Industry Internship Report

On

LARSEN AND TOUBRO LTD.

A-9/A-10, MIDC, Ahmednagar-414 111,

Maharashtra, India

by
Mr. Pratik Dilip Thakre
VII C-59

Under the supervision of

Mr.Rajeshkumar V
( NPE-BBT )

Department of Mechanical Engineering

G.H. Raisoni College of Engineering, Nagpur
(An Autonomous Institute affiliated to
RastrasantTukadojiMaharaj Nagpur University, Nagpur)
2019-20
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Declaration

I, hereby declare that the Industry Internship report on “Larsen & Toubro Pvt. ltd.
ESP, A-9, MIDC, Ahmednagar 414111 Maharashtra , India ”submitted herein has been
prepared by me as a student of VII semester B.E.(Mechanical Engineering) programme of the
Department of Mechanical Engineering of G.H. Raisoni College of Engineering, Nagpur.

Mr. Pratik Dilip Thakre

VII C-59
Date: 02-11-19
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Certificate

The Internship report on “Larsen & Toubro Pvt. Ltd ESP, A-9, MIDC, Ahmednagar 414111
Maharashtra , India ” submitted by Pratik Dilip Thakre has been carried out under my
supervision in the Department of Mechanical Engineering of G.H. Raisoni College of
Engineering, Nagpur. The report is comprehensive, complete and fit for evaluation.

Mr. Rajeshkumar V Dr. R S Shelke

Asst. Manager (NPE-BBT) Internship Guide & Head
L&T Electrical and Automation, Dept. of Mechanical Engineering
Ahmednagar GHRCE, Nagpur

Dr. Sunil Nangrani Dr. Preeti Bajaj

Dean- Industry Relations , Director,
GHRCE , Nagpur GHRCE, Nagpur
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Acknowledgement
The internship opportunity I had with Larsen & Toubro Limited is a great experience for
learning and professional development. Therefore, I consider myself as a very lucky individual
as I was provided with an opportunity to be a part of it. I am also obligated for having a chance
to meet so many wonderful people and professionals who led me though this internship period.

Larsen & Toubro is a major technology, engineering, construction and manufacturing company
with global operations. L&T operates in 33 countries in the world. Beginning with the import of
machinery from Europe, L&T took on engineering and construction assignments of increasing
sophistication. Today, the company sets engineering benchmarks in terms of scale and
complexity. L&T has different Operating Divisions.

I am using this opportunity to express my deepest gratitude and special thanks to the HR of
Larsen & Toubro Limited who in spite of being extraordinarily busy with his duties, took time
out to hear, guide and arranged all facilities to make life easier. I choose this moment to
acknowledge his contribution gratefully.

I express my deepest thanks to Mr.Rajeshkumar V (Assistant Manager(NPE), L&T ESP) for

taking part in useful decision & giving necessary advices and guidance and keep me on the
correct path and allowing me to carry out my project at their esteemed organization and
extending during the training.

This report is about my work I had done in this organization containing the information about my
daily work and the projects I have completed in organization. It is how I improve my observation
skills, my entire 6 months experience in company. This report discusses the skills gained during
the training period.

I perceive as this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on my
improvement, in order to attain desired career objectives.

Pratik Thakre

05/11/2019
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TABLE OF CONTENT

Title Page

Acknowledgements……………………………………………………………………...

Table of Content…………………………………………………………………………

List of tables……………………………………………………………………………..

List of Figures…………………………………………………………….......................

1. Industry Introduction

1.1. Introduction to Larsen and Toubro ………………………………………… 13

1.2. Introduction to Electrical and Automation Business Company Profile……..14

1.3. Company Profile…………………………………………………………….16

1.4. Plants In india………………………………………………………………17

1.5. Products…………………………………………………………………….18

2. About Industry supervisor

2.1 Designation , Key Executives , Area of expertize……………………….....19

2.2 Organisational Structure…………………………………………………..…19

3. Internship Duration

3.1. No. of Working Days ………………………………………………………20

3.2.Working Hours……………………………………………………………….20

4. Department Allotted

4.1. Introduction To New Product Engineering Department…………………….21

4.2. Introduction To Busbar Trunking System (BBT) ……………………………22

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5. Work Done As a Intern

5.1.Daily work……………………………………………………………...…….28

5.2.Project Work( Development) ………………………………………………...30

6. Case study

6.1. Case study I…………………………………………………………………..32

6.1.1. Introduction & Problem identification………………………………..32

6.1.2. Solution of the Problem……………………………………………….33

6.2. Case study II

6.2.1. Introduction…………………………………………………………....34

6.2.2. Problem identification………………………………………………....35

6.2.3. Solution no. 1 to the Problem ……………………………………...….35

6.2.4. Solution no. 2 to the Problem ……………………………………...….37

7. Conclusion…………………………………………………………………...……38

8. References…………………………………………………………………………39
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1.1 Introduction to Larsen and Toubro

• Larsen & Toubro is a major technology, engineering, construction and

manufacturing company with global operations. L&T addresses critical
needs in key sectors like :-

1. Electrical and Automation

2. Heavy Equipment

3. Power generation

4. Construction

5. Information Technology

6. Rapid Transit

7. Ship Building

8. Defence Equipment

9. Financial services

• L&T operates in 33 countries in the world. Beginning with the import of

machinery from Europe, L&T took on engineering and construction
assignments of increasing sophistication. Today, the company sets
engineering benchmarks in terms of scale and complexity. L&T has
different Operating Divisions. They are as follows:

o Engineering and Construction Projects.

o Machinery & Industrial Products.

o IT & Engineering Services.

o Electricals & Electronics Business Group (EBG):

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1] Electricals & Electronics Business Group (EBG):

Electrical & Electronics Division (EBG) is one of the core businesses of Larsen & Toubro
Limited (L&T). The division has operations at different locations in India (two in Mumbai and
one each in Ahmednagar, Mysore, Faridabad and Coimbatore) and one unit for manufacturing
operations in China. EBG has a comprehensive quality, environment and safety management
system.

1.2 Introduction to L&T Electrical and Automation Business

Larsen and Toubro Ahmednagar

L&T Ahmednagar branch was established in October 1982. L&T acquired land
admeasuring 70.2 acres from MIDC, Ahmednagar on 1st August 1977. It was decided to set
up a Switchgear Unit there under 'Electrical Business Group'. The factory was started with a
capital investment of 12.94 Crore, in October 1982. A batch of 40 Daily Rated was inducted
trained to shoulder the responsibility of manufacturing. The first product to roll out was FB
Fuse Switch Unit. Mr. N. M. Desai, the then Chairman & President formally inaugurated the
unit on 06 March 1984. On 21 September 2006, CMD Mr. A M Naik visited ASW. This
visit was biggest milestone in history of ASW.
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In this visit he announced ASW as a growth Centre with additional investment of around 100
Crore. Before this visit at ASW there was production of Starter & SDF with support of Tool
Room (ATL). After the visit numbers of product groups are added in ASW Basket like Control
Gear (CG), Modular Devices & Units (MDU), Vacuum Circuit Breaker (VCB), Low Voltage
Switchboard (LV), and Medium Voltage Switchboard (MV) in short span of a time. Next 2 years
were full of development activities at ASW Campus.

Today ASW campus is having two different factories ESP & ESE. ESP has a plot A-9 with area
of 38.9 acres & ESE has a plot A-10 with area of 31.3 acres. Till 2006 in ASW there were 4
modules. Today in ESP there are 10 modules
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1.3 Company Profile

Name of the industry LARSEN AND TOUBRO (E&A), ESP,

Ahmednagar.

Location of the industry A-9/A-10, MDC, Ahmednagar-414 111,

Maharashtra, India.

Year of Establishment October 1982

Founder and co-founder Mr. Henning Holck Larsen & Mr. Soren Kristian
Toubro

Type Public Company, Listed on BSE and NSE.

Headquartered L&T House, Ballard Estate, Mumbai.

Key people Mr. A. P. Pargaonkar (factory head)

Turn over Rs.127, 524.72 crore (2016).

Employee Base 45000 (March 2014)

Network of operation Operates in more than 33 countries

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1.4 Plants In india

➢ Mumbai
➢ Ahmednagar
➢ Vadodara
➢ Coimbatore
➢ Mysore
➢ Talegoan
➢ Chennai
➢ Odisha
➢ Banglore
➢ Kacheepuram
➢ Faridabad
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1.5 Products of L&T

➢ FDP:
I. MCB (Miniature Circuit Breaker)
II. Mini MCB
III. RCB (Residual Circuit Breaker)
IV. RCCB

➢ Control Gear:
I. Contactors
II. Relays

➢ Starter
I. 3 phase controllers
II. 1 phase controllers
III. Starters

➢ Conductors
I. Busbar Trunking System (BBT)
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2.1 About Industry supervisor

➢ Name :- Mr. Rajeshkumar V

➢ Designation :- Assistant Manager ( New Product Engineering

Busbar Trunking System)

➢ Area Of Expertize :-

1. New Product Development

2. Tools ,fixtures , products design
3. Product Costing
4. Material Management , SAP activities
5. Product Indstrialisation activities

➢ Key Executive :- Mr. A.J. Bhise

➢ Designation :- Dy. General Manager

(New Product Engineering)

➢ Area Of Expertize :-

1. New Product Development

2. Tools ,fixtures , products design
3. Product Costing
4. Material Management , SAP activities
5. Product Industrialization activities
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3.1 Internship Duration

➢ Joining Date :- 17th May , 2019

➢ Completion Date :- 17th Nov , 2019

➢ Total No. of Working Days :- 185

3.2 Working Hours :-

➢ Monday To Friday 8:30 AM to 5:45 PM

➢ Saturday :- 8:30 AM to 1:00 PM

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4.1 Introduction To The New Product Engineering Department

New product engineering is a part of Switchgear Design and Development centre .

Process Diagram For NPE – New Product Engineeing

With What?( Resources) With who? (Resources)

- SAP,PRO-E,CAD SOFTWARE & SYSEMS
- Testing facilities ad equipments
- Information/know-how on exsting and new
materials and processes
- Support and interaction with Design , ETS ,
Sourcing ,SQR,Manufacturing
- Concerned planning engineers
- Group Heads and Project Leaders
- Cross Functional Teams comprising of -
representatives from Product Design, Sourcing, LCM
Engineering , Manufacturing SQR, Product Marketing
etc.

- Outputs
- New Products
Inputs - Documents
- office Note / Release meno Process
➢ Sap Masters
- Design BOM New Product
e.g. Production BOM , Routing
- Release Drawings Engineering ➢ Industrialization Documents
- CD seets e.g. PFC , CP , PFMEA
- Design Changes(TCN/PCN) ➢ Production Infrastructure
- DFMEA e.g. Assembly Line , Test Benches ,
Tools and Fixtures , Machines

How?
- PFMEA , Control Plan What Results ? (KPI)
- Tool Development request , Job ticket - Compliance to Product Cost
- Purchase Requisition , NISR - Industrialization Time
- Cost Estimates for New products - Product Quality
- Routings , Process sheets , Process Layouts , - Yield
SOP - Process Capability
- Work and time studies to improve
productivity and optimize the cost
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4.2 Introduction To Busbar Trunking System (BBT)

Busbar Trunking System In electric power distribution a Busbar is a metallic strip or bar
(typically copper, brass or aluminium) that conducts electricity within switchgear,
distribution board, substation, battery bank, or other electrical apparatus. Its main purpose is
to conduct a substantial current of electricity, and not to function as a structural member. The
material composition and cross-sectional size of the busbar determine the maximum amount
of curr ent that can be safely carried. Busbar trunking system in compact design is the most
efficient, safe and ideal system for electricity supply to industrial installations and high rise
structures, offering a wide current range from 125A to 2000A in type CBC (Copper
conductor) and 160A to 1250A in type CBA (Aluminium conductor). The system has been
designed especially for installations and projects where power supply has to be made
available rapidly
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L&T acquired Malaysia-based Henikwon Corporation Sdn Bhd, a leading manufacturer of Low
Voltage (LV) and Medium Voltage (MV) bus duct systems through its Malaysian subsidiary
Tamco Switchgear in July 2012. Henikwon brand is globally well recognized and offers high
quality products under compliance to international quality standards.
Since busduct is a modern, efficient and cost effective means of providing motive power and
replaces the conventional cabling system, the acquisition complements the E&A portfolio and
facilitates comprehensive offerings for the building and infrastructure segments. In addition to
enhancing E&A’s presence in South East Asia, it has facilitated catering to Indian and Middle
East markets
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System components

1.Feeder

Feeder Busduct takes power directly from A to B usually from power transformer to switchboard

2. Plug-in Feeder

• Plug-in feeder are used for power distribution.

• Power is distributed through plug-in Boxes.
• For power output upto 400A.
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3. Tap-off Feeder
• Tap-off feeders are used for power distribution.
• Power is distributed through tap-off boxes .
• Used when required power output is between 630A to 1250A

4. Plug-in Box
• Plug-in box can be equipped with MCCB , MCB.
• Enclosure is made up of GI
• Tap-off box are suitable for copper cable termination
• With door interlock using ROM
• Earth contact of plugin-box makes first and breaks last.
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4. Tap Off Box

• The tap-off box is provided with fixed contact from busduct
• The tap-off box can be equipped with MCCB .
• The enclosure is made up of GI .
• Tap-off box are suitable for copper cable termination
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➢ Comparision between Busbar Trunking system with

Conventional Cables
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5.1 Assignment completed as a Intern in New Product Engg Dept.

➢ The work done are enlisted below :-

1. Made Eight SOPs of Various assemblies of Mechanical Interlock-Plugin Box(MIL-PIB)

i) Plunger assembly

ii) Mechanical Interlock Assembly

iii) Left Bush Assembly

iv) Right bush Assembly

v) Door Defeator Assembly

vi) Cu-Jaw Braid Assembly

vii) Contact Assembly

viii) Box Assembly

2. Statistical Process Control Report (cp, cpk report)

Process Capability report & SIR study of 100 samples of Copper jaw for its indigenization.

3. SAP works

i. Viewing updated components drawing

ii. Checking material Quantities in stock
iii. Purchase requisition/request floating to producton planning department.
iv. Purchase requisition status checking
v. Purchase order status tracking
vi. Bill of Material

3. Completed Potential Failure Modes and effects Analysis( Process FMEA) report for
MIL-PIB

4. Helped in PCN implementation of MIL-PI

5. Regular interactions in VE , APQP , TCN/PCN , DWM meetings.

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6. Made well organized Shortage list using Excel for easy tracking of shortage components
of Mechanical Interlock plugin-box.

7. Feasibility checking of drawings , packing instruction sheets , product inserts of

components.
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5.2 Worked On Project :- Development Of Mechanical Interlock Plugin Box

1. MIL-PIB(Mechanical Interlock Plugin-Box)

Unique Features of MIL-PIB project

1. Safety Feature :- Unejectionable from Busbar During the MCCB switch ON condition

2. Safety Feature :- Door not openable during MCCB ON condition

3. Safety Feature :- Red LED on during MCCB switch ON condition

4. Operating Handle Lever :- For Ease of on/off operation with least Efforts

5. Improved Aesthetics
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Co-ordinaton to BBT Team in development of Project:-

Phase Transposition Unit Of BBT

A busbar trunking unit which changes the relative positions of the phase conductors within the
enclosure to balance inductive reactance or to facilitate connection between items of fixed
equipment
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6.1 CASE STUDY:- 1

6.1.1 Title :- Time consuming transportation of Plugin-Boxes between workstation

6.1.2 Defination of problem:-

1. While moving the heavy plugin boxes from station 1 to station 2 on worktable after
performing sequence of operations and assemblies , the boxes are moved with lifting and
placing method by worker.
2. It is time consuming and require large effort to shift the plugin box between stations .
3. Due to arrangement of rubber mat on worktable , it is difficult to slide the boxes

Transportation of Boxes on rubber Mat either by sliding or lifting.

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6.1.3 Solution suggested to the Problem

Title :- Use of roller arrangement on the worktable for smooth production flow.

Detail of solution:-

1. In order to save the effort and time the rolling arrangement can be employed on worktable
between the adjacent stations on worktable ,
2. Rolling arrangement ensures the smooth production flow and allows the workers to give
enough time to do proper assembly by reducting the moving time of boxes between the
stations .

Cost of Roller arrangement Worktable:-

Purchase:- Standard Purchase

No. of stations on worktable :- Six

Cost :- 10,000 INR

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6.2 CASE STUDY:- 2

Title :- MCCB Stopper screw removing powder coating of MCCB mounting plate after
several on/off/trip operations

6.2.1 Introduction of Case Study :

1. In Mechanical Interlock Plugin Box the MCCB knob is operated by Operating Handle
lever .

2. During the resetting of MCCB , the operator operates the handle downward by applying
force.

3. Due to the momentum of handle there are the chances of breaking the MCCB knob.

4. To avoid this there is a provision of MCCB stopper screw which is callibrated to strike
the MCCB mounting plate after the MCCB reset point is achieved.

5. This Bare screw scratches the mounting plate when strikes and removes the powder
coating.

6. Thus the mounting plate begins to corrode from that scratch

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6.2.2 Problem Definition :

1. Stopper screw strikes the mounting plate and removes powder coating and produces
scratch on plate.

2. With time the mounting plate starts Rusting/Corroding from that scratch .

3. Leakage Current may start flowing through mounting plate.

6.2.3 Solution 1:

Title:- Fastening of polycarbonate sheet barrier between the Mounting plate and stopper
screw

Placed Polycarbonate 2mm thick sheet between screw and plate

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Methodology of Solution Provided:

1. Initially we cut down the 2 mm polycarbonate sheet barrier in required dimension.

2. Drilled two holes at the location of screw of mounting plate .

3. Fastened the Polycarbonate barrier overlaping on the stopper scratching Area.

4. Performed On/off/trip operations Several times .

5. No scratch and no powder coating removal observed on the mounting plate.

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6.2.4 Solution 2: Welding L-clamp with tapping/nut on mounting plate

with Callibrated screw

Methodology of Solution Provided:

1. The L-clamp having M4 tapping/nut is welded on the mounting plate.

2. The operating handle is moved downward till the point of reset condition and holded
there.

3. The stopper screw is (Tightened/callibrated ) till it touches to driver link.

4. Thus we have done several trials and no issue was seen with this solution
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7. Conclusion :-
It’s been much more value adding 6 months of my life during the internship in New
Product engineering department of Larsen and toubro ltd ahmednagar.

Along my training period, I got exposure to the Industrial culture as well as I realize that
observation is a main element to find out the root cause of a problem. Not only for my project
but daily activities too. During my Internship at L & T, I cooperate with my colleagues and
operators to determine the problems. Moreover, the project indirectly helps me to learn
independently, discipline myself, be considerate/patient, self-trust, take initiative and the ability
to solve problems. Besides, my communication skills is strengthen as well when communicating
with others. During my training period, I have received criticism and advice from engineers and
technician when mistakes were made. However, those advices are useful guidance for me to
change myself and avoid myself making the same mistakes again.The things I got to learn :-

• Critical and Analytical Thinking

As working with New product engineering which is quite similar to Research and development
require deep thinking of every aspect , engineering skills , conceptual thinking .

• Time Management

Having daily agenda and making the agenda of next day helps us to an effective time
management allows us to do our assignment efficiently and meet our schedules. Scheduling
avoids time wastage and allows us to plan ahead, and gaining more as a result.

• Goal Management

During working with L & T , I got to learn the management of goal/target which needs to be
completed earlier within the time as well as it helped in understand planning is key factor is goal
achievement.

• Colleague Interactions

While working as a team I understand regular interaction make things easier . In larsen and
toubro the peoples in the New Product Engineering Department ,Life cycle management
Department, Strategic Sourcing Group Department, Purchase Department, Engineering Cell ,
Marketing and Research Department have regular interactions to solve any problem .
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8. References:

www.lntebg.com

https://en.wikipedia.org › wiki › Larsen&Toubro

L&T BBT catalogue

L&T New product engineering Guidelines