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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


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


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


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


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


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

  • Towards Green Mobility

    The global automotive industry is on the verge of disruption. The transport sector is the highest consumer of oil and the second-highest contributor to CO2 emissions worldwide. Rapid developments in electric mobility will transform the automotive industry by addressing the growing concerns of environment and energy security in the transport sector.

  • Carbon Capture Technology

    Global climate change and the technologies to minimize the greenhouse gas emissions are at the centre of discussion in every global environmental forum. Carbon capture technology is one of such techniques which can be implemented to reduce atmospheric emissions of carbon dioxide from industrial installations.

  • Go Modular

    Economic scenario of the world is changing rapidly. Due to the volatility in oil and natural gas prices, there is still uncertainty in supply, demand and pricing of chemicals. Considering advancements in technology, new investments are happening in remote areas which are close to either raw material sources or to the end user.

  • Industrial filed instrument progression to smart digitization enabling IIOT

    Consistent technology maturity over centuries in industrial automation domain firing off from field instrumentation to control system(s) enables more plant productivity, more automation enabling stress free life for plant operators, remote monitoring and operation of plants including but not limited to critical data availability on mobile phones empowering supervision and expert advice/controls from anywhere across the globe with internet access.

  • Overview: Second Generation Bioethanol Process Technology

    Biofuels provide an attractive and sustainable energy option as they are considered to be clean fuels having ‘very low to no sulphur’ content. Biofuels therefore help in creating a positive environmental impact. Bioethanol is one such fuel that can be blended with gasoline. Typically and conventionally, bioethanol is extracted from sugars. Bioethanol can be produced at industrial scale through the sugar fermentation route. The bioethanol technology is termed as either first generation (1G) or second generation (2G) depending upon the origin of such sugars.

  • Statistical Assessment of Lifecycle of Process Plant

    Continuous Annealing and Processing Line (CAPL) produces value added high quality advanced high strength CRCA (cold rolled close annealed) steel of varying thickness in the range of 0.4 mm to 2.3 mm which is mostly used in the automobile manufacturing industries. One of our customers intended to evaluate the useful life of the plant and machinery of a CAPL steel plant. Tata Consulting Engineers Ltd (TCE) was retained as a consultant to carry out a study for assessment of the existing condition of the plant and evaluate the useful life, based on the available data, plant visual inspection, technical discussion with plant operation & maintenance personnel and data/ information collected throughout the project.

  • Strengthening of Reservoir Embankments

    Power plants, chemical and industrial plants have very large requirements of raw water for their process needs. Water which is very scarce these days is got from a source nearest to the plant; which can be a river, lake or a dam reservoir and this water is then pumped and stored within plant limits in a raw water reservoir built by enclosing a low lying area within the plant boundary with the help of earthen bunds. As water is precious; some amount of water to help run the plant for a few days/ weeks in case of an emergency or to tide over dry season; is generally stored within the plant limits. In addition to storing raw water, industrial plants also need to store wastes like ash, sludge, slime etc. in reservoirs outside plant limits constructed with the help of high earthen embankments.

  • Concrete Volute Pumps

    Coal fired thermal power plants generally require huge quantity of cooling water for the operation of plants. Water requirement increases with number of units and unit capacity. For coastal power plants seawater is a normal source of such cooling water. In one of the executed power plant cooling water requirement was in the order of 630,000 m3/hour for the total capacity of plant.

  • Flexible foundation of stalker reclaimer

    Stacker reclaimer is the equipment for raw material handling & management in Steel, Power, Cement and many other Plants. Stockpile of material is built to augment feeding when regular supply of the same is suspended. Stacker Reclaimer is mounted on wheels which travel on rails over a long stretch of stacking bed depending on the requirement.

  • Sewage Collection System in India – Addressing the Gaps

    This paper is to enable better understanding of the sewage network systems & it’s management in India. The reasonable gaps / challenges at broad level in this sector are identified and addressed with proper techno-economic approach and design criteria to enable this sector to develop on a sustainable basis.

  • Practical Approach to Sox and NOx Measurement.

    The sustainment of all living things is due to a combination of gases in defined proportion that collectively form the atmosphere. Any increase or decrease in percentage of these gases will cause imbalance and can be harmful for survival. Emission of gases that contain Sulphur oxides (SOx) and nitrogen oxides (NOx) are the main source of the acidifying substances in the environment. The pollution norms for these are becoming stricter day by day. In recent years the emission norms for SOx and NOx for Thermal power plants have been revised to 100 mg / Nm3 for all plant installed from 1st January 2017. In view of this, accurate measurement of SOx and NOx in the flue gases is very important.

  • Guidelines for SWAS Panel Type Selection From Latest Available Options

    Steam & water analysis system (SWAS) is dedicated to analysis of steam & water in power plant to ensure protection of boiler and turbine from impurities; by preventing corrosion/salt deposition in boiler tubes and corrosion, salt/silica deposition, erosion in turbines blades. The measured parameters are pH, conductivity, silica, sodium, dissolved oxygen, chloride etc. Power plant SWAS system consists of 2 units. One is wet panel i.e., sample conditioning panel & other is dry panel with microprocessor based electronic analyzers.

  • Electromagnetic Compatibility (EMC) and Electromagnetic Immunity (EMI)

    Electromagnetic Compatibility (EMC) is used to describe how well a device can function in its EM environment without causing any unwanted effects to the surrounding equipment. Electromagnetic Interference (EMI) is a result of electric or magnetic fields acting on the device causing it to malfunction. The absence of EMI in a system is called EMC. EMI can be due to all types of signals such as DC, AC, RF etc.

  • Reduction of Product Loss in Dryers

    In one of the soda ash production facility, there was significant quantity of product loss in the drying process. The product was spilling from the inlet flanges of the rotary dryers. The target was to minimise the loss of product so as to enhance the production by minimising the down time of the dryers.

  • Greenhouse Gas reduction Techniques in Petroleum Refinery

    Greenhouse gases are generated from various industrial processes. Though power generation is a known major contributor of the greenhouse gas (GHG) emissions, considerable amount of greenhouse gases are released from other energy intensive industries as well. The petroleum refining is one such energy intensive industry. The source of energy is mainly in form of fossil fuels which give rise to GHG upon combustion. Due to this, refining industry is considered as a significant source of greenhouse gas emissions. Apart from the direct fuel combustion, various refinery processes like fluid catalytic cracking unit (FCC), sulphur recovery plants, Hydrogen generation units, etc. also contribute to the GHG emissions. Waste gas flaring also adds to the overall emissions from petroleum refinery. This paper provides an overview of options available to track reduce GHG emissions.

  • Pipeline Leak Detection Technique

    Pipeline is the fastest and most reliable means of fluid transportation compared to other transportation modes like rail or road tankers. However, leakage is the main threat for pipeline transfer. The pipelines often carry hazardous materials and may pass through areas of human population. Any leak through the pipeline results in not only loss of product but also impacts environment and may pose a hazard to the nearby human population. Pipeline leak monitoring is also necessary to detect thefts. The leak detection techniques help to minimize the product losses. Selection of a reliable leak detection system is crucial in achieving safe and economical pipeline transport objective. This article briefly discusses various pipeline leak detection techniques and their working principles.

  • Coal to Liquids: Overview of Process Integrity Issues

    Coal is primarily used as fuel in power generation. However, coal can also be used as an alternate source for making liquid fuels. Recent advancements in technology have successfully demonstrated conversion of coal into liquid fuels and into many other useful chemicals. CTL (Coal to liquid) technology can be considered as an alternate source to crude oil or natural gas in producing liquid fuels. The fuels made from coal are cleaner as compared to the fuels made using crude oil, owing to the process schemes followed.

  • Energy Management System for Utilities in Industrial Projects

    Utilities such as air, water, gas, electricity etc. are required for process and manufacturing industry. The quantity of such utilities needs to be monitored in a precise way to ensure efficient usage. This can be monitored through Energy Management System (EMS) and controlled effectively to increase usage efficacy and reduce wastage. This will in turn help to reduce operating cost. EMS also provides readily available statistical data of utility systems, which will be very useful at the time of energy audit.

  • Value Addition in Pre Engineered Building

    TCE provides services as Design engineering Consultant/ Owner’s engineer/ Project Management consultant for many industrial projects wherein the buildings are generally PEB. TCE plays a crucial role in conceptualisation and framing the specifications of the PEB structures so that client gets the best possible techno-economic solution from a holistic view point and not limited to specific considerations such as cost of PEB, lowest kg/sq mt etc.

  • Mitigation of Fire Hazard in Cable Tunnels

    Cable tunnels are mainly used for distribution of bulk power across large scale plants, substations and smart cities. Cables are routed through cable trays installed in tier formation on either side of the cable tunnels. Fire hazard is one of the major concerns in underground cable tunnels as it spreads rapidly causing accumulation of high temperature toxic smog. This makes the job of firefighting personnel extremely difficult to extinguish fire. Considering the large number of cables required for distribution of bulk power, fire in a cable tunnel results in disruption of power supply to a large area leading to huge loss in industrial production. It has been a challenging task to reduce fire hazards in cable tunnels to limit the extent of damage and its consequences.

  • Pitfalls in Process Simulation

    Process simulation is useful and powerful tool to model chemical process flowsheets of varying complexity. Modern day simulators are built with comprehensive pure component databank, exhaustive library of thermodynamic systems and physical property estimation methods, initial estimate generators, in built algorithms for every unit operation in a very user friendly graphical interface manner. These simulators have capability to solve and optimize virtually any flowsheet synthesis problem. Despite such in-built sophisticated and rigorous modelling capabilities, process simulations at times fail to represent real life plant data correctly.

  • Up-gradation of Pollution Control Devices

    Emission regulations have become more stringent with the latest Notification issued by Ministry of Environment and Forest in Dec.’2015. Many operating power plants need to revamp their flue gas pollution control devices to meet the prescribed environmental norms. The most commonly used pollution control device in India to regulate particulate emission is electrostatic precipitator (ESP). The ESPs in many operating plants need upgrade to enhance their particulate collection efficiency in order to meet the latest pollution control norms. Upgrading collection efficiency of ESP in an operating plant needs customized solution as the challenges in terms of enhancement in collection efficiency requirement, gap in design & operating parameters, site constraints are unique to each and every plant.

  • Challenges And Mitigation For Capacity Augmentation Of Tailing Ponds

    Beneficiation plant in the Iron mines separates contaminants & finescalled tailings from the ore. These tailings in a slurry form are generally disposed in a vast area of land encompassed by embankment called as tailing pond.Under the present socio-political scenario with limited availability of land,capacity enhancement by upstream raising of the height of the embankment made partly/ fully of the tailings/ mine wastes is apreferred option. This invites risk of slope failure of embankment because of soft tailinglayer in base unless proper engineering is done using appropriate technology for improvement of properties of the tailing layer. TCE has successfully mitigated this challenge by providing perforated vertical drains (PVD) and Geogrids.

  • Effective Method Of Handling Mill Rejects (Pyrites)

    In thermal power plants, Mill Reject Handling System (MRHS) is provided to evacuate mill rejects (Pyrites) from the pyrite hopper and convey it to the mill reject silo. The conventional methods of MRH system include Pneumatic type, Mechanical type (By Belt / Chain conveyors) and Hydraulic type. Pneumatic conveying system is more flexible in layout and requires less space but consumes more power. Mechanical system is a more positive system but is not flexible. Hydraulic system is generally not provided due to high water consumption.

  • Protection And Strengthening Of Rock Surfaces

    Protection and strengthening of rock surfaces within optimum time, cost and with adequate reliability is among the challenges on the projects. This article shares TCE’s experience in protecting and strengthening of rock surfaces in deep excavation, valley and hilly terrain.

  • Slope Stability Analysis Of Soil Strata–in Natural And Man Made Conditions

    Slope stability analysis in soil strata helps in optimizing slope for cost and time effective construction. This article describes about procedure of carrying out slope stability analysis by using Geo-studio and Phase 2 software’s. Slope stability analysis has numerous application in various constructions such as of road embankments, sewerage pumping station, Master Balance Reservoir, Ash Ponds, Mining, slope beneath berthing structure, dredging, site grading, basements and structures like wagon tippler, pump house, nuclear buildings, hilly terrain etc.

  • Drive Selection For Boiler Feed Pumps

    Coal fired utility power generation plants are primarily designed as base load units in India. In order to meet the load demand of future industrial growth large capacity power plants with super / ultrasuper critical technology are envisaged which offers higher efficiencies with lower emissions. In a power plant, Boiler Feed Pumps (BFPs) including its drives is one of the cost intensive auxiliaries and also consumes significant auxiliary power; about 3.5% of gross power generated. For this reason it is utmost important to select the most optimum drive and configuration for BFPs that offers maximum overall benefit to power plant without compromising on its availability.

  • Dynamic Study of Integrated Steam Systems in a Large Process Plant

    Combined heat and power plant which is generally referred as cogeneration-plant produce both power and steam is installed to meet process plant requirements. Any change of demand in either power or steam would affect the other. In progressive process plants interconnection of units generating steam at various pressure levels is not uncommon. However, this makes the operation of the system more complex to handle especially during upset conditions. This situation can be handled effectively by carrying out dynamic study of the entire steam system to operate the plant in a safe and at optimum level within the constraints, if any.

  • Enter the future: Robotic gallery, Science city, Ahmedabad

    The prestigious Robotic gallery is an iconic project, first ever of its kind in India. A world class facility to educate the people in the field of robotics and provide the young brains a platform to showcase their innovations. Built by the Gujarat Council of Science City, Department of Science and Technology, the gallery is an epitome of our honourable PM Sh. Narendra Modi’s Digital India movement .

  • Steam Audit: A case study

    Energy cost is one of the significant contributors of production cost for most of the Industries. Hence, reduction in energy consumption electrical, thermal or in any other form always helps in business sustenance and growth. Moreover, as most of the energy is derived from fossil fuels, any reduction in energy consumption would also mean conservation of natural resources and most importantly less environmental impact.

  • Innovative approach of collecting and disposing coarse fly ash:

    Conventionally in most of the thermal power plants, ash from the Economiser (ECO) and Air Preheater (APH) hoppers will be evacuated in slurry form and mixed with the Bottom Ash (BA) which is also extracted in slurry form for further disposal. The ECO and APH ash will not be mixed with Fly Ash (FA) as these are course and not useful for manufacturing the cement.

  • 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.



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.



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


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


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

Hydrocarbon & 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.