ASSET INTEGRITY
MANAGEMENT
including Case Study of
Engagement with
International Client
Asset Integrity Management – Overview
Asset Integrity Management
Enhance
Preamble Asset
To facilitate an asset’s performance as Performance
per required function; effectively and
efficiently whilst protecting health,
safety and environment and complying
to all regulatory standards. Meet ASSET Ensure
Regulatory INTEGRITY Safety in
Standards MANAGEMENT Operations
Philosophy
Create a robust asset integrity
management framework, rigorous
implementation and knowledge
Enabling
management protocols to enable
Asset Life
optimal asset performance. extension
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AIM Life Cycle Process Flow
Inspection Inspections & Pre
AIM Framework Training Execution
Strategy Report Engineering
1. Objectives, 1. Check List, 1. Training 1. Inspection, 1. RFQ for 1. Repair
2. Roles & 2. Road Map, Plan, 2. RAM Matrix, Engineering, 2. Refurbish
Responsibilities, 3. Resource 2. Training 3. Inspection 2. Go Ahead, 3. Replace
3. Standards & Plan, material, Report, 3. OSR,
Regulatory 4. Stake 3. Training 4. Decision 4. Detail
Requirements, holders Making Engineering,
4. Learning & mgmt. 5. Enquiry
Development, Documents
5. Management of for
Change Execution
3
AIM Life Cycle Process Flow
Inspection Inspections & Pre
AIM Framework Training Execution
Strategy Report Engineering
Notifications
Emergency Call outs
AIM Develop (Imminent Risk /
(Engineering by
Framework/ Action High Impact
Strategy Plans onsite team)
Instances)
Inspections
Learning (Onsite Inspectors)
Performance Deploy
Projection and Action
Comparison Plans
notifications Pre-engineering
(Tangible asset (Engineering at
Track Risk) home office)
accomplishme 4
nt
AIM – Inspection to Rectification Process
Pre Engineering Pre Engineering Pre Engineering On Site
Inspection Decision Gate – Estimation – Approvals Execution Implementation
1.AIM Framework 1.Inspection Report 1.Enquiry Document 1.Techno-Commercial 1.Purchase Order / 1.Detail Drawings /
2.Inspection Strategy 2.SAP Notifications (RFQ) Proposal (TCP) Approvals Technical
Inputs
with Checklists 3.Existing drgs. / docs. 2.Inspection Report 2.Resources (Chief 2.Resources (TCE Specifications
3.Resources 4.Ressources 3.Existing drgs. / docs. Engineer, Site Team, home office team and 2.BOQ
(Inspectors, (Champions, SMEs) 4.Resources (TCE SME, Commercial Coordinators at Site)
Operators, Tools) home office team and Team)
Coordinators at Site)
1.Study of Existing
Drawings /
Documents of the 1.Preparation of
1.Preparation and 1.Review of Techno- 1.Selection of
Activity
Asset Enquiry Specification 1.Engineering
Submission of Commercial Proposal Contractors
2.Inspection of the for Home Office Solutions
Proposal (TCP) 2.Execution
Asset Engineering
3.Analysis of the
Inspection carried out
1.Basic Engineering
1.Inspection Report 1.Review and approval
Document including
including Summary, of documents from
Output
1.Release of Purchase OSR / Detail
Problem Statement 1.Enquiry Document 1.Techno-Commercial Contractors
Order / Approval of Drawings / Technical
and Rec’dations (RFQ) Proposal (TCP) 2.Witness & approve
the Man-Hours Specifications
2.RAM Matrix contactor site work up
2.Calculations / BOQs
3.SAP Notifications to commissioning
3.Cost (Client Inputs)
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Case Studies - Assignments Undertaken
Project Approach Scope of work Value created
Power Plant Life 1. Extend Power plant 1. Detailed process study 1. Increased power output by 10%
extension and operating life 2. Create efficiency improvement plan 2. Increased BF gas consumption from
efficiency 2. Maximise BF Gas for various subsystems 100m3 to 110m3
improvement Consumption 3. Creating O&M strategy to enable 3. Improvement in boiler efficiency
3. Improve Efficiency of enhanced parameters (reduced fuel CV and reduced duct
Asset Life operations 4. O&M support with training and pressure)
extension 4. Environmental compliances development programs to operators 4. Additional safety features added to
reduce operational risk
program
Water 1. Detailed AS IS process 1. Detailed cross functional review of 1. Improved output of each stream by 250
treatment plant review with detailed design and performance capabilities M3 - an increase of 30%
interactions with operations 2. Create efficiency improvement plan 2. Improved regeneration efficiency
team 3. Create O&M improvement plan 3. Rinsing duration by more than 70% (90
Operations 2. Evaluate operating costs - based on findings min to 20 min)
develop strategy to optimise 4. On the job training programs
Optimi-
3. Validate process chemistry
sation
EOT Cranes 1. Create Asset Integrity 1. Study of the existing system with 1. Created a program for 280+ cranes
system reliability management framework inputs from O&M team across locations
enhancement 2. Create inspection strategy 2. Provide subject matter expertise to 2. Created Asset Integrity framework which
with checklists interpret the on field issues and create included proactive inspection strategies,
3. Thorough site inspections standards to mitigate issues checklists and training modules
Asset 4. Create reports, action plan 3. Create proactive asset health 3. Created specific life extension plans for
and training modules improvement and life extension plan 18 business critical cranes
Integrity 4. Ensure compliance to health and 4. Conducted rigourous training regime -
Mgmt safety standards reduced downtime and safety risks
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Case study - Safe dismantling of complex LIVE building structure
ASSET RISK
TCE VALUE ADDITION
• C-Tower -a transfer tower built in 1960 used to transport
material to blast furnaces. It is redundant, but provides • Design checks carried out to ensure structural stability at
support to live utility services and cables. The building different stages of dismantling.
has undergone partial collapse in few areas; Internal • Protective coverings on live utilities planned
structures partially removed. Partial collapse of
• Dismantling of brick walls sequence planned to minimize
supporting beams has increased possibility of further
collapse. Earlier attempt for safe dismantling by a vendor transmission of vibration
was not successful. PROJECT SAVINGS
• TCE provided 3 D model based engineering for its safe • GBP 475K against GBP 1500K planned Expenditure through
dismantling. TCE Intervention
CHALLENGES
• Support to various gas mains, service utility lines and
electrical cables.
• Space Constraint due to close proximity of other
structures and facilities.
• Partial collapse of supporting beams increases safety
concern..
• Presence of Asbestos.
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3D Engineering and AIM : Challenges and Issues
Technical: Way of Working: Meeting the Expectation:
Acquaintance with newer Orientation of mindset to work on As Built 3D To understand the expectation
standards like ISO 55000 series, Models reconstructed from 3D scanning and of International contractors for
NEN 2767 series etc., over and accept the fact of non-availability of as built 2D handing over the Pre-
above the knowledge of relevant drawings in most cases engineered pack
design standards of the specific Orientation of mindset for working on As Built To understand the Project
country Assets rather than building new ones Management requirement of
Acquaintance with various safety Change in working in the way that engineering to the specific country
norms for plants and equipment be done on part upon understanding the whole, To understand the quality
Acquaintance with country rather than doing engineering for the whole demand of International client
specific legislative standards To reach to ideal resource mix for this type of work with respect to Indian client
Knowledge of Fatigue,
Dynamics, and aging effect from
natural forces
Knowledge of effect of
sustaining process/equipment
behavior after prolonged period
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References
Plant Digitization
Refinery Plant – As Is Site Condition Explosion Proof
Laser Scanning
by Z+F
Model Centric AIM
Engineering Drawings Scan PDF to 2D
Individual Asset Unstructured Data
(Digital Handover)
Final Validated Drawings and Documents
Interlinking of all the documents with 3D Model for Asset Integrity
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Plant Digitization
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Plant Digitization – Petrochemical Case Study
Project Phase-2
Point cloud Data Objectives
a) Replacement of the Heat Exchangers & 140
Pipelines
b) Re-verification of existing data
c) Digitization of plant for future engineering
d) Change the material from CS to SS
Challenges Faced
a) Revamping lines are in between of big bore lines; so
many places scanning was not possible
3D Model Output
b) Because of the Scaffolding, data was not captured
properly
c) Line tagging was not available on line; so faced
issues for identification of lines
d) Scanning equipment could not be carried to few
locations, due to its heavy weight; so captured
sections for reference only
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Plant Digitization – Metals Case Study
Steel Plant Laser Scan Development - Blast Furnace 6 - Revamp
Point cloud Data Objectives
a) Blast Furnace was old and has to under go Revamp
b) Re-verification of existing data
c) Digitization of plant for future engineering
d) To change and upgrade the Furnace
Challenges Faced
a) Old Plant - availability of data was less for Revamp
b) Because of the Scaffolding, data was not captured
properly
3D Model Output c) Line tagging was not available on line, so faced
issues for identification of lines
d) P&IDs were not available - difficult to identify lines,
Valves, Instrument tags etc.
e) Scanning equipment could not be carried to few
locations, due to its heavy weight; so captured
sections for reference only
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Smart Cities – our footprint
All figures in Rs. Cr.
Madhya Pradesh
Bhopal Smart City
Satna Smart City
Total Investment (in Cr) - 4126
Assam
Guwahati Smart City
Total Investment (in Cr) - 2100
Gujarat
Ahmedabad Smart City Tripura
Vadodara Smart City Agartala Smart City
Surat Smart City Total Investment (in Cr) - 2018
Gandhinagar Smart City
Dahod Smart City
Silvasa Smart city Chhatisgarh
Total Investment (in Cr) – 5722 Raipur Smart City
Total Investment (in Cr) - 3939
Odisha
Karnataka
Rourkela Smart City
Hubballi Dharwad Smart City
Total Investment (in Cr) - 2500
Shivamogga Smart City
Total Investment (in Cr) - 3670
CONFIDENTIAL 14
Smart City Components
24x7 water supply
Add Photo or Graphic if SCADA / DMA
Smart water meters
available from site visit / Reuse of treated Sewage water and Dual plumbing
system
site appreciation /
waste water collection network
Manhole monitoring system
Google Earth
Sewerage Treatment Plant of 4MLD
Green streets for storm water percolation
Add Photo or Graphic if
Installation of solar roof topping
available from site visit /
Utility Corridor
Smart Meters – Bidirectional meter
site appreciation /
Energy Efficient
LED Street Lights
Google Earth
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Command and Control Centre
AAQMS
IOC
DATA CENTER & CONTACT / CALL
STORAGE CENTER
OPEN ACCESS
NETWORK
PASSIVE CITY
INFRASTRUCTURE
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Mines – Tailing Dams
Real time monitoring & health management of tailing dams
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Mines – Material Handling
• Rope Tension Monitoring
• Conveyor Health Monitoring
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4000MW UMPP, Mundra
• Owner : CGPL4000MW UMPP, Mundra
• Client : CGPL
• Capacity : 5 X 800MW
• Turbo Generator building : 43 meters X 510 meters X 39 meter
• Structural steel (Approx.) : 28000 tonnes
• Project Stage : completed c
• Salient Features : 2X 240 T Tandem operated crane
• TCE Scope of Works : Conceptualization, Layout studies, optimization Studies,
Constructability studies, design & detailing of TG building including
TG Foundation, procurement services, review of fabrication drawings, field
engineering services
CONFIDENTIAL 19
TSTPP, Ramagundam, Telengana Main Power House with CCR
• Owner : NTPC Ltd
• Client : Alstom Bharat Forge Power Pvt Ltd.(ABFPPL)
• Capacity : 2 X 800MW
• Turbo Generator building : 41 meters X 290.5 meters (including control room) X 38 meter
• Structural steel (Approx.) : 14000 tonnes c
• Project Stage : Under Construction
• Salient Features : Differential settlement analysis carried out as per NTPC requirement
• TCE Scope of Works : Design & detailing of TG building including TG Foundation, review of
fabrication drawings
CONFIDENTIAL 20
Main Power House
#2
• M/s National Thermal Power Corporation Limited intends to
set up Telangana Super Thermal Power Project, Stage-I
(2X800MW) and Stage-2 (3x800MW) capacity near
Ramagundam, Karimnagar district of Telangana State.
• M/s NTPC has awarded STG package for Stage-1
(2x800MW) to M/s Alstom Bharat Forge Power Pvt. Ltd. Tata
Consulting Engineers Limited is providing the consulting
engineering services to M/s ABFPL for this project.
• The scope of services includes Structural & Architectural
works for Main Power House with Control Building, Service
Building, CPU Re-Generation Building, H2 Cylinder Shed and
other Miscellaneous works like Roads, Drains, Landscaping
related to the STG package
Snapshots from POSCO 335MW STG Building
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STATUE OF UNITY
PROJECT COST
2989 Cr.
YEAR OF COMPLETION
40 Months
(Construction)
Owner - SVPRET
Employer - SSNNL
PMC
• Turner, Meinnhardt
,MGA consortium
PC - Egis TCE JV
EPC Contractor - L &T
STATUE OF UNITY
AT SADHU ISLAND, KEVADIA- GUJARAT; PROOF CONSULTANCY SERVICES BY (EGIS & TCE ) JV.
Super structure Description
Primary Cladding - support steelwork
Viewing Gallery (193 m)
Area for plant And TMDs
Coupling Walls
Connecting ‘Torsion Slabs’ Typically at 11m
Bottom of Connecting Walls (116 m) vertical centres for Height of coupling walls
Cores
Drum Structure below
Drum roof level (83 m)
Statue Design: Structural Considerations/Challenges
Steel space frame to support cladding
Damper
To counter wind
effect.
Observation Deck
Elevators
Cladding Material
Some degree of
perforation required
to reduce wind load.
Small Base
Design Challenge
(most statues have
wide bases)
Two cylindrical reinforced concrete cores to match diameter of
legs
Structural Value Addition
• Foundation thickness originally proposed by ARUP UK was 3m and that is increased 4m around core areas
where concentrations of forces were significant under sever load combination and same was accepted by
L&T, accordingly execution of raft foundation done.
• Detailing of reinforcement in main cores and connection to other cross shear walls and outer core in base are
improvised to absorb and transfer forces very effectively with incorporation of boundary elements.
• Configuration of coupling wall connecting both the cores with changes in detailing of reinforcement for better
and effective structural behaviour.
• Configuration of steel framing to support bronze façade was improved to handle large cantilever under higher
forces at large heights
• Statue base and statue structural system and detailing were improvised for transfer forces effectively to
foundation and to impart additional redundancy into the structure under all worst load combination with
alternate load paths under accidental loads case.
• Torsion slab connecting cores at different levels are also improvised to handle torsion effectively under wind
or seismic of different directions.
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