Archives: Case Studies

Largest Solar PV Park In Bangladesh: Working Towards Clean Energy for all

Zetwerk has aided in the design, supply, execution, and commissioning of Bangladesh’s largest solar park. The 275 MWp solar power project is the largest in the country and has commenced power generation & transmission to the national grid.

Given the tight timeline and variables at play, our in-house project management software helped optimize the time required to identify the specified manufacturer for the design. Parallel manufacturing and supervision by expert quality control Engineers deployed at each factory ensured on-time production. Our dedicated logistics and production monitoring teams handled material delivery from 12 Indian states, including 20,000 MT of steel, 6.5 Lakh meters of cable, 16 inverter duty transformers with HT/LT panels & switch gears, and other major materials parallelly manufactured in six months.

To accommodate the tight project delivery timelines, we used multiple modes of transportation, including roadways, waterways (barge), and air freight.

Challenge

Located 45 kilometers from the main city of Rangpur, Bangladesh’s largest solar power park was set to be executed in a remote village in the Gaibandha district. A solar project of this scale requires a variety of expertise – from concept to commissioning – with effective project management. Add a difficult terrain and strict timeline to the mix, you’ve got a tight challenge on your hands. And with the site located along the banks of the Brahmaputra, it became imperative to cautiously execute the project without any environmental impact. Owing to the unique soil conditions of the area, the solar piles required a special helical design, and were packaged along with customized inverters and drums.

On average, it takes 138 hours and 55 signatures to move one truck from India to Bangladesh. With 2008 trucks to be moved across the border in the span of 330 days, shipping material from 50 locations across India, Zetwerk’s Renewables team rose to the challenge and effectively moved one truck every four hours.

Impact

The Gaibandha solar power park will offset over 375 billion tonnes of CO2 emissions, thereby working towards a greener planet that uses decarbonised energy sources.

This cause is in line with the UN’s SDG goals of access to affordable, reliable, sustainable & modern energy for all.

In enabling this “Make in India, for the World” project, Zetwerk is contributing to India’s GDP, while simultaneously helping a neighboring country achieve a green goal as a step towards the vision of the “Look and Act East” Policy. All this, while safely working along the Brahmaputra River with zero impact to the environment.

Advantage

Zetwerk’s proprietary tools & technology enabled seamless project management from design to delivery. With a robust network of reliable suppliers across India, and all the required approvals in place, we were able to efficiently deliver heavy materials across the border and into Bangladesh via specialised quality and logistics teams. This ultimately led to shorter lead times and timely delivery of the full project.

ZETWERK through its robust renewables operations, has been able to create real impact across India and beyond. With increasing consumer awareness, the renewable energy sector is poised for a significant growth spurt.

ABHAY ADYA

Business Head – Renewables

Covid-19 And Logistical Challenges Overcome: Bridge Delivered

Champa City, located in Chhattisgarh, was facing significant logistical challenges due to the COVID-19 pandemic. One of the critical infrastructure projects affected was the construction of a rail bridge aimed at reducing rail traffic congestion. The timely execution of this project became a pressing concern due to transportation restrictions and the need to transport heavy structural materials amidst the pandemic.

Challenge

The primary challenge was to build a 60.5-meter open web girder for the rail bridge in Champa City. This involved overcoming logistical constraints caused by the pandemic, such as restricted transportation and supply chain disruptions. The transportation of 515 tonnes of steel structures for the bridge amidst these challenges added complexity to the project. The goal was to reduce rail traffic congestion and improve travel time for passengers and freight.

Impact

ZETWERK’s involvement in manufacturing and supplying critical steel structures for the open web girder bridge had a far-reaching impact on the project’s outcomes. The successful completion of the 60.5-meter bridge significantly reduced congestion and halved travel time for rail traffic in the region. This had a direct positive impact on passenger convenience, freight logistics, and overall economic growth in Champa City and its surrounding areas.

Advantage

Leveraging our robust network of suppliers and expertise in fabricating and transporting heavy steel structures, ZETWERK ensured the timely delivery of 515 tonnes of materials for the rail bridge. This facilitated the smooth construction process and contributed to the bridge’s strength and stability. It has become a catalyst for economic growth, empowering businesses in Champa and beyond.

Our expertise not only reinforces the bridge’s strength but also significantly reduces travel time, marking a transformative leap for both passengers and freight.

Nishant Goel

Business Unit Head – Railways & Metro

Excellence in Engineering: Project Execution of Mounded LPG Storage Tanks in Harsh Conditions and Stringent Compliance Standards

A leading oil-producing PSU entrusted ZETWERK with supplying, fabricating, erecting, testing, and commissioning 3 x 600 MT mounded-type pressure vessels for LPG storage and three cone-roof firewater storage tanks. This venture represents a project in excellence, innovation, and socioeconomic development. Moreover, the harsh environmental conditions of Rajasthan, including temperature fluctuations and sandstorms, added complexity to fabrication and erection. Furthermore, ensuring compliance with statutory regulations such as PESO (Petroleum and Explosives Safety Organization) approval necessitated meticulous planning and execution.

Challenge

The project’s technical intricacies posed formidable challenges. Adherence to stringent codes such as PD 5500 (British Standard for safe design, construction, and testing of unfired pressure vessels, ensuring integrity across industries) and BS EN 288-3: 1992 (qualification tests for welders on metallic materials, ensuring their competency for safe and effective welding), precise mechanical design, and finite element analysis were imperative. Ensuring compatibility with IS:2041 (Indian Standard for steel plates in pressure vessel fabrication, ensuring strength and safety) Grade R355 plate material while fabricating the mounded vessels demands meticulous planning and execution.

Impact

We avoided displacing communities and employed a local workforce. Comprehensive testing parameters ensured structural robustness and operational reliability. Hydrostatic pressure testing guaranteed the vessels’ integrity.

Radiographic examination, encompassing 100% radiography for LPG tanks and magnetic particle examination for nozzleto-shell welds, ensured weld quality in adherence to stringent codes. Dimensional checks, alignment verification, and material identification, supervised by Third Party Inspection Agencies, validated adherence to design specifications and regulatory standards.

Advantage

ZETWERK’s approach to every facet of the project, from mechanical design conforming to IS:2041 Grade R355 plate material to meticulous fabrication and rigorous quality assurance, every step exemplified excellence. Leveraging advanced techniques like finite element analysis and adhering to stringent codes like PD 5500, and ZETWERK ensured structural integrity and operational efficiency. Moreover, our proactive engagement with regulatory bodies ensured seamless compliance with statutory requirements.

While executing this project, the region saw infrastructural improvement and delivered substantial savings in transportation costs.

VIJAY PERI

Business Head – Renewables

Redeveloping Kota Railway Station: Improving Passenger Comfort

ZETWERK is redeveloping Kota Railway Station currently on a turnkey basis. We will be executing the entire project that is spread across an area of around 1.5 lac SQFT. This will include detailed designing of the station building and associated structures, and construction of all associated rooms, structural works, and MEP works.

This project started around 5 months back, and we have achieved a progress of around 10%. This includes the demolition of certain existing buildings and, the building up of temporary accommodation at all platforms, and certain works are in progress such as foundation work of the railway institute building, community hall building, etc. ZETWERK is now focusing on creating new rooms within the station building and carrying out MEP (mechanical, electrical,plumbing) work.

Challenge

The rebuilding of the live train station presented several initial challenges. Relocating utilities such as cables, sewer pipelines beneath and under the platform proved to be a complex task. Significant hours were spent on identification and planning of these cable routes and sewer pipeline shifting and then getting necessary approvals from authorities for their shifting. Additionally, designing a roof that connects the foot over bridges (FOBs) and concourse, as well as constructing interconnected structures and girders in busy areas, required meticulous planning.

However, our team is diligently working to secure all necessary clearances and approvals to streamline operations at the site.

Impact

Presently, Kota Railway station caters to approximately 1.15L passengers per day. With the proposed development, we anticipate an increase in capacity to accommodate around 1.75L passengers per day. To enhance passenger comfort, the station will be equipped with modern amenities such as VIP lounges, restaurant spaces, skywalks, escalators, and welldesigned parking facilities. Furthermore, Kota station will showcase traditional folk art and motifs, adding an aesthetically pleasing touch to the overall ambiance.

Advandage

Team ZETWERK was able to complete the dismantling work of certain buildings such as community halls before the scheduled completion time to further take up work of the new Railway institute and community hall buildings. The temporary booking counter at platform number four was completed before time for smooth ticket booking arrangements.

ZETWERK through its strong project execution capabilities is a significant contributor to making the rail infrastructure future-ready via the National Rail Plan. Our current work in Kota showcases our commitment in modernizing railway stations under the Amrit Bharat initiative.

Nishant Goel

Business Head – Railways

Indian Domestic Shipment Tracking & Validation: Tech-Driven Solution for Compliance & Operational Efficiency

ZETWERK manages over 5,000 domestic customer deliveries monthly. However, we faced significant operational challenges as GPS tracking is largely nonexistent for trucking operations. Additionally, compliance checks required intensive scrutiny, and the volume of shipments meant that we would have needed to deploy dedicated manpower, which would have proven counter-productive to validate all vehicular movement.

Therefore, the project’s main objective was to revolutionize this framework by integrating technology-driven solutions to streamline operations and compliance, ensure timely deliveries, and enhance operational efficiency for customer satisfaction.

Challenge

Although this traditional approach of shipping via non-GPS truck was cost-effective, it hindered real-time shipment visibility, leading to inefficiencies in customer communication, delivery updates, and operational excellence.

The primary challenge for ZETWERK was to eliminate laborintensive manual compliance processes for domestic movements and integrate automated tracking systems to overcome operational bottlenecks, increased errors, and hindered our ability to provide real-time customer updates, which ultimately impacted operational efficiency.

Impact

ZETWERK’s strategic tech overhaul had a transformative effect on our operations. By automating compliance checks, we have achieved an impressive 80% improvement in operational efficiency

Data integration provided comprehensive compliance visibility, and leveraging government databases via Unified Logistics Interface Platform (ULIP), enabled robust tracking of vehicle movements, enhancing operational insights significantly. Automating the recording of supplier movements further streamlined logistics workflows, leading to faster processing times and improved customer service.

Advantage

The advantage of our tech overhaul lies in its comprehensive approach. By integrating government API solutions such as FASTag and VAHAN via ULIP, alongside policy and process reforms.

We revolutionized our logistics operations by eliminating manual-driven compliance checks and enhanced visibility, ensured regulatory compliance, optimized operational costs, and delivered customer satisfaction.

ZETWERK was among the first organizations to join hands with ULIP. Through ULIP, ZETWERK has gained the capability to achieve real-time shipment visibility via the Fastag API, validate transportation vehicles using the VAHAN API, access e-way bill information from the EWB API, and ensure the integrity of their transportation processes. We take pride in our association with ZETWERK as they endeavor to enhance customer satisfaction, achieve operational excellence, and drive innovation forward.

ULIP TEAM

Supply, Manufacturing, Testing, and Delivery of Gas Pressure Vessels for a Leading PSU

A leading Indian gas PSU was required to enhance its infrastructure by installing pressure vessels critical for its operations. The project involved the supply, manufacturing, testing, and delivery of Pressure Vessel – CS (26-50 MM) and Pressure Vessel – CS (UP to 25 MM) under Limited Domestic Competitive Bidding.

These vessels were integral to their operations, necessitating high-quality standards and adherence to stringent industry regulations. The project timeline was particularly tight, requiring efficient coordination between all stakeholders to ensure timely delivery and installation of the pressure vessels.

Challenges

Advanced Material Integration into the pressure vessel design while ensuring structural integrity and compliance with industry standards

Additive Manufacturing Adoption to improve efficiency, reduce costs, and enhance the quality of pressure vessel components

Regulatory Compliance Complexity and Standards governing the design, manufacturing, testing, and delivery of pressure vessels in the oil and gas sector in a delivery timeline of nine months

Impact

The project created employment opportunities in manufacturing, engineering, and related sectors, contributing to economic growth and skill development.

Delivering and installing these pressure vessels enhanced the client’s infrastructure, enabling them to improve operational efficiency and meet growing demands in the oil and gas sector.

Compliance with regulatory requirements ensured that the project adhered to environmental standards, promoting sustainable practices within the industry.

Advantage

ZETWERK’s expertise in advanced manufacturing technologies and our ability to navigate complex regulatory frameworks gave us a competitive advantage in securing and executing the project for our client.

The successful completion of the project within the specified timeframe and budget showcased ZETWERK’s commitment to quality, innovation, and client satisfaction.

Our partnership with the PSU to deliver high-quality pressure vessels underscores our commitment to excellence and innovation in the manufacturing sector. By overcoming technical challenges and regulatory complexities, we’ve met our client’s expectations and set new standards in the industry.

Vijay Peri

Business Unit Head – Oil & Gas

Enhanced Air Defense Capabilities: OSA AK Missile System Upgrade

The Osa AK missile system, a Russian-origin system acquired by India in the 1980s, is for the country’s air defense strategy. Designed for quick reaction surfaceto-air defense, it is deployed for airfield protection by the Indian Air Force and tank protection by the Indian Army. Over the years, the system faced challenges in accuracy, operational setup time, and system uptime, prompting an upgrade need.

Challenge

The original system encountered three significant challenges. Firstly, the alignment system’s ability to identify target locations and incoming vectors wasn’t up to standards. Next, the setup process required twenty soldiers and two hours to deploy. Additionally, the various sub-systems that constituted the system failed frequently and were cumbersome due to its use of largely outmoded technologies.

Impact

The combat vehicle carrying the Osa AK system underwent significant improvements and now has higher accuracy and efficacy, making it a reliable last line of defense, thanks to the revamped automated antenna deployment mast, and wireless communication between the alignment system vehicle and the combat vehicle carrying the missiles. The reduced setup time via the new alignment system ensures accurate target acquisition and quick reaction capabilities. The missile checkout system has eliminated the need for a second vehicle and improved the launch sequence initiation and accurate and automated go/no-go decision-making.

Advantage

Pinaka, a ZETWERK company has also taken on the MRO of the Auxiliary Power Unit of the Osa AK. Having indigenized substantial parts of the engine, we service an APU within three weeks as against six months by the OEM. The missile launch checkout system entailed a ground-up design with multiple sensors and actuators, implements the initiation of the missile launch procedure, and a go/no-go algorithm microsecond-level decision-making capability. We have miniaturized the equipment, replacing an entire truck trailer with a trolley-mounted system that can be mounted to any other vehicle for the platform’s high operational availability.

Our revamped Osa AK system sets a new standard in air defense. With improved accuracy, rapid deployment, and cutting-edge technology, we’ve transformed challenges into strengths, ensuring swift and precise protection for critical assets.

Abhishek Sinha

Business Head – Aerospace & Defence

Crushing and Briquetting Plant Expansion: Completed

A leading Indian company required a significant expansion project at Dolvi and Bellary. The focal point of this endeavor was the establishment of a Crushing & Briquetting Plant. Given the complexity and scale of the project, they partnered with ZETWERK to oversee the fabrication, installation, and commissioning of equipment.

Challenge

Coordinating Diverse Structures and Vendors: The primary challenge lay in orchestrating the fabrication, installation, and commissioning of a diverse range of structures and bought-outs. With ZETWERK as the one-stop solution provider, managing the intricacies of twenty-three vendors handling conveyor galleries, columns, building structures, coal bunkers, handrails, monorails, and more became a collaborative effort to ensure seamless integration and timely project completion.

Impact

Parallel Manufacturing and High Throughput: The decision to engage ZETWERK impacted the project substantially. Our implementation of parallel manufacturing processes proved instrumental, achieving an impressive throughput of 1500-2000 MT per month. This accelerated the project timeline, ensuring a continuous and efficient production flow, and ultimately contributing to the overall success of the Plant Expansion Project.

Advantage

Streamlined Operations and Project:By outsourcing 30% of the project to ZETWERK, we optimized resources, minimized bottlenecks, and ensured the timely fabrication, installation, and commissioning of equipment. ZETWERK’s expertise and approach enhanced efficiency and allowed for better project control and faster response to challenges.

Utilizing ZETWERK’s fabrication and installation capabilities enabled the client to overcome challenges and achieve remarkable throughput in large-scale endeavors.

This strategic collaboration sets a new standard in the industry, emphasizing the importance of coordination, efficiency, and streamlined operations for successful project execution

Rajat Gupta

Business Head – General Fabrication (GFB)

Zetwerk-Unimacts Pioneering a Global Paradigm Shift in Solar Pile Supply Chain Dynamics

For the solar energy industry, the importance of a dependable and cost-effective supply chain cannot ignored. Zetwerk-Unimacts has positioned itself as a transformative entity, playing a crucial role in reshaping the worldwide landscape of solar pile supply for US-based EPC firms. On account of rising steel and shipping costs, the company initiated a strategic plan, commencing with establishing a pile factory in North America.

Challenge

US-based EPC firms were grappling with challenges stemming from the increasing costs of steel and shipping, impacting the cost-effectiveness of their supply chains. Zetwerk-Unimacts responded by setting up a pile factory in North America as part of a broader initiative to address these challenges.

Impact

Zetwerk-Unimacts has positioned itself as a pivotal global and local supplier of solar piles, directly addressing the challenges faced by global EPC firms. The establishment of the manufacturing facility in North America had significant impacts. We now respond rapidly globally, helping solar energy firms meet project deadlines. Furthermore, our solar piles cost 10% or more below market rates, ensuring substantial cost savings for clients and enhancing the financial viability of solar projects.

Advantage

Zetwerk-Unimacts’ advantage lies in its ability to deliver comprehensive solutions for the solar pile supply chain. With manufacturing facilities in North America and India, complemented by a global distribution network, we ensure a seamless and integrated customer experience. This end-to-end approach simplifies the procurement process, guaranteeing the quality and reliability of solar piles. Zetwerk-Unimacts has redefined the dynamics of the global solar pile supply chain. Through strategic initiatives like establishing manufacturing facilities in North America, we are a reliable and cost-effective supplier for US-based EPC firms.

The combination of swift response times, substantial cost savings, and a comprehensive solution positions Zetwerk-Unimacts as the preferred partner in the solar energy industry, leading the way in facilitating the seamless and efficient realization of solar projects worldwide.

IRCON 04: Powering 73 TKM Of Railway Electrification

ZETWERK has been actively involved in railway electrification endeavors spanning 600 track kilometers (TKm) across West Bengal. A notable milestone in our portfolio is the completion of 73 TKm P-2A CRS (Commissioner of Railway Safety) on March 28, 2023. This project showcases ZETWERK’s efforts to enhance railway electrification infrastructure and contribute to the modernization of transportation networks in the region.

Challenge

ZETWERK faced challenges in coordinating large-scale electrification works across 73 TKm, ensuring compliance with safety regulations, and successfully conducting statutory inspections. The need to achieve full sectional speed (100 Kmph) in the NMZ – Dalgaon section added complexity, requiring planning and execution. Casting 90 foundations in a single day, while maintaining quality standards, presented a notable challenge that ZETWERK successfully addressed.

Impact

The completion of the 73 TKm P-2A CRS on March 28, 2023, marked a significant achievement for ZETWERK. Successful statutory inspections, followed by speed trials at full sectional speed, demonstrated the company’s capability to deliver railway electrification projects with precision and efficiency. The electrification works in the NMZ – Dalgaon section contributed to improved transportation infrastructure, enabling faster and more reliable train services. Handing over 61 TKm sections underscored ZETWERK’s commitment to project completion and client satisfaction.

Advantage

ZETWERK’s successful engagement in railway electrification projects, especially the completion of the 73 TKm P-2A CRS, positioned the company as a key contributor to the modernization of West Bengal’s rail infrastructure. Casting 90 foundations in a single day highlighted the company’s operational efficiency and capability to meet project timelines. ZETWERK’s expertise in large-scale electrification projects solidified its standing as a trusted partner for railway infrastructure development.

With the electrification of the 73 TKm P-2A CRS project in West Bengal, ZETWERK has showcased precision and efficiency while overcoming challenges, including statutory inspections and achieving full sectional speed.

Abhay Adya

Business Head – Transmission and Distribution