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Nuclear Power

10 CFRpart 50appendix B

10 CFRPart 71

10 CFRPart 72

10 CFRPart 21

Larsen & Toubro Limited, Heavy EngineeringPost Box 8901, Powai Campus, Mumbai 400 072, INDIATel: 6705 2526, 6705 2630, 6705 4146nuclearteam@Larsentoubro.com

www.Larsentoubro.com

Corporate Sustainability

A Tribute to Henning Holck -Larsen

Safety

Five Star rating for Health & Management System by British Safety Council, U.K.

A brand of Larsen & Toubro Limited

The Company Today, Larsen & Toubro Limited is a leading engineering, construction and technology company with global operations.

A strong, customer-focussed approach and the constant quest for top-class quality have enabled L&T to attain and sustain leadership in its major lines of business for more than seven decades.

L&T has a global spread of offices, and works closely with leading international consultants. For the past two decades, L&T has been supplying Heavy Engineering equipment to prestigious customers, including Fortune 100 companies. Engineering and construction projects have been executed in the Middle East, the African sub-continent and South East Asia.

Larsen & Toubro is one of the most remarkable success stories in industry. The company owes its name, origin and history to two enterprising Danish engineers, Henning Holck-Larsen and Soren K. Toubro. They came to India in 1938 set up a small partnership firm in Mumbai.

A Global Presence

OfficesEngineering & Construction ProjectsProduct & Equipment SupplyManufacturing / Fabrication FacilitiesAgents

Note: Map is broadly representative of L&T’s presence in markets worldwide.For details of establishments within India, please refer to ‘Nationwide Network’.

Nationwide Network

Registered OfficeCampus OfficesKnowledge CityLeadership Development AcademyConstruction Skills Training Institutes*

*Part of L&T’s Corporate Social Initiatives

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CHANDIGARH

GHAZIABAD

NEW DELHI

FARIDABAD

JAIPURLUCKNOW

AHMEDABAD BHOPAL

PITHAMPURVADODARA

ANKLESHWAR

HAZIRA

MUMBAIPANVEL

LONAVALA

AHMEDNAGAR

TALEGAONPUNE

NAGPUR

JAMSHEDPURKOLKATA

ROURKELA

BHUBANESWAR

VISAKHAPATNAM

HYDERABAD

BANGALORE

MYSORE

COIMBATORE

KOCHI

KATTUPALLICHENNAI

KANCHEEPURAMPUDUCHERRY

GUWAHATIJODHPUR

JAMNAGAR

RAJKOT

UDAIPUR

RAIPUR

RANCHI

VIJAYAWADA

GOA

MADURAI

CUTTACK

BAHADURGARH

SURAT

DURGAPUR

HUBLI

CHANDIGARH

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Nuclear Power Peer Recognition

L&T's performance in operational safety, export, environment conservation and human resource development has been widely acknowledged by professional bodies.

• Ranks among the Top 10 in Environment, Social andGovernance Performance on S&P ESG India Index (S&P, CRISIL & KLD), 2012

• Won National Award for Export Excellence fromEngineering Export Promotion Council of India in 2012

• Won CNBC TV18’s Infrastructure Excellence Awardin 2012

• CII-ITC Sustainability Award received at the hands ofthe President of India for L&T’s Hazira ManufacturingComplex in 2013

• Ranked world’s 9th most innovative company byForbes Asia 2012

• Emerged among Top 5 ‘Best Companies to Work For’in Business Today survey in 2013

L&T has been supplying critical equipment and systems for the Indian nuclear power programme since the mid-1960s.

A pioneer in the field of manufacturing technology development, equipment manufacture and site / plant services for the Indian nuclear power plant program, L&T is a recipient of the prestigious INS Industrial Excellence Award for outstanding contribution in the nuclear power plant sector.

L&T is uniquely positioned as a total solutions provider in India's nuclear industry. It is the only company in India with wide ranging expertise and experience covering EPC capabilities integrated with manufacturing, construction and services.

It was L&T that pioneered the development of indigenous manufacturing technology for nuclear power projects in India. It has contributed to all indigenous nuclear reactors in the country. Continual investment in upgrading technology has led to globally bench-marked facilities.

L&T is authorized to use ASME ’N', ‘NPT', 'NA' stamps and 'NS' certification for construction of Class 1, 2, & 3 vessels including scope for supply of ferrous and non-ferrous material as Material Organization (MO). Manufacturing campuses are qualified to stringent US nuclear standards of 10CFR PART 50 APPENDIX B.

Special dust-free enclosures with temperature and humidity control enable the Company to achieve manufacturing excellence in Class 1 nuclear island components. L&T manufactures reactor vessels, steam generator, pressurizer, control rod drive mechanisms (CRDMs), dummy fuel rod sub-assemblies, fuel transfer equipment, primary heat transfer systems, heavy water upgrading columns and internals, high pressure safety heat exchangers, high and low-level waste storage tanks, special equipment for in-service-inspection and thermal insulation panels.

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Hazira Manufacturing Complex

Manufacturing Facilities

Powai Campus, Mumbai

Heavy Engineering

L&T Heavy Engineering has established a reputation for high-quality equipment in the global market with its strong engineering capabilities and state-of-the-art manufacturing facilities.

Ranoli Works, Vadodara

Coimbatore Works, Coimbatore

Sohar Works Complex, Oman

L&T has achieved a 'preferred supplier' relationship with major EPC contractors and has been recognized as the ‘Most Valuable Supplier' by Fluor Corporation, USA. Key customers have affirmed L&T’s quality and on-time delivery performance by awarding prestigious orders for critical equipment on nomination basis.

L&T’s Hazira Manufacturing Complex, sprawled over 900,000 sq.m., comprises fabrication workshops measuring 70,000 sq.m., a large-equipment manufacturing facility of 90,000 sq.m., and an assembly

and load-out area of 100,000 sq.m. Large-size over-dimensional equipment can be directly loaded onto ocean-going barges/vessels, as the facility has direct access to the Arabian Sea.

This is the world’s largest covered nuclear manufacturing facility at a single location, and specializes in the manufacture of reactors and steam generators.

L&T's Powai Campus, in suburban Mumbai, is spread over a total area of 385,000 sq.m., with 37,500 sq.m. dedicated to fabrication shops. The shops can handle equipment of 6m dia x 55m-long weighing over 400 MT.

For power, L&T offers LP/HP feed water heaters and complex internals for coal gasifiers.

L&T is extending its manufacturing capabilities in the nuclear space with captive facilities for nuclear grade heavy forgings. A heavy forge shop - one of the largest of its kind in Asia - is being set up at Hazira in collaboration with Nuclear Power Corporation of India Limited (NPCIL).

L&T’s Ranoli workshop specializes in fabrication of equipment of special-grade SS, aluminium, other exotic materials and composites.

The workshops are designed to manufacture nuclear steam generator, reactor pressure vessel internals and metal reflective thermal insulation panels.

L&T supplies dry shielded canisters and metallic casks for spent fuel transportation and storage to the US and Europe.

L&T’s Coimbatore Works specializes in precision-engineered systems and components for the nuclear and aerospace sectors.

The workshops are designed to manufacture nuclear control rod drive mechanisms, fuel handling systems, fuel assembly components, precision reactor sub-assemblies and coolant channels.

L&T's new facility in Sohar, Oman is a high-tech ASME approved workshop and a modular fabrication yard with ISO and OHSAS certifications.

With its proximity to the GCC, the Sohar Works Complex will strengthen L&T's relationship with the region's industry, and enhance its delivery capabilities.

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Comprehensive Capabilities in Nuclear Power

Tarapur Atomic Power Plant - 3 & 4

L&T has a proven track record in setting up nuclear power plants in India.

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Design & Engineering

Heavy and Precision Manufacturing

Project Management

Construction & Erection

Valves and NSSS Piping

Control & Instrumentation

Electrical Systems

Nuclear Reactor Services

Spent Fuel Handling Equipment

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World-class Forging Facility

L&T Special Steels & Heavy Forgings (LTSSHF) – India's largest integrated steel-making, forging and machining facility is a joint venture of L&T and Nuclear Power Corporation of India Limited (NPCIL)

Located at L&T's Hazira Manufacturing Complex, LTSSHF sprawls over a 100-acre campus, and is the only facility in India capable of producing nuclear-grade heavy forgings.

LTSSHF has the capacity to meet almost all the heavy forging requirements of critical sectors – refineries, fertilisers, hydrocarbons, petrochemicals, rotor and generator shafts for supercritical turbines, ship-building, steel and most of the nuclear sector. It can provide the widest range of finished forgings for nuclear reactors, pressurisers and steam generators. Its product range includes:• Ingots up to 300 MT• Forgings up to 120 MT• Shells, tube sheets, shafts, steel rollers and rotor shafts.

The facility's layout allows for enhancement of up to 600 MT ingots and 250 MT forgings. Its annual steel melting capacity exceeds 400,000 MT.

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LTSSHF’s capabilities are augmented by testing facilities and a load-out jetty for shipment of heavy consignments to any part of the globe – all year round.

Records

• India's first hollow ingot

• India's longest forged slab: 13 m long and 300 mm thick

• India's biggest stainless steel ingot: 50 MT

• India's biggest steel ingot: 100 MT

• India's first Directional Solidification Ingot (LSD), 50 MT

• Shaft: 60 MT

• Lowest level of hydrogen achieved in bottom poured ingots: 0.7 PPM in SA336 F22V

• Lowest level of nitrogen achieved in bottom poured ingots: 40.4 ppm in DIN 1.2727

India's biggest open-die hydraulic press (9000 MT) and manipulator (150 MT) on the shopfloor

Fully Integrated process – Steel Melting to Finished Forgings

Scrap / DRI Forging Heat Treatment

Melting EAF Reheating Testing

Refining LF Ingot Stripping Machining

Vacuum Degassing Ingot-casting Finished Forge Component

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Products & ProjectsL&T has been involved in the manufacture of reactor and nuclear equipment for India's PHWR series. Starting with 220 MWe, followed by 540 MWe, L&T currently executes orders of 700 MWe PHWR projects.

End shields ( 700 MWe, 540 MWe, 220 MWe )

Control rod drive mechanism

Heavy water distillation column

Heavy Water Plants•• High-pressure heat exchangers• Purification towers & separators

Site Services in New and Operating Plants • Enmass coolant channel replacement• Installation of end shield and calandria• Installation of coolant channel assembly• Installation of reactivity devices• In service inspection

Exchange unit towers & internals

Equipment for Pressurized Heavy Water Reactors

• Calandria (reactor vessel)

• End shields

• Steam generators

• Control rod drive mechanism (CRDM)

• Standby cooler

• Bleed condenser

• Stand pipe thimble

• End fittings & liner tubes

• Shielding & sealing plugs

• Bearing sleeves & journal

• Fuel-handling system

Research Reactors •

- Deck plate- Fuelling machine

- Carriage & trolley• TOKAMAK vessel (ultra-high vacuum)• High-level radioactive waste storage tanks• Steam generator test facility

Dhruva reactor

Plasma ReactorActive participation in international collaborative research project of International Thermonuclear Experimental Reactor (ITER), manufacturing the cryostat - the world’s largest vacuum vessel.

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Products & ProjectsL&T is associated with India's Fast Breeder Technology programme, having manufactured reactors and nuclear equipment for the first 500 MW Prototype Fast Breeder Reactor (PFBR). The reactor vessels and other large equipment - meeting tolerances that are among the world’s best - were manufactured at a special fabrication shop at the site. PFBR Steam Generators and Heat Exchangers are manufactured within dust-free enclosures at L&T's workshops.

Reactor safety vessel

Fast-breeder Reactors for 500 MWe

• Main vessel

• Safety vessel

• Steam generator

• Roof slab

• Sodium & argon buffer storage tanks

• Metal reflective thermal insulation panels

• Inclined fuel transfer arm

• Boron carbide shielding structure

• Dummy fuel blanket sub-assemblies Steam generator for PFBR

Metal reflective thermal insulation panels with mirror finish conforming to finish No.8 as per ASTM A480/480M with 0.05 micron finish.

Reactor roof slab

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Design & Engineering

Special

L&T's engineering capabilities are geared to design equipment of Class 1 category for nuclear reactors as per international codes and standards.

L&T’s design engineers generate optimum solutions for the fabrication of nuclear reactor equipment under the highest safety standards as per global benchmarks. These reactors are guaranteed under the most severe service conditions. The capability of equipment safety analysis adds guaranty on product performance for its design life.

• Finite Element Analysis - Static linear / non-linear- Dynamic

• Thermal - Steady-state / transient

• Fatigue and fracture

• Seismic

• Shock / vibration

• Piping and flexibility

• Lifting and transportation

• Safety analysis for postulatedaccidental condition

Analysis

• Design tointernational codes and standards

• ASME Section IIIDivision 1 subsection NB, NC, ND, NF

• Seismic design as perReg. guidelines

Mechanical

Thermal /Thermo-hydraulic

• Member of HTRI / HTFS

• CFD - ComputationalFluid Dynamics - 1D /3D for steam generatorand heat exchangers

• Flow-induced vibration

• 3D modeling for static and dynamic assembly andsimulation through virtual reality

• CAE - Computer Aided Engineering

• Thermal/Mechanical transient analysis

Project Management

L&T’s team of highly skilled engineers and technicians continually undergo structured training programmes to ensure that they follow the precise requirements of the nuclear sector in terms of nuclear work culture and code requirements. The workforce seamlessly designs innovative engineering solutions for the customer.

Workforce

Enterprise Resources (ERP) - BaaN Critical Chain Project Management (CCPM)

L&T Heavy Engineering has implemented Critical Chain Project Management, based on Dr. Eli Goldratt's 'Theory of Constraints' (TOC) using Concerto software.

The management philosophy by Dr. Eli Goldratt states:• Only few elements (constraints) in a business,

control the results of the entire organization• TOC tools identify these constraints and enable the

entire organisation through CCPM to focus on simple and effective solutions to problems that seemed very complex and unsolvable using 5 focusing steps.1. Identify the constraint2. Exploit the constraint3. Subordinate everything else towards the constraints4. Elevate the constraint5. Go back to step-1

CCPM helps in proposing the best possible realistic deliveries to the customer before the order. Concepts of Full-kit, Optimal Resource allocation along with Active task Management (ATM) and Buffer Management (BM) help to manage the projects in execution and meet contractual deliveries. It provides a common view of project execution to all stake holders across its manufacturing locations.

Product Lifecycle Management (PLM)L&T Heavy Engineering has implemented Enovia Product Lifecycle Management from Dassault Systemes. The standardisation of Engineering Processes created a central

repository, with role-based access for document management by project teams. The adoption of online workflows have improved collaboration and increased efficiency through greater visibility.

The PLM system has integrations with e-mail, BaaN-ERP, Concerto-CCPM, MS-Desktop, UG-NX, CATIA and other CAD packages and with AUTOVUE viewer for viewing different file formats. PLM has improved the storage, search and re-use of data across projects, enhancing Knowledge Management.

Customer Relationship Module (CRM)Customer Relationship Modules enable clients track the progress of jobs from their desktops, thus saving on communication and travel expenses.The module is customer- and contract-specific.

L&T pioneered the manufacturing technology for India’s nuclear power programme through indigenous technology development. Strategically located global sourcing offices staffed by technical personnel in the USA, China, Japan, Italy and Russia ensure timely delivery of nuclear-grade quality materials at competitive cost.

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Fabrication WeldingL&T's world-class fabrication capabilities have been achieved through perfect integration of efficient material handling, forming, precision machining and welding processes for a range of material in varying thicknesses, backed by technological excellence in design & engineering and responsive quality systems.

Dust-free enclosure for FBR steam generator assembly

Despatched single-piece equipment over 1500T in weight and 16m in diameter

•of 1000 T

• Height Under the Hook 23 Meters

Crane Capacity

Furnaces in shops are suitable for equipment of dimension 14m long x 9.5m wide x 9m high and can handle weight up to 350 tonnes.We also have the capability for Modular Furnaces with no size restriction.

Quality Assurance and InspectionFacilities include:Linear Accelerator• Capacity: 12 MeV Max. Thk: 500 mm

Gamma Ray Radiography• IR-192 & Co-60 Camera Unit • Ultrasonic flaw detectors• Shear wave techniques• Time of Flight Diffraction Technique (TOFD)• Helium leak detector magnetic particle testing

450MT American Hoist Crane, 400T gallow frame arrangement and heavy-duty RO-RO trailers enable loading of heavy cargo onto ocean-going vessels from the Hazira waterfront facility.

Comprehensive Welding CapabilitiesContinuous improvement in welding technology has enabled L&T to develop 6000 welding procedures qualified as per international codes and standards - ASME, BS, EN/ISO, AS/NZ - for a variety of materials in a range of thicknesses (0.5mm to 800mm) covering the complete spectrum of welding processes. Specialised fabrication facilities include 100,000 Class dust-free enclosures with areas of 1000 sq.m and 400 sq.m.

Welding Processes• SMAW• GTAW• GMAW• FCAW• SAW• PAW• ESW• Arc Stud Welding• CD Stud Welding• Electron Beam Welding• Laser Beam Welding

Materials Welded• Carbon steels• Low alloy steels including Cr-Mo-V• Quenched & tempered steel• Austenitic stainless steels• Duplex, super duplex & hyper duplex

stainless steel• Super austenitic stainless steel• Nickel based alloys (inconel, incoloy,

hastelloy, monel)• Copper-based alloys (cupro-nickel,

aluminium bronze, brass)• Titanium & titanium alloys• Aluminium & aluminium alloys• Maraging steel• Clad steels with stainless steel, inconel,

monel, cupro-nickel, titanium, etc.

Specialised Welding Techniques• Tandem / Twin SAW• Semi-Automatic GTAW/SAW• Robotic• Hot Wire GTAW• Activated - TIG• Narrow Gap SAW/GTAW• Pulsed GTAW/GMAW• Internal Bore Tube to Tubesheet• Self-Shielded FCAW• Orbital GTAW• Strip Cladding

Automatic tube-to-tubesheet welding 150mm-wide SS weld overlay on forged shell by Electro Slag Strip Cladding (ESSC)

800mm-thick weld joint by narrow gap SAW

Narrow gap tandem SAW on 322mm-thick forged reactor circular seam Robotic welding

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MachiningThe capabilities of CNC floor-mounted and special purpose machines aresupported by a battery of general-purpose machines, all geared to the precision machining needs of a world-class fabricator.

CNC floor-mounted horizontal boring machines at L&T's Hazira workshop.Spindle diameter: 200mm. Travel: 5m x 17m.

Machine finished plate cutting by CNC Water Jet Cutting Machine upto 4m X 8m long plate

5-Axis Hass VMC

Co-ordinate measuring machine in controlled atmosphere enclosure

CNC vertical multi-spindle deep hole drilling machine. Drilling depth: 900mm.Number of spindles: 2.

Deep-Hole Drilling MachineHor. Column Traverse: 5mHeadstock Vehicle Traverse: 3mMax. Depth: 1000mm

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Quality Assurance

The Total Quality Management approach ensures that deliveries stringently conform to customer specifications.

L&T’s quality procedures guarantee that safety and reliability of operations are built into the equipment and systems delivered.

L&T’s manufacturing facilities at Powai and Hazira are authorized to use ‘N’ ‘NPT’ and ‘NA’ stamps and ‘NS’ certification for manufacturing nuclear power plant equipment with material organisation scope. L&T’s quality assurance program complies with 10 CFR guidelines (10 CFR 50 Appx. B, 10CFR 21, 10CFR 71, 72) of US Federal Regulatory Requirements.

L&T’s workshops are ASME-certified and authorized to use U, U2, U3 and S stamps.

The quality systems - right from personnel training, vendor development to final equipment commissioning - are covered under ISO 9001, ISO 14001 and OHSAS 18001 certification. The workshops have MLO registration for exports to China, and are authorized for CE-marking for exports to European countries.

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