INSTRUMENT FITTING / PROGRAMME OUTLINE

DURATION: 9 Months

Section 1 Core Modules

•GENERAL INDUSTRIAL SAFETY

1.Personal Safety •Personal protection: eyes, head, hands and feet. •Lifting Safety •Machine Safety

•Pinch Points •Everyday Safety

2. Power Tools Safety •Personal protection: goggles, etc. •Inspection of Cords and Plugs •Proper position for use

•Maintenance •Fire Safety •Fire Triangle •On the job fire hazards •Fire prevention •Use of Fire Extinguishers

•Compressed Gas Safety •Handling and storage •Protective equipment •Identification •Handling leaks •Appropriate use

•Guarding Equipment •Reasons for guarding •Procedure for removal •Specifications for guards •Chemical Safety

•Common hazardous chemicals •Personal safety •Dangerous combinations •Detergents and cleaning agents

•Dealing with spills •Environmental Safety Issues •Ground and Atmospheric Effluents •Pollution – leaks and noises

•Chemical and Product Spills •Housekeeping •First Aid •Who should render First Aid

•First Aid for: cuts, burns, electric shock, broken bones and fractures •Artificial Resuscitation

•APPLIED SCIENCE/MATHS

•Basic Principles of Physics •Density •Specific Gravity •Volume/Pressure/Temperature Relationship •States of Matter

•Effect of heat on solids and liquids •Physical Properties of Materials •Conductivity •Brittleness •Malleability •Ductility

•Identification of materials •Effects of dissimilar metals •Pressure Measurements

•Units of Measure Metric/SI and Conversions •Length •Area •Volume •Weight •Pressure •Temperature •Mensuration

•Addition, Subtraction, Multiplication and Division •Simple Equations and Problems •Powers and Indices •Graphs

•Revision of Arithmetic

•PLANT INSTALLATION DRAWING

•Orthographic Projections •Isometric Projections •Freehand Sketching •Interpreting Drawing Signs and Symbols

1. Reading Blue Prints 2. Interpreting Drawings and Blue Prints •P and I Drawings1. Reading and Interpreting P & ID's

•PRESSURE GAUGES

1.Types and Use of Gauges- Special Service Gauges

•Principles of Operation- Dampening- Uses of Gauges and Installations

3.Maintenance and Repair of Gauges

- Maintenance of Gauges- Repair of Gauges- Installation of Gauges- Calibration of Gauges

4.Sensors, Types, Use and Care- Use and Maintenance-Types- Identification

5. Installation of Gauges

6. Manometers, Use, Care and Application - Use and Maintenance- Types-Applications- Limitations

WORKSHOP PRACTICALS

•INSTRUMENT PIPE FITTING

•Classification of Tubing and Pipe up to ¾”

- Fittings for Tubing and Pipe: tees, ells cross, bends, reducers, strainers and valves

•Threading •Brazing and soldering •Applications for Pipe Materials •Use of materials for different services

•Copper, Stainless Steel, Brass, Mild Steel, Plastic and Aluminum •Reading Piping Schematics

•Tubing and Pipefitting Copper, Stainless Steel, PVC •Flaring, Tubing Threading Pipe •Pipe Laying Exercises

•Plant Installation •Installation of instruments and associated equipment •Control Room Installation

•Laying of Pipe and Tubing •Cabinet, Post, Pedestal and Overhead Mountings •Pressure and leak testing

•Storage and Handling of Instrumentation Equipment- Storage of tube and pipe, insulation, fragile and sensitive material.

•Handling of fragile, heavy and sensitive equipment •Storage and Handling of Mercury •Fasteners for Instrument Fitting jobs

WORKSHOP PRACTICALS

•IDENTIFY AND INSTALL COMPONENTS

•Controlling and Measuring Units •Controllers – Valves and accessories •Rotometers, Orifice Meters

•Controller/Recorders •Identify Flow Pressure, Level and Temperature Devices •Flow Devices •Temperature Devices

•Pressure Devices •Level Devices •Storage and Handling of Instrumentation Equipment •Storage of Valves and accessories

•Handling of Valves and accessories •Storage and handling of sensitive instruments

•Storage and handling of fragile equipment •Interpret Instrument Specifications

•Principles of Operation Flow, Temperature Level and Pressure Devices •Test and Calibration Equipment

•Conditions for Testing and Calibration •Test instruments in the field and Control Room

•Testing in the Workshop •Calibration Techniques •Instrument Specifications

WORKSHOP PRACTICALS

•PRINCIPLES OF HYDRAULICS AND PNEUMATICS

•High pressure Fluid Safety •Identifying Pneumatic and Hydraulic Signs and Symbols

•Pneumatic and Hydraulic Signs and symbols •Reading Simple Schematics •Building Simple Circuits

WORKSHOP PRACTICALS

•BASIC ELECTRONICS

•Safety Devices •Static Devices •Soldering Devices •Component Devices •Static Discharge Devices

•Capacitor Discharge Devices •Fuse Pullers •Identifying Electronics- Digital Symbols and Components

•Building Basic Circuits- Electrical Circuits- Analogue Circuits- Digital Circuits- Analogue Symbols and Components

•Testing and Measuring Components• Electrical Components• Digital Components• Analogue Components

•Analogue and Digital Electronics-Analogue: Diodes, Transistors, Thyristors, SCRs and Power Amplifiers

- Digital: Logic Gates, Flip-flops, Vibrators and IC's

•BASIC TELEMETERING

•Analogue •Transducers •Controllers •Recorders •Positioners •Digital Electronic Signals •Transducers •Controllers

•Recorders •Positioners •Compare Nos. 1 and 2 with pneumatic 3-15 psi Signaling

•BASIC PROCESS CONTROL

•Basic Process Control Theory •Cascade Control •Feed Back Control •Feed Forward Control

•Principles of Operation of Smart Vales, Valve Positioners, I/P Converters, Stepper Motors, Variable Speed Motor Driven Pumps.

WORKSHOP PRACTICALS

Section 2 Supplemental Modules

4 Weeks: BASIC ELECTRICITY AND SIGNALLING

•Electrical Safety •Principles of Electricity •Ohm's Law • Kirchoff's Law •Electrical Symbols and Components

•Types of electrical supply •Electrical Phases Types and Use •Electrical Conductors •Measuring Electrical Variables

•Basic Electrical Circuits •Resistive Circuits •Capacitive Circuits •Inductive Circuits

•Instrumentation of Electrical Conductors

•Instrumentation of Co-Axial Transmission and Twisted Pair 10-Base Network Cables• Grounding Methods

• The different types of ground e.g. Solid Earth

WORKSHOP PRACTICALS

4 Weeks: BENCHFITTING

•Tools – Cutting and Non-Cutting •Layout of Work Pieces •Use and Care of Tools •Measurements

WORKSHOP PRACTICALS

2 Weeks: WELDING GAS AND ARC

•Welding Safety •Theory of Gas Welding •Theory of Arc Welding

•Connecting and preparing Oxy Fuel Apparatus for Gas Welding

•Relating of Oxy Fuel for Gas Welding/Cutting

•Setting current for different electrodes

•Preparation of Work piece for Oxy Fuel and Arc Welding

WORKSHOP PRACTICALS

OSHA CONSTRUCTION SAFETY (30 hrs.)

1 Week: COMPUTER FUNDAMENTALS

•Basic Computer Outline •Microsoft Word •Microsoft Excel •Internet

1 Week: LIFE LONG LEARNING