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Control System Integration for Water
Treatment Plants for a Utilities Major

                                               The Achievement
                                               Over 200 person years of effort in less than 3 years emphasizing extremely
                                               high resource ramp-up capability at onsite and offshore.

                                               The Project
                                               The project involves end to end control systems integration for over 300
                                               water & waste water treatment plants of one of the large utilities company
                                               in England. It covers design, development and implementation of control
                                               systems to cater to the redefined process requirements as mandated by the
                                               regulatory authorities.

                                               Project Genesis
                                               The Asset Management Programs, having an execution period of 5 years, are
                                               one of the most complex programs in terms its scale of operation in Water
About Plant Automation
                                               Industry. The statistics for this project are:
Services Practice
TCS provides vendor neutral services which
                                                  ● Work involves a large number of water treatment works,
                                                      wastewater treatment works and UIDs
leverage domain, technology and software
                                                  ● Plants spread across large geographical area England
expertise in the areas of Manufacturing
Execution Systems, Control Systems
                                                  ● Multiple Kit Framework suppliers responsible for supply of various
                                                      components of the systems
Integration and Process Optimization,
enabling clients to reduce the global system      ● Client working along with Engineering Service Providers, Design &
deployment time, integrate business and               Build Contractors to manage and deliver the whole capital
plant systems in real time, and achieve               expenditure program
higher levels of process efficiencies.

About EIS Business Unit                        Project Technologies
Engineering and Industrial Services (EIS)      TCS has used following tools and technologies for this project
is one of TCS’s strategic businesses that         ● PLC platforms: Siemens S5 and S7, Rockwell PLC 5, Siemens TI, ABB
provides single window solutions globally            Sattcons, Alstom PLCs, Texas PLCs, etc.
to help clients realize efficiencies in            ● Human Machine Interfaces based on Siemens and Rockwell
innovation, operations and capital and               interfaces
asset management strategies, using best-          ● SCADA: WinCC, RsView, AFE SCADA, Intellution, etc.
in-class technologies, processes and
                                               Project Implementation
                                               TCS has used onsite-offshore delivery methodology based on Global
                                               Engineering principles for carrying out this project achieving huge cost
                                               benefits for the client.

                                               Offshore activities:
                                                  ● Design
                                                  ● Logic development
                                                  ● Graphics development
                                                  ● As built documentation
                                               Onsite activities
                                                  ● Optioneering and Site requirements analysis
                                                  ● Factory Acceptance Test assistance
                                                  ● Site Acceptance Test assistance
                                                  ● Commissioning assistance
                                                  ● Training

                                                                               ENGINEERING AND INDUSTRIAL SERVICES

Control System Integration for Water
Treatment Plants for a Utilities Major

                                            Scope of work
                                            For each of the over 300 projects, TCS is carrying out the following
                                                1. Reviewing the design statement prepared by the consultant/
                                                2. Plant visit to gather site conditions and information about legacy
                                                3. Design the new control architecture and prepare a Bill of
                                                    Materials (BOM) on the basis of which the automation hardware
                                                    will be purchased.
                                                4. Understanding the design statement and preparing a detailed
                                                    Functional design Specification (FDS) for the PLC software being
                                                5. PLC logic and graphics development and test procedures
About TCS                                       6. Pre-FAT in India, using PLC Simulators.
Tata Consultancy Services (TCS) is among        7. Site activities at UK like FAT, SAT and commissioning, training.
the leading global information technology
consulting, services, business process      Staffing
outsourcing and engineering services           ● A fixed size onsite ‘Core’ team stationed in the UK for the entire
organizations. Pioneer of the flexible             duration of the project
global delivery model, TCS focuses on
delivering cutting edge technology led
                                               ● A fixed size offshore ‘Core’ team based in TCS, India, for carrying
                                                  out Project Management activities.
business solutions to customers across
varied industries.
                                               ● A variable size onsite ‘Implementation’ team that would be
                                                  ramped up and down as the number of projects (plants taken
                                                  up for upgradation) vary.
For More Details, Contact:
Engineering and Industrial Services
                                               ● A variable size offshore ‘Implementation’ team that would be
                                                  ramped up and down as the number of projects (plants taken up
Business Unit
                                                  for upgradation) varies.
Tata Consultancy Services Limited
11th Floor, Air India Building
Nariman Point
Mumbai 400021                                  ● The job required highly competent people at various levels
                                                   ranging from Program Managers and Engineering Managers
Phone: +91-22-5550 9999                            through Team Leads, PLC Programmers, and Technical Assistants.
Fax: +91-22-5550 9455                          ● Since the volume of work would be fluctuating over the period of
                                                   execution, it was required to have a team that can be ramped up                                    and down based on demand.                  ● Cost and time were major constraints, and had to be done to
                                                   top quality standards. Any compromise on quality had severe
                                                   legal implications due to our client being part of the regulated
                                               ● Presence of large variety of legacy systems
                                               ● Interface with a large team of organizations related to
                                                   Engineering design, civil and M&E contracts and host of
                                                   other product and service providers

                                               ● Standardization leading to higher Re-use
                                               ● Highly structured Documentation
                                               ● Knowledge base (IP) for future
                                               ● Information infrastructure for an integrated enterprise

                                                                          ENGINEERING AND INDUSTRIAL SERVICES

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