INFRASTRUCTURE OVERVIEW

Blue Star's enviable presence in the infrastructure segment has added to its extensive and intensive contracting experience. Blue Star enjoys a preferred partner status in the infrastructure segment, with unparalleled hands on experience in airports, metro rail projects, power plants and power transmission & distribution. Prestigious projects that Blue Star has been a part of include airports in Aurangabad, Ahmedabad, Trivandrum, Goa, Raipur, Varanasi, Pune, Mangalore, Madurai and Dehradun, amongst others. Particularly noteworthy are the air conditioning and fire-fighting works executed for the Mumbai International Airport. Blue Star's cooling systems also operate in the underground stations of Bangalore Metro and Delhi Metro.

INFRASTRUCTURE SERVICES​

Blue Star provides a complete range of mechanical, electrical and plumbing services for the infrastructure segment, delivered through highly skilled experts and experienced project management teams who cater to the specific requirements of our clients.

Air Conditioning & Ventilation

  • Air conditioning plant (chilled water/DX)
  • Chilled water distribution system (primary/secondary/tertiary pump and insulated piping)
  • Condenser water system (cooling towers and piping)
  • Forced ventilation & exhaust system (supply/return/exhaust air fans, air washers and ducting)
  • Air distribution system (AHUs, FCUs, ducting and fans)
  • Thermal insulation of ducts and under-deck insulation
  • Acoustic treatment of AHU and plant room, ducts
  • Life safety system (smoke exhaust)

Electrical

  • Substation installation upto 220 kV
  • Power supply distribution for 415 V upto 220 kW
  • Earthing systems
  • Lighting systems (internal & external)
  • Lightening systems
  • Cables & cable supply systems upto 220 kV
  • SCADA and substation automation system
  • Transmission & distribution upto 220 kV
  • Electrical & instrumentation system
  • Digital control system
  • Extra low voltage system

Plumbing & Fire-fighting

  • Water supply & drainage system
  • Sanitary fixtures & CP fittings
  • Plant & utilities
  • Water treatment plants
  • Rain water harvesting
  • Sewage treatment plants
  • Hydrant & sprinkler system
  • Fire extinguishers
  • Fire detection & alarm system
  • Gas suppression system

Low Voltage Systems

  • CCTV
  • Access control
  • Public address systems
  • Pressure balancing for critical applications
  • Rodent repellent control system
  • Data & voice networking
  • BMS & SCADA
  • UPS
  • Audio-visual system
  • Room automation
  • Telecommunication network

ClientLocationScopeTotal Value (INR Cr)Year Of CompletionName of Underground Stations
Delhi Airport Metro Express New DelhiMEP2522011 New Delhi, Shivaji stadium, Dhaula Kauan, Aerocity, IGI, Dwarka
Delhi Metro Rail Corporation New DelhiElectrical & Plumbing 151 Ongoing Janakpuri West, Dabri Mor, Dashratpuri, Indira Gandhi Domestic Airport
Delhi Metro Rail Corporation New DelhiHVAC 129 2011 New Delhi, Chawri Bazar, Chandni Chowk, GTB Nagar, Line 2 (Saket, Malviya Nagar, Hauz Khas) & Line 6 (Central Secretariat, Jungpura, Khan Market, JLN stadium)
Bangalore Metro (ECS) Bengaluru HVAC84Ongoing Cubbon Park, Vidhan Saudha, Visvesvaraya Central College, Kempe Gowda, City Railway, K R Market, Chickpet
Delhi Metro Rail Corporation Gurgaon Electrical 14Ongoing Rapid Metro Depot

ClientLocationScopeTotal Value (INR Cr) Year Of Completion
Mumbai International Airport, Terminal 2 Mumbai HVAC & Plumbing 150 2014
Goa Airport Goa HVAC 142014
Trivandrum Airport TrivandrumHVAC 92012
Raipur Airport RaipurHVAC 82012
Aurangabad Airport Aurangabad HVAC 82009
Nagpur Airport Nagpur HVAC 52008
Varanasi Airport Varanasi HVAC 52011
Pune Airport PuneHVAC 52009
Mangalore Airport Mangalore HVAC 42010
Madurai Airport MaduraiHVAC 42010
Dehradun Airport Dehradun HVAC 22010

Client Project Location Scope Total Value (INR Cr) Year Of Completion (or Ongoing)
M P Paschim Kshetra Vidyut Vitran Co. Ltd. Ujjain33/11kV Substation, 33kV & 11kV Lines 31Ongoing
BSES Rajdhani Power Ltd. Najafgarh, New Delhi 66/11kV Out Door Grid Substation including all civil works on Turnkey Basis 16Ongoing
Keppel Puravankara Development Pvt. Ltd. Bengaluru 66/11 kV, 1 x 12.5 MVA Sub-Station, 13 x 11 kV VCBs, 3 Runs of 5 KM of 66 kV 1C x 630 sq mm XLPE Cable 162009
BSES Rajdhani Power Ltd. Jasola Media Centre, New Delhi 66/11kV Out Door Grid Substation including all civil works on Turnkey Basis 15Ongoing
Tata Power Delhi Distribution Limited, RG 30 Rohini Delhi 66/11 kV Substation on turnkey basis 15Ongoing
Tata Power Delhi Distribution Limited, Burari Delhi 66/11 kV Substation on turnkey basis 15Ongoing
Tata Power Delhi Distribution Limited, RG 34 Rohini Delhi 66/11 kV Substation on turnkey basis 13Ongoing
AP TRANSCO Chittoor 220/132kV Rachagunneri Substation and a 1.26km, 220kV transmission line and a 18km, 132kV transmission line 112014
AP TRANSCO Narasannapeta/Srikakulam 132/33kV Narasannapeta Substation and a 33km, 132kV transmission line 92012
AP TRANSCO Ananthapur 132/33kV Tanakallu Substation and a 33km, 132kV transmission line 82014
AP TRANSCO Godavari 132/33kV Kothapeta Substation and a 16km, 132kV transmission line in East 72013
OPTCL Bhubaneswar Bhubaneshwar 220 KV and 132 KV Bay Extension 42012
AP TRANSCO Nalgonda 132/33kV Disincherla Substation 32011
AP TRANSCO Secunderabad 132/33kV Chintal Substation 32011

Customer Name Project Name Project Location Scope Total Value (INR Cr) Year Of Completion (or Ongoing)
Reliance Infrastructure Limited 6x660 MW Reliance Sasan Power Plant Amlohri, Madhya Pradesh Power Supply Distribution system 55Ongoing
Jindal Power Limited 4x600 MW O P Jindal Power Plant Tamnar, Chattisgarh Air Conditioning, Ventilation 34Ongoing
Abir Infra Projects 2x600 MW Athena Chattisgarh Power Plant Singhiterai, Chattisgarh Air Conditioning, Ventilation 23Ongoing
Korba West Power Company Limited 1x600 MW Korba West Power Company Limited Raigarh, Chattisgarh Balance of Plant - Electrical Package 17Ongoing
Powerjen Infra 5x660 MW Tiroda Thermal Power Station Tiroda, Maharashtra Air Conditioning, Ventilation 13Ongoing
BGR Energy 2x500 MW Madwa Tendubhata Power Plant Madwa, Chattisgarh Air Conditioning, Ventilation 11Ongoing
Power Plant Engineers Limited 2.5 MTPA Jindal Steel & Power Angul, Odisha Air Conditioning, Ventilation 9Ongoing
NTPC Ltd 2x660 MW NTPC Brah Barh, Bihar Air Conditioning 9Ongoing
NTPC Ltd NTPC Muzaffarpur Muzaffarpur, Bihar Air Conditioning, Ventilation 9Ongoing
BHEL 1x500 MW Bokaro TPS Jharkhand AC Supply Bokaro, Jharkhand Air Conditioning, Ventilation 8Ongoing
Indu Power Limited 2x250 MW Korba West Stage 3 Power Plant Korba, Chattisgarh Air Conditioning, Ventilation 8Ongoing
Reliance Infrastructure Limited Reliance Raghunathpur Raghunathpur,West Bengal Air Conditioning 8Ongoing
BGR Energy 2x500 MW Chandrapur Super Thermal Power Station Chandrapur, Maharashtra Air Conditioning 6Ongoing
NTPC 2x250 MW Seepat Thermal Power Plant Seepat, Chattisgarh Air Conditioning 62010
Reliance Power Limited 1x600 MW Vidharbha Power Butibori, Maharashtra Air Conditioning, Electrical 6Ongoing
Bhartiya Rail Bijlee Company Ltd NTPC Nabinagar Nabinagar, Bihar Ventilation 6Ongoing
BHEL Durgapur Power Plant Durgapur, West Bengal Air Conditioning 6Ongoing
BHEL 2x500 MW Simhadri TPP Stage Visakhapatnam, Andhra Pradesh Air Conditioning, Ventilation 52002
Adhunik Power & Natural Resources Ltd Adhunik, Jamshedpur Padampur, Jharkhand Air Conditioning, Ventilation 5Ongoing
BGR Power System BGR Power Plant Krishnapatnam, Andhra Pradesh Air Conditioning 5Ongoing
BHEL WBSEB Santaldia,West Bengal Air Conditioning 5
2013

Delhi Metro Rail Corporation Limited (DMRC), a milestone in infrastructure development in Delhi NCR and various cities, has given Blue Star an order for electro-mechanical works of 5 underground stations that come under Line No. 8 of DMRC at Botanical Garden in Janakpuri West. The project, valued at Rs. 152 crores, includes design verification, detail engineering, supply, installation, testing and commissioning of electrical & mechanical systems, including fire & hydraulic systems for underground stations of DMRC Phase III.

DMRC has commissioned and is running various lines in two separate phases. DMRC has been given responsibility of starting metro operations outside NCR as well, in Jaipur and several other cities. Currently, DMRC has initiated its third phase of operations for the underground stations.

DMRC has received an ODA loan from Japan International Cooperation Agency (JICA) for an amount of 127917 Million Yen towards a part contract for the DMRC project, Phase III of Delhi Mass Rapid Transport System and intends to apply a portion of the proceeds of the loan to payments under this contract.

The service consultant for this project is Ayesa from Delhi and the civil contractors are L&T and Pratibha.

Blue Star has booked an integrated MEP order valued at Rs. 13 crores for tunnel works at Gujarat International Finance Tec-City (GIFT) in Gujarat. Gujarat International Finance Tec-City Company Limited (GIFTCL) is a joint venture between the Government of Gujarat (GOG) through its undertaking, Gujarat Urban Development Company Limited (GUDCOL) and Infrastructure Leasing & Financial Services (IL&FS), to develop and implement the GIFT project. GIFTCL proposes to implement GIFT as a globally benchmarked international finance city with a built-up area of 85,000,000 sq ft.

Blue Star has executed two other projects for GIFT, and the positive past experience prompted the customer to award this project as well. The electrical scope consists of supply, installation, testing and commissioning of HT compact sub station, distribution boards, cables, trays, power & lighting distribution in the tunnel (2.9 km long), earthing, wiring, fire alarm, access control, rodent control & SCADA. The ventilation scope of the project includes supply, installation, testing and commissioning of ventilation fans and associated piping, ducting and insulation works, sensors, motorised smoke dampers, PLC as well as starter panels. The fire-fighting scope comprises supply, installation, testing and commissioning of fire pumps, panels, GI piping, valves, cables, fire equipment and fire extinguishers.

Tata Consulting Engineers Ltd from Mumbai is the consultant for the project.

Blue Star has been awarded an order valued at Rs. 11 crores by Abir Infrastructure Pvt. Ltd. towards HVAC works for a proposed 2 x 660 MW Bhavanapadu Thermal Coal-Based Power Plant (BTPP) - Phase I at Srikakulam, Andhra Pradesh.

The BTPP project is being developed by East Coast Energy Pvt. Ltd. (ECEPL) near Kakarapalli village in Srikakulam district, Andhra Pradesh. The plant is to be developed in two phases with a total generation capacity of 2640 MW. Each phase is planned with a capacity of 1320 MW comprising two units of 660 MW.

The scope of the project includes HVAC works comprising supply, installation, testing and commissioning of two 150 TR vapour absorption chillers, one 150 TR screw chiller, associated pumps, cooling towers, AHUs, air distribution, piping works, electrical panels & PLC system.

Blue Star was earlier associated with this client for HVAC works for their Singhitarai power project at Chhattisgarh.

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.

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 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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