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CASE STUDY Control System Integration for Water Treatment Plants for a Utilities Major The Achievement Over 200 person years of effort in less than 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 redefined process requirements as mandated by the regulatory authorities Project Genesis 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 efficiencies 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 efficiencies in innovation, operations and capital and asset management strategies, using bestin-class technologies, processes and competencies The Asset Management Programs, having an execution period of 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 benefits 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 CASE STUDY Control System Integration for Water Treatment Plants for a Utilities Major 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 flexible 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 Scope of work For each of the over 300 projects, TCS is carrying out the following activities: Reviewing the design statement prepared by the consultant/ contractor Plant visit to gather site conditions and information about legacy system Design the new control architecture and prepare a Bill of Materials (BOM) on the basis of which the automation hardware will be purchased Understanding the design statement and preparing a detailed Functional design Specification (FDS) for the PLC software being written PLC logic and graphics development and test procedures documentation Pre-FAT in India, using PLC Simulators Site activities at UK like FAT, SAT and commissioning, training Staffing ● A fixed size onsite ‘Core’ team stationed in the UK for the entire duration of the project ● A fixed 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 fluctuating 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 Benefits ● Standardization leading to higher Re-use ● Highly structured Documentation ● Knowledge base (IP) for future ● Information infrastructure for an integrated enterprise ENGINEERING AND INDUSTRIAL SERVICES ...CASE STUDY Control System Integration for Water Treatment Plants for a Utilities Major About TCS Tata Consultancy Services (TCS) is among the leading global information