lfR(I'-~Ril' lfR(I' Lab...

Sk II India .Ril' lfR(I'-~Ril' lfR(I'

Lab Specifications Welding

An initiative of Ministry of Skill Development & Entrepreneurship, Govt. of India and National Skill Development Corporation

LAB SPECIFICATIONS WELDING

Shri Narendra Modi Honourable Prime Minister

~f we have to promote the

development of our country

then our mission has to be

'skill development' and

'skilled India'. '

LAB SPECIFICAllONS WELDING

OVERVIEW

The lab standardization guidelines envisions to standardize the lab infrastructure for welding trades across sectors. The document intends to ensure industry linked training with state-of-art infrastructure.

IILAB SPECIFICATIONS WELDING

WELDING SECTOR 1. Description of Lab

2. List of Tools & Equipment Welding

3. 3D Representation of Welding Lab

4. Illustrative Architectural Layout of Lab

5. Illustrative Pricing of Tools & Equipment

6. Safety Instructions

LAB SPECIFICATIONS WELDING II

DESCRIPTION OF LAB

Lab Specifications for the Listed Sectors I Job Roles

1. Capital Goods Sector Skill Council

a GMAW

b SMAW (Level 2 &3) c Fitter Fabrication

2. Indian Iron & Steel Sector Skill Council a GTAW

b Plasma Cutter

3. Mining Sector Skill Council

a Mining Welder

4. Automotive Sector Skill Council

a Welding Technician Level 2 - 4

Proposed Batch Size

25

Machine - Man Ratio

1 :4 for Level 1-3 Job Roles 1:3 for Level4 Job Roles 1 :2 for GMAW International Models


LIST OF TOOLS &EQUIPMENT -WELDING

s. No.

Equipment Nama Qty MMAW/Minlng Walder L2-1..3

GMAW/ FCAW

GTAW WTLaval2· Laval3

WT· Laval4

Plama Cutter

Machines

1 Arc Welding Machines (Inverter Based Welding

Rectifiers Min 250 V) 5 5 2 2 3 3

2 Gas Cutting 2 2 2 2 1 1 2

3 Plasma Cutter, 3 Phase, Capacity Upto 15 mm MAX 1 1

4 Regulator for any Gas (CO/Argon/Helium/Nitrogen/Hydrogen) 4 2 4 4 2 2 4

5 Hand Grinders (AG 4) 5 5 5 5 2 2 2

6 Hand Grinders (AG 7) 5 5 5 5 2 2 2

7 Fume Extractors (1 Set for 7 Machines/Booths) 1 1 1 1 1 1 1

8 Electrode Driving Over Thermostatically Controlled Temperature 0-250 Celcius, 1 Okg CAP 2 2 2 2 1 1 1

9 Power Saw 1 1 1 1 1 1

10 Scrap Box (3 x 3 x 1.5) 2 2 2 2 2 2 2

11 Power Backup 125KVA (Diesel Generator) 1 1 1 1 1 1 1

12 Equipment for Destructive & Non Destructive Tests 1 1 1 1 1 1

13 Welding Simulator (Indicative) 1 1 1 1 1 1

Tools

14 Benchwise 8 8 8 8 8 8 15 Anvil 1 1 1 1 1 1

16 D.E. Grinder 30 em, Wheel Motorised Pedestal Type 1 1 1 1 1 1

17 Spindle Key (For Opening Cylinder Valve) 4 2 4 4 2 2 4

18 Tip Cleaner 4 2 4 4 2 2 4

19 Pipe Wrench 25 em and 35 em 4 4 4 4 4 4

20 Steel Tape 182 em Flexible in Case 10 10 10 10 10 10 10


LIST OF TOOLS & EQUIPMENT -WELDING

s. No.

Equipment Name Qty MMAWIMinlng WelderL2-1..3

GMAW/ FCAW

GTAW WT Leve12Level3

WTLevel4

Plasma Cutter

21 GTAW Machines with Water Cooling Unit 300 ampsAC/DC 5 5

22 GMAW /FCAW Complete Unit with Gas Stands and Trolley 300amps

5 5

Hand Tools

23 Number Punch (For Iron Use) 4 4 4 4 4 4 4

24 Chisel 6 6 6 6 6 6

25 File Set 6 6 6 6 6 6

26 Center Punch 6 6 6 6 6 6

27 Try Square 6 6 6 6 6 6 6

28 Scriber 6 6 6 6 6 6 6

29 Dot Punch 6 6 6 6 6 6

30 Hacksaw Frame 10 8 8 8 8 8

31 Flat Tongs 8 8 8 8 8 8 8

32 Steel Rule 10 10 10 10 10 10 10

33 Divider 6 6 6 6 6 6 6

Personal Protective Equipment

34 Hand Shield 15 15 15 15 15 15 15

35 Head Shield 10 10 10 10 10 10 10

36 Grinding Helmet 15 15 15 15 15 15 15

37 Leather Apron 25 25 25 25 25 25 25

38 Goggles 25 25 25 25 25 25 25

39 Leg Guard 25 25 25 25 25 25 25

40 Hand Guard 25 25 25 25 25 25 25


LIST OF TOOLS &EQUIPMENT -WELDING

s. No.

Equipment Name Qty MMAWIMinlng Welder L2-L3

GMAW/ FCAW

GTAW WT Leve12Level3

WTLevel4

Plasma Cutter

41 GTAW Welding Gloves 25 25 25 25

42 MMAWGioves 25 25 25 25 25 25 25

43 Safety Shoes 25 25 25 25 25 25 25

Supporting Infrastructure

44 Fitting Tables for Bench Vices Made of MS 4 x 4 x 2.5 4 4 4 4 4 4 2

45 Welding Booths with Size 6 X 4 8 5 5 3 5 5 3


3D REPRESENTATION OF WELDING LAB

List of Equipment

SMAW Machines

GTAW Machines

Fume Evacuation System

Trainee Job Display Units

Hand Tools

Scrap and Waste Disposal

Fire and Helmet Stands

GMAW Machines

Incubators

Fitting Tables

Tool Display Units

Work Benches

Raw Material Stands


ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB

17075

~~ 3000

' Student Entry Student Entry ~

~

;::~

g ~

'<-----

I Store 2400 X 3000 r

IL 8 ~

CLASSROOM 4500x6500

bQQ?QibQQI Qi lifQ;l~Qi bQQ?QibQQI bQQ?QibQbQ kQkQQikQkQ

4500

List of Items in the Above Figure

1. Gas Cylinder

2. Welding Machine

3. Welding Jig

4 Grinding Machine

5. Fitting Table with Bench Vice

and Tools Storage

~ ~ n n n

F~ & Extinguisher

RAW MATERIAL STORE

u Oven / Incubator

Grinder Scrap Box Machine DrillingDisplay I Pow~[] D

Dc=J Machin Hacksa

900 1()00 1' 900 r1' 10- Welding Booth1-WeldlngBooth ~·

0 ~rn WorkTable WorkTable

900 ,. 1000 900

0 ~ru ,~~CJ O ~J1 1'

2- Welding Booth 9- Welding BoothDemonstration Table

Work Table

, ~

3- Welding Booth

8- Welding Booth~ 4- Welding Booth 7- Welding Booth5- Welding Booth 6- Welding Booth

1900 12000

6. Raw Material Stand

7. Demonstrator Table

8. Classroom with 25 Capacity

9. Trainee Display Unit

10. Store Room

11. Scrap Box

12. Entry

13. Fire Exit

14. Oven /Incubator



Welding Booth

16 o. me aheel

40x40x5 mm oroa

35x35x5 mm argll b BB8B

TOP VIEW INSIDE VIEW TABLEVIEW

WELDING 80011-1 WELDING BOOlH WELDING 800 11-1

Fitting Table

151D, ' I

I • •

, 151D , ' ~~====~=========~==~~ .......... .........

' I] ' ' TOP VIEW SIDE VIEW

FmtNGTABLE FITTlNG TABLE



Helmets Stand & Fire Bucket

450

FRONT VIEW

40 x410 mm hollow eactton

18mm aq. bBI hookfcrhelm81

HELMETS STAND & ARE BUCKET

/

1500

g g

~ ~ ~ "' D

~ .

~ =

40 x 40 mm hollow 1118tltion = .... ~

SIDE VIEW

HELMETS STAND & ARE BUCKET

Raw Material Stand

401D

40 .w mm oollow 118C11onj' ,_X

!:!

SIDE VIEW

RAW MATERIAL STAND RAW MATERIAL STAND

FRONT VIEW


ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT

S.No. Equipment Name Qty UnH Price• (INR) Amount (INR) Brand•"

Machin•

1 Arc Welding Machines(Mmaw AC I DC) 300 amps 5 65,000 3,25,000 Ador Welding, ESAB,

Panasonic, Kempi, Riland, Rilan, Miller or Equivalent

2 Gas Cutting 2 3,500 7,000 Ador Welding, ESAB, Messer or Equivalent

3 Plasma Cutter 1 1,50,000 1,50,000 Ador Welding, ESAB, Messer or Equivalent

4 Regulator (2 Sets of Oxygen &Acetylene) 4 2,500 10,000 CE/BIS/ISI Marked and

Ador Welding, ESAB, Messer or Equivalent

5 Hand Grinders (AG 4) 5 3,500 35,000 Bosch, Dewalt or Equivalent

6 Hand Grinders (AG 7) 5 3,500 35,000 Bosch, Dewalt or Equivalent

7 Fume Extractors (1 set for 7 Machines I Booths) 1 2,00,000 2,00,000 Customised/Non Branded

8 Electrode Driving Over Thermostatically Controlled Temperature 0-250 C 1 Okg I CAP 2 25,000 50,000 CEIBIS/ISI Marked

9 Power Saw 1 15,000 15,000 Bosch, Dewalt or Equivalent

10 Scrap Box (3 x 3x 1.5) 2 7,500 15,000 Customised/Non Branded

11 Power Backup 125KVA (Diesel Generator) 1 3,25,000 3,25,000 Kirloskar or Equivalent

12 Equipment For Destructive & Non Destructive Tests 1 15,000 15,000 Non Branded

13 Welding Simulator (Indicative) 1 10,00,000 10,00,000

Tools

14 Bench Wise 8 3,500 28,000 Non Branded

15 Anvil 1 3,000 3,000 Non Branded

"Price is indicative for the majorbrands, similar tools/equipment may be used "*Brands are illustrative, other brands with same specifications may be used

IllLAB SPECIFICATIONS WELDING



16 D.E. Grinder 30 em, Wheel Motorised Pedestial Type 1 5,000 5,000 Non Branded

17 Spindle Key (For Opening Cylinder Valve) 4 1,500 6,000 Non Branded

18 Tip Cleaner 4 280 1,120 Non Branded

19 Pipe Wrench 25 em and 35 em 4 350 1,400 Non Branded

20 Steel Tape 182 em Flexible in Case 10 300 3,000 Non Branded

21 GTAW Machines with Water Cooling Unit 300amps AC/DC 5 1,50,000 7,50,000 Ador Welding, ESAB,


22 GMAW/FCAW Complete Unit with Gas Stands and Trolley 5 1,50,000 7,50,000 Ador Welding, ESAB,


Hand Tom.

23 Number Punch (For Iron Use) 4 200 800 Non Branded

24 Chisel 6 220 1,320 Non Branded

25 File Set 6 500 3,000 Non Branded

26 Center Punch 6 220 1,320 Non Branded

27 Try Square 6 300 1,800 Non Branded

28 Scriber 6 320 1,920 Non Branded

29 Dot Punch 6 300 1,800 Non Branded

30 Hacksaw Frame 10 500 5,000 Non Branded

31 Flat Tongs 7 300 2,100 Non Branded

32 Steel Rule 10 30 300 Non Branded

33 Divider 6 100 600 Non Branded

"Price is indicative for the majorbrands, similar tools/equipment may be used ..Brands are illustrative, other brands with same specifications may be used




Personal Protac:tlve Equipment

34 Hand Shield 15 300 4,500 Ador Welding, ESAB/ Welspring or Equivalent

35 Head Shield 10 650 6,500 Ador Welding, ESAB/ Welspring or Equivalent

36 Grinding Helmet 15 350 5,250 Ador Welding, ESAB/ Welspring or Equivalent

37 Leather Apron 25 300 7,500 Ador Welding, ESAB/ Welspring or Equivalent

38 Goggles 25 225 5,625 Ador Welding, ESAB/ Welspring or Equivalent

39 Leg Guard 25 220 5,500 Ador Welding, ESAB/ Welspring or Equivalent

40 Hand Guard 25 150 3,750 Ador Welding, ESAB/ Welspring or Equivalent

41 GTAW Welding Gloves 25 500 12,500 Ador Welding, ESAB/ Welspring or Equivalent

42 MMAWGioves 25 350 8,750 Ador Welding, ESAB/ Welspring or Equivalent

43 Safety Shoes 25 400 10,000 Ador Welding, ESAB/ Welspring or Equivalent

Supporting lnfrutrurctuN

44 Fitting Tables for Bench Vices Made of MS 4 x 4 x 2.5 4 8,000 32,000 Customised/Non Branded

45 Welding Booths with Size 6 x 4 6 20,000 1,20,000 Customised/Non Branded

Total 39,71,355

"Price is indicative for the majorbrands, similar tools/equipment may be used "*Brands are illustrative, other brands with same specifications may be used


SAFETY INSTRUCTIONS

Given below Safety Instruction posters should be placed at appropriate places in the lab. The posters should be digitally printed and pasted on sun board.

Welding Personal Protective Equipment

CI)~-Safety Glasses Safety Shoes Hearing Protection

cro@®Respirator Full Face Shield Gloves

@(j)(j) Welding Shirts/Arm Bands Harness Apron/Chaps

1fJ 1fJ Skill India Skill India

olml'l>m'ft·f'l"'lml""""-·f""'

Weld Geometry ASME 9 Welding Positions

~8 :::~ :=.:: . , ..~-"""'G ~::::"'!""~:--=,::....6G • Pipe lncl"** U" (60) Downwards

SG • P .... Wekled~Up )G • .._Waldedv..tka!Down lF• FIIIMw.ldv.rtlci!I Up

() ~ l ) IPipe Fixed Horizontal I


SAFETY INSTRUCTIONS

Basic Safety Rules for Welding I Fabrication:

Following safety rules should be followed:

1. Ensure that adjusting screws on regulators are released before opening valves

2. When opening a valve, stand on the opposite side ofthe regulator

3. The cylinder valve has to be opened slowly, releasing the oxygen initially. After the oxygen has been released, turn the valve by a quarter ofa tum to release acetylene

4. Set working pressure as prescribed fora specific welding process

5. Do notuse oxygen as a substitute for compressed air

6. Keep heat, flames and sparks away from combustibles


SAFETY INSTRUCTIONS

Electrical Hazards - Follow the Listed Precautions to Avoid Electric Shock

Welding generally uses low voltage, however, there is still a dangerofelectric shock

• Do not work in wet orcramped up work spaces

• Ensure no naked or loose wires are present in the lab

Electrical exposure can lead to falls, fractures and brain damage. Heavy shocks may also lead to death

Electrical Safety

• Use dry gloves

• Wear rubber soled shoes

• Use insulating layers

• Protectyourselffrom surfaces that conduct electricity

• When working on electrically powered machinery, make sure the frame is grounded

• Keep insulation on all welding equipment and components dry and in working condition

• Do not change electrodes with bare hands, wet gloves orwhile standing on wet or ungrounded surfaces


' We are a youthful nation.

Our youth is our

strength.The world and

India need a skilled

workforce and we are

committed to achieve this

mission.''

-Shri Rajiv Pratap Rudy Minister of State (1/C) for Skill Development & Entrepreneurship Govt. of India

-



~"GI'>ffi MINISTRY OF SKILL DEVELOPMENT

& ENTREPRENEURSHIP GOVERNMENT OF INDIA

Sk It India .R'I1!Ril·f'R'11!Ril

N S · D· C National Skill Development Corporation

Transforming the skill landscape

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