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

CERTIFICATE

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
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

5
6 Product Ranges 19
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

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 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+

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1.5 LHP at a glance
Unit I Unit II Total

Establishment 1981

Plant area 16,000 square 20000 square 36000 square meters

meters meters
Manufacturing 10000 square 5000 square 15000 square meters
area meters meters
Exports 25%

Installed 20,000 Motors per month + 1000 Nos of

Capacity Gear Motors and Gear boxes per month
Manpower 390 ( 180 277 ( 95 667
Technical) Technical)
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
STORAGE FOR METAL BARS

R & D STORAGE FOR STORAGE FOR

CORRUGATED PACKING WOODEN PACKING
DEPARTMENT MATERIAL MATERIAL

PACKING PRODUCT STORAGE FOR WOODEN STORAGE FOR

STORAGE FINISHED GOOD
PACKING MATERIAL
MATERIAL

STORAGE FOR FINISHED

PRODUCT DEVELOPMENT GOODS
ASSEMBLY COOLING
STORAGE STORAGE ASSEMBLY ASSEMBLY TOWER
LINE FOR
FOR FOR LINE FOR LINE FOR HOT
LARGE WELL
COMPONE- COMPONE- SMALL MEDIUM
MOTORS
NTS NTS MOTORS MOTORS

WELDING
RECEIVING

INSPECTION MACHINE SHOP

MACHINE MACHINE
FOR LARGE
SHOP SHOP
MOTORS
FETTLING FOR SMALL FOR
WELDING
SMALL
AND STORAGE
SHOP
AND FOR
MEDIUM
WINDING MEDIUM CASTING
MOTORS
VARNISH & MOTORS
BACKING VARNISH &
OF
BACKING OF
CASTING SMALL
LARGE SIZED
AREA SIZED
MOTORS
MOTORS
ENTRY
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3. MOTOR MANUFACTURING PHOTO GALARY

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 4. PRODUCTS
4.1 PRODUCTS:-

IE 3 MOTOR ROLLER TABLE MOTOR

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

PROCESS PUMP SPECIAL GEAR MOTOR

13
STANDARD MOTOR OPENWELL SUBMERSIBLE PUMP

MONOBLOCK PUMP LHP EURA AC DRIVES

SOFT STARTER Naval / Marine Duty Motor

14
 5. SPECIFICATION OF MOTORS

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 4/6/8
Mounting Standard / Special as per IPSS
specifications
Frame Upto355L
Voltage 415VACor(upto660V)

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 Frequency 50Hz
Stalled rotor withstand time up to 15 minutes max or as per custormer
requirement
Insulation HClass
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 wire
3. Copper rotor
4. Carbon / Stainless Still Thrust bearing
5. Bronze bush bearings with special alloy for wear resistance
6. Stainless steel shaft to preven! rusting
7. Stainless steel shaft sleeve
8. Can withstand voltage fluctuations from 300V to 440V
9. Anti-corrosive paint for external surface
10. Foundation and foot vaIve not required when installed under water
11. Buill meticulously for meeting the growing domand of customers
12. Compact in size and easy to installin an open will, river and on a surface as well.

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5.2.2 HORIZONTAL OPENWELL SUBMERSIBLE PUMP SET:-

Type Head 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:-

Type Head Range Discharge

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

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)

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5.3.2 APPLICATIONS:-

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

Range Up to 315 kW

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.

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 6. PRODUCT RANGE

6.1 The LHP Product Portfolio:-

6.1.1 Motors

Product/Description Frame Size Range

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
1.1 to 45 KW( with 15 min. stall
Roller Table Motor 112 to 355L time)
0.25HP/0.19KW to 270
Flame-Proof Motors(Ex'd') Up to 315L HP/200KW
0.75HP/0.55KW to
Increased Safety Motors(Ex'e') Up to 315L 270HP/200KW
0.16HP/0.12KW to 425HP/355
Non-sparking Motors(Ex'e') Up to 355L 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
Up to 425HP/315KW for VFD
Crane and Hoist Duty Motors Up to 355L 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

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6.1.2 GEAR DRIVE
TYPE RATING OUTPUT
0.35 to 560 RPM and 15000
Energy efficient Helical Gear Motor and 0.16 HP to 40HP N-M
Gear Boxes 0.12KW to 30 KW Torque

0.35 to 560 RPM and 15000

Helical Gear Motor and Gearboxes 0.16HP/40HP 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 m
Open well Pumps(Vertical and Horinzontal
Pumps) Up 20HP/15KW Up to 105m
Monoblock Process Pumps Up to 20HP/15KW 78m
Single Stage Horizontal Centrifugal Self
Priming, 14 HP to 10 KW 25 to 30 m
non-colg pumps (Mud Pumps)

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7. TESTING PROCEDURE OF THE MOTOR

ROUTINE TEST BLOCK

MEGGER TEST
OK

HIGH VOLTAGE TEST

OK
RESISTANCE MEASUREMENT
TEST
OK

REDUCED VOLTAGE RUNNING TEST

OK

NO LOAD RUNNING TEST

OK

LOCKED ROTOR TEST

OK
SAMPLING TYPE TEST

OK

PAINTING

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22
 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.

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 d) Keep the pipe size as recommended.
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 b) Set overload relay at 110% of rated full load
rated current. current punched on Nameplate.

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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 e) Start stop the relay continuously till motor, pick up
heavy inertia. 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

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.

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

Causes Remedies

a) Loose connection of capacitor in a) Ensure the tight connection of capacitor in circuit as

Terminal Box. per connection diagram.

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

25
 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.
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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