71

50

48
60 3 58
Raw material After rough filing

Portion to be
removed
After marking & punching After hack sawing
15 20
10

EVALUATION OF JOB ACCURACY

12

S.No. Part Name Actual Obtained Variation

20
48

1. A 58
2. B 48
R16
3. C 10
R16 58
4. D 15
After finishing
D E
5. E 20
6. F 12
C

7. G 20
8. R1 16
G
B

9. R2 16
,

CUTTING AND FILING OF A PROFILE

R2
R1 A All dimensions are in mm

72
 FITTING
Ex. No.1. CUTTING AND FILING OF A PROFILE
Aim :
To make a workpiece as per the given dimension from a mild steel flat piece
using fitting operations.

Raw material :
Mild steel flat of size 60 x 50 x 3 mm

Tools required :
1) Bench vice 2) Steel rule 3) Surface plate 4) Vernier height gauge
5) Scriber 6) Try square 7) Dot punch 8) Ball peen hammer
9) Divider 10) Hacksaw 11) Flat file 12) Triangular file
13) Half round file

Sequence of operations :
1) Rough filing 2) Marking 3) Punching 4) Sawing 5) Smooth filing

Procedure :
1) The given raw material is checked for its size 60 x 50 x 3 mm.
2) The workpiece is fixed rigidly on the vice and all the edges are filed using flat file
so that they are at right angles to each other. The squareness is checked with try
square.
3) Chalk is applied uniformly on the surfaces of the workpiece.
4) The workpiece is marked as per the given dimension with reference to the
datum using surface plate, steel rule, vernier height gauge and divider.
5) Dots are punched along the marked lines using dot punch and hammer.
6) After giving allowance for filing, the unwanted portions are removed by cutting
with hacksaw.
7) The curved edges are filed using half round file and the straight edges are filed
using triangular file.
8) Finally, the finished job is measured for the correctness of dimensions.

Result :
The workpiece is made as per the given dimension from the raw material using
fitting operations.

73
 48
50
5
58
60
After rough filing
Raw material
15
2 x M14 x 1.5

15

15
Ø12, 2 Holes 15
After drilling, reaming &
After marking & punching
tapping
(Finished job)

EVALUATION OF JOB ACCURACY

A
D Tapping S.No. Part Name Actual Obtained Variation
1. A 58
C

2. B 48
3. C 15
B

4. D 15
5. E 15
E

6. F 15
F 7. Dia. 12
Dia.
8. Tapping M14 x 1.5

DRILLING, REAMING AND TAPPING

All dimensions are in mm

74
Ex. No.2. DRILLING, REAMING AND TAPPING
Aim :
To prepare a job as per the given dimensions from a mild steel flat piece using
drilling, reaming and tapping operations.

Raw material :
Mild steel flat of size 60 x 50 x 6 mm

Tools required :
1) Bench vice 2) Steel rule 3) Surface plate 4) Vernier height gauge
5) Scriber 6) Try square 7) Centre punch 8) Ball peen hammer
9) Drilling machine 10) Flat file 11) 12mm twist drill 12) 12mm reamer
13) 14mm tap with tap wrench

Sequence of operations :

1) Rough filing 2) Cutting 3) Marking 4) Punching

5) Drilling 6) Reaming 7) Tapping

Procedure :
1) The given raw material is checked for its size 60 x 50 x 3 mm.
2) The workpiece is fixed rigidly on the vice and all the edges are filed using flat
file so that they are at right angles to each other. The squareness is checked
with try square.
3) Chalk is applied uniformly on the surfaces of the workpieces.
4) The workpieces are marked as per the given dimension with reference to the
datum using surface plate, steel rule and vernier height gauge.
5) The centres of holes to be drilled are marked using centre punch and hammer.
6) The correct size drill bit is fitted in the spindle of the drilling machine.
𝑫𝒓𝒊𝒍𝒍 𝒔𝒊𝒛𝒆 = 𝑻𝒂𝒑 𝒔𝒊𝒛𝒆 − (𝟎. 𝟔𝟐𝟓 × 𝟐 × 𝒑𝒊𝒕𝒄𝒉) = 𝟏𝟒 − (𝟎. 𝟔𝟐𝟓 × 𝟐 × 𝟏. 𝟓) = 𝟏𝟐. 𝟏𝟐𝟓 ≈ 𝟏𝟐 𝐦𝐦
7) Four holes of 𝛟𝟏𝟐 mm size are drilled at correct places as shown in the figure.
8) Four holes are finished using 𝛟𝟏𝟐 mm reamer.

9) Two of the drilled holes are tapped, as shown in the figure, using the correct
size tap set as per the order – first tap, second tap and finishing tap.
10) Finally, the finished job is measured for the correctness and accuracy of
dimensions.

Result :
The job is prepared as per the given dimensions from a mild steel flat piece using
drilling, reaming and tapping operations.

75
 48
50
3
29 29
60
Raw material After rough filing & cutting

Portion to be
removed
After marking & punching
After hack sawing & cutting
14 15
15
48

33

EVALUATION OF JOB ACCURACY

S.No. Part Name Actual Obtained Variation
15 29 1. A 29
After finishing & fitting 2. B 15
A B 3. C 48
4. D 15
D

5. E 33
C

L - MATING
C
E

All dimensions are in mm

B A

76
Ex. No.3. L – MATING
Aim :
To prepare a L – mating as per the given dimension from mild steel flat pieces
using fitting operations.

Raw material :
Mild steel flat of size 60 x 50 x 3 mm

Tools required :
1) Bench vice 2) Steel rule 3) Surface plate 4) Vernier height gauge
5) Scriber 6) Try square 7) Dot punch 8) Ball peen hammer
9) Hacksaw 10) Flat file 11) Triangular file

Sequence of operations :
1) Rough filing and Cutting 2) Marking 3) Punching 4) Sawing 5) Smooth filing

Procedure :
1) The given raw material is checked for its size 60 x 50 x 3 mm.
2) The workpiece is fixed rigidly on the vice and all the edges are filed using flat
file so that they are at right angles to each other. The squareness is checked
with try-square.
3) The workpiece is cut into two equal parts as shown in the figure. Chalk is applied
uniformly on the surfaces of the workpieces.
4) The workpieces are marked as per the given dimension with reference to the
datum using surface plate, steel rule and vernier height gauge.
5) Dots are punched along the marked lines using dot punch and hammer.
6) After giving allowance for filing, the unwanted portions are removed by cutting
with hacksaw.
7) The surfaces are filed using triangular file to correct dimension and geometrical
accuracy.
8) The two finished workpieces are fitted correctly to make L-joint.
9) Finally, the finished job is measured for the correctness of dimensions and
required class of fit.

Result :
The L – mating is prepared as per the given dimension from the raw material using
fitting operations.

77
TWO LAMPS CONNECTED IN SERIES AND
CONTROLLED BY ONE-WAY SWITCH

Lamp-1 Lamp-2

Neutral

230 Volts
AC supply

Phase
One-way
Switch

Circuit diagram

78
 WIRING
Ex. No.4(A). TWO LAMPS CONNECTED IN SERIES AND
CONTROLLED BY ONE-WAY SWITCH
Aim :
To make wiring for two lamps connected in series and controlled by one-way
switch, and verify the circuit connection.

Requirements :

Materials Tools
1) Wooden board for wiring 1) Hand drilling machine
2) Wooden round blocks 2) Hack saw
3) Wood screws 3) Hammer
4) PVC pipes and elbows 4) Cutting plier
5) PVC clamps 5) Screw driver
6) PVC wires for connection 6) Electrician’s knife
7) Batten holders 7) Poker
8) One-way switch 8) Mallet
9) Electric lamps 9) Electrical line tester
10) Insulation tape 10) Multimeter

Procedure :
9) Draw the wiring circuit diagram on the wooden board using white chalk piece.
10) Fix the PVC pipes and elbows as per the circuit diagram using PVC clamps and
screws.
11) Insert required length of PVC wires through the pipe for connection.
12) Fix the wooden round blocks at the correct place using wood screws.
13) Connect the switch and batten holders through wires as per the circuit diagram.
14) Verify the circuit and apply corrections if required.
15) Fix the lamps in the holder. Turn on the power supply and switch.
16) If the lamps glow, the connection is correct. Otherwise detect and rectify the
fault in the connection and verify the circuit again.
Result :
The wiring for two lamps connected in series and controlled by one-way switch
is made. The correctness of connection is verified.

79
TWO LAMPS CONNECTED IN PARALLEL AND
CONTROLLED BY ONE-WAY SWITCH

Lamp-1 Lamp-2

Neutral

230 Volts
AC supply

Phase
One-way
Switch

Circuit diagram

80
Ex. No.4(B). TWO LAMPS CONNECTED IN PARALLEL
AND CONTROLLED BY ONE-WAY SWITCH
Aim :
To make wiring for two lamps connected in parallel and controlled by a one-
way switch, and verify the circuit connection.

Requirements :

Materials Tools
1) Wooden board for wiring 1) Hand drilling machine
2) Wooden round blocks 2) Hack saw
3) Wood screws 3) Hammer
4) PVC pipes and elbows 4) Cutting plier
5) PVC clamps 5) Screw driver
6) PVC wires for connection 6) Electrician’s knife
7) Batten holders 7) Poker
8) One-way switch 8) Mallet
9) Electric lamps 9) Electrical line tester
10) Insulation tape 10) Multimeter

Procedure :
1) Draw the wiring circuit diagram on the wooden board using white chalk piece.
2) Fix the PVC pipes and elbows as per the circuit diagram using PVC clamps and
screws.
3) Insert required length of PVC wires through the pipe for connection.
4) Fix the wooden round blocks at the correct place using wood screws.
5) Connect the switch and batten holders through wires as per the circuit diagram.
6) Verify the circuit and apply corrections if required.
7) Fix the lamps in the holder. Turn on the power supply and switch.
8) If the lamps glow, the connection is correct. Otherwise detect and rectify the fault
in the connection and verify the circuit again.

Result :
The wiring for two lamps connected in parallel and controlled by one-way switch
is made. The correctness of connection is verified.

81
 CEILING FAN CONTROLLED BY
ONE-WAY SWITCH AND REGULATOR

Ceiling
Fan Motor

Neutral

230 Volts
AC supply

Phase
One-way
Switch Fan
Regulator
Circuit diagram

82
Ex. No.5. CEILING FAN CONTROLLED BY
ONE-WAY SWITCH AND REGULATOR
Aim :
To make wiring for ceiling fan controlled by one-way switch through regulator,
and verify the circuit connection.

Requirements :

Materials Tools
1) Wooden board for wiring 1) Hand drilling machine
2) Wooden round blocks 2) Hack saw
3) Wood screws 3) Hammer
4) PVC pipes and elbows 4) Cutting plier
5) PVC clamps 5) Screw driver
6) PVC wires for connection 6) Electrician’s knife
7) One-way switch 7) Poker
8) Fan regulator 8) Mallet
9) Ceiling fan and accessories 9) Electrical line tester
10) Insulation tape 10) Multimeter

Procedure :
1) Draw the wiring circuit diagram on the wooden board using white chalk piece.
2) Fix the PVC pipes and elbows as per the circuit diagram using PVC clamps
and screws.
3) Insert required length of PVC wires through the pipe for connection.
4) Fix the wooden round blocks at the correct place using wood screws.
5) Connect the switch, fan regulator and fan motor through wires as per the
circuit diagram.
6) Verify the circuit and apply corrections if required.
7) Turn on the power supply and switch.
8) If the ceiling fan rotates, the connection is correct. Otherwise detect and
rectify the fault in the connection and verify the circuit again.
Result :
The wiring for ceiling fan controlled by one-way switch and regulator is made.
The correctness of connection is verified.

83
 STAIRCASE WIRING

Lamp

Neutral

230 Volts
AC supply

Phase

Two-way Two-way
Switch-1 Switch-2

Circuit diagram

84
Ex. No.6. STAIRCASE WIRING
Aim :
To make staircase wiring for one lamp controlled by two-way switches at
different locations and verify the circuit connection.

Requirements :

Materials Tools
1) Wooden board for wiring 1) Hand drilling machine
2) Wooden round blocks 2) Hack saw
3) Wood screws 3) Hammer
4) PVC pipes and elbows 4) Cutting plier
5) PVC clamps 5) Screw driver
6) PVC wires for connection 6) Electrician’s knife
7) Batten holders 7) Poker
8) Two-way switches 8) Mallet
9) Electric lamp 9) Electrical line tester
10) Insulation tape 10) Multimeter

Procedure :

1) Draw the wiring circuit diagram on the wooden board using white chalk piece.
2) Fix the PVC pipes and elbows as per the circuit diagram using PVC clamps and
screws.
3) Insert required length of PVC wires through the pipe for connection.
4) Fix the wooden round blocks at the correct place using wood screws.
5) Connect the two way switches and batten holders through wires as per the circuit
diagram.
6) Verify the circuit and apply corrections if required.
7) Fix the lamp in the holder. Turn on the power supply and switch.
8) If the lamp glows, the connection is correct. Otherwise detect and rectify the fault in
the connection and verify the circuit again.

Result :
The staircase wiring for one lamp controlled by two-way switches at different
locations is made and the correctness of connection is verified.

85
INSTALLATION, CHARGING AND
TESTING OF A BATTERY

Cathode plates

Anode plates

Electrolyte

LEAD ACID BATTERY

Rubber
bulb

Glass
tube

Float
Constant Current Charging
(Connecting batteries in Series)

Constant Voltage Charging

BATTERY
(Connecting batteries in Parallel)
HYDROMETER
BATTERY CHARGING

86
Ex. No.7. INSTALLATION, CHARGING
AND TESTING OF BATTERY
Aim :
1) To install and charge a battery
2) To test a battery with hydrometer

Requirements :

1) Given battery 2) Hydrometer

3) Battery charger 4) Ammeter
5) Voltmeter 6) Spanner set
7) Screw drivers 8) Cutting pliers
9) Distilled water 10) Cleaning brush

Procedure :

Battery installation

1) The positive and negative terminal nuts and bolts of the battery are cleaned with
cleaning brush and loosened using appropriate spanners.

2) The positive cable is first connected with the positive terminal of the battery.

3) Then the negative or earth cable is connected with the negative terminal of the
battery.

4) The nuts on both the terminals are tightened securely.

5) The vent caps are removed from the battery cells and filled with sufficient distilled
water.

6) The battery is placed in a secured place.

Battery charging

The charging of battery is done under two methods :

(i) Constant ampere method : In this method, the current input to the battery is
kept at a constant value. The batteries are connected in series while charging.

(ii) Constant voltage method : In this method, the voltage input to the battery is
kept at a constant value. The batteries are connected in parallel while charging.

87
Tabulation :

Specific Voltage
Sl.No. Cell No. Remarks
gravity (V)

88
The procedure for charging a battery is as follows :
1) The battery is placed on the work bench with all vent holes completely opened.
2) The clips of the charger are connected with the battery. The black clip is connected
to the negative post and red colour clip is connected to the positive post.

3) The battery is initially charged with 30 Amperes current for 30 minutes and 20
Amperes current for the next 3 hours.

4) For slow charging of battery it is set for 5 to 9 Amperes uniformly. It is noted that
during charging the temperature of battery should not exceed 50oC.

5) After charging the specific gravity should be analysed as required.

6) Then all the vent holes of battery is closed and washed with water thoroughly.

Battery testing using hydrometer (Specific gravity test)

1) The vent caps are removed from the battery cells.
2) The hydrometer suction bulb is squeezed and the pickup tube is inserted into the
cell closest to the battery's positive (+) terminal
3) The bulb is slowly released to draw in sufficient electrolytes to cause the float to
rise.

4) The specific gravity indicated on the float is noted.

5) The procedure is repeated for the remaining cells and the readings are recorded.

Result :
1) The battery is installed and charged with constant ampere / constant
voltage method.
2) The given battery is tested with hydrometer (specific gravity test). The
specific gravity of electrode is ______________.

89
 INSTALLATION OF TAP

Main pipeline Tee

from tank

Water tap

Elbow
Coupler

Piping layout for installation of water tap

90
 PLUMBING

Ex. No.8. INSTALLATION OF TAP

Aim :
To install a tap using different PVC pipe accessories.

Materials and fittings required :

1) ½” Water tap 2) ½” PVC pipes 3) ½” Tee

4) ½” Elbow 5) ½” Coupler 6) Flexible drain pipe
7) Solvent cement

Tools required :
1) Pipe vice 2) Hack saw 3) File 4) Steel rule
5) Scriber 6) Measuring tape 7) Brush

Sequence of operations :
1) Sketching of layout 2) Marking 3) Cutting of pipe into lengths
4) End finishing 5) Assembling

Procedure :
1) Draw the piping layout for fitting and accessories.
2) Mark the required length on the PVC pipe after adding overlaps for fittings and
cut into pieces using hack saw. The cut ends to be perpendicular to the axis of
pipe.
3) The burrs in the pipe ends is cleaned by using files.
4) Mark the position of various fittings in the correct places and assemble the
fittings. Check the accuracy and apply correction if required.
5) Apply the solvent cement on the mating surfaces using brush and assemble the
components together to complete the required pipe line work.

Result :
The water tap is installed using different PVC pipe accessories.

91
 INSTALLATION OF WASH BASIN / SINK

Main pipeline Tee

from tank

Water tap

Wash basin
Elbow
Coupler

Flexible drain hose

Piping layout for installation of wash basin

92
Ex. No.9. INSTALLATION OF WASH BASIN / SINK

Aim :
To install a wash basin or sink with a tap using different PVC pipe accessories.

Materials and fittings required :

1) Wash basin / Sink 2) ½” PVC pipes 3) ½” Tee
4) ½” Elbow 5) ½” Water tap 6) ½” Coupler
7) Flexible drain pipe 8) Solvent cement

Tools required :
1) Pipe vice 2) Hack saw 3) File 4) Steel rule
5) Scriber 6) Measuring tape 7) Brush

Sequence of operations :
1) Sketching of layout 2) Marking 3) Cutting of pipe into lengths
4) End finishing 5) Assembling

Procedure :
1) Draw the piping layout for fitting and accessories.
2) Mark the required length on the PVC pipe after adding overlaps for fittings and
cut into pieces using hack saw. The cut ends to be perpendicular to the axis of
pipe.
3) The burrs in the pipe ends is cleaned by using files.
4) Mark the position of various fittings in the correct places and assemble the
fittings. Check the accuracy and apply correction if required.
5) Apply the solvent cement on the mating surfaces using brush and assemble the
components together to complete the required pipe line work.

Result :
Thus the wash basin or sink with tap is installed using different PVC pipe
accessories.

93
 INSTALLATION OF RAIN WATER
HARVESTING SYSTEM

Wire mesh
Roof top

Water to filter
Filter
First rain
seperator Sand
Gravel
Filtered
water to Overflow
Ground level storage

Pebbles

Storage tank
To ground
water
recharge
To supply
for usage

Piping layout for installation of

rain water harvesting system

94
Ex. No.10. LAYING PIPES FOR RAIN WATER
HARVESTING SYSTEM

Aim :
To lay pipelines for the installation of rain water harvesting system in a building.

Materials and fittings required :

1) GI pipes 2) Tee 3) Elbow
4) End cap 5) Couplers 6) Wire mesh

Tools required :
1) Pipe vice 2) Hack saw 3) File 4) Steel rule
5) Scriber 6) Pipe wrench 7) Threading die with holder

Sequence of operations :
1) Sketching of layout 2) Marking 3) Cutting & threading of GI pipes
4) Laying out pipe line

Procedure :
1) Mark the required length on the GI pipe and cut external threads at the ends.
2) Install the pipe line for first rain separator using Elbow and Tee. Fix a End cap
at the end of the pipe.
3) Install the pipe line to water filter using Tee and Elbow.
4) From the outlet of the filter, install the pipe lines to water storage system.
5) Provide a pipe for over flow in the top of the storage system. Connect the
overflow pipe to the ground water recharge system.
6) Install pipe line from the bottom of the storage system to supply main. It may
be a motor to pump the water to overhead tank.
7) Provide a wire mesh at the entry of pipe in the roof top.
8) Check the accuracy of fittings and apply corrections if required.

Result :
The pipe line for the installation of rainwater harvesting system in a building is
laid and the accuracy of fittings is verified.

95