KEMPPI-AMAL JYOTHI CENTREFOR WELDING & CERTIFICATION

KACWAC

KACWAC

Kemppi-Amal Jyothi Centrefor Welding & Certification

Contact Info

Amal Jyothi College of EngineeringKanjirappally, Koovappally P.O.

Kottayam District, Kerala, India – 686518,

Phone: +91 989 57 36 781 / +91 95 44 033 111

Metallurgy Department

Amal Jyothi is a mega complex of nearly 13.5 lakh sq.ft. built-up area

overlooking the busy Kanjirapally-Erumeli stretch of the Kottayam-Sabarimala

state highway. The two campus hostels, taken care of by dedicated Catholic

priests and nuns, have a capacity of 2200 inmates. The campus has 100 Mbps

internet connectivity with WiFi. Amal Jyothi is the only engineering college in

the state to have a Catholic priest as Principal who secured first rank in both

B.Tech (Calicut University) and M.Tech (IIT Kharagpur)

Welding is precision work where the quality requirements are very

high. Today, there is high demand for welding professionals and

industries experience a continuous shortage of welders in India

year after year. Though welders from abroad are plentifully

available, the language barrier often restricts their employability.

The importance of local welders is emphasized at welding sites

where it is not enough to produce a straight weld. KACWAC is

planning to cater primarily in this area by training welders (men

and women). In addition to the short term courses of 8 to 16

weeks on specific welding procedures, the institute also provides

Some facts about Arc Welding

Arc-based welding refers to the fusing of pieces of metal by using heat. The

heat produced by the arc melts the pieces together.

Usually a welding rod having approximately the same melting point and

composition as the material to be welded is melted by the arc and

deposited along the edges of the weld pieces shaped into a suitable

welding groove creating a molten weld pool. For the weld to be durable, the

molten weld pool must be protected from oxidation and protected from the

surrounding air using a shielding gases or slag. The shielding gas is fed into

the molten weld pool with the welding torch. The welding electrode is also

coated with a material that produces shielding gas and slag over the molten

weld pool.

The arc in welding is a burst of electricity between the welding electrode and

the weld piece. The arc is generated when a sufficiently high voltage ionizes

the air gap, with a temperature of the order of 10,000 C. A continuous current

from the welding power supply to the work piece is established through the

welding electrode, and therefore the work piece must be grounded with a

grounding cable in the welding machine before welding is started.

The welding technique of the welder affects the smoothness of the arc and,

subsequently, the quality of the weld. The distance of the welding electrode

from the groove and a steady speed of the welding torch are important for

successful welding. Assessing the correct voltage and wire feed speed are an

important part of the welder's competence.

Amal Jyothi College of Engineering, Kanjirapally, is the first new generation engineering college

in Kerala to secure the prestigious NBA accreditation for prime departments. The main features of the

college comprise world- class infrastructure, top-flight faculty, high pass percentage, excellent placement

record and unique student projects.

IN BRIEF

Kemppi Oy of Finland, a leading global name in the field of

arc welding equipment. They have a manufacturing

facility in Chennai, the first production unit of Kemppi

outside Finland. KEMPPI, Chennai, for fulfilling their social

responsibilities as a leading corporate has initiated in

collaboration with Amal Jyothi College of Engineering,

Kanjirappally a Kemppi-Amal Jyothi Centre for Welding &

Certification (KACWAC) at Amal Jyothi College campus.

Our Mission

To create technically qualified world-class professionals with social commitment through

career-oriented courses conducted by high profile faculties, complemented with globally

interactive learning processes and leading edge technology.

Our Vision

To be a centre of excellence in technical higher education, research and

support services, capable of making significant contribution to individual and

societal empowerment.

a two weeks on specific welding procedures, the institute also provides a two semester complete welding training

course in all aspects of various arc welding procedures. The course has been tailored for unemployed persons and

working people alike who wish to supplement their professional competence.

Welding courses under this school is designed to impart basic skill of different welding processes combining

theoretical and practical aspects of structural welding. The courses are planned with 30% theory and 70% practical.

Amal Jyothi College of Engineering, Kanjirappally in collaboration with Kemppi, Chennai opens a new avenue for

young boys and girls who cannot afford to get admission to engineering schemes. KACWAC is open both boys and

girls who have passed 12th standard with proficiency in English. 50% of the seats are reserved for girls.

KACWAC KEMPPI-AMAL JYOTHI CENTREFOR WELDING & CERTIFICATION

Our Mission

æ Technical excellence in skilled labour

æ Empowering women in skilled labour

It is understood between the parties that at the end of the course, KEMPPI and/

or KEMPPI's dealerships shall have a privilege to select the students, who have

undergone training at KACWAC. However the students will be free to exercise

their option. KEMPPI may also try to introduce the successful trainees to other

corporates who use KEMPPI welding machines. This training shall never be

considered as creating the employer and employee relationship between

KEMPPI and students.

The welding field remains a male-dominated workplace Very few young women enter into the

school phase of life with the idea to become a qualified welder. While woman boldly take up the

role of welders in a foreign country, this training program will hopefully attract women

enthusiasts to become a qualified for various development works in Kerala.

Metal Inert Gas (MIG) Welding / GasTungsten Arc Welding (GTAW/TIG)

The course has been designed for those who intend to acquire

welding proficiency in Metal Inert Gas Arc Welding (MIG) and TIG

welding process. The course aims to provide (a) the basic

principles and operation of AC-DC transformer type welding

machines, (b) fundamentals of MIG / TIG welding process (c),

influence of heat ranges, polarities, and the use of wire electrodes

and shielding gases. Eessential skills in welding of mild steel,

stainless steel, aluminum and its alloys in flat, horizontal, and

vertical positions will be provided so as to cope with the demand

of industrial sector. Safety in welding and the use of tools and

equipments will be emphasized throughout the course.

Course content

æ Introduction to principles of MIG welding

æ Familiarization of GTAW/TIG process

æ Safety precautions during welding

æ Welding symbols

æ Welding tools, equipments, accessories

and power sources used

æ Handling of equipments

æ Types of joints and their preparation

æ Welding electrode and their selection

æ Selection of tungsten electrode and

shielding gases

æ Selection of filler metal and their care

æ Welding technique

Shielded Metal Arc Welding (SMAW)Structural and Pipe 6G positions

Initially Oxy-Acetylene cutting of mild steel in a safe and efficient manner will

be perfected. This program is designed to develop skilled welders with

theory based knowledge and practical training for using proper techniques

for the SMAW process for various welding geometries and positions. At the

conclusion of this course trainees will be able to produce defect free welds

and demonstrate new and/or improved skills using the SMAW in various

positions. The students will be trained for pipe welder qualification &

certification as per ASME. This is essential before any welder can be

permitted to weld pressure vessel/piping jobs. A student successfully

completing this course will be capable of welding pipe using the SMAW

process in the 6G position. Students will be able to take the ASME/AWS 6G

pipe certification after completing this course.

Course content

æ Basics of Oxy-Acetylene flame

æ Oxy-Acetylene flame adjustment for

cutting and welding

æ Safety precautions in handling oxygen

and acetylene

æ Introduction to principles of SMAW

æ Safety precautions during welding

æ Welding symbols

æ Welding power source

æ Types of joints and their preparation

æ Welding electrode and their selection

æ Welding techniques

æ Defects in welding – causes and remedies

æ Inspection and testing of weldments

æ Economics of welding

æ Pulsed TIG welding

æ Weld inspection

æ Process related defects and remedies

Course No: KACWAC-2Duration : 16 weeks Course fee : Boys ` 21,000/- Girls ` 19,000/-

Pre-requsite : Knowledge of SMAW Certification : Welder MIG/TIG

Course No: KACWAC-1Duration : 16 weeks Course fee : Boys ` 21,000/- Girls ` 19,000/-

Pre-requsite : A pass in 10th Certification : Welder SMAW

Facilities @ KACWAC

Advanced Welding Training Course

This program is designed for certified welders who are out of touch for a long time. This training program will be useful for

them to refresh their skills and experience. This program will be mostly (75%) practical oriented using different arc welding

processes on plates and pipes in all positions. Upon completion of the course, students will be able to pass trade test and

obtain entry level jobs in construction of bridges, fabrication of structural components, pipeline welding and other job shop

applications.

Course No: KACWAC-3Duration : 8 weeks Course fee : ` 15,000/-

Pre-requsite : Knowledge of SMAW, MIG and TIG welding

Introduction

æ This course is meant for the

students who want to become a

professional welder specializing

in arc welding process.

æ This course is structured for

having the basic skill in oxy-

a c e t y l e n e f l a m e a n d a r c

welding.

æ Skills in TIG / MIG Welding will

be offered to the students who

are conversant in SMAW.

Terminal Competencies/Deliverables

After successful completion of this course the trainee

shall be able to perform the following skills with

proper sequence.

æ Straight, Bevel & Circular cutting on MS plate by Oxy-

Acetylene cutting process

æ Joining of MS sheets using Oxy-Acetylene welding

æ Setup and Weld Lap, “T”, corner and butt joint on mild steel,

stainless steel and Aluminium by SMAW process

æ Welding of M.S. Plate in all position by SMAW process.

æ Welding of Tubes by SMAW process

æ Welding using MIG process

æ Welding using TIG process

æ Repair & Maintenance works

COURSE INFORMATION

Items to be owned by students

The following items shall be owned by students (both boys and girls)

æ Boiler suit (Colour to be decided)

æ Safety shoes (leather)

æ Aprons (leather preferred)

æ Hand gloves (Leather and cotton)

æ Spark lighter

æ Stainless steel rule 300mm

æ T- square 6”

æ Scriber 150 mm double point

æ Centre punch 9 mm x 127 mm

æ Dividers 200 mm

Items available to the students @ KACWAC

æ S.S Wire brush 5 rows and 3 rows

æ Arc welding single coloured glasses 108 mm x 82 mm x 3 mm.

æ Gas welding Goggles with Colour glass 3 or 4A DIN

æ Safety goggles plain

æ 6” Grinding wheels

æ Welding helmet fiber

æ Welding hand shield fiber

æ Chipping hammer with metal handle 250 Grams

æ Chisel cold flat 19 mm x 150 mm

æ Flat Tongs 350mm long

æ Hack saw frame fixed 300 mm

æ File flat 350 mm

æ File half round bastard 300 mm

æ Weld simulator

Employment opportunities

On successful completion of this course, the

candidates shall gain adequate knowledge to be

fully employed in the following industries:

æ Structural fabrication like Bridges, Roof structures,

Building & Construction.

æ Infrastructure, Automobile, Railways and allied industries

æ On site construction activities for Power Stations,

Petrochemical Industries (ONGC, IOCL, HPCL etc), Mining

industries etc

æ Ship building and repair

æ In public sector industries like BHEL, BEML, NTPC, DAE,

ISRO etc

æ Private industries in India and abroad.

æ Self employment

KACWAC

Welding booth with fume extractor 5 nos

Classroom with LCD projector 1 no

Weld pad preparation room with pug cutting machine 1 no

KEMPPI Make IGBT Inverter Based Welding Rectifier Model: Hi Arc S 400R 1 no

KEMPPI Make IGBT Inverter Based Welding Machine Model: MASTER-2500MLS. 1 No

KEMPPI Make IGBT Inverter Based Single phase TIG Welding Machine

Model: MINARC TIG EVO 200 MLP. 1 no

KEMPPI Make IGBT Inverter Based Welding Rectifier Model: Hi Arc S 400A 5 nos

KEMPPI Make IGBT Inverter based MIG/ MAG Welding Machine

Model: KEMPACT MIG-2530 1 no

KEMPPI Make IGBT Inverter based Multi Purpose MIG/MAG Welding

Machine Model: Fast MIG X 450 with CC/CV Characteristics 1 no

Qualified (M.Tech – Welding) faculties and Instructors