oct - dec 2012 • volume-35 • issue-4 in-house journal of l&t

Oct - Dec 2012 • Volume-35 • Issue-4In-house Journal of L&T Construction

FocusThis issue of ECC Concord begins with coverage on an automobile factory built by L&T Construction for Renault Nissan at Oragadam near Chennai - considered the Detroit of South Asia. We take you to the Himalayan heights of Uttarakhand where L&T is building a Hydel project for GVK at Shrinagar. L&T Construction’s Heavy Civil Infrastructure IC is setting new benchmarks at this project with a large concrete gravity dam including the construction of Asia’s largest de-silting basin.

From the Power Transmission and Distribution IC we are covering a power and communication project bagged by L&T as part of developmental works of Ras Laffan Industrial city at Qatar. Once completed, this part of Ras Laffan is sure to usher in a new economical impetus through trade and commerce.

This issue also covers Bhilai Steel Plant’s 7 MTPA expansion projects where the Metallurgical & Material Handling IC is commissioning a Blast Furnace apart from Installation of a Sinter Machine at the plant. This issue is also special considering that it consolidates almost thirteen projects done by the Water and Effluent Treatment business for Delhi Jal Board. Through these ambitious projects which are spread over a decade of time, L&T has been an integral part of catering to the water needs of India’s Capital region.

The Kaleidoscope section comes with its usual coverage of all the corporate events that happened towards the end of the calendar year 2012.

Wish you all a happy reading!

- Editor

In this issueOct - Dec 2012 • Volume - 35 • Issue - 4

Editor : V. S. Ramana

Editorial team : V. Ramesh Kumar | Gopi Kannan. S

Ashwin Chand | Mayura. K

Subha Anand | Shamala Nadendla

Photography : V. S. Natanavelu

Design & layout : Global Print Design, Chennai

Kaliedoscope

New Orders ..................................49Project News .................................51Events ...........................................55Awards ......................................... 60

Renault Nissan a fast track

automobile project

330 MW Srinagar HEP Setting benchmarks in the

Himalayan heights

Power and communication to Ras

Laffan Qatar

SAIL - BSP 7 million ton expansion projects

Catering to the water needs of India’s capital

311232939

ECC CONCORD Oct - Dec 2012 3

Renault Nissan – a fast track automobile project


Many automotive brands have made

this expanse of land at the outskirts of

the Chennai city their production hub of India

from where not only domestic demands are met, but also exports to neighbouring countries

take place

The skyline of the once barren land located 25 km east of Kancheepuram

and south of the city suburbs of Chennai is changing fast and how! This has now become the biggest automotive hub buzzing with industrial activity that it has earned the identity of being called “The Detroit of South Asia”.Many automotive brands have made this expanse of land at the outskirts of the Chennai city their production hub of India from where not only domestic demands are met, but also exports to neighboring countries take place. Some of the reputable name brands include Renault-Nissan, Daimler, Ford, Hyundai, Nokia, Apollo Tyres, Sanmina and JK Tyres. This spurt of industrialisation has also triggered the mushrooming of smaller automotive parts units around this area.

Renault Nissan at Chennai

Renault Nissan set-up its plant at Chennai in the year 2010

with an investment of INR 45 billion and with a capacity to produce over 400,000 units at full ramp-up. The manufacturing process in this sophisticated unit allows the plant to seamlessly mix production of both Renault and Nissan products on the same line. The unit began its production activities with Nissan Micra, a global sub-compact, and slowly added many other models to its line including luxury sedans MPVs and SUVs.

Scope of works

The scope of works for L&T includes Design & Construction of Machining & Casting shop for Renault Nissan Automotive India Pvt. Ltd. – Chennai. Aimed at increasing productivity this project promises to bring about

Usage of man lifters for truss erection


Aimed at increasing productivity this

project promises to bring about a torrent of new vehicles from both parties of the

venture to the Indian market and thus to

the roads.

starts from small car to the big segments including – MPVs and SUVs which would suit styles of different target market. For L&T Construction, this is one of the fast track automobile projects with design, build with

Major Quantities

Earthwork : 169000 cu.m

Concrete : 21500 cu.m

Reinforcement Steel : 1493 t

Structural Steel : 2754 t

Form Work : 42800 sq.m

Laser Screed Flooring : 43459 sq.m

Galvalume roof sheeting & Cladding : 50500 sq.m

Drains : 2.6 km

Roads : 1.5 km

False ceiling & False flooring : 5156 sq.m

Doors & Windows : 354 nos

Painting : 17100 sq.m

High Speed Shutters : 16 nos

HT Cables : 4 km

LT Cables : 68 km

Cable Trays : 15 km

Earthing : 19 km

Conduiting : 12 km

HT & LT Panels : 46 sets

Transformers 2.5MVA : 6 Nos

Light Fittings : 3111 Nos

HVAC-VRV/AC units : 123 units

Roof Ventilation Fans : 131 nos

Fire Fighting Pipe Line : 2.8 km

Compressed Air Pipe Line : 1.8 km

LPG Pipe Line : 1.5 km

Domestic & industrial Water pipe lines : 7.6 km

ETP Pipe Line : 1.6 km

Sewerage PVC Pipe line : 2.2 km

Digital Public Addressing System : 1 set

a torrent of new vehicles from both parties of the venture to the Indian market and thus to the roads. The range of cars

Work in progress for Retaining Wall using aluminium formwork


all civil, structural, sheeting, MEP and external works. The design study and the preparation of drawings are done by L&T’s EDRC team.

Challenges faced

The entire construction was inside a fully functional plant with a strict code for material passage, safety and permits. A lot of planning and interface with the client was required to overcome delays and speed up execution. The design constraints considering their first plant construction reflections are duly taken into by L&T’s design team. The scope of design in integrating the Civil, Structural and MEP services in such a fast track project is truly a phenomenal task. Continuous tracking of the changes in the design and drawings

were coordinated between site planning team and the EDRC representative at site. This ensured minimal delays in providing the required details to the execution team.

The scope for the shop included sheets of extensive lengths, which at certain areas measured as

much as 60m. These sheets were to be rolled out and fastened quickly so that the flooring works could progress in tandem as scheduled. There was also an explicit demand from the client that no one was to step on the sheets so as to minimize damages. To overcome this challenge, the profiling machine rolling out the sheets was lifted to the working height of the two buildings which was at a height of 10 m at the machining shop and 15 m at the Casting Shop. Heavy cranes lifted the sheet profiling machine and placed it on the roof where the profiled sheets were immediately used for roofing without the possibility of any damages. The profiled sheets were shifted from one area to another by placing an array of

The entire construction was

inside a fully functional plant with

a strict code for material passage,

safety and permits.

Profling of sheets at roof top


rollers, drastically minimizing the required labour force, and ensuring adherence to the client requirements and also conforming to high safety standards.

Shot/grit blasting was a prerequisite to painting as a corrosion control method. This process dispensed particulate emissions which could scratch

the surface of the vehicles in the plant. To prevent this from happening, a shed was constructed with ventilating ducts that took these particulates

The LPG piping team had the

daunting task of connecting the two new shops with the

already existing and functioning line supplying gas to the

remainder of the plant.

PUF Panel Rooms

Inside view of completed facility


Machine Shop160 m x 160 m x 8 m height

Structural steel with Galvalume sheet roof, Industrial flooring, Steel Doors, High speed shutters and Aluminium windows

Casting Shop100 m x 100 m x 13m height

Structural steel with Galvalume sheet roof building Industrial flooring, Steel Doors, High speed shutters and Aluminium windows, Girders for Gantry crane & hanging cranes, Equipment Foundation pits

Retaining Wall 360m Length x 5m Height

Ancillary Buildings

Substation – 2 nos RCC Building – 35m x 18 m each

Tool Room 40m x 20m – Structural steel and Galvalume roof sheets

QA Labs – 2 nosRCC building 20m x 20m x 5.5 m with false ceiling and gypsum partition works

Administration BuildingRCC buildings – 60m x 20 – 2 floors with meeting and conference rooms with all interior finishes False ceiling and false flooring works

ACP Cladding works

Dining Hall30m x 20 m with granite flooring Waste collection and Bain Marie provisions

Chip Treatment30m x 20m Structural steel and Galvalume Roof sheet with Collection pit and trenches

Lean To Roof structureStructural steel with Galvalume Roof Sheet works Laser screed industrial flooring

CanopiesStructural steel with Galvalume Roof Sheet works

Laser screed industrial flooring

Maintenance warehouse

RCC Building – 30m x 20m x 6m with epoxy coatings

Shop Floor Office -2 nos

RCC Building – 30m x 20m x 6m with Vitrified tiles and false ceiling works

Lockers- 2 nos RCC Buildings – 20m x 20m with all interior finishes

Toilets – 6 nos RCC Buildings – 10 x 10 m with all interior finishes

Sensitive Equipment Rooms – 10 Nos

PUFF panel rooms with AC and Epoxy coatings, Window and Doors

Training Rooms – 2 nos RCC Buildings – 20m x 20m with all interior finishes

Roads – approach and Truck parking

10000 sq.m of Asphalt road with main approach, 855 sq.m of Truck parking and loading and unloading bays

Storm water and Roof water drains

RCC drains with cover slabs

Oil storage and LPG unloading platforms

RCC platform with fence and grating works

Cooling Towers and PRV stations

Foundation and fence works

Sewerage Network with STP

10m x 6m x 10m with pumping stations

Electrical Services Machine shop, Casting shop and RCC building areas

HVAC All RCC buildings, Training Rooms and Puf Rooms

PHE works Toilets and Treatment plant supply

Utility Pipings – LPG, Air, Water, ETP lines

Piping works from existing utility building to new shops

FPS and PA systems All shops and RCC Buildings


into a water-logged pit where they settled as sediments, hence protecting the client’s interests.

There was an LPG pipe running along the project site which was a critical utility for the existing and operational plant. The LPG piping team had the daunting task of connecting the two new shops with the already existing and functioning line supplying gas to the remainder of the plant. This was a high-risk activity due to the extreme levels of safety concerns. The LPG line could be worked upon only during periods of plant shut-down and consequently L&T engineers handled this challenge exceptionally by working on 20 consecutive Sundays of 20 hour shifts.

Due to the poor quality of sub soil layer by layer back filling was done for every 150 mm to the height of 4 m. Mini rollers were engaged in carrying out this activity to ensure uniform compaction.

There was an unprecedented delay in receipt of sheet coils from Korea which posed as a threat to delay the progress of flooring works. Temporary GI sheets were used to cover 8000 sq.m of machine shop area so that the flooring work could proceed as scheduled.

Mechanization played a key role in the success of the project. Height works were a major aspect of the project scope and transcended all departments. By engaging 14 boom lifts and 3 scissor lifts, the post-erection height activities within the shop and outside it were carried out with exceptional speed, quality, high safety standards and comfortable working conditions.

Mechanization played a key role

in the success of the project.

Height works were a major aspect of the project scope and transcended all departments.

Another view of plant


Design Complexities

The fabrication yard was located 1.5 km away from the project site and due to the design of the structural elements, transportation proved to be a major challenge. This design aspect incorporated smaller sections for the main load bearing elements at intervals where the factor of safety was more than necessary. Due to this, the trusses had a tendency to buckle unless they were properly handled. Safety and site engineers carefully executed each loading and unloading process to ensure that the trusses were delivered safely to the site in the exact quality and shape desired.

One of the most critical requirements of this project was

the very close tolerances and the high quality of the flooring. The flooring was to be levelled with tolerances of ±2mm and therefore, the project team employed the use of LASER Screed Flooring. This is a technique

used to measure and achieve highly finished and precision flooring - a prerequisite in modern automotive plants. The expansion joints of the floor were covered with SS plates in order to protect the flooring from wear and tear.

The sheeting profile was of a seamless nature. This complicated the skylight poly carbonate sheet laying. The seamless sheets did not have inclusions for the skylight sheets. Thus, separate flashings and purlins were laid to enable skylight fixing at all the locations.

C. SivakumarProject Head

The flooring was to be levelled with

tolerances of ±2mm and therefore,

the project team employed the use of LASER Screed

Flooring.

View of plant form the yard


330 MW Srinagar HEPSetting benchmarks in the

Himalayan heights


Uttarakhand, a state in northern India is often referred to as the “Land

of the Gods” due to the numerous pilgrimage centers scattered across this region. The mighty Himalayas is the predominant part of Uttarakhand along with a large network of rivers and canals including India’s holiest river, The Ganges, which thereby provides an immense scope for hydro-power energy.

Hydro power, considered a renewable, economic, non-polluting and environmentally benign source of energy has inherent ability for instantaneous starting, stopping, load variations etc. and helps in improving reliability of power systems. Hydro stations are also arguably the best choice for meeting the peak demand of power.

Located on river Alaknanda, a major tributary of Ganga, the Srinagar

Hydro power plant is a 330 MW (4x82.5) unit owned by Uttar Pradesh Power Corporation Limited (UPPCL). This unit was later taken over by Alaknanda Hydro Power Company as concessionaire for 30

years and further given to GVKPTSL (GVK Projects and Technical Services Limited) on EPC basis for construction.

GVKPTSL chose L&T Construction’s, Hydel Business unit to execute all major civil works due to the experience L&T holds in offering “Water-to-Wire” turnkey solutions. With an objective of increasing the generation capacity of the plant to 330MW, achieved by utilizing a head of 65m and design discharge of 140m3/s, the main components of the project include:

y Upstream and Downstream Coffer Dam

y Construction of Diversion Tunnel

y Construction of 90m high concrete gravity diversion dam with 8 spillway bays and 4 under sluices

y 6 Head Race Tunnel (HRT) Intakes with gate hoist buildings

Hydro power, considered a

renewable, economic, non-polluting and environmentally benign source of energy has

inherent ability for instantaneous starting, stopping, load variations etc.

Aerial view of dam structure


y Two 1 km long head race tunnels

y HRT outlet connecting to a De-silting basin

y 4 km concrete lined Power channel

y Forebay intake

y By-pass intake and channel

y Surface Powerhouse

y Tail race channel

y Box culvert bridge

Scope of work

Dam

Dam in Srinagar HEP is concrete arch cum gravity type of height 90m, top width approximately 52m, bottom width approximately 76m and top length of 248m which is constructed to carry a gross storage of 78 Mm3 of water such that its own weight resists the external forces. This dam has

eight ‘ogee’ type spillways for releasing excess flood water of the river during monsoon season and to act as an energy dissipating device via formation of hydraulic jump at the basin. Here spillways are of width 14.5m in eight vents and are provided with radial gates whose axis or Trunnion is held to anchorages that are fixed to hydraulic cylinder hoist. The pre-stressing works of around 150 t in piers was also done by L&T. Movement of the gates can be done by cylinder hoists, as and when required, using hydraulic action which was one of the typical inclined hydro mechanical structure of dam. Dam has 4 under sluices of 4mx3m with bell mouth opening, which is constructed to divert excess water in peak flow season and later it will be helpful to remove silt from Dam upstream. Apart from this Foundation Gallery,

Upper Gallery, instrumentation gallery and GOC chambers are also constructed. Gate operating chamber (GOC) will be used for operating hydraulic gates and Dam gallery is built to intercept any seeping water from the reservoir through the upstream face of the dam to reduce the uplift pressure and provide stability to dam. The foundation drainage gallery which is parallel to dam axis have slope of 1 in 1000 from both sides to drain away the collected water in the side drain up to a sump at the lowest level from where the water may be pumped out to the downstream side of the dam. Scope of consolidation and curtain drilling of around 25,000 RMT and grouting of around 2500 MT is done by L&T in dam gallery. These works will be followed by Diversion tunnel plugging and grouting in later stages.

View of dam gallery


The dam is divided into 15 blocks of total length 248m with total quantity of 5, 30,000 cu.m of concrete which was poured via Rotec tower belt, Creter crane, Tele-belt, boom placer, concrete pump and tower crane within 3 years with effective utilization of manpower. It was a challenging engineering task of constructing a massive structure across a flowing river while tackling the monsoon flows and floods and getting the better of it.

HRT- intake

HRT intake is a structure through which water passes to head race tunnel as they provide an easier and more precise control of the water level in the stream channel. This project includes six intake structures which are connected to two head race tunnels. Total length of HRT intake is 96m with each intake of

width 16m and length 23.25m which are provided with three stop log gates, service gate and trash rack gates of height 29.7m. Trash rack prevents entry of large debris into the head race tunnel, where as stop log gates controls the flow of water into HRT, in case stop log maintenance/repair is required

then it is controlled via service gates. Concreting, Formwork and Reinforcement for all Intake structures, Gate Hoist Buildings and Control buildings is done by L&T. Gate Hoist buildings and Control buildings are constructed for operation of the hydraulic gates.

Head Race Tunnel

HRT is the first part of the water conducting system which is designed to take discharge of around 385 cumecs of water per tunnel. There are two Head Race Tunnels of length 1k.m. each, whose excavation was done by customer earlier and lining work was given in the scope of L&T. Lining was commenced by mobilizing lining shutters and traveler which was fabricated, installed and operated for full-round horse shoe shaped tunnel gantry for first time by L&T. The traveler has

GVKPTSL chose L&T Construction’s, Hydel Business unit to execute all major

civil works due to the experience L&T holds in offering “Water-to-Wire” turnkey

solutions.

Head Race Tunnel designed to take discharge of 385 cumecs of water per tunnel


a function of transporting, setting up and dismantling the steel form section. It is portal type, provided with telescopic legs and longitudinal beams with framework to allow movement of workmen, materials and machinery. L&T’s scope also includes consolidation drilling and grouting, curtain drilling and grouting, followed by Adit Plugging later to strengthen the parent strata.

HRT-Outlet (Supanah Nallah)

This forms the second part of water conducting system and is the structure that connects HRT and De-silting basin via transition zone. Its total length is 258m, width 26m and height 12.8m with a total concrete quantity of 40,000 cu.m. L&T’s scope of work includes concreting with proper compaction and curing apart from planning, supply and installation of system formwork and reinforcement works.

Desilting basin (DSB)

The 447m long, 158.5m wide and 29m high De-silting tank, is the third part of water conductor system and Asia’s largest DSB which is built to settle the heavy silt carried by the Himalayan River Alaknanda. All the silt will be collected in a tank; which will be subsequently flushed out through 350m long silt flushing pipes back to the river.

There are three main components of De-silting basin: U/S Transition, Desilting Tank and D/S Transition. Desilting Tank is the major component in the Desilting basin; it is having two tanks separated by concrete wall at centre line of Desilting Basin. Each tank is 200m long and 77 m wide. The maximum water level in the tank is at EL 602.40m and the top of the walls is at EL 603.40m. De-silting basin has 19 blocks in which total quantity is 3, 46,000 cu.m. In

order to save time, a different type of construction methodology was adopted, replacing conventional concrete by using structural hopper and precast arrangement. This methodology also helped in reducing 20% of the construction cost. The quantity of reinforcement is 21000 t, which constitutes to 40% of total project reinforcement quantity.

L&T’s scope of work includes reinforcement fixing and system formwork for concreting. The placement of concrete was done using Creter Cranes & Conveyor Belt assembly and Concrete Pump/Boom Placer.

Power Channel

The power channel is the fourth part of water conductor system which will be used to carry the desilted water from DSB to the power house through a 4 km long open channel. However, L&T’s scope of work was

447m long, 158.5m wide and 29m high - Asia’s largest desilting basin


limited to concreting of 600 m of power channel, a bridge and expansion joint treatment works.

Intakes for Forebay and Bypass Channel

Forebay is an open structure upstream of Power House connected through penstocks. Forebay acts as a temporary reservoir to control the surging of water resulting from sudden operation of valves due to load variation in the grid power. L&T’s scope of work includes construction of 4 intake structures of length 92m, width 32.8m and height 20.75m which includes Bell mouth opening, stop log gates, service gates and trash rack gates and four anchor blocks in the upstream of power house was constructed. Also four Gate Hoist Buildings of height 10m each, from where hydraulic movement of gates is controlled is constructed by L&T. For By-pass channel L&T constructed three Spillways of length 35m, two abutments and two piers of height 11m and three top slabs of 11x13m which are incorporated with special and proprietary ‘God bole’ gates in different stages via effective communication and planning with hydro mechanical team.

Power House

Surface power house is of 330 MW consisting of four units of 82.5 MW each which will run on Francis Turbines. L&T’s scope of work includes construction of power house structure consisting of assembly bay, four units and erection bay in coordination with Hydro mechanical and electro mechanical contractors. Each unit is of 21.5m width, 52m length and 43m in height which is divided from

Salient features of structuresDiversion Tunnel

Length 534 m

Diameter 8 m

Shape Modified Horseshoe

Diversion Discharge 700m3/s

Dam

Type Concrete Gravity

Length 275 m

Maximum Height of Dam From Deepest Foundation

90 m

Height of Dam From Deepest River Bed 66 m

Number and Size of Spillway Bays 8 Bays of 14.0 M Widths Each

Gross Storage 78 million cu.m

Head Race Tunnel Intake

No. of Intake 6

Invert Level of Trash Rack E.L.591.30

Design Discharge 119.3m3/s per Gate

Diameter of Ginger Tunnel 6.2m

Shape Circular

Head Race Tunnel

Number 2

Length 1100m (approx.)

Diameter 9.8m

Design Discharge 358m3/s per tunnel

Shape and Lining Circular and Concrete Lined

Desilting Basin

Length of Inlet Transition 170 m

Length of Desilting Basin 200 m

Length of Outlet Transition 88 m

Width (Including Divide Wall) 158.5 m

Water Depth 18.75 m at Desilting Basin

Particle Size to be Removed 0.25mm and above

Flushing Discharge 100 m3/s

Power Channel

Type Trapezoidal Lined Section

Length (Including Transition) 4.05 km

Design Discharge 616m3/s

Forebay Intake

No. of Intakes 4

Minimum Draw Down Level E.L. 600.30

Full Reservoir Level E.L. 601.30


“A” line to “D” line. A-B represents auxiliary buildings which consist of separate floors such as battery floor, operating floor etc. on top of it there is fire protection wall of 300mm of height 10.9m and length 48m in each unit. B-C represents machine hall where the main turbine is set up, it again is constituted of different floors such as draft tube floor, turbine floor and generator floor. C-D represents the outlet of draft tube which connects it to tail race channel, apart from this it consist of draft tube vents, piers, abutments, and slab and gate arrangement for draft tube. The concrete works occurs in three stages in which each is separated via interfacing of either hydro mechanical or electro mechanical works such as draft tube, spiral casing etc. In front of D line there is tail race channel which consist

By Pass Channel

Type of Fall Structure at Head Ogee Type

Fall 11.8 m

Crest Level E.L. 596.80

Bays At Head b bays 1.5 m Each with 2 piers of 1.5 m each

Total Width 48 m

Design Discharge 616m3/s

Penstocks

Numbers 4

Diameter 5.6 m

Length 114 m

Power House

Type Surface

Size of Machine Hall 25.25 m X 21.25 m Each

Installed Capacity 330 MW (4 Units of 82.5 MW)

Type of Turbines Vertical Francis

Gross Head 67. 20 m

Exterior view of powerhouse


of slope rafts of length 48m and height 1m, with both side rafts of height 2m and retaining wall of length 78m and height 8m and tail race bridge of length 100m, width 5.5m and height 7.2m is being done by L&T.

A total concrete of 1, 50, 00 cu.m was poured via concrete pumps, boom placer and tower crane in various units of the powerhouse structure. The shuttering and reinforcement were handled by providing 2 nos. tower cranes. On customer demand, the generator barrel of the 4th unit of Power House was constructed by L&T in a record time of 42 days for which appreciation letter was given by the Chairman of GVK.

Dhari Devi Temple

This was an important scope awarded to L&T during the progress

of the project. The upstream of the project had a popular temple of historical importance which would be submerged once the plant is commissioned. This temple was to be elevated after moving the idol

to a temporary temple structure during which time the new temple was being built. The scope of works include construction of temporary and main temple and also an approach bridge from the village to the temple. Main Temple is built by 17 circular columns of 1m and height max 27m with top slab of 23mx 32.5m by L&T and left in shutter with respect to slab and beam which consist of around 100 t steel structure designed by L&T’s EDRC department. L&T fabricated and erected this 60m long structural steel bridge in just 4 days for which appreciation letter was issued by Chairman of GVK.

Challenges

This project was conceived by UPPCL way back in the 1980’s and the progress stalled due to funding issues. It was later revived under

L&T had taken over the project works

which were stalled for over three

decades and after a lot of planning, executed the civil

works which is presently close to

completion.

Commissioning of turbine in progress at the power house


PPA (Power Purchased Agreement) by a company called Duncans in 1996 and it equivocated out due to land issues. The project was taken over by TATA in 2003 as AHPCL and it remained stand-still

once again due to land issues and it was taken over by GVK group in 2005. Finally the construction commenced in the year 2007 through local contractors and it was subsequently awarded to

L&T in the year 2009. Right from 2009, L&T had taken over the project works which were stalled for over three decades and after a lot of planning, executed the civil works which is presently close to completion.

The Alaknanda river marked the district boundary with one bank

Major Quantites

Concrete (cu.m) Reinforcement (t) Formwork (sq.m)

Dam 520183.914 10500 94000

Head Race Tunnel

70226.185 0 0

Desilting Basin 346000 21000 133000

Power House 150000 10200 85000

HRT Intake 40000 1500 19000

Supanah Nallah 37000 3500 25000

Power Channel 70000 4000 38000

Forebay and Bypass Intake

57000 1200 20000

Dhari Devi 2000 500 3000

TOTAL 1292410.099 52400 417000

Major quantities also includes total steel structural works of 1690 t in De-silting basin and Maa Dhari Devi temple

The Srinagar Hydro Project is perhaps

the only hydel project that is set amidst a densely populated

town with almost 17 villages surrounding

the dam site.

Work in progress for the relocation of Dhari Devi temple


being Tehri district and the other side belonging to Pauri district. The project administration team had to co-ordinate with two district administrations based on jurisdiction to sort out each and every issue.

The Srinagar Hydro Project is perhaps the only hydel project that is set amidst a densely populated town with almost 17

villages surrounding the dam site. This gave rise to numerous local issues frequently because certain land issues were yet to be settled. This affected the productivity of the project to a great extent but was overcome effectively through sensitization drives in order to win the confidence of the villagers.

Srinagar was the first hydro project for L&T in which all major

civil components of the dam was in the scope. So handling such major civil works with effective engineering, resource and manpower planning was one of the most challenging tasks.

Flash Floods, which was common in the Himalayan terrain was one of the major challenges that the project team had to face as the work progress was hampered almost thrice in three years. Due to flash flood there was also a major loss of P&M equipment such as Tower Crane, Compressor etc., along with some formwork material which was completely swept away.

L&T’s project team also faced a lot of interface issues as only the civil portion was awarded to L&T while the Electro Mechanical and Hydro Mechanical jobs were awarded to different organization such as BHEL, P&R, PIL etc. This called for seamless interfacing and up-to-the-minute co-ordination with the client also. In order to facilitate this, technology was widely used for frequent communication through MMS apart from IP cameras, e-mails and conference calls. A unique implementation for the first time in a Hydel project was the setting-up of sophisticated IP cameras to which multiple

Asia’s largest Desilting Basin that is completed by L&T despite numerous

local problems and land issues

Internal view of powerhouse


Unit # 4 Generator Barrel of Power

House was constructed in

a record time of 42 days setting a

benchmark in hydel construction.

users can log in and operate to get live streaming video of project activities. The project management teams could not only plan and monitor progress seamlessly but also avert interface issues with the other contractors executing the other packages.

Due to the scale and complexity of the project there were frequent changes in the drawings which were sorted out with expert suggestions from the design team at L&T and through implementation of innovative ideas which were aimed at reducing resources.

The relocation of Dhari Devi temple was also a challenging task as it was a temple that attracted a lot of devotees and hence a temporary structure was to be arranged in the time that it took to build the main temple. Since the relocation of this ancient temple was socially important, any act of negligence would have cost a huge loss for the reputation for both L&T and the client. Therefore the works were executed with utmost care and

safety, always taking the villagers into confidence at every stage.

Achievements y Asia’s largest Desilting

Basin that is completed by L&T despite numerous local problems and land issues

y Srinagar is the first concrete Gravity Dam that L&T has ever constructed for a Hydro power project.

y Unit # 4 Generator Barrel of Power House was constructed

in a record time of 42 days setting a benchmark in hydel construction.

y L&T has achieved 7 million safety man hours as on 31st December 2012 in this project

y Completion of HRT lining of around 2 km ahead of schedule

y Completion of HRT Intake (six nos.) concreting works before schedule

y Completion of Fore Bay Intake concreting works before schedule

y Achieved benchmark of 3080 cu.m of dam concreting in a single day.

View of power canal

Another view of power canal


y For the first time in a Hydel project, IP cameras were installed for the effective management and monitoring of the progress.

y This is one of the first Hydel projects where around 150 rural youth were empowered by imparting training under L&T’s Construction Skill Training Institute and were absorbed in the Organization under the semi-skilled category.

y Won the Quality Trophy in the year 2011 for effectively implementing Quality Management System.

y Successful completion of a hydel project which has historically faced stiff local resistance due to the high density of population in the

area which is almost as high as 200 persons per sq. km.

P&M achievements y Sophisticated Creter Cranes

(130 cu.m/hr) for long distance pour of concrete was used for the first time in L&T.

y Frequent shifting of tower cranes from one location to another due to paucity of space and as per the changing requirement of the structure was one of the main challenges mitigated using in-house team.

y Dewatering was done using 1500 HP pumps continuously for over two whole months to ensure smooth operation and project progress in the dam pit which was water logged and submerged.

y There was heavy silt deposition due to floods; sand removal in the under-sluice area was done by using gang Vibrator attached with excavator bucket. About 300 cu.m of sand was excavated from this area.

y Gang Vibrator was used effectively for compaction of bigger concrete pours

y Various capacities of batching plants were used. Some were installed similar to line production system using conveyors to enable continuous pour.

Rakesh Kumar Jha

Project Manager

Overall view of dam upstream and downstream along with desilting basin


Power and communication to

Ras Laffan, Qatar


Qatar is one of the world’s largest producers of natural gas with most of

the Gas Processing plants located in an area called Ras Laffan which is touted as one of world’s fastest growing industrial hubs located 80 km north of Doha. Ras Laffan industrial city is one of the three major manufacturing hubs of Qatar Petroleum in Qatar which produces gas with major producers such as Qatar Gas, Ras Gas, Shell and Oryx.

Following rampant growth in industrialization, Qatar Petroleum felt the need for attracting many support industries and support services industries to set up their facility in Ras Laffan to serve the needs of the Gas Processing Facilities. Qatar Petroleum felt that the setting up of ancillary and support industries close by would further boost the economic development of Qatar since Ras Laffan had its own Sea Port

which further enhanced the logistical feasibility of this location.

Accordingly, a project was conceived to develop the west-end side of

the Ras Laffan industrial city, which was originally a green land, into completely developed industrial plots with all utilities such as Power, Telecom, Potable water, water and sewage network. The project was divided into two major packages - one for Electrical and Telecom utilities and another for Water and Effluent Treatment utilities. L&T Construction’s Power Transmission & Distribution Independent Company was awarded the order for the electrical and telecom package in August 2009.

The significance of this project was to ensure a reliable power and communication facilities to these industries to promote their business.

Scope of Works

The project scope comprised of Engineering, Procurement,

A project was conceived to develop

the west-end side of the Ras Laffan

industrial city, which was originally a green land, into completely developed industrial

plots with all utilities such as Power,

Telecom, Potable water, water and sewage

network

100 MVA 132/33 kV Transformers


Installation and Commissioning of Electrical and Telecom Utilities for Support Service Area (SSA) Phase I & II and West -End Extension at Ras Laffan City (RLC), Qatar for Qatar Petroleum. This is one of the biggest Electrical infrastructure project undertaken by Qatar Petroleum and the project was bagged by L&T under stiff international competition.

Electrical

Establish a Power Transmission / Distribution network with Power Management System (PMS), consisting of 132kV system, 33kV system, 11kV system and 0.433kV system to cater to the power requirements of Support Service Area phase I and II and other ongoing developments of RLC West - End Extension with provision for future expansion.

Telecom

Establish a fibre optic communication network and OSP (Outside Plant) infrastructure for RLC West - End extension and integrate the network into the existing East-end RLC network.

Electrical scope of work

The electrical scope consisted of 132/33kV RLF-4 substation comprising of 2X100MVA 132/33kV transformers, 33kV switchgear and substation auxiliaries. It also included one 33/11kV substation (S/S No.1) comprising of 33/11kV transformers, 11kV switchgear and substation auxiliaries apart from two 33/11kV substation (S/S No.2 and S/S No.3) comprising of 33kV switchgear, 11kV switchgears and substation auxiliaries. Apart from this, the electrical scope of work also included:

y Two 132kV cable feeders from RLF-3 220/132/33/11kV S/S (C700 & C600) to RLF-4 132/33 S/S

y 33kV cable feeders from RLF-4 to all the three 33/11kV substations

y 11kV distribution system comprising of 11kV cable ring main network, 20 RMUs, (Ringmain Units)44 package substations for feeding power to the end users and for the sewage, potable and fire water pumping stations, street lighting and traffic signaling systems

y Power Management System for west side and integration of existing RLC east side Power Management system with the west side PMS system

LVAC Board and Battery Charger


y Power supply equipment for telecom buildings

y Street lighting comprising of 190 high mast lighting, 22 feeder pillars, LV cabling and earthing system

y Traffic signals and control system for 5 intersections

Telecom Scope of work

The scope for telecom work included two telecom buildings for accommodation of STM-16 SDH nodes of new RLC West End Ring. One building was to be located in the Support Service Area and another in

the Support Industry Area. The scope includes OSP Fibre optic cables for the connections between West End Ring nodes and the existing telecomm networks apart from Pilot Fibre optic cables for connections between all the substations for teleprotection and Power management system communication. Apart from the above, the scope also included:

y Cable infrastructure which comprises cable ducts and manholes

y Outdoor Fibre optic distribution hubs

y PABX

y Telephone facilities for substations and telecom buildings

y Telecom supervision system

y Updation of network management system

y Passive equipment and 33/11 kV Cable Basement in SS2

Fire Water Pump House


accessories (main distribution frames, fibre optic distribution frames, equipment rack cabinets)

y Integration of Fire Alarm System in substations and telecom buildings into existing RLC fire alarm network

Challenges

During the initial stages of the project, many engineering issues were raised and there was an unprecedented delay in design approvals. This challenge was mitigated by conducting engineering

workshops with the client, consultants and vendors which helped to resolve the issues for early approval of the engineering documents.

At the time of tender, the specifications were based on Kahramaa Phase VIII details. But at the time of execution

At the time of tender, the specifications

were based on Kahramaa Phase VIII

details. But at the time of execution Kahramaa insisted on the latest specification which

was phase IX.

11 Ring Main Unit

132/33 kV Substation


RLIC (Ras Laffan Industrial City) where Consolidated Permit to Work (CPW) system had to be followed. This permit was mandatory for each and every aspect of the work, and was to be endorsed on a daily basis. In order to ensure the scheduled project progress and to achieve smooth operation, a dedicated person was nominated for this activity since no activity could be taken up without a valid permit. For procuring the permit L&T had

Kahramaa insisted on the latest specification which was phase IX. This involved major changes in the transformer construction which was not possible as L&T had already placed the order as per the original specifications. The matter was represented and after coordination meeting, Kahramma agreed to this aspect as a ‘one-off’ case.

The project scope involved numerous underground power and fiber optic cable laying works. During execution, over fifteen other contractors were working in the same area in the allotted corridor which led to many interface issues. There were a number of crossing issues, access issues and clashing of corridors between two utilities. These issues were sorted out smoothly by conducting regular interface meetings with the other contractors and the client.

The project was falling within the jurisdiction of Qatar Petroleum’s

to submit an approved method statement and Job Safety Analysis along with the approved drawings. The whole exercise called for a lot of prior planning and coordination before the actual work commenced at the project site.

The electrical and telecom scope of Ras Laffan project has been one of the biggest Electrical Infrastructure Project in the Gulf region consisting of underground EHV and MV power cables (275 km), fiber optic cables (160 km) 11 kV package substations (44 nos), stand-alone RMUs (20 nos) 35 m High Masts (190 nos), Traffic signals (5 nos) etc., all executed within a short time successfully for a highly demanding client under complex working conditions and environment. The systems have been energized and are presently feeding power to the RLIC network to the full satisfaction of the clients.

Krishnan Lakshminarayanan Project Manager

The electrical and telecom scope of

Ras Laffan project has been one of the biggest Electrical

Infrastructure Project in the Gulf region

Illuminated view of Substation


SAIL- BSP7 million ton expansion projects


Bhilai Steel Plant’s (BSP) expansion drive of 23 MTPA crude steel plant by 2012

forms a major part of Steel Authority of India’s (SAIL) expansion drive. Under its corporate plan SAIL - BSP has envisaged enhancement of crude steel production capacity up to 7.0 MTPA from the existing 4.5 MTPA by 2012. Due to some delays in the implementation process the modernization project is expected to be completed by 2014.

The expansion project involved many packages of which the installation of Blast Furnace # 8 complex (Package-010) and Installation of 2nd Sinter Machine (360m2) for 2nd strand in Sinter Plant No.3 (Package-020) was entrusted to a consortium of L&T on an EPC basis. Both these projects are being implemented within the existing facilities.

Sinter Plant no 3B Project

The new 360 sq.m Sinter Machine with associated facilities is envisaged in the existing Sinter Plant No.3 complex to produce 3.706 MTPA of gross sinter to meet the additional sinter requirement of Blast Furnaces. This sinter plant project

was awarded to a consortium with the L&T Construction’s MMH Independent Company as the leader and Outotec GmbH, Germany as a partner, on 28th of August’2010 on EPC basis with a project completion schedule of 30 months. MECON were nominated by SAIL-BSP as the project consultants.

Scope of workScope of work includes design, engineering, manufacture, supply, handling, storage, civil works, mechanical erection, painting, testing, commissioning of plant and equipment and demonstration of performance guarantee parameters of the sinter plant complex in a coordinated and integrated manner. Outotec GmbH will provide the basic technology of the sinter plant and supply some of the critical equipment like Sinter Cooler, Sinter Machine, Mixer and Noduliser.

Bhilai Steel Plant’s (BSP) expansion

drive of 23 t crude steel plant by 2012 forms a major part of Steel Authority of India’s (SAIL) expansion drive.

WG Fan House


L&T Construction is involved in the design and detail engineering of complete civil and structural works, fabrication and supply of structural steel, construction of civil works, and erection of structural, mechanical and electrical equipment apart from other utilities.

The project involves execution of the following facilities of the new Sinter Machine installation:-

y Sinter Machine and Proportioning Bin unit.

y Mixing Unit.

y Sinter Cooling Unit.

y Cold Sinter Crushing Units.

y Cold Sinter Screening Units.

y Waste Gas Handling Unit.

y Waste Gas Heat recovery unit

y Flexowell Conveyors, Junction Houses and Conveyor Galleries.

y Pneumatic Conveying System for Lime Dust.

y Pneumatic Conveying system for ESP dust.

y Emergency Sinter Storage unit.

Basic Plant Data: y Sinter Machine Area : 360 m2

y Consortium : L&T & Outotec

y Rated Productivity : 1.3 t m2/h

y Annual Production(Gross) : 3.706 MTPA

y Size of finished Sinter : 6- 50 mm

y Sinter M/c Bed Height : 650 - 700 mm

y Cooler Area : 375 m2 (35 m dia., 1.5 m bed height)

y Avg. Temp of Cooled Sinter : 100 Deg. C

y Exhaust Dust Content : < 50 mg / Nm3

The Sintering Process

Sintering is a technology for agglomeration of iron ore fines into useful Blast Furnace (BF) burden material. The major advantages of using sinter in BF are:

y Better reducibility of burden and smooth operation of blast furnace due to improved high temperature properties.

y Use of iron ore fines and metallurgical wastes.

y Reduction in fuel rate in blast furnaces

Sintering is a technology for agglomeration

of iron ore fines into useful Blast

Furnace (BF) burden material.

Sinter Machine Support Structure


y Increased productivity due to high burden of 65 to 70%.

y Improved quality of hot metal

The raw materials for sinter making are as follows - Iron ore fines (-8 mm), coke breeze (-3 mm), lime stone & dolomite fines (-3mm), mill scales, BF return sinter fines and other metallurgical wastes. The mix is loaded on sinter machine through a feeder onto a moving grate (pallet) and then the mix is rolled through segregation plate so that the coarse materials settle at the bottom and fines onto the top.

The top surface of the mix is ignited through ignition burners at 1200-1300oC. As the pallet moves forward, the air is sucked through wind box situated under the grate. A high temperature combustion zone is created in the charge-bed due to combustion of solid fuel of

the mix and regeneration of heat of incandescent sinter and outgoing gases. While the pallet car moves in the forward direction of the pallet, the sintering process travels vertically down. Sinter is produced as a combined result of locally limited melting, grain boundary

diffusion and recrystallization of iron oxides.

On the completion of sintering process, finished sinter cake is crushed and cooled. The cooled sinter is screened and (+) 5 mm fraction is dispatched to blast furnace and -5 mm is re-circulated as return sinter.

WG Process and De-dusting

Sl No

MaterialNo. of

Bins

Each bin volume,

(Effective) m3

Moisture %

Storage capacity t (approx)

Storage capacity,

hr (approx)

1. Iron ore fines 5 600 5.4 6000 15.8

2.Composite flux

2 600 2.0 1920 27

3. Coke breeze 2 300 6 360 10

4. Mill scale 1 300 - 600 60

5. Flue dust 1 300 - 600 135

6. IPRF 1 300 540 3

7. BFRF 1 300 540 7

8. ESP Dust Bin 1 100 200 30

9.Calcined Lime

2 200 - 400 50


Major units of Sinter Plant

Storage and Proportioning unit

This building will house fourteen proportioning bins for storage of various raw materials including ESP waste. The bins are of Cylindro-Conical shape and are constructed from fabricated steel plate. For iron ore fines, composite flux, solid fuel, mill scale and flue dust bins, in 1/3 portion of conical portion of bins is provided with SAILHARD liners ( 240 deg) and Castadour diamond plate [ 8mm thick MS + 4mm thick chromium carbide along the direction of flow (120 degree)]. SS 304 liner of 6mm thickness shall be provided in the conical portion of calcined lime bins. No liners are envisaged for return fines bin as it will be of stone box design.

Iron ore fine bins shall be provided with air canon system to ensure free flow of materials from bins. All bins will have bin level measuring system with two load cells and two tilt bearings. Bin aeration system shall be provided for Calcined Lime Bin.

The distribution of bins for storage of different materials in storage and proportioning unit along with their

storage capacities (in hours) are indicated in the table below:

Mixing and Nodulising Unit

Mixing and granulation is performed in a separate high intensity mixer. Mixing unit will house one Eirich type intensive mixer. Raw mix will be fed to intensive mixer (4m dia) through belt conveyors and one reversible conveyor. Mixer dedusting system shall consist of wet scrubber, and dedusting ducts etc. Slurry generated from mixer after dedusting in wet scrubber, will go back to the mixer via the dedusting duct.

Lime of size less than 2 mm will be pneumatically fed to lime bins (rated cap 20 tph) from lime tankers. Bag filters of suitable capacity shall be provided at the top of lime bins for dedusting purpose. Three lime tankers of 12 t capacity each are included in the package. Bin aeration system shall be provided for lime bins.

Nodulising shall be carried out in a separate Noduliser (dia 4m) housed at the top of sintering and cooling unit at the feed end sinter machine. Dedusting duct shall be provided at the top of granulator to let out fumes to atmosphere. After granulation, raw mix shall be directly discharged to shuttle distributor for feeding to raw mix hopper above feeding station of sinter machine.

Sintering & Cooling Units

The unit will house granulator, shuttle distributor, sinter machine with raw mix and hearth layer feeding system, ignition furnace, post heat hood, wind boxes, down comers, wind main, double cone valves, pallet lifting and lowering station, crush deck, hot sinter breaker, grizzly, direct transfer discharge chute, circular sinter cooler, Friction Drives,

cooler fans, vibro-feeder below Discharge station etc. along with handing equipment.

Cold Sinter Crushing unit

For Sinter Stabilization, Cooled sinter from cooler is discharged to the cascade chute by a belt conveyor. Sinter is separated in to less than 50 mm and greater than 50 mm fractions in cascade chute. Sinter exceeding 50mm in size is passed through the downstream double roll crusher with a rated capacity of 200 tph for further size reduction and the balance sinter (less than 50mm) is directly fed to belt conveyor bypassing double roll crusher.

Mixing and granulation is performed in a separate high

intensity mixer. Mixing unit will

house one Eirich type intensive mixer.

WG Stack (120M)


Cold Sinter Screening Unit

This unit will house two separate streams of linear motion cold sinter screens each i.e. product/hearth layer and return fines screens.

Cooled sinter will be fed to two lines of product/HL screens in cold sinter screening unit through belt conveyor and movable saddle with stone box construction. Product/HL screen shall be provided with single deck having two apertures (20 and 10 mm). (+) 20 fraction of sinter will be separated out in product/HL screens and fed to product belt conveyor. (10 – 20) mm fraction as hearth layer from this screen will be fed to a series of belt conveyor and side wall conveyor for onward transmission to HL bin above sinter machine. (-)10mm faction extracted from product/HL screen will be fed to RF screen and (6 – 10) mm return fines will be collected by return fines conveyor and transported to proportioning building by belt conveyors and a side wall conveyor. Product of size 6-50 mm will be collected by the belt conveyor.

Waste Gas Handling Unit

This unit shall consist of waste gas deduction ESPs, exhaust fans (2nos), duct work from wind main of sintering and cooling building to waste gas ESPs, waste gas ESPs, to exhaust fans and exhaust fans to stack. Sinter plant can be run at 50% of rated capacity with one exhauster in operation.

Waste Gas Heat Recovery Unit

Effective cooler waste heat recovery unit will be provided near cooler which will house combustion air fans, hot air fan and multi-cyclone etc. Hot air at 300 – 400 deg.C coming out from hot sinter receiving section of cooler will be sucked by combustion air fans and supplied to ignition furnace as combustion air after cleaning in a multi-cyclone and air sucked by hot air fan will be supplied to Annealing Hood installed

For Sinter Stabilization, Cooled

sinter from cooler is discharged to the cascade chute by a belt conveyor. Sinter

is separated in to less than 50 mm and greater than 50 mm fractions in cascade

chute.

Electrical Works - Cable trays/racks


just after the ignition furnace to avoid sudden cooling of processed sinter.

Flexowell Conveyors, Junction Houses and Conveyor Galleries

Various belt conveyors, interconnecting structural galleries and junction houses facilitate the movement of the raw materials and product to various interconnecting facilities within the Sinter Plant layout. The Flexowell conveyors will transport the Hearth Layer and return fine materials.

Pneumatic Conveying system for lime

Pneumatic conveying system is provided for handling calcined lime. Calcined lime will be carried near the mixer building by lime tankers (3 nos. of capacity 12 t each) from the lime plant of purchaser. ESP’s dust from de-dusting ESP will be

transported to ESP dust bin in proportioning building by pneumatic dust transportation system.

Emergency Sinter Storage unit

A new emergency sinter storage unit shall be installed parallel to the existing emergency sinter storage unit of first sinter machine (320

sq.m) to take care of the mismatch of the supply of the sinter in the event of reduced intake or shutdown of blast furnaces. The storage unit shall consist of concrete bunker of capacity 9 x 1050 cu.m effective volumes with manually operated rack pinion gate and vibro-feeders below it. Idler belt weigher shall be provided for one incoming conveyor to sinter storage and one outgoing conveyor from sinter storage.

Blast Furnace # 8 Project

A state-of-the-art new Blast Furnace-8 having a useful volume of 4060 cu.m with a rated capacity of 2.8 MTPA (Millions Tonnes Per Annum) of Hot metal (equivalent to 8030 TPD capacity) is being constructed as a part of the 7 MTPA expansion of SAIL-BSP. The new furnace features modern design and environment

This Blast Furnace project

was awarded to the consortium of M/s Paul Wurth Italia,

Paul Wurth India & L&T Construction’s

MMH IC.

Hot Stoves


friendly technology, equipped with features like Top Recovery Turbine, Waste Heat Recovery System, Energy efficient Equipment, Pollution Control Measures etc. MECON Limited is the consultants appointed by SAIL-BSP to provide consultancy services for the Design and Engineering.

Scope of works

This Blast Furnace project was awarded to the consortium of M/s Paul Wurth Italia, Paul Wurth India & L&T Construction’s MMH IC. M/s Paul Wurth Italia is the leader of the consortium and the Technology Supplier. This contract specification calls for complete turnkey execution of the job covering the design, engineering, manufacture, supply, handling, storage, erection, painting, testing, commissioning of plant & equipment and demonstration of performance guarantee parameters of the BF complex in a coordinated and integrated manner.

M/s Paul Wurth Italia is providing the basic technology for the plant and is also involved in the supply of critical technological imported equipment.

L& T Construction is involved in the design and detail engineering of complete civil and structural works, supply, storage, erection, testing of mechanical and electrical equipment, refractory works and utilities including commissioning of the project.

The BF8 project site stretches to about 7 km radius within the plant premises starting right from the stock house upto the slag disposal conveyors. The large project site area makes execution very challenging in an operating plant. L&T’s workshops were involved in the manufacturing

and supply of some of the major technological equipments.

Major Units of Bf Complex

BF Proper

The BF Proper is of free standing type with all facilities for state-of-the-art furnace operation having four poster structure and all necessary accessible platforms, bell less top charging system (BLT), BF off gas system including uptakes, off takes and down comers. Latest generation of Paul Wurth BLT System is designed to handle a maximum top gas temperature of 6000C and normal top gas temperature of 1500 C to 2000 C. The Blast Furnace is provided with a state-of-the-art cooling system. The entire BF is provided with four closed circuit soft water cooling including double chamber Tuyeres and Tuyere coolers.

Cast House

The scope consists of Twin Cast House with four tap holes (2 tap holes per Cast House) with two Cast House Defuming Systems (one of each Cast House), two Cast House Slag Granulation Plants (SGP) and four dry slag pits (2 for each cast house), three railway tracks for each Cast House.

The Cast House is equipped with state-of-the-art equipment such as 4 clay guns, 4 tap hole drilling machines, 4 portable drain port drilling machines (jack dam drill) 4 trough cover manipulators, and 4 tilting Iron Runners, Cast House EOT Cranes, Jib Cranes and other hoisting and handling equipment.

Hot Stoves

Three Hot Stoves are provided for supply of straight line hot blast

The BF8 project site stretches to about 7 km radius within the plant premises starting right from

the stock house upto the slag disposal

conveyors.

Blast Furnace proper and cast houses


temperature of 1250 0C. Hot Blast Stoves are of internal combustion type designed with ceramic burners and a waste heat recovery system also is provided. Stove operation is through online automatic stove model. There is also provision for installation of 4th stove in the future, for which the scope of foundation construction is in the existing contract.

The fuel gas available for stove heating is as follows:

1. BF Gas Calorific Value.: 875 Kcal/Nm3

2. CO Gas Calorific Value.: 4000 Kcal/Nm3

3. Mixed Gas(BF & CO)

Waste Heat Recovery System is installed for increasing the temperature of BF gas and combustion air by using the stove flue gas and by using the energy of waste gas from Stove.

Gas Cleaning Plant (GCP)

Gas Cleaning Plant based on PW AGE design is of wet type, single tower annular gap cone scrubber with two stage cleaning system designed for gas having dust content less than 5mg/Nm3 at the outlet of GCP. The scrubber is coated and lined with ceramic tiles. A demister is provided to maintain the moisture of clean gas at the outlet of GCP.

Top Recovery Turbine

A Top Gas Recovery Turbine (TRT) is required to be installed for a minimum power generation of 14MW to recover the pressure energy from the clean BF gas to generate power.

Slag Granulation Plant

Two slag granulation Plant (INBA) for 100% processing of slag generated with suitable pumping, cooling, clarification as required for each cast house is provided. Two dry slag pits for each cast house is also provided. A conveyor gallery carrying two parallel conveyors of about 4.5 km carrying granulated slag from BF area to dumping yard is envisaged. This conveyor system consists of 14 conveyor galleries, 11 junction houses, one storage bin for dewatering the slag and one storage bin at the dumping area.

The coal pulverization and injection system is installed and integrated with the operation of

the BF.

Layout of Blast Furnace - 8


Coal Pulverization and Injection System

The coal pulverization and injection system is installed and integrated with the operation of the BF. The system shall basically comprise of the following:

a. Coal Pulverization System - Two imported grinding mills each of capacity (40t tph) to produce pulverized coal of 90% below 74 micron size.

b. Pulverised Coal Injection (PCI) System - PCI System is distributed to the tuyeres by minimum 3 pressure vessels and coal distributors catering to all the tuyeres. Average coal injection rate is 150 kg/thm and maximum injection rate of 200 kg/thm. Nitrogen is the carrying media for PCI coal.

Stock House

BF#8 stock house shall have raw material feeding arrangement at the top of the stock house along with:

y Fine storage bunkers and conveyors between stock house and fines building

y Stock house collecting conveyors feeding materials to BF charging conveyors

y BF charging conveyor

y Stock house dedusting system (ESP based)

y Two size sinter and three size coke charging including nut coke charging provision in stock house

y The design of raw material feeding to stock house, stock house proper and charging system including fines handling shall have redundancy & interchangeability for uninterrupted and smooth operation of BF#8.

Technical parameters

Capacity of the furnace : 2.8 MTPA

Consortium : L&T and Paul Wurth

Daily Production (Avg) : 8030 TPD

Daily Production (Max) : 8400 TPD

Hearth Diameter : 13.4 m

Useful Volume : 4060 cum

Working Volume : 3445 cum

No. of Tuyeres : 36

No. of cast houses : 2

No. of Tap holes : 4

High Top Pr. : 2.5 bar

Apart from the above scope there were other associated facilities such as effluent treatment plant, pump house, water tank, main control building and electrical

terms of limited approaches, space constraints, underground obstructions, existing operating facilities, large dismantling work etc.

Execution of the work was to be carried out without affecting the operation of the existing facilities and also should not have any hindrances to the production. The standard operating procedures were to be strictly adhered to within the plant premises with regard to safety, work permission and front clearances.

The execution plan however, was primarily based on the front clearances provided by BSP and sequenced in a manner that civil, mechanical and electrical works were executable simultaneously.

CMPC was involved in the preparation of the erection schemes and work methodology for critical structures and equipment. The project is expected to be completed by December 2013 depending on front clearance for some of the areas.

Plant & Machinery

Demag-2800 Crane (600 t) : 1 No.

Monitowac crawler crane (250 t) : 1 No.

Tower crane Kroll 1400 (30 t) : 1 No.

Monitowac crawler crane (80 t) : 7 Nos.

Zoomlion crane (50 t) : 2 Nos.

Mobile Crane husky (40 t) : 4 Nos.

Batching plant (30 cu.m/hr) : 1 No.

Transit mixers : 6 Nos.

Mobile Crane Husky 40 t : 4 Nos.

Hydraulic Rig SR 40 : 2 Nos.

R Suresh Kumar Chief Project Manager

Pranab Saha Project Manager (BF#8)

Matta Satyanarayan Project Manager (SP#3)

The entire project being brownfield had its own constraints in terms of limited

approaches, space constraints,

underground obstructions, existing operating facilities, large dismantling

work etc.

buildings housing various kinds of mechanical equipment and electrical control panels and equipment required for the operation of the Blast Furnace which were included in the scope of the existing contract.

Challenges faced

The entire project being brownfield had its own constraints in


Catering to the water needs of

India’s capital

16 MGD Recycling and Water Treatment Plant at Haiderpur for Delhi Jal Board


Delhi jal board, (DJB) the institution providing water to more than 15 million

people in the capital is always coming up with various projects in augmenting the water requirements of the state to maintain the numero uno status in supplying the highest per capita water in the country.

L&T has maintained healthy relationship with DJB and in the last decade alone executed many vital projects for them. This association between L&T and DJB is going strong and it is poised to cross bigger milestones in the years to come as the projected investment in the water segment is as high as 3.2 lakh crore Rupees for the entire country as explained in ‘The India infrastructure report-2011’.

The Sonia Vihar Clear Water Transmission Mains Project (Phase-I)

was awarded on 10.06.2001 and it was the 1st project from Delhi Jal Board. Since then L&T has carried forward its journey and successfully completed several projects while some of the major / challenging projects are still in progress. After award of Rehabilitation of Bhagirathi

WTP project, L&T has reached a milestone of 13th project from the same client i.e Delhi Jal Board which implies the trust DJB has on L&T’s performance, quality and timely completion of the various projects. Details of the Projects are as mentioned below:

Sl No. Name of Project

1. Sonia Vihar Clear Water Transmission Mains Project (Phase-I)2. Sonia Vihar Clear Water Transmission Mains Project (Phase-II)3. UGR and BPS, Nangloi4. UGR, BPS and Peripheral mains, Sarai Kale Khan5. Replacement of 1500 mm dia old effluent main on ring road6. 1200 mm dia Wazirabad Okhla Raw water Transmission main7. Dwarka water Supply scheme Package-1A8. Dwarka water Supply scheme Package-III9. 20 MGD WTP, Okhla

10. 16 MGD Recycling and WTP Haiderpur

11.Wazirabad Chandrawal Pipeline and Rehabilitation of VT Pump house

12. Supply and Installation of Water Meter

13.Rehabilitation, Automation and O&M of 110 MGD Bhagirathi WTP

Settling tank and Raw water pump house for Dwaraka Water Supply Scheme


In this issue of ECC Concord, a few significant projects executed by L&T Construction in catering to the needs of India’s Capital city has been highlighted.

Dwaraka water supply Package -1 ADwarka Water Supply Scheme (DWSS) is one of the most prestigious projects identified in Delhi’s City Development Plan for augmentation of water supply and distribution network. DWSS was formulated by Delhi Jal Board to meet the water demand of Dwarka, Delhi Airport region, Ujwa and Daulatpur.

Raw water for the scheme is drawn from the new Carrier Lined Canal (CLC) between Munak and Haiderpur, being constructed parallel to the Delhi branch of existing Western Yamuna Canal. The parallel carrier lined channel

results in saving of more than 160 cusecs of raw water which provides raw water for the Dwarka water supply scheme. Raw water from this channel is drawn at the Intake works at Iradat Nagar and pumped through Raw Water Pump House (55 MGD present capacity and 100 MGD ultimate capacity) via 1500 mm dia M.S. twin mains to the WTP located near Dwarka. Clear water is pumped to the ten command tanks in Dwarka and other areas.

Scope of work

The major scope of work includes the construction of intake facilities including electrical & mechanical works and laying of 24 km of 1500 mm dia MS Pipeline from intake works to Mundka Railway Station.

Raw Water Intake Works

It includes the construction of the

following major civil structures and complete electrical, mechanical and automation works:

Approach Channel - 2 nos. (110 m x 2.3 m x 2.5 m)

By-pass Channel (250 m x 2.4 m x 4.2 m)

Settling Tanks 2 nos. (125 m x 48.2 m x 4.9 m)

Raw Water Sump (67 m x 19.5 m x 7 m)

Pump house (67 m x 8.5m x 15 m)

DG Sets –2 Nos. of 1250 KVA each and 1No. 200 KVA

Automation: Full automation of the intake plant units is carried out and it is operated with PLC system and SCADA system at control room. The complete data is transmitted to Dwarka WTP and this is integrated with the total Dwarka Water Supply Scheme.

Segment view of 9.50 km long above ground Sonia Vihar clear water transmission mains


1500 mm Dia MS Raw Water Twin Main

The scope of work includes design, supply, installation, laying, jointing, testing and commissioning of 1 yr. DLP and 5 yr. O&M of Raw Water Twin Mains from intake works to Mundka Railway stations. The approx. length of twin main is 12 km (total length 24 km). The scope of work also included the finalization of alignment, survey, soil investigation and getting permissions from various land owning agencies.

The pipe lines are designed for a flow of 55 MGD at 30 m head in phase I and 100 MGD at 55 m head in phase II. Pipes are manufactured at PSL, Jaipur as per IS 3589: 2001. The pipes are internally cement mortar lined and coated outside as per specifications. The trenchless crossing pipes are provided with

internal 1 mm thick food grade polyurethane and externally 3LPE coating. The pipes laid above ground are internally coated with cement mortar lining and with external polyurea coating. Flow meters and valves are provided at interconnection of both lines at intake and enroute to pipeline alignment apart from carrying out allied civil works for laying of pipelines in different terrain this project becomes more challenging as the complete pipelines were laid just below a live 220 kV HT line.

Dwarka Water Supply Scheme – Pkg-IIIThe major scope of work includes Design, construction, supply, laying & jointing , testing & commissioning of MS clear water mains from the 50 MGD WTP at Dwarka to various areas of Dwarka, Najafgarh,

Daulatpur, Ujwa & IGI Airport. The diameter of MS pipes vary from 700 mm to 1600 mm and covers 26 km across the Dwarka Sub-City.

Clear water mains are laid in the service lanes constructed by DDA. The challenging nature of the project was to cross all the major roads by trenchless technology including one railway crossing near Shahbad Mohammadpur station enroute to airport. There were five major nallah crossings which were crossed by construction of structural bridges. The rising mains are feeding treated water to ten command tanks / underground reservoirs. While working on the roads fouling of various utilities such as sewer lines, electrical cables etc. had to be encountered. All the command tanks / UGRs are integrated with WTP by way of SCADA system.

Work in progress at a section of Dwarka Water Supply Scheme Package - I A


1200 mm dia Wazirabad - Okhla raw water transmission mainThe 1200mm dia Wazirabad Okhla Raw Water Transmission Main was designed to feed raw water from existing Pump House at Wazirabad to WTP at Okhla. Treated water from WTP at Okhla is used to augment water supply to the residents of South Delhi.

The complete scheme comprises of laying the following:

1. 9.00 km of 1200mm dia M.S. pipe on pillar

2. 11.25 km of 1200mm dia M.S. pipe laid underground

3. 1.05 km of 1200mm dia M.S. pipe by trenchless method

4. 0.25 km of 1200mm dia M.S. pipe on structural bridge across nalah

22 MGD raw water is pumped through the MS transmission mains measuring 21.55 km. The pipes

have internal cement mortar lining and outside painting on above ground pipes / wrapping and coating for underground pipes. The trench-less crossing pipes were provided with inside food grade epoxy and outside bituminous epoxy painting. The pipelines are laid on the right bank of Yamuna River and in some parts of South Delhi. Scope of work also included construction of 9 Nos. structural bridges for crossing of Perennial nallahs.

The scope of work also included the execution of pipeline and civil works for trestle supports, anchor blocks, thrust blocks, valve chambers, out fall arrangements, piers for bridges over nallah crossings, installation of 35 nos. expansion joints of 1200 mm dia, 6 nos. sluice valves of 1200 mm, 2 nos. electromagnetic flow meters of 1200 mm, scour valve, air valve, inter-connections of newly laid transmission main

with the pipeline, flushing and dis-infection of pipelines, commissioning and trial run of the total scheme including 1 year of O&M during DLP.

Challenges Faced1. Laid 80 meter of 1200mm

dia pipeline by trenchless method in a single length at Yamuna Vihar area. The major challenge was the presence of high water table above the pipe line.

2. Laid 1200 m of 1200mm dia pipeline inside River Yamuna. This task was accomplished by doing pile foundation and anchoring each pipe with the pile cap. Enough cover was also ensured to take care of uplift.

3. Nos. of Thrust Block was reduced by properly deciding angle of bend during pipe laying.

40m wide Nallah Crossing for laying of 1900 mm dia Twin Main for Wazirabad Chandrawal Pipeline Project


Twin raw water mains from Wazirabad to Chandrawal & Rehabilitation of Wazirabad VT Pump HouseWazirabad Water Works is located on the right bank of river Yamuna and having 3 nos. existing raw water pump houses within the WTP premises and out of these 90 MGD VT pump house has been rehabilitated and up-graded. The existing VT pump house was pumping raw water to Surghat with 6 m head pumps through 4 nos. 1100/900 mm dia CI pipelines and from Surghat, the raw water was supplied to Chandrawal WTP I & II through 5 Nos. bricks/concrete ducts.

These ducts were constructed way back in 1935 by the British Govt. and the system was getting raw water from Wazirabad pump house no-1 & 2. Subsequently the VT pump house

was constructed in 1965 and all the 3 pump houses were interconnected to the Wazirabad Plant with control valves. Over a period of time, the pumps and electrical system were continuously under breakdown and DJB was facing difficulties in supply of raw water to Chandrawal WTP - I & II. Similarly, all the raw water ducts were in a precarious condition and DJB was losing approximately 20% water due to leakages.

In order to overcome these difficulties, Delhi Jal Board decided to replace the raw water ducts by laying of 1900mm dia MS twin mains, carry out rehabilitation and up-gradation of VT pump house from 90 MGD to 120 MGD and also construct a new 8 MGD capacity sump and pump house at Chandrawal WTP for pumping the recycled waste water to the plant.

After implementation of this scheme, both the WTP’s at Chandrawal are

getting uninterrupted raw water supply which has resulted in regular supply of treated water to all VIP’s areas of New Delhi, Civil lines and Delhi University.

Major Scope of Work y Rehabilitation of existing

vertical pump house within the Wazirabad Water Works premises, including jacketing of columns, strengthening of old structures, construction of MS structural platforms for mounting of new 30 MGD VT pumps, roof water-proofing, and allied civil works after carrying out NDT tests of existing structures and evolution of the strength by the design team.

y Augmentation of the pump house capacity by replacing the existing 8 nos. raw water pumps (4 working+4 standby)

Rehabilitated VT Pump House at Wazirabad


of 22.5 MGD capacity each with new pumps of 30 MGD each, keeping the size of the sump unchanged by providing additional accessories like Cruciform and false back walls inside the sump, based on the recommendations of pump manufacturer and after carrying out CFD analysis.

y Replacement of existing 6.6 kV electrical system to 3.3 kV new electrical system by construction of new substation building with installation of 2 nos. 3150 KVA, 11/3.3kV and 100 KVA, 11/0.433 kV dry type transformers, 11 kV & 3.3 kV HT switchgear panels, HT and LT cables along with ancillary work. The work also includes the construction of new substation building inside Wazirabad WTP.

y Providing online flow measuring instruments, water quality analyzers, level transmitters and PLC to integrate the system for control and monitoring from a single screen. Work also includes the provision for transmission of data on pump house to DJB Headquarters.

y Isolate the pipelines of existing vertical pump house from all other pump houses so that it is dedicated to Chandrawal Water Works I and II.

y Manufacturing of spirally welded pipes, carrying out internal cement mortar lining, external wrapping and coating/epoxy painting at PSL factory, Jaipur.

y Laying of 1900mm dia M.S. twin mains to carry raw water from the 120 MGD vertical pump house at Wazirabad to Chandrawal water works I & II along the alignment of

the existing gravity channels, including carrying out the civil and mechanical works en-route. The work also includes construction of 3 nos RCC/structural bridges over nallah (crossing), construction of RCC supports, anchor and thrust blocks, supply and installation of valves, expansion joints, flow meters etc. The main Wazirabad Road and Baba Ram Das Marg were crossed by trenchless method.

y Laying of new pipelines has stopped the wastage of water through leakages from existing old and dilapidated gravity ducts and enabled delivery of water at Chandrawal I at the higher head as required by the Chandrawal water works.

y Construction of 8 MGD sump and pump house and supply & installation of submersible pumps for pumping 8 MGD treated effluent from the 8 MGD Recycle Plant into the inlet chamber of the 40 MGD Chandrawal water works I.

y Detailed planning methodology for execution of the above works with only part shutdown of the scheme without affecting the raw water supply was very crucial.

Challenges Faced

1. Structural Bridges : - The project needed to cross the Najafgarh Drain having a width of approx.. 40 m and depth of 15 m containing the sewage from half of Delhi for laying of 1900 mm dia twin mains. Due to the continuous flow and foul conditions, it was not possible to construct intermediate piers in this drain and after carrying out the detailed study it was

proposed to cross the Nallah by constructing single bridge of span 40 m having width of 6 m. Specially fabricated platforms were placed over the running Raw water ducts for movement of crane for erection purpose. This was a great challenge faced which was overcome by proper planning and work methods.

2. 1900 mm dia Pipeline:-The 1900 mm dia twin main were to be laid between the running water ducts without interruption of raw water supply to CWW-I & II. Total 5 Nos. ducts were carrying water from Surghat to CWW I & II and based on the feasibility report , it was proposed to lay the twin mains on pedestal supports ( below ground ) in between duct no 4 & 5. Since the ducts were running and in precarious conditions, L&T had to provide MS mats/platforms over the duct no 2, 3 & 4 for movement of excavators, dumpers and cranes. The excavation was carried out by deploying rock breaker and carrying out simultaneous dewatering. Water was leaking continuously from the old ducts which further worsened the site conditions.

3. 120 MGD VT Pump House :- Collecting the data of the existing sump, various dimensions of pumps, fittings, etc. and provide the input for designing the higher capacity pumps suitable to existing sumps; assessing the strength of existing RCC wall, columns etc. to work out the rehabilitation methodology and design the structural supporting system for mounting the new VT pumps over the same; to take up the shutdown of 50 % pump house for a limited period


and isolate the old system and replace 50 % of pumps & install new electrical system; to take the shutdown of balance half of the system, install balance new pumps and electrical equipment and keep the 1st half of the pump house in working condition; to carry out the interconnection of new system at various points near pump house and convert the gravity duct system into pipeline system for two ducts upstream and downstream of the ring road and finally, the challenge was to complete the balance interconnections near pump house and convert balance 2 ducts into pipeline system of ducts upstream and downstream of ring road were indeed a great achievement.

This task is the first-of-its-kind scheme undertaken for rehabilitation by DJB after 45 years of installation

and therefore was indeed a great challenge which L&T successfully encountered.

20 MGD WTP at Okhla & Raw Water Pumping Station at WazirabadDelhi Jal Board has set up a 20 MGD (91 MLD) Water Treatment plant in South Delhi. The Raw water from Munak Canal near Haiderpur plant is diverted through twin gravity main (under separate contract) to the Yamuna river near the newly constructed Raw water pumping station. As an alternate source, an intake is also constructed in river Yamuna to feed raw water pump house during the maintenance period of the main source i.e. the Haiderpur canal.

The Raw water so received at the proposed raw water pumping station at Wazirabad is pumped through a

raising main upto the new water treatment plant at Okhla, from where it is supplied to the outer Delhi areas of South Delhi.

The project is constructed with state-of-the-art facility including high degree of automation (PLC/ SCADA operations) with GPRS communication facility between WTP at Okhla and Raw Water Pump house at Wazirabad located about 22 km apart.

Raw Water Pumping stationIncludes construction of wet sump, intake & forebay channel, pumping station, and MCC Building.

20 MGD WTP at OkhlaSome of the important process structures in this plant are as follows:

1. Cascade Aerator (1No) 1300 mm dia

2. Primary Clarifier (2Nos) of size 40500 mm dia each.

20 MGD Okhla WTP constructed for Delhi Jal Board


3. Reactor Clarifier (4Nos)

4. Rapid Gravity Filters Beds (10 Nos) each of capacity 526.04 m3/hr.

5. Filter Waste water recovery tank (1 no) size 9000mm x 18000mm x 3000mm SWD

6. Sludge thickener (2 Nos) of size 20750mm dia x 4000mm SWD

7. Chlorine Contact Tank (1 no) of size 43000mm x 14000mm x 3500mm SWD

110 MGD Bhagirathi Water treatment plantDesign, Construction, Supply, Automation, Testing, Commissioning, Trial run Operation & Maintenance of 110 MGD Bhagirathi Water treatment plant and distribution area in Delhi for 10 years. This is a first-of-its-kind project in the history of DJB and also for L&T.

Scope of work1. Complete rehabilitation

of existing 100 MGD WTP with replacement of old machineries with new ones without interrupting the water supply to East Delhi, construction of new chemical house building, bifurcation unit, renovation of existing administrative building, filter houses, pump houses and other buildings.

2. Installation of instruments and water quality analyzers for Intakes, 100 MGD WTP plant, Distribution UGRs and Booster Pumping Stations to monitor the water quality and effective utilization of water and reduce wastage of water.

3. Automation of complete 100 MGD plant, intakes and distribution areas for monitoring of

the water supply and construction of control rooms at Mandawali and DJB headquarters.

4. Automation of existing 10 MGD WTP within premises.

5. Automation of existing 6 MGD reactor thickener recycle plant within the premises.

6. Automation of Sangam Pump House (Alternate source of raw water to Bhagirathi WTP) with replacement of E&M equipment and associated civil works.

The Scope of O&M includes ensuring uninterrupted water supply with healthy conditions of plant along with safety and security of plant with safety committee formation, use of PPE’s , visitor pass system, operational dispensary with one doctor for routine check-up of workers and staff apart from other provision of advanced security systems for the plant.

Challenges Faced 1. The water treatment plant was

under the control of DJB till 22/12/2011 and immediately after receiving the work order L&T had mobilized the required resources and manpower to operate and maintain the plant. There was a strong opposition from the DJB employees and workers unions that posed many operational difficulties, which were successfully overcome.

2. As this is an old and operational plant, L&T had to take the physical measurements of all the structures/equipment, collect the data of various equipment/structures from field and compile the same for checking the compatibility of the new equipment in old structures. L&T overcame this and major equipment has

already been ordered while the rehabilitation and construction works are in progress.

16 MGD Recycling & Water Treatment Plant at HaiderpurThe scope of this project covers Design, Construction, Supply, Installation, Testing, Commissioning, Trial run of 16 MGD (72.64 MLD) Recycling Water treatment plant and another Water Treatment Plant of similar capacity at Haiderpur, Delhi.

This Plant aims to reduce the wastage of water from the existing 200MGD WTP by recycling the water through treatment units and recovering good quality water for drinking purpose which otherwise would have been wasted. The recycle plant is designed to handle any amounts of solids in the waste water from the existing plant.

L&T successfully executed the O&M of this project for three years and won the contract for O&M of the plant for the next five years which is now in progress.

Challenges y This was a first-of-its-kind

project implemented by Delhi Jal Board. L&T faced a lot of difficulties at the design & process stage in sizing of the various process units and especially in finalization of layout in a very limited space provided by the client for this pilot project.

y The plant is located adjacent to the running western Yamuna canal. The ground water table was very high and a complete dewatering system was installed especially for the construction of the Equalization Tank.


for the supply of meters. This job has provided a new exposure to L&T as the project team had to interact with consumers who do not have any link with contract agreement but are the authority to certify the work quality.

L&T achieved installation of a maximum of 1800 meters in a day which is indeed a herculean achievement considering the existing scenario. As a result, L&T completed the project eight months ahead of the scheduled contract completion date and earned the bonus claim apart from establishing its presence in yet another new domain in the water business.

R.K.Jain, K.Vijayakumar and R.S.Giri

Partailly rehabilitated filter house of Bhagirathi WTP-internal view

United Nations has announced the year 2013 as the International year of water co-operation and L&T is glad to play a major role in extending its contribution to the green cause through its sustainability initiatives.

Know about L&T’s sustainability initiatives, visit: www.Lntsustainability.com

Since 2002 April, L&T’s Construction arm has been engaged in the concept-design, printing and distribution of its very unique Panchangam Calendars based on the Indian Almanac. These calendars touch upon the cultural heritage of India which is deep-rooted with sustainability concepts. Visit: http://www.Lntecc.com/homepage/common/panchangam.htm to access the decade long collection of L&T’s Panchangam Calendars.

Supply & Installation of Water Meters for Delhi Jal BoardThis project involves installation, operation and maintenance of

2.5 Lakh water meters in specific

areas of Delhi. The installation

work had a time frame of 2

years. M/S. Itron India - a leading

manufacturer of water meters were

associated with L&T in this project


NEW ORDERS

` 1439 Cr Orders for Residential Projects L&T Construction has secured new orders valued over

` 1439 crores in September 2012.

The Buildings & Factories IC of L&T Construction

has bagged new orders worth ` 1439 crores from

leading developers for the design & construction of

major residential building projects in the National

Capital Region, Delhi.

L&T Construction’s Buildings and Factories IC (B&F IC)

has been offering pioneering solutions in residential

buildings that cover design and construction of large

townships and high-rise apartments.

L&T Construction Secures Orders Valued ` 1063 CrL&T Construction has won new orders valued over

`1063 crores across various business segments in

October 2012.

In the Building & Factories IC, the Company has

secured new orders worth ̀ 323 crores for construction

of an IT campus facility in Pune.

In Water & Effluent Treatment Business Unit, L&T

Construction has bagged new orders worth ` 371

crores. A major order was received from Krishna

Bhagya Jala Nigam Limited, Government of

Karnataka, to design and construct a Lift Irrigation

system at Hanamapur, Karnataka. Another order

is from the Public Health Engineering Department,

Government of West Bengal for a water supply

system in the Bankura District of West Bengal.

The Power Transmission & Distribution IC has also

bagged new order worth ̀ 109 crores for construction

of a 765 /400 kV switchyard package in Uttar

Pradesh.

In yet another development, the Infrastructure IC,

secured orders valued at `158 crores from Rail Vikas

Nigam Limited (RVNL) for railway construction works

consisting of doubling of lines between Villupuram

and Dindigul section in the Madurai division of the

Southern Railway.

L&T Construction has also secured additional

orders worth ` 102 crores from various ongoing

projects.

L&T led JV wins ` 1252 Cr Delhi Metro ContractAdditionally L&T Construction receives further

Orders of ` 644 Cr

The Infrastructure IC of L&T Construction has bagged

a major order worth ` 1252 crores from Delhi Metro

Rail Corporation (DMRC). The order will be executed

as a joint venture with Shanghai Urban Construction

Group (SUCG). The joint venture will design and

construct a tunnel between Shankar Vihar and Hauz

Khas as well as underground stations at Vasant

Vihar, Munirka, R.K. Puram, IIT and Hauz Khas. L&T

Construction’s share in the project is ` 852 crores.

Another recent order includes a ` 644 crores

contract secured by the Buildings & Factories IC

for construction of a permanent campus facility

for IIT, Hyderabad. The scope of works includes

construction of engineering blocks, faculty and staff

housing, student hostels, dining halls including

ancillary and other associated works.

Orders Valued ` 2503 CrL&T Construction has won new orders valued over

`2503 crores across various business segments.

The Infrastructure IC of L&T Construction has secured

a prestigious order, valued ` 1985 crores (excluding

taxes) from GVK Project and Technical Services. L&T


will execute major portion of works for 850 MW Ratle

Hydroelectric Power Project located on the Chenab

in the Kishtwar district of Jammu & Kashmir. The

Company has received ‘Limited Notice to Proceed’ to

commence operations.

The Buildings & Factories IC, has bagged new

orders worth ` 397 crores for the construction of a

commercial building in Mumbai, including additional

orders from various ongoing projects.

In yet another development, the Water & Effluent

Treatment business has received an order worth

` 121 crores from the Public Health Engineering

Department - Government of Rajasthan for water

supply in Fatehpur - Laxmangarh, Rajasthan.

Orders Valued ` 1178 CrL&T Construction has secured new orders valued

over `1178 crores across various business segments

in November 2012.

The Buildings & Factories IC, has won new

international orders in UAE worth `595 crores for

the construction of a hospital building and other

associated facilities.

In the Solar Business sector, L&T Construction -

India’s largest player in solar power has bagged new

EPC orders worth ` 280 crores for the construction

of Solar PV systems in Rajasthan from multiple

customers.

L&T Construction has also secured additional

orders worth ` 303 crores from various ongoing

projects mainly in airports, factories, minerals

& metals and power transmission & distribution

business segments.

` 1002 Cr Orders in Domestic & International MarketsL&T Construction has secured a slew of new

orders valued over ` 1002 crores across various

business segments in November and till date in

December 2012.

Its Power Transmission & Distribution Business

bagged orders worth ` 742 crores in domestic and

international markets.

This includes a major order secured in Qatar for

setting up of a 220 kV, 515 MVA cable system and

for the construction of a 220/66/11 kV substation.

L&T has established itself among the major players

in the power transmission and distribution sector

in the Gulf.

On the domestic front, the Company re-

affirmed its position as a leader in the ‘EPC’

space by winning an order from the Tamil Nadu

Transmission Corporation for a 400/ 230-

110 kV AIS substation at Kayathar, Thirunelveli

and a 230/110 kV GIS Substation at Guindy,

Chennai. Another turnkey order received from

the West Bengal State Electricity Transmission

Company Limited involves construction of seven

transmission lines of 220 kV and 132 KV at

various locations in West Bengal.

In addition, L&T Construction has secured orders

worth ` 260 crores from ongoing projects across

various business units.

Orders Worth ` 1009 CrL&T Construction has secured new orders valued

over ` 1009 Crores in the month of November and

till date in December 2012.

The Buildings & Factories business of L&T

Construction has secured new orders worth ` 852

Crores for the design and construction of a major

IT campus facility in NCR, Delhi and also for the

construction of multistoried residential towers in

Bengaluru from major clients.

In yet another development, the Metallurgical &

Minerals Handling business of L&T Construction in

consortium with LUET China has bagged an order

valued at ` 206 Crores from Steel Authority of India

Limited for rebuilding & construction of a Coke Oven

Battery at Durgapur Steel Plant. L&T’s share of the

order is ` 157 Crores.


PROJECT NEWS

Taking L&T’s capabilities in 765kV installations to a new high, the project team of Jhatikara 765/400kV transformer package has accomplished the commissioning of 6X500MVA Hyosung make and 3X500MVA BTW make Interconnecting Transformers in a short time span of 45 days.

These projects (T1 and T3) for Power Grid Corporation of India Limited are intended for the strengthening of 765kV system for the central part of the northern grid.

Due to the resolute efforts of the project team, all twelve transformers with one spare were made ready for charging by the 29th of September 2012. However, in view of the readiness of substation nine transformers got charged at 04:45 hrs on 30th September 2012 with a capacity to feed 9X500 MVA Power to Jhatikra - Mundka and Jhatikara - Bamnauli Transmission Lines.

L&T sets benchmark in commissioning 765/400kV ICT banks at Jhatikara

The substation got charged from Jhatikara – Bhiwani 765kV transmission line.

It was a remarkable feat that on the same day at 23:10 hrs all the nine transformers got into commercial operation and started transmitting power to the 400kV transmission lines.

Scope of work for the project involves design, engineering, ex-works supply of on-shore items with installations including associated civil works, testing and commissioning of seventeen 765/400kV Hyosung make Transformers under T1 package at Jhatikara and Moga and another seventeen 765/400kV Baoding make transformers under T3 package at Jhatikara, Meerut & Bhiwani.

Commissioning nine 765/400kV ICTs within 45 days from receipt of the transformers is indeed considered a milestone achievement in the industry.


L&T Commissions Sinter Plant at Bhushan Steel

L&T’s Bhushan Steel project, team has successfully commissioned Sinter Plant #2 of 2.3 MTPA capacity, measuring 204 sq.m for phase # 3 of 2.2 MTPA Integrated Bhushan Steel Plant at Angul on 18th October 2012.

The scope of work included incoming raw material conveyors and outgoing product delivered to the existing blast furnace and the 2nd blast furnace.

With the commissioning of one Sinter Plant out of two units being executed, L&T has achieved the 1st milestone in consortium with M/s. OUTOTEC, Germany.

Mr.Atulya Kumar Verma, Chief Operating Officer (COO) along with top officials from M/s, Bhushan Steel Limited along with Mr.Tinanjan Mitra, Project Manager and Mr.Tarun Ghosh, Package head of Sinter Plant of L&T, inaugurated the plant.

L&T’s project team, under the leadership of Mr.Tinanjan Mitra, has executed the project with highest international standard of quality, safety, superior execution and project management to the client’s full satisfaction.

L&T has been entrusted with the following packages in Bhushan Steel’s 3rd Phase expansion from 2.2 to 5.5 MTPA:

y Complete EPC for 2.5 MTPA (3814cu.m) Blast Furnace #2

y Complete EPC for 2 x 2.3 MTPA capacity (2 x 204 sq.m) Sinter Plant #2&3

y Complete EPC for 2.5 MTPA Coke Oven Plant of 74 Oven, 7.6m. high Battery (1st time in India)

y Civil & Mechanical Erection of SMSIII consisting of 2 nos. Slab Caster, 2 nos. Basic Oxygen furnace (BOF)

y Complete Raw material handling system of 2.5 MTPA Integrated Steel Plant consisting of 21 machines (Stacker cum Reclaimers, Wagon Tipplers, Barrel Reclaimers) and 19 km long Conveyors with Civil & Structural Works of 19 km of long conveyor.

y Complete Design, Supply of Coal Crushing System & Screening System.


Kohinoor Square Project completes 203 m Central Tower Corewall

This has been achieved by meticulous monitoring of concrete design, batching, pumping & placing and knowledge sharing regarding various aspects of high-rise construction.

Omkar Malad Sales Project records Highest Concrete Production at site The Omkar Malad Sales project, Mumbai set a National Record recently by pouring 2300 cu.m of M40 Raft Concrete of in 42 hours through a 56 cu.m/hr Schwing Stetter- H1 model Batching Plant. Peak production was 58 cu.m/ hr and an average rate of 55 cu.m/ hr was achieved with due adherence to OEM cycle time.

Schwing Stetter has witnessed and declared this achievement as a “NATIONAL RECORD” for producing highest concrete quantity using a 13 year old Batching Plant.

This feat was made possible due to the following:

y Micro level planning of all resources – Men, Machine & Materials

y Well planned logistics chain of concrete production, transportation & placement

y Well=defined roles & responsibilities for each activity

y High reliability of P&M, adherence to EHS & quality

This challenge was accomplished with the dedication of the site team led by Omkar Project Head - Mr P S Parthiban, L&T’s Project Manager - Mr P S Suresh, and P&M Incharge - Mr S C Chhatre.

Web Casting facility launched at TL Testing & Research Station, KancheepuramPT&D IC’s state-of-the-art testing station, the Transmission Line Testing & Research Station (TLTRS) at Kancheepuram launched Web Casting facility on 22nd November in the presence of Dr. K. Natarajan, Head IC Corporate Services, Power Transmission & Distribution IC.

TLTRS installed this facility by providing high definition cameras to capture the tower / insulator testing ‘LIVE’ and the same is transmitted to the

On 30th October, L&T Construction’s Kohinoor Square Project successfully completed the concreting of the Corewall of its Central Tower upto the final level of 203m. The Corewall houses a battery of 24 high speed elevators that will service various zones of the structure, apart from two staircase shafts. It will be topped up by a Helipad that marks the crown of this iconic diamond-shaped tower.

As per the Council on Tall Buildings & Urban Habitat (CTBUH), the Kohinoor Square is the highest constructed/under-construction, commercial/mixed-use project in India.

The completion of the Corewall is also a significant milestone in high-rise pumping, with specially designed high strength M50 grade concrete being successfully pumped to a vertical height of 270m using high capacity concrete pumps and floor climbing placer booms.


Solar Business Unit launches a Centralized Monitoring System customers worldwide. This unique facility, is an added advantage to the customers particularly from overseas, in reducing the cycle time for tower testing, as most often Visa/Ticketing of the customers was a major bottle-neck for the testing to start as scheduled. It is a matter of significance that this facility is not available in any of the testing stations in India.

L&T Construction Solar BU reached another milestone in its efforts towards improving the performance of its solar plants by launching a Centralized Monitoring System (CMS). This remote monitoring system, which will help in keeping track of the real-time performance of the solar plants built by L&T located anywhere in the world by sitting in the dedicated centre (located in the 5th Floor, D Wing) was inaugurated by Mr.S.Rajavel, (Executive Vice President – Water & Solar SBG) on 5th December, 2012. Later, this center is planned to be rechristened as “L&T Energy Management Center”.

The objective of the initiative is to measure the actual generation, generate reports and ensure efficient O&M of the solar plants thereby helping in tracking and optimizing their yield which would ultimately translate to maximizing the developers solar investment. This data management system would also act as a central repository of data and real-time information for the Design, SCM & Operations team. The diagnostic data at inverter (even string level) will facilitate tension-free trouble shooting for the O&M staff.

The project, in the first phase has integrated the 20MW Solar Power Plant built in Gujarat, India. The Plant’s complete data from Inverters till Feed in Energy Meters can be monitored and the data can be fetched for analysis. The Second Phase of this initiative plans to integrate L&T’s Roof Top Installations executed across the Corporate Headquarters (Manapakkam), CSTI Locations (Kancheepuram) and the 1MW Plant in Rajasthan.

The team behind this initiative at L&T Solar headed by Mr. Shaji John (Head- Solar Business) believes that this would take L&T a long way in improving the customer satisfaction by ensuring that the customer gets higher return on investment.

1200 kV AC UHV National Test Station at Bina inauguratedThe 1200kV UHV National test station at Bina (M.P) was dedicated to nation on 26th December. This is the world’s highest voltage level 1200kV substation and is the first ever to be commissioned in Asia. Hon’ble Union State Power Minister (Independent Charge) Shri.Jyotiraditya Madhavrao Scindia along with the Hon’ble CMD PGCIL, Shri R. N. Nayak inaugurated this facility established by L&T Construction.

The towering task was accomplished by the team headed by Mr. S. K. Saxena and the entire project was headed by Mr. N Kalingarajan. The entire erection, testing and commissioning along with designing of all foundations, 1200kV towers and equipment structures have been successfully completed under phase-1 of the project.

Sixth Annual Competition for the Best Welding Engineer & Best Welder-Structural / PipeSixth Annual Competition for the Best Welding Engineer & Best Welder-Structural / Pipe was organised by Indian Institute of Welding (IIW) Chennai Branch in association with L&T at CSTI-Kanchipuram, on 8th December, 2012.

Mr.N.Sundara Rajan, Administration from CSTI welcomed the delegates from IIW and the participants and the program was inaugurated by Mr.V.Muralidharan, Vice Chairman, IIW Chennai Branch.

Mr. M.Krishnamurthy - Secretary, Mr. R.Ravichandran - Joint Secretary and Mr. M.V.Venkatesan - Treasurer & S.Chandran-Member from IIW addressed the participants.

The selected candidate from this competition will participate in the National Level Competition for the Best Welding Engineer & Best Welder categories organised by Indian Institute of Welding, Kolkata scheduled to be held at Benguluru during first week of February 2013.

As many as 30 enthusiastic Engineers & Welders participated in this event. L&T has hosted this annual program for the sixth consecutive year in its CSTI campus.


EVENTS

L&T Solar Conclave makes a big impact at the 6th REI Expo

L&T Construction in association with UBM India organized a Solar Conclave, a niche solar-focused “parallel event”, on the first day of the REI Expo held on 7th November at Greater Noida.

The conclave created an interactive forum to discuss and exchange visions, experiences and solutions for scaling up and making solar energy mainstream by bringing together leading solar power developers, financers, utilities, power trading agencies, sector specific consultants and policy makers. Around 80 delegates, handpicked by L&T and UBM India, participated in the event on the first day, which was kick-started by Mr. S Rajavel, EVP and Head of Water & Solar Strategic Business Group of L&T. Delegates from all the fields of solar sector participated in this conclave and deliberated on opportunities, challenges and way ahead for the Indian Solar Industry.

The conclave had some of the best known solar industry stalwarts as speakers. Among them was Michael Rogol, CEO of PHOTON Consulting L.L.C USA, and the

most widely followed analyst in the solar power sector globally; Ardeshir Contractor, MD and CEO of Kiran Energy, one of India’s leading solar power developers and Mr. Shaji John, Head of Solar Business at L&T Construction.

In addition to the presentations, the conclave also hosted a “CEO Forum” led by chairperson and moderator Vineeth Vijayaraghavan (founding editor of Panchabuta), which included eminent panelists from solar developer fraternity.

Mr. S Rajavel, EVP and Head of Water & Solar Strategic Business Group congratulating Mr. Shaji John, Head of Solar Business at L&T Construction


Minister of Rural Development visits Railway Workshop Projects, Jhansi

Shri.Pradeep Kumar Jain Aditya, Minister of State -Rural Development visited the Railway Workshop Projects, Jhansi on 12th October. He was accompanied by the CWM and other higher officials from the ministry and from North Central Railways.

The minister was briefed about the project and the capacity of the Workshops and its future expansion plans. L&T’s Project Manager Mr.Ravinder Singh Muker explained about the way L&T has quickly progressed after taking possession of the constructible site of MLR only after Jan’2012 even though the project’s start date was in September, 2010.

After his visit, the Hon’ble Minister informed the press that he is very much satisfied with the progress shown by L&T and he added that the project is expected to become operational in 2013 providing job opportunities for many in and around the Jhansi region.

L&T Construction has been designing and producing

Panchangam calendars for the last Eleven Years.

These are designed and evolved on concepts of

Indian Art, Culture, Values and Mythology.

The L&T Panchangam Calendars formed a part of

Bharatiya Vidya Bhavan’s Cultural Festival 2012 at

Mylapore. These calendars were on display for public

view at the 1st floor, pre-entrance lobby.

The exhibition was held throughout the festival

dates from the 21st of November through 12th of

December 2012.

Noted singer Smt. Aruna Sairam and public – art &

music lovers, visited the gallery and appreciated the

company’s efforts.

A Decade of L&T Panchangam Calendar - On Display at the Bhartiya Vidya Bhavan - Mylapore

Shri.Pradeep Kumar Jain Aditya, Minister of State - Rural Development at the Railway Workshop Projects

Smt. Aruna Sairam appreciating the efforts of L&T in preserving the culture and heritage of India while Mr. V. S. Ramana, GM & Head - Corporate Communications explains the concepts of Panchangam Calendars


L&T participates in Intersolar Expo - Mumbai

L&T Construction’s Solar Business Unit exhibited its comprehensive Solar EPC capabilities at the Inter Solar Conference & Trade Exhibition held at Mumbai from 5 – 8 November, 2012.

The Conference was attended by Industry stalwarts as they congregated to chart the growth of the Indian Solar Power Market. Mr. Rajeev B.Agarwal represented L&T in the conference where he shared L&T’s views on “Large-Scale PV Systems: Installation, Operation & Maintenance”.

The immense footfall of visitors comprising of both industry insiders and others who were both curious and excited about L&T’s capability to deliver trademark quality in solar project execution were well received by L&T’s team of eight competent engineers.

L&T was nominated in the running for the Intersolar AWARD for the category ‘Solar Projects in India’ (which was presented for the first time at Intersolar India) for executing the 6 MWp Solar PV project at Charanka Solar Park, Gujarat. The entire capability spectrum of L&T was displayed through actual site photographs of executed solar projects.

L&T signs an MOU with Power Finance Corporation

L&T Construction and Power Finance Corporation (PFC), New Delhi have signed a MoU on 5th October to impart Skill Development Programme for 300 youth belonging to SC/ ST/ OBC & EWS communities in Maharashtra through CSTI Panvel.

Mr. S. Natarajan General Manager & Head Construction Skills Training and Mr. V. Jeyakumar – General Manager, Power Finance Corporation signed this MoU at L&T’s Manapakkam campus. Under this MoU PFC shall take care of the funding and financial obligations pertaining to the Skill Development Programme while L&T will provide skill training for the youth.

Chief Minister of New Delhi inaugurates 33 kV GIS substation A 33 kV Gas Insulated Substation constructed by PT&D IC at Netaji Nagar, New Delhi was inaugurated by the Honourable Chief Minister of New Delhi - Smt. Sheila Dixit along with the Chairperson of NDMC (New Delhi Municipal Council) - Ms.Archna Arora (IAS) on 23rd October. Also present during the event was

Mr. K. S. Tanwar, Member of Legislative Assembly along with the Chief Engineer of NDMC - Mr. N. S. Sagar.

L&T has been trusted by Power Grid Corporation of India Ltd. (PGCIL) for the implementation of 66 kV & 33 kV GIS substations and augmentation of existing substations on deposit work basis for New Delhi Municipal Council.

The scope of work as specified below includes complete project management, design, engineering, type testing, manufacture, testing at manufacturer’s works, delivery, insurance, unloading at site, storage, erection, testing and commissioning of the complete 66 kV & 33 kV GIS substations and augmentation of existing substations at site on single source responsibility basis.

1. 66 kV GIS New Substations – 2 nos

2. 66kV GIS Substation Augmentation works Excluding Building – 1 no

3. 33kV GIS New Substation – 5 nos

4. 33kV GIS Substation Augmentation works Excluding Building – 8 nos


fib-days 2012 - International conference hosted by L&T

International conference fib-days 2012 was hosted by L&T on 10th and 11th January 2013, for The Institution of Engineers (India) by Indian Member committee of fib (IMC-fib). This conference was held to enlighten about the activities of fib in general and to impart the knowledge of last two events of fib viz. the International Symposium held at Prague in 2011 and Stockholm, Sweden in 2012) to the Engineering fraternity in India.

The conference was formally inaugurated by lighting the lamp as a symbol of enlightenment through knowledge by Mr. S.N. Subrahmanyan, Wholetime Director and Sr. Executive Vice President (L&T-Infrastructure and Construction), Mr.C.R. Alimchandani, Chairman IMC-fib & MD, STUP consultants Pvt.Ltd, Mr. Gordon M. Clark, President fib-2013-14, Dr.Gyorgy L. Balazs, President fib-2011-12, Mr.R.K.Sanan, Major General (retired), Secretary and Director General, The Institution of Engineers (India) and Dr.Nagesh R. Iyer, Director, SERC, Chennai.

Mr.S. Kannappan, EVP and Chief Executive, L&T GeoStructure & CTO introduced the dignitaries and the chief guest Mr. S. N. Subrahmanyan to the audience and stressed upon the need to increase the growth of construction industry in India by introducing new materials, innovative design approach and optimal use of materials.

This was followed by a welcome speech by Dr.Nagesh R. Iyer, who set the context for the fib-days 2012. He touched upon the responsibility of Engineers on the sustainability aspects of construction – 3Rs (Reduce, Reuse & Recycle) and towards social, environmental and economic aspects, carbon reduction, utilization of construction and demolition waste, apart from engineering new high-performing and durable materials.

The chief guest of the event, Mr.S.N. Subrahmanyan, in his inaugural speech, mentioned that there will be a tremendous amount of development and growth of construction in India and the need for innovative materials to speed and scale-up the construction process. He insisted upon the use of precast construction and the challenges faced in terms of excise duty restrictions and logistics and also mentioned that a Handbook on precast construction is under preparation by Dr. A. Ramakrishna, Former President and Dy. Managing Director L&T and Director, International Infrastructure Consultant and team. He mentioned that some of the challenges facing construction industry are sourcing high quality materials at low cost, mining issues for aggregates, availability of workmen and accident rates at project sites. He urged the L&T’ites in particular and the construction fraternity in general to constantly improvise in order to meet the future challenges.

Mr. S.N. Subrahmanyan, Wholetime Director and Sr. Executive Vice President (L&T-Infrastructure and Construction) addressing the gathering


Mr. A.M. Naik Launches 5th Sustainability Report

The technical sessions of the 2 day conference comprised a series of invited lectures by International and national experts in the field of structural concrete, its applications, new trends and the practical challenges faced by engineers.

Highlights of the topics presented in the seminar: y International experts and the eminent Indian

Engineers presented the most up-to-date knowledge in the following fields,

y Precast Prestressed Bridges: Inspection of posttensioned bridges and lessons learnt, Innovations in bridge engineering, Rehabilitation and strengthening of bridges

y Seismic design and Construction of precast structures

y Precast concrete construction y Special concrete used in India y Multifunctional cementitious construction materials y Geopolymer concrete, Materials for sustainable

concrete in India y Use of concrete in Hydroelectric and irrigation

projects, Concrete construction for Metros –materials and techniques

y Use of Fibres in concrete y Elevated corridors for road connectivity y Sustainability aspects – Durability and service

life design, concrete materials, renovation and upgradation of structures

y Concrete and construction technology

Lays Stress on Implementation Aspect of CSR

Mr. A.M. Naik, Executive Chairman, released L&T’s 5th Corporate Sustainability Report on November 30, 2012 in Mumbai along with Mr. K. Venkataramanan, Managing Director & CEO, Mr. M.V. Kotwal, President, Heavy Engineering & Member of the Board and Mr. R.N. Mukhija, Advisor to the Chairman.

Speaking on the occasion, Mr.Naik emphasised the importance of ensuring effective implementation of the Company’s plans and programmes for sustainability, and calibrating results. The quality of an idea, he stressed, depends on the success of its implementation. While complimenting the Sustainability Team on its performance, he advised them to adopt global performance yardsticks and enlarge from an India-centric perspective.

Earlier, Mr. Ajit Singh, Executive Vice President, Corporate Infrastructure & Services, Powai, presented an overview of the theme of 2012 report - ‘Colours of Change’ in the backdrop of multiple economic, environmental and social challenges. Mr.Alok Sharma, General Manager, Corporate Sustainability, revealed the highlights of the 2012 Report, including the Company’s growing green portfolio, the ‘water neutral’ status of Powai Campus and the community initiatives reaching half a million beneficiaries.

It is a matter of pride that for the fifth year in a row, L&T’s Sustainability Report received the ‘GRI Checked A+’ rating from the Netherlands-based Global Reporting Initiatives, signifying the highest level of disclosure.

Mr. A.M. Naik, Executive Chairman, releasing L&T’s 5th Corporate Sustainability Report


AWARDS

The Learning Center and Dining Complex at L&T’s Management Development Centre, Lonavla was certified LEED INDIA GOLD Rating with 39 points. The LEED INDIA GOLD trophy was presented by Indian Green Building Council, Hyderabad and was received by Mr. Ajoy Kumar Muhury - Project Manager L&T Construction and Mr. M. Suresh – Head Administration MDC Lonavala on 30th October.

This is an excellent recognition for L&T Construction in being instrumental in transforming a Learning Centre - Management Development Centre into a Sustainable Site, positioning it in the World Map.

The Technology Center III building located in L&T Construction’s Manapakkam campus at Chennai was certified LEED INDIA SILVER Rating with 34 points.

Green building certifications for L&T Construction

Cognizant Technology Solution, Sholinganallur, Chennai has been certified under LEED INDIA New Construction 2011 – GOLD Level Provisional Certification for the ongoing project

The 3M R&D Centre Project, Bangalore constructed by B&F IC has been awarded ‘LEED India for New Construction Gold’ by the Indian Green Building Council (IGBC).

Mr. Ajoy Kumar Muhury (Project Manager) & Mr. M. Suresh (Head Admin) of MDC receiving the award for MDC Phase II Project) & Mr. Rajan Venkateswaran (Head - CEFD) and Dr. Raj Kumar (Engg. Manager - CEFD) represent B&F IC receiving awards for all L&T green building rated projects from Mr. C N Raghavendran (Chairman, IGBC - Chennai Chapter) during the award distribution ceremony in GREEN BUILDING CONGRESS 2012.


In recognition of the outstanding contribution made by Mr. A.M. Naik, Executive Chairman, L&T, to the chemical industry, the Mumbai-based Indian Chemical Council (ICC) has honoured him with the coveted D.M. Trivedi Lifetime Achievement Award for 2011.

The award highlights the critical role played by L&T, under Mr.Naik’s leadership, in providing the industry with a range of plant, systems, projects and construction services.

The citation for the award reads: ‘L&T, under Mr.Naik’s leadership, has immensely contributed to the growth of the Indian chemical industry by being the largest Indian engineering & construction company and also the largest supplier of equipment to the chemical industry. In addition, it is engaged in rapid development of infrastructure in India’.

Mr. S.N. Roy, Whole-time Director & Sr. EVP (Corporate Affairs & Power), L&T, accepted the award on behalf of Mr.Naik from Dr. Ashok Ganguly, Member of Parliament, in Mumbai on October 12, 2012

Mr. A.M. Naik Honoured With ICC Lifetime Achievement Award

Chapparchiri War Memorial project Mohali wins ICI’s Outstanding Concrete Structure award The Punjab M e m o r i a l s Team won the O u t s t a n d i n g Concrete Structure of the Year 2012 award from Indian Concrete Institute (ICI) for the construction of Chapparchiri War Memorial, Mohali. This honour was received on 21st November at JW Marriott Hotel, Chandigarh by Project Manager Mr.Ramjee on behalf of Cluster Project Manager Mr. L Rama Krishnan accompanied by the Planning Manager Mr.Saurabh Madaan and Accounts Officer Mr.S.K.Sinha.

Mr. S.N. Roy, Whole-time Director & Sr. EVP (Corporate Affairs & Power), L&T, accepting the award on behalf of Mr.Naik from Dr. Ashok Ganguly, Member of Parliament


Infrastructure Company of the Year award for L&T Construction

L&T Construction awarded at the Hospital Build & Infrastructure India 2012 Awards

L&T Construction bagged the Infrastructure Company of the Year award at the 3rd EPC World Awards 2012 held on 15th December at Hotel Ashok, New Delhi.

Mr. N.K. Puri – Segment Head, Heavy & Light Factories, FSBU, RB&F, B&F IC received this award on behalf of L&T in the presence of eminent industry stalwarts from the Infrastructure & Construction industry.

This EPC World award recognises companies/individuals broadly covering the entire Infrastructure & Construction industry on the basis of their qualitative and quantitative performance during the year 2012. In the light of L&T’s exceptional contribution in the infrastructure and construction sector, with fine examples of works & projects delivered, the Organizing committee, Jury and Knowledge Partner - Ernst & Young unanimously decided to honour L&T as the Infrastructure Company of the Year.

L&T Construction was awarded the ‘Best Builder / Construction Company award’ at the Hospital Build & Infrastructure India 2012 Awards & Expo held at Mumbai between 14th & 16th December. This event was organized jointly by Informa & Hosmac and the award selection was evaluated by a panel consisting of Dr.Chandrasekhar – Chief Architect, Ministry of Health & Family Welfare, Govt. of India and Dr.Akash Rajpal CEO & Founder EKO Health & Lead Acessor Nabh & Hosmac.

Mr. V. M. Muttur – Project Head Omkar Bhoiwada Rehab Project and Mr.Kaustubh Pathak - Project Manager received this award on behalf of L&T.

Newsweek Ranks L&T 4th GloballyL&T’s commitment to green initiatives and its eco-consciousness are wining increasing global recognition. Newsweek, the globally respected and widely read news magazine has published ‘Green Rankings’ - a comparative score card of the top 500 green companies.

L&T is placed fourth in the Industrial Goods category worldwide, ahead of many of its global peers including GE, ABB, Schneider, amongst others, and is the highest in India in this category.

L&T also features among the world’s top 100 companies across all categories. The Newsweek Green Rankings has scored companies by comparing their actual environmental footprints, management approach (policies, programmes, initiatives) and disclosures. This score is derived from three components: Environmental Impact, Environmental Management and Environmental Disclosure. Companies were scrutinized based on their Sustainability Reports, online disclosures and databases, government sources, NGO research and other industry sources.

The rankings methodology was formulated in consultation with an advisory panel comprising Corporate Sustainability experts drawn from Harvard Business School and other reputed institutions including Environment Defence Funds (USA), Sustain Ability (UK), Tellus Institute and Business Ethics publication (USA). Two leading research organizations, TRUCOST (UK) and SUSTAINALYTICS worked as knowledge partners.


KVR was conferred with a Life Time Achievement Award under the Supreme Engineers Awards 2012 which was held at The Oberoi Hotel, New Delhi on 1st December, 2012.

This special category award has been conferred in recognition of his innovative project engineering and leadership skill and experience, over so many decades, in some of the most extreme and hostile climates and terrains of India.

Due to KVR’s busy schedule, Mr Rajan Malhotra, Regional Manager DLRO & Head- Special Initiatives North for Infra IC received the honour at a glittering function held in Delhi with Dr.Sudhir Krishna IAS, Secretary, Ministry of Urban Development and Shri. Amitabh Kant IAS, CEO & MD Delhi Mumbai Industrial Corridor Development Corporation as the Guests of Honour. Mr. Rajan Malhotra shared the message from KVR during this occasion.

KVR conferred with a Life Time Achievement Award

Mr. A.M. Naik Ranked 32nd Best Performing CEO In The World

The Harvard Business Review in its January-February 2013 edition has named L&T’s Executive Chairman, Mr. A.M. Naik, as the 32nd Best Performing CEO in the world. In the industrial sector Mr.Naik is ranked 4th Globally.

The Harvard Business Review is one of the most respected business journals in the world. Mr.Naik has been ranked in a global study of 3143 CEOs from 1862 companies representing 64 nationalities and from companies based in 37 countries.

Former Apple Chief, Steve Jobs, who passed away last year, has topped the list followed by Jeff Bezos of Amazon.com in No. 2 spot and Yun Jong-Yong of Samsung Electronics in the third place.

The evaluation criteria included how much shareholder returns had changed over their tenure and the overall increase in market capitalization.

Mr Rajan Malhotra, Regional Manager DLRO & Head - Special Initiatives North for Infra IC receiving the honour on behalf of KVR

Printed at Lokavani Southern Printers Pvt. Ltd., Chennai. Edited by Mr. V.S. Ramana for L&T Construction from L&T Construction Headquarters, Manapakkam, Chennai - 600 089. The views expressed in this magazine are not necessarily those of the Management. The contents of this magazine may not be reproduced without the written permission of the Editor. Not for sale. Only for free circulation among employees of L&T Construction and their customers.

L&T Bags Top Infrastructure Company Award

Recognizing L&T’s contribution in developing the infrastructure in India and to the growth of the country, Dun & Bradstreet (D&B) and Axis Bank have honoured the Company with Top Infrastructure Company Award for 2012. L&T bagged the award in the category: Construction – Infrastructure Development.

Mr. K.V. Praveen (General Manager & BU Head Road, Runways & Elevated Corridors Infra IC - L&T) and Mr. B.N. Sheth (Head Special Initiative West & RM Mumbai B&F IC-L&T) received the award from Mr. U.P.S. Madan, VC & MD, Maharashtra Airport Development Company Limited, in Mumbai on October 23, 2012.

Also, L&T Infrastructure Development Projects Limited (L&T IDPL), the wholly-owned subsidiary of L&T, won four D&B–Axis Bank Infra Awards for its project, L&T

Panipat Elevated Corridor Limited. These were given under the categories: Roads & Highways, Public Private Partnership, Social / Community Impact, and Environmental Sustainability.

D&B is a leading information solutions provider with worldwide presence. Axis Bank is the third largest private sector bank in India. The D&B-Axis Bank Infra Awards recognize and felicitate India’s leading infrastructure companies. This is the second edition of ‘D&B-Axis Bank Infra Awards 2012’. D&B used a proprietary model to select the award winners based on various qualitative and quantitative factors. Projects were evaluated based on nominations received form companies. Industry experts and eminent professionals from infrastructure and allied sectors formed part of the independent jury.

Mr. K.V. Praveen (General Manager & BU Head Road, Runways & Elevated Corridors Infra IC - L&T) and Mr. B.N. Sheth (Head Special Initiative West & RM Mumbai B&F IC-L&T) receiving the award from Mr. U.P.S. Madan, VC & MD, Maharashtra Airport Development Company Limited

oct - dec 2012 • volume-35 • issue-4 in-house journal of l&t

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