The Project The project involves end to end control systems integration for over 300 water & waste water treatment plants of one of the large utilities company in England.. The statistic
Trang 1CASE STUDY
The Achievement
Over 200 person years of effort in less than 3 years emphasizing extremely high resource ramp-up capability at onsite and offshore
The Project
The project involves end to end control systems integration for over 300 water & waste water treatment plants of one of the large utilities company
in England It covers design, development and implementation of control systems to cater to the redefi ned process requirements as mandated by the regulatory authorities
Project Genesis
The Asset Management Programs, having an execution period of 5 years, are one of the most complex programs in terms its scale of operation in Water Industry The statistics for this project are:
● Work involves a large number of water treatment works, wastewater treatment works and UIDs
● Plants spread across large geographical area England
● Multiple Kit Framework suppliers responsible for supply of various components of the systems
● Client working along with Engineering Service Providers, Design & Build Contractors to manage and deliver the whole capital expenditure program
Project Technologies
TCS has used following tools and technologies for this project
● PLC platforms: Siemens S5 and S7, Rockwell PLC 5, Siemens TI, ABB Sattcons, Alstom PLCs, Texas PLCs, etc
● Human Machine Interfaces based on Siemens and Rockwell interfaces
● SCADA: WinCC, RsView, AFE SCADA, Intellution, etc
Project Implementation Methodology
TCS has used onsite-offshore delivery methodology based on Global Engineering principles for carrying out this project achieving huge cost benefi ts for the client
Offshore activities:
● Design
● Logic development
● Graphics development
● As built documentation Onsite activities
● Optioneering and Site requirements analysis
● Factory Acceptance Test assistance
● Site Acceptance Test assistance
● Commissioning assistance
● Training
ENGINEERING AND INDUSTRIAL SERVICES
Control System Integration for Water
Treatment Plants for a Utilities Major
About Plant Automation
Services Practice
TCS provides vendor neutral services which
leverage domain, technology and software
expertise in the areas of Manufacturing
Execution Systems, Control Systems
Integration and Process Optimization,
enabling clients to reduce the global system
deployment time, integrate business and
plant systems in real time, and achieve
higher levels of process effi ciencies
About EIS Business Unit
Engineering and Industrial Services (EIS)
is one of TCS’s strategic businesses that
provides single window solutions globally
to help clients realize effi ciencies in
innovation, operations and capital and
asset management strategies, using
best-in-class technologies, processes and
competencies
Trang 2Scope of work
For each of the over 300 projects, TCS is carrying out the following activities:
1 Reviewing the design statement prepared by the consultant/ contractor
2 Plant visit to gather site conditions and information about legacy system
3 Design the new control architecture and prepare a Bill of Materials (BOM) on the basis of which the automation hardware will be purchased
4 Understanding the design statement and preparing a detailed Functional design Specifi cation (FDS) for the PLC software being written
5 PLC logic and graphics development and test procedures documentation
6 Pre-FAT in India, using PLC Simulators
7 Site activities at UK like FAT, SAT and commissioning, training
Staffi ng
● A fi xed size onsite ‘Core’ team stationed in the UK for the entire duration of the project
● A fi xed size offshore ‘Core’ team based in TCS, India, for carrying out Project Management activities
● A variable size onsite ‘Implementation’ team that would be ramped up and down as the number of projects (plants taken
up for upgradation) vary
● A variable size offshore ‘Implementation’ team that would be ramped up and down as the number of projects (plants taken up for upgradation) varies
Challenges
● The job required highly competent people at various levels ranging from Program Managers and Engineering Managers through Team Leads, PLC Programmers, and Technical Assistants
● Since the volume of work would be fl uctuating over the period of execution, it was required to have a team that can be ramped up and down based on demand
● Cost and time were major constraints, and had to be done to top quality standards Any compromise on quality had severe legal implications due to our client being part of the regulated industry
● Presence of large variety of legacy systems
● Interface with a large team of organizations related to Engineering design, civil and M&E contracts and host of other product and service providers
Benefi ts
● Standardization leading to higher Re-use
● Highly structured Documentation
● Knowledge base (IP) for future
● Information infrastructure for an integrated enterprise
CASE STUDY
About TCS
Tata Consultancy Services (TCS) is among
the leading global information technology
consulting, services, business process
outsourcing and engineering services
organizations Pioneer of the fl exible
global delivery model, TCS focuses on
delivering cutting edge technology led
business solutions to customers across
varied industries
For More Details, Contact:
Engineering and Industrial Services
Business Unit
Tata Consultancy Services Limited
11th Floor, Air India Building
Nariman Point
Mumbai 400021
Phone: +91-22-5550 9999
Fax: +91-22-5550 9455
www.eis.tcs.com
corporate.engineering@tcs.com
ENGINEERING AND INDUSTRIAL SERVICES
Control System Integration for Water
Treatment Plants for a Utilities Major