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Case Studies - Urban Planning

Assignment: Infrastructure development of two cities, Jodhpur and Bikaner in Rajasthan and commissioned by the Government of Rajasthan under Rajasthan Urban Infrastructure Development Plan

The assignment received the Infrastructure Excellence Award in the category of Best Design Project.

Scope :Road sector: Traffic studies and solutions for single lane, two lane and four lane carriageway; bituminous and concrete roads and construction of bridges over railway crossing were proposed.

The drainage sector: The plan for construction of 52 km length of drains and re-sectioning / strengthening of existing drains, providing solutions for flood prone areas of Jodhpur and Bikaner proposed.

Solid Waste Management: Centralised solutions for collection of waste using modern equipment and disposal through landfills was proposed.

Slum Improvement: Area development works like roads, sewerage, drains and water supply facilities in slum areas of Jodhpur and Bikaner.

Water & Sewerage Sector: water treatment plant, two packages for transmission network, distribution network strengthening and NRW management, water distribution stations, construction of new pumping station, refurbishment of existing pumping machineries, raw water earthen impounding reservoir, technology solutions for distribution of water, ELSRs/GLSRs ,sewerage collection network and out fall sewer, one 20 MLD sewage treatment plant, technology solutions for sewage management was proposed.

Fire-fighting Systems: Fire station buildings consisting of four garages in each fire station along with Drill Tower for training was proposed. Fire service equipment for six cities was tendered. TCE's solutions helped put safety systems in place in the towns.

GIS and Mapping: A database covering details of existing water supply, sewerage pipelines and proposed utilities under different contracts is prepared for Jodhpur and Bikaner.

Heritage: The proposal included environmental improvement of water bodies and conservation/restoration of old heritage sites.

Emergency Health Services: Construction of advanced medical facilities and improvement/extension of satellite hospitals and dispensaries in Jodhpur and Bikaner were proposed.

The Challenge: The project had components from different disciplines and necessitated the deployment of experts from various fields. Working with three associate consultants and applying its singular expertise in individual sectors in one large area, called for a lot of coordination and precision in planning.

Value Additions: People living in the area round Khatarnak Puliya and Raikabagh in Jodhpur were relieved from the water logging menace thanks to the drainage solutions provided by TCE.

112 Kacchhi bastis of Jodhpur and Bikaner were benefited by the slum improvement solutions. 20,000 households in Bikaner came under the property connections network and 33000 households in Jodhpur came under the sewerage collection network bringing a source of revenue for the Bikaner and Jodhpur townships

The proposed water system was planned keeping in mind climate change concerns and a focus on reducing the carbon foot print. Total cost of energy for existing system was Rs 2.12 per Kl. After re-organisation of water system, the energy cost for the combined system has become Rs 1.41/Kl. This has resulted in total energy cost saving of Rs 222 lakhs per annum.

The rehabilitation of slums, makeover of an abandoned lake, increase in revenue by bringing consumers in the fold of the water and sewer disposal network, flood and water logging solutions, etc benefitted nearly 1,90,000 people

 

Case Study: ITER - India

ITER is an international fusion reactor which is being constructed under the collaborative efforts of seven participating countries namely European Union, United States of America, Russia, Japan, Korea, China and India. The main objective of ITER is to demonstrate the scientific and technical feasibility of a controlled fusion reaction by producing about 500MWth of fusion power by Deuterium - Tritium Plasma at Cadarache, France.

The Indian scope of the project is being accomplished through ITER India, Institute for Plasma Research (IPR), an autonomous institute under Department of Atomic Energy (DAE), Government of India. ITER-India has entrusted TCE the responsibility for detailed engineering of the project for Component Cooling Water System (CCWS), Chilled Water System (CHWS) and Heat Rejection System (HRS).

A team from Tata Consulting Engineers is currently working on these assignments. For the systems engineered by Tata Consulting Engineers, the scope of work ranges from design basis report and system optimization to tender specifications. It also includes Reliability, Availability, Maintainability and Inspectability analysis (RAMI) and Failure Modes, Effects and Criticality analysis (FMECA).

 

Power System Control Revised Case Study

Interruption of power supply and its impact can have serious repurcussions on the production cycle, facilities, equipment performance and human productivity. Power outage management is a critical area were technology solutions are required to mitigate the impact of power outages. There are a number of measures available to minimize the possibility of occurrence of black outs, or, mitigate its adverse effects on important class of consumers.

Electric power system comprises components and systems like Generators, transformers, transmission lines and distribution networks, each of which is liable to be affected by insulation failure, due to over voltage or over load. They may also fail under normal service conditions owing to aging or poor quality of material or of manufacturing process. The conductors comprising the transmission and distribution network are also exposed to the elements like lightning, rain, wind, snow etc. which can cause short circuit faults or otherwise damage supporting structures. Insulation failure due to any of these causes lead to trip outs and other disturbances which at times be severe enough to culminate in wide spread power outages or black outs.

 

Bengal Aerotropolis Project Limited (BAPL), Burdwan district of West Bengal

Project features:

Simultaneous development of Underground Coal Mines and Aerotropolis

The Project area hosts a number of regionally persistent coal seams having substantial reserves and also rich in Coal Bed Methane (CBM).

Tata Consulting Engineers conducted various technological investigations to assess the possibilities for simultaneous development of BAPL Project, underground mining of coal and plan of exploitation of CBM. Tata Consulting Engineers carried out the studies in the following three stages:

Impact assessment

Preparing a mining plan and Detailed Project Report for Underground mining with zero subsidence at surface

Approach to exploit CBM potential within the BAPL project area from outside the BAPL area.

On the basis of TCE investigations, the BAPL Project was given 'green signal' by the West Bengal State Government in consultation with Ministry of Coal (MoC) and Ministry of Aviaion (MoA).

 

Towards cleaner sponge iron manufacturing
in West Bengal - World Bank funded Sector Study of Sponge Iron Industry

A World Bank funded initiative, the West Bengal Pollution Control Board appointed Tata Consulting Engineers a sector study of sponge iron (SI) industry in West Bengal in 2012-13.

The Challenge

The principal alternative route in iron making is Direct Reduction of Iron (DRI) by use of coal. The sponge iron sector is characterized by operators ranging from small scale capacity of maximum 50 or 100 tpd units to large scale enterprises of about 500 TPD. The process is dependent on sized iron ore and non-coking coal of 25% ash content.

Due to the scarcity of such non-coking coal with 25% ash content the industry depends on high ash coal which results in inferior product quality as well as poor environmental compliance.

Assignment Scope

Tata Consulting Engineers was entrusted with the assessment of Environmental pollution impact of sponge iron units in West Bengal vis-à-vis the rest of India and suggest clean technology options.

This includes scope for use of clean coal bed methane (CBM), which is available in Eastern coal fields and use in direct reduction substituting coal partially in 60 sponge iron (SI) units across West Bengal. This would ultimately lead to a path for future technology transformation to gas based reduction with CBM. About 10 (ten) SI units has been visited for monitoring the emissions and assessing the status of environmental management and overall nearly sixty (60) Units surveyed in five (5) districts of West Bengal.

The Study Report aims at facilitating capacity build up of Environmental Compliance Assistance Centre (ECAC), an independent Centre presently under WBPCB in achieving environmental compliance and directing the policy decision makers and industry stakeholders for a re-positioning of this industry sector throughout India in the years ahead.

Value Additions

Tata Consulting Engineers carried out the studies from the environmental, commercial and technological angle and put forth recommended solution such as Tunnel Kiln technology, coal quality management, etc. The assessment report and recommendations are expected to benefit the state of West Bengal and the sponge iron industry sector here.

 

Turnkey execution of India's largest blast
furnace for steel plant in Rourkela

Scope:

Rendered civil and structural works comprising furnace foundation, 4-poster structure, equipment foundation, roads, railway tracks, drawing and sewerage. Utilities and auxiliaries comprised off furnace cooling system, compressed air, nitrogen, steam, oxygen for blast furnace proper, gas cleaning plant, cast house, bell-less top charging system, stove valve cooling, air-conditioning and ventilation systems.

Value Additions:

The plant construction and commissioning was been done in a record time and in line with international stand.

Innovative engineering solutions:

Design and engineering of 4-poster structure thereby eliminating the need for pouring concrete into the hollow structures Engineered sequence of installation of the down comer connecting blast furnace and gas cleaning plant

Blast furnace foundation was designed, critically examined and approvals for construction procured to suit site conditions such that no re-engineering was called for.

Design/Engineering of systems and sub-systems were critically examined to enable problem-free construction.

Design inputs from various agencies were compiled and integrated in design for construction in record time. State-of-the-art safety solutions were provided in design, basic engineering inputs, operational maintenance, extensive fire fighting systems, fire detection systems were incorporated and gratings were provided to ensure accident-free operations.

The innovations, safety measures and timely delivery provided cost efficiencies to the client

 

Case Study: Asia's largest decorative paint
facility with capacity of 300,000 kl per annum of paint

Scope

Tata Consulting Engineers was entrusted with basic and detail engineering, procurement services, inspection and expediting and construction supervision services for the decorative paint plant.

Value added

'Pigging' technology solution helped reduce the complexity of the plant, simplified the piping lines and made it easier for plant automation. This involved the pigging for transfer of liquid raw materials and products. This technology helps transfer various chemicals through a dedicated pipe and is also useful in cleaning the pipelines. This helped to reduce the number of transfer lines thereby reducing the complexity of the plant around the equipment. By simplifying the piping requirements, it is possible to make the plant fully automatic. An automatic equipment cleaning system (automatic CIP) system was also part of the engineering plan.

The design engineering and planning was done on a fully-integrated 3D engineering platform with a client review interface. This helped in infusing predictability to the project. PDMS modelling of entire plant including civil, underground facilities, mechanical, equipment, piping, electrical and instrumentation also ensured greater accuracy and quality in the design.

Plant designed on zero discharge concept

Waste management solutions reduced fresh water intake. The 100% tertiary treatment and recycle of sewage reduced fresh water intake by about 40% ..

Around 30% of total plot area has been ear-marked as green-belt zone

 

Technology & cultural integration – Construction management for Brownfield coke oven and by-product

The construction management of this huge plant with 88 oven chambers meant - Bringing together 11 domestic and international partners,

Interpreting Chinese technology and implementing in Indian conditions, Multiple Indian contractors to be oriented into stringent safety standards & all this managed with no downtime of existing plant.

Technological feats

Dismantling top structural arrangements and brick lining five layers of top coming from a height of 145 meters for a chimney from the outer-side

Erection of coal conveyor gallery between two coal towers at a height of 54 metres.

Construction of junction house and coal conveyor gallery with 12 metres depth alongside existing coal conveyor

Installation of large numbers of stainless steel burner pipes, cleaning nozzle pipes in each block of battery within very close tolerance for their locations.

Construction and retrofitting of new cooling tower in by-product area and dismantling of existing cooling tower for clearing front for scrubbers and compressor house.

Construction of cooling tower basin on the roof of process chiller plant

Construction of 68 metres high quenching tower wall along with refractory work and installation of de-dusting nozzles at 58 and 43 metres inside the quenching tower

 

International safety standards,commissioning
in record time and retrofitting with no downtime

There were several other challenges especially on account of retrofitting a large facility upgrade with no downtime. These challenges were addressed with innovative solutions which have now become benchmark practices for such a facility erection. The Construction Service unit helped to commission the plant in record time and in concurrence with international safety standards.

 

Skill Building Programs

IT-enabled drafting for ITI Students

Objective:

Employability for students in the ITI courses

Program execution:

Independent program conducted by TCE employees

Computer aided design (CAD) and mechanical drafting are entry level skills that are core to our design engineering services. Several technical institutes in India have the draftsman trade in their curriculum. These courses are taken up by youngsters who cannot afford regular skill building programs. However these trades do not involve computer and IT applications. This skill gap which makes the youngsters enrolled in the government-supported ITI programs more employable is met with our unique Draftsman Design Application course as a CSR & Affirmative Action initiative.

TCEndeavour's Affirmative Action program to provide education and employability is designed to impart practical knowledge in TCE's core expertise. This program will help increase employability of SC/ST students with requisite qualifications. The plan is to provide training in IT drafting applications for 2nd year SC/ST students in the ITI draftsman trade. The program comprises three levels of training – Basic, Advanced & Specialist with a certification at the end of each level.

The pilot program is presently running in Bangalore and Chennai as a series of weekend courses. The TCEndeavour Champs

Volunteered to serve as Trainers. The students found the program extremely relevant as the training filled a skill gap in their regular ITI program. The students in Bangalore requested a fast-track course and completed the basic program in time for their ITI campus job interview schedules. The basic course covers the basics in AUTOCAD drafting application. This will provide students an edge over others in the campus recruitments.

The advanced course entails detailed application orientation that will help students qualify for apprenticeships in the industry. The specialist programs will involve training in piping, electrical and aspects of detailed design engineering. Students will be provided a certificate once they complete and qualify at each phase of the program. The basic course for the students in the pilot program is complete and some students found placements in the industry. The program will be extended to other locations in a phased manner.

 

Pollution Management Solutions

Scope:

Tata Consulting Engineers was appointed consultants to a steel-making giant for pollution control and emissions management

Objective :

To meet and exceed stringent environmental norms recommended to manage the overall ambient air quality.

Value Added:

Tata Consulting Engineers helped commission a CEMS (Continuous Emission Management System) which has ensured greater transparency and commitment by the client.

Tata Consulting Engineers' technology solutions helped in selecting the appropriate air pollution control equipments to reduce the stack emissions. The design also takes care of workplace air quality to maintain OSHAS norms. The project was carried out in a Brownfield site with operational challenges of shutdown requirement, space crunch and safety requirements.

Tata Consulting Engineers has recommended solutions for continuous improvement and the system is among the largest in the country.

 

Resource conservation in the infrastructure planning of an Aerotropolis township

Scope:

Design and project management of integrated infrastructure for the township of 1,700 acres covering water, sewerage, drainage, solid waste management, fire, disaster management, electrical distribution, telecommunication, safety and security aspects.

Value Added:

The solution proposed included rainwater harvesting and water management designed to retain 22 ponds covering over 11 hectares of area. These ponds are being preserved and over 300 ml of rainwater will be harvested in these ponds. The drainage system has been planned to route the surface water runoff surrounding through these ponds. The annual mass balance for the ponds reveals that at least, minimum water level will be maintained through summer.

Based on zero discharge concept, sewage generated from the township is proposed to be treated by Sequential Batch Reactor ( SBR ) process at the sewage treatment plant. It is proposed to provide tertiary treatment. Post tertiary treatment, the treated sewage water will be used for flushing and irrigation. The prescribed solution will result in 50% reduction of fresh water intake from 38 mld to 18 mld

Press Releases

  • September 7, 2015 Tata Consulting Engineers geared to serve as solutions partners to co-create value in Africa
  • November 13, 2014 KPMG lists world's most innovative Indian infrastructure projects. TCE is proud to have partnered with two of them
  • Tata Group's Bombay House is the first heritage building to receive the Benchmar Sustainability Gold rating
    Ecofirst team converted a 90-year-old heritage structure into a benchmark for environment-friendly buildings View Link
  • February 2, 2014 Amsterdam ArenA enters Indian market through local tie-ups.
  • February 2, 2014 Ecofirst Services signs MOU with Amsterdam ArenA for developing sports infrastructure.
  • September 24, 2013 Tata Consulting Engineers Ltd. & Autodesk announce strategic partnership to bring Building Information Modeling (BIM) Solutions for the Building and Infrastructure sectors.
  • 14 May, 2013 Tata Consulting Engineers Inaugurates Delivery Centre at NCR.
  • 18 March, 2013 Tata Consulting Engineers to provide Project Management Consultancy for Dangote Group's $1.9 billion fertilizer plant.
  • February, 2013 Issue Chemical Engineering World, February 2013 Issue Panel Discussion with Mr J P Haran, Managing Director Tata Consulting Engineers and key leaders on their capabilities and their strategies to deal with the prevailing issues in the EPC industry.
  • 5 February, 2013 Tata Consulting Engineers Limited acquires Ecofirst, strengthens sustainability offerings.
  • Dainik Jagran — 11 Jan, 2013 Centre for Engineering & Technology (CET,SAIL) and Tata Consulting Engineers Ltd sign MOU.
  • Safety has to be planned and achieved right from the time the project is planned, designed procured, constructed and commissioned, " Mr J P Haran, MD Tata Consulting Engineers Limited in an interview with the magazine Project Vendor, Dec 2012 Issue. Project Vendor Interview - J P Haran Click here for flipbook
  • Free Press Journal — Shipping Times -6 Dec, 2012 JNPT awards consultancy services to Tata Consulting Engineers .
  • Press Release —11 October, 2012 Tata Consulting Engineers and Dassault Systèmes Announce Partnership to Bring to Market Innovative Industry Solution Experiences.
  • Hindustan Times — 09 October, 2008 Tata firm to invest in Qatar science park.
  • The Economic Times — 08 October, 2008 Tata firm to invest $12 million in Qatar science park.
  • Deccan Herald — 26 September, 2008 Bangalore-based TCE to tap African markets.
  • DNA — 29 March, 2008 Empowering Energy.
  • DNA — 28 November, 2007 Infrastructure Mumbai Makeover — Building Mumbai.
  • Financial Express — November, 2006 Engineering a Better Tomorrow.

Next : News
 

Annoucements

S Padmanabhan takes over from Prasad Menon as Chairman, Tata Consulting Engineers

Tata Consulting Engineers Limited has been honoured with the Star Performer Award for Engineering Services under Large Enterprise Category at the 46th EEPC Award

TCE wins the Bentley 2015 Be Inspired award for "Innovation in Land Development". The award was presented at an event held in the UK.

Tata Consulting Engineers was presented with the Star Performer Award for export excellence at the 45th EEPC India Award function held in Mumbai on 22 January 2014.

Tata Consulting Engineers. Honoured with "Best Consultant Award for TCE"

 

S Padmanabhan takes over from Prasad Menon as Chairman, Tata Consulting Engineers

Mr S Padmanabhan has taken over as Chairman, Tata Consulting Engineers Ltd with effect from 23 Jan 2016. He succeeds Mr Prasad Menon who retires after a distinguished stint on the board of Tata Consulting Engineers Ltd.

 

Tata Consulting Engineers. Honoured with "Best Consultant"

Tata Consulting Engineers. Honoured with "Best Consultant" Award instituted by the Council of Power Utilities at the 6th India Power Awards 2013 ceremony held at Taj Krishna, Hyderabad on Friday, November 22, 2013. Chief Minister of Andhra Pradesh, Mr Kiran Kumar Reddy, was the Chief Guest.

 
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