 Syllabus of Employability skill - Block – I
7.2 Practical Training (On-Job Training)
7.2.1 Broad Skill Component to be covered during on-job
training- Block – I
Assessment Standard 25-27
8.1 Assessment Guideline
8.
8.2 Final assessment-All India trade Test (Summative
assessment)
9. Further Learning Pathways 28
10. Annexure-I – Tools & Equipment for Basic Training 29-32
11. Annexure-II – Tools & Equipment for On-Job Training 33
12. Annexure-III - Guidelines for Instructors & Paper setter 34

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 1. ACKNOWLEDGEMENT
The DGT sincerely express appreciation for the contribution of the Industry, State Directorate,
Trade Experts and all others who contributed in revising the curriculum. Special acknowledgement to
the following industries/organizations who have contributed valuable inputs in revising the curricula
through their expert members:

1. Larsen & Turbo, Mumbai.

2. TATA Steel, Jamshedpur
3. Sulzer India Pvt. Ltd., Pune
4. Kirloskar Brothers Limited (KBL), Pune

Special acknowledgement is extended by DGT to the following expert members who had
contributed immensely in this curriculum.

Co-ordinator for the course: Sh. NirmalyaNath., ADT

Sl. Name & Designation Organization Expert Group

No. Sh./Mr./Ms. Designation
1. K V Reddy, W/S In-Charge & LTIT – Mahape, Navi Mumbai Expert
Sr. Faculty

2. M. K. Verma, Sr. Manager SNTI, TATA Steel Ltd. Expert

3. B. C. Hara, Sr. Instructor SNTI, TATA Steel Ltd. Expert

4. M. Thamizharasan, JDT CSTARI, Kolkata Expert

5. N. Nath, ADT CSTARI, Kolkata Expert

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 2. BACKGROUND
2. 1. Apprenticeship Training Scheme under Apprentice Act 1961

The Apprentices Act, 1961 was enacted with the objective of regulating the programme of training of
apprentices in the industry by utilizing the facilities available therein for imparting on-the-job
training. The Act makes it obligatory for employers in specified industries to engage apprentices in
designated trades to impart Apprenticeship Training on the job in industry to school leavers and
person having National Trade Certificate(ITI pass-outs) issued by National Council for Vocational
Training (NCVT) to develop skilled manpower for the industry. There are four categories of
apprentices namely; trade apprentice, graduate, technician and technician (vocational)
apprentices.
Qualifications and period of apprenticeship training of trade apprentices vary from trade to trade.
The apprenticeship training for trade apprentices consists of basic training followed by practical
training. At the end of the training, the apprentices are required to appear in a trade test conducted by
NCVT and those successful in the trade tests are awarded the National Apprenticeship Certificate.

The period of apprenticeship training for graduate (engineers), technician (diploma holders and
technician (vocational) apprentices is one year. Certificates are awarded on completion of training by
the Department of Education, Ministry of Human Resource Development.

2. 2. Changes in Industrial Scenario

Recently we have seen huge changes in the Indian industry. The Indian Industry registered an
impressive growth during the last decade and half. The number of industries in India have increased
manifold in the last fifteen years especially in services and manufacturing sectors. It has been realized
that India would become a prosperous and a modern state by raising skill levels, including by
engaging a larger proportion of apprentices, will be critical to success; as will stronger collaboration
between industry and the trainees to ensure the supply of skilled workforce and drive development
through employment. Various initiatives to build up an adequate infrastructure for rapid
industrialization and improve the industrial scenario in India have been taken.

2. 3. Reformation
The Apprentices Act, 1961 has been amended and brought into effect from 22 nd December, 2014 to
make it more responsive to industry and youth. Key amendments are as given below:

 Prescription of number of apprentices to be engaged at establishment level instead of trade-

wise.
 Establishment can also engage apprentices in optional trades which are not designated, with
the discretion of entry level qualification and syllabus.
 Scope has been extended also to non-engineering occupations.
 Establishments have been permitted to outsource basic training in an institute of their choice.
 The burden of compliance on industry has been reduced significantly.

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 3. RATIONALE
[Need for Apprenticeship inWelder (Gas & Electric) trade]

Apprenticeship course in the trade of Welder (Gas & Electric) tradeis necessary due to
following reasons:
 This course is meant forthe candidates who aspire to become a professional welder.

1. It will enhance the ability to carry out surface preparation and welding at various positions e.g.
Flat, Horizontal, Vertical and Overhead.
2. It will help the trainees to learn Oxy-acetylene welding, cutting torch and use of high pressure
oxygen & acetylene cylinders/manifold with safety precautions.
3. It will enhance the ability to perform Gas welding on various objects, Brazing, Soldering of
different joints of MS sheets.
4. It will help the trainees to appreciate Welding Procedure Specification (WPS) and Procedure
Qualification Record (PQR) consequently enhances quality welding.
5. It will enhance the ability to select the welding process for a given application, understand
welding defects and their prevention.
6. It will enhance the ability to set up and basic maintenance of various welding machines.
7. It will enhance the ability to use of different types of welding Electrodes, fluxes, their baking
and drying.
8. It will enhance the ability to perform Shielded Metal Arc Welding, 1G/2G positions, groove/
fillet joints of MS parts in various positions.
9. It will enhance the ability to minimize distortion by weld sequence / heat input, Preheating &
Post heating of welds, Reclamation of worn-out parts and Hard facing etc.
10. It will help the trainees to practice Gas Metal Arc Welding, Gas Tungsten Arc Welding, Purging
techniques, Submerged Arc Welding, Resistance Spot and Seam Welding etc.
11. It will help the trainees to learn various methods of testing and inspection of welds and use of
weld gauges.

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 4. JOB ROLES: REFERENCE NCO

Brief description of Job roles:

Welder (Gas & Electric) while doing gas weldingfuses 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 (Gas & Electric) while doing Arc welding,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 (Gas & Electric) operates spot welding machine to joint metal sheet by resistance welding
method. Feeds metal sheets to be welded according to type of machine and welds them by pressing
paddle, or by automatic arrangements.

Welder (Gas & Electric) while doing 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.

Welder (Gas & Electric) while doing gas brazing, 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.

Welder (Gas & Electric)while doing Gas Tungsten Arc welding also known as Tungsten Inert
Gas (TIG) welding 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 Aluminiun metals.

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Welder (Gas & Electric)while doing Gas Metal Arc welding also known as MIG/MAG Welding,
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 preheater 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.

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
i) NCO-2004: 7212.10
ii) NCO-2004: 7212.20
iii) NCO-2004: 7212.40
iv) NCO-2004: 7212.50
v) NCO-2004: 7212.65

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 5. GENERAL INFORMATION

1. Name of the Trade : Welder (Gas & Electric)

2. N.C.O. NCO-2004 :7212.10, 7212.20, 7212.40, 7212.50,
7212.65.
3. Duration of Apprenticeship Training

(Basic Training + Practical Training) : 15 Months

3.1 For Freshers: -Duration of Basic Training: -
a) Block –I : 3 months
Total duration of Basic Training: 3 months
Duration of Practical Training (On -job Training): -
a) Block–I: 12 months
Total duration of Practical Training: 12 months
3.2 For ITI Passed: - Duration of Basic Training: - NIL
Duration of Practical Training (On -job Training): 12 months

4. Entry Qualification :Passed 8th Class Examination

5. Selection of Apprentices : The apprentices will be selected as per
Apprentices Actamended time to
time.
6. Rebate for ITI passed trainees : i) Three month in the trade of Welder

Note: Industry may impart training as per above time schedule, however this is not
fixed. The industry may adjust the duration of training considering the fact that all the
components under the syllabus must be covered. However the flexibility should be
given keeping in view that no safety aspect is compromised and duration of industry
training to be remain as 1 year.

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 6. COURSE STRUCTURE

Training duration details: -

Time 1-3 4-15

(in months)
Basic Training Block– I -----

Practical Training ---- Block – I

(On - job training)

Components of Training Duration of Training in Months

1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5
Basic Training Block - I
Practical Training Block - I

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 7. SYLLABUS
7.1 BASIC TRAINING(BLOCK – I)
DURATION: 03 MONTHS

GENERAL INFORMATION

1) Name of the Trade :Welder (Gas & Electric)

2) Hours of Instruction : 500 Hrs.
3) Batch size : 20
4) Power Norms : 16 KW for Workshop
5) Space Norms : 80 Sq.m.
6) Examination : The internal assessment will beheld on
completion of the eachBlock.
7) Instructor Qualification :

1.INSTRUCTORS’ QUALIFICATION : Degree in Mechanical / Metallurgy / Production

Engineering/Mechatronics with on year
experience in relevant field.
OR
Diploma in Mechanical and allied with two years
experience in relevant field.
OR
10 Class Pass + NTC/NAC in the Trade of
th

“Welder” With 3 years post qualification

experience in the relevant field.
2. DESIRABLE QUALIFICATION : Preference will be given to a candidate with CIC
(Craft Instructor Certificate) in Welder trade.

8) Tools, Equipments & Machinery required : - As per Annexure – I

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 7.1.1 DETAILSYLLABUS OF CORE SKILL

Block– I
Basic Training

Sl.No. Workshop Duration Engineering Duration

Calculation and (hrs.) Drawing (hrs.)
Science
1. Unit: Systems of unit- 20 Introduction to Engineering Drawing 30
FPS, CGS, MKS/SI unit, and Drawing Instruments :
unit of length, Mass and
time, Conversion of units - Conventions
- Viewing of engineering drawing
sheets.
- Method of Folding of printed
Drawing Sheet as per BIS SP:46-
2003
- Drawing board, T-Square,
Drafter (Drafting M/c), Set
Squares, Protractor, Drawing
Instrument Box (Compass,
Dividers, Scale, Diagonal Scales
etc.), Pencils of different Grades,
Drawing pins / Clips.

2. Basic Mathematics - Lines :

BODMAS rule
Fraction-Addition, - Definition, types and applications
Subtraction, in Drawing as per BIS SP:46-2003
multiplication and - Classification of lines (Hidden,
Division-Problem centre, construction, Extension,
solving, Decimal-
Dimension, Section)
Addition.
- Drawing lines of given length
Simple calculation (Straight, curved)
using Scientific - Drawing of parallel lines,
Calculator.
perpendicular line
- Methods of Division of line
segment

3. Conversion of Fraction Free hand drawing of

to Decimal and vice-
versa. - Lines, polygons, ellipse, etc.
- geometrical figures and blocks

11
 withdimension

Transferring measurement from the

given object to the free hand
sketches.

4. Percentage: Drawing of Geometrical Figures:

Introduction, Simple Definition, nomenclature and practice
calculation. of
Changing percentage
to fraction and decimal -Angle: Measurement and its
& vice-versa. types, method of bisecting.
- Triangle -different types
- Rectangle, Square, Rhombus,
Parallelogram.
- Circle and its elements.

5. Material Science : Sizes and Layout of Drawing Sheets

Definition, properties
(physical & - Selection of sizes
mechanical) and uses - Title Block, its position and
of Metal, Non-metal, content
Alloy &Insulator. - Item Reference on Drawing
Types of ferrous and Sheet (Item List)
Non-ferrous metals.
Difference between
Ferrous and Non-
Ferrous metals.
6. Mass, Weight and Method of presentation of
Density: Mass, Unit of Engineering Drawing
Mass, Weight,
difference between - Pictorial View
mass and weight. - Orthographic View
Density, unit of - Isometric view
density. Relation
between mass, weight
& density.
Simple problems
related to mass,
weight, and density.
7. Mensuration : - Drawing of Solid figures (Cube,
Area and perimeter of Cuboids, Cone) with
square, rectangle, dimensions.
parallelogram, triangle,

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 circle, semi circle,
Volume of solids –
cube, cuboid, cylinder
and Sphere.
Surface area of solids –
cube, cuboid, cylinder
and Sphere.

8. Elasticity: Free hand Drawing of Solid figures

Elastic & Plastic (Prism, Pyramid, Frustum of Cone
material. Stress & and Pyramid.) with dimensions.
strain and their units.
Young’s modules.
Ultimate stress and
breaking stress.
9. Heat & Temperature: Free Hand sketch of hand tools and
Heat and temperature, measuring tools used in respective
their units, difference trades.
between heat and
temperature, boiling
point, melting point,
Scale of temperature,
relation between
different scale of
temperature.
Thermometer,
pyrometer.
Transmission of heat,
conduction,
convection, radiation.
10. Basic Electricity: Projections:
Introduction and use of - Concept of axes plane and
Electricity. quadrant.
- Orthographic projections
AC, DC & their
- Method of first angle and third
comparisons.
angle projections (definition and
Current,
difference)
Voltage,Resistance&
- Symbol of 1st angle and 3rd angle
their units.
projection as per IS specification.
Power, Energy & their
units.
Insulator and
conductors & their
uses.

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 11. ----- Drawing of Orthographic projection
in 3rd angle.

7.1.2 DETAIL SYLLABUS OF PROFESSIONAL SKILLS & PROFESSIONAL

KNOWLEDGE
Block –I
Basic Training Institute Level Training: -
Week Practical Theory
no.
1. Induction training: General
- Familiarization with the Institute. - Importance of Welding in Industry
- Importance of trade Training - Safety precautions in Shielded
- Machinery used in the trade. Metal Arc Welding and Oxy-Acetylene
- Introduction to safety equipment and their Welding and Cutting.
use etc. - Introduction and definition of welding.
- Hack sawing, filing square to dimensions. - Arc and Gas Welding Equipments, tools
- Marking out on MS plate and punching. and accessories.
- Arc and Gas Welding terms and
definitions. Different process of metal
joining methods: Bolting, riveting,
soldering, brazing, seaming etc.
- Types of welding joints and its
applications.

2. Gas welding Practice Gas Welding

- Setting of oxy-acetylene welding - Types of oxy-acetylene flames and
equipment, Lighting and setting of flame. uses.
- Fusion run without and with fillerrod on - Acetylene gas properties and
M.S. sheet 2 mm thick in flat position. generating methods.
- Butt joint on MS sheet 2 mm thick in flat - Oxygen gas and its properties
Position
- Fillet “T” joint on MS sheet 2 mm thick in
flat position
3. Gas welding Practice Gas Welding
- Square Butt & Lap joint on M.S. sheet 2 mm - Oxygen and Dissolved Acetylene gas
thick by brazing cylinders and Color coding for different
- Silver brazing on copper tube to tube gas cylinders.
- Gas regulators, types and uses.
- Difference between gas welding blow
pipe and gas cutting blow pipe

4. Gas Cutting Practice Gas Welding

- Marking and straight line cutting of MS - Gas welding techniques. Rightward and
plate. 10 mm thick by gas. Leftward techniques.
- Beveling of MS plates 10 mm thick by gas - Manifold system

14
 cutting. - Gas welding filler rods, specifications
and sizes.
- Gas welding fluxes – types and
functions.
- Gas Brazing & Soldering : principles,
types fluxes & uses
- Gas welding defects, causes and
remedies
Oxy-Acetylene Cutting- Equipment
principle, parameters and application.

5. MMAW Practices MMAW

- Setting up of Arc welding machine & - Basic electricity applicable to arc
accessories and Striking an arc welding and related electrical terms &
- Straight line beads on M.S. plate 10 mm definitions.
thick in flat position. - Principle of arc welding.
- Weaved bead on M. S plate 10mm thick in - Arc welding power sources:
flat position. Transformer, Motor Generator set,
- Fillet “T” joint on M.S. Plate 10 mm thick in Rectifier and Inverter type welding
flat position. machines and its care & maintenance..
- Advantages and disadvantages of A.C.
and D.C. welding machines
6. - Straight line beads and multi layer practice MMAW
on M.S. Plate 10 mm thick in Horizontal - Welding positions as per EN & ASME:
position. flat, horizontal, vertical and over head
- Fillet “T” joint on M.S. plate 10 mm thick in position.
Horizontal position. - Welding symbols as per BIS & AWS.
- Straight line beads and multi layer practice - Arc length – types – effects of arc
on M.S. Plate 10 mm thick in Vertical length.
position. - Polarity: Types and applications.
- Weaved bead on M.S Plate 10mm in - Arc blow – causes and methods of
vertical position. controlling.
-Fillet “T” joint on M.S. plate 10 mm thick in
vertical position.

15
7. GMAW Practices MMAW
- Setting up of GMAW welding machine & - Electrode : types, functions of flux,
accessories and Striking an arc coating factor, sizes of electrode Coding
- Depositing straight line beads on M.S Plate. of electrode as per BIS, AWS,
- Fillet weld – “T” joint on M.S plate 10mm - Effects of moisture pick up.
thick in flat position by Dip transfer. - Storage and baking of electrodes.
- Fillet weld – “T” joint on M.S. sheet - Arc Welding defects, causes and
3mmthick in flat position by Dip transfer. Remedies.
- Safety precautions in Gas
Metal Arc Welding and Gas Tungsten
Arc welding.
- Introduction to GMAW -equipment –
accessories.
- Advantages of GMAW welding over
SMAW , limitations and applications
- Process variables of GMAW.
- Modes of metal transfer – dip or short
circuiting transfer spray transfer and
globular transfer and Pulsed metal
transfer.

8. GMAW Practices GMAW

- Fillet weld – “T” joint on M.S plate 10mm - Wire feed system – types – care and
thick in Horizontal position by Dip maintenance.
transfer. - Welding wires used in GMAW, standard
- Fillet weld – “T” joint on M.S. sheet 3mm diameter and codification as per AWS.
thick in Horizontal position by Dip transfer. - Types of shielding gases and gas
- Fillet weld – “T” joint on M.S plate 10mm mixtures used in GMAW and its
thick in verticalposition by Dip transfer. applications.
- Fillet weld – corner joint on M.S. sheet - Flux cored arc welding – description,
3mm thick in vertical position by Dip advantage, welding wires, coding as per
transfer. AWS.
- Fillet weld – “T” joint on M.S sheet 3mm - GMAW defects, causes and remedies
thick in over head position by Dip
transfer.
9. GTAW practices: GTAW
- Depositing bead on Aluminium sheet 2 mm - GTAW process -brief description
thick in flat position. Difference between AC and DC welding,
- Square butt joint on Aluminium sheet equipments,polarities and applications.
1.6mm thick in flat position. - Power sources for GTAW - AC & DC
- Tungsten electrodes –types & uses,
sizes and preparation
- GTAW Torches- types, parts and their
functions
10. GTAW practices: GTAW
- Fillet weld – “T” joint on Aluminium - GTAW filler rods and selection criteria

16
 sheet1.6 mm thick in flat position. - Edge preparation and fit up.
- Depositing bead on SS sheet 2 mm thick in - GTAW parameters for welding of
flat position. different thickness of metals
- Fillet weld – “T” joint on Stainless steel - Pulsed TIG welding - brief description,
sheet 1.6 mm thick in flat position. pulse parameters slope up and slope
down.
- Argon / Helium gas properties – uses.
- GTAW Defects causes and remedy.
11-12 Resistance welding practices: Other Processes
- MS sheets joining by Resistance Spot - Resistance welding process -types,
welding principles, power sources and welding
parameters, Applications and
limitations.
- Submerged arc welding process –
principles, equipment, advantages and
limitations
Metals & Properties
- Classification of steel.
- Welding of low, medium and high
carbon steel and alloy steels.
- Effects of alloying elements on steel
- Weldability of metals and importance
of pre heating, post heating
- Stainless steel: types- weld decay and
weldability.
- Aluminium and its alloys, properties
and weldability, Welding methods
- Arc cutting & gouging,
- Cast iron and its properties types.
- Welding methods of cast iron.

13 Testing practices Inspection

- Testing of weld joints by visual inspection . - Weld quality inspection, common
- Inspection of welds by using weld gauges. welding mistakes and appearance of
- Dye penetrant test, good and defective welds
- Magnetic particle test. - Weld gauges & its uses
- Nick- break test. - Types of Inspection methods
- Free bend test. - Classification of destructive and NDT
- Fillet fracture test. methods
- Welding codes and standards
- Welding Procedure Specification (WPS)
and Procedure Qualification Record
(PQR)

17
 7.1.3 EMPLOYABILITY SKILLS
GENERAL INFORMATION
1) Name of the subject : EMPLOYABILITY SKILLS

2) Applicability : ATS- Mandatory for fresher only

3) Hours of Instruction : 55Hrs.

4) Examination : The examination will be held at the end of

two years Training by NCVT.

5) Instructor Qualification :

i)MBA/BBA with two years experience or graduate in sociology/social

welfare/Economics with two years experience and trained in Employability skill
from DGET Institute.
And
Must have studied in English/Communication Skill and Basic Computer at 12th
/diploma level
OR
ii) Existing Social Study Instructor duly trained in Employability Skill from DGET
Institute.

18
 7.1.3.1 SYLLABUS OF EMPLOYABILITY SKILLS
Block – I
Basic Training

Topic Topic Duration

No. (in hours)

English Literacy 7
1. Reading
Reading and understanding simple sentences about self, work and environment

2. Writing
Construction of simple sentences Writing simple English

3. Speaking / Spoken English

Speaking with preparation on self, on family, on friends/ classmates, on know,
picture reading gain confidence through role-playing and discussions on current
happening job description, asking about someone's job habitual actions. Taking
messages, passing messages on and filling in message forms Greeting and
introductions office hospitality,Resumes or curriculum vita essential parts, letters of
application reference to previous communication.
I.T. Literacy 10
1. Basics of Computer
Introduction, Computer and its applications, Hardware and peripherals,
Switching on-Starting and shutting down of computer.
2. Word processing and Worksheet
Basic operating of Word Processing, Creating, opening and closing Documents, use
of shortcuts, Creating and Editing of Text, Formatting the Text, Insertion & creation
of Tables. Printing document.
Basics of Excel worksheet, understanding basic commands, creating simple
worksheets, understanding sample worksheets, use of simple formulas and functions,
Printing of simple excel sheets.
Use of External memory like pen drive, CD, DVD etc,
3. Computer Networking and INTERNET
Accessing the Internet using Web Browser, Downloading and Printing Web Pages,
Opening an email account and use of email. Social media sites and its implication.
Communication Skill 18
1 Introduction to Communication Skills
Communication and its importance
Principles of Effective communication
Types of communication - verbal, non verbal, written, email, talking on
phone.
Non verbal communication - components-Para-language
Body - language
Barriers to communication and dealing with barriers.
2 Listening Skills
Listening-hearing and listening, effective listening, barriers to effective listening

19
 guidelines for effective listening.

3 Motivational Training
Characteristics Essential to Achieving Success
The Power of Positive Attitude
Self awareness
Importance of Commitment
Ethics and Values
Ways to Motivate Oneself
Personal Goal setting and Employability Planning.
4 Facing Interviews
Manners, Etiquettes, Dress code for an interview
Do's & Don'ts for an interview
Entrepreneurship skill 8

1. Concept of Entrepreneurship
Entrepreneurship- Entrepreneurship - Enterprises:-Conceptual issue.
Source of business ideas, Entrepreneurial opportunities, The process of setting
up a business.
2. Institutions Support
Role of Various Schemes and Institutes for self-employment i.e. DIC, SIDA,
SISI, NSIC, SIDO, Idea for financing/ non financing support agencies to
familiarizes with the Policies /Programmes& procedure & the available
scheme.
Productivity
1. Productivity
Definition, Necessity.

2. Affecting Factors
Skills, Working Aids, Automation, Environment, Motivation
How improves or slows down.
3. Personal Finance Management
Banking processes, Handling ATM, KYC registration, safe cash handling,
Personal risk and Insurance.
Occupational Safety, Health & Environment Education 6
1 Safety & Health
Introduction to Occupational Safety and Health importance of safety and
health at workplace.
2 Occupational Hazards
Basic Hazards, Chemical Hazards, Vibro-acoustic Hazards, Mechanical Hazards,
Electrical Hazards, Thermal Hazards. Occupational health, Occupational hygienic,
Occupational Diseases/ Disorders & its prevention.
3 Accident & safety
Basic principles for protective equipment.
Accident Prevention techniques - control of accidents andsafety measures.
4 First Aid
Care of injured & Sick at the workplaces, First-Aid & Transportation of sick

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 person
Labour Welfare Legislation

1 Welfare Acts
Benefits guaranteed under various acts- Factories Act, Apprenticeship Act,
Employees State Insurance Act (ESI), Employees Provident Fund Act.
Quality Tools 6

1. Quality Consciousness :
Meaning of quality, Quality Characteristic
2. Quality Circles :
Definition, Advantage of small group activity, objectives of quality Circle, Roles and
function of Quality Circles in Organization, Operation of Quality circle. Approaches
to starting Quality Circles, Steps for continuation Quality Circles.
3. House Keeping :
Purpose of Housekeeping, Practice of good Housekeeping.
4. Quality Tools
Basic quality tools with a few examples

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 7.2 PRACTICAL TRAINING (ON-JOB TRAINING)

(BLOCK – I)

DURATION: 12 MONTHS

GENERAL INFORMATION

1) Name of the Trade :Welder (Gas & Electric)

2) Duration of On-Job Training : As per Apprenticeship Act amended time to
time.
3) Batch size :a) Apprentice selection as per Apprenticeship
guidelines.
b) Maximum 20 candidates in a group.
4) Examination : i) The internal assessment will be held on
completion of the block
ii) NCVT exam will be conducted at the end of
Apprenticeship Training
5) Instructor Qualification :

(A) : Essential (any one of the below)

(i) NTC/NAC with Three years Experience in relevant field with Craft Instructors
Training Certificate.
(ii) Diploma in Mechanical and allied with two years experience in relevant field.
(iii) Degree in Mechanical / Metallurgy / Production Engineering/Mechatronics with
oneYear experience in relevant field.
(B) Desirable qualification: for (ii) & (iii) Craft Instructors Training Certificate.

6) Infrastructure for On Job Training : - As per Annexure – II

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7.2.1 BROAD SKILL COMPONENT TO BE COVERED DURING ON- JOB
TRAINING

BLOCK – I (Duration- 12 months)

The candidate should be competent to execute following operation/ skills after completion of the
industrial training: -

1. Instructions in safety precautions on the shop floor and use of PPE.

2. Use of shop floor material handling equipments
3. Reading and interpreting of fabrication drawing & welding symbols. Interpret and apply
mechanical drawings of layout/assemblies and perform measurements
4. Cutting of sheet metal to size
5. Edge preparation & fitting practices as applicable to the welder trade and assembling
components using clamps, Jigs & Fixtures
6. Practice Oxy-acetylene welding & cutting (using Oxygen and acetylene cylinders/manifold
system)observing safety guidelines
7. Practice Oxy-acetylene gauging.
8. Preparation of surfaces for welding
9. Gas welding and brazing of different joints of MS sheets in Down hand, horizontal & vertical
positionsusing of different types of gas welding filler rods and flux
10. Braze welding of Cast iron in down held position (Optional)
11. Practice Silver alloy braze on similar and dissimilar metals.
12. Gas welding of pipe & tubes in different configuration
13. Significance of WPS and PQR, its variablesand Inspection Test Plan (ITP).
14. Identify Welding defects and their correction.
15. Baking and drying of welding electrodes
16. Groove and fillet joints of MS parts in down hand, horizontal, vertical and overhead
positions by SMAW
17. Groove joints of grey cast iron/stainless steel parts in down hand positions by SMAW
(optional)
18. Pipe joints in 1G & 2G positions by SMAW
19. Reclamation of worn-out parts by SMAW

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20. Hard facing practice by SMAW
21. Preheating, post heating of welds and Post weld heat treatment of welds
22. Plasma cutting
23. Fillet and groove joints of MS parts in down hand, horizontal, vertical and overhead
positions by GMAW
24. Fillet & groove joints by GMAW-Pulse and Flux Cored Arc Welding. (Optional)
25. Butt and Fillet joints of Aluminium and SS parts in down hand, horizontal and vertical
positions by GTAW.
26. Welding of SS by purging techniques
27. Select operating parameters for the submerged arc welding(SAW)&weld thick plates by
SAW
28. Welding of thin sheets by resistance spot and seam welding
29. Welding objects/assemblies according to drawing
30. Inspection and testing of welds and use of weld gauges
31. Testing of welds destructive and non destructive methods

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 8. ASSESSMENT STANDARD
8.1 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 to be given while assessing for
team work, avoidance/reduction of scrape/wastage and disposal of scarp/wastage
as per procedure, behavioral attitude and regularity in training.

The following marking pattern to be adopted while assessing:

a)Weightage in the range of 60-75% to be allotted during assessment under

following performance level:

For this grade, the candidate with occasional guidance and showing due regard for
safety procedures and practices, has produced work which demonstrates
attainment of an acceptable standard of craftsmanship.

In this work there is evidence of:

 Good skill levels in the use of hand tools, machine tools and workshop
equipment
 Many tolerances while undertaking different work are in line with those
demanded by the component/job.
 A fairly good level of neatness and consistency in the finish
 Occasional support in completing the project/job.

b)Weightage in the range of above75%- 90% to be allotted during assessment

under following performance level:

For this grade, the candidate, with little guidance and showing due regard for safety
procedures and practices, has produced work which demonstrates attainment of a
reasonable standard of craftsmanship.

In this work there is evidence of:

 Good skill levels in the use of hand tools, machine tools and workshop
equipment
 The majority of tolerances while undertaking different work are in line with
those demanded by the component/job.

25
 A good level of neatness and consistency in the finish
 Little support in completing the project/job

c)Weightage in the range of above 90% to be allotted during assessment under

following performance level:

For performance in this grade, the candidate, with minimal or no support in

organization and execution and with due regard for safety procedures and
practices, has produced work which demonstrates attainment of a high standard of
craftsmanship.

In this work there is evidence of:

 High skill levels in the use of hand tools, machine tools and workshop
equipment
 Tolerances while undertaking different work being substantially in line with
those demanded by the component/job.
 A high level of neatness and consistency in the finish.
 Minimal or no support in completing the project

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 8.2 FINAL ASSESSMENT- ALL INDIA TRADE TEST

(SUMMATIVE ASSESSMENT FOR ONE YEAR TRADE)

SUBJECTS Marks Sessional Full Pass Marks Duration of

Marks Marks Exam.

Practical 300 100 400 240 08 hrs.

Trade Theory 100 20 120 48 3 hrs.
Workshop Cal. & Sc. 50 10 60 24 3 hrs.
Engineering Drawing 50 20 70 28 4 hrs.
Employability Skill 50 50 17 2 hrs.
Grand Total 550 150 700 -

Note: - The candidate pass in each subject conducted under all India trade test.

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 9. FURTHER LEARNING PATHWAYS

 On successful completion of the course and 10th standard,trainees can opt

for CITS course.

Employment opportunities:

On successful completion of this course, the candidates may be gain fully

employed in the following industries:

 Structural Fabrication like bridges, Roof structures, Building &

construction.
 Automobile and allied industries
 Site construction activities for power stations, process industries and
mining.
 Service industries like road transportation and Railways.
 Ship building and repair
 Infrastructure and defense organizations
 In public sector industries (Central/State) and private industries in India &
abroad.
 Petrochemical industries.
 Self employment

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 ANNEXURE – I

TOOLS & EQUIPMENT FOR BASIC TRAINING

INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL KNOWLEDGE

TRADE:WELDER (GAS AND ELECTRIC)

LIST OF TOOLS & EQUIPMENTS FOR 20APPRENTICES
A: TRAINEES TOOL KIT:-

SI. No. Name of the items Quantity

1 Welding helmet fiber 20 nos.

2 Welding hand shield fiber 20 nos.

3 Chipping hammer with metal handle 250 Grams 20 nos.

4 Chisel cold flat 19 mm x 150 mm 20 nos.

5 Centre punch 9 mm x 127 mm 20 nos.

6 Dividers 200 mm 20 nos.

7 Stainless steel rule 300mm 20 nos.

8 Scriber 150 mm double point 20 nos.

9 Flat Tongs 350mm long 20 nos.

10 Hack saw frame fixed 300 mm 20 nos.

11 File half round bastard 300 mm 20 nos.

12 File flat 350 mm bastard 20 nos.

13 Hammer ball pane 1 kg with handle 20 nos.

14 Tip Cleaner 20 nos.

15 Try square 6” 20 nos.

29
B: INSTRUMENTS& GENERAL SHOP OUTFIT: -

SI. No. Name and Description of Tools Quantity

16 Spindle key 4 nos.
17 Screw Driver 300mm blade and 250 mm blade 1 each
18 Number punch 6 mm 2 set
19 Letter punch 6 mm 2 set
20 Magnifying glass 100 mm .dia 2 nos
21 Universal Weld measuring gauge 2 nos
22 Earth clamp 600A 6 nos
23 Spanner D.E. 6 mm to 32mm 2 sets
24 C-Clamps 10 cm and 15 cm 2 each
25 Hammer sledge double faced 4 kg 1 no.
26 S.S tape 5 meters flexible in case 1 no.
27 Electrode holder 600 amps 6 nos.
28 H.P. Welding torch with 5 nozzles 2 sets
29 Oxygen Gas Pressure regulator double stage 2 nos.
30 Acetylene Gas Pressure regulator double stage 2 nos.
31 CO2 Gas pressure regulator, with flow meter 2 set
32 Argon Gas pressure regulator with flow meter 2 set
33 Metal rack 182 cm x 152 cm x 45 cm 1 no.
34 First Aid box 1 no.
35 Steel lockers with 8 Pigeon holes 2 nos.
36 Steel almirah / cupboard 2 nos.
37 Black board and easel with stand 1 no.
38 Flash back arrester (torch mounted) 4 pairs
39 Flash back arrester (cylinder mounted) 4 pairs

General Installation

40 Welding Transformer with all accessories ( 400A, OCV 60–100 V, 60% 1 set
duty cycle)
41 Welding Transformer (or) Inverter based welding machine with all 1 set
accessories (300A , OCV 60 – 100 V, 60% duty cycle)
42 D.C Arc welding rectifiers set with all accessories (400 A. OCV 60 – 100 1 sets
V, 60% duty cycle )
43 GMAW welding machine 400A capacity with air cooled torch, Regulator, 1 set
Gas preheater, Gas hose and Standard accessories
44 AC/DC GTAW welding machine with water cooled torch 300 A, Argon 1 set
regulator, Gas hose, water circulating system and standard accessories.
45 Air Plasma cutting equipment with all accessories, capacity to cut 12 mm 01 set
clear cut
46 Air compressor suitable for above air plasma cutting system. 01 no
47 Auto Darkening Welding Helmet 2 nos.
48 Spot welding machine to 15 KVA with all accessories 01 set
49 Portable gas cutting machine capable of cutting Straight & Circular with 01 set
all accessories
50 Pedestal grinder fitted with coarse and medium grain size grinding 1 no.

30
 wheels dia. 300 mm
51 Bench grinder fitted with fine grain size silicon carbide green grinding
1 no.
wheel dia. 150 mm
52 AG 4 Grinder 2 Nos
53 Suitable gas welding table with fire bricks 2 Nos
54 Suitable Arc welding table with positioner 6 nos.
55 Trolley for cylinder (H.P. Unit) 2 nos.
56 Hand shearing machine capacity to cut 6 mm sheets and flats 1 no.
57 Power saw machine 14’’ 1 no.
58 Portable drilling machine (Cap. 6 mm) 1 no.
59 Oven, electrode drying 0 to 350°C, 10 kg capacity 1 no.
60 Work bench 340x120x75 cm with 4 bench vices of 150 mm jaw opening 4 sets
61 Oxy Acetylene Gas cutting blow pipe 2 sets
62 Oxygen, Acetylene Cylinders 2 each*
63 CO2 cylinder 2 Nos. *
64 Argon gas cylinder 2 Nos. *
65 Anvil 12 sq. inches working area with stand 1 No.
66 Swage block 1 No.
67 Die penetrant testing kit 1 set
68# Magnetic particle testing Kit 1 set
69 Fire extinguishers (foam type and CO2 type) 1 no.
70 Fire buckets with stand 4 nos.
71 Portable abrasive cut-off machine 1 no.
72 Suitable Gas cutting table 1 no.
73 Welding Simulators for SMAW/GTAW/GMAW 1 each (Optional)

NOTE:
1. * Optionally Gas cylinders can also be hired as and when required
2. No additional items are required to be provided for unit or batch working in the Second shift except the
items under trainee's tool kit and steel lockers.

Note: In case of basic training setup by the industry the tools, equipment and machinery
available in the industry may also be used for imparting basic training.

31
 INFRASTRUCTURE FOR WORKSHOP CALCULATION & SCIENCE AND
ENGINEERING DRAWING
TRADE: Welder (Gas & Electric)
LIST OF TOOLS& EQUIPMENTS FOR 20APPRENTICES

1) Space Norms : 45 Sq. m.(For Engineering Drawing)

2) Infrastructure:
A: TRAINEES TOOL KIT:-

Sl. Quantity
Name of the items
No. (indicative)
1. Draughtsman drawing instrument box 20 nos.

2. Set square celluloid 45⁰ (250 X 1.5 mm) 20 nos.

3. Set square celluloid 30⁰-60⁰ (250 X 1.5 mm) 20 nos.

4. Mini drafter 20 nos.

5. Drawing board (700mm x500 mm) IS: 1444 20 nos.

B: FURNITURE REQUIRED
Sl. Quantity
Name of the items
No. (indicative)
1 Drawing Board as required
2 Models : Solid & cut section as required
3 Drawing Table for trainees as required
4 Stool for trainees as required
5 Cupboard (big) 01 no.
6 White Board (size: 8ft. x 4ft.) 01 no.
7 Trainer’s Table 01 no.
8 Trainer’s Chair 01 no.

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 ANNEXURE – II

INFRASTRUCTURE FOR ON-JOB TRAINING

TRADE: Welder (Gas & Electric)

For Batch of 20APPRENTICES

Actual training will depend on the existing facilities available in the

establishments. However, the industry should ensure that the broad skills defined
against On-Job Training part (i.e. 12 months) are imparted. In case of any short fall
the concern industry may impart the training in cluster mode/ any other industry/
at ITI.

33
 ANNEXURE-III

GUIDELINES FOR INSTRUCTORS AND PAPER SETTERS

1.Due care to be taken for proper & inclusive delivery among the batch. Some of the
following some method of delivery may be adopted:

A) LECTURE
B) LESSON
C) DEMONSTRATION
D) PRACTICE
E) GROUP DISCUSSION
F) DISCUSSION WITH PEER GROUP
G) PROJECT WORK
H) INDUSTRIAL VISIT

2. Maximum utilization of latest form of training viz., audio visual aids, integration
of IT, etc. may be adopted.

3. The total hours to be devoted against each topic may be decided with due
diligence to safety & with prioritizing transfer of required skills.

34