• CISDI Engineering Co., Ltd.

    Tata Steel TSK Plant No. 2 Blast Furnace Project in India

    Kalinga Nagar, Orissa, India

Project Summary

Project

At a capacity of 5,873 cubic meters, the TSK Plant No. 2 is currently the largest blast furnace under construction in the world. The owner, Tata Steel, contracted CISDI Engineering, a technology-intensive engineering company majority-owned by China Metallurgical Group Corporation, to build the furnace in the industrial town of Kalinga Nagar on the coast of Odisha, India. The large, complex design of the facility had to meet strict international design standards. Additionally, the design process involved numerous specialists distributed over three offices, making communication and collaboration difficult. Despite the CNY 2.5 billion project’s size and challenge, Tata Steel required design work to be finished within 22 months. Therefore, CISDI determined the project could not be completed on schedule with traditional design methods.

Solution

To unify the large volume of work created by 16 different design teams, CISDI adopted a building information modeling methodology within an open, connected data environment that facilitated communication among the offices. Additionally, the organization transferred more than 13,000 P&ID 2D design attributes into the 3D model, eliminating the need to repeatedly input the same data during modeling and saving resource hours. CISDI further improved design efficiency by creating proprietary modeling capabilities within Bentley applications and generating numerous databases for pipelines and equipment. Using innovative 3D and 4D applications helped the project team visualize the design, more effectively optimize the construction schedule, and solve potential construction problems during the design phase.

Outcome

By using a connected data environment, CISDI improved communications between far-flung contributors within numerous disciplines, saved 500 resource hours, and established trust with the project owner. BIM methodology within that environment improved the design process and streamlined data entry, saving an additional 600 resource hours. The project team’s 3D model iteration greatly enhanced the design by reducing the weight of the air heater shell by 5%, improving the safety of hot and cold air pipelines by 30% and 15%, respectively, and lowering the temperature of the work platform by up to 2 degrees Celsius. Using a federated 3D model, design teams detected and resolved more than 1,500 design clashes, which improved work quality and saved CNY 3 million in potential rework.

Software

ProjectWise and Navigator established an open, connected data environment and helped improve communications with Tata Steel. Within MicroStation, CISDI created models of 2,192 different pieces of equipment, and lowered model drawing time from one minute to 10 seconds. The equipment models were assembled within various Bentley applications, including OpenPlant for pipes, supports, and hanger equipment, as well as Bentley Raceway and Cable Management for cable trays. LumenRT provided 3D visualization of the federated model and generated a virtual reality experience that CISDI presented at expos worldwide.

Project Playbook: AutoPIPE, Bentley Raceway and Cable Management, LumenRT, MicroStation, Navigator, OpenBuildings Designer, OpenPlant, ProjectWise, SYNCHRO

Outcome/Facts
  • CISDI used 3D modeling to design the world’s largest blast furnace, which when finished will process 4.375 million tons of iron each year.
  • A BIM methodology improved the design process and streamlined data entry, saving over 600 resource hours.
  • CISDI created models of 2,192 different pieces of equipment using MicroStation, which lowered individual model drawing time from one minute to 10 seconds.
  • Working within a federated model allowed designers to detect and resolve over 1,500 design clashes, which improved work quality and saved CNY 3 million.
Quote:
  • Thanks to the openness of Bentley’s applications, we have developed many BIM design software features on their platform. In total, we have developed 38 tools, which have enhanced collaboration and coordination among different disciplines, as well as modeling efficiency.

    Zhen Liu Technical Director CISDI Engineering