.!1°MP OF~PREm.:;t~J?_~.~~.REGJ_QN)'
Ba~BAy (
~Traininq ProQramme for M~echal1..:iG~.tF~e.rin~ ,ap~:9£_~~, . . .- ' .
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The major functions of Mechanical Engineers in the
sugar mills are -
. ( (
'a)b)
Maintenance of the machinery in different plants.
Carry out the preventive maintenance programme. ,
c). Procurement of spares required for effective
maintenance. "
d) Procurement of cons~mables,like lubricating oils,
greases, fuels etc.
e)
f)
Manufacture of spares in ~he workshop.
Handling of material stores etc.
The programme is divided into two parts.
a)
b)
Orientation training
Departmental training
~. 1 week.
.. 51 weeks.
During the period 'of orientation training the
apprentice. will be given information on th~ history and working, . .. -
of organisation, staff structure, produGts, bye-products and. ,'. standing orders,
production capacity, Lsafety precautions ,.rules regarding testing. '..' ,....
of pressure vessels, chain pulley blocks etc., amenities
c.
available to employees etc. He will be taken round the
departments/sections and acquainted with the work done.
Dep~rtmental training programme envisages on-the-job
training in each department for a specified period. On the
completion of training the apprentice is expected to acquire
reasonable degree' of competency as maint~nance'engineer.
Every apprentice should maintain acliary to keep a
record of the work done, information collected, study made. ..
etc. during the period of training.
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A. Machine Shoj2 . .. 20 weeks-
ii)
iii)
iv)
v)
vi)
.: .-,11:... ",- .""".." .'
i) . Study of ""the laydu't' of the machine shop,
diff~';~nt; m~thine 'tools such as lathes, milling,. . ,
shaping drilling machines etc., installed in the,machine' shop.
Specification of all the machine tools and their
accessories.
Operation and different 'functions of the machine
tools, marldrig techniques used for heavy castings
for machinihg. l
Differerit cutting ;.t6bls used in the machine shqp.
Different ferrous/non-ferrous metals processed in
. the machine shop.
Speeds/feeds, limits, fits and tolerances etc.
being adjusted for different jobs as per the
drawing~.
\ vii)' Coolants and lubric'ants used in the machine shop.
vi;ii)
ix)
xi.)
xii)
xiii)
xiv)
xv)
xwi)
Jigs & fixtures used in the machine shop.
Prevent~ve and routine maintenance' of ~11 the
x)
machine tools,. used in the machine shop.
Arc & gas welding machines, welding techniques,
electrodes used etc.
Preparation of drawings and patterns of spares
to be manufactured.
Schedule of machine loading; l6~ding of heavy
castings and rollers.
Safety aspect 'and industrial relations', lighting,
ventilation etc. in the machine shop.
Inspe~tion & Q.C. use of instruments such as
micrometers, verniers, comparators, dial test
indicato~s etc. .
Study of various types of pumps, fans, compressers,.
blowers etc.
Causes and prevention of corrosion. .. .3
....
"-....
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xvii)
xviii)
xix)
B. ~o,il er ,Hou s~~
f)
if)
iii)
iv)
vi)
vii)
viii)
ix)
xi)
xii)
xiii)
~
3..
Costing of each job done ~ithrespect -to
market prices.
Stores & Puxchase system.
Working of the foundry equipments, materials
used, jobs done, metal~urgical study and
testing.
...24 weeks
Layout of steam generating/plant~
Number of boilers used, their types.
Specification of each boiler, capacities,
different mountings, gauges etc. fitted on
the boiler.
Constructional details 6f the boilers, accessories,
v)
and gauges.
Preventive and routine maintenance of boilers,
feed pumps, blowers, pipe lines etc.
Different fuels u~ed, their calorific values and
consumption rate.c
Different t~es of heat recovery units used and
their details.
Safety devices used.
Boiler Act & Rules and responsibilities thereunder.
x) Study of the different feed pumps, blowers etc.'-
and th~ir maintenance.
Study of heat balance and thermal efficiency.
Bagas~~ conveying, handling, batching and
stocking.
Boiler feed water treatment.
c. Can,e- handlin"g~._9D.g__~a.D"§_j).I'epa}?atJ.on. .p,l.an.!--:.. . . I week
.,
i),.\ ..
.Constructional details of 'the.machines/
equipments inst-a'lied in the C~:U1ehandling plant.
ii)
iii)
iv)
4.
Components vulnerable to breakages, their
materials and procurement/manufacture.
Study of driving systems, use of gears, pulleys,
.chains etc. Industrial rules regarding testing
of chain pulley blocks.
Routine maihtenance of the machines, lubrication
v)
and greasing schedule.
Use of safety guards and other s~fety aspects.
vilPreparation of index and its role in milling.
vii)
D. Mill ,House:. ......
i)
ii)
Manual cane handling system.
... 1 week
"
Layout 0f the mill house machinery.
Constructional details of the machines.
.".
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j)
i1i) 'Study of mechanical components such as rollers,
iv)
vi)
vii)
viii)
ix)
xi)
inter carriers, brackets, brasses etc.,Depth
and size of the grooves in the rollers.'
Fitting of each component and material' \
specification.
v) Types of equipments used for hydraulic
pressure.
Different driving mechanism, gear arrangements.etc~ )
Study of steam engines/steam turbines used,
their types, construction working .and
spec ific ation.
Instruments and gauges fitted on the engine -
their rating, construction and maintenance.
Lubrication and greasing schedule, their
x)
specification and procurement.
Down time analysis and preventive maintenance
planning.
Maceration method of application and its
control.
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" '--xii) ,...Mills settings..
xiii) Milling ef'ficiency indicat,ions..~ their,
"
xiv)
determinati~n and interpreta,!:iOI"L.for.technical
control.
Mill operation contro.l data and norms, mill:
'- sanitation.
-. ..xv) '. "Man power/Labour strength.."-
.',
'- '-
E. Juice Classification" section:, T' ~ *,'-_' ~ .'- -.-".,-~ .'
.. .. ". 1 wee k .i) SttJdyof v.a.rious equipments used, their
const.ruction and components etc..
ii} . Preventive and rouiine maintenance.
., .' ,iii) Lubrication and greqsing schedule.
- iv}:. Differe~t pumps used, their duty conditions~
characteristics and maintenance~
F~ ., EV:ap..9~:r;ati~onPla.lLS-
i)
ii)
1 Week.
Principles of multiple effect 'evapo'r.ations..
Heat transfer .. theory and practice.,
.. iii) ,Steam vapour economy sy~tems.
iv)
,,-' '. ..
..- v)vi)'
- vii)
Construction and design of evaporation
,equipment in use.
Juice transfer.
Study off operaticzn conditions..
Removal-condensate and extraction systems.
viii.), Syrup' extr.action.
ix)- , Removal. of non condensable ga.ses.
xl Vaccurn. systems ,condense'rs knj ection' water &
'.
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xi)
~ .. xii)
,xiii)
xiv)
spray systems.
Evaporation Heat & material balance and
,pe;rformancC' rati.ng.I
Entrainment and its preven~ion..
Investigating troubles~.
!esting.
.. 0,.6
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xv)
xvi)
6.
Scaling and cleaning.
Operational and preventive mainte~ance.
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G. P<!D §tation".. , ...' 1 week. \\i
i)
ii)
. iii)
. iv)
, v)
vi)
vii)
viii)
ix)
x)
xi)
Principles ,of pan boiling.
Equipment - its design & construction.
Vaccum system.
Product storage at pan floor.,
Feeding system.
Boiling scheme and products.
Steam and vapour supply.
Pan operation cycle - start up - shut down. JOperating conditions and their maintenance.
Material balance.
Maintenance spares.
H. ~~~~}~llipa~i9n-£n~ Cur~ng_~e~~19D~ . . . 1 wee~..
ii)
iii)
iv)
v)
i) Constructional details of the centrifugal
machines, their drives and sp~ed control.
Drive mechanism used.
Lubrication and greasing schemule.
Screens and other spares. )
Opetation cycles - Frequency diagrams.
I. Sugar Drnmac .and b~tI).9~..§J~ction: ...1 week.
ii)
iii)
iv)
:1.) Constructional details of conveyors and
elevators used, and their working.
Preventive and periodical maintenance of
conveyors, elevators.
Lubrication and greasing schedule.
utility services and ancillaries - water,
Electricit~,material handling system, strength
. charts, management systems and reports etc.
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J. Stores, and O.C._._,._.,~,~_..='''--- - ... 1 week.
i)
ii)
iii)
iv)
v)
vi)
Study of store organisation.
Storing and up keep of materials as per
classification.
Purchase procedure.
Material inspection.
Indenting procedure etc.
Costing of maintenance jobs in relation to the
prevailing market prices.