The Metals and Mining business unit successfully completed engineering consultancy for a blast furnace for a steel plant in Rourkela, India. A showcase project for Tata Consulting Engineers, marked by timely completion of project and innovative solutions. Tata Consulting Engineers undertook turnkey execution of the project. The Metals and Mining business unit rendered civil and structural works comprising furnace foundation, 4-poster structure, equipment foundation, roads, railway tracks, drawing and sewerage. Utilities and auxiliaries comprised 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.

The plant construction and commissioning was done in record time and in line with international standards.This project had several innovative engineering solutions such as – design and engineering of 4-poster structure, thereby eliminating the need for pouring concrete into hollow structures; and the engineered sequence of installation of the downcomer 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 required. Design/engineering of systems and sub-systems were critically examined to enable problem-free construction and faster execution. Design inputs from various agencies were compiled and integrated into the design for construction in record time. State-of-the-art safety solutions were also provided in the design. Basic engineering inputs, operational maintenance, extensive fire fighting systems and fire detection systems were incorporated and gratings were provided to ensure accident-free operations.

The innovation, safety measures and timely delivery provided cost-efficiencies to the client and the quality standards were benchmarked to international standards. The success of this project attributed to the Metals and Mining business unit’s understanding of the steel manufacturing process, familiarity with international quality norms and, most of all, the capability to work with multiple entities handling complex assignments.

Tata Consulting Engineers strengthened its goodwill, establishing a long-term working relationship with the client.