.!1°MP OF~PREm.:;t~J?_~.~~.REGJ_QN)'

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~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

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Layout 0f the mill house machinery.

Constructional details of the machines.

.".

'

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,

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xiv)

determinati~n and interpreta,!:iOI"L.for.technical

control.

Mill operation contro.l data and norms, mill:

'- sanitation.

-. ..xv) '. "Man power/Labour strength.."-

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'- '-

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)

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..- 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.

7

,...

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.