TCE Covid Response TCE Covid Response

Engineering Life
COVID Emergency Response
by Tata Consulting Engineers (TCE)

TCE Response for Combating COVID

Engineering Solutions to Combat Challenging Times

The ongoing pandemic second wave required urgent actions towards enhancing the country's Oxygen generation and distribution capacity. Tata Consulting Engineers Limited (TCE) has made sincere efforts towards contributing to the requirement, focusing on agility, indigenisation aligned to Atmanirbhar Bharat, quality and cost competitiveness.

In this second wave of COVID19, India is witnessing a shortage of medical Oxygen in hospitals. Even though Oxygen used for industrial purpose is being diverted for medical use, this may not be enough to meet the increasing demand. Alternative modes of oxygen generation may be required considering the colossal demand, especially at remote locations.  Therefore, there is a need to look for additional sources through which Oxygen can be generated quickly near the consumption point leading to a surge in demand for the portable oxygen concentrator.

A task force was set up at Tata Consulting Engineers to study all possible options and work on engineering the fastest and best-suited option in the current circumstances. Alternate and out of box solutions for storage and distribution of Oxygen were also investigated and published as the whitepaper, including conversion of CO2 fire extinguishers and LPG cylinders for medical oxygen service.

All these methods involve Statutory, Legal and other approvals. They must be done with the proper involvement of Government authorities. Adequate cleaning and colour coding of the cylinders are required for safety reasons. A governance mechanism involving government officials, PESO, Controller of Explosives, Fire Department, Medical Department (Min. of Health) and administrative authorities are also required for related compliances and approvals.

COVID19 Whitepapers Published

COVID19 Manuals and Guidelines Published

Oxygen Efforts: As of 29th May 2021

225+ 1,00,000+ 10,000+ MT/day 300+ Hospitals
  • 75+ Nitrogen Plants conversions
  • 50+ New Oxygen Plants
  • 60+ MT of Zeolite provisioned
  • 100+ Oxygen Plants consulted
  • 250+ MT/day PSA Oxygen plants
  • 20,00,000 LPM Oxygen
  • 4000 MT/day Oxygen
  • 200+ Innovators involved
  • 50+ MSME involved
  • 3000+ enquiries
  • Oxygen 250+ MT/day PSA Plants
  • Oxygen 4000 MT/day O2C generation
  • Oxygen 6000 MT/day O2 handling Cylinders 8 Million Cylinders (Cylinder Conversion Pilot and approval awaited)
  • 10+ States
Oxygen Plants Under Commissioning Oxygen Concentrators Proposed for Manufacturing Oxygen Impacted Oxygen Enabled

 

TCE Oxygen Concentrator Prototype

Indigenous Opensource Oxygen Concentrator Design

With COVID patients requiring between 5-20 LPM and keeping in mind the need for such devices in villages and interior parts of the country, we targeted the specification for up to 20 LPM design. The prototype leveraging opensource design (www.oxikit.com) was accomplished in less than five (05) working days, with complete local parts as available in India (except Zeolite) and with benchmark results of 10-20 LPM of 90-95% oxygen concentration. Necessary design changes and process refinements were incorporated to ensure benchmark results under Indian conditions.

Oxikit opensource concentrator is based on proven PSA technology. It utilises a molecular sieve to adsorb gases and operate on the principle of rapid pressure swing adsorption of atmospheric nitrogen onto zeolite minerals at high pressure. PSA technology is a reliable and economical technique for small to mid-scale oxygen generation.  Read More...

Technical Details & FAQs

Webinar recording on TCE Oxygen Concentrator

 

Conversion of Existing PSA Nitrogen Plants for the Production of Oxygen: 75+ Nitrogen Plants Under Conversions

Conversion of existing PSA nitrogen Plants for oxygen production emerged as the most practical solution given the current situation. The technology has been in existence since 1970, so workability was not an issue, the only concern was to see it working in front of us, and that too quickly as time was of the essence.

The basic configuration and technology for both Nitrogen and Oxygen PSA units are similar. The significant difference being the adsorbent material. When the adsorbent material (activated carbon molecular sieve – CMS) of the nitrogen generating units is replaced (by Zeolites), the same unit that produced nitrogen will now be suitable for producing Oxygen. The OEMs also confirm this point. However, when such conversion is implemented, the nameplate capacity of the converted unit will be reduced roughly to 25% of the original nitrogen generation capacity.Read More...

Technical Details and FAQs

Emergency Oxygen -TCE -IIT Bombay –Spantech (Hindi Video)

Emergency Oxygen -TCE -IIT Bombay –Spantech (English Video)

The Plant Prototype Piloted with IIT Bombay

1st Converted PSA Plant in Jodhpur

1st Converted PSA Plant in Varanasi

1st Converted PSA Plant in Visakhapatnam

1st Converted PSA Plant in Bhilwara

1st Converted PSA Plant in Bharuch

1st Converted PSA Plant in Valsad

2nd Converted PSA Plant in Bharuch

1st Converted PSA Plant in Palwal

1st Converted PSA Plant in Padra

1st Converted PSA Plant in Pilani

1st Converted PSA Plant in Indore

1st Converted PSA Plant in Vapi

1st Converted PSA Plant in Ratnagiri

2nd Converted PSA Plant in Visakhapatnam

1st Converted PSA Plant in Faridabad

Gandhi Hospital, Hyderabad

Navodaya Hospital, Raichur

Camlin Plant

Virchow Plant

7 Cube Meter/Hr Oxygen plant at a Charitable Trust hospital and College at Ahemad Nagar Maharashtra

Uttam Vishnu Plant

Aurbindo Pharma Visakhapatnam

CO2 Cyclinder

LPG Cylinder

Explore Use of CO2 Fire Extinguisher and LPG Cylinders for Medical Oxygen

Plenty of fire extinguishers are already available and in use across all the locations, be it offices, malls, theatres, residential complexes, etc. Since offices, malls, theatres are not in operation, and people are working from home, every city already has the availability of these storage devices. These fire extinguishers can be used without worrying about fire safety as buildings are not occupied. Moreover, these are lightweight, easy to transport, and quick to fabricate in bulk. They can be potential candidates for converting and utilising for storing medical Oxygen during emergencies like the COVID19 pandemic.

Some essential considerations for checking the suitability of CO2 fire extinguisher cylinders as medical oxygen cylinders include confirming its pressure rating specifications, the material of construction, and the available cylinder’s capacity.

LPG cylinders are widely available, and the network of the supply chain has matured. As an alternative solution during emergencies, the use of LPG cylinders for medical Oxygen can be explored. LPG cylinders are rated for a much lower pressure than conventional medical oxygen gas cylinders. Read More...

Technical Details & FAQs

Standard Tata Unit: Modular Health Facility for COVID-19

To meet the COVID19 challenge requiring urgent strengthening of health infrastructure, Tata Consulting Engineers (TCE) and its subsidiary Ecofirst designed a ‘ready to implement’ modular health facility. Each module is equipped with air-conditioning, five beds and one toilet. This ready to use design can be implemented immediately as an extension of an existing hospital or a completely new COVID19 hospital anywhere in India. These modular units put together can expand to any number of beds, are self-sufficient, sustainable, and can be easily repurposed or dismantled in the future.

The design of these modular units incorporates inputs received from medical planners, COVID doctors, virologists, architects, HVAC and ventilation experts. Tata Consulting Engineers shared these designs freely with many implementing or donor agencies for immediate use.Read More...

Technical Details & FAQs

Standard Tata Unit Hospital

Standard Tata Unit Hospital Inside

Zeolite Arrival in India

Zeolite Loading in Europe

Oxygen Plant Rajpipla

Supported PSA Plants with Sourcing of Zeolite from Europe: 50+ New Oxygen Plants

While creating the prototypes and pilots, Tata Consulting Engineers (TCE) realised the acute shortage of a vital component, Zeolite, to convert PSA Nitrogen plants to produce Oxygen. The same is also required for installing new oxygen plants.

TCE partnered with Tata Chemical for the required sourcing of Zeolite from Europe. With the support of the Ministry of Commerce, PSA, DSIR & CSIR, we received GOI – IAF support for urgent airlifting of this critical resource to convert and install new oxygen plants.

With the support of Tata Chemicals and Central Pollution Control Board, TCE created a process of due diligence and project managed the allocation of this raw material to more than 75 plants, ensuring timely availability of the essential resource at an affordable price.

 

Oxygen Ventilator

Multiple Ventilator design were studied feasibility under emergency conditions was evaluated (No prototypes were done, only feasibility evaluations)

OpenSource Medtronics Ventilator was finally zeroed upon, and manufacturing firms were conveyed to explore tie-up and manufacturing

Emergency Ventilator Research

 

Medtronic Opensource Ventilator

Oxygen Supply

Consulting on Oxygen Generation Supply Chain and Capacity Enhancement

As the COVID-19 pandemic posed newer medical challenges. Hospitals across the country face infrastructure challenges for increasing the Oxygen Generation and then ensuring the last mile connectivity of this oxygen. Tata Consulting Engineers (TCE) is consulting across various States, namely Rajasthan, Maharashtra, Uttar Pradesh, Odisha, Andhra Pradesh, Silvassa and Gujarat to help with the supply chain and capacity enhancement.

TCE is also helping various NGOs and hospitals including Tata Medical Centre for their Oxygen augmentation and readiness

TCE along with its subsidiary has designed and distributed the designs for emergency Modular Units with Oxygen, AC and Medical support

Technical Details & FAQs

Project O2 for India

The office of the Principal Scientific Adviser to the Government on Sunday said ‘Project O2 for India’ has been initiated to ensure supply of critical raw materials such as zeolites, setting up of small oxygen plants, and manufacturing of compressors. The second wave of COVID-19 saw an increase in demand for medical oxygen in different parts of the country, it said in a statement.

The manufacturing and supply consortium includes Bharat Electronics Limited (BEL); Tata Consulting Engineers (TCE); C-CAMP, Bengaluru; IIT Kanpur; IIT Delhi; IIT Bombay, IIT Hyderabad; IISER, Bhopal; Venture Center, Pune; and more than 40 MSMEs.

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In the Media

 

Project O2 India