INDEX Name Security Printing And Minting Corporation Of India Limited Security Printing And Minting Corporation Of India Limited Security Printing And Minting Corporation Of India Limited Sal Institute Of Technology & Engineering Research Airports Authority Of India, Bhubaneswar Airports Authority Of India Airports Authority Of India Airports Authority Of India Airports Authority Of India Braithwaite & Co. Limited Autoprint Machinery Mfg Pvt Ltd National Buildings Construction Corporation Limited National Buildings Construction Corporation Limited National Buildings Construction Corporation Limited Adani Power Limited Beml Limited Beml Limited Ongc Tripura Power Company Limited "Delhi Tourism & TransportationDevelopment Corporation (Dttdc) Ltd." Hscc (India) Ltd. Hindustan Aeronautics Limited Vedanta Aluminium Ltd. Vedanta Aluminium Ltd. Vedanta Aluminium Ltd. Vedanta Aluminium Limited, Lanjigarh Larsen & Toubro Construction Mahimtura Consultants Pvt. Ltd. Csir-Cftri Hll Lifecare Limited Csir-Central Building Research Institute, Roorkee-247667, India Cesc Limited Jk Files (India) Limited Ring Plus Aqua Bharatiya Nabhikiya Vidyut Nigam Limited (Bhavini) Uranium Corporation Of India Limited Globus Infocom Limited
Project Name Modernization Of Bank Note Press, Dewas Modernization Of Ink Factory, Bank Note Press, Dewas Indigenization Of Banknote Paper Production Novel Drip Irrigation,Novel Speed Breaker,Novel Water Power Clock Construction Of New Terminal Building At B P Airport,Bhubaneswar Construction Of New Expandable Modular Integrated Terminal Building At Raipur Airport. Construction Of New Integrated Passenger Terminal Building At Birsa Munda Airport, Ranchi. Construction Of New Domestic And International Terminals At Chennai Airport. New Integrated Passenger Terminal Building, Kolkata Btfln Wagon Manufactured First Time For Indian Railways Checkmate 65 – Print Inspection System Indian Institute Of Corporate Affairs, Manesar (Hr) Epc Of Complete Civil, Structural And Architectural Work Of Main Power Plant And Procurement & Erection Of Eot Crane For 2X250 Mw Unit 1 & 2 Korba (East) Thermal Power Station, Chhattisgarh To Carry Out Planning, Designing, Construction As Well As Liasoning For Various Approvals For Cbi Head Quarter Building At Envelope 5-B, Cgo Complex, Lodhi Road, New Delhi. Adani Power Limited, Mundra – 4620 Mw Design And Development Of 150 Ton Electric Ac Drive Dump Truck Design & Development Of World Class Stainless Steel Electrical Multiple Units (Ss Emu’S) Ongc Tripura Power Company Ltd Dilli Haat At Pitampura, New Delhi Specialised Centre For Treatment Of Sports Injuries Weaponisation Of Advanced Light Helicopter ‘Rudra’ (Alh-Mk-Iv) Conversion Of Esp To Hybrid Esp Initiatives For Reduction In Energy Consumption By Slotted Anodes Revese Osmosis Treatment Of Effluent Water Red Mud Filtration And Recovery Of Valuable Metals Pragati - G+ 23 Storeys Total Precast Residential Building Wankhede Stadium At Mumbai Development Of Machinery For Traditional Foods- A Continuous Chapati (Indian Unleavened Flat Bread) Machine Automation Of Needle Assembly In Blood Bags Csir-Cbri Liquid Extinguishant Fire Extinguisher For Common Man'S Fire Safety Distribution Related Engineering Asset Management System (Dreams) Redesign & Technology Infusion In “Engineering Files” Manufacturing Process. Automated Shaft Bearing Assembly Line Prototype Fast Breeder Reactor Project (Pfbr) Remote Asset Tracking In Ucil'S Underground Mine Magic Studio
Shri. Praful Patel
Shri Sushil Kumar Singh
The Rise of India over the years has seen a significant contribution from the indigenous engineering sector predominantly led by the Public Sector Enterprises. The private is nevertheless catching up in helping the country become self�reliant in core engineering and technologies.I believe that this engineering excellence awards 2013 to celebrate the engineering marvels created by the engineers/scientists/technologists working relentlessly in various engineering organisations.
I offer my thanks to Engineering Watch magazine for their Engineering Excellence Award wherein they are felicitating the engineering marvels across the country. It will encourage our engineering community to work for more betterment and development of the country.
Minister of Heavy Industries and Public Enterprises
Member of Parliament, Aurangabad, Bihar
Shri O. P. Rawat
Dr. S. S. Mantha
Engineering Excellence Awards is an important initiative facilitating engineering skills, creation & innovation and demonstrating them to the society. Events like Engineering Excellence Awards help in bolstering the engineering developments in our country.
There is a big difference between what engineers do and what technology is built around an engineering concept. Engineering needs reformation and Engineering Excellence Awards is an initiative towards re窶親ngineering India.
Secretary [Department of Public Enterprise, Ministry of Heavy Industries & Public Enterprises
Chairman, AICTE
Prof. Tarkeshwar Kumar Director, NIT Durgapur
I strongly believe that the young generation of the engineering field would be getting more inspiration, motivation to work in the field of engineering. This will help to prove their vast knowledge as well as their skill. The efforts of "Engineering Watch" to recognize and ward the engineering talent will ultimately help in the development of our country.
Dr. Ajit Pathak
Dy. General Manger (Corporate Communication), India Oil National President, Public Relation Society of India (PRSI)
Excellence to me is a way of like and is something which gives you an edge over others. Out of box thinking, creativity ,new thinking is what is required in today's world. In today's time when the whole world is looking at India as an emerging power this excellence is going to support our cause. We in Public Relation Society of India (PRSI) believe in getting associated with any project which gives India an edge over others. This reorganization of the good work will certainly promote excellence and this is what is the mission of Public Relation Society of India (PRSI).
Prof. P. B. Sharma
Vice Chancellor, Delhi Technological University
Engineering has tremendous future and the effort of Engineering Watch magazine in recognizing and rewarding the best engineering marvels created in this country would go a long way and will create vital excitement in the minds of young generation. Let Engineering Excellence Award be the inspiration for pursuing engineering with more devotion and commitment to create bright future for the coming generation.
Prof. Madhusudan Chakraborty Director, Indian Institute of Technology, Bhubaneswar
Engineering Watch
Engineering Marvels of India AIRPORTS AUTHORITY OF INDIA, BHUBANESWAR, ODISHA
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
Very economical roof structure
Completed the total work with saving of more than
Most economically designed with
The state of art new terminal
The building is so designed that to
equipped with modern amenities which not only catapulted the flow of passenger to the state capital but also augmented the issue providing international connectivity
cater for future growth up to five
design with App 44.00kg/ sqm of steel utilization. Profile of roof structure developed
10% in overall cost of the project. By adopting sloping down approach in car park
with blend of locale and contemporary art.
area, it resulted in cost saving on account of earth filling and as well as limited use of natural resource(earth/moorum, etc)
The concept of building evolved
There are 42 numbers agencies with different
from requirement of short and direct flow from city side to aircraft.
approach and mind set worked together in close coordination to integrant various systems to achieve the completion without cost overrun and later stage dismantling etc.
Segregated internal, external
arriving and departing forecourts. Liogicle sequential layout of correct
Energy efficient light fittings and Building
sized space set to meet column free large area
management system to reduce the power consumption. By provision of slant sky lights in roof no lighting is
required in day time for main converse of building. Power supply is planned by using solar power for
sustainable development partly. Accident free execution of complete project and
not even a single tree cut in the project execution
most energy efficient 5 star rating in meeting green norms Maximum utilization of solar energy
in the way of sky light in building and solar panel for power generation. Absolutely nil requirement of power for lighting inside the terminal in day tme.
Now Bhubaneswar city on global
map encouraging and attracting the global investor to look towards state Odish for their various industries & tourism projects.
Horizontally expandable user
The new terminal has created job
friendly modular design to ensure smooth flow of passengers
opportunity to the several and thus helping in overall economic growth in the region
All parameter to protect the
environment and natural resource has been adopted by providing rain water harvesting system as well as recycling the treated water from STP for gardening.
The state has immensely helped
with growing number of inflow of tourist The new project has developed by
keeping in view the future requirement with modular design concept thus self sustainable for long time.
years The structure is so designed that
horizontal expansion is possible without disturbing the existing facility. For long term requirement. The space for commercial activities,
Hotels & Restaurants are identified & resume for future growth. State Government feeder bus
service connecting the airport with rail head & road head is in place for convener of passengers. Total 816 acre of land is available
which can be exploited for various civil aviation activities, commercial activities and tourism activities.
Engineering Watch
Engineering Marvels of India
NEW INTEGRATED PASSENGER TERMINAL BUILDING, KOLKATA Kolkata Airport's New Integrated (Domestic & International) Terminal reflects the vision of a world class terminal that integrates cutting edge technology blended with unique local cultural heritage. This modern glass-steel structure is constructed based on Green Building concept, Environment friendly technology and world-class passenger facilitation.
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
It is a complete green concept building
Cost of the building is only 2200 crore comparatively
Boost up the economy of the state by
Big facilities and relief to the
It can handle 20 million passengers in
with maximum use of natural sunlight extensive interior & exterior greenery, rain water harvesting, energy efficiency & other environment friendly features.
less than other major Airport Terminal building in India such as Delhi, Hyderabad, Bangalore, when compared on per sq mtr cost basis.
passenger moving in and out to the Kolkata.
future as compared to 11 million passengers as of now.
north east India & south Asia – link for business & tourism development.
Green energy Airport with minimum in
Building is Designed for the year 2020
Shall allow more domestic &
Use of local architecture like Tagore
international airlines to fly in & out thereby more passenger connectivity & more prospects for business.
script and bamboo like ceiling in the terminal building.
Use of Long span steel structure of
span more than 100 mtr and using state-of-the art modern technology and with the help hydraulic jack of capacity (200 MT & 140 MT) to lift the truss of more than 125 mtr length & weighing 135 MT. Underground Car park with landscape
on top of the structure for better aesthetic look, enhancing exterior greenery & environmental friendly features. Innovation in architecture design for
minimize the travel transit time of passenger through terminal by providing self-sufficient Baggage Handling System to match the facilities with the world class standardization airport infrastructure.
Major project completed with in approval time frame
without any cost over run. Ground area was a pond, it was a herculean task to
execute the work and to excavate almost 5 lakh Cam operator, 4 lakh cum of concrete, 50,000m of steel and 11,000 mt of structure steel.
direct and indirect employment. Shall work as aviation hub airport for
Innovative technology used for
Almost accident free execution and construction of
construction in this project has provide expertise to local engineers like hydraulic lift jack for structure etc will help in future construction work.
building by adopting utmost safety and security parameters.
It is a showcase project for Airports
Mobilization of huge resources including almost 5000
labour as daily basis.
Authority of India which has unique architecture design matching any of the world class airport infrastructure and lead to expertise in domestic as well as foreign airport projects.
consumption of electricity.
for Domestic & 2023 for International passengers. Design of the building is based on the
Passing the standard of the PSU's
green building & energy efficient concept making the terminal future demand compliance.
equal to or above the level of Pvt. Sector.
Building has been designed with
Upgradation of passenger facilities for
enhanced passenger & airline comfort resulting in improved organisational image for Airports Authority of India.
modular terminal concept facilitating easy and cost economic expansion plan to meet future traffic growth. Rain water harvesting, energy
efficiency & environment friendly features is used in the building resulting into optimum utilisation of natural resources.
Engineering Watch
Engineering Marvels of India
AIRPORTS AUTHORITY OF INDIA, TAMIL NADU
INNOVATION
OPERATIONAL EXCELLENCE
The airport is elegant modern
structures defined by dramatic, twin wing-like hovering roofs providing 300 meter long, column free space.
The Implementation of this project has been carried out in a busy brown field airport in India.
Site has been handed over in Domestic in 6 phases , International in 7 phases and elevated corridor in 11 phases.
The buildings are open-web, steel
superstructure subtly rises to support twin curved roofs that define a light and open, columnfree terminal. Skylights highlight the geometry of
the trusses, further defining the structural framework to allow natural light to permeate the terminal with a constantly changing pattern of shade and shadow. The Arrival tube connects the land
side with the airside operations through the central court yard. Use of latest technologies, HVAC
chiller load management through micro processor controls, lux sensors in lighting controls, CFL & T5 lamps in illumination.
The execution of Project also involved of creating alternate arrangement for crucial and important infrastructure for Electric cable and operational cable, sub station to avoid disturbance in important installations. Though the time of execution has exceeded from original plan because of above mentioned reasons, but in brown-field airport project, when it compare to similar situation, it is very competitive and can termed as well performed project. To mitigate the inflation of market only escalation as terms of contract paid & otherwise the whole project is within the approved cost.
Self Reliance
After completion of the project, added to self reliance on Tourism. More numbers of tourist are expected in the southern India from domestic & international and will boost the economy of the country. Vast expansion of the airport will definitely help in growth of industries in the south India. After the construction of new terminal, will definitely increase employment in indirect & indirect way. AAI being a Government Organization, can also built such a wonderful and huge Terminal Building in brown field airport to compete in the market.
Impact
It has made a positive impact on the growth of Tourism sector in the southern India also boost the economy of the country.
Future Readiness
New buildings are modular in design and constructed for future modernization of existing terminals. The expansion can be carried in place of existing terminals with similar model giving extended look.
The elevated corridor connecting the new international and domesticterminal is constructed.
Considering the future requirement, car parking space has been planned for construction of Multi Level car parking.
Sub-Station is constructed and fully equipped for catering power for future requirement.
Chennai Airport shall have Metro rail station inside the Airport premises in future with terminal having concourse, platform, parking for Metro and Airport Users.
New World class terminals have the added advantage on growing of various industries It met the continuous demands in aviation sector, where more airlines can operate, also has an impact on generating employment. It added a great impact in competence that a PSU can also built such a wonderful and huge Terminal Building in brown field airport to compete in the Transportation sector with private parties. This modern and world class terminal having the huge capacity of passenger handling has made the great impact on enhancing the education and medical facilities in Chennai and Southern part of India.
Engineering Watch
Engineering Marvels of India
AIRPORTS AUTHORITY OF INDIA, JHARKHAND
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
Various energy efficient/ conservative
Various energy efficient/conservative measures were
The Integrated Terminal Building,
This project has increased the peak
The Terminal Building is of modular
adopted in the terminal building making it effective/efficient use/conservation of precious energy like HVAC SYSTEM, BAGGAGE HANDLING CONVEYOR SYSTEM, AIR ASPIRATION SYSTEM, etc
Ranchi having both Domestic and International facilities can be utilized to operate air connectivity to any foreign countries.
hour handling capacity from 250 (Domestic) to 700 (Domestic & International).
construction, which can be easily expanded depending upon the future growth without disturbing the present facilities available.
measures were adopted in the terminal building making it effective /efficient use /conservation of precious energy. The terminal building is installed with
latest technology equipment like HVAC SYSTEM, AIR ASPIRATION SYSTEM, PUBLIC ADDRESS SYSTEM,HYDRO PNEUMATIC, etc
A 100 KWp Solar Power Plant (Off grid) is being installed on terrace of building. With its operation energy expenditure will reduce.
Various sustainable development measures are taken
like solar power plants, back wash water, etc
receive International Flights at Ranchi.
With the improved/ new infrastructure
direct and indirect employment increased, thereby booming on employment opportunities in aviation, tourism, industry sectors. The new infrastructure and better air
connectivity results in growth of economy in tourism sector of the State and overall growth for nation.
In this building measures are taken to
depict Jharkhand culture through display of the following themes of Murals and art work.
This project has created facilities to
Increase in air connectivity, increase in visit of tourists and increase in business potential will improve the economic condition of Jharkhand State.
With free night parking facilities airline
operators are willing to operate more flights from Ranchi, better facilitation to Ranchi air passengers.
Water from STP is utilized for makeup
water of cooling tower and that from ETP is utilized for flushing of toilets & gardening there by water consumption of terminal building has been drastically reduced.
With the improved/ new infrastructure
direct and indirect employment increased, thereby booming on employment opportunities in aviation, tourism, industry sectors.
With the new infrastructure, the old
passenger terminal building is proposed to convert into Cargo Complex which will boost the Cargo operation from this airport, facilitation to Jharkhand State and source of revenue to airport authority. With the improved/ new infrastructure
direct and indirect employment increased, thereby booming on employment opportunities in aviation, tourism, industry sectors. Plans are in hand for installing solar power
plants in the operational area of airport in a phased manner to reduce the electrical energy consumption/ expenditure of commercial power supply. The STP/ETP plant installed along with
new terminal building is proposed to be utilized for a treatment of sewerage/effluent discharging from other buildings in the airport area viz old terminal building, new technical block and control tower building, CISF barracks building etc. The treated water from STP/ETP will be used on HVAC, urinal / WC flushing purpose thereby the demand on raw water supply can be drastically reduced.
Engineering Watch
Engineering Marvels of India
AIRPORTS AUTHORITY OF INDIA, CHHATTISGARH
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
Highly complex geometry of
Despite delay in completion, the project cost has
Materials palliate has been
It will add to the economic
It is a spacious building with about
primary roof trusses, bi-directional curvature with skylight throughout provides beautiful view from inside.
been maintained within estimated cost by continuous monitoring and taking timely cost cutting measures but without compromising on functional requirements.
optimized to use most locally available materials.
development, improve connectivity and promote tourism.
An Indian firm has executed the
It will inspire others to promote
26.5 sqm, plinth area per passenger in peak hours. It provides scope to deal with increasing traffic demand for next 10 years or so.
Lot of space and short travel distance for
work with Indian expertise. The consultant is an Indian firm.
greenery around man-made structures.
Currently there is no international
Successful completion of
A solar power plant of 100 KW has
Its organic form deriving its genesis
from an “avian” is conceived with a sliced dome at the centre and multiple wings elevating the roof profile towards the sky. A green belt with a meandering
water channel cladded with glass tiles and art pieces provides the passenger a refreshing view.
circulation inside for the passengers.
The system has the capability to power saving
marvelous building with most of Indian materials and technologies will generate self confidence in Indian organizations associated with such project in various ways. Even the Indian manufacturers will be inspired to produce materials which had to be imported.
mode by provision of skylight and glazed walls to keep the building lighted in day time.
been established on roof of service block to generate solar power. Sewerage treatment plant for recycling treated water for horticulture purpose has been established. All of these efforts contribute to use of non conventional means of power and preservation of water resources.
Display of local Indian arts inside
The terminal building has inspired
terminal building will generate interest among domestic/ international tourists about Indian handicrafts, which will boost local handicraft industry as well.
State Govt. to make additional land available for future expansion.
All required facilities had been installed for
physically challenged passengers & mothers with small babies with world class mechanical and electrical equipment. The sturdy and maintenance free materials had
been Outside greenery, beautiful
landscapes, waterfalls and fountains provide a perfect blend man-made structure and nature's beauty. Parking cars on green grass adds to
the rain water harvesting as well.
used in the construction.
Successful completion of this
project has highlighted capacity of AAI as an organization to deliver such project at competitive cost.
operation but provisions have been made to start the same without problem whenever demand arises. There are possibilities of expansion
through modular design. It is a structure with contemporary
urban form.This will ensure that building doesn't look old fashioned in coming years. Generation of solar power, rain
water harvesting, and use of recycled sewage will help to tackle future needs of energy and water.
Engineering Watch
Engineering Marvels of India
ADANI POWER LIMITED MUNDRA ‐ 4620 MW
INNOVATION First Supercritical unit commissioned in
India First Subcritical unit of 330 MW capacity in
India Glass Reinforced Plastic (GRP) pipe of
largest diameter (2800mm) used for first time in India for cooling water system in a power plant. First 660 MW unit with sea water based
Flue Gas Desulphurisation (FGD) First Power plant in India in the Private
sector, with +/- 500kV High Voltage Direct Current (HVDC) Transmission lines
OPERATIONAL EXCELLENCE 80% Ash utilization
Self Reliance Education: Adani Foundation provides
support in the areas of infrastructure improvement and material support to make schooling more attractive & meaningful, various programs are organized to make education fun and interesting.
High standard of operational safety with implementation
of Lock out Tag out (LOTO) and standard isolation procedure Water conservation through dry Fly ash handling system
and Bottom ash and service water recycling
Community Health: Arranging multi-
disciplinary medical camps at villages, spread the awareness on health and sanitation issues, promoting the Kitchen Garden concept
Minimum Demineralised(DM) water make up by
optimizing soot blowing and leakages Optimum Man/MW ratio with increased productivity Outstanding energy saving initiatives with 2 consecutive
Bureau of Energy Efficiency (BEE) awards in last 2 years.
Sustainable Livelihood Projects: We aim
to make the livelihood of people in the community sustainable in three ways: increase income if they are already
earning equip them to earning if they are
unemployed
encourage savings
Rural Infrastructure Development: Rural
Infrastructure Development like hand pump installation, repairing public wells, anganwadi buildings, overhead water tank, water pipe lines construction etc have been completed as part of this initiative
Impact Strict environmental norms being fully
adhered to Large scale Greenery development in a
dry coastal area Improvement of livelihood in the nearby
villages Development of Roads in that area Increase of Employment opportunities in
that region
Future Readiness Used the best-in-class technologies which
are also upgradable. In order to ensure sustainability, we have
got accreditation with Quality Management System – ISO 9001-2008 & OHSAS 18001-2007.
Engineering Watch
Engineering Marvels of India
AUTOPRINT MACHINERY MFG. PVT. LTD
INNOVATION Works at very high speed of
OPERATIONAL EXCELLENCE
Self Reliance
To integrate Camera for Print Inspection.
Very reliable system similar to Currency Inspection.
Change of Manual process to Complete Automation.
Presently there is no manufacture in India and very few in developed countries.
150m/min. Inspects about 50,000 cartons per
hour.
Segregating good and bad jobs.
Smoothly differentiate Good /
Rejection.
Setting flexible standard for inspection.
Impact
100% assured quality to customers.
Quality as a culture in the organization.
Minimize rejections through process control.
good cartons. MIS reports on Inspection data. Top loading nonstop operation.
Locating and highlighting errors.
Fully indigenous product without any collaboration.
So far dependent on Imports, now self reliable. Product quality to end user is 100% assured. Helps in process control and process improvement.
Presently this sector is not automated Need for Automation in view of shortage of skilled labour. Need for consistent quality in view
of raising exports. Need to control rejections/process
Servo Controlled orderly delivery of
Future Readiness
Faster turnaround time.
in order to control costs Need to compet with Global
Effective Utilization of Man power.
manufactures to provide quality products. Need for faster turnaround time in
view of technological advancements.
Engineering Watch
Engineering Marvels of India
BEML LIMITED
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
AC Drive technology is the most
This project was entirely handled by BEML -
This project has demonstrated
Electric drive Dump trucks will mark
This product features latest
inherent technological strength of Indian companies to design and develop such products.
the beginning of new technology era in mining operations.
advanced diagnostic element with data acquisition which enables tracking the equipment health parameters offline and online.
sophisticated driveline technology available today. State-of-the-art-Truck features
diagnostics tool that consolidates truck diagnostic information to speed up troubleshooting and reduce downtime. Equipped with Dashboard mounted
AC provides maximum comfort to operator.
Technology division. It is the first 150 ton dump truck designed and
developed by an Indian company and on deployment will become first 150T AC truck to operate in Indian mines. Project completed within 12 months against
targeted 18 months. Project cost around Rs 12 crores well below
High-end Operator seat along with
tillable telescopic steering column ensures continuous comfort to operator and increases Equipment productivity and operator efficiency. Engine rate for mining application
with MCRS technology ensures optimum fuel consumption and ensures responsive engine under most demanding conditions.
budgeted cost of Rs 20 crores. This truck offer many advantages like improved
cycle time due to higher speed and grade ability, fewer components delivering lower maintenance and higher availability and reduced wear on the primary braking system due to electrical retarding.
The Product being on par with
international players resulted in substantial savings to Indian mining companies who otherwise have to import and depend on foreign suppliers. The successful launching of this
product has paved way for design and development of bigger and more innovative products in this sector thereby reducing dependence on foreign suppliers. The completion of this project has
created manufacturing base for similar products. This product serves as import
substitute and thereby helps in saving foreign exchange.
This project has given vital input to
mega scale mining projects and paves the way for cost effective operations with indigenous equipment. Maintenance free operations
guarantee highly reliable performance, high MTBF and excellent availability of equipment. The launch of this product has
created confidence in Indian mining operators and future possibilities of custom designed machinery by Indian companies All our present customers mainly
Coal companies have evinced lot of interest and equipment demonstrations made during the inspection.
The safety features ensure 'right
truck operation' and giving utmost protection to equipment and Operator. Brake system is all hydraulic type
and operates in tandem with electric retardation of the AC drive system for maximum effectiveness and longer brake life. Product has built-in diagnostic
display and quick coupler for pressure mapping, which speed up troubleshooting and helps to keep downtime to minimum. This product meets safety
requirements prescribed by DGMS (Director General of Mine Safety).
Engineering Watch
Engineering Marvels of India
BEML LIMITED
INNOVATION
The Stainless steel EMU Carbody has been designed, developed, tested and supplied to Indian Railways for the first time in the country through in-house R&D efforts without any foreign collaboration. Spot welding has been used extensively for joining the various parts of the carbody & the complete manufacturing process for stainless steel carbodies has been established. The SS EMU carbody requires special Austenitic Stainless Steel which was developed to withstand the corrosive coastal atmosphere after close interaction with indigenous Stainless Steel manufacturers in the country, eliminating dependence on foreign suppliers. The SS EMU front nosed cone has been aerodynamically & aesthetically designed with FRP with indigenous design, making the nation self-reliant in Rail car exterior design technology.
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
The use of Stainless Steel in the EMU body is
After introduction of the SS EMU
An innovative stainless steel 3.66 m
Complete carbody designed out of
going to increase the life of the coaches and is expected to provide extra revenue to Indian Railways.
coaches into revenue services and recognizing the long run advantages over the existing mild steel coaches, Indian Railways plans to replace the existing 3000 no's of mild steel EMU coaches with the newly developed Stainless steel EMU's. The total business expected from SS EMU is about INR 1000 crores per year. Considering the technological and commercial benefits of SS EMU's, all the future production of EMU's is expected to be manufactured with stainless steel only. Even the Tier- II Metro corporations are considering to adopt the SS EMU design as an option for low cost Metro Rolling Stock.
Development of sub-vendors has enhanced the
capability of stainless steel fabrication technology in the country. The SS EMU developed by BEML facilitates the
common man in India to get pleasure of traveling in the SS EMU at the same affordable price, which gives a feel of traveling in the world class coaches. Based on the successful commercial service of
prototype rake, Indian railways have placed additional supply order for 4 rakes of SS EMU valuing about 84 crores. Also, Mumbai Rail Vikas Corporation (MRVC) were impressed by unique features of the SS EMU prototype rake and have floated tender for 153 SS EMU Coaches for their harbour line.
wide carbody design is capable of withstanding super dense crush load of 16 passengers / sqm and does not require any painting which eliminates the periodic maintenance and the associated downtimes involved in the conventional painted EMU's.
The interiors of SS EMU have been
innovatively designed to be on par with that of the world-class coach interiors with extensive use of FRP panels
The windows have been designed
in such a way that it not only cater to the present requirement of non-AC EMU's but also for future requirement of Air Conditioned EMU's.
Ergonomically designed passenger
seats with polycarbonate material and with dual tone shade to match the FRP interiors.
The conventional mild steel
structure front end of the motor coach has been replaced with an aerodynamically designed FRP cab mask and cab skirt which provides a modern aesthetic appeal to the coach.
Stainless Steel offers longer life and hence additional revenue without having to invest on new coaches. Aerodynamically designed front nose cone along with reduction in tare weight leads to lesser specific energy consumption and lower operational cost. Because of stainless steel usage and elimination of painting, the maintenance down times are reduced and hence higher availability of coaches leading to higher revenue. Ergonomically designed passenger seats provide more comfort to passengers. FRP interiors decrease the drivers' fatigue. SS EMU developed by BEML facilitates common man in India to get pleasure of traveling in a world class SS EMU coaches at the same affordable price.
Engineering Watch
Engineering Marvels of India BRAITHWAITE & CO. LIMITED, KOLKATA
INNOVATION
OPERATIONAL EXCELLENCE Self Reliance
Impact
Future Readiness
Company interacted with RITES &
BCL received order on August 2010. The Wagon
The tare weight has
BCL has established its position of having
During the year 2012-13, the
RDSO approached some innovative breakthrough in respect of design & material specification.
was ready for commercial production in February 2012 after overcoming several hurdles faced due to corrections in design / drawing & material availability/specification. Finally the Order has been completed on 30th Sept'12 (as per schedule) without getting an imposition of any liquidation damage by Railway Board.
reduced by 4T resulting in about 7% improvement in carrying capacity.
capabilities of executing similar types of new assignments.
company has received repeat order of 480 nos of BTFLN Order which is under execution.
BCL successfully completed
contract of 250 Nos of Wagons in time.
There is no cost overrun of the Project as it was BTFLN product is upgraded with
latest design, capable of higher carrying capacity and equipped to run with higher speed. BTFLN has all welded construction
in which the barrel is mounted on two cradles and a central longitudinal member running all through the length of the wagon between the bodies bolsters. High Tensile Steel has been used to
keep the manufacturing cost lower while ensuring higher strength.
completed as per schedule.
The Company is in preferred position to get The wagon has exactly
repeat order of the same wagon, whose demand is very much visible in future.
same length and pitch of loading / unloading valves as the existing BTPN wagon to ensure full interchange-ability.
Railway Board has already released order for
High Tensile Steel has been
The Wagon has already been established in
selectively used to take care of special requirement of the design to keep the manufacturing cost lower.
market. Hence, BCL has an opportunity to increase both its top line and bottom line by manufacturing this wagon in bulk manner.
manufacturing 480 Nos BTFLN wagons to BCL.
The wagons were manufactured using latest
quality practices. The BTFLN wagons are running successfully into
Indian Railways track. The design of frameless tank wagon (BTFLN)
with a pay to tare ratio of 2.5 using bogies, bogie mounted brakes & CBC has reduced the tare weight by 4T resulting in about 7% improvement in carrying capacity.
New sizes of steel introduced in Indian market Equipped with a state-of-art
Braking mechanism. India now has an advance
discharge system which is a value addition in terms of advanced technology.
The know-how being of mostly used
in advanced Countries (like Ukraine) and BCL having manufacturing capability of the same, BCL will have advantage in penetrating export market in advanced Countries. By manufacturing this new type of
wagon, BCL has also developed new vendors which will help to increase source of availability of materials.
for commercial availability. Now BCL is equipped with
manufacturing capability of any type of tank wagon. This is the first type of tank wagon
fitted with BMBS system, with this BCL could able to cope up the advanced technology of tank wagon.
Engineering Watch
Engineering Marvels of India HINDUSTAN AERONAUTICS LIMITED
INNOVATION
C o m p o s i t e Te c h n o l o g i e s f o r manufacturing of Blades and Structural assemblies.
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
About 500 Hours of ground and flight testing has been
It reduces the dependence on imported
The Defence services have got a potent
Absorption of Composite manufacturing
carried out towards obtaining the Initial Operational
helicopter gunships and support for which could be denied during times of need.
platform and easily maintainable fleet capable of performing in adverse and allweather conditions.
technology as composites will majorly
Clearance (IOC) of ALH-WSI.
Isolation System (ARIS) / 2nd generation Active Vibration Control System (AVCS) and Vibration monitoring using Vibration Monitoring System (VMS)
All the electronic, optical and weapon systems have been
The on-board engines were replaced with
Supply-chain management across international markets
higher powered engines jointly developed with a French Partner.
as weapon system components were to be sourced from
tested individually and together as an integrated lot, the
been used in construction to achieve weight reduction.
Composite Parts, technology for which is only available in very restricted sources globally.
Future Helicopter platforms like Light
Combat Helicopter (5.5 Ton Class), Light Utility Helicopter (3 Ton Class) and Multi Role Helicopters (10 Ton Class) are built with extension of technological know-how spin-off from this project.
way they will operate in real conditions. Indigenous design & manufacturing of
globally established players.
ALH was configured to incorporate
Carbon fibre composite materials have
future.
Indigenous design & manufacturing of
Vibration reduction using Anti Resonance
Weapon and Targeting Systems using a Glass Cockpit incorporating MultiFunction Displays (MFDs), Control & Display Units (CDUs) and Display & Mission Computers (DMCs) providing redundancy to on-board operations / computations.
cater to helicopter build material in near
Transmission System Indigenous design & manufacturing of
Structural assemblies In-house capability of Helicopter Analysis
The project was sanctioned in July 2005. A time budget of
around 8 years was assessed. The IOC was obtained in Feb 13 (target- Nov2013).
agility and has got added benefits of excellent handling at high altitudes.
management.
Design of Operational Capability in
mission mode at rarefied atmosphere.
Design & Development of Rotary Unmanned Aerial Vehicle (R-UAV) with mission-control expertise.
Software defined communication / navigation equipment & control.
(Stress, Dynamics & Aerodynamics) Localisation of Technology will help in
growth of Military Industrial landscape in India which is in very nascent stage at present.
Design collaboration/sourcing for rotors are designed to
have high response control power that translate into good
Expertise gained on Attack- mission
Enhanced export potential of Indian
Military machine & hardware.
All weather Flight Control Learning for
development of Unmanned Aerial Vehicle technology
Engineering Watch
Engineering Marvels of India
LARSEN & TOUBRO CONSTRUCTION
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
A G+23 storey total precast system
Erection of Superstructure elements of Towers
This project proved to the Indian
Proved that Precast Technology is
Feasibility and acceptability of
super structure was designed and detailed in conformance to Indian Standard Codal requirements to prevent progressive collapse in precast systems.
was completed in a record time of 12 months. Peak erection achieved was 10 dwelling units per day out of 1012 dwelling units in total.
feasible for high rise in seismic conditions.
Pragati project used Precast Technology which
using Precast Technology for a 24 storeyed structure in seismic zone 3 demonstrates the future readiness of using precast technology in future residential building projects in India.
Panel layouts were optimized to
offered elimination of activities such as plastering, block work.
construction industry that precast technology is feasible in residential construction. Complete structure is built using high strength precast concrete and hence serviceability of buildings is addressed and structure will have longer life span. The yards and fabrication of moulds was suitably modified to cater to the Indian construction industry which can be used to lend the cost competitiveness to the future projects. The entire design and joint details of the Pragati project were developed in accordance to our codal provisions especially for ductility requirement in seismic zones in consultation with our associated consultants worldwide. Reduction in wastage of materials was achieved as elements were cast in strictly controlled factory conditions and hence contributed to sustainability.
suite Indian construction industry’s standard cranes by considering the shape and weight of the individual elements in the project. Monolithic casting of specialized
modular units for WC and bathrooms for WC and Bath portions ensured water tightness and has eliminated the probability of leakage in bathrooms and toilets in this project. Pragati project consists of
overlapping concrete lips at joints provided on the external wall joints which act as an architectural feature as well as eliminate ingress of water from the exterior surface of wall joints.
The activities at site involved less labour when
compared to conventional construction which not only decreased the cost but also increased the cost competitiveness of the precast technology. After standardization of elements, the moulds
were used in such a way that increased efficiency in casting of elements and achieved high speed of production. Also, castings of elements were carefully planned for achieving maximum utilization of the moulds and also implement savings in cost for moulds. All building materials, equipments, debris, workers
were transported to the site directly for installation. This reduction in traffic congestion was even more successful as elements were transported during off peak hours (night).
Pragati project is able to address
the demand and supply gap faced by the construction industry.
Completion of superstructure shell Pragati towers took quality to a
whole new dimension as the finishes obtained in the project were immaculate and still being cost competitive even for slum rehabilitation project. Created a keen awareness and
excitement amongst the end user with respect to the methods used for the erection of precast building structure. People were amazed to see that walls, modular units were erected with ease on the massive structure.
for three numbers of towers in a period of 12 months and that too within the congested areas of south Mumbai has amicably demonstrated the sheer success of precast technology. Early project completion means that the projects can be put to use before the planned deadline thereby increasing the credibility factor of the construction industry. Architectural features were
customized at Pragati towers as per the requirement of client. Precast technology reduces the
dependency on labour by involving technology.
The construction pace provided by
Precast Construction helped in achieving project completion goals which would otherwise be difficult in conventional construction.
Pragati towers achieved greater
durability, cost effectiveness, speed with high quality end product at comparable costs with the existing technology in construction industry.
Engineering Watch
Engineering Marvels of India
NATIONAL BUILDINGS CONSTRUCTION CORPORATION LIMITED
INNOVATION
OPERATIONAL EXCELLENCE
Highly efficient external glass
The project is completed in 3years within
reducing ingress of heat inside the building and reducing energy requirement for air-conditioning. Highly efficient glass enabling work
to continue even without the electric power during day. In RCC structure no expansion
joints are required for buildings having length of 105 mtr. Thus preventing leakages etc. The building has international green
building features like Sewage Treatment Plant, Solar Heating System, energy efficient light fixtures, Innovative air-condition system using variable frequency drives in AHUs and chillers, VRV air-conditioned system, use of MERV filters, use of RG 410 gas for AC, under deck roof insulation, high efficiency glass, using recycled water for gardening and cooling towers etc.
Impact
Future Readiness
All products integrated in the project
The design and subsequent
Building has a large network of
approved cost ofRs. 201.10 Crores without any escalation until 2011
are either of Indian origin or sourced in India.
method of occupied working environment has generated a new image of CBI.
Safety measures were followed religiously and no
Local labour and materials were
cable trench placed on modules to accommodate changing technology infrastructure with ease.
accident was recorded.
Self Reliance extensively used.
Provision is made for operation and maintenance
Engineering skills and methods are
of specialized services for 5 years while finalizing vendors for specialized services so that operational cost is bare minimum and the vendor executes the work with highest quality
through in-house engineers or through consultants in India.
The Intelligent Building Management system is
provided to minimize operational and maintenance problems. The various services can be controlled from centralized control room having LCD Displays to control major service like. Air handing units, pumps etc. and also to identify the location of fire etc.
All Architectural services and
An open working environment with due importance to confidentiality work simultaneously has generated the transparency of work.
Introduced a more humane
engineering designs are consciously designed to suit local conditions, working methods and climate.
working ambiance to the staff and seniors reflecting the changing method of working environment indiscriminating with respect to posts.
Water recycling system through
An inbuilt security system without
STP and rain water harvesting system also helps to added in the self-reliance of India
being obstructive and interfering. An energy efficient model work with
use of natural light and individual control of lighting to ensure energy saving.
Modular furniture and partitions
system to adapt to changing requirement for future. Spaces are moldable to adapt to
increased manpower allocations by the department for future with-out congesting. Provision is made for future expansion and staff requirement is considered for next 20 years. Vertical transportation by lifts is
calculated and provided to take increased population for future.
Engineering Watch
Engineering Marvels of India
NATIONAL BUILDINGS CONSTRUCTION CORPORATION LIMITED
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
The power house building was
Completed the project without any cost & time
Utilizing the service of Indian
Reduce the gap between demand
The power plant is designed to carry
designed meticulously covering an area of 8400 sqmt. Modern exterior finishing of the
Power House Building. Pouring of 70,000 Cumt of
Concrete & 7000 MT of Reinforcement steel.
overrun.
of Structural Steel with maximum fabrication & erection of 1650 MT during Jan'2006.
& supply of power in our country.
The project was commissioned (Unit#1) on
The entire work was executed
Improve the living standards of the
30.03.2007 & (Unit #2) 11.12.2007 i.e. 31 Months & 40 Months respectively as per schedule.
through Engineers, Technocrat and Technician available in India.
Citizen of India living in the vicinity of Power Plant.
Chhattisgarh state became one of
Create opportunity for setting up
This project had earned handsome profit margin.
the Power Surplus States. Micro Planning at all stages i.e. from Design till
execution. Fabrication & erection of 24000 MT
consultant.
Utmost importance given for the safety during
execution resulted in minimizing accidents.
out power generation up to 25 Years. Provision has been made to
carryout future expansion without affecting the existing power plant.
new Industries & improve the economic growth of Nation.
The power plant is well supported
NBCC proved their capability in the
Availability of natural resources
Power Sector to the Power Developers.
increases the expansion possibilities.
with all infrastructure needs.
To prove the world that India is self-
reliant in generation of Power. Materials available within India
have been used in construction. Ministry of Urban Development-
Govt. of India approved NBCC to carry out business to generate, supply and sell Power and build Power Plant. Successful completion of Project
has enhanced the self-belief of NBCC to execute high magnitude jobs.
Engineering Watch
Engineering Marvels of India
NATIONAL BUILDINGS CONSTRUCTION CORPORATION LIMITED
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
Utilizes natural conditions
A building low on maintenance costs because of
A careful selection of components
The project by employing locally
The building utilizes modular
to ensure products' equipments is manufactured in India or is of Indian origin.
available labour and material and harnessing talent has created a unique advantageous position to the state in which it is located and also its immediate surroundings.
structural, architectural and electromechanical services grid for technology amalgamation at any point of time in the future.
resources like light, water with optimum energy consumption. Natural green terraces provide
insulation and landscaped ambience. All international green building
norms adopted and implemented during construction.
Recycling of all waste.
Unique structural and services
design for flexibility in use.
energy efficient engineering. Structural design for speedy construction to reach
time line targets. Overall cost within estimation /approval. Supportive services for office and residential are
self-supportive and also collaborative for augmentation as and when required. Materials used are sustainable, regenerative to an
extent and requiring minimum maintenance.
Provides assistance to project
through a constantly evolving image of India and the rich talent that is trained and harnessed in the institute. Provides a glimpse to visiting
faculty from different parts of the world, how institute and India respond to the corporate and rejuvenates this sector to give it a competitive edge. Project has been accomplished
with entirely Indian talent, in house consultants. The project showcases what can be achieved by India in complex engineered structure and responsive services infrastructure. Inviting campus environment that is
comparable to the best in the world, a contemporary and progressive institute, organic in growth and responds to ever-changing needs
The project has provided a “Home Office” to the corporate world and the administration that monitors & nurtures the corporate world.
The Campus has qualitative living
conditions that has enthused faculty to live in the campus there by reducing unnecessary expenditure /stress on transportation from Delhi and back. The project has a modular physical
growth structure that is concaved as a whole but looks complete in its individual phases. Infrastructure within the campus
provides a city with in a city concept but yet conducive, productive, inclusive and collaborative to its local conditions and environs.
E ff i c i e n t A r c h i t e c t u r a l a n d
Engineering design facilitates addition of buildings or infrastructures without disturbing functioning of the campus. The campus provides for recycling
of waste, rainwater harvesting with provision for of all additional requirement for the future. Segregation of pedestrian
/vehicular traffic management has been designed for the entire development including future additions so that there is no congestion at any point of time. Internal furniture systems are modular and relocate- able depending on changing human resource requirements, retrofit, therefore can be achieved without disturbing working environments.
Engineering Watch
Engineering Marvels of India
ONGC TRIPURA POWER COMPANY LIMITED
INNOVATION
Single largest investment in NE India, without GOI grant. Ensuring timely dispatches of several components of plant and machinery from multiple .
OPERATIONAL EXCELLENCE
Manufacturing Units of BHEL, spread across the Country, to synchronize with erection sequence, meeting the commissioning schedule.
First largest power plant based on natural gas in North East, using Natural Gas which was lying unutilized for around two decades. Highly fuel efficient, advance CCGT Technology, Heavy Duty 9 FA Gas Turbine manufactured by GE. Laying of 662 kms long 400 kV transmission line, first time ever in the NE Region, traversing through the difficult Hilly region and forest.
Non-availability of skilled manpower for construction & erection, non-availability of raw material – steel, cement, bricks etc had to be transported through difficult logistics. Logistics for transportation of heavy equipments (ODCs – 325MT wt, 23.4 mtr length,5.4 mtr width,5.5 mtr height, using 18 axle hydraulic trailers), building of 16 by-passes over the water bodies in Bangladesh. Close monitoring on the sequencing of dispatches of several components of plant & machinery supplied by multi-location manufacturing units of BHEL, spread across the length and breadth of the country.
Least time over-run compared to similar Power plants developed during the same period, like (i) Indraprastha Power project, Bawana, Delhi (ii) Pipava.
Cost over-run limited to (i) changes in the scope and (ii) IDC, less than 10% over a span of seven years.
Self Reliance
Impact
Supply of Power to the Energy starved North Easter Region of the Country.
Stimulate the economic development of Tripura and NE Region.
Earning large carbon credits Project registered under UNFCC as CDM Project.
the state of Tripura.
Scope for employment generation through industrialization, with the availability of quality and
Utilization of Significant idling natural gas reserves in Tripura. Exploring and Production of additional Gas reserves, by ONGC to meet the long term commitment for the Project.
Social economic development in
Future Readiness
uninterrupted Power supply.
Adding to the Power generation capacity in the Country.
Developing a new route for connectivity of NE Region to the Main land Through Bangladesh.
Stimulation of economy in the state of Tripura and NE Region.
Exploring new options in Power Sector i.e. hydro, Solar, Wind etc.. Business development plan in fast pace. Dynamic growth plans of ONGC under consideration. Scope for further enhancing generation capacity. Parental advantage of two strong infra structured conglomerate viz ONGC & IL&FS.
Engineering Watch
Engineering Marvels of India
NOVEL DRIP IRRIGATION, SPEED BREAKER POWER GENERATION, WATER MOBILE AND LAPTOP CHARGER AND WATER POWER CLOCK. A novel speed breaker will utilize the speed and weight of the moving vehicles to generate electricity. A novel drip irrigation system will save water and much economical in compare to current drip irrigation system. A novel water power clock will replace all the clock which run on cell, because the present invention will run the clock with the help of water. A novel water power mobile and laptop charger will charge the mobile and laptop with the normal house tap water force.
INNOVATION
They are designed on the GREEN CONCEPT, very much economical and beneficial to society in compare to current situation. They all are Eco-friendly and does not produce any pollution. This inventions will help the developing countries to turn in future developed country. The inventions will self generate the power without the use of any conventional source. The efforts taken for feedback from the industry by faculties after 100% Industry defined projects were highly phenomenal & recognized by the industry.
OPERATIONAL EXCELLENCE
The Novel speed breaker power generation unit will utilize the vehicle mass and convert the kinetic energy to special design unit which will generate the electricity on every pass. A Novel drip irrigation system will save water and very much economical in compare to current drip irrigation system. A Novel water power clock will replace all the clock which run on cell, because the present invention will run the clock with the help of water. A Novel water power mobile and laptop charger will charge the mobile and laptop with the normal house tap water force and this invention will not waste the water. The cost of all the inventions on the initial stage is high but when it is installed on the proper place then it will possess the capacity to recover the cost in very short period of time.
Self Reliance
The main objective is to conserve the energy and try to develop extra energy from the surrounding environment. The invention are very reliable and user friendly to mankind and will prove to be adopted by the society.
Impact
It is best suited for the India because of the heavy traffic and will develop large power. It meets the current demand of the energy which is one of the major crises of India, and will help in reducing the demand of the energy to certain level. It is working on the green concept and this will be the new concept for the India.
All the above mention projects had received award in different category. All the inventions are inspected by government and very appreciated by the local people. A novel speed breaker and water power clock are also selected by the Gujarat government to make their implementation of real working model. The proposal of the project is also accepted by government A novel speed breaker power generation is recently nominated in the top 50 invention of the MIT young innovation award.
Future Readiness
The main objective behind all this invention is to conserve the energy and try to develop extra energy from the surrounding en vironment.
Normal speed bump just use to reduce the speed of vehicle but A novel speed breaker will generate electricity and also serve the purpose of the speed breaker.
They will not produce any pollution and help in reducing the dependence of the energy.
All the inventions will be more beneficial in compare to current situation.
All the inventions can be used anywhere from commercial to noncommercial zone. They are design in such a way that they can be benefited to everyone from village to city.
Engineering Watch
Engineering Marvels of India
INDIGENIZATION OF BANKNOTE PAPER PRODUCTION Design, Supply, Erect, Install and Commission three (3) state-of-art Banknote Paper making Machines compatible along with slitter, sheet cutter, inspection-packaging-line, mould cover plant, facilities to incorporate security features like water mark, windowed security thread, security fibers, etc. and another allied items.
INNOVATION State of the Art banknote paper
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Presently, Banknote Paper is only
Environmental impact- Aiming Zero
manufacturing lines are being installed in India.
manufactured by Security Paper Mill, Hoshangabad in India & these paper lines aims at augmenting banknote production by 18000MT per annum.
Advanced Levels of automation
Indigenization of sovereign product
making facilities (best in the world) After 1967,new banknote paper
w i t h Te c h n o l o g i c a l b a s i c optimization of the paper making process. Building Skill set based Manpower
in banknote paper manufacturing process.
i.e. Currency Paper Saving Foreign Exchange Building skill-set based self-reliant
manpower in banknote paper manufacturing process.
discharge
Economic benefit to the society Indigenization of sovereign product and self -reliance Use of locally grown basic raw material (cotton)
Import substitution-Saving of
foreign exchange Direct and indirect employment
generation Local area development through
CSR activities Building base for R & D facilities for
banknote paper manufacturing.
Proposition of export building
capacity for banknote paper
Future Readiness
Engineering Watch
Engineering Marvels of India
MODERNIZATION OF INK FACTORY, BANK NOTE PRESS, DEWAS Enhancement of existing security ink manufacturing (Quick Set Intaglio Ink & Dry Offset ink) capacity from 240 MT to 1160 MT.
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
BNP Dewas presently cater the
Production capacity has been increased radically.
Dependency for foreign supplier
Meets the requirement of various
During last financial year, it has
type of printing inks of Bank Note Press, Dewas and also of the sister units like Currency Note Press, India Security Press, Nashik Road;Security Printing Press, Hyderabad and many others
produced 484 MT QSI which is the
requirement of Quick Set Intaglio (QSI) ink for both the currency printing presses of SPMCIL which saves a huge amount of foreign exchange. After Field Trail of BRBNMPL
presses it is expected that after complete of modernization activity, Ink factory would be self reliance unit for supplying QSI as well as other security inks to SPMCIL as well as BRBNMPL's presses. During last financial year, Ink
factory, BNP, Dewas has produced & supplied 484 MT QSI ink to SPMCIL presses which is about to 2 times supply made in previous year. Dependency of foreign country for
supplying of security ink has been reduced. It produces International standard
security ink.
has been reduced gradually
In house production cost is less than half of
imported ink.
Dependency of foreign supplier has reduced.
Save huge amount of foreign exchange.
Apart from catering the requirement of CNP & BNP, it is targeted to supply BRBNMPL so that all the bank notes in India are
Quality of inks is International standard.
produced with security ink
Quality of ink has been improved
produced at Ink Factory, Dewas.
Production has doubled now,
expected to quadruple to the original capacity.
Save huge amount of foreign
exchange. It is capable to produce most of the
security inks (except OVI ink) used for India bank notes at CNP & BNP
Import of ink has reduced
Save huge amount of foreign
exchange
highest ever annual production. It cater the requirement of QSI ink
for BNP, Dewas as well as CNP, Nashik. BNP manufactured Quickset
Intaglio Inks departmentally for use on Super Orlof Intaglio printing machines.
Engineering Watch
Engineering Marvels of India
MODERNIZATION OF BANK NOTE PRESS, DEWAS Replacement of one line of Printing Machines at Bank Note Press, Dewas
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Compatible for machine readable
The machines are state-of-art with higher speed
Having world class state of the art
and shall have capability for incorporation of sophisticated print-based security features which will help in reducing counterfeiting of currency notes.
currency printing equipment with online inspection system. The Printing Machines are
This machine improves productivity as well as
compatible for machine readable features.
features. The one line printing machine 2011
model is having features to accommodate 10 colors offset printing, 4 orlof pattern printing cylinders and linking units on Super Orlof Intaglio machines and Numerrota machines are having 3 colours letter press printing facilities. Gives option to make online
segregation of printed sheets for their defects. This results in better quality inspection and saving in manpower engagement Machines have modular type with 3
Nos. delivery piles expandable up to 7 delivery piles against 3 delivery piles of earlier machines. The printing machines have online
inspection system which provides facility to make online correction in case of deviation in printing quality. It saves the manual inspection, increases quality and reduces rejection through immediate corrective action.
optimizing consumption of raw materials specially ink due to availability of colorimeter, densitometer etc. Due to integration of central software system (i.e.
Inprint core server software) in the machines, it optimized the manpower requirement. The Printing Machines are compatible for
machine readable features. The new generation machines are energy efficient and operation friendly equipped with state of the art gadgets keeping pace with the latest technology.
Impact Reduce manpower deployment Print precise/ high quality of
banknotes
These machines have got capability
to print state of the art based security features.
Reduced wastage percentage Productivity of banknotes has been
increased
Future Readiness
Engineering Watch
Engineering Marvels of India
RED MUD FILTRATION AND RECOVERY OF VALUABLE METALS UTILIZATION AND NEUTRALISATION OF RED MUD FOR BETTER WASTE MANAGEMENT
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
Developed from Laboratory scale
Vanadium recovery projects helps in additional
Generation of vanadium will help in
15% reduction in caustic
Sustainability of alumina plant with
and tested at pilot scale within the
generation of revenue. Vanadium sludge is sold at a price of Rs 5 Lakh per ton against alumina price of around 18000 Rs per ton.
cutting down cost of import of vanadium sludge.
consumption which results in savings of 6 $/T of alumina
plant without any assistance from outside process licencor.
COP of alumina is reduced by 4% to 5% as caustic
soda is one of the major raw materials. Vanadium recovery makes the
country self-sufficient in meeting demand of vanadium as most of
Operational hazards due to handling of caustic
slurry are eliminated due to generation of powdery red mud.
these raw materials is imported to make Ferro vanadium. Caustic consumption will come
down by 15%
The total time taking from concept to
commissioning was less than two years, however part of the capital investment return was started within four months. On completion of the project as envisaged it will
bring a revolution in making alumina refineries as zero discharge and zero waste. It eliminates all environmental risks.
Will help in utilization of all red mud
for making cement/pig iron.
Reduction in caustic consumption
will help in minimizing import of caustic and may be domestic production in future meets the requirement of caustic for alumina industry.
Red mud can replace the natural An in-house process for extraction
It can be used for cement Minimization of land requirement by
Recovery of titanium and gallium in
future as a part of second phase of the project will help in making country self-sufficient.
It is considered as innovative, cost
Use of dry red mud in construction
effective and environment friendly besides ensuring optimum utilization of natural resources.
Minimizing land requirement will
help in making land available for agriculture.
soil, thus conserving the natural resources
of V2O5 involves simple operations with very low energy consumption.
having vertical stacking of powdery red mud.
of nuclear power plants for absorbing radiations will help in minimizing import of high iron cements.
continuous red mud disposal
The produced red mud may be used
in cement industries, building materials industry etc.
production, Iron production by replacing the iron ore and laterite thus conserving the natural resources Waste lands reclamation with bulk
utilization of red mud for agriculture and forestry.
Production of mineral wool by using red mud.
Engineering Watch
Engineering Marvels of India
REVESE OSMOSIS TREATMENT OF EFFLUENT WATER Two smelters with a capacity of 0.5 MTPA (operational) and 1.1 MTPA (commission phase) respectively. Inline to its conservation and environment friendly policy. Zero discharge of effluent from its smelter plant and reduction of fluoride level in effluent to a level of 1ppm, and for this Reverse Osmosis technology of 50 m3/hr is used.
INNOVATION
Use of RO technology for effluent treatment particularly fluoride in aluminium smelter effluent is one of its kind in major smelting industry. Accelerated RO reject evaporation through installation of mist fans (atomizers) for increasing surface areas of the rejects. Use of solar panels for heating the air which is blown through the RO rejects for faster evaporation.
100% recycling of treated effluent.
Advantage over other fluoride treatment options like ion exchange methods where in regeneration of resin, resin replacement and other operational inefficiencies are involved.
OPERATIONAL EXCELLENCE
Fully automated system without any manual intervention. Consistency in output treated water quality even with variant inputs. Recycling of effluent water for any industrial application.
Self Reliance
Reduction in fresh water consumption (conservation of natural resources).
Impact
Future Readiness
Zero discharge industrial wastes to
Reduction of fluoride level to less
Conservation of natural resources
Ensures hygienic working environment and reduces operators’ exposure to hazards.
Recycling of waste water (reduction in environmental emissions). This system can be used for treating flouride contaminated ground water for domestic application. Increased productivity of manpower through automation. Conservation of land through improvized solar pond (accelerated/forced evaporation) as it can be done in 1/6th of the area compared to conventional ways.
than 1ppm ensures future stringent stipulations.
ambient water.
by 100% water recycle and less water consumption for industrial purpose. Improved work environment.
Restriction of land and water usage
in industrial application.
Restriction on usage of conventional energy for auxiliary consumption.
Use of renewable energy sources
Avoidance of health hazards
(solar energy) for forced evaporation.
leading to a safe and clean working environment.
Reduction of fluoride load to
environment.
Handling of diversified/changed
influent characteristic in the RO facility.
Engineering Watch
Engineering Marvels of India
INITIATIVES FOR REDUCTION IN ENERGY CONSUMPTION The focus of this project was on to reduce the DC power consumption. Minimizing of the anode gas bubble voltage drop was to reduce energy consumption or improve energy efficiency by reducing overall cell voltage while maintaining optimal current efficiency for aluminum smelters.
INNOVATION
Inhouse design engineering to calculate the appropriate slot height and slope. Design of slanted slot was performed for gas evacuation and in smelter also. Specific anode preparation receipe was formulated which resulted in optimum density and minimum coke dusting. Design modifications have been made in the anode forming equipment (Vibro- compactor). Slot blades of variable height and slope were fabricated into the equipment. Slot cleaning machine was installed in bake oven to remove the packing coke.
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
Slotted anode allows us to reduce pot voltage
Energy consumption is reduced by
Benefit realization during trial – 35.5
Slotted anodes have proved to be a
343.39 MU/year, this has helped in conservation of natural resources particularly coal.
Kwh/MT of Al (11.09 mV reduced) Benefit realization on full implementation – 67.3 Kwh/MT of Al (11.65 mV reduced)
boon in form of energy conservation and saving of environment. Future plan is for online slot cutting
Current efficiency improved by
instead of press forming in vibrocompactor.
0.3%, Hot metal volume increased by – 0.007 MT/Pot/Day.
VAL may modify design of slots.
without sacrificing current efficiency. Reduction in gas bubble voltage leads to reduced
pot voltage fluctualtion. Slotted anodes has also helped in reducing the
Anode effect frequency which increases the current efficiency.
Emissions of green house gases
(PFC) has been reduced by 50%. Manpower productivity has
Implemention of slotted anodes have also helped
in reducing fugitive emissions into the environment. This initiative has helped us in reducing power
consumption and thus decreasing the power generation.
improved. After implementation of slotted anodes the Anode effect frequency decreased to a large extent. Reduction trend was seen in
consumption of green poles as the AEF had reduced by 50%. Elimination of health hazard during
anode effect killing as the operators are now less exposed to hot furnace conditions.
Amperage increased by 1.7%.
This would help in further more energy saving by reducing noise and increasing pot stability.
Anode effect frequency has
decreased by 53%. CO2 emissions decreased by –
Increased hot metal volume
through current ramp up and process optimization.
50% Initiatives are being planned in form
of cathode modification and pot controller up gradation in which modified slots will compliment in further energy reduction.
Engineering Watch
Engineering Marvels of India
CONVERSION OF ESP TO HYBRID ESP HYBRID ESP, Retrofitting of ESPs to convert into Hybrid ESPs Impact on Suspended Particulate Matter after ESP retrofit
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
Conversion of conventional ESP fields
Completion of the project without any disturbance to
Reductions in emissions below the
Reduction in SPM to 30 mg/Nm3
Improvement in ash collection &
pollution control board norms of 50 mg/Nm3.
which is now less than statutory environmental norms
Reduction of particulate emission below 30 mg/Nm3 well below the anticipated stringent norms of 50 mg/Nm3.( Present norm 100 mg/Nm3)
to Hybrid ESP (combination of Bag filters and electrical field) after the commissioning of the plant. Improvement in the performance and
life of ESP. Able to operate the unit after
modification even in case of non availability of one ESP field with emissions below 50 mg/Nm3. Use of PPS as bag material resisting
up to 190 deg centigrade temperature. Improvement is ash collection &
Reduction of particulate emission below 30 mg/Nm3 well below the anticipated stringent norms of 50 mg/Nm3.(Present norm 100 mg/Nm3)
the running system.
Zero Loss Time Injury during the project execution.
Timely completion of the project as per schedule.
Reduction in emissions to almost one fourth. Removal of ammonia dosing system (Hazardous gas).
Significant impact on the ambient air
quality. Emissions are maintained within the
limits prescribed by few international standards like World Bank, IFCI
Sustainable availability and reliability
Improvement in the availability of the
PPS fibre is technologically advanced
power plant due to operation of the same in case of failure of few of the ESP fields which are dependent on electrical power. Improvement in reliability due to less
mechanical components thus ensuring no further degradation in air quality.
of the power plant.
and will be widely used in future power projects considering the stringent environmental norms. Considerable reduction in operating
cost of the power plant.
Engineering Watch
Engineering Marvels of India
DILLI HAAT AT PITAMPURA, NEW DELHI The popularity of ’Dilli Haat’ at INA, New Delhi led DTTDC to conceive its 2nd ‘Dilli Haat’ project at Pitampura, in West Delhi on the 7.2 acre plot land allotted by DDA to it on revenue sharing basis.
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
One of the first public space
Efficient design that uses the Haat Concept to
Provides valuable support to the
Provides a valuable leisure space
Spaces planned to accommodate a
projects with 'green roofs' in the city.
minimize the need for artificially lit and airconditioned spaces reducing operational costs and improving operational efficiency.
crafts sector allowing crafts persons from different parts of the country to access the large market for their products in urban areas helping preserve native crafts and skills.
in North-west Delhi which previously lacked any space for cultural activity.
constantly changing range of crafts and activities.
Use of materials and finishes from
the surrounding regions. Durable finishes and materials that minimize wear A wide range of finishes, materials
and landscapes that create a diverse range of spaces and offer users a wide range of experiences. Has helped establish a new type of
public space which is cost-effective, popular and is now being widely replicated due to its success in Delhi. Most importantly, has provided a
platform to crafts persons from around the country to directly sell to customers in Delhi, eliminating middlemen and improving their livelihood.
and tear.
Attracts tourists and visitors to the
area.
Durable construction and materials
to minimise the need for maintenance.
Provides a central venue for crafts DTTDC started the project in December' 2006,
with stipulated completion by January' 2008. By its better project management, DTTDC was able to complete the project before time in December' 2007. DTTDC completed the project within the
earmarked funds by the Govt.
persons from all over the country and abroad to meet, collaborate and share ideas through workshops, demonstrations and other interactions.
Has improved the profile and
Adequate open space and buffers
visibility of the Netaji Subhash Place District Centre and the Pitampura Area.
that will can comfortable accommodate increasing numbers of visitors.
Establishes a financial viable model
At any given time provides income
Use of Day lighting and natural
for the planned development of informal markets in urban areas that can also be applied to other products such as fruits and vegetables, flea markets, flower markets, etc.
to around 100 crafts persons and their families who sell their products at the Haat. The economic effect is significantly amplified as the crafts persons change every two weeks.
ventilation minimises energy consumption. This is particularly important in a scenario where power is becoming increasingly scarce and more expensive.
Has become a significant player in
Provides a stimulus to the
Sets precedence for development
of a new type of public space that is humane, affordable and equitable. Provides an alternative to malls and
other such high energy and resource consuming recreation and commercial spaces.
promoting and sustaining the crafts sector in the country.
development of cultural spaces and activities in North-west Delhi that lacked such venues and desperately needed these facilities.
Engineering Watch
Engineering Marvels of India
AUTOMATION OF NEEDLE ASSEMBLY IN BLOOD BAG SYSTEM The needle assembly consists of three components: Needle holder (Hub) Stainless steel needle (16G / 17G) The re-cappable needle cover (Inner PVC cover and outer PP cover)
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
First time an indigeneous machine
Manpower Cost / Annum – Came down from 66.06
Indigenisation – We used to import
on needle assembly is designed and developed
Lakh Rupees to 9.44 lakh Rupees Manpower Requirement Reduced from 30 per day
Online canula pull test system – first
Automatic slot system – Another
First Automatc camera inspection
system for 5 parameters
Foreign exchange savings Cost reduction of needle – from 11
Rejection % – came down from 3.2% to 1.5 % Payback Period – 3 years and 3 months 7 time increase in productivity (from 1000 per
rs to 5.5 rs – leading to overall reduction in cost of blood bags at improved quality – Has brought down the cost of a significant component in helathcare delivery
person to 7000 per person) Improving technical competence in
Recapable type cap assembly –
first automated line india
Future Readiness
Manpower reduction
Needle bevel orientation
Consistency in quality – by
Spot UV curing of adhesive
components from Singapore
to 4 per day
time ever developed in India
Impact
operating and maintaining sophisticated systems
reducing human involvement Machine cost reduction Improvement in GMP minimising
human handling Space saving
Siliconisation
Vision system Identification and selection of
suitable marking system
Engineering Watch
Engineering Marvels of India
AUTOMATED SHAFT BEARING ASSEMBLY LINE Description of the technology implemented: – Automatic assembly for integral shaft water pump bearings which are used in wide applications such as water pumps, electric fans, vane pumps, electric motors etc.
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Shift over from manual gauging &
Assembly was the bottleneck section for us and
Adoption of automated controls
The machine can assemble 1700
ensuring error free bearing
bearings in the same time thus improving productivity by a huge margin.
ball selection-ball feeding process to auto gauging through LVDT probes & auto selection of correct number and size of balls through PLC logics The designing of the machine has
with this machine it has been exploited. worker can make in 8 hours is around 500 whereas the machine can assemble 1700 bearings in the same time thus improving productivity by a huge margin
been done in-house and 31 pokayokes have been introduced to ensure fool proof operation.
Display of trouble shooting messages, hence
Error proofing at each stage for
Effective space utilisation i.e. 50% space saving
defect prevention.
Reduced manual intervention.
Improvement in productivity.
assembly.
The avg. number of bearings that a highly skilled
reduced down time. as compared to conventional assembly. Auto segregation of Ok & Not ok products at
different stages.
Indigenous design
Operator safety is also considered
while designing this machine
All sub-operations are performed
sequentially & interlinked, hence no chance of operation missing Automated assembly line was a
The automated assembly line
ensures 100% error-proofing with almost zero human intervention. Reduced manual intervention and
also ensures a competitive edge over competitors.
requirement from a lot of OEM’s, as they have also wanted to reduce human intervention in assembly. We’ve received potential orders to the tune of Rs. 15 crores per annum due to the automated assembly line. Capacity expanded by 5000 pcs /
day, increase in 50% of earlier capacity, with just addition of one operator per shift
Future Readiness Automated controls Improve productivity Reduce manual intervention &
operation safety. Better space utilization Readiness for horizontal
deployment
Engineering Watch
Engineering Marvels of India REDESIGN & TECHNOLOGY INFUSION IN “ENGINEERING FILES” MANUFACTURING PROCESS. This project focuses on the entire product chain of Manufacturing rather than in bits and pieces. The age old machinery & process are redesigned for Energy efficiency & effective manpower utilization.
INNOVATION
OPERATIONAL EXCELLENCE
Self Reliance
Impact
Future Readiness
This project focuses on the entire
We were able to reduce the Throughput time from
Availability of the product at the
It will improve the overall
Efficient utilization of energy & non
product chain of Manufacturing rather than in bits and pieces.
7 days to 2 Days, thus ensuring the maximum availability of our product in the market.
The machines are designed with
The projects have helped us in being cost effective
most competitive price & superior q u a l i t y, t h u s l o w e r i n g t h e opportunities of entrance to the global players.
quick replace subassemblies and all major parts used are Standard parts.
& maintaining our margins even in the toughest market conditions, thus delighting our customers.
New packaging in Single piece
helped in strengthening the brand image, as well as curbs the counterfeit in the market. Zero Decarburization in the input
raw material by introduction of induction heating & Peeling, hence significantly reducing the further processing & wastage. Combination of Multiple operations
in a single machine.
The project has eliminated the hazardous working
environment & the safety of the workers has been enhanced. The project focuses on Energy Conservation &
thereby saving the fuel & reducing the cost. Also the Non-conventional source of Energy is used to conserve the Mother Nature. The machinery used for files manufacturing are all
SPMs with an age old design go hand in hand with all the new SPMs which all are “First in World” kind.
productivity. It will reduced the working WIP in
the Plant, thus keeping the operating capital minimum & in rolling.
All machines are designed &
developed in India. Use of non-conventional source of
energy helps to strengthen the Indian power sector. Being the largest manufacturers of
File in the world & 50% of production being exported to other countries, it will contribute to the strong economy of India. Improvement in the Yield, reduces
the input steel required for same no. of products & thereby reducing the consumption of Steel, enabling the availability of Steel for other Infra Projects.
Enhanced the working environment leading to the Safety of the workers.
Improved the Quality & the
Consistency of the product leading lesser rejections & improved customer satisfaction. Reduced the Energy Consumption
of the plant.
– conventional source of energy will help us to be cost competitive in the market. Deskilling of the operation has
removed the human touch factor & leading to a consistent Quality output. Automation helped us efficiently
utilizing the manpower, as manpower is a resource which will be far expensive & scare in the future. Counterfeit products in the Market
will be effectively curbed down by new packaging. Availability of products at all times in
the market, with value for money proposition.
Engineering Watch
Engineering Marvels of India
Distribution Related Engineering Asset Management System (DREAMS) This web based state of the art software has been developed in-house to facilitate the management of 24,000 odd Electrical Engineering Assets related to Distribution Services of CESC Limited.
INNOVATION Integrated Asset Register with state of the
art tools for searching assets based on
OPERATIONAL EXCELLENCE
Time: 1 year starting from conceptualisation to implementation. The time required is very less considering
different criterion. Details of all observation/work done for all
the fact that the asset records for this huge number of assets
kinds of maintenance activities are stored
were lying scattered in many different premises situated at
inside the system.
different locations of the twin cities of Kolkata & Howrah.
Provision for access control to the software
Cost: There was no cost of development as it is entirely
based on Privilege Matrix for users along with audit trail incorporated in the system. Automatic representation of test results of
dissolved gases inside the transformer into Duval Triangle, thus making the condition of the transformer immediately apparent. Software comprehensively dealing with
both pre-commissioning activity details and post-commissioning maintenance activities.
developed in-house.
Self Reliance
Impact
Future Readiness
This project increases the efficiency of
Visiblity of all the Engineering Assets
The software has the potential to make it
operations in Distribution of Electricity keeping in line with the national goal of
through single integrated asset register. Tracking of asset throughout its lifecycle.
revamping the Power sector in India. Reduction of un-planned maintenance
activities.
scalable at the enterprise level by including assets of Generation and Transmission. The software has the capability for
integration with company-wide ERP for Finance & Purchase divisions.
More focus on planned maintenance like
The software can also be integrated with
Condition Monitoring, Condition based Maintenance etc. This project leads to the reduction in the cost of maintenance and optimization of asset performance.
Geographical Information Systems (GIS)
Engineering Watch
Engineering Marvels of India
Wankhede Stadium at Mumbai INNOVATION
The 25 meter cantilevered roof is the most
OPERATIONAL EXCELLENCE
Wankhede Stadium has all the in-house facilities including the IT
Self Reliance
interesting feature of the proposed stadium.It
related aspects at par with world standards for conducting
only encourage the Game of Cricket, but also give
completely opens up the stands so no obstruction
international matches.
immense pleasure to Cricket lovers watching
come in the way of viewers.
matches in a modern environments & venues like
Heavy column sections extending beyond the top
action of the columns for earthquake resistance. Encasing of
edge of the stadium and each unit weighing in
structural steel impart fire resistance to the columns.
benchmark in India for other Stadiums to be constructed in future. The various important
same old space and congested locality. It had no possibility of any
features of the stadium are 360 degree
horizontal expansion. In view of these constraints, the East & West
uninterrupted view, column free spectator stands,
The Stadium is located in a very much restricted,
stands were renovated, structurally strengthened to cater to
covered roofing using fabric material (rather than
sensitive zone with lot many constraints.
enhanced spectator capacity. Existing columns were jacketed and
use of cancerous material which was being used in
extended till required height
the past) wide enough walk ways, specious seating
diameter MS pipes.
The Wankhede stadium has put India in the list of countries having an International standard Cricket Stadium.
BCCI has stood to the challenge and showed it to the worlds that it has all the capabilities & expertise, & is self reliant
arrangement, dedicated elevators for physically
Inspection and quality checks for the structural
Future Readiness
Creating of such a high class stadium in India shall provide an uninterrupted Opportunity to our Cricket Hero’s and Budding Cricketers to excel their skill in this segment of Sport in further.
Column free stadium is an International concept, now followed in India in construction of Wankhede Stadium. The 360 degree view during a match give immense pleasure to the viewers is an USP of Wankhede Stadium.
Construction of more similar kind of Stadiums in India would help in development of the Game of Cricket,
Aesthetically appealing roof cover out of textile fabric has given an opening to new industries manufacturing Textile fabric thereby helping in economical growth of India.
The new concept of auctioning of spectators box, modern corporate lounges to the various businesses has begun and there is long way for further improvisation from revenue generation point of view in India.
Construction of Wankhede Stadium had raised the
The major hurdle was to accommodate proposed, new stadium within
pipes in a triangular profile fabricated out of various
the ‘Wankhede Stadium’, in India.
The structural design is carried out taking into account the composite
tonnes were fabricated out of 3 tubular hollow
Availability of such a facility in Mumbai, would not
Impact
At Wankhede Stadium, the entire project team was from India, is now a Landmark structure in this category
The Stadium shall be Good Revenue generation source for India once various international matched are played at Wankhede Stadium
challenged people and high security for players and
steel inspection, fabrication and erection work was
up dated surveillance system etc.
undertaken implementing stringent QAP (Quality Assurance Plan) and ITP (Itemized testing plan) norms witnessed by an expert third party inspecting agency at various locations.
The spectacular view of ‘Queen’s Necklace’ at the Marine Drive, location of the stadium at the Sea and an appealing look of the Stadium is an USP of Wankhede Stadium.
Engineering Watch
Engineering Marvels of India
Development Of Machinery For Traditional Foods‐ A Continuous Chapati (Indian Unleavened Flat Bread) Machine Chapatis are in the form of circular discs prepared from 90-95 % extraction flour. Growth in industrialization as well as mushrooming of nuclear families in the present times, has vested an increased demand for Ready-to-eat and Easy-to-carry foods. Hence mechanizing the preparation of traditional foods like chapatis
INNOVATION
Manual handling of the dough is avoided, eliminating human factors and making the entire operation hygienic Higher production capacity than any other systems and the chapatis produced are uniform in diameter and thickness Continuous operation with provision of material recycling, with no re handling of the dough
OPERATIONAL EXCELLENCE
Hygienic design and construction – No stickiness of the dough to any part of the device The parts of the machine can be easily dismantled and assembled so that contact parts can be cleaned and inspected regularly The equipment is versatile, has high tolerance of moisture, fat and type of flour. During baking varied temperature and residence time can be set depending upon the thickness of chapati and moisture content in the dough
large quantities are prepared. A single operator is enough to prepare and feed the dough continuously and operate the machine
Energy efficient and is designed for continuous operation. Due to mass production, there is significant reduction in energy consumption
Reduction in the cost of chapatis and savings in labour while
Self Reliance
Unit does not need skilled persons for operation
Low cost machine, needs low investment and less floor space. No pollution
Increased production rates
Growth in industrialization has vested an increased demand for ready-to-eat and easy-to-carry foods. The present development elevates the operation of chapati preparation from home scale to industrial scale catering to the increased demand through the establishment of tiny ancillary units to manufacture chapatis thus promoting the growth of small and medium scale entrepreneurship (SME) The machine offers ready- to-eat and easy-to-carry chapatis, saving time and drudgery in the preparation of chapatis at thus promoting the spirit of self employment and entrepreneurship among rural and urban women. The various sectors benefiting from the development include, industrial canteens, institutional kitchens, large hotels, mass feeding centres and small and medium scale entrepreneurs. The system is energy efficient and is designed for continuous operation. Due to mass production, there is significant reduction in energy consumption In times of natural catastrophes and calamities like, earthquakes, cyclones, and famine where large mass feeding is essential, this machine can put to good use to prepare huge quantities hot chapatis in a lesser time under hygienic conditions. The same applies in times of war
Impact
Licensee(s) / beneficiary utilizing /benefitting from
Future Readiness
In times of natural catastrophes and calamities like, Earthquakes, Cyclones, Famines and Floods this machine can be put to good use to prepare huge quantities hot chapatis in a lesser time under hygienic conditions
Can be used in industrial canteens, railway stations, hospitals and midday meal scheme centres, where large quantity of chapatis are required to be produced in a short time and
The product produced an be preserved in ready -to -eat, form which can be consumed as such where cooking facilities are limited and non-existent
The chapatis produced from the machine can complement as ‘Food Aid’ to meet the global crisis of malnutrition, tackling extreme poverty and hunger ensuring that all citizens can afford the cost of basic nutrition
the development are 6 in number at present with a licence Fee – Rs. 1,000,00 (Rs. One lakh only) and Royalty on recurring basis at the rate of 3% of the ex-factory sales per unit quantity of machine made used and or sold, both licence fee and royalty to be paid to CSIR-CFTRI for a period of 14 years
The machine has been sold to many industries and organizations across India by the licensees including export to Middle east countries
The machine offers ready- to-eat and easy-to-carry chapatis, saving time and drudgery in the preparation of chapatis thus promoting the spirit of self employment and entrepreneurship amongst rural and urban populace including jail inmates.
Machine was put to good use during Tsunami, Gujarat Famine and Uttrakhand Floods relief activities. Ready-to-eat chapatis were prepared from the indigenously developed chapati making machine, on a large scale
Engineering Watch
Engineering Marvels of India
CSIR‐CBRI Liquid Extinguishant Fire Extinguisher For Common Man’s Fire Safety To develop an affordable new/novel fire extinguisher for common man’s fire safety
INNOVATION
It’s a green, zero Ozone depleting Potential(ODP) and simple technology for common man’s fire safety at an affordable price of Rs. 100/- to 200/- for a half litre to oneLitre plastic spray-bottle versions. Rapid fire extinguishment (in 8 to 10 seconds on 100 cm2 Size Class A & B Fires and 25- 30 on 1000 cm2 Fire) with multiple uses No Propellant or a Compressed Gas or pressurized Aerosol driven-It’s absolutely Risk free, 100% safe, and easy to operate Multiple Outputs as and when required from a single unit. Light-weight and can be made available in sizes: 250ml, 500ml, 750ml, 1000ml, 1250ml and 2000ml extinguishers or even larger capacities.
OPERATIONAL EXCELLENCE
No over-run of time as it was done on schedule.
Development of liquid fire extinguisher has great significance with respect to environmental safety impact in terms of its zero Ozone depletion Potential(ODP) being halogen Cl-, Br-, and I –free
Simple Handheld Spray Operation
No Propellant or a Compressed Gas or pressurized Aerosol driven-It’s absolutely Risk free, 100% safe, and easy to operate
Can be made in Low Price-Versions of Rs. 100/-; Rs. 200/-; Rs.300/-; Rs. 400/- & Rs. 500/- and Rs. 1000/- for common-man house-hold to any users in any occupancy for “Class A all-type Combustible material Fires”, Class B Flammable Liquid Fires, “Class C Gaseous Fires”, “Electrical fires” and “Class K Kitchen Fires”.
Self Reliance
Development of ½-Litre Capacity and 1-Litre Capacity Low Cost affordable, handy Liquid Extinguishant Fire Extinguishers for common house-holds and rural/semi-urban/urban occupancies with fire extinguishment time of 810s and discharge rate of 1 to 5 g/s on Class A, Class B, Class C, Electrical fires and Kitchen fires at 1/5th of Cost will bring tremendous impact on societal fire safety as well as on nation with self-reliance by an indigenous development.
Self-reliance by everybody’s safety and the safety of the building premise from getting engulfed into big fires before the arrival of state/municipal fire brigade- thus saving life & property before hand -thus reducing the building operational losses and downtimethereby improving building daily working productivity.
Impact
The development of Low-cost CSIR-CBRI Liquid Extinguishant Fire Extinguisher in the public fire safety interest will bring tremendous impact on societal fire safety as well as on nation at lower cost with higher fire suppression efficiency.
Impact on Public Goods, Private Goods, Social/Societal Goods and Strategic Goods as well as on nation as fire can occur in any premise/occupancy.
Impact on Self”s fire safety and his/her living and work place’s fire protection at an incipient stages of the occurrence of fire- a great achievement.
No smoke development by extinguishant during fire suppression Contribution to CSIR-800 Mission for Societal impact on bottom-line 800million of economical hierarchy
Future Readiness
Development of innovative Fire suppression technologies–using novel liquid extinguishants in 10,000nm to 1,00,000nm size range
Development of non-halogenated Low ODP(Ozone Depletion Potential) (Developmental Target range as per UNEP 0.01 to 0.5) -based fire extinguishing materials for common man users for inclusive growth and improved quality of life for India’s 800 million citizens
Export-oriented Approach.
Employment Generation in the Rural/SemiUrban and Urban Sectors in the related field
New Entrepreneurship development in the related field
Engineering Watch
Engineering Marvels of India
Prototype Fast Breeder Reactor Project (PFBR) Prototype Fast Breeder Reactor (PFBR) is first of its kind 500MWe pool type, sodium cooled nuclear reactor in the country, On completion, this reactor will not only produce 500MWe power but also pave way for abundant power production using indigenous materials & indigenous technology.
INNOVATION
The manufacture of over dimensional reactor components (diameter greater than 12 meters and thickness upto 40mm)are made for the first time in the country. The tolerance achieved during manufacture of above vessels is within specified 10mm for the 12 meters diameter, which is one of the great challenge.
OPERATIONAL EXCELLENCE
Various proactive measures are being taken by every team member to achieve more
Self Reliance
PFBR project has given ample opportunities for improving
PFBR Steam Generator is one of the most critical equipment as it separates liquid sodium and water/steam. Due to high operating pressure and temperature, the steam generators must possess a high degree of reliability against failure. The manufacturing activities such as tube to tubesheet welding, hot forming of nozzle pullouts, Post Weld Heat Treatment and shell fabrication is carried out meeting all the stringent specification requirements. The straightness of 26 meters length fabricated steam generator is achieved within 3mm for all the 8 nos. of steam generators, which is really one of the engineering excellence.
and more excellences in civil construction, tendering, equipment fabrication, QA,
In addition to “Industrial Safety Award” by Atomic Energy Regulatory Board (AERB),
International competition.
procedures and achieving very good performance in safety in the construction sector.
The project has moved with robust demonstration of Indian
The weld between the primary pipe & grid plate of the reactor cannot be accessed for in-service inspection. Any failure of above weld during reactor operation would lead to inefficient decay heat removal from the reactor core. Space constraints & lack of accessibility makes the welding & inspection challenging. Due to complex constructional features, non-uniform mass & centre of gravity, the handling and erection of over dimensional reactor components is extremely difficult and challenging task. Utmost care and varieties of control measures were required to ensure specified horizontality, elevation, alignment, coplanarity, axis orientation, co-axiality of centres of various reactor components. These reactor components were required to be erected in the constrained space and access at site. Various mock ups were carried out simulating the actual job handling conditions for validation of the process irrespective of huge cost involved. All reactor components are handled and erected successfully meeting all the stringent specification requirements without a single dent on the component. Huge quantity (i.e. 1750 tones) of highly reactive liquid sodium (which is a coolant for the reactor) is handled and transferred to the designated location at site.
BHAVINI has been actively engaged in public outreach programme since its inception from October 2003. About
construction. PFBR project presentations have been given
technological capability in terms of indigenous design,
to the every team who has visited PFBR site. Senior
indigenous material specification, indigenous
BHAVINI management officials have been periodically
manufacturing technology, advanced handling & erection
visiting schools, universities, engineering colleges, arts &
techniques with high standard quality control and quality assurance.
science colleges and given presentation about the nuclear energy for about 1-lakh student communities. These activities have given good impact, motivation and positive
A pivotal role is played by BHAVINI towards socially responsible activities for neighbourhood development. the thrust has been mainly towards the betterment in education, infrastructure, health & hygiene, water supply, development of rural & coastal areas and other welfare activities, and this has helped sustain global recognition.
Future Readiness
The department has huge plan of electricity production during
second stage of India’s Nuclear Power Programme through Fast Breeder Reactors (FBRs). Technology of commercial FBRs has been launched in the country with commencement
23,000 students have visited PFBR site since start of its
National Safety Council of India has awarded “Suraksha Puraskar” to BHAVINI in recognition for development and implementation of effective management systems &
Fast Breeder Reactors to be built in the country.
are complex in its constructional features. The enriched confidence to the Indian industries for entering into the
Vast construction experience of PFBR has provided lots of confidence for construction and commissioning of future
now capable of manufacturing any kind of equipment, which
industrial safety, human resources,etc
the quality standards for the industries and industries are
manufacturing experience of PFBR components has given
Impact
energy to the students, public, academic & research institutes for the development of the country.
of PFBR construction.
Engineering Watch
Engineering Marvels of India
Remote Asset Tracking in UCIL’s underground mine It was decided to design and develop this project initially as a tracking system for locating personnel and equipment at a level approx. 150m below ground using RFID technology. While RFID technology is used widely all over, the difference in our case was to design and apply it to underground environmental conditions of heat, dust & moisture.
INNOVATION Application in an underground uranium
OPERATIONAL EXCELLENCE Productivity improvement
mine Technological upgradation in IT arena in a
Improved safety figures i.e much lesser loss of mandays
new domain
Self Reliance With wider application in mines all over
the country such systems can help in bring about greater productivity improvements.
With equipment tracking the same operator is being Training of workforce towards system
adaptation and usage Usage of indigenous components
deployed on another machine/ or another job, if the initial work given has been completed. Was not always possible earlier.
Mining Costs can be brought down
through better monitoring.
Impact System visibility
Future Readiness With add-on facilities the project shall be
upgraded from the present voice/ data
Production optimisation
Safety improvement Multiskilling Pride in technology adoption
communication to continual video images of the underground workings The equipment diagnostic modules of all
critical underground equipment can be interfaced to this system.
The government can provide subsidies A futuristic outlook
Communicating on I P Phones from their underground
equipment to their supervisor instils a sense of pride in the operator ( the’ star wars’ feeling).
for the system components thus making it possible for even small mining companies to adopt.
The central server can be connected to
similar mines ( in India or abroad) to access/transmit information from experts in case of critical equipment failure/mine
Large mining companies can adopt more
IT applications underground for overall improvement. The data generated from mines in India
will be actual figures
collapse, flooding. rock blasts etc.
Engineering Watch
Engineering Marvels of India
Specialised Centre for Treatment of Sports Injuries World class Super Speciality Sports Injury Centre has been set up at Safdarjung Hospital with a aim to serve as a full-fledged Sports Injury Centre. It is a specialised Hospital Module on a 0.648 acre site. It is a centrally air-conditioned 2 level basement, Ground plus 7 floor structure with a constructed area of 7500 sq.m.
INNOVATION
Created to provide facilities of advanced medication involving hip, knee and shoulder-joint surgeries and arthroscopy.
OPERATIONAL EXCELLENCE
The value of work awarded was Rs. 32.5 crores (for civil construction)
Self Reliance
and final cost of construction is Rs. 34.00 crores for civil works, which is well within the acceptable range
A green lawn provides open waiting zone for the patients /attendants waiting zone. Space planning on all floors ensures a sense of fluidity while moving through the complex through a combination of alcoves and short connecting corridors, lobby, waiting area etc.
The iconic use of contemporary materials and also latest construction materials and their soft palette colours enhance the overall facility.
With the setting of Sports Injury Centre at Safdarjung Hospital, a World Class Super Speciality Sports Injury Centre has been established (first of its kind in Asia). With its operation, thousands of athletes and general patients would be getting state-of-the-art advanced medication involving knee and shoulder-joint surgeries. The Centre handles more than 5000 patients on OPD basis in a month and more than 100 Arthroscopy & Joint Replacement Surgical Procedures are performed monthly.
The Sports Injury Centers is dedicated to delivering the highest standards of diagnosis, prehabilitation, treatment, rehabilitation and full recovery care for its patients.
The Centre is approved by Indian Orthopaedic Association for super specialized training in the field of arthroscopy and sports injuries & is visited by observers from all over the country and abroad.
The contrasts of Alucobond, granite and steel and the steel-see-through screen on the roof of entrance porch with its attention to the details.
Impact
Unique facility of its kind in the health care in particular and sports in general has been built.
The facility is comparable to international standards.
Sports person from different parts of the globe find it valuable.
State of the art technology to treat medical emergencies
Patients are being benefited with the quality of services.
Future Readiness
It is providing integrated diagnostic, surgical and rehabilitative services under one roof for the sports persons of our country at par with international standards
Inside this marvellous new facility, specialized surgical expertise, latest technology & equipment are available to treat sportsperson plagued with some of the world’s most complex sports injuries
Thousands of sports personnel and commoners are going to have an opportunity to benefit from this set up.
The Centre has 3 ultra-clean air Modular Operation Theatres with cutting edge equipments where more than 100 complex surgeries are conducted per month. These procedures involve not only knee and shoulder but also hip, elbow, ankle and wrist joints as well.
The Centre has a separate Cardio and Strength Gym with latest machines for rehabilitation and training of sportsperson
Engineering Watch
Engineering Marvels of India
MAGIC STUDIO A POWERFUL USER-FRIENDLY AND PORTABLE DESKTOP SOLUTION WITH THE ABILITY TO CONVERT 2D CONTENT TO 3D CONTENT
INNOVATION Our product/ solution is unique
and innovative due to its features, design and internal components.
It is an integrated solution
which has an inbuilt projector, p ro c e s s o r, s p e a ke rs a n d amplifiers.
It has interactivity feature
inbuilt which can make any wall interactive.
The design and form factor is
extremely appealing and rugged.
The power saving feature in
spite of having so many components inside, is at a respectable and minimal point.
OPERATIONAL EXCELLENCE Ease of installation. Portable, user friendly, plug‐n‐play
interactive classroom. Intelligent color adjustment. Enhances group learning which increases
interests of students. Minimal Power consumption, energy
efficient, environment friendly.
Self Reliance
Impact
Future Readiness
A basic necessity of these days
This product is specifically
Our R&D team continuously is
classroom is deviced in Magic Studio.
designed for classrooms to simplify and ease the life of educators.
working to make this product more convenient, hassle free and aesthetically most beautiful as a package.
A simplified technology with
rugged design. A user friendly device for ease
of use
Educators do not have to
struggle with the installation but just have to insert one single power cable and they are ready with their presentations.
A Teacher is able to deliver
knowledge more effectively with the help of the solution.
We have a model which has a
lamp inside with lamp life of 6000 hours in eco mode and now we would be coming with a LED model soon.
This product completely
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We have a 3‐D model also
launching. The power saving would further
go down which makes it highly environment friendly as well