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com Career Railways

SYLLABUS OF SEMESTER SYSTEM

FOR THE TRADE OF

REFRIGERATION AND
AIR CONDITIONING

Under

Craftsmen Training Scheme (CTS)

(Two years/Four Semesters)

………

Redesigned in
2014

By
Government of India
Ministry of Labour & Employment (DGE&T)
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GENERAL INFORMATION

1. Name of the Trade : REFRIGERATION AND AIR CONDITIONING

2. N.C.O. Code No. : 845.706

3. Qualification pack : ELE/Q3501

4. Duration of Craftsmen Training : 4 Semesters (2 Years)

th
5. Entry Qualification : Pass in 10 Class under 10+2 system of
Education
6. Unit strength : 20

7. Space norms : a) Workshop: 80 Sq. meters.

b) Class room: 30 sq.meter.

8. Power norms : 6.82 KW

9. Job role :To repair and service in refrigerator, water

cooler, bottle cooler, deep freezer, Visi
Cooler, Walk in Cooler, Ice candy plant,
Cold storage, Ice plant, Split Air
Conditioner, Package Air Conditioner,
Central Air Conditioner, Auto mobile Air
Conditioner, Transport refrigeration, Air
craft Air conditioning, Rail way Air
conditioning, Ship Refrigeration and Air
conditioning.

10. Instructors Qualification : : NTC/NAC in Mechanic Refrigeration & Air-conditioning trade

with 3 years’post qualification experience OR
Degree in Mechanical Engineering from
recognized engg. college/university with one year experience in
the relevant field OR
Diploma in Mechaical Engineering from recognized board
of technical education with two years
experience in the relevant field

11. Desirable qualification : Preference will be given to a candidate with CITS. (If
not done CITS must be trained with in 2 yrs of joining)
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Syllabus for the Trade of “RAC” Under Craftsman Training Scheme

First Semester (Semester Code no. RAC- 01)

Duration : Six Months

Syllabus for TT and TP

Week PRACTICAL THEORY

No
Familiarization with workshop & Introduction to trade, general safety
machineries. Safety precautions. precautions and first aids, history of
1 Familiarization of refrigeration tools, Refrigeration and Air conditioning.
instruments & equipments. Care and Function, working, use, specifications
maintenance of tool, instruments and of refrigeration tools, instruments and
equipments. equipment.

2 FITTING FITTING
Familiarization of tools, instruments and Study the different types of Fitting
machines used in fitting. Marking/Layout hand tools, power tools, precision
practice as per Blue Print. Cutting, filling, measuring instruments & their use.
drilling, grinding & Chipping by using Equipments used in fittings like
hand tools and power tools. drilling machines, grinding machines,
types, specifications and care and
maintenance.
3 FITTING FITTING
Filing flat, square & curved surfaces. Slots, Study the function, construction,
grooves angular profile, Drilling clear and working of fitting hand tools, precision
blind hole, Threading &Tapping, Counter measuring instruments & their use.
sinking, counter boring, drill bit grinding Specification & their application.
and reaming. Use of Hand and Power
drills.
SHEET METAL SHEETMETAL
Familiarization of tools, instruments and Study the function, construction,
machines used in sheet metal. Marking, working, use, and application,
4 measuring, cutting, bending, folding, specification of Sheet metal tools,
riveting, joints, soldering in sheet metal. instruments and equipment. Care and
maintenance of tools. Types of sheet
metal joints and their use. Rivet &
riveting- their types and use.
5 ELECTRICAL: ELECTRICAL
Familiarization of Electrical tools. Wire joint Electrical terms such as AC and DC
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practice, Soldering and Brazing practice. supply, Voltage, Current, Resistance,

Verification of Ohm’s law. Identification of Power, Energy, Frequency etc. Safety
phase and neutral of AC supply. precautions to be observed while
Construction of a load circuit with single
working on electricity. Conductors and
phase AC and DC supply. Measurement of
Voltage, Current, Resistance, power, Insulators, Materials used as conductors.
Frequency and energy consumed in an Measuring Instruments such as
electrical circuit. Measurement of earth voltmeter, ammeter, ohm meter, watt
resistance. Insulation and continuity test. meter, energy meter and frequency
meter. Earthing and its importance. Earth
resistance. Insulation and continuity test

6 Construction of RL,RC and RLC circuits, Inductors and capacitors. Effects of

measurement of electrical parameters and inductor and capacitors in an AC circuit.
calculation of impedance and power factor. Inductive reactance, capacitive reactance,
Construction of Star and Delta connection in Impedance and power factor. Lagging
three phase supply and measurement of Line and leading power factors. Single phase
voltage, Line current, Phase voltage and and Three phase supply system. Star and
Phase current. Three phase power and power Delta connection and their comparison.
factor measurement. Line voltage, Line current, Phase voltage
and Phase current. Methods of improving
power factor.

7 Familiarization with split phase AC motors AC motors and their types. Advantages
and identification of the terminals. of AC motor over DC motor. Revolving
Identification of starting and running coil. field theory. Phase splitting theory.
Resistance measurements of windings. Capacitor method and inductor method
Familiarization with capacitor start induction used to split the single phase. Torque –
runs motors and identification of the starting torque and running torque. Split
terminals. Identification of starting and phase induction motors, working
running coil. Resistance measurements of principle and construction. Starting
windings. Familiarization of DOL starter winding and running winding. Starting
and checking of its function. Starting of split current and running current. Method of
phase motor through DOL starter, changing the direction of rotation
measurement of starting current and running (DOR).Capacitor starts induction run
current and changing of DOR. Starting of motor, working principle and
capacitor start induction run motor through construction. Centrifugal switch and its
DOL starter, measurement of starting current function.
and running current and changing of DOR.
Starter and its necessity.DOL starter and
the safety devices incorporated in it.
8 Starting of capacitor start capacitor run Capacitor starts capacitor run motor,
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motor through DOL starter, measurement of working principle and construction.

starting current and running current and Starting capacitor and running capacitor
changing of DOR. Starting of shaded pole Shaded pole motors, working principle
motor through DOL starter, measurement of and construction. Torque comparison
starting current and running current and among various single phase AC motors.
changing of DOR. Fault rectifications. Common faults, causes and remedies in
Insulation test on windings, continuity test, motors.
open circuit test and short circuit test.

9 ELECTRONICS ELECTRONICS
Identification of Electronic components Introduction to Electronics. Basic
and tools & instruments, colour coding of Principles of semiconductors,
resistors, verification of ohms law, use of Principles and application of Diodes
voltmeter, ammeter, multi meter, Practice
of soldering & de soldering.
10 Identification of transistors, resistors, Rectification, Zener diode as voltage
capacitors, diodes, S.C.R, U.J.T, I.Cs. used in regulator – transistors parameters- CB,
refrigeration & AC, CE, CC, configuration, amplification.
Full wave and bridge rectifier circuit, SCR
voltage regulators. Construction of low
voltage Power Supply. Construction of
transistor amplifier circuit.
11 Multi-vibrator circuits and RC wave Photo diodes, photo transistors, multi
shaping circuits. Wiring of SCR, UJT for – vibrator, CR & LR circuit. SCRs, UJTs,
power control circuits, applications of OP ICs.
–AMP, Applications of photo transistor.
12 WELDING WELDING
Identification of gas welding equipments Introduction to basic principles of
& accessories, setting up of a)AIR-LPG, commonly used Welding processes,
b)O2-LPG Arc welding, oxy fuel gas welding /
c) O2-C2H2. Familiarization with the cutting, brazing & soldering
practice of
1) Oxy Acetylene Gas welding, brazing and
cutting on thin sheet metal.
2) Safety in handling of Oxy Acetylene
Cylinders, Regulators etc.,
13 Welding tools and equipment care and Welding tools and equipment type
safety. Setting oxy-acetylene plant, specification and use. Safety method in
lighting and adjustment of flame-simple welding. Method of gas welding, gas
joint on M.S. Preparing close fitting lap used and flames adjustment.
joints for both soldering/ brazing cu to cu, Difference between soldering and
cu to MS. Importance of wetting and Brazing in terms of temperatures, filler
capillary action. Use of appropriate materials, joint strengths and
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torches, Nozzles, Types of flames and applications. Use of Oxy Acetylene,

fluxes, Practice on Oxy Acetyl Oxy LPG and Air LPG for
brazing/soldering
14 BASIC REFRIGERATION. BASIC REFRIGERATION
Familiarization & use of general and Study the function, working, use,
special tools used in refrigeration work specifications of refrigeration tools,
practice. instruments and equipment.
Fundamentals of Refrigeration, units
and measurements, Pressure & its
Measurements. Thermodynamics law.
15 Identification of various Refrigeration Science related to refrigeration, work,
equipments, components of vapour power, energy, force, Heat and
compression system like compressor, Temperature, Different temperature
condenser, expansion valve and scales, Thermometers, Units of heat,
evaporator etc sensible heat, latent heat, super
heating and sub-cooling, saturation
temperature , pressure, types, units.
16 Working on soft copper tubing like, Types of Refrigeration systems, Ton of
cutting, bending, flaring, swaging, Refrigeration, Study the construction
pinching, brazing. and working of vapor compression
cycle, low side & high side of vapour
compression system. Applications of
vapour compression cycle.
17 Brazing of tube joints (Cu to Cu, Cu to Construction and working of V.C Cycle,
Steel, Cu to Brass) using fundamental operations, sub cooling
(i)Air-LPG (ii) 02-LPG (iii) 02-C2 H2 set and super heating.
up & use of the above gases with the right
torches, Brazing Filler Rods.
Distinguishing good joints from bad joints.
18 REFRIGERATOR (Single Door) REFRIGERATOR ( Single Door)
Familiarization of electrical Function, construction ,working of
and mechanical components of single door refrigerator, specifications,
refrigerator. trouble shooting,
Check and replace electrical components, care and maintenance
leak test, evacuation ,gas charging in
refrigerator, wiring circuit of refrigerator,
installation of refrigerator, faults and
remedies in refrigerator.
19 REFRIGERATOR.( SINGLE DOOR)
Familiarization of electrical
and mechanical components of single REFRIGERATOR (SINGLE DOOR)
door refrigerator. Trouble shooting , Study the construction & working of
Stripping accessories & cleaning / single door Refrigerator. Study the
inspection and installing refrigerator, electrical components of refrigerator.
testing of components, Checking Door Study the mechanical components of
refrigerator and their types. Study the
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alignment & replacing of gaskets. Tracing heat exchanger, door gaskets, Heat
the electrical and mechanical components Insulation materials. Care and
of sealed refrigerator. Check and test maintenance of refrigerator.
relay, OLP, capacitor, windings,
thermostat.
20 Testing of compressor, Identification of Importance of flushing in evaporator
motor terminals, Starting of compressor and condenser, necessity of replacing
without relay & starting with Relay, capillary and drier. Evacuation, leak
testing OLP and other electric safety testing, gas charging method in
devices. Reassembly the components & refrigerator, Refrigerants used in
Test performance. Cleaning, Flushing, Refrigerators and its properties.
replacing capillary and drier, fault
rectification, install gauge manifold in the
system, evacuation, leak testing, gas
charging in Refrigerator. Check electrical
wiring of refrigerator.
21 FROST FREE REFRIGERATOR: FROST FREE REFRIGERATOR
Tracing Electrical circuit, checking and Study the construction and working of
testing of electrical accessories like, Frost Free (2 or 3 door) Refrigerator
thermostat, Timer, Defrost Heaters, Bi- parts particularly, the forced draft
metal etc., checking air distribution cooling, Air Duct circuit, temperature
system, servicing of refrigerator, testing control in Freezer & cabinet of
of components. Test the performance of Refrigerator, the automatic defrost
refrigerator. system. Study of Electrical accessories
& their functions (Timer, Heater, Bi-
Metal, Relay, OLP, T/S etc,.)
Refrigerator cabinet volume
calculation.
22 Identify three and four door no frost Study the construction and its working
refrigerators , Stripping of components. of two and three door frost free
Tracing electric circuit, Installation, refrigerator. Care and maintenance,
testing components, evacuation, leak installation method.
testing, gas charging, testing, fault finding,
rectifications, evacuation and gas
charging.
23 Project work Project work
24 Revision Revision
25 Revision Revision
26 EXAM EXAM
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Trade : MECHANIC REFRIGERATION AND AIRCONDITIONING

Semester : II

Week Trade Practical Trade Theory

No
1 COMPRESSOR COMPRESSOR
Dismantling of Hermetic Function, construction, working ,application
compressors, Identification of of compressor like, Reciprocating, rotary ,
components, Servicing, cutting scroll type.
gaskets, lapping and assembling
of compressors used in
refrigerators, window & split A.C,
and assembling.
2 Dismantling & Study the construction & working of centrifugal
assembling of Hermetic compressor, wobble & swash plate
compressors like, reciprocating, compressor. Compressor efficiency factors,
rotary, wobble, swash plate & wet compression, oil, properties, lubrication
scroll type compressors. Identify methods.
the parts and rectify the defects
3 MOTORS MOTORS
Starting of compressor motor by Motors used in refrigeration And Air
RSIR, CSIR, PSC & CSR method. conditioning system, types, construction,
Check and test relay, capacitors & working & their starting methods. Function of
OLP’s, Faults and rectification, Starting relay, Capacitors, OLP’s.
installation.
4 Familiarization with Squirrel cage Production of rotating magnetic field by three
induction motor and identification phase AC supply. Working principle of three
of terminals. Phase sequence test of phase induction motor. Terms such as torque,
SCIM. Starting of SCIM through slip, rotor frequency and their relation.
DOL starter, measurement of Construction of squirrel cage induction motor.
starting current and running current Importance of phase sequence. Construction of
and changing of DOR Starting of slip ring induction motor Comparison between
SCIM with Star – Delta starter and SCIM and SRIM. Three phase motor starters
Auto Transformer starter. such as DOL starter, Star – Delta starter, Auto
Familiarization with Slip ring transformer starter and Rotor resistance starter.
induction motor and identification Common faults, causes and remedies in three
of terminals. Starting of SRIM phase AC motors
through Rotor resistance starter,
measurement of starting current and
running current and changing of
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DOR. Fault rectifications.

Insulation test on windings,
continuity test, open circuit test and
short circuit test.

5 CONDENSER CONDENSER
Familiarization with condensers Function of condenser, types, Construction of
used in Refrigerators, Bottle air cooled condenser. Effect of chocked
coolers, visible coolers, Deep condenser. Advantages, de scaling of air
freezer, window and cooled condenser.
Split A.C, Cleaning, Flushing and
servicing of air cooled condenser,
leak testing of condenser
6 De scaling of air cooled Types of air cooled condenser, application,
condenser. and advantages. Liquid receiver, pump down,
application, types, function and working.
7 DRIER DRIER
Replacing drier & capillary tube, Function of drier, types, application and its
in refrigerator and window AC. advantage.
8 EXPANSION VALVE EXPANSION VALVE
Install capillary tube, Test and Expansion valve used in domestic
adjust expansion valves. refrigeration and air conditioning systems.
Capillaries, Automatic and Thermostatic Ex.
Valves.
9 EVAPORATOR EVAPORATOR
Servicing of evaporators in Working principle, Function, types of
refrigerators, bottle cooler, water evaporators used in refrigerator, water
coolers, window and split A.C, coolers, bottle coolers, window and split A.C,
Installation, Leak test, remove oil Super heating in evaporators, Function of
from evaporator, Flushing, accumulator and types. Methods of defrosting,
Defrosting. heat exchanger.
10 REFRIGERANT REFRIGERANT
Identification of refrigerant Classification of refrigerants, Properties,
cylinders, Identification of Chemical name and formulas, HFC, CFC. Ozone
unknown refrigerants, Recovery rule, substitute of CFC, Montreal protocol
& Transfer of refrigerant, &India’s CFC/HCFC phase out schedules.
Ozone rules 2000.
11 Safe handling Cylinders and Refrigerant leak detection methods,
Valves, Leak testing, Evacuation, Substitute refrigerants in lieu of CFC ARE
Charging refrigerants in their properties & comparison with CFCs,
Refrigerator. HFCs and HCs.
12 RETROFITTING RETROFITTING
Retrofitting of a CFC filled Changes of components & practices while
Domestic Refrigerator with retrofitting CFC appliances with HC
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Hydrocarbons (HC) using sealed refrigerants. Properties of HCs

components.
13 THERMAL INSULATION THERMAL INSULATION
Filling insulation materials in Function, types, thermodynamic properties of
refrigeration systems. heat insulation materials used in refrigeration
and Air Conditioning systems.
14 WINDOW AIR CONDITIONER WINDOW Air conditioner.
Identify the electrical and Their types, applications. Construction and
mechanical components, working, care and maintenance,
servicing and maintenance,
trouble shooting, installation,
tracing wiring circuit, evacuation,
leak testing, and gas charging in
window Air conditioner.
15 WINDOW AIR CONDITIONER WINDOW AIR CONDITIONER
Identify the electrical and Study the construction and working of
mechanical components, window A.C, Care and Routine maintenance,
servicing and maintenance, installation procedure.
trouble shooting, installation,
tracing wiring circuit, install
gauge manifold in the system,
evacuation, leak testing, gas
charging.
16 SPLIT A.C SPLIT A.C
Identifying various components, Construction and working principle, types,
electrical circuits, testing trouble shooting & care and maintenance.
components, fault detection, leak
testing, evacuation, gas charging,
Installation, trouble shooting in
split A.C.
17 SPLIT A.C SPLIT A.C (Wall mounted)
(Wall Mounted) Construction and working principle, types,
Identifying various components, trouble shooting. Description of electrical
electrical circuits, testing components used in split A.C. Study the wiring
components, fault detection, circuit .
install gauge manifold in the
system, leak testing, evacuation,
gas charging, Installation, trouble
shooting.
18 SPLIT A.C SPLIT A.C (floor & Ceiling mounted)
(Floor & Ceiling Mounted ) Construction and working principle, types,
Identifying various components, trouble shooting. Description of electrical
electrical circuits, testing components used in split A.C. Study the wiring
components, fault detection, leak circuit .
testing, evacuation, gas charging,
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Installation, trouble shooting.

19 SPLIT A.C ( Duct ) SPLIT A.C ( Duct )

Study of the Duct able split AC, its
Identifying various components, Construction and working principle, types,
electrical circuits, testing trouble shooting.
components, fault detection, leak Description of electrical components used in
testing, evacuation, gas charging, split A.C. Study the wiring circuit .
Installation, trouble shooting.
20 MULTI SPLIT A.C MULTI SPLIT A.C
Identifying various components, Study the construction and working, various
electrical circuits, testing components, electrical circuits, testing
components, fault detection, leak components, fault detection, leak testing,
testing, evacuation, gas charging, evacuation, gas charging, Installation, trouble
Installation, trouble shooting. shooting.

21 CAR AIR CONDITIONING CAR AIR CONDITIONING

Identifying various components, Study various components, electrical circuits,
electrical circuits, testing testing components, fault detection, leak
components, fault detection, testing, evacuation, gas charging, Installation,
install gauge manifold in the trouble shooting, Magnetic clutch operation,
system, leak testing, evacuation, free wheeling
gas charging, Installation, trouble
shooting, testing magnetic clutch,
regular maintenance, compressor
overhauling, condenser de
scaling, add refrigerant.

22 CAR AIR CONDITIONING CAR AIR CONDITIONING

Identifying various components, Study various components, electrical circuits,
electrical circuits, testing testing components, fault detection, leak
components, fault detection, leak testing, evacuation, gas charging, Installation,
testing, evacuation, gas charging, trouble shooting, Magnetic clutch operation,
Installation, trouble shooting, freewheeling, care and maintenance.
testing magnetic clutch, regular
maintenance.

23 Project works Project works

24 Project works Project works
25 Project works Project works
26 Exam Exam
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Trade: Mechanic Refrigeration and Air conditioning

Semester: III

Week no Trade Practical Trade Theory

1 COMMERCIAL COMPRESSOR COMMERCIAL COMPRESSOR
Dismantling of Commercial type Function, types, Construction & working,
reciprocating compressor, applications of compressors used in
centrifugal compressor, commercial refrigeration.
checking of components & Volumetric efficiency, Capacity control, factor
accessories. Checking & influencing volumetric efficiency.
servicing valve plate and piston
assembly, lapping valve plate
etc. Preparing gasket, check belt
tension and replacing.
2 Checking lubricating Compressor oil, types, properties, types of
system, servicing oil pump, lubrication methods such as splash, forced
Checking and servicing of feed.
capacity control of the
compressor
3 Checking and servicing of Study the Construction and working
bearing, shaft seal etc. Fitting principle of Centrifugal and Screw
and testing, cutting gasket, compressor.
assembling of compressor,
testing efficiency of
compressor.
4 WATER COOLED CONDENSER WATER COOLED CONDENSER
Servicing of water cooled Study the water cooled Condenser, its type
condenser & receiver. Checking and capacity, construction and working, de
leakage, Repairing and testing, scaling, application.
De Scaling of condenser.
5 Servicing evaporative type Evaporative condenser- their function,
condenser, checking, repairing construction and application. Liquid receiver,
and testing, Pump down of gas. function. Drier, types and application.
6 COOLING TOWER COOLING TOWER
Servicing of cooling tower & its, Cooling tower, types, Construction, capacity,
care and maintenance advantage & disadvantages of different types
of cooling tower. Efficiency, approach and
Cooling tower range.
7 Servicing of water circulating WATER TREATMENT
pumps, dismantling, repairing Water treatment necessary, Causes of water
and assembling. contamination control of scale deposit,
corrosion, Slime and algae, Water softening
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and De-scaling method, pump and fan used,

8 EXPANSION VALVE EXPANSION VALVE
Testing & Installation of Expansion valve types and function,
thermostatic Ex. Valve. Internal construction, working principle, & their
& external equalizer advantage & disadvantages..TXV, AXV, Float
connection, super heat valves, fixed and modulating orifice controls &
adjustment in TXV. electronic Ex. Valves.
9 Automatic EX valve fitting Selection of Ex. valves, and capillaries for
& checking, High side, Low side various Refrigeration and Air Conditioning
float valves checking and fixing. applications.
10 EVAPORATOR EVAPORATOR
Servicing of extended surface Function, types, Plate & Tube forced air DX
forced air cooled evaporators. evaporators. Types of Defrost system .Water/
Servicing of Water/ brine Brine chillers. Types of brine used as
chillers, check De- Frost system, secondary refrigerant. Accumulator, its
Oil removing. function.
11 Servicing of suction-liquid Heat- suction-liquid Heat-exchanger, their function,
exchanger construction, application & advantages
12 WATER COOLER WATER COOLER
Identify parts, Controls & Study the refrigeration cycle of water cooler,
accessories, electric circuit. types, construction & working, Capacity &
Soldering of Cu tube on applications. Study the electrical and
Stainless steel, trouble shooting mechanical components of storage type
of commonly faced problems water cooler. Insulation material used in
like condenser fan failure, water cooler, refrigerant used in the system.
corrosion etc. install gauge
manifold in the system, Leak
testing, evacuation, Charging
Refrigerant. Installation,
Servicing & maintenance of
water cooler.
13 VISIBLE COOLER AND VISIBLE COOLER AND
BOTTLE COOLER BOTTLE COOLER
Checking & servicing of Visible Visible cooler & bottle coolers. Description,
cooler & Bottle cooler Construction & working, Substituting R-12
preventive maintenance & with R-134a or Hydrocarbon, care and
trouble shooting Retrofitting maintenance, testing electric components.
with Hydrocarbons or HFC-
134a, Checking wiring circuit,
test components, replacing
components, evacuation, gas
charging, Installation, testing
performance.
14 DEEP FREEZER DEEP FREEZER
Deep freezer Checking & Deep freezer description, Construction,
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servicing , preventive working, specifications, function, care and

maintenance & trouble shooting maintenance, faults and remedies.
Checking wiring circuit, test
components, replacing
components, install gauge
manifold in the system,
evacuation, gas charging,
Installation, testing
performance.
15 ICE CUBE MACHINE ICE CUBE MACHINE
Checking & servicing of ice cube Ice cube machine description, Construction,
machine, preventive working, reverse cycle functioning & Circuit
maintenance & trouble diagram, installation method.
shooting. Trace the Electrical
Circuit diagram. Dismantle the
wiring & reconnect. Servicing
the unit involving Evacuation,
leak testing & charging.
Checking defrosting system.
16 ICE CANDY PLANT ICE CANDY PLANT
Identify parts, Controls & Function, construction, working principle,
accessories Specification, Circuit diagram, capacity & types of
Checking ice candy plant compressor used. Brine composition to
temperature maintaining. maintain required temperature. Operation,
Function of agitator, preparing maintenance.
Brine solution, trouble
shooting, servicing, Checking
wiring circuit, test & replace
components, install gauge
manifold in the system, leak
testing, evacuation, gas
charging, Installation, testing
performance.
17 ICE PLANT ICE CREAM PLANT
Identify parts, Controls & Details about components of Ice plant
Specification of Ice plant their functioning, working principle, Circuit
temperature maintaining., diagram, capacity & types of compressor
trouble shooting, servicing, used, temperature maintaining.
Checking wiring circuit, test
components, replacing
components, evacuation, gas
charging, Installation, testing
performance, plant operation.
18 WALK IN COOLER & REACH IN WALK IN COOLER & REACH IN CABINET
CABINET Details about components, their functioning,
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Identify parts, Controls & working principle, Circuit diagram, capacity

accessories Specification of & types. Care and maintenance.
Walk in cooler & Reach in
cabinet preventive maintenance
& trouble shooting, Servicing of
components, wiring circuit.
Install gauge manifold in the
system, leak testing,
Evacuation, gas charging.
19 COLD STORAGE COLD STORAGE
Identify parts, Controls & Study of cold storage plant, parts,
accessories Specification, Construction, applications, controls &
Servicing of Cold storage plant. electrical diagram used in cold storage plant.
Operation of cold storage. Food preservation spoiling agents- controlling
Testing electrical controls, of spoiling agents, preservation by
cooling system, mechanical refrigeration system, maintaining
components, add oil, add temperature in different places. Types of cold
refrigerant, test leak, storage and its details.
evacuation, gas charging,
periodic maintenance.
20 Installing compressor.
Electrical wiring of the Cold storage- type construction, capacity and
compressor and checking the specification. Use of vibration eliminator and
wiring system of the plant. shock absorber, Study the lay out and electric
wiring of the storage plant .Mobile
refrigeration in transport vehicles.
21 Cold storage pressure testing, Method of pressure testing, evacuation &
evacuation, charging & charging to the system and testing efficiency.
performance testing of the unit. Cold storage plant operation, its common
Cold storage plant operation trouble & remedies. Deep freezing, freezing
and its maintenance. tunnel, blast freezer its function and working,
its application.
22 Project work Project work
23 In plant Training In plant Training
24 In plant training In plant Training
25 Revision Revision
26 Exam Exam
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TRADE: MECHANIC REFRIGERATION AND AIRCONDITIONING

SEMESTER: IV

Week Trade Practical Trade Theory

No.
1 2 3
1. PSYCHROMETRY. Fundamentals of Central Air
Find DBT, WBT, RH & other Conditioning, requirements of comfort
properties by using psychometric A.C, study of psychometric terms, DBT,
chart. Use of psycho meter. WBT, RH, enthalpy, dew point, and
specific humidity.
2. Use of Anemometers for measuring Types of Central air conditioning
Air flow, use of monometers, (Direct and indirect system)
measuring air flow, pivot tube for air Construction, working, components,
flow measurement. faults, care and maintenance,
3. Servicing of Fans & blowers, motors, Description of blowers& fans, function
used in Air conditioning system. and types, static and velocity pressure
measurements.
4. DUCT DUCT
Installation of ducts, construction of Function, types, materials, duct
ducts, understanding Duct lay out designing, duct insulation, air
drawings, selection of ducts, and distribution methods, air flow, AHU,
insulation in ducts. Longitudinal and fan, blower.
transverse joints.
5. AIR FILTERS AIR FILTERS
Servicing and maintenance of Function of air filters, types,
different filters, Installation of filter construction, maintenance, effect of
chocked Air filter.
6. SPLIT A.C ( Duct ) SPLIT A.C ( Duct )
Study the Duct able split AC, its
Identifying various components, Construction and working principle,
electrical circuits, testing types, trouble shooting.
components, fault detection, leak
testing, evacuation, gas charging,
Installation, Trouble shooting.

7. MULTI SPLIT A.C ( Duct ) MULTI SPLIT A.C ( Duct)

Identifying various components, Study various mechanical and electrical
electrical circuits, testing components construction and working,,
components, fault detection, leak electrical circuits, testing components,
testing, evacuation, gas charging, fault detection, trouble shooting.
Installation, Trouble shooting.
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8. PACKAGE A.C PACKAGE A.C

Identifying various components, Study Package AC, types, construction
electrical circuits, testing and working principle, trouble
components, fault detection, install shooting, and various applications. Duct
gauge manifold in the system, leak system, AHU.
testing, evacuation, gas charging,
Installation, Trouble shooting.

9. Identifying various components, Care and maintenance, installation

electrical circuits, testing method, capacity calculation.
components, fault detection, install
gauge manifold in the system, leak
testing, evacuation, gas charging,
Installation, Trouble shooting.

10. SPLIT PACKAGE Identifying various SPLIT PACKAGE

components, electrical circuits, Construction and working principle,
testing components ,fault detection, types, Study various electrical and
leak testing, evacuation, gas mechanical components, trouble
charging, Installation, Trouble shooting.
shooting.

11. CENTRALISED/INDUSTRIAL CENTRALISED/INDUSTRIAL

AIRCONDITIONING. Identifying AIRCONDITIONING.
various components, electrical Construction and working principle,
circuits, testing components, fault types, maintenance of Industrial Air-
detection, leak testing, evacuation, conditioning plant. Humidification and
gas charging, Trouble shooting, dehumidification methods. AHU.
Servicing AHU. Check air flow, Check
temperature & pressure, operation of
plant, Decaling condenser and
cooling tower.

12. Pump down of gas, add oil to Temperature and pressure controls
compressor, add gas in the system, used in AC plant, its construction,
trouble shoot and repair air working, safety devices, cooling towers,
conditioner. Check temperature and chilled piping lines,
pressure controls.
13. DIRECT EX.SYSTEM DIRECT EX.SYSTEM
Identifying various components, Understanding Direct expansion
electrical circuits, testing system. Operation & Preventive
components, fault detection, leak Maintenance Schedule of central AC
testing, evacuation, gas charging, plant.
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Installation, Trouble shooting.

Operation &Maintenance of Central
AC plant.

14. Check and test VRF system. Details of VRF system.

15. INDIRECT/CHILLER SYSTEM INDIRECT/CHILLER SYSTEM

Identifying various components, Understanding central station AHU and
electrical circuits, testing FCU, Air washers used in chilled water
components, fault detection, install system, understanding lay out,
gauge manifold in the system, leak modulating valves for temperature
testing, evacuation, gas charging, control. Expansion tanks.
Installation, Trouble shooting..

16. Chilled water piping and insulation. Study of Humidification &

Servicing of FCU and water controls De-humidification. And Humidifier’s &
valves. Mixing dampers, bypass De-humidifier’s.
dampers checking.
17. Servicing and trouble shooting of Construction and study of commercial
direct, indirect A.C Plant, erection of A.C plant, package chiller, screw chiller,
commercial type condensing unit, reciprocating chiller.
vibration eliminator, water proofing
insulation.
18. Check controls used in Packaged AC Controls used in AC system,
systems, trouble shooting. Electromechanical, pneumatic and
electronic.
19. Installing compressor and other Introduction to heat load calculation in
components, electrical wiring in AC building. Sensible & latent heat load.
central AC and checking HVAC Basic of HVAC and its applications
20. AUTOMOBILE AC (car) AUTOMOBILE AC
Repair and maintenance of Car AC Study the refrigeration cycle in
system, servicing, testing magnetic automobile AC, its Construction,
clutch operation, compressor working of car AC, Magnetic clutch
overhauling, leak testing, evacuation, operation, freewheeling.
gas charging, oil charging. Testing
wiring system.
21 Repair and maintenance of car AC Construction & working of car AC,
system, servicing, testing magnetic Magnetic clutch operation, frees
clutch, leak testing, evacuation, gas wheeling. Effects of speed of engine.
charging, check air flow, measure Trouble shooting in car A.C.
temperature and pressure. Check
solenoid valve.

22 Studying / Execution of Repair and Planning for Preventive maintenance

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Preventive maintenance of different and scheduling of maintenance

Commercial units at site activities in large AC and Refrigeration
plant
23 INPLANT TRAINING INPLANT TRAINING
24 INPLANT TRAINING INPLANT TRAINING
25 REVISION REVISION
26 EXAM EXAM

Trade: Mechanic (Refrigeration and Air-Conditioning)

LIST OF TOOLS & EQUIPMENT

A. TRAINEES TOOL KIT FOR 16 TRAINEES +1 INSTRUCTOR

SL.NO Name of tools Broad specifications Quantity Life

span
1. File flat rough double cut 200mm 10
17 nos.
Years
2. File, half round, fine double length 150mm
17 nos. 10
cut,
3. File, round, fine double cut length 150mm 17 nos. 10
4. File flat, fine double cut, length 150mm 17 nos. 10
5. File square, fine double cut, length 150mm 17 nos. 10
6. File triangular fine double length 150mm
17 nos. 10
cut
7. Scriber 150mm length 17 nos. 10
8. Centre punch length 100mm 17 nos. 10
9. Try square 150 mm 17 nos. 10
10. Divider spring joint length 150mm 17 nos. 10
11. Caliper spring joint in side length 150mm 17 nos. 10
12. Caliper, odd leg, spring joint length 150mm 17 nos. 10
13. Hammer ball pain 220 gms 17 nos. 10
14. Cold Chisel flat and cross cut length 150mm 17 nos. 10
15. Engineers rule 300mm long 17 nos. 10
16. Tape measuring 10m graduation in
17 nos. 5
mm
17. Pliers combination length 200mm
17 nos. 10
insulated
18. Pliers long nose 200 mm 17 nos. 10
19. Pliers flat nose 150mm 17 nos. 10
20. Line tester 500 v heavy duty 17 nos. 5
21. Tweezers 10 cm 17 nos. 10
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22. Surface plate 45 x45 cms 1no. 15

23. Oil can 500 ml 5 nos. 5
24. Surface Gauge universal 150 mm 5 nos. 10
25. Bench vice 300mm jaw 10 nos. 10
26. Hack saw tubular metal 300mm
10 nos. 5
frame adjustable
27. Snip sheet metal straight 200 mm
10 nos. 5
nose
28. Snip sheet metal curved 200 mm
10 nos. 5
nose
29. Anvil 100X200mm 1no. 5
30. Stakes [ different Types] 100mm 1 no each 5
31. Tin smith 400mm 1 No. 5
32. Wooden mallet /Nylon 500 gm good finish
5 Nos. 5
mallet
33. Round Punch 3mm,4mm,6mm 5 Nos.
10
each
34. Grover set 4mm forming 1 set 5
35. Electrical drill portable drill capacity 6.4mm
5 nos. 5
with chuck and key,
36. Tape measuring graduation 2m
5nos. 5
in mm
37. Screw driver, plastic handle, 6mm TIP length
6nos. 5
100mm to 150mm
38. Screw driver, plastic handle, 10mm TIP length
6 nos. each 5
Flat tip 200mm & 250mm
39. Philips screw driver – complete set in
5 nos. 5
leather case
40. Screw driver, plastic handle, handle 3mm TIP
Flat tip length 100mm to 5 nos. 5
150mm insulated
41. Soldering iron exchangeable 65 watts
10 nos. 5
copper tip
42. Knife folded stainless steel – 150mm 10 nos. 5
43. Tong tester (clamp on multi 0-10-30 amps 0-500 v
5 nos. 5
meter)
44. Voltmeter, AC/DC portable 0 to 500 volt
precision grade Digital 5nos. 5
Panel board type
45. Ammeter, AC/DC portable 0 to 30 amp
precision grade Digital 5nos. 5
Panel board type
46. Megger 1000v 5nos. 5
47. Wattmeter multi-range up 1 KW 1no. 5
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to
48. Multi meter digital type 5nos. 5
49. Tenon saw 250 mm 5nos. 5
50. Firmer chisel 6,12,25mm 2 nos. 5
51. Rawal plug tool 6 mm 2 nos. 5
52. K.W. meter 0 -1 K w 4 no. 1
53. Fire extinguisher ABC dry powder
1 no. 1
type2 kg capacity
54. Fire buckets 10 Litre 1 no. 5
55. D.E spanner 6-32 mm 5 set 5
56. Ring spanner 6 -32 mm 5 set 10
57. Diagonal cutter 15 cm 5 nos. 10
58. Service Oscillator 1 no. 5
59. C.R.O Single beam 5 MHZ 2 nos. 5
60. C.R.O Dual trace/ Double 60 MHZ
2 nos. 5
beam
61. A.F.O Oscillators 2 nos. 5
62. Tong, Close mouth and pick
1 no. 5
up
63. Welding table for gas/Arc 1200x760 1each 15
64. Flaring tool set, single type 4.7mm to 16mm O.D
5 nos. 10
for tube.
65. Swaging tool, punch type, 4.7mm to 16mm O.D
5sets 10
set of size for tube.
66. Swaging tool, screw type 4.7mm to 16mm O.D.
with adaptor set of size for 5sets 10
tube
67. Bending spring external 3mm to 16mm DIA
5sets 10
type, for copper tube
68. Pipe cutter miniature for 3mm to 16mm DIA
5sets 10
copper tube
69. Pinch of tool, for copper 6mm to 18mm DIA
5sets 10
tube,
70. Ratchet spanner of 6.4 sq.mm reversible 5sets 10
71. Capillary plug gauge 5sets 10
72. Piercing pliers & reversing 6-18mm
5sets 10
valve with access fitting
73. Spanner double ended 4.7mm to 16mm 5sets 10
74. Ring spanner off set 4.7mm to 16mm 5sets 10
75. Wrench adjustable length 150mm 5sets 10
76. Wrench adjustable length 200mm 5sets 10
77. Wrench adjustable length 250mm 5sets 10
78. Valve key handle[Treated as – 4.7mm & 6.4mm sq.
5sets 10
consumable]
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79. Pressure gauge Digital type diameter 63mm with

5sets 3
recalibration set
80. Compound gauge, diameter 63mm, with
Digital type recalibration set
screw, scale vacuum 5sets 3
76mm. Pressure 15
Kg/sq.cm
81. Service man thermometer in – 30 C to +30 C
5sets 2
metal case
82. Scissor, gasket cutting length 25mm
5sets 10
stainless steel
83. L-Allen key set size 1.5mm to
5 sets 10
6.4mm
84. T-Allen key set size 5/32” to 1/8” 5sets 10
85. Pipe cutter with built in 3mm to 32mm
reamer and space cutter, for 5nos. 10
copper tube
86. Pipe /Tube bender lever 3-16 mm
1 no each 10
type
87. Spanner double ended 19mm to 31.8 mm 5nos. 10
88. Pipe wrench size 50mm to 150mm 5nos. 10
89. Gas leak detector for
5nos. 5
halogen gas
90. Sling psychro meter scale 50 C to +50 C
5nos. 10
mounted on aluminum back,
91. Lapping plate 250mm x 200mm 2nos. 10
92. Hammer ball peen 450 gms 5nos. 10
93. Puller 3 legged with flexible 300mm
5nos. 10
arm
94. Hand blower portable 1/10 HP
2nos. 10
complete
95. Spirit level precision 200mm
2nos. 10
metallic
96. Stop watch 2nos. 10
97. Tap set with matching drills 3 mm to 16mm 3nos. 5
98. Tap set with matching drills ¼’’ to 5/8’’ 3nos. 5
99. Refrigerant cylinder 2.5 Kg 3nos. 10
100. Vernier caliper length 250mm 2nos. 10
101. Micrometer outside 0 to 25mm
2nos. 10
measurement
102. Heating kit with infrared (200 w capacity)
2nos. 5
bulb
103. Plumbing hammer weight 200 gm 2nos. 10
104. Multi meter analogue type 5nos. 5
105. Tachometer digital, multi 0 r m p to 3000 r m p. 2nos. 10
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range Portable small size in

leather case
106. Micron vacuum gauge capable of reading up
2nos. 5
to 20 microns
107. Sensor thermometer -50 degree Celsius
(digital) to150 degree
2nos. 5
23Celsius

108. Fin straightened/fin comb. With strong steel wire

based combing on 3nos. 10
wood
109. Filler gauge 0.05 mm – 1 mm 3nos. 10
110. Wire gauge metric and Steel plate embossing
with worth converse of British & 2nos. 10
Metric
111. Dial thermometer remote 75mm – 50C to +50 C
control, armored capillary 3nos.
dial
112. Anemometer Digital type 1no. 10
113. Compressors testers for Fixed with electrical
small hermetic compressors input/ output 2nos. 5
indicating facilities
114. Engineers square 150mm with 5’
5nos. 10
tolerance
115. Digital thermometer Graduated disc
1no. 5
[Treated as consumable] analogy type
116. Temperature &Humidity Capacity to record 24
1no. 5
recorder hrs record
117. Instrumentation screw 100mm
5nos. 5
driver set
118. Digital weighing machine 100 kg 1no. 5
121. Cylinder 134 a 5 kg 1 no. 5

B. General Machinery Shop Outfit

Sl. No Name of Equipment Broad specifications Quantity Life

span
1. Split phase induction ¼ hp, 230 V
1 no. 5
motor
2. Capacitor start induction ½ Hp, 230 V
1 no. 5
motor
3. AC 3 Phase motor, 2 Hp
1 no. 5
400/50 Hz
4. Star delta starter 2 hp 1 no. 5
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5. Auto Transformer starter 3 hp 1 no. 5

6. D.O.L Starter 2 hp 1 no. 5
7. Portable air – LPC 2 kg. LPC cylinder,
brazing kit torches, houses, stand 1 no. 5
make
8. Oxy-acetylene welding cylinders, regulators
set complete welding torches with 1 no. 5
difference nozzles
9. Refrigerator 165L carrying with HFC-
2 Each 7
134a, & HC
10. Frost free refrigerator 200L carrying with HC
2 nos. 7
blend
11. Three/four door 300L carrying with HC
2 nos. 7
refrigerator R-600a
12. Bench Drilling machine 20 mm capacity,200-
1 no. 10
2500rpm
13. Grinding Machine 200mm,3000rpm,Double
1 no. 10
ended1/2 hp
14. Evacuating and 1 no.
refrigerant charging
station, consist of
10
a)Rotary two stage
vacuum pump and motor
(with gas ballast and anti
such back)
b) manifold with gauges
and valves and capable of
pulling vacuum up to 50
microns of Hg and with
provision of connecting
to a microns level
vacuum gauge

b)Graduated charging
cylinder with provision
for temperature (CAP. 2 kg. In lieu of (b)
correction and all above and with accuracy
necessary isolating valves of +/-1 g for charging 1 no.
hydrocarbons)
II) Evacuating and
charging station as above
but fitted with weighing
scale
15. Two stage rotary vacuum capacity approx. 60 – 1 no. 10
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pump 10rmp capable of

evacuating to 50 microns
of Hg and fitted with gas
ballast, anti such back
valve and single phase
motor
16. Air compressor, two stage for oil – less 1 no. 10
dry air, with rush proof
tank assembly, heater
and controls max. pr. 10
kgs /sq.m Capacity 45
ltr. Motor 1 hp.
17. Reciprocating provision of capacity 1 no. 10
compressor control etc. for
demonstration. Capacity
2 ton open type.
18. Dry N2 in cylinder 2 stage regular or 1 no. 10
commercial N 2 in
cylinder with drier unit
and 2 stage regular
7meter cube
19. Window A.C 1 Ton with R-22 or HFC 2 nos. 10
Blend reciprocating
compressor
20. Split A.C 1.5 Ton with R134a or R- 2 nos. 10
22 reciprocating
compressor
21. Duct able split A.C 1.5 ton 1.5 Ton with R134a or R- 1 no. 10
22 reciprocating
compressor
22. Recovery unit with CFC & 134 a 1 each 10
cylinders
23. Cassette Air conditioner 4500 kcal/hr 1 no. 10

24. De scaling pump set with stainless steel 1 no. 10

impeller and housing
complete with motor 1/2
hp and accessories
25. Fan coil unit with water valves (2 & 3 1 no. 10
way)
26. Shell and tube, DX 5 Ton with Cu tubing 1 no. 10
chillers (small) only
27. Circulating water pump 0.5 H.P with stainless 1 no. 10
(small) steel tank capacity 20
liters within let/ outlet
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provision.
28. Shell and tube type 5 Ton 1 no. 10
condenser
29. Rotary hermetic 2 Ton 1 no. 10
compressor
30. Screw compressor 5Ton 1 no.
31. Bottle cooler visible 200 L carrying with HFC- 1 no. 10
134a& reciprocating
compressor
32. Deep freezer 200 L carrying with HFC- 1 no. 10
134a& reciprocating
compressor
33. Water cooler storage 200 L carrying with HFC- 1 no. 10
type 134a& reciprocating
compressor
34. Ice candy plant 2 ton with capacity to 1 no. 10
make 32 ice candy at a
time with Forma tray,
stainless steel tank on
trolley
35. Air-conditioning, direct Complete with all 1 no. 10
and indirect system. controls including
humidity control
capacity 15000Kcal/hr
36. Package A/C 5 ton capacity, Air 1 no. 10
cooled type with open
type compressor
reciprocating type
37. Car A.C components(full 1 Set 10
kit)
a) Wobble plate
compressor with
mounting
brackets.
b) Serpentine
Evaporator
c) Parallel Flow
Condenser
d) Hoses, tubes,
Receiver, Ex.
valve.
e) Electrical
components &
wiring Harness
38. CAR AC tutorial model 1 set
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C. WORKSHOP FURNITURE

SL. Name of Furniture Broad specifications Quantity

1. Class room table One table for each trainee
size of 2.5 provisions with
open rack. Frame square 10 nos.
conduit of1”.top ½” sun
mica ply board
2. Work bench 2000 x1000 x 700 mm with
2” pipe frame. Top with teak
6 nos.
slab and fixing with3/4”
good quality rubber sheet.
3. Almirah 195 x90 x 48 cm outer sheet
20 SWG inner partition with 4 nos.
four selves of 22Swg
4. Lockers 195 x 90 x 48 set six locker
2 nos.
in one structure
5. Glass board 2.5’X4’ with stand
2 nos.
portable
6. Instructor table 4’X2’X2.5’ with steel tubular
1 no.
frame & sun mica top
7. Instructor chair Standard revolving with
1 no.
wheel
8. Computer table Standard with drawers & self
1 no.
to accommodate UPS&CPU
9. Computer chair Revolving type metal based
1 no.
& metal wheel standard one
10. White board 4’X3’ ferrous base sheet to
hold magnetic duster with 1 no.
white finish surface.
11. Chart stand 6’X3’ providing with hanging
1 no.
clip top & bottom plate
12. Computer latest Ddr-3 -1333Mega Hz, GB -
version with printer 6,hard disc -
1terabite,processor-I5 1 no.
second generation, laser get
,LED monitor 32”
13. LCD PROJECTOR / Big Size
1 no.
LED / LCD TV
14. Laptop Latest version 1 no.
15. UPS 650 VA 1 sets
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16. Stool 2’ x 1.5’ 10 nos

17. Book Self with glass 6’ x 3’
1 No.
panel
18. Storage rack 6’ x 3’ 2 nos
19. Storage shelf 6’ x 3’ 2 nos

D. LIST OF CONSUMABLES.

SL. Name of consumables Broad specifications

1. Copper tube ¼”,5/16”,3/8”,7/16”,1/2”,5/
8”
2. Capillary tube 0.026 to 0.64”
3. Flare nut ¼”,5/16”,3/8”,7/16”,1/2”,5/
8”
4. Straight union ¼”,5/16”,3/8”,7/16”,1/2”,5/
8”
5. Half union ¼”,5/16”,3/8”,7/16”,1/2”,5/
8”
6. Elbow ¼”,5/16”,3/8”,7/16”,1/2”,5/
8”
7. Tee ¼”,5/16”,3/8”,7/16”,1/2”,5/
8”
8. Brazing rod Cu to Cu
9. Brazing flux Borax
10. Kerosene
11. Diesel
12. Cotton waste
13. Baniyan waste
14. Nitrogen
15. L p g brazing kit
16. Lapping paste Hard and Soft
17. Refrigeration oil Capilla – D- Oil
18. Charging line 500 psi
19. Carbide
20. Door switch 5 amps
21. Refrigerator Bulb 15 watts
22. Box type relay 1/6, 1/8 Hp
23. Open type relay 1/6, 1/8 Hp
24. Thermal relay 1/6, 1/8 Hp
25. OLP 1/6, 1/8 Hp
26. Thermostat -15degree Centigrade
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27. Door Gasket 15 mm

28. Drier D N 50, 150
29. De frost heater
30. Defrost timer 4 -6 Hr
31. Bimetal thermo
32. Wiring leg 5 mm
33. Hand shut off valve ¼“
34. Solenoid valve 230 V, ¼ “
35. L P Cut out 40 psi
36. H P Cut out 240 psi
37. Oil pressure cut out 40 psi
38. Tread seal 10 mm
39. Starting capacitor 60-80 Mfd
40. Running capacitor 40 Mfd
41. Fan Capacitor 4 mfd
42. Flexible Wire 1.5 mm
43. Freon gas 12
44. Freon gas 22
45. HFC 134 a
46. Match box
47. Washing soap
48. Incandescent lamp 500 W
49. Cell 12 V
50. L.M.S relay ¼, 1/6, 1/8 HP
51. Sand paper
52. Stove pin
53. Epoxy compound/ M seal
54. Gloves for welding[Treated as
consumable]
55. Leather Apron [Treated as
consumable]

Note:- 1, Consumables may procure according to skills requirements.

2, Specification may change depends upon availability of market.

3,Quantity depends up on number of trainees.

aglasem.com Career Railways

SEMESTER-1

Syllabus for Workshop Sc. and calculation

Week No Workshop sc. and calculation

1 General simplifications. Fractions, Types of fractions, common fractions,

Decimal fractions with examples Addition, subtraction, multiplication and
division of fraction

2 Addition, subtraction, multiplication and division of fraction

Reduction of common fraction to decimal.

3 Square & Square root Square root of perfect square, Square of whole number
and decimal.

4 Methods of finding the square roots.

Division method
Factorization method,
Log tables using method.

5 Problems using log for finding cube, fourth, fifth root

6 Applications of Pythagoras theorem and related Problems.

7 Percentage & its application

8 Unit & Measurements Introduction, Definition, classification of System of

units, Fundamental & derived units. C.G.S, M.K.S,. F.P.S, & S.I System of units

9 Metric system of weight and measurement unit and conversion factors,

problems.

10 Laws of indices or exponents with examples.

11 Introduction, use of Electricity, Molecule, Atom, and How Electricity is

Produced, Electric current, voltage, Resistance and their units. Ohm’s law.

12 Relation between V.I.R & Problems.

13 Series & Parallel circuits & Problems

14 Electrical Power and energy & their units & calculation

15 Magnetic Induction, Self & Mutual Inductance, EMF generation.

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16 METALS:
Properties and use of cast iron, wrought iron Plain carbon steel, Alloy steel.
Effect of Alloying elements and properties of metals

17 Properties and uses of copper, zinc, lead tin, aluminum etc., Properties and uses
of Brass, Bronze as bearing material.

18 Meaning of tenacity, elasticity, malleability brittleness, hardness, ductility

19 Meaning of tenacity, elasticity, malleability brittleness, hardness, ductility.

20 Heat and Temperature,

Measurement of Temperature, Boiling and melting points.

21 Interchange of heat, (Principle of calorimetry)

Co-efficient of linear expansion, Related problems

22 Vapors and gases. Saturated and superheated vapors, Critical pressures and
temperatures. Heat transfer conduction, Convection, Radiation. Thermal
conductivity and Insulations.

23 Revision

24 Revision

25 Revision

26 Exam

SEMESTER -2

Syllabus for Workshop Sc. and calculation

Week No Workshop sc. and calculation

1 Ratio & Proportions,

Introduction, Examples Types of Proportions, direct proportion

2 Indirect proportions compound (Combined) proportions.

3 ALGEBRA
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Algebraic symbol, addition, subtraction

4 ALGEBRA
Multiplication and division.

5 Simple equations

6 Standard formulas, simple simultaneous equations with two and three

unknown quantities.

7 Simple algebraic problems. Factorization Quadratic equations, Related

problems.

8 Pressure Atmospheric, Absolute barometric and gauge pressures and

vacuum pressure, Bourdon gauges, compound and vacuum gauges.

9 Evaporation Boiling condensation Freezing Effect of pressure on these. Study

of Tables & Charts.

10 Gas Laws Perfect and real gases,

Boyle’s law
Charles’s law
Dolton’s law.
Pascal’s law
Joule’s law

11 Chemistry of common elements, like carbon, oxygen, Hydrogen & halogens.

12 Chemistry of common elements Hydrogen & halogens.

13 Chemistry of Ammonia, Co2, CFCs, HCFCs, HFCs and HCs.

14 Work, power, Energy, Definitions and Their units, related problems.

15 Horse power of engines- IHP, BHP, Mechanical Efficiency- and Related

problems
16 Uses and Sources of Energy. Kinetic and Potential Energy. Their applications
& related problems
17 Transmission of Motion & Power transmission By belt drive, gear drive,

18 Problems related to belt drives. Slack side, light side.

=
19 Problems related to gear drives.
=
20 Compound gears and simple problems,
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21 Speed & Velocity Definition & Units. And Related calculations.

22 Rest & Motion, Scalars and Vector quantities, displacement, speed, velocity,
acceleration & Retardation
Equations of motion of a body. Motion under the force of gravity.

23 Revision

24 Revision

25 Revision

26 Exam

SEMESTER -3

Syllabus for Workshop Sc. and calculation

Week No Workshop sc. and calculation

1 Mensuration
Geometric properties. Line, angle, triangle and circle.
2 Mensuration --Area of square, triangle

3 Mensuration --Area of circle and ellipse

4 Calculation of area of triangle, polygon etc

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5 Calculation of Volume & weight of simple solid bodies.

6 Volume & weight of regular cone sphere.

7 Volumes & weight of simple hollow bodies

8 Logarithms introduction,

9 Logarithmic reading from table, determination of characteristic &

antilogarithm.
10 Applications of logarithms. Finding cube roots, square roots. Etc... Using log.

11 Solution of complex problems using logarithms.

12 Simple machines Effort & Load, mechanical advantage, velocity ratio,

efficiency of machines
13 Relationship between mechanical advantage, velocity ratio, efficiency of
machines.

14 Simple machines such as Pulley block, inclined plane, simple wheel and axle,
differential wheel and axle ,simple screw jack,

15 Stress, strain,
Introduction & their units. Types of stress,

16 Modulus of Elasticity, Ultimate strength. Yield point, Ultimate stress, &

working stress.
17 Stress- Strain graph. Modulus of Rigidity. Poisson’s Ratio, Bulk modulus,
Related problems.

18 Archimedes principle. Law of floatation, and use of Hydrometer.

19 Examples of floatation Study of weight, gravitation and centre of gravity.

20 Methods of finding centre of gravity figures, & centre of gravity of certain

geometrical figures.
21 Study of Matter, mass. Volume Density & specific gravity. Related Problems,

22 General laws of Thermodynamics 1st & 2nd laws, Mechanical equivalent of

heat.
23 Revision

24 Revision
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25 Revision

26 Exam

SEMESTER -4

Syllabus for Workshop Sc. and calculation

Week No Workshop sc. and calculation

1 Graph-
object & use of graph, Rules of plotting, graph interpolation
2 The plotting of coordinates, Representation of simple equation.

3 Estimating and costing Applied problems.

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4 Trigonometry, definition & Trigonometric functions-

5 Standard formulae.

6 Relationship between Trigonometrically ratios.

7 Problems

8 Measurement of angles.

9 Use of natural trigonometric table

10 Problems using natural trigonometrically table

11 Use of Logarithmic trignometrical tables

12 Problems using Logarithmic trignometrical tables

13 Trigonometrically values of certain degrees, Trignometrical values for any

angle.
14 Area of triangle using Trigonometry,

15 Solution of triangles using sine rule and Cosine rule.

16 Heights and Distances. Angle of elevation, Angle of Depression.

17 Height and distance --Applied problems

18 Hygrometry, properties of Air relative and absolute humidity and other

Properties.
19 Heat load calculations of Air Conditioning plant. Calculation of volume of
room, various heat loads, A.C Tonnage calculation.

Heat Treatment,
Function of heat treatment, Critical temperature, Different processes of heat
20 treatment.
Annealing, Normalizing, Hardening, Tempering, Case hardening.

Corrosion, corrosive. Action due to electrolytic and galvanic corrosion.

Corrosion protection FORCE
21 Definition, Units. Resultant force, Space and vector diagrams,
Representation of force, Parallel force, couple, Law of Parallelogram forces,
Law of triangular forces, kinds of equilibrium with some examples. Lamia’s
Theorem. Resolution of forces, Applied problems,-
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22

23 Revision

24 Revision

25 Revision

26 Exam

SEMESTER -1

Syllabus for Engineering Drawing

Week No Engineering Drawing

1 Introduction to Engineering Drawing and Drawing instruments.

2 to 3 Sheet lay out, line, types, dimensioning, types and symbol for drawing.

4 to 5 Lettering of alphabets and numbers. Single stroke ( vertical and inclined)

5 to 6 Dimensioning, Aligned and unidirectional system, Arrangement of

dimensions.
6 Scales, full scale and Half scale

7 to 9 Free hand sketching of simple solid cube, rectangular block, cylinder etc.,

10 to 12 Geometrical constructions. Lines, angles, triangle, quadrilaterals, polygons,

Ellipse and types etc..
12 to 15 Introduction to Isometric views of simple objects such as cubes, rectangular
block, prism, pyramid etc..
16 to 21 Introduction to orthographic views of simple objects such as cubes,
rectangular block, prism, pyramid etc.. In 1st angle projection.

22 REVISION

23 REVISION

24 REVISION

25 REVISION
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26 EXAM

SEMESTER -2

Syllabus for Engineering Drawing

Week No Engineering Drawing

1 to 3 Simple isometric views of solid & hollow object.

4 to 7 Simple orthographic views of solid & hollow object in 3rd angle projection.

8 to 11 Isometric views of Machining object.

12 to 15 Orthographic views of Machining object. In 3rd angle projection.

16 to 18 Drawing of different types of Screw threads, locking devices, keys & cutters.

19

Trade Related symbols Electrical, Electronic and Mechanical

20 to 21 Free hand sketches of trade related tools, instruments & machines.

22 REVISION

23 REVISION

24 REVISION

25 REVISION

26 EXAM
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SEMESTER -3

Syllabus for Engineering Drawing

Week No Engineering Drawing

1 to 4 Sectional Blocks and views and types of sections, (full, Half, Offset
Sectioning)
5 to 7 Drawing of rivet & riveted joints.

8 to 11 Drawing of different types of nuts & bolts, Studs, machine screws, Washers,
foundation Bolts, Set screw and Grab Screw.
12 to 15 Drawing different types of clutches, coupling, bearing and lubrication
systems.
16 to 17 Drawing of pulley and pulley drive gear and gearing

18 to 19 Trade related Drawing of compressor and pump parts such as piston,

connecting rod, crankshaft valve etc.,
20 to 21 Trade related Drawing involving electrical Circuit Diagram.

22 Development of surface of simple object.

23 REVISION

24 REVISION

25 REVISION

26 EXAM
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SEMESTER - 4

Syllabus for Engineering Drawing

Week No Engineering Drawing

1 to 2 Curves of Interpenetration

3 to 6 Isometric and Orthographic Views of complicated objects.

7 to 9 Conversion of simple orthographic views to Isometric views.

10 to 12 Blue print Reading.

13 to 14 Trade related wiring circuit of window, Split, package and central Air
conditioning.
15 to 19 Prepare charts related to trade like Refrigerator, water coolers, freezers,
Vapour compression cycle, vapour absorption cycle and all types of
compressor & Expansion valves, working cycle sketches.
20 to 21 Computer aided drafting.

22 REVISION

23 REVISION

24 REVISION

25 REVISION

26 EXAM
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Trade Testing and Certification

Same as for other similar Engineering Trades.

Further Learning options

After successful completion of CTS Course in the trade of RAC, the trainees have the
option to continue their further studies by joining the CITS Course in the same trade,
which is of two semester’s duration. (Or) The trainees can apply 3 year Diploma
course in polytechnic.
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