A

VOCATIONAL INPLANT TRAINING

REPORT

ON

“LAXMI HYDRAULICS PVT. LTD. SOLAPUR”.

Submitted By:- Mr. CHIKHALE UMESH MADHUKAR

B.E. (MECHANICAL ENGINEERING)

(ROLL NO. A- )

DEPARTMENT OF MECHANICAL

ENGINEERING

COLLEGE OF ENGINEERING,

PANDHARPUR.

Academic Year:-2017-2018

1

College of Engineering, Pandharpur

This is to certify that the vocational inplant training in “LAXMI

HYDRAULICS PVT. LTD. SOLAPUR,” has been completed successfully

and the report of the same has been submitted by ‘ Mr. CHIKHALE

UMESH MADHUKAR’ of B.E.(MECHANICAL) class (A) in the

partial fulfillment of the curriculum laid by Solapur University, Solapur

during the academic year 2017-2018.

T & P Head

Co-ordinator Dept.of Mech. Engg.

PRINCIPAL

2

CERTIFICATE

3

ACKNOWLEDGEMENT

It is with great sence of gratitude that I acknowledge the support given to me by

number of individuals in the preparation of this report.

I thank to the staff of the company for their kind support and help which proved to

be a source of knowledge and addition to the learning of engineering in a better

way.

I would like to thank to Prof. .Dr. P. S. KACHARE, Head, Department of

mechanical Engineering and the other teachers whose unending effort, advise,

motivation and encouragement at every step made this work possible.

I take this opportunity to also thank Principal of the college for being a source of

inspiration for students.

Lastely I thank my all friends who have helped directlyor indirectly to bring this

report to stage of completion.

Mr. CHIKHALE UMESH MADHUKAR

B.E.(MECH) (DIV-A)

4

INDEX

Sr.No. Contents Page no.1 Introduction 7

1.1 Background 7

1.2 The Future 8

1.3 Location 9

1.4 General Information of Industry 9

1.5 LHP at a glance 10

1.6 Achievements 10

2 Plant Layout 11

3 Motors Manufactiring Photo Galary 12

4 Products 13

5 Specification of Motors 15

5.1 Roller Motors 15

5.1.1 Features 15

5.1.2 Applications 15

5.1.3 Application Standards 16

5.2 Openwell Submersible Pump 16

` 5.2.1 Features 16

5.2.2 Horizontal openwell Submersible pump set 17

5.2.3 Multistage vertical openwell Submersible pump set 17

5.3 Naval / Marine Duty Motor 17

5.3.1 Features 17

5.3.2 Applications 18

5.3.3 Application Standards 18

6 Product Ranges 19

5

6.1 The LHP product Portfolio 19

6.1.1 Motors 19

6.1.2 Gear Drives 20

6.1.3 Pumps 20

7 Testing Procedure of the Motor 21

8 Causes and Remedies 23

8.1 Pump does not deliver water 23

8.2 Discharge less than speed 23

8.3 Motor starts and gets trips (star delta starter) 23

8.4 Motor connected but does not picks up full speed 24

8.5 Noise 24

8.6 Starting speed less or Motors does not start(Single Phase Motor) 25

9 Conclusion 26

6

1.INTRODUCTION

1.1 BACKGROUND:-LHP laid its foundation in 1981 as a motor and pump manufacturer at Solapur in India.

 

During the 80s - the first decade of its operations, the company invested its time and

resources to be future-ready by researching the needs of various industry verticals, developing

and establishing proper manufacturing methods, inducting and training a team of like-minded

engineers and technicians, and by developing a committed vendor base.

Once equipped, in the 90s the company expanded its product range, taking the tally to

more than 2500. LHP focused on reaching out and winning confidence of several companies

in India from various industry segments. The ever-growing client list included major

corporates, PSUs and OEMs.

After gaining a firm footing in the market, the first decade of the 21st century was the

time to consolidate position and be ready for a quantum leap. The company established a new

world-class, environmentally-friendly plant possessing the capacity of manufacturing nearly

240,000 motors per annum. The plant employs state-of-the-art manufacturing technology and

system and, ensuring economical production. Our competency in providing solutions to

specific customer requirement has helped us to develop the product basket of more than 6000

product variants including advanced technology energy-efficient motors, flame-proof motors

and gear motors.

Today, we take pride in associating with more than 4000 prestigious clients . Our International

Business Division is growing rapidly with recognition from the Europe, Middle East and

Africa.

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1.2 THE FUTURE:-

With these credentials and commitment, now LHP is poised to cross new

frontiers. Our products are reaching every corner of the country and several parts

of the world and are preferred because of the assurance of quality, reliability,

safety, quicker deliveries and efficient service.

Considering the ever-growing demand from across the globe, we are

investing in technology, expanding our manufacturing capacity, widening

product offerings and strengthening reach.

While adhering to international standards and marketing our products

globally, we are aiming to achieve business excellence for a single reason -

Customer Delight.

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1.3 Location:-

Laxmi Hydraulics Pvt.Ltd.

B-11, MIDC, Chincholi,

Solapur-413 255 INDIA

Tel:- +91- 217- 2357001(5 Lines)

Fax: +91-217-2357006.

1.4 General Information of Industry:-

Establishment :- 1981

Plant Area :- 15700 square meters

Manufacturing Area :- 5200 square meters

Office area :- 600 square meters

Average annual compounded

Growth rate :- 18%

Export (Direct and Indirect) :- 25%

Installed capacity :- 20,000 motors and

Pumps per month

Manpower :- 500 (180 technical)

Certification :- ISO 9001:2008

Standard product range :- 6000+

Regular clients :- 4000+

9

1.5 LHP at a glance  Unit I Unit II Total

Establishment 1981

Plant area 16,000 square meters

20000 square meters

36000 square meters

Manufacturing area

10000 square meters

5000 square meters

15000 square meters

Exports     25%

Installed Capacity

    20,000 Motors per month + 1000 Nos of Gear Motors and Gear boxes per month

Manpower 390 ( 180 Technical)

277 ( 95 Technical)

667

Certification     ISO 9001-2008

Product range     6000 +

Regular clients     4000 +

1.6 Achievements:-

Outstanding Productivity Performance Award

by the State Government-for Maharashtra.

ISO 9001: 2008 by Bureau Veritas

Rajiv Gandhi National Quality Award

National Award for Quality Products

By Government of India

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2. PLANT LAYOUT

11

VARNISH &

BACKING OF

LARGE SIZED

MOTORS

MACHINE

SHOP

FOR SMALL

AND

MEDIUM

MOTORS

RECEIVING

INSPECTION

VARNISH &

BACKING OF

SMALL

SIZED

MOTORS

FETTLING

CASTING AREA

WELDING

SHOP

WINDING

WELDING

MACHINE

SHOP

FOR SMALL

AND

MEDIUM

MOTORS

STORAGE FOR

CASTING

STORAGE FOR METAL BARS

PACKING PRODUCT STORAGE

STORAGE FOR CORRUGATED PACKING

MATERIAL

STORAGE FOR WOODEN PACKING MATERIAL

STORAGE FOR WOODEN PACKING

MATERIAL

STORAGE FOR FINISHED GOOD

MATERIAL

PRODUCT DEVELOPMENT

STORAGE FOR COMPONE- NTS

STORAGE FOR COMPONE- NTS

STORAGE FOR FINISHED GOODS

ASSEMBLY LINE FOR SMALL MOTORS

ASSEMBLY LINE FOR MEDIUM MOTORS

ASSEMBLY LINE FOR

LARGE MOTORS

COOLING TOWER

HOT WELL

R & D

DEPARTMENT

ENTRY

MACHINE SHOP

FOR LARGE

MOTORS

3. MOTOR MANUFACTURING PHOTO GALARY

12

4. PRODUCTS

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4.1 PRODUCTS:-

IE 3 MOTOR ROLLER TABLE MOTOR

Flame-proof Motor (IE1, IE2 & IE3) ENCODER MOTOR

PROCESS PUMP SPECIAL GEAR MOTOR

14

STANDARD MOTOR OPENWELL SUBMERSIBLE PUMP

MONOBLOCK PUMP LHP EURA AC DRIVES

SOFT STARTER Naval / Marine Duty Motor

5. SPECIFICATION OF MOTORS

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5.1 Roller Table Motor:-

5.1.1 Features:-

Established in 1981, LHP is a reputed manufacturer of a wide  range of  high-quality  motors up  to  355  L Frame (315 kW). The range includes various types of motors such  as Standard Induction, Geared, Brake,  Dual  Speed, Non- Sparking, Crane & Hoist Duty and Special Purpose Motors to name only a few. The range has been proving its worth for different applications in various industries. LHP Motor is the preferred choice of major corporates, MNCs & OEMs due  to the product quality, performance, timely deliveries and competitive prices.

The  ISO 9001-2008 certification, CE mark,  3 BIS licences and National Awards for Quality Products have made LHP Motors the customer's 'First Choice'.

LHP   Roller   Table   Motors   are    designed  taking   into consideration the experience of users in steel plants over the years.

 5.1.2 APPLICATION :-

1. In steel  plants for conveying steel  billets  for processing through roller mills.2. Suitable for Geared Motors operating with VVVF Power Source

Range 355LFrame

Pole 4/6/8Mounting Standard / Special as per IPSS

specificationsFrame Upto355LVoltage 415VACor(upto660V)Frequency 50HzStalled rotor withstand time up to 15 minutes max or as per custormer

requirementInsulation HClass

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Duty S3,S4,S1,S5,S6&S7

 5.1.3 APPLICATION STANDARDS :-

IPSS- 1-03-007 Interplant standard for steel industries

IS- 325 (IEC 34-1) Specificationsfor 3 phase induction motors

IS- 4691 (IEC 34-5) Degrees of protection provided by enclosure for rotating electrical machinery

5.2 Openwell Submersible Pumps

5.2.1 FEATURES:-

1. Models with wide range of discharge & head combinations.2. Wet type winding wIth polyester wrapped winding wire3. Copper rotor4. Carbon / Stainless Still Thrust bearing5. Bronze bush bearings with special alloy for wear resistance6. Stainless steel shaft to preven! rusting7. Stainless steel shaft sleeve8. Can withstand voltage fluctuations from 300V to 440V9. Anti-corrosive paint for external surface10. Foundation and foot vaIve not required when installed under water11. Buill meticulously for meeting the growing domand of customers12. Compact in size and easy to installin an open will, river and on a surface as well.

5.2.2 HORIZONTAL OPENWELL SUBMERSIBLE PUMP SET:-

TypeHead Range Discharge

0.5 HP to 30 HP Up to 78m 3.25 m3/h (2100 lpm)

5.2.3 MULTISTAGE VERTICAL OPENWELL SUBMERSIBLE PUPMP SET:-

17

5.3 Naval / Marine Duty Motor:-

5.3.1 FEATURES:-

Established in 1981, LHP is a reputed manufacturer of a wide range of high-quality  motors up to 355 L Frame (315 kW).The range includes various types of motors such as Standard Induction, Geared, Brake, Dual Speed, Non- Sparking, Crane & Hoist Duty and Special Purpose Motors to name only a few. The range has been proving its worth for different applications in various industries. LHP Motor is the preferred choice of major corporates, MNCs & OEMs due to the product quality, performance, timely deliveries and competitive prices.

The ISO 9001-2000 certification, CE mark, 3 BIS licences and National Awards for Quality Products have made LHP Motors the customer's 'First Choice'.

Motors are suitable for(a) Continuous duty (S1) Short time duty (S2)(b) Periodic duty (S3)

5.3.2 APPLICATIONS:-

Cranes, Hoists,  Lifts, Material handling equipment, Machine tools, Cement industries, Paper & Steel plants

Range Up to 315 kW

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TypeHead Range Discharge

3 HP to 20 HP Up to 105m Up to 54 m3/h (1600 lpm)

RPM 3000, 1500, 1000, 750 (sychronous)

Mounting Foot (B-3), Flange (B-5), Face (B-14) and combinations

Frame 63 to 355 L

Protection IP 55

Insulation F Class

Voltage 415 V, 380 V or as per requirement

Frequency 50 HZ / 60 HZ or as per requirement

Duty S2, S3, S4, S5, S7, & S

 

5.3.3 Applicable Standards:-

 IS:4722 Specificationsfor rotating electrical machine.

IS:325 (IEC 34 - 1) Specificationsfor 3 phase induction motors.

IS:4889 (IEC 34 - 2) Methodof determination of efficiency of rotating electrical machines.

IS:4691 (IEC 34 - 5) Degrees of protection provided by enclosure for rotating electrical machinery.

IS:12824 Typeof duty & class of rating assigned to rotating assigned to rotating electrical machines.

6. PRODUCT RANGE

6.1 The LHP Product Portfolio:-

6.1.1 Motors

  Product/Description Frame Size Range

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 Three Phase Sq. Cage Induction Motors Up to 355L Up to 425HP/315KW

 Single Phase Motors (CSR,CSIR & CSCIR) Up to100L Up to 2HP/1.5KW

  Brake Motors Up to 250M Up to 75HP/55 KW

  Roller Table Motor 112 to 355L1.1 to 45 KW( with 15 min. stall time)

  Flame-Proof Motors(Ex'd') Up to 315L0.25HP/0.19KW to 270 HP/200KW

  Increased Safety Motors(Ex'e') Up to 315L0.75HP/0.55KW to 270HP/200KW

  Non-sparking Motors(Ex'e') Up to 355L0.16HP/0.12KW to 425HP/355 KW

  Energy Efficient Motors Up to 355L Up to 425HP/315KW

  (Standard And Flame Proof)    

  Helical Gearmotors Up to 225 0.16HP/0.12KW to 40HP/30 KW

      0.3 TO 560 RPM

  WVF Motors Up to 355L Up to 425HP/315KW

  Crane and Hoist Duty Motors Up to 355LUp to 425HP/315KW for VFD duty

      Up to 25HP/18KW DOL Starting

  Lift Duty Motor Up to 315L Up to 215HP/160KW

  Cooling Tower Motor Up to 315L Up to 215HP/200KW

6.1.2 GEAR DRIVE

TYPE RATING OUTPUT

Energy efficient Helical Gear Motor and 0.16 HP to 40HP0.35 to 560 RPM and 15000 N-M

Gear Boxes 0.12KW to 30 KW Torque

Helical Gear Motor and Gearboxes 0.16HP/40HP 0.35 to 560 RPM and 15000

20

HIGH VOLTAGE TEST

N-M

0.12KW to 30 KW Torque

6.1.3 PUMP

Product/Description Range Head Range

Single Phase Domestic Pump 2HP/1.5KW 48m to 50 m

Monoblock Pumps up 40 HP/30KW 78 mOpen well Pumps(Vertical and Horinzontal Pumps) Up 20HP/15KW Up to 105m

Monoblock Process Pumps Up to 20HP/15KW 78mSingle Stage Horizontal Centrifugal Self Priming, 14 HP to 10 KW 25 to 30 m

non-colg pumps (Mud Pumps)

7. TESTING PROCEDURE OF THE MOTOR

ROUTINE TEST BLOCK

MEGGER TEST

OK

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RESISTANCE MEASUREMENT

REDUCED VOLTAGE RUNNING TEST

NO LOAD RUNNING TEST

LOCKED ROTOR TEST

SAMPLING TYPE TEST

PAINTING

OK

OK

OK

OK

OK

OK

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8. CAUSES AND REMIDIES

8.1 PUMP DOES NOT DELIVER WATER:-

Causes Remedies

a) No water in pump a) Fill water in pump

b) Foot valve is not emerged in water. b) Ensure that foot value is emerged in water.

c) Too many bends to suction pipe. c) Reduce the bends.

d) Leakage in suction Pipe. d) Ensure that there is no leakage in suction pipe.

e) Suction lift more than 6 mtr. e) Keep suction lift less than 6 mtr.

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8.2 DISCHARGE LESS THAN SPEED:-

Causes Remedies

a) Suction lift more than 6 mtr. a) Keep suction lift less than 6 mtr.

b) Suction/delivery pipe line blocked. b) Clean the pipe line.

c) Strainer of foot value is blocked. c) Clean the strainer.

d) Pipe size used are smaller than

recommended.

d) Keep the pipe size as recommended.

8.3 Motor starts and gets trips (star delta starter):-

Causes Remedies

a) Timer setting on lowest step a) Set timer on proper setting.

b) Relay setting on lower reading

than rated current.

b) Set overload relay at 110% of rated full load

current punched on Nameplate.

c) Terminal voltage is low. c) Ensure rated voltage OR increase realy setting

slightly.

d) Backup fuse blowing. d) Correct rating of back-up fuse to be used.

e) Starting current is high due to

heavy inertia.

e) Start stop the relay continuously till motor, pick

up full speed.

If problem persist, Contact LHP and inform Gd2 of

load.

f) Misalignment. f) Ensure proper alignment.

8.4 MOTOR CONNECTED BUT DOES NOT PICKS UP FULL SPEED:-

Causes Remedies

24

a) No supply of voltage a) Check voltage between each two phases.

b) Motor jam b) Check freeness of motor without coupling it to load.

c) Motor may be overloaded c) Reduce load.

d) Loose connection. d)Tight connection properly.

8.5 NOISE:

Causes Remedies

a) Too high delivery head. a) Ensure total head is within specified range.

b) Too high suction lift. b) Keep suction lift less than 6 mtr.

c) Suction line or impeller block. c) Trace the blockage & clean.

d) Air entrapped in water. d) Ensure that all joints are airtight.

e) Bearings worn out. e) Replace bearing.

8.6 STARTING SPEED LESS O R MOTOR DOES NOT START. (SINGLE PHASE MOTOR):-

Causes Remedies

a) Loose connection of capacitor in

Terminal Box.

a) Ensure the tight connection of capacitor in circuit

as per connection diagram.

b) Centrifugal switch open. b) Check contact of centrifugal switch.

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9. CONCLUSION

Undergoing vocational training in esteemed good organization like Laxmi

Hydraulics Ltd. Solapur was very in distinguished period in my educational

life. The manufacturing of stator,rotor, pressing of rotor into the stator,etc. Also

various test performed on motor such as Megger test, high voltage test,

resistance measurement test,locked rotor test, etc. and to obtain final quality

product is having immence potential & very skilled and experienced manpower.

I observed various process like coil making,winding,heat treatmenton on

rotor pressing of rotor into the stator,all motor assembly and various test

performed on motors.

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It is a good company with many versatile machines and various motors.

Also learned how to maintain good relationship between workers & supervisors,

which results in increasing the productivity It was excellent experience working

here. The training has encouraged me and gives guidance how to behave in

industry and work as part of it.

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