TECHNICAL TRAINING CENTRE DIESEL LOCO MODERNISATION … Booklet.pdf · TECHNICAL TRAINING CENTRE DIESEL LOCO MODERNISATION WORKS PATIALA Information pertaining to Technical Training

TECHNICAL TRAINING CENTRE DIESEL LOCO MODERNISATION WORKS

PATIALA Information pertaining to Technical Training Centre / DMW/ Patiala

(a) Basic details :-

Name of the Training Centre Technical Training Centre ( TTC )

Name of the Principal Sh. Sanjeev Garg

Address Dy CME / Planning Diesel Loco Modernisation Works, Patiala -147003

Phone No. 09779242001

Fax Number 0175-2397247

Email-ID [email protected]

Vision & Mission statements, if any ----

Classroom Timings Monday : 07 00 to 12 00 Hrs & 13 00 to 17 00 Hrs Tuesday to Friday : 07 00 to 12 00Hrs & : 13 00 to 16 30 Hrs Saturday : 07 00 to 12 00 Hrs

Hostel Facilities 28 bed Hostel

Classroom Facilities Classrooms are equipped with chairs, tables and white boards.

Messing Facilities Nil

(b) Details of Faculty – Gazetted and Non-gazetted: As per annexure ‘A’

(c) Calendar of training courses: As per annexure ‘B’

(d) News letter of the training centre: Nil

(e) Photographs of the training centres: As per annexure ‘C’

(f) Important activity undertaken by the training centre:

Machine maintenance course (Electronics & Hydraulics) started for

Supervisors and artisans of DMW and Zonal Railways.

(g) Study material, lecture notes, case studies, question bank etc, as per Annexure ‘D’.

ANNEXURE-A

S. No.

Name (S/Sh.) Designation Qualification Experience

1 Sanjeev Garg Dy CME/Planning BE / Elect. Engg. (Hons)

29 years experience in various fields

2 S. L. Sharma WM/IE ME in Mech. Engg. 29 years experience in various fields

3 G. P. Singh CWI DIP in Mech. Engg. 15 years in plant maintenance, 03 years in RITES, 2-1/2 years in incentive & M&P cell and 7-1/2 years in TTC.

4 N. R. Sharma SSE DIP in Elect. Engg. 17 years in production shops (Rebuilding and Manufacturing of ALCO Loco), 09 years in material planning & Inspection ,01year in TTC.

5 N. S. Sidhu SSE DIP in Mech. Engg. 19 years in Jig & Tool Drg. 04 years in Plant Drg & 01 year in TTC.

6 C. P. Shrivastva SSE DIP in Elect. Engg. 10 years in Quality Control, 04 years in Sale Deptt.,07years in production shop (Remanufacturing of AC & DC Machines for ALCO Loco) and 04 year in TTC.

7 S. K. Dogra SSE AMIE/Mech Engg. 14 years in production shops (Rebuilding and & Manufacturing of ALCO Loco), 02 years in planning and 08 years in TTC.

8 N. C. Singla SSE ME/Industrial Engg. 09 years in production, 07 years in PCO, 05 years in Incentive cell and 06 years in TTC.

9 Khushwant Singh SSE ITI, Intermediate. App. Mech.

02 years in installation,16 years in production 02 years as IMA (Tr. JE), 07 years in TTC.

ANNEXURE-B DIESEL LOCO MODERNISATION WORKS, PATIALA

An ISO 9001, ISO 14001 & IS 18001Certified Organisation

TRAINING CALENDAR 2015-16

Kindly send nomination for course no 19&20 in advance by E-mail: [email protected], [email protected]

S.No Course Description APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR

REFRESHER COURSES

Exclu

siv

ely

fo

r D

MW

Sta

ff

1. Supervisor Development Prog. 04-19 07-22 07-22

2. Machinist 20-24 01-05 20-24 21-25 05-09 14-18 04-08 06-10

3. General Fitter & Tool Maker 06-10 22-26 17-21 05-09 07-11 01-05

4. T M Fitter 25-29 22-26 17-21 21-25 02-05 01-05

5. Diesel Fitter 20-24 08-12 24-28 05-09 14-18 04-08 06-10

6. T & C Fitter 04-08 06-10 16-20 08-12

7. MW Mechanic 04-08 13-17 03-07

8. MW Electrical & Electrical Fitter 06-10 06-10 07-11

9. Crane Driver, Rigger & Driver Tech.

13-17 20-24 16-20

10. Painter 25-29

11. Carpenter 15-19

12. Welder 13-17 01-05 24-28 13-17

13. Telecommunication 07-11

14. RAC 13-17 12-16

SPECIAL COURSES

15. Industrial Safety 09 07 04 09 06 10 08 05 10 07 04 09

16. First-Aid 08 05 07 09 08

17. Fire – Fighting 16 14 11 16 13 24 15 19 17 14 11 16

18. CNC Machine Programming Course for DMW Artisan

25-29 06-10 03-07 02-06 11-15

19. CNC Machine Programming Course for Supervisors

Fo

r D

MW

&

Z-R

LY

16-2

1

04-09 20-25 05-10

20. CNC Machine Maintenance Course (Electronics & Hydraulics)

Sup 14-19 08-13

Artisan 16-21 23-28 17-22 03-08

04-09

ANNEXURE ‘C’

TECHNICAL TRAINING CENTRE, DMW, PATIALA

VIEW OF SEMINAR IN TECHNICAL TRAINING CENTRE

MACHINE SHOP ELECTRICAL LAB

CNC LATHE TRAINER

WORKING CUT MODELOF DIESEL LOCO HYDRAULIC TRAINER

VIRTUAL WELDER TRAINER

HYDRAULIC TRAINER

VIEW OF CLASS IN MECHATRONIC LAB

ANNEXURE ‘D’

COURSE CONTENTS FOR SPECIAL COURSES

01 SUPERVISOR DEVELOPMENT PROGRAMME:

INTRODUCTION

Introduction to the subject course, need & objectives,

Short view of the syllabus to be covered during this programme. FINANCE –1

Budget, its appropriation,

Stages of review,

Continuity of the process. FINANCE –2.

Role of audit,

control function expenditure,

What is audit, who is competent to audit, answerability to ability. PERSONNEL MANAGEMENT-1

Suspension, penalties, disciplinary authorities, applets authorities, reviewing authorities, serving of orders and notices.

DAR inquiries, procedures for imposing penalties.

Do’s and Don’ts for inquiry officers,

Do’s and Don’ts for presenting officer. PERSONNEL MANAGEMENT-II

Need for industrial relations.

Healthy workers participation and management relationship.

A capsule on Factory Act

Role of trade unions, constitution and election of office bearers, levels of functioning of trade unions, issues to be discussed with trade unions.

PERSONNEL MANAGEMENT-III

Personnel function (Scope & Organisation)

Selection (Process & methods), performance appraisal, wages & salary

Administration, selection of Employees, grievances, workers participation

PREM

A capsule on Workmen’s Compensation Act. PERSONS WITH DISABILITY ACT 1995

Rights and entitlements of persons with disability,

Sensitization towards disabled staff,

Creation of free environment for disabled persons,

Non discriminating environment for disabled persons. MANAGEMENT - 1

To manage resources like Men, Machines, Materials, Time & Capital.

To strive of optimum utilization thereof.

Planning, Organisation, staffing, controlling. MANAGEMENT – 2

Communication process,

Styles of speakers, Listening, barriers to communicate,

Communication channels. MANAGEMENT - 3

Priority of needs & motivation,, Marlow’s Hierarchy needs, factors, motivation.

Leadership styles, poor relationship & styles ( Personality, Develop Leadership, Action wise theories)

Defining and planning a project, implementation stages controlling, work in

progress, feedback ,project completion. MANAGEMENT – 4

Types of Decisions, Steps & aids in decision making, giving choice in decision.

Common problems (procrastination policy delegator)personal sense of time, identifying long term goals & plans, planning the day, time effectiveness in offices.

MANAGEMENT – 5

Stress management counseling,

Factors responsible for creating stress,

Life styling and attitudes to cope with stress, relaxation techniques.

MATERIAL MANAGEMENT /INVENTORY

Organisation and control,

Material planning and budgeting,

Codification and standardisation,

ABC analysis, sources, selection, and inventory of railways.

HEALTH AND NUTRIATION

Balance diet,

Medical Check up,

First-Aid Box,

Contribution of health of manpower in production

HEALTH EDUCATION & MEDICAL PSYCHOLOGY

Nutrition, Hygiene’s,

First-Aid and Medical check-ups,

Behaviour, Emotions & Stresses,

Attitudes , Learners habits, Personality,

Intellegenous and life cycle of family,

PREVENTION OF NON - COMMUNICABLE DIEASES & FAMILY PLG.

Aids, Obesity, Diabetes, Hypertension,

Coronary artery diseases and family Planning.

ROLLING STOCK PROGRAMME

Rolling stock programme,

M&P programme, works programme,

Preparation at preliminary and final stages.

DISASTER MANAGEMENT

Introduction of disaster management,

Main type of disasters,

Preparation for pre-disaster,

Action during disaster and after disaster,

Responsibilities of management and responsibility of supervisor. SAFETY

Safety precautions to be observed in workshop,

Legal observation,

Duties of Shop Incharge and responsibility of management as per Factory Act. VIGILANCE

Role of vigilance, a guide,

Listening precautions. CUSTOMER CARE

Customer care and Courtesy- importance of customer,

Concept customer friendly, courtesies which may be extended. FUTURE TRENDS

Emerging trends on Indian Railways.

What are the future plans on Indian Railways,

Production of 3100 HP Loco & 4000 HP GM Loco. GENERAL

Organisation of railways,

Various departments,

Inter departmental working and any day-to-day working of railways. ISO

Brief introduction to ISO,

Awareness of Quality Management System ISO 9001:2008, Environmental Management System ISO 14001:2004 and Occupational Health and Safety System (OHSAS 18001:2007) ,

Status of ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 in DMW

Quality, Environmental and Occupational Health and Safety Policy of DMW. FEED BACK:

Feed back of the course,

Shortcomings & suggestions to improve the course further.

Discussions on the queries of participants about the course.

02 FIRST AID:

Introduction & Principal of First Aid,

Handling & Transportation of Injured Person,

Respiration & Asphyxia,

Wounds & Bleeding,

Fracture & Dressing/Bandage,

Diarrhoea & Fever,

Management of an unconscious patient & Bites,

Burns & Poisoning,

AIDS,

Don’ts in First Aid,

Practical Demonstration of First Aid.

03 INDUSTRIAL SAFETIES:

Introduction to Industrial safety,

Use of personnel Equipments,

Requirement of industrial safety,

Right to safety and safety principles,

Various causes of accidents,

Prevention of accidents,

Various types of hazards,

Types of various kinds of accidents and their reporting,

Role of management, supervisors & workers on industrial safety,

Safety Committee Meeting and its functions,

Conducting of mock drills and any other.

04 FIRE FIGHTING:

Introduction,

Identification of unsafe condition for fire prevention,

Organizing for fire protection,

Control of emergencies,

Disaster control organization,

General organizational consideration.

05 CNC MACHINE PROGRAMMING:

Introduction to part program,

What is programming,

What the programmer has to do,

Preparatory (G) Functions as: ISO 646 (Fanuc sys & Sinumeric latest), Miscellaneous (M) Function as: ISO 646 (Fanuc sys & Sinumeric latest),

Common Codes & Addresses for Lathe/ Milling & Drilling Machines,

Procedure associated with part program,

Structure of part program in the tabulation with Example,

Co-ordinates System, Programming Modes,

Absolute & Incremental Modes,

Diameter and Radius Programming,

Program of Step Turning (Absolute),

Program of Step Turning (Incremental),

Step Turning & Threading, Taper Turning,

Step turning with Taper Turning,

Radius Clock Wise, Radius Center Clock Wise,

Parting Subroutine,

Milling Circular & Canned Cycle function,

Milling Rectangular & Canned Cycle function,

Letter Function A, Letter Function C,

Circular Angle Function, Mirror Function, Scaling Function,

Drilling with Repeat Function,

Pick drilling cycle.

6 CNC MACHINE MAINTENANCE:

Basic electronics,

Description of semiconductor devices,

Visit to electronics lab,

Block diagram of CNC,

Detail of PLC of a CNC machine,

Explanation of plc and CNC faults,

Shop floor visit for awareness of electronics circuits & practical implications of electronics circuits,

DC and AC drive of CNC control,

Different types of controls,

Feedback devices & troubleshooting of CNC machine,

Shop floor visit for awareness of electronics circuits & practical implications of electronics circuits.,

Features of different type of machines.,

Basics hydraulics, Machine maintenance.,

Practical on hydraulics in Mechatronics Lab,

Shop floor visit for awareness of hydraulic system,

Hydraulic maintenance.,

Hydraulic trouble shooting.,

Shop floor visit for awareness of hydraulic system.

REFRESHER COURSES 01 Machinist:

Introduction, Tool Materials & Tool Geometry, General purpose machines & special purpose

machines , CNC Part Programming, CNC Tooling and qualified tooling, CNC Machine advantages

and disadvantages, Machining operations, Engine Block & Con. Rod manufacturing process,

Capacity utilization, Carbon Brush Manufacturing Process, Cam Shaft Manufacturing Process, Gear

manufacturing and testing processes, ISO awareness, Disaster Management.

02 Diesel Fitter:

Introduction, Two Stroke & Four Stroke I.C. Engines, Turbo Super Charger, Construction details and

specifications of Diesel Electric Locomotive, Fuel Oil System & Fuel Injection Equipments, Air Brake

System, Lube Oil System & Water Cooling System, Under Frame Camber, Buffers & CBC Coupling,

Bogie Constructional Details, and Modifications carried out on Diesel Electric Locomotive. Practical

demonstration on simulator for assembly of Diesel components. ISO Awareness, Disaster

management.

03 Gen. Fitter:

Introduction Engineering Drawing, Limits, Fits and Tolerance, Hand Tools, Jigs & Fixtures, Fasteners,

Threads and Joints, Measuring Instruments, Destructive Testing & Non-destructive testing, Power

transmission, Bearings mounting & dis –mounting , Heat Treatment, Revision and clarification

session & feedback, ISO awareness , Disaster Management.

04 Welder:

Basic knowledge of Electricity, Various type of Electrodes, Gas Welding & Oxy Cutting Welding, MIG

& TIG Welding, Practical training on Virtual welder, Welding of Cast Iron & Stainless Steel, Welding

defects & its remedies, Submerged & Plasma Arc Welding, Health & Safety aspects in Welding, Arc

Welding principles D.C & A.C, Welding Plant & current requirement, Inspection& non-destructive test

of welding, Robotic welding techniques/ Automation of welding & its advantages, Heat Treatment

Process, ISO awareness, Disaster Management.

05 T&M Fitter:

Introduction to Electrical Engineering, Insulating materials used for rewinding of Traction Motors and

Traction Generators, Traction Machines, Commutator and its construction, Armature Winding &

Stator winding, Process of manufacturing of Stator & Armature coils, Process of rewinding of Traction

Motor and Traction Generator & Alternator, Testing facilities for TM , TG & Traction Alternator,

Common defects on D.C. Machines and their remedial measures, EMD TA Manufacturing & repairs,

Overhauling of AC Traction Motors (Siemens Make ), ISO awareness and disaster Management.

06 T & C Fitter:

Basic Electrical fundamentals. Electrical control components i.e. Relay, contactors, Switches etc.

Excitation Control System D.C. Machines overhauling and rewinding Safety devices and working.

Other features Microprocessor Control System M.C.B.G. Governor Comparison between WDM2,

WDM3A,WDM3D&WDG3A Locomotives Latest Electrical Modifications during Rebuilding of

Locomotives Load box testing of Locomotives ISO awareness & Disaster Management.

07 Crane Drivers:

Signals & Safety Rules, Construction features of Crane, Functioning of Electrical System, Daily

cleaning and lubricating schedule, Working of Crane, Working of Diesel Engine, Trouble shooting of

Diesel Engine, Preventive Maintenance of Cranes, Slings, Tackles, Wire Ropes and Knots, Safety

and First Aid, ISO Awareness & Disaster Management.

08 Rigger:

Use of Measuring tape and other simple Measuring instruments, Preparation before cutting a rope for

Splicing, Length of rope to be left for Splicing, Knowledge of tool used for Splicing, Splicing a wire rope

with or without Thimble, How to Splice a Cotton or Manila rope, How to remove slight kinks from wire

rope, Strength of wire ropes, Chain / manila ropes, Cotton ropes & Nylon ropes etc, Crane Signal,

Different Weight that can be lifted with Crane at corresponding angle of Jib, Crane breakdown & power

failure, Rigging Tackles, Preventive maintenance of Wire ropes, Chain Slings & Lifting Tackles, First

Aid, Fire Fighting & Safety at work, ISO Awareness and Disaster Management.

09 Driver Tech :

Knowledge about Road rules and Symbols, Knowledge of various parts of vehicles which are

important with respect to safety such as brakes, steering, gear and control etc, Working and

difference between two stroke and four stroke engines, Control and knowledge of speed, acceleration

and tyre pressure and driving on all types of roads, Knowledge about all types of dashboard meters

such as oil pressure, temperature, ampere meter, charging of battery etc, Working and difference

between Petrol Engine and Diesel Engine, Awareness about allowed and safe load. (Carrying

capacity of vehicle.) Knowledge of daily maintenance of Battery such as terminals cleaning,

electrolyte level and general safety, Knowledge about running maintenance such as oiling, brake

adjustment, ignition adjustment and oil level etc, Knowledge of driving of all vehicles such as car, fork

lifter, truck, bus etc and knowledge of their parts, Knowledge about starting, stopping & driving of

vehicle, should hold heavy duty driving license, Knowledge about lubrication. (Parts which are not

lubricated automatically), ISO Awareness & Disaster Management.

10 Carpenter:-

Introduction, Classification of Timber. Types of timber, Structure of a Timber tree, The specific uses

of different types of timber. Conversion and market forms of timber, Seasoning of wood. Common

defects in timber, Plywood and preservation of timber, Carpentry marking and measuring tools,

Carpentry cutting tools. Sharpening of wood working tools. Care and safety precautions during

working, Carpentry processes such as making, sawing, planning, boring, grooving etc. Safety in

carpentry shop, Types of wooden Joints & precautions while making joints, Auxiliary materials used in

wood making, Wood polishing materials as Paints, Varnish and Lacquers etc, Estimation of cost, ISO

awareness, Disaster Management.

11 Painter:

Knowledge of colours and paints such as primary and secondary colour, synthetic enamel, deco

paint, stowing paints etc, Knowledge of various types of putties, their preparation and specific use,

Knowledge of various types of thinners used in painting, their specific use and knowledge of other

solvents used in painting, Knowledge of methods for removal of old paints, Procedure for painting

interior and exterior surfaces. Uses of under coat and final coat, Knowledge of stencil cutting and

working, letter writing in English, Hindi and Colour-coding, Knowledge of various types of equipments

such as sanding disc, putty applying tool, putty cutting etc, Knowledge of various types to machines

and their maintenance used in painting such as cup gun, pressure feed, air less painting etc,

Knowledge of calculating the quality of paint required for specific use under standard conditions,

Knowledge of simple drawing used in painting and preparation according to the drawings, ISO

awareness, Disaster Management.

12 Electrical Fitter:

Basics of Electricity, Power factor improvement, causes of low power factor and losses of low power

factor, Indian Electricity Rules, Electrical Accidents, Earthing and safety, Maintenance of Electrical

sub station and transformers, Testing and Commissioning of Electrical installations, ISO awareness,

Disaster Management.

13 RAC:

Basics about Air Conditioning & Refrigeration and its definition, Comfort Air Conditioning for human

being, Refrigeration & Air Conditioning equipments used in DMW, WAC, Split AC, Refrigerator, Deep

freezer, cooling cabinet, Water cooler Panel AC’s central AC plant, Types of compressors used in Air

Conditioning / Refrigeration i.e. open type, semi-sealed, thematically sealed, Rotary, Introduction of

different parts of central AC Plant i.e. DX type, Chiller type, Latest developments in Refrigeration &

Air Conditioning, ISO awareness, Disaster Management.

14 Telecommunication:

Ohm’s Law, Series and Parallel connection of resistance, Basic Electricity, Maintenance of telephone

instrument, Maintenance of power plant, Maintenance of line plant, Knowledge of PA system

microphone, amplifier horn type and box type speaker, Basic knowledge of FAX machine operator

console, Type of telephone exchange there facilities and uses, General knowledge of walkie-talkie

set, VHF set etc, UHF & Microwave equipments, Cable jointing, General knowledge of fault finding of

under ground and overhead cables, Knowledge of OFC cable, General knowledge of PRS, ISO

awareness,.

15. M W Mechanical:

Features of different types of machines, Types of machine maintenance, Maintenance tools, Machine

Foundation and Leveling, Power Transmission mechanism, Automobiles, Lifting Tackles, Fluid Power &

Hydraulics (Training in Mechatronics Lab), Pneumatics (Training in Mechatronics Lab), Bearings, ISO

Awareness, Disaster Management.

16. M W Electrical:

Electricity and introduction to electronics Knowledge of relays, contactor and switches A.C.

fundamentals and electrical ckts. Transformer Study of D.C. Machine Study of A.C. Machine

Knowledge about different control components Measuring instruments Voltage stabilizer and D.C.

stepper motor Earthing and cable maintenance ISO awareness and disaster Management.

17. Tool Maker:

Hand tools used by Tool Maker. Limits, Fits & Tolerances Introduction to Measuring instruments.

Digital & conventional measuring instruments, Reading , calibration , handling and their uses etc.

Cutting tools their types, uses and materials. Surface finish , Lapping, honing , polishing and

scrapping Heat treatment and metallurgy Engineering drawing Jigs and fixtures Machine operations,

grinding operations and machine cutting tools Simple workshop calculations and their conversions

Various types of Fasteners, locking devices & their uses ISO Awareness Disaster Management