January-March 2006

INTHISISSUE
Overall view of NHT/CRU Plant for CPCL at Manali near Chennai
Focus
Editor
Editorial Team
Photography
Cover Design & Layout
L&T has extensive experience and
expertise to execute all types of
hydr ocar bon pr oj ect s, such as
Refineries, Petrochemical plants, Oil &
Gas installations including LNG plants. It
is the only Indian EPC company pre-
qualified for executing large, process-
intensive projects, and offers single-
point responsibility for execution of these
pr oj ec t s . I t has engi neer ed,
manufactured and delivered world-class
pl ant and equi pment ; of f er s
comprehensive construction services
and provides the complete range of
engi neer i ng ser vi ces i ncl udi ng
procurement and commi ssi oni ng
assistance to refinery, petrochemical, oil
& gas projects.
In the following pages, we bring out
some of the projects recently executed
by ECC, L&T's Construction Division,
whi ch has made a si gni f i cant
contribution to the development of
country's hydrocarbon industry.
V.S. Ramana
K. Sridharan Alex Benjamin
V.D.S. Prasad V. Ramesh Kumar
Ashwin Chand V. Eswar
Subha Anand
V.S. Natanavelu
Romaa Communications
L&T Fuels the Nation's
Progress 2
Panipat Refinery Expanded 9
Anand-Rajkot Gas Pipeline 19
Mora Vapi Pipeline 21
Songo Songo Gas Pipeline 22
Cryogenic Storage Tanks 26
LPG Underground Storage 28
Magadi Soda Project 30
HDS Reactor-HPCL, Vizag 33

Projects Commissioned 34
New Orders 39
Papers Presented 40
Awards/Rewards 43
Exhibitions 48
Functions 50
Inaugurations 53
January -March 2006 Vol.28,No.4
L&T Fuels the Nation's Progress
Hydrocarbons are organic molecules that capacity of the country stood at 127.4 million
consist exclusively, or primarily, of carbon metric tonnes for the year 2004-05. To meet
and hydrogen atoms. While many of the the ever increasing demand for oil products,
hydrocarbon compounds occur free state in existing refineries are rapidly expanding their
nature (under the earth's crust), some are capacities and new refineries are slated to
artificial in origin. Crude oil and natural gas come up in the near future with the Ministry
are mixtures of hydrocarbons of natural of Petroleum & Natural Gas (MoP&NG)
origin formed by the decomposition of living contemplating to ramp up the countrys
organisms, under the earth. Natural gas refining capacity. The additional refining
contains hydrocarbons in gaseous state while capacity for exports will help India offset its
crude oil contains hydrocarbons in liquid huge crude oil import bill and take up exports
state, either saturated or unsaturated, at room so as to compete with refineries in Singapore
temperature. and West Asia. According to Hydrocarbon
Vision 2025, the demand for oil products is
estimated at 155million tonnes for 2006-07,
The origin of the oil industry in India can
195 million tonnes for 2011-12 and 368
be traced back to the last part of the 19th
million tonnes by 2024-25.
century when petroleum was discovered in
Di gboi i n north-east I ndi a. After
independence, the industry - with Burmah With the increasing environmental
Shell, ESSO and Caltex as major players, was concerns, Indian refineries recently
nationalised. Every activity - exploration, upgraded their operations to meet Euro III
devel opment, producti on, refi ni ng, norms.
marketing, distribution - was controlled by
the various public sector companies in the
Natural Gas
field.
Known as the fuel of the twenty-first
India is currently the fourth largest oil
century, natural gas has emerged as the most
consumer in the Asia-Pacific region after
preferred fuel due to its inherent
Japan, China and South Korea. Estimated to
environmental advantages, greater efficiency
grow at the rate of 7% a year, the demand for
and cost effectiveness. The demand for
petroleum products, in absolute terms is
natural gas globally has gone up sharply in
expected to be 155 and 195 million tonnes
the last two decades. In India too, the natural
respectively for the years 2006-07 and
gas sector has gained importance,
2011-12.
particularly over the last decade.
Refining
Production of natural gas at the present
level is around 87 million standard cubic
As of March 2005, there are 18 refineries meters per day (MSCMD). The main
in the country (including one in the private producers of natural gas are Oil & Natural
sector). The downstream refining through put Gas Corporation Ltd. (ONGC), Oil India
2
CRU Heaters for Chennai Petroleum Corporation Ltd (CPCL), Manali
Limited (OIL) and JVs of Tapti, Panna-Mukta L&T's cutting edge technology coupled While the E&C Division of L&T has
and Ravva. Under the Production Sharing with business processes and systems has engineered, manufactured and delivered
Contracts, private parties are also producing enabled the company to sustain its world-class plant and equipment to
gas from some of the fields. Government leadership in the domestic market as well as hydrocarbon related projects, ECC, L&T's
have also offered selected blocks under New unfurl its flag in project sites in the Middle Constr ucti on Di vi si on, of f er s
Exploration Licensing Policy (NELP) to East, Russia, CIS countries, Asia Pacific and comprehensive construction services for
private and public sector companies with the Africa. hydrocarbon related projects. This apart,
right to market gas at market determined L&T's joint venture company, L&T Chiyoda
L&T's core strength lies in its ability to prices. Out of the total production of around Limited, provides the complete range of
offer i ntegrated engi neeri ng and 87 MSCMD, after internal consumption, engineering services including proposal,
construction services for critical projects extraction of LPG and unavoidable flaring, front-end engineering and design (FEED),
involving process design, basic and detailed around 74 MSCMD is available for sale to procurement and commissioning assistance
engi neeri ng, proj ect management, consumers. to refinery and petrochemical projects.
equipment fabrication, procurement,
construction and commissioning all types of L&T has executed several refinery Liquefied Natural Gas (LNG)
plant & equipment for the core sector packages including the fast-track Diesel
industry including infrastructure projects, Hydro de sulphurisation (DHDS) projects on
The first LNG receiving terminal of the
with single-point responsibility. Strategic a Lump sum Turnkey (LSTK) basis for
country was set up by Petronet LNG, at
alliances with world leaders enable L&T to reducing the sulphur content in diesel to
Dahej in Gujarat. The plant was designedto
access advanced know-how and deliver meet the Bharat / Euro norms as required by
handle 5 MMTPA (20 MSCMD) of LNG and
projects that meet stringent quality the country's statutory bodies.
is doubling its capacity to 10 MMTPA (40
requirements and time frames.
MSCMD). To date, there are 2 LNG
It has fabricated and supplied critical
terminals operational in India while four
equipment and systems for refineries and gas
EPC Projects LNG receiving terminals are proposed to be
cracker plants. The range includes high
set up in the country.
pressure, high temperature reactors like
L&T, as builders to the Nation with its
hydrocrackers, DHDT & DHDS reactors for
wel l known commi tment to the
Larsen &Toubro Limited
' cl ean fuel ' proj ects. An area of
development of India's core sector Oil & Gas
specialization includes fabrication and
industry, has a major presence in
Larsen & Toubro Limited (L&T) is India's
supply of critical equipment like FCC
hydrocarbon related projects. L&T is the largest engineering and construction
reactors and regenerators to international
only Indian EPC company pre-qualified for organization. With a sales turnover
standards & specifications of well-known
exceeding US $3.5 billion, L&T has an
executing large, process-intensive projects,
process licensors (reactors as large as16.3
international presence with a global spread
and offers single-point responsibility for
metres in diameter and 1200 tonnes in
of operations.
execution of these projects.
weight).
3
Over the years L&T has acquired vast
experience in design, engineering,
procurement, fabrication and construction of
other packages like Sulphur Recovery Units
(SRU), Mini refineries, Skid mounted Sulphur
Recovery units, Skid mounted Mini refineries
and Skid mounted Gas Processing Plants.
L&T's E&C Division has been certified for
conformity to ISO-9001, ISO-14001 and
OHSAS-18001 standards and accreditations.
Oil &Natural Gas
Apart from its involvement in the
construction of downstream projects, L&T is
also actively involved in the execution of
critical projects for the upstream oil and gas
sector including construction of offshore oil
platforms, cross country pipelines and oil &
gas terminals. A number of repeat orders and
challenging assignments won against stiff
competi ti on through i nternati onal
competitive bidding from Oil & Natural Gas
Corporation (ONGC) as well as the cross-
country pipeline projects executed by ECC
involved in the construction of the Assam Oil ECC undertakes turnkey construction of for Oil & Gas Public Sector Companies bear
Refinery way back in the 1950s, when it Refinery & Petrochemical, Chemical, testimony to its growing presence in
executed the piping and equipment erection Fertilizer, Cross-country pipelines and Oil & developing this core sector industry in India.
works. Since then there has been no looking Gas projects involving comprehensive
back and ECC has been associated with services, civil construction works, structural
ECC's Constructive Contribution
al most al l the refi nery proj ects, fabrication and erection, piping fabrication
petrochemical and oil & gas related projects and erection, fabrication and erection of
Many of the major refinery projects in
including the cross country oil & gas pipeline equipment, erection of heavy lifts, electrical
India have benefitted from L&T's engineering
projects. system design and project electrification
and construction expertise. ECC, was
including instrumentation works.
Floating roof tank for HPCL Vizag
Pipe laying for Jamnagar - Loni Gas Pipeline Project
4
their gas cracker plant at Nagothane and of
the World's largest refinery at Jamnagar for
Reliance Petroleum including their units at
Patalgana and Hazira.
Refineries and Petrochemicals
The range of services offered by ECC
includes:
! Design and construction of all civil
works for cooling towers, equipment &
pipe-rack foundations, electrical sub
station and control buildings including
geo-technical investigations and
solutions.
! Design, procurement and construction
of plant structures and non-plant
buildings
! Design, procurement and construction
of storage tanks with floating and fixed
roof tanks
! Electrical system design including
Its track record includes turnkey Corporation Ltd (HPCL); Mangalore
procurement and project electrification
construction of major refinery, petrochemical Refineries and Petrochemicals Ltd (MRPL),
aswell as installation of equipment,
and oil & natural gas projects involving Gas Authority of India Ltd (GAIL), Gujarat
control and automation systems.
multiple challenges, such as technical State Petronet Ltd (GSPL). In addition, ECC

complexities, faster construction periods; was actively involved in the construction of
logistics, high risks, safety and environmental the project for Indian Petrochemicals
issues etc. Corporation Limited (IPCL) at Baroda and
ECC has built a vast reservoir of in-house
capabilities and expertise in design and
construction of cross-country oil & gas
pipelines, terminals, offsite facilities, storage
tanks with floating / fixed roofing systems,
cooling towers and cooling water systems,
electrical & instrumentation including fire
protection system.
A specialised team of erection engineers
provide erection schemes for lifting all types
of heavy and odd size equipment, towers,
columns, reactors, regenerators, absorbers,
converters etc. with precision arrangements
using heavy lift cranes as well as the strand
jack lifting systems. It will not be out of place
to mention that L&T is the only organization
in India, which has executed the maximum
number of fast track shut-down assignments
in virtually every refinery, under operating
conditions, close to highly hazardous and
congested areas prone to high risks, meeting
the complete safety requirements and
stringent time schedules.

ECC's clientele includes Indian Oil
Corporation (IOC) and its subsidiary,
Chennai Petroleum Corporation Limited
(CPCL); Bharath Petroleum Corporation
Limited (BPCL) and its subsidiaries
Numaligarh (Assam) Refinery Ltd, and Kochi
Refineries Ltd, Kerala; Hindustan Petroleum
Reformer, PSA Vessels and heaters for CPCL, Manali
Piping works executed for BPCL at Mahul
...Contd on page 8
5
E&C Division has successfully executed Infrastructure at MFF:
projects for international clients such as
Kuwait National Petroleum Company
Area
L&T has state- of - the ar t (Shuaiba Refinery), Songas-Tanzania
! Total developed
manufacturing facilities which are (onshore and offshore pipeline), Qatar
area : 180,000 Sqm
capable of meeting the challenges of Petroleum, and Gasco Bu Hasa, Abu Dhabi.
! Fabrication and
technology, quality conformance and
Load-out : 173,000 Sqm
del i very, whi l e ensuri ng cost
! Piping shops : 1,900 Sqm
competitiveness. L&T's manufacturing
! Covered stores : 1,500 Sqm
units are located at:
! Offices : 3,600 Sqm
! Jetty/Wharf
L&T's Modular Fabrication Facility (MFF)
! Powai (Mumbai)
Main Jetty : 100 m x 18 m
meets exacting quality standards with
! Heavy load-out
compressed delivery schedules. Located at
! Hazira (Surat) - with its own water
facility : 80 m x 42 m
Hazira, 295 km north of Mumbai and 21 km
front and a Ro-Ro (roll-on/ roll-off)
! Roll-on-roll-off jetty: 60 m x 40 m
from Surat, on the banks of the river Tapi, the
jetty
facility has unimpeded passage to the
Range
Arabian Sea, 8 km away.
! Ranoli (Vadodara) dedicated to
! Offshore platforms
handling stainless steel, non-ferrous
! Process modules and skid-mounted
One of the largest of its kind in South
and exotic materials
equipment
Asia, the MFF is capable of manufacturing
! Fired heaters
several large modules simultaneously.
L&T has been associated with leading
! Modular process plants like
Fabricated modules are tested and pre-
EPC contractors and engineering
Continuous Catalyst Regeneration
commissioned onshore to ensure rapid and
consultants in this sector. Large numbers
(CCR) unit,
trouble-free hook-up at site. The MFF
of critical equipment have been exported
Sulphur recovery unit
conforms to international standards of safety
to every continent including North
! Heat recovery steam generators
and quality and has ISO 9001-2000, ISO
America, South America, Europe, the
! Desalination plant and equipment
14001 and OHSAS 18001 accreditations and
Middle East, South Africa, the former
! Barge-mounted plant
a certificate of authority to use the API
Soviet Union, Australia and the Asia-
! Modular and marine structures
monogram for products manufactured as per
Pacific region.
! Pipe reels
specifications API 5L and API 2B.
Engineering & Manufacturing Capabilities
A view of L&Ts Hazira works on the banks of the river Tapi
Modular Fabrication Facility
Heavy Engineering
6
! Technol ogy eval uati on/l i censor
To ensure smooth and timely
selection
execution of its projects, LTC has state-of-
! Basic engineering
the-art IT facilities and a rich talent pool of
! Front-end engineering design
experienced and highly competitive
! Detailed engineering Knowi ng the potenti al for
engineering manpower. The quality of
! Procurement assistance
hydrocarbon projects in the country, in
LTC's engineering deliverables is
! Inspection and expediting services
1994 L&T went in for a technical
maintained through implementation of
! Start-up and commissioning assistance
collaboration and set up a joint venture
ISO 9000:2001 quality system into the
! Total project management
engineering company with Chiyoda
project execution.
consultancy Services
Corporation of Japan, a world renowned
! Revamp and modernisation
EPC organisation for undertaking the
LTC has executed more than 60 major
Studies
construction of large hydrocarbon
projects with the latest engineering
projects specifically in the area of grass
technologies to the complete satisfaction
LTC has developed high-end engineering
root petroleum refineries, oil and gas (on
of domestic clients such as IOCL, BPCL,
capabilities such as process simulation,
shore and off shore) processing,
CPCL, KRL, IPCL, ONGC, GAIL, Cairn
intelligent P&IDs, intelligent 3D plant
petrochemicals, liquefied natural gas
Energy, etc as well as international clients
modeling, composite analysis, finite element
plants and terminals on EPC basis.
such as TOC (Thailand), Sipchem (Saudi
analysis, piping stress analysis, etc. in a short
Arabia), QAFAC (Qatar), FERTIL (Abu
period of time.
L&T-Chiyoda Limited (LTC) is a joint
Dhabi), etc.
venture engineering company of L&T
(holding 50% of equity) and Chiyoda
Corporation, Japan, international
integrated engineering and construction
contractor with five decades of
experience in hydrocarbon and related
fields.
LTC offers total engineering
solutions to process industries such as:
! Petroleum refineries
! Chemical & Petrochemical units
! Oil and gas processing facilities
! LNG & LPG terminals
! Fertilizer plants
The engineering and consultancy
services provided by LTC include:
! Techno-economic feasibility reports
71m high, 210t Demethaniser (left), 83m, 395t Ethylene Rectifier being erected for the
petrochemical complex of Reliance Industries (Phase II) at Hazira
Well head platforms ready for load out from L&Ts Hazira Works for Oil & Natural Gas Corporation
L&T-Chiyoda Limited
7
! Construction of LNG terminals and LPG ...contd. frompage 5
construction of civil, mechanical,
storage facilities.
electrical and instrumentation for
! Procurement and construction of fired
composite station works, cathodic
heaters involving massive structural
! Engineering, procurement, construction
protection system for pipelines/stations.
fabrication and process plant piping
and commissioning of storage facilities
i ncl udi ng speci al i zed wel di ng
for LPG underground caverns.
techniques using inconel, hastalloy,
! L&T entered into laying of onshore
titanium, etc.,
! Erection of high capacity gas compressors cross country pipelines in1992 and so far
and associated facilities. has laid about 3300 Km of pipelines
! Procurement and construction of
M. Ramkumar ranging from 12 to 30 in diameter and
mounted bullets and horton-spheres
General Manager now is in a position to manage 5 spreads
(Hydrocarbon Construction & Pipelines)
simultaneously.
! Erection of static and rotary equipment
including heavy lift erection of tall
columns, reactors, re-generators, etc.,
! Complete shutdown maintenance and
revamping works.
Cross-country Pipelines and Oil &Gas
Terminals
ECC offers a wide range of services like:
! Execution of cross-country pipeline
projects involving pipe-laying (including
OFC), horizontal directional drilling
(HDD), testing, pre-commissioning and
commissioning of pipelines including
design, engineering, procurement and
Illuminated view of the Reliance Patalganga project
Naptha cracker plant for Reliance Industries, Hazira
8
Panipat Refinery is the seventh refinery turpentine oil, bitumen, sulphur, etc. highly challenging as well as satisfying as all
of Indian Oil Corporation Limited (IOCL), a Besides, about 2.4 lakh tonnes of cooking the packages had very stringent completion
Global Fortune 500 company with a vision gas per annum is being supplied from the schedules and the progress was monitored
to become a maj or, di versi fi ed, Refinery. by IOCL at the highest levels with their
transnational, integrated energy company. Director (Projects) attending all the monthly
Backed by state-of-the-art technologies from Currently the Refinery's capacity is review meetings and reporting to the
global majors, Panipat Refinery is being expanded to 12 MMTPA and L&T has Chairman, said Mr. S.K. Sampath, ECC's
considered a technically advanced refinery. played a major role in the construction of the Project Manager (since posted as Chief
Built in an area of around 2,200 acres of land same through five packages as follows: Manager, Larsen & Toubro [Qatar] LLC). In
at a project cost of Rs. 3868 crore (including the initial stages the clients had serious
marketing and pipeline installations), the ! Diesel Hydro Treater Unit (DHDT) & reservations about timely completion of the
Refinery has an installed capacity of 6 Hydrogen Generation Unit (HGU) various packages but in course of time L&T
million metric tones per annum (MMTPA). ! Reformer Packages within Hydrogen was able to remove all these apprehensions.
Designed for processing both indigenous Generation Plant
and imported crude oil, since its ! Purified Terephthalic Acid (PTA) On seeing the speedy progress, IOCL
commissioning in 1998, the Refinery has ! Coke Drum System Package (CDSP) developed so much confidence that they
processed about twenty-five types of ! Raw Water Treatment Plant (RWTP). even contemplated offloading to L&T some
imported crude oil from different countries. of CDU/VDU works which were entrusted
While the first four packages were to other contractors, said Mr. Sampath.
The Refinery is capable of producing bagged by L&T's E&C Division as EPCC Further, he said that the close interaction of
about 8 lakh tonnes of petrol, 3 lakh tonnes contracts, with ECC taking responsibility for ECC with IOCL and their Consultants
of jet fuel, 12 lakh tonnes of kerosene and 26 the construction part, the fifth package for Kvaerner Powergas helped them to address
lakh tonnes of diesel annually. Other RWTP was awarded as a direct EPC contract a number constructability issues at the
products include naphtha, mineral to ECC. Execution of Panipat Project was design stage itself.
Panipat Refinery Expanded To 12 MMTPA
PTA Plant at IOCLs refinery, Panipat
9
construction work, initially valued at Rs.75 mobile tower crane of 45 meters height was
DHDT and HGU Plants -
crore, on September 23, 2002 with soil placed in the passage between the hydrogen
Worlds Largest
investigation. Piling was taken up on plants to lift various structures and
December 4, 2002 and mechanical mechanical equipment as part of the
IOCL awarded the DHDT/HGU package
completion achieved on July 28, 2005. The mechanical erection work. This tower crane
to E&C Division of L&T on August 27, 2002
scope included piling, civil works, was used round the clock for civil and
through International Competitive Bidding.
fabrication & erection of structures, mechanical erection and electrical work as
The scope of work included residual process
underground and aboveground piping, well and substantially quickened the
design, detailed engineering, procurement,
erection of static/rotary equipment, grit progress of construction.
supply, transportation, fabrication, storage,
blasting & painting, design/engineering,
construction, installation, testing, pre-
procurement and construction of fire fighting
Critcal Wall Piping
commissioning, commissioning and
system, installation, testing & commissioning
performance guarantee test run of DHDT &
of electrical & instrumentation work for the For welding of heavy wall piping joints, a
Hydrogen Generation Unit. The completion
entire DHDT/ HGU and Reformer Package. fully automatic welding machine was
time for the package, valued at Rs.581 crore,
This involved fabrication and erection of imported from Luberdi Diametric of USA
was pegged at 27 months.
complex and heavy structures using state-of- because of its cutting edge technology and
the-art P&M. Execution of this unique project high productivity. The machine was used to
IOCL subsequently awarded to M/s
involved several challenges and ECC with its weld about 100 joints of diameter ranging
Haldor Topsoe A/S and L&T, the 2 x 70,000
meticulous planning and systems approach from 12 to 24 and thickness varying
TPA Reformer packages, to be constructed
faced every obstacle with ease and between 16 mm and 40 mm. It is capable of
within the Hydrogen Generation Plant.
successfully completed the project to the welding 16 dia and 32 mm thick joints in a
entire satisfaction of the client. Following are matter of thirty minutes whereas, if done
ECC played a major role in the some of the construction highlights of our conventionally, the same work would take
construction of the 3.50 MMTPA capacity work: one full day. The machine greatly helped in
DHDT Unit (world's largest) and the 2 x completing critical heavy wall piping in
70,000 MTPA capacity hydrogen plants reaction area with a high level of quality and
Tower crane for mechanical erection
(Asia's largest), valued at Rs.109 crore and accuracy and in saving considerable
Rs. 18.3 crore well ahead of the given execution time.
Since the two hydrogen plants, had to be
schedule of 35 months and 24 months.
constructed in a congested and restricted
Radiant Chambers
area of 153 m x 125 m with intricate
The DHDT/HGU project at Panipat, a
structures already in place, it was not feasible
The reformer fabricated for IOCL at
first of its kind in the world, proved to be a
to use cranes for erection work as originally
Panipat has two streams and is Asia's biggest
challenging task. ECC commenced the
envisaged. After a lot of brainstorming, a
in terms of its size and capacity. Radiant
A View of DHDT/HGU Plant at IOCL, Panipat
10
chambers for reformers are normally
fabricated in panel Form. However, due to
excessive heat generated during welding it
was very difficult to achieve the stipulated
tolerances. Further, this method was found
to be time-consuming and posed safety and
quality problems. In view of this and the
tight construction schedule, ECC adopted
the modular concept for the radiant
chamber. In all 40 modules of size 13.10 m
x 3 m x 3 m, weighing 18 tonnes, were
fabricated in a record time of 106 days and
pre-assembled in the fabrication shop and
later erected at site. By this method the site
could achieve the required tolerances and
save on time and cost.
Bobcats
Bobcats are compact lifting machines,
made of longer wheelbase and skid-streer,
used for various activities during
construction where working space is a
constraint. At Panipat, these compact and
agile machines were used for multi-tier
working due to limited workspace amidst
heavy structures, thereby ensuring that the
movement of men and materials were made
easy and kept to the minimum and also
meeting standards.
Safety Record
Challenging as the task on hand was, the
site team did not lose sight of the equally
important aspects of quality and safety and
achieved 24 million safe man-hours without
any lost time or accident. In recognition of
This performance L&T won the following conventi onal management styl e,
awards: participative style of management was
brought in. By this method, every staff was
! Silver Award for Occupational Safety allocated a definite area of operation, and he
from Royal Society for the Prevention of was empowered to carry out his assignment
Accidents (RoSPA) for the period 2003-2004. without waiting for instructions from the
seniors. He asserts, Our engineers were
! Best Safety Conscious Project (Above given the freedom to interact directly with
Rs.500 crore Contract) Category by IOCL the clients whenever required. This brought
Panipat Refinery Award February 2005. down considerably the time for any
communication or instructions to percolate
! Safest Trophy for Major Job site in ECC for down the line.
the period April 2004 to March 2005.
The Hydrogen Generation Unit was
! ISO 9001-2000 Certificate for Quality commissioned on November 18, 2005 and
Management System in IPU Sector. DHDT Plant went on stream on December
21, 2005 smoothly and flawlessly much to
Mr. Sharad Kumar (SK), Project Manager, the delight of all associated with this mega
attributes the success of the DHDT/HGU project. Significantly, IOCL's commissioning
project to certain measures introduced at site team members commented this has
for better results. In place of the never happened before
HGU Plant at IOCL Panipat
Technological Structures of DHDT Unit
11
! Driven Cast In Situ Piles
(450 mm dia,
18.5 m long) : 4107 nos.
! RCC/PCC Concrete : 25000 Cum
! Structural fabrication
& Erection : 7300 t
! RCC pavement &
Ironite flooring : 45000 Sqm
! Fire proofing of
structures : 60600 Sqm
! Under ground : 49737 IM
Piping /20000ID
! Above ground : 491772 ID
Piping /576241 IM
! Fire fighting system : 50180 IM
! Static Equipment
Erection : 3000 t
! Heavy Lift Equipment
Erection : 2000 t
! Rotary Equipment
Erection : 1006 t
! Painting of
Structures & Piping : 175000 Sqm
KVA- 12 nos., Batching plant 20 cubic /Hrs- ! Impulse Piping : 2225 Tags
Major resources employed
1 no., Transit Mixture 4 cubic/ 6 cubic- 5 (43200joints)
nos., Weld Generator / Rectifier- 6 nos., ! Electrical &
Following are the major resources
Hydrolic Test Pump- 6 nos., Gantry Crane- 2 Instrumentation Cabling : 950 km
deployed during peak for DHDT / HGU &
nos ! Cable Tray & Duct
Reformer project including E&I.
Installation : 135 km

! Equipment & panel
Hydrogen Reformer &Heaters
Installation : 478 nos. Plant &Machinery :
! Fabrication & Erection
This 2 x 70000MTPA capacity hydrogen
of Duct/Cable Supports : 1000 t
Link belt Crane 700 t Capacity-1no.,
reformer (the biggest reformer in Asia)
! Calibration of
American Crane 225 t Capacity- 1 no., Tower
converts hydrocarbons and methane into
Instruments : 6138 nos.
Crane G3/33B T2 60 m 12 t Capacity- 1 no.,
hydrogen, carbon monoxide and carbon-di-
! Installation of
Fully Automatic Orbital Welding M/c- 1 no.,
oxide. Valued at Rs.18.30 crore, this
Instruments : 6301 nos.
Crawler Crane 75 t Capacity- 5 nos., Crawler
involved three main process features
! Impulse Tubing : 13161 nos
Crane 20 t Capacity- 4 nos., Hydra Crane
hydrocarbon reaction section, furnace
! Installation of Lighting
20/30/40 Mt Capacity- 10 nos., Trailer
heating section and waste heat recovery
Poles & Fixture : 6961 nos.
20/40t / TRUCK- 11+1 nos., Hydra Crane
section and the entire work was executed in
10 t- 9 nos., DG Set - 380 KVA /250 KVA/125
24 months
Each of the two reformers having a
capacity of 70,000 MTPA, has the following
identical features:
! 360 burners in 6 horizontal rows
installed on the two side walls of the
duplex fire box
! 240 nos. of catalyst tubes - 120 in each
box
! 240 nos. of hair pin tubes - 120 in each
box
Gas is used as the main fuel for burners,
but Naptha is also used as an alternate fuel.
Diesel Hydro Treater (DHDT) unit of IOCLs refinery at Panipat
2 x 70000MTPA capacity hydrogen reformer (the biggest reformer in Asia)
Major quantities
12
A View of Silos at the PTA Plant of IOCL Panipat
During the process, the fuel gas flows Major Quantities Appreciation from the client
upward through the outlet provided at the
top of the chamber whereas the process gas
Following are major items of work
flows downwards through the catalyst tube
executed for Reformers & Heaters:
(provided inside) and gets collected in cold
collector at the bottom of the furnace. The
! Radiant Section : 1329 t
process gas leaving the tubular reformer
! Structural : 822 t
passes through a waste heat boiler (RG
! Ducting (CS) : 406 t
Boiler), where saturated HP steam is
! Ducting (AS) : 335 t
produced. This process gas is again cooled
! Stack : 862 t
in a BFW pre-heater.
! CS Piping : 33245 ID
! Jacket Piping : 65434 ID
Thereafter, the process gas enters
! S.S Piping
Hydrogen generation unit (HGU) for further
(Heavy) : 1981 ID
heat recovery and finally it is sent to PSA
! A.S. Piping : 2251 ID
system for purification to produce 99.99%
! Piping supports : 34 t
pure Hydrogen.
! Inlet distributor : 224 ID
! Inlet hairpin tubes : 960 ID
The waste heat generated by the fuel gas
! Catalyst tube : 2400 ID
and let out from the reformer furnace, has a
! Cold collector : 984 ID
temperature of around 1060C. This heat is
! Static Equipment
recovered and used for:
erection : 1602 t
! Rotary Equipment
! Pre heating of Reformer feed
! erection : 174 t
! Pre heating of Pre-reformer feed
! Grit Blasting
! Superheating of steam
& Painting : 75335 Sqm
! Heating of combustion air
! Generation of superheated HP steam
! Preheating of Combustion air
13
To: pr-krishnamoorthy@enc.ltindia.com
From: MANOHARANC@iocl.co.in
Date: 11/21/2005 03:16PM
Subject: Safeandsuccessful commissioningof Hydrogen Unit
November 21, 2005
Dear Shri Moorthy,
It gives me immense pleasure to convey my heartiest
congratulations to you and your team associated with
Panipat Refinery Expansion Project for the safe and
successful commissioning of the largest capacity Hydrogen
Plant in the country on 18th November, 2005. This is a major
landmark achieved in the ongoing commissioning activities
of PREP.
As you are aware, this is the largest capacity Hydrogen
Unit in the country and also the largest Haldor-Topsoe
(HTAS) licensed Plant in the world. The construction /
commissioning of such mega Hydrogen Plant has been the
most challenging task in the total PREP. Successful
accomplishment of this task is definitely going to boost up the
pace of the construction / commissioning activities of other
units / facilities in PREP and PX-PTA.
You can be proud of the fact that the first chain of this
mega plant could be commissioned and stabilized in the first
attempt itself. I know that this could be made possible due to
your excellent leadership and also with the hard work,
dedication and teamwork by all the concerned personnel of
L&T, IOCL and other agencies.
With regards,
C. Manoharan
General Manager(T)
Panipat Refinery
October 2003 and were completed on granite, tiles and Burma teak for doors, is PTA Plant
November 16, 2005. Construction of such a bound to become a benchmark for process
Plant was not an easy task considering the plants in the future. One has to see it to
The PTA Plant of 5,53,000 MTPA
magnitude as well as the intricacies involved. believe it for, it is a different world by itself.
capacity constructed by L&T for IOCL at
Moreover, the harsh climatic condition of
Panipat is Asia's biggest. It is the largest
Panipat also proved a hurdle to speedy
Major Parameters of PTA Plant turnkey project awarded in India and also the
completion of the project. Summer
biggest EPC contract for L&T so far, valued at
temperature was as high as 49 C and winter
Rs.1,242 crore. This project marked IOCL's ! EPC Value of PTA
drops were as low as 10 C. Mobilisation of
entry into petrochemical sector and is also
Package (EPCC III) : 1242 Crore
3,800 workmen and extended working
L&T's largest EPC contract to date. The
! Construction
hours in such weather itself is a great
success of the project is due to the synergy
Value : 200 Crore
achievement. This was achieved with pro-
and seamless working brought in by E&C and
! RC Driven Cast in
active support from site management such as
ECC Divisions of L&T. Mr. S.N. Roy, Project
Situ Piles : 3400 nos.
free warm clothing to workmen in winter,
Manager, E&C, echoes the sentiment and
! Excavation -A : 60000 Cum rest sheds during summer, free refreshments
says that for the first time in projects involving
during peak period. PTA Plant comprised ! Earth Filling : 140000 Cum
E&C and ECC, it was jointly decided to have
construction of Plant buildings, Process Plant
! Concreting (Excl
the Resident Construction Manager (RCM)
and Warehouse. Every building has some
from ECC instead of E&C as in the past, and Piling & Pavement) : 42000 Cum
unique components not seen in other
the change has yielded good results. He ! Pavement : 67000 Cum
conventional process plants.
believes this arrangement should continue in
! Fire Proofing : 12000 Sqm
future as well. This coming together had also
! Formwork : 130000 Sqm
helped in bringing down the staff Electrical Control Room
! Reinforcement : 7150 t
requirement by 100. There was no
! Bitumastic Flooring : 45000 Sqm
supervision over supervision and the two
Though buildings such as control room,
! Pre-coated Sheets : 55000 Sqm
Divisions worked hand in hand as one
substation, D.G. room and operators cabin
! Structural
unified L&T team so much so that Mr. P.R.
are common in any process plant, at IOCL-
Fabrication, Erection
Das, Executive Director (Projects), IOCL, had
Panipat they had special requirements. The
& Painting : 9500 t
this to say to Mr. A.M. Naik: The PTA team is
control room had blast-proof concrete outer
a totally dedicated and seamless team. ! Under Ground Piping : 112000 IM
walls while the console room was made
! Above Ground Piping: 500000 IM
soundproof using lightweight concrete
blocks and the doors were made of fireproof Though the contractual commencement ! Non-destructive
steel. The control room, with its world-class date was March 31, 2005, site mobilisation Testing : 70000 ID
architectural finishes and electrical fixtures & was started in February 2003. Actual
! Equipment Erection : 4650 t
fittings and clad with superior quality marble, construction activities stabilised from
State-of- the-art control room for IOCLs PTA Plant at Panipat
14
Compliments from IOCL
I am happy to see a very high level of
motivation in the entire PTA team.
Considering our maiden venture, we have
done very well in project execution. I look
forward to a very successful commissioning
of the plant."
- Mr. S. Behuria. Chairman
"Visiting the control room of PTA Plant
and the plant itself today was a fantastic
experience, the quality of construction as
seen today is of highest order. The three
teams of L&T, IOCL & EIL have worked
shoulder to shoulder for the last over two
years to bring the plant to a stage of near
readiness for commissioning without a
si ngl e LTA. Thi s i s a marvel ous
achievement. I wish the three teams all the
best in remaining activities of construction
and of course in smooth commissioning of
the plant."
- Mr Jaspal Singh, Director (Refineries)
Process Plant
The heavy-duty pavements in the plant DEGUSSA regarded worldwide as the ideal
above the process area pavement (31,000 anti-corrosive lining material.
PTA is a product derived from paraxylene
Sqm) were made of steel fibre reinforced
passing through various oxidation processes.
concrete with a 50 mm thick carpet to make
As the spillages and effluents arising out of
Asia's Largest Warehouse
the floor and pavement abrasion-resistant. It
the processes are highly corrosive in nature,
was a totally mechanised operation -
special technologies and materials were used
The PTA Warehouse at IOCL-Panipat is
cleaning the broomed surface, application of
to make the floors and drains highly anti-
Asia's largest warehouse with an area of
bonding agent, immediate spreading of
corrosive. All chemical trenches and effluent
44,363 Sqm (109 m x 407 m) and has four
concrete by a spreader and final trowelling
tanks were constructed with stainless steel
rows of 22.43 m high concrete columns and
involving time-bound activities which, if
(SS304) lining. This was highly demanding
a structural steel roof with precoated
delayed, could have impacted the carpet
work since even a minor defect would mean
galvolume sheets. The structural steel roof
quality. In line with the recommendation of
dismantling the trench and doing the work all
weighs 2,750 t. To withstand the corrosive
the process licenser DuPont, specific areas
over again. However, the task was
nature of PTA, the floor was made of 250 mm
were covered with acid resistant tiles and
accomplished by ECC's highly skilled
thick VDF (Vacuum Dewatering Floor)
UCRETE, a patented product of MBT /
workmen and well-motivated supervisors.
concrete over 200 mm thick sand layer used
as sub-base floor. VDF offers the advantage
of minimal moisture content and lends very
high compressive strength to concrete. Over
the VDF, 30 mm thick Bitumastic flooring
(Prodorphalt-W) was applied to make it acid-
and corrosion-resistant. The Bitumastic
flooring of 44,500 Sqm was done in a record
time of five months, deploying five boilers for
bitumen cake melting.
After completion of civil & structural
works, the fire fighting system design was
changed to accommodate large quantities of
spray nozzles including header lines. All
purlins were strengthened at erected
condition and support structures were
provided on civil columns through anchor
fasteners. It was a unique experience to
accommodate 176 nos. of 20 mm dia anchor
fasteners in an area of 1.5 Sqm per column
without touching rebar. High precision rebar
detectors were used to detect the rebar and a
specilalist agency from Chennai was
requisitioned to fix the anchor fasteners.
Electrical Panels installed in the control room
Interior view of the warehouse at PTA plant
15
Erection of Process Air Compressor
(PAC)
It was a pre-requisite from the
Manufacturer M/s. Mann Turbo of Germany
that the Assembled Compressor be erected in
roofed shed at foundation level at 6 m. Total
Weight of PAC being 212 t with a volume of
742 Cum (23.31 m Long x 5.96 m Wide x
5.34 m High), it was a tough proposition to
lift and slide inside the shed. But construction
Engineers were made to achieve such
difficult propositions.
After careful study of all arrangement,
Sliding Strand Jack System was as found the
only suitable arrangement for such a job. A
The contract for theCoke Drum System Coke Drum System core team of Heavy lift experts from site was
Package (CDSP), considered to be the heart of
deputed to execute the erection of PAC. Basic
DCU, was awarded to ECC on September 18, The Delayed Coker Unit (DCU) at design parameters were obtained from
2003 at Rs.22.41 crore (later revised to Rs. Panipat Refinery is designed to process 2.4 Heavy lift wing at ECC-HQ, Chennai. And all
31.15 crore). Coke drum systems of similar million tonnes per annum of Vacuum preparatory arrangements were commenced
capacity have so far been completed in thirty- Resi due (VR) and other resi dual at site.
three months. However, true to its reputation products/materials from various units of the
ECC completed the job in the month of June Refinery.
Supporting structures of strand jack
2005 (i.e. in twenty-two months), pending
system:
incorporation of free issue materials from the The products are Green Petroleum Coke,
client. Coker Fuel Oil (produced optionally), Heavy
Supporting structures are made of 191 t of
and Light Gas Oils, Light and Heavy
built up beams and ISMB 600 and 65 t of pipe
A major highlight in this package is the Naphtha, mixed C3-C4 LPG and Fuel Gas,
trestles. Height of supporting structures was
coke drum foundation structure with 2.4 m etc. It works normally on a 48-hour cycle i.e.
17 m load test on erected structure was
thick foundation slab, which is the tallest 24 hours of on-line Coke Drum filling and 24
carried prior to lifting.
hours of off-line Decoking.
Night view of DHDT Unit at IOCL Panipat

Eerection Package Wt. (mt) Installation Size
sequence elevation* l (m) x b (m) x w (m)
1 Coolers with
base frame -1 58.6 100.3 13.48x5.96x3.2
2 Base frame - 2 14 100.3 9.83x5.96x1
3 Turbine skid 87.1 105.016 13.29x6x4.73
4 Base frame 3 for
generator 37.6 105.016 11.97x6x5.34
5 Compressor skid 122.5 105.016 8.11x5.21x5.31
6 Generator 48.8 105.016 ~4x~4x~4.75
7 Expander & gear 33.05 105.016 ~5.5X~4X~4.75
Basic methodology / sequence of erection
With ref to ground lvl.
*
16
foundation in India at a height of 27.353 m
from ground level. A total of 1,419 tonnes
of reinforcement went into the work. Using
three concrete pumps, a massive quantity of
1,360 Cum of M25 concrete was poured into
the dense reinforcement (weighing 315 t) of
4 layers of 36 mm Torsteel each at top and
bottom, with 16 mm Torsteel as stirrups at a
height of 27 m. 5,000 tonnes of heavy duty
towers and L&T formwork were used
extensively for the top foundation slab alone.
This type of mass concrete foundation slab
was carried out for the first time in India. The
timely completion of the structure was
possible with the tower crane, which was
used to lift heavy-duty towers of 24 m length.
The entire load of reinforcement and wet
concrete of the foundation slab was
transferred to the H-Beam placed over ISMC
125, which in turn was transferred to the HD
Tower.
For the coke drum structures, weighing
The CDSP project has another first to its of working at heights, increased the quality of
2,800 tonnes, the modular concept was
credit - the highest capacity bridge crane ever workmanship and saved considerable time.
adopted for the first time in India. Universal
used in India, with a self weight of 250 The site used CO2 welding machine and
columns and beams were used to raise the
tonnes, a travel speed of 95 metres per achieved a productivity of 24 Kg per day
structures from the ground level to a height of
minute and a loading capacity of 44 tons, was compared to 6 Kg per day with SMAW.
103 m around four coke drums over the 2.4
erected at this site. The crane has a span of 23
m thick slab at 27 m level. The Coke Drum
m excluding a cantilever portion of 10 m Total piping scope was 50,000 inch-dia
Structures consisted of eight modules of 2
span with level difference of 8 m between out of which 23,500 inch-dia piping was of
nos each weighing 160 t, 190 t, 80 t and 84 t
both ends supporting carriage. high alloy steel (P5 and P9). High alloy steel
respectively. All eight modules were
pipe welding needs preheating, post-heating,
fabricated and assembled at ground level and
post-weld heat treatment and 100%
The heavy lift operation was done with
were lifted by Link Belt FMC crane of 750 t
radiography. The work was completed with
the help of FMC Link Belt Crane having a
capacity (On Ringer). The modules were
a high degree of accuracy and quality,
lifting capacity of 750 t mounted on ringer
placed one over the other to a height of 103
requiring only 1.3% re-work. The critical
foundation. It was for the first time in India
m from ground level within 15 days. The
part of the work was vertical pipe (diameter
that we used full boom length of the FMC. All
critical part of the structure was the slope of
ranging from 0.5 to 42 dia) erections at a
modules and four Coke Drums were lifted in
5.24 degrees, which gradually tapers from 64
height of 77 m from ground level. The
a single operation. One Fractionator
m to 103 m towards top. The modular
highest hydro test pressure in the project was
Column, an elevator structure of 67 m (in 2
concept helped in overcoming the criticality
444 Kg/Sqcm.
parts) and the Bridge Crane were also lifted at
one go. Altogether the FMC crane was used
for lifting and erection of 2,822 t of
structures/equipment.
The si te won the Best Safety
Performance Award for the year 2005 from
IOCL after clocking 4 million safe manhours
with 'zero' Accident. It also received
Certificate of Merit for achieving 2 million
Lost Time Injury Free Manhours, Certificate
of Merit for achieving 3 million Lost Time
Injury Free Manhours and Certificate of Merit
for Zero Accident rate.
Automated Heading and Unheading
system is a fully automatic hydraulic system
for opening and closing of Coke Drum. This
is an imported system and has been installed
for the first time in India. The hydraulic
system consists of pneumatic SS tubes
varying from 0.5 to 1.5 (total 8 Km)
connected with double compressed fitting.
Coke Drum System Package Unit
A view of the PTA Process plant
17
Inside view of the Filter house of 120 MLD RWTP at IOCL Panipat
Mr. V. Ravichandran, Project In-Charge construction, installation, testing, pre- commissioning of phase-I of the plant as per
for CDSP from E&C Division, says that the commissioning and commissioning of client's requirement.
modular concept we used for fabrication of RWTP. This is the first 120 MLD raw water
structural items in this package greatly treatment plant ever executed by ECC. The
helped in timely completion of the project. work was awarded on September 15, 2003
This would pave the way for out securing and the plant was commissioned on May 5,
similar packages in IOCLs future projects at 2005 while the mechanical completion was ! Excavation : 115080 Cum
other locations. For design/engineering of achieved on September 30, 2005. ! RCC & PCC : 27480 Cum
structural items L&T-Chiyoda, EDRC and an ! Steel : 1750 t
external agency were engaged. IOCL awarded the site the best safety ! Shuttering : 80000 Sqm
performance trophy for achieving 4 million ! Waterproofing : 6015 Sqm
Mr. Anil Kumar Bansal (AKB), lost time, injury-free manhours. ! Piping Fabrication : 58011 ID
Construction Manager, says that almost 70% ! Piping erection : 38075 IM
of the work involved working at heights, The raw water treatment plant treats ! Pumps : 60 nos.
maximum being 103 m, and this required water upto 5,000 Cum/hr capacity and has ! Electrical cable trays : 4000 Rm
even greater attention to safety aspects. special equipments like sludge thickener and ! Electrical cabling : 29950 Rm
However, by fabricating and assembling the belt filter press. One of the special features of ! Instrumentation
entire coke drum structures in modular form, the plant is that it has zero discharge of waste cabling : 19875Rm
the quantum of work at heights was kept to liquid. All the sludge from clarified
the minium and construction cost brought water/dirty back wash water is extracted by
down by almost 30%. The site achieved 3 means of belt filter press and dry sludge cakes Mr. S.K. Banerjee, Construction
million lost time injury free manhours and are transported to a designated dumping Manager, says that one major problem faced
won Best Safety Performance Award for the place. The water thus re-cycled is used in during execution was the complete
year 2005 from IOCL. Thanks to good various refinery processes, thereby submergence of filter water sump and pump
construction planning, 1080 tonnes of conserving water. house area during rainy season. However,
fabricated steel structures in modular form additional resources equipment, men and
were erected in a matter of 15 days. AKB During the execution of the project, ECC materials were immediately deployed to
adds that in terms of quality as well, the faced several hurdles, such as - the complete successfully overcome the situation and we
clients were highly satisfied with our work, submergence of filter water sump and pump could hand over the pump house for Phase-I
particularly in piping joints where welding house area during rainy season, because the commissioning of the plant as required by
repair percentage was as low as 1.3%. entire area was excavated 10 m deep from the client.
ground level for the foundation and piling
work (72 nos. driven cast in situ piles). The clients were very happy with the quality
120 MLD Raw Water Treatment Plant
However, ECC surmounted this by of our work as well as water supplied from the
immediately deploying additional resources plant. Mr. Banerjee adds that with the
The package i ncl uded proj ect
and managing the situation efficiently. Thus, successful execution of this project, ECC will
management, desi gn/engi neeri ng,
ECC completed the project and handed over be well placed to secure similar project
procurement, manufacture, suppl y,
the pump house for i mmedi ate orders in future.
transportation, storage, fabrication,
Major quantities
18
Welding in progress
Trenching and laying of pipes
The Anand-Rajkot Pipeline Project
123 km long 24 dia line for transmission of Natural Gas
Gujarat State Petronet Ltd. (GSPL) is
currently implementing a high-pressure
pipeline project covering various industrial
belts and cities of Gujarat. Considering the
importance of such a pipeline network and
realizing Gujarat's aim of emerging as the
'Petro Capital' of the Country, the State
Government has accorded 'Infrastructure
Project' status to GSPL's project.
In a bid to establish a systematic,
integrated and seamless infrastructure for
gas transmission from supply points to
various demand centers in the state, GSPL
has been l ayi ng underground gas
transmission network across Gujarat. At
present around 742 Km of gas pipeline is
under construction. The EPC contract for the
123 Km long 24Natural Gas Pipeline from
Anand (Gana) to Chuda, awarded to L&T, is
the first section (Section A)of the Anand-
Rajkot pipeline laying programme of GSPL.
Project overview
The project envisages setting up of a
! The Pipeline will transport natural gas launching facilities at Gana, six nos. of
high-pressure natural gas pipeline system.
from Anand to Rajkot for domestic, intermediate sectionalized valve stations and
The pipeline system broadly consists of the
automobile, commercial and industrial an intermediate pigging station at Chuda.
following:
consumers.
! ARPL is originating from the existing
Peep hole
L&T's scope as an EPC contractor in this Sectionalizing Valve Station No. 2 of
project includes design and detailed Baroda-Ahmedabad-Kalol Pipeline
The Anand Rajkot Gas Pipeline Project
Engineering, supply and laying of 123 Km (BAKPL) situated at Gana Village of
Section A (ARPL-A) was awarded on 7th July
pipeline, construction and installation of Anand District in Gujarat.
2005 with a tight completion target of 13
months including commissioning and one-
month operational acceptance. This being a
full-fledged high-pressure pipeline, all
parameters right from procurement of all
specialized materials and equipment to
delivery, execution including pipeline laying
and HDD at Sabarmati river, testing and
commissioning of the pipeline needed to be
meticulously planned and executed. With
excellent coordination between site
management, HCP BU at HQ, North Zonal
and Ahmedabad Regional Office, the project
has seen smooth and steady progress till date,
which has earned profound appreciation of
the client.
This project had set tough challenges for
the Site Management which rose to the
occasion by evolving effective strategies and
implementing the same. Following are some
of the strategies the site adopted. This not
only yielded the desired result but also
resulted in achieving the targets as per
schedule.
19
! The thi rd and most i mportant
line team and pipe delivery coordinator. This Strategies adopted
achievement was welder selection and
helped everyone concerned to clearly
their qualification at site. The sub-
understand their role in the activity and ! The contract required approved work
contractors were called and instructed to
facilitated smooth delivery of pipes at site. procedures for almost all activities.
mobilize welders immediately. On
The whole exercise was so well-planned that Hence the first thing the site did was to
arrival of welders, they were interviewed
the actual mainline welding started the very draw up procedures and submit them to
and screened. The welder qualification
next morning on receipt of the first pipe with client for approval. This helped in
activity followed immediately and the
zero loss of time. obtaining approved procedures much
site was ready with welders before the
before the actual start of job, which gave
mainline pipes arrived.
the frontline engineers enough time to Effective resource management
study and understand the procedures.
! Similarly it was ensured that welding
This in turn guaranteed execution with
A project of this magnitude with an asking
machines and other equipment were
absolute conformity with contract
rate of 120 joints per day would generally
received, inspected and made ready
specifications and saved time and cost of
require mobilisation of ample resources.
before the mainline pipes were received
rework and repairs.
Keeping in view the limited resources
at site. All efforts were made for early
allocated to this project, a detailed and
i mport of el ectrodes. El ectrode
! The approved procedures required
effective resource allocation was worked out
qualification tests were also successfully
'procedure qualification'. This meant the
at site. Low-priced and easily available
completed before the mainline pipes
sequence of activities for pre- and post-
alternatives (12t Hydras) to unavailable
arrived.
welding are performed on actual
resources (Pipelayers / Tata320) were
mainline pipes and tested for viability of
mobilised at site for stringing activities.
Unloading and stringing of pipes
the procedure. However, the pipes were
Similarly resources in other activities were
to reach site three months later. So,
allocated in such a manner that the
waiting till then meant a delay of at least It was decided that pipes be directly availability of equipment would help and
one week in start of production because unloaded at site and stringing be done complement the smooth progress of work.
actual job could be started only after simultaneously during unloading. Keeping in This resulted in achieving 120 to 150 welded
Procedure Qualification. view the hundreds of trailer loads of pipes to joints per day.
be received, this task needed close and
To overcome this situation, the clients meticuolous coordination between pipe
Quality assurance
were persuaded to arrange for a small manufacturer and the frontline team. To
quantity of pipes immediately, on which ensure accurate delivery at desired locations,
The site management made it a policy to
we coul d carry out procedure it was decided to depute one of our senior
keep weld joint repair percentage below 2%.
qualification and return them at a later personnel at the manufacturer's works to
To achieve this target, a strategy was
stage. Thus a lot of time was saved and coordinate with site and the transporter, to
established to analyse and find out the root
procedure qualification obtained much monitor progress and expedite third party
causes of repair. Once the root cause was
before arrival of mainline pipes. inspection. As part of this effort, a meeting
found out, the frontline engineers, sub-
was held between the manufacturer, the front
contractor supervisors and welders were
given feedback and advised of the preventive
action to be taken to stop further recurrence
of repair. This was quite educative for the
front line team and helped them achieve a
repair percentage of as low as 1.2%, which is
one of the most commendable achievements
of the project.
ECC's success in the project proves that a
strategy can work only when it is worked out
with a vision at the back of everyone's mind.
The site team worked with diligence in
turning the strategies into concrete results.
The relentless efforts of the whole team with
firm commitment to achieve targets both
quantitatively and qualitatively have been
commendable.
V. Thirumalaisamy
Project Manager
Dev Nandan Das
Planning Engineer
Pipe laying work in progress
20
Horizontal directional drilling for one of the
major crossings
Pipe Lowering under progress

Mora Vapi Pipeline
Gujarat State Petronet Limited (GSPL) is which involved installation of 30 carrier
one of the emerging players in the pipe inside 36 casing pipe.
transportation of gas through pipelines
connecting various supply and demand
Present status
centers in Gujarat and is playing a key role in
the development of Gujarat. GSPL aims to
At the outset of the eleventh month of the
complete approximately 600km pipeline
project, 70% of the work has been
across the state of Gujarat as part of Phase 1
completed. The major works competed are-
of the Gas Grid Project as a service provider
(link between supplier and user) to quench
! 100 Km of mainline welding.
the thirst of the Industries in this region
! 65 Km of Lowering.
(Diversified area coverage). The 128 Km
! Completion of all station civil works.
Mora Vapi Pipeline Project is currently in
! Completion of 22 nos. of cased
installation stage as part of Phase I.
crossing.
! Completion of 5 nos. of HDD
Project features
Constraints faced
Mora Vapi Pipeline project is 30 OD,
128 km long pipeline project which runs
! Due to heavy torrential rains during the
from Mora to Vapi and is considered the
initial phase of the project, the pipeline
most prestigious project in view of the
installation works were affected badly.
industrial development and the presence of
The whole area was flooded with water
mega industries along its course. The project
and the work was at a standstill for
caters to the needs of major industrial areas
around 3 months.
at Sachin GIDC, Navsari, Vapi, Valsad and
highly committed team and available Silvassa.
! HDD works, the most important activity
resources, ECC is confident of completing
of the project, were getting delayed due
The project, valued at Rs.351.9 crore
to unforeseen problems.
was awarded to ECC on an EPC basis with a
the project in time in tune with its reputation. project duration of 15 months. This involved
Challenges
retain the glory created in the past projects. design, procurement, installation, testing
and commissioning of pipeline including
As the completion date is drawing to a
Mukesh Kumar
construction of 2 receiving stations,
close, ECC has the daunting task of catching
Asst. Manager, HCP - BU
launching station, intermediate pigging
with up the progress. With the efforts of a
Ahmedabad Regional Office
station and 5 sectionalized stations and one
tap off station.
Project highlights
! This is the first higher dia (30 OD) EPC
Gas pipeline project in the History of
L&T and the entire pipeline route passes
through cultivated land wherein main
crops are mango, sapota, sugarcane etc.
! The scope of work includes design,
procurement & supply, fabrication,
installation, inspection, testing, pre-
commissioning, commissioning and
performance testing along with
associated works.
! Horizontal Directional Drilling (HDD)
methodology was used for the 12 major
river crossings. HDD works were done
indigenously for the first time in the
pipeline history by 250 t rig specially
procured for this project.
! 33 nos. of cased crossings across canals,
roads, railways were done by boring
21
Aerial view of the Songo Songo Gas Pipeline, Tanzania
Songo Songo Gas Pipeline, Tanzania
The United Republic of Tanzania, Development Corporation (TPDC) and Pan Scope of Work
located in East Africa, is bounded on the African Energy. The World Bank and
north by Kenya and Uganda, on the east by European Investment Bank (EIB) are the Work under LOT-1 comprised detailed
the Indian Ocean, on the south by lenders to the project through the design engineering, procurement, supply,
Mozambique, Malawi and Zambia and on Government of Tanzania. The Total Project transportation, installation, testing, pre-
the west by the Democratic Republic of cost was US$ 350 Million. commissioning and commissioning of:-
Congo, Burundi and Rwanda.
Songas developed Songo Songo gas field ! One 70 MSCFD (million standard cubic
The country's territory includes the in Kilwa District, Lindi Region and invited feet per day) processing plant (2 trains,
islands of Zanzibar and Pemba and other bids for constructing the gas processing each of 35 MSCFD)
Islands including the Songo Songo Island (25 facilities on Songo Songo island and the
km off the country's southern coast) in the pipeline network to transport natural gas to ! Three offshore wellhead structures
Indian Ocean. Dar es Salaam where it will be used as the
principal fuel supply for five gas turbine ! 5 Km of 168.3 mm flowlines from the
When natural gas was discovered in electricity generators. three offshore gas wells to the gas
Songo Songo Island in 1974 the Government processing facility in Songo Songo Island
of Tanzania decided to implement a Gas-to- The pipeline will then continue to supply
Electricity Project for producing power to power to the Wazo Hill Cement Plant. The ! 1.3 Km of 114.3 mm flowlines from the
feed the existing 110 MW gas turbine power project will produce reliable electricity for the two onshore gas wells to the gas
plant. The project implementation was national grid and also bring gas to other processing facility on Songo Songo Island
entrusted to Songas Limited, Tanzania, a industrial users in Dar es Salaam.
local joint venture company formed by ! 25 Km of 12 marine pipeline from Gas
Globeleq (majority stockholder), Tanzania The project was divided into 6 Lots and Processing facility on Song Songo island
El ectri c Suppl y Company Li mi ted L&T were the successful bidders for two lots to the landfall point (LFP) near Somanga
(TANESO), Tanzani a Petrol eum Lot 1 and Lot 2. Funga in Lindi Region
22
LOT-2 involved of final engineering,
detailed design, procurement supply,
transportation, installation, testing, pre-
commissioning and commissioning of:-
! 204 Km 16 dia. Mainline from LFP tie-in
to Ubungo Power Plant in Dar-es-Salaam
including 15 Km flood plain crossing at
the Rufiji River
! 15.7 Km 8 dia. Lateral Spurline from
Ubungo to Wazo Hill Cement Plant
! Metering facilities and Pressure
Reduction Station (PRS) at the Ubungo
Power Station including supply line and
turbine pressure control equipment
! PRS and metering facilities at the Wazo
Hill Cement Plan
! On-Wayleave Restoration and Erosion
Control works
M/s. Granherne of UK carried out the
! 2.45 Km - 12 diameter mainline from ! 440 mtrs. of pipeline section across Rufiji
basic engineering for Songas Limited
LFP to Somanga river was laid by Horizontal Directional
Drilling (HDD) Method
The onshore route selected by Songas
! 15.7 Km - 8 diameter Spurline to Twiga
Limited had minimized the impact on the
(Wazo) Cement Plant at Wazo Hill ! The terrain in upstream of Ubungo
physical and social environment of the
Station and the spur line was highly
coastal area that it passed through.
undulated. More than 1500 cold bends
! One intermediate Pigging Station at
were installed in this 25 Km section
Somanga Funga
Salient Features
! 6 major crossings were completed, of
! 66 Km of Flood Plain designed for Anti-
! 204 Km - 16 diameter main pipeline
which two were railway crossings and
bouyancy measures like 13000 saddle
from IP Station at Somanga to Ubungo
four were road crossings which were
weights and 15 Km of coated concrete
Power Plant in Dar-es-Salaam
executed by Horizontal Thrust Boring
pipes in the Rufiji Flood Plain
Method
! 2 crossings, each 100 mtr wide, at trunk
roads with heavy traffic, were executed
by HDD method
! 9 Main Line Block Valve stations along
the pipeline way leave were built
! Girth Weld Joints were coated with Heat
Shrink Sleeves (HDD portion was done
by DIRAX Sleeves)
! Laying of 223 Km of FOC (Fibre Optic
Cable) along with the pipeline for
SCADA
! Cathodic protection of pipeline: both
temporary (during execution) and
permanent (for 20 years)
! Pressure Reducing Station at Ubungo and
Wazo Cement plants
Pipe line passing through steep area at channel 158
Holiday check being done before lowering of pipeline
23
! Caliper Pigging of 15.7 Km of 8, 2.45 ! A s a cost savi ng method, ! The project was exempted from various
Km of 12 and 203 Km of 16 Lines. documents were exchanged with clients, duties and VAT. Proper planning and
HQ and associates over electronic documentation in the initial stages of
media, viz. e-mail, etc. procurement minimized the difficulties
! Swabbing, Drying, Pre-commissioning &
in clearing the consignments. This also
Commissioning
! In Tanzania, convincing the authorities to helped in our taking full advantage of
issue work permits for the expatriates was exemptions of duties and VAT. VAT paid
! Intelligent Pigging 15.7 Km of 8, 27.45
a major problem. Matter was taken up at for small items, tools & tackles, etc.
Km of 12 (Including Offshore line) and
all levels in the government including the purchased locally during execution was
203 Km of 16 Line
Labour department and immigration subsequently refunded by TRA.
through Tanzania Investment Center.
Songo Songo Gas-to-Electricity project ! Kiswahili, the local language, has a few
Experiences
was one of the biggest projects words similar to Hindi/ Urdu. Picking
completed recently in Tanzania and these words and with the help of local
! This was the first overseas cross-country
hence this was seen as a dream project to drivers who knew a little bit of English,
pipeline project executed by ECC on
overcome the unemployment problems our staff could establish communication
Engi neeri ng, Procurement &
to a large extent. As specialist workmen, and manage the day-to-day works.
Construction (EPC) basis. This is also the
downhill welders, pipeline equipment Training was also given to local workmen
first project for ECC in Africa. As the
operators, radiographers etc. were not in spoken English as well as Kiswahili
proj ect was i n a total l y new
locally available, we could employ the English and Kiswahili.
environment, it posed challenges right
locals in the semi-skilled and unskilled
from the conceptual planning stage to
categories only. However, this point ! Advance Planning and identification of
project management and execution.
needed to be substantiated to the plant and machinery and staff with cross-
Government authorities with the country pipeline experience in India,
l ukewarm response recei ved to coupled with timely completion of
! The project schedule prepared on
recruitment ads in the local media. formalities with Reserve Bank of India
primavera helped in reading out the
Finally, 400 expatriate workmen and 40 (RBI) and other authorities augured well
critical path from time to time and taking
staff were mobilized for this project. for the project.
corrective actions as and when required.
Golden tie-in welding in progress
24
! The terrain was quite difficult and the
The fol l owi ng maj or i tem of
work involved advance planning for
construction equipments were mobilized
fabrication of cold bends to avoid
from India for the execution of this
interruption of work during mainline
prestigious project.
welding.
! Pipe Layers / Side Booms - 18 nos.
! The work in flood plain of 50 Km stretch
! Excavators - 16 nos.
was taken up on top priority and was
! Motor Grader - 2 nos. completed before the onset of monsoon
during November 2003. A mini crew
! Dozer - 5 nos.
was formed to accomplish the task on
! Diesel Welding
time.
Generators - 25 nos.
! Compressor 1100 Cfm - 1 no.
! There were frequent thefts, threats and
! Compressor 600 Cfm - 1 no. dacoities during the execution of this
project on the pipeline route and also in
! Bending Machine - 3 nos.
the camp. The staff and workmen
! Boring Machine - 1 no.
showed courage in facing the situation
! Water Filling Pump - 2 nos.
and kept up their morale.
! Hydro test Pump - 2 nos.
! Laying of Pipeline across the river Rufiji
was cri ti cal for the successful
! Clearing of right-of-way involved cutting
completion of the project. This activity
down some trees through the dense
suffered a setback several times but went
forests. Local workmen and heavy
through successful l y wi th the
construction equipment such as ! 1.5 Km- Intertidal Zone from Land Fall
mobilization of a suitable rig from France.
excavator, dozers, etc. were deployed Point was filled up by the scooping
The work was carried out by HDI, a
for this work which was carried out in method.
specialist agency from France, and was
line with the Environmental Social
appreciated by our client.
Management Plan.
! As an erosion control measure, slope
breakers were provided during lowering
and backfilling.
! The construction work was completed in
time in spite of all the difficulties
encountered. Swabbing, drying and-
commissioning were done in a phased
manner. The mainline, spur line and
pressure reducing station at Ubungo
Power Plant as well as Wazo Hill Cement
plant were commissioned in July 2004.
Commercial production commenced
from July 21, 2004.
! Songas commended the safety standards
maintained by L&T to achieve one
million safe man-hours and issued a
certi fi cate acknowl edgi ng the
performance.
! Financially too the project has done well.
The final contract value was US$
41,269,789.
! Finally, it is worth mentioning that M/s
Songas Limited, owners of the project,
were highly appreciative of L&T's
performance in making their dream
project a reality.
S.N Eachampati
Project Manager
Pradumna Tripathy
Planning Engineer
Pipe floating in bentonite filled trench
Saddle weight installed for anti bouyancy measure
25
Cryogenic Storage Tanks
L&T has acquired a leadership position in
India for turnkey construction of cryogenic
storage tanks and terminals for a variety of
products such as, ethylene, propylene, LNG
and LPG. Cryogenics deals with very low
temperature operations, in the region of
-40 C.
Creating History
L&T has come a long way since its entry
into this new technology arena, way back in
1989 with an award of the first order from
Reliance Industries Limited for turnkey
execution of cryogenic ethylene storage
tanks and terminal facilities at its Hazira
Complex in Gujarat. The project involved
construction of cryogenic storage tanks for
storage of liquid ethylene at -104 C under
atmospheric pressure in 2 x 10000 tonne
capacity double wall tanks along with
unloading facilities, boil-off gas refrigeration
system and send out facility. This project
was executed for Reliance's Vinyl Chloride-
Monomer (VCM) plant on the banks of river
The jetty was designed for unloading operated through hydraulic power system Tapi in Hazira. L&T's scope of work included
ethylene from ocean-going vessels at a flow and electric panel. PUF insulated cross- detailed engineering, procurement,
rate of 600 Cum/hr. The marine unloading country pipelines were used to transport fabrication and erection at site, civil works,
system comprised three unloading arms ethylene from the jetty to tanks. testing and commissioning.
Reliance Petrochemical Complex at Hazira
A propylene storage tank at Hazira
26
L&T completed this project in 1995. It Subsequently, it executed a maiden Building A Track Record
involved cryogenic ethylene receiving, contract for cryogenic propylene storage
unloading, storage and truck loading tank of 10000 tonnes capacity from Reliance
Following the successful completion of
facilities. I ndustri es Li mi ted for i ts Hazi ra
the Ethylene Terminal Facility at Hazira, L&T
petrochemical complex. The storage
secured a contract from Finolex Industries
temperature in case of propylene was
It also included design and construction Limited for setting up cryogenic ethylene
-47.7C. The project was successfully
of import jetty in the open sea, unloading storage tanks and receiving terminal facility
completed in 1996.
facility for ethylene from ships into the cross at Ratnagiri in Maharashtra. The project
country pipelines which carry it to the two involved 2 x 5700 tonne capacity double
ethylene storage tanks, in the first phase for The complete Process engineering wall storage tanks. The jetty was designed for
the requirement for Finolex's PVC Complex activities comprising conceptualization, unloading liquid ethylene from ocean going
at Ratnagiri in Maharashtra. process simulation, process flow diagrams tankers at the flow rate of 280 t/hr.
(PFDs), process control philosophy, P&l
diagrams, thermal design and equipment
sizing were carried out by L&T's Chemical
Plant team of engineers.
This is a landmark project for L&T in
cryogenic storage systems and with the
successful completion of various projects for
cryogenic storage and handling, L&T is now
fully geared up to take up projects on
Lumpsum Turnkey (LSTK) basis in the areas
of ethylene, propylene, LPG and LNG
receiving terminals and storage tanks.
L&T is also proud of successful
completion of Indias first LNG Project at
Dahej with execution of equipment and
piping works at Jetty and terminal area for
Toyo Engineering India Ltd.
Cryogenic ethylene storage tanks built by ECC for Reliance Industries at Hazira
170 m long Open sea jetty for Finolex Pipes Limited, Ratnagiri
27
Panoramic view of underground cavern under construction for SALPG Visakhapatnam
ECC, the Construction Division of L&T is Water Curtain Gallery 15m above the cavern added support of a water curtain gallery.
executing an engineering marvel, deep will maintain the hydrostatic pressure to
down the earth's crust, under a 13-acre ensure leak-proof LPG containment within Construction of underground LPG
greenfield site at the foot of a hillock, named the cavern. caverns calls for an avant-garde technology
Dolphin's Nose, that juts out into the sea at that is gaining worldwide currency as man
Vizag port. Valued at Rs.208 crore ECC seeks to capture and subjugate more territory Above Ground Package
bagged this order in the teeth of stiff for use under land and undersea. The
competition from major domestic and successful completion of this rock cavern will Under this package ECC will construct
international players. patently propel L&T-ECC into the vanguard of all process facilities for unloading bulk
a new business line in India, considering that shipments of propane and butane, blending
South Asia LPG (SALPG) Company a in the near future the creation of more caverns them into LPG prior to transfer into the
50:50 joint venture between Hindustan are envisaged for storage of LPG and crude cavern through the Access Shaft and
Petroleum Corporation Ltd. (HPCL) and oil, the production of which is on the rise. The evacuating it whenever required from the
Total Gas and Power India (TGPI), subsidiary project is thus the cynosure of all eyes in the cavern through the Operating Shaft for
of French oil major Total are the clients for industry. commercial distribution/export.
the project. As a special purpose vehicle
.
SALPG will develop, own and operate this Sunken bulk storage of LPG offers many
India's first
facility. M/s Geostock of France, a world advantages such as safety from natural
leader in underground cavern design, is calamities and various forms of sabotage
The mined bedrock cavern will be
providing the geological and design including bombings during war not to
India's first underground storage facility and
consultancy for the project. The Technical mention the hazards of leakage of the
the world's deepest LPG cavern. The design
Advisor to the project is M/s IDEA-Chennai. inflammable gas besides tremendous spatial
for sub-surface gas storage relies on the
economy when compared to conventional
principle of water pressure in surrounding
ECC is executing this EPC contract, in pressurised spheres and refrigerated tanks
rock being more than the 'escape' pressure
two packages as follows: used for surface storage of the gas.
of the stored gas.Though there are a few such
scattered caverns, they cache either butane
Underground Package Vizag was chosen as the location for the
or propane gas, for which the depth needed
project because of the ideal sub-soil stratum
is 100m to 160m.The SALPG cavern would
This involves construction of a 60,000 t (with highly water saturated hard rock layer of
be storing either butane or/and propane
capacity Underground Rock Cavern -200m minimal joints) for cavern construction that
blended as LPG, which exerts much greater
below sea level for storing LPG together with the chosen site offers in addition to the
escape pressure. Because of this the cavern
attendant Access and Operating Shafts. A advantages of existing port infrastructure for
depth has been extended to 200m, with the
LPG Underground Storage Cavern, Vizag
India's First and the World's Deepest
28
receiving large tankers, high demand in the shafts would also allow access for building Procurement, Constructi on, Pre-
region and along the east coast for LPG and its the ramp and inclined cavern connector Commissioning and Commissioning of the
re-exporting potential to South-East Asia. shafts at three levels: Header, Bench-1 and entire unloading, storage and loading
Bench-2 system, plus various utilities including 33kV
Once the project is operational, LPG transmission line.
distribution will be significantly streamlined A diaphragm wall is constructed in the
and enhanced in the region, especially as overburden section of the soil strata through This also included construction of plant
Vizag Port has an exclusive LPG berth. which the vertical shafts, OS and AS, have buildings, such as DG Room, Electrical Sub-
Imported bulk LPG sourced from refrigerated been sunk. station, Compressor House, 33kV Supply
ships would be piped to the cavern and Station, Maintenance Workshop, Control
evacuation through HPCLs pipeline network Room & Administration building and Water Curtain
as also through the Vizag-Hyderabad Analyser Laboratory as well as seawater
pipeline of Gas Authority of India Ltd. for intake pump house. This also included two This wide curtain of water created 15m
commercial distribution. blast proof buildings. above the Main Cavern with the aid of a
water tunnel having horizontal boreholes,
ECC's scope of supply comprises Process facilities drilled laterally from both sides, is charged
underground and aboveground civil, with bacteria free water to prevent microbial
structural and mechanical works with clogging in the rock cracks. The seepage of This involved procurement and erection
attendant engineering services, which water from these boreholes create over the of imported and indigenous equipment like
include electrical works and instrumentation. cavern a curtain of water that saturates the LPG Unloading Arms, Cavern LPG and
underlying rock, preventing escape of LPG. seepage water pumps, 1.2mV HTDG set,
The Underground (UG) Package LPG Booster Pumps and Sea Water Heat
Exchanger for enhancing temperature of LPG Main Cavern
This involves hard rock excavation, shaft from (-) 21C upto 3C prior to letting it into
sinking, construction of the main cavern and the cavern. The LPG process facilities
This has a overall dimension of 352m in
providing the water curtain which calls for involved erection of marine loading and
length and 20m in width and 20m in height
l,30,000 cu.m of hard rock excavation, unloading arms as also LPG receiving
(equivalent to 6-storeys). The 135168cu.m
34,000sq.m of shotcreting, 115t of rock facilities. Two refrigerated pipelines will
cavern will be hewn out of hard garnet gneiss
bolting and 175t of grouting and comprises connect the jetty area to the heating and
bedrock, 200m below ground. Drilling and
the following salient features: radio control installation to unload butane
blasting methodology is adopted for carving
and propane. It also covers setting up of
out the cavern.
Seawater Heat Exchanger System to heat the Shaft Sinking
flow, in shaft equipment for LPG pump line,
Plugging the Water Curtain Gallery and
seepage water pumps, level measurement
This involves construction of two major the Access/Operating Shafts will be the final
lines, level alarm line, temperature sensors,
vertical shafts - 4m dia Operation Shaft (OS) act that will provide the safety seal after
vent/safety valves etc. and connection to
and 6.5m dia Access Shaft (AS). They provide completion of underground operations.
existing facilities.
shaft-only approach not just for construction
of Cavern and Water Curtain Gallery but
Chittarajan Sahoo
would also serve as conduit for piping in the
The Aboveground (AG) Package
Construction Manager
propane/butane shipments after blending as
LPG through the AS, and piping out of stored
This EPC contract package involved
LPG from the cavern via'the OS. These main
Project Management, Engineering Studies,
Tunnel for SALPG at Visakhapatnam
29
L&T secured an EPC Contract for
365,000 TPA Pure Soda Ash Plant of The
Magadi Soda Company Limited (MSCL),
Kenya against stiff international competitive
bidding. MSCL is a wholly owned
subsidiary of Brunner Mond, UK who are
the second largest producer of Soda ash in
Europe and sixth in the World.
The exiting plant of MSCL in Kenya has a
capacity of 300,000 TPA and exports 90 %
of Soda Ash to South East Asia, India, Middle
East and Republic of South Asia.
This project is funded by International
Finance Corporation (IFC), EIP and Dutch
FMO. Bosch Projects Pty Limited, South
Africa is the Project Management Consultant
appoi nted by MSCL. Akzo Nobel
Engineering b.v, Netherlands is the Process
Consultant and Jacobs H&G, India is the
Detail Engineering Consultant appointed by
L&T for execution of this job. Contract Value
for L&T is USD 58.56 Mn and Project
Duration is 27 months.
Major Quantities/Scope of Work
Mechanical
! Refractory works : 280 t ! LT PCC : 2 Verticals
! Insulation works : 14,000 Sqm ! LT MCCs : 11 nos.
! Excavation : 20,348 Cum
! Triple circuit overhead
! Concrete (all grades) : 10,025 Cum
line : 250 m Electrical
! Shuttering : 22,098 Sqm
! Electrical switchgear
! Structural steel & tank
rooms : 3 nos.
Power distribution for the plant from5.5kv
erection : 2,140 t
! Variable speed drives : 28 nos.
level
! Piping works : 58,718 IM
! Lighting, earthing and
! 5.5kv Switchboard : 11 Verticals
! Equipments erection : 2,625 t
lightning protection : 1 Lot
! 5/3.5 MVA transformers : 2 nos.
! Cabling : 110 Km
(approx.)
Instrumentation
! DCS : 1 Lot
! Field transmitters : 227 nos.
! Mag. flow transmitters : 25 nos.
! Control valves : 141 nos.
! Dust monitoring system : 3 Sets
! Flue Gas Analyser System : 1 Set
General Flow of Engineering
The Magadi Project Cell coordinated the
complete Design & Engg Activities from HQ.
The flow of engineering information
between Engineering Consultants and
Magadi Project Cell is depicted above: (See
Chart)
Magadi Pure Ash Soda Project, Kenya
Flash Calciner area of Magadi Soda project, Kenya
JacobsH&G Mumbai, India
Utilities Consultant,
Mech. Design & Detailed engg
L&T EDRC Civil, E&IDesign
& Detailed Engg
HPD Systems [Veolia]USA
Crystallization
Package
Akzo Nobel EnggNetherlands
Process Consultant
L&T-ECC
Magadi Project Cell
FFEMinerals
USA
GEA Process(L&T Niro)
Baroda, India
Fluid Bed Dryer

Other Vendorsfor
Equipmentsupplies
Magadi Soda Company
L&T ProjectSite,
Magadi, Kenya
30
! Centrifugal Pumps : Sulzer
Procurement Items /Vendors
Pumps, India
! Vertical & Slurry : CH Warman,
Following are the International and
Pumps South Africa
domestic suppliers for some of the process
! Compressors : Ingersoll Rand,
packages:
India
Process Package Vendor
Project Execution Strategy
! Roller Mill & Flash : FFE Minerals,
Project Management, Engineering and Calciner USA
Procurement Services were provided from
! Crystallization
HQ. All structures, Tanks, Product silos and
Package : US Filter, USA
stack were pre-fabricated in Mumbai and sent
! Fluid Bed Dryer : GEA Process
to Kenya by sea under direct supervision of
Engineering
MEAZ. Most of the Project Imports
(L&T Niro)
(equipment, Piping materials, etc) were
! Steam Boiler : Thermodyne
dispatched through Mumbai Sea Port and
India
MEAZ coordinated all these Transport
Other Equipment
logistics with the support from HQ-Materials.
! Classifier/ Settler : HDO, India
Local Civil contractors (from Kenya)
! Kelly Filters/ Sieve
were engaged for all civil works at Magadi.
Bend Screen : HDO, India Specialized Contractors from India with
proven track record were mobilized to carry ! Hydro Cyclones : Krebs
out mechanical works such as structural Engineering,
erection, equipment assembly, erection and USA
Piping. Highly skilled electricians, electrical
! Belt Conveyors : Cobit
fitters and instrumentation technicians from
Engineering,
India were employed for E&I works.
India
A view of the Roller Mill Unit
Pure Soda Ash is obtained by
washing, calcining & crystallizing
the 'TRONA' a naturally occurring
form of Sodium sesquicarbonate,
dredged from Lake Magadi in Kenya.
The alkali deposits of TRONA at Lake
Magadi exist as solid crystals with
interstitial saturated alkaline liquor.
This TRONA is dredged from
the Lake and pumped to Washery
Section of the Plant. At Washery, all
mud and other impurities (insoluble)
are removed with the help of Hydro
cyclones, Classifier and centrifuges.
Screen and Delumper are used to
screen the oversized TRONA and
crush into required size of 8 mm. The
Product coming out of Washery is
called 'Crushed Refined Soda' (CRS),
which contains 97.5% TRONA, 2%
sodium fluoride, up to 0.45%
insolubles, and about 0.05% sodium
chloride.
CRS is then conveyed to Roller
Mill where TRONA is ground to the
size of 105 microns. Using Mill and
ESP Cyclones, TRONA is transported
to Calciner Cyclone wherein
TRONA is made to react with Hot Air
at a temperature of 800 Deg C and all
organics in the TRONA are burnt.
Then the Product (Sodi um
Carbonate) coming out of Calciner
Cyclone is fed in to Crystalliser
Package which comprises set of
Crystalliser (1st & 2nd Stage),
Anhydrous Reactor, set of Elutriator
Legs and Centrifuges (1st & 2nd
Stage). In this section, Sodium
Carbonate particles of size 105
microns are grown into 350-400
micron crystals and Sodium Fluoride
(NaF) is removed (from 2 % to 0.01
%) through Elutriator legs.
These Sodi um Carbonate
crystals are conveyed to Fluid Bed
Drier wherein moisture (both free &
trapped) is removed in Drying and
calcining sections. Then Final
Product is cooled in cooling section
and transported through conveyors
into Product Silo (5000 T Cap).
From Product Silo, Pure Soda
Ash will be bagged through bagging
plant or will be transported in bulk
through Rail wagons.
Soda Manufacturing Process
31
The Cell monitors the progress as well as
cost aspects of the Project and provides
feedback to the Management for
information and corrective action wherever
required. As part of the control measures,
the following activities will also be carried
out.
! Resource deployment for in-house
activities
! Review/ Suggestion to advance certain
milestones activities for better
Utilization of Resources
! Monitoring adequacy of Logistic
services
Site Construction :
Project Site has fully dedicated
Planning Team / Site Engineers under the
Project Manager. The entire team is
working hard to complete the project
within the agreed schedule.
At present, site is going through peak
construction activity and mechanical
completion is expected to be achieved by
mid-June 2006. Pre-commissioning of part
of plant has already started and the project
is expected to be commissioned by mid
August 2006, which is well within in the
contractual completion date.
S. Balasundaran
Manager
Magadi Project Coordinator
K. R. Chandramouli
Procurement Manager
Semi skilled and unskilled workmen Contract Management/Invoicing
required for Mechanical and E&I works were
recruited in Kenya to support the highly
The Magadi Project Cell ensures
skilled workmen from India. Mobilization of
continuous attention and focus to meet
all staff and expatriate workmen from India
various requirements of the contract with
was also well coordinated by MEAZ.
MSC (Magadi Soda Company). Based on the
agreed Billing schedule, the Cell raises
monthly invoices to MSC in line with the
Monitoring &Scheduling
actual progress and covering both onsite and
offsite activities.
Immediately on award of the contract, a
Magadi Project Cell was formed at ECC HQ,
The Cell also identifies and finalises
Chennai to co-ordinate project management
vendors for various offsite activities, in
functions as well as all engineering &
consultation with HQ Finance and Materials
procurement services. The detailed
Departments, and ensures formal release of
scheduling of project activities was done
orders by HQ-Materials.
using Primavera (P3e) software.
Performance Reviews, MIS, Cost
Based on schedule, all activities are
Control
monitored against real time/time elapsed.
The progress is reported every month on the
Job performance review, MIS and cost basis of weightage points allocated against
control also form part of the Cell's functions. each activity/milestone.
Washery Unit at Magadi Soda project, Kenya
Equipment erection in progress
32
ECC secured a lumpsum turnkey (LSTK) activities including erection of the HDS II time. Initially HPCL authorities had some
contract, valued at Rs. 14.30 cr., from HPCL Reactor and its enabling facilities, even as the apprehensions and criticized our new
for execution of civil, Mechanical, Electrical, DHDS - the most vulnerable unit was on erection scheme and insisted on us to follow
Instrumentation works associated with new stream. Therefore, we had to carefully plan the scheme adopted by us for similar reactor
HDS reactor including Residual Process all our activities and take up very limited and at their Mumbai refinery. However, we were
design, Detailed Engineering, Survey, highly essential works like the welding of so very confident in our strategy that, they
Transportation & Erection of reactor, Testing, hook up joints and structural platforms applauded our work on successful
Pre-commissioning and providing Assistance through shutdown of the unit. completion of the erection and remarked it is
for Commissioning and Performance an engineering fete and L&T will do things
Guarantee run of the erected facilities at their The fabrication and supply of the Reactor beyond their imagination.
Visakh Refinery, Visakhapatnam. The was done by L&T-Hazira and this was
overall concept of the project is to produce delivered to HPCL at Visakhapatnam Port. The rest of the activities including shut down
diesel as per Euro III standard. From the port, it had to be transported on activities were completed as per schedule.
24nos. self propelled hydraulic axles by road The residual engineering and detail
An important focus and highlight of this for a distance of 6.5km up to its actual site of engineering was outsourced.
project is the transportation and erection of erection. Since none of the existing plant
HDS II Reactor, which had a height of main roads were suitable for transportation Procurement involved supply of both
34.870m DIA of 5.039m and weight of 475 of such a huge equipment, we had to imported and indigenous materials with in
tonnes. develop some approach roads including an three months. We encountered difficulties in
entrance into the refinery by breaking the procurement of SS sch 80 seamless pipes, as
This was a critical project in every sense of the compound wall. In addition, the existing there were very few manufacturers of these
term, as we had to complete most of the plant roads were also widened and pipes and no one was ready to supply within
strengthened, wherever required. Even a short time. However, we convinced our
though the entrance to the DHDS unit was vendors about the importance of the project
congested, the equipment had to be safely and meeting the deadlines. Through
maneuvered and successfully unloaded at its continuous follow up by a dedicated
location. coordinator and the quality department we
worked in tandem for timely procurement of
Since no heavy lift crane could reach this materials. Also, specialized agencies were
location, the erection was carried out by mobilized for internal fixing and catalyst
Strand Jack Lifting method, an unique loading.
Bitta. Ashok kumar methodology specially designed by our
Construction Manager, HPCL -Vizag
special projects team and the equipment was
lifted and placed in its position in a record
HDS I I Reactor-an erection feat at HPCL, Vizag
33
DHDS plant for HPCL at Vizag. Inset: Erection of HDS II reactor
Selvi J Jayalalithaa, Chief Minister
of Tami l Nadu dedi cated the
comprehensive drinking water supply
and sewerage project to the residents of
Tirupur and nearby villages on Tuesday
February 7, 2006.
Among others Mr. K.P. Anbalagan,
Minister for Information and Rural
Development; Mr. David T. Hopper,
U.S. Consul-General in Chennai; Ms.
Shei l a Pri ya, Secretary, Rural
Development and Water Supply, and Mr.
Sameer Vyas, Managing Director, New
Tirupur Area Development Corporation
were present at the Secretariat, from
where the Chief Minister dedicated the
project.
The N ew Ti r upur Ar ea
Development Corporation Limited
(NTADCL), a public limited company
with private sector participation,
implemented the project. The NTADCL
L&T was engaged for the execution entire network was operated through
entrusted the constructi on and
of the EPC - II contract for the Tirupur SCADA System for effective water
maintenance of the systems to the
water project by the M & M Consortium distribution management.
Mahi ndra & Mahi ndra (M&M)
and the scope of work included:
Consortium on Build, Operate and
! Supply and laying of various kinds of
Transfer (BOT) basis for 30 years. This is
! Water Supply System from the Main pipes:
the first public-private partnership
Balancing Reservoir to the Tirupur
project in the water sector in India.
townshi p, whi ch i nvol ved a) Inside Tirupur Municipality:
construction of 36 Water Distribution DI Pipe - 62 Km; MS Pipe - 12 Km
The new project has a capacity to
Stations (WDS). Each WDS is a b) Outside Tirupur Municipality:
supply 185 million litres of water per day
complement of one Ground Level and DI Pipe - 119 Km; MS Pipe - 36 Km
and services nearly 1000 textile units and
one Elevated-Level Reservoir with c) Industrial Connections: 616 nos.
over 0.6 million residents in and around
pump house and MCC Room. The (HDPE Pipe - 83.5 Km)
Tirupur.
! Sewerage System compri si ng
collection through RCC Pipe
(7 Km) and Stoneware Pi pe
(116 Km) including 4200 manholes
(1.5m x 7m depth); four sewage
pumping stations and one Sewerage
Treatment Pl ant of 15 MLD
capacity.
The major highlights of the work are
constructi on of the Feedermai n
(93.65Km), Distribution System (218 Km),
Concreting (37968 Cum), Steel (3075t)
and Shuttering (99220 Sqm)
The construction work which began
in October 2002 was completed ahead of
schedule.
Master Balancing Reservoir and Water Distribution Station located at Tirupur
500 mm dia RCC sewer pipe laying work in progress
Tirupur Water Supply Project dedicated
34
K
a
l
e
i
d
o
s
c
o
p
e
P
r
jec
s
o
t
C
o
issio
n
ed
m
m
The Kol kata Muni ci pal booster pumps each of 3400 Cum. /hr. responsibility of the client.
Corporation (KMC), in order to meet the and 1800 Cum./hr capacity.
increasing demand for drinking water ! The construction of 6 m deep and
supply in Kolkata, entrusted L&T with a Following are the notable features of the 3000 Sqm area Semi underground
Rs. 24.78 crore Turnkey Contract for the project: Reservoir in the congested area in
construction of 8 MGD (36mld) Capacity the midst of old and dilapidated high
Modern Drinking Water Treatment Plant ! The entire plant was constructed in a rise buildings nearby was a tough job
at Jorabagan Park including Operation restricted area of 7500 Sqm. by which was achieved using sheet
and Maintenance of the same for three adopting space saving Inclined Plate piles to avoid damage to the
years. Settler unit. The construction of structures, meeting high safety
Inclined Plate Settler with Sludge standards.
This plant receives the raw water Scrapper Mechanism for the purpose
from River Hooghly and the treated of clarification of coagulated raw ! The site achieved 1.08 million safe
water is distributed for drinking purpose water uses the parallel plate manhours.
to Nimtala, Chitpur, Sova Bazaar and sedimentation principle by lamella
adjoining areas in North Kolkata. plate arrangement, as per modern With the commissioning of this
technology in replacing clarifiers to project, good quality drinking water is
Construction work began on the minimize space. made available on taps to the major
project in April 2004 and the same was population of North Kolkata eliminating
successfully completed to the entire ! Entire plant is controlled by their dependence on tube wells
satisfaction of the client by January 2006. Programmable Logic Controller ass ociated with high risk of Arsenic
The scope of work involved construction (PLC) backed by SCADA system. contamination.
of collecting well, parshall flume, flash
mixer, flocculation tank, inclined plate ! A children's park and wrestling club L&T also won the appreciation of
settler , rapid gravity filters, underground have been accommodated over the its client and the population of North
treated water reservoir of 15900 Cum. roof of the semi underground Kolkata in recognition of its high quality
and pump house installed with two reservoir, as a part of corporate social work.
Filter House of Jorabagan Drinking Water Treatment Plant
Jorabagan Modern Drinking Water Treatment Plant Commissioned
35
Saint-Gobain Glass India Limited The ancillary structures consisted of the concrete, 3900 tonnes of reinforcement,
commissioned its second float glass line cullet and RMFG, which had a total area 1.20 lakh Sqm of formwork, 2730
on February 17, 2006 at Sriperumbudur, of 14300 Sqm. tonnes of structural steel, 53000 Sqm of
near Chennai. With this the float glass sheeting & cladding, 66,000 Cum of
capacity has been doubled to about The quantum of work involved 1.0 controlled filling and 39,800 Sqm of
1,500 tonnes a day. lakh Cum of excavation, 51000 Cum of soling.
ECC played a vital role in setting up
this plant as well as its first phase project
(completed in 1999), which had a
capacity to produce 650 tonnes of float
glass a day.
The second float line, which went
on stream ahead of schedule on
November 11, 2005, was to have been
commissioned by mid-2006. This 800
tonnes per day plant was executed by
ECC on a 'Design & Build' basis. Having
a total of 1.2 million Sft. of roof area, this
facility is the single largest integrated
glass complex in the Saint-Gobain family
to be set up in recent times in India.
ECC's scope included construction
of civil and structural works for the main
plant and the Zipee-Batch House, which
comprised the furnace (2700 Sqm), float
glass unit (4200 Sqm), annealing plant
(3650 Sqm) and warehouse (2500 Sqm).
A view of Saint-Gobains Glass factory at Sriperumbudur, Chennai
Second Float Glass line Commissioned for Saint-Gobain Glass
36
Maruti Udyog Limited (MUL), including follow-up for obtaining elevation for the entire area of
India's leading car manufacturer, is statutory approvals from local Penthouse. This shed also involved
setting up a Vehicle Assembly Plant for authorities and submission of as-built ancillary structures like paint store,
diesel cars at the new ultra modern drawings on project completion. mixing room, annexe building, paint
industrial model town (IMT), Manesar, body storage and sludge pit.
35 km from its existing factory at ! Construction of the Industrial Shed as
Gurgaon in Haryana. The Project per given design specifications and Major Items of Work
consists of various units such as Press standards. This involved detailed
Shop, Weld Shop, Paint Shop, Assembly planning, mobilization of required ! Earthwork : 72,000 Cum
Shop including Diesel Plant and other resources, sequencing & monitoring ! Concrete works
utility structures. the operations and completing the (PCC & RCC) : 13,150 Cum
project within the specified contract ! Reinforcement : 987 t
MUL entrusted the Rs.35 crore duration. ! Structural Steel : 3,523 t
Design & Construction contract for the
! Brickwork : 1,820 Cum
Paint Shop to ECC, L&T's Construction ! Project Management Consultancy ! Roof Sheeting : 18,423Sqm
Division, on May 19, 2005. This was services on behalf of MUL for ! Side Cladding : 12,231 Sqm
awarded on item rate basis with a execution of the Paint Shop. This ! Roof waterproofing
stipulated completion schedule of 15 involved co-ordination of design & (Cellular concrete
months from June 2005. However, the construction services to ensure the With 3 mm APP
Production area and Penthouse are to be functional requirements of MUL, Membrane) : 17,000 Sqm
ready for functional cccupancy in 12 liaison with the local authorities for ! VDF Flooring : 19,000 Sqm
months and 13 months respectively. obtaining statutory approvals for the ! Internal Plumbing
drawings, day-to-day supervision & Sanitary : 1 Package
and monitoring the construction
Project Information ac t i vi t i es & r eso ur c es;
Project Planning &Execution
implementation of and ensuring the
quality control management system The work i nvol ved desi gn,
The project was initially planned for
and safety procedures during construction and providing Project
completion in 12 months and the
execution and certification of Management Consultancy services for
mobilization was done in right earnest to
measurements of the contractor and execution as follows:
cater to the pace of the project. The
documentation.
construction activities commenced on
! Design & Engineering for the Paint
June 6, 2005.
The Paint Shop, which is an Shop (an Industrial shed), with a
Industrial shed, had a dimension of 190m plinth area of 15,200 Sqm with a
x 80m. This included the production area mezzanine floor of 5,200 Sqm built
which had a height up to 13m; a up area. For this building, ECC had
Penthouse of 4,200 Sqm with 20m height to prepare and submit detailed
and a RCC mezzanine slab at 13 m structural & architectural drawings
Mr. A.K. Tripathi, ECC Project Manager, Maruti Paint Shop Site, receiving the Reward Cheque of
Rs. 100 lakhs from Mr. Tsuneo Ohashi, JMD of MSAIL and Mr. R. Dayal, Chief Gen. Manager of MUL.
Paint Shop for Maruti Udyog
Earned Rs. 100 lakhs bonus for early completion
37
A U I M R T
U U I S Z K

Flo , e a r a h B i ing 5- t r nd Mag , ew lhi 10 1 1th or J ev n P ak s u ld , 2 Kasub a Ga hi r N De 1 00
A U I M R T
U U I S Z K
Flo , e a r a h B i ing 5- t r nd Mag , ew lhi 10 1 1th or J ev n P ak s u ld , 2 Kasub a Ga hi r N De 1 00
In July 2005, MUL expressed their project and resources were organized in a crashing the duration of construction
revised requirement for crashing the systematic manner to achieve the targeted impressed the clients to a great extent.
schedule for functional occupancy by 3 strike rate.
months for Production area and by 4 The various cost control measures
months for Penthouse of the Paint Shop. As a result, all the activities in the adopted at the site resulted in the
L&T agreed to the revised schedule with Production Area & Penthouse were improvement of Financial Parameters of
additional cost implication on account of completed successfully and the areas were the project. In addition, the site
mobi l i zi ng extra resources and handed over to MUL for Functional implemented highest safety standards
completed the work to high quality and Occupancy, 45 days in advance of the and achieved zero accident rate.
safety standards, adopting mechanized scheduled date.
methods. Messrs. Maruti Udyog Limited were
Innovative ideas like providing Metal very pleased with the performance and
The construction operations were Decking instead of conventional Formwork rewarded ECC with a bonus of Rs. 100
sequenced to maintain the pace of the for Mezzanine Slab of 5,700 Sqm area for lakhs and a letter of appreciation.
The bhoomi pooja and market The City Railway Station and bus stand consists of bigger size 2 and 3-bedroom
launch of 'Green Park', L&T's second are within a few minutes' drive from Green apartments, Blocks B, C and D will have
property development project in Park. Though located away from the hustle 2 and 3-bedroom apartments of a
Coimbatore, took place on December and bustle of the City it is close to the hub of smaller size.
11, 2005. Coimbatore.
All the blocks will have basic
Located on a serene setting behind Spread over 1.94 acres of land, Green amenities such as passenger elevators,
the Agri cul tural Uni versi ty off Park comprises four blocks with stilt car DG back-up for common areas and
Marudamalai Road, the project is parks, two blocks being stilt plus seven floors servi ces, chi l dren' s pl ay area,
coming up near prime localities like RS and the other two being stilt plus six floors. In gymnasium, solar heaters and sewerage
Puram and Saibaba Colony. all there will be 136 apartments with a mix of treatment plant. The project, with Mr. R
two and three-bedrooms. While Block A Vasu and Others of Coimbatore as joint
venture partners, i s
expected to be completed
in two years' time i.e. by
the end of 2007.
Bookings are made
in a phased manner and
more than 80% of the
apartments in the first
Block were booked soon
after the launch. Bookings
for the other blocks will
open shortly.
Kharche & Associates,
Chennai are the Architects
while Engineering Design
& Research Centre (EDRC)
unit of ECC are the
structural designers.
For more details contact:
Coimbatore:
0422-2311462 / 2322562
mobile: 9843522204
Chennai: 9444398305
Bangalore:9845331071
Perspective view of Green Park, Coimbatore
Green Park - Coimbatore launched
38
48 Km of PVC pipes of varying diameters period of 15 years. The Project involves
ranging from 200 mm to 560 mm will be widening of the existing two-lane
laid for 40 Km and DI pipes of 8 Km will corridor to four lanes, construction of six
be used for pressure main and associated major bridges, twenty minor bridges, two
L&T secured an order from the Abu
pumping station and related works. Work ROBs, one flyover, fourteen underpasses,
Dhabi Water and Electricity Authority
on the project will commence in March two toll plazas and other wayside
(ADWEA) for the construction of 85 km
2006, and is scheduled to be completed amenities.
long 220 kV transmission lines, against
in 18 months.
stiff international competition. Valued at
L&T will design, engineer, finance,
AED 117.470 million (INRs.144 cr.), the
construct and maintain the above road
project is to be completed in 24 months
stretch for a period of 17.5 years through
from January 2006. Mott MacDonald
a special purpose company formed
are the project consultants.
exclusively for the project - L&T Interstate
ECC has bagged a contract valued at
Road Corridor Limited. Using state-of-
The scope of work involves Rs. 258 crore. from Tata Consultancy
the-art equipment, L&T will construct and
compl eti on of a 220 kV gri d Services (TCS) for executing the main
maintain this project to world-class
interconnection by connecting Sweihan civil works for their new campus at
standards.
440/220 kV Grid Station with Al Hayer SIPCOT IT Park in Chennai, to be
220 kV Grid Station (35 route km) and completed in 18 months. The scope of
Ramah/Al Khazna 220 kV overhead line work involves construction of three
[OHL] (50 route Km). The project also engineering blocks and a general service
involves live line replacement of existing block having a common basement, utility
earthwire / 8 fibre optical fibre ground building, security blocks, AC plant room,
Larsen & Toubro Limited (L&T),
wire (OPGW) by new 32 fibre OPGW for TES tank room and substation comprising
India' s leading engineering and
a length of 92 Km in three different a total built-up area of 2,45,643 sq.m.
construction conglomerate, has bagged
circuits. The main OHL comprises

an Engineer-Procure-Construct contract
double circuit twin aluminium conductor
valued at Rs. 581 crore (37.98 million
steel reinforced (ACSR) 'Dove' conductor
Kuwaiti Dinar) from Kuwait Aviation
with single OPGW.
Fuelling Company (KAFCO) for its new

fuel depot project at Kuwait International
L&T, in consortium with Patel
The towers will be designed in- Airport. To be completed in a stringent
Engineering Ltd., bagged an order valued
house by the Engineering Design and time frame of 24 months, L&T won the
at Rs. 439.07 crore from National
Research Centre, and will be sourced contract through i nternati onal
Hydroelectric Power Corporation Ltd. (a
from the Transmission Line Towers competitive bidding. A subsidiary of
Government of India Enterprise) for the
manufacturing facilities in Pondicherry Kuwait Petroleum Corporation, KAFCO
execution of the 520 MW Parbati Hydro
and Pithampur. On completion of this provides high quality aviation fuel to
Electric Project Stage (III) in Himachal
project, Sweihan Station will be Kuwait International Airport and
Pradesh. The consortium will complete
connected to the 220 kV network maintains the fuel storage facilities in the
the entire project, which includes river
consisting of Ramah, Khazna, Al Hayer, vicinity of the airport. The new project
diversion, rockfill dam, intake, desilting
Dahma, Salamat substations in UAE thus will cater to the expanding needs of the
chambers, 5.8 Km long headrace tunnel
increasing the stability of 220 kV international airport by pumping fuel
and other associated works, within 56
network. through underground pipelines from
months. The project is located in district
Mina Al-Ahmadi Refinery to the storage
Kullu on the Sainj, a tributary of the Beas.
depot.
L&T will be engaged in installation
of new pumping units at MAA Refinery,
Larsen & Toubro (Oman) LLC, a
laying of cross country jet fuel pipeline
Muscat-based subsidiary of L&T, has
ECC, L&T's Construction Division, from the refinery to fuel depot,
secured a Rs. 96.5 crore (RO. 8.210
has bagged its first annuity-based road construction of six 33-m dia and 11 m
million) order from the Ministry of
project from National Highways high fuel tanks at the new storage depot,
Regional Municipalities, Environment
Authority of India (NHAI) through installation of an interconnecting
and Water Resources (MRMEWR) for the
international competitive bidding, for pipeline from the new fuel depot to
construction of a sewage treatment plant
four laning of the 76 km Palanpur - existing hydrant system of the airport,
including a sewerage network at Willayat
Swaroopgunj stretch located on the East construction of headquarters building,
Nizwa, Oman.
West Corridor on NH-14, linking Gujarat providing state-of-the-art depot control

and Rajasthan states. The project valued system with associated instrumentation
The sewage treatment plant, with a
at Rs. 550 crore will be executed in 30 works and the complete electrical
capacity of 5,600 cu.m. per day, will have
months. NHAI will pay the annuity as system including the total power backup
a sewerage network extending over
equated half-yearly instalments for a facilities.
TL Order from UAE
IT Park for TCS, Chennai
Parbati Hydro Electric Project
New Fuel Depot, Kuwait
STP in Oman
First Annuity Road Project
NEW ORDERS
39
Dr. B. Sivarama was adopted to formulate HPC mixtures. Sustainable Sky-cities
Sarma (BSS), A ternary combination of cementitious and Towers in the
DGM & Head materi al s [Cement, Fl yash and Present Millennium.
R&D, made a Microsilica] was formulated to achieve This brought out the
t e c h n i c a l very high strength of greater than 1000 advantages of concrete
presentation at kg/cm2 with very high durability (< 250 over other building
t h e 7 t h Coulombs in Rapid Chloride Penetration materials for design and
I nternati onal Test) and workability limits and was construction of tall buildings. Thermal
Conference on proposed for use in the mega columns of damage and softening in normal concrete
Multipurpose High Rise Towers and Tall high-rise buildings. is quite similar to steel with respect to
Buildings, held at Dubai during temperature level of the elements. The fire
December 10-11, 2005, organized by the protection properties of concrete are at
The paper also outlined the need for
International Federation of High Rise least five times better than those of steel
a holistic approach towards the usage and
Structures (IFHS). The address was on due to inherent property of low heat
understanding of High Performance
Experimental Investigation on High conductivity and the size of concrete
Concrete (HPC) in high-rise buildings.
Performance Concrete (HPC): For Use in member which is generally much larger
Case study projects were also brought out
Mega Columns of High-Rise Buildings. than steel. Therefore, the combination of
for better understanding of HPC
The paper was co-authored by Mr. V. these two effects shows that concrete can
constituents and its characteristics.
Senthil Kumar (VSK), Asst.Manager perform better than steel under high
R&D. temperature exposure.
Mr. S. Veeramani
(Engineering Manager,
The presentati on With distinguished keynote speakers
EDRC) and Mr. Anand
highlighted the results and about 75 peer-reviewed technical
Gupta (Sr. Desi gn
of the experimental papers, this conference offered a valuable
Engineer, EDRC) also
investigation conducted opportunity to exchange latest information
presented a paper on
at L&T Construction on developments in the construction
Future Trends:
Research and Testing industry. It was well attended by
Concrete As The Best
Centre (LTCRTC), practitioners and researchers in planning,
Material For The Design
Chennai, to develop design, construction and management of
And Construction Of
high performance high- tall buildings and towers across the globe.
Tall Buildingsat the same conference.
strength concrete of 1000 Kg/cm2. A
modern approach of mix design of HPC
Their paper focuses on the theme Future
using the principles of particle packing
Dr. K. Natarajan, Head (EDRC- an enabl i ng
TLRE BU), made a Techni cal technology it is
Presentation at the Eighth Annual India m a k i n g a
ESRI User Conference, held during s i gn i f i c an t
December 1 - 2, 2005, at Noida on Use di fference i n
of GIS Techniques for Optimum Routing planning, policy,
of Transmission Line Towers. The and projects that
paper was well appreciated by the make i t an
conference participants, numbering 800, indispensable tool for good governance,
drawn from all fields of engineering. better business, and a healthy planet.
ECC is the first organisation to The Paper was co-authored by Mr.
apply Geographic Information System Shashank Pachhade and Mr. Abdul Hanif
(GIS) technology for transmission lines. Khan, EDRC-TL Design. It focuses on the
GIS is more than a software or importance and need of application of GIS
application, it is a world of digital data, techniques in TL routing and also their
online portals, Web services, and experience of application of this technique
location services that enable access to in one of ECC projects and the learnings
information when and where needed. As derived.
Mr. S. Virapan,
En gi n e e r i n g
Manager, Building
U t i l i t i e s
Competency Cell,
presented a paper
o n L a t e s t
Technol ogi es I n Sewage
Treatment Plants (STP) at the
Pondicherry Engineering College
on November 11, 2005.
Highlighting the importance of
STP as a means to protect
environment, the paper also
discussed on the types of process
involved in sewage treatment
with relevant case studies. The
presentation was well received
by the envi r onmental
engineering students.
International Conference on Tall Buildings, Dubai
GIS Techniques for Optimum Routing of Transmission Lines
Latest Technologies In
Sewage Treatment Plants
e
i
P
a
s
T
ch
n
ca
l
p
er

P
e
resen
t
d
40
Mr. S. Manohar, The paper dealt with the use of using flyash as a substitute for cement had
R&D, presented a flyash (in partial replacement of cement) better strength characteristics and superior
technical paper in roller compacted concrete (RCC) durability than controlled concrete.
on Studies on which is a key material for construction of Studies were also conducted to establish
Roller Compacted dams and pavements and helps step up field density, surcharge required in the lab
Concrete wi th speed of construction of dams. mix to correlate field density, flexural
large volumes of strength and heat of hydration.
Flyash at the Experimental studies conducted by
Flyash India 2005 L&T at its Construction Research and The paper also discusses the
I nternati onal Testing Centre showed that RCC can be experimental results and detailed
Congress, held in designed for M10 and M20 grades with conclusions on the correlation of
New Delhi during December 4-7, 2005, very low cement content. The raw laboratory VeBe time with respect to field
organi zed by Fl yash Mi ssi on, materials used were locally available density, adiabatic temperature rise and
Technology Information, Forecasting and materials and the mix was designed as per strength characteristics.
Assessment Counci l (TI FAC), US Corps method.
Government of India. The paper was About 450 delegates from various
adjudged as the best paper in the In order to obtain maximum government bodies like CRRI, CBRI,
Technical Session on Hydro Power & density, optical packing model was CECRI, CPRI, RRL, academic institutions,
Water Resources Sector. It was co- adopted. The VeBe time was kept construction industry and scientists and
authored by Dr. B. Sivarama Sarma, Mr. between 15 and 25 seconds for easy consultants from Australia, Botswana,
S. Manohar, Mr. R. Inian and Mr. N. workability and to obtain maximum Greece, the Netherlands, Pakistan, Russia,
Raghavan. density. It was found that concrete Turkey, the UK and USA participated in the
mixtures based on particle packing model Congress.
Mr. Arabinda Guha, Regional Manager,
Ahmedabad Region, made a presentation on
Managing Construction Projects - Trends
Present & Future at a seminar organized by
Ahmedabad Management Association (AMA)
on February18, 2006.
The paper, while highlighting the
development attained in last the 50 years,
brought out that there is a lot more to be
achieved in the next 10 - 15 years in various
sectors of Indian economy.
The potential for investments in various
growth sectors, the challenges it throws up and
emerging issues that need to be addressed were
discussed in detail.
The focus was on the need to integrate
various aspects of project management in future
and formulation of an Integrated National Policy
to take a holistic approach to reach the targets.
The presentation was well received by the
audience that included practising engineers,
engineering & management students,
representatives from various government and
private sector organizations.
Mr. Arabinda Guha lighting the lamp to inaugurate the seminar. Other dignitaries
from Left to Right: Mr. Sunil Shah, Secretary AMA, Mr. Surendra Patel, Member of
Parliament, Mr. Safaya, HDFC, Mr. Rajiv Vastupal, President, AMA
Roller Compacted Concrete with Flyash
Managing Construction Projects - Trends Present & Future
41
An international seminar on
Mineral Processing Technology (Towards
excel l ence i n qual i ty & cl ean
environment), jointly organized by the
Indian Institute of Mineral Engineers,
National Metallurgical Laboratory and
Tata Steel, was held at Chennai during
March 8-10, 2006. L&T was one of the
main sponsors of this event. Vedanta
(India), Outokumpu (Germany), FFE
minerals were among the other sponsors.
Prominent International Mineral Engg
companies like Multotech, Bateman
Minerals of South Africa, TZMI, Roche of
Australia and several eminent foreign
scholars and delegates participated in the
seminar.
The event assumed greater
si gni fi cance on the eve of the
announcement of the proposed
construction of Mineral Sands Processing Altogether 160 research & technical carries selected / invited papers by experts
Plant from coastal beach sands by Tata papers were presented and discussed on contemporary topics of Mineral, Coal
group at Thisayanvilai near Tuticorin during the seminar on important topics Processing research and so on.
(Tamilnadu) to produce 500000 tons of like Beach Sand Processing, Mineral
Ilmenite. L&T in consortium with PAH Characterization & Processing, Pyro & Mr. R.P. Das, Sr D.G.M (Minerals &
(Pincock Allen & Holt, USA) and Hydro Metallurgy, etc. An Indo-Korean Metals Business Unit), who represented
Outokumpu (Germany) has been workshop on Waste Recycling in Mineral L&T in the Seminar, served on the
awarded the contract for feasibility & cost Engg was also conducted. A souvenir National steering committee for the
study of the project. released to commemorate the event, event.
Mr R.P.Das Senior D.G.M, Minerals & Metals BU, delivering his address at MPT - 2006
Mr. P. Sivasankaran, Manager, Quality, ECC, Delhi
Region made a presentation on Quality Assurance in
Welding at the National Welding Seminar in the Indian
Institute of Welding (IIW), Bhilai on December 17, 2005. The
paper focuses on quality assurance in welding, process piping
and process vessels. His technical presentation was well
received and the IIW committee presented him a memento in
appreciation of his article and presentation.
Mr. S. Kanappan, Head EDRC - Buildings & Factories,
delivered a lecture on Large Span Structures: Design and
Management organised by Association of Consulting Civil
Engineers (India) at the National Seminar held at Mysore
during February 24-25, 2006. The presentation was well
received and the organizers in a letter of appreciation
expressed that the lecture was extremely interesting and
highly educative.
Mr. P. Sivasankaran, Manager, Quality, receiving the memento
Mr. S. Kanappan, Head EDRC-B&F, delivering the lecture on
Large Span Structures at the National Seminar in Mysore
Mineral Processing Technology 2006
Quality Assurance in Welding
Large Span Structures: Design and
Management
42
The Management instituted the Business Unit-wise. The parameters according to their importance.
Quality Rolling Trophy as an annual considered in picking the winners are:
feature in the year 2002-03. The Trophy product quality, housekeeping, procedure
The winners under this scheme for
has since become a coveted acquisition compliance assessment, customer
2003-04 and 2004-2005 were felicitated
with Business Units enthusiastically complaints and redressal, construction
by Mr. K.V. Rangaswami at a function
competing for it every year. time planned vs. actual, ACE vs. actual
held on April 5, 2006 at ECC HQ,
cost, safety performance and cost of
Chennai. Following are the list of winners.
rework. The final result is the weighted
Participation in the award process The recipients names are given in
average of the various parameters
is voluntary and winners are chosen brackets:
Winners of the Quality Rolling Trophy with Mr. K.V. Rangaswami, including their respective Regional Managers and Senior Executives
Winners of 2004 - 05
Winners of 2003 - 04
Vizag Industrial Water Supply Project, Oberoi Park View Tower, Hazira Port & LNG Terminal Project,
Hyderabad Region (R. Dinakar) Mumbai Region (V.M. Muttur) Ahmedabad Region (M.A. Ashok)
Sidhpur Sanganer Pipeline Project, 200 kV D/C Satgachia-Krishnanagar Telecommunication PDT
Ahmedabad Region 2A Package, Transmission line tower Project,
(A.N. Alagappan) Kolkata Region (A.N. Rana) Kolkata Region (P.R. Lakshmi Narayanan)
Intel SRR1 Project, Satara-Kolhapur Road Project, Al Khoud Interchange Project,
Bangalore Region (L.K. Joseph) Mumbai Region (R.K. Bansal) Oman (A. Sajay Sharma)
Lakshachandi Heights, Shiplift site, TWAD Pollachi,
Mumbai Region (Palwinder Singh) Bangalore Region (Murulidharan) Chennai Region (S. Giridharan)
Microsoft Campus, Primary Piping, TAPP, Supply and erection of LT/HT lines DTC,
Hyderabad Region Mumbai Region (Rajeev Kumar) Laying of cables Pune,
(S. Radhakrishnan / A.A. Shaji) Mumbai Region (Abbasi Saifee)
PTA Project Panipat,
Baleshwar to Laxmannath Road, Delhi Region (P.L.N. Murthy) Sipat Seoni 400 kV
Kolkata Region (A. Chaterjee) Transmission line Project,
Blast Furnace G TATA Hyderabad Region
SVBTC site Kolkata, Steel Jamshedpur, (S.G. Mohanty)
(T.S. Ananthkumar) Kolkata Region (D.M. Shah)
Vemagiri CCPP,
PJMB site Dubai, NTPC-Vindhyachal Plant, Hyderabad Region
(Mr. R. Ethirajan) Delhi Region (N. Devan) (R. Jayachandran)
Quality Rolling Trophy for Performance Excellence
43
A
rd
/R
ew
a
r
s
w
a
s
d
Rewards for team efforts at sites It has become customary to give
have been an annual feature in ECC. away Team Rewards to the winners in a
These are awarded after an evaluation public platform to motivate people and
that takes into account a site's recognise the efforts and commitment of
performance in terms of job complexity, project execution teams. Accordingly at
timely completion, financial parameters, the Annual Day Celebrations of ECC
quality, safety, industrial relations, Recreation Club, Chennai, on January 29,
client/consultant relations, etc. The 2006, Mr. K.V. Rangaswami, Executive
rewards are for best site of the year in Director & Head-Construction, presented
three categories under each of the sectors, the Team Rewards to the team leaders of
the categories being small (contract value: various sites. Following are the sector
Rs.10-25 cr.), medium (Rs.26-50 cr.) and wise recipients of team rewards:
large (Rs.50 cr. and above).
Buildings & Factories BU
Large Category
Intel SRRI Project, Bangalore (54.56 Cr)
Project Manager Lochan K. Joseph
Medium Category
Hosiptal Complex Shillong,
Kolkata Region (49.98 Cr) - Viju Varkhey
Hydel & Nuclear
Medium Category
Khopoli New Water Conductor System,
Mumbai Region (32 Cr)- K.S.R.K. Verma
Power Transmission & Distribution
Medium Category
HVDS Project,
Delhi Region (40.70 Cr) - S.K. Saxena
Industrial Projects & Utilities
Large Category
Sinter Plant #3, Jamshedpur,
Kolkata Region (143.79 Cr) -S. Raja
Medium Category
Sri Sathya Sai Water Supply Project,
Ananthapur,
Hyderabad Region (11.71 Cr)
P.R. Harikrishna
Transportation Infrastructure
Large Category
Shell Hazira Package 5&6,
Ahmedabad Region (328.63 Cr)
M.A Ashok
Mr. Lochan K. Joseph, Intel SRRI
Project, Bangalore
Mr. K.S.R.K. Verma, Khopoli
New Water Conductor System
Mr. S. Raja, Sinter Plant,
Jamshedpur
Mr. Viju Varkhey, Hospital Complex,
Shillong
Mr. S.K. Saxena, HVDS Project,
North Delhi
Mr. P.R. Harikrishna, Sri Sathya
Sai Water Supply Project, Ananthapur
MR. M.A. Ashok, Shell Hazira Work,Hazira Port
Team Rewards 2005 Presented
44
ECC, the Construction Division of Larsen & Toubro Coordinators received the awards from Mr. Chandra Sekhar
Limited, has bagged three awards from the National Safety Sahu, Hon'ble Union Minister of State for Labour and
Council India (NSCI) under the Construction Safety Awards Employment. Mr. K.M. Sahni, IAS, Secretary, Ministry of Labour
Scheme 2005, introduced for the first time in the country. This & Employment, Govt. of India, was present on the occasion.
demonstrates ECC's deep commitment to all-round safety. The
categories of awards and the award-winning sites are: The awards are given in recognition of efforts to develop
and implement highly effective health, safety & environment
(HSE) systems and procedures and achieve outstanding Silver Safety Award
performance in construction projects across the country. Both DHDT & HGU Project, IOCL, Panipat
owners and contractors are eligible to apply for the awards,
which will be given annually under four categories: 1-NSCI Silver Safety Award
Golden Safety Award; 2-NSCI Silver Safety Award; 3-NSCI Intel SRR1 & SRR2 Project, Bangalore
Bronze Safety Award; 4- Commendation Certificate. For ECC it
is a matter of great pride to win these awards in the very first year.
Bronze Safety Award
Microsoft Project, Hyderabad
The criteria for evaluation focus not only on the safety
performance achieved but also on HSE management systems The awards were presented at the inaugural function of the
and proactive measures taken. The applications for the awards 11th National Conference on Safety, Health and Environment on
were evaluated by a nine-member award committee headed by April 5, 2006 at New Delhi. The respective Site Safety
Mr. Kumar Mangalam Birla, Chairman, NSCI. Coordinators, Project Managers and the Regional Safety
Winners of the the Construction Safety Awards Scheme 2005
L&T bags Construction Safety Awards 2005
45
Mr. R. Shankar Raman, Executive Vice President (Finance), L&T,
receiving the award from the Honourable Union Minister of
Company Affairs, Mr. Prem Chand Gupta.
The Institute of Chartered Accountants of India (ICAI),
New Delhi, has adjudged the Annual Report of L&T for 2004-
05 as the second best among the entries received for its
annual competition ICAI Awards for Excellence in Financial
Reporting. L&T received the award in the Infrastructure &
Construction Sector category.
The awards were presented at a function held in New
Delhi on February 2, 2006. Mr. R. Shankar Raman, Executive
Vice President (Finance), L&T, received the award on behalf
of L&T from the Honourable Union Minister of Company
Affairs, Mr. Prem Chand Gupta. The ICAI has been holding
annual competition for awards for excellence in financial
reporting since 1958 to recognize and encourage excellence
in the presentation of financial information so as to promote
highest standards in financial reporting.
L&T has won two Export Awards from
The Project Export Promotion Council of
India. The awards are in recognition of
export projects promoted and executed by
an Indian Company for the year 2004-2005.
Mr.V.B. Gadgil, EVP (Operations), ECC,
received the award from Mr. E.V.K.S.
Elangovan, Union Minister of State for
Commerce, during the awards presentation
ceremony in New Delhi on December 12,
2005. The categories in which L&T won the
export awards are:
! Maximum foreign exchange earned
and repatriated to India from
overseas construction contracts.
! Maximum turnover in overseas
construction contracts.
Mr.V.B. Gadgil, EVP (Operations), ECC, receiving the Project Export Award from Mr. E.V.K.S.
Elangovan, Union Minister of State for Commerce, in New Delhi on December 12, 2005
ECC-Hyderabad Region received the "Best Service Tax
Payer Award" for the year 2005-06 in Hyderabad
Commissionerate-II out of 2000 assesses. The award was
presented to Mr. K. A. Shyamsundar, Regional Manager -ECC
HYRO by Mr. G. Raghu Ram, Hon'ble Judge, High Court of
Andhra Pradesh, who was the Chief Guest at the 63rd Central
Excise Day Celebrations at Hyderabad on February 24, 2006.
Mr. I.J. Rao, IRS (retd.), Member-Central Excise & Service Tax
Appellate Tribunal and Mr. A. Battacharyya, IRS, Chief
Commissioner of Customs and Central Excise, Hyderabad
Zone, were present on the occasion.
This is the second such award received by ECC
Hyderabad Regional Office from the Government, the first
being the Diligent Tax Payer Award for the year 2000-01 from
the Commercial Taxes Department, Government of Andhra
Pradesh.
Project Export Awards
Best Service Tax Payer Award For ECC Hyderabad
L&T's Annual Report Bags Award From ICAI
Mr. K. A. Shyamsundar, Regional Manager ECC - Hyderabad,
receiving the award from Mr. G. Raghu Ram, Hon'ble Judge,
High Court of AP.
46
IMC Ramkrishna Bajaj National Quality Award, 2005
ECC has been awarded the IMC
Ramkrishna Bajaj National Quality
Award for 2005 in the services category.
Mr. K.V. Rangaswami, Member of the
Board and Senior Executive Vice-
President (Operations), L&T, received the
award and certificate from Dr. R.
Chidambaram, Principal Scientific
Advisor to Government of India, at a
function organised by Indian Merchants'
Chamber (IMC) in Mumbai on March 6,
2006.
The award instituted by IMC in
1995, is one of the most prestigious
awards for quality and business
excellence in the country. Modelled on
the Malcolm Baldrige National Quality
Award from the US, it is awarded to
companies that demonstrate outstanding
customer orientation and quality
management systems. Acknowledging
the award, Mr. Rangaswami said it is a
recognition by the Industry for the good
work L&T has been doing.
Amity International Business School, NOIDA, UP, a
well-known institution in the field of research, consultancy
and teaching, has conferred on L&T the 'Amity Corporate
Excellence Award 2006'.
At the Eighth Amity International Business Summit and
Research Conference held on February 22, 2006, Mr. K. R.
Palta, Vice-President (Corporate Affairs), L&T, received the
award.
The International Business Summit held by the School
is an annual event attended by academicians and
distinguished industrialists. This year, Mr. P. C. Jain, CMD of
NTPC, was the chief guest, and Mr. R. P. Singh, CMD, Power
Grid Corporation of India Limited, was the guest of honour.
The award is based on the results of a survey conducted
by a team of students and faculty from Amity Business School
by which they identify the strengths and core competencies
of leading corporates across different sectors in India. The
jury consists of industrialists, scholars and academicians.
This year, the data was gathered through databanks of
renowned research consultancies such as Dun & Bradstreet,
IMRB and the Media such as CNBC.
Mr. K. R. Palta, Vice-President (Corporate Affairs), L&T, receiving the
Amity award
Mr. K.V. Rangaswami, Senior Executive Vice-President (Operations), L&T, receiving the award
and certificate from Dr. R. Chidambaram, Principal Scientific Advisor to Government of India.
Looking on at left are: Mr. M.K. Mohanty, Vice-President & Head-Intl. (East Zone),
Mr. J. Ganguly, Executive Vice-President (Operations)
Amity Corporate Excellence Award For L&T
47
ECC participated in IT Kerala 2006 -
the third edition of the bi-annual event -
jointly organized by the Government of
Kerala and Kerala Infopark during
January 31-February 4, 2006 at Infopark,
Kochi.
ECC's stall in an area of 36 Sqm
displayed photo panels depicting its
expertise in promoting IT and Theme
Parks by L&T Infocity Limited and its
turnkey construction capabilities. Posters
highlighting "Tejomaya'" - the first phase
of the state-of-the-art IT Park in Kochi and
other prime projects promoted and
executed in India and abroad were the
cynosure of all eyes. About 50
companies representing the ICT industry
participated in three different expos
(Connect Biz; Digital Lifestyle Expo and
ICT 4 All). The exhibition was
i naugur ated by Mr . Vakkom
Purushothaman, Hon. Minister for
Finance and Excise, Govt. of Kerala in the
presence of Mr. Ibrahim Kunju, Hon.
Minister for Industries & Social Welfare,
Govt. of Kerala on January 31, 2006.
Both the ministers visited our stall and
were greatly impressed with Tejomaya,
coming up in Kochi. Many visitors
showed keen interest in L&T's first IT
venture in Kochi.
ECC took part in the RACHNA
2006 exhibition organised by the Indian
Institute of Architects at Nagpur during
January 27-30, 2006.
The exposi ti on showcased
innovative trends and materials in
archi tecture, engi neeri ng and
construction. ECC's stall in an area of 160
Sqm di spl ayed i ts engi neeri ng
capabilities with a focus on Ready Mix
Concrete (RMC) and L&T Formwork.
The exhibition was well attended
by practising architects, consulting
engineers, developers, builders and
government officials. Visitors welcomed
the advent of L&T Concrete (RMC) in
Nagpur.
Enchanting view - L&T Stall at IT Kerala 2006
Visitors exchanging pleasantries at ECC Stall in RACHNA 2006
IT Kerala 2006
RACHNA 2006
48
n
E
x
h
ib
itio
s
The Renewable Energy Exposition,
was held in HITEX, Hyderabad during
February 9-11, 2006. ECC took part in the
Expo by taking up a 12 Sqm stall and
displayed its turnkey construction
capabilities in hydropower and irrigation
proj ects, transmi ssi on l i ne and
distribution systems.
The stall highlighted ECCs
strengths in manufacture/supply of wind
mill towers and design and construction
of captive/ combined cycle power plants.
The exhibition was inaugurated by Mr. K.
Jana Reddy, Hon'ble Minister for Home,
Jails, Fire Services, Welfare & Housing,
Govt. of Andhra Pradesh.
Around 50 companies participated
in the event, including some from
Germany, USA and Switzerland.
ECC parti ci pated i n the
International Exhibition and Conference
on Building Materials and Construction
Technologies (BMCT) held at Hall No.7,
Pragati Maidan, New Delhi during March
18-21, 2006.
Organised by FICCI, this expo
offered a unique opportunity for
construction industry to showcase new
products and technologies. ECC took
part in this show and displayed two of its
versatile building products L&T
Concrete and L&T Formwork. In fact,
ECC's stall in an area of 144 sq.m was
made out of vari ous formwork
components and proved to be a major
attraction.
Around 100 organi sati ons
participated in this expo, which was
inaugurated by Mr. Ajay Maken,
Hon'ble Union Minister of State for
Urban Development. The numerous
visitors consisting of construction
companies, builders, developers,
agencies and consultants showed interest
in the application of different formwork
systems and L&T Concrete.
An array of L&T Formwork components on display at BMCT Expo
Renewable Energy gallery of ECC at the Expo
Renewable Energy Expo
Building Materials and Construction Technologies Expo
49
Thebirthcentenary of Mr. Soren Kristian It can truly be
said that much of die Toubrowas celebratedin a solemn andsimple
L&T spirit and the
manner at Holck-Larsen Centre, ECC HQ,
Company's success
Chennai on February 27, 2006 with senior
over the years is
executives and staff members paying floral
attributable, in equal
tributes toMy. Toubroandsilently recallingthe
measure with Mr.
values he espoused and stood by: hard work,
Holck-Larsen, to Mr.
customer serviceandcommitment.
Toubro's efforts and
personal example.
Tomark thebirthcentenary of SKT, a new
buildinghas been namedafter him. Known as the
H e w a s a
Toubro Construction Technology Centre
perfecti oni st and
(TCTC)at ECC-Manapakkam, this new facility
would not tolerate
was formally inauguratedby his son Mr. OleK.
anything not well
Toubro on April 3, 2006. This is the second done. His tenacity,
buildingin thecampus tobenamedafter Mr. doggedness and
determi nati on to Toubro, the first being Toubro Block in ECC
succeed played an
Convention Centre.
important role in
L&T's growth and
Mr. Soren Kristian Toubro, the Co-
success.
founder of Larsen & Toubro Limited, was
born on February 27, 1906. Mr. Toubro, a
He i nduced
qualified civil engineer from Denmark,
people to work hard
came from Copenhagen to India in 1934
by setting an example
to help in erection and commissioning of
h i ms e l f . H e
machinery for cement companies. One of
men t o r ed h i s
the first things he read on landing in India
younger colleagues
was a statement of Gandhiji which reads,
that no effort was too
"(I am) not leading a movement to rid
great to ensure
India of its white colonial masters in order
customer satisfaction,
to substitute them with brown ones."
that there must be
Such an India, Mr. Toubro had felt sure,
Mr. Toubro had great love for India
attention to detail in the quest for
would offer great opportunities to anyone
and used to look forward to his annual
perfection and that there must be pride in
wi th modern technol ogi cal and
trips to the country when he visited
whatever one does.
management skills. And so India became
Kodaikanal, where he had a large house
his home for nearly fifty years.
and estate, now managed by his son. Mr.
Mr. Toubro supervised many of the
Toubro endeared himself to everyone in
company's projects directly and, as an
In 1938, he and Mr. Henning Holck-
L&T and the Group Companies and had
avid photographer chronicled them,
Larsen, a schoolmate and fellow Danish
many friends. He enjoyed the love and
including the bridge and the set built by
chemical engineer, established a firm in
close companionship of his late devoted
the Company in the jungles of Sri Lanka
their names that was die genesis of Larsen
wife, and his children - a daughter and a
for the film The Bridge on the River Kwai -
& Toubro Limited (L&T), India's leading
son. He lived a full and rich life.
the all-time Hollywood classic.
Engineering and Construction major.
From 1946 to 1956, Mr. Toubro was
Like her husband, Mrs. Grete
In 1963, having worked for nearly 25
alternating with Mr. Holck-Larsen as
Toubro too was greatly attached to India
years, Mr. Toubro decided to relinquish
Chairman of L&T.
and lived in her adopted land for the
his executive responsibilities and retire
major part of her life. In fact, her last years
from L&T (Management) Pvt. Ltd., the
On many occasions Mr. Toubro
were spent entirely in India - at
managing agents of L&T at that time. He,
sacrificed personal pleasures for the
Kodaikanal - till the end came.
however, continued to serve on the Board
benefit of the organization, or of an
of Directors of L&T and Engineering
individual, and the same generous spirit
Mr. Toubro had often said, "The
Construction Corporation Limited (a
prevailed when L&T became a Public
secret of happiness is not in doing what
wholly-owned subsidiary of L&T, merged
Limited Company in 1950. He took great
one likes but in liking -what one has to do.
with the parent company in 1984) till
interest and pride in a healthy
There are two ways of being happy - we
1981, after which he returned to
Indianization of the Company and spared
either diminish our wants or augment our
Denmark. On the 4th of March the
no effort to convey and explain his basic
means."
following year, Mr. Toubro breathed his
ideas of sound business and service.
last.
SKT Remembered
on his 100th Birth Anniversary
Mr. Soren Kristian Toubro, (February 27, 1906 - March 4, 1982)
50
u
s
F
n
ctio
n
'CRR at the Peak', a book on Mr.
C.R. Ramakrishnan, former Joint
Managing Director, Larsen & Toubro
Limited, was released at ECC Convention
Centre, L&T, Chennai on Friday, March
31, 2006. The book is an English
rendering of 'Sigarathai ettiya CRR'
written by Mr. S. Ayyadurai and
published by MTS Academy, Chennai,
and released over a year ago. The English
version, by Mr. N.V. Subbaraman, has
also been published by the Academy.
The first copy of the book was
released in a glittering function by Mr. K.
Venkataramanan, whole time Director &
President (E&C Projects), L&T.
Receiving the first copy of the book,
Mr. G.V. Ramakrishna, former Chairman
of SEBI and Disinvestment Commission,
response to the felicitations, Mr. Academy and Mr. S. Ayyadurai also
said Mr. Ramakrishnan, popularly known
Ramakrishnan thanked all the speakers spoke on the occasion while Mr.
as CRR, had built a name for himself and
for their praise and said he was no role Subbaraman proposed the vote of
his company in India and abroad with
model himself but only followed in the thanks.
foresight and vision. He described Mr.
footsteps of the Company's founders
Ramakrishnan as an aristocrat among
Messrs. Henning Holck-Larsen and Mr. The book is priced at Rs.160/- and
technocrats. Mr. S.P. Ambrose, IAS
Soren Kristian Toubro. can be had from M.T.S. Academy, Tamil
(retd.) and Mr. A. Ramakrishna, former
Nadu Open University Information
Deputy Managing Director, L&T,
Earlier Mr. K.V. Rangaswami, Centre, Mangollai, Mylapore, Chennai
felicitated Mr. Ramakrishnan. While Mr.
Executive Director & Head-Construction, 600 004 (tel: 24951415).
Ambrose recalled his association with
L&T delivered the welcome address.
CRR, AR dwelt on the contribution of
Dr. Cheyon, Hony. Secretary, MTS
CRR to L&T right from its early days. In
Mr. K. Venkataramanan, Director & President, L&T, releasing the first copy of the book
At the book release function (from left to right): Dr. Cheyon, Mr. K.V. Rangaswami, Dr. G.V. Ramakrishna, Mr. C.R. Ramakrishnan,
Mr. K. Venkataramanan, Dr. S. P. Ambrose, and Mr. A. Ramakrishana
CRR at the Peak - Book released
51
A new corporate advertising campaign has
been launched from April 10, 2006, with the
objective to reposition L&T as a vibrant company
engaged in high end technology and engineering,
while retaining the existing perception of L&Ts
strengths.
This campaign will indirectly help L&Ts
various business divisions in improving their
market positions through a higher level of brand
recognition. It is also expected to have a positive
impact on financial institutions, market analysts,
investors, government, business partners,
customers and prospective employees.
Ogilvy - the world's leading advertising
agency was commissioned to develop the
campaign and the tagline. It was decided to adopt a
tagline - It's all about Imagineering- to reflect the
nature and character of L&Ts businesses. It
signifies the fusion of imagination with
engineering.
The press campaign in all leading
newspapers, countrywide, will be followed a few
weeks later by an outdoor campaign on
hoardings across 20 cities. Feedback and
comments on the campaign may be sent to
feedback@lth.ltindia.com. These series of
advertisements will heighten the company's
image, improve public awareness and give yet
another reason for L&T-ites to be proud of their
company.
L&T launched a foreign currency convertible bonds
issue denominated in Japanese yen aggregating to
USD 100 million in the international markets on
January 4, 2006. This is the first Japanese yen
denominated convertible bond issue launched in
India.

The zero-coupon convertible bonds have a
maturity of 5 years and are convertible into Global
Depository Shares at a premium of 35% over the
BSE closing share price of Rs.1850.70 on January 4,
2006. The bonds will be listed in an international
exchange.

Proceeds from the bond issue would finance
the capital expenditure plans of the Company and
further international acquisitions. The issue will
augment the Company's resource base as it aims for
accelerated organic and inorganic growth.
L&T Brand Campaign Launched
Its all about imagineering
With L&T Infocity Limited, Hyderabad as the lead partner, the new SPV,
L&T Infocity Lanka Private Limited has developed a 2.0 lakh sq.ft Built-
to-Suit IT Park Facility at Rajagiriya, in Colombo Sri Lanka, close to the
Parliament of Sri Lanka. The facility has been exclusively leased to HSBC
for its BPO operations for an initial lease period of 9 years.

From concept to commissioning, L&T Infocity Limited executed the
entire project and this was commissioned in April 2005. This is first
project of L&T Infocity on a foreign soil and it has immensely contributed
to enhancing its potential as a Business Space Solution provider.
For the year 2005-06, L&T Infocity Lanka Private Limited achieved a
sales turnover of USD 970,615/- profit after tax of USD 425,427/- and
declared a dividend of 20% amounting to USD 340,000/- in its very first
financial year of its operations, proving its success, strength and growth
potential.
L&T Infocity Lanka declares 20% maiden dividend
L&T Launches India's First
Yen Convertible Bonds Issue
Mr.R. Sridaran, Chief Operating Officer, L&T Infocity Limited, Hyderabad, welcoming
His Excellency, Mr. Hamid Karzai, President of Afghanistan during his visit along with
a high level delegation to Cyber Towers in HITEC City on April 11, 2006
52
A view of Technology Centre II for L&T Infotech Limited at Manapakkam, Chennai
ECC, L&T's Engineering Construction & Business Units. It is designed to augment the
Contracts Division, located on Mount existing Centres software development and
Poonamallee Road at Manapakkam in client servicing deliverables.
As the names suggest both are meant for
Chennai, has given rise to two more imposing
technology development in tune with
structures that will join the company of world
changing environment. And, Technology is Built on 1.5 lakh Sq.ft of area,
class, award winning structures in the
the most important source of growth and Technology Centre II is a state-of-the-art
Company's 26 acre sprawling campus. The
productivity, which has a positive impact on structure built to facilitate among other
new structures, with unique architectural and
the prosperity and economy of the society as things, the setting up of offshore
structural design features, are:
well as the nation. development Centres for overseas clients.
Technology Centre II for Larsen &
As Builders to the Nation, L&T has been The building, designed and constructed
Toubro Infotech Limited, having an area of
in the forefront of developing the country's on a turnkey basis, (including interiors) by
14040 Sqm. (1.51 lakh Sq.ft) and Toubro
physical infrastructure for providing shelter, L&T's ECC Division, has a unique shape. The
Construction Technology Centre (TCTC) for
energy and transportation facilities for its basic concept is of an expanding floor plate
L&T Construction Division - 8720 Sqm
citizens, government, industries and to provide a lighter base in harmony with the
(94,000 Sq.ft)
institutions. ECC is a pioneer in introducing existing development in the campus.
several innovative technologies in the field of
Both of these new structures are built by construction and it has always had the cutting
The building has been organized with a
ECC on a turnkey basis and both were edge of competitiveness, when it comes to
central core, containing service facilities with
declared open in a glittering function held in application of modern construction
an organization of plan providing for large
the campus on April 3, 2006. techniques and methods.
column-free office space. All the common
facilities are organized on the ground floor to
While Mr. A.M. Naik, Chairman & provide a secure office space on the upper Technology Centre II
Managing Director, L&T declared open the floors.
new facility TC-II for L&T Infotech, Mr. Ole
This New Software Development Centre
K. Toubro, son of late Mr. S.K. Toubro
The Centre is a ground plus four-storied
of L&T Infotech is a 1300-seat Centre, and is
inaugurated The Toubro Construction
building. The ground floor houses the
located on the Manapakkam campus of L&T,
Technology Centre (TCTC).
corporate facilities like Senate Room,
and will house BFSI and manufacturing
New Facilities opened @ ECC Campus, Manapakkam
Changing environment
53
a
ra
o
n
I n
u
g
u
ti
s
Video Conference room, Executive Food functional requirements as and when need technologies and competencies.
Court, discussion rooms, BMS room and a arises even after 50 years.
300 capacity Multi-purpose Hall. The upper And, TCTC's road map caters to
floors is detailed for housing modular office M/s R. Chakrapani & Sons, Chennai, are the following five critical areas for building
facilities. The terrace houses the service the Architects for this project. competencies and complementing the
backbone facilities like chiller plant, lift efforts of the strategic business units (SBUs) of
machine room, pump rooms and water tank. three major sectors Buildings & Factories,
Soft and hard landscaping has been provided Transportati on I nfrastructure and
around the building to enhance the Developmental Projects. In addition, the
aesthetics. Information Systems Department (ISD)
In the light of the changing economic provides all necessary support for
The innovative and exclusive structural environment, global competition, steady developing the knowledge base through its
system comprises post-tensioned expanded growth and sustainable development, ECC is enterprise information portal (EIP).
polystyrene embedded flat slabs for the main rapidly moving with technology-intensive
All the Competency Cells function as
office areas, supported by central reinforced strategies. ECC believes that knowledge,
independent units in acquiring the required
concrete core and peripheral reinforced competence bui l di ng and modern
knowl edge, ski l l s and devel opi ng
concrete shear walls/columns resting on pile technologies create a sound base for
competency through well structured
foundation. The building is designed for successful growth. It also believes in
training, continuing education and
seismic zone-III with ductile detailing as per keeping abreast of and acquiring/investing in
implementation of standard business
the latest Indian codes of practice and other the long-term building of these vital
practices including use of standard tools
relevant Indian standards. resources for technological development
necessary for successful professional
i ncl udi ng conti nuous uti l i zati on,
practice. Besides, the Cells provide the
The service systems have been designed upgradation and implementation of the
support for technology upgradation, vendor
as per the total load requirement. The entire same.
devel opment, techno-commerci al
building has been provided with centralised
eval uati on of offers, trai ni ng and
air-conditioning, designed for a total tonnage Society today needs faster decisions,
development, scheduling & monitoring of
of 648 TR and air-cooled type screw chillers quick results and high quality at reasonable
project execution.
have been used. The entire building is price. This has resulted in demand for
provi ded wi th automati c anal ogue integration of design, engineering and
Foundation Engineering Competency
addressable fire detection and alarm system construction services including supply chain
Cell (FECC)
and has a 100% power back-up. management to improve productivity.
FECC offers comprehensive services in
The construction is an example of Competency Cells
geo-technical engineering, soil investigation
innovative and pioneering technology and
and recommendations for economical and
the building is architecturally and structurally Toubro Construction Technology Centre
speedy construction of foundations. It has
an outstanding structure. As a result of its (TCTC) has been rightly built to meet the
sophisticated soil and concrete laboratories
unique structural system, the building has the growing needs of the industry and enhance
and site testing facilitates to carry out
flexibility to undergo any modifications in its its performance through developing new
integrity and dynamic load testing of piles.
Toubro Construction Technology Centre (TCTC) at ECC-HQ, Chennai
Toubro Construction
Technology Centre
54
! Building Automation & Fire Protection H aving a total built-up area of 8,736 Sqm Concrete Technology Cell (CTC)
Systems and (94,000 Sq.ft) with a floor plate of 2,800 Sqm
(30,140 Sq.ft) at each level, the building has
This Cell upgrades the skills of concrete
! Public Health Engineering & Finishing 55 cabins, thirteen conference rooms, two
laboratory personnel through intensive
Works. rooms with video conferencing facilities and
training & monitoring to achieve excellence
two 16-passenger capacity elevators for
in concrete products and provide sound
The spectrum of services covers vertical transportation.
solutions for testing of raw materials, mix
complete electro-mechanical services such
design and quality of concrete. It has already
The building has flexible interiors, a main as HVAC, fire protection, building
introduced some new technologies such as
entrance staircase, two fire-escape staircases management servi ces, verti cal
lightweight foam concrete for the housing
and all service facilities. At present the transportation, surveillance and security
project in Haldia, self-compacting concrete
building has about 600 occupants. systems, communi cati on networks,
for Delhi Metro and Khopoli Hydropower
electrification, kitchen, laundry, water and
Project, and polymer modified concrete for
TCTC houses offices for the following
effluent treatment, plumbing & sanitary,
HSBC buildings in Visakhapatnam and
business sectors, competency cells and
landscaping and horticulture etc.
Colombo.
departments:
Quality Management Competency Cell
Formwork Competency Cell for
Ground floor
(QMCC)
Execution (FCCE)
Global Engineering Services, a full-
Through wel l -structured qual i ty
FCCE handles all formwork operations of
fledged Laboratory for L&T Construction
management systems, QMCC ensures good
ECC including Slipform technique of
Research & Testing Centre (LTCRTC) and an
quality, safety, and reliability at every stage of
continuous construction for all vertical
archives area of 225 Sqm.
construction including cost control, with a
structures, Tunnel Form operations, by
view to enhancing customer satisfaction and
which room size walls and slabs are cast
First floor
continuous improvement, thus adding value
together, like a portal in a single pour of
to the stakeholders.
concrete. It also provides the knowhow for
Bui l di ngs & Factori es Sector,
Prestressing of long span bridges, building
Transportation Infrastructure Sector,
frames and floor slabs as well as marine
Developmental Projects Sector and
structures, roads and runways.
competency cells for: Building Utilities;
Concrete Technology; Formwork; and
Building Utilities Competency Cell
The Toubro Construction Technology
Quality Management.
(BUCC) Centre (TCTC) is a simple and elegant,
rectangular three-storeyed (ground + two
Second floor
floors) structure conceptualised by Messrs. R. BUCC functions in three specific areas, viz.:
Chakrapani & Sons (architects) and designed Hydel & Nuclear Power Projects Sector,
! by L&T's Engineering Design & Research Heating, Ventilation & Air Conditioning Foundation Engineering Competency Cell
Centre (EDRC). (HVAC), and Information Systems Department.
TCTC - Structural Features
Interior view of the work stations at Toubro Construction Technology Centre
55
Printed by Srusti A & C, #37, Venkataramana Colony, Khairatabad, Hyderabad-500004. Mobile: 9885091119. Edited by Mr. V.S. Ramana for Larsen &
Toubro Limited - ECC Division, from ECC - HQ., Manapakkam, Chennai - 600 089. The views expressed in this magazine are not necessarily those of
the management of Larsen & Toubro Limited. The contents of this Magazine should not be reproduced without the written permission of the Editor.
Not for sale-only for circulation among the employees, business associates and customers of ECC - L&Ts Construction Division.
At the inauguration of TCTC building at ECC Campus in Chennai on April 3, 2006: Mr. Ole K. Toubro (son of late Mr. S.K. Toubro, Co-founder of
L&T), Mr. A.M. Naik, Chairman & Managing Director, L&T, Mr. C.R. Ramakrishnan, Former Joint Managing Director, L&T and Mr. K.V. Rangaswami,
Executive Director & Head Construction, L&T
At the inauguration of Technology Centre II of L&T Infotech Limited at ECC Campus in Chennai on April 3, 2006: Mr. A.M. Naik, Chairman &
Managing Director, L&T, Mr. K.V. Rangaswami, Executive Director & Head Construction, L&T, Mr. N.M. Desai, Former Chairman, L&T, Mrs. Dana
Toubro (wife of Mr. Ole K. Toubro), Mr. C.R. Ramakrishnan, Former Joint Managing Director, L&T, Mrs. Anjani Desai and Mrs. Geeta Naik