SUMMER INTERNSHIP REPORT

Title: Summer Internship at Udaipur Cement Works Limited

Submitted By:
Name: Hussain Magar
Roll Number: 22BEE044
Program: Bachelor of Technology
Department: Electrical Engineering
University: Nirma University

Submitted To:
External Guide: Mr. Pawan Kumar Sharma
(Designation: Manager, Electrical & Instrumentation Department, UCWL)
Internal Guide: Mr. Tejas Panchal
(Designation: Asst. Professor, Electrical Engineering Department, Nirma University)

Internship Organization:
Organization Name: Udaipur Cements Works Limited (JK Organisation)
Department: Electrical & Instrumentation Department
Traning Duration: 16th May – 16th June
Submission Date: 3rd July 2025

Declaration:
I hereby declare that this internship report is my original work, prepared under the guidance of my
academic and organizational supervisors. It has not been submitted elsewhere for any academic or
professional purpose.

Signature
1
PREFACE

This report is a comprehensive account of the summer internship I undertook at Udaipur Cement
Works Limited (UCWL), Udaipur, as a part of the academic curriculum for the Bachelor of
Technology in Electrical Engineering at Nirma University, Ahmedabad.

The internship was conducted from 16th May 2025 to 16th June 2025, during which I was assigned
to the Electrical & Instrumentation Department of the plant. The primary objective of this
internship was to bridge the gap between theoretical knowledge and practical industrial exposure.
Through this experience, I gained a deeper understanding of various electrical systems, load
distribution mechanisms, substation components, and safety protocols in a large-scale cement
manufacturing facility.

The contents of this report encapsulate the knowledge gained through field visits, interactions with
experienced engineers, and direct involvement in monitoring and analyzing electrical operations.
The observations and technical data presented are based on real-time processes and plant activities
encountered during my tenure at UCWL.

This internship has been instrumental in enhancing my technical skills, problem-solving abilities,
and professional attitude, and it has contributed significantly to my journey as an aspiring electrical
engineer.

2
ACKNOWLEDGEMENT

I take this opportunity to express my sincere gratitude to all those who guided and supported me
throughout the course of my Summer Internship at Udaipur Cements Works Limited (JK
Organisation) from 16th May 2025 to 16th June 2025.

First and foremost, I would like to extend my heartfelt thanks to the management of Udaipur
Cements Works Limited for providing me with the opportunity to undertake this internship and
gain valuable exposure to the industrial environment. I am especially thankful to Mr. OP Gadhvi,
Head of Department of Electrical & Instrumentation Department and Mr. Pawan Kumar
Sharma, Manager of the Electrical & Instrumentation Department, for their leadership,
encouragement, and for allowing me to be a part of their esteemed department. Their guidance and
support were instrumental in enhancing my learning experience.

I am also grateful to my supervisors at the company Mr. Shailendra Singh, Mr. Kalpesh Rawal,
Mr. Suraj Pal, Mr. Anup Shrimali, Mr. Kuldeep Singh, Mr. Jangir, Mr. Hitendra Kr., Mr.
Rakesh Kumar, Mr. Rahul Joshi, Mr. Gajraj Singh, Mr. Chattar Singh for their valuable
mentorship, constant support, and insights throughout the internship. My sincere thanks to the entire
team of the E&I Department at Udaipur Cements Works Limited for their cooperation, technical
guidance, and for making the work environment so enriching and welcoming.

I would also like to thank Mr. Tejas Panchal, my Faculty mentor at Nirma University, for their
continuous academic support and feedback during the preparation of this report.

Lastly, I wish to thank my family and friends for their unwavering encouragement and support
during this internship journey.

Hussain Magar
B.Tech (Electrical Engineering)
Nirma University

3
CONTENTS
PREFACE ........................................................................................................................................... 2

ACKNOWLEDGEMENT ................................................................................................................... 3

COMPANY PROFILE ........................................................................................................................ 6

OBJECTIVES OF THE INTERNSHIP ............................................................................................... 8

ORIENTATION AND INDUCTION ................................................................................................ 10

SAFETY......................................................................................................................................... 10

Personal protective equipments in cement plant: ....................................................................... 10

CEMENT MANUFACTURING PROCESS FLOW & RELATED ELECTRICAL

OBSERVATIONS ............................................................................................................................. 11

Mines (Limestone) ......................................................................................................................... 11

Crusher ........................................................................................................................................... 12

Transportation (OLBC) .................................................................................................................. 14

Stacker/Reclaimer .......................................................................................................................... 15

Vertical Roller Mill ........................................................................................................................ 16

Continuous Flow (CF) Silo [Pyro Process].................................................................................... 18

Pre-Heater ...................................................................................................................................... 18

Kiln Burner and Cooler .................................................................................................................. 19

Vertical Coal Mill .......................................................................................................................... 21

Ball Mill (Cement Mill) ................................................................................................................. 22

Cement Silos .................................................................................................................................. 24

Packing Plant.................................................................................................................................. 25

MRSS AND 132 KV SWITCHYARD AT UCWL: POWER BACKBONE OF CEMENT

PRODUCTION .................................................................................................................................. 28

Introduction .................................................................................................................................... 28

132 kV Switchyard – Grid Interface .............................................................................................. 28

Main Receiving Substation (MRSS) – The Distribution Core ...................................................... 29

HT Panel Infrastructure (6.6 kV & 3.3 kV) ................................................................................... 30

4
 LT Distribution (415 V Systems) ................................................................................................... 30

Safety, Redundancy & Modernization ........................................................................................... 30

WASTE HEAT RECOVERY SYSTEM (WHRS) AT UCWL......................................................... 31

Introduction .................................................................................................................................... 31

WHRS-1: AQC Boiler-Based System ........................................................................................... 31

WHRS-2: SP Boiler-Based System ............................................................................................... 32

WHRS Load Center ....................................................................................................................... 33

INTEGRATION OF RENEWABLE ENERGY SOURCES AT UCWL ......................................... 34

Introduction .................................................................................................................................... 34

Solar Power Plant 1 – Ground-Mounted Solar PV System ........................................................... 34

Solar Power Plant 2 – Secondary Ground Solar PV System ......................................................... 35

Floating Solar Power Plants ........................................................................................................... 37

KEY LEARNINGS AND SKILLS ACQUIRED .............................................................................. 39

CHALLENGES FACED ................................................................................................................... 41

OBSERVATIONS AND SUGGESTIONS ....................................................................................... 42

CONCLUSION .................................................................................................................................. 43

REMARKS ........................................................................................................................................ 44

5
COMPANY PROFILE

Name & Legal Status

Udaipur Cement Works Limited (UCWL) is a Public Limited Company, incorporated on 15
March 1993, with its registered office located in Udaipur, Rajasthan.

Parent Company & Conglomerate

UCWL is a subsidiary of JK Lakshmi Cement Limited (JKLC)—a well-known name in the
Indian cement sector for over four decades—and both companies are part of the JK Organisation,
a diversified business group with over 135 years of legacy, operating across sectors like Cement,
Tyres, Paper, Agri-Genetics, Dairy, and more.

Legacy & Operations

• The JK Organisation began in the 19th century, founded by Lala Juggilal and Lala
Kamlapat Singhania, and has since expanded across six continents and 100 countries,
with a workforce of over 40,000 and revenues exceeding USD 4 billion.
• UCWL’s integrated cement plant is supported by a diverse product portfolio that includes
Ready-Mix Concrete (RMC), Gypsum Plaster, Autoclaved Aerated Concrete (AAC)
blocks, and other value-added construction materials.

Production Capacity & Sustainability

• The plant has an installed production capacity of 4.7 million tonnes per annum (MTPA).
• Sustainability is central to UCWL’s operations: certified in ISO 9001 (Quality), ISO 14001
(Environment), ISO 45001 (OHS), and ISO 50001 (Energy) .
• The company has also quantified its carbon and water footprints according to ISO
14064-1 and ISO 14046.
• As of FY 2021–22, 45% of UCWL’s energy needs are met through renewables—with
14.45 MW of installed solar plus Waste Heat Recovery Systems (WHRS)—preventing
approx. 85,000 tCO₂ emissions, mirroring the impact of 3.4 million trees.
• The company follows a 2x water-positive approach, conserving resources by substituting 3.6
lakh tonnes of virgin raw materials with waste-derived alternatives.

Vision, Mission & Values

6
Vision: “To provide best-in-class building solutions and deliver exceptional stakeholder experience
by leveraging technology and enabling human capital.”
Mission:
• Become the most preferred brand through superior product quality and service
• Establish industry benchmarks in operational excellence and technology
• Achieve ₹2,000 crore turnover by 2025
• Lead sustainability efforts and drive meaningful CSR
Core Values:
• Caring for People
• Commitment to Excellence
• Integrity through Transparency, Fairness & Trust

Leadership
• Ms. Vinita Singhania – Non-Executive Chairperson
• Mr. Shrivats Singhania – Director & CEO
• Mr. Naveen Kumar Sharma – Whole-Time Director
• Other independent board members support governance and strategic oversight.

Products & Brands

• Platinum Heavy Duty Cement utilizes advanced PSD technology for enhanced volume,
higher early strength, durability, and workability.
• Platinum Supremo Cement, marketed as the “Roof Specialist,” focuses on strength,
fineness, bonding, service, and premium packaging.

Awards & Achievements

UCWL has received multiple accolades, including:
• Asia’s Most Promising Brand (2021)
• Enercon 2020 for green energy initiatives
• Gold for Best Industrial Security in the 8th Exceed Awards
• Recognition by The Economic Times Promising Brands 2021.

Contact & Office Locations

• Plant & Registered Office: Shripati Nagar, CFA, P.O. Dabok, Udaipur-313022,
Rajasthan (CIN: L26943RJ1993PLC007267).
• Corporate and marketing offices across Delhi, Jaipur, Ahmedabad, and other locations .

7
OBJECTIVES OF THE INTERNSHIP

The primary objective of the summer internship was to bridge the gap between academic learning
and real-world industrial practices in the field of Electrical Engineering. During the 4-week
internship at Udaipur Cement Works Limited (UCWL), the focus was to gain practical exposure
to industrial electrical systems, control architectures, automation processes, and safety protocols
while working in a high-demand cement manufacturing environment.

Aligned with the institutional goals of the summer internship, the objectives were as follows:

1. Understand Current Trends and Practical Challenges : To explore and understand the
practical aspects of modern industrial electrical systems including HT/LT power
distribution, PLC/DCS control systems, load centers, VFDs, and energy management in the
context of cement production. The internship aimed to expose students to recent innovations
and real-time problem-solving approaches in industrial automation and electrical
maintenance.
2. Problem Formulation and Functional Simulation : To analyze system-level challenges
such as load balancing, motor startup characteristics, and process interlocks. The exposure
enabled students to identify how electrical systems are designed to optimize performance,
reliability, and safety.
3. Design and Implementation Insight : Though not directly involved in design tasks, the
internship provided an opportunity to observe how electrical infrastructure is
implemented—from Single Line Diagrams (SLDs) to Motor Control Centers (MCCs),
SCADA integration, and efficient cabling methods. Interacting with engineers also helped
understand the reasoning behind various design decisions in industrial projects.
4. Tools, Techniques, and System Analysis : To gain hands-on exposure to system
monitoring tools, load management protocols, energy audit practices, and relay
coordination. It helped in understanding the application of tools like SCADA, thermal
scanning, and real-time data logging in preventive and predictive maintenance.
5. Project Documentation and Reporting : To develop the ability to document daily
learnings, analyze system components, and compile the overall experience into a structured
report. This nurtured skills in technical writing, comprehension, and presentation.
6. Independent and Critical Thinking : The internship encouraged students to critically
analyze the functioning of electrical systems, question existing practices, and understand

8
 areas where improvements could be suggested—be it through better insulation, load
management, or automation.
7. Safety, Ethics, and Resource Optimization : To inculcate the importance of adhering to
industrial safety norms, use of Personal Protective Equipment (PPE), and ethical
engineering practices. It also involved understanding how UCWL replaces virgin raw
materials with waste-derived alternatives, promoting sustainable and energy-efficient
operations.
8. Team Collaboration and Communication : Working with electrical and instrumentation
teams helped in understanding the role of coordination in plant operations. The internship
emphasized effective communication with supervisors, adherence to protocols, and
professional conduct.

9
ORIENTATION AND INDUCTION

SAFETY
Personal protective equipments, commonly referred to as “PPE”, is equipment worn to minimize
exposure to a variety of hazards. Examples of PPE includes such items as gloves, foot and eye
protection, protective hearing devices (earplugs, muffs) hard hats, respirators and full body suits.
Personal protective equipments in cement plant:
➢ Eye & Face protection
• Safety glasses or face shield during welding, cutting, grinding & nailing.
• Safety glasses for protection against intense light, UV rays, infra-red rays (radiation from
hot objects) and flying objects, such as wood chips, dust particles and metal pieces.

➢ Hand protection
• Heavy duty rubber gloves for concrete work.
• Welding gloves for welding.
• Insulated gloves & sleeves for electric work.
• Leather gloves protect against sparks, moderate heat, blows, chips, and rough objects.

➢ Hearing protection
• Earplug or earmuffs in high noise work areas.
• Ear protection devices inserted devices inserted in the car shell be fitted or determined
individually by competent person.
• Plain cotton is not an acceptable protective device.

➢ Foot & Leg protection

• Safety shoes during working in cement plant.
• Footwear must protect the ankle sole, and toes. Safety footwear with a CSA green triangle
symbol meets these requirements.

➢ Head protection
• They might bump their heads against fixed objects, such as exposed pipes or beams.
• A chinstrap or ratchet may be required if your job involves constant bending and your head
is below the waistline.
• Head protection (hard hats) for protection against falling objects

10
CEMENT MANUFACTURING PROCESS FLOW &
RELATED ELECTRICAL OBSERVATIONS

The cement manufacturing process at UCWL follows this sequential flow:

1. Mines (Limestone)
2. Crusher – Jaw & Cone Crusher
3. Transportation – Via 5.8 km Long Belt Conveyor
4. Stacker/Reclaimer
5. Vertical Roller Mill – Grinding
6. Continuous Flow (C.F.) Silo
7. Pre-Heater
8. Kiln Burner and Cooler
9. Vertical Coal Mill
10. Ball Mill (Cement Mill)
11. Cement Silos
12. Packing Plant
Each stage integrates electrical equipment, control logic, and protection schemes vital for
operational continuity, efficiency, and safety.

Mines (Limestone)
The cement manufacturing process begins at the limestone mines, where raw material is extracted
through surface mining techniques. The electrical systems here are essential for powering heavy
excavation and transportation equipment.
Key components include:
• Excavators and Drilling Rigs: Powered by high-capacity diesel-electric systems or mobile
gensets.
• Lighting Systems: High-mast lighting towers connected to LT panels for extended visibility
during low light conditions.
• Safety Interlocks: Emergency push-button stations and earthing rods ensure personnel
safety during blasting and operation.
• Power Supply: Temporary HT/LT lines are extended to mining areas via armored cables
with weatherproof panels.

11
Though basic compared to downstream process areas, electrical infrastructure at mines ensures
uninterrupted raw material extraction, maintaining the upstream supply chain for cement
production.
➢ Location & Purpose: Visited Daroli limestone mines near Udaipur to observe controlled
deep-hole blasting operations.
➢ Mining Method:
• Open-pit, mechanized mining using HEMM (excavators and dumpers).
• Zero overburden due to high-grade limestone.
• Annual production: ~1.6 million tonnes; reserves: ~125 million tonnes (as of 2023).
➢ Blasting Details:
• Drilling: 115 mm dia holes with water injection to suppress dust.
• Explosives: ANFO + boosters, air decking used to control vibrations and fly rock.
• Safety: Blasting restricted to daytime only, advanced controlled blasting minimizes ground
impact.
➢ Environmental & Safety Measures:
• Dust control: Water injection, road sprinklers, covered conveyors, bag filters.
• Vibration control: Precision blasting reduces impact on surroundings.
• Waste management: No topsoil/overburden, minimal rejects.
• Monitoring: PM10/PM2.5, noise, water quality tracked regularly via Pollution Board–
approved labs.
➢ Rehabilitation Efforts:
• Over 6,400 saplings planted with ~80% survival.
• Progressive green belt development and regular PMCP reporting.
➢ Regulatory Compliance:
• ₹2.53 crores invested (FY 2017–18) in environment improvements.
• Regular inspections and compliance with IBM and PCB norms.
➢ Operational Flow:
• Drilling → Charging → Blasting → Loading → Haulage (via dumpers and OLBC) → Two-
stage crushing (with dust control).

Crusher
The Crusher section involves size reduction of limestone and additives before they are conveyed
further. Typically, this stage includes jaw crushers and hammer crushers driven by high-torque
induction motors. The electrical and control systems here play a crucial role in ensuring operational
reliability and protection against overload conditions.
12
Key Electrical Components:
• Main Crusher Motors: Usually slip-ring induction motors (rated 132–250 kW) for high
starting torque.
• Motor Starters: Include Liquid Rotor Starters (LRS) or Grid Resistance Starters (GRR) for
smooth acceleration.
• Motor Protection: Overload relays, short-circuit breakers (MCCB), and temperature
sensors.
• Control Panels: PLC-integrated Motor Control Centers (MCC) with status indication,
emergency stop buttons, and interlocks.
• Vibration and Flow Sensors: Installed to ensure material feed and crusher efficiency,
interfaced with DCS.
These systems are monitored through the Central Control Room (CCR) where operators can assess
motor current, status alarms, and remotely start/stop the crusher motors.

o Crusher Type: Jaw

Crusher
o Make: M/S Sandvik
o Model: CJ 815
o Design Capacity: 700 TPH
(Tons per Hour)
o Motor Rating: 200 kW

Figure 1. Jaw Crusher

Process Flow
1. Dumping: Limestone is brought in by dump trucks and dumped into the receiving hopper.
2. Primary Crushing: The Jaw Crusher crushes larger rocks into smaller fragments.
3. Secondary Crushing: Further size reduction using cone crushers.
4. Dust Collection: Dust is controlled using the installed dust collector system.
5. Transportation: Crushed material is transported via conveyor belts to further processing
areas.

13
Transportation (OLBC)

The Overland Belt Conveyor

(OLBC) system is responsible
for transporting crushed
limestone and additives
across a distance of 5.8 km
from the crusher to the plant
site. Electrical systems are
vital for continuous conveyor
operation, protection, and
synchronized drive
performance.
Figure 2. OLBC

Key Electrical and Control Features:

• Drive Motors: 3 × 335 kW squirrel cage induction motors – one master and two slave units
for synchronized operation.
• Drive Configuration: Controlled via VFD (Variable Frequency Drive) to match torque-
speed characteristics during start/stop and under varying loads.
• Sensors and Safety:
o Zero Speed Switch (ZSS): Detects belt stoppage.
o Belt Sway Switch (BSS): Detects misalignment.
o Pull Cord Switch (PCS): Emergency shutdown mechanism.
o Metal Detector & Magnetic Separator: Ensure removal of ferrous/non-ferrous
debris.
• Energy Chain System: Supplies 3-phase power to the moving parts with cable
management.
• Control Panel: Includes ammeters, rotary switches, protection devices, and interlocks.

The OLBC is centrally monitored through DCS, with fault diagnostics and trend analysis accessible
in real-time. Motor currents, belt load, and switch status are continuously supervised to prevent
operational disruptions.

14
Stacker/Reclaimer
The Stacker/Reclaimer system is used for homogenizing and storing crushed limestone in
longitudinal stockpiles before it enters the grinding section. Both stacker and reclaimer machines
operate on rail-mounted mechanisms with several electrical systems ensuring coordinated and
uninterrupted operation.

Figure 3. Stacker Figure 4. Reclaimer

Key Electrical Systems and Equipment:

• Travel Motors: 3-phase induction motors drive the longitudinal movement of both stacker
and reclaimer.
• Luffing and Slewing Drives: Operated by motors controlled via DOL or VFD-based
starters.
• Boom Conveyor Drives: Motorized conveyors fitted with belt tensioning and alignment
systems.
• Control Panel: Includes MCBs, contactors, VFDs, and SCADA-compatible PLC systems.
• Instrumentation:
o Proximity Sensors for position feedback.
o Level Sensors for pile height control.
o Limit Switches to restrict over-travel and prevent collisions.
• Power Supply: LT switchboards distribute power from Load Centers to these moving
machines through drag chains or festoon systems.

Both stacker and reclaimer operations are semi-automated and monitored via HMI/DCS. Manual
override switches are available for maintenance and emergency scenarios.

15
Vertical Roller Mill
The Vertical Roller Mill
(VRM) is used for fine
grinding of raw materials
(limestone, silica, etc.) into
a uniform raw meal. It
plays a central role in the
energy consumption of the
plant and integrates
advanced electrical drives,
automation, and condition
monitoring systems. Figure 5. Vertical Roller Mill

Key Electrical Components and Systems:

• Main Mill Motor: Typically a high-capacity slip-ring induction motor (rated up to 3000
kW), controlled via LRS for smooth startup and torque handling.

Table 1. SRIM Specifications

Parameter Value/ Description

Manufacturer Bharat Heavy Electricals Limited (BHEL)
Serial No. 43023A422-11-01
Frame 1RR7718-6
Duty Continuous
Rated Speed (RPM) 993 rpm
Rated Power (kW) 3000 kW
Stator Voltage 6600 V
Stator Current 322 A
Rotor Voltage 1930 V
Rotor Current 822 A
Frequency 50 Hz
Number of Phases 3 Phase
Power Factor 0.85

16
 Efficiency 96%
Insulation Class F (temperature withstand up to 155°C)
Ambient Temp 50°C
Temperature Rise Limit 70°C

Table 2. LRS Specifications

Parameter Details
Manufacturer Pioneer Electrical Work, Palghar, Maharashtra
Model P.L.R.S. (Pioneer Liquid Rotor Starter)
Supply AC, 3 Phase, 50 Hz
Rated Motor power 3000 kW
RV (Rotor Voltage) 1930 V
RA (Rotor Amperes) 935 A
Serial Number 1631/22/6459

• Separator Motor: Squirrel cage motor with precise speed control via VFD to regulate
particle size.
• ID Fan, Cyclone Fan & Gas Ducting Fans: High-speed induction motors with DOL or
soft starters, depending on power rating.
• Lubrication System Motor: Ensures smooth operation of bearings and roller assemblies.
• Instrumentation:
o Temperature Sensors at bearings and rollers.
o Vibration Sensors for predictive maintenance.
o Load Cell Feedback for grinding pressure control.
• Control & Protection:
o MCC with auto/manual switch.
o Overload, earth fault, and under-voltage relays.
o SCADA/DCS integration for real-time parameter monitoring and setpoint control.
• Transformers (TR1 and TR2)
o Type: Step-down transformers.
o Input: 3.3 kV from MRSS (Main Receiving Substation).
o Output: 440 V for plant loads.

17
Continuous Flow (CF) Silo [Pyro Process]
After the completion of process of vertical roller mill, material comes out from VRM through chute
and is further transferred to air slide. From air slide it is transferred to bucket elevator and is fed into
CF SILO. The Continuous Flow (CF) Silo is a large vertical storage unit designed for raw meal
homogenization before feeding into the pre-heater system. Electrical systems here ensure
uninterrupted flow and aeration, maintaining material uniformity and system efficiency.
(Power is distributed at 415 V, 3-phase, and protected via MCCBs, ACBs, and intelligent relay
modules.)

Main Electrical Features:

• Aeration Fans: Motor-driven fans installed at the silo base to ensure continuous blending
through fluidization of raw meal.
• Discharge System: Rotary feeders and air slides powered by small motors to control
material exit rate.
• Level Measurement Instruments: Ultrasonic or radar-based level sensors ensure material
height monitoring and control.
• Vibration Monitoring: Sensors detect any inconsistency in flow or blockage.
• Power Supply: Dedicated LT feeders and MCC panels for aeration and discharge system.
These electrical systems are interlocked and synchronized with the pre-heater feed rate using PLC
and DCS platforms. Real-time data acquisition enables efficient inventory management and
troubleshooting in case of system failures.

Pre-Heater
The Pre-Heater system
facilitates the initial heating of
raw meal using hot gases from
the kiln, thus significantly
improving thermal efficiency. It
consists of a multistage cyclone
arrangement where raw material
is preheated before entering the
rotary kiln. Electrical systems
here are focused on material
handling, gas flow control, and
system safety.
Figure 6. Pre-heaters
18
Key Electrical Systems and Components:
• Cyclone Feed Motors: Screw conveyors and bucket elevators feed raw meal into each
cyclone stage using DOL or VFD-controlled motors.
• Induced Draft (ID) Fans: High-capacity motors (typically 500–800 kW) draw hot gases
upward through the cyclones. These motors are protected by overload relays and soft
starters.
• Dust Collection System:
o ESP (Electrostatic Precipitator) or Bag Filters powered by dedicated LT feeders.
o Motors operate rapping and air pulsing mechanisms to clean dust-laden gases.
• Temperature & Pressure Sensors: Monitored via DCS to prevent overheating or pressure
buildup.
• Control Integration:
o PLC/DCS-based interlocks prevent operation without material flow or gas draft.
o Interfacing with kiln temperature and flow parameters ensures optimal feed rate and
heat exchange.

Kiln Burner and Cooler

The rotary kiln is the heart of the cement manufacturing process where raw meal is calcined at
temperatures exceeding 1400°C. It is followed by a cooler that rapidly reduces clinker temperature
using ambient air.

Figure 7. Rotary Kiln

A. Kiln Burner System:

• Kiln Main Drive Motor: A high-power
slip-ring induction motor (typically 500–800
kW), controlled via Liquid Rotor Starter
(LRS) for soft starting and torque control.
• Burner Fan Motors: Supply secondary air
for combustion, often controlled via VFD to
regulate flame intensity.
Figure 8. Kiln Burner
19
 • Flame Scanner & Ignition Systems: Powered and interfaced through PLCs for continuous
monitoring of flame presence.
• Interlock Systems: Ensure that burner operates only when sufficient airflow and raw meal
feed are confirmed.

B. Clinker Cooler:
• Grate Cooler Fans: High-speed centrifugal fans (up to 450 kW), essential for air quenching
of clinker.

Cooler Fan Motor (471 FN 6)

o Rated Power: 425 kW
o Voltage: 3300 V
o RPM: 1486
o Power Factor: 0.9
o Efficiency Class: IE3
o Bearing Type: DE & NDE with
grease-lubricated bearings

Figure 9. Clinker Cooler

• Waste Heat Recovery System (WHRS): Drives linked to WHRS for thermal energy
recycling.
• Clinker Transport Drives: Conveyor motors with soft starters or VFDs.
• Instrumentation:
o Thermocouples and RTDs for clinker and air temperature.
o Pressure sensors to monitor airflow.

Figure 10. Thermocouple, RTD and Pressure sensor

20
Control & Monitoring:
• DCS-based control room provides trend data for flame temperature, kiln speed, fan current,
and fault conditions.
• MCCs are equipped with thermal overloads, MCBs, and earth fault relays.
Electrical engineers ensure balanced phase loading, emergency shutdown wiring, and motor health
analysis using IR, PI, and vibration testing.

Vertical Coal Mill

The Vertical Coal Mill is essential for grinding coal to the required fineness for combustion in the
kiln burner. It operates under a closed-circuit system where coal is dried, ground, and transported
using hot air. Electrical systems here ensure safe, efficient, and continuous grinding.
Key Electrical Systems and Equipment:
• Main Mill Motor: High-capacity slip-ring induction motor (typically 800–1000 kW),
controlled via LRS for high starting torque.
• Classifier Motor: Regulates the separation of fine and coarse particles. It is VFD-controlled
to maintain desired fineness.
• Mill Fan Motor: Draws hot gases to dry and transport pulverized coal. Soft starter or DOL
used depending on rating.
• Bag Filter System:
o Motors operate pulse jet systems and rotary airlock valves.
o Electrical heaters installed to prevent condensation.
• CO and Temperature Sensors: Ensure fire and explosion safety.
• Fire Suppression Systems: Electrical solenoid valves control water/foam discharge in case
of fire detection.
Control and Safety Integration:
• Interlocks: Ensure mill doesn't start unless inert gas, CO monitoring, and system purge are
confirmed.
• SCADA/DCS Control: Monitors motor current, outlet temperature, air-fuel ratio, and
alarms.
• Motor Protection: Overcurrent, thermal overload, earth fault, and locked rotor protection
provided through MCCs.
Electrical safety is crucial in this section due to the risk of coal dust ignition. All motors and panels
are explosion-proof (FLP) rated. Routine IR tests and motor alignment checks are carried out by
plant electrical staff.

21
Ball Mill (Cement Mill)
The Ball Mill, also known as the Cement Mill, is the final grinding stage where clinker is ground
with gypsum and other additives to form cement. This equipment involves heavy-duty electrical and
mechanical systems due to its large size and operational load.

Figure 11. Ball Mill

Cement Mill Process Overview:

➢ Raw Material Handling:
o Clinker, gypsum, and additives are dumped into a dump hopper (42 MT capacity),
transferred via a push feeder (250 TPH rated) to belt conveyors.
o A 3-way pneumatic gate divides material flow between different storage hoppers.
➢ Pre-Crushing & Screening:
o Vibrating screens (100 TPH) separate fine (<10mm) and coarse (>10mm) clinker.
o Coarse material is sent to a hammer crusher (30 hammers, 100 TPH) to reduce size.
➢ Weigh Feeding System:
o Calibrated weigh feeders adjust belt speed to ensure uniform feed to the mill based on
load feedback.
➢ Ball Mill Section:
o Two-chamber rotary ball mills (Dia 3.8m, Length ~12.52–13.52m) perform:
▪ Chamber 1: Crushing with larger grinding media (90–40mm)
▪ Chamber 2: Fine grinding (30–17mm media)
o Internal liners (Hi-Chrome) protect the shell and optimize impact energy.
➢ Mill Drive & Shell:
o Driven by high-capacity 1492–1500 kW motors at ~985–990 RPM using a twin drive
system
o Supported by trunnion bearings with hydrostatic lubrication
➢ Separation & Collection:
o Air classifiers/separators separate fine cement from coarse particles.

22
 o Cyclones use vortex action to further clean air/dust mixture.
o Bag filters and dust collectors ensure minimal emissions and capture fine particulates.
➢ Fly Ash Addition:
o 30% fly ash is added for PPC cement using a dedicated circuit, stored in 500 MT silo
and conveyed via air slides using solid flow feeders, blowers, and load cells for precise
blending.

Key Electrical Components and Systems:

➢ Main Motor Drives:
o Cement Mill 1, 2, 3 and 4:
▪ Motors: Twin-drive induction motors (Crompton Greaves & BHEL)
▪ Rating: 1492 kW (CM-1), 1500 kW (CM-2), 1500kW (CM-3), 1500kW (CM-4)
▪ Voltage: 3.3 kV
▪ Current: ~297 A
▪ RPM: ~990
▪ Insulation Class: F
▪ Enclosure: SPDP
▪ Bearings: NU 328C3/NU 224C3 with Servo Gem 3 lubrication
➢ Power Factor Correction System
o High Voltage APFC Panel
▪ Manufacturer: Unistar, Satna (M.P.)
▪ Voltage Rating: 11 kV
▪ Bank Rating: 1600 kVAr
▪ Step Configuration: 400 kVAr × 4
▪ Current: 83.97 A
o Low Voltage Hybrid APFC Panel
▪ Voltage Rating: 440 V
▪ Bank Rating: 900 kVAr
▪ Step Configuration: 4x50 kVAr + 6x100 kVAr + 100 kVAr SVG
▪ Bank Current: 1252.08 A
▪ Use Case: Installed in Cement Mill-04 for dynamic reactive power control.

Instrumentation and Protection:

• Vibration Sensors on motor bearings and mill shell for predictive maintenance.
• Temperature Sensors to monitor gearbox, motor, and bearing temperatures.

23
 • Current Monitoring to detect load fluctuation and system faults.
• Control Panels: Equipped with MCCBs, contactors, relays, and VFDs for energy-efficient
operation.
DCS and SCADA Monitoring:
• All key parameters like motor current, separator speed, material flow, and pressure are
continuously displayed and logged in the CCR.
Electrical safety includes the use of flameproof enclosures, earthing, lightning protection, and
isolation during maintenance. Routine thermography and insulation testing ensure uninterrupted
operation.

Cement Silos
Cement Silos are used to store the final product before it is dispatched to the packing plant. Proper
electrical systems are crucial to maintain material flow, prevent clogging, and monitor stock levels.
Key Electrical Features:
• Aeration System Motors: Small induction motors operate blowers to aerate the cement and
maintain fluidity within the silos.
• Discharge Gate Drives: Motor-operated gates regulate the outflow of cement to the
packing section. These are typically operated via PLC or manual switches.
• Level Sensors:
o Ultrasonic or radar-type sensors provide real-time level indication.
o Capacitive sensors detect minimum and maximum levels.
• Vibrators and Flow Aids: Pneumatic/electric vibrators powered by control circuits help
prevent arching and buildup.
Instrumentation & Control:
• Interfaced with DCS for level alarms, blower status, and flow rate.
• Local control panels include overload relays, contactors, and indicators for blower
operation.
Power Distribution:
• Supplied from nearby LT panels via armored cables.
• Equipped with MCBs, isolators, and emergency trip buttons.
Periodic electrical maintenance includes checking motor insulation, verifying sensor calibration,
and inspecting terminal tightness. Ensuring reliable aeration and level monitoring helps avoid
production interruptions and silo overflows.

24
Packing Plant
The Packing Plant is the final stage of cement production where bulk cement is packed into bags
using high-speed automatic machines. This section relies heavily on precise motor control,
automation, and instrumentation.
The packing process involves the following equipment and steps:
1. Silos: Four silos store bulk cement, which arrives via a bucket elevator and air slide.
2. Bucket Elevator: Vertically transports cement from lower levels to silos using buckets
mounted on a belt.
3. Air Slide: Moves material horizontally using low-pressure air.
4. Control Gates: Pneumatic, motorized, and manual gates regulate cement flow from silos to
bins.
5. Vibrating Screen: Separates lumps and foreign particles (>5 mm) to ensure smooth flow.
6. Bag Filters: Three bag filters of 18000 m³/hr, 15000 m³/hr, and 12000 m³/hr capacities
ensure dust collection.
7. Storage Bin: Holds cement before it enters the rotary packer (capacity ~34.5 MT).
8. Rotary Packer: FLSmidth 8-spout rotating packer packs 2400 bags/hr using impeller
systems, load cells, and HMI units.
9. Bag Discharge Line: Transfers filled bags via belt conveyors to the loading area.
10. Truck Loading Machines: Automated systems load bags into trucks using drum motors
and trolley-driven conveyors.

Figure 12. Rotary Packer

25
 Figure 13. Truck Loader

Table 3. Truck Loader Specifications

Make Capacity Length Feeding Conveyor Loading Conveyor Luffing Gear

box
FLSmidth 2000 Bags/hr. 15.3 MTR Belt width 650 MM Belt width 750 MM Make ELECON

Drum motor Drum motor Ratio 10/1

- - - 2.2 KW 2.2 KW

Key Electrical and Automation Components:

• Rotary Packing Machines: Equipped with multiple filling spouts, each driven by
independent motors. These motors are typically controlled using contactors or VFDs.
• Conveyor Systems: Motorized belt conveyors, screw conveyors, and bucket elevators
transport bags and bulk cement.
• Automatic Bag Placers: Robotic arms or pneumatic systems, powered and controlled via
PLCs.
• Weighing Scales and Load Cells: Digitally monitored and calibrated for consistent filling.
Connected to HMI/PLC.
26
Control and Monitoring Systems:
• PLC Panels: Control packing speed, bag count, motor start/stop, and fault detection.
• Sensors:
o Proximity Sensors for bag position.
o Limit Switches for mechanical positioning.
o Photoelectric Sensors for bag detection.
• HMI Interfaces: Allow operators to select product type, monitor bagging rate, and
troubleshoot alarms.
Electrical Safety & Maintenance:
• Emergency stop switches, thermal overload protection, and proper earthing ensure safe
operation.
• Routine maintenance includes IR testing, motor cleaning, and software diagnostics for
PLCs.
This section is critical for customer satisfaction and plant output. Efficient automation and robust
electrical design improve packing rate, reduce downtime, and enhance overall plant efficiency.

27
MRSS AND 132 KV SWITCHYARD AT UCWL:
POWER BACKBONE OF CEMENT PRODUCTION

Introduction
The electrical infrastructure at UCWL is anchored by its 132 kV switchyard and Main Receiving
Substation (MRSS)—together forming the central nervous system of the entire cement plant.
These installations manage the intake, transformation, protection, and distribution of power from
the utility grid to various low- and medium-voltage process zones, enabling smooth operation of
heavy-duty equipment across manufacturing lines.

132 kV Switchyard – Grid Interface

The 132 kV switchyard acts as the primary interface between UCWL and the external utility grid.
Its function is to receive high-voltage electrical power, isolate and protect electrical equipment, and
transmit reliable supply to the MRSS.

Figure 14. Switchyard

Key Components and Observations:

• Circuit Breakers (CBs): Gas-insulated (SF₆) type breakers observed; provide high-speed
interruption and are preferred for their compactness and low maintenance.
• Current and Potential Transformers (CTs and PTs): Mounted near busbars; critical for
protection, control, and metering.
• Isolators: Manual or motor-operated, used for visible isolation during maintenance.
Mechanically interlocked with CBs.
28
 • Lightning Arresters: Installed for surge protection due to lightning or switching transients.
• Busbar Arrangement: Likely single or double bus configuration; supported on porcelain or
polymer insulators, ensuring flexibility and reliability.
• Grounding System: An integrated grounding mesh system observed, with
copper/aluminum strips running along breaker foundations to ensure personnel safety and
effective fault current dissipation.
Protection Philosophy:
• Relays for overcurrent (50/51), differential protection (87), and distance protection (21)
ensure precise isolation during faults.
• Control wiring and interlocks are present for safe remote/local operations and SCADA
connectivity.
This switchyard ensures uninterrupted and safe reception of power at 132 kV level, which is then
passed on to the plant via the MRSS.

Main Receiving Substation (MRSS) – The Distribution Core

Located adjacent to the switchyard, the MRSS receives the 132 kV supply and steps it down to
operational voltages suited for different plant areas such as Line-1, Line-2, and the solar
integration zone.

Figure 15. Main Receiving Substation

29
Transformer Layout at UCWL:
Section Transformer IDs Voltage Level
Line-2 TR-4, TR-5 132/6.6 kV
Line-1 TR-1, TR-2, TR-3 132/3.3 kV
Solar Plant 2 Transformers 33/3.3 kV and 11/3.3 kV
These transformers are oil-cooled step-down transformers, equipped with Buchholz relays, silica
gel breathers, and off-load tap changers for maintaining voltage levels under varying load
conditions.

HT Panel Infrastructure (6.6 kV & 3.3 kV)

The MRSS houses multiple HT panels for distributing the stepped-down voltages.
Key Equipment Observed:
• VCBs (Vacuum Circuit Breakers): Used for feeder protection and isolation; spring-
charged mechanisms with manual trip/close levers.
• Micom Numerical Relays: Installed for overcurrent, earth fault, and undervoltage
protections.
• Energy Meters & Multifunction Meters: Enabled real-time monitoring of load conditions.
• Annunciator Panels: Provide visual alarms for breaker trip/fault conditions.

LT Distribution (415 V Systems)

HT is further stepped down to 415 V using LT transformers feeding MCCs (Motor Control Centers)
across plant zones. Notable MCC Features:
• MCCBs, push buttons, selector switches for operational control.
• Proper cable termination chambers and labeled feeders.
• Protection via overload relays, short circuit, and phase failure relays.

Safety, Redundancy & Modernization

• Interlocks: Electrical and mechanical interlocks ensure no unsafe operations occur.
• Numerical Protection Relays: Allow user-defined settings and intelligent protection
schemes.
• Strategic Upgrades: The voltage transition from 3.3 kV to 6.6 kV in Line-2 indicates a
modernization initiative to accommodate higher loads and reduce transmission losses.
• Renewable Integration: Inclusion of step-down transformers for solar energy highlights
UCWL's sustainable growth initiatives.
30
WASTE HEAT RECOVERY SYSTEM (WHRS) AT
UCWL

Introduction
The Waste Heat Recovery System (WHRS) at Udaipur Cement Works Ltd. is a key energy
efficiency initiative aimed at utilizing the otherwise lost thermal energy from kiln and preheater
exhaust gases. This energy is recovered to generate electricity, significantly reducing grid power
consumption and enhancing plant sustainability. WHRS at UCWL is divided into two main heat
sources—the AQC Boiler (from kiln cooler exhaust) and the SP Boiler (from Suspension
Preheater exhaust), collectively powering two separate turbine-generator systems.

WHRS-1: AQC Boiler-Based System

WHRS-1 captures hot gases from the Air Quenching Chamber (AQC) and uses them to generate
steam in the AQC Boiler. This steam drives a turbine coupled to a 3.3 kV HT generator to
produce electrical energy.

Figure 16. DCS operation of WHRS Line-1

31
Key Electrical Components:
• Turbine Generator Output: ~5.9 MW @ 3.3 kV
• Excitation System: Brushless exciter with dual-channel AVR (Channel A & B)
• Control System: PLC-SCADA based (Emerson platform), with real-time SCADA HMI for
monitoring steam and electrical parameters
• Boiler Feed Pump-1: 90 kW, IE3 motor
• Steam Generation: ~29.65 TPH
• Feedwater Flow: ~18.77 TPH
This system demonstrates high automation, redundancy in excitation, and effective monitoring,
making it a critical contributor to UCWL’s in-house power generation.

Figure 17. WHRS Line-1

WHRS-2: SP Boiler-Based System

WHRS-2 uses thermal energy from the Suspension Preheater (SP) Boiler. The steam generated is
routed to another turbine-generator unit.
Key Electrical Components:
• Generator Output: ~6.0 MW @ 3.3 kV
• Turbine Control Panel: Equipped with protective relays, sensors, and indicators
• Control Cabinets: Emerson Ovation system (Controller, Marshalling, Network)
• Auxiliary Motors:
o Boiler Feed Pump-2: 90 kW, IE3 motor
o Auxiliary Drive: 150 kW Siemens motor, IE2 class
• Steam Flow: LP ~3.77 TPH, MS ~2.80 TPH
• Feedwater Flow: ~6.42 TPH
32
This setup mirrors WHRS-1 in layout and function but focuses on another waste stream, thereby
improving overall energy recovery.

WHRS Load Center

The WHRS Load Center manages the power generated from both WHRS-1 and WHRS-2. It
ensures controlled distribution, protection, and synchronization with the plant grid.
a) Power Generation & Distribution:
• Generator: 10 MW, 6.6 kV synchronous machine
• 6.6 kV Bus: Connected through VCBs (1500 A, 40 kA/3 sec) and CT/PT panels
• Transformers: Two 1600 kVA, 6.6 kV/415 V units feeding:
o Bus-A: MCCs, PMCC, DG panels
o Bus-B: EMCC, lighting, water treatment
b) Protection System:
• Relays: Overcurrent (51/50), Reverse Power (32), Voltage (27/59), Earth fault (64G),
Differential (87G), and Vector Surge (78)
• CT/PT: Used for both metering and protection (CL 0.2–5P20)
• Lightning Arresters & Surge Capacitors: Installed for overvoltage protection
c) Metering & Synchronization:
• Multifunction Meters (MFM) and ABT meters on feeders
• Synchronizing Panel with AVR, sync check relay, and DCS interfacing via analog signals
This Load Center is engineered with precision, ensuring efficient, safe, and reliable integration of
WHRS-generated power into the plant’s electrical network.

Figure 18. WHRS Load Center

33
INTEGRATION OF RENEWABLE ENERGY SOURCES
AT UCWL

Introduction
Udaipur Cement Works Ltd. (UCWL), as part of its commitment to sustainable development and
energy efficiency, has taken significant steps toward integrating renewable energy sources into its
power infrastructure. Cement manufacturing is an energy-intensive process, and renewable energy
integration helps UCWL reduce its carbon footprint, enhance energy security, and optimize
operational costs. The integration primarily includes land-based solar photovoltaic (PV) plants
and floating solar power systems, contributing substantially to the plant’s in-house power
generation capabilities.

Solar Power Plant 1 – Ground-Mounted Solar PV System

UCWL's Solar Power Plant 1 is a large-scale ground-mounted grid-connected solar power system
designed to meet part of the cement plant’s base load.

Figure 19. Solar Power Plant 1

System Overview:
• DC Capacity: 10.13 MWp
• Modules Installed:
o 14,060 modules of 325 Wp
o 17,380 modules of 320 Wp
• Pitch & Tilt: 7.3 m pitch; tilt angles of 8° and 30° for seasonal optimization
• Inverters: 76 total, rated 100 kW each (SUNGROW SG110CX)

34
 • Transformers: 33 kV/0.433 kV, 2400 kVA oil-cooled type
Key Electrical Highlights:
• Grid-tied with 33 kV HT panel infrastructure
• Inverter-level real-time monitoring with Multi-Function Meters (MFM)
• Daily Generation: ~11.47 MWh, Exported: ~11.3 MWh
• Performance Ratio (PR): ~66.15%, Plant Load Factor: ~4.65%
Control & Monitoring:
• SCADA and mobile monitoring systems were used for tracking string voltages, inverter
outputs, and performance metrics.
• Wiring was well-organized with labeled terminal strips, aiding in smooth troubleshooting
and operation.

Figure 20. SCADA and mobile monitoring systems

Solar Power Plant 2 – Secondary Ground Solar PV System

Solar Power Plant 2 serves as a supplementary solar generation facility at UCWL, focused on
modular, scalable energy generation.

Figure 21. Solar Power Plant 2

35
Technical Specifications:
• DC Capacity: 4.35 MWp
• AC Capacity: 3.60 MW
• Modules: Trina Solar TSM-545DE19, 545 Wp
• Inverter System: Sungrow SG250HX-IN (200 kW rated)
• Transformer Rating: 3500 kVA, 11kV/800V, ONAN cooling
Monitoring & Performance:
• AI-enabled SuryaLog® monitoring system
o Zero Export Control
o PV-DG synchronization
o Real-time string-level logging
• Live Performance (as of 5th June 2025):
o Generation: 6.43 MWh
o Live Output: 2.61 MW
o CO₂ Emission Saved: 5.08 tons
o Plant Availability: 100%, PR: ~90.95%
Notable Observations:
• Excellent panel condition and inverter performance.
• Suggestions included sensor cleaning and addressing mild rust near panel mounts.

Figure 22. Live Monitoring on SCADA

36
Floating Solar Power Plants
UCWL has pioneered the use of Floating Solar Photovoltaic (FPV) systems, deployed on water
bodies such as old quarry pits, which offers a space-efficient and environmentally friendly
alternative to land-based solar.

Figure 23. Floating Solar Farm

Installed Capacity:
• Floating Solar 1: 1 MWp & Floating Solar 2: 2.7 MWp
• Total Floating Capacity: 3.7 MWp, synchronized at 6.6 kV level
Electrical Layout(of Floating Solar 2):
• Modules: Oriena Solar, 595 Wp (total 4620 modules)
• Inverters: 9 Sungrow string inverters (295 kW, 1500V DC/800V AC)
• Transformer: Step-up transformer (800V to 6.6kV)
• Switchgear: Indoor 6.6 kV Siemens switchboard labeled SOLAR-3 & SOLAR-4
Engineering & Design Features:
• Special floating mounting platforms to support PV modules
• Water-based earthing system due to the aquatic environment
• Radiator fins and Buchholz relays used in transformers
• Protection systems with relays, hooters, voltmeters integrated into ICOG panels
• Use of SYMATIC automation and integration with centralized SCADA

37
 Advantages of Floating Solar:
• No land requirement
• Reduced water evaporation
• Higher module efficiency due to cooling
• Better thermal management of inverters
Challenges:
• Cable routing and waterproofing
• Maintenance access over water
• Risk of corrosion and structural degradation

✓ As part of my independent project titled “Use of AI in Solar Power Systems,” I explored how
Artificial Intelligence can enhance the performance of floating solar arrays. The study showed that
AI tools, such as drone-based thermal imaging and machine learning models, can help detect algae
formation, panel misalignment, and electrical imbalances. These solutions are particularly useful in
dynamic aquatic environments and could be gradually incorporated to improve real-time monitoring
at UCWL’s floating solar farms.

38
KEY LEARNINGS AND SKILLS ACQUIRED

During my internship at Udaipur Cement Works Limited (UCWL), I gained extensive exposure to
the application of electrical engineering in a large-scale, process-intensive industry. The hands-on
experience and guided observations allowed me to build several technical and professional skills,
including:
• Understanding of Industrial Electrical Infrastructure:
I learned the structure and operation of HT/LT systems, Main Receiving Substation
(MRSS), switchyards, and power distribution architecture used in the cement industry.
• Exposure to Automation and Control Systems:
I developed a strong understanding of Distributed Control Systems (DCS), SCADA, PLCs,
and the integration of these systems with field instrumentation and plant operations.
• Familiarity with Electrical Components:
I worked with and studied the function of MCC panels, VFDs, LT/HT switchgear,
protection relays, starters (DOL, LRS), busbars, APFC panels, and various industrial sensors
and motors.
• Technical Analysis and Interpretation:
I observed load flow, monitored equipment behavior via real-time SCADA displays, and
understood the role of energy auditing, predictive maintenance (IR testing, vibration
monitoring), and motor health analysis.
• Energy Management and Renewable Integration:
I studied the working of the Waste Heat Recovery System (WHRS) and Solar Power Plants,
understanding their contribution to energy efficiency and sustainable practices.
• Professional Communication and Safety Compliance:
I practiced safety norms, used PPE appropriately, and followed plant protocols. Regular
interaction with plant engineers helped me develop workplace communication skills and
professional discipline.

Additionally, I completed two focused technical projects during my internship:

• Project 1: Importance of Earthing in Electrical Systems – This project helped me
understand the design and evaluation of earthing systems used across various units such as
the MRSS, WHRS, and solar installations. I conducted field analysis on earthing resistance
values, studied fault management protocols, and interpreted IEEE Std. 80 guidelines. I also
examined challenges like step and touch potential and how they are mitigated in high-

39
 voltage environments.
• Project 2: Use of AI in Solar Power Systems – I studied the application of AI-based
solutions in UCWL’s solar power plants (both ground and floating). I analyzed real-time
monitoring systems (like SuryaLog), predictive maintenance strategies, and drone-based
inspections. I also explored AI models such as LSTM and CNN for forecasting and anomaly
detection, which can significantly improve solar plant efficiency and reliability.

40
CHALLENGES FACED

Although the internship was enriching, there were certain challenges that I encountered during the
training:
• Limited Hands-On Operation: Due to safety and operational restrictions, direct handling
of live electrical systems was limited. Most learning was observational and knowledge-
based rather than practical.
• High Technical Complexity: Industrial processes and system configurations were
sometimes beyond undergraduate coursework, requiring extra effort to understand advanced
components such as turbine excitation systems, relay coordination, and high-voltage
protection.
• Time Constraints: Given the vastness of the plant and its systems, the four-week duration
felt short to explore every unit in depth, especially those operating in multiple shifts.
• Environmental Limitations: Areas like the kiln section and substation posed challenges
due to high temperatures and restricted access during operation, making it difficult to
observe every process live.
Despite these limitations, proactive mentorship and structured walkthroughs helped overcome most
learning barriers effectively.

41
OBSERVATIONS AND SUGGESTIONS

Observations:
• UCWL demonstrates a high level of electrical system integration, from large-capacity
motor drives to automated process control.
• There is a clear emphasis on energy efficiency, with advanced renewable integrations such
as WHRS and floating solar systems.
• The plant maintains robust safety standards, incorporating interlocks, alarm systems, and
routine diagnostics to minimize risks.
• Power infrastructure like the 132 kV switchyard and MRSS forms a critical backbone,
ensuring continuous power to all plant operations.
• During site visits and measurements in the Cement Mill and WHRS areas, I observed that
some earth pits lacked clear identification and a few showed resistance levels beyond the
ideal thresholds (≥1.5 Ω). This was reinforced by my dedicated project on the Importance
of Earthing, which emphasized the need for regular earth resistance testing, corrosion
protection at terminals, and strict adherence to IEEE/CEA norms to ensure operational
safety.

Suggestions:
• Interactive training modules or simulators for interns could enhance understanding of live
systems in a safe environment.
• Real-time data analytics dashboards for energy usage and system performance could
further improve process visibility and intern learning.
• Inclusion of short projects or assignments (e.g., relay setting calculation, motor load audit)
would enable deeper engagement and application of academic knowledge.
• Cross-departmental exposure to automation or instrumentation could be added to the
internship to broaden interdisciplinary awareness.
• Based on my study titled “Use of AI in Solar Power Systems”, I suggest expanding the
current SuryaLog monitoring system by integrating AI-based predictive models for panel
cleaning schedules, inverter performance diagnostics, and string-level fault detection. This
can increase solar power plant efficiency by up to 10%, reduce downtime, and align with
UCWL’s sustainability goals.

42
CONCLUSION

My internship at Udaipur Cement Works Limited was a transformative learning experience that
successfully bridged the gap between theoretical knowledge and real-world application. Through
structured plant visits, technical sessions, and interactions with experienced professionals, I gained
valuable insights into the electrical infrastructure, automation systems, and energy management
practices in a modern cement plant.
I understood the importance of precision, safety, and reliability in electrical systems that support
continuous industrial operations. The exposure to systems like WHRS, solar power plants, kiln
control, and SCADA-based monitoring greatly enhanced my technical competency.
This internship has significantly strengthened my confidence, broadened my industrial
understanding, and reinforced my commitment to pursuing a career in electrical engineering with a
focus on power systems and automation.
The completion of two key projects — “Importance of Earthing in Electrical Systems” and “Use of
AI in Solar Power Systems” — added substantial value to my internship. These projects offered
hands-on exposure to both traditional safety systems and modern AI-integrated energy solutions.
They not only strengthened my understanding of industrial power protection and energy analytics
but also introduced me to interdisciplinary tools crucial for next-generation electrical engineering.

43
REMARKS

I would like to express my heartfelt gratitude to Udaipur Cement Works Limited for offering
such a well-structured and insightful internship program. The professionalism, mentorship, and
openness of the Electrical & Instrumentation Department provided me with a dynamic learning
environment where I could understand real-world challenges and industrial best practices.
The knowledge and skills gained during this internship will serve as a strong foundation for my
future endeavors as an electrical engineer. I am thankful to my mentors and the entire UCWL team
for their support, and I sincerely hope to contribute to similar forward-thinking organizations in the
future.

44