Air-Conditioning & Refrigeration (ACR) Tutorial Course – Level 1

Course outline

Introduction to Refrigeration and Air Conditioning (6 hours)

• Define refrigeration
• Identify the basic components of a refrigeration cycle
• Identify the various gases (refrigerant) and their importance to a basic knowledge of physics
• List six modern-day applications serviced by the refrigeration and air conditioning industry

The Compression Refrigeration Cycle (6hours)

• Explain why a liquid boils and changes to a saturated vapour and conversely, why a saturated vapour changes to a liquid
• Describe a refrigeration system. Explain the function of a receiver. Explain the function of metering devices.

Refrigeration Evaporators (6hours)

• Identify various types of evaporators
• Evaluate evaporator coil performance criteria
• Select proper fin spacing for a particular application
• Match the evaporator capacity to the condensing unit
• Describe the evaporator selection process. Identify proper evaporator locations
• Explain the need for defrosting

Capillary Tubes (6 hours)

• Explain the function of the capillary tube
• Identify the capillary tube’s application characteristics
• Explain the principles of capillary tube operation
• Describe what should and should not be done to ensure satisfactory performance in a system that uses a capillary tube

Thermostatic Expansion Values (6hours)

• Describe how a thermostatic expansion value operates
• Name the three pressures that affect the opening and closing of a TEV
• Explain when a TEV with a remote charge is normally used
• Specify where a gas-charged TEV should be installed in relation to the bulb
• Explain the difference between internal equalizers and external equalizers
• Discuss the importance of a properly selected TEV to the efficient operation of a refrigeration system

Split – Unit Air-conditioning System (30 hours)

• Introduction of product (including models, capacities, voltages, etc)
• Working with R-410a refrigerant
• Installation requirements and procedures including but not limited to:
  • Brazing of refrigerant lines/ need for nitrogen purge
  • Selection and installation of refrigerant piping
  • Evacuation requirements
  • Refrigerant charging calculations and methodology
  • Installation and supporting of indoor and outdoor units
  • Installation/interfacing of accessory items
  • Required installation clearances
  • Power wiring requirements
  • Control wiring requirements
  • Operating characterises
  • System commissioning including:
    • Pre start up checks and inspections
    • Sequence to start the system
    • Auto addressing of system
    • Controls programming
  • Post start up checks including voltage, amperage, pressure
  • Hands-on Practical system operation
  • Connection and use of Service Diagnostic Tool (Time Permitting)

Duration of Course: 60 hours

Automotive Technology (AUT) Tutorial Course – Level 1

Course outline

Engine Service (30 hours)

Students are trained to service and replace automotive engine components. They are able to diagnose simple engine mechanical problems; completely disassemble and reassemble a petrol engine. Carry out measurement, inspection on engine components. Rectify simple fuel system, cooling system and lubrication system faults.

Transmission Service (30 hours)

Students are trained to service and replace automotive transmission components. They are able to diagnose clutch and transmission and axle problems. Overhaul clutch and manual gearbox on a vehicle. Carry out testing, inspection and rectify simple transmission faults.

Control service (30 hours)

Students are trained to service and replace automotive control system components. They are able to diagnose steering, suspension and brake systems’ problems. Overhaul manual steering, mechanical suspension and hydraulic braking systems on a vehicle. Carry out testing, inspection and rectify all the control system mechanical faults. Balance wheel and carry out safety inspection on vehicle under-carriage.

Autotronics (30 hours)

Students are trained to interpret measure and troubleshoot electrical and electronic circuits and systems. They are able to diagnose vehicle lighting, charging, starting and other electrical systems’ problems. Overhaul starter motor, alternator, lighting, and other vehicle electrical systems on a vehicle. Carry our testing, inspection and rectify all the electrical faults on vehicle. Maintain vehicle battery and carry out safety inspection on vehicle electrical systems.

Duration of Course: 120 hours

Basic Mechanical Technology (BMT) Tutorial Course – Level 1

Course outline

Mechanical Fabrication (15 hours)

1. Using common hand tools
2. Using calipers to verify dimensions to an accuracy of 0.02mm
3. Fabrication
   • Square and peg fitting
   • Dovetail and parallel slides assembling

Industrial Piping and Valve System (15 hours)

1. Assemble a pipe-work with bending and threaded fitting (galvanized)
2. Service of Lift-type fluid valves (Globe and Gate valves)

Machinery Maintenance (15 hours)

1. Service a chain-block
2. Replace anti-friction bearing
3. Service roller chain drive
4. Replace Vee belt drive

Industrial Pneumatics and Hydraulics (15 hours)

1. Assemble basic pneumatic circuits
2. Assemble basic hydraulic circuits

Duration of Course: 60 hours

Advance Mechanical Maintenance (AMM) Tutorial Course – Level 2

Course outline

Electro-pneumatics (40 hours)

• Replace electro-pneumatic system
• Design and assemble basic electro-pneumatic circuits using logic function in direct & indirect control of pneumatic cylinder
• Design and assemble basic electro-pneumatic circuits using latching function of pneumatic cylinder
• Assemble electro-pneumatic sequencing circuits using electrical memory method
• Design and assemble electro-pneumatic sequencing circuits using Electrical Cascading Method
• Assemble electro-pneumatic sequencing circuits using control method
• Troubleshoot and rectify faults in electro-pneumatics system
• Classroom tutorial

Machinery Maintenance (20 hours)

• Align the tailstock of a centre lathe machine using dial-gauges
• Service gear drives transmission until of machine
• Service the tailstock of a centre lathe machine
• Service slides and slide-ways mechanism of machine
• Service feed mechanism of machine
• Classroom tutorial

Electrical Maintenance (20 hours)

• Demonstrate the correct safe work practices and proper use of electrical testing equipment and electrical accessories used in the workshop
• Connect a single-phase magnetic switch and single-phase direct-on-line motor starter and perform testing of electrical components
• Connect a single-phase magnetic switch and 3-phase direct-on-line motor starter and perform testing of electrical components
• Classroom tutorial

Plant Equipment Maintenance (40 hours)

• Service a Centrifugal pump
• Service a Reciprocating air compressor
• Service a Air-operated diaphragm pump
• Pipe threading using a threading machine
• Classroom tutorial

Duration of Course: 120 hours

Electronics (ECS) Tutorial Course – Level 1

Course outline

1. Common Electrical and Electronic Components and their uses
   • Resistors, Capacitors, Inductors, Switches, Fuses, Mains plug, Loudspeakers, Cables
   • Resistor Colour Code, Reading Resistor and Capacitor values
   • Types of switches and their connections
   • Ohm’s Law – series and parallel connections
2. Semiconductors
   • Semiconductors and PN junction
   • Forward and reverse bias
   • Junction diode, zener diode, LED and their uses
3. AC and DC values
   • AC waveform
   • Peak, peak-peak, average and RMS values
   • Calculation of above values
4. Rectification and Power supply
   • Half wave, Full wave and Bridge connection
   • Capacitor filter
   • IC regulators eg LM7805 and LM317
5. Transistors
   • PNP and NPN transistors
   • Biasing of transistor circuits
   • Common emitter, common collector and common base connections
   • Simple gain calculations
   • Simple analysis of a common emitter amplifier
6. SCRs, Triacs and Diacs, Photoelectric devices
   • Brief introduction of above components and their uses
7. Operational Amplifiers
   • Brief introduction
   • Inverting, Non-inverting and Voltage follower
   • Typical IC Op-Amp-LM741
8. 555 Timer IC
   • Typical IC layout and circuit
   • Uses of the IC timer
9. Digital Circuits
   • Simple Boolean Algebra – And, Or, Not, Nand and Nor
   • Logic Diagrams and Truth Tables
   • Typical IC and their diagrams
   • Other logic circuits like Flip-flops and simple counter/decoder circuits

Practical Assignment and Exercise

1. Familiarization and use of tools and equipment
   • Tools - Soldering Iron, Iron stand, Desoldering Tool, diagonal cutter, long nose plier, test pen, strip board(veroboard) cutter, bench drill, bench vice, files, etc
   • Equipment – DC Power Supply, Analogue Multimeter, Digital Multimeter, Function generator, Analogue Oscilloscope, etc
2. Reading of Resistor and Capacitor values
   • Connection of series and parallel circuits and their measurements
   • Ohm’s Law – Resistance, Current and Voltage – Reading resistance, current and voltage
   • Use of DC power supply, analogue and digital multimeters
3. Reading of Capacitor values
4. Soldering practice exercises using wires and on strip board
   • Reading of circuit drawings (including data sheets) and soldering connections to strip board
   • Identify components and Plan layout of components and wires (20 to 25 components)
   • Check of accurate and correct connection and quality of solder joints
5. Using function generator and oscilloscope
   • Familiarize with the various controls
   • Adjustment and calibration for measurement
   • Observation of sine, triangle and square waveform
   • Measurement of peak and peak-peak voltage
   • Measurement of period and frequency
   • Measurement of circuit under test (eg half-wave and bridge rectifier circuits)
6. Reading and testing of diodes and transistors, including LEDs (normal and 7-segment)
   • Measurement of transistor voltage wrt ground using multimeter
   • Applying input signal and observe input and output waveforms
   • Measure the peak and peak-peak values
7. Simple logic experiments
   • AND, OR, NOT, NAND and NOR gates
   • Logic levels
   • Reading digital IC pin layout
8. Project Construction, eg
   • Common emitter amplifier (1 or 2 stages)
   • Simple dc power supply
   • Logic probe
   • 7- segment display
   • 555 timer circuit
   • Combination of above circuits
9. Troubleshooting of electronic circuits(25 to 50 components)
   • Use the theory knowledge and practical skills to understand the function of the circuit and circuit components
   • Reading the circuit from the PCB side
   • Carrying out measurements - voltage, resistance and waveform observation (able to use power supply, function generator, analogue and digital multimeters, oscilloscope and connection cables)
   • Using the theory understanding to deduce the possible fault (one fault)

Duration of Course: 60 hours

Electrical Technology (ELT) Tutorial Course – Level 1

Course outline

Circuit Connection (10 hours)

1. Reading of electrical measuring equipment
   • Single Scale
   • Dual Scale
2. Assessment on meter reading
3. Connection of electrical measuring instruments
   • Ammeter
   • Voltmeter
4. Circuit connection with resistors, capacitors and inductors
   • Series circuit
   • Parallel circuit
   • Series – parallel circuit
5. Circuit connection in a balance load
   • Star connection
   • Delta connection
6. Assessment on circuit connection

PVC Trunking (8hours)

1. Prepare trunking bends and bridges
2. Complete assembly for PVC trunking installation
3. Interpret wiring diagram
4. Design and draw circuit for a final circuit
   • One-way control of lightning
   • Two-way control of lightning
5. Socket outlet connection using a radial circuit method
6. Socket outlet connection using a ring circuit method
7. 15A socket outlet connection
8. Connection of consumer unit
9. Selection of overcurrent protective devices
10. Assessment on circuit drawing and installation in PVC trunking

Conduit (10 hours)

1. Threading of conduit
2. Use of conduit bender
3. Preparing conduit bends
4. Assembling of conduit and accessories
5. Drawing of cables into the conduit
6. Assessment on conduit assembly

Motor control (10hours)

1. Identify the type of starters
   • DOL starter
   • Forward/Reverse starter
2. Differentiate between power and control circuit
3. Draw main circuit for DOL and Forward/Reverse starter
4. Draw control circuit for DOL and Forward/Reverse starter
5. Connect remote station to starter circuit
6. Assessment on motor control circuit with remote station

Fault Finding on Motor (10 hours)

1. Connection of motor in star and delta
2. Use and read a multi-meter
3. How to use a meggar
4. Identify possible faults in a motor
5. Use of measuring instrument to locate faults in a motor
6. Assessment on fault finding on motor

Duration of Course: 48 hours

Electrical Technology (ELT) Tutorial Course – Level 2

Course outline

Automation & control (30 Hours)

• Program PLC for sequence operation
• Produce a ladder diagram from a given set of codes
• Design and install a PLC control project
• Assessment on PLC programming

Switchboard installation (30 Hours)

• Wire up indicating instruments
• Wire up protective devices of a switchboard
• Testing of over current protective devices
• Maintain LV main switchboard control panels

Electronic Principles (20Hours)

• Understanding of logic gates
• Connect simple digital circuits
• Check semiconductor devices(diode, zerne and transistor)
• Build simple electronic circuit

Electronic Drives (20 Hours)

• Determine the characteristics of a DCC machine
• Determine the characteristic of a 3-phase induction motor
• Determine the characteristic of a 3-phase alternator
• Connect and test Electrical Drive System for DC motor
• Connect and test Electrical Drive System for AC motor

Computer –Aided Design & Drafting (20 Hours)

• Use editing tools in AutoCAD
• Draw electrical symbols
• Produce electrical SLD drawings for residential premises
• Produce electrical SLD drawings for industrial premises
• Produce drawings of main switchboard

Duration of Course: 120 hours

General Welding (GWG) Tutorial Course – Level 1

Course outline

Oxy-Fuel Gas Cutting

Perform cutting and bevelling on steel plates and pipes in flat, horizontal and vertical positions

Air Carbon Arc Gouging

Perform air carbon-arc gouging on steel plates in flat, horizontal and vertical positions

Shielded Metal Arc Welding

1. Weld fillet joints on steel plates in 1F, 2F and 3F positions;
2. Weld fillet joints on steel pipe-to plate / flange in 2F position;
3. Weld single V-butt joints on steel plates in 1G, 2G & 3G positions; and
4. Weld single V-butt joints on steel pipes in 1G and 2G positions

Gas Metal Arc Welding

1. Weld fillet joints on non-ferrous metal plates and sheets in 1F, 2F and 3F positions;
2. Weld single V-butt joints on non-ferrous metal plates and sheets in 1G, 2G and 3G positions;
3. Weld fillet joints on steel plates in 1F, 2F and 3F positions;
4. Weld single V-butt joints on steel plates in 1G, 2G & 3G positions;
5. Weld single V-butt joints on steel pipes in 1G and 2G positions; and
6. Weld fillet joints on steel pipe-to plate/flange in 2F & 3F positions;

Gas Shielded Flux-Cored Arc Welding

1. Weld fillet joints on steel plates in 1F, 2F and 3F positions;
2. Weld single V-butt joints on steel plates in 1G, 2G and 3G positions;
3. Weld single V-butt joints on steel pipes in 1G and 2G positions; and
4. Weld fillet joints on steel pipe-to plate / flange in 2F position.

Gas Tungsten Arc Welding

1. Weld single V-butt joints on ferrous and non-ferrous metal plates and sheets in 1G, 2G and 3G positions; and
2. Weld single V-butt joints on ferrous and non-ferrous metal pipes in 1G and 2G positions

Duration of Course: 48 hours

Precision Engineering (PEG) Tutorial Course – Level 1

Course outline

Conventional Milling (20 Hours)

1. Interpret technical drawings of machine parts component drawn in the 1st and 3rd Angle Projection
2. Explain the safety precautions in operating the Vertical milling machines
3. Describe the types and applications of work holding devices used in milling machines
4. Mill components on a Vertical milling machine involving plain milling, drilling and boring, slot milling of T-slots and keyways and profile milling using rotary table
5. Perform routine maintenance on the Vertical milling machines
6. Practical Assignments

Conventional Grinding (20 Hours)

1. Interpret technical drawings of machine parts component drawn in the 1st and 3rd Angle Projection
2. Explain the safety precautions in operating the Surface & Cylindrical grinding machines
3. Describe the types and applications of work holding devices used in the Surface & Cylindrical grinding machines
4. Grind components on a Surface & Cylindrical grinding machines involving flat and round surfaces. Prepare a grinding wheel for grinding operations
5. Perform routine maintenance on the Surface & Cylindrical grinding machines
6. Practical Assignments

Conventional Turning (20 Hours)

1. Interpret technical drawings of machine parts component drawn in the 1st and 3rd Angle Projection
2. Explain the safety precautions in operating the Centre lathe machines
3. Describe the types and applications of work holding devices used in the Central lathe.
4. Turn components on a Centre lathe involving parallel turning, drilling and boring, taper, thread-cutting and profile turning
5. Perform routine maintenance on the Centre lathe
6. Practical Assignments

Duration of Course: 60 hours

Precision Machining (Turning) Tutorial Course – Level 2

Course outline

1. Grind high-speed steel lathe tools using the pedestal grinder
2. Set up and turn work pieces on a centre lathe involving operations such as linear turning; #taper turning ; profile turning; facing; drilling; boring; #recessing; chamfering; corner rounding; #thread cutting and knurling. # Internal and external
3. Write part programs for the CNC turning operations according to specifications
4. Program the CNC turning operations using a CAD/CAM system
5. Verify CNC turning part programs including programs alternations
6. Perform tool offset and compensation using a tool pre-setter
7. Set up and turn work pieces on CNC lathe involving operations such as linear turning; taper turning; profile turning; facing; boring; recessing; chamfering; corner rounding; thread cutting; stock removal cycle; finishing cycle and thread cutting cycle
8. Prepare a project scheduling plan
9. Measure components for conformity to dimensions and surface roughness
10. Assemble machined components using common hand tools and gauges
11. Observe safety protocols
12. Practical Assignments

Duration of Course: 48 hours

Precision Machining (Milling) Tutorial Course – Level 2

Course outline

1. Set up and mill work pieces on a conventional milling machine involving operations such as milling of horizontal, vertical and angular surfaces; milling of keyway and groove; drilling; reaming; boring; counter-boring; profile milling; external spline; spur gear.
2. Perform bench fitting processes
3. Write part programs for the following CNC milling operations such as X-Y linear interpolation; drilling; reaming; counter-boring; profile milling; pocket milling; boring; tapping with canned cycles
4. Program the following 2 ½D CNC milling operations using the built-in controller system such as paraxial milling; continuous-path milling; hole production by drilling; reaming and tapping with canned cycles.
5. Prepare part programs for CNC machining
6. Verify CNC milling part programs including program alterations
7. Perform tool offset and compensation using a tool pre-setter and gauge block
8. Set up and mill work pieces on CNC milling machines involving operations such as linear interpolation; drilling; reaming; counter-boring; profile milling; pocket milling; boring; tapping with canned cycles
9. Measure the milled components for conformity to dimensions and surface roughness requirements
10. Assemble machined components using common hand tools and gauges
11. Observe safety protocols
12. Practical Assignments

Duration of Course: 48 hours

Electrical Fitting (ELF) Tutorial Course – Level 1

Course outline

1. Maintenance of AC motors (Low Voltage – LV)
   • Conducting motor insulation tests
   • Conducting motor current check
   • Performing free run check
   • Performing rotation and speed check
2. Cable connections of motors
   • Correct identification of motor and start/stop switch
   • Isolating power supply to the motor including locked out
   • Checking of insulation resistance of the cable and motor coil before termination
   • Checking and installation of protection covers after termination
3. Installation of surface cable (ladders, trays and conduits)
   • Installation of cable according to size, type and length as specified in the installation works’ instructions
   • Prescribed procedures and methods of cabling
4. Check and maintenance of LV armoured cables
   • Routine check and maintenance of cable outersheath
   • Cleaning of outersheath to ensure for oil-free bonding of resin
   • Terminating wire conductors according to given specifications
   • Linking of steel wire armours
   • Insulation of crimped joints
   • Testing joints for cable continuity and insulation resistance requirements
   • Sealing cable joints in accordance with manufacturer's instructions
   • Correct usage of splicing kit
5. Installation of metal trunking and metal conduit
   • Marking and cutting of proper dimensions and angles on metal trunkings and conduit
   • Producing bends, offsets and bridges in accordance with the given angles and dimensions
   • Alignment of metal trunkings and conduit
   • Tightening of metal joints
6. Identification and troubleshooting of defective lamps
   • Performing troubleshooting for indoor and outdoor lamps
   • Identifying, testing and replacing defective lamps
   • Testing and measuring defective components
   • Performing fitting tests for successful operation run
7. General maintenance of batteries
   • Measuring and recording battery terminal voltage and charge/discharge current
   • Measuring and recording of Electrolyte specific gravity
   • Measuring and recording of Electrolyte temperature
   • Preparing dilute sulphuric acid of pH 1.4 from concentrated sulphuric acid and distilled water

Duration of Course: 48 hours

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