January-March 2006

IN THIS ISSUE

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 hydrocarbon projects, 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 p r o j e c t s . I t h a s e n g i n e e r e d , manufactured and delivered world-class p l a n t a n d e q u i p m e n t ; o f f e r s comprehensive construction services and provides the complete range of eng ineer ing serv ices inc lud ing procurement and commissioning 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, which has made a s ign i f icant contribution to the development of country's hydrocarbon industry.

V.S. Ramana

K. Sridharan Alex BenjaminV.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 2006Vol.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 country’s 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

Digboi in nor th -eas t India . Af ter 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 development, production, refining, norms.marketing, distribution - was controlled by the various public sector companies in the Natural Gasfield.

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

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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 C o n s t r u c t i o n D i v i s i o n , o f f e r 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 o f fe r in teg ra ted eng ineer ing 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 engineering, project 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 ProjectsLNG 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 we l l known commi tmen t t o t he Larsen & Toubro Limited'clean fuel' projects. 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).

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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 compet i t ion through internat ional 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 Contributiona lmos t a l l the re f ine ry p ro jec t s , 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

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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

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E&C Division has successfully executed Infrastructure at MFF: projects for international clients such as Kuwait National Petroleum Company Area

L & T h a s s t a t e - o f - t h e a r 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 de l i ve ry , wh i le ensu r ing cos t ! Piping shops : 1,900 Sqm competitiveness. L&T's manufacturing ! Covered stores : 1,500 Sqmunits 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 mfrom 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 equipmentAsia, 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 reelsspecifications API 5L and API 2B.

Engineering & Manufacturing Capabilities

A view of L&T’s Hazira works on the banks of the river Tapi

Modular Fabrication Facility

Heavy Engineering

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! Technology eva lua t ion/ l icensor 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 Knowing t he po t en t i a l f o r 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 ServicesCorporation 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&T’s Hazira Works for Oil & Natural Gas Corporation

L&T-Chiyoda Limited

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! Construction of LNG terminals and LPG ...contd. from page 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 inc lud ing spec ia l i zed we ld ing 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. Ramkumarranging from 12” to 30” in diameter and

mounted bullets and horton-spheres General Managernow 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

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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 major , d ivers i f ied , 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 Plantand 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 IOCL’s refinery, Panipat

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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 World’s Largestinvestigation. 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 Pipingcommissioning, 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 Chambersarea 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

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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 co n v e n t i o n a l man ag e me n t s t y l 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

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! 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 SqmKVA- 12 nos., Batching plant 20 cubic /Hrs- ! Impulse Piping : 2225 Tags Major resources employed1 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 & HeatersInstallation : 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 IOCL’s refinery at Panipat

2 x 70000MTPA capacity hydrogen reformer (the biggest reformer in Asia)

Major quantities

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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 tprocess gas leaving the tubular reformer ! Structural : 822 tpasses through a waste heat boiler (RG ! Ducting (CS) : 406 tBoiler), where saturated HP steam is ! Ducting (AS) : 335 tproduced. This process gas is again cooled ! Stack : 862 tin a BFW pre-heater. ! CS Piping : 33245 ID

! Jacket Piping : 65434 IDThereafter, the process gas enters ! S.S Piping

Hydrogen generation unit (HGU) for further (Heavy) : 1981 IDheat recovery and finally it is sent to PSA ! A.S. Piping : 2251 IDsystem for purification to produce 99.99% ! Piping supports : 34 tpure Hydrogen. ! Inlet distributor : 224 ID

! Inlet hairpin tubes : 960 IDThe waste heat generated by the fuel gas ! Catalyst tube : 2400 ID

and let out from the reformer furnace, has a ! Cold collector : 984 IDtemperature of around 1060°C. 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

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To: pr-krishnamoorthy@enc.ltindia.comFrom: MANOHARANC@iocl.co.inDate: 11/21/2005 03:16PM

Subject: Safe and successful commissioning of Hydrogen Unit

November 21, 2005Dear 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. ManoharanGeneral Manager(T)Panipat Refinery

October 2003 and were completed on granite, tiles and Burma teak for doors, is PTA PlantNovember 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 Crore3,800 workmen and extended working L&T's largest EPC contract to date. The

! Constructionhours in such weather itself is a great success of the project is due to the synergy Value : 200 Croreachievement. 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 Cumrest sheds during summer, free refreshments says that for the first time in projects involving during peak period. PTA Plant comprised ! Earth Filling : 140000 CumE&C and ECC, it was jointly decided to have construction of Plant buildings, Process Plant ! Concreting (Exclthe Resident Construction Manager (RCM) and Warehouse. Every building has some from ECC instead of E&C as in the past, and Piling & Pavement) : 42000 Cumunique components not seen in other the change has yielded good results. He ! Pavement : 67000 Cumconventional 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 SqmDivisions 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, ErectionDas, Executive Director (Projects), IOCL, had Panipat they had special requirements. The & Painting : 9500 tthis 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 IMwalls while the console room was made ! Above Ground Piping : 500000 IMsoundproof 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 IDarchitectural finishes and electrical fixtures & was started in February 2003. Actual ! Equipment Erection : 4650 tfittings and clad with superior quality marble, construction activities stabilised from

State-of- the-art control room for IOCL’s PTA Plant at Panipat

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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 single LTA. This is a marvelous 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

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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-Res idue (VR) and o ther res idua l 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 9.83x5.96x13 Turbine skid 87.1 105.016 13.29x6x4.734 Base frame 3 for

generator 37.6 105.016 11.97x6x5.345 Compressor skid 122.5 105.016 8.11x5.21x5.316 Generator 48.8 105.016 ~4x~4x~4.757 Expander & gear 33.05 105.016 ~5.5X~4X~4.75

Basic methodology / sequence of erection

With ref to ground lvl.*

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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 site 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

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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 IOCL’s future projects at 2005 while the mechanical completion was ! Excavation : 115080 Cumother locations. For design/engineering of achieved on September 30, 2005. ! RCC & PCC : 27480 Cumstructural items L&T-Chiyoda, EDRC and an ! Steel : 1750 texternal agency were engaged. IOCL awarded the site the best safety ! Shuttering : 80000 Sqm

performance trophy for achieving 4 million ! Waterproofing : 6015 SqmMr. Anil Kumar Bansal (AKB), lost time, injury-free manhours. ! Piping Fabrication : 58011 ID

Construction Manager, says that almost 70% ! Piping erection : 38075 IMof 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 Rmeven greater attention to safety aspects. special equipments like sludge thickener and ! Electrical cabling : 29950 RmHowever, by fabricating and assembling the belt filter press. One of the special features of ! Instrumentationentire coke drum structures in modular form, the plant is that it has zero discharge of waste cabling : 19875Rmthe 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 PlantHowever, 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 inc luded pro jec t and managing the situation efficiently. Thus, successful execution of this project, ECC will managemen t , de s i gn /eng inee r ing , ECC completed the project and handed over be well placed to secure similar project procurement, manufacture, supply, t h e p u m p h o u s e f o r i m m e d i a t e orders in future. transportation, storage, fabrication,

Major quantities

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Welding in progress

Trenching and laying of pipes

The Anand-Rajkot Pipeline Project123 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 laying 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 24” Natural 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 holeL&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.

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! The th i rd and most impor tant line team and pipe delivery coordinator. This Strategies adoptedachievement 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 import of electrodes. Electrode ! 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 pipesthe 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 assurancewere 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 could 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. ThirumalaisamyProject Manager

Dev Nandan DasPlanning Engineer

Pipe laying work in progress

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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 statuscenters 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 HDDProject features

Constraints facedMora 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 completingof 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 Challengesretain 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 Kumarconstruction of 2 receiving stations, close, ECC has the daunting task of catching Asst. Manager, HCP - BUlaunching 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

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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 Worklocated 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 structuresIndian 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 Islandof 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 Islandentrusted 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 Electr ic Supply Company Limited L&T were the successful bidders for two lots to the landfall point (LFP) near Somanga ( T A N E S O ) , T a n z a n i a P e t r o l e u m Lot 1 and Lot 2. Funga in Lindi Region

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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 LimitedLFP 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 sectionSomanga 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

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! Caliper Pigging of 15.7 Km of 8”, 2.45 ! A s a c o s t s a v i n g m e t h o d , ! 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 E n g i n e e r i n g , P r o c u r e m e n t & 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 pro jec t was in a to ta l ly 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, lukewarm response received 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 fo l lowing ma jo r i t em o f 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 Weldingtime.

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 crit ical 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 th rough succes s fu l l y w i 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 ce r t i f i c a t e acknowledg ing t he 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 EachampatiProject Manager

Pradumna TripathyPlanning 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 Recordinvolved 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. Indus t r ies L imi ted for i t s 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 -47.7°C. 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 India’s 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 Packagebagged 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 firstfacility. 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, VizagIndia's First and the World's Deepest

28

receiving large tankers, high demand in the shafts would also allow access for building P r o c u r e m e n t , C o n s t r u c t i o n , P r e -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 facilitiesdrilled 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 (-) 21°C upto 3°C 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 Sahoowould 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 appointed 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 from 5.5kv 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

Jacobs H&G Mumbai, IndiaUtilities Consultant,

Mech. Design & Detailed engg

L&T EDRC Civil, E&IDesign & Detailed Engg

HPD Systems [Veolia] USACrystallization

Package

Akzo Nobel Engg NetherlandsProcess Consultant

L&T-ECCMagadi Project Cell

FFE MineralsUSA

GEA Process (L&T Niro) Baroda, India

Fluid Bed Dryer

Other Vendors for Equipment supplies

Magadi Soda Company

L&T Project Site,Magadi, Kenya

30

! Centrifugal Pumps : Sulzer Procurement Items /Vendors Pumps, India

! Vertical & Slurry : CH Warman,Following are the International and Pumps South Africadomestic suppliers for some of the process

! Compressors : Ingersoll Rand, packages: India

Process Package VendorProject 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

IndiaMEAZ 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 USAPiping. 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 P roduc t ( Sod ium 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 Sodium 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. BalasundaranManager

Magadi Project Coordinator

K. R. ChandramouliProcurement Manager

Semi skilled and unskilled workmen Contract Management/Invoicingrequired 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 & Schedulingactual 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

Controlmonitored 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 kumarmethodology specially designed by our Construction Manager, HPCL -Vizagspecial projects team and the equipment was

lifted and placed in its position in a record

HDS II 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 o f Tami l Nadu ded ica ted 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. She i l a P r iya , Sec re ta ry , Rura l 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.

T h e N e w T i r u p u r A r e a 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 construction 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.Mah indra & Mahindra (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.t o w n s h i p , w h i c h i n v o l v e d a) Inside Tirupur Municipality: construction of 36 Water Distribution DI Pipe - 62 Km; MS Pipe - 12 KmThe 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 Kmand 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 compris ing collection through RCC Pipe (7 Km) and Stoneware Pipe(116 Km) including 4200 manholes (1.5m x 7m depth); four sewage pumping stations and one Sewerage Treatment Plant of 15 MLD capacity.

The major highlights of the work are construct ion of the Feedermain (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

Kale

idosc

ope

Pr jec s o t

Coissio

ned

mm

T h e K o l k a t a M u n i c i p a l 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 a ss oc iat ed 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-Gobain’s 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 Workconsists of various units such as Press standards. This involved detailed Shop, Weld Shop, Paint Shop, Assembly planning, mobilization of required ! Earthwork : 72,000 CumShop 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 CumPaint Shop to ECC, L&T's Construction ! Project Management Consultancy ! Roof Sheeting : 18,423SqmDivision, on May 19, 2005. This was services on behalf of MUL for ! Side Cladding : 12,231 Sqmawarded 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 Sqmready for functional cccupancy in 12 liaison with the local authorities for ! VDF Flooring : 19,000 Sqmmonths and 13 months respectively. obtaining statutory approvals for the ! Internal Plumbing

drawings, day-to-day supervision & Sanitary : 1 Packageand monitoring the construction

Project Information a c t i v i t i e s & r e s o u r c e s ; Project Planning & Executionimplementation of and ensuring the quality control management system The work involved design, 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 UdyogEarned Rs. 100 lakhs bonus for early completion

37

A U IM R TU U IS Z K

Flo , e a r a h B i ing 5- t r nd Mag , ew lhi 10 11th or J ev n P ak s u ld , 2 Kasub a Ga hi r N De 1 00

A U IM R TU U IS Z K

Flo , e a r a h B i ing 5- t r nd Mag , ew lhi 10 11th 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 mobilizing 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 Agricultural Universi ty of f 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 services, children's play 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 ven tu re pa r tne r s , 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

comple t ion o f a 220 kV gr id 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 con t r ac t t h rough in te rna t iona l 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 Sa rma (BSS ) , A “ternary combination” of cementitious and Towers in the DGM & Head ma te r i a l s [Cement , F lyash 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 n t e r n a t i o n a l 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 . Vee r aman i

(Engineering Manager, T h e p r e s e n t a t i o n With distinguished keynote speakers EDRC) and Mr. Anand highlighted the results and about 75 peer-reviewed technical Gupta (S r . Des ign 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 “ F u t u r e T r e n d s : Research and Testing industry. It was well attended by Concrete As The Best C e n t r e ( L T C R T C ) , 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 Buildings” at 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- a n e n a b l i n g TLRE BU) , made a Techn ica l technology it is Presentation at the Eighth Annual India m a k i n g a ESRI User Conference, held during s i g n i f i c a n t December 1 - 2, 2005, at Noida on “Use d i f f e rence in of GIS Techniques for Optimum Routing planning, policy, of Transmission Line Towers”. The and projects that paper was well appreciated by the m a k e i t a n 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, E n g i 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

T e c h n o l o g i e s I n S e w a g e 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 b y t h e e n v i r o n m e n t a l engineering students.

International Conference on Tall Buildings, Dubai

GIS Techniques for Optimum Routing of Transmission Lines Latest Technologies In Sewage Treatment Plants

ei

Pas

T chn cal per

Pe

resent 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 with 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 n t e r n a t i o n a l 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 o rgan ized by F l ya sh Mi s s ion , materials used were locally available density, adiabatic temperature rise and Technology Information, Forecasting and materials and the mix was designed as per strength characteristics.A s s e s s m e n t C o u n c i l ( T I F A C ) , 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 lence in qual i ty & c lean 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 significance 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 mementoMr. 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 RegionSVBTC 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

Ard /Rewar s

wa sd

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, KhopoliNew 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, BangaloreBronze 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 awardand 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 n a u g u r a t e d b y M r . V a k k o m 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 expos i t ion showcased innovative trends and materials in a r c h i t e c t u r e , e n g i n e e r i n g a n d construction. ECC's stall in an area of 160 Sqm disp layed i t s engineer ing 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

nExhibitio

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 projects, t ransmission l ine and distribution systems.

The stall highlighted ECC’s 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.

E C C p a r t i c i p a t e d i n t h e 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 various formwork components and proved to be a major attraction.

Around 100 organ i sa t ions 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

The birth centenary of Mr. Soren Kristian It can truly be said that much of die Toubro was celebrated in a solemn and simple 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 to My. Toubro and silently recalling the measure with Mr. values he espoused and stood by: hard work, Holck-Larsen, to Mr.

customer service and commitment.Toubro's efforts and personal example.

To mark the birth centenary of SKT, a new building has been named after him. Known as the H e w a s a Toubro Construction Technology Centre perfectionist and (TCTC) at ECC-Manapakkam, this new facility would not tolerate was formally inaugurated by his son Mr. Ole K. anything not well Toubro on April 3, 2006. This is the second done. His tenacity, building in the campus to be named after Mr. doggedne s s and

determinat ion 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 H e i n d u c e d 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 m s e l f . H e machinery for cement companies. One of m e n t o r e d 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 g r e a t t o e n s u r e 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 with modern technological 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)

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us

F nction

'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&T’s strengths.

This campaign will indirectly help L&T’s 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&T’s 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 LaunchedIt’s 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 Centre’s 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

ara on

In ugu 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 T ranspor ta t ion In f ra s t ruc tu re 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 building and modern knowledge, ski l ls and developing 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 inc lud ing con t inuous u t i l i za t ion , 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.deve lopmen t , t e chno - commerc i a l building has been provided with centralised evaluation of offers, t raining 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

provided with automatic analogue 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 m a n a g e m e n t s e r v i c e s , v e r t i c a l 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, communication 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 well -s tructured quali 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 floorcontinuous improvement, thus adding value together, like a portal in a single pour of to the stakeholders.concrete. It also provides the knowhow for Bu i ld ing s & Fac to r i e s Sec to r ,

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&T’s 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