A

Report
On
Industrial Internship
Taken At
“Hindustan Concrete Solution India Pvt .Ltd”

Under
Supervision of
“Mr. Amit Kumar Bapodara”
Maintenance Manager
Submitted By
Student Name :- Rahul Patodi
Enrolment Number:- 2021BTEE009

For the practical completion of the Degree &Branch as

B. Tech Electrical

Session: 2024-25
2 Internship Report for Internship taken at ”Hindustan Concrete Solution”

Page Index

Internship Certificate

Acknowledgement

Abstract

1. Introduction
1.1 Company profile
1.2 Importance of electrical engineering in RMC Plant
2. Objectives of the Internship
2.1 To Understand Industrial Electrical Systems
2.2 To Gain Hands-On Experience in Maintenance and Troubleshooting
2.3 To Learn Power Management and Energy Efficiency Practices
2.4 To Understand and Implement Electrical Safety Standards
2.5 To Develop Professional Skills and Work Ethic
2.6 To Bridge the Gap Between Theory and Practice
2.7 To Prepare for a Future Career in Electrical Engineering
2.8 To Understand Energy Efficiency and Sustainability Practices
2.9 To Gain Insight into Industrial Electrical Power Systems
2.10 To Learn About Electrical Equipment Testing and Calibration
2.11 To Understand the Role of Electrical Maintenance in Quality Control
2.12 To Explore Use of SCADA and Control Room Operations
2.13 To Develop Understanding of Industrial Communication Protocols
2.14 To Develop Time Management and Organizational Skills
2.15 To gain Confidence in Practical Engineering Applications
3. Internship Activities and Learning
3.1 Orientation and Introduction to the Company
3.2 Study of Electrical Infrastructure
3.3 Maintenance of Electrical Equipment
3.4 Troubleshooting and Fault Diagnosis
3.5 Power Management and Energy Efficiency
3.6 Electrical Safety Practices
3.7 Learning from Supervisors and Team Members
3.8 Documentation and Reporting
3.9 Installation and Commissioning of Electrical Equipment
3.10 Monitoring and Controlling Electrical Loads
3.11 Participation in Safety Audits
3.12 Exposure to Preventive and Predictive Maintenance Practices
3.13 Documentation and Reporting

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3.14 Interaction with Different Departments

3.15 Interaction with Different Departments
4. Technical Knowledge and Tools
4.1 Electrical Machines and Equipment
4.2 Power Distribution Systems
4.3 Electrical Maintenance and Testing Tools
4.4 Software Tools and Documentation
4.5 Electrical Wiring and Cabling Systems
4.6 Power Quality Monitoring
4.7 Backup Power Systems
4.8 Motor Control Circuit
4.9 Energy Conservation and Sustainability
4.10 Advanced Electrical Technologies (Overview)
4.11 HVAC and Utility Electrical Systems
4.12 Lighting Systems and Energy Efficiency
4.13 Uninterruptible Power Supply (UPS) and Battery Backup System
4.14 Earthing and Grounding Systems
4.15 Lightning Protection Systems
4.16 Electrical Energy Audits (Conceptual Exposure)
4.17 Internet of Things (IoT) in Electrical Monitoring
4.18 Alarm and Safety Interlock Systems
4.19 Cable Management and Insulation Techniques
5. Plant Overviews
5.1 Instrumentation and Sensors
5.2 Motor’s are used in RMC Plants
6. Projects
7. CONCLUSION
8. REFERENCES

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ACKNOWLEDGEMENT
First and foremost, I would like to express my sincere gratitude to Hindustan Concrete
Solution India Pvt. Ltd., Ahmedabad, for providing me with the valuable opportunity to
undertake my internship in their esteemed organization. This internship has been an
incredible learning experience that has significantly contributed to my personal and
professional growth.
I am extremely thankful to the management and the entire team at Hindustan Concrete
Solution for their warm welcome, constant support, and cooperation throughout the
internship period. Their willingness to share knowledge and practical insights helped me gain
a thorough understanding of the electrical systems and processes in the textile industry.
I would especially like to thank my on-site internship supervisor, Mr. Amit Kumar
Bapodara, whose guidance, encouragement, and expert advice enabled me to learn
effectively and perform assigned tasks diligently. Their patience in explaining complex
concepts and providing hands-on training was invaluable. I am also grateful to my university
faculty at Sangam University, Bhilwara, for their continuous motivation and support.
Special thanks to the internship coordinator and my academic mentor for assisting me in
securing this internship and monitoring my progress.
Furthermore, I appreciate the cooperation of the electrical department staff and other
colleagues at Hindustan Concrete Solution pvt ltd who welcomed me as part of their team
and helped me understand the real-world applications of electrical engineering in a
manufacturing setup.
Lastly, I would like to thank my family and friends for their encouragement and moral
support throughout the internship journey.
This internship has not only enhanced my technical skills but also strengthened my
confidence and work ethics. I hope to carry forward these learnings in my future career.
Thank you all for being a part of this enriching experience.

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ABSTRACT
. This internship at Hindustan Concrete Solution India Pvt. Ltd provided hands-on experience
in industrial electrical engineering, focusing on power distribution, motor controls, and
automation in ready-mix concrete production. The training involved understanding electrical
systems in batching plants, troubleshooting control circuits, and optimizing energy efficiency.
Key learnings included practical applications of control systems, digital signal processing,
and safety protocols in an industrial setting. The experience reinforced theoretical knowledge
and enhanced problem-solving skills in real-world scenarios.

The internship provided exposure to the challenges faced in an industrial electrical setup,
including dealing with frequent electrical faults, power fluctuations, and coordinating timely
repairs to minimize production downtime. Practical use of electrical testing tools such as
multimeter insulation testers, and clamp meters was an essential part of the learning process.
Moreover, the experience enhanced my understanding of electrical safety procedures,
lockout-tag-out systems, and the importance of maintaining power quality through devices
like power factor correction units. The internship also highlighted the critical role of effective
teamwork and communication in resolving technical issues promptly.
Key learning areas included the maintenance and troubleshooting of electrical equipment
such as induction motors, transformers, circuit breakers, and control panels that play a vital
role in ensuring uninterrupted textile production. I gained hands-on experience in power
distribution management, preventive maintenance, fault diagnosis, and adherence to
industrial safety standards.
In conclusion, the internship at Hindustan Concrete Solution Pvt Ltd. was an enriching
experience that significantly strengthened my technical knowledge, practical skills, and
professional attitude towards industrial electrical engineering. This training has prepared me
to face future challenges in the electrical engineering field, particularly within manufacturing
industries, with greater confidence and competence.

Chapter 1: Introduction

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1.1 Company Profile

Hindustan concrete solution India Pvt. Ltd is
one of the known infrastructure company in
Gujarat Started in 2011, Hindustan concrete
solution India has total 11 plant.
Ready-mix concrete has become a vital part in
construction industry. It is a easy way to
provide concrete to any construction process .
It is well suited industry where a construction
site can get a hassle free mixed concrete by
replacing the old method of mixing concrete at
site. Ready-mix concrete has its own benefits
of fast mixing process, maximum quantity of
concrete can be provided in short durations
and also it provides a dust free environment in
sites by avoiding manual mixing. The automatic precise process in production will help the
construction sites in getting a quality concrete as designed for the construction . Easy
installation and execution of ready-mix plants makes it a vital part of any construction
industry. It is fully auto missed making it a precise mix formulas for any construction.

Hindustan Concrete Solution India Pvt. Ltd is one of the well-known Infrastructure company
in Gujarat. Company are Ahmedabad’s No. 1 RMC manufacturer. Started in 2011,
HINDUSTAN expanded business rapidly and currently owns a total of 11 RMC plants
covering entire Ahmedabad – Gandhinagar belt from Changodar to Gandhinagar to Ramol.
The total serviceable area amounts to more than 15,000 sq. km.

Our plants are located at Adalaj, Shela, Navapura, Hebatpur 1, Hebatpur 2, Ramol,
Vaishnodevi, Nana Chiloda, Sanand GIDC, Sanand GIDC 2, and GIFT City each leading to
a combined monthly production amounting to nearly 1,50,000 m3/month.

Company have 11 RMC manufacturing Plants, 100+ Transit Mixers, 30+ Concrete Pumps, 1
Boom Pump, 11 Wheel Loaders, 8 Pump Towing Vehicles, 5 DG’s for Electric back-up, 1
Water Chilling Plant for Temperature Controller Concrete and a strong family of around
1000+ members.

Company are ISO 9001:2015 Certified Company and Company are producing and supplying
concrete by the brand name of “Hindustan”. Company are also the only QCI RMCMA
certified plant in the whole city with an in-depth focus on systematic processes, product
quality, technology, innovation and customer service.

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1.2 Importance of Electrical Engineering in RMC Plant

Electrical engineering plays a vital role in the textile industry by ensuring the proper
functioning of all electrical and electronic components involved in the manufacturing
process. Some of the key responsibilities and contributions of electrical engineering include:
 Maintenance and Repair: Regular inspection and preventive maintenance of
electrical equipment like induction motors, transformers, pumps, and control panels to
minimize unexpected breakdowns.

 Power Distribution: Designing and managing the distribution of electrical power

from the main supply to various machines and sections of the plant, ensuring optimal
voltage and current levels.

 Automation and Control Systems: Implementation and upkeep of automation

equipment, including Programmable Logic Controllers (PLCs) and motor drives,
which improve the precision and efficiency of textile machinery.

 Energy Efficiency: Monitoring and optimizing electrical consumption by

incorporating devices like power factor correction units and energy-efficient motors to
reduce operational costs and environmental impact.

 Safety: Ensuring electrical safety compliance by installing protective devices such as

circuit breakers, fuses, and emergency shutdown systems, as well as enforcing safe
work practices to protect personnel and equipment.

In essence, electrical engineers in textile plants are responsible for maintaining uninterrupted
production by ensuring that electrical systems run smoothly, efficiently, and safely. Their role
directly impacts product quality, plant productivity, and operational costs.

Chapter 2: Objectives of the Internship

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The primary purpose of undertaking this internship at Hindustan Concrete Solution India
Pvt Ltd . was to gain practical exposure to the industrial environment and understand the
application of electrical engineering principles within the textile manufacturing sector. The
objectives were designed to align with both my academic curriculum requirements and
professional development goals. Below are the detailed objectives of the internship:
2.1 To Understand Industrial Electrical Systems
One of the key objectives was to gain a comprehensive understanding of the electrical
infrastructure used in a Rmc plant. This includes learning about:
 The layout and functioning of electrical power distribution networks within the plant.

 Different types of electrical equipment commonly used, such as induction motors,

transformers, switchgear, control panels, and drives.

 How power is managed and monitored to ensure continuous and reliable operation of
the production machinery.

2.2 To Gain Hands-On Experience in Maintenance and Troubleshooting

The internship aimed to provide practical experience in maintaining electrical equipment and
systems. This included:
 Performing preventive maintenance tasks such as cleaning, lubrication, tightening
connections, and testing electrical parameters.

 Diagnosing and troubleshooting electrical faults in machines to minimize downtime

and avoid production losses.

 Learning ho w to use electrical measuring instruments like multimeters, clamp

meters, insulation testers, and others effectively and safely.

2.3 To Learn Power Management and Energy Efficiency Practices

Efficient power management is critical in industrial operations for cost savings and
sustainability. Through this internship, I aimed to:
 Understand the methods used for power factor correction and load balancing in the
plant.

 Observe how energy consumption is monitored and how electrical loads are
optimized for better efficiency.

 Learn about the impact of electrical losses and ways to minimize them through proper
equipment maintenance and system upgrades.

2.4 To Understand and Implement Electrical Safety Standards

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Safety is paramount in electrical engineering, especially in an industrial environment. The

internship objective was to:
 Learn about electrical safety protocols and practices implemented at the plant.

 Understand the use of Personal Protective Equipment (PPE) and safety devices such
as circuit breakers, fuses, and emergency stop systems.

 Observe lockout-tag out procedures and other methods used to ensure safe working
conditions during maintenance and repairs.

2.5 To Develop Professional Skills and Work Ethic

Beyond technical knowledge, the internship was aimed at developing professional skills that
are essential in the workplace, including:
 Improving communication and teamwork by collaborating with engineers,
technicians, and other staff members.

 Understanding the workflow, organizational structure, and production schedules

within an industrial setting.

 Enhancing problem-solving abilities and decision-making skills by addressing real-

world technical challenges.

2.6 To Bridge the Gap Between Theory and Practice

An important objective was to apply theoretical concepts learned during academic
coursework to practical situations in the industry. This includes:
 Relating classroom knowledge of electrical machines, power systems, and control
systems to actual equipment and processes in the plant.

 Observing how engineering principles are adapted to solve industrial problems

efficiently.

 Gaining insight into the constraints and considerations faced by electrical engineers in
a production environment.

2.7 To Prepare for a Future Career in Electrical Engineering

Lastly, the internship was intended to provide clarity on career pathways and develop
readiness for professional roles by:
 Experiencing a real work environment and understanding the expectations from an
electrical engineer.

 Building confidence in handling industrial electrical tasks independently..

2.8 To Understand Energy Efficiency and Sustainability Practices

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 To participate in basic energy audits aimed at identifying inefficiencies and

suggesting energy-saving measures.

 To observe the use of energy-efficient lighting, motors, and control systems in the
plant.

 To gain awareness of sustainable manufacturing practices and corporate social

responsibility in the textile sector.

2.9 To Gain Insight into Industrial Electrical Power Systems

 To understand the design and operation of industrial power distribution systems
including transformers, switchgear, and circuit breakers used in rmc plant.

 To learn about power factor correction techniques and their importance in reducing
electrical losses and penalties from utility providers.

 To observe the load management strategies implemented to balance power demand

and avoid peak load charges.

2.10 To Learn About Electrical Equipment Testing and Calibration

 To gain experience in testing electrical components such as motors, relays, and
protective devices to ensure they meet operational standards.

 To learn calibration procedures for instruments and sensors to maintain accuracy in

process control systems.

 To understand the importance of regular testing and calibration for maintaining

system reliability and product quality

2.11 To Understand the Role of Electrical Maintenance in Quality Control

 To recognize how electrical system reliability directly influences in rmc plant by

preventing process interruptions.

 To observe coordination between electrical maintenance teams and quality assurance

personnel to quickly resolve production issues.

2.12 To Explore Use of SCADA and Control Room Operations

 To understand the basics of Supervisory Control and Data Acquisition (SCADA)
systems used in monitoring and controlling RMC processes.

 To gain exposure to control room operations including real-time monitoring of

equipment status, alarms, and process parameters.

 To appreciate of automation in enhancing operational efficie

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2.13 To Develop Understanding of Industrial Communication Protocols

 To learn about communication standards like Modbus, Profibus, and Ethernet/IP used
in connecting PLCs, sensors, and control systems.

 To observe how data from various machines is integrated for centralized control and
monitoring.

 To understand challenges involved in network security and data integrity in industrial

environments.

2.14 To Develop Time Management and Organizational Skills

 To plan and prioritize daily tasks during the internship to maximize learning and
productivity.

 To adapt to shifting priorities in a dynamic industrial setting while meeting deadlines.

 To improve personal discipline and organizational skills essential for professional

success.

2.15 To Gain Confidence in Practical Engineering Applications

 To build self-confidence by working on real equipment and facing practical
challenges.

 To learn from experienced professionals and apply feedback to improve technical and
interpersonal skills.

 To prepare for professional responsibilities after graduation through hands-on

exposure.

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Chapter 3: Internship Activities and Learning

During the internship at Hindustan Concrete Solution India Pvt. Ltd., I was exposed to
various practical activities related to electrical engineering within the RMC environment.
These activities allowed me to gain valuable hands-on experience and deepen my
understanding of the theoretical concepts studied during my B. Tech program. This chapter
details the key activities I performed and the learning outcomes achieved during my
internship period.
3.1 Orientation and Introduction to the Company
My internship began with an orientation session where I was introduced to the company’s
history, organizational structure, manufacturing processes, and safety policies. This helped
me understand the scale of operations and the role of electrical engineering in supporting the
textile production line.
3.2 Study of Electrical Infrastructure
I studied the plant’s electrical infrastructure, including:
 The layout of the electrical power distribution system, such as transformers,
switchgear, and distribution panels.

 Types and ratings of motors used in different sections like main motor, skip motor,
conveyor motor, agitator motor, vibrating motor

 Overview of control systems including Programmable Logic Controllers (PLCs) and

motor drives.

This study helped me appreciate the complexity of managing electrical power in a continuous
production environment.
3.3 Maintenance of Electrical Equipment
One of my primary responsibilities was assisting in the maintenance of electrical machines
and systems:
 Conducting preventive maintenance activities such as cleaning motor windings,
checking insulation resistance, tightening electrical connections, and lubricating
motor bearings.

 Performing routine inspections of switchgear and control panels to identify signs of

wear, overheating, or corrosion.

 Assisting in calibration and testing of protective devices such as circuit breakers and
overload relays.

These tasks helped me understand the importance of regular maintenance in preventing

unexpected failures and ensuring smooth plant operation.

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3.4 Troubleshooting and Fault Diagnosis

During the internship, I participated in troubleshooting various electrical faults:
 Diagnosed motor failures caused by issues like winding faults, bearing problems, or
power supply interruptions.

 Investigated electrical faults such as short circuits, overloads, and grounding issues in
machines and wiring systems.

 Used electrical testing tools such as multimeters, clamp meters, and insulation testers
to measure voltage, current, resistance, and insulation quality.

This practical exposure enhanced my problem-solving skills and ability to quickly identify
and resolve electrical problems.
3.5 Power Management and Energy Efficiency
I learned about the plant’s power management system, including:
 Monitoring power consumption and load distribution across different machines and
sections.

 Understanding the use of power factor correction capacitors to improve energy

efficiency and reduce reactive power charges.

 Observing energy conservation practices such as switching off idle machines and
optimizing motor operating conditions.

These insights highlighted the role of electrical engineers in reducing operational costs and
promoting sustainable manufacturing.
3.6 Electrical Safety Practices
Safety was a critical aspect of my internship experience. I was trained in:
 The correct use of Personal Protective Equipment (PPE) including insulated
gloves, safety shoes, and helmets.

 Understanding lockout-tagout (LOTO) procedures to ensure safe isolation of

electrical equipment before maintenance.

 Awareness of electrical hazards and emergency response protocols within the plant.

Adhering to these safety standards is essential to protect personnel and prevent accidents in
an industrial environment.

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3.7 Learning from Supervisors and Team Members

Throughout the internship, I worked closely with experienced electrical engineers,
technicians, and plant operators who shared valuable insights about industry practices,
troubleshooting techniques, and maintenance strategies. Their mentorship greatly enhanced
my learning and confidence
3.8 Documentation and Reporting
I was involved in maintaining logs of maintenance activities, fault reports, and safety
inspections. This helped me understand the importance of systematic documentation for
effective plant management and compliance with regulatory standards.
3.9 Installation and Commissioning of Electrical Equipment
 Assisted in the installation of new electrical motors, control panels, and lighting
systems within the plant.

 Learned the step-by-step process of commissioning equipment, including wiring,

testing, and calibration before putting machines into operation.

 Understood the importance of alignment, grounding, and safety checks during

installation to ensure long-term reliability.

3.10 Monitoring and Controlling Electrical Loads

 Observed real-time monitoring of power consumption across different production
units.

 Assisted in adjusting load distribution to avoid overloading circuits, which could

cause equipment damage or power outages.

 Participated in scheduling machine operation times to optimize energy use and reduce
peak load charges.

3.11 Participation in Safety Audits

 Took part in electrical safety audits carried out by the engineering team.

 Inspected electrical panels, wiring, earthing systems, and emergency shutdown

mechanisms to ensure compliance with safety standards.

 Reported observations and suggested improvements under supervision, gaining

insight into safety management practices.

3.12 Exposure to Preventive and Predictive Maintenance Practices

 Participated in daily and weekly preventive maintenance schedules to keep equipment
in optimal condition.

 Learned about predictive maintenance techniques such as vibration analysis and

thermography to anticipate failures before they occur.

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 Understood how maintenance data is used to plan repairs and replacements to

minimize downtime.

3.13 Documentation and Reporting

 Maintained detailed logs of electrical faults, maintenance activities, and repair work
for record-keeping.

 Prepared reports summarizing troubleshooting steps and corrective actions taken.

 Learned how accurate documentation supports plant management in decision-making

and regulatory compliance.

3.14 Learning from Real-World Challenges

 Experienced the challenges of working in a live production environment where
machine downtime directly impacts productivity.

 Observed the importance of quick decision-making and effective teamwork during

equipment breakdowns.

 Gained awareness of resource constraints and how engineers prioritize tasks to

maintain continuous operation.

3.15 Interaction with Different Departments

 Coordinated with the production team to schedule maintenance without disrupting
operations.

 Collaborated with the quality control department to understand the impact of

electrical issues on product defects.

 Engaged with procurement and inventory teams to track spare parts availability for
electrical components.

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Chapter 4: Technical Knowledge and Tools

During my internship at Hindustan Concrete Solution India Pvt. Ltd., I acquired in-depth
technical knowledge about various electrical systems and tools essential for the smooth
operation of a RMC plant. This chapter elaborates on the key technical concepts I learned and
the electrical instruments and software tools I worked with during my training.
4.1 Electrical Machines and Equipment
A fundamental part of my learning was understanding the different types of electrical
machines and equipment used in the plant, including:
 Induction Motors: These are the primary drivers of textile machinery. I learned
about their working principle, types (squirrel cage and wound rotor), and their
application in driving machines such as spinning frames and knitting machines.

 Transformers: Used to step down or step up voltage levels for different sections of
the plant. I learned how transformers are rated and maintained for efficient operation.

 Switchgear and Protection Devices: Including circuit breakers, fuses, contactors,

and overload relays, which protect electrical circuits from faults like overload and
short circuits. I understood their working and importance in plant safety.

 Control Panels: These panels house relays, switches, and PLCs that control the
operation of motors and other equipment. I gained practical experience in monitoring
and troubleshooting control panels.

4.2 Power Distribution Systems

I learned about the electrical power distribution layout within the plant:
 Incoming Power Supply: The main supply from the local electricity board is
received through a high-voltage feeder and stepped down via transformers to usable
voltage levels.

 Distribution Panels: Power is distributed to different sections through busbars and

distribution boards. I studied the layout and operation of low-voltage switchboards.

 Load Management: Balancing electrical loads to prevent overload and reduce power
losses was an important aspect I observed.

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4.3 Electrical Maintenance and Testing Tools

Hands-on experience with various electrical measuring and diagnostic tools was a vital part
of my internship:
 Digital Multimeter (DMM): Used to measure voltage, current, resistance, and
continuity in electrical circuits. I regularly used the DMM for routine checks and fault
finding.

 Clamp Meter: Allowed me to measure current flowing through a conductor without

disconnecting the circuit, which is critical for safe testing in live systems.

 Insulation Resistance Tester (Megger): Used to check the insulation quality of

cables and motor windings, which helps prevent electrical breakdowns and hazards.

 Earth Resistance Tester: To ensure proper grounding systems are in place for safety.

4.4 Software Tools and Documentation

Although the plant primarily uses manual and semi-automated methods, I was introduced to
some basic software tools used for documentation and electrical system design:
 Microsoft Excel and Word: For preparing maintenance logs, reports, and data
recording.

 AutoCAD Electrical (basic overview): For understanding electrical schematics and

wiring diagrams used in plant layouts.

4.5 Electrical Wiring and Cabling Systems

 Cable Types and Specifications: Learned about different types of industrial cables
used, such as Steel-wire armoured cables, control cables, and power cables, and their
selection criteria based on current rating, voltage, and environmental conditions.

 Cable Laying and Management: Observed how cables are routed through cable
trays, ducts, and conduits to ensure safety, ease of maintenance, and protection against
mechanical damage.

 Terminations and Jointing: Understood the importance of proper cable terminations

and splicing techniques to maintain electrical integrity and prevent faults.

4.6 Power Quality Monitoring

 Voltage Stability and Fluctuations: Monitored plant voltage levels to detect
fluctuations that can affect machine performance and product quality.

 Harmonics and Noise: Learned about the impact of harmonics generated by non-
linear loads and electronic drives, and the measures taken to minimize them.

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 Use of Power Quality Analyser’s: Gained insight into using power quality
analyser’s to assess power disturbances and improve system reliability.

4.7 Backup Power Systems

 Diesel Generator Sets (DG Sets): Observed the operation and automatic transfer
switch (ATS) systems that provide backup power for uninterrupted production.

4.8 Motor Control Circuits

 Direct On-Line (DOL) Starters: Studied basic motor starting methods for small
motors and their protection features.

 Star-Delta Starters: Learned about starting methods for reducing the starting current
of large motors used in heavy machinery.

 Soft Starters: Observed the use of soft starters for smooth acceleration and
deceleration, reducing mechanical stress and electrical peaks.

In a Ready-Mix Concrete (RMC) plant, electrical machines and sensors play a crucial role
in automation, efficiency, and quality control.

4.9 Energy Conservation and Sustainability

 Energy Audits: Participated in basic energy audits to identify energy-saving
opportunities in the plant.

 Use of LED Lighting: Observed replacement of conventional lighting with LED

systems to reduce energy consumption.

 Automation for Energy Saving: Noted how automation systems reduce energy
wastage by running machines only when required.

4.10 Advanced Electrical Technologies (Overview)

 Renewable Energy Integration: Briefly explored the potential use of solar
photovoltaic systems to supplement plant power needs.

 Industrial Internet of Things (IIoT): Understood the future prospects of integrating

sensors and cloud systems for predictive maintenance and real-time monitoring.

 Studied importance of insulation classes and thermal ratings of cables and motor

4.11 HVAC and Utility Electrical Systems

 Studied the electrical systems of industrial HVAC (Heating, Ventilation, Air
Conditioning) units used in maintaining humidity and temperature for yarn quality.

 Understood motorized dampers, air handling unit (AHU) controllers, and

temperature sensors.
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 Observed how control panels for HVAC are integrated with Building Management
Systems (BMS).

4.12 Lighting Systems and Energy Efficiency

 Analyzed different lighting layouts, including LEDs, CFLs, and high-pressure
sodium lamps used in production and storage areas.

 Participated in lux level measurement using light meters to ensure proper

illumination.

 Suggested upgrades for energy-efficient lighting in utility areas to reduce costs.

4.13 Uninterruptible Power Supply (UPS) and Battery Backup Systems

 Learned the role of UPS systems in maintaining critical control systems during power
failures.

 Understood battery bank configurations, charging cycles, and inverter ratings.

 Studied maintenance protocols for batteries, including specific gravity checks and
terminal cleaning.

4.14 Earthing and Grounding Systems

 Studied types of earthing used—plate, pipe, and chemical grounding.

 Understood the concept of equipotential bonding, and how it prevents electric shock.

 Conducted tests on earth resistance using Earth Tester (fall-of-potential method).

4.15 Lightning Protection Systems

 Observed installation of lightning arresters on rooftops and their connection to earth
pits.

 Learned the role of surge protection devices (SPDs) in safeguarding sensitive

control equipment.

4.16 Electrical Energy Audits (Conceptual Exposure)

 Attended discussions on energy audit practices followed periodically at the plant.

 Reviewed energy audit reports highlighting high-consumption areas like winding

units.

 Discussed possible energy-saving recommendations, including motor rewinding and

VFD retrofits.

4.17 Internet of Things (IoT) in Electrical Monitoring

 Gained initial exposure to smart sensors and IoT-enabled panels used for predictive
maintenance.

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 Learned how data logging and cloud-based dashboards are used to track energy
performance.

 Discussed the integration of remote diagnostics in modern textile machines.

4.18 Alarm and Safety Interlock Systems

 Understood the working of emergency shutdown systems, motor interlocks, and
overload trips.

 Studied how alarm systems (both visual and audio) alert staff to critical electrical or
mechanical failures.

 Participated in fire safety drills, including role of electrical shutdown switches

during emergencies.

4.19 Cable Management and Insulation Techniques

 Observed best practices in cable routing, use of armored cables, and ferrule
tagging.

 Studied importance of insulation classes and thermal ratings of cables and motors.

 Participated in megger testing of cable insulation resistance.

Chapter 5: Plant Overviews

Aggregate feeders – Feeding unit is one of the important component.
There are bins located side by side to facilitate feeding of coarse
aggregates and sand. The different number of bins are there which will
hold different sized aggregates / sand into different compartment. The

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reason behind putting each material (size wise) into separate bins is that each material will be
weighed separately as per designated mix ratio.

Aggregate weigh conveyor – Weigh conveyor usually sits below the aggregate feeders.
It is suspended and hanging on load cells. It is to weigh aggregates one by one and then
transfer the same to charging conveyor of skip. Aggregates are discharged to the weigh
conveyor by opening and closing of pneumatic cylinders.

Charging conveyor / Skip – Charging conveyor or a skip is to carry the weighed

aggregates to the mixing unit.

Cement weigh scale – Cement weigh scale will hold the cement in small quantity that is
transferred from the cement silo / hopper via a screw conveyor. Its task is to weigh the
aggregates prior to dispatch into the mixing unit.

Water weigh scale – Water weigh scale receives water from water pump. It will hold
water and weigh the water as per the recipe set in the control panel and then add the same
into the mixing unit.

Additive weigh scales – Additive weigh scales are suspended on load cells and they will
weigh the additive material prior to dispatch into the mixer.

Cement silo / hopper with screw conveyor – Cement silo is to

hold large volumes of cement that comes in bulk trucks. It is usually
provided with safety accessories. A screw conveyor of suitable diameter
and length is at the bottom enabling transfer of cement into the cement
weigh hopper. Many small capacity of batching plant machines are
equipped with a cement hopper. The opening of the hopper is big and it
facilitates adding of cement that comes in bags. Bags have to be placed on
top of the hopper and once they are torn, cement will fall into the hopper.
Cement hoppers are also provided with screw conveyor for transfer of
cement into the weigh hopper. Usually a weigh hopper has 2 openings on
top for inlet of 2 screw conveyors.

Mixing unit – This is the most critical part and heart of the concrete batch mixing plant.
The job of the mixer is to receive all the ingredients and mix them thoroughly for a fixed
time. Then it will discharge the contents into a
transit mixer or a concrete pump.

Control panel – Control panel will control the

working of the machine. Latest machines are
equipped with PLC panel for ease of usage. It is
also possible to save and print mix material
recipes in the latest equipment. Control panel
assist in fast and accurate measurements of the
ingredients. With growing demand for high
quality and accurate concrete it becomes important to produce quality material without any
wastage. This is where control panel helps to control all components of the batching plant.

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Air compressor – Air compressor is one of the

important components here. It is used to control all the
pneumatic operations of the concrete batch mixer like
opening and closing of cylinders that control the feeder
gates, opening and closing of butterfly valves fitted with
weigh hoppers, opening and closing of the mixing unit gate,
etc

5.1 Instrumentation and Sensors

1. Load Cells – Measure the weight of aggregates, cement, and water for accurate
batching.
2. Moisture Sensors – Detect water content in sand and aggregates to adjust mix
proportions.
3. Proximity Sensors – Ensure proper alignment and movement of conveyor belts and
mixers.
4. Flow Sensors – Regulate the flow of water and admixtures for precise mixing.

Load Cell’s :-

A load cell is a sensor used to measure force or weight by converting it into an electrical
signal.

Load Cells Are Used in RMC Plants:

1. Weighing Hoppers: Load cells measure the weight of
raw materials before mixing.
2. Batching Systems: They ensure correct proportions of
cement, sand, and aggregates.
3. Water & Admixture Measurement: Load cells regulate
liquid quantities for precise mixing.
4. Conveyor Belt Monitoring: Used to track material flow
and prevent overloading.

Moisture Sensors :-

Moisture sensor in a Ready-Mix Concrete (RMC) Plant are used to

accurately measure moisture level in aggregates, which are then used
by the plant’s control system to adjust water addition and ensure
consistent concrete production. These sensor are crucial for
optimizing mix designs, reducing cement usage, and improving the
overall efficiency of the production process.

Proximity Switch Sensor :-

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detecting the presence of materials, monitoring conveyor belts, and controlling batching
processes,

Flow Sensors :-
Flow Regulation: Valves ensure the correct amount of water
and admixtures are added to maintain concrete consistency.

1. Sequencing: Admixtures are introduced at specific stages to

optimize cement hydration and performance.
2. Preventing Cross-Contamination: Different admixtures
must not mix prematurely to avoid unwanted chemical
reactions.
3. Automation: Controlled by PLC systems, valves open and
close based on pre-set batching sequences.

5.2 Motor’s are used in RMC Plants :

In RMC (Ready Mix Concrete ) plant various types of electrical motors are used
likes (main motor, skip motor, potentially conveyor
motor, agitator motor, and vibrating motor)
Main motor
These motors are typically used to drive the main mixing
equipment such as the mixer drum or twin-shaft mixer, with
power rating ranging 50 HP.
Skip motor
These motors are used to operate the skip hoist or elevator system that lifts aggregates
and cement into the mixing drum these motors power rating ranging 20 Hp
Conveyor Motor
These motors are used to power conveyors that transport aggregates, sends and other
materials.
Agitator Motor
These motors are used to drive the agitator
systems within the mixer drum, enduring proper
mixing of the concrete ingredients.
Vibrating Motors
These motors are used in vibrating feeders,
screens, and other equipment for material
handling and weighing.

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6. Projects

 Hitachi Hi-Rel

 Gift City Bridge

Gift City Bridge is one of major Bridge
A/C River Sabarmati on proposed New
Route the institute area of Rayasan to
GIFT Taluka & District Gandhinagar.
The bridge was constructed in the Span
of 41.8 mt. x 16 nos and the Length of
the bridge – 668.80 Rmt.

 Claris Pharma

 ISRO

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7.CONCLUSION

The internship at Hindustan Concrete Solution India Pvt. Ltd Plant provided invaluable
hands-on experience in industrial electrical engineering, particularly in power distribution,
motor controls, and automation within the ready-mix concrete industry. Throughout the
training, I gained practical insights into electrical systems in batching plants, troubleshooting
control circuits, and optimizing energy efficiency. The exposure to real-world challenges
reinforced my theoretical knowledge and enhanced my problem-solving skills. This
experience has strengthened my understanding of control systems and digital signal
processing, preparing me for future professional endeavour’s in industrial automation and
electrical engineering.

REFERENCES :-
[1] Mr Rituraj Sir “H.R”
[2] Mr Amit Kumar Bapodara “Maintenance Manager ”
[3] Mr Girish Sir “Production Manager”

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