ZIMBABWE

MINISTRY OF HIGHER AND TERTIARY EDUCATION, SCIENCE AND

TECHNOLOGY DEVELOPMENT

HIGHER EDUCATION EXAMINATIONS COUNCIL

2018

REGULATIONS AND SYLLABUS

FOR

NATIONAL CERTIFICATE

IN

FABRICATION ENGINEERING

Course Code: 324/18/CR/0

Implementation Date: January 2019

1.0 PREAMBLE

The course is designed to develop an artisan with knowledge, skills and attitudes to competently
practice Fabrication in the Mechanical industry. The total duration of the course is 1640 notional
hours spread over a period of two (2) years and one (1) year On- the- Job Education and Training
(OJET). The minimum entry requirements into this course are English Language, a relevant
Science subject and Mathematics passed at Ordinary Level with grade C or better and any other
two subjects or National Foundation Certificate (NFC) subjects or equivalent. The course is
offered on a full time, part time, Block release or Open Distance e-Learning (ODeL) basis. The
assessment is through continuous assessment and written examination and On the Job Education
and Training (OJET). The course will consider gender mainstreaming, sustainable development,
physical challenges, health dispositions and the intersections between race, class and culture. It
shall embrace innovative heritage based education and training philosophy to solve national
problems and to produce goods and services for industrialization and modernization.

2.0 CONSULTATIONS
YEAR
1. ZENT 2018
2. Cochrane Engineering 2018
3. Zimbabwe Power Corporation 2018
4. Delta Beverages 2018
5. NRZ 2018
6. Agri Foods 2018

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PART 1
REGULATIONS

1.0 TITLE AND LEVEL OF AWARD

National Certificate in Fabrication Engineering

2.0 AIM

The aim of the course is to develop Boiler Maker artisan with knowledge, skills and
attitudes required to service the needs of the mechanical engineering and allied industries.

3.0 OBJECTIVES

By the end of the course, students should be able to:

3.1 apply the theoretical and technological principles of welding and fabrication
engineering.
3.2 demonstrate the technological principles of welding and fabrication
engineering.
3.3 apply mathematical concepts to solve mechanical engineering problems.
3.4 apply engineering science principles to solve mechanical engineering
problems
3.5 generate engineering drawings using a drawing board.
3.6 generate engineering drawings using CAD software.
3.7 demonstrate patriotism to national issues
3.8 operate a sustainable business.
3.9 apply communication skills in the engineering field.
3.10 demonstrate the Fabrication Engineering practices to real world of work.

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4.0 COURSE STRUCTURE

NOTIONAL
NO. SUBJECT TITLE CODE
HOURS
1. Workshop Technology 324/18/S01 220
2. Workshop Practice 324/18/S02 510
3. Engineering Mathematics 340/18/S02 150
4. Engineering Science 340/18/S03 150
5. Engineering Drawing 324/18/S03 220
6 Basic Communication 310/18/S02 80

7. Computer Applications in 359/18/S05 150

Mechanical Engineering
8. National Studies 401/18/S01 80
9. Entrepreneurial Skills Development 402/18/S01 80
10 On The Job Education and Training 324/18/S04 1 Year
TOTAL 1640 hours+1 year

5.0 DURATION

The course duration is 1640 notional hours spread over two (2) years and one (1) year
On -the Job Education and Training (OJET).

6.0 ENTRY REQUIREMENTS

English Language, Mathematics and a relevant Science subject passed at Ordinary Level
with grade C or better and any other two Ordinary level subjects or relevant National
Foundation Certificate subjects.

7.0 MODE OF STUDY

Full time : 1640 notional hours

Part time : 1640 notional hours
Block Release: 1640 notional hours
ODeL : 1640 notional hours

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 8.0 ASSESSMENT

8.1 ASSESSMENT SCHEME

SUBJECT TITLE MODE OF STUDY WEIGHTI

AND CODE NG
WRITTEN CONTINUOUS ASSESSMENT
EXAMINATION 60%
40%
A minimum of:
Workshop Technology • 3 field work based Assignments
2 x 3 hour written
324/18/S01 A 30% 100%
papers
324/18/S01B ( Weighted 10% each)
Skills Competency Testing 30%
A minimum of:
Engineering Science • 3 field work based Assignments
3 hour written
340/18/S03 30% 100%
paper
(common) ( Weighted 10% each)
Skills Competency Testing 30%
A minimum of:
Engineering
• 3 field work based Assignments
Mathematics 3 hour written
30% 100%
340/18/S02 paper
( Weighted 10% each)
(Common)
Skills Competency Testing 30%
A minimum of:
• 3 field work based Assignments
Workshop Practice 40 hours practical
30% 100%
324/18/S02 Fabrication project
( Weighted 10% each)
Skills Competency Testing 30%
A minimum of:
Engineering Drawing
2 x 3 hour written • 3 field work based Assignments
324/18/S03A 100%
papers 30%
324/18/S03B
( Weighted 10% each)

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 Skills Competency Testing 30%
Basic Communication A minimum of:
310/18/S02 • 3 field work based Assignments
3 hour written
(Common) 30% 100%
paper
( Weighted 10% each)
Skills Competency Testing 30%
1x 3 hour theory A minimum of:
Computer Applications in
paper • 3 field work based Assignments
Mechanical Engineering
1 x3 hour practical 30%
359/18/S05
paper ( Weighted 10% each) 100%
(Common)
Skills Competency Testing 30%

National Studies A minimum of:

401/18/S01 • 3 field work based Assignments
3 hour written
(Common) 30% 100%
paper
( Weighted 10% each)
Skills Competency Testing 30%
Entrepreneurship Skills A minimum of:
Development • 3 field work based Assignments
3 hour written
402/18/S01 30% 100%
paper
(Common) ( Weighted 10% each)
Skills Competency Testing 30%
On The Job Education
and Training As per logbook Submit marks 100%
324/18/S0

9.0 GRADING
0% to 49% - Fail
50% to 59% - Pass
60% to 79% - Credit
80% and above - Distinction

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10.0 CONDITIONS OF AWARD

10.1 A candidate should attend at least 85% of learning sessions to qualify for
examinations.

10.2 The final mark should be obtained through aggregation provided the candidate
scores at least 50 % in each of continuous assessment and examinations.

10.3 The pass mark shall be 50%.

10.4 Candidates should pass all subjects

11.0 RE-WRITE

11.1 Re-write(s) should conform to current course structure.

11.2 Candidates should pass at least two thirds of the course to qualify for a
referral.

11.3 Any candidate who fails to pass at least two thirds of the course should repeat the
whole course, including the subjects they would have passed.

11.4 There is no time limit for which to re-write a failed examination.

11.5 There is no aggregation for re-writes.

11.6 All re-writes should pass on performance in the examination.

11.7 If a candidate fails continuous assessment he/she repeats the subject.

12.0 EXEMPTIONS

12.1 Exemptions are only granted in subjects already attained from a completed
accredited qualification provided an exemption certificate specifying subjects of
exemption is produced.

12.2 Exemption Certificate should be applied for at enrolment and produced before
registration for examinations.

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13.0 IRREGULAR PRACTICES

13.1 Cheating in examinations will result in disqualification from the whole course and
all other HEXCO courses. The candidate will be suspended for two years.

13.2 Plagiarisms in any of the assessments will result in automatic disqualification in

the course and any other HEXCO courses and the penalty as in 13.1 will apply.

14.0 RESOURCES

14.1 Lecturer Qualification

Minimum of National Diploma Fabrication Engineering or equivalent.

14.2 Tools and Equipment

HAND AND MAKING OUT TOOLS

SPECIFICATION QTY
1. Combination Spanner Set 12
2. Combination Pliers 12
3 Long-Nosed Pliers 12
4. Vice grip Pliers 12
5. Grip Welding Clamps (for Plates) 12
6. Welder’s Hammer 12
7. Ball Pen Hammer 12
8. Copper – Tipped Hammer 12
9. Plastic Hammer 12
10. Rubber Mullet 12
11. File Card Brush 12
12. Wire-Bush 12
13. Hacksaw (300 mm blade) 12
14. Junior Hacksaw 12
15. Stud Remover set 12
16. Screw Extractor Set 12
17. Tin snips straight 12
18. Tin strips curved 12
19. Pop Rivet Set 12
20. Allen key sets (both Metric & Imperial) 6
21. Universal surface gauge 6
22. Scraper and chisel set 6
23. Puller set *3
24. Scriber 12

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25. Scribing block 6
26. Punch Set 12
27. Height Gauge 6
28. Vernier Gauges 12
29. Inside Micrometer set (10mm – 400 mm) 6
30. Contour Marker 12
31. Engineer’s File set 6
32. Bolt Cutter (minimum 16 mm) 2
33. Screw Pitch Gauge 8
34. Radius Gauges 12
35. Universal test Indicator Set 6
36. Dial Test Indicator + magnetic Base 6
37. Toolmakers Clamps 8

38. Engineer’s Square 12

39. Adjustable Engineers Try Square 12
40. Centre Square 12
41. Wire Gauge (Imperial) 12
42. Wire Gauge (metric) 12
43. Depth Gauge (Reversible base) 12
44. Depth Gauge (Protractor base type) 12
45. Callipers (Inside) 12
46. Callipers (Outside) 12
47. (Callipers (Jenny legs) 12
48. Bevel Protractor 12
49. Trammel Heads 12
50. Engineer’s straight edges 12
51. Engineer’s levels 12
52. Vee Blocks (pair) 6
53. Angle Plates (open end types) 12
54. Marking Punches (letters and Numbers 4
55. Sheetmetal 4
56. Folding Tong (Off-set) 6
57. Outside micrometer Imperial (10 – 200 mm) 6
58. Outside micrometers: Imperial (0” – 2”) 6
59. Tap and Die set (Metric and Imperial) 4
60. Mole Sheet Metal grip 12

MACHINE AND CUTTING TOOLS/EQUIPMENT

61. Bench grinder (Double-Ended) 3

62. Pedestal Grinder 3
63. Drill Bit Sharpener 3
64. Pillar Drill 13 mm 4
65. Centre Lathe 1000mm straight bed 1
66. Centre Lathe Accessory Kit 1
67. Machine Vice/3 Way Angle Vice 4
68. Knurling Tool Holder (Set) 1

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69. Parting Off Blades (Set) 1
70. Universal Milling Machine + Accessories 12
71. Arbor Press 2
72. Power Hacksaw (Two Speed: 75-105 steps/mm) 2
73. Cutting Off Machine 2
74. Guillotine (to cut up to 1.6 mm thick M steel)
75. Box Pan Folder (to fold up to 2 mm thick mild steel) 2
76. Pipe/tube bending equipment 6
77. Flat steel bending machine 6
78 CNC Lathe 1
79 CNC Milling 1
80 CNC Drilling 1
81 CNC Guillotine 1
82 CNC Press Brake 1
83 CNC Tullet Puncher 1

84. Fly Press 4

85. Metal Arc Welding Equipment (60 – 130A) 12
86. T.I.G. Welding Equipment (100 – 350A rated 6
output)
87. M.I.G/T.I.G. Tran cooler (Flow rate: 3 litres/m9ins 6

88. M.I.G. Welding Equipment (Output: 250A/26/5V) 6

89. Electrode drying oven & Arc welding accessories 1
90. Gas Welding and Cutting Equipment 12
91. Gas Welding Accessory Set: Lighter
Regulator Spanner, Outfit Spanner, Spindle Key,
‘O’ Clip Pliers, Nozzle Cleaners. Cylinder Trolley
and Sapphire Gas Economiser 12
92. Pipe Cutting and Bevelling Machine 2
93 Spot Welding Gun: Hand Held 6
94. Spot Welding Machine: Pedal Operated 4
Twist drill Set (1 – 13mm)
95. Thread Repair Kit Metric) 12
Thread Repair Kit (Imperial) 1
Twist Drill Set (1/64” to ½”) 1
Electric Hand Drill 12
Pneumatic Drill 12
Manual Hand Drill 4
Angle Grinder (Electric) 6

GENERAL WORKSHOP EQUIPMENT

96. Forge: Hearth of Single Fire Type2 2

97. Oil Bath 1
98. Pneumatic Rivet Gun 6
99. Mobile Hoist 2
100. Overhead Crane 1

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101. Block and Tackle Equipment (Set) 5
102. Anvil and stand
103. Swage block and Stand 3
104. Taper Mandrel Cone 3
105. Leg Vice and Table 3
106. Pneumatic Appliance Circuitry 1
107. Heavy Duty Air Compressor (Fuel/Electric) 1
108. First Aid Equipment (Boxes) 1
109. Fire fighting equipment.

14.4 SUGGESTED REFERENCE BOOKS

AUTHOR YEAR TITLE PUBLISHER TOWN

1. Barlenschlager 2016 Metal Engineering textbook Verlag Europa Haan

et-al 1st Ed Lehrmitter Graiten
2. William D. C 2007 Materials Science and John Wiley and New York
Engineering An Introduction Sons Inc
3. Jack. B. R 2006 Safety Engineering John Wiley and New York
Sons Inc
4. Rajender. S 2006 Introduction to Basic New Age New Delhi
Manufacturing Processes International
and Workshop Technology
5. McCormac J. 2012 Structural Steel Design 5th Prentice Hall Boston
C and Edition
Csernar. S. F
6. Merritt F. S 2000 Building Design and McGraw Hill New York
And Rickette. Construction Handbook
J. T
7 Dickson ,S. (2000) Geometry of Sheetmetal Pitman London
Work
8 Heap and (2008) Sheetmetal Technology Casses London
Smith

9 Greffen and (2015) Pipe Welding Dellmar USA

Roden

Page 11 of 53
PART II

SYLLABUS CONTENT

COURSE STRUCTURE

NOTIONAL
NO. SUBJECT TITLE CODE
HOURS
1 Basic Communication 310/18/S02 80
2 Workshop Technology 324/18/S01 220
3 Workshop Practice 324/18/S02 510
4 Engineering Mathematics 340/18/S02 150
5 Engineering Science 340/18/S03 150
6 Engineering Drawing 324/18/S03 220
7 Computer Applications in
359/18/S05 150
Mechanical Engineering
8 National Studies 401/18/S01 80
9 Entrepreneurial Skills Development 402/18/S01 80
10 On The Job Education and Training 324/18/S04 1 Year
TOTAL 1640 hours+ 1 year

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SUBJECT TITLE: WORKSHOP TECHNOLOGY

SUBJECT CODE: 324/18/S01

DURATION: 220 hours

1.0 AIM

The aim of the subject is to equip the student with an understanding of theoretical information
used in the welding and fabrication engineering industry.

2.0 OBJECTIVES

By the end of covering the subject content, the student should be able to:
2.1 explain fabrication engineering work workshop safety rules and regulations.
2.2 explain correct techniques in the use of hand and power equipment appropriate to
basic welding and fabrication Engineering.
2.3 apply the principles of marking and measuring out.
2.4 detail out the various procedures of sheet templates and layout.
2.5 explain different materials and heat treatment
2.6 give account of machines operations and processes.
2.7 explain plate work processes.
2.8 outline various thermal and mechanical cutting
2.9 detailed of various joining and fastening processes
2.10 explain various corrosion mechanism
2.11 explain various welding processes.
2.12 describe the process of boiler construction
2.13 explain the processes of pipe work
2.14 detail out the methodologies of structural steel work
2.15 describe quality control in welding and fabrication.

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3.0 TOPICS
WORKSHOP SAFETY
HAND AND POWER TOOLS
MARKING AND MEASURING OUT
TEMPLATE AND LAYOUTS
MATERIAL HANDLING
MATERIALS AND HEAT TREATMENT
MACHINES AND PROCESSES.
PLATE WORK.
THERMAL AND MECHANICAL CUTTING
JOINING AND FASTENING
CORROSION
WELDING
BOILER CONSTRUCTION
PIPEWORK
STRUCTURAL STEEL WORK
QUALITY CONTROL

4.0 CONTENT
4.1 WORKSHOP SAFETY
a) Identify and conform to safety regulations laid down for the workshop.
b) Identify safety guards on machinery and explain functions of these guards.
c) Identify safety colour coding
d) Describe the use of equipment in a safe and prescribed manner.
e) Identify and report unsafe conditions and unsafe acts.
f) Explain the accident and fire prevention techniques and equipment in the
workshop.
g) Describe the correct handling of gas and electrical equipment in the workshop.
h) Describe basic first aid procedures.
- It must be noted that safety is part of every procedure
performed and its emphasis is crucial
i) Interpret health and safety policies.
j) Interpret NSSA statutory instruments.

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4.2 HAND AND POWER TOOLS
a) Identify the following hand and power tools.
Hammers, spanners, drifts, dollies and holders-on, chisels, backmark, bevel
gauges turn over dogs, pinch bars, files, G-Clamps, Sash Clamps, Vice grips,
hacksaws, sheet metal tools, Hand drills, Angle grinders, nibblers,
b) Describe the correct use of items in 4.2 (a) above.
c) Explain basic repairs and maintenance to items in 4.2 (a) above.
d) Describe the storage procedure of the above hand and power tools listed in 4.2(a)

4.3 MARKING AND MEASURING OUT

a) Identify the following marking and measuring out tools.
Square, Dividers, Trammels, V-blocks, Scribing blocks, Combinations set,
Vernier height gauges, Angle Plates, Marking out table, Centre punches, Tape
measures, Vernier Callipers, Micrometers, Inside and Outside Callipers, Odd Leg
Callipers, Spirit Level, Straight edge, Chalk Line, Dumpy Level, Back mark and
Bevel gauges.,
b) Describe the correct use of items in 4.3 (a) above.
c) Explain basic repairs and maintenance to items in 4.3 (a) above.
d) Describe the storage procedure of the above marking and measuring out tools
listed in 4.3 (a)

4.4 TEMPLATE AND LAYOUTS

a) Define templates and loft.
b) Identify different types of templates, their uses and storage.
c) Identify materials used to make templates
d) List tools and machines used to produce templates
e) Outline information recorded on templates
f) State the safety precautions when working in a loft.

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4.5 MATERIAL HANDLING
a) Identify uses of the following material handling equipment:
• Overhead cranes
• Mobile cranes
• Gantries
• Tripods
b) Identify different riggings procedures.
c) Identify different type of lifting tackles listed below and outline their uses:
• Wire ropes
• Chain slings
• Wire slings
• Shackles
• Hooks.

4.6 THERMAL AND MECHANICAL CUTTING

List and explain the following mechanical and thermal cutting methods.
A. Mechanical Cutting
- Sawing
- Cropping
- Shearing
- Punching
- Notching
- drilling and reaming
- End milling, planning and turning
- Grinding (Pedestal)
B. Thermal Cutting
- Oxy-fuel cutting (profile cutting and calculation of diameter of templates)
- Plasma cutting
- Laser beam cutting
- Gouging

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4.7 MATERIALS AND HEAT TREATMENT
a) Explain the Production of Iron and steel, Copper and aluminium
b) List and explain different forms of materials (metals and non-metals).
c) Identify different forms of alloying elements
d) List and explain different alloys.
e) Outline applications of different materials.
f) Explain the heat treatment processes of carbon steels.

4.8 MACHINES AND PROCESSES.

a) Explain the following machines processes using conventional and non-
conventional machines:-
• Bending
• Rolling (spiral and conical rolling, as well as angle iron rolling.
• Metal spinning
• Jenning
• Wheeling
• Forming/ Formers

4.9 PLATE WORK.

a) Explain the plate work sequence of operation
• Bending allowances
• Presetting prior to rolling
• Sequence of jointing

4.10 WELDING.
a) Define welding
b) Identify and outline the application of different welding symbols.
c) Identify and explain the following welding processes:-
- Manual metal arc/ Electric arc.
- Submerged arc
- Stud welding
- Electron beam

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 - Electron slag
- Plasma arc
- CO2 welding
- MIG/ MAG welding
- TIG/ TAG welding
- Resistance (spot, seam, projection)
- Gas welding
- Braze welding
- Brazing
- Soldering
d) Define weld distortion.
e) State and explain different methods of minimising weld distortions.
f) Identify and explain weld defects.

4.11 QUALITY CONTROL

a) Identify and explain the following weld tests based on the BS449 and ASME157
Standard specification and dimension :-
• Destructive testing
• Non-destructive testing

4.12 JOINING AND FASTENING

a) Identify the following permanent and temporary joining methods:
• Rivets ( Solid and hollow)
✓ types of rivets.
✓ riveting sequence.
✓ riveting calculations.
✓ rivet defects.
• Bolts, nuts and washers
✓ types of bolts and washers.
✓ bolting calculations.
• Self- secured joints

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4.13 CORROSION
a) Identify and explain different methods of surface preparation prior to surface
protection.
• flame cleaning
• blast cleaning
• pickling process
b) Identify different types of corrosion.
c) Explain the effects of corrosion on common materials.
d) Identify and explain surface protection methods based on the following
categories:-
• metallic coating.
• non-metallic coating.

4.14 PIPEWORK
a) Identify different of types of pipes and their applications.
b) list and explain different types of pipe bending (Hot and Cold)
c) Outline pipe joining methods
d) list different pipe supporting techniques.
e) Identify and explain external and internal protective coatings
f) Explain uses of expansion bends.
g) Outline the site erection procedures.

4.15 STRUCTURAL STEEL WORK

a) Identify different types of steel sections and applications.
b) List and explain different types of structures
c) Define jigs and fixtures
d) Outline the following structural components:-
• portal frames
• camber construction.
• stiffeners (gussets)
• girders
• trusses

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 • castellated beams.
e) Explain the different types of structural connections and joints
f) Outline the assembly and installation process.
g) Outline the sequence of connection structures on site

4.16 BOILER CONSTRUCTION

a) Define a boiler and state its uses
b) State maximum nitrogen content to be found in boiler steel (0.008).
c) State what type of steel it is (mild steel) 0.15 to 0.25% carbon content.
d) State what minimum thickness plate provides margin for safety (after
allowing for normal service wear and tear) (9.5mm)
e) Identify the correct bending method for these plates (over rolls not
hammered into shape) to avoid stress and weakness.
f) Identify and state formulae for calculating strength of boiler steels etc.
2𝐹 𝑓𝑡 𝑃𝐷𝐹
𝑃= and 𝑡 =
𝐷𝐹 2𝐸𝐹

(refer to Boiler makers assistant page 74)

g) State requirements for riveted lap joints.
h) Calculate strength of riveted joints using 1of 3 stated formulae page (78
of " Boiler Makers Assistant)
i) Understand in detail use of valves in boilers.
i. State in detail the use of valves in boilers
ii. State and describe types and sizes of valves (using sketches).
iii. Identify horizontal (sliding action) and vertical (vertical lift) types
of valves, stating when to use either.
iv. Identify safety valves and draw them
- Identify and state formulae to be used in conjunction with
dimension of fulcrum valves and the mass at end of lever.
- State (when operating pressure is known) what formulae
must be utilised (see page 78 boiler maker's Assistant)
v. Identify the following boilers.
- Shell boiler/ Fire tube boilers
- Water-tube boilers

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 - State legal requirements governing the manufacture of
boilers.
j) Outline pressure vessel testing procedure for boilers.

5.0 ASSESSMENT

5.1 ASSESSMENT GRID

TOPIC
TOPIC Hours WEIGHT%
NO.
1 Workshop Safety 6 3
2 Hand and Power Tools 6 3
3 Marking and Measuring out 6 3
4 Template and layouts 6 3
5 Materials Handling 6 3

6 Thermal and Mechanical cutting 25 11

7 Materials and Heat treatment 25 11
8 Machines and Processes 25 11

9 Plate work 12 6
10 Welding 36 16
11 Quality Control 6 3
12 Joining and Fastening 6 3
13 Corrosion 6 3
14 Pipe work 12 5
15 Structural Steel work 25 11
16 Boiler Construction 12 5
TOTAL 220 100

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6.0 SUGGESTED REFERENCES
Brink, C. McNamara, B. (2008) Engineering Fabrication and Boiler Making. Pearson Education.
South Africa.
Rajput, R.K. (2005) Comprehensive Basic Mechanical Engineering, Firewall Media.
Rajput, R.K. (2005) Comprehensive Workshop Practice, Firewall Media
Murgai, M.P. Chandra, R.(1990) Boiler Operations, New Age International.
Bernstein, M.D. Yoder, L.W. (1998) Power boilers, ASME Press.
Ford, W.H. (2007) Boiler Making for Boiler Makers: A practical treatise on work in the shop,
Read Books.
Jeffus, L. Bower, L. (2009) Welding Skills, Processes and Practices for Entry-Level Welders,
Cengage Learning.
NCCER, (2010) Boilermaking Level 1 Trainee Guide, 2nd Edition, Prentice Hall
Harris, K.N. Model Boilers and Boilermaking.
NCCER, (2003) Safety level 2: Safety Technician Participant Guide, Pearson/Prenctice Hall.
NCCER, (2009) Welding, level 1: Trainee Guide, Prentice Hall.
Chattopadhyay, P.(2009) Boiler Operation Engineering: Questions and Answers, Tata McGraw.

7.0 PAPER STRUCTURE

PAPER 1 Code 324/18/S01A FORMAT (Aggregate Examination Weight is 50%)

1.1 Consists of two Sections : Answer ALL

SECTION A: Answer ALL questions (20 marks)

Question One Ten Short answer question covering the whole syllabus

SECTION B: Answer All questions (80 marks)

Question Two Plate work and Structural steel work (16 marks)

Question Three Heat treatment (8 marks)

Question Four Riveting (8 marks)

Question Five Thermal/ Mechanical cutting (8 marks)

Question Six Quality control (8 marks)

Question Seven Corrosion (8 marks)

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 Question Eight Materials (8 marks)

Question Nine Machine processes (8 marks)

Question Ten Welding symbols (8 marks)

7.0 PAPER 2 Code 324/18/S01B FORMAT (Aggregate Examination Weight is 50%)

1.2 Consists of three Sections :

SECTION A: Answer Five questions out of Six (5/6) (40 marks)

Question One Workshop safety (8 marks)

Question Two Thermal/ Mechanical cutting (8 marks)
Question Three Welding (8 marks)
Question Four Riveting (8 marks)
Question Five Machine processes (8 marks)
Question Six Welding defects (8 marks)

SECTION B: Answer Three questions out of Four (3/4) (30 marks)

Question Seven MIG/ TIG (10marks)

Question Eight Thermal/ Mechanical cutting (10 marks)

Question Nine Thermal/ Mechanical cutting (10 marks)

Question Ten Joining & Fastening (10 marks)

SECTION C: Compulsory (30 marks)

Question Eleven Structural steel works

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SUBJECT TITLE: WORKSHOP PRACTICE

SUBJECT CODE: 324/18/S02

DURATION: 510 Notional hours

1.0 AIM

The aim of the subject is to provide the student with knowledge, competencies and attitudes
required in Fabrication Engineering environment.

2.0 OBJECTIVES

By the end of covering the subject content, the student should be able to:
2.1 identify and use workshop safety
2.2 perform the following practical Bench work in welding and fabrication workshop
i. marking out and measuring
ii. hand and power tools
iii. filing
iv. measuring and layout
2.3 identify and use various joining processes as listed below
i. forming and joining
ii. manual metal arc welding
iii. gas welding and brazing
iv. Metal Inert Gas (M.I.G) welding
v. Tungsten Inert Gas (T.I.G.) welding
2.4 perform various welding and fabrication machines operations
2.5 identify and perform various mechanical and thermal cutting operations as used in
the welding and fabrication workshop.
2.6 develop templates
2.7 develop rectangular, cylindrical and conical fabrication patterns
2.8 perform the following pipe work operations
i. pipe bending
ii. pipe protection
iii. pipe erection

Page 24 of 53
3.0 TOPICS
WORKSHOP SAFETY
MARKING OUT AND MEASURING
HAND AND POWER TOOLS
FILING
BENCH WORK
MEASURING AND LAYOUT
FORMING AND JOINING
MANUAL METAL ARC WELDING
GAS WELDING AND BRAZING
METAL INERT GAS (M.I.G.) WELDING
TUNGSTEN INERT GAS (T.I.G.) WELDING
MACHINES OPERATIONS
MECHANICAL AND THERMAL CUTTING
TEMPLATES
RECTANGULAR, CYLINDRICAL AND CONICAL FABRICATION
PIPE BENDING
PIPE PROTECTION
PIPE ERECTION

4.0 CONTENT
4.1 WORKSHOP SAFETY
4.1.1 Demonstrate a practical awareness of safety standards and precautions in a
light metal workshop.
(a) Identify and conform to safety regulations laid down for the
workshop.
(b) Identify safety guards on machinery and explain functions of these
guards.
(c) Identify safety colour codings
(d) Use equipment in a safe and prescribed manner.
(e) Identify and report unsafe conditions and acts.

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 (f) Recognise and apply accident and fire prevention techniques and
equipment in the workshop.
(g) Perform basic First Aid.

4.2. MARKING OUT AND MEASURING

4.2.1 Perform various measuring and marking out techniques.
- Identify the measuring and marking out instruments.
- Demonstrate the correct use of measuring and marking out
instruments.
- Apply marking techniques using standard dimensions such as pitch,
edge distance, back marks:
This includes using datum lines and squaring off of material.
- Produce temporary and permanent templates.

4.3 HAND AND POWER TOOLS

4.3.1 use various hand and power tools used in sheet metal work.
- Identify the various hand and power tools.
- Demonstrate the correct use of items in 3.1 above.
- Perform basic repairs and maintenance to items in 3.1 above.
- Demonstrate ability to store the above hand tools.

4.4 FORMING AND JOINING

4.4.1 Demonstrate the application of metal forming and jointing techniques used
in light metal work.
- Identify the various metal forms (e.g. bends) and joints (e.g.
Pittsburgh Lock).
- Identify functions of metal forming.
Machinery and Cutting Equipment
- Produce various self-securing joints using hand and bench tools,
using standard joint allowances.
- Produce soldered joints to required connections and standards.
- Produce riveted joints using blind and solid rivets.

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 - Form simple articles using forming equipment.
- Fabricate cylindrical work according to specifications.
- Fabricate rectangular work to specifications.
- Produce various joints using resistance spot welding equipment.

4.5 MANUAL METAL ARC WELDING

4. 5.1 Perform with confidence various welding assignments in all positions using
the manual metal arc welding process.

- Identify and use all types of A.C. and D.C. welding machines and
their accessories.
- Recall and apply the principles of basic electricity as applicable to
arc welding current.
- Select current electrode and welding current.
- Perform various welding techniques on various steel sections and
plate using appropriate electrode type.
- Trouble-shoot and take corrective measures before, during and after
a weld.
- identify and perform electric –arc welding in the recommended
welding positions.
- prepare weld joints on common steels and cast iron in relation to
materials type and thickness.

4.6 GAS WELDING AND BRAZING

4.6.1 Perform gas weld beads and fillets in all recommended positions on basic
joints: braze weld.

- Identify the oxy-fuel gas welding apparatus and demonstrate

applications.
- Assemble, operate, shutdown, maintain and repair oxy-fuel gas
welding apparatus.

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 - Select appropriate welding positions and perform gas welding in
those welding positions
- perform leftward and rightward welding.
- Demonstrate the procedure for gas welding non-ferrous metals.
- Braze weld similar and dissimilar metals.

4.7 GAS CUTTING

4.7.1 Perform freehand and guided cuts on sheets, plate and other steel structural
sections.
- Identify apparatus and perform cuts using profile cutting apparatus.
- Identify apparatus and perform cuts using semi-automatic straight
line cutting equipment.
- Perform free-hand and guided manual cuts.
- Identify and select nozzles considering thickness of material and
type of cut e.g. gouging.

4.8 METAL INERT GAS (M.I.G) WELDING

4.8.1 Perform basic welding using metal Inert Gas and CO equipment.
- Identify and select correct equipment and consumables for the
M.I.G. Process.
- Identify problems in process and procedure, and apply trouble-
shooting and corrective measures for M.I.G Process.
- Set speeds and current to suit material type and thickness.

4.9 TUNGSTEN INERT GAS (T.I.G) WELDING

4.9.1 Perform basic welding using Tungsten Inert Gas equipment.
- Identify and select correct equipment for the T.I.G and thickness.
- Identify problems in process and procedure, and apply trouble
shooting and corrective measures for the T.I.G. Process.
- Identify problems in process and procedures, and apply trouble
shooting and corrective measure for the T.I.G Process.

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4.10 TEMPLATES
4.10.1 Produce patterns using triangulation, parallel and radial methods.
4.10.2 Compute bending allowances when determining cutting sizes.
4.10.3 Use templates as a means for checking accuracy.
4.10.4 Use templates as a source of information e.g. bending instructions.
4.10.5 Properly store templates for future use/reference.

4.11 RECTANGULAR, CYLINDRICAL AND CONICAL FABRICATION

4.11.1 Demonstrate skills in producing fabrications both oblique and right for
cones, cylinders chutes and hoppers.
4.11.2 Use rolling equipment i.e. both pyramid and pinch type.
4.11.3 Show conversancy with standard pre-setting techniques prior to rolling.
4.11.4 Produce spiral work.
4.11.5 Produce plate work using fly press, V tools and press brakes.
4.11.6 Differentiate between oblique and right plate work.
4.11.7 Apply allowance for welding e.g. open corners.

4.12 PIPE BENDING

4.12.1 Demonstrate skills in the bending of various diameter pipes in the hot or
cold state.
4.12.2 Identify the types of pipes and their functions.
4.12.3 Show conversancy with pipe bending equipment.
4.12.4 Show conversancy with hot bending techniques
4.12.5 Select the most appropriate technique: depending on pipe type and
diameter.

4.13 PIPE PROTECTION

4.13.1 Select the most suitable anti-corrosion technique and substance as directed
by the intended use of the pipe.
4.13.2 Identify types of pipe protection techniques and substances for industrial
application.
4.13.3 Coat pipe prior to/or after fabrication has occurred.

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 4.13.4 Show familiarity with pipe insulation techniques.

4.14 PIPE ERECTION

4.14.1 Demonstrate skills in erecting pipe work on site.
4.14.2 Select and use tools required for erection e.g. spirit levels.
4.14.3 Demonstrate ability to product secure joints by welding or bolting.
4.14.4 Demonstrate ability to produce flanges of accepted standards.
4.14.5 Demonstrate ability to fabricate pipe supports where necessarily.

5.0 ASSESSMENT SPECIFICATION GRID

WORKSHOP PRACTICE 324/18/S01 PRACTICALS ASSESSMENT GRID

PAPER FORMAT FOR WORKSHOP PRACTICE EXAMINATION

• Candidates to sit for a standard 40 hour common practical workshop examination
Fabrication project.
• Regions to avail all necessary materials for the exam.
• HEXCO rules and regulations for conducting practical examinations to be adhered to.
• Advance information is required for this practical paper. The information should reach
regions 4 weeks before the date for the practical examination.

CONTINOUS ASSESSMENT

Item Assessment Model Test Competencies Weighting

• Measuring
• Marking out
• Cutting
• Drilling
• Filing
1 Bench work • Reaming 20%
• Taping
• Counter Boring
• Trepanning
• Spot Facing
• Counter sinking
• Grinding
Sheet metal and
2 • Sheet metal work 35%
welding
✓ Bending

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 ✓ Folding
✓ Punching
✓ Cropping
✓ Trepanning
✓ Wheeling
✓ Routing
✓ Forming
✓ Riveting
• Welding
• Oxy-acetylene
• Soldering
• Brazing
• TIG
• MIG
• Spot Welding
• Seam Welding
• Grinding
• Drilling
• Thermal and Mechanical
Cutting
• Folding
• Bending
• Welding
• Bolting
Pattern Development,
• Riveting
Structural steel
3
engineering and Pipe • Oxy-acetylene 45%
Work • Gusset
• Trusses
• Portal Frames
• Girders
• Pipe work
✓ Pipe Fabrication
✓ Pipe installation
✓ Pipe Maintenance
✓ Riveting
Aggregate Marks 100%

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6.0 SUGGESTED REFERENCES

Brink, C. McNamara, B. (2008) Engineering Fabrication and Boiler Making. Pearson

Education. South Africa.
Rajput, R.K. (2005) Comprehensive Basic Mechanical Engineering, Firewall Media.
Rajput, R.K. (2005) Comprehensive Workshop Practice, Firewall Media
Murgai, M.P. Chandra, R.(1990) Boiler Operations, New Age International.
Bernstein, M.D. Yoder, L.W. (1998) Power boilers, ASME Press.
Ford, W.H. (2007) Boiler Making for Boiler Makers: A practical treatise on work in the shop,
Read Books.
Jeffus, L. Bower, L. (2009) Welding Skills, Processes and Practices for Entry-Level Welders,
Cengage Learning.
NCCER, (2010) Boilermaking Level 1 Trainee Guide, 2nd Edition, Prentice Hall
Harris, K.N. Model Boilers and Boilermaking.
NCCER, (2003) Safety level 2: Safety Technician Participant Guide, Pearson/Prenctice Hall.
NCCER, (2009) Welding, level 1: Trainee Guide, Prentice Hall.
Chattopadhyay, P.(2009) Boiler Operation Engineering: Questions and Answers, Tata McGraw.

7.0 INDUSTRIAL VISITS

7.1 Industrial visits / educational tours should be conducted during training in the specialist
areas of welding and fabrication engineering.

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SUBJECT TITLE: ENGINEERING DRAWING
SUBJECT CODE: 324/18/S03
DURATION: 220 Hours

1.0 AIM
The aim of the subject is to provide the student with knowledge, competences and attitudes
required in order to apply Mechanical Engineering Drawing principles in the fabrication and
welding.

2.0 OBJECTIVES
By the end of covering the subject content, the student should be able to:
2.1 identify and use basic engineering tools and equipment.
2.2 demonstrate the use and application of dimensioning.
2.3 demonstrate the application of pictorial drawing..
2.4 demonstrate the use and application of sectioning
2.5 demonstrate the use and application of geometric construction as used in welding
and fabrication
2.6 reading and interpreting engineering drawings
2.7 demonstrate the use and application of conventional representations
2.8 demonstrate the use and application of abbreviations and welding symbols
2.9 demonstrate the use and application of templating systems
2.10 produce orthographic drawings
2.11 produce working drawing in accordance with International Standards

3.0 TOPICS
INTRODUCTION TO ENGINEERING DRAWING.
FREEHAND SKETCHING
DRAWING INSTRUMENTS AND MATERIALS
LAYOUT
LINEWORK AND LETTERING
GENERAL ARRANGEMENT OF DRAWINGS
DIMENSIONING
PICTORIAL DRAWINGS

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 SECTIONING
GEOMETRY
READING AND INTERPRETING ENGINEERING DRAWING
CONVENTIONAL REPRESENTATIONS
ABBREVIATIONS AND SYMBOLS
TEMPLATING SYTEMS
ORTHOGRAPHIC DRAWINGS
WORKING DRAWING
SPECIFICATION

4.0 CONTENT
4.1 INNTRODUCTION TO ENGINEERING DRAWING.
4.1.1 Define Engineering drawing.
4.1.2 State the purposes of Engineering Drawing.
4.1.2 FREEHAND SKETCHING
a) Understand the very important role that ‘free hand sketching’ plays in technical
drawing.

- Freehand sketch a “Matchstick Man and Woman” in order to assist

visualizing graphic communication.
Isometric axis, free hand sketch
b) Identify the “Most Representative” view, as the ‘front’ view, the ‘top’
view and finally the one remaining as the ‘side’ view. (left or right, depending).
c) Convert the ‘sketched’ isometric drawing to 1st Angle orthographic projection
d) Insert construction and projection lines throughout; outlines, dimension lines,
limit lines, dimension figures and arrowheads. (NB to be taught in line work and
lettering).
e) Differentiate between sketching and drawing.
f) List 3 (on-the-job) situations where only a freehand sketch would be
possible (in a breakdown/maintenance situation) to facilitate the
manufacture of a urgently required component part.

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4.4 DRAWING INSTRUMENTS AND MATERIALS
a) Identify drawing boards and the correct positioning and ‘setting up’ them.
- Identify drawing boards and the correct positioning and ‘setting up’ of
them.
b) Identify drawing sheets listed below, their different sizes, list them and
position them on the board. Designation in millimetres
A0 841 x 1189
A1 594 x 841 15 mm border
A2 420 x 594
A3 297 x 420 10 mm border
A4 210 x 297
A5 148 x 210 5 mm & under

c) Identify ‘Tee’ squares, set squares, compasses, rulers, protractors, rubber,

2 H & HB pencils and indicate exactly where and how they are used on the
drawing board.

4.5 LAYOUT

a) Understand the necessity for INTERNATIONAL STANDARDS to be adhered to

in LAYOUT (standardization).

b) State why every country must adhere to laid down ‘Drawing’ standards.
c) Identify
- Border/margin
- Revision & heading section
- Title block
- Material list and
- Drawing area
d) Identify and insert correct ‘spacing’ above, below, left, and in-between drawings (view).
e) State two organisations that ensure ‘standardization’ is adhered to. (BSI & ISO)

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 f) Identify the connection between heading section and entire drawing sheet, by interpreting
the information.
g) Identify and draw correct heading section structure and complete all information required
in its.

4.6 LINEWORK AND LETTERING

a) Understand the need for special types of line work and lettering.
b) Identify the various qualities (i.e. shades and drawing; draw them and name them.
- Outline
- Centre line
- Projection line
- Construction line
- Dimension line
- Leader line
- Limit line
- Phantom line
- Extension line
- Break lines
- Cutting plane line
- Hidden detail line.
c) Utilize the correct line in the correct place, clearly illustrating knowledge thereof.
d) Identify letters of acceptable style and use them correctly on the drawing e.g.
- Open style
- Condensed style
- Sloping style
- Open style (lower case)
- Open style (free hand
- Sloping style (free hand)
e) Identify and illustrate the difference between capital and low case letters by printing
information in both.

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4.7 DIMENSIONING
a. Understand the necessity for components to have dimensions and for these to be accurate.
b. Identify correct use of dimension lines (& their arrowheads), dimension figures and limit
& extension lines by illustrating their application on a drawing.
c. Indicate and interpret, symbols which mean.
- Radius
- diameter
- phi
- conspicuous dot
- equidistance
- symmetry
d) Draw and dimension partial views.
e) Exhibit cognisance of dimensioning rules on drawings.

4.8 SCALE
a) Understand how to identify and ascertain the application of scale.
b) Interpret scales & their relationship to the actual size of a component on a drawing.
c) Identify and draw to scale of: 1: 1 (full size), 1: 2 (reduction) & 2.1 (Enlargement).
d) Identify and draw.
- a dual scale
- a diagonal scale
- a plain scale.

4.9 PICTORIAL DRAWINGS

a) Understand that all pictorial drawings are 3 dimensional (i.e. have length, depth and
height).
b) Identify 3 different pictorial drawings.
- So metric
- Oblique
- Perspective
c) Identify correct positioning of drawing (pictorial) utilizing correct
‘spacing’ (procedure to centralise drawing.

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 - draw a pictorial drawing (in isometric)
- on an isometric axis
- in a isometrics box
d) draw a pictorial drawing (in oblique)
- on the oblique axis
- in an oblique box
- in cabinet & in cavalier projection
e) Draw circles on all 3 faces of isometric
drawing and all 3 faces of the oblique
drawing. State findings.
f) Draw a pictorial drawing in
- 1 point perspective
- 2 point perspective

4.10 ORTHOGONAL DRAWINGS (Positions of View)

a) Understand that orthogonal drawings (1st or 3rd angle orthographic projection) of a
steeped block in 3rd angle orthographic projection, leaving construction and projection
lines.
b) Illustrate the principle of orthographic projection by clearly drawing a steeped block in
3rd angle orthographic projection, leaving construction and projection lines.
c) Draw a steeped block in 1st angle orthographic projection, leaving construction and
projection lines.
d) Ensure correct ‘Spacing’ is implemented in-between and around the views.
e) Identify and draw auxiliary views from each front view.
f) State the purpose of auxiliary views.

4.11 SECTIONING
a) State the reasons for sectioning components.
b) List any 4 items that are never sectioned (i.e. cross hatched)
c) State what a hatching line is.
d) Insert “cutting plane” lines and those that change direction too.
e) Identify special features of sections.

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 f) Draw half sections (especially on cylindrical bodies).
g) Identify various flanges & pipe fittings and draw them in cross – section.

4.12 LIMITS & FITS (inc. Tolerance on dimensions)

a) Understand the importance of tolerance on dimensions with regard to “limits of fists”.
- State how may “bases of Fit” there are (ans 2 – holes & shaft)
- Define the following terms:
o Hole
o Shaft
o Nominal size
o Actual size
o Basic size
o Limits of size
o Tolerance
o Allowance
o Grade
o Deviation
o Maximum metal condition
o Unilateral & bilateral limits

b) Identify the expressions ‘limits of size’ and ‘Fitting together of

components parts’ as being derived from the topic, “limits and Fits”.
c) State how many ‘types of Fit’ there are, and identify them.
Ans : - clearance
- transition
- interference
d) Identify and utilize information contained in the I S O “Fits” (Hole Basis) charts
(extracted from BS 4500).
e) Identify and utilize information from a ‘shaft basis’ chart.
f) Identify a ‘tolerance as being a permitted ‘variation’ from a nominal dimension an
explain it.

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4.13 GEOMETRY
a) Define a geometrical tolerance and its purpose and how it differs from tolerance on
dimensions.
b) State and draw the recommended symbols for tolerancing ‘shape or form’ and their
tolerance characteristics.
e.g. - straightness
- roundness
- flatness
- cylindricity
- profiles of a line
- profiles of a surface
c) Identify and draw the 1.S.O. recommended symbols for tolerncing ‘location’ and their
tolerance characteristics.
e.g. - position
- concentricity
- symmetry
d) Identify and draw 1.S.O. recommended symbols for tolerancing and their tolerance
characteristics.
e.g. - parallelism
- squareness
- angularity
- runout
e) Apply geometrical tolerances to drawings with reference to B.S. 308 part

4.14 READING AND INTERPRETING ENGINEERING DRAWING

a. Understand that in all orthogonal drawings, it is necessary to project at least 2 views of a
3 dimensional object; or one view and an adequate description in some simple cases.
b. Draw the front view of a ball bearing race by drawing:-
- A circle in the first view
- A rectangle in the second view

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 c) Draw “identical” plans (above views) of an object showing all 4 front views to be
different: showing all 4 front views to be different; thus demonstrating the necessity to
draw at least 2 views of any 3 dimensional object.
d) Exercise “imagination” by identifying and interpreting engineering drawings; realising
that the more complex a drawing is, the more important it will be for sufficient (3+)
views of it to be drawn.

e) Identify and successfully interpret the correlation between General arrangement

drawings, Production drawings, Working drawings, Detail drawings and assembly
drawings.

4.15 CONVENTIONAL REPRESENTATIONS

a) Understand the need for “International Agreements” (as in Drawing conventions), when
representing “Features” in Engineering Drawings.
b) Draw the following features in conventional representations:-
- Screw threads
- Springs
- Ball and Roller bearings
- Knurling (straight and Diamond)
- Shaft (splined and serrated)
- Holes (on P.C.D.) and on linear pitch)
- Square section on shafts
- Breaks in long sections, as in:
- solid bar
- tube (sectional)
- rectangular bar
c. Identify all features on drawings in accordance with BS 308.

4.16 ABBREVIATIONS AND SYMBOLS

a. Recognise and apply abbreviations and symbols used in technical drawing.
b. Select and apply weld symbols to drawings with reference to BS 499 part II
c. Compare with BS 499 other methods of indicating welds, e.g. ANS and ISO symbols.

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 d. Indicate and illustrate abbreviations and symbols used for surface textures and finishes
with regard to drawings using BS 308 part II.
e. Identify machining and Draughting symbols.

4.17 TEMPLATING SYSTEMS

a. Understand a system of templating.
b. State and define the terms:
- template
- jump-joints
- lap
- welts
- butt plates
c. Draw development of cylinder, cut by plane at an angle.
d. Develop junction of two cylinders of equal diameter (2 types).
e. Develop the rake of a funnel of a steamship.
f. Develop the plates for a dome to fit on the topside of a boiler or anywhere on the side of a
boiler.
g. Develop a connecting pipe between a boiler and a super heater.
h. Develop a plate to form the overhanging front of a boiler.
i. Develop the plates of an egg – ended boiler.
j. Develop the taper of the frustum of a cone (without continuing the taper to a point).
k. Find the rise and radius of a cone by calculation.
l. State rules governing minimum distances between rows of rivets, and between
rivets and any edge of a plate.

4.18 GENERAL ARRANGEMENT DRAWINGS

a. Understand the purpose of “G A” drawings and how to interpret them.
b. Identify and explain construction (erection and structural) information used in
Fabrication Engineering’s “G.A.” drawings.
c. Identify and explain the role of the “ERECTION SECTION” in the construction industry
(use sketches).
d. Explain that “G.A.” drawings for Fabrication Engineering are used to:

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 - Outline important dimensions and identification marks for use by
assemblers, erectors, and customers.
- Show overall position of components in a Fabrication structure of sheet
metal layout.

e. Prepare a “G.A” drawing from a set of given data.

f. Draw a “Rigging Pole”.

4.19 WORKING DRAWING – (A)

a. Understand the use of Assembly and Sub-assembly drawings.
b. Identify a “completely assembled construction” as an ”assembly” drawing and draw it.
c. Identify and illustrate how (when complete information is given) assembly drawings may
be used for working drawings (i.e. when complex detail is either little or non-existent).
d. Identify and draw what is of particular value in Assembly drawings i.e.

- The way parts go together (i.e. shown).

- Appearance of construction shown as a whole.
- Provide dimensions necessary for installation, space necessary, foundation
electrical or hydraulic connections.
e. List and describe advantages of using different sheets for different views when the size of
assembled construction is large.(N.B. The same scale must be used on al sheets).
f. Identify and draw “Special” assembly drawings which make reference to the
identification of parts to be used for assembly. (N.B tabular list and selection of
dimensions given on drawings).
g. Identify and draw a ‘part assemblies’ drawing (for a group of parts).
h. Identify drawings for use in assembling or erecting a machine and drawings to give
directions for maintenance/operations.
i. Identify and draw the “Design Layout”., from which the “detail” drawings are made.

4.20 WORKING DRAWINGS

a. Understand the use of “Detail drawings” and what it is that they express.

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 b. Explain that detail drawings are used to provide detailed information for construction and
manufacturing purposes.
c. Demonstrate how 1st and 3rd angle projection are often sued simultaneously on fabrication
drawings.
d. Discuss the advantage of using sections, part sections and enlarged detail drawings.
e. Explain the interpretation and provision of general notes on detail drawings.
f. Demonstrate the ability to use information provided in structural steel work tables
including.
- back marks
- hole centres
- size of notches on beams
- carrying capacity of H.S.F.G. bolts
- shearing and bearing values for black and precision bolts.
- Strength of butt and fillet welds for steels
g. Draw various types of ‘lattice girders’ roof trusses, beams, portal frames, wind
braces, portal frames, windbraces, purlins, cleats, stanchions and Facia Frames
h. Identify and draw a simple “ ERECTON POLE” used for ‘RIGGING’ roof
trusses, lattice girders etc. (in upright position)

4.21GEOMETRY AND (E) PATTERN DEVELOPMENT

4.21.1 GEOMETRY
4.21.1.1 Apply geometrical principles in relation to identifying and constructing
Geometrical constructions such as:-
a) Plane geometrical shapes:
- Lines
- Angles
- Triangles
- Squares
- Polygons
- Pentagon
- Hexagon
- Heptagon

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 - Octagon
- Nonagon
- Decagon
- Circle
- Tangent
- Ellipse
- Pyramid/cone
- Prism/cylinder
4.21.1.2 Draw an ellipse by at least 3 different methods:-
a) concentric circles method
b) rectangular method
c) trammel method

4.21.1.3 Apply geometrical constructions for “LOCI” in relation to “Mechanism

operations”.
a) construct a parabola
b) construct an ellipse
c) Construct a hyperbola
d) Construct an involutes
e) Construct various conic sections
f) Construct a cycloid.
4.21.1.4 Understand methods of determining menstruation.
a) Determine areas and volumes of rectangular solids.
b) Determine the circumference and area of a circle.
c) Determine the diameter, given the circumference
d) Determine the approximate length of an arc of a circle.
e) Determine the area of a ring (angle iron, round bar, etc)
f) Determine the area of a sector of a circle.
g) Determine the circumference of an ellipse.
h) Determine the areas of a triangle.
i) Determine the surface area of a sphere.
j) Determine the volume of a sphere.

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4.21.1.4 Apply geometrical principles in the development of bodies which ‘taper’ to an
Apex. (Pyramid Class) using radial line method.
a) Cone and related conical shapes
b) Pyramid (square and rectangular)

4.21.1.5 Apply geometrical principles in the development of bodies which maintain a

constant shape of cross-section throughout their length. (PRISM CLASS) (parallel line
method).
4.21.1.6 Apply geometrical principles to developing
a) pipes
b) cylinders
c) chutes
d) lobster back bends

4.21.1.7 Apply geometrical principles in the development of bodies by triangulation.

a) Utilize geometry on sheet metal to fabricate a

- Transformer (square to round)

- Stove elbow connection
- Breeches pieces on square base
- Junction piece.

4.21.1.8 Apply geometrical principles in the development of intersections by cutting

planes.
a) Method of cutting planes.
b) Method of auxiliary projection, with specific application to:-
- Cylinder cut by a plane
- Cone cut by a plane
- Sphere cut by a plane

4.21.1.9 Apply geometrical principles in the drawing up of auxiliary and double

projections.

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 a) Projections on a straight line
b) Projection on a straight prism
c) Projection on a right cone
d) Projection on a chute from screw conveyer
e) Projection on a cylindrical elbow on cylindrical main (double projection).

4.21.1.10 Apply geometrical principles in the development of complex patterns and spiral
chutes:
a) To a rolled-surface transition piece.
b) To a flared ventilator head
c) To a spiral chute
d) To divided feed tropper

4.21.1.11 Apply geometrical principles in the development of “DUCT” LAYOUTS

together with developments of junction pieces.
a) A fume hood and extraction duct clearly highlighting
- The branch piece
- The “Fume” ductwork
- Two way junction piece
- Square to two circles.
4.21.1.12 Apply geometrical principles of auxiliary projection.
a) Project auxiliary views and sections of cylinders, cones, pyramids and other
plane figures to produce shapes of sections other than circular, square and of
rectangular form
b) Project auxiliary view to simplify surface development of a transformer,
aperture openings and true shape of sections.
c) Project auxiliary views to determine joint lines between cones and cylinders
other than those that have axes that ar parallel or at 90 degrees to each other.
d) Apply the principles of 1.13 (a) to 1.13(c) to determine the joint lines of
cylindrical and rectangular branches into cones other than at 90 degrees to the
central axis.
4.21.1.13 Apply the principles of ‘cutting planes’ to determine joint lines.

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 a) Determine the joint lines of cylindrical branches interesting right and oblique
cones set at 90 degrees or parallel to the cutting planes.
b) Determine the joint lines of rectangular ducts intersecting right and oblique
cones set at 90 degrees or parallel to the cutting planes.
c) Determine the joint lines of cylindrical or rectangular ducts, interesting right
cones, set at angles other than 90 degrees or parallel to the cutting planes of
the cone.
d) Determine the joint lines of square or rectangular branches intersecting
transformers set at 90 degrees of parallel to the cutting planes of the
transformer.
e) Determine the joint lines of square or rectangular branches intersecting
transformers set at 90 degrees or parallel to the cutting planes of the
transformer.
f) Determine joint line of 1.14 (a) to 1.14(e) both on and off centre to the central
axis.
4.21.1.14 Apply the principles of the common central sphere.
a) Apply the principles of common central sphere to offset and breaches pieces
of two, three and four way connections, in the same plans of
- Cone – cylinders
- Cone – cones
- Cylinder – cylinders

4.21.1.13 Determine junction details and allowance necessary for structural and thick plate
applications.
a) Determine junction details. By projection method of structural framework set
at angles to one another including “dihedral” angles.
b) Determine allowance on layout and templates for thickness of plate.
c) Determine joint detail of welded connections when thick plate is used.

4.21.1.14 Apply the principle of “Double Projection” in solving problems of intersection

between cylinders and ducts whose axes are in double rake to each other.

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 a) Construct centre line views to gain true length and angle of connections by
rotation and “double projection”.
b) Construct auxiliary views to gain joint details of double offset cylinders, ducts
and frameworks.
c) Construct by double projection, auxiliary views to determine joint details on
other elevations and patterns for cylinder.
d) Construct by double projection, auxiliary views to determine ‘true shape’ of
pattern for double offset elbows, branches and breeches, pieces of cylinders
and ducts of equal cross-sections.
e) Construct by double projection, true lengths of structural sections for hip
rakers, brackets, struts and ties for structural frame works.

4.22 PATTERN DEVELOPMENT

4.22.1 Understand exactly what is meant by pattern development and what its
relationship to “templating” is.
a) Explain the terms:-
- pattern drafting
- pattern development
- pattern stretch out
- pattern template
- surface development
b) Identify pattern drafting/surface development, as that which is measured and
marked out on either paper, cardboard or “white line chip board” and used for
one off jobs.
c) Identify a template as being the “thin, sheet metal plate” that has had the
“initial” pattern draft/development transferred onto it and is used on a more
“permanent” basis as in Mass Production.
4.22.2 Identify the four classes of Geometrical From, with their accompanying methods
of surface development, namely:-
Class Method
- Pyramid Radial line method
- Prism Parallel line method

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 - Transformer Triangulation method
- Sphere (various) hollowing; raising;
spur pressed; fabricated in
segments

a) Identify the system and principles of radial line surface development utilising
them to make a “Right” Cone; then an “Oblique” cone, then a square based
pyramid.
b) Identify the principles of “Parallel Line” surface development, utilising them
to make a:
- Cylinder
- Chute
- Lobster back bend.
c) Identify the principles and system of “TRIANGULATION”, employing them
to make a:
- Circle to oval
- Square to round
- Square to square (twisted)
d) Identify and implement the methods available for the fabrication of spheres,
spheroids and hemispheres.
i. Showing how spheres are:

- pressed
- spun
- hollowed
- raised
- fabricated in segments
ii. Calculate the diameter of a circular disc/blank which would be
required to produce a “Hemispherical Bowl” of 305 mm diameter
and of the same gauge of material, and make it. (use raising
method).
iii. Make “Spherical Corners” for storage tanks and/or urinals using:-

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 - triangle with curved sides methods
- The method of manufacturer of “pressed” spherical corners.

e) Identify appropriate methods of calculation and fabrication and utilise them to

fabricate.
- A hemispherical dome using a8 segments and a spherical cap.
f) Apply the principles of
- Parallel line
- Radial line, and
- Triangulation methods to the determination of patterns for surface
developments.
g) Select methods and construct patterns for applications taken from Geometry.
h) Select methods and construct patterns for ducting components, hoppers, hoods
and chutes based on right cones and pyramids.
i) Select methods and construct patterns for ducting components, hoppers, hoods
and chutes based on oblique cones and pyramids.
j) Construct patterns for transformers between two inclined planes by
triangulation.
k) Determine the placing and forming angles of kinked sides on hoppers and
ducts.
l) Develop patterns of long taper and change section components, whose ends
are inclined or parallel to each other.
4.22.3 Apply the principle of parallel line development to develop patterns of ducts of
square and rectangular cross – section and bends of 90 degrees.
a) Construct and develop patterns for rectangular 90 degrees bends with simple
changes section and parallel flat sides.
b) Construct and develop patterns for rectangular 90 degrees bends with tapering
(non-twisted) sides.
c) Construct and develop patterns for tapering square/ rectangular ducts, with
single and multi sided taper between parallel planes.

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 d) Construct and develop patterns for swan neck with/without taper, placing
correct radii to give smooth air flow on offset and double offset connections.
4.22.4 Apply Geometrical Principles to recognise and develop true twisted surfaces, helix
surface and tapering bends with single twisted surface.

a) Recognise the helix angle and surface from the straight line of the developed
helix.
b) Construct and develop patterns for spiral chutes composed of a helix surface
with sides.
c) Vary the “pitch” of helix to patterns and models to slow down/accelerate
materials on chutes of one to three revolutions, including halves and quarters
to change direction.
d) Construct and develop patterns for tapering bends with single twisted sides.
e) Construct and develop patterns for screw conveyors.

5.0 ASSESSMENT

5.1 ASSESSMENT GRID

TOPIC TOPIC HOURS WEIGH

NO. T%
1 INTRODUCTION TO ENGINEERING DRAWING. 15 7
2 DIMENSION 10 5
3 PICTORIAL DRAWING 25 11
4 SECTIONING 26 12
5 GEOMETRY (PATTERN DEVELOPMENTS)
43 19
6 READING AND INTERPRETING ENGINEERING
10 5
DRAWING
7 CONVENTIONAL REPRESENTATIONS 10 5
8 ABBREVIATIONS AND SYMBOLS 9 4
9 TEMPLATING SYSTEMS 16 7
10 ORTHOGRAPHIC DRAWINGS 36 17
11 WORKING DRAWINGS 20 9
TOTAL 220 100%

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6.0 SUGGESTED REFERENCES
1 RANA, R. (2015) A Text book of Engineering Drawing: I. K. International
Publishing. (Pvt) Ltd
2 Simmons, C. H. & Maguire, D. E. (2004) Manual of Engineering Drawing. 2nd Ed.
Amsterdam
3 Miller, H. W. (2015) Engineering Drawing. Machigan Publishing
4 Ladnecki, P. (2008) Descriptive Geometry 1. Butterworth-Heinemann.
5 Gill, P. S. (2008) Descriptive Geometry. Kataria. S & Sons. India.

7.0 PAPER 1 FORMAT (Aggregate Examination Weight is 50%)

Consists of three Sections : Answer ALL
SECTION A: Answer both questions (30 marks)
Question One Geometry Drawing (15 marks)
Question Two Pictorial drawing (15 marks)
SECTION B: Answer All three questions (20 marks)
Question Three Welding symbols (8 marks)
Question Four Abbreviations used in Eng drawing (8 marks)
Question Five Convectional symbols (4 marks)
SECTION C: Answer both questions (50 marks)
Question Six Sectioning (30 marks)
Question Seven Orthographic drawing (20 marks)

7.0 PAPER 2 FORMAT (Aggregate Examination Weight is 50%)

Consists of three sections:

SECTION A: Answer one question out of two (30 marks)

Radial line developments

SECTION B: Answer one question out of two (30 marks)

Parallel line Developments

SECTION C: Answer one question out of two (40 marks)

Triangulation Developments

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