National Mineral Development Corporation

TABLE OF CONTENTS

Chapter CONTENTS Page. no

1 Introduction 3
1.1 Location & Etymology 5
1.2 Operational Overview 6
1.3 Infrastructure & Facilities 7
1.4 Historical Highlights 8
1.5 Environmental & Social Initiatives 8
2 Literature Survey 10
2.1 Details 10
2.2 Explanation 10
2.3 Problem Statement 12
2.4 Proposed Solution 13
2.5 Outcome 14
3 Methodology 15
3.1 Prepare the chassis 15
3.2 Mount the motors and wheels 15
3.3 Mount the electronics 16
3.4 Connect the components 17
3.5 Test and Calibrate 17
3.6 Add finishing touches 17
4 Block Diagram 19
5 Wiring Diagram and Working 20
5.1 Wiring Diagram 20
5.2 Working 21
5.2.1 Power supply & regulation 22
5.2.2 Remote control & command decoding 22
5.2.3 Microcontroller 23
5.2.4 Motor drive &motor control 23
5.2.5 Obstacle detection &avoidance 24
5.2.6 Night vision & wireless video transmission 24
6 Hardware Components 25
7 Experimental Setup and Results 32
7.1 Experimental Setup 32
7.2 Results 34
8 Advantages, Disadvantages and Applications 35
8.1 Advantages 35
8.2 Disadvantages 37
8.3 Applications 39
9 Conclusion 40
References 41

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TABLE OF FIGURES

Fig. no List of Figure Page. no

3.1 Block Diagram 19

5.1 Wiring Diagram 20

6.1 AT89S8253 Microcontroller 25

6.2 DTMF Decoder 26

6.3 DTMF Module 26

6.4 L7805CV Voltage Regulator 27

6.5 LM358P Operational Amplifier 27

6.6 L293D Motor Driver 28

6.7 Control DC Motors 28

6.8 Capacitors 29

6.9 Resistors 29

6.10 Address bus Cable 30

6.11 LED Bulbs 30

6.12 General Circuit Board 30

6.14 IR LEDs Camera 31

7.1 Working Model 32

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CHAPTER – 1
INTRODUCTION
The Donimalai Iron Ore Mine, operated by NMDC Limited, is a major mining facility
located in the Sandur taluk of Bellary district in Karnataka, India. Established in 1977, this
mine has played a vital role in supplying high-grade iron ore to domestic steel producers.
NMDC, a Navratna Public Sector Enterprise under the Ministry of Steel, Government of India,
owns and operates this mine. Donimalai is strategically positioned about 325 kilometers from
Bengaluru, near the town of Toranagallu and the industrial hubs of JSW Steel. The name
"Donimalai" is derived from the Kannada words 'Doni' (boat) and 'Malai' (hill), inspired by the
boat-shaped hill formations in the region.

The Donimalai mine is designed to produce approximately 7 million tonnes of iron ore per
annum, with estimated reserves of around 127.6 million tonnes. In recent years, the mine
produced 5.316 million tonnes of ore in 2022 and 5.729 million tonnes in 2023. It also includes
nearby operations like the Kumaraswamy Iron Ore Mine and a 1.2 MTPA pellet plant that
processes ore fines into value-added pellets. The Donimalai complex features comprehensive
infrastructure, including a well-developed township with amenities for employees such as
schools (e.g., Kendriya Vidyalaya), healthcare, and recreational facilities.

Operations at Donimalai faced a brief suspension due to lease-related issues but successfully
resumed in 2021 after renegotiations with the Karnataka government. Historically, the mine
also contributed to exports through major ports like Chennai and Mormugao, though it now
primarily serves the domestic market. NMDC emphasizes sustainable mining and community
development, actively investing in environmental conservation and the welfare of local
populations. Donimalai stands as a model for responsible and efficient mining, significantly
contributing to India's industrial and economic growth.

The Donimalai Iron Ore Mine, operated by the National Mineral Development
Corporation (NMDC) Limited, is one of India’s most prominent and strategic iron ore mines,
located in Donimalai Township in the Sandur Taluk of Ballari (formerly Bellary) district,
Karnataka. This fully mechanized mine began operations in 1977 as part of NMDC’s
expansion to meet the growing demand for iron ore by Indian steel manufacturers. The region
is rich in mineral wealth, particularly high-grade hematite iron ore, making it a key contributor
to India's raw material supply chain for steel production.

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The word "Donimalai" is a combination of the Kannada words ‘Doni’ (boat) and ‘Malai’
(hill), symbolizing the boat-shaped hill formations surrounding the area. The mine is situated
about 58 km from Bellary, and approximately 325 km from Bengaluru, with the nearest
railhead at Toranagallu, around 19 km away. Its strategic location supports easy rail
connectivity to major industrial centers and ports like Chennai and Mormugao, although recent
operations focus largely on domestic supply.

The Donimalai mine was initially developed with support from Japan, both in terms of
financing and equipment, under an agreement to supply iron ore to Japanese steel mills. It was
one of the earliest fully mechanized iron ore mines in the country, featuring large-scale
operations with heavy-duty equipment including shovels, dumpers, crushers, and screening
plants. Its annual production capacity stands at 7 million tonnes, with estimated reserves of
around 127.6 million tonnes of high-grade ore, making it one of NMDC’s most productive
assets.

In terms of infrastructure, the mine complex includes crushing plants, screening plants,
loading facilities, and conveyor belts, all designed to handle high throughput efficiently. It
also features a 1.2 million tonne per annum pellet plant, aimed at converting low-grade fines
into valuable iron ore pellets, thus improving resource utilization and minimizing waste. The
Donimalai township itself is a well-planned residential area with housing for employees,
educational institutions such as Kendriya Vidyalaya Donimalai (established in 1974),
hospitals, and recreational amenities, reflecting NMDC’s commitment to employee welfare.

The mine has experienced operational disruptions in the past. Notably, operations were
suspended in 2018 due to lease renewal issues with the Karnataka government. However, after
negotiations, mining resumed in 2021 under a new lease agreement that included a premium
payment structure. This development marked a major policy shift, as Donimalai became one of
the first NMDC mines to operate under a commercial lease model instead of legacy
agreements.

NMDC, a Navratna Public Sector Undertaking under the Ministry of Steel, ensures strict
adherence to environmental and safety norms. The Donimalai project follows a comprehensive
Environmental Management Plan (EMP), which includes afforestation, dust suppression,
water management, and biodiversity preservation initiatives. NMDC has also undertaken
several Corporate Social Responsibility (CSR) initiatives in the surrounding areas, including
investments in health, education, sanitation, skill development, and rural infrastructure.
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In terms of economic impact, Donimalai significantly contributes to the local and national
economy by supporting downstream industries, creating direct and indirect employment, and
generating substantial royalty and tax revenue for the Karnataka state government. The
Donimalai Iron Ore Mine, operated by NMDC Limited, stands as a significant mining
operation in India, located in the Sandur taluk of Bellary district, Karnataka. Established in
1977, this mine has been instrumental in supplying high-grade iron ore to the domestic steel
industry.

1.1 Location & Etymology

 Donimalai is situated approximately 325 km from Bengaluru, nestled amidst forested hills.
The name "Donimalai" is derived from Kannada words: 'Doni' meaning boat and 'Malai'
meaning hill, reflecting the area's boat-shaped hill formation . The township is about 19 km
from Toranagallu Railway Station and 58 km from Bellary
.mmwudonimalai.netlify.app+1Wikipedia+1Wikipedia+1mmwud
onimalai.netlify.app+1

1.2. Operational Overview

 Operator: National Mineral Development Corporation (NMDC), a Navratna Public Sector

Enterprise under the Ministry of Steel, Government of India .Wikipedia+3India
Infoline+3steel.gov.in+3
 Inception: Mining operations commenced in 1977 .Wikipedia
 Capacity: The mine has a designed production capacity of 7 million tonnes per annum
(MTPA) .steel.gov.in+4Environment Clearance+4Global Energy Monitor+4
 Ownership: Fully owned and operated by NMDC .Wood Mackenzie
 Reserves: Estimated total reserves of approximately 127.6 million tonnes .Global Energy
Monitor
 Recent Production:

2022: 5.316 million tonnes

2023: 5.729 million tonnes .steel.gov.in+2Wood Mackenzie+2Wikipedia+2

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1.3. Infrastructure & Facilities

The Donimalai complex encompasses:

 Kumaraswamy Iron Ore Mine: Located nearby, enhancing the region's mining
capacity .NMDC Limited
 Pellet Plant: A 1.2 MTPA pellet plant to process iron ore fines into pellets, adding value to
the raw material .steel.gov.in
 Township Amenities: The Donimalai township offers residential facilities, educational
institutions like Kendriya Vidyalaya (established in 1974), and other amenities for
employees and their families .Wikipedia

1.4. Historical Highlights

 Suspension & Resumption: Mining operations were suspended for two years due to lease-
related issues but resumed in 2021 after NMDC negotiated terms with the Karnataka
government .Wood Mackenzie
 Export: Historically, iron ore from Donimalai was exported through Chennai and
Mormugao (Goa) ports. However, current operations primarily cater to domestic steel
producers .Wikipedia

1.5. Environmental & Social Initiatives

NMDC is committed to sustainable mining practices, focusing on:

 Environmental Conservation: Implementing measures to minimize ecological impact.

 Community Development: Investing in local infrastructure, education, and healthcare
facilities to uplift surrounding communities

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CHAPTER –2

OBJECTIVES OF INDUSTRY

2.1 Resource Exploration and Development:

 To systematically explore, identify, and develop India’s mineral resources, especially iron
ore, but also other strategic minerals like copper, gold, diamonds, and lithium.
 To conduct geological surveys and feasibility studies for expanding the mineral reserve
base, both in India and abroad.

2.2 Sustainable Mineral Production:

 To operate large-scale mechanized mines efficiently, ensuring high productivity with

minimal wastage of natural resources.
 To achieve consistent production targets in alignment with national steel and infrastructure
development goals.

2.3 Value Addition and Downstream Integration:

To establish value-added facilities such as:

 Pellet plants
 Beneficiation plants
 Sponge iron and steel plants
 To move from raw material supplier to value-added product manufacturer, enhancing
profitability and market reach.

2.4 Technological Advancement:

To adopt and implement modern mining technologies such as:

 Autonomous drilling and hauling systems

 Digital mine management (e.g., SCADA, GPS, and sensor networks)

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 Mineral beneficiation techniques for low-grade ores

 To invest in R&D and innovation to improve mining efficiency and reduce environmental
impact.

2.5 Environmental Stewardship:

To carry out mining activities with minimal environmental disturbance by implementing:

 Green mining practices

 Land reclamation and afforestation
 Waste and water management systems
 To comply with national and international environmental laws and sustainability
frameworks.

2.6 Safety and Occupational Health:

 To maintain world-class safety standards for employees, contractors, and stakeholders.

 To ensure zero harm through rigorous implementation of safety protocols, training
programs, and regular audits.

2.7 Social Responsibility and Community Development:

 To undertake Corporate Social Responsibility (CSR) initiatives in healthcare, education,

skill development, and infrastructure development in mining-affected areas.
 To uplift local communities and contribute to inclusive growth and regional development.

2.8 Global Expansion and Strategic Partnerships:

 To expand NMDC’s footprint internationally through strategic collaborations, joint

ventures, and acquisitions in mineral-rich countries.
 To diversify the company’s mineral portfolio beyond iron ore to reduce dependency on a
single commodity.

2.9 Operational Excellence and Cost Efficiency:

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 To maintain competitive cost structures through process optimization, energy efficiency,

and logistics management.
 To increase profitability through better resource utilization, productivity improvement, and
reduced downtime.

2.10 Human Capital Development:

 To attract, train, and retain skilled human resources across disciplines.

 To create a work culture based on innovation, performance, ethics, and inclusiveness.

2.11 Contribute to National Development Goals:

 To support the Indian government’s “Atmanirbhar Bharat” (self-reliant India) and “Make
in India” missions by securing mineral self-sufficiency.
 To contribute significantly to India’s GDP, export earnings, and infrastructure growth.

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CHAPTER – 3
SAFETY MEASURES

3.1. Personal Protective Equipment (PPE):

Mandatory PPE usage is enforced at all operational zones. This includes:

 Safety helmets (IS certified)

 High-visibility jackets
 Steel-toed boots
 Protective gloves
 Safety goggles or face shields
 Dust masks or respirators in dusty areas
 Hearing protection in high-noise zones

3.2. Training and Safety Induction:

 Comprehensive safety induction for all employees, interns, and contractors before
entering the mine site.

Periodic safety drills, mock evacuations, and refresher training on:

 First-aid
 Fire safety
 Hazard identification
 Emergency response
 Specialized training for high-risk jobs like blasting, equipment handling, and working at
heights.

3.3. Monitoring and Supervision:

 Safety Officers are deployed across shifts and departments to ensure compliance.
 Regular safety inspections, audits, and surprise checks are conducted.
 Use of CCTV and surveillance in key operational areas.

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 Deployment of IoT-based monitoring systems in advanced locations to track temperature,

vibration, gas levels, and equipment health.

3.4. Equipment Safety:

 All machinery and vehicles are inspected daily before use (Pre-start Checks).
 Regular Preventive Maintenance (PM) and condition monitoring schedules.
 Use of reverse alarms, fire suppression systems, and automatic braking systems in
dumpers and shovels.
 Enforcement of zero mobile phone use while operating heavy equipment.

3.5. Standard Operating Procedures (SOPs):

 Detailed SOPs for all operations like drilling, blasting, loading, and transporting ore.
 Employees must follow Job Safety Analysis (JSA) before executing any task.
 Strict protocol for handling explosives, including storage in licensed magazines and
transport in specialized vehicles.

3.6. Traffic and Haul Road Safety:

 Clearly marked one-way haul roads with separate paths for light and heavy vehicles.
 Speed limits and designated parking areas within mine premises.
 Use of flagmen and signal lights during loading and blasting operations.

3.7 Blasting Safety:

 Use of delay detonators and electronic blasting systems to control fly rock and vibration.
 Strict demarcation of blasting danger zones with hooters and sirens before each blast.
 Access restricted during blasting periods; complete evacuation of blast zones monitored.

3.8 Fire and Emergency Response:

 Installation of fire extinguishers, hydrants, and fire alarms at critical points.

 Regular fire drills and mock rescue operations.
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 Dedicated emergency control room and quick-response teams.

 First-aid kits and stretchers at every work area, and trained first-aiders on every shift.

3.9 Health and Industrial Hygiene:

 Periodic health checkups and occupational health monitoring (lung function, hearing,
vision, etc.).
 Dust control measures such as water sprinkling, dust extraction units, and green belts.
 Proper sanitation facilities and safe drinking water provision across the worksite.

3.10 Statutory Compliance:

NMDC complies with safety regulations under:

 Mines Act, 1952

 DGMS (Directorate General of Mines Safety) Rules
 Factory Act, 1948 for plant operations
 Environmental Protection Act
 Submission of periodic safety reports and attendance in statutory safety committee meetings.

3.11 Behavioral and Cultural Safety:

 Promotion of a “Safety First” culture among all staff and laborers.

 Safety awards and recognition for employees who demonstrate exceptional safety
practices.
 Encouragement of near-miss reporting and open-door safety feedback policy.

3.12 Digital Safety Enhancements (New Initiatives):

 Use of drones for inspection of high-risk or inaccessible areas.

 Installation of Proximity Warning Systems (PWS) on mining equipment to avoid
collisions.
 Integration of digital twin and real-time monitoring dashboards for safety analytics.

These safety measures are integral to NMDC’s goal of achieving Zero Harm in mining
operations. The company not only follows mandatory regulations but often exceeds them by
adopting global best practices in safety and risk management.

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CHAPTER – 4
OBSERVATIONS OF SUB-STATION
1. Purpose of the Substation:

 The substation observed at NMDC Donimalai acts as a central power distribution hub.
 It receives high-voltage electric power from the state electricity board (like Karnataka
Power Transmission Corporation Limited - KPTCL) or captive power plants.

This power is stepped down and distributed across various operational areas:

 Mine lighting and equipment

 Crusher and conveyor systems
 Pump houses and dewatering units
 Administrative buildings and township

2. Substation Type and Capacity

 The substation is likely an outdoor type with step-down transformer capacity ranging
from 33 kV/11 kV or 132 kV/33 kV, depending on load demand.

It may include:

 Power Transformers (e.g., 10 MVA or higher)

 Distribution Transformers
 Control panels and feeder bays

3. Key Equipment Observed

a. Power Transformers

 Stepped down incoming voltage (e.g., from 132 kV to 33 kV or 11 kV).

 Oil-cooled and conservator-type transformers.
 Equipped with Buchholz relay, temperature gauges, and breather units.

b. Circuit Breakers

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 Used for isolating faulty lines or equipment.

 Types observed: SF6 circuit breakers and Vacuum circuit breakers (VCB).
 Remote control and automatic tripping mechanisms via relay systems.

c. Current and Potential Transformers (CTs & PTs)

 CTs used for current measurement and relay protection.

 PTs used for voltage monitoring and metering purposes.

d. Bus Bars

 Conductive metal bars (usually copper/aluminum) interconnecting multiple components.

 Insulated and mounted on ceramic insulators.

e. Isolators and Earth Switches

 Observed in open position before maintenance.

 Used for physical isolation and grounding of sections before manual work.

f. Lightning Arrestors

 Installed near transformers and incoming lines.

 Protect the substation from lightning strikes and voltage surges.

g. Control Panels and Relays

 Contain protection relays (overcurrent, earth fault, differential, etc.).

 Interface between field equipment and SCADA (Supervisory Control and Data
Acquisition) system.
 Remote control, auto-tripping, and alarm signaling observed here.

4. Safety Features Observed

 Clear safety signage and fencing around HT zones.

 Use of earth mats and grounding to ensure personnel safety.
 Proper maintenance of fire extinguishers, sand buckets, and foam-type extinguishers.

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 Use of PPE by all maintenance staff (insulated gloves, safety shoes, arc flash suits where
necessary).
 Emergency shutdown procedures and lockout/tagout (LOTO) in place during maintenance.

5. Environmental and Maintenance Observations

 Transformer oil levels and temperatures monitored regularly.

 No visible signs of oil leakage or overheating.
 Routine infrared thermography used for hot spot detection.
 Dust and vegetation kept clear around outdoor components.
 Regular checks on earthing resistance values using Earth testers.

6. Learning Outcomes and Understanding

 Learned how power is distributed from grid to end users in an industrial setting.
 Understood the importance of load balancing, transformer protection, and relay
coordination.
 Gained exposure to real-time SCADA monitoring systems.
 Observed coordination between electrical maintenance teams and plant operators for load
scheduling and fault management.

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CHAPTER – 5
TRAINING ACTIVITIES AND DEPARTMENTAL
EXPOSURE
5.1 Power Distribution Systems:
Activities Observed:

 Visit to the main substation (typically 132/33 kV or 33/11 kV) which steps down power
for mine operations.

Distribution of power to critical facilities such as:

Crushers

Conveyors

Dewatering pumps

Township and lighting systems

Key Learnings:

Understanding single-line diagrams (SLDs) and distribution layouts.

Role of transformers, isolators, CTs/PTs, and lightning arrestors.

Concepts of load balancing, demand management, and voltage regulation.

5.2 Substation Equipment and Protection Systems:

Activities Observed:

 Inspection of power transformers, outdoor circuit breakers (VCB/SF6), and control

panels.
 Working of protective relays (Overcurrent, Earth fault, Differential protection).
 Use of battery banks and DC control supply systems.

Key Learnings:

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How protection systems isolate faults and prevent damage.

Importance of relay coordination and fault discrimination.

Real-time monitoring and control through SCADA systems.

5.3 Motors and Industrial Drives:

Activities Observed:

 Operation and maintenance of three-phase induction motors (used for conveyors,

crushers, dewatering pumps).
 Introduction to soft starters, VFDs (Variable Frequency Drives) for speed control.
 Motor control centers (MCCs) and starter panels.

Key Learnings:

Construction and working of motors used in mining.

Troubleshooting techniques for motors and starters.

Application of drives in energy-saving and performance optimization.

5.4 Automation and Instrumentation:

Activities Observed:

 Basics of PLC (Programmable Logic Controllers) used in automated control of crushers

and conveyors.
 Sensors and transducers for measuring temperature, pressure, and level.
 Control room visit to observe HMI/SCADA displays and system feedback.

Key Learnings:

Role of automation in process control and safety.

Communication between field devices and control systems (wired/wireless).

Interfacing of sensors with controllers and alarms.

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5.5 Electrical Safety Practices:

Activities Observed:

 Safety precautions taken before operating HT/LT equipment.

 Procedures for Lock-Out Tag-Out (LOTO) during maintenance.
 Use of insulated tools, arc flash suits, and earthing rods.

Key Learnings:

Importance of safety in high-voltage environments.

First-aid procedures for electrical injuries.

Regular insulation resistance testing, earth pit testing, and equipment grounding
checks.

5.6 Preventive and Predictive Maintenance:

Activities Observed:

 Maintenance schedules for transformers, switchgear, motors, and panels.

 Infrared thermography for identifying hotspots in panels and connections.

Use of testing equipment like:

Megger (for insulation testing)

Multimeters, clamp meters

Earth testers

Key Learnings:

Early detection of faults through predictive maintenance.

Documentation of maintenance logs and fault reports.

Role of preventive maintenance in minimizing downtime.

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5.7 Renewable and Emergency Power Systems:

Activities Observed:

 Solar panel installations in township and admin blocks (if applicable).

 Diesel generator (DG) sets for emergency backup power supply.
 Changeover systems during grid failure.

Key Learnings:

Integration of renewable energy in industrial power systems.

Load prioritization during power outages.

Fuel efficiency and environmental considerations for DG sets.

5.8 Documentation and Engineering Drawings:

Activities Observed:

Study of electrical layouts, panel wiring diagrams, and protection schemes.

 Understanding equipment datasheets, wiring schedules, and as-built drawings.

 Updating of maintenance records and relay coordination charts.

Key Learnings:

Reading and interpreting technical drawings and diagrams.

Importance of record keeping for compliance and troubleshooting.

Exposure to electrical standards (IS, IEEE, IEC norms).

5.9 Overall Experience and Learning Outcome:

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 The internship provided a solid foundation in understanding the electrical backbone of a

mining operation, bridging classroom concepts with practical industrial applications. Key
takeaways include:

Practical knowledge of power systems, motor drives, and industrial automation.

Real-world exposure to safety protocols and preventive maintenance strategies.

Inter-departmental coordination for efficient and uninterrupted operation.

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CHAPTER - 6

OBSERVATIONS OF TELEPHONE EXCHANGE

1. What is a Telephone Exchange?

A telephone exchange is a system that connects telephone calls by switching voice paths
between users on local lines. In industrial or institutional networks, the most common types are:

 EPABX (Electronic Private Automatic Branch Exchange): Analog/digital system for

internal communication.
 IP-PBX (Internet Protocol based PBX): Uses VoIP (Voice over Internet Protocol) to
manage internal calls through computer networks.

Working:

The telephone exchange system at NMDC Donimalai is a critical component of the internal
communication infrastructure, ensuring smooth and uninterrupted voice connectivity between
various departments, operational zones, residential quarters, and external networks. The
exchange is typically composed of both analog and digital communication systems, namely the
EPABX (Electronic Private Automatic Branch Exchange) for internal analog calls and an IP-
based telephone system (IP-PBX) that enables digital communication using data networks. The
hybrid nature of this system allows for a seamless transition from legacy communication
methods to modern, internet-based telephony, catering to a wide range of communication needs
across the mining and township areas.

In the analog system, each telephone connection is wired using a twisted-pair cable—
commonly referred to as the tip and ring—where the "tip" is positive and the "ring" is negative.
These connections are bundled in multi-core cables, often 25-pair, 50-pair, or more, depending
on the building or department's communication requirements. To manage and identify these
numerous pairs, a standardized 25-pair color code system is used. This coding method
combines five primary (major) colors—White, Red, Black, Yellow, and Violet—with five
secondary (minor) colors—Blue, Orange, Green, Brown, and Slate (gray)—to create 25 unique
pairings. For example, the first pair in the cable is White-Blue, the second is White-Orange, the

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third is White-Green, and so on. These color codes are consistent throughout the wiring system,
allowing technicians to identify, trace, and maintain connections efficiently and without error.

The cable pairs are terminated at various distribution points such as the Main Distribution
Frame (MDF) and Intermediate Distribution Frames (IDFs). These termination points use
punch-down blocks, commonly Krone or 110-type blocks, where each cable is securely
connected and labeled according to its destination and extension number. The MDF is typically
located in the main telephone exchange room and connects the internal extension network to
the external service provider lines (such as BSNL). From the MDF, lines are distributed
through IDFs in different buildings or blocks, which then connect to individual office
telephones. In the event of faults like no dial tone, cross-talk, or noisy lines, the color-coded
cable system and centralized patching help technicians troubleshoot and isolate problems
efficiently.

In the digital or IP-based telephone system, communication takes place over the existing Local
Area Network (LAN) using Ethernet cables—typically Cat5e or Cat6—which follow the
T568A or T568B wiring standards. The T568B standard is more commonly used and assigns
specific color codes to each wire pair within the RJ-45 Ethernet cable. The primary pairs
include white-orange/orange, white-green/green, white-blue/blue, and white-brown/brown.
These cables connect IP phones directly to network switches, which are, in turn, connected to
an IP-PBX server. The server handles functions like call routing, voicemail management, call
forwarding, and SIP (Session Initiation Protocol) trunking for external communication. Unlike
the analog system, where voice is transmitted as electrical signals, the IP-based system converts
voice into data packets and transmits them over the network using protocols like SIP and RTP
(Real-Time Transport Protocol).

To ensure reliability and continuity, both analog and digital systems are backed by power
supply units with UPS (Uninterruptible Power Supply) support, especially in critical locations
like the exchange room and control centers. Lightning arrestors and surge protectors are
installed to safeguard the equipment from voltage spikes and electrical surges, particularly
during thunderstorms—a common concern in hilly mining areas. Cable routing is done using
conduits and trays, and all terminations are clearly marked to prevent cross-connection errors.

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CHAPTER – 7
INTERNSHIP ROLE AND RESPONSIBILITY
Department: Electrical Maintenance / Power Distribution / Process Plant Operations
Duration: [From 03 MARCH 2025 to 16 MARCH 2025]
Location: NMDC plant, Sub-station, Telephone exchange, VTC training of aptitude and safety
measures]

RESPONSIBILITIES TAKEN:

1. Substation Operations and Maintenance

Substations are crucial parts of any industrial setup, as they handle the distribution of electrical
power across different sections of the plant. My responsibilities and observations in this section
included:

i. Power Distribution Systems

 Studied the layout and design of substations, including Single Line Diagrams (SLDs)
showing how electricity flows from incoming supply lines to transformers, busbars, and
feeders.
 Understood the functioning of High Tension (HT) and Low Tension (LT) systems in
controlling and stepping down voltage for industrial usage.

ii. Electrical Equipment and Components

 Observed the installation and working of power transformers, current transformers

(CTs), potential transformers (PTs), and lightning arrestors.
 Gained an understanding of the use of circuit breakers (VCB, ACB) and isolators in
power interruption and maintenance safety.

iii. Maintenance Activities

 Participated in routine inspection and preventive maintenance of equipment to avoid

power failures.

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 Helped monitor temperature, oil levels in transformers, and read load current values using
multimeters and clamp meters.

iv. Safety Protocols

 Learned about lockout-tagout (LOTO) procedures and grounding systems to ensure

safety during maintenance work.
 Attended safety briefings on arc flash protection, proper PPE usage, and hazard
awareness.

2. Telephone Exchange System (EPABX)

Efficient communication is essential in large industrial setups like NMDC. The telephone
exchange department ensures reliable internal communication across various departments of
the plant.

i. Introduction to EPABX

 Learned about the Electronic Private Automatic Branch Exchange (EPABX) system,
which acts as a centralized communication system allowing internal calls without using
public telephone networks.
 Observed how extensions are configured and how calls are routed through the exchange
panel.

ii. Wiring and Distribution

 Visited the telephone control room, where cabling and distribution systems were
maintained.
 Assisted in identifying faults in telephone lines and worked on basic troubleshooting
techniques, such as checking line continuity and signal strength.

iii. Practical Experience

 Understood the use of patch panels, jumper wires, line testers, and telephone junction
boxes.
 Monitored how telephone lines are tagged, connected, and maintained for stable and
uninterrupted communication.

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3. VTC (Vocational Training Centre) – Aptitude & Soft Skill Development

The Vocational Training Centre (VTC) at NMDC conducted sessions to prepare engineering
interns for professional roles by enhancing their soft skills and technical aptitude.

i. Aptitude Skill Development

 Attended structured training sessions on quantitative aptitude, logical reasoning,

analytical thinking, and verbal communication.
 Solved problem sets, participated in quizzes, and practiced time management techniques
for competitive exams and interviews.

ii. Soft Skills and Interview Training

 Engaged in mock interviews, group discussions, and public speaking exercises to build
confidence and presentation skills.
 Received feedback from trainers on resume writing, body language, and communication
strategies.

iii. Safety and Industrial Training

 Took part in training on industrial safety measures, emergency protocols, and fire
safety awareness.
 Understood the importance of discipline, teamwork, and punctuality in a professional work
environment.

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CHAPTER – 8

SPECIFICATIONS OF EQUIPMENTS

8.1. Sub-Station

1. Single line diagram(SLD)

Fig.1 Single line diagram(SLD)

i. Incoming Power Supply (33 kV Side)

The SLD starts with incoming 33 kV power supply received from the Gulbarga
Electricity Supply Company (GESCOM) or local grid.

The incoming feeder is connected through Circuit Breakers (CBs) and Current
Transformers (CTs)/Potential Transformers (PTs) for protection and measurement.

The 33 kV incoming line feeds into two main t

ransformers, each rated 5 MVA and stepping down voltage from 33 kV to 11 kV.

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ii. Main Transformers (33/11 kV)

There are two 33/11 kV transformers working either in parallel or as standby-

redundant.

These transformers feed power into the 11 kV HT switchgear panel.

Each transformer has protection relays (like Buchholz relay, overcurrent, earth fault)
and circuit breakers to isolate in case of fault.

iii. 11 kV HT Panel

The 11 kV panel contains:

Outgoing feeders to different plant areas (e.g., beneficiation plant, crushing

unit, workshops)

Vacuum Circuit Breakers (VCBs)

Bus couplers for interconnection between sections

Every outgoing feeder has a protection system and CT/PT metering for current and
voltage monitoring.

Feeders are labeled with designations such as Feeder 1, Feeder 2, etc., indicating
destinations (conveyors, crushers, workshops).

iv. Step-Down Transformers (11/3.3 kV)

There are two 2 MVA, 11/3.3 kV transformers that step down 11 kV to 3.3 kV for use
in specific high-capacity industrial motors.

Used to power heavy machinery such as:

Conveyor drives

Crushers

Ball mills or pump sets

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These transformers also have protection and control circuits.

v. 3.3 kV Switchgear Section

The output from 11/3.3 kV transformers is distributed via 3.3 kV panels.

Each line is equipped with:

VCBs

Protection relays (OCR, EFR)

Control relays and interlocks

Ensures controlled and isolated delivery to motors and process plants.

vi. Measurement & Protection

The SLD shows integration of:

CTs/PTs for voltage and current measurement

Multifunction meters

Relay panels (for monitoring faults like overvoltage, undervoltage, overcurrent,

etc.)

All critical components are monitored from the control room through SCADA/PLC
systems.

vii. Safety & Control Systems

Interlocking mechanisms are in place between busbars and feeders to avoid

simultaneous operations.

Isolators, Earth Switches, and Relay panels are placed for:

Safe maintenance

Arc flash prevention

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Earth fault protection

Why This SLD Is Important in NMDC:

Ensures efficient power flow from the 33 kV supply to various plant systems.

Helps in fault isolation, load management, and maintenance without full shutdown.

Supports redundancy with dual transformers for uninterrupted operations.

Critical for running crushers, conveyors, and beneficiation plants used in mining
operations.

2. Incoming lines

Fig.2 Incoming lines

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i. Incoming 33 kV Line Termination

The three lines at the top represent the three phases (R, Y, B) of the 33 kV supply.

These are coming from overhead transmission lines, likely from a nearby 33/132 kV
grid substation.

They terminate into the substation via pin or post insulators.

ii. Lightning Arrestors (LAs) – Leftmost Section

These are the three vertical devices on top of the incoming structure.

Their role is to protect the substation equipment from:

Lightning strikes

Switching surges or transient overvoltages

They divert high-voltage surges safely to the ground.

iii. Isolator / Disconnector Switches – Manually Operated

Clearly visible in the middle section.

These are horizontal blade switches, one for each phase.

Used to isolate the line for maintenance or in case of a fault, only when no current is
flowing.

Do not interrupt load or fault current – that's the job of a circuit breaker.

iv. Drop-Out Fuse (DOF) or Horn Gap Fuse (if present)

Sometimes visible in these types of installations.

Acts as a sacrificial protective device, blowing off under fault or overload conditions.

Easy to visually inspect and replace.

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v. Busbar or Connection to Breaker Panel (Downstream)

The wires coming down from isolators likely go to:

33 kV vacuum circuit breaker (VCB) panel or

Power transformer input (to step down 33 kV to 11 kV)

vi. Safety Signage and Earthing

Yellow and red warning signs for “33 kV – Danger” clearly shown for safety
compliance.

Earth wires are often connected from lightning arrestors and equipment structures to a
ground grid to safely discharge fault currents.

vii. Flow of Power

Overhead Line (33 kV)

Lightning Arrestors (Surge Protection)

Isolators (Manual Disconnection)

Line Goes to Circuit Breaker or Transformer

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3. Transformer-1

Fig.3 Transformer-1

 Basic Specification:

Rating: 5 MVA (Mega Volt Ampere)

Voltage Ratio: 33 kV / 11 kV

Phase: 3-phase

Cooling Type: ONAN (Oil Natural Air Natural) – as indicated by the large radiators

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i. Main Transformer Body (Core & Windings)

Located centrally.

Contains the primary (33 kV) and secondary (11 kV) windings wrapped around a
magnetic core.

Steps down the voltage from 33 kV (incoming) to 11 kV (distribution side).

Immersed in transformer oil for insulation and cooling.

ii. Conservator Tank (Top Cylinder)

Maintains the oil level in the transformer.

Accommodates oil expansion and contraction due to temperature changes.

Connected to the main tank through a pipe and contains a breather.

iii. Breather (Silica Gel Container)

Usually attached to the conservator tank (not clearly visible, possibly on the opposite
side).

Filled with silica gel that absorbs moisture from the air entering the conservator tank.

Prevents moisture contamination in transformer oil.

iv. Buchholz Relay (If Present, Inline Pipe)

A gas-actuated protective device placed between the conservator tank and main tank
(not visible but usually inline).

Detects internal faults like short circuits, insulation failure by sensing gas
accumulation.

v. Temperature & Oil Level Gauges

Seen in the front panel (the meters on the blue box).

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Oil Temperature Indicator (OTI) and Winding Temperature Indicator (WTI) help
monitor operating conditions.

Essential for transformer health checks.

vi. Radiators (Cooling Fins)

Clearly visible on both sides.

Dissipate heat generated inside the transformer.

Cooled by natural air circulation (ONAN type cooling).

vii. Bushings (Top of Transformer)

High voltage insulated terminals for connecting incoming (33 kV) and outgoing (11 kV)
cables.

Made of porcelain or epoxy resin.

Prevent electrical breakdown and ensure safe connection.

viii. Cable Termination & Earthing

Incoming and outgoing cables are usually terminated at the base or side of the
transformer.

Proper earthing provided for safety and fault clearance.

WORKING PRINCIPLE

Primary Side (33 kV): Receives high voltage supply from the grid or transmission line.

Magnetic Core: Induces magnetic flux between windings.

Secondary Side (11 kV): Delivers stepped-down voltage for internal plant use or local
distribution.

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4. Transformer-2

Fig.4 Transformer-2

 Transformer Specification

Rating: 2 MVA (Mega Volt Ampere)

Voltage Class: 33 kV / 11 kV

Phase: 3-phase

Type: Oil-immersed Distribution Transformer

Cooling Method: ONAN (Oil Natural Air Natural)

Manufacturer (Visible): Siemens

i. Core & Windings (Inside the Tank)

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The heart of the transformer.

Primary winding is connected to 33 kV.

Secondary winding steps down the voltage to 11 kV.

Both are immersed in transformer-grade mineral oil for insulation and cooling.

ii. Conservator Tank (Top Horizontal Cylinder)

Maintains an optimal oil level by accommodating thermal expansion/contraction of

the oil.

Connected to the main tank via a pipe.

iii. Buchholz Relay (Likely between main tank and conservator)

A fault-sensing device (not clearly visible in the image).

Detects gas build-up due to internal faults and trips the transformer to prevent damage.

iv. Breather Unit (Silica Gel)

Located on the right-hand side of the conservator pipe (blue-colored cylinder).

Filled with silica gel crystals that absorb moisture from the air entering the conservator.

Prevents moisture contamination in oil.

v. Radiators (Cooling Fins)

Present on both sides of the transformer.

Dissipate heat from the hot oil as it circulates naturally through the radiator and main
tank.

Cooled by ambient air – no fans or pumps (ONAN type).

vi. Bushings (Insulated Terminals)

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Located at the top of the transformer (not clearly visible in this front view).

Provide a safe entry/exit point for 33 kV and 11 kV cables.

Made of porcelain or composite materials for high insulation.

vii. Oil Level Indicator (OLI) and Temperature Gauges

Located near the top or side.

Ensure safe operation by monitoring oil level and winding/oil temperature.

Prevent overheating and dry-out conditions.

viii. Nameplate (Right-hand side)

Usually contains crucial data:

Serial number

Year of manufacture

Tap changer details

Impedance

Vector group (e.g., Dyn11)

ix. Operation Summary

Table.1

Parameter Details

Input Voltage 33,000 Volts (33 kV)

Output Voltage 11,000 Volts (11 kV)
Power Capacity 2,000 kVA = 2 MVA
Frequency 50 Hz
Cooling ONAN – No external fans/pumps
Phase 3-Phase

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5. 11KV indoor Switchgear room OR Panel room

Fig.5 11KV indoor Switchgear room OR Panel room

i. 11 kV HT Panels (High Tension Panels)

Each vertical cabinet is an HT panel rated for 11,000 Volts (11 kV).

These panels house circuit breakers, protection relays, isolators, metering, and
control systems.

Each panel typically includes:

Table.2

Section Function
VCB (Vacuum Circuit Breaker) Protects the system from overloads and short circuits
Detect abnormal conditions (overcurrent, earth fault,
Relays (like OCR, EFR, UVR)
under-voltage)
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Measure current, voltage, power factor, energy (kWh),

Meters
etc.
Indications LEDs indicate breaker ON/OFF, trip, fault, etc.
Control switches Manual ON/OFF, Auto-Manual modes
Provide measurement inputs for metering and
CTs & PTs (internal)
protection

ii. Feeder Panels

Labeled by numbers (e.g., Feeder-1, Feeder-2, etc.) — each feeds a separate outgoing
line.

These distribute power to different local substations, transformers, or industrial

units.

iii. Incoming & Bus Coupler Panels

One panel receives the incoming 11 kV from the transformer (5 MVA or 2 MVA).

A bus coupler may be used to interconnect two busbars for load sharing or
redundancy.

iv. SCADA or Control Interface (Optional)

Some panels are integrated with SCADA systems (not clearly visible in the image) for
remote control and monitoring.

v. Auxiliary Equipment in the Room

Control desks or mimic panels: Overview of breaker status and line health.

Battery banks (in adjacent room): Provide backup DC power for relay operation and
tripping.

Air conditioning: Maintains temperature to prevent overheating of sensitive relays and

electronics.

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Earthing system: Ensures operator safety by grounding all panel enclosures.

Working Principle

Incoming Supply: 11 kV from transformer enters the main incoming panel.

Distribution via Busbar: Power flows through a busbar that connects to each feeder.

Feeder Circuit Breakers: Each feeder is protected by a VCB, controlled locally or

remotely.

Protection & Monitoring: Relays detect faults and automatically trip breakers when
needed.

Control & Status: Operators monitor loads, power flow, and faults through meters and
indications.

6. 33 Kv Indoor Switchgear Room

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Fig.6 33 Kv Indoor Switchgear Room

i. Labeled Panels:

Clear labels like "33 kV Panel", "BUS PT PANEL", etc.

Danger signboards indicating "DANGER - 33000 Volts" (confirms 33 kV

system).

ii. Control and Instrumentation:

Digital protection relays

Analog meters (Ammeter, Voltmeter)

Selector switches and indication lamps (R/Y/B, Trip, On, Off)

iii. Breaker Handles:

Indicating the use of Vacuum Circuit Breakers (VCB).

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Used to manually operate or isolate feeders.

iv. Feeder Panel Labels:

Example: "33kV GIL 11kV TR2 FEEDER PANEL"

Suggests that this panel feeds a 33 kV to 11 kV step-down transformer (TR2).

v. Bus PT Panel:

Potential Transformer (PT) for bus voltage measurement.

Used for metering and protection logic.

vi. Components and Functions

Table.3
Component Description
Used for switching and protecting high-voltage
VCB (Vacuum Circuit Breaker)
circuits. Quenches arc in a vacuum.
Current Transformers (CTs) Measure current for metering and relay inputs.
Potential Transformers (PTs) Step down voltage for metering and protection.
Relays (like Overcurrent, Earth
Detect faults and trip breakers automatically.
Fault)
Control Switches For local/remote breaker operation.
Indication Lamps Show ON, OFF, TRIP, PHASE indicators.
Displays load current, bus voltage, power factor,
Metering Panel
energy consumed, etc.
Links sections of the switchgear for flexibility and
Bus Coupler/Busbar Sections
redundancy.

Operation Flow

33 kV INCOMING supply enters via an overhead line or underground cable.

The Incoming VCB panel receives and protects the circuit.

Through busbars, the power is distributed to various feeder panels.

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A feeder panel sends 33 kV to a 33/11 kV transformer (e.g., TR2).

After stepping down, the 11 kV output goes to the 11 kV panel room (shown in your
previous image).

Protection relays trip VCBs in case of faults like overload, short circuit, or earth fault.

7. 11 kV Outdoor VCB Panel Room:

Fig.7 11 kV Outdoor VCB Panel Room

i. Panel Sections

South Block Panel (Left):

Clearly labeled.

Likely an outgoing feeder for the “South Block” area.

Older design—might use oil circuit breakers or legacy VCBs.

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North Block Panel (Center):

Similar to the South Block, this is likely an outgoing feeder supplying power to
North Block.

Has an external cable connected — suggests active power distribution.

Modern VCB Panels (Right Side):

These are 11 kV VCB (Vacuum Circuit Breaker) panels.

Panels include:

Protection Relays

Energy meters

Control switches

Indication lamps

Danger signage (3300V/11kV) for safety.

Panel types: likely include Incoming, Bus Coupler, and Outgoing feeders.

ii. Electrical Room Environment

Enclosed, ventilated room with elevated windows and ambient light.

The facility is in Donimalai Township, known for NMDC’s iron ore mining
operations — hence reliable HT distribution is vital.

Cables from the panels lead to external loads (North/South Block buildings,
transformers, etc.).

Components
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Table.4
Component Function
Interrupts current during faults (safe & arc-
VCB (Vacuum Circuit Breaker)
free operation).
Protects feeder lines from faults (OC, EF, UV,
Digital/Numerical Relays
OV, etc.).
Displays current, voltage, power factor,
Meters (Digital/Analog)
energy usage.
Status of breaker (ON, OFF, TRIPPED) and
Indication Lamps
phase availability (R/Y/B).
Control Switches & Push Buttons Manual control for breaker operations.
Danger Labels & Interlocks Ensures operator safety and system integrity.

iii. Purpose of This Room in Power Distribution

This HT switchgear panel distributes electrical power from the incoming 11 kV feeder (likely
from a nearby substation or transformer) to different load centers:

North Block

South Block

Other parts of Donimalai Township (housing, plants, offices)

It ensures:

Reliable 3-phase power delivery

Automatic protection during faults

Monitoring and metering for energy usage

Why VCB and 11 kV?

11 kV is the standard medium voltage for internal power distribution.

VCB (Vacuum Circuit Breaker) is ideal for 11 kV:

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Long life

Minimal maintenance

Safe arc extinction

Summary
Table.5
Feature Description
Location Donimalai Township, Karnataka
System Type 11 kV Indoor HT Switchgear
Application Distributes 11 kV power to township blocks (North/South)
Main Components VCBs, Relays, Meters, Control Switches
Safety Features Interlocks, Indicators, Signage
Power Source 33/11 kV Transformer Output (Incoming Feeder)

8. 11 kV VCB Switchgear Room:

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Fig.8 11 kV VCB Switchgear Room

i. VCB Panels (Main Row on Right)

These panels use VCBs (Vacuum Circuit Breakers) for safe switching and fault
protection at medium voltage.

Clearly labeled with feeder names like "North Block", "South Block", etc.

Components include:

Numerical relays (for protection against overcurrent, earth fault, etc.)

Energy meters (digital and analog)

Ammeter/Voltmeter

Control and status indicators (Red: ON, Green: OFF, Yellow: Trip, etc.)

Mimic diagram painted or stickered for showing the circuit route.

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Manual breaker control switches and push buttons.

ii. Older Panels (Left Side)

Older design with legacy meters and analog indicators.

Marked as "North Block" and "South Block".

These may be auxiliary control panels or connected to different transformers or feeders.

iii. Key Components and Their Functions

Table.6
Component Function
Interrupts circuit safely in case of fault. Works
VCB (Vacuum Circuit Breaker)
in a vacuum to prevent arc.
Protects against overcurrent, earth faults,
Numerical Protection Relay
under/over voltage, etc.
Records energy consumption for each feeder
Energy Meter
(block/section).
Ammeter/Voltmeter Monitors current and voltage on each circuit.
Show breaker status (ON/OFF/TRIP) and
Indication Lamps
phase health (R/Y/B).
Ensures safety awareness about live 11 kV
Danger Signage
circuits.
For manual breaker operation
Control Switches/Push Buttons
(Close/Open/Reset).

How This Works in Power Distribution

Incoming Power:
Power typically comes from a 33/11 kV transformer, stepping down to 11 kV.

Incoming VCB Panel:

First panel receives and controls the 11 kV incoming supply.

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Busbar System:
Distributes 11 kV across multiple feeders inside the panel.

Outgoing Panels (Feeder Panels):

Feeders supply power to different buildings or load centers:

North Block

South Block

Workshops, mining machinery, street lighting, etc.

Protection System:
Each feeder is protected using relays and VCBs. In case of a fault, the respective VCB
trips to isolate the fault without affecting other feeders.

Summary Table

Table.7
Attribute Description
Panel Type 11 kV Indoor HT VCB Switchgear
Main Function Distribute and protect 11 kV power to various blocks
Main Equipment VCBs, Relays, Energy Meters, Control Switches
Protection Devices Numerical Relays, Trip Circuits, Interlocks
Voltage Level Medium Voltage (11,000 volts)
Location Use Township, Mining, Industrial Plant (Donimalai)
Safety Features Danger labels, Mimic diagrams, Interlocks, Lamps

9. Power Distribution Room:

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Fig.9 Power Distribution Room

i. ACDB Panel (Left Side)

Label: Clearly says “ACDB PANEL”

Purpose: Distributes AC (Alternating Current) power to various systems.

Visible Features:

Analog meters: For monitoring voltage and current.

Push buttons and indicator lights: For control and status indication (ON/OFF,
fault, etc.).

MCBs/MCCBs (Miniature/Moulded Case Circuit Breakers): For individual

circuit protection.

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ii. DC Distribution Board (Right Side)

Label: Clearly says “DC DISTRIBUTION BOARD”

Purpose: Distributes DC (Direct Current) power, likely for control systems, protection
relays, or communication devices.

Visible Features:

DC meters: For voltage/current monitoring.

DC MCBs/Fuses: For protecting DC circuits.

Control knobs or switches

iii. General Room Layout:

Located indoors with barred windows for ventilation.

Rubber mats on the floor: These are insulating mats for operator safety (preventing
electric shocks).

Cable ducts and pathways seem to be installed behind or under the panels.

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10. RTCC Panel(Remote Tap Changing Control Panel):

Fig.10 RTCC Panel(Remote Tap Changing Control Panel)

i. Transformer Info:

Two transformers are monitored:

TRAFO-I

TRAFO-II

Rating: 5 MVA, 33/11 kV, Step-down transformers (used in power distribution)

ii. Panel Functions:

Remote Voltage Regulation: Allows changing the tap of the transformer remotely to
maintain constant secondary voltage despite load variations.

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Monitoring: Real-time parameters such as voltage, tap position, load current, and
frequency.

iii. Visible Instruments and Indicators:

Digital Voltmeters/Ammeter Displays:

Shows primary and secondary voltages and currents.

Red “apn” display indicates active phase monitoring.

iv. Analog Meters (Ammeters/Voltmeters):

Provide real-time line voltage or current.

v. Tap Position Indicators:

Located near the bottom in rectangular windows (red LED display showing
numbers like "11").

vi. Control Switches & Push Buttons:

For raising/lowering tap position.

For auto/manual mode selection.

Emergency stop buttons.

vii. Alarm Indicators (LEDs):

Red and yellow lamps likely indicate faults (e.g., overvoltage, tap changer
failure).

Buzzer (sound alarm) may be part of the setup.

viii. Protection Relays:

Likely included internally or externally connected.

Ensure the transformer is protected from faults or overloading.

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ix. Nameplate & Branding:

Manufacturer: Schneider Electric

Transformer capacity and panel name clearly labeled.

11. Outdoor Substation Structure

Fig.11 Outdoor Substation Structure

i. Visible Structure:

The metallic frames and insulators support high-voltage conductors.

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You can see large black insulated cables coiled and connected — these are high-
tension power cables, likely feeding to or from a transformer or switchgear.

ii. Signboard Reads:

“WTP S/S” – This likely stands for:

WTP: Water Treatment Plant (or similar facility name)

S/S: Substation

This means the feeder or connection seen is associated with the Water Treatment Plant
Substation.

iii. Foundation & Protection:

All structures are mounted on cement concrete foundations with gravel bed — a
standard design to:

Minimize step potential.

Improve drainage.

Reduce growth of vegetation.

Blue markings on bases indicate demarcation and possible earthing points.

iv. Surroundings:

The substation is fenced with barbed wire for safety.

Located in a semi-rural or industrial area, which matches Donimalai’s

mining/industrial zone.

v. Components Possibly Present (though not all visible):

Lightning Arresters

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Insulators

Isolators/Disconnectors

CTs & PTs (for metering and protection)

Incoming/Outgoing feeders

Busbars

8.2. Telephone exchange

1. Telephone Distribution Frame:

Fig.12 Telephone Distribution Frame

i. Terminal Block Rows:

Each row has terminals where pairs of wires (twisted-pair) are terminated.

Typically used for analog signal routing, voice lines, or control signals in:

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Telephone exchanges

Electrical substations

Control rooms

SCADA systems

ii. Number Labels (1–20):

A handwritten chart on the side labels each terminal pair (for identification).

Used to easily trace wiring during maintenance or fault finding.

iii. Wiring:

The connected wires are twisted pairs, with color codes (like red-white, green-white,
etc.) which follow standard telephone/control wire color coding.

The wiring technique is looped and soldered or punched down, depending on the type
of block.

iv. Mounting Surface:

All terminals are mounted on a wooden or bakelite board, secured with bolts.

This is an older or more traditional method, typically seen in legacy telecom or

substation panels.

2. Fuse Type Tag Block:

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Fig.13 Fuse Type Tag Block

i. Glass Fuses:

Each horizontal slot contains a glass cartridge fuse, usually rated for low current
(typically mA to a few amps).

The fuses provide overcurrent protection for each signal line—preventing damage to
control systems or RTUs in the event of faults.

ii. Numbered Identification Chart:

On the side, there's a list (handwritten or printed) for easy reference.

Each fuse corresponds to a specific signal line or terminal circuit.

iii. Terminals Behind the Block:

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The other side (as shown in the previous image) contains terminals where the incoming
and outgoing wires are connected.

The fuse is in series between the two terminals (protecting the load side).

How It Works:

Input Signal Wire comes from the field or another panel and is connected to one side
of the fuse.

Output Wire goes to the control system (e.g., SCADA, RTU, PLC, protection relay).

If a short circuit or overload occurs, the fuse blows, isolating the fault and protecting
the equipment.

Technicians can visually identify a blown fuse and replace it easily.

3. Relay Room Tag Block Panel:

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Fig.14 Relay Room Tag Block Panel

i. What is a Telephone Exchange?

A telephone exchange is a system that connects telephone calls by switching voice paths
between users on local lines. In industrial or institutional networks, the most common types are:

 EPABX (Electronic Private Automatic Branch Exchange): Analog/digital system for

internal communication.
 IP-PBX (Internet Protocol based PBX): Uses VoIP (Voice over Internet Protocol) to
manage internal calls through computer networks.

Working:
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The telephone exchange system at NMDC Donimalai is a critical component of the internal
communication infrastructure, ensuring smooth and uninterrupted voice connectivity between
various departments, operational zones, residential quarters, and external networks. The
exchange is typically composed of both analog and digital communication systems, namely the
EPABX (Electronic Private Automatic Branch Exchange) for internal analog calls and an IP-
based telephone system (IP-PBX) that enables digital communication using data networks. The
hybrid nature of this system allows for a seamless transition from legacy communication
methods to modern, internet-based telephony, catering to a wide range of communication needs
across the mining and township areas.

In the analog system, each telephone connection is wired using a twisted-pair cable—
commonly referred to as the tip and ring—where the "tip" is positive and the "ring" is negative.
These connections are bundled in multi-core cables, often 25-pair, 50-pair, or more, depending
on the building or department's communication requirements. To manage and identify these
numerous pairs, a standardized 25-pair color code system is used. This coding method
combines five primary (major) colors—White, Red, Black, Yellow, and Violet—with five
secondary (minor) colors—Blue, Orange, Green, Brown, and Slate (gray)—to create 25 unique
pairings. For example, the first pair in the cable is White-Blue, the second is White-Orange, the
third is White-Green, and so on. These color codes are consistent throughout the wiring system,
allowing technicians to identify, trace, and maintain connections efficiently and without error.

The cable pairs are terminated at various distribution points such as the Main Distribution
Frame (MDF) and Intermediate Distribution Frames (IDFs). These termination points use
punch-down blocks, commonly Krone or 110-type blocks, where each cable is securely
connected and labeled according to its destination and extension number. The MDF is typically
located in the main telephone exchange room and connects the internal extension network to
the external service provider lines (such as BSNL). From the MDF, lines are distributed
through IDFs in different buildings or blocks, which then connect to individual office
telephones. In the event of faults like no dial tone, cross-talk, or noisy lines, the color-coded
cable system and centralized patching help technicians troubleshoot and isolate problems
efficiently.

In the digital or IP-based telephone system, communication takes place over the existing Local
Area Network (LAN) using Ethernet cables—typically Cat5e or Cat6—which follow the
T568A or T568B wiring standards. The T568B standard is more commonly used and assigns

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specific color codes to each wire pair within the RJ-45 Ethernet cable. The primary pairs
include white-orange/orange, white-green/green, white-blue/blue, and white-brown/brown.
These cables connect IP phones directly to network switches, which are, in turn, connected to
an IP-PBX server. The server handles functions like call routing, voicemail management, call
forwarding, and SIP (Session Initiation Protocol) trunking for external communication. Unlike
the analog system, where voice is transmitted as electrical signals, the IP-based system converts
voice into data packets and transmits them over the network using protocols like SIP and RTP
(Real-Time Transport Protocol).

To ensure reliability and continuity, both analog and digital systems are backed by power
supply units with UPS (Uninterruptible Power Supply) support, especially in critical locations
like the exchange room and control centers. Lightning arrestors and surge protectors are
installed to safeguard the equipment from voltage spikes and electrical surges, particularly
during thunderstorms—a common concern in hilly mining areas. Cable routing is done using
conduits and trays, and all terminations are clearly marked to prevent cross-connection errors.

4. SCADA Communication Rack / Control System Rack:

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Fig.15 SCADA Communication Rack / Control System Rack

i. Modular Rack System (Top 4 Shelves):

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These shelves house modular control units, which appear to be:

PLC CPUs / RTUs: These are programmable controllers or Remote Terminal Units
responsible for logic control and data acquisition from field devices.

I/O Modules: Each black slot is typically a digital/analog input-output module for
monitoring sensor and relay states.

Power Supply Modules: Likely present at the edge of each rack (where caution
symbols are visible).

ii. Communication Cables and Labeling:

Ethernet / Serial cables are used to interconnect the racks and modules for
communication (IEC 104, Modbus, PROFINET).

Tags are attached to the cables for signal tracing (e.g., RTU1-TX, COMMS2-IN).

iii. Bottom Unit (Communication Switch Panel):

This section includes:

Managed Ethernet Switches (Siemens SCALANCE or similar): For network routing

and secure communication.

Communication Gateways: Converting signals between field protocols (e.g., Modbus

RTU to IEC 61850 or DNP3).

Multiple RJ45, Fiber, or Serial Ports are visible — indicating SCADA networking.

CHAPTER-9
ADVANTAGES, DISADVANTAGES AND APPLICATIONS
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9.1 Advantages of Telephone Exchange System:

1. Centralized Communication

 Ensures smooth internal communication across all departments and units.

2. Cost-Effective

 Internal calls via EPABX/IP-PBX reduce dependence on external telecom networks.

3. Quick Access with Extensions

 Simple extension dialing enables faster communication within the organization.

4. Emergency Connectivity

 Enables quick contact with fire stations, hospitals, and security teams during emergencies.

5. Flexible Integration

 Supports both analog and digital systems (VoIP/IP phones), ensuring long-term scalability.

6. Ease of Maintenance

 Color-coded cabling and structured layout allow easy troubleshooting and repairs.

7. Advanced Features

 Voicemail, call forwarding, auto-attendant, and conferencing improve communication

efficiency.

8. Reduced Downtime

 Battery backups (UPS) ensure the system stays functional during power failures.

9. Secure Communication

 Internal network reduces chances of interception or external interference.

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10. Supports Operational Coordination

 Essential for routine updates, production communication, and inter-departmental

collaboration.

9.2 Advantages of Electrical Substation:

1. Reliable Power Distribution

 Ensures continuous and safe supply of electricity to the entire mining and township area.

2. Voltage Regulation

 Steps down high-voltage grid power to safe levels for plant and residential use.

3. Operational Continuity

 Maintains power to critical operations like crushers, conveyor belts, lighting, and control
systems.

4. Safety Systems

 Equipped with circuit breakers, relays, and lightning arrestors to protect equipment and
personnel.

5. Load Management

 Allows balanced distribution of electrical load to prevent system overloads.

6. Backup and Redundancy

 Often includes alternate supply routes or transformer units for uninterrupted supply.

7. Energy Efficiency

 Proper voltage regulation and transformer sizing reduce power losses.

8. Central Monitoring

 Supervisory systems (like SCADA) allow real-time control and fault analysis.

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9. Support for Expansion

 Scalable to handle additional loads when plant or residential capacity increases.

10. Critical Infrastructure Backbone

 Supports all plant machinery, buildings, lighting systems, and communication equipment.

9.3 Disadvantages of Telephone Exchange System:

1. High Initial Installation Cost

 Setting up an EPABX or IP-PBX system with wiring, hardware, and configuration can be
expensive.

2. Complex Cabling and Maintenance

 Multi-core cable management and fault tracing in analog systems require skilled
technicians.

3. Limited Mobility in Analog Systems

 Traditional landline phones are fixed and not portable, unlike mobile or wireless systems.

4. Risk of Line Faults

 Twisted-pair cables are susceptible to damage, moisture, and interference, leading to call
drops or noise.

5. Power Dependency

 In case of UPS or power backup failure, communication can be disrupted.

6. Scalability Issues in EPABX

 Traditional systems have limited capacity for expansion without replacing hardware.

7. Obsolescence of Analog Equipment

 Analog systems may become outdated with the advancement of digital VoIP technologies.

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8. Cybersecurity Risk in IP Systems

 VoIP systems, if not secured properly, may be vulnerable to hacking or unauthorized

access.

9.4 Disadvantages of Electrical Substation:

1. High Installation and Maintenance Costs

 Building and maintaining substations with transformers, switchgear, and protection

systems is costly.

2. Complex Operation

 Requires skilled electrical engineers and regular monitoring to operate safely and
efficiently.

3. Risk of Electrical Hazards

 High-voltage systems pose serious risks like electric shock, arc flashes, or equipment
explosions if not handled properly.

4. Space Requirements

 Substations require large, secure areas which may not be available in space-constrained
environments.

5. Susceptibility to Environmental Damage

 Outdoor equipment is exposed to weather, lightning, and dust, requiring regular

inspections and cleaning.

6. System Failures Can Halt Operations

 Any major fault in the substation can cause widespread power outages, affecting mining
and residential areas.

7. Noise and Heat

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 Transformers and other components generate noise and heat, which may require cooling
and soundproofing solutions.

8. Regulatory and Safety Compliance

 Must comply with stringent government and safety regulations, increasing administrative
workload.

9.5 Applications of Telephone Exchange System:

1. Internal Communication

 Enables fast and reliable communication between departments such as mining, electrical,
mechanical, administration, and security.

2. Emergency Services Access

 Connects critical departments like hospitals, fire stations, and security control rooms
through dedicated emergency lines.

3. Administrative Operations

 Supports daily operations, meetings, and coordination between management and field
personnel via internal calling.

4. Residential Communication

 Connects residential quarters to central offices for routine services and urgent
communication needs.

5. Public Address System Integration

 Can be connected to PA systems to make announcements across work zones or residential

areas.

6. Call Logging and Monitoring

 Tracks call records for auditing, productivity analysis, and resolving internal issues.

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7. Interfacing with IP Networks

 Modern IP-PBX systems allow integration with LAN/WAN for unified communication,
including video and messaging.

8. Hotline Setup

 Enables direct lines between key operational units for faster coordination and decision-
making.

9.6 Applications of Electrical Substation:

1. Power Distribution

 Distributes electrical power to all plant sections, including crushers, conveyor belts,
processing units, and lighting systems.

2. Voltage Transformation

 Steps down high-voltage electricity from transmission lines to suitable levels for industrial
and residential use.

3. Load Regulation and Balancing

 Ensures balanced power supply across various departments to avoid overload and maintain
system stability.

4. Power Supply to Residential Areas

 Provides electricity to staff quarters, schools, hospitals, and recreational facilities within
the township.

5. Support for Electrically Operated Machinery

 Supplies power to heavy equipment like pumps, compressors, and control systems used in
mining operations.

6. Emergency Power Routing

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 Ensures backup and rerouting of electricity during equipment failures or maintenance

activities.

7. Energy Monitoring and Control

 Equipped with SCADA or manual systems to monitor power usage and efficiency, aiding
in energy conservation.

8. Fault Isolation and Protection

 Detects and isolates faults quickly using relays and breakers to protect machinery and
ensure safety.

CHAPTER-10
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CONCLUSION

The internship at NMDC Donimalai provided an invaluable opportunity to gain

firsthand experience in the functioning of a large-scale industrial and mining
organization. The exposure to various departments, particularly the Electrical,
Electronics, Substation, and Telephone Exchange units, offered deep insight into
the core infrastructure that supports continuous operations in such a complex
environment. Observing the substation operations helped understand the critical
aspects of power distribution, protection systems, and load management, while
the telephone exchange department demonstrated the importance of effective
communication networks in ensuring smooth coordination and emergency
responsiveness. Practical exposure to structured cabling, equipment layouts, safety
protocols, and real-time problem-solving greatly enhanced technical understanding
and professional confidence. Overall, the training bridged the gap between academic
learning and industrial practice, developing both technical knowledge and a sense of
responsibility in working within a disciplined, safety-driven, and process-oriented
environment. This experience has laid a strong foundation for future endeavors in
the fields of electrical and electronics engineering.

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REFERENCES

 mmwudonimalai.netlify.app+1Wikipedia+1Wikipedia+1mmwudonimalai.netlify.app
+1

 Wikipedia+3India Infoline+3steel.gov.in+3

 steel.gov.in+4Environment Clearance+4Global Energy Monitor+4

 Global Energy Monitor

 steel.gov.in+2Wood Mackenzie+2Wikipedia+2

 NMDC Limited

 steel.gov.in

 Wikipedia

 Wood Mackenzie

 Wikipedia

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