Forging Plant, Shirdi MIDC

A forging plant on a plot of about 40 hectares in the industrial area at Shirdi, with 1,44,414 sq m of construction: one 17.5 m high production shed of 536.8 x 74.66 m (about 40,075 sq m), five 15 m high sheds of 256.56 x 72 m (18,475 sq m each) and a two-storey administration building, with material storage, lean-to sheds for utilities and open space for transformers, tanks and treatment plants. The process is power-hungry - induction heaters, forging and nosing presses of 1,200 to 2,200 kW, heat-treatment furnaces, CNC machining and hot and cold water systems - so the first questions were how much power the plant needs, how it is brought in and where it sits on the plot. The environmental clearance also asks how the plant saves energy, charges vehicles and treats and reuses water, and every answer has to be drawn on the plot.

Power: we listed every machine of the two plants line by line - 21,837 kW connected and 17,470 kW of demand at 0.8 - and sized the supply from it: 20,552 kVA at 0.8 maximum demand, met by two 2,250 kVA (33 kV / 575 V) and four 5,000 kVA (33 kV / 433 V) transformers, with a 33 kV SF6 switchboard of vacuum breakers, an 8,000 A busbar on the 433 V side and 7%-reactor power-factor panels of 1,500 kVAr. Two 500 kVA diesel sets carry the essential load of about 856 kW: sheds, offices, street lights, fire-water, effluent and sewage treatment. Energy: the clearance calls for savings, so we sized rooftop solar at 12% of demand - 2,096 kW from 3,882 panels of 540 W, about 3.14 million kWh a year - solar street lights on 591 fittings, and variable-frequency drives on conveyors, cranes, fans and pumps, which together save 4.12 million kWh a year, 8.07% of the plant's annual consumption. Charging: 30% of the car bays are given charging points - 180 in four charging stations. Water and drainage: a demand statement for 1,000 people and the landscape, domestic, flushing and fire storage (45 kL, 15 kL and 450 kL, in two fire tanks of 2.25 lakh litres with a 70 sq m pump room), a 45 to 50 kLD sewage plant, rainwater recharge pits with bore and filter, de-siltation pits and storm-water gutters, and a 150 mm fire-hydrant ring. We issued the sets in January and February 2026 and revised them as the architect's drawings changed.