Engineering transformation with

digital engineering & Industrial IOT

3D, 4D, 5D to re-invent

engineering services. Digitised

plant assets for low cost

plant upgrades.

Our engineers have adopted SiD…

Safety in design is the core

SAFETY – No shortcuts here. It runs

all the way up and down


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.

  • 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!

Predictability, Cost Efficiency, Speed, Value Engineering
The convergence of information technology, engineering and manufacturing with the ‘Industrial Internet of things’ is redefining the traditional capital project and operational sustenance activities of our clients.

In a changing landscape, customers increasingly require short project cycles, value additions and cost efficiencies. There is also a need for both Capex an Opex related services with focus on asset sweating. Clients require us to partner them in driving their optimization programs.

Tata Consulting Engineers is geared to provide integrated engineering consultancy services using high end digital engineering suites. New digital tools converge with engineering domain expertise to provide a new line of services that provide incredible value to customers.

Multi-dimensional digital engineering suites are used for integrated plant design, buildings, urban planning and complex infrastructure projects such as Nuclear Plants, Power Plants, Chemical Plants, Water Distribution Systems, Waste management Systems, Towns, Hospitals, Buildings and Smart Cities.. 3D, 4D, 5D Digital Engineering typically involves Conceptualization, Modeling, Design, Detail engineering, Clash and Interference Checks and Time and Resource Simulations.

We enable engineering transformation with3D,4D, 5D enabled digital engineering services and plant engineering solutions. We provide:

Industry 4.0 ready solutions

Industrial Internet of Things consultancy

Modularisation solutions specific to each industry sector

Value engineering

3D Modelling and walkthrough

4D Construction simulation for clash detection, construction sequencing, safety management

What-if scenario planning

Analytics, system engineering, condition monitoring

Plant efficiency and controls

Sensor-based plant/factory intelligence

Proactive maintenance

Outage management

Asset Refurbishment & retiring asset management

We have multi-disciplinary talented pools of specialist engineers who are equipped with digital tools to provide cutting-edge technology-enabled engineering services. Our delivery models are flexible and fashioned to clients’ unique needs. We deliver services through a combine of – Dedicated engineering centres for large scale delivery Virtual delivery systems On-site and off-site combine to converge multi-disciplinary talent Cost efficiencies resulting from digitally-enabled engineering solutions

Digital solutions help move the cost component and efforts to the design and planning stage such that construction costs escalation due to design clashes and need for iterations at this critical stage can be avoided. Short project schedules as design iterations are reduced Clashes during construction which is the major cause for cost escalation is arrested 4D simulation helps with project and construction sequencing in complex projects Error-free implementation and accurate cost estimation Plants data generated using digital tools make asset modernization and retiring asset management a cost effective process Asset modernization in real-time with minimum downtime



Case Studies

4D Simulation

Digital Engineering

Chemical Sector

Mining Sector

Smart City Planning


Conceptualization - conceptualization and layout planning using computer systems for power plants, nuclear plants, refineries, buildings, malls, smart cities, roads, bridges, etc

Design and analysis - visualizing aspects of stability, stress, strain, durability, serviceability, etc of the master design. Several iterations and reviews are possible at this stage.

Detailed engineering – Enrichment of 3D models are done based on design validations using engineering tools

3D walkthrough - Engineered models are rendered through virtual simulation of Plant or Projects as walkthrough. These walkthrough are used for visual checks for clashes and interferences. The system is also enabled with capability to detect clashes and interferences.

4D Simulation – The walkthrough is used to validate project schedule, constructability, construction sequencing of plant or infrastructure facilities. Construction sequencing, scheduling, constructability check, safety checks, etc are visualized and planned. This is a critical stage as all iterations are done prior to construction which saves cost, effort and time. Projects can be pipe-lined, collaborative teams can work simultaneously on various aspects, reducing timelines drastically.

5D involves cost and resource scheduling. The detail modeling ensures project specific data is input in the engineering plan. The 5th Dimension inputs various project milestones, assesses the cost and resource needed at each milestones. This helps in predictability and planning of cash flows and the efficient deployment of resource at the right time.

Asset Life Cycle Management, Training, Outage management, Refurbishment and Demolition of Asset are the future use of Digital Engineering post commissioning of plant or Infrastructure facility.