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Home > Case Study

Case Study

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Helium LRC System

Compressed Air Plant

Helium Gas Compressor

ECCS Compressor System

Chiller System

Boiler Feed Pumps

Chiller System

Oxygen Generation Plants

CO2 Reciprocating Compressor Package

Marine Air Compressor

Pneumatic Winches and Hoists

NFPA20 / UL FM Fire Pumps

Fresh Water Maker

Scuba Diving Equipment

Compressed Air System – Metro Projects

IPDS Electrical Distribution Project

Helium LRC System

Client: Punj Lloyd Limited


End User: NPCIL, KAPP-3 & 4, RAPP 7 & 8



Key Achievements


  • →  D2O Control & Measurement in various Liquid Zones inside reactor building.
  • →  Prototype development & testing in order to demonstrate performance.
  • →  Designed as per ASME Section III, ND.
  • →  Flow – 125 Nm3/hr @12 bar (g)
  • →  In process inspection and seismic testing as per approved Quality Assurance Plan.
  • →  Performance Testing with Air at 74°C and Helium gas.

Challenges Faced


  • →  To be tested for OBE Seismic requirements
  • →  Development of forged parts for leak tightness in vacuum excess of 10-7 mbar
Compressed Air Plant

Client: Compressed Air Plant


End User: NPCIL, Kudankulam 3 & 4



Key Achievements


  • →  Vast scope involving compressors, dryers, compressed air storage, centralized monitoring, plant piping and instrumentation
  • →  Low pressure compressors of 1 MW rating and high pressure compressors
  • →  Designing of complete plant in 3D software, piping stress analysis
  • →  Seismic testing of critical components and piping structures
  • →  Designing of large Vessels designed as per ASME Section VIII


Challenges Faced


  • →  Intricate instrumentation interlocking for safety trips
  • →  Timely approval from NPCIL and manufacturing of package components
Compressed Air Plant

Client: Directory of Purchase and Stores


End User: BARC



Key Achievements


  • →  Requirement for Cryo-Liquefaction Plant for cryogenic cooling of superconducting magnets.
  • →  Parameters – 100 grams per second at 17 bar.
  • →  Designing of complete plant in 3D software, piping stress analysis
  • →  Performance Testing with Helium gas
  • →  Performance Testing for at 100% load in accordance with AHRI-550 standard.
  • →  System Integration at site
  • →  Operation & Maintenance contract undertaken for 8 years.


Challenges Faced


  • →  Control philosophy for closed loop operation
  • →  Rotor to be made of Forged Carbon steel
ECCS Compressor System

Client: Punj Lloyd Limited


End User:NPCIL, TAPP-3&4, KAPP-3&4 and RAPP-7&8



Key Achievements


  • →  Enabled the use of Light water instead off heavy water
  • →  Incorporated as a permanent design in all PHWR Reactors.
  • →  Part of PHWR design as per AERB Guidelines.
  • →  Flow – 81 Nm3/hr @45 bar (g)
  • →  Coolers designed as per API 661
  • →  Seismic Qualification by Analysis & by Shake Table Test
  • →  No need to provide inert gas inventory


Challenges Faced


  • →  Heavy duty N2 cylinders to be deployed as standby.
  • →  Periodic Storage inspection
Chiller System

Client: Larsen & Toubro ECC


End User:NPCIL, KAPP-3 & 8, RAPP 7 & 8



Key Achievements


  • →  Design & Documentation as per ASME Sect-VIII, Div-1
  • →  ASME Qualification of Heat Exchanger
  • →  On job ASME qualification of pressure vessels was achieved
  • →  Performance Testing for at 100% load in accordance with AHRI-550 standard.
  • →  Scope- 240 TR x 8 Nos. Chillers, complete instrumentation and concomitants.


Challenges Faced


  • →  Single Party Approved Vendor for Last 30 to 40 Years.
  • →  Development of new OEM to meet stringent nuclear requirements
Boiler Feed Pumps

Client: Dodsal


End User:NPCIL, KAPP-3 & 4



Key Achievements


  • →  Seismically Qualified design of pump, Shake Table tested Instruments & Panels.
  • →  Customized and non-standard lube oil system
  • →  Motor capacity of 5.5 MW at 6.6 KV HT power supply
  • →  Single point responsibility by CORE for entire package
  • →  Further details can be discussed with CORE higher management
Chiller System

Client: Directory of Purchase and Stores


End User:BARC



Key Achievements


  • →  Scope- 300 TR x 2 Nos. Chillers, complete instrumentation, Control panel and hook up to central BMS
  • →  Chillers subjected to endurance and variable load during test run
  • →  Stage inspection of chiller during manufacturing
  • →  First of a kind Non-OEM standard PLC controller implementation
  • →  Non-standard unit designed in accordance with stringent BARC specification with only one deviation


Challenges Faced


  • →  Non-standardization
  • →  Logic and programming of panel in conjunction with existing BMS
Oxygen Generation Plants

Client: HITES, United Way, Oxfam


End User:Hospitals & Healthcare Facilities



Key Achievements


  • →  Inhouse and ingenious development of PSA and PVSA based oxygen generation plants
  • →  Plant designs with capability of oxygen purity up to 98%
  • →  Plants installed till date with a cumulative capacity of 95,00,000 Litres Per Day
  • →  First of a kind Non-OEM standard PLC controller implementation with IoT based remote monitoring
  • →  Certified as per ISO 13485:2016 for medical equipment


Challenges Faced


  • →  Timely delivery of plants within few weeks of intimation
  • →  Sourcing of high-quality lithium and sodium-based zeolite.
CO2 Reciprocating Compressor Package

Client: Deepak Fertilizers and Petrochemicals Corporation Limited



Key Achievements


  • →  First Installation of Atlas Copco Make CO2 Reciprocating Compressor in India.
  • →  Bare shaft compressor manufactured at ACIL Crepelle, France.
  • →  Indigenization of major components of Compressor Like – Electric Motor, Instrumentation, Control Panels, Suction Vessels.
  • →  Integration of all components at Site & Performance Test at site.
Marine Air Compressor

Client: ONGC



Key Achievements


  • →  Design, Engineering & Documentation as per ISO 1217
  • →  Design, Engineering & Documentation as per ISO 1217
  • →  Cooling system MOC as Duplex steel to withstand Seawater corrosion.
  • →  Performance Testing
  • →  System Integration at Rig
  • →  Painting as per marine standards


Challenges Faced


  • →  Defined space requirements
  • →  Exposure to harsh environment
  • →  Design to compensate for roll and pan angles
Pneumatic Winches and Hoists

Client: Reliance


Project:Jamnagar J3 Refinery



Key Achievements


  • →  Design and engineering done specifically for hazardous and explosive environemnt
  • →  Project successfully accomplished at world’s largest coke gasification complex and petrochemical plants.
  • →  First of its kind project for this refinery
  • →  Performance Testing
  • →  System Integration at Rig
  • →  Painting as per marine standards

Capacity Quantity Installed
Air Winch - 5 MT 3 Nos.
Air Winch - 18 MT 10 Nos.
Air Winch - 3 MT 2 Nos.
Air Winch - 6 MT 1 Nos.


Challenges Faced


  • →  Constricted space Requirements
  • →  Electric Classification Area Zone 2 Gas Group IIC Temp. Class T3
  • →  ATEX Certification
Frictionless Rail, Hoist & Vacuum Lifting System

Client: NPCIL, TAPS 3 & 4, KELLOG India Pvt. Ltd.



Key Achievements


  • →  Supply, installation and Commissioning of TAWI make Vacuum Lifting solution for fragile applications
  • →  Supply installation and commissioning of IR Make Frictionless Rail & Hoist System
NFPA20 / UL FM Fire Pumps
  • →  Installation & Commissioning of Fire Pumps as per NFPA20
  • →  Testing of fire fighting systems as per NFPA25 & FM Global Standards
  • →  AMC of fire fighting Diesel Pump,Electrial pump & Jockey pump & maintaining PUMP as per FM global Standard

Clientele: Mc Cain Foods, Cummins Generator Tech, Sandvik Asia, Victualic, Atlas Copco, Emerson, John Deere, Johnson & Johnson, SKF, Alfa Laval and many more.

Fresh Water Maker

Client: ONGC



Key Achievements


  • →  Distillation type water maker working on waste heat recovery
  • →  Parameters – 35 Tonnes/day at 10 PPm
  • →  To be designed for corrosive environment
  • →  System Integration at Site

Name of Rigs No. of Water Maker Installed
Sagar Jyoti 2 Nos.
Gaurav 1 Nos.
Shakti 1 Nos.


Challenges Faced


  • →  Constricted space Requirements
  • →  Maintain maximum salinity of 10 PPM
Scuba Diving Equipment

Client: MTDC



Key Achievements


  • →  Design, Engineering of compressors confirming to CGA and NFPA norms and certified by ASME and DOT authorities.
  • →  Parameters
    • - Flow – 400 LPM @200 Bar
    • - Maximum discharge pressure – 300 Bar
  • →  MOC Duplex steel to withstand Seawater corrosion.
  • →  Scuba diving apparatus complete with breather, suit, gauges and O2 cylinder
  • →  Performance Testing and commissioning at site
Compressed Air System – Metro Projects
  • →  Pneumatic System for Tunnel Ventilation at 6 stations & in Depot for Delhi Airport Metro Limited Comprising of Cu piping in underground stations.
  • →  Compressed Air System for Versova Depot in Mumbai Metro Phase-1
  • →  Compressed Air System for Depot stations and Tunnel ventilation for Navi Mumbai Metro Phase-1
Hydro Pneumatic Systems
  • →  Installation of Water Level control system during Renovation of Wankhede Stadium for 2011 World cup
  • →  Scope- Hydro-actuating system consisting of Float switches, control panel & electrical control valves for overhead and underground Tanks.
  • →  Balaclava Resort, Mauritius for Supply of Pumps and auxiliaries.
IPDS Electrical Distribution Project

Client: MPPKVCL



Key Achievements


  • →  33/11 KV Substation
  • →  HT / LT Lines
  • →  Distribution Transformers
  • →  Smart Meters and Roof Top Solar Panels
  • →  Executed under the IPDS Scheme
  • →  Appreciation from MP government for excellent project execution


Project Insight


  • →  Circles Handled :- Damoh, Katni, Balaghat
  • →  Total Line :- 713.51 KM
  • →  Total KVA :- 1,18,565 KVA

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