ADVANCED WELDING TRAINING INSTITUTE

ICF, CHENNAI - 38.

TrainingCalendar

2020-2021

KNOWLEDGECENTREONWELDINGTECHNOLOGY

GET TRAINED GET CERTIFIED

ADVANCED WELDING TRAINING INSTITUTE

ICF, CHENNAI – 38.

General Information Name of the Principal M.E.Srinivasan

Mobile No. 9003141003

Phone No. 044-26147672

Fax No. 044-26281227

Email-ID ptc@icf.railnet.gov.in

Vision Innovate, Indigenize, Inculcate& Integrate

Mission Qualifying welders as per standards through quality training

Training Timings Monday to Friday: 08:00 to 12:00 Hrs& 12:30 to 17:00 Hrs Saturday : 08:00 to 13:00 Hrs

Hostel facilities ICF Subordinate Rest house for Supervisors & Apprentice Hostel for Artisan Trainees

Classroom Facilities Equipped with LCD projector,Smart Board& AC

Contact Numbers of faculty members of AWTI Name of Faculty Rly. Phone Mobile Number BSNL

T.S.Ravichandran 47211 9003149549 044-261 47211

S.Annadurai 47210 9003149500 044-261 47210

M.Selvamani 47210 9003149476 044-261 47210

D.Selvakumaran 47212 9003149538 044-26147212

P.Vijayakumar 47220 9003149387 044-261 47220

V.Gnanamoorthy 47222 9003149623 044-261 47222

Abdul Razaack(SSE-Hostel) - 9003149716 -

Apprentice Hostel 47757 - 044-261 47757

Subordinate Rest House 47756 - 044-261 47756

List of Holidays for the year 2020 Date Occasion Date Occasion Date Occasion

01-01-20 New Year’s Day 25-05-20 Ramzan 25-12-20 Christmas

15-01-20 Pongal 15-08-20 Independence Day 26-12-20

to 31-12-20

Factory Holidays

26-01-20 Republic Day 22-08-20 VinayagarChaturthi

14-04-20 Tamil New Year 02-10-20 Gandhi Jayanthi

01-05-20 May Day 14-11-20 Deepavali

About the training centre Established in the year 2010 as per Railway Board guidelines

Provided with state of the art training facilities

Offers welding training for processes like MMAW, GMAW, TIG, SAW &RSW

Caters to the welding training needs of Zonal Railways like SR, SCR, SWR,CR,WR in addition to ICF

Assists to prepare Welding Procedure Specification (WPS) for all types of joints.

Conducts welder certification programs as per ISO: 9606 / IS: 7310 / IS: 817

Provides training and consultancy for ISO:3834 & ISO:15085 certifications

Organizes welding seminars

SCHEDULE FORREGULAR TRAINING MODULES

MOD. No.

COURSE TITLE

DU

RA

TIO

N

Cap

acit

y

YEAR 2020 YEAR 2021

Co

urs

e In

Ch

arge

Ap

ril

May

Jun

e

July

Au

gust

Sep

tem

be

r

Oct

ob

er

No

vem

be

r

De

cem

ber

Jan

uar

y

Feb

ruar

y

Mar

ch

TM010 BASIC COURSE FOR BEGINNERS& ICF PQ 4 wk 20 06 11 15 20 24 28 27 23 -- 04 01 08 MSM

TM020 REFRESHER COURSE FOR WELDERS 3 wk 20 04 13 21 16 18 01 NHS

TM030 TIG WELDING FOR ARTISANS 1 wk 10 20 22 24 19 14 15 SA

EM040 WELDING COURSE FOR SUPERVISORS, INSPECTORS AND CMT STAFF

3 wk 20 22 23 TSR

TM080 STAINLESS STEEL WELDING FOR WELDERS

1 wk 20 18 27 28 02 18 22 PVK

EM090 STAINLESS STEEL WELDING FOR SUPERVISORS

1 wk 30 16 18 06 15 10 25 DSK

TM110 SHORT REFRESHER COURSE FOR WELDERS

1 wk 20 27 01 03 12 07 22 NHS

EM150 COST REDUCTION METHODS IN FABRICATION

3D 30 06 19 18 17 KCS

TM240 TROUBLE SHOOTING OF MIG / MAG WELDING PLANT

3D 15 16 03 SA

EM340 WELDING COURSE FOR DESIGN & PLG. ENGINEERS

3D 30 03 09 STR

EM350 SELECTION OF WELDING CONSUMABLES 3D 30 08 20 KCS

EM370 HEAT TREATMENT OPEARTIONS BEFORE AND AFTER WELDING.

3D 30 25 RN

EM380 WELDING POWER SOURCES AND ITS SELECTION

3D 30

16 KCS

EM400 AWARENESS ON ISO: 17024 & PERSONNEL CERTIFICATION PRACTICES

2D 30 15 02 MSM

EM410 WELD MEASUREMENT & USAGE OF GAUGES

3D 30 13 26 10 TSR

EM420 TRAINING ON ADVANCED WELDING PROCESSES (CMT, ROBOTIC & LASER WELDING)

2D 30 22 22 21 06

PVK

EM430 TRAINING PROGRAM ON QUALITY MANAGEMENT

3D 30 08 07 07 08 AG

SPECIAL TRAINING COURSES

TM160 WELDER QUALIFICATION AS PER ISO: 9606 (WORKSHOPS AND ZONAL RLYS)

2D Programme to be finalized in consultation with PTC/AWTI/ICF (Eligibility: Welders should have qualified in IS 7310 standard)

STR

EM180 PROGRAMME ON WELDING STANDARDS ISO:3834 & EN:15085

3D 30 09 MSH

EM190 NON- DESTRUCTIVE TESTING OF WELDS FOR CMT STAFF AS PER ISO-3834 & EN-15085 REQUIREMENTS

3D 20

01 07 VGM

EM290 WPS PREPARATION AS PER ISO: 3834 REQUIREMENTS

3D 15 02 17 SA

EM360 COURSE ON VISUAL INSPECTION AS PER ISO : 3834 REQUIREMENTS

1 wk 30 15 16 12 28 09 10 MSH

EM900 WELDING COORDINATORS FOR RAILWAY APPLICATIONS

8D 15

21 08 DSK

OTHER PROGRAMS OFFERED AGAINST SPECIFIC DEMAND FROM THE CUSTOMERS

MOD. No.

COURSE TITLE DURATION CAPACITY Course

incharge

EM050 WELDING COURSE FOR NEW RECRUIT JEs & SSEs [As per Rly Bd:MRT-10 for STCs / Zonal Rlys]

1 Week 30 KCS

TM130 TRAINING PROGRAMME FOR ASSEMBLY FITTERS 3 Days 30 MSH

VM200 WELDER QUALIFICATION FOR VENDORS AS PER ISO:9606 1 Day 12 MSH

TM300 SELF INSPECTION COURSE FOR WELDERS 1Day 10 KCS

TM320 OXY-FUEL GAS CUTTING AND PLASMA CUTTING PROCESSES 1 Week 10 NHS

TM330 TRAINING ON GMAW WELDING PROCESS 1 Week 10 NHS

COURSE CONTENTS

Mod. No. Course Title Target Audience Topics Covered

TM010

Basic Course in welding for Beginners

New recruits / Technicians from other trades redeployed as welders

Introduction to different welding processes. Weld defects causes and remedies. Introduction to Oxy-acetylene gas cutting. Practical in MMAW. Test for IS: 817 standard. (About 30 Hours Theory & 100 Hours of Practical)

TM020 On the Job Continuous Improvement Training(RefresherCourse)

Welders who have completed Basic Welding course (TM010)/ welders of all grades.

Principles and techniques of welding (MMAW, GMAW & SAW). FCAW with CO2 gas shielding. Weld defects causes and remedies. Distortion and its control. Different positions welding in GMAW. Introduction to ISO 9606 standards. (About 25 Hours Theory & 75 Hours of Practical)

TM030 TIG Welding for artisans

Welders who have completed TM010 or TM020 or welding technicians with 2 yrs experience.

Introduction to TIG welding process. TIG welding accessories, consumables and techniques. TIG Welding defects causes and remedies. Practical training on TIG welding.Introduction to ISO: 9606 / IS:7310 testing standards. (About 8 Hours Theory & 28 Hours of Practical)

TM080 Stainless Steel Welding for Welders

Welders who have completed Basic Welding course / welders of all grades

Introduction to stainless steel welding techniques. Defects causes and remedies. Distortion control. Practical in MMAW, FCAW & MIG welding for stainless steel. Introduction to ISO 9606 / IS 7310 testing standards. (About 8 Hours Theory & 28 Hours of Practical)

TM110 Refresher course for welders

Welders of all Grades with minimum 2 years of experience.

Principles of CS & SSWelding (MMAW, GMAW, FCAW & TIG). Weld Joint Preparation. Weld defects causes and Remedies. Distortion Control. Critical Weld Joints in ICF coaches. Introduction to ISO 9606 / IS 7310 testing standards. (About 8 Hours Theory & 28 Hours of Practical)

TM130 Training Program for Assembly Fitters.

All fitters involved in fabrication of details & assemblies including millwright& tool room

Weld Joints &symbols. Edge preparation. Effects of assembly deviation. Acceptance criteria for gap, mismatch and other fitment deviations. Assembly techniques and tack welding method for Stainless Steel. Understanding of ICF, RCF & LHB drawings.(About 12 Hours Theory & 6 Hours Practical)

TM160 Certification for welders as perISO 9606-1

IS: 7318/IS: 7310 qualified welders with 2yrs experience

Introduction to ISO 9606-1 and its need in the present scenario. Explaining welders about the evaluation procedure followed by test.(2 hours briefing followed by practice and test)

TM240

Troubleshooting of MIG / MAG welding plants

Welders of IR having minimum 2yrs of experience or who have completed TM020 module.

Setting up MIG welding plant & wire feeder. Understanding recommended parameters for welding. Good maintenance practices in welding plant and wire feeder. Usage of different shielding gases. Trouble shooting in MIG torch. (About 6 Hours Theory & 12 Hours of Practical)

TM300 Self-inspection course for welders

Welders of all grades

Points to be checked before, during & after welding. Types of defects and their identification. Corrective and preventive actions to be followed. (About 6 Hours Theory & 12 Hours of Practical)

TM320

Oxy-fuel gas cutting and plasma cutting process

Welders, fitters and helpers

Introduction to oxy-gas cutting principles. Plasma cutting of stainless steel. Safety precautions to be followed. (About 8 Hours Theory & 28 Hours of Practical)

TM330

Training on MIG welding Welders who have completed Basic Welding course

Introduction to MIG welding process. MIG power source, accessories, consumables and techniques. MIG Welding defects causes and remedies. Practical training on MIG

/welders of all grades.

welding. (About 8 Hours Theory & 28 Hours of Practical)

EM040

Training for welding supervisors, Welding inspectors and CMT staff in service

Supervisors, Inspectors and CMT staff.

Introduction to various welding processes. Welding metallurgy. Inspection and testing of welding. Welding defects causes and remedies. WPS & PQR preparation as per ISO: 15609, ISO: 15614 & ISO: 9606 requirements. EN 15085 & ISO 3834 standards, Welding economics. Objective Test

COURSE CONTENTS

Module No.

Course Title Target Audience Topics Covered

EM050

Training for Newly Recruited Supervisors in Welding and NDT

Apprentice JEs and SSEs (Direct recruits from RRB and promotees).

Introduction to welding processes and metallurgy. Introduction to SS welding. Inspection and testing of welding. Welding defects causes and remedies. Introduction to Oxy- acetylene gas cutting and plasma cutting.Resistance welding, LASER welding, Introduction to ISO 3834standards.Objective type Test.

EM090 Stainless Steel Welding Course for Supervisors

The supervisors engaged in fabrication / repair of coach and wagon using Stainless Steel welding-

Introduction to SS welding. Application of TIG, MIG, Pulse MIG. Dissimilar metal welding. Welding defects causes and remedies. Welding codes and practices. WPS&PQR preparation as per ASME Section IX. EN 287, EN 15085 & ISO 3834 standards. Distortion control. Post weld surface treatment for SS. Welding practice. Objective Test.

EM150

Cost reduction methods in fabrication for JEs & SSEs

All SSE, JE, & CMT staff of Indian Railways including Design staff.

Productivity improvement, automation and robotics, Time study methods, Lean Manufacturing, 5S principles, 6 sigma & 7 QC tools as applicable to fabrication. Welding economics. Welder qualification, WPS &PQR, welding repairs and re-works and awareness of ISO 3834 & EN 15085 standards. Objective Test.

EM180

Awareness program on welding standards ISO3834&EN15085.

All SSE, JE, & CMT staff of ICF including Design staff.

Introduction to EN 15085 & ISO 3834, its significance in the present design. Introduction to stress category, safety category, weld performance class, quality levels for imperfections, inspection class and testing and their relationship. Design requirements as per EN 15085 PART-3. Recommendation for joint preparation as per ISO 9692. WPS & PQR as per ISO 15614. Welder qualification as per ISO-9606.

EM190

Non- destructive tests of welds for CMT staff as per ISO-3834 & EN-15085requirements

CMT staff of ICF and other workshops & zonal railways

Introduction to EN 15085 & ISO 3834, and their significance. Introduction to NDT techniques like VT, DPT, MPT, UT & RT. Practical demonstrations. Practical usage of gauges for weld measurements.Acceptance criteria as per ISO 5817.

EM290

Welding procedure specification as per ISO 3834 requirements.

Supervisors of Mechanical & CMT department of Indian Railways

Process Parameters and their influence on weld quality, Importance of Procedure qualification, Preparation and Evaluation of test coupons, Preparation of WPS, Welders Performance Qualification Record and its purpose, Referring International standards for welding. ISO- 15614

EM340

Welding course for design & planning engineers.

Design and planning engineers of Production Units, Workshops, Zonal Railways of IR.

Introduction to various welding processes. Design of weld joints. Design requirement as per EN 15085, welding symbols as per ISO- 2553. Weld defects, causes and remedies. WPS as per ISO 15609. Pre and Post weld heat treatments. Failure analysis. Cost saving ideas for design engineers. Checklist for prototype inspection including usage of gauges and other instruments.

EM350

Selection of welding consumables

All SSE, JE, & CMT staff of Indian Railways including Design staff.

Introduction to weldability of materials. Selection & classification of consumables for MMAW, GMAW & TIG welding. Classification of fluxes & wire flux combinations for SAW. Shielding gas selection & economics. Inspection of

electrodes as per various standards.

EM360

Certification course on Visual inspection as per ISO 3834 requirements

Inspection and Production Personnel of Indian Railways engaged for rolling stock fabrication & maintenance.

Introduction to ISO 3834 & EN 15085 standards. Visual inspection as per ISO 17637. Welding defects causes and remedies. Material grouping as per ISO/TR 15608. WPS preparation as per ISO 15609. Welder qualification as per ISO 9606. Practical usage of gauges for weld measurements. Acceptance criteria as per ISO 5817. Examination (both theory and practical) (About 16 Hours Theory & 8 Hours of Practical)

COURSE CONTENTS

Module No.

Course Title Target Audience Topics Covered

EM370

Heat treatment operations before and after welding

All SSE, JE, & CMT staff of Indian Railways including Design staff.

Basics of heat treatment, thermal stresses and distortion due to welding, Preheating, Post weld heat treatment, temperature calculations.

EM380

Welding Power source and its selection

SSEs & JEs of ICF and other Railway workshops

Types of power sources, Thyrister, MOSFET & IGBT controlled, elementary level trouble shooting

EM400

Awareness on ISO : 17024 & personnel certification practices

SSEs & JEs of ICF and other Railway workshops(Trainers)

Awareness on ISO: 17024 standard. Good practices to be adopted in personnel certification like management of impartiality, confidentiality, security, assessment, examination & decision on certification

EM410 Weld measurement & usage of gauges

SSEs & JEs of ICF & other Railway workshops

Weld dimensions like Leg Size, Throat Size, etc. Welding defects measurement procedures. Usage of measuring instruments like Cam gauge, Universal gauge, Vernier caliper, depth gauge etc.

(About 16 Hours Theory & 8 Hours of Practical)

EM420

Training on advanced welding processes (CMT, robotic & laser welding)

Supervisors of IR working in welding related activities

Introduction to Advanced Welding Processes, Working principles and machine layout. Shop visit to demonstrate working of machines. (About 8 hours Theory & 8 Hours of machine working demo)

EM430 Training program on quality management

SSEs & JEs of ICF & other Railway workshops

Inspection and testing procedures in shell & furnishing. Quality Assurance Plan (QAP). Quality Deficiency Cost (QDC). Work test certificates (WTC). Rejection & replacement procedures. Role of Inspection agencies (RITES, RDSO, TUV, etc). Customer complaint analysis

EM900 Welding coordinators for railway applications

All SSEs and JEs with prior work experience in welding area

Various welding processes, materials, welding metallurgy, DT & NDT, ISO: 3834 requirements, Welder qualification, welding procedure specification, role of welding coordinator.

VM200 Welder certification programs as per ISO:9606

Welders from vendors of ICF/ other Railways having sufficient experience.

Introduction to ISO 9606-1 and its need in the present scenario. Explaining welders about the evaluation procedure followed by test. (2 hrs briefing followed by practice and test)

FACULTY PROFILE

NAME OF FACULTY QUALIFICATION PROFESSIONAL QUALIFICATION IN WELDING

T.S.Ravichandran (TSR) M.Sc, AMIE. IWE, CWI

S.Annadurai (SA) M.Tech. IWT,CWI,SNT-TC-IALevel II (UT,RT) ,ISO: 9712 Level-II(VT)

M.Selvamani (MSM) AMIE, MBA IWT, CWI, ISO: 9712 Level-II(VT)

D. Selvakumaran (DSK) BE IWT,CWI,SNT-TC-IALevel II (VT,MPT,DPT)

M. Sreehari (MSH) AMIE, ME, MBA IWT, SNT-TC-IA Level II (VT,MPT,DPT),ISO: 9712 Level-II (VT)

P.Vijayakumar(PVK) AMIE. IWT, SNT-TC-IA Level-II(VT), ISO: 9712 Level-II(VT)

S.TirupatiRao(STR) AMIE IWT, ISO: 9712 Level-II(VT)

N.HariharaSwaminathan(NHS) AMIE, BBA, PGDCA IWS, SNT-TC-IA Level II (VT), ISO9712 Level-II (VT),CWI

V.Gnanamurthy (VGM) M.Sc., AIIM. SNT-TC-IALevel II (VT,MPT,UT,RT,DPT), ISO: 9712 Level-II (VT,MPT,DPT)

A. Ganesh (AG) B.Tech., MS SNT-TC-IA Level II (VT,MPT,UT,RT,DPT),ISO: 9712 Level-II (VT,UT)

R.Niranjan(RN) B.E ISO: 9712 Level-II (MPT,DPT), SNT-TC-IALevel II (UT)

G.Sugumar(GS) DME Workshop practical trainer

PHOTO GALLERY

Welding Workshop of AWTI Cold Metal transfer (CMT) Welding

Ultrasonic testing of weld samples Tensile testing of weld samples in UTM

Presentation of 3 technical papers by AWTI faculties at International Conference- 2020 held in Mumbai

National Best Women Welder Award – 2019 received by AWTI trainees in two categories

Smart Class room Weld Samples Cut sections

Route map to AWTI

How to Reach

By train: From Chennai Central- Catch suburban train towards AVADI direction and alight at Loco Works /VillivakkamRailwaystation then by walk /Auto rickshaw

By Bus :Bus No.20,20A,20B,20C &120 from Chennai Central & 22B,27D&27K from Chennai Egmore Bus Stop –KambarArangamon KonnurHigh road.

IMPORTANT INSTRUCTIONS

All trainees coming for training at AWTI shall adhere to following instructions

1. Discipline, sincerity and punctuality are the foremost qualities expected from the trainees.

2. Trainees shall bring their own safety shoes and working dress for doing welding practice.

3. Trainees having corrected vision must wear their spectacles during welding.

4. Trainees shall report with Photo ID card and relieving letter.

5. Trainees shall bring two passport size photographs.

6. Hostel accommodation is available.

7. At present, no mess facility is available in the hostel.

8. No cooking is allowed in the hostel.

For additional information please contact: Principal: (BSNL) 044-26147612, Mobile: 09003141417, Tele Fax:044-26281227, Railway Phone: 47612

Chief Course Coordinator:(BSNL) 044-26147211, Mobile: 09003149549 Railway Phone: 47211

Email: ptc@icf.railnet.gov.in