MALABAR CEMENTS LIMITED

(GOVT. OF KERALA UNDERTAKING)

INTERNSHIP REPORT

SUBMITTED
BY

ACHYUTHAN R
BHAVYA DAS
GAYATHRI C

DEPARTMENT OF ELECTRICAL & ELECTRONICS

ENGINEERING

NSS COLLEGE OF ENGINEERING, PALAKKAD

678008
 CONTENTS

1. INTRODUCTION
2. CEMENT MANAFACTURING PROCESS
• MINING
• GRINDING
• CLINKER MANAFACTURING
• CEMENT MILL
• PACKING SECTION
3. ELECTRICAL SECTION
• POWER SUPPLY
• LOAD CENTER
• PROTECTING DEVICES
4. CONCLUSION

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 INTRODUCTION

Malabar Cements Limited is a government-owned cement

manufacturing company located in Kerala, India. The company was founded
in 1978 as a fully owned subsidiary of the Government of Kerala, with the aim
of producing high-quality cement for the state's infrastructure development.
Malabar Cements is the largest cement manufacturer in Kerala and one of the
leading manufacturers in South India, producing cement under the brand
names of "Malabar King" and "Malabar Classic." The company has its
headquarters in Palakkad and operates two manufacturing plants, one at
Walayar and another at Cherthala.

Malabar Cements has a strong focus on sustainable and eco-friendly

manufacturing practices. It uses state-of-the-art technology to produce cement
that meets international quality standards while minimizing its impact on the
environment. The company's products have been used in various landmark
projects in Kerala.

Malabar Cements has been recognized with several awards for its
outstanding performance and contribution to the cement industry. The
company's commitment to producing high-quality cement and its focus on
sustainable manufacturing practices has made it a preferred choice for
customers in Kerala and other parts of South India.

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 CEMENT MANAFACTURING PROCESS

The cement manufacturing process involves several stages, including

mining and crushing of raw materials, blending and grinding of the materials
to form a raw meal, and then burning the raw meal in a kiln at very high
temperatures to produce clinker. The clinker is then ground with a small
amount of gypsum to produce cement.

The raw materials used in cement manufacturing typically include limestone,

clay, sand, laterite etc. These raw materials are extracted from quarries or
mines and transported to the cement plant. The raw materials are crushed and
blended in the appropriate proportions to form a raw meal.

The raw meal is then fed into a rotary kiln, where it is heated to temperatures
of around 1450°C. This high temperature causes chemical reactions to occur
that result in the formation of clinker. The clinker is then cooled and ground
into a fine powder, along with a small amount of gypsum. This ground powder
is known as cement, which is then stored in silos before being packaged and
shipped to customers.

The cement manufacturing process is highly energy-intensive, and companies

are continuously exploring ways to optimize their processes and reduce their
environmental impact. Several innovations, such as using alternative fuels and
improving energy efficiency, have been introduced to make cement
manufacturing more sustainable.

MINING

Mines at walayar is at about 6.5 km from the factory, inside the forest. The
main raw material-lime stone is in the form of hard rocks these rocks are drilled
and blasted. The boulders of lime stone are reduced in size to 25 mm using two
crushers namely primary crusher and secondary crusher. This lime stone of 25

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mm size is transported to the factory at walayar through a ropeway system.
Mono cable Ariel ropeway is used to transport the crushed limestone in
Malabar cements Ltd. 67 towers are fixed between mines and unloading
section. DC motor used in transporting operation. Pneumatic system which is
pushes the buckets into unloading hopper. Lime stone received in the plant is
stacked in the stockpile-meant for the same. This raw material has been named
as MCL lime stone.

GRINDING

After the raw materials have been transported to the plant, the limestone and
shale which have been blasted out of the quarry must be crushed into smaller
pieces. Some of the pieces, when blasted out, are quite large. The pieces are
then dumped into primary crushers which reduce them to the size of a softball.
The pieces are carried by conveyors to secondary crushers which crush the
rocks into fragments usually no larger than 3/4 inch across.

CLINKER MANUFACTURING PROCESS

The clinker manufacturing process starts with the extraction of the raw meal
from the homogenization silo to insure that the raw meal is stable and
homogenized in order to produce consistent clinker quality. The preheating of
the material takes place in pre-heater cyclones fitted with a pre-calciner fired
with petroleum, natural gas or coal. The calcinations of the material begin
during this stage, changing its phase to the oxide phase for each component to
be ready for the burning process. The burning phase takes place in a rotary
kiln. The clinker temperature in the kiln burning zone has to reach 1,500°C and
then it is cooled in a cooler by air which decreases the temperature. The entire
manufacturing process is continuously monitored and controlled from the
central control room.

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CEMENT MILL PROCESS

Gypsum and fly ash from respective stock yards are stored in r-1 respective
hoppers. From these hoppers respective materials are fed to the mill in required
ratio and quantity with the help of electronic weigh feeders and belt conveyors.
This material is gridded using steel balls M the mill. a sophisticated dry fly ash
feeding system with latest PLC and SCADA is employed the dried the dry fly
ash is then conveyed to the silo with the help of compressor air. The required
quantity of fly ash is fed to the mill. The cement is then conveyed to the
separator. From the separator the powdered cement is separated to coarse and
fine. Fine powder is conveyed to cement silos. A water spray system is
employed to regulate the cement temperature below 140C.

PACKING SECTION

Cement from silo is fed to rotary screen where the foreign particles are
removed and then fed to packer hoppers. After weighting cement from packer
hopper, the cement is packed in 50kg bags and is conveyed to Lorries or
wagons for dispatch. MCL uses types of packers. Once is mechanical and other
id electronic type rotary packer.

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 ELECTRICAL SECTION

Malabar cements Ltd is a huge concern consuming around 10MW of power

per day. The power of the plant is fed from Kanjikode substation. There are
two feeders of 110kV that provides electrical supply to the plant. This 110kV
is further stepped down to required levels using transformers to feed the high
tension (HT) and low tension (LT) motors that are used in various applications
like rotary kiln, grinder, mill, packing unit etc.

The transfer of power from feeders to the low tension motors requires many
electronically controlled switching devices like thyristors and protection
devices like circuit breakers, isolators etc. Inorder to feed the DC motors bridge
rectifiers using SCR are used to convert the incoming AC supply into DC.

In applications like mills, fan, grinders, packing unit etc constant speed
operation of drives are required. So slip ring induction motors are employed in
such applications due to their brushless operation, high efficiency and easy
maintenance. Both HT and LT slip ring induction motors are used according
to the application.

POWER SUPPLY

The whole factory is fed by two 110/6.6kV transformers of rating 10MVA and
12.5MVA which are fed by two 110kV feeders from Kanjikode substation.
This 6.6kV supply is distributed throughout the factory and the township by
three load centers named LC-1, LC-2 & LC-3. The breaker for both the
transformers kept in LC1. The supply from transformer goes to LCI which then
feeds the machines like compressors, raw mill motors, vent fans, etc. It also
feeds LT machines using 6.6kV/440V transformer.

The output from transformer 2 is taken to LC3 using high tension

underground cables which then feeds the two cement mill motors and two 6.6k
V/430V transformers which is feeding LT machines.

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One Line Diagram

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The substation has two sections, one for KSEB and other for MCL. The KSEB
section has 110 KV equipments and measuring equipments. They have
lightning arrestors, circuit breakers, current transformers, potential
transformer, energy meter etc.. The 110 KV line is given to the circuit breaker
which are then connected to potential transformer and current transformer.
These equipments are provided for each feeders separately. Entering to MCL
section there are two transformers supplying power to different load centers.
In this section, they have provided separate measuring and protective
equipments. There are two transformers in MCL section of yard feeding the
load center The transformer rating is: TRANSFORMERI: 110/6.6 KV 10
MVA Y/Y and: TRANSFORMER 2: 110/6.6 KV 12.5 MVA Y/Y. The
transformers are provided with on load tap changer, there is also change over
switch to transfer the entire load to one transformer in case of any failure in
one transformer. Supply from transformer one goes to load centre one and
transformer two goes to load center three. There are again two transformers
11/6.6 KV and 11/440 KV. An isolated supply is ensured by 440/220 V
transformer for lighting purpose.

LOAD CENTER

It is a dangerous task to supply high voltage directly from the substation to

equipment's. Here the distribution scheme divides the total load into three
sections called load centers. The load centers can be considered as the
exchanging media for the power transfer from substation to HT driver
distribution transformer and motor control center. Load center is the place
where load concentration is talking place.

A load center consist of incoming circuit breaker, potential transformer, step

down transformer, bus coupler, battery charger, metering equipment's, gears,
power factor meters, frequency meter, watt meter, tap changers, voltmeter,
capacitors and controlling equipment relays.

In the load centers, during the working periods, the relays are operated from
the thyristorised dc output and under supply failure, charged battery can supply
necessary power to relay. The uninterrupted function of the relay is possible is
the load center. The capacitor banks are provided for the power factor
improvement. There are three load centers situated at MCL and load center in

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the mines. The HT panels consist of potential transformers, current
transformers, relays, measuring units, contactors, isolators, circuit breakers etc.

LOAD CENTER 1

Load center 1 consist of raw mill loads. It is fed by 10MV, 110/6.6KV

transformer. It has separate control panels for both transformer 1 and
transformer 2 along with distribution boards for various HT & LT machines.
Under normal opera tins, feeder supplies the power to LC 1.

The HT side supplies to two raw mill motors (1650KW). Where compressors
(325KW), Two compressors (450KW), vent fan motors (500KW), air
separator motor (250kw), and ID fan (575KW). The LT supply is used in
unloading stations, motor controlling stations (MCC1, 2, 3A, 3B, 4), for
lightning purpose and the pollution control project. Separate HT & LT supply
capacitor banks are used to control power factor and to the pollution control
project. Separate HT & LT supply capacitor banks are used to control power
factor and to limit current usage during starting. It also has an interconnector
panel to LC2 used for feeding back power and also to driver LC2.

LOAD CENTER 2

Load center 2 consist of kiln loads, it gets power either from LC1 or from LC3.
Currently it is fed by LC3. These interconnections are provided as a safety
measure to avoid accidents. The 6.6KV supplied is obtained from either of the
two load centers is distributed from the incomer using a bus to HT motors
devices like kiln motor drive (225KW), coal mill drive (500KW), cooler ID
fan (500KW), ESP fan (280KW) etc. It also has transformers under its control.
Two of which are for LT purpose and hence it is step down transformer
(6.6kV/430V). It also has a 6.6/1kV step up transformer for feeding power to
township.

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LOAD CENTRE 3

Load center 3 consist of packing section loads. It is fed by 12.5MVA,

110/6.6kV transformer. 1.C3 can also connected to the LC 2 for the continuity
of supply at the case of single feeder. Here two 6.6k V/430V step down
transformers are used for LT connection. LC 3 will control the MCC of the
package system, milling works of air slides, fly ash plant etc. Therefore most
of the production works after the clinker formation is under LC 3.

PROTECTING DEVICES

I. PROTECTIVE RELAYS

A relay is automatic device which senses an abnormal condition of electrical

circuit and closes its contacts. These contacts in turns close and complete the
circuit breaker trip coil circuit hence make the circuit breaker tripped for
disconnecting the faulty portion of the electrical circuit from rest of the healthy
circuit.

Over Current Relay

In an over current relay, there would be essentially a current coil. When normal
current flows through this coil, the magnetic effect generated by the coil is not
sufficient to move the moving element of the relay, as in this condition the
restraining force is greater than deflecting force. But hen the current through
the coil increased, the magnetic effect increases, and after certain level of
current, the deflecting force generated by the magnetic effect of the coil,
crosses the restraining force as a result, the moving element starts moving to
change the contact position in the relay.

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Directional Overcurrent Relay

When the power system is not radial (source on one side of the line), an
overcurrent relay may not be able to provide adequate protection. This type of
relay operates in on direction of current flow and blocks in the opposite
direction. Three conditions must be satisfied for its operation: current
magnitude, time delay and directionality. The directionality of current flow can
be identified using voltage as a reference of direction.

Over Voltage Relay (OVR) & Under Voltage Relay (UVR)

Over voltages occur in a system when the system voltage rises over 110% of
the nominal rated voltage. Overvoltage can be caused by sudden reduction in
loads, switching of transient loads. lightning strikes. failure of control
equipment such as voltage regulators, neutral displacement. Overvoltage can
cause damage to components connected to the power supply and lead to
insulation failure, damage to electronic components, heating, flashovers, etc.

Overvoltage relays can be used to identify over voltages and isolate equipment.
These relays operate when the measured voltage exceeds a predetermined set-
point. Under voltage relays are used for protection against voltage drops, to
detect short-circuit faults, etc. The voltage is usually measured using a
Potential Transformers.

Auxiliary relay

An auxiliary relay is a relay that assists another relay or device in performing

an action. It does this when its operating circuit is opened or closed. These
relays are used in nearly all electronic devices to assist them in functioning
correctly. Essentially, it is as simple as an action done to the relay causing a
circuit to be opened completed or closed and not allow power to travel through
it.

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Earth Fault Relay

An external fault in the star side will result in current flowing in the line current
transformer of the affected phase and at the same time a balancing current
flows in the neutral current transformer, hence the resultant current in the relay
is therefore zero. So this REF relay will not be actuated for external earth fault.
But during internal fault the neutral current transformer only carries the
unbalance fault current and operation of Restricted Earth Fault Relay takes
place. This scheme of restricted earth fault protection is very sensitive for
internal earth fault of electrical power transformer. The protection scheme is
comparatively cheaper than differential protection scheme.

Motor Protective Relays

The electric motor is most essential drive in modern era of industrialization.

From fractional hp AC motor used for different home appliances to giant
synchronous motor and induction motor of up to 10.000 hp used for different
industrial applications, should be protected against different electrical and
mechanical faults for serving their purposes smoothly The motor
characteristics must The abnormalities in motor or motor faults may appear
due to mainly two reasons be very carefully considered in selecting the right
motor protection scheme.

1. Conditions imposed by the external power supply network.

2. Internal faults, either in the motor or in the driven plant.

MM30 Motor Protective Relay

MM30 is a Microprocessor based Comprehensive Motor Protection Relay

designed for Medium and Large Motors

Features:

➢ Auto setting of parameters

➢ 8 digit alpha numeric display
➢ Real Time Measurements

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 ➢ 8 LED's for fault indication.
➢ Control on number of starts of motor
➢ Measurement and display of actual & trip data recordings.

Buchholz Relay

A Buchholz Relay is a safety device mounted on some oil filled power

transformers and reactors equipped with an external overhead oil reservoir
called a conservator. The Buchholz Relay is used as a protective device
sensitive to the effects of dielectric failure inside the equipment.

II. CIRCUIT BREAKERS

MCB (Miniature Circuit Breaker)

Rated current not more than 100 A.

Trip characteristics normally not adjustable. Thermal or thermal-magnetic

operation.

MOCB (Minimum Oil Circuit Breaker)

This type is also known as poor oil or small oil circuit breaker. In the bulk oil
circuit breakers, the oil serves as both arcs extinguishing medium and main
insulation. The minimum oil circuit breakers were developed to reduce the oil
volume only to amount needed for extinguishing the arc - about 10% of bulk
oil amount. The arc control for the minimum oil breakers is based on the same
principle as the are control devices of the bulk oil breakers. To improve breaker
performance, oil is injected into the arc.

In MOCB, The current interruption takes place inside "interrupter". The

enclosure of the interrupter is made of insulating material, like porcelain.
Hence, the clearance between the line and the enclosure can be reduced and
lesser quantity of oil would be required for internal insulation.

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 ABCB (Air Blast Circuit Breaker)

• Rated current up to 10,000 A.

• Trip characteristics often fully adjustable including configurable trip
thresholds and delays.
• Usually electronically controlled-some models are microprocessor
controlled.
• Often used for main power distribution in large industrial plant, where
the breakers are arranged in draw-out enclosures for ease of
maintenance.
VCB (Vacuum Circuit Breaker)

• With rated current up to 3000 A.

• These breakers interrupt the are in a vacuum bottle. These can also be
applied at up to 250 kV. Vacuum circuit breakers tend to have longer
life expectancies between overhaul than do air circuit breakers.
ISOLATOR OR DISCONNECTOR

In electrical engineering, a disconnector, disconnect switch or isolator switch

is used to ensure that an electrical circuit is completely de-energized for service
or maintenance. Such switches are ften found in electrical distribution and
industrial applications, where machinery must have its source of driving power
removed for adjustment or repair. High-voltage isolation switches are used in
electrical substations to allow isolation of apparatus such as circuit breakers,
transformers, and Transmission lines, for maintenance. The disconnector is
usually not intended for normal control of the circuit, but only for safety
isolation. Disconnector can be operated either manually or automatically
(motorized disconnector).

LIGHTNING ARRESTER

A lightning arrester is a device used on electrical power systems and

telecommunications systems to protect the insulation and conductors of the
system from the damaging effects of lightning. The typical lightning arrester
has a high-voltage terminal and a ground terminal. When a lightning surge (or
switching surge, which is very similar) travels along the power line to the
arrester, the current from the surge is diverted through the arrestor, in most
cases to earth.

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 CONCLUSION

Malabar cements uses the state of the art, dry process technology for
manufacturing Of cement and the quality is much the national standard. This
company is the back bone mainly for the construction of industries, dams etc.
even though it is polluting, pollution controls methods adopted for reducing
the rate of emission. The internship at MALABAR CEMENT LIMITED
(MCL) from 08-05-2023 to 12-05-2023 was highly informative, both
theoretically, and practically. Provided by first-hand exposure to experience
the real time situations in the industry with otherwise would have been
confined to text books alone. This internship has helped us to understand how
engineering principles are applied to real time situations.

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