Archives: Case Studies

ZETWERK undertook two critical railway electrification projects, namely CORE Gr. 295 and CORE Gr. 296, covering a combined distance of 64 TKm in Karnataka. These projects aimed to contribute significantly to the modernization of rail infrastructure, showcasing ZETWERKS’s commitment to delivering high-quality and reliable solutions in the transportation sector.

Challenge

The projects presented ZETWERK with several challenges, including stringent regulatory compliance and inspection requirements for railway electrification works. Successfully meeting these requirements involved conducting statutory inspections and speed trials at full sectional speed (100 Kmph) in two distinct sections: Shivamogga – Kumsi (26 TKm) and Chikbanavar – Solur (38 TKm). Managing the scale and complexity of electrifying 64 TKm across diverse sections in Karnataka required effective coordination with various stakeholders.

Impact

ZETWERK’s accomplishments have had a significant impact on the railway electrification landscape. Successful statutory inspections and speed trials, ensuring the safety and efficiency of rail operations. The commissioning of 26 TKm in CORE Gr. 295 and 38 TKm in CORE Gr. 296 marked crucial milestones in the Transmission and Distribution Business Unit, showcasing ZETWERK’s prowess in executing largescale electrification projects.

Advantage

ZETWERK has solidified its expertise in railway electrification, positioning itself as a leading player in the sector with a proven ability to meet statutory inspection deadlines, conduct successful speed trials, and enhance its reputation for reliability and efficiency. The successful completion of the CORE Gr. 295 and 296 projects, along with the PCEE inspection milestone has made us a preferred choice for railway electrification projects and opening doors to expanded opportunities in the railway infrastructure sector

Sharp Tanks and Structurals Pvt. Ltd. (STSPL), a ZETWERK company. was engaged by a leading player in the energy sector based in Tuticorin, Tamil Nadu to execute a comprehensive project spanning the design, engineering, procurement, fabrication, and commissioning of two refrigerated storage tanks of 15,000 MT each. Specifically engineered for the storage of propane and butane, the project aimed to meet the exacting standards of the BVIS 2022 guidelines. The project scope was to be completed in phases, including third-party inspection, mechanical completion, precommissioning, commissioning assistance, calibration, and demonstration of performance guarantee parameters.

Challenge

The project’s specifications included an Outer Tank with dimensions of 46.8 meters in diameter and 20 meters in height, along with an Inner Tank measuring 45.2 meters in diameter and 18.4 meters in height. The project progressed through various phases, encompassing design, engineering, procurement, supply, fabrication, erection, third-party inspection, mechanical completion, pre-commissioning, commissioning assistance, calibration, and the demonstration of performance guarantee parameters. The project had to adhere to BVIS 2022 standards. Additionally, the storage of propane and butane introduced another layer of complexity, emphasizing the need for precision engineering in both the design and construction phases to ensure the safety and operational efficiency of the storage tanks.

Impact

STSPL addressed the project challenges through a comprehensive solution to deliver a robust and safetycompliant design. Rigorous quality control measures, including third-party inspections, were implemented during fabrication to guarantee structural integrity. The project benefited from the oversight of a highly skilled and experienced team across various phases, from fabrication to commissioning, ensuring adherence to the highest standards.

Advantage

The results were notable, with the project delivered on time despite its complexities. The refrigerated storage tanks successfully met all BVIS 2022 standards, undergoing thorough testing to ensure fitness for purpose and compliance with safety regulations. Client satisfaction was evident, as the client expressed contentment with the quality of work, adherence to timelines, and the overall professionalism demonstrated by STSPL throughout the project.

Conclusion

The successful completion of the refrigerated storage tanks project for the company showcased Sharp Tanks and Structurals Pvt. Ltd.’s commitment to precision engineering, compliance with industry standards, and client satisfaction. The project’s success further solidified STSPL’s position as a trusted partner in providing comprehensive storage tank solutions for clients in the energy sector.

Managing the launch of 31 aluminum extrusion dies is no easy feat; add a strict timeline to the mix and you have a challenge. That’s where ZETWERK came in and took on the project head-on. ZETWERK mobilized its robust network of suppliers to manufacture custom aluminum extrusions to exact specifications. Our dedicated Quality Manager and expert personnel were brought in to ensure quality control at every stage of the production process.

ZETWERK’s dedicated Project Manager and our proprietary in house project management software enabled complete visibility of project progress, from design to production to delivery. In addition, we worked closely with the client’s SQE team to audit the production plant and inspect all the extrusions. Approvals are an important part of any precision manufacturing project. To adhere to the client’s tight timelines, ZETWERK engaged in additional resources to expedite the DFM/PPAP/FAIR schedule

Challenge

With an increase in demand for the customer, the prospect of meeting deliveries with the existing supply chain were difficult. The customer was on the verge of losing out on orders, and with business on the line, it became essential to develop another supply chain with robust quality and minimized lead time. That’s where ZETWERK pitched in, to develop tools, establish the supply chain, and manage production, quality, approvals, and timely deliveries as per customer requirements.

Impact

ZETWERK sequentially completed Tooling, First Article, and Production, ensuring zero pauses between phases. We developed and approved samples for 31 tools within 45 days. Production for parts of all sizes of extrusion was completed within 25 days. Our dedicated team streamlined logistics to enable shipping & delivery to the warehouse within 45 days.

ZETWERK’s Quality Team completed FAIR on-site, ensuring no time was lost in transit. This supply chain stabilization enabled on-time deliveries across the US, enabling the customer to fulfill the required orders with the new supply chain established by ZETWERK, ensuring no loss of demand.

Advantage

ZETWERK’s proprietary tools and technology-enabled seamless project management from design to delivery. With a robust network of reliable suppliers and all the required approvals in place, we were able to efficiently deliver containers of highquality aluminum extrusions to the client’s manufacturing plants across the US, right on schedule.

Our specialized quality and logistics teams ensured adherence to timelines and faster delivery. In addition, ZETWERK offered customer warehousing options, ensuring Just-in-Time delivery of parts as per demand. This led to a 3X increase in demand from the customer and a strong pipeline of orders going forward

By creating true partnerships with our suppliers, we’ve been able to streamline the manufacturing supply chain and set up systems that help us deliver on time, every time. At ZETWERK, we’re truly invested in understanding our clients’ pain points and adapting solutions accordingly.

ANIRUDH REDDY

Business Head – North America Business

A leading Indian energy organization entrusted Sharp Tanks and Structurals P. Ltd., a ZETWERK company, with a comprehensive project at Krishnapattanam Port, Andhra Pradesh. The assignment involved the design, engineering, procurement, supply, fabrication, inspection, transportation, storage, construction, installation, insulation design, and application, as well as testing, pre-commissioning, and commissioning of two state-of-the-art Full Integrity Double Walled Storage Tanks, each with an impressive capacity of 15,000 MT.

Challenge

The tanks, intended for the storage of propane and butane, featured outer tank dimensions of 46 meters in diameter and 21.59 meters in height, while the inner tank measured 44 meters in diameter and 20 meters in height. The design requirements, engineering specifications, and the complexity of managing the project from procurement to commissioning demanded high technical proficiency. Additionally, we had to ensure the integrity of the double-walled storage tanks, meet safety standards, and adhere to the regulations outlined by LRS 2022. The sheer scale of the storage tanks and the need for insulation design and application further underscored the challenges faced by the engineering team.

Impact

Successfully meeting and surpassing these challenges, we delivered two impeccably engineered and constructed Full Integrity Double Walled Storage Tanks to the client at Krishnapattanam Port. The impact of this achievement was substantial. It solidified Sharp Tanks’ reputation as a comprehensive solution provider for complex projects in the energy sector. The client benefited from enhanced storage capabilities, operational efficiency, and reliability

Advantage

The successful execution of this project further established Sharp Tanks and Structurals P. Ltd. as a preferred partner for companies seeking expertise in the design, fabrication, and installation of large-scale storage tanks. The ability to seamlessly handle every aspect of the project, from conception to commissioning, showcased our versatility and proficiency in the energy infrastructure domain.

Sharp Tanks and Structurals P. Ltd., a ZETWERK company undertook a significant project for an Indian oil PSU at Kandla, Gujarat. This project involved revamping Double Wall Refrigerated LPG Storage Tanks and Allied Facilities at the LPG Import Plant. The scope of work included comprehensive upgrades to enhance the operational efficiency and safety of the existing facilities. The project specifically focused on double-wall refrigerated LPG Storage Tanks, each with a capacity of 10,000 MT. The outer tank had dimensions of 46.8 meters in diameter and 20 meters in height.

Challenge

Revamping the double-wall refrigerated LPG Storage Tanks at the client’s Kandla facility posed several challenges for Sharp Tanks and Structurals P. Ltd. The intricacies of working with refrigerated storage systems, ensuring compatibility with existing infrastructure, and implementing upgrades without disrupting ongoing operations demanded meticulous planning and execution. Additionally, adhering to their stringent safety standards, meeting regulatory requirements, and maintaining the integrity of the double-wall structure were critical challenges. The need for precision engineering to enhance the efficiency of the storage tanks added complexity to the project.

Impact

Sharp Tanks and Structurals P. Ltd. successfully addressed the challenges and completed the revamping project at the Kandla LPG Import Plant. The impact of this endeavor was substantial. The upgraded double-wall refrigerated LPG Storage Tanks and Allied Facilities contributed to the client’s operational reliability and safety standards. The project’s successful execution enhanced the overall infrastructure at the LPG Import Plant, ensuring IOCL’s ability to meet the growing demands of the region. The project’s adherence to safety standards and efficient completion reflected positively on the reputation of both the client and Sharp Tanks and Structurals P. Ltd.

Advantage

The successful revamping of the double-wall refrigerated LPG Storage Tanks at the Kandla facility positioned Sharp Tanks and Structurals P. Ltd. as a reliable partner for the energy industry’s infrastructure enhancement projects. The company’s ability to navigate the complexities of revamping existing facilities while maintaining operational continuity showcased its expertise. This success further solidified Sharp Tanks and Structurals P. Ltd.’s position in the market, providing an advantage in securing future projects within the energy and petrochemical sectors. The company’s commitment to quality and safety standards reinforced its reputation as a trusted engineering solution provider.

A leading Indian mobile accessories brand sought to localize its smartwatch manufacturing. The decision to produce smartwatches domestically was to contribute to the ‘Make in India’ initiative while ensuring a swift time-to-market for their products.

Challenge

The challenge brand needed to find an end-to-end manufacturing partner and deliver the first batch of smartwatches within an ambitious timeline of 100 days. The brand required a partner with expertise in design, manufacturing, and assembly, capable of executing the entire process seamlessly within the timeframe. Zet Town, A ZETWERK company established the first dedicated Electronics Manufacturing Service (EMS) and Original Design Manufacturing (ODM) facility to create a robust infrastructure encompassing design, manufacturing, and assembly while incorporating cutting-edge online testing and diagnostics.

Impact

Leveraging our expertise, we produced the initial batch of 10,000 smartwatches ahead of the 100-day deadline. The factory ensured a monthly production capacity of 100,000 units. Within an impressive timeframe of 60 days, our team collaborated with chipset and mechanical component designers to develop ten distinct smartwatch products. Through meticulous system integration, testing flows, and a trained workforce, we delivered 500 sample watches.

Advantage

Setting up a dedicated EMS & ODM facility laid the foundation for sustained manufacturing excellence, enabling the brand to maintain a steady supply of innovative products to meet growing consumer demand. The efficient execution of this project has reinforced our reputation as a trusted partner for endto-end manufacturing solutions in the consumer electronics industry.

ZETWERK was approached by a large Indian MNC to build 21-meter-high steel girders on the Mumbai-Ahmedabad Bullet Train Corridor. ZETWERK has demonstrated its prowess in the fabrication and erection of these steel girders for this prestigious project by fabricating and erecting these structures to highly exacting specifications that were earlier not accomplished in India.

Challenge

The Mumbai-Ahmedabad Bullet Train project posed engineering challenges, necessitating advanced solutions such as the fabrication of steel girders. Initially, the lack of local expertise in India led to importing these girders from Japan. ZETWERK took up this challenge and engaged Japanese experts at its fabrication plant to ensure compliance with the stringent manufacturing standards.

Impact

ZETWERK fabricated a substantial 10,000 metric tons of steel girders for the MAHSR project, valued at approximately Rs. 150 crore. The collaboration with the principals has showcased ZETWERK’s prowess and demonstrated its ability to form strategic partnerships with industry leaders, harnessing collective expertise for the successful execution of complex projects.

Advantage

ZETWERK’s engagement with Japanese experts served a dual purpose – meeting project specifications and enhancing the skills of its workforce. By integrating imported expertise into its operations, ZETWERK overcame the initial challenge of lacking local knowledge. This investment in skill development ensured immediate project success and positioned ZETWERK as an industry leader with improved operational capabilities, emphasizing a commitment to excellence and continuous improvement.

Conclusion

ZETWERK’s 21-meter steel girder success is testimony to collaborative efforts. We have showcased our prowess by fabricating highperformance structures and innovating to overcome challenges. Our dual-benefit approach positions us as an industry leader, marking a significant milestone and establishing our reputation in complex steel structures.

Sharp Tanks and Structurals Pvt. Ltd., a ZETWERK company, undertook a significant project for a leading Indian energy supplier at Kandla, Gujarat, involving the fabrication, erection, and testing of two cryogenic storage LPG tanks. These tanks, with a capacity of 24,000 MT each, were designed to store a combination of propane and butane. The project was initiated in partnership with PDIL as the client, with the execution taking place throughout 2021.

Challenge

The tanks’ intricate design, with dimensions of 49m in diameter and 26.29m in height for the outer tank and 47m in diameter and 25m in height for the inner tank and presented technical challenges. Secondly, navigating regulations of liquefied petroleum gas (LPG) added complexity, requiring compliance with safety and environmental standards. Lastly, coordinating the fabrication, erection, and testing processes necessitated careful planning to meet project timelines and ensure client satisfaction, avoiding potential financial and reputational impacts.

Impact

The successful execution of the project, highlighted the company’s competence in handling large-scale and technically demanding endeavors. The seamless completion of the project within the stipulated timeline underscored the company’s commitment to excellence. The project has enhanced our reputation as a reliable and capable player in cryogenic tank construction as the company is increasingly recognized for its successful track record.

Advantage

The successful completion of the project showcased Sharp Tanks and Structurals Pvt. Ltd.’s technical expertise in handling complex cryogenic tank construction.

The company’s ability to execute such projects adds to its portfolio, making it a competitive force in the cryogenic tank fabrication and construction sector

Sharp Tanks and Structurals P. Ltd., undertook a significant project for a major Indian energy company in Haldia, West Bengal. The project involved the fabrication, erection, welding, testing, and calibration of two Cryogenic LPG Double-walled Tanks with Suspended Decks.

Challenge

These tanks, with a massive capacity of 12,500 MT each, were designed to meet the stringent requirements set by PDIL (Projects and Development India Ltd.). The outer tank had dimensions of 37 meters in diameter and 26 meters in height, while the inner tank measured 35 meters in diameter and 25 meters in height. The precision required in welding, the adherence to strict safety standards, and the complexities of working with cryogenic materials were significant hurdles as was meeting the specifications set by PDIL.

Impact

Sharp Tanks and Structurals P. Ltd. delivered two impeccably crafted Cryogenic LPG Double-walled Tanks to the client in Haldia. The impact of this achievement was manifold. Firstly, the completion of the project strengthened Sharp Tanks’ reputation as a reliable and skilled player in the fabrication and structural engineering domain. The successful delivery of the tanks also bolstered the client’s operational capabilities, providing them with state-of-the-art storage facilities for LPG. The adherence to safety standards ensured a secure operational environment, meeting both regulatory requirements and industry best practices.

Advantage

The successful completion of this project provided Sharp Tanks and Structurals P. Ltd. with a competitive advantage in the market. The company’s ability to handle complex and large-scale fabrication projects, especially in the cryogenic domain, positioned it as a go-to solution provider for clients with demanding requirements. The experience gained from this undertaking further solidified their technical expertise and project management capabilities. This success not only enhanced the company’s portfolio but also opened doors for future collaborations in the energy and petrochemical sectors, where precision and reliability are paramount.

Facing challenges with OEM-supplied missile checkout system, obsolete technologies, hard to maintain, bulky and difficult to deploy, inefficient to operate – Pinaka seized an opportunity for innovation. The Digitized AKIPS, with its compact design, overcame bulkiness, enabling easy transport and deployment in diverse environments. Simultaneous testing of two missiles enhanced throughput, addressing time limitations.

Legacy programs were replaced with contemporary software technologies, better IPC and modern GUI for ease of operations, streamlining configuration and execution processes. The impact of Digitized AKIPS on missile check-out is profound. It comprehensively evaluates subsystems simultaneously, optimizing assessments, saving valuable time during wartime operations, and importantly, improving trustworthiness of the launch. The modernized interface ensures easy adaptation to evolving requirements, placing Digitized AKIPS at the forefront of missile testing technology. Pinaka’s innovation sets a new standard for efficiency and adaptability in defense technology, ensuring reliability and performance for future defense forces.

Challenge

Legacy missile checkout systems built on old technologies, including poor computational ability and inefficient communication, pose challenges for operational deployments. The OEM-supplied missile checkout system is bulky, hindering mobility and increasing logistics requirements for deployment. The system also forced users into a sequential workflow, limiting the ability to launch missiles faster. Older systems heavily relied on legacy programs, making it cumbersome to adapt to evolving testing requirements and technological advancements.

Impact

Recognizing challenges in traditional missile launch go/no-go testing, Pinaka Aerospace, a ZETWERK company innovated with Digitized AKIPS, revolutionizing testing. Its compact design enables easy deployment, overcoming bulky legacy system limitations. Simultaneous testing of two missiles increased throughput, saving time. Replacing legacy programs with a modern IPC and GUI streamlined processes, enhancing deployment efficiency. Digitized AKIPS has a far-reaching impact, allowing defense professionals to check various subsystem parameters simultaneously, optimizing assessments. This includes the Radio Control Unit, RF subsystem, radio Fuse, Analog and Digital commands, Electrical power, and Pneumatic subsystem. Simultaneous testing ensures quicker assessments, saving valuable time. The modernized interface adapts easily to evolving requirements, solidifying Digitized AKIPS at the forefront of missile testing technology.

Advantage

With the execution of such complex projects and the development of advanced systems with leading-edge technologies for the defense and aerospace market, Pinaka Aerospace has established itself as a leader in hardware design, software development, integration, and testing for mission-critical programs of national importance, and the creation of solutions with immense export potential.

Proven in defense and aerospace, we deliver quality solutions certified by ISO/CEMILAC/AS/DGAQA. Expertise in Embedded Solutions, Test & Measurement, and Support & Maintenance.

ABHISHEK SINHA

Operations Head – Aerospace & Defence