CASE 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 redened 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
benets 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 efciencies.
About EIS Business Unit
Engineering and Industrial Services (EIS)
is one of TCSs strategic businesses that
provides single window solutions globally
to help clients realize efciencies in
innovation, operations and capital and
asset management strategies, using best-
in-class technologies, processes and
competencies.
Scope 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 Specication (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.
Stafng
A xed size onsite Core team stationed in the UK for the entire
duration of the project
A 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 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
Benets
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 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