r

..

-~
'.

!1MP OF ~PREm.:;t~J?_~.~~.REGJ_QN)'

..

'

Ba~BAy

~,

Traininq
,
. . .-

ProQramme for M~echal1..:iG~.tF~e.rin~

'
.

ti

J,

The major
sugar

mills

are

------

functions

'a)

Maintenance

b)

Carry

c).

Procurement

of Mechanical

of the

machinery

out the preventive

of

spares

greases,

required

Manufacture

f)

Handling

of spares

Orientation

b)

Departmental

stores

c.

'..'

~.

.. 51 weeks.

training

be given

1 week.

'of orientation

information

the

training

on th~ history
.

and working

staff structure,

,....

available

to

employees

departments/sections

training

in each department

completion

of training

reasonable

degree'

the

of the work done,

the period

be taken
with the

for a specified

period.

is expected

on-the-job
On the
to acquire

as maint~nance'engineer.

should
information

maintain

acliary

collected, .

..

to keep a
study

made

of training.

.. .2
radha/1Oiv

testing

work done.

envisages

apprentice

and

round the

programme

of competency

Every apprentice

during

He will

etc.

and acquainted

Dep~rtmental

etc.

etc.

training

period

oils,

produGts,
bye-products
standing
orders,
capacity, Lsafety
precautions
,.rules
regarding
vessels,
chain pulley blocks etc.,
amenities

production
.
of pressure

training

effective

lubricating

,'.

record

for

into two parts.

of organisation,

programme.

in ~he workshop.

of material

a)

will

plants.

etc.

The programme is divided

apprentice.

in different

of cons~mables,like

fuels

e)

During the

in the

"

Procurement

Engineers

maintenance

maintenance.
d)

,ap~:9_~~

--

A.

Machine

...

Shoj2
.: .-,11:...

i)

",-

.""".."

20 weeks-

...
"- ....

.'

Study of ""the laydu't' of the machine shop,

diff~';~nt;

m~thine

'tools

such as lathes,

, drilling

shaping

milling,

machines

etc.,

installed

.\

in the

machine' shop.
ii)

Specification

of all

the machine

tools

and their

accessories.
iii)

Operation
tools,

and different

'functions

marldrig techniques

for machinihg.

used for

Differerit

cutting

v)

Different

ferrous/non-ferrous

vi)

;.t6bls

used

in the

machine

metals

shqp.

processed

in

shop.

Speeds/feeds,
being

heavy castings

iv)

. the machine

of the machine

limits,

adjusted

for

fits
different

and tolerances
jobs

etc.

as per the

drawing~.
\

...r

vii)'

vi;ii)

'

ix)

Coolants
Jigs

&

and lubric'ants
fixtures

Prevent~ve
machine

x)

in the

and routine

machine

Arc & gas welding

shop.

maintenance'

of ~11 the

tools,. used in the machine

electrodes
xi.)

used

used in the machine shop.

machines,

shop.

welding

techniques,

and patterns

of spares

used etc.

Preparation

of drawings

1"''''/'''

to be manufactured.
xii)

'"

xiii)

Schedule

of machine

castings

and rollers.

Safety

aspect

ventilation
xiv)

indicato~s
Study
blowers
xwi)
.~....

Causes

l6~ding

of heavy

relations',

in the machine

lighting,

shop.

& Q.C. use of instruments

micrometers,

xv)

'and industrial
etc.

Inspe~tion

loading;

verniers,
etc.

of various

comparators,

such as
dial

test

.
types

of pumps,

fans,

compressers,.

etc.
and prevention

of corrosion.

.. .3

3
..

xvii)

Costing
market

xviii)
xix)

of each job done ~ithrespect

-to

prices.

Stores & Puxchase system.

Working of the foundry equipments, materials
used, jobs done, metal~urgical

study and

testing.
B.

~o,il er

...24 weeks

,Hou s~~

f)
if)
iii)

Layout of steam generating/plant~

Number of boilers used, their types.
Specification
different

of each boiler,

mountings,

capacities,

gauges etc. fitted on

the boiler.
iv)

Constructional
and

v)

details

accessories,

gauges.

Preventive and routine maintenance of boilers,

feed pumps, blowers,

vi)

6f the boilers,

Different
consumption

pipe lines etc.

fuels u~ed, their

calorific

values

and

rate.

vii)

Different t~es

of heat recovery units used and

their details.
viii)
ix)

x)

Safety

devices

used.

Boiler Act & Rules and responsibilities

Study of the different

feed pumps,
'-

thereunder.

blowers

etc.

and th~ir maintenance.

xi)
xii)

Study of heat balance and thermal efficiency.

Bagas~~ conveying, handling, batching and
stocking.

xiii)
c.

Can,e-

Boiler

feed water treatment.

handlin"g~._9D.g__~a.D"_j).I'epa}?atJ.on.

.p,l.an.!--:..

. .

I week

,.\ ..

i)

.Constructional
equipments

.,

details

of 'the.machines/

inst-a'lied in the

C~:U1ehandling

plant.

4
.

ii)

Components vulnerable to breakages, their

materials and procurement/manufacture.

iii)

Study of driving systems, use of gears, pulleys,

.chains

etc.

Industrial

rules regarding

testing

of chain pulley blocks.

iv)

Routine

maihtenance

and greasing

v)

D.

Mill
.

Manual

lubrication

schedule.

Use of safety guards

vilPreparation
vii)

of the machines,

and other s~fety

aspects.

of index and its role in milling.

cane handling

system.

,House:
......

... 1 week
."
j)
.

"

i)
ii)

i1i)

Layout 0 f the mill house machinery.

Constructional details of the machines.
'Study of mechanical
inter carriers,

components

brackets,

and size of the grooves

iv)

such as rollers,

brasses

etc.,Depth

in the rollers.'

Fitting of each component and material'

specification.
v)

Types of equipments used for hydraulic

pressure.

vi)
vii)

Different

types, construction

spec ific

and gauges

turbines

used,

working .and

fitted on the engine -

rating, construction

Lubrication

and greasing

specification
x)

gear arrangements.etc~

at ion.

Instruments
their

ix)

mechanism,

Study of steam engines/steam

their

viii)

driving

and maintenance.
schedule,

their

and procurement.

Down time analysis

and preventive

maintenance

planning.

xi)

Maceration

method

of application

and

its

control.

. . .5

'

-'---,

.'.

'--xii)

"

,...Mills

settings..

Milling

xiii)

ef'ficiency

determinati~n

indicat,ions..~

and

their,

interpreta,!:iOI"L.for.technical

control.

"

Mill

xiv)

operation

contro.l

data

and norms,

mill:

sanitation.

'.',

xv) '. "Man

power/Labour
"-

-. ..

'-

'-

E. Juice
Classification"
,
T'
~
~ .'

i)

*,'-_'

SttJdyof

section:
.'-.-".,-

., .' ,iii)

.. .. ".

v.a.rious

const.ruction

ii}

strength..

used,

and components

Preventive

and rouiine

Lubrication

- iv}:. Differe~t

equipments

and

characteristics

their

etc..

schedule.

their

duty

conditions~

and maintenance~
1 Week.

F~ ., EV:ap..9~:r;ati~onPla.lLS-

i)
ii)
..

iii)
iv)

Principles
Heat

vapour

Construction
,equipment

..-

vi)'

'. ..

,,-'

v)

vii)

viii.),
'.

economy

and practice.,
sy~tems.

in use.

Study

off operaticzn

Removal-condensate

conditions..
and extraction

xii)
,xiii)
xiv)

systems.

extr.action.

Vaccurn. systems ,condense'rs

ga.ses.

knj ection'

water

systems.

.,'

xi)

'evapo'r.ations..

and design of evaporation

transfer.

spray

..

.. theory

Juice

Syrup'

effect

ix)- , Removal. of non condensable

xl

of multiple

transfer

,Steam

maintenance.

greqsing

pumps used,

1 wee k

Evaporation

Heat & material

,pe;rformancC'
I

rati.ng.

Entrainment

and its

Investigating

balance

and

preven~ion..

troubles~.

!esting.
.. 0,.6

&

,
.'

'"

6
.
.

xv)

Scaling

xvi)

and cleaning.

Operational

and preventive

mainte~ance.
\.

G.

P<!D tation"..
i)

Principles

,of pan

\
i

boiling.

Equipment - its design & construction.

ii)

Vaccum

. iii)
.

...' 1 week.

system.

Product storage at pan floor.

iv)

, v)

Feeding

system.

vi)

Boiling

scheme and products.

vii)

Steam

viii)

Pan operation

ix)

Operating
Material

x)
xi)
H.

and vapour

Cur~ng_~e~~19D~

machines,

v)
Sugar

:1.)

iii)
\

their drives

and sp~ed control.

and greasing

schemule.
)

cycles - Frequency

Constructional

diagrams.
...1

details

of conveyors

week.

and

used, and their working.

Preventive

and periodical

conveyors,

elevators.

Lubrication

iv)

used.

.and b~tI).9~..J~ction:

elevators
ii)

wee~..

and other spares.

Opetation

Drnmac

of the centrifugal

Lubrication
Screens

. . .

details

Drive mechanism

iv)

I.

spares.

Constructional

iii)

and their maintenance.

balance.

~~~~}~llipa~i9n-n~

ii)

cycle - start up - shut down.

conditions

Maintenance

i)

supply.

and greasing

maintenance

of

schedule.

utility services and ancillaries - water,

Electricit~,material
.

handling

system,

strength

charts, management systems and reports etc.

7

,...

J.

. ..

Stores, and O.C._._,._.,~,~_..='''--i)

ii)

Study of store
Storing

1 week.

organisation.

and up keep of materials

as per

classification.
iii)
iv)
v)
vi)

Purchase

procedure.

Material

inspection.

Indenting
Costing
prevailing

procedure

etc.

of maintenance
market

prices.

jobs

in relation

to the