October - December 2008 • Vol. No. 31 • Issue No. 3€¦ · Singoli-Bhatwari Hydro Electric Project - Small Step for A Giant Leap 30 Tapovan Vishnugad Hydro Electric Power Project

October - December 2008 • Vol. No. 31 • Issue No. 3

Editor V.S. ramana

Editorial tEam K. Sridharan | alex Benjamin | V. ramesh Kumar | ashwin Chand | V. Eswar | Subha anand

PhotograPhy V.S. Natanavelu

dESigN & layout Srishti graphics design, Chennai.

ContentsVol. No. 31 • Issue No. 3

Overview of Hydel Power Projects 3

Specialised Support Services for Critical and Complex Structures 6

Subansiri Lower HEP – A National Powerhouse in Making 8

Parbati HEP – A Landmark Project 12

Allain Duhangan Hydroelectric Project (L&T’s Endeavour at the highest altitude of 2750 m) 26

Singoli-Bhatwari Hydro Electric Project - Small Step for A Giant Leap 30

Tapovan Vishnugad Hydro Electric Power Project with TBM Technology 34

Kuttiyadi Hydroelectric Project 38

Kaleidoscope 42

Man-made reservoirs are vital to agricultural development and

power generation using low energy inputs. To resource this

effectively, massive excavation and construction of concrete

structures that can withstand enormous pressure have to be

built with utmost care and skill.

L&T offers comprehensive construction services for building

hydropower projects including geo-technical and foundation

engineering works. Areas of expertise include engineering,

procurement and construction of underground tunnels,

diversion wiers, all types of dams, large underground caverns,

pressure shafts, surge chambers, underground and surface

power houses; fabrication and erection of gates and penstocks;

barrages, canals, aqueducts, covering civil, hydro-mechanical

and electro-mechanical works.

In this issue of ECC Concord, we present to you a wide variety

of complex hydro power projects a under execution in extremely

difficult conditions. Happy reading!

Head Race Tunnel (HRT) for Subansiri Hydro Electric Project (HEP)

India is blessed with a total installed capacity of 1, 41,080 MW of electricity as per reports by the

Ministry of Power, Government of India. Of this nearly 64.4% (90,895 MW) comes from thermal generation, 24.95% (35,208 MW) from hydro power, 2.8% (4120 MW) from nuclear power and the rest from renewable energy resources.

As India’s per capita electricity consumption at present is very low at 631 kWh when compared to the four and five digit figures in developed countries, the National Electricity Policy envisages that the per capita availability of electricity will be increased to over 1,000 kWh by 2012. To achieve this, the government is expecting a total capacity addition of about 78,577 MW by end of 2012 of which about 58,644 MW is expected from thermal, 16,553 MW from hydro and 3,380 MW from nuclear.

Hydro PotentialThe exploitable hydro-electric potential in terms of installed capacity is estimated to be about 141,080 MW, out of which a capacity of 30,164 MW (20.3%) has been developed so far and 13,616 MW (9.2 %) of capacity is under construction. In addition, 6,782 MW in terms of installed capacity from small, mini and micro hydro schemes have been assessed. Also, 56 sites for pumped storage schemes with an aggregate installed capacity of 94,000 MW have been identified. The government expects to harness its full potential of hydropower by 2027 with a whopping 5,000 billion Rupees investment.

It is also to be noted that the untapped hydro electric potential is generally spread across in the North and North-eastern states of India. Hydel power is a renewable and reliable power system

Overview of

Hydel Power Projects

Diversion weir with gates for Varahi HEP in Karnataka

ECC Concord | Oct - Dec 083

that is non-polluting and an environmentally benign source of energy having inherent ability for instantaneous starting, stopping and correcting load variations. The growth in Hydel power is also encouraged due to depletion of oil reserves apart from its very low operating costs. The ideal Hydel Thermal mix of 40:60 could be achieved only if we exploit the available potential quickly. The targeted capacity addition during 11th plan (2007-12) and 12th plan (2012-17) are 15,627 MW and 37,562 MW respectively. In fact, the target for 12th five year plan is equal to the capacity addition achieved since independence.

Track Record

Larsen & Toubro is one of the key players in providing Engineering, Procurement and Construction (EPC) services for different industrial sectors and Hydel Segment is no exception to it. L&T made its foray in to Hydel Segment when it secured the first order for renovation and modernization of 150 MW Bhira Pumped Storage project during early 1990s. Subsequently, it executed the penstock works for 72 MW Bhivpuri hydroelectric station, both projects for Tata Power Company in Maharashtra.

Infrastructure Business

Followed by this, a slew of projects were successfully executed by L&T, such as the 20 MW Chilime HEP, 30 MW Trishuli-Devighat, Sunsari Morang Head works in Nepal and 1020 MW Tala project in Bhutan. Most of these projects were executed as a part of the heavy civil works and erstwhile “Infra Business Unit” till early 2000 along with Roads, Runways, Bridges, Ports, Harbors, etc. Foreseeing the huge business potential in the sector, it was decided to have a separate Business Unit to facilitate a better customer focus, business development and foster growth of the business in line with the organizational vision and objectives. Accordingly, Hydel & Irrigation Business Unit was formed during the year 2002-03.

Challenges

Generally, hydel projects are developed on hilly regions at high elevations, far away from cities by virtue of its inherent nature. As such, execution of hydel projects presents several challenges in terms of accessibility, logistics and resources. Getting the right kind of people to execute the project is yet another challenge. However, L&T’s superior project execution capabilities were aptly supported by various people centric initiatives and L&T was successful in getting the right people for execution of these projects by a judicial mixture of lateral recruitment and intensive training for in-house staff. Many sophisticated BU specific equipment were also added to strengthen the existing fleet of equipment.

Over a period of time, the business unit achieved a steady growth and excellent all round progress with management support, guidance and nurturing coupled with the collective and dedicated efforts of all staff and workmen. As a result, the BU has consolidated its position and enhanced its strengths in several areas including finance, technology development, resources augmentation, pre-qualification strengths, etc. Moreover, successful execution of some of the major projects apart from instilling confidence in the team also established L&T’s brand name in the Hydel segment. Today, L&T is one of the top five companies in Hydel sector in India. Some of the remarkable achievements of the BU in this sector include construction of a number of hydro

Penstock for Tata-Bhira HEP in Maharashtra

ECC Concord | Oct - Dec 08 4

power projects aggregating to 6550 MW capacity (including both completed and ongoing projects) involving construction of 74 km of tunnels, 118 km of canals and 7 dams / weirs including the LPG Cavern at Vizag which is one of the deepest Underground caverns for storing LPG. This project won several international awards.

Specifically, the successful completion of 1020 MW Tala HEP in Bhutan as well as the Purulia Pumped Storage Project in West Bengal and the Cavern project at Vizag paved the way for prequalification of certain major tunnel and cavern related works.

In a short span, L&T secured orders for some of the most critical projects and enhanced its value chain in Hydel / irrigation projects. Some of these projects include construction of the Concrete Dam at Veligonda, Tunnel & Surface power house for India’s largest hydropower project (2000 MW Subansiri Lower HEP), Cutoff wall and rock-fill dam at Parbati (Stage III) HEP, Tunnel Construction by Tunnel Boring Machine at Tapovan Vishnugad HEP etc.

Hydel/Irrigation projects are undertaken on EPC basis, such as 100 MW Kuttiyadi Additional

Extension scheme, Veligonda Dam, Polavaram Main canal etc.

A full fledged Hydel design/engineering unit has been constituted at Faridabad and this is currently operating with 40 engineers.

L&T’s entry into Hydel power development on BOT basis is yet another milestone achievement and it will not be out of place to mention that Singoli Bhatwari project is the first BOT project being developed by L&T in Uttaranchal state.

On the whole L&T is playing a critical and significant role in the development of India’s power / energy scenario. In the process, it is continuously learning and improving several of its systems, operations and project management capabilities in Hydel segment with the ultimate objective of customer delight. No doubt, L&T has grown from a fledgling to a major contributor in the field, building on its strengths and competencies and taking up major projects with bigger challenges and complexities and leaping forward in to the future for energising the lives of the people.

P. NIRANJANA General Manager & Head (Hydel & Nuclear BU)

4 x 225 MW Purulia Pumped Storage Power Project, West Bengal


Construction Methods and PlanningA dedicated Construction Methods Planning Cell (CMPC) at Chennai presently known as Infrastructure Engineering and Technical Services-CMPC (H&N) focusses on the developing construction methods and design of enabling works for all types of hydel and nuclear power projects. CMPC has experienced engineers, technical personnel including state-of-the-art hardware and software for providing fast and accurate solutions. CMPC has made detailed study and standardized the engineering for enabling structures including site camp facilities and workshops. Through continuous learning, innovation and value engineering, it is planning to set global benchmarks.

Highlights of major projects

Underground Cavern Project, Vizag

Underground Cavern Package: CMPC developed construction methods along with the detailed working drawings for execution of shaft sinking, horizontal galleries and cavern muck hoisting. CMPC provided a foolproof, very high efficient cavern muck hoisting system against all odds to the complete satisfaction of Geostack, France (Consultant) as well as Shaftsinker, South Africa – a world leader in mines.

Intake structure and aboveground piping package: A methodology was adopted for the headgear (used in UG package) as a guide structure for installing a group of LPG piping each 24” dia and weighing around 50t.

Specialised Support Services for critical and complex structures

Asia’s largest under-ground cavern for storing LPG at Visakhapatnam


Veligonda Dam

Tower crane for dam concreting: Provided a self erecting type track beam for the 25t capacity tower crane at upstream and downstream and tyre-mounted gantry crane for handling formwork above the reach of towers during the construction of dam.

Complete engineering for aggregate cooling system (transportation, cooling & feeding up to Batching plant) to produce low slump concrete with 150mm down aggregates at 12° C temperature as against 50° C ambient temperature.

Parbati Hydro-electric Power Project

A hydraulically operated tunnel concrete lining gantry was provided to construct diversion tunnels with horse shoe shape. This proved cost effective and efficient.

Tapovan - Vishnugad Hydro-electric Power Project:

Complete engineering has been done in-house to set up a factory for manufacturing precast segments for tunnel lining with tools and tackles for handling of precast elements in steep hills of Himalayas near Joshi Mutt.

Design and consultancyEngineering Design and Research Centre (EDRC) – the design arm of L&T located at Faridabad, offers basic study, conceptual design, detail engineering and consultancy services for all projects coming under the classification of Hydro Power Plants and Irrigation projects.

It has the capacity for conducting river flood analysis, detailed site survey and investigations, hydrological, power potential and geological studies, Environmental Impact Analysis, conceptualization, project layout and design, detail engineering, derivation of BOQ, rate analysis, project cost and economic evaluation of hydroelectric projects. The design capabilities extends to construction of dams (concrete, earthen, rock-fill and roller compacted concrete), barrages and weirs; river diversion; de-silting chambers; intake structures; all types of tunnels for water / transportation; pressure / surge shafts and penstocks; power houses (above

and underground); river interlinking projects and irrigation structures such as canals, cross drainage works, aqueducts, super passages, etc. Basic engineering and detailed designs/drawings are also produced for hydro-mechanical works and basic engineering and integration studies for electro-mechanical works.

Other areas of expertise include preparing feasibility reports, detailed project reports, technical specifications and construction engineering for the above projects.

Foundation EngineeringThe Foundation Engineering group of EDRC offers engineering solutions for the entire gamut of Geotechnical and Foundation Engineering designs.

It has wide ranging capabilities for the design of shallow foundations, deep foundations, deep excavations, dewatering, ground improvement, sheet piles, diaphragm walls, well foundations etc. It is equipped with the latest advanced software such as Talren, Modflow and Plaxis for all geotechnical analyses. It also prepares foundation recommendation reports based on investigations and co-ordinates closely with other competency cells and prepares designs based on appropriate construction methodologies.

The group has contributed to considerable savings in Geotechnical and Foundation Engineering areas for various hydel and nuclear power projects. Caption Caption....

Hydraulically operated tunnel concrete lining gantry


Subansiri Lower HEP –

A Nationalin the making

Powerhouse

AnIl KUMAR PAnDEy Project Manager

Portal for Adit to Head Race Tunnel

Harnessing the available hydel energy potential of the Country symbolizes growth. Moreover,

hydropower is amongst the cleanest, efficient and a major renewable energy resource for economic development. The present installed generating capacity of power in the country is approximately 1.10 lakh MW, out of which, the share of hydropower is approx 0.28 lakh MW that is around 25%.

India is endowed with a vast amount of hydro electric potential and it ranks 5th in terms of exploitable hydro-potential on global scenario. As per the assessment made by Central Electricity Authority, India is endowed with economically exploitable hydropower potential to the tune of 1,48,700 MW of installed capacity. Out of this, approximately 66,065 MW is assessed in Brahmaputra basin itself.

Subansiri Lower Hydro Electric Project (SLHEP) with its 2000 MW potential forms a part of three mega hydroelectric projects to be constructed on river Subansiri, a major tributary of river Brahmaputra. The Subansiri River at Dam site forms the boundary between Assam and Arunachal states. The Gerukamukh village in

Assam is located in the left bank and Dollungmukh in Arunachal Pradesh is located in the right bank of the Subansiri River.

SLHEP is the largest hydro power project in India and South-East Asia, taken up by India’s leading Central Public Sector Undertaking (CPSU) National Hydroelectric Power Corporation (NHPC) Limited. The Construction works for the project has been divided in to four major packages and awarded to four different agencies for convenience of execution. A plan showing the general layout of the project is given below.

L&T – ECC has been entrusted with Package - 2 of the SLHEP covering Construction of HRT Intake Structures, Head Race Tunnels, Surge Chamber, Pressure Shafts, Tail Race Channel, Adits and Surface Power House. Valued at Rs 921.59 Crore.

Scope of WorksThe major scope of works for the Project includes: • 55lakhcu.mofexcavationinSurfacefor

Access Roads, Power house & HRT Intakes using Drill & Blast method.

Project layout of Subansiri Lower HEP in Arunachal Pradesh


• 6lakhcu.mofexcavationinSurfaceforSurgeChamber using Mechanized Excavation methods.

• 10 lakhcu.mof excavation inUnderground for Adits, Head Race Tunnels & Pressure Shafts using Mechanized Excavation methods.

• 11 lakh cu.m of concreting for Surface &Underground.

• 75000tonsofreinforcement

The project is the largest single order secured by L&T in the Hydel BU and the same is being executed as a “Task Force” being led by Mr. P Niranjana, stationed at ECC Head Quarters Chennai and represented at site by Mr. Anil Kumar Pandey, Project Manager. Mr. K S R K Verma, Hydel HQ, Faridabad is the Cluster Project Manager.

For execution of this project, L&T has deployed a large fleet of highly sophisticated Plant & Machinery, with an equally large work force of staff and workmen.

The Project execution is marked with unique mechanized construction methods adopted for the first time in a major hydro electric project in India. As per technical specifications of the contract, excavation of the Surge Chamber in Surface and Underground were supposed to

be carried out using mechanized excavation methods. This stipulation was necessitated due to poor Geological conditions with low strength of the rocks in general and closer alignment of head race tunnels. It was felt that carrying out drilling and blasting in these rocks may damage the surrounding rock mass, resulting in probable failure of same during construction.

In order to meet this contractual obligation with safety measures, ECC deployed higher capacity roadheaders. Currently ECC has deployed five roadheaders at site for carrying out underground excavation. An average progress of 45m per face has been achieved with above roadheader machines and the work is progressing as per schedule. Recently the project team was congratulated by NHPC Limited for achieving an internal milestone of “Completing 900m of HRT Excavation” ahead of schedule.

During the course of execution, the design of surge chamber underwent major changes due to the unstable geology and uncertainties involved in stabilization of the surge chamber. This necessitated incorporation of surge tunnel in place of surge chamber.

For the first time, ECC used a highly sophisticated Excavator Mounted Rock Cutters, Road Headers

Excavation for Power House in progress


installed with a raise-borer for carrying out the excavation of five 97.5m deep Vertical Pressure Shafts in this project. Being a specialized work, the sub-contract for same was awarded to Bergteamet, Sweden who executed the above works in a period of 3 months.

Infrastructure for the projectBeing a critical project located on a remote place it lacks many basic amenities. Therefore, L&T management decided to provide excellent infrastructure for the project. The site has been installed with a captive power plant of 1.50 MW capacity using Heavy Furnace Oil (HFO) facility to cater to the exclusive needs of power for 400TPH capacity crushing plant and 200 cum/hr batching plant. A fully mechanized double storied cement godown having integrated conveyors for cement transportation and bag splitter for cement feeding to batching plant silos has also been installed. The Project has also installed a fully automatic rebar processing plant (70 MT/day) capacity to cater to the project requirements.

Amenities for staffThe site is also provided with a state of the art executive living facilities and dining mess for the bachelor staff with “first time” features like automatic Idli & Dosa making machines, automatic dishwasher, etc. Self contained, well equipped staff colony is established for the bachelor and family accommodation. These facilities are contributing to keeping the staff members happy and motivated for staying at this remote place.

To sum up, the complex technical features coupled with a very tight project schedule makes the construction of Subansiri Lower Hydro Electric project an immensely daunting and challenging task for the Engineers of L&T. However, each team member of the project understands that this is a flagship project for the H&N BU of L&T-ECC and the experience gained from this project will be immensely helpful for establishing L&T as a major force to reckon with in the blooming hydro sector. This feel keeps all of them motivated and committed for delivering the project in time to the customer.

Head Race Tunnel for Subansiri HEP


ParbatiHEP – A Landmark

Project

S. K. UPADHyAy Resident Project Manager

T.M.URAnKAR Construction Manager

D. R. PAnT Chief Geologist/ Construction Manager

n.K SIngH Construction Manager

R. RAVI KUMAR Construction Manager

The Parbati Hydroelectric Project Stage III (520 MW) is a run-of-the-river scheme on Sainj River located 800 m downstream of its confluence with Jiwa Nallah in Kullu district of Himachal Pradesh. It envisages utilization of waters released from tailrace of Parbati Hydro-electric Project (Stage-II) powerhouse at Suind as well as discharges of Sainj River in the Beas catchment.

Salient Features

The project mainly involves construction of:

• A43mhighrock-filldamhavingacrestlengthof 186.425m;

• Two circular shaped concrete lined diversioncum spillway tunnels - 391m x 6.75m dia and 440m long x 5.0 m dia with a thickness of 0.4m

• Twopowerintaketunnels475m&430mlongfeeding two desilting chambers 250m long, 12.2m wide, 22.50 m high

• Concretelinedheadracetunnel7.875kmlongand 7.25m diameter

• SurgeShaft20mdiameterx133.75mhigh

• Twosteellinedpressureshafts510m&460mlong both having a diameter of 4.50m and each bifurcating into two 3.0 m diameter penstocks

• Anundergroundpowerhouse chamber 122mlong x 22m wide and 41.7m high housing four vertical axis Francis turbines to drive four generators of 130 MW capacity each,

• An underground transformer cavern 98.2mlong x 15.5m wide and 25.2m high with a 8.1m diameter 2.67 km long tailrace tunnel.

Scope of Works

At Parbati Hydroelectric Power Project, L&T has been entrusted with LOT-1 package, which involves Civil Works for the construction of Diversion cum Spillway Tunnels including Gates, Coffer Dams,

43 m high Rockfill Dam along with Diaphragm wall, Orifice type and Chute Spillway. Civil works for Intake works consisting intake tunnels, Desilting Chambers and flushing systems including branch tunnels, and 7.25 m diameter horseshoe shaped part Head Race Tunnel of length 5.90 km and other associated works.

The Head Race Tunnel (HRT) is being excavated through 3 access tunnels - Adit-1, Adit-2 and Adit-3 meeting HRT at chainage 17m, 3974m and 7782m having length of 145m, 715m and 154m, respectively.

Himalayan TerrainReliable snow-fed rivers with steep topography in Himalayas have attracted hydropower developers to invest in this sector due to the ever increasing demand of power. Hydropower developments in the Himalayan terrain have always been a challenge to civil engineers, geologists/geotechnical experts due to the rugged nature and complex geological conditions. In view of its virgin quality, for which Himalayas are famous for and the limited investigations that have been carried out to understand the strata below, geological surprises during implementation of projects are inevitable.

The headrace tunnel (HRT) of the Parbati Hydroelectric Project Stage – III is infested with typical problems related to unpredictable geology and topographical complexity. Problems during tunnelling mainly, cavity formation in HRT (Face-2) as a result of weak zones, were tackled by adopting an innovative technique called “Pipe Roofing Techniques” employed by L&T for the first time.

Rock mass encountered mainly consisted of Class –IV with few sections of Class V and Class-III. Poor stretches of tunnel were stabilized by several application of shotcrete followed by fore-poling, steel set installation with concrete backfilling. In Class V rock, heading and benching methodology was adopted.

Tunnelling in theHimalayan Geology


Headrace Tunnel

Excavation methodology adopted as well as support measures provided in tunnel varied from place to place depending upon site geological condition encountered at the work face.

Tunnel Support

After removal of excavated material from the face, the exposed rock is supported before taking up the next operation of blasting. Rock support is decided based on rock condition at the face. To quantify rock at the face, rock mass classification system called “RMR” (rock mass rating) is being used.

Support Methodology

Shotcrete

This involves applying a mixture of cement and

water sprayed by shotcrete machine fitted with robot arm.

Rock Anchor/Bolt

Drilling of hole for the rock bolt is being carried out by Tamrock machine. Rock bolt is inserted in the hole and grouted either by cement grout or resin grout. A plate is placed outside on rock on the installed bolt and tightened by nut.

Wire mesh

Wire mesh in rolls is brought to work face and fixing is done manually by using scissors platform. Wire mesh will be firmly fixed to the rock by fixing clips into the surface. Fixed wiremesh is completely covered by shotcrete layer of designed thickness.

Steel Rib

Structural steel ISHB sections are fabricated and bent to the required shape, size and pieces

Boomer

Adit-2 portal – access tunnel to HRT


Construction of Diversion Cum Spillway Tunnels including Gates and Hoists, Coffer Dams, Rockfill Dam, Spillway, Intake Structures and part of Head Race Tunnel.

The Parbati Hydroelectric Project Stage III is located in Kullu District of Himachal Pradesh in the Himalayan zones. Project Head quarter is at Sainj about 250 km from Chandigarh on NH 21 and Sainj is 20 km interior from Aut on NH 21.

The Project is located on Sainj river and comprises of construction of 43 m high Rock fill Dam across river Sainj. A 7.875 km concrete lined Head Race Tunnel on the left bank of river conveys water to the underground Power house. The water from the Power House is discharged back into Sainj river through 2.67 km long Tail Race Tunnel.

• Client : National Hydro Electric Power Corporation Limited.

• Design Consultants: National Hydro Electric Power Corporation Limited.

• Contract Value: 439.07 crore

• Commencement date: 15-12-2005

• Duration: 56 Months

• location: Sainj

• District: Kullu

• River : Sainj (a tributary of Beas river)

• location of Dam: Rockfill Dam on river Sainj at Suind village.

• nearest Rail Head: Kiratpur

• nearest Airport: Bhunter

Scope of works

• Excavation : 1800000cu.m

• Embankment : 500000cu.m

• Concreting : 440000cu.m

• Reinforcement : 11000t

• Structuralsteel(ribs): 3000t

Achievements

• Completion of of HRT Excavation - 3000meters on schedule

• Completion of concreting of both DesiltingChamber Cavern Domes achieved on 23rd Feb’08 i.e. 81 days ahead of schedule.

• DiaphragmWallcompletionachievedon17thJuly’08 i.e. 150 days ahead of schedule.

• Placement of 2,00,000 cu.m of Rockfillmaterial, Graded material, Clay Filling & Riprap achieved on 17th Dec 08 i.e. 301 days ahead of schedule.

PRojECT HIgHlIgHTS

Branch tunnels to Head Race Tunnel


to suit the tunnel profile. Excavators and scissor platform are used for erecting the steel ribs in position. After anchoring ribs with rock, lagging is placed followed by bulkhead and backfill concreting.

Concrete lining

Concrete lining of HRT is taken up once the tunnel excavation is completed. Concrete lining is the final support system in the tunnel and will be done in three stages using CIFA Gantry system. The three stages of concrete lining include Kerb Concrete, Overt Concrete and Invert Concrete.

Concrete will be pumped through pipes installed on the Gantry. After concreting the required area, gantry will be moved to the next position and concreting will continue as stated above. 6 cu.m capacity transit mixtures supply the concrete in to the tunnel.

Special Tunnelling Techniques

Where very poor rock conditions are prevailing or tunnel face is unable to advance with conventional excavation methods, special tunnelling techniques are employed. For such extremely poor conditions with adverse geology, following special tunnelling techniques viz. pregrouting, fore poling & pipe roofing are followed.

Installation of pipe roofing

Drilling and placement of 89mm diameter 21m long seamless pipes by Symmetrix drilling system around periphery of tunnel at spacing of 300mm. Drilling and installation of pipes was done first in heading (above spring line of tunnel).

To begin with grouting of primary holes were taken up, followed by secondary holes. Primary holes are spaced at 600mm and secondary holes in between primary holes.

Thus, pipe roofing and stabilization of tunnel with cavity formation was treated.

Instrumentation

To monitor the effect of installed support and monitoring of tunnel movement in underground structures, specialized geotechnical instruments as follows are installed:

Tape Extensometer - To measure convergence or divergence of tunnel

Borehole Extensometer - To measure rock deformation in the boreholes

Load Cell- To measure load on the installed rock bolt/anchor

Survey Target Point – To measure movement in rock and installed supports

Steel rib support in Adit 2 to HRT


Instrumentation is an extremely important part of tunnelling activity and is highly useful in monitoring the behaviour of tunnel during construction. Careful monitoring on regular basis can prevent loss of life and equipment due to tunnel failure. Abnormal reading observed from the instruments should be examined carefully and remedial measures like installation of additional supports should be undertaken immediately to avoid accident.

Quality, Safety & Environment Management Plan

Proper care has been taken to ensure work being executed as per the required standards and specifications. All site activities are monitored with proper co-ordination to ensure the quality, safety and minimum disturbance to the environment.

lessons from experience

From the above, it is very clear that projects in Himalayas are required to be conceptualized and planned for implementation considering unpredictable geological situations as an integral part of project execution.

In addition to geotechnical investigation during construction stage, adequate and timely rock

mass support during implementation is also equally important for safe and timely execution of the works.

Project construction schedule should consider unforeseen geological conditions during tunnelling in Himalayas.

Selection of proper tunnelling equipment for normal and specialized operation should be available for use for timely completion of project with safety.

Arrangement for advance technology like pipe roofing, pregrouting should be available at site to cope with any unforeseen and adverse geological conditions.

Skilled manpower is a key aspect of any works but more so in underground works where past experience counts a lot to execute the work safely and efficiently.

Hardships of working in remote areas with unfriendly weather conditions including underground situation are well recognized by the management and staff/ workers. Accordingly they are highly encouraged to keep up the quality with utmost safety.

Completed portion of the tunnel


For the first time L&T is constructing Desilting Chambers (an underground structure) at

Parbati Hydroelectric Project in the Himalayan region. Rivers flowing from the Himalayan ranges normally carry lots of silt due to high velocity of the river water. In power generation, if the silt is allowed to enter the turbine, the turbine blades are likely to get scoured resulting in costly maintenance. Desilting Chambers are thus constructed to prevent the formation of silt particles.

In Parbati Hydroelectric Project, the Desilting Chambers are designed to remove sediments of particle size 0.3 mm and above. To flush the silt, Desilting Chambers are provided with 2 Silt Flushing Tunnels of size 2.0 m x 2.2 m which combine together to a 3 m x 3 m size D-shaped Silt Flushing tunnel back into Sainj River.

Two Dufour type 250 m long Desilting Chambers having a width 12.2 m and depth 22.5 m are constructed downstream of intake tunnels. A, D-shaped Adit of size 6.0 m x 6.5 m, has been built for facilitating the construction of Intake Tunnels and upstream portion of Desilting Chambers. The same Adit branches into another construction Adit leading to the center of Desilting Chamber at its bottom to facilitate construction.

Construction of

Desilting Chambers

Scope

•Undergroundexcavation : 180000cu.m

•Rebar : 3200t

•Liningconcrete : 41000cu.m

MethodologyConstruction Sequence

The construction sequence involved the following operations:

Pilot drift excavation & side slashing – The first pilot drift is excavated from construction Adit to


Desilting Chamber by using conventional Drill Blast Method. Drifts of both Chambers are excavated in parallel. The sequences of activities carried out for the excavation included:

Side slashing excavation was taken up after the completion of Pilot drift by conventional drilling & blasting method and rocks supported by rock bolts, wire mesh and 100mm shotcrete in two layers.

Concrete Lining of the Chamber portion - A structural steel gantry of length 7.5 m was fabricated and erected for concrete lining of the Desilting Chamber. A scissor platform was erected well in advance for carrying out the reinforcement work followed by concreting. The concrete was conveyed by transit mixers and pumped in by concrete pump.

Bench excavation in stages - After the completion of chamber concreting works, contact grouting with low pressure was carried out to fill the cavities around the concrete. The 12.0 m deep bench excavation was carried out in four benches each of 3 m depth by using conventional drilling and

blasting techniques. Then the rocks were supported by rock bolts, wire mesh and shotcrete.

Lining concrete wall - L&T Formwork & Scaffolding was used for shuttering and platform. Necessary reinforcement was laid well in advance and the concrete was conveyed by transit mixers and placed in position using a concrete pump.

Excavation of hopper portion was carried out from the bottom Adit of the Desilting Chamber by conventional Drill Blast Method.

Lining of hopper portion – After excavation was completed, concrete lining work commenced from invert, wall and then this was taken to the slope portion. L&T formwork and scaffolding were used for the concreting.

Achievements

Enlargement of Desilting Chamber Crown achieved on 10th Aug’07 against scheduled 14th Sep’07 i.e. 35 days ahead of schedule.

Lining of Desilting Chamber Crown achieved on 23rd Feb’08 against scheduled 14th May’08 i.e. 81 days ahead of schedule.

Gantry for concrete tunnel lining in desilting chamber


A dam is rarely constructed on a perfectly water tight ground mass, there is (nearly)

always underground water flow. The discharge of this seepage while affecting the pressure also endangers the exit gradient and the performance of the structure itself, besides affecting the profitability of the dam on the whole. Considerable developments have taken place during the last few years to prevent the aforesaid problems and the cast-in-situ diaphragm wall technique has been successfully adopted to construct watertight curtain walls. This is due principally to the possibility of adjusting the composition with different types of filling materials.

For the first time, Cut off wall construction using trench cutter technology has been adopted by L&T at Parbati Hydroelectric Project. A cut off wall is a type of subsurface vertical barrier constructed by backfilling a trench with a mixture of cement, bentonite, coarse aggregate, sand and water. Cut off walls are typically constructed using the slurry trench method. This involves excavating a narrow trench that is stabilized during construction by filling the trench with bentonite slurry. The method is used to construct cut off walls and structural diaphragm walls as well as soil-bentonite cut off walls. As the excavation proceeds along one end of the trench, the other end of the trench is backfilled with plastic concrete after clearing

Construction of Cut-Off Wallworking bentonite with fresh bentonite and Q/C tests. The bentonite from the slurry combines with the natural fines of the cement and creates a cement bentonite backfill that has a low hydraulic conductivity.

Construction Sequence

geotechnical Investigation

In addition to initial investigation holes, six more core holes were drilled with continuous coring to fine tune the estimation of the bed rock level.

In general, the rock mass encountered in and around dam site is made of Metavolcanics with subordinate bands of chlorite schist and chloritic phyllite.

Pre-grouting treatment

To consolidate the ground to safely construct the cut off wall, Odex drilling and Tube-a-manchete – permeation grouting was done on both sides of the proposed cut off wall area.

guide Wall

Throughout the stretch of the cut off wall connecting both banks of the river, L&T has constructed an RCC guide wall. This has been done as a guide for the Grab & Cutter and also to aid the tremie concreting.

State-of-the-art equipment in operation for the construction of cut-off wall


Panel Sequence

Panel layout has been earmarked as Primary 2.8 m and Secondary 2.2 m considering an over cut of 30 cm on the already completed Primary panels. Both primary and secondary panels were excavated in one single bite of 2.8m long. When two adjacent primary panels were filled with concrete and adequately aged the grabbing of secondary panel was started in between using the same procedure as done for primary panels.

Pre-excavation

Mechanical grab type excavator has been used for pre-excavation in Clay core portion, before commencing the actual cutting work. This 10m long guided mechanical grab is 1.0 m deep and 2.8m wide. Suspended by ropes, the grab is operated by crawler crane.

Bentonite Management

Bentonite slurry was used for trench stability. Due to bouldery & highly permeable ground, the management of bentonite was a crucial aspect. Preliminary tests were carried out to define the best composition bentonite slurry. The bentonite slurry was prepared by mixing the bentonite powder to the water in a high speed mixer.

After hydration, the bentonite mud was delivered to the tanks for bentonite storage tanks. Bentonite slurry was circulated between trench and storage tank through mud pump, booster pump and desanding plant.

De-Sander

De-sanding equipment comprises of a series of vibrating screens to remove sand, gravel and hydro-cyclones to remove silt from trench slurry.

Trenching

Hydromill type trench cutter, 1.0 m deep, 2.8 m wide and 11.4 m tall mounted on Crawler crane with inbuilt electronic system to monitor the performance of cutter during the time of its operation was used. While the cutting wheel’s of the cutter, cuts & mides with bentonite shurry and a power mud pump bring the cutting to DG sanding plant.

Trench Cutter Monitor

Trench cutter monitor is used to display the vertical and horizontal deviation in both X and Y direction, the load applied on the cutter wheels and the rotation speed.

Chiselling

A specially designed heavy chisel was used to advance trenching through boulders encountered during trenching.

Rock Socketing

Confirmation of bed rock was certified jointly by Geologists of L&T & NHPC and a minimum of 500mm penetration was achieved in bed rock before terminating the panel.

Koden Test

Construction of large structures today requires foundations with much greater bearing capacity than in the past. While large and deep bored piles or cut off walls are used, the quality control of these subsurface structures depends purely on certain characteristics like trench size, alignment, and verticality. Engineers should evaluate the quality condition of these parameters to ensure the quality of the Trench profile.

Koden equipment was used to test the actual deviations of wall from the planned alignment.

Pre-grouting works


Cut-off wall Highlights

Max. Depth of Panel 46 m from+1300m level

Thickness of Wall 1000mm

Soil trenching area 3200 sq.m.

Rock trenching area 200 sq.m (approx.)

Embedment in bedrock 0.50m (min)

Type of overburden soil Bouldery alluvial deposit

Boulders Gneissic and Quartzitic

Bed rock type Chloritic schist with bands of chloritic phyllite

Compressive Strength 74.19 MPa (perpendicular to foliation) Quartz boulders up to 165 MPa

RBM Boulders, pebbles and cobbles of intrusive and metamorphic rocks with silty clay/sand

Permeability 10-1 - 10-5 cm/s

Bed rock depth Elevation: 1295-1254m

Trench cutter in operation

Desander for Bentonite management


Plastic Concrete

As per the technical requirements, a plastic concrete mix was designed and manufactured with strict quality control to the entire satisfaction of client.

Tremie Concreting

Concreting of the trenched panel was done by tremie method by which the concrete was poured under bentonite slurry without any mixing of concrete and bentonite slurry.

Monitoring

A very close monitoring of the entire cut off wall execution was systematically done through

• Dailyactivitylogging

• DailyqualitycontroltestsonBentonite

• KodenTest

• Q/CtestsonPlasticconcrete(Internal&External).

• Monitoringrocklevel

Achievements

• 1283sq.mtrenchinginrockinthemonthof May 08 which surpassed international benchmark productivity levels.

• Jobcompleted150daysaheadofschedule–Mile stone no.6

• AppreciationletterfromNHPCforthemilestone achievement

• Totalaccidentfreeoperation

• Compliedwithallqualitystandardsandallpanel reports got approved.

Chiseling

Tremie concreting


Parbati Hydroelectric Project Stage III is situated on River Sainj. The Rockfill Dam is under

construction at an elevation of 1302m above mean sea level, 3 km from village Sainj in Kullu District of Himachal Pradesh. This is the second Rockfill Dam in India after Dhauliganga in Uttranchal having a plastic concrete cut-off wall. Following are the salient features of the dam:

Salient Features

• LengthoftheDamincludingspillway-218m

• BaseWidth-168m

• TopWidth-10m

• HeightoftheDam-43m

• QuantityofImperviouscore-76000cu.m

• Quantityofrockfill-2.64Laccu.m

• Quantityoftransition&filtermaterial-1.03laccu.m

• Reservoircapacity-166.79ha-m

• Lengthofreservoir-1.05km

• RiverbedLevel-1290m

• FullReservoirLevel-1330m

• LengthofCut-offwall-117m

Construction of Diversion Tunnel

Before commencing the construction work on the dam project, the flow of river had to be diverted from the main dam area. For this purpose, it was proposed to divert the river through two diversion tunnels at the right bank of the dam. The tunnels were of 6.75 m finished diameter, horseshoe in shape having a length of 391m and 440m respectively. They were designed to carry a discharge of 800 Cumecs (Cubic meter per second) of water. Each tunnel is provided with an inlet structure having three gates namely service, emergency and stop log gates for regulating the flow of water.

A letter of appreciation was issued by NHPC for achieving the river diversion with adverse weather conditions and heavy rains.

Construction of upstream and downstream cofferdam

After diversion of the river, upstream and downstream coffer dams were constructed. This was required to completely dry up the river bed so that the excavation work can be taken up. The upstream cofferdam prevented the water from spilling over to the construction area and the downstream coffer dam prevented the backwater to seep through. The height of upstream coffer dam was 15m and downstream coffer dam was 5m. Curtain grouting was carried out through the coffer dams to further increase the impermeability of the coffer dams. The coffer dam consisted of central impervious clay core followed by filter zone rock fill and riprap.

Construction sequence of Rockfill Dam

Construction of rock fill dam involved the following sequence of operations:

• Theentireareaof thedam requiredclearing,stripping, and trimming to commence the foundation work, followed by excavation for the trench along the line of the cut-off wall.

Construction of

Rock-fill Dam

1286.80 5.76

Clay1

2

12 1.75

1

5.00

5.005.00

7.50

MAIN DAM

23B

1

3C

0.2

11

0.2 0.5

1

3B1.75

1

11.3

11.3

3C

1290

1300

1310

1320

1280

1250

1260

1270 1.0m. THICK CUT-OFF WALL

2B0.5

1

3A

2A2A

CUT OFF TRENCH2A

10.001333.00

1313.00

1320.00 1320.00

1313.00

1300.00

168.55

3A

NSL

?

ROCK LINE

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DAM AXIS

1


• Constructionofthecut-offwall.

• Consolidationandcurtaingrouting.

• Embankment placing may be performedsimultaneously or as an independent activity on the cut-off wall

• Placingtheembankmentfillsuptotheleveloffoundation of the parapet wall.

• Constructionoftheparapetwallalongthedamcrest.

• Placingofremainingfillmaterialsonthedamcrest, up to specified camber levels.

• Installationofsurfacetargets.

Achievements

• Deployment of equipment achieved onschedule.

• Riverdiversionachievedonschedule

• Diaphragmwallcompletion150daysaheadofschedule.

• Placementof2,00,000cu.mofRockfillmaterial,Graded material, Clay Filling and Riprap achieved 301 days ahead of schedule.

Diversion tunnel inlet Diversion tunnel outlet

Construction of rock-fill dam in progress


Allain DuhanganHEP – L&T’s endeavour at the

highest altitude of 2750 m

K. SRIDHARAnCorporate Communications Department HQ-Chennai

Head regulator

Allain Duhangan Hydroelectric Project (ADHP) is a 192 MW run-of-the river hydroelectric

project coming up at the confluence of Allain and Duhangan rivulets at Prini Village in Manali Town of Kullu District, Himachal Pradesh. Located at 2750 m above mean sea level, this project can aptly be called as L&T’s project on top of the world for its high altitude. No project of L&T has been executed on such a high altitude, though it has worked on many projects in the Himalayan ranges in different locations.

ADHP consists of a high-head power plant that utilizes a combination of glacial melting of the snow during summer and rain waters during monsoon months – both fed from the catchment basins of the Allain and Duhangan rivers to the power station through tunnels.

This build-own-operate project is owned by Allain Duhangan Power Company Limited (ADPCL), which is jointly owned by Statkraft Norfund Power

Invest AS (SN Power, Norway) and LNJ Bhilwara Group.

Valued at Rs.116 crore, L&T is executing two packages at the project, which involves Package I – Construction of Barrage, Desilting Chamber, Spillway and Reservoir. Package II - Construction of three Adits and Head Race Tunnel.

According to Mr. Subrata Das, Construction Manager, L&T, the scheme of the project envisages utilisation of flows from two streams viz., Allain and Duhangan by means of separate water conductor system, which is a D shaped concrete headrace tunnel of length 3850 m. Both of these HRTs leads to a common pooling point, the surge shaft from where a pressure shaft takes off leading to the powerhouse and thereafter discharging through a tailrace tunnel to a suitable location.

There is an intermediate storage reservoir of live storage capacity of 2.24 lakh cu.m capacity, which

Steel rib for HRT


will be fed through headrace tunnel from Allain diversion barrage.

The highlight of this project is that the entire construction work with complete infrastructure facilities are built on steep terrains of the Himalayas. Indeed, "Himalaya" means "abode of snow" and hence snow and cold temperatures are characteristic of high mountain areas and no exception to ADHP.

To approach the project, one has to pass through Manali town and take the highway to Leh. From Manali town, it takes about one hour to reach the project by road and ascend steep terrains, negotiating several sharp curves and narrow stretches of the newly formed road by the project authorities. While it was a terrifying experience to ride on these roads and dizzying heights to reach the project, the sight of the beautiful snowy-white Mountain stretches, bluish sky with silky white clouds and the meandering Beas river with its sweet humming sound, the astounding and awe-inspiring views of yawning Kulu and Manali valleys with green patches of vegetation, tall pine and cedar trees together with biting cold makes one totally forget the problems and enjoy the idyllic beauty of the nature, which is characteristic of the Himalayas. At the same time, even if one could find some inhabitations here and there, the population is very sparsely distributed in view of the tough living and climatic conditions.

Mr. Das said “A special project of this kind has its own peculiarities and perils associated with it, however, the operating company has to encounter and overcome these problems and turn them to our own advantage”. While there are several logistic problems, L&T faced many other critical problems in executing this special project mainly due to its geographical location and extreme climatic conditions.

Snow fall Being an avalanche prone area, working conditions were very tough (touching subzero temperature), specifically for three months during January to March, when there will be a 7 feet cover of snow. During this period, he said “No major work takes place and the site experienced minus 10 degree Celtius during February 2008”. During this period the site remains cut off with rest of the world because of road blocks due to heavy snow fall.

Maintaining the Plant & Machinery during extreme cold climate is yet another critical aspect. All equipment have to be cleared off snow and start the engine at every three hours interval in order to see that the engine doesn’t get seized.

Tyres of Heavy equipment have to be fitted with chains so that this doesn’t slip and jerk during movement. Snow Cutters & Dozers were pressed in to action to clear the snow on the road for better visibility and smooth passage of vehicles.

on-site campIn view of the remote location of the project, staff colony and workers’ camps are provided on-site with mess and recreation facilities for ease of operation, faster mobility, better control of work fronts and retreat. Unlike the normal accommodation at regular sites, Allain Project called for on-site staff quarters and worker colonies, built with special materials such as thermo insulated roof and walls to withstand the extreme climatic conditions. This consists of three layers – the outer corrugated GI sheet, the middle thermocole panels and plywood on the inside. In addition, room heating devices were provided for each unit to keep them warm. 46 staff and nearly 700 workmen were employed during peak.

Site establishment and P&M during the snow fall - a tough working condition


Staff colony and worker camps are supplied with piping hot water for all purposes as the cold lines gets frozen due to freezing temperature. A full fledged dispensary with a registered medical practitioner was also made available in the camp for 24 hours to take care of the medical emergencies. Warm clothing, snow boots including bedding and woolen blankets are provided to all staff and workmen for keeping them warm and fit.

An on-site canteen for workers and a mess for staff met the culinary requirements and provided them the needed succor for thought and action. As a matter of abundant caution and preparedness, all essential food items were procured and stocked in the provisional store well in advance to meet the long term needs.

In general, it is said that due to active tectonic movement and dynamic monsoon, the rock mass in the Himalayan region is relatively weak and fragile and hence predicting rock mass quality and analyzing the stress induced problems, in particular is found to be an extremely difficult task during planning stage. In practice, L&T also encountered considerable discrepancies between predicted and actual rock mass conditions.

Surmounting all these difficulties, L&T completed several activities ahead of time like the river diversion through under sluice in rainy season, completing and making a breakthrough in tunnel excavation and concrete lining of the tunnels which are in advanced stage of completion.

Value additionAll these unprecedented and unforeseen activities made every staff and workmen undergo insurmountable amount of pressure and tension as they had to meet the schedules within budget and cost and at the same time withstand the forces of nature and expose themselves to working at high altitudes, extreme cold and snow as well as rains, etc. Though they were almost buckled under terrible pressure, certainly they were not broken, but they have taken these elements as opportunities in disguise for learning of a different kind and value addition to similar projects in the future. In other words all these problems are considered as prospects for working in similar environment to build a better tomorrow.

SAlIEnT FEATURES

1. HyDRology

• CatchmentareaatbarrageAxis : 128.9sq.km

• DesignFlood

– 50 year return flood period : 662.0 m3/sec

– 100 year return flood period : 730.0 m3/sec

2. DIVERSIon BARRAgE

• Type : Gated

• Maximumwaterlevel : 2752m

• NumberofSpillwaybays : 2

• Widthofeachbay : 10m

• NumberofUndersluicebays : 2

• Widthofeachundersluicebay : 5m

• Dimension : 95.62mX90.95mX29.30m

3. HEAD REgUlAToR

• NumberofBays : 4

• DesignDischarge : 22.6m3/sec

• Dimension : 55.8mX33.8mX21.5m

4. DESIlTIng ARRAngEMEnTS

• NumberofDesiltingBasins : 4

• FlushingVelocity : 4.5m/sec


• Dimension : 80mX38.5mX14m

5. InTERMEDIATE SToRAgE RESERVoIR

• LiveStorage : 224000m3

• FullsupplyReservoirLevel : 2748m

• MinimumReservoirLevel : 2733.5m

• TypeofRetainingWall : RCCStructuralWall

• PlanArea : 18902sq.m

• WallHeight : 13m

Entire floor area was water proof, done with geo membrane

6. oVERFloW STRUCTURE

• WidthofCrest : 25m

• LevelofCrest : 2748m


7. AllAIn HEAD RACE TUnnEl

• SizeandShape : 3.4mDiameter (Circular Shaped)

• Length : 3844m


• Velocity : 2.19m/sec


“If you want to feed a hungry person, give him food. If you want to feed a Generation Sow a Seed !”

-A Chinese Proverb

It needs vision and tremendous courage to think and plan for future and particularly to build a hydroelectric project and that too on ownership basis, in a remote corner on the Himalayan hills.

While addressing a gathering of L&T-ites and customers of L&T on the occasion of the 70 year celebration of L&T and the birth centenary of Henning Holck-Larsen at Mumbai on December 21, 2007, The Union Minister, Mr.P. Chidambaram said “L&T is unique, it is not Public Sector, it is not Private Sector, it belongs to the National Sector. It is a company of the people of India ”.

In tune with the words and true to the spirit of the statement made by the Union Minister, L&T

has ventured into the hydel sector to tap the environment-friendly and everlasting hydro electric potential for the benefit of the country, and for the benefit of the people of India.

Singoli-Bhatwari Hydro Electric Power Project, a 99 MW run-off-the river- scheme across river Mandakini in Rudraparayg District of Uttarakhand is the first hydro electric project to be implemented by L&T on Build-Own-Operate & Transfer (BOOT) basis.

In this, it has accepted the challenge of setting up a benchmark in delivering to the nation a quality project on time with quality.

The Government of Uttarakhand, or “Dev Bhumi” as it is fondly called by all, has entrusted this project to L&T for implementation. L&T has formed an SPV in the name of “L&T Uttaranchal Hydropower Limited” for speedy execution and effective implementation of the project.

Whereas the L&T Infrastructure Development Projects Limited (L&T-IDPL) is managing the overall implementation of this project, the Hydel Business Unit (HBU) of ECC, L&T’s Construction Division in Chennai is executing the construction of this project.

Singoli-Bhatwari Hydro Electric Project (SBHEP) is located at an elevation of 1000 m above MSL, 25 km from Rudraprayag on the National Highway NH-109 towards Kedarnath.

The project involves construction of a Barrage - 54m long x 29.250m wide x 21.500m high above river bed, consisting of 5 bays each of 8 m clear span and fitted with radial gates to regulate flood discharge.

The Full Reservoir Level (FRL) of the barrage is at EL 1017m and the top of the barrage including free board is fixed at EL 1020m.

The barrage, on its downstream side, will have an apron of size 54m length x 45m width x 3.5m thickness.

Singoli-Bhatwari HEP - small step for a giant leap

Adit 1 portal construction in progress


The clear water is then passes through gate arrangements and fed into the intake pool - 42m x 42m and then through the intake gate chamber of size 16m (L) x 15.5 (W) x 20.5m (H) which channelises the discharge of 59.6 cu.m into the Head Race Tunnel (HRT).

The diversion of the river will be handled in two stages for constructing (a) the Barrage and (b) Desilting chambers & Intake respectively. Thus, the diverted water, will take the 11.230 km long journey through a 4.77m, D-Shaped, concrete lined Head Race Tunnel.

In order to construct the HRT, three adits have been proposed, first one near the Barrage site, second one near Damar Nala crossing and the third one near Dangi Nala crossing. These adits will give four faces of simultaneous working. Maximum length of tunnel section to be excavated from the Adit will be 3.20 km and this will form the critical segment in HRT construction.

The alignment in the last segment of the tunnel after Adit-3 is so modified now to avoid passing of tunnel under an existing village, to allow for the sentiment and apprehension of the villagers.

The HRT ends at the bottom of a Surge Shaft of size 10m finished DIA x 103m high, tapering to 5m dia x 35m high. This open to sky shaft, helps in relieving the water pressure, in case of opening and closure of turbines at powerhouse end.

The water from HRT is then allowed to travel through steel lined Pressure Shaft with the vertical portion of shaft having a dimension of 3.8m finished dia x 125m height and horizontal portion having a finished dia of 3.8m x 284m length, constructed through the hard rock on the hills, and ending up as three penstock manifolds, entering the Surface Power House, which has a dimension of 53m (L) x 17.6m (W)

Thus, between the Barrage and the Powerhouse, an hydel energy of 186m net head is being built up. This energy head is unleashed on vertical shafts having three Francis Turbines of 33 MW capacity each, embedded in the Powerhouse sub-structure, which gives necessary rotational power to the Rotors of the Generators. On an average estimate, this project can produce 474 million units of energy in an 90% dependable year.

This energy is fed to the State grid from an open Switchyard of size 150 m (L) x 65 m (W), to be constructed near the Power house.

The Hydro-mechanical works of this project involves erection of 5 Radial Gates at Barrage and Trash-rack including gate structures at Intake Pool entrance, at Intake structure, and the bulk-head gate at Surge shaft including 3 sets of Gates at Draft tube outlet in Powerhouse. Total tonnage of all the above structures will be 950 tonnes.

Hydro-mechanical works also involves fabrication of 1307 tons of steel liner of 3.8 m for Pressure Shafts made of SAILMA 450 HI grade with thickness

70m span steel bridge across river Mandakini

Another view of the steel bridge


varying from 16 to 28 mm. In addition, 614 tons of SAILMA steel will be used for steel liner under the Dangi Nala portion and Soft tunneling of HRT.

The construction schedule prepared by L&T envisages 44 months for completion of the project and all works relating to HRT is on the critical path. L&T is already gearing up appropriate tunneling methodology, mobilizing men, material & machinery including planning and development of skilled workmen to handle the works.

During the course of construction, L&T is bound to encounter several challenges.

Construction of the Barrage poses challenges of taming the mighty Mandakini and the monsoon, the Head Race Tunnel works and other below ground works like Pressure shaft and Surge Shaft poses greater challenges in dealing with the virgin unpredictable geology of the Himalayan terrain.Dangri road to Adit 3 under construction

Damar road, which leads to Adit 2 under construction


beginning the main project works on time. About 600 workmen of various skills and categories need to be mobilised from external and local sources.

Significant achievements made at the project include:

• ConstructionofboxculvertonNH-109whichserves as the portal for Adit-1 and completion of Adit-1.

• Constructionof2kmlongDamarroadleadingto Adit-2 on the other side of river Mandakini, with the associated protection works, cross drainage works and 19m span steel bridge across Damar Nala near the Adit-2 portal

• Construction of 70m long span steel trussbridge across river Mandakini.

• Construction of 2.7 km long road at Dangi,which will be further extended by 1.3 km to access Adit-3.

• ConstructionofProjectcampstoaccommodate568 workmen at three different locations viz. Sansari (184 persons), Damar (200), and Phalai (184)

• AStaffCampatGiwadiGaontoaccommodate32 families and 50 bachelors has been completed. Construction of a guest house in the same campus for the visiting staff is under progress.

• CompletionofMainStores,P&M,QualityandSafety offices, etc at Chandrapuri.

• CompletionofExplosiveMagazinebuildingatDamar.

• Commissioning of a 50 TPH Crusher Plantat Damar and 30 cum/hr Batching Plant near Barrage site are in advanced stage.

L&T has already tied up with financial institutions/ agencies and all frameworks are ready for achieving financial closure and initiation of necessary fund/cash flow. L&T has also started the process of tying up with various industries and agencies for marketing the sale of power in future.

Design & Engineering are being carried out by L&T’s in-house team at EDRC and reviewed by MWH, USA. Already the process of vendor selection and finalization for Hydro-mechanical and Electro-mechanical works on back-to-back basis have been set in motion.

L&T’s team is very enthusiastic in building the first power plant on PPP basis.

Logistically, this project also faces the challenge of dealing with the limited Highway of Uttarakhand, which is either prone to landslides during monsoon or full of pilgrims during the normal season.

Geographically, the project is dispersed to a stretch of 15 km on left bank highway and another 10 km stretch of roads across river Mandakini to reach Adit sites.

The quantum of works involved in the project can be assessed from the following table.

Quantities of Major Works

Description UOM Qty.

Excavation cu.m 7,41,148

Backfilling cu.m 1,50,188

Concreting cu.m 2,34,281

Reinforcement tons 4,736

Structural Steel tons 1,201

SFRS cu.m 10,710

Formwork sq.m 57,529

Rock Bolts RM 1,18,270

Grouting t 3,013

Dewatering kWH 40,02,230

Pressure vessel Steel (SAIL MA 350) t 1,921

HM Steel Structures t 950

This quantum needs to be seen in conjunction with several logistical constraints. These are further compounded by other man-made challenges like local unrest by villagers and other hurdles for dealing with land acquisition and other statutory clearances etc.

Unfazed by the problems or pressures and with unremitting efforts, L&T has already obtained major clearances like Environment, Forest, DPR, NOC from Pollution Control Board, Explosive Magazine License, Diesel Dispensing Unit, License for using river borne materials for aggregate production and stacking etc in a short span of time.

Moreover, in parallel, it has mobilized the manpower and machinery resources right at site, and is progressing with the required infra works like Roads, Buildings, Project Camps etc for


Tapovan Vishnugad HEP

with TBM technologyK. VIjAyA BHASKAR Project Manager

Aerial view of the site showing the batching plant and other infrastructure facilities created on tough terrains of Himalayas

Larsen & Toubro & Alpine Mayreder Bau GmbH, Austria, are jointly executing the challenging

“Head Race Tunnel” Package of Tapovan Vishnugad Hydro Electric Project (TVHEP) awarded by NTPC Limited in November, 2006. TVHEP is a Hydel Power Project with installed capacity of 520 MW (4 X 130MW).

The scope of Head Race Tunnel Package involves excavation of 11.50 km of Head Race Tunnel and Three Adits of total length 1.25 km. Adits are to be excavated using Drill Blast Method and Excavation by Roadheader. 3.50 km of Head Race Tunnel is to be excavated using mainly Roadheader or need based Drill Blast Method depending upon the geological conditions. 8 km of Head Race Tunnel is to be excavated using Tunnel Boring Machine (TBM). The finished Dia. of Head Race Tunnel will be 5.60m and the excavation Dia is 6.20m. Excavation of Tunnel using TBM in Himalayan Geology is a very challenging assignment and what is more challenging than the tunneling work itself is the transportation of the TBM to Project Site located at an elevation of 1820m above Mean Sea Level.

The site is located in Joshimath, one of the towns of Chamoli District in Uttranchal. Joshimat is a town on the greater Himalayan Mountains on National Highway 58. From the project location the holy Badrinath shrine is just 40 km away.

During the Badrinath Yatra season (May to Oct), there will be heavy traffic on this narrow hilly road. Complete traffic movement takes place only during day time as night traffic is not permitted. The Road distance from Delhi to Joshimath is 506 km. The nearest city from the project is Haridwar and Dehradun. From Delhi, Haridwar is 229 km away and Haridwar to Joshimath is 277 km. The entire stretch between Haridwar to Joshimath are dotted by holy towns such as Haridwar – Rishikesh Deoprayag – Srinagar – Rudraprayag – Gauchar – Karnprayag – Nandpryag – Chamoli – Pipalkoti – Joshimath. From Rishikesh to the Project Site it is a hilly terrain involving a climb of over 1500m. While the condition of the road is fairly good up to Rudraprayag, it is very bad beyond this point with very narrow stretches and high gradients.

Double Shield Hard Rock Tunnel Boring Machine ordered from Herrenknecht, Germany (in the Month of February 2007) will be used for the first time for a Hydel Power Project in India. The L&T-AM JV Team had around one year leeway for preparation of transportation arrangements for the machine, scheduled to be shipped by January 2008 and reach site by April 2008. Various agencies were contacted for transportation of TBM, but few turned up for accepting the challenge. Ultimately, J M Baxi & Co.(the Clearing & forwarding agents) came forward and took up the challenge and

Tunnel boring machine


completed the transportation successfully with the help of J C Motors Transportation Company. The heaviest and biggest piece of Machine was Cutter Head, circular in shape with Diameter of 6.50m and weight of 101 tonnes. Bringing this in single piece to project site was a next to impossible task; keeping in view, the road conditions and hilly terrain.

Route Survey (Rishikesh to site) NH-58 “Raiwala (12 km. short of Rishikesh) Rishikesh bypass – Tehri – Badrinath Junction – Laxman Jhula – Kandiyala – Devprayag – Bhagwan – Rudraprayag bypass – Karna Prayag junction – Chamoli – Helang – Tapovan – Vishnugadh Power house – Selang Junction – Selang L&T site involved an approx. distance 267 km. The road clearance and overhead clearance restricted to 3.20m width and 4.2m height due to rocks protruding towards the road.

Two months before commencement of the transportation of TBM, liaisoning was done with the local authorities and all permits were obtained before the actual transshipment.

To overcome the biggest challenge in logistics, ie, transportation of TBM from Mumbai Sea Port to project site, L&T-AM JV made separate teams for proper coordination, and for unloading the TBM consignments properly at site, which had severe space constraint.

The transport team escorted all the major consignments from Rishikesh to Project Site tackling many hurdles on the way and successfully completed the transportation of TBM by May 6,

2008, just one day before starting of Yatra Season at Badrinath. The consignments were transported during night as there was heavy traffic during the day time which can disrupt the movement of the trailers. However, the road improvement team tackled the hurdles such as civil works (Widening of road, strengthening of bridge, etc.) at various critical points.

With difficulties, this giant machine crossed all the hurdles and reached the project site safely without any major incident, a day before commencement of Yatra Season. This was a grand success for the project team at site and everyone greeted each other with utmost joy and happiness writ large on their glowing faces. Amidst excitement and thrill this also brought a great sigh of relief as it was the culmination of challenging and painful labour of almost a year. Ever since the machine was ordered continuous efforts were made by the planning and execution team at the project to ship and transport the machine to India. The consequence of something untoward happening during the transshipment could delay the project schedule drastically which would be a big commercial risk for the performance of the project. Also, transportation of such a big consignment during Yatra with traffic jams and monsoon season with landslides on a hilly terrain like this could have increased the difficulties manifold. To ensure alround safety and also mitigate the very many risks, necessary protective measures were taken well in advance. TBM with all back-up systems was successfully commissioned in February 2009 and the tunneling activity is progressing at a faster pace.

Moulds inside the yard


Caption Caption....

L&T is currently executing the Contract of Construction of External Access Road to

Sawalkote Hydro Electric Project, on Engineering, Procurement and Construction basis for the sawalkote Hydro Electric Project in the Ramban District for Jammu & Kashmir State Power Development Corporation.

L&T's scope of works include

• Survey,designandengineering

• Site clearance, earth work, pavement, slopeprotection, retaining structures, drainage & cross drainage works, road furniture

• Constructionof10mwideand18.50kmroad

• RoadattherightbankofriverChenab

• Constructionoftwomajorsteelgirderbridgesand two minor bridges

• BridgeacrossriverChenab

• Constructionof500mlongTunnel

Quantum of workRoad

Excavation in soil : 5.48 lakh cu.m

Excavation in rock : 9.82 lakh cu.m

Earth work in filling : 0.950 lakh cu.m

Pavement Works

Granular sub base : 0.24 lakh cu.m

Crushed run macadam : 0.22 lakh cu.m

DBST : 0.04 lakh cu.m

Concrete for road and bridge : 5512 cu.m

Structural steel : 1520 t

ViaSys, Sweden are the basic designer and

Construma Consultancy Pvt Limited are the

consultants for this Project. L&T Ramboll is the

Design Consultant and the Engineering Design

and Research Centre is also actively involved.

The contract for the construction of the only access

road to the Hydropower project commenced in

November 2004. As the project is located in a very

remote, isolated and highly militancy prone area,

there was delay in the initial period. After proper

security cover, the work started moving at good

Speed. Adequate and proper men and machines

are being deployed for hassle-free execution.

With all the quality checks, tests and meticulous

planning and reviews, the work at this project is

fast moving towards the completion.

Infrastructure for Sawalkote Hydro Electric Project

Road construction work in progress


Kuttiyadi Hydroelectric Project

M.V. RAMACHAnDRAn Project Manager

Head Race Tunnel

Hydroelectric Project

Kerala State, which lies almost at the Southern tip of Western India, occupies a narrow strip

of land between the Arabian Sea on the West and the Western Ghat ranges on the East. The state of Karnataka and Tamil Nadu lies on the North-East and on the South-East respectively.

South-West monsoon bless Kerala from June to middle of August, while North-East monsoon from September to end of November. The period between December and middle of May is generally dry and the months between March and April experiences hot summer.

Kuttiyadi River takes its origin on the Western slopes of the Wynad range of hills at elevations 915 to 1065m above MSL. After its initial run in a North-South direction, the river takes a sharp turn towards west and the Kuttiyadi dam is constructed in a little upstream of the bend. The catchment area above the dam site is 39 sq.km. The area comprises mostly of thick virgin forests except for a stretch of abandoned cardamom plantation. The catchment area is roughly rectangular in shape and this lies in a North-East direction.

The Karamanthodu locally known as Churanipuzha originates on the Eastern slope of Wynad hill ranges. It flows in a North-Eastern direction and joins Vennayotpuzha, a stream running parallel to Karamanthodu in the upper reaches to form the Panamarampuzha, tributary of Kabini. The catchement area of the stream at this dam site is 54.4 sq.km and this consists of mostly private and forest lands with patches of cultivated lands.

The existing Kuttiyadi Reservoir has a live storage of 33.98 million cu.m. against inflow of 210 million cu.m. Due to the very limited storage at Kuttiyadi Reservoir, the water spills at Kuttiyadi Dam during Monsoons. The existing Kuttiyadi Extension Scheme (1x50 MW) is mainly built for utilization of the spills for power generation in a separate Power House.

With the completion of Kuttiyadi Augmentation reservoir which has a live storage of 186.25 Million cu.m against an inflow of 438 Million cu.m there are plans for additional Power generation. However, construction is underway for an economical installation 100 MW (2x50MW) hydroelectric

power plant. This scheme will be constructed as an annex to the existing Kuttiyadi Extension Scheme 1x50 MW and 3x25 MW Schemes. By this a total of 225 MW continuous generation can be achieved during peak hours for the non-monsoon period.

Water from the powerhouse is fed through Tail Race channel and 3x1.25 MW is generated with this tail race water, located at end of tail race channel.

Kuttiyadi – A Trailblazer Up above the high rugged hillocks and amidst meandering ghatways and verdant rain forests is perched the The Kuttiyadi Hydro-Electric Power Project – one of Kerala’s multipurpose projects. With an installed capacity of 125 MW, it is considered a power hub that supplies much of Kerala’s power needs in addition to aiding irrigation. Here, ECC - the Construction Division of L&T, is engaged in the design, engineering and execution of all civil and hydro-mechanical works for the 2x50MW Additional Extension Scheme. When completed, the project will achieve a total 225MW continuous generation during peak hours for the non-monsoon period.

This is the first EPC Hydel Project bagged by L&T in Consortium with BHEL against Global Competitive Tender on LSTK Basis. The scope of work involves engineering by EDRC and execution of all civil & hydro-mechanical works by Hydel & Nuclear (H&N) OC and design, engineering and execution of all Electro-Mechanical works by BHEL.

Project Highlights Project : Design, Build, &

Turnkey Execution of 2x50MW Additional Extension Scheme of Kuttiyadi Hydro Electric Power Project

Client : Kerala State Electricity Board

Contractor : BHEL - L&T Consortium

Contract Value : INR 16241.30 Lakhs


Salient Features Key parameters & scope of work

Installed Capacity : 2x50MW

FRL : +757.72m

MDDL : +743.00m

Sill Level of Intake : +738.00m

Max. Discharge : 21.50 cu.m/sec.

Power House Runner Level : +91.75m

Avg. Gross Head at Powerhouse : 658m

Major Quantum of WorksDescription Unit Quantity

Open Excavation

a. Soil cu.m 246200

b. Rock cu.m 102300

Underground Excavation cu.m 8600

Back Filling cu.m 23300

Concreting cu.m 28300

Reinforcement t 1200

Shuttering sq.m 37250

Structural Steel t 210

Penstock & Specials t 3200

Gates & Trash Racks t 75

Civil & Hydro-mechanical Works (by l&T)Intake structure shaft : 4.65x2.60x19m; approach channel

and trash rack structure

Head race tunnel : Horseshoe shape, 3.0m DIA finish, 692m long

Surge shaft : Circular-5.0m DIA finish, 74m deep

Low pressure penstock : Tunnel: 2.40m DIA; Liner: 2m DIA; 87m long

Butterfly valve chamber : 12m x 9m

Penstock track : 10m Wide-Track, A. Blocks & RG. Supports

Powerhouse : 32m x 22m x 20m

Tail race channel : 8m x10m x 80m

Hydro-mechanical works : Intake gates, trash rack panels & DT. Gates Penstock OD-2.05 m x 2160 m long, thickness varies from 12- 46 mm of Grade ASTM A537 Cl.1 & ASTM A517 Grade F. Total Quantity: 3200 tons

Approach roads to structures : 5 km.

Electro-Mechanical Works (by BHEl)Turbines are made of vertical shaft Peloton Wheel Turbine having 500rpm, 70000HP rating and 56.60 MW output. BHEL is also supplying Generator, Power Transformer,Auxiliary Mechanical & Electrical Equipment including the Outdoor Switch Yard Equipment - 110kV

In spite of the several uncertainties and problems faced in the project, L&T went on executing the project with high quality standards. This has won the hearts of many project authorities which are reflected in their appreciation letters for achieving many milestones and breakthroughs:

• TunnelBreakthroughwithprecisealignment

• FabricationofPenstocks&specialswithhighquality standards

• Blasting operations – Safety & Methodsadopted

• SCC – Usage of Technologically advancedtechniques

Penstock erection


Super Passage Channel at Varahi HEP

The river Varahi takes its birth at a height of 730m in the Western Ghats at Hebbagilu, near

Agumbe in Shimoga District. It joins the Arabian Sea near Kundapur. After a 25 km initial run, this swift and powerful river falls 455 m in cascades to form the bellowing Kunchikal falls.

The Varahi Hydro power project is a small containment run-of-the river project of 22.5 MW installed capacity, comprising 3 units of 7.5 MW each. It is located on lower reaches of western scarps of Western Ghats in the Udipi District of Karnataka near Hosangadi village in Kundapura Taluk. Sandur Power Company Limited (SPCL), Bangalore, are the owners of the project.

The project generates approximately 120 GWh of electricity per annum and sells it to Karnataka Power Transmission Corporation Limited (KPTCL) through a Power Purchase Agreement (PPA).

ECC was awarded two packages at this project viz., Construction of Civil and Appurtenant works and Head Race Tunnel by M/s Sandur Power Company of value INR 459.2 million. The project consisted of Diversion Weir, Approach Channel, Intake Structure, Head Race Tunnel with three Adits, Surge Shaft, Penstock Tunnel, Power House, Tail Pool, Tail Race, Super Passage, River Regarding and Rapids. This Project work, which began in October 2002 was completed in all respects in 25 months including two monsoon periods.

The major components of this project are:• Diversionweir across river Varahi about 40m

downstream of confluence of Underground Power House Station tail race channel.

• ApproachchanneljustdownstreamofVUGPHtail race on right bank of river to divert water to HRT through intake structure

• Straight tunnel intake structure to HRT fromdiversion weir to regulate flow of water into the HRT

• Horseshoe shaped, HRT from intake up tosurge tank with concrete lining

• Surgetankatridgepoint• Penstocktunnelwithconcreteliningtakingoff

from surge shaft

• Steel penstockbranching off to 5 nos individual penstocks

• Power house on rightbank of river Varahi accommodating 5 units of turbines

• Tail race channelcrossing Super passage joining river Varahi & other allied civil works.

Super Passage Channel during Flash Floods

During the execution of the project, while connecting the power house and trail race, one perennial nulla was intercepting at different elevations. Due to early on-set monsoon, the execution of the super passage could not be carried out as per initial schedule, even though this structure was under critical path for the commissioning of the 22.5MW Hydro project.

Super Passage Channel consists of an RCC structure, which had a dimension of 15 m x 24 m x 11 m height, perpendicular to Tail Race Canal and this involved construction of 12 circular columns of 600 mm dia, supported by continuous beams on longitudinal directions and slabs of thickness 300 mm with walls on adjacent sides having stubs on both sides. The RCC walls of the Tail race canal were of 12 m height and they were constructed using M20 concrete.

The continuous flow of flash floods during the season necessitated the construction of the Super passage by using innovative construction methods to cast the RCC columns and suspended formwork for the casting of RCC beams, slabs etc. In fact ECC successfully executed the structure undeterred and braving against the flashing floods of over 11m high tail race water. In addition, the concreting of the super passage pier was done under water after the bed was cleaned of accumulated silt and slush with the help of divers using tremie pipes. The total process of construction was completed within 30 days.

Completed portion of the passage channel


K A l E I D o S C o P En E W o R D E R S

Rs 1450 crore orders in Buildings & Factories Segment

L&T’s including add on orders from on going works at its airport projects.

The orders for construction of IT & Office space buildings have been received from major players around the country including TCS & Godrej Developers Private Limited .

These orders enhance the order book of the Company which had secured major design-&-build orders in the airports, IT Parks and commercial space and L&T has a significant market share in these segments.

Another Rs 5000 crore orders in Buildings & Factories Segment

L&T’s newly formed Buildings & Factories Operating Company – part of its Construction

Vertical – has bagged several large-value orders aggregating to around Rs.5000 crores in the second quarter of 2008-09 for the construction of a slew of institutional, commercial, residential and factory buildings.

The orders have been received from major players around the country including NESCO Limited, Godrej Properties Limited, PBEL Property Development (India) Pvt Ltd, Om Prakash Jindal Grahmin Jan Kalyan Sansthan and Mahi Cement.

These orders boost a growth trend that earlier saw the Company securing major design-&-build orders in the airports, IT Parks and commercial space.

L&T has been engaged in virtually all the modern airports in India that have been built or are under execution including those at Hyderabad, Bangalore, Delhi and Mumbai.

Rs 937 crore EPC orders in Water Business

L&T has bagged three major orders aggregating to Rs. 937 crores during September and

October 2008 in Delhi and Andhra Pradesh.

An EPC water supply project of value Rs. 582 Crores was bagged by L&T from Hyderabad Metro Water Supply and Sewerage Board (HMWSSB) under prestigious Godavari Drinking Water Supply Project Phase-I. The project involves construction of trunk mains of MS pipe for 58 km to bring 735 Million Litres per Day (MLD) treated water to Hyderabad city. The contract period is of 24 months.

Two EPC projects from Delhi Jal Board valued at Rs. 355 Crores were secured by L&T. The project envisages design, providing, laying, jointing, testing and commissioning of MS twin-pipeline from Bawana to Dwaraka (Package 1A) and design & construction of 20 Million Gallons per Day (MGD) water treatment plant (WTP) at Okhla. This WTP will have clarifloculator, flash mixer, filters, pre-sedimentation tanks as major units along with the intake system. Both projects are to be completed in 21 months.

Rs. 1,372 crore orders from Metallurgical SectorLarsen & Toubro (L&T) has secured major orders aggregating to Rs. 1,372 crore from various customers like Vedanta Aluminium Limited, Utkal Alumina International Limited and Bhushan Steel Limited.

L&T has secured an order valued Rs. 516 crore from Vedanta Aluminium for setting up of a 3 million tonnes per annum (MTPA) alumina refinery at its Lanjigarh plant in Orissa. The scope involves civil, structural, tanks, equipment erection, piping and commissioning assistance for the alumina refinery. The project is to be executed in 20 months.

L&T has also secured order valued Rs. 455 crore from Utkal Alumina International for setting up of 1.5 MTPA green field alumina refinery at Doraguda near Rayagada in Orissa. The scope involves civil, piling, structural and tanks for the alumina refinery. The project is to be executed in 24 months.

New Orders


In an another development, L&T secured an order valued Rs. 401 crore from Bhushan Steel for civil, structural, equipment erection and piping for its Phase-III expansion at Angul in Orissa which includes setting up a Steel Melt Shop and Coke Oven. L&T is already executing the other orders of a 3,800-cubic-metre blast furnace and 2x204-square-metre sinter plants for Bhushan Steel for Phase-III.

These orders, from major producers in ferrous & non-ferrous sector in the metallurgical field, portray the enormous confidence the industry has in L&T’s expertise in engineering, construction and project management.

l&T-Scomi to Build India’s First Monorail System

A consortium led by Larsen & Toubro with Scomi Engineering Bhd, Malaysia has bagged

a Rs. 24.6 Billion (Rs. 2460 Crore) order from the Mumbai Metropolitan Region Development Authority (MMRDA) to implement the country’s first Monorail System in Mumbai.

Larsen & Toubro is India’s leading Technology, Engineering & Construction Company and is a premier builder of infrastructure projects in India with track record of successful implementation of several large turn key projects. Scomi Engineering is one of the world’s top three monorail manufacturers, and offers urban transportation solutions by providing the latest monorail electro-mechanical systems and rolling stock.

The project involves Designing, Constructing, Installation, Testing & Commissioning and Integrated Testing including Train Trail with initial

Operation & Maintenance from Gadge Maharaj Chowk (Jacob Circle) to Wadala (approx. 11 kms) and Wadala to Chembur via Mahul (approx 9 km) corridor on a Lump Sum Turnkey (LSTK) basis. The Monorail will have 18 stations enroute. The project is to be completed in a tight schedule of 30 months.

The Straddle type Monorail System complies with the highest international standards of safety and reliability. It is a modern urban transport system where the cars move on a single beam in an elevated corridor. The design makes it possible to execute the project on a fast-track as it requires a small foot- print and facilitates implementation with minimal demolition of structures. Other advantages include greater reliability, high manoeuverability, lower cost and an eco-friendly design. These factors make Monorails an attractive option for Mumbai where land is a scarce resource. The Monorail also helps in negotiating sharp curves and can handle gradients up to 6%. The Monorail is a quiet system with sleek exteriors, and air-conditioned cars, adding to commuter comfort.

This will be the first Monorail System in India and is expected to ease the congestion in the highly crowded Jacob Circle, Wadala and Chembur area. The monorail will provide interconnectivity to the existing sub urban railway (Mahalaxmi and Lower Parel Station of Western Railway, Curry Road, Dadar & Wadala Station of Central Railway, etc) and forthcoming Metro Rail as a part of multimodal transport system and on being commissioned will be a boon to the citizens of Mumbai.

Rs 1100 crore orders in Buildings & Factories Segment L&T’s Buildings & Factories Operating Company-part of its Construction Division- has bagged add on orders aggregating around Rs 1100 crores in the third quarter of 2008-09 from its ongoing developmental projects like mixed use developments at Chandigarh, Darley Road Tower in Sri Lanka, Airport Hotel at Bangalore and add on works at its airport projects.

These orders further enhance the order book of the Company which had already secured major design-&-build orders in the airports, IT Parks and commercial space. L&T has a significant market share in these segments.

New Orders


New Orders

l&T oman Bags Construction orders Valued at Rs. 1198 crore Larsen & Toubro (Oman) LLC, one of the leading companies in the field of engineering and construction in the region has secured major orders cumulatively valued at Rs. 1198 crores (USD 245 million), against stiff international competition. The orders cover construction of a hotel and apartments for the 2nd Asian Beach Games, a mosque and underground cabling.

The 2nd Asian Beach Games complex is being developed by Oman Tourism Development Company - the government of Oman’s tourism development, and its investment arm. The project comprises construction of a hotel, marine apartment buildings, administrative buildings for the Games and an athletes’ village. All these projects are scheduled to be completed in less than two years.

Engineering, Cost and Project Management Consultants for the project are M/s W.S. Atkins, NWS International and Faithful+Gould. The mosque being built by L&T Oman is developed by a reputed business group of Oman. It embodies Omani architecture and is poised to change the skyline of Oman. The project is scheduled for completion within 35 months.

Underground Cabling works from Oman Electricity Transmission Company (OETC), comprises replacing a portion of 220 and 132 KV Overhead lines in Muscat Governorate with Cabling works of

60 Km to be completed in 18 months. Mott Mac Donald is the consultant for the project.

Larsen & Toubro (Oman), a joint venture of Larsen & Toubro Limited and the Zubair Corporation, has a strong presence in Oman, and across the last decade has emerged as a leading construction company of Sultanate of Oman.

Gross Sales of Larsen & Toubro Limited for the quarter ended December 31, 2008,

at Rs. 8700 crore, has grown by 35% over the corresponding quarter of the previous year. Despite an environment of tight liquidity, cautious investment in the Oil & Gas and the Core sectors, and a general slowdown in domestic infrastructure spending, the Company has been able to secure fresh orders totaling to Rs. 14620 crore during the quarter, exceeding the order inflow of Rs. 13019 crore achieved during the same quarter of the previous year when the economic climate was significantly better.

Performance for the quarter ended December 31, 2008Sales grow by 35% - 216% increase in overall PAT - PAT from normal operations grow by 25%

The Company is well on its way towards consolidating its overseas presence, as reflected in its share of Sales from international business at 18.5% for the quarter. Profit before Interest and Tax from normal operations for the quarter ended December 31, 2008, at Rs. 1009 crore, has risen by 37%, when compared with the corresponding quarter of the previous year. The Company has reported Profit after Tax at Rs. 604 crore from normal operations during the quarter, recording an increase of 25% y-on-y, after absorbing a higher incidence of borrowing costs.

Two new Hydro Electric Power Project ordersInfrastructure Operating Company of ECC has recently bagged two new orders worth Rs.1544 crores. The first contract valued Rs.299 crore is to execute 330 MW Shrinagar Hydro Electric Power Project in Pauri Gharwal District, Uttarkhand for Vertex Projects Limited. Scope of work include construction of main dam, water body-canal (Part 1 – desilting basin), surface power house and head race tunnel and entire work will be completed in 36 months.

The second contract valued Rs.1245 crore is to execute the concrete gravity package for 1200 MW Punatsangchhu-1 Hydro Electric Project in Bhutan. This MC1 contract package involves construction of diversion tunnel, dam, intake and desilting arrangement including hydro-mechanical works will be completed in 66 months.


On a overall basis, Profit after Tax for the quarter ended December 31, 2008 at Rs. 1520 crore, which included an extraordinary gain of Rs. 916 crore (net of tax) from the sale of the Company’s Ready Mix Concrete business, grew by 216% y-on-y. For the nine month period ended December 31, 2008, the Company’s Sales at Rs. 23468 crore grew by 41%, and Profit after Tax from normal operations at Rs. 1567 crore went up by 30%, over the corresponding period of the previous year. Including extraordinary gain from sale of Ready Mix Concrete Business, the Profit after Tax for the nine month period ended December 31, 2008 stood at Rs. 2483 crore, a growth of 106% y-on-y.

Engineering & Construction Segment

Bucking the current industry downturn, the segment has bagged healthy project orders during the quarter, reaffirming the Company’s leadership position in turnkey project execution, infrastructure and capital goods sectors. The segment Order Inflow, at Rs. 13379 crore registered a growth of 17% over the corresponding quarter of the previous year. The segment revenues for the quarter at Rs. 7633 crore grew by 54% y-on-y.

Cumulatively for the nine month period, the segment Order Inflow at Rs. 34126 crore rose by 36% and segment revenue at Rs. 19165 crore grew by 51% over the corresponding period of the previous year. The Segment Order Book as at December 31, 2008 stood at a record high of Rs.67029 crore, providing visibility to the growth trajectory of the segment’s performance in the medium term. The share of International orders in the Order Book as on December 31, 2008 was 15%.

For the nine month period, the segment has been able to sustain its margins at the same level as realized during the corresponding period of the previous year, despite pressures of input cost increases witnessed during most part of this period. This was possible due to suitable escalation clauses in a majority of its contracts with the customers, and on-time execution of the projects.

Electrical & Electronics Segment

The Segment posted revenue of Rs. 647 crore for the quarter, marginally exceeding its revenue for

the corresponding quarter of the previous year. This was achieved despite a severe credit crunch and deferment of expenditure by the Building and Industrial sectors, which adversely impacted the demand for the segment’s products & services. Export efforts were stepped up during the quarter to supplement the sluggish domestic demand, boosting the share of international sales to 18%. The segment profitability for the quarter was under strain due to lower volume, under-utilization of capacity and competitive pressures prohibiting higher price realization.

Machinery & Industrial Products Segment

The Segment reported a drop in revenue at Rs. 529 crore for the quarter ended December 31, 2008 severely impacted by a sharp drop in capital expenditure by the Indian Industry, especially the Construction sector. Low fund availability in the hands of the prospective customers worsened the situation. The segment also saw a drop in margins primarily due to squeeze on end-product prices and under-recovery of the fixed costs. The performance of the segment on the export front was encouraging with exports touching 23% of its total revenue for the quarter.

outlook

The Indian economy is going through a challenging phase during the current financial year. While the year began with a spurt in oil prices and high inflationary conditions, the current trend indicates a slowdown in the economy. Despite the best efforts of the government to shore up the investment climate, the capital goods industry is expected to grapple with the impact of slowdown, which is likely to continue through 2009-10. The Company is constantly assessing the emerging developments in the country and abroad, and monitoring their impact on its growth strategy in the medium term. The Company’s foray into the new Railway business has resulted in a few important order inflows, with more prospects on the anvil. Its renewed venture into Power business also holds significant potential. Its current initiatives on building a business opportunity in the nuclear power sector, are likely to bear fruit over the longer term. In the near term, the Company expects to meet its growth projections backed by a healthy Order Book.


W o R K S H o P S / S E M I n A R S

Mr. Somayajulu, a M.Tech Engineer from IIT Delhi, has made a research on “Power Quality Improvement in Commercial Buildings using Custom Power Devices” and submitted the three “Technical Papers” on the subject to IEEE (Institute of Electrical & Electronics Engineers), the world's leading professional association for the advancement of technology. The papers, which were well appreciated and accepted by IEEE was presented by Mr. Somayajulu in the technical conference “TENCON 2008” held at Hyderabad on November 19, 2008. All the papers are hosted

in IEEE’s website www.ieeexplore.ieee.org

He has also presented a thesis on “Application of a DSTATCOM, a Custom Power Device and a special kind of transformer (Zig-zag Transformer) to compensate for the Power quality problems in Commercial loads” at the BIS Conclave held on August 30, 2008. ECC Concord wishes Mr. Somayajulu to continue his innovation and findings.

Four technical papers presented on innovation in electrical works

The Institution of Civil Engineers (ICE) inaugurated its Chennai Chapter by organized guest lectures on Challenges in Civil Engineering on August 30, 2008. Mr. K. V. Rangaswami (KVR), President (Operations) and Member of the Board, L&T and Dr. A. Ramakrishna (AR), Former Deputy Managing Director, L&T jointly inaugurated the chapter and kick-started the activity by lighting the lamp in the presence of special invitees.

Dr. B. S. Sarma, MICE, Country Representative – Chennai, invited all the members and briefed the

Challenges in Civil Engineeringinitiatives taken by ICE to promote professionalism in civil engineers through various programmes. KVR emphasized the need for HR initiatives, soft skill improvement and innovation and creativity in civil engineers to do challenging jobs.

The keynote speakers Dr. N. Lakshamanan, Director, Structural Engineering Research Centre, Chennai and AR addressed the gathering on the theme “Challenges in Civil Engineering” They elaborated the importance of civil engineers in the scenario of extreme growth in construction industry.

Civil engineers play a vital role in addressing the issues like availability of land and good construction materials, tackling natural hazards and pollution standards, awareness of green house construction practices, management of explosive growth problems in urban cities, limited understanding of new building materials and very limited availability of skill manpower for execution. Only with advanced structural analysis, design and construction practices and through the partnership of engineers, industry and government, these key issues can be resolved systematically, they added.

From left to right: Dr. N. Lakshamanan, Director, Structural Engineering Research Centre, Chennai; Dr. A. Ramakrishna, Former Deputy Managing Director, L&T; Mr. K. V. Rangaswami, President (Operations), L&T and Dr. B. S. Sarma, MICE, Country Representative – Chennai during the seminar

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ICE - Chennai Chapter in association with Asian Concrete Construction Institute - Singapore

and Larsen & Toubro Limited, ECC-Division organized a workshop on “precast technology in housing and infrastructure – a global scenario” for urban development during September 24–26, 2008 at ECC Convention Centre, Chennai. The workshop provided an opportunity to discuss various innovative precast technology adopted for infrastructure development in different countries.

The faculties of the workshop discussed in length about how India is poised for huge infrastructural growth and so more in buildings, factories and infrastructure projects. The workshop focused more on housing sector and the multi-storied buildings concept and precast concrete technology, demonstrated in countries like China, Honk gong and Singapore to provide mass housing. This technical workshop focused on precast technology and its application in development of urban housing and infrastructure.

The workshop has drawn the attention of many senior executives and managers from L&T and other companies in construction business. There were about 20 technical sessions spanning two and half days. Mr. K. V. Rangaswami, Patron, ICE Chennai Chapter inaugurated the workshop and released the workshop proceedings.

Prof. Devdos Menon and Dr. V.V. Nori, respectively enumerated the fundamentals of materials, structural members and the innovative precast structural configurations which, were applied since 1960’s in the construction of various industrial and infrastructures facilities in India.

Other eminent speakers from Asian Concrete Construction Institute, Dr. Alfred A Yee, Dr Tony Chi, Poul B Mork, and Tan Wee Teck have conducted the workshop sessions covering various topics like PC Modules; PC Drawings; PC Economy; PC Components and Finishes; PC Colombo Example Architecture and Structure, Design considerations of composite precast and prestressed concrete structures in seismic areas, Basic fundamentals, fabrication, erection, devices, connection details and with sample structures, Ocean Thermal Energy Conversion; Marine concrete barges and

platforms, the use of Precast Prestressed Hollow core slabs, Industrialized method of construction for industrial buildings, Hong Kong Housing Projects & Japanese Construction Management.

Former Deputy Managing Director of L&T. Dr. A. Ramakrishna, explained chronologically about the development works and application of precast technology adopted by L&T in various projects. He has stressed the need of taking forward the precast technology in future with good detailing practice which should be simple, efficient and durable.

All the delegates visited L&T’s R&D Centre to understand various on-going R&D works applicable in the construction of different concrete structures. At the end of the workshop, in the panel discussion, salient points were analysed and it was concluded that it is the time ripe for India to revive precast technology.

Dr. B. Sivarama Sarma, Head - R&D, L&T and ICE Country Representative - Chennai organised and co-ordinated the entire event for ICE.

Workshop on precast technology in housing and infrastructure

From left to right: Mr. K. V. Rangaswami, President (Operations), L&T and Dr. B. S. Sarma, MICE, Country Representative – Chennai and Mr. K.P. Raghavan, Executive Vice President & Head (Divisional Corporate), L&T during the inaugural day of the seminar


The Metallurgical, Material Handling & Water (MMH&W) Operating Company of ECC has qualified for ISO 9001:2008 Certification. Lloyd’s Register Quality Assurance Limited (LRQA) conducted the Quality Management System (QMS) audit.

MMH&W OC of ECC is third in India to qualify for LRQA’s Quality Management Systems certification for the 2008 version.

The QMS certificate is applicable to Strategic Planning, Marketing, Tendering, Engineering, Project Management, Management Information Systems and Project Execution of EPC and

Non-EPC projects, Turnkey and Non-turnkey projects, Human Resources, Health, Safety and Environment, Plant & Machinery, Procurement, QA/QC, Testing, Commissioning and Maintenance during the warranty period till December 28, 2011 at the following business units and covers their operations in Headquarters and the cluster offices.• Minerals&Metals• BulkMaterialHandling• Water&EffluentTreatment

This is a major step towards ‘attaining Global Benchmark’ and accomplishing the vision of excellence in Quality Management System.

ISO 9001: 2008 for MMH&W Operating Company

Technical Paper on Underground LPG Storage Project

Twin Recognition Dr. K. Natarajan, Head – Engineering (TLRE Sector), has been invited by College of Engineering Guindy, Anna University, Chennai, to serve as member in Syllabus Committee for revising the curriculum and syllabus of regulations 2009, for the PG programmes in M.E.(Structural Engineering) and M.E. (Construction Engineering & Management).

He has also been invited to join the Board of Studies of Hindustan University for a period of two years (2008-10). The board is responsible for framing curriculum and syllabus for undergraduate/postgraduate Engineering programmes.

A technical paper entitled “A SUMMARY ON FIRST INDIAN CAVERN” on Underground LPG storage cavern project at Visakhapatnam was presented by Mr. S. Elangovan (DP BU - HQ) at World Tunnel Congress (WTC) 2008 held at Agra during September 19-25, 2008.

This WTC 2008, organized by International Tunneling and Underground Space Association (ITA) and Tunneling Association of India (TAI) was the 34th in the series and held for the first time in India.

The paper co-authored by Mr. K. Vijayabhaskar (HN BU – Topovan Vishnugarh HEP) and Mr. K.S.R.K. Verma (HN BU – Faridabad) highlighted the construction sequence, environment and safety aspects. The presentation made Mr. S. Elangovan on September 23, 2008 was well received and appreciated by the international delegates.


India’s first mission to the moon was successfully launched from the Sriharikota Space Port. India's

Polar Satellite Launch Vehicle PSLV-C11 placed the 1380 kg Chandrayaan-I Spacecraft in an elliptical orbit.

While this is a historic moment for all Indians, it is a special occasion of pride for L&T-ites as the Heavy Engineering Division (HED) has been closely involved with this effort.

launch

The 44.4-metre, 316-tonne PSLV-C11 was rocketed into orbit using S139 Motor Casings (Middle segments MS58, MS60 & MS63) manufactured at the Aerospace Shop of HED.

Electronic packages are mounted on upper stage of PSLV-C11 and Heat Shield using honeycomb deck panels. These honeycomb deck panels are manufactured at L&T’s Advanced Composite facility at Ranoli.

Tracking

The spacecraft is being tracked using a Deep Space Network Antenna at ISTRAC's tracking facility near Bangalore. This 32 m dia antenna was installed and commissioned by HED-Aerospace. The Antenna Mount Structure and 13m-diameter Bull Gear (made for the first time in India) were also manufactured by HED-Aerospace.

PSLV-C11 was tracked by C-Band Precision Monopulse Tracking Radar developed indigenously by HED-Weapon Systems & Sensors, up to a range of nearly 1300 km for 380 seconds. This radar was recently commissioned at Satish Dhawan Space Centre-Sriharikota and included in the Radar Tracking Network.

L&T-made radars performed the best among all the SHAR radars.

Chandrayaan-1 Launch Successful L&T-made Equipment Engaged in Launch & Tracking

P R o j E C T n E W S prOject New

s


Mr. A. M. Naik, Chairman & Managing Director – Larsen & Toubro, inaugurated ‘Knowledge

City’ - a state-of-the-art engineering campus at Vadodara on January 2, 2009. Located at Waghodia, near Vadodara, ‘L&T Knowledge City’ extends across a 112-acre campus. The state-of-the-art engineering campus at Vadodara will meet the high-end design and engineering needs of the hydrocarbon and power sectors. In the hydrocarbon space, it will cater to the needs of the upstream, midstream and downstream sectors, and in power, design support for complete projects.

L&T expects to generate project exports revenue of over Rs. 2000 crores within five years, and will provide employment to 4000 - 5000 technical professionals in next four to five years. The new campus will leverage our nation’s strength in engineering design, augment the country’s technology base and will provide a cutting edge to project-related businesses. As an integrated campus, ‘Knowledge City’ will enable L&T to extend and further develop its existing capabilities in process engineering, product development,

mechanical design and analysis, process evaluation and technology adaptation. The facilities will provide a growth platform for a broad range of knowledge-intensive businesses.

The master plan for the L&T Knowledge City envisages a pioneering initiative in setting up a ‘Institute of Project Management’. The Institute for Project Management will develop leading-edge project managers across the domains of engineering, procurement, construction and manufacturing. The faculty will comprise outstanding academics and project management professionals.

L&T Knowledge City has been designed and built to high environmental standards, incorporating technologically advanced systems for rainwater harvesting, waste-water management and the effective utilisation of solar energy.

L&T’s achievements in high-technology areas have won the recognition of national and international professional societies and research institutes, as well as leading trade and industry associations.

L&T Knowledge City Vadodara’ Inaugurated

L&T Knowledge City, Vadodara


L&T has completed Delhi airport’s third airstrip - Asia’s longest at 4,430 metres and the trial run was done on August 21, 2008.

An Air India aircraft touched down the new runway without passengers. The runway lighting systems are one of the most advanced in the world. A new code F runway of 4.43 km is one of the longest in Asia and it is equipped with CAT III B ILS.

The new runway has an advanced instrument landing system, which allows aircraft to land in visibility as low as 50 metres. DIAL upgraded several new aircraft parking stands to meet this standard.

The runway construction involved 2.3 million metric cubes of earthwork and embankment filling. That is enough to form a 210 km long freight train. The runway is more than two metre thick, comprising seven layers of filling, concrete-treated base and over 650,000 tonnes of asphalt concrete. Eco-friendly methods like fly-ash in concrete and other cement-based material was used to construct the runway and the taxiways. The new runway is expected to nearly double the airport’s peak hour capacity from 35-40 aircraft movements currently to about 75. Currently, the two existing parallel runways handle nearly 700 flights a day.

New Runway Commissioned for Delhi International Airport

Completed portion of the runway with inset approach lights at Delhi International Airport


Mr. K.V. Rangaswami, Member of the Board & President (Construction) inaugurated the

new facility for Construction Skills Training Institute (CSTI) at Panvel near Mumbai on January 28, 2009 by unveiling the insignia plaque amidst many special invitees. Mr. J. Ganguly, Head - Divisional Strategic Services, ECC declared open the hostel buildings by cutting a ribbon.

“All Construction Companies including Larsen & Toubro (L&T), the largest construction organisation in India is facing this shortage of trained and skilled manpower, which is plaguing the industry as a whole,” said Mr. K.V. Rangaswami during the inauguration function.

Recognising the risk faced by the industry due to shortage of skilled workmen and to mitigate this growing problem, L&T initiated necessary action for skills development, way back in 1994-95 and started the CONSTRUCTION SKILLS TRAINING INSTITUTE (CSTI) in Chennai followed by Panvel in Raigad District of Maharashtra, in 1996. Subsequently, such Institutes were opened in five other locations in 2005 – Bangalore, Ahmedabad, Delhi, Kolkata and Hyderabad.

All these Institutes impart a structured system of training through its modular training schools with well defined infrastructure and curricula, testing and certification. The entire programme is accredited by National Council for vocational Training (NCVT), New Delhi.

Going ahead CSTIs have trained more than 2000 candidates during 2006-07 and 3700 candidates

during 2007-08 and L&T has set an ambitious target of training 10,000 youth annually by 2010 by augmenting the infrastructure facilities in each location.

In line with this thinking, L&T opened this new facility at CSTI Panvel and dedicated this to the nation in the interest of the Construction Industry fraternity. Spread across 10 acres of land, this new facility with all necessary infrastructure can impart training to 400 youth at a time in various construction skills.

Presently CSTI Panvel imparts training in the following Construction trades and intends to add more trades in a phased manner.

1. System Formwork Carpentry

2. Bar Bending & Steel Fixing

3. Masonry [ Brick works & Block works]

4. Welder [Structural]

5. Welder [Piping]

KVR highlighted and commended that no such parallel facility exist of this kind in India. While also mentioning that this facility would not only train a pool of skilled workers - very much required for the business and industry, he also highlighted this to be a very good CSR initiative of L&T ECC.

He reiterated the 5 M’s that are required for any project – material, men, money, machinery and management. Emphasizing the intervention on the men aspect – productivity of workmen was seen

L&T Opens Construction Skills Training Institute at Panvel

Mr. K.V. Rangaswami, Member of the Board & President (Construction) unveiling the plaque during the inauguration of Construction Skills Training Institute at Panvel near Mumbai.

Mr. J. Ganguly, Head - Divisional Strategic Services inaugurating the hostel building by cutting the ribbon.


as the critical issue. In order to improve this area it was found that in Singapore, one such good model existed there. With the help of the Henry Boot, UK team, who helped us with sound syllabus, this was initiated in Chennai which for all purpose was a mother institution. In the recent past, creation of one CSTI centre at each region meant taking right steps in this direction, he added.

Highlighting Panvel’s excellent facility he urged that this quantum jump in infrastructure – both in terms of quality and quantity is worth emulating everywhere.

Earlier, Mr. M. Ramesh Mohan, Regional Manager (Mumbai) welcomed the gathering.

Mr. S. Natarajan, Head – CSTI made a brief presentation on the highlights of the facilities of Panvel.

Mr. S.K. Bansal, Head of CSI, training faculties, Regional Managers and other special invitees including the project managers from Mumbai project sites participated in the inaugural function.

They also spent time to address issues as well as effecting the right steps so as to taking the right initiatives for this trained youth to be inducted into the main workmen stream, and to work with the subcontractors at our own project sites. All delegates also participated in tree plantation session as a part of greening the environment.

Institute Administrative Building

Comprising of ground plus one storey (total built up area of 1600 sq.m - 17000 sq.ft), this

building has facilities for all administrative and utility services involving:

• 9classroomseachof32seats

• Trade’sdisplayhall

• Traineescreeninghall

• Librarycumreadinghall

• Conferenceroom

• Staffroom

• Toiletblocksforstaffandtrainees

• Opencourtyards

Hostel Building

Comprising of ground plus three stories (total built up area of 1930 sq.m - 20,700 sq.ft), the hostel building can accommodate a total of 416 candidates. This consists of:

• 104roomsonsharingbasisfor4personsineach room

• Wardenroom

• Officeroom

• Toiletblocksineachfloor

• 148seatcapacitydininghallwithkitchen

• Opencourtyards

Trade Practice – open yards

To provide hands on experience training in systems formwork, bar bending & steel fixing including masonry (brick & block works) a total of 10500 sq.m (1.13 lakh sq.ft) of open area has been earmarked. This also accommodates 24 bar bending work tables and 70 t of system formwork materials to impart training in System Formwork Carpentry trade.

Trade Practice – Covered sheds

There is a 680 sq.m (7300 sq.ft) area of covered sheds with facilities for:

• Carpentryworkshop

• Rebarcutting/bendingworkshop

• WelderstrainingworkshopInstitute Administrative Building

Hostel Building


In the 40th Structural Steel Design Awards Dinner 2008 sponsored by the British Constructional

Steelwork Association, a commendation certificate was presented for the roofing work done by us at “The Worrell Weekes and Walcott Stand” at Kensington Oval Stadium, Barbados. This was the only project selected from outside of the former British Isles (England, Scotland, Wales and Ireland)

The objective of the award is to recognize the high standards of structural and architectural design attainable in the use of British steel and its potential in terms of efficiency, cost effectiveness, aesthetics and innovation.

The Worrell, Weekes and Walcott Stand is the largest and most ambitious structure and provides seating for 4000 spectators in two radial tiers surrounding the ground, as well as housing the president’s suite and VIP boxes. The design concept is derived from the necessity to provide uninterrupted column free views of the cricket in a light and comfortable atmosphere. The stand combines reinforced concrete for the stand structure with lightweight steel framing for the roof canopy. The main canopy cantilevers up to 25m

to prove drip line cover and shade to all stand’s inhabitants, whilst maintaining column free views. To achieve this, the canopy unites the radial grid of the lower tiers with the orthogonal grid of the box levels through the use of steel cantilevered truss frames, which vary in depth in response to the spanning requirements.

While awarding the commendation certificate for the Kensington Oval Stadium, judges commented that “This is a good planning response to updating this hallowed cricket ground. It is gives an enhanced sense of place in the town, whilst retaining much of the former character. The design copes well with the many issues of climate, function and economy. The UK prefabricated steelwork addresses the complex geometry and yet was constructed in the relatively unsophisticated local built environment. The challenges were answered well and the internal work handled successfully.”

Mr. Miles F Weekes, Chief Facilities Development Officer of World Cup Barbados Inc received this certificate on L&T’s behalf at a function held at the Victoria and Albert Museum in London, UK on July 8, 2008.

Structural Steel Design Award for Kensington Oval Stadium, Barbados

The Worrell Weekes and Walcott Stand at Kensington Oval Stadium, Barbados.

A W A R D S


The prizes were given away by Mr. B.P. Ahuja, Director of Mines Safety, Chennai region during the valedictory function held at Madhuker Mines, Trichy on 31st August 2008.

Description Prize Quarries

1 Standard of Supervision First Karadidihalli

2 Standard of Supervision Second Boothanahalli

3 Welfare amenities & Medical facilities Second Karadidihalli

4 Blasting, Storage & Use of Explosives First Boothanahalli

5 Standard of Transport & Workshop Second Karadidihalli

6 Use of Personal protective equipments First Karadidihalli

7 Over all performance First Karadidihalli

8 Over all performance Second Boothanahalli

Awards Galore for Best Safety Practices in Quarry Operations

To give due recognition to outstanding safety performance, Ministry of Labour, Govt. of India

instituted National Safety Awards (Mines) in 1983 and during August every year on the basis of outstanding performance, National Safety Awards (Mines) are presented to various mines in different zones.

Based on the best mining practices adopted in terms of overall performance, supervision, welfare and medical facilities to the workmen, handling, usage & storage of explosives, safety measures, etc., quarries were selected and awards are presented. The safety inspection team of Tamil

Nadu – Kerala state Mines Safety Association under the aegis of the Director General of Mines Safety visited around 150 stone quarries in Salem Zone during August 2008 and evaluated the safety performance.

Accordingly, two ECC quarries at Boothanahalli and Karadidihalli attached to Krishnagiri - Thopur Toll Road (KTRP) project in Tamil Nadu were selected for awards in eight different categories as follows:

awards

M/s Srinivas, Ravindran and Lakshminaryan receing the prizes from the Director of Mines Safety, Mr. B.P. Ahuja


The Council of the Institution of Civil Engineers, UK has conferred Overseas Prize Award for the technical paper submitted on underground LPG storage cavern project in Visakhapatnam, Andhra Pradesh. This paper authored by M/s. N. Raghavan, S.R.K.V. Kosuri, K.V. Bhaskar, P. de Laguerie, P. Roux, P. Vaskou and A. Saint was published in by Thomas Telford, UK in the journal “Energy”.

Overseas Prize for the Technical Paper on LPG Cavern

Mr. N. Raghavan, former Vice President & Head (H&N), L&T receiving the award

The cavern in Visakhapatnam, India is one of the world’s deepest and Asia’s biggest underground liquefied petroleum gas (LPG) storage project. The paper highlighted the significance and complexity of the facility, basic principles of storage, engineering & design aspects, various phases of construction work, quality, health, safety and environmental aspects. The sequence and methods adopted to construct diaphragm walls for the fore-shafts, sinking for the rock-shafts, installation of water curtain tunnel and excavation for the main storage cavern are detailed in the paper. Special features of the project like construction methodologies, achievements, critical success factors and advantages of having such projects are presented interestingly with diagram, sketches and photographs.

Mr. N. Raghavan, former Vice President & Head (H&N), L&T received the award at a ceremony held in the Great Hall at the ICE Campus at London on October 24, 2008.

ECC bags Two Awards at the 6th Annual Construction World Awards 2008•Largest&MostProfitableConstructionCompanyinIndia(FirstRank)

•OneofIndia’sTopTenMostAdmiredConstructionCompanies

One of India’s largest circulated construction business magazines, Construction World,

honoured ECC, L&T’s Construction Division with two prestigious awards for excellence in construction.

Mr.V.B. Gadgil, Senior Vice President & Head Electrical & Gulf Projects Operating Company, received the Awards from Mr. Anil Deshmukh, Minister of Public Works, Government of Maharashtra at a glittering function held at Taj Land’s End in Bandra, Mumbai on October 24, 2008.

Constituted by ASAPP Media, the Construction World Awards recognized the exceptional work done by Construction Companies and felicitated the achievers and industry leaders in the field.

Mr.V.B. Gadgil, Sr. Vice President & Head (Electrical & Gulf Projects Operating Company) receiving the award from Mr. Anil Deshmukh, Minister of Public Works, Govt. of Maharashtra.


The Indian Concrete Institute (Tamil Nadu Chapter) awarded the prestigious ‘Ultratech

Award for Outstanding Concrete Structure of Tamil Nadu – 2008’ to ECC, for the design and construction of Technology Centre (TC–II) of L&T Infotech at ECC campus, Chennai.

The award which recognizes most outstanding and innovative structures built using concrete was received by Mr. S. Kanappan, Vice President & Head - EDRC during the concrete day celebrations in Chennai on September 13, 2008.

TC-II of L&T Infotech, Chennai was selected for its unique state of the art technological features, implemented for the first time in India, like the use of self compacting concrete for the entire superstructure, expanded polystyrene blocks embedded in prestressed concrete floor slabs to reduce dead weight and the use of bottom up

ECC Wins the Ultratech Award for Technology Centre-II (Building) of L&T Infotech, Chennai

concreting in the construction of the large sized fin walls.

Amongst others, the concrete day celebration was attended by leading Engineers, Architects, Builders and Consultants.

Mr.S. Kanappan, Vice President & Head – EDRC, B&F OC receiving the award.

Outstanding Concrete Structure Award for Passenger Terminal Building at Hyderabad AirportThe Passenger Terminal Building (PTB) at Rajiv Gandhi International Airport has been recognised as “Outstanding Concrete Structure of Andhra Pradesh - 2008” by Indian Concrete Institute (Andhra Pradesh Chapter)

L&T has designed and built the PTB, which can handle 12 million passengers per annum. Dedicated futures of this seven-level integrated PTB include unique concept of airport village, 130 check-in desks with CUTE and 16 self check-in kiosks, 46 immigration counters for quick processing, in-line baggage handling system with level-4 security system - a first of its kind in India. The total built-up area of the PTB is 1.17 million sq.ft and special features of construction like Kalzip roof sheeting, temple leafs for tapping natural light with great aesthetics and bull-nose cladding surrounding was used.

L&T was felicitated with Certificate of Commendation and a Trophy at a function held at Hotel Grand Kaktiya on September 27, 2008. Mr. A.K. Chugh, Regional Manager (Hyderabad) received the award.

Mr. A.K. Chugh, Regional Manager (Hyderabad) receiving the award.


Forbes Asia’s Fabulous 50 is a selection of the best of Asia’s biggest listed companies. Criteria include long-term profitability, sales and earnings growth, and projected earnings for companies with revenues or market capitalization of at least $5 billion. The list recognises the excellence of the business models pursued by the companies and marks them out as leaders in their fields.

Forbes is an American publishing and media company with global coverage, and carries articles on issues, trends, events and the personalities that shape the business world today and will determine the future. It is well-known for drawing up lists based on several critical criteria.

L&T is one of just ten Indian companies to feature on the ‘Fabulous 50’ list. The others are Bharat Heavy Electricals, Bharti Airtel, HDFC Bank, ITC, Infosys, Mahindra & Mahindra, Reliance, Tata Steel and Wipro (in alphabetical order).

L&T Scores Hat-trick - Forbes Asia’s ‘Fabulous 50’

L&T has made it to the coveted Forbes Asia’s ‘Fabulous 50’ for the third year in a row.

Mr. R. N. Mukhija (President – Electrical & Electronics), L&T received the coveted award on behalf of the company at a glittering ceremony in Shanghai on December 9, 2008.

Mr. R.N. Mukhija, President (Electrical & Electronics), L&T (in the centre) with the award.

Information System Department of ECC bagged the First Chairman’s Rolling Trophy for “IT EFFECTIVENESS 2008” formulated by L&T Corporate IT. Nominations were sought from all operating divisions and the evaluation was based on Alignment, Value & Benefits, Risk Management,

Total Cost of Ownership, and Service & Support on a rating scale of 5.

ISD-ECC emerged the winner for best “IT EFFECTIVESS” for its various IT applications and initiatives. Mr. Anantha Sayana, Head, Corporate IT, in his congratulatory note to President (Construction), Mr. K.V. Rangaswami mentioned “Your support and the effective participation of the business in all the IT initiatives of ECC is a key factor for this success besides the great work that Mr. B. Srinivasan and his team have done.”

Mr. A.M. Naik, Chairman & Managing Director, L&T, presented the award to Mr. B.Srinivasan, Head, ISD-ECC at a glittering function on February 9, 2009, in the presence of CMC members, senior business leaders and IT teams from ODs.

The award further endorses ECC’s progress and hard work in making EIP a success story in achieving value to the construction business.

Chairman’s Rolling Trophy for ECC’s “IT EFFECTIVENESS”

Mr. B. Srinivasan, Head-ISD and his team receiving the award from Mr. A.M. Naik, CMD, L&T


L&T’s Investor Relations function has bagged a double honour. Asiamoney, the prestigious

Hong Kong based financial magazine, recently conducted a poll on corporate governance in which L&T was voted the ‘Best for Investor Relations’ in India, and Mr. Pramod Kapoor, General Manager, Investor Relations, L&T as the ‘Best Investor Relations Officer’.

Asiamoney is widely read by analysts, equity fund managers and finance ministry officials across Asia. Respondents comprising CEOs, CFOs, research heads and other senior finance personnel from leading Asian corporates were asked to rank companies on a number of stringent criteria including: companies that were the most pro-active in enhancing their profile in the market; the best in communicating with shareholders and providing investor access to senior management;

and companies that have done the most to improve investor relations over the last year. Respondents were also asked who they considered the best Investor Relations Officer in the country. Across all these criteria, an overwhelming majority of respondents voted L&T as the best.

The poll results are an affirmation of L&T’s deeply entrenched values, ethical practices and corporate governance practices.

L&T is ‘Best for Investor Relations’: Asiamoney L&T-ite voted ‘Best Investor Relations Officer’

L&T bags KPMG-Infrastructure Today Award

Management consultancy firm KPMG and leading infrastructure news magazine

Infrastructure Today ranked L&T as the most admired infrastructure company in India, and presented it the prestigious KPMG-Infrastructure Today Award 2008.

Mr. K. R. Palta, Vice President (Corporate Affairs), L&T, received the award from Dr. Montek Singh Ahluwalia, Dy. Chairman, Planning Commission, Govt. of India, at a function in New Delhi on December 10, 2008.

KPMG is a globally reputed firm that provides audit, tax, and advisory services in 148 countries. Infrastructure Today is published by the Mumbai-based ASAPP Media Information Group, which also brings out well-known periodicals like Construction World, and Projects Info.

KPMG and ASAPP Media teamed up to recognise the contribution and role of players in the infrastructure sectors by instituting annual awards.

Mr. K.R. Palta, Vice President (Corporate Affairs), L&T receiving the award from Dr. Montek Singh Ahluwalia, Dy. Chairman, Planning Commission, Govt. of India.


L&T’s Chairman & Managing Director,

Mr. A. M. Naik was conferred one of the country’s most coveted honours – the Padma Bhushan.

The prestigious Honours List released by the President of India on Republic Day 2009 bore Mr. Naik’s name, citing his contribution to Indian industry, and the role that the Company played in nation building. On receiving the intimation from the President’s office, Mr. Naik chose to share the national honour with the employees of the Company, and said:

“Leading a company that is helping to build the nation is a matter of pride in itself. To receive high national recognition for this service is indeed heartening. It will be my privilege to accept the Padma Bhushan on behalf of all the employees of the Company for whom the L&T story is always interwoven with the larger interests of India.”

Padma Bhushan for Mr. A. M. NaikMr. Naik is the second L&T-ite to be honoured with the Padma Bhushan. L&T’s co-founder, Mr. Henning Holck-Larsen received the Padma Bhushan in 2002.

Mr.A.M. Naik flanked by the Board Members at the felicitation function held at Powai, Mumbai.


On Saturday, January 17, 2009 at an eagerly awaited function attended by a galaxy of corporate chieftains, L&T’s Chairman & Managing Director, Mr. A. M. Naik, received the prestigious Economic Times – Business Leader of the Year Award from the Prime Minster of India, Dr. Manmohan Singh.

It was an occasion made even more special, because after being postponed in the wake of the Mumbai terror attacks, it was held at the same venue – The Trident, Mumbai, which was one of the targets of the terror attacks.

Accepting the award, Mr. Naik said: “This is one of the proudest moments for the whole company, for I believe that the CMD and the company are two sides of the same coin.”

Other award winners included: E. Sreedharan, MD, Delhi Metro Rail Corporation (Policy Change Agent of the Year); Kamal Nath, Union Commerce & Industry Minister (Business Reformer of the Year); Arun Sarin, Former CEO, Vodafone Group (Global Indian of the Year); Shikha Sharma, MD

In recognition of the pivotal role played by Mr. A. M. Naik, Chairman & Managing Director, in sustaining L&T’s unique ethos and upholding its professional value system, the Indian Merchants’ Chamber and the Asian Centre for Corporate Governance & Sustainability (ACCGS) conferred him with their prestigious ‘Transformational Leader Award – 2008’.

The award was presented at the 9th International Conference on Governance, Sustainability & Corporate Citizenship jointly organised by Indian Merchants’ Chamber and the ACCGS in Mumbai on November 20, 2008. Present on the occasion was Mr. Ernst Ligteringen, Chief Executive, Global Reporting Initiative (GRI), Amsterdam – the organization that virtually sets the international standard for sustainability reporting guidelines.

The awards committee was chaired by Ms. Chanda Kochhar – Joint MD, ICICI Bank.

Mr. A. M. Naik conferred Transformational Leader Award

ACCGS is a non-profit institution set up in 2001 with a mission to improve corporate governance practices in Asia.

Incidentally, Mr Naik has launched the maiden edition of L&T’s Corporate Sustainability Report on November 26, 2008.

& CEO, ICICI Prudential (Business Woman of the Year); Ashok Ganguly, Former Chairman, HLL (Lifetime Achievement Award); and Tata Steel (Company of the Year).

Mr. A. M. Naik - Business Leader of the Year Receives Award from the Prime Minister

awards

Mr. A.M. Naik receiving the Business Leader Award from Hon’ble Prime Minister Dr. Manmohan Singh.

Mr. A.M. Naik receiving the Transformational Leader Award.


Mr. A.M. Naik, Chairman & Managing Director, L&T has added another feather to his cap. He was honoured with the coveted E&Y Entrepreneur of the Year Award in the professional category by Ernst & Young at a function held in Mumbai on November 26, 2008.

The winners for the awards, which are now in the 10th year, was selected by an eminent six-member jury, chaired by ICICI Bank Managing Director and CEO, Mr. K. V. Kamath. There were over 291 nominations received this year, the highest since the awards were launched in 1999.

Mr. Naik received the award from the Chairman & Global CEO of Earst & Young, Mr. James Turley.

Mr. A. M. Naik bags E&Y Entrepreneur of the Year Award

The Ernst & Young Award has become a symbol and measure of entrepreneurial success around the world. Originated in Northern America, it has now spread into a movement that is celebrated across 135 cities in 50 countries.

L&T’s Chairman & Managing Director, Mr. A. M. Naik, received Gujarat’s highest state honour

– the Gujarat Garima Award (‘Pride of Gujarat’) – presented by the Chief Minister of Gujarat, Mr. Narendra Modi.

The award – a shawl, a citation and a memento – was presented on January 12, 2009 – the inaugural day of the ‘Vibrant Gujarat’ exhibition held at Ahmedabad. The award was presented in the

presence of a galaxy of state ministers, diplomats, visiting state guests, dignitaries from around 40 countries, senior government officials, business leaders and over ten thousand people.

The citation highlighted Mr. Naik’s philanthropy and his contribution to several social initiatives, in Gujarat as well as in other parts of India, and his achievements as a professional in transforming L&T into an engineering powerhouse.

The award acquires special significance in view of the fact that Mr. Naik has risen from a humble school-teacher’s family in rural Gujarat to the highest echelons of corporate leadership. In a glowing speech, Mr. Modi recalled Mr. Naik’s outstanding contribution to the uplift of rural Gujarat and his role in the development of the state. Mr. Modi also invited Mr. Naik’s wife, Mrs. Geeta Naik, to the dais, and complimented her for her role in facilitating Mr. Naik’s numerous achievements.

In his acceptance speech, Mr. Naik said this award carried special emotional value as it came from his birthplace, Gujarat. Mr. Naik said this high recognition to the son of a middle-class teacher and grandson of a Gold Medalist primary teacher would be a source of encouragement to the youngsters of today. He quoted from the L&T Anthem which dwells on the debt that we owe to the land our birth, and spoke about the key projects executed by L&T in Gujarat.

Earlier recipients of the Gujarat Garima Award include business leaders like Mr. Ratan Tata, Mr.Mukesh Ambani, and eminent personalities in the fields of social work, and philanthrophy.

Mr. A.M. Naik Conferred Gujarat’s Highest State Honour - ‘Gujarat Garima Award’

Mr. A.M. Naik accepting the shawl from Mr. Narendra Modi, Chief Minister of Gujarat.


L&T’s first Corporate Sustainability Report for 2007-08 was released by Mr. A. M. Naik,

Chairman & Managing Director, in Mumbai. It communicates L&T’s sustainability performance to all its stakeholders and will help in benchmarking with international peers.

This is the first corporate sustainability report to be brought out by an engineering & construction company in India. It is a matter of pride for all L&T-ites that the report secured the highest rating of ‘A+’ given by the Global Reporting Initiative (GRI), Amsterdam.

Releasing the report, Mr. Naik remarked that like the smiling girl on its cover, we would like to see smiles on the faces of our shareholders. “For this we need to put extra efforts to improve performance, reduce costs, and create higher shareholder value,” he said.

Sustainability reports disclose a company’s performance on Economic, Environmental and

Mr. A.M. Naik releases L&T’s First Corporate Sustainability Report

Social parameters. Reporting can go a long way in satisfying stakeholders’ demands for transparency on corporate responsibility.

Mr. A.M. Naik, CMD, L&T releasing the first copy of ‘Corporate Sustainability Report’.

In recognition of the outstanding contribution to the development of Indian industry and society,

the Federation of Indian Chambers of Commerce & Industry (FICCI) has honoured L&T with its Annual Award 2007-08 for ‘Outstanding Corporate Vision’.

L&T bagged the award in the category of the Corporate Triple Impact – Business Performance: Social & Environmental Action and Globalisation. Mr. R. N. Mukhija, President (Electrical & Electronics), and Board Member, L&T, received the award from Mr. Pranab Mukherjee, Union Minister for External Affairs and Finance, at the inaugural session of FICCI’s 81st Annual General Meeting in New Delhi on February 12, 2009.

A 30-second film highlighting L&T’s business performance, its contribution to community service and its achievements in globalizing its

operations was produced for the occasion. FICCI was established in 1927 as a central organisation of industry, trade and commerce in India. Now it has a nationwide membership of over 1500 corporates and over 500 chambers of commerce and business associations.

L&T bags FICCI Award for Outstanding Corporate Vision

Mr. R.N. Mukhija, President (Electrical & Electronics), L&T receiving the award from Mr. Pranab Mukherjee, Union Minister for External Affairs and Finance. ECC Concord | Oct - Dec 0863

Printed by Universal Print Systems Ltd., Chennai, 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.

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