l&t presentation seminar by adrian roy

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1TOPIC : INPLANT TRAINING AT L&T

BY:ADRIAN ROY2155002ME5GAB3 BATCHVth SEM

L&T Heavy Engineering

L&T Heavy Engineering 2011 Larsen & Toubro Limited : All rights reserved

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2IntroductionI 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 MAINTENANCEI HAVE GAINED HANDS ON KNOWLEDGE OF ALL THE INSTRUMENTS AND TOOLS IN THE WORKSHOP AND SHOP FLOORI HAVE ALSO INCREASED MY CONFIDENCE AND CAN WORK AT ANY COMPANY IN THE FUTURE WITH FULL CONFIDENCETHIS 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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3My role in the departmentI USED TO HELP THE WORKERS AND SUPERVISORS WHERE EVER POSSIBLE TO INCREASE MY CONFIDENCEI 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 TORCHESI HAVE ALSO HAD THE OPPORTUNITY TO WORK ON THE OVERHEAD CRANE WHICH WAS A VERY GOOD EXPERIENCE FOR MEI HAVE ALSO LEARNED HOW TO USE VERNIER CALLIPER,DIAL CALLIPER,BORE GAUGE,T-METER,MICROMETER AND MANY MORE INSTRUMENTS



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4MAINTENANCE OF SMALL TOOLS STR IN THE SPAN OF ONE MONTH

NAMETOTALNAMETOTALBOSCH GRINDER18LPG0840 GRINDER13GRINDER EXT BOX3852 GRINDER1324 VOLT EXT. BOX8869 GRINDER4230 VOLT EXT. BOX4TIG TORCH0HAND LAMP23WELDING CABLE12OVEN4EARTHING CABLE11JACK11SAW CABLE4POWER PACK5OXYGEN ACETYLENE7MIG TORCH1ARGON1VALVE4



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CLASSIFICATION OF MAINTENANCE



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6PRODUCTIVE MAINTENANCE

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



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7Maintenance of WAGONOld System : 60 T Wagon Was operated on Petrol or LPG/BMCG

New System :AC Motor & Belt drive Installed.

Petrol tankFiat engineGearbox

Gas supply to engine through regulator

LPG/BMCG Cylinders using regulator



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8WORKING:AC electric motorBelt driveGear boxGear trainPROBLEMS: Gear box housing brokenADVANTAGES AND USES:Non hazardous No petrol or LPGEasy to operateLess maintenanceSkilled manpower not requiredLow maintenance costSpare AC motor usedNo pollutionLess jerks while starting the enginePRECAUTIONS :Electric cables should be kept away from the railDuring movement cable should not get stretched or entangledCable should be looped properly after useCORRECTIVE ACTION:Push pull arrangementGear box removed and dismantledNew gear box details and costCONSTRUCTION:GB 1:63DRIVER GEAR 20TEETHDRIVEN GEAR 60 TEETHIDLE GEAR 21 TEETHHELICAL 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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11CORRECTIVE MAINTENANCE

Underwater Plasma pit (NTM)



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12Maintenance of Messer Plasma cutting machine(underwater & above water)WORKING:Plasma torchHydrogen gasNitrogen gasArgon gasWater coolantThe sheets which has thickness more than 50mm and less than 300mm is cut using this methodPlasma is the 4th state of matter after solid liquid and gasIt 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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13PROBLEMS:The gas cap brokeThe 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

NozzleWater coolant pipeArgonHydrogenNitrogen



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15BREAKDOWN MAINTENANCE

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



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16CRANE NO 16 (CT)Make:ELECTROMECH WORKING:Four motors and four gear boxesCross travel, long travel, main hoist and auxiliary hoistLimit switchesAnti collision sensorsStopperRemoteCAPACITY: MAIN HOIST 60T & AUX HOIST 10TPROBLEM: The gear got worn out for cross travel gearboxROOT CAUSES:Less lubricationMisalignmentMeshing of gears had a problem Poor gear ratioSomething went wrong inside the gear boxIMMEDIATE ACTION:We went on top of crane no. 16We dismantled the housing of gear boxWe dismantled the gearWe took the remote and kept it separate so that no one uses the craneSTEPS 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 diagramHelix output gear



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Broken teeth of Helical input gear11 teethOutput gear 77teeth

L&T Heavy Engineering 2011 Larsen & Toubro Limited : All rights reserved 19PREDICTIVE MAINTENANCE OF CONVEYOR BELT OF TOS FHB

Multi axis horizontal boring machine

L&T Heavy Engineering 2011 Larsen & Toubro Limited : All rights reserved 20WORKINGGear boxMotorClutch plateSprocket wheelShaftLimit switchBeltUSES: Used to remove burr and scrap from the boring machine to the bin.PROBLEMSThe 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

L&T Heavy Engineering 2011 Larsen & Toubro Limited : All rights reserved 21MAINTENANCE OF SKZ BORING MACHINEWORKING:Motor and gearboxTachometerEncoderPanelPROBLEMS: 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.

EncoderTachometer

L&T Heavy Engineering 2011 Larsen & Toubro Limited : All rights reserved 22MAINTENANCE OF HYDROPRO JR7WORKING:Solenoid valveFilterAirPneumatic cylinderRegulatorPROBLEM: 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.

L&T Heavy Engineering 2011 Larsen & Toubro Limited : All rights reserved 23

Holes drilled using deep hole drilling machineBlock diagram of hydropro

L&T Heavy Engineering 2011 Larsen & Toubro Limited : All rights reserved 24

PSLV MK III MS200 for ISROUnder VSSC

From outside PPT S200

20% work done for GSLV MK II

L&T accidents

L&T Heavy Engineering 2011 Larsen & Toubro Limited : All rights reserved 25THANK YOU

Straight type tube heat exchanger L-150m Capacity-200metric TDouble shell and tube type heat exchanger
