VISVESVARAYA TECHNOLOGICAL UNIVERSITY BELAGAVI INTERNSHIP Report on KIRLOSKAR ELECRTIC COMPANY PVT. LTD Submitted by 1, Pranit Rajesh Patil 4BBI5SME412 2, Abhishek Ashok Thorat 4BB1SME401 Under the Guidance of Mr. Madhusudhan k § (HR Officer Kirloskar Electric Company Pvt. Ltd.) DEPARTMENT OF MECHANICAL ENGINEERING Babubali College of Engineering ‘Shravanabelagola-573 135 2017-18 DEPARTMENT OF MECHANICAL ENGINEERING, DCE, SHRAVANABELAGOLA, 1KAR ELECTRIC COMPAL KIRLOSKAR ELECTRIC COMPANY PVT, LTD, GOKUL ROAD, HUBBALLI - 580030 CERTIFICATE This is to certify that the report entitled “INTERNSHIP AT KIRLOSKAR ELECRTIC COMPANY PVT. LTD.” Is a boni ied out by PRANIT RAJESH PATIL and ABHISHEK ASHOK THORAT in completion of internship at_at Kirloskar Electric Company Pvt. Ltd, Hubballi, e work & ii DEPARTMENT OF MECHANICAL ENGINEERING, ICE, SHRAVANABELAGOLA,KIRLOSKAR ELECTRIC COMPANY PVT.LTD. HUBBALLL AKNOWLEDGEM: The satisfaction accompanies the successful completion of any task would be incomplete without the mention of people who made it possible whose constant guidelines, support and encouragement crown all the success We sincerely extend our thanks to Mr, Madhusudhan K S (HR Officer Kirloskar jectric Company Pvt, Ltd.) who gave us this opportunity. We sincerely thank all the respondents whose spared their valuable time and have provided all the information required to us. Lastly we are grateful to our parents and friends for their co-operation and invariable support. I. PRANIT RAJESH PATIL 2, ABHISHEK ASHOK THORAT iii INEERING, ICE, SHRAVANABELAGOLA, 3 TMANICALLOSKAR ELECTRIC COMPANY PVT.LTD. HUBIALLL DECLARATION We Mr. Pranit Rajesh Patil and Mr. Abhishek Ashok Thorat, students of Bahubali College of Engineering, Shravanabelagola, studying in 8" semester BE. in Mechanical engineering. Thank our institution for giving us this opportunity. We had been for internship at Kirloskar Electric Company Pyt, Ltd. Hubballi, We hereby affirm that this report on “Internship at Kirloskar Electric Company Pvt, Ltd. Hubballi” has been undertaken by us during the said as part of my academic curriculum, We further declare that this project report is the result of our own efforts and has not been submitted carlier to any other college for any other degree. Place: Hubballi Submitted By, Date: 22/02/2018 Mr. Pranit Rajesh Patil Mr, Abhishek Ashok Thorat DEPARTMENT OF MECHANICAL ENGINEERING, CE, SHRAVANABELAGOLA, 4KIRLOSKAR ELECTRIC COMPANY PVT. LTD. HUBIALLL CONTENTS Sl.No. Particulars Pg. No. 1 CERTIFICATE ii 2 AKNOWLEDGEMENT iti |" 3 [DECLARATION —————~—SOCS~*~“—<‘“S;~C;<; ifthe curent-carrying wire is bent into a loop, then the two sides of the loop whien are at Drovide a more uniform torque eae nagnetic ‘and the magnetic tield is ‘experience forces.in on Senna cease: ‘arrangement called the field Principle of How Motors Work DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 20LOSKAR ELECTRIC COMPANY PVT LTD. HUBMALLL 1, Electrical current flowing in a loop of wire will produce a magnetic field across the loop, 2. When this loop is surrounded by the field of another magnet, the loop will um, producing a force (called torque) that results in mechanical motion Motor basic parts: Electric machines are classified into two categories D.C. and A.C. motors, the basic parts for each type will be different for each type as follows: 1- AC Motor Basie Pat AC Motor Basie Parts The basic parts for AC motors are as follows: 1 Enclosure. Stator. Rotor. Bearings. Conduit Box. Eye Bolt aekey DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA 2Enclosure PaeuntyAaserblos Menor Enclosure The enclosure consists of a frame (ar yoke) and two end brackets (or bearing housings). A motor’s enclosure not only holds the motor's components together, it also protects thie intemal components from moisture and containments. The degree of protection depends on the enclosure type, In addition, the type of enclosure affects the motor’s cooling, 2. Stator DEPARTMENT OF MECHANICAL, ENGINEERING, OCE, SHRAVANABELAGOLA, 2‘The motor stator consists of two main parts: A. Stator Core The stator is the stationary part of the motor's electromagnetic circuit. The stator is electrical circuit that performs as electromagnet, The stator core is made up of many thin metal sheets. called laminations. Laminations are used to reduce energy losses that would result if'a solid core were used, B., Stator (Windings) Stator laminations ate stacked together forming a hollow cylinder, Coils of insulated wire are inserted into slots of the stator core. When the assembled motor is in operation, the stator windings are conneeted directly to the power source, Each grouping of coils, together with the steel core it surrounds, becomes an electromagnet when current is applied. Electromagnetism is the basic principle behind motor operation, 3. Rotor ‘Conair Bar many Cutaway View of Rator Rotor The rotor is the rotating flirt of the motor’s electromagnetic cireuil. Magnetic field fhom the stator induces an opposing magnetic fleld onto the rotor causing the rotor to “push” away from the stator fie ‘There are a lot of rator types like Squirrel cage rotor and wound rotor, they will be explained later. DEPARTMENT OF MECHANICAL ENGINEERING, DCE, SHRAVANABELAGOLA. 3BKIRLOSKAR ELECTRIC COMPANY PVT.LTD. HUBMALLL 1. Bearings: Bearings, mounted.on the shafl, support the rotor and allow it to turn, Not all bearings are suitable for every application; a universal, all-purpose bearing does not exist. The choice of bearing arrangement is based on the following qualities: «Load carrying capacity in the axial and radial direction, # Overspeed and duration, * Rotating speed. + Bearing lite, “The size of the bearing to be used is initially selected on the basis of its load carrying capacity, in relation to the load to be carvied, and the requirements regarding its life and reliability, Other factors must also be taken into consideration, such as operating temperature, dirty and dusty environmental conditions, and vibration and shocks affecting beatings in running and resting conditions, Bearings Types: ‘There are many types of bearings on the market, each with different characteristics and different uses, these types are as follows: A. Deep groove ball bearings Deep groove ball bearings Deep groove ball bearings are the mest cammon type of bearing, and can handle both radial and thrust loads. Due to their low-frictional torque, they are suitable for high speeds. In.a ball bearing, the load is transmitted from the outer race to the ball and from the ball to the inner race. Since the ball is a sphere, it only contacts the inner and outer race at a very small point, which helps it to spin very smoothly. This also. means that there is not very much contact area holding the load, so if the bearing is overloaded, the balls can deform, ruining the bearing. DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 24LOSKAR ELECTRIC COMPANY B. Cylindrical roller bearings Cylindrical roller bearings ‘These roller bearings are used in applications where they must hold heavy radial Joads. In the roller bearing, the roller is a eylinder, so the contact between the inner and outer race is not a point but a line. This spreads the load out over a larger area, allowing the bearing to handle much greater radial loads than a ball bearing, However, this type of bearing is not designed to hat much thrust loading. C, Angular contact ball bearings Angular contact ball bearinas Angular Contact ball bearings have raceways in the inner and outer tings which are displaced with respect to each other in the direction of the bearing axis. This means that they are suitable for the accommodation af combined loads such as simultaneously acting radial and axial loads in vertical machines. DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 25Lip stint D, Spherical roller thrust bearing Spherical roller thrust bearing In Spherical Roller thrust bearings, the load is transmitted from one raceway to the other at an angle to the bearing axis. They are suitable for the accommodation of high axial oads in addition to simultaneously acting smuall radial loads. Spherical roller thrust bearings are also self-aligning. E. Sleeve Bearings Sleeve bearings Sleeve beatings have no moving parts, they rely on a thin film of oil to reduce friction and allow the moior shaft to turn freely. This film of oil is critical to the life of a sleeve bearing. When properly lubricated, there is actually no physical contact between the bearing an! the shaft. If for some reason the oil film breaks down, metal-to-metal contact between the shaft and the bearing will cause the bearing to wear very quickly and soon fail. Sleeve bearings are often chosen because of their relatively quiet operation and lower cost compared to ball bearings, DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 26CTRIC COMPAS 5. Conduit Bax Conduit Box Point of connection of electrical power to the motor’s stator windings, Bolt Eye Bolt Used to lift heavy motors with a hoist of erane to prevent motor damage Magnetic Poles: Poles in a motor are always an even number and come in south). In an AC motor, the number of poles work in conjun determine the synchronous speed, ts of two (north and m with frequency to Number of pie Synchronous Speed, rpm 50.Cyeles (Hz) jest (Hz) [S00 | 720 DEPARTMENT OF MECHANICAL ENGI ERING, CE, SHRAVANABELAGOLA, aLOSKAR ELECTRIC COMPANY Kirloskar Electric Company Pvt. Ltd. Hubballi brane! Production Department: ‘This department is responsible for all the production activities carried out by the unit. The whole running of unit depends on this department the proper and timely functioning of this department helps in product reaching the customer at the time. Objectives: 2. To follaw up the production schedules as per the plan, 3. To maintain close and key relationship with other departments. 4. To upgrade the technical efficiency of the production Shop I: ‘The manufacturing functions are carried out in this shop. In this shop all the raw materials are pooled up then given a shape, which is semi ready, Various steps are carried out here t give final shape of various parts of the products like shaft, base milling, machining ic. boring, drilling, tapping, covers are also done here. To avoid the run out 360 degree balancing is done, Here additional balaneing type is adopted, Pressure testing is carried out to know if any leakage, blowholes. If they are present it's rejected. Shop 2: In this shop only die casting is done, icc. shape of body and name plates are given in their final shape. Here all three body shape and name plates are dane with aluminum, which is heated upto 750 to 800 degree centigrade. This molten aluminum itself takes the given shape after cooling. Machine used is H660, Pre-treatment shop: It is also known as painting shop. Here the components used in the motors are pretreated and painted, A unique innovation technology called UNIBAKES, installed in 1992 used for drying the components to be used in export motors DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 28ASKARELECTRIC COMPANY FT: 1D. HUIBMNALLL Shop 3: ‘This is assembly shop, where the products will get ready upto 9% here. Onily final Finishing stajges will be left at this stage. The frame size 63-180 motors are assembled here. ‘The assembling i.e, fixing covers, screws and nuis are done manually, The shalt is fixed through hydraulic pressing machine, ‘The product comes to connection wing where electrical connections are given and then later on electrical parts are checked. The product is given first coat of painting. Shop 4: This shop is known as INVOTECH CENTER i.c, R&D division of the firm in this shop, the product development is the main function. This shop is closely related to the engineering department and hence carries on its activities in accordance with the engineering departinent. The activities of this shop include tests for future department, vibrators testing reliability ete. Shop 5: ‘This shop is for assembly. In this shop there are two sections. One deal with AC motors and other one with AC generator. In this section of AC motors, the assembling of machine tipts 200-450 frames is dente here. In this séctian of AC motors, the process begins the shaft being inserted into rotor through’ hydraulic press machine. This also has own Painting and dispatch section, Material management department: Material management department is one of the important department for any industry or manufacturing unit, raw materials are necessary. But only processing of raw material is not sufficient, The quality, delivery time and price factor are all to be considered and this is not as simple as it seems, It inyalves lot of inspection negotiation, Henve KSL has established a separate department which takes care of all the above mentioned factors. DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 29ASKAR ELECTRIC COMPANY FT. 11D. HUBINALLL Manufacturing and engineering department: ‘This department is’ respon: activity using appropriate methods. Ke for capital equipment and their design and dies Funetions: |. Preparation of drawing jigs, fixtures, dies, tooling storage devices and gauges, 2. Providing guidelines tor revision of drawing introducing design changes. 3. To-explain the methods of conducting designs. 4. Finalizing the manufacturing process, 5. Verification of jigs and fixtures, 6. Fi alizing the specification, procurement and machines for manufacturis Quality assurance: ‘The role of quality is so functional division in achieving and maintaining level of specified quality requirements economically. Quality assurance department maintain quality systems as [SO 9001-1994 Funetions: 1. Incoming raw material testing. 2. Resinspection of product which are required to meet specified requirements. 3. Ensuring that calibrated instruments are used for measurements and coordinating: with calibration, 4. Final product inspection. 5. Assisting for customer inspection of products when required quality. DEPARTMENT OF MECHIANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 30KIRLOSKAR ELECTRIC COMPANY PVT LTD. HUBMALLL AC motors product range inchides: ‘Open Type Cage Spectrum KEC designs, manufacture and supply open type cage spectrum motors to suil the exact requirements of the application resulting in satisfactory performance and operation, Clase Type Cage Spectrum KEC designs, manufacture and supply close type cage spectrum motors to suit the exact requirements of the application resulting in tory performance and operation. Primo KEC designs, manufacture and supply close type cage primo mators to suit the exact requirements of the application resulting. in satisfactory performance and operation. Nema EPAct Compliant 1-200 HP ‘This is TEFC Cast Iron Inverter Compatible industrial AC Induction motor meeting NEMA MGeI standards. Open Type Wound Rotor Spectrum KEC designs, manufacture and supply open type wound spectrum motors to suit the exact requirements of the application resulting in satisfactory performance and operation. Clase Type Wound Rotor KEC designs, manufacture and supply close type wound spectrum motors to suit the exact requirements of the application resulting in satisfactory performance and operation DEPARTMENT OF MICIARICAL ENGINEERING, OCF, SHRAVANABELAGOLA 3KIRLOSKAR ELECTRIC COMPANY PVT.LTD. HUBMALLI Special Crane Duty Wound Rotor Kirloskar Electric's AC cage/wound rotor crane duty motors are specially designed for crane applications, The mechanical features are particularly made for tough tasks involving weirs and sluices, lifts and auxiliary motors in rolling mills, etc. Elame Proof Motor KEC Plame Proof Motors are versatile and designed for driving wide range of hazardous area application like pumps, fans in mines, petrochemical industries. These are suitable for Zone [and Zone II area of operation. Nertical Hollow Shaft Motors Kirloskar Electric's Vertical Hollow Shaft motors are well proven for jon and industrial appliations. They are mainly used for driving deep well multistage pumps. Kirloskar Electric's specially designed Wind Generators are light weight generators suitable for mounting at approximately 30 meter height, Advanced engineering techniques and materials used for manufacturing these generators conform to various intemational standards and meet the customer's requirement. Kirloskar Electrie’s Spectrum X F is a series of three phase large AC induction Motors, DEPARTMENT OF MECHANICAL, ENGINEERING, BCE, SHRAVANABELAGOLA, 32OSKAR ELECTRIC COMPANY FYE LTD_HUBBALLL AC Motors High Voltage Motors: Megapack Closed Type Cage Operating & Supply Conditions an Ambient Temperature -10 to +50°C Altitude Not exceeding 1000 m above mean sea level Atmosphere Non corrosive & non hazardous Relative Humidity — Upto 100% Voltage 415V, 690V, 6.6kV, 3.3KV, HIKW +/- 10% Frequency S0Hz +/- 3% Combined Variation +/-10% Duty SI (continuous) Service factor Lo ‘CEMENT ‘CHEMICAL FERT & CHEM MINING PAPER POWER STEEL SUGAR INT OF MECHANICAL ENGINEERING, ICE, SHRAVANABELAGOLA, 33LOSKAR ELECTRIC COMPANY PVT.LTD, HUBIALLL a acon 2° o& om, Operating & Supply Conditions Ambient Temperature -10 to +50°C Altitude Not exceeding 1000 m above mean sea level Atmosphere Non corrosive & non hazardous Relative Humidity Up to 100% Voltage 41SV, 690V, 6.6kV, 3.3KV, L1KV +/- 10% Frequency S0Hz +/- 3% Combined Variation +/-10% Duty S1 (continuous) Service factor 10 INDUSTRY APPLICATIONS (CEMENT DEPARTMENT OF MECHANICAL ENGINEERING, DCE, SHRAVANABELAGOLA, 34LOSKAR ELECTRIC COMPANY, Lr imnatu ‘CHEMICAL FERT & CHEM MINING PAPER POWER STEEL SUGAR ALSTOM HYCO #. WERGAEEN A TTC Latest @o a ozs High Voltage Motors: Speetrum Closed Type Cage Operating & Supply Conditions Ambient 1010 450°C: Temperature Altitude Not exeeeding 1000 m above mean sea level Atmosphere Non corrosive & nan hazardous Relative Humidity — Up to 100% Voltage G.GKY, 3.3KV, LIK 4/- 10% DEPARTMENT OF MECHANICAL E NEERING, RCE, SHRAVANABELAGOLA, 35LOSKAR ELECTRIC COMPANY PVT. LTD, HUBBALLL Frequency S0Hz +/- 5% Combined Variation +/-10% Duty SI (continuous) Service factor 10 High Voltage Motors: Spectrum Closed Type Wound Operating & Supply Conditions Ambient +1010 +50°C ‘Temperature Altitude Not exeeeding 1000 m above mean sea level Atmosphere Non corrosive & non hazardous Relative Humidity Up to 100% Voltage 6.6KV, 3.3KV, LIKV 41> 10% Frequency SOHz+/- 5% Combined Variation +/-10% Duty SI (continuous) Service factor 1.0 DEPARTMENT OF MECHANICAL ENGINEERING, DCE, SHRAVANABELAGOLA, 36OSKAR ELECTRIC COMPANY PVT.LTD, HUBIALLL Low Voltage Motors: Open Type Series Operating & Supply Conditions Ambient Temperature -10 to 50°C Altitude Not exceeding 1000mitrs above mean sea level. Atmosphere Relative Humidity — Upto 100% Voltage 41SV £10% , 3 ph. Frequency 50H 45% Combined Variation 10% Duty SI (continuous) Service factor Lo Low Voltage Motors: Wound Open Type Series DEPARTMENT OF MECHANICAL ENGINEERING, DCE, SHRAVANABELAGOLA, a7KIRLOSKAR ELECTRIC COMPANY PVT.LTD. HUBIALLL Operating & Supply Conditions Ambient Temperature -10 to +50°C above mean sea level. Altitude Not exceeding 1000mt Atmosphere Non Corrosive & non Hazardous Relative Humidity — Upto 100% Voltage 415V10% , 3 pH Frequency S0Hz 45% 10% Duty S1 (continuous) Service factor Lo Low Voltage Motors: Wound Close Type Series DEPARTMENT OF 8 HANICAL ENGINEERING, BCE, SHRAVANABELAGOLA, 38KIRLOSKAR ELECTRIC COMPANY PVT.LTD. HUBIALLL Operating & Supply Conditions Ambient Temperature -10 to +50°C above mean sea level. Altitude Not exceeding 1000mt Atmosphere Non Corrosive & non Hazardous Relative Humidity Up to 100% Voltage 41SV £10%, 3 ph. Frequency S0Hz 45% 10% Duty S1 (continuous) Service factor Lo Low Voltage Motors: Vertical Hollow Shaft Motors OFM HANICAL ENGINEERING, BCE, SHRAVANABELAGOLA, 39COMPANY PVT.LTD. HUBBALL Operating & Supply Conditions Ambient Temperature -10 t0+50°C Altitude Not exceeding 1000mtrs above mean sea level. Atmosphere Non corrosive & non Hazardous Relative Humidity Up to 100% Voltage 415V £10%, 3 Ph, Frequency SOHz 45% Combined Variation 10% Duty Si(continuous) Service factor 10 LEARNING OUTCOMES: DEPARTMENT OF MECHANICAL ENGINEERING, DCE, SHRAVANABELAGOLA, 40KIRLOSKAR ELECTRIC COMPANY PVT.LTD. HUBIALLI ny Ability to analyse a given engineering problem, identify an appropriate problem solving methodology, implement the methodology and propose a meaningful solution. ‘This training helps to bridge the gap between the theoretical knowledge imo practical, Ability to apply prior acquired knowledg. problem solving Ability to identify sourees of hazards and identify appropriate health and safety measures. Ability 10 work ina team, Ability to take initiatives. Ability to effectively communicate solution to a problem, Ability to adopt a factual approach to decision making. Ability to take engineering action. DEPARTMENT OF MECHANICAL \GINEERING, INCE, SHRAWANABFLAGOLA. 4LOSKAR ELECTRIC COMPANY PVT LTD. HUIBALL REFERENCE 1. www.google.com 2. www.kirloskarin 3. Wikipedia 4, AC Motors Wikipedia DEPARTMENT OF MECHANICAL ENGINEERING, CE, SHRAVANABELAGOLA, 42