• Rajasekar Madhavan

Tata Innoverse - Season 6- Topics & Details

Updated: Jan 5, 2019

Reward: 3,00,000 INR to 10,00,000 INR

Organizer Details:

Tata innoverse was started by Tata industries, to provide open innovation platform to solve challenges for various problems. By this initiative the industry is targeting to solve many real world problems by reaching out to skilled solvers internationally and also to provide them a best platform to demonstrate their ideas, skills and creativity to develop unique and best solutions to solve real world industry challenges. The best problem solvers get rewarded, and also they become trusted technology partner with Tata industries.



Problem Statements:

1. Inspection and condition monitoring of insulated chilled water pipe lines

(Closing Date: 27/Mar/2019)

Tata plant has about 100 km of chilled water pipes with a diameter of 50 to 300 mm. These pipelines are distributed throughout the plant at a height of 20 to 50 m above the ground. The pipe network is welded every 6 m, with bends and pipe fittings. The ambient temperature around the pipeline varies between 40 and 75 ° C. These water pipes are insulated with thermocol, steel mesh and the outer layer of cement or aluminum foil. Many times there is condensation in the surroundings which leads to rust and weakening of the pipe. The pipe supports are made of metal and are not insulated, which leads to condensation and therefore rust. Since the chilled water pipes pass through factories, leaks can lead to water infiltration and damage to spare parts / equipment. The failure of the cooling water system is a serious safety concern due to the location of pipelines in areas such as the torpedo area or near the EOT crane supply rails. Currently, the insulation must be broken at random places to know the state of the pipeline. After measuring the thickness using ultrasonic testing, the pipe is re-insulated at the broken part. If the ultrasonic test is used directly on the top of the cemented part, the variation of the thickness measurement readings is enormous because of the metal portions of the wire mesh and the support hinges. Therefore, the accuracy of the readings is questionable. In addition, the current method is time consuming and requires a lot of work.


2. On time communication system to monitor the gap formed between main rail and switch rail

(Closing Date: 27/Mar/2019)

There are approximately 500 points and level crossings on the railways throughout Tata plant. Points and level crossings are used to change the movement of rolling stock from one lane to another. Of these 500, manual control takes place on 400 and the main challenge lies in these manually controlled points.Sometimes, due to the incorrect operation of the lever box handle or the erroneous switching of local ground team points from local semi-automated points, space is created between the main rail and the switch rail . If the ground crew gives authorization to the locomotive operator to advance on the points and the passage area, the wheel flange will enter through this space and the derailment of the rolling stock will take place at a point where the gauge distance is greater than 1676 mm. Due to a derailment, movements of rolling stock in incoming, outgoing and intra-factory logistics are affected. The supply chain is disrupted at the level of finished raw materials and shipping areas, which affect overall production. Thus, in order to prevent any derailments and disturbances that may result, any discrepancy between the main rail and the switching rail due to human error when setting the points must be immediately alerted to the control room and key persons by an audiovisual alarm and an SMS. with the location of this space, to take corrective action in real time. These errors must also be monitored centrally via software.


3. Prevention and protection of Steel Structures from extreme levels of corrosion

(Closing Date: 27/Mar/2019)

Tata plant produces metallurgical coke with an installed capacity of 1.6 MT / year. The wet-type coking quench process is adopted and the water used for the quenching process has a chloride level of 4900 ppm (maximum). The coking car and the steel structures of the coking conveyor gallery adjacent to the quench tower are exposed to the coke cooling water vapor. Steel structures are replaced at regular intervals and the approximate cost is Rs. 2.0 Cr./annum. The painting of conveyors and other structures is a regular activity which is carried out all the year except the months of monsoon. The annual expenses incurred are up to Rs 2.5 Cr.


4. Elimination of Rail Track Foundation Settlement

(Closing Date: 27/Mar/2019)

Tata factory was built on a plain filled with fly ash and dredged sand. It has 4 rows of coke oven batteries with heat recovery. Each row includes 88 ovens, with 480 m long rails on each side, for push cars and quenching cars. The foundation of the push-car track was built on 33 m piles with an offset spacing of 3.0 m, the gauge of the track being 12 m. The foundation of the quenching car track was constructed on 18 m piles with a spacing of 2.06 m, the gauge of the track being 10 m. In recent years, we have struggled to maintain both lanes due to the establishment of track foundations up to 120 mm in some areas. Due to the rippling / settling of the tracks, the operation of the battery of our coke ovens is hampered. In addition, because of the settlement of the railway, we are faced with problems of positioning the pusher and the extinguisher car during pushing operations due to the rolling of the car. The power collector is damaged and the components of the car pushed and extinguished are faulty. In addition, the press plates bend under the railway because of the cracking of the underlying concrete. Therefore, the challenge is to eliminate the problem of settlement of railway foundations to ensure proper operation of Pusher and Quencher cars.


5. Eliminating remnant coal in wagons after tippling at coal wagon tipplers

(Closing Date: 27/Mar/2019)

In coal cars, there is a certain amount of material remaining in the cars after the switchover. The coal remaining in the cars must be cleaned manually, which requires a lot of labor. To perform the cleaning, cleaning personnel must move inside and outside the empty cars at the end of the scale while the empty cars are pushed. This manual cleaning of unloaded cars should be done while the unloading process is taking place at Tippler and is a very dangerous activity. About 30 to 50 tons of spilled coal are generated on average per day due to coal residues in cars that overtake during the monsoon season. Residual coal from different rakes accumulates after cleaning, which is converted into a mixture of spilled coal and is a loss of domestic and imported premium coal. The challenge is to remove residual coal from cars after tipping, eliminating car cleaning and the generation of spilled coal.


Proposal Questions:

1. Title

2. Please share your solution

3. What other solutions have you seen in the market for this problem? What have been the flaws in those solutions?

4. Please define the problem statement as understood by you

5. What positive and unique results do we expect to see from your solution?

6. What is the estimated investment required to implement your solution at our end?


For more details visit the link below:

Contest link: www.tatainnoverse.com

Category of contest: Hardware contest, Industry contest


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"Every Innovator Needs to Dream,

Every Dream Needs an Innovation,

Every Innovation Needs a Platform"

--  Prof. Rajasekar Madhavan 

      Contest Consultant & Innovations Speaker

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