Case Studies

Chhatrapati Shivaji International Airport (CSIA), Mumbai

Chhatrapati Shivaji International Airport (CSIA) is one of India's busiest airports, with passenger traffic of over 30 million per year. CSIA has three domestic terminals at Santa Cruz and two international terminals at Sahar in operation.

Mumbai International Airport Pvt. Ltd. (MIAL), a joint venture between the GVK-led consortium (74%) and Airports Authority of India (26%), was awarded the mandate of modernising and upgrading CSIA in 2006.

MIAL's master plan was to build the integrated terminal with a vision and framework to modernise this airport as one of the best airports in the world. The separate international and domestic facilities have been merged into a new integrated terminal building, Terminal 2, also known as T2. T2 is spread across 4.4 million sq ft, and is equipped to cater to 40 million passengers per annum. T2, which was inaugurated on January 10, 2014, has commenced operations on February 12, 2014.

Blue Star has successfully completed the air conditioning as well as plumbing of the integrated Terminal Building, Terminal 2 of CSIA, Mumbai.

Project Scope

The work of the new integrated Terminal Building was split into two phases. While Blue Star was awarded the contract to air condition the South West Pier in 2009, it later won the contract to execute the air conditioning and plumbing works of T2, valued at about Rs. 150 crores. Blue Star's scope of work included supply, installation, testing, commissioning, handover, training, maintenance and warranty of all HVAC, as well as plumbing systems.

The equipment and material supplied under the HVAC scope included 6 cooling towers of 2,500 TR each, 80 floor mounted AHUs - ranging between 25,000 CFM to 55,000 CFM - 311 ceiling suspended AHUs and FCUs, 290 inline centrifugal and axial fans, 1,600 variable air volume boxes, 21 primary and secondary chilled water pumps and condenser water pumps, 3.35 lakh sq m of air conditioning and ventilation ducting, 23 km of piping, 2.65 lakh sq m of thermal insulation, 80,000 sq m of underdeck insulation, 30,000 sq m of room acoustics, 2,600 jet nozzles, about 5,500 air outlets, 3,500 fire and volume control dampers, 60,000 sq m of fire rated ducting as well as the corresponding electrical and building management systems.

Challenges & Achievements

Blue Star faced several challenges while executing this project. Under HVAC, being a Brownfield project, there were several concerns with respect to equipment and material handling, project clearances and material storage, which were all efficiently managed by Blue Star.

A high calibre project of such a kind also required meticulous planning of resources, in terms of manpower, materials, tools and tackles, amongst others. Stringent safety and quality systems led to numerous stages of inspection, at each and every activity level. Seismic supports were provided for all equipment and pipes. Special custom supports were designed and installed for ducts supported by purlin, making the entire structure earthquake-proof. The supports in the plant room were also duly designed to withstand seismic vibrations. The working height at the terminal ranged from as low as 4.5 m to a height of 26 m, which was another challenge that Blue Star overcame efficiently.

Under plumbing, Blue Star provided storm water drainage, domestic water supply, flushing water and soil waste for the entire airport. Providing storm water drainage for the head house roof area, which was close to 30 acres, was a challenge since it was executed at a height of 26 m. Special safety precautions were carried out to create an accident-free installation for jobs being executed at heights. Modern equipment, such as cherry pickers and scissor lifts, were used in executing various jobs. 14 km of HDPE pipes were laid out, while 17 km of PPR pipes and 19 km of galvanised pipes were installed. 3 km of RCC pipes, encased in concrete, were laid out.

Significant Milestone

Blue Star is proud to be part of this landmark project; where the Company has played a role in the transformation of CSIA, to one of the best airports in the world. Blue Star's seamless turnkey MEP solutions, superior project management skills and impressive track-record of on-time completion has been the key to this achievement.

Blue Star has also air conditioned several other airports including Aurangabad, Ahmedabad, Thiruvananthapuram, Mangalore, Nagpur, Jaipur, Amritsar, Madurai, Dehradun, Varanasi, Raipur, Goa and Pune.

APTRANSCO (Andhra Pradesh Transmission Corporation), Andhra Pradesh and Telangana

The Andhra Pradesh State Electricity Board (APSEB) is responsible for the generation, transmission and distribution of electricity in the state of Andhra Pradesh. Under the Electricity Sector Reforms Agenda, the Government of Andhra Pradesh promulgated Andhra Pradesh Electricity Reforms Act, 1998, under which the erstwhile APSEB was unbundled into six separate companies: a generating company (APGENCO), a transmission company (APTRANSCO) and four distribution companies (APDISCOMs).

APTRANSCO came into existence on February 1, 1999. APTRANSCO is a buyer of power from various generators and a seller to DISCOMs. As part of its services, APTRANSCO needs regular establishment of power transmission infrastructure across the state.

In 2010, Blue Star won the tender covering different packaged projects worth approximately Rs. 40 crores. The tender included jobs across various locations in and around Andhra Pradesh, and areas which now fall in the newly-created state of Telangana.

Project Scope

Blue Star's scope of work included supply of heavy equipment as well as materials including current transformer, potential transformer, circuit breaker, isolators, tower and structure parts as well as conductors and copper control cables, amongst others.

The job also entailed civil works comprising construction of the control room, foundation of the bay kiosk room, metal spreading in the switchyard and RCC road formation in the sub station, amongst others.

Electrical works such as erection of towers and structures, installation of equipment, testing and commissioning of the complete switchyard equipment, bus bar formation as well as stringing of conductors also fell under the purview of this order.

Challenges & Achievements

All the projects including five 132/33 kV substations and a 220/132 kV substation have been charged, commissioned as well as made operational within the given stringent timelines specified in the contract without any failure or defects in the processes as well as across the equipment and material. The location and size of the projects are as follows:

  • 132/33kV Chintal substation in Secunderabad
  • 132/33kV Disincherla substation in Nalgonda District
  • 132/33kV Narasannapeta substation and a 33km, 132kV transmission line in Coastal Andhra in Srikakulam District
  • 132/33kV Kothapeta substation and a 16km, 132kV transmission line in East of Coastal Andhra in Godavari District
  • 132/33kV Tanakallu substation and a 33km, 132kV transmission line in Seemandhra, in Anathapur District, Kadri Mandal
  • 220/132kV Rachagunneri substation and a 1.26km, 220kV transmission line and an 18km, 132kV transmission line in Chittoor District, Srikalhasthi Mandal

The transmission line for all the above projects consists of 325 towers and a line length of 100 km. Tower foundation, erection and stringing work was executed in rocky, hilly and water logged areas and also across railway crossing patches. All the substations executed are suitable for automation, which is a first in the Andhra Pradesh Zone. An additional control room has been provided in each switchyard area (called the Bay Kiosk room) apart from the main control room to control and monitor HV/LV side equipment.

Currently, all the projects are complete and commissioned in service by the end-user DISCOMs. Blue Star has also constructed a 2km compound wall in Rachagunneri substation.

Sasan Coal Mines, Moher and Moher-Amlohri, Madhya Pradesh

Sasan Ultra Mega Power Project (UMPP) is an upcoming, 3,960 MW coal-based power plant project in Sasan, Singrauli district, Madhya Pradesh. It is owned and developed by Sasan Power Limited, a wholly owned subsidiary of Reliance Power.

The project is the biggest integrated pithead coal-based power project in India and amongst the largest in the world. The coal mine is being developed in a record time frame for any greenfield mine in India. The state-of-the-art mining equipment used in the project are the largest ever used in the history of the Indian coal mining industry and have been sourced from global leaders. The plant is also connected to the National Grid.

Coal production for the Sasan UMPP is carried out at Moher and Moher-Amlohri Coal Mines, Singrauli, from where the coal is transported to the power plant via a 14 km long conveyor.

Reliance Infrastructure, a subsidiary of Reliance Power, awarded Blue Star with an order valued at Rs. 55 crores for the Power Supply Distribution System (PSDS) package of Sasan Coal Mines, Moher and Moher-Amlohri at Singrauli, Madhya Pradesh in December 2010. At that time, this was the largest order for Blue Star in electrical works in the power sector. The electrical design of the PSDS package was developed by M/s Development Consultants Pvt Ltd, one of the most renowned consultants in the industry, and the in-house design team of Reliance Infrastructure.

Project Scope

Blue Star's scope of work included supply, installation, testing and commissioning of all equipment associated with 132/33/6.6 kV PSDS along with associated civil works on a turnkey basis.

Based on the voltage distribution level, the scope comprised the following:

  • 132/33 kV outdoor switchyard and control room
  • 33/6.6 kV power distribution system comprising 33kV & 6.6 kV indoor switchgear; 15 MVA, 33/6.6 kV dry-type transformer; 6.6 kV unitised substation; 6.6 kV skid-mounted panels and 6.6 kV trailing cables; amongst others
  • Substation automation system of the entire substation
  • 33 kV ring main overhead line
  • 6.6 kV overhead line
  • Entire illumination system for the mine comprising service road as well as haul road illumination

Challenges & Achievements

The Sasan Coal Mine PSDS package has been a unique and prestigious project for Blue Star, since this is the first electrical power distribution project in a coal mine taken up by the Company.

Some more of the key challenges and achievements were as follows:

  • Supplied, installed and commissioned two units of 80/100 MVA, ONAN/ONAF, 132/33 kV transformer (from Alstom) with OLTC supplied, installed and commissioned six units of 15 MVA, 33/6.6 kV dry-type transformers (from BHEL) - highest rated state-of-the-art dry-type transformers installed in India by Blue Star
  • Supplied and installed 9 km of 6.6 kV trailing cables
  • Substation Automation System for a complete substation

Blue Star overcame several challenges to meet the objective of producing a quality piece of infrastructure. The team was appreciated for their dedication and hard work in maintaining high quality standards in the execution of the project.

The customer's positive experience with Blue Star in terms of the quality of execution and timely completion of the Sasan PSDS package project prompted Sasan Power Limited to award Blue Star with a repeat order of Rs. 9 crores for carrying out electrical works for the Workshop Area at Sasan Coal Mines, Singrauli, Madhya Pradesh.

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