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simulation solutions

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paper manufacturing project

 

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

White Papers

  • Modularisation- A New trend

    Digital Engineering and its visual simulation capabilities make it possible to look, see, experience and construct. However, this is just scratching the surface when it comes to application of these tools to engineering design. New business models and service delivery options are being discovered from plant engineering for power plants to steel and metal process industries and more. The challenge of the day is reducing cost and project time overruns. These two aspects are key for profitability. Bringing in business process efficiency and using digital engineering tools to implement these processes is the new business model that is being fast adopted by visionary organizations. The automotive industry and manufacturing plants have used standardization and modularization to bring about efficiencies in production. Applying this concept to plant engineering, can design solutions be modularized and put up on the shop window? The answer apparently is YES, Indeed!


  • Facilitating Construction with added 'D'imension –4D simulation

    Time bound construction is essential for any project to optimise the cost and for quicker reverse cash flows. Construction simulation using 4D model enables effective planning of construction activities, identify the problems during construction and helps planners to troubleshoot. The sequences of construction activities can be optimally planned through simulation , interferences can be identified in advance during the planning stage. The construction schedules could be improved while being realistic. 4D modelling is a powerful tool for visualization and helps in constructability reviews, enables better understanding of project constraints and milestones, construction & resource plans, etc. We can visualise the construction activities at planning stage itself.


  • Pinch Analysis for the Application in Steel Plants

    By Nitin Gupta & T. K. Pal, Mechanical, TCE

    The term 'Pinch Technology' is a new set of thermodynamically based methods that guarantee the design of heat exchanging networks with minimum energy levels. The equations are primarily based on the First Law and the direction of heat flow is determined by the Second Law of Thermodynamics. This method is very useful for the large and complex industrial facilities and identifies the best energy saving opportunities. Pinch analysis is used in complex processes with extensive exchange of thermal energy. This article outlines the process of Pinch Analysis and study the applicability of pinch analysis in steel plants along with its advantages.


  • Role of Modern Fuel Gas Analyser in a Thermal Power Plant

    By Sugata Bandyopadhyay, Instrumentation and Control, TCE

    The concern for Global Warming and Climate change has already made a social impact on the planet earth and corporate strategy on mitigating plan needs to be adopted to restore ecological balance. While any economic growth is associated with Industrial developments, which will trigger a new concern to the environment, innovative adoption of various energy efficient processes will ensure better carbon foot print. In India for any sustained growth the requirement of Power will always increase and new Power Stations will need to be set up. While setting up Power stations consideration needs to be given for selecting appropriate technology, size & selection of energy efficient process and equipment, optimize the combustion process. Role of analysers for measurement and control plays a major role to optimize the process operation & reducing fuel and energy wastages. Further selection of the appropriate technology for analyser, proper installation practices and control strategy based on the analysis and its response time are the key considerations for successfully implementing automatic combustion Control. This paper aims to describe the challenges in the selection of the appropriate gas analysers for the measurement based on the various technological versions, the analysis of the result & implementation of control to improve Carbon Foot Print.


  • Creating a better tomorrow with digital engineering

    Creating a better tomorrow is all about working closely with our clients, industry visionaries, policy makers, public and financial institutions. It is about leveraging our past experiences, our partnerships and our key assets, our employees, in the best possible manner. However to be able to do this, one must be aware of the ecosystem, environment, market and few trends that will shape our future.

    Trends that are shaping the future
    Key trends that are influencing the future with respect to Infrastructure, manufacturing, design, engineering and architecture fall under five categories.

    1. Collaboration of Minds driving Innovation
    2. Global Rebalancing
    3. Work Culture Shift
    4. Integrated Ecosystem and Value Chains
    5. Shorter Project/Product/Plant Lifecycles


  • Sustainable Clean Ganga Mission

    International Conference on " Sustainable Clean Ganga Mission " was held on 12 December 2014 in Delhi, organized by Everything About Water. About 150 delegates attended the conference including the officials from Ministry of Water Resources and Ganga Rejuvenation, Upper Yamuna River Board, Embassy of the Kingdom of the Netherlands, Central Water Commission and IIT Kanpur.

    TCE made presentation in the conference on topic " Planning and Design of Sewers using Advanced Techniques for Proposed Sewerage System of District- I for Kanpur City under National Ganga River Basin Authority Project ". Technical presentation was submitted by Mr. Sanjay L. Lalan, Mr. J. K. Singh and Mr. A.S. Gupte. Technical presentation was presented by Mr. J. K. Singh. Mr. Dheeraj Kaushik, Mr. J. K. Singh and Mr. Sanjay L. Lalan participated in the conference. TCE presentation and presence was well recognized in the conference.


  • Managing Risk- Dredging in India

    Since dredging takes place in a natural environment, uncertainty and therefore risk has to be accepted. This uncertainty can be reduced by undertaking modelling or additional studies but in such a complex system it can not be eliminated.

    • Discussion may arise between those involved in a dredging project (client, permitting agency, conservation organisations or environmental NGO's etc) on how to assess and manage risks. Risk perception varies between groups and individuals and is value driven. There is no quick solution to this potential conflict; early and open communication is considered essential.
    • Thorough site investigations are a must before embarking on a dredging project – bathy, side scan, seismic profiler, magnetometer, marine boreholes, modelling studies etc.
    • Choice of appropriate type of contract with optimum risk sharing between the contractor and client
    • Using international best practices in estimation and design as highlighted in CIRIA and PIANC publications
    • Using standard FIDIC documents (2010 RECOMMENDED) for preparing tenders. Minimal changes to standard FIDIC general conditions

  • Power System Dynamics and Control

    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.

  • Super Critical Steam Generator Technology

    In the fossil fuel fired power plants successful operation of once through steam generator technology and drive to achieve higher thermal efficiencies made possible for the development of supercritical steam generators. The paper discusses key factors to the success of supercritical technology.

  • Coal Stockpiles in Indian Power Plants

    Managing the coal stockpiling system under environment-friendly conditions.

  • An Insight into Advanced Technology in Circulating Fluidised Bed Combustion Steam Generators

    The requirement of high efficiency in power generation and environmental considerations, installation of power plants with Circulating Fluidized Bed Combustion (CFBC) technology with lignite as main fuel would be a techno economically viable option. This paper outlines the present status of CFBC technology and details of existing installations in India and abroad. .

 
  • High Speed Conveying System as Applicable to the Indian Plants

    Generally the belt conveyors in the Indian Industries are low speed type with belt speeds in the range of 2 to 3 mps. There are few installations with speeds up to 4.5 mps. Most of the conveyors existing in India are short distance conveyors with length up to 1 km. There are few installations in the mines and ports with higher lengths.

  • Wagon Loading and Unloading System

    This paper covers the aspects of the wagon loading and unloading system currently in vogue in the Indian Industry. Generally the wagon loading systems are required in the mines and ports for loading the material into the wagons for further transportation to the process plants.

  • Harnessing the Power of IT for Improvement of Power Plant Performance

    Information technology can effectively be used to virtually operate a number of power stations as a single unit to improve the plant performance, plant availability and cost of plant operation.

 

Announcements

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

Tata Consulting Engineers to provide PMC services for South Asian University

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

Tata Lockheed Martin Aerostructures conducts empennage delivery ceremony of facility engineered by Tata Consulting Engineers

John Deer Tractor Plant at Indore engineered by Tata Consulting Engineers inaugurated on 22 Oct 2013

 

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.

 

Tata Lockheed Martin Aerostructures conducts empennage delivery ceremony of facility engineered by Tata Consulting Engineers

Tata Lockheed Martin Aerostructures Ltd (TLMAL)) conducted Empennage Delivery Ceremony on 11-11-2013 at Hyderabad. Mr. David Tucker (CEO) of TLMAL described the aircraft parts assembly facility as a 'world class facility' built in India. Tata Consulting Engineers is proud to have done the complete engineering and construction management for this facility.

 

John Deer Tractor Plant at Indore engineered by Tata Consulting Engineers inaugurated on 22 Oct 2013

The John Deer Tractor Plant at Dewas near Indore was inaugurated on 22nd October by Mr. Samuel R. Allen Chairman and CEO, Deer and Company and Mark von Penz, President Agriculture and Turf Division Europe, Asia & Africa. During the inauguration, efforts by Tata Consulting Engineers in creating John Deer's world class facility was appreciated.

 

Tata Consulting Engineers to provide PMC services for South Asian University

Tata Consulting Engineers signed an agreement with the South Asian University along with the consortium partners for the Construction of Campus for South Asian University , Phase I . TCE will provide Project Management Consultancy Services for construction of the campus to be based in New Delhi.

Businesses

Infrastructure

Tata Consulting Engineers has successfully managed complex engineering projects across the infrastructure spectrum.


Power

The Power Business of Tata Consulting Engineers is a leader in energy engineering solutions.

Nuclear

Tata Consulting Engineers' Nuclear Energy business is part of the country's nuclear power program right from its very beginning.

Chemicals

Our innovative chemical process engineering translates to smart business solutions for our customers.

Steel Metal and Mining

Our focus areas include raw material handling system, coke oven, sinter plant, blast furnace, direct reduction etc.

 
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