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India's Largest Steel Manufacturer

COMOS for Plant Data Hub Twin

This is one of the leading steel manufacturing companies in India. The company produces a variety of steel products and is recognized for its use of advanced technology in production processes. They aim to position itself as a leading global player in the steel industry. Their annual turnover is around ₹1.67 trillion (about $21 billion)

Problem Statement

Steel plants mostly have various systems from multiple OEMs. For most recent expansion plant for steel manufacturing at Vijayanagar, close to 5MT. They wanted to create a Digital Twin for this new plant and as part of Phase 1 wanted to achieve the following:

  • Asset Management Portal, containing all asset detailed out with their documents and navigable to all associations including 3D model
  • Standardization on Asset numbering, drawing symbols, related documents like: GA, Manuals, Inspection records, trials and start-up reports
  • Complete visualization of the plant and a Single Source of Truth
  • Report out the balance, missing and critical documents for operations

Our Solution

COMOS with following modules:

  • COMOS Platform – 20
  • COMOS FEED, P&ID – 4
  • COMOS EI&C and Logical – 4
  • COMOS Pipespec Management – 1
  • COMOS MRO, SAP interface tool kit – 1
  • COMOS Mobile Solutions of WEB – 75
  • COMOS WalkInside and 3D Rendering Server – 2

We digitize following documents in COMOS in intelligent format:

  • PFD – 250
  • P&ID – 1350
  • Hydraulic Circuits – 1175
  • SLD – 983
  • Circuit Diagrams – 73260
  • Linked more than 2200K documents to respective Assets
  • Laser Scanned the complete plant (generating 12TB of point cloud data)
  • Prepared BIM models for Blast Furnace, Hot Stip Mill and Steel Melt Shop and linked to COMOS via WalkInside

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