L&T Presentation Seminar by Adrian Roy

L&T Heavy Engineering
© 2011 Larsen & Toubro Limited : All rights reserved
1
TOPIC : INPLANT TRAINING AT L&T
BY:
ADRIAN ROY
2155002
ME5GA
B3 BATCH
Vth SEM

© 2011 Larsen & Toubro Limited : All rights reserved 2
Introduction
1. I COMPLETED MY ONE MONTH INPLANT TRAINING AT L&T
POWAI IN THE HEAVY ENGINEERING DEPARTMENT HEIC AT
PC-2 IN ONE OF MY FAVOURITE DEPARTMENT THAT IS
MAINTENANCE
2. I HAVE GAINED HANDS ON KNOWLEDGE OF ALL THE
INSTRUMENTS AND TOOLS IN THE WORKSHOP AND SHOP
FLOOR
3. I HAVE ALSO INCREASED MY CONFIDENCE AND CAN WORK
AT ANY COMPANY IN THE FUTURE WITH FULL CONFIDENCE
4. THIS TRAINING HAS HELPED ME IN FINDING OUT THE
APPLICATIONS OF WHAT I HAVE LEARNED IN THEORY
DURING COLLEGE LECTURES AND REDUCED THE GAP
BETWEEN THEORETICAL AND ACTUAL APPLICATIONS

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My role in the department
1. I USED TO HELP THE WORKERS AND SUPERVISORS WHERE
EVER POSSIBLE TO INCREASE MY CONFIDENCE
2. I WAS LOOKING AFTER THE STR DEPARTMENT THAT IS SMALL
TOOL REPAIR WHERE THEY USED TO REPAIR SMALL ITEMS
SUCH AS GRINDERS,EXTENSION BOX,HAND LAMPS ,HYDAULIC
JACKS,TIG AND MIG TORCHES
3. I HAVE ALSO HAD THE OPPORTUNITY TO WORK ON THE
OVERHEAD CRANE WHICH WAS A VERY GOOD EXPERIENCE
FOR ME
4. I HAVE ALSO LEARNED HOW TO USE VERNIER CALLIPER,DIAL
CALLIPER,BORE GAUGE,T-METER,MICROMETER AND MANY
MORE INSTRUMENTS

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MAINTENANCE OF
SMALL TOOLS STR
IN THE SPAN OF
ONE MONTH
NAME TOTAL NAME TOTAL
BOSCH GRINDER 18 LPG 0
840 GRINDER 13 GRINDER EXT BOX 3
852 GRINDER 13 24 VOLT EXT. BOX 8
869 GRINDER 4 230 VOLT EXT. BOX 4
TIG TORCH 0 HAND LAMP 23
WELDING CABLE 12 OVEN 4
EARTHING CABLE 11 JACK 11
SAW CABLE 4 POWER PACK 5
OXYGEN ACETYLENE 7 MIG TORCH 1
ARGON 1 VALVE 4

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CLASSIFICATION OF
MAINTENANCE

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PRODUCTIVE MAINTENANCE
Wagon is used to transport Heat
exchanger jobs from one shop to
another shop

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Maintenance of WAGON
Old System :
60 T Wagon Was operated on Petrol or
LPG/BMCG
New System :
AC Motor & Belt drive Installed.
Petrol tank
Fiat engine
Gearbox
Gas supply to engine through
regulator
LPG/BMCG Cylinders using
regulator

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WORKING:
1. AC electric motor
2. Belt drive
3. Gear box
4. Gear train
PROBLEMS: – Gear box housing broken
ADVANTAGES AND USES:
1. Non hazardous
2. No petrol or LPG
3. Easy to operate
4. Less maintenance
5. Skilled manpower not required
6. Low maintenance cost
7. Spare AC motor used
8. No pollution
9. Less jerks while starting the engine
PRECAUTIONS :
1. Electric cables should be kept away from
the rail
2. During movement cable should not get
stretched or entangled
3. Cable should be looped properly after use
CORRECTIVE ACTION:
1. Push pull arrangement
2. Gear box removed and dismantled
3. New gear box details and cost
CONSTRUCTION:
1. GB 1:63
2. DRIVER GEAR 20TEETH
3. DRIVEN GEAR 60 TEETH
4. IDLE GEAR 21 TEETH
5. HELICAL SPRING 16 (2 EACH WHEEL)

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Gearbox
housing broken
Layout of wagon
Immediate action
taken:PULLED USING 160T
PULLER

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The new gearbox
The new gearbox connected
to the AC motor using belt

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CORRECTIVE MAINTENANCE
Underwater Plasma pit (NTM)

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Maintenance of Messer Plasma cutting
machine(underwater & above water)
WORKING:
1. Plasma torch
2. Hydrogen gas
3. Nitrogen gas
4. Argon gas
5. Water coolant
6. The sheets which has thickness more than
50mm and less than 300mm is cut using
this method
7. Plasma is the 4th state of matter after solid
liquid and gas
8. It is formed when we heat gas up to a
temperature of about 6000 degree Celsius.
Cutting holes of dia 50mm
and thickness100mm

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PROBLEMS:
1. The gas cap broke
2. The hydrogen gas pipe had leakage
problems
IMMEDIATE ACTION: We removed the
gun assembly and we purchased a new gun
from Messer and we replaced the gas pipe
Underwater plasma cutting
operation Dia 50mm
thickness 160mm
Gas cap
broken

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Assembly
of old torch
New plasma torch
Nozzle
Water coolant
pipe
Argon
Hydrogen
Nitrogen

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BREAKDOWN MAINTENANCE
Overhead cranes are used to
sling jobs from one place to
another in the shop floor

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CRANE NO 16 (CT)
Make:ELECTROMECH
WORKING:
1. Four motors and four gear boxes
2. Cross travel, long travel, main hoist and
auxiliary hoist
3. Limit switches
4. Anti collision sensors
5. Stopper
6. Remote
CAPACITY: MAIN HOIST 60T & AUX
HOIST 10T
PROBLEM: The gear got worn out for cross
travel gearbox
ROOT CAUSES:
1. Less lubrication
2. Misalignment
3. Meshing of gears had a problem
4. Poor gear ratio
5. Something went wrong inside the gear box
IMMEDIATE ACTION:
1. We went on top of crane no. 16
2. We dismantled the housing of gear box
3. We dismantled the gear
4. We took the remote and kept it separate so
that no one uses the crane
STEPS TAKEN:
We contacted the company and took the necessary action and we brought a new gear box and
we also checked the reason why we had wear and tear.

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Cross travel
gearbox
Input gear
diagram
Helix output gear

Broken teeth of
Helical input gear
11 teeth
Output gear 77teeth

PREDICTIVE MAINTENANCE OF
CONVEYOR BELT OF TOS FHB
Multi axis horizontal boring
machine

WORKING
1. Gear box
2. Motor
3. Clutch plate
4. Sprocket wheel
5. Shaft
6. Limit switch
7. Belt
USES: Used to remove burr and scrap from the
boring machine to the bin.
PROBLEMS
The clutch overload did not get actuated due to
which the sprocket wheel got worn out and
limit switch could not detect the rotation.
IMMEDIATE ACTION: We removed the
shaft and sprocket wheel and clutch plate. We
had to make the whole shaft and sprocket
wheel in MMS.
Clutch overload

MAINTENANCE OF SKZ BORING
MACHINE
WORKING:
1. Motor and gearbox
2. Tachometer
3. Encoder
4. Panel
PROBLEMS: It was not giving high speed at
high voltage DC supply So we put an encoder
with the tachometer.
We made housing for the encoder and we
connected it to the tachometer and we could get
high speeds during high load condition.Minor
tweaks were made in the SIEMENS software.
Encoder
Tachometer

MAINTENANCE OF HYDROPRO JR7
WORKING:
1. Solenoid valve
2. Filter
3. Air
4. Pneumatic cylinder
5. Regulator
PROBLEM: The solenoid valve was damaged
due to which the filter could not filter the air so
there was moisture and due to this there was
water leakage problem.
USED: It is used to expand the tubes of heat
exchanger to get close tolerances so that there
is no direct load on the tubes.
IMMEDIATE ACTION: We opened the cover
of Hydropro and we removed the valve and
replaced it with a new valve.

Holes drilled using deep hole
drilling machine
Block diagram of hydropro

PSLV MK III
MS200 for ISRO
Under VSSC
From outside
PPT S200
20% work done for GSLV MK II
L&T
accidents

THANK YOU
Straight type tube heat
exchanger L-150m
Capacity-200metric T
Double shell and tube type
heat exchanger

L&T Presentation Seminar by Adrian Roy

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