INDIA’S BUSIEST - L&T Construction Journal of L&T Construction April - June 2013 • Volume-36 • Issue-2 Six-laning of one of INDIA’S BUSIEST Highways Water project catering

April - June 2013 • Volume-36 • Issue-2In-house Journal of L&T Construction

Six-laning of one of

INDIA’S BUSIEST Highways

Water project catering to

13.4 lakh People

Bhushan Steel -

INDIA’S LARGEST

Manufacturer of auto - grade steel

Gujarat’s

LARGEST IT Park

India’s first

800 kV HVDC Transmission Line

FocusThis issue of ECC Concord brings with it some very interesting projects from across the business segments of L&T Construction. From the Buildings and Factories IC, we have featured Garima Park – a world class IT infrastructure at Gandhinagar, Gujarat, which is on the verge of getting completed for Tata Consultancy Services. From the roads segment, this issue covers the six laning of one of the most important highways of the country - the Krishnagiri Walajahpet Road Project, where L&T’s engineers have executed fervently a complicated project alongside live and heavy traffic flow.

This issue also covers the country’s largest automotive steel manufacturing facility, Bhushan Steel, where L&T has been associated in most of the phases of expansion. From the Power Transmission and Distribution IC, we cover India’s first 800 kV HVDC transmission line project running from Assam to Uttar Pradesh, a part of Power Grid’s project that will help transfer surplus power from the north eastern region to the power deficit northern and western regions of the country.

From the Water and Renewable Energy IC, we feature the prestigious Hogenakkal Water Supply and Fluorosis Mitigation Project, which when completed, will become a fifty year ‘dream come true’ project for the water starved people of the Krishnagiri and Dharmapuri districts of Tamil Nadu. The issue also covers snippets of news from projects, orders won and awards among other corporate events in the Kaleidoscope section.

Wish you all a happy reading!

- Editor

In this issueApril - June 2013 • Volume - 36 • Issue - 2

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 ................................. 50Project News ................................ 51Corporate ..................................... 57Events .......................................... 58Awards ......................................... 59

Garima Park at Gandhinagar

Krishnagiri Walajahpet Road Project

Bhushan Steel

India’s first 800 kV HVDC Biswanath Chariyali -

Tangla Transmission Line

Hogenakkal Water Supply Project

311

3743

21

ECC CONCORD April - June 2013 3

Garima Park at Gandhinagar


Located 35 km from Ahmedabad, TCS Garima Park is poised to become one of the most

sophisticated IT infrastructures in the state of Gujarat and perhaps even in India. This facility, which is being developed by TATA Consultancy Services is situated at Gandhinagar, near Info City and adjacent to the NIFT campus. The campus is also strategically located on the National Highway 8 C that connects Delhi to the financial capital of the country, Mumbai.

This ‘build-to-suit’ IT & ITES development has a construction area of 1.65 million sq.ft located on a 25.5-acre land plot. The project is being developed with standards meeting IGBC Gold rating for LEED certification. With about 98% of the seats handed over to TCS for operations, the project is almost on the verge of completion. Completion certificate of phase-1 has been

already received and the final completion of phase-2 is expected by 31st July, 2013.

Scope of work

Design and Build for Construction of IT SEZ, Garima Park, Gandhinagar, Gujarat, for Tata Consultancy Services Limited (TCSL).

The IT Park is envisaged to accommodate over 10,000 seats with services offered from spheres such as BPO’s, IT and training centers. Garima Park is the largest IT

park in Gujarat and is expected to generate employment for the local residents and the IT professionals from the neighboring region.

It is also expected that once fully functional, the IT hub would provide a great fillip to the regional economy in the form of better infrastructure apart from providing employment due to the upcoming hotel industry, housing, markets, security agencies, housekeeping, food & beverage etc.

Apart from the revenue generating model of offices, TCS is also in the fray to provide IT training facilities for all the primary Government schools through virtual class rooms which is part of the Garima Park premises.

L&T as a principal contractor has also done the structural design through its dedicated team – Engineering Design and Research Centre for the client Tata Realty and Infrastructure

The campus is also strategically located

on the National Highway 8 C

Block-1 front view


y VRF/VRV Units (13 ODUs – 120 HP)

y Ventilation Fans

Electrical

y Transformers (15.5 MVA)

y DG Sets (10 MVA)

y UPS (7.24 MVA)

y HT & LT Panels

y HT & LT Cables (130 km)

y Bus Bar Trunking System (500 m)

y Circuit Wiring ( 2027 km)

y Switch sockets (55000 nos)

Elevators

y Passenger Elevators

y 1.5 mps – 24 nos (16 & 24 passage capacity)

y Machine Room

y VVVF Drives

(client’s representative). The project commenced on the 3rd August 2010 with a completion schedule of 24 months. Subsequently due to the changes in design requirements and additional works, the completion schedule of the project was further extended.

CIVIL

Earthwork & Backfilling – 193210 cu.m

Reinforcement – 9000 t

HT Strand – 450 t

Formwork – 387885 sq.m

Concrete – 113195 cu.m

Brickwork – 16175 cu.m

Plaster – 181265 sq.m

Flooring – 90000sq.m

Façade – 23860 sq.m

Painting – 240000sq.m

External Landscapes, Roads, Drains, Compound wall Sports Facility etc.

MEPHVAC

y Water Cooled Centrifugal Chillers (4000 TR)

y Pump sets (25 Nos)

y Cooling Tower (4 nos)

y AHUs – 128 Nos (15 lac cfm)

y Precision Air Conditioners – 59 Nos (1032 TR, 518650 cfm)

Garima Park is the largest IT park in

Gujarat

This ‘build-to-suit’ IT & ITES

development has a construction area

of 1.65 million sq.ft located on a 25.5-

acre land plot.

Atrium view of Block-2

View of south entrance gate


Fire protection

y Fire Pump Sets (4 nos)

y Piping (52 km)

y Hydrant Valves & accessories (160 nos)

y Sprinklers (16000 nos)

Plumbing

y Water & Sump Pumps

y Solar Panel (for Hot Water)

y Sanitary Fixtures – 120 nos. toilets

y Water Supply pipes – G.I/CPVC

y Soil / Waste / Vent / Rain Water Pipes - CI

y STP & WTP

y Solid Waste Management

y Storm Water Drainage

y Kitchen Equipment

IBMS

¾ HVAC

¾ Electrical

¾ Plumbing

¾ FPS

¾ Elevator

y Fire Detection & Alarm System

¾ FA Panel - 3 nos

¾ Smoke Detectors – 5050 nos

y Public Address System

y Security System – Indoor and outdoor CCTV System

Interiors

The scope for interior includes partition / glass partition, loose furniture, column finishes, wall finishes, false ceiling and lighting, specialized flooring, chairs, modular furniture/ work stations, carpet, blinds, glass doors , interior doors, acoustic treatment, auditorium interiors, CCTV and access control, network cabling, etc.

The entire project was done in two phases with a total of four blocks. While phase 1 included blocks 4, 3 and 2 (partially) to be completed in 15 months, phase 2 included the remaining scope in block 2 and block 1. The total number of floors for the blocks ranged from three to six floors along with the basement. The total built-up area measures up to 16.27 lakh sq.ft.

The entire project was done in two

phases with a total of four blocks.

View of connecting corridor of Block-1 & 2 along with northern side exit


Challenges

One of the most significant challenges for the team was in the form of frequent design changes. Apart from the design change, there were several additional requirements from the client which called for revision in planning the activities.

There were inordinate delays in receiving the drawings which delayed the project progress during several occasions. Such delays were overcome by efficient planning and by deploying additional resources to complete the project as scheduled.

The project also faced an acute

shortage of aggregates imposed due to several governmental policy factors. This was overcome through efficient co-ordination and networking with the suppliers.

Since Gandhinagar is one of the most happening places with a lot of construction activities happening,

The project faced an acute shortage

of aggregates there was an

acute shortage for labour and skilled

construction workmen

View of roof garden on the second floor of Block-1

Interior view showing workstation modules


there was an acute shortage for labour and skilled construction workmen were in high demand. Various welfare measures were implemented at the site aimed towards creating a more conducive work environment which thereby enhanced the retention rates of the workmen. This in turn led to a substantial increase in the estimated cost for labour.

Construction methodology

In order to reduce the requirement of concrete, pre-stressed concrete flat slabs were used at module areas while conventional system was used for the others areas.

The north side was structurally glazed using 12000 sq.m of glazing panels while the south side, back and front was stone clad for 18700 sq.m.

Green building features

The project has been provided with some unique green features as it is designed for LEED Gold rating.

y Occupation sensors

y Day light dimmable sensors

y Provision of Extruded Polystyrene insulation board on walls and terrace to reduce the u value, subsequently reducing the heat load of the building thereby reducing the recurring power consumption of chillers

and the HVAC system for the lifetime of the facility.

y Use of LED light fixtures to reduce power consumption, enhanced life and lumen levels

y Use of sandwiched copper bus ducts

y Use of copper bus bars to reduce transmission losses

y Use of solar heaters for hot applications in kitchen and cafeteria

y Use of solar power panels for 2.5% of the total building load

y Use of nitrile rubber insulation material which gives better insulation characteristics over the traditional glass wool with POP material. This also prevents heat loss to a great extent and provides a better finish. Even the acoustic insulation is of nitrile rubber

Pre-stressed concrete flat

slabs were used at module areas

View from the Northern side


y The facility has been designed as Zero discharge facility with an incoming WTP plant for 640 KLD and the same capacity of STP with zero discharge into municipal sewer mains. The treated water is being used in cooling towers, toilet flushing and for horticulture

y 84 nos. of rain water harvesting percolation pits have been

provided to recharge the ground water table

y VFD ‘s in AHU have been used for power saving and controllability

y PICV valves are used for chilled water piping

y Heat recovery wheels have been used to reduce the power consumption by cooling the ambient air temperature through these HRU units, thereby reducing the load on the chillers down the line.

The batching plant was

operated with 9 transit mixtures,

2 concrete pumps and 1 boom

placer.

Wooden bridge of Block-2

Block-4 plant room with fire pumps


y Use of variable refrigerant flow systems as a stand-by for hub rooms to provide uninterrupted cooling during off peak hours when chillers are not running

y Use of dual feed precision air conditioners for data centre and UPS rooms

Resources

Two batching plants of 30 cu.m/hr capacities were installed and a maximum of 11000 cu.m per month production was achieved. The batching plant was operated with 9 transit mixtures, 2 concrete

pumps and 1 boom placer. The site also had 3 tower cranes of 65 m boom length. During peak period of the project, there were 120 staff and 3000 workmen.

Formwork

Most portions, which is, 3.85 lakh sq.m, was done using L&T Aluma table form system in flat slabs for 120000 sq.m area, L&T Alfo for columns and MS fabricated shutters were used for an area of 55000 sq.m. L&T conventional systems such as Wooden H beam, HD towers and Plywood were also used at some places. For external scaffolding, Ringlock system materials were used for completing external cladding works

Anuj Chouhan Project Manager

Terrace view of Block-2 featuring skylight with polycarbonate sheets

Lift lobby at Block-1


Krishnagiri Walajahpet

Road Project


Krishnagiri Walajahpet Road Project is a world-class road corridor which forms

an important link between the two major South Indian metros of Chennai and Bangalore. This forms a 148.3 km long stretch of the erstwhile NH-46 (National Highway) that connected NH-4 and NH-7.

The Krishnagiri Walajahpet corridor passes through several cities and towns of historical importance such as Arcot, Vellore, Ambur and Krishnagiri. The scenic backdrop of hills, mangroves and coconut farms makes this highway a traveller’s delight.

The Krishnagiri Walajahpet Road Project involves six laning of the existing four lane road and construction of 31 new underpasses and two major bridges.

Being a DBFOT project in nature, the key to making value addition other than operational resource efficiency lies in optimization in design of the project highway. This requires a clear understanding of contract terms, specifications and other design codes. Thus a design

steering committee was constituted with representation from in-house and client design teams, client execution team and senior members of in-house execution team. This committee along with members of the operation and maintenance team would discuss and deliberate the design approach proposed by the design consultant in line with the contractual and codal framework and come out with the most viable and optimal design.

Logistics and Control

The entire stretch was divided into three sections of 50 km each headed by a Project Manager supported with services such as planning, quality, safety, quarry and crusher operating. All the sections were well equipped with self-sufficient resources and were fully empowered to act independently with responsibility

The Krishnagiri Walajahpet corridor

passes through several cities and towns of historical importance such as

Arcot, Vellore, Ambur and Krishnagiri.

30 cu.m/hr Schwing Stetter make concrete batching plant


Employer National Highway Authority of India

Concessionaire L&T Krishnagiri Walajahpet Tollways Ltd.

Independent Engineer M/S Roughton - Theme JV

Project Management Consultant EGIS India Consulting Engineers Pvt. Ltd.

Design ConsultantM/S Sai Consulting Engineers, India, Pvt. Ltd.

to achieve the set objectives in line with L&T’s corporate policies and business ethics.

The overall operations were monitored by a central project office team headed by the chief project officer and departmental heads.

KWRP advocated organizational entrepreneurship and hence an Operational Excellence Program, in collaboration with Bain & Co, AECOM was implemented at the site. This has led to several good practices such as preparation of micro – schedule, resource

performances, recording, analysing and status presentation by sectional – in- charges on a monthly basis. The advocation of entrepreneurship has created a positive transformation among the employees and the outcomes of the performances were

Sl. No. Structure / Road Furniture Scope

1 Pipe Culvert 99 nos

2 Box Culvert 174 nos

3 Minor Bridges (SR) 11 nos

4 Minor Bridges (MCW) 2 nos

5 Major Bridges 2 nos

6 Vehicular Underpass 14 nos

7 Pedestrian Underpass 13 nos

8 Flyover 3 nos

9 Toll Plaza 2 nos

10 Metal Beam Crash Barrier 66.73 km

11 Bus Bays 81 nos

12 Truck Lay Bye 1 no

13 Major Junctions 7 nos

14 Minor Junctions 425 nos

200 TPH Metso make semi-mobile crusher plant


Major Quantities

Sl. No. Item Quantity Unit

1 Earthwork 24.51 lakhs cu.m

2 GSB 5.33 Lakhs cu.m

3 WMM 4.59 Lakhs cu.m

4 Kerb 196.70 km

5 BC/DBM 3.78 Lakhs cu.m

6 RE Wall 1.27 Lakhs sq.m

7 Concrete 2.0 Lakhs cu.m

8 PSC Voided Beams 344 nos

9 Pile Length (1.2m dia) 1297.45 LM

10 RCC Precast Deck Planks 400 nos

11 Reinforcement 12750 t

13 Strip Seal Expansion Joints 1091.70 LM

14 Pipe Drain 84.26 km

15 RCC Crash Barrier 30.43 Km

16 Gabion Retaining Wall 1.40 km

extremely encouraging. This initiative has also been able to reduce material wastage and enhance productivity greatly.

Scope of Work y Six laning of existing 4 lane -

Total Stretch – 148.3 km

y Period of Construction – 30 months

y Date of Commencement – 7th June, 2011

y Date of Completion – 7th December, 2013

y Important Towns – Krishnagiri, Bargur, Vaniyambadi, Ambur, Pallikonda, Vellore, Walajahpet

Challenges y Implementing the project under

high density of highway traffic conditions was the biggest challenge. As the toll collection

was continuing during the construction period, there was an added responsibility to provide road users a safe and comfortable road journey at any

given point of time. The task was taken up very sincerely and implemented by the effective use of user friendly barricading and diversions, advance warning

135 TPH Marinie make hot mix plant


signs, sophisticated reflecting gadgets for night driving guidance, etc. These efforts yielded a satisfactory result with appreciation from road users, district officials and the clients as well.

y Roadwork involves a huge amount of natural resources such as soil / gravel, sand and aggregates. This had to be sourced from nearest

possible locations along the road corridor by obtaining various approvals from district officials as well as public representatives. In addition to this, the state government had imposed various environmental

clearances for quarry / borrow area operation of any size. Unfazed by these constraints, the project team overcame this by proactive approach, efficient networking and continuous follow up.

Implementing the project under high density of highway traffic conditions was the biggest

challenge.

One of the major bridges having 16 spans of 40.4m span length. Box Girder type super structure completed in a record 1 year time

View of 260 TPH Marinie make hot mix plant


Achievements y Commencement of laying of

bituminous concrete within 4 months from the commencement of the project

y Completion of major bridge (700m long) within a year, despite delay in commencement due to certain design complexities.

y Due to Supreme Court ruling for obtaining environmental clearances for quarrying earth,

stone and other material there were abnormal delays. It took considerable time for the project team to understand and streamline the approval process for the mining of these resources. In spite of these initial delays, the team rose to the occasion and put in extra efforts to achieve the intermediate milestones set forth in the contract.

Recycling of Dismantled Material

Expansion of roadways results in generation of a huge amount of road waste such as asphalt or concrete debris. Asphalt waste particularly has a leaching or contaminating effect on the soil and creates an imbalance in the salinity levels therefore making it difficult to dispose of safely. This waste material was put to good use at KWRP by suitably crushing and mixing it along with Granular Sub

Base (GSB) material. It created a material called Blended GSB which helped to substantially reduce quarrying and crushing. Moreover, dismantled pieces of existing PCC structures have been used as boulders for floor apron and pitching work in the project.

The team also envisaged the reuse of existing RCC drains. With the

By this initiative of retaining the existing drains

KWRP project team has been able to cut down CO2 emissions by around 1500 t.

Asphalt waste was put to good use at KWRP by suitably

crushing and mixing it along with Granular

Sub Base

Vogele make asphalt sensor paver


able support from site P&M team, the existing drain was cut using saw / wire rope driven cutting technique. These cut pieces were then placed suitably and joined with a sealant. It not only resulted in tremendous cost savings but also by way of retaining the concrete and steel in the existing drain, it eventually saved burning of substantial amount of coal for producing steel

and cement by the manufacturers. Approximately 927 kg of Carbon Di-oxide gas is emitted per 1000 kg of cement production. By this initiative of retaining the existing drains KWRP project team has been able to cut down CO2 emissions by around 1500 t.

Further, the team also suggested implementing circular hume pipe drains in the new locations in the place of rectangular RCC drain as shown in the contract. This initiative resulted in substantial reduction in consumption of concrete and steel as compared

Concrete design mixes incorporating

m-sand was prepared and implemented

successfully in all works.

Load testing in progress at major bridge 94

BC paving in progress at km 103


to the rectangular RCC drain section, thereby also leading to environmental sustainability.

Use of Alternative Material

It is an accepted fact that excessive sand-and-gravel mining causes degradation and deepening of rivers, apart from increasing the erosion of the river banks. Nevertheless, the demand for river sand is ever increasing. KWRP has been able to totally replace the use of natural sand by the use of m-sand or manufactured sand. M-sand is an alternative material with the same properties as that of natural sand. For the production of m-sand, a sand classifier was procured and attached to the crusher system. Concrete design mixes incorporating m-sand

was prepared and implemented successfully in all works.

Zero Emission Levels at Hot Mix Plant

Although emission levels of a hot mix plant is below the restricted limits and the setting up of it is permitted by state laws, there was an urge within the project management team to bring down the levels to zero. Dust that emitted was of size 150 micron and could be harmful for workers. An arrangement was maintained that excess filler dust fell into a covered pug mill, where it was mixed with water and transformed into slurry. Ultimately this slurry was disposed of with proper care. This initiative brought down the air pollution to absolute zero.

Over 500 trial mixes for concrete was conducted with

various admixtures to achieve a design

mix containing the lowest cement

content.

Name / Capacity of P&M

Qty. nos

Road Related

Hot Mix Plant ( 260 TPH ) 1

Hot Mix Plant ( 120 / 135 TPH )

2

Wet Mix Plant ( 200 TPH ) 1

Wet Mix Plant ( 60 TPH ) 3

Paver Finisher 10

Motor Grader 13

Vibratory Soil Compactor ( 18 t )

2

Vibratory Soil Compactor ( 10 t )

7

Pneumatic Tyre Roller ( 27 t ) 5

Tandem Vibratory Roller ( 8 t )

14

Mini Vibratory Roller ( 2.7 t )

16

Concrete Related

Batching Plant - 30 ( cu.m / hr )

4

Slipform Paver - SP 15 1

Boom Placer 1

Transit Mixers 23

Common Service

Crusher - 150 / 200 TPH 3

500 KVA DG 10

Wheel Loader 9

Crane ( 75 t ) 2

Crane ( 40 t ) 2

Crane ( 15 / 12 / 10 t ) 22BC paving in progress at km 26


Every 50 km had a quality

personnel working under a central quality head.

SP-15 Paver for Crash Barrier Construction

The construction of RCC crash barrier using slip form paver WRITGEN SP – 15 was done as a first time initiative in L&T. When compared to the conventional system of formwork crash barrier, the slip form paver provided a high cost benefit apart from faster completion of the entire scope of work. The job was completed within 4 months whereas by conventional system it would have taken 7 months.

Quality

Understanding the complexity and length of the project, every 50 km had a quality personnel working under a central quality head for the purpose of continuous material testing, training and evaluation of staff / workmen, internal auditing and fixing of critical situations as and when they arise. This meticulous pursuit of quality in each and every

aspect of the job resulted in the project winning the internal Quality Trophy 2012 from among all projects of the Roads and Runways Business Unit of L&T Construction.

Over 500 trial mixes for concrete was conducted with various admixtures to achieve a design mix containing the lowest cement content. This was implemented in all works.

SP 15 paver in operation

WMM laying with sensor paver at km 58


During the peak period there were 200 staff and about 2000 workmen. KWRP has also been home to almost 40 trainees (Graduate Engineer Trainees and Diploma Engineer Trainees). With structured classroom as well as hands-on training programs they have blossomed into effective site / planning engineers and have now become an asset to the company.

EHS management

Strict compliance to PPE and sustained efforts from the EHS cell at KWRP has helped in achieving 11 million safe man hours. KWRP has received two awards at the Mines Safety Week 2012 held at ACC Madukarai; First prize for “Injury Rate Performance” and second prize for “Welfare Amenities and Medical Facilities” (South Zone). Being a

road expansion project, almost all stretches had live traffic plying when the work was being executed. Safety of road users, workmen and equipment were of the topmost priority for the entire team. KWRP has ensured smooth traffic flow at structure locations even in very congested and busy areas with the help of efficient diversion plans.

The EHS cell at KWRP has taken up the initiative for conducting medical / eye camp for the operators and

workmen at regular intervals of time. RO plants were provided for providing safe drinking water for the workmen. Apart from this, monthly award schemes for workmen and staff were also initiated. Various quizzes and debates were conducted to spread awareness about EHS.

KWRP has always given prime importance to the environment. Right from the commencement of Clearing & Grubbing activities, care was taken to minimize cutting down of trees to the greatest possible extent even if it resulted in not having much free space for operating machineries. A major chunk of the uprooted trees were replanted in L&T’s quarry campuses. Borrow area top soil which was removed was replaced to maintain the fertility of the soil.

R.Prabakaran Project Manager

Care was taken to minimize cutting

down of trees to the greatest possible

extent.

Elevated view of underpass approach in one of the completed sections


Bhushan Steel


The state of Odisha is endowed with vast mineral resources and occupies a prominent place in

the country as a mineral rich state. Abundant reserves of high-grade Iron ore, Bauxite, Chromite, Manganese ore along with other minerals such as Coal, Limestone, Dolomite, Tin, Nickel, Vanadium, Lead, Graphite, Gold, Gemstone, Diamond etc. are extensively available here. This has opened up immense possibilities for locating mineral based industries for manufacture of Steel, Ferro-alloys, Cement, Alumina/ Aluminum, Refractories, Thermal Power etc., along with setting up of other auxiliary and ancillary downstream industries.

The Dhenkanal district of Odisha covers a geographical area of 6232 square kilometers and supports a population of about 12.70 lakhs. Although newly formed, it is one of the most advanced district with highest return of revenue to the

Government due to vast coal mines located in its abode.The state is also endowed with large reserves of iron ore which is estimated at almost 35% of the country’s resources (approx. 5.42 billion tons) and convenient access to the sea through the port of Paradip. Consequently, there is a tremendous scope for utilizing these reserves for steel, pig iron and sponge iron plants, and therefore providing a great impetus to the steel industry.

This region has been attracting several large scale industries, PSU’s and their ancillary industries. At present, there are ten large and medium scale industries including 5 PSUs, besides a few large projects that are currently under the pipeline.

Bhushan Steel Limited (BSL), one of India’s largest manufacturer of auto-grade steel is presently building a 5 Million Ton Per Annum (MTPA) integrated steel plant in Meramandali, Odisha located 130 km from Bhubaneswar at a cost of around INR 25,000 crore. The capacity can is expected to go up to 7 MTPA.

The association between L&T and Bhushan Steel is legendary as L&T has been an integral part of all significant projects and expansions plans of the steel major. Through this association, L&T has earned the record of executing all major units of iron and steel making of an

Bird’s eye view of conveyors of the Raw Material Handling System

The state is also endowed with large reserves of iron ore which is estimated

at almost 35% of the country’s

resources


integrated steel plant concurrently in a single location.

The first phase was commissioned with the following units in the scope y Four Kilns

y 110-MW power plant

y Steel melt shop and raw material handling facilities.

y Sponge iron (6,80,000 TPA)

y Billet (3,00,000 TPA) has already been started.

Consolidated Major Quantities

Work in progress at HSM roughing mill

Bhushan Steel Limited (BSL), one of India’s largest

manufacturer of auto-grade

steel is presently building a 5 Million

Ton Per Annum (MTPA) integrated

steel plant in Meramandali,

Odisha


The second phase (capacity 2.2 MTPA) with the following major units is being executed and is supplied by various technologically superior players from around the world:

Executed by L&T

y Steel Melt Shop # 2 by SMS Siemag, Germany,

y Hot Strip Mill by SMS Siemag, Germany and Siemens, Germany,

y 2 X 64 Batteries Coke Oven-1 by Beijing Shougang, China,

y Re-Heating Furnace by Tenove, Italy,

y 300 TPD Lime Calcination Plant by Qualical, Italy,

Executed by other parties

y 1X177m2 Sinter Plant # 1 by Soughang-China,

y 1683m3 Blast Furnace#1 by Danieli Corus

The confidence of BSL on L&T for timely deliveries has resulted in further orders following the second phase expansion which enhances overall production capacity to 5.5 MTPA. According to these orders that are presently under execution, L&T has been solely entrusted with all the units as per the following scope:

y Complete Engineering, Procurement and Construction of 2.5 MTPA (3814 cu.m) Blast furnace

y Civil and Mechanical erection work including design and

supply of 2 x 2.3 MTPA capacity (2 x 204 sq.m) Sinter Plant

y Civil and Mechanical erection work including design and supply 2.5 MTPA Coke Oven Plant of 74 Oven, 7.6m. high battery (1st time in India)

y Civil, Structural, Equipment and Piping works of SMS III consisting of 1 nos. Slab Caster, 1 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 18 km long Conveyors with civil and structural works and erection of machines

y Complete Design, Supply of Coal Crushing System and Screening System with Erection

Re-Heating Furnace in operation

The confidence of BSL on L&T for

timely deliveries has resulted in further

orders


Major Functional Unit already commissioned

1. Steel Melting Shop

Steel Melting Shop:

Capacity : 180t

Tapping : Eccentric Bottom Tapping

Power Rating : 145 KVA

Lancing : Oxygen Top

: Door lancing

: EBT lancing

2. Re-Heating Furnace

Re Heating Furnace

Capacity : 300TPH

Furnace length : 37.5m

Hearth length : 16m

Walking Beam : 4 nos

Fixed Beam:

Charging Side : 5 nos

Discharging Side : 6 nos

Slab Caster

Type: Single Strand Vertical Bending

Mould Type: Vertical Compact type

Capacity: 2MTPA

Casting Radius : 8 m

Slab Thickness: 230 mm

Slab Width: 800-1680 mm

Main Units of Phase-II expansion

View of Electric Arc Furnace for SMS-II


Slab Length: 6-12.5 m

Casting Speed: 0.25 -12.5 m/min

Machine length: - 37.450 m

Salient Features: Ladle Furnace

Capacity:-180 t

Bottom Argon Stirring

Top Argon Lancing

Alloy wire feeding

Power Rating: - 35 KVA

3. Hot Strip MillRoughing Mill

Type:4 High

Max Thickness Reduction up to 50 mm

Main Drive: 2X16000 KW (650nos. motors)

Finishing Mill

Strand : 6 nos.

Type: 4 High Tandem Strands

Main Drive: 6X7500 KW

Major Achievements y 65 million safe man-hours

y 10,000 t of structural fabrication in a single month

y 40,051 cu.m concreting in a single month

y 50,449 sq.m shuttering in single month

y 10,000 t structural erection in a single month

y Erection of Asia’s heaviest crane girder 42m x2.4 x1.16 m weighing 181 t in a single lift

Major Technological Units

y Blast Furnace Proper & BLT

y Cast House with De-dusting System

y Hot Blast Stoves

y Gas Cleaning Plant (GCP) & Clean Gas Main

y Slag Granulation Plant (SGP)

y Top Recovery Turbine (TRT) System

y Stock House with De-dusting & Charging System

y Electrical Power & Distribution System

y Instrumentation & Level 1 & 2 Automation

y HVAC System

y Water Cooling System

y Coal Grinding & PCI System

y Blower System

y Utilities

y Fire Fighting System

Major Scope of works

y Concreting : 73009 cu.m

y Structural Works : 27449 t

y Sheeting works : 57847 sq.m

y Piping : 477507 IM

y Equipment : 19952 t

y Refractory : 23732 t

y Cable laying : 1079 m

y Cable termination : 37476 nos.

Blast Furnace #2 Cast House


y 4,340 cu.m concreting of blast furnace raft in a record time of 49 hours

y 1,207 t structural erection in a single day on 30th Jan. 2011

y 2,00,000 t of structural erection in 57 months.

y 4008 t structural erection in the month of Dec-2012 at Raw Material Handling System packages.

Blast Furnace-2

The scope included engineering, procurement, construction and commissioning of 2.5 MTPA Blast Furnace for Bhushan steel at Meramandali, Dhenkanal, Odisha.

The project is being executed by a consortium formed by L&T and Paulwurth Italy S.P.A (PWIT) on a turnkey basis. PWIT, the technological partner, has done

the basic engineering and supply of technological equipment for the project. The hearth diameter is 13 m with working volume of 3230 cu.m and maximum production of 7850 tons per day with four tap holes and 34 nos tuyeres on both sides of the cast house.

Supply of indigenous equipment, technological and building structures, plant utilities, water system facilities, air conditioning and ventilation, firefighting, coal grinding system, electrics and instrumentation, civil

works including roads, drainage, railway track etc., were done by L&T.

Challenges

1. Change in technology of slag granulation system form hot INBA to cold INBA by client resulted in delay of completion in INBA and also caused erection hindrance to nearby cast house. However this was overcome by the allotment of necessary resources to complete the job on time.

2. There was some delay in dispatch clearance for equipment and electrics by client which resulted in delay in delivery of equipment by one year. However the works were completed on schedule.

3. Storage of material, fabrication and assembly were a great challenge during the initial

Exterior View of BF#2 Cast House

4,340 cu.m concreting of Blast Furnace Raft in a record time of 49

hours.


phases of the project as the space provided was insufficient. However through proper logistics and erection planning, works were carried out efficiently.

4. Erection of MB2 conveyor trestles and gallery was a major challenge due to shortage of space and access to the erection area.

5. Centralized Electrode drying room was established to ensure proper baking and thus improving the weld quality.

Achievement

1. 4,340 cu.m concreting of Blast Furnace Raft in a record time of 49 hours. Proper planning along with logistics of concrete millers, concrete pumps, ice was done to avoid cold joints in concrete. Ice blocks (total 211 t)

were used to avoid hot cracks in concrete.

2. Kroll tower crane upgraded from 30 to 60 t and Hot Stove dome each weighing 58 t erected in single lift for all three stoves.

3. Bustle pipe of outer diameter 24.6 m, pipe diameter 2.6 m and weight 100 t erected

circumferentially outside the furnace at a height of 17.72 m in single lift using Kobelco SL6000.

4. Charging conveyor erection: MB2 conveyor from stock house to blast furnace runs in a narrow space between operational power plant and another power plant which is in project phase. The challenge was to erect the conveyor gallery in tandem lift using one Kobelco SL 6000 550 t crane and Demag CC2800-1 600 t crane. L&T’s erection engineers in co-ordination with Construction Methods Planning Cell team of L&T successfully erected the gallery of MB2 conveyor.

5. Stock house bunker hoppers each weighing 60 t was preassembled on ground in inverted position and fitted using

Overall view of Sinter Plant #2

Stock house bunker hoppers each

weighing 60 t was preassembled on

ground in inverted position and fitted using cranes and

erected in single lift


cranes and erected in single lift thus saving manpower and cost.

6. Steel brackets were used in casting dome part of overhead tank thus eliminating the usage of huge formwork of up to 61 m elevation.

7. BF shells were assembled with 3 to 4 rings together at ground level so that quality weld joints can be prepared with minimum cost while ensuring maximum safety.

SINTER PLANT

Scope included design, manufacture and supply of indigenous equipment, erection, testing, and assistance to commissioning including civil and structural works.

Basic Design Parameters:

y Production of Gross sinter

Approx. – 2,300,000 t/year (6,764 t/day) of each Sinter plant.

y Net Sinter: - 18,70,000 tph ( 5,500 t/day) of each sinter plant.

y Raw material: Iron Ore, Lime stone, Dolomite, Coke Breeze

y Fuel Type: BF Gas, LPG.

y Utilities – Clarified water for makeup, Drinking water, firefighting water.

y Industrial Gases – Compressed air plant grade, Instrument air, Nitrogen.

y Sinter plant product – sinter discharge, Intermediate, size distribution

Current Project Schedule:

y Project Start date: Nov’2009

y Expected Completion: June’2013

Major Highlights & Milestone :

y SP#2 was successfully commissioned on 18th Oct’2012.

y SP#3 was commissioned on May’2013.

y 46,513 cu.m of RCC structure executed

y 15,976 t of Structural Fabrication & Erection has been done

y 12,190 t equipment works executed

y 1, 21,802 IM of piping

y 59,028 sq.m of sheeting completed

Major process units of Sinter plant

A. Ignition furnace

Ignition furnace consists of main furnace, pilot burner and combustion chamber. It

Sinter Machine Area of Sinter Plant #3.


has been designed for the caloric value of BF- Gas which is 800 Kcal/ m3 at Normal Temperature and Pressure (NTP). Pressure at Ignition Furnace 600-650 mm Wc. Combustion Chamber mainly handles mixed gases. Volume of the Air flow is at 1.7 m3/s at NTP. Volume of flow gas -0.18 m3/s at NTP. Value -4000 Kcal/m3. Combustion Chamber essentially consists of- Burner, 3- Way Damper and Gas Regulating Valve.

B. Sinter Machine

Sinter machine is having a suction area of 204 m2 .The drive used is an adjustable 3-phase asynchronous motor with frequency converter of power supply. The operating strand will be approximately 3m/min and adjustable in

range from 1 to 4 m/min. The discharge section of the sinter machine operates at a minimum of friction and cable is compensating thermal expansion. The pallets are deigned to cope with the tensile stress and dimension in such a way as to prevent the flange from exceeding an average temperature of 350 to 400oC maximum.

C. Sinter Cooler

Sinter Cooler is one of the most important equipment of Sinter plant. Direct chute is used to feed hot sinter from sinter breaker to sinter cooler and the cooling troughs to ensure uniform loading of the hot sinter to sinter cooler pallet.

D. Waste Gas Fan

Waste gas fan is used for suction of sinter machine combustion through spillage chute, waste gas main, waste gas and electrostatic precipitator.

Coke Oven #2

Bhushan steel Limited envisaged the setting up of a new 1.306 MTPA capacity (gross coke), 7.6m tall, 74 oven, top-charged coke oven battery along with By-Product

2.5 km long conveying feeding

and product conveyors

commissioned in just a year.


Plant (BPP) having a gas processing capacity of 75,000Nm3/h which is the first-of-its-kind and the largest in India at the time of commencement.

The scope of work covers indigenous supplies, engineering, fabrication and erection of steel structure, testing, commissioning, and demonstration of performance guarantee parameters of the coke oven as per the agreed technical specifications.

Coke, being a prime source of fuel in the blast furnaces, is manufactured as an integral part of any integrated steel industry. Coke is used as a fuel and as a reducing agent in smelting iron ore in a blast furnace. The carbon monoxide produced by its combustion reduces iron oxide (hematite) in the production of the iron product.

Slab Caster

No. Of Casters 3Nos.

Annual Production 2000000 t

Ladle capacity 200 t

Tundish Capacity 36 t

Strands 1 X 1

Slab Width 800-1680 mm

Slab Thickness 230 mm

Slab Length 6-12.5 m

Machine type Vertical Bending

Mould Vertical Compact type

Mould Length 900 mm

Oscillation Hydraulic

No of segment 17

No of Drives 18

Casting Speed 0.25-2.5 m/min

Major Units y Coke Oven Battery

y By Product Area

y Utilities & HVAC

Coke Oven:

1. Battery Proper

1.1 Cellar Area

1.2 Oven Area

View of Coke Oven II


2. Coal Tower

3. Wet Quenching

4. Coke Wharf

5. PECS

6. Moving Machines

Quantitative Scope :

y 6550 t of structural fabrication & erection.

y 950 t of tank & vessel fabrication & erection.

y 15500 t of equipment erection.

y 470000 IM of piping fabrication & erection.

By Product:

4. Primary Cooler

5. Electrostatic Detarring

6. Exhauster

7. Scrubber

8. Sulphur Recovery Unit(Claus )

9. Tar Area

Basic Oxygen FurnaceScope of work involves civil and mechanical works for SMS III, BOF (2converters) and 2nos. slab caster

Civil and mechanical work for SMS-III expansion project includes the following units

y 2 nos. Hot metal de-sulphurisation

y 2 nos. Continuous casting machine

y 2 nos. Basic Oxygen Furnace

y 2 nos. Rinsing Station

y One Ladle Heating Furnace

y One CAS-OB

y Gas Cleaning Plant

BOF Converter-Technical Data

y Nominal capacity : 180 t

y C Content of hot metal : 43%

y Total reacting oxygen : 900 Nm³/min

Salient Features of Converter

y Maximum thickness of weld metal :150mm

y Total butt weld length: 372.578 m

y Total fillet weld length : 161.678m

y Maximum welding electrode consumption: 8.141 t

y Maximum no of welders engaged till date: 1569 nos.

y Total Ultrasonic conducted length till date:227.141 m

y Total Rework length till date: 2.265 m.

y Trunnion ring assembly and welding was completed within one month. It was a very critical job due to the entry point measuring only 600mm dia hole and the welding area of only 370X2140mm where welding temperatures went to 150-250 oC.

Basic Oxygen Furnace Converter


y Blowing time : 14 min

y Tap to tap, average : 42 min

y Height( Overall) : 10000mm (aprx.)

y Tilting Torque : 3200 kNm(aprx.)

y Tilting Speed(rpm) : 01-10

y Tilting Angel : 360°

y Oxygen-flow rate design : 720 Nm³/min

y Oxygen-blowing pressure : 20-22 MPa

y Total circulating quantity : 200 m³/h

y Operating lance 190 m³/h

Major Milestones :

y 2,74,799 cu.m of RCC Structure Executed

y 81,303 t of structural fabrication & erection has been done.

y 17,067 t equipment works executed.

y 5,97,829 IM of piping works has done.

y 1,26,343 sq.m of sheeting done.

It is globally acknowledged that Basic Oxygen Furnace (BOF) produces more steel than any other process, and it is one of the primary steel production methods. Basic Oxygen Furnace (BOF) is a pear shaped vessel where the pig iron from blast furnace, and

ferrous scrap, is refined into steel by injecting a jet of high-purity oxygen through the hot metal.

More specifically, in a BOF, unwanted impurities are removed and the carbon content of pig iron, which is typically 4-5%, is reduced to varying levels below 1% depending on the product specifications.

Approximately 50 Nm3 of oxygen, which is produced in another plant, is required for every ton of liquid steel. As the reactions taking place in the BOF are highly exothermic, the temperatures in the furnace usually reach 1600-1650 °C. Scrap, or scrap substitutes, that meet purity requirements are often added to control excessive temperature raises. However, the pig iron input stays at the levels of 65 to 90% for every ton of steel produced. Impurities are dissolved by the added limestone and formed into a slag.

Twin Boom Stacker in operation

The erection of stock house hoppers (weighing 50 t) was done in assembled

condition which helped reduce

60% welding work at field joints.


During the BOF processes a gas with high CO content is formed. If no gas recovery is exercised, CO is converted to CO2 by combustion at the mouth of the furnaces with open hood, and through flaring after gas cleaning in furnaces with a closed

hood. BOF shops are often followed by secondary metallurgy processes - in ladle or in vacuum - to give the product its final characteristics. BOF operations can be a net producer of energy if the chemical energy leaving the furnace is recovered and utilized.

Raw Material Handling System

Supply, civil, structural and mechanical work for RMHS-I and New RMHS-II packages for feeding of Sinter Plant # 1, 2 & 3, Coke Oven # 1 & 2, Blast Furnace # 1& 2, Power Plant, and associated yard machines and conveyors for 5.5 t integrated steel plant for Bhushan steel at Meramandali, Dhenkanal, Orissa.

View of the Barrel Reclaimer

Since the labour strength was close to 12,144 workmen during peak period,

EHS was given a special thrust.

View of Stacker 7


Phase-I includes three Stacker Reclaimer machines and Conveyor Packages.

Phase-II includes 23 Yard Machines and Conveyor Packages

Engineering / Supply / Construction Scope :- RMHS-I & II consists of the following packages,

a. Yard Machine Package (26 Nos Machines - 10 Nos. Stacker-Reclaimers, 2Nos Wagon tippler, 8Nos paddle feeders, 1Nos twin boom stacker, 4Nos Apron feeders, 1 Barrel Reclaimer)

b. Conveyor Package-2002 (39 Conveyors of 6.5 km length) & Conveyor Package-2006 (48 Conveyors of 7.8 km length) for feeding Sinter Plant #1, Blast Furnace #1 & Coke Oven #1 areas

c. Package-395 : Feeding to Sinter plant 2 & 3 and Blast Furnance#2-Stock House.

d. Package-396 : RMHS from Wagon Tippler # 4 & 5, Track Hopper-1 & 2 to Stockyard

e. Package 399 : Coal & Coke preparation and handling system for Coke Oven #2

f. Package-408 : Prime Coal Crushing & Screening system for Power Plant

g. Package 405 : Coal conveying system from Coal Washery Building

h. Package-395A : Sinter fines return Route from Stock House-2

Major Scope of works y Concreting : 177610 cu.m

y Rebar :- 15000 t

y Shuttering – 3 lakh sq.m

y Structural Works : 58163 t

y Sheeting works : 4.8lakh sq.m

y Equipment : 32395 t

Major Technological Units:- y Belt/Shutt leConveyors/Bel t

Feeders-23 km

y Junction Houses-60 nos

y Process Buildings-14 nos

y Stacker Reclaimers- 10 nos

y Barrel Reclaimer (cap 1500/1950 TPH) - 1nos.

y Twin Boom Stacker (cap 1500/1950 TPH)- 1nos.

y Rod/Hammer Mill-13 nos

y Wagon Tippler and Side Arm Charger- 2 nos each

y High Angle Conveyors-(cap 200/300/750/900 TPH)- 9 nos.

y Flip Flop Screens-(cap 200 to 300 TPH Material : Coal & Flux)- 9 nos.

y Vibrating Grizzly Feeder--(cap 400 Material : Coke)- 2 nos.

y Paddle Feeders- 8 nos

y Apron Feeders- 4 nos

Laddle Furnace in operation


Achievements y Achieved 15100 cu.m of

concrete in January 2012.

y 3102 t of Structural Fabrication done in November 2012.

y 4008 t of Structural Erection being erected in December 2012.

y 5 Stacker Reclaimer commissioned in 14 months.

y Sinter Plant #2 (2.5 km long conveying feeding) and product conveyors commissioned with product discharging to BF#1 in just a year.

Construction Methodology

For the construction of dome

portion of the water tank, the project team planned for climbing formwork system over the traditional HDT system. Through this methodology, only 26 kg of shuttering per sq.m was needed when compared to the 91 kg/sq.m that would have been needed for the conventional system. Considerable amount of cost and time was also saved due to this innovation.

The erection of stock house hoppers (weighing 50 t) was done in assembled condition which helped reduce 60 % welding work at field joints.

The project team deployed ‘Torbosol’ automated plastering machine which not only provided significant savings in cost but also enhanced productivity apart from providing excellent surface finish.

Safety

Since the labour strength was close to 12,144 workmen during peak period, EHS was given a special thrust. Right from the commencement of the project induction and safety awareness programmes were conducted consistently. Consequently, the project clocked an all time record of 65 million safe man hours for the period 15th July 2011 to 1st August 2012 apart from an international award from British Safety Council for the year 2008 and the internal, half yearly Safety Rolling Trophy two times consecutively.

Hare Ram Project Manager

Illuminated view of BF #2


India’s first 800 kV HVDC Biswanath Chariyali – Tangla

Transmission Line


The Biswanath Chariyali-Agra line running from Assam to Uttar Pradesh is a part of

Power Grid’s northeast to northern/western interconnector-I project that will help transfer surplus power from the northeastern region to the power deficit northern and western regions of the country. The main sources of power will be the mega hydropower projects coming up in Kameng and Lower Subansiri basin in Arunachal Pradesh.

Envisaged with an investment of over Rs 11,130 crore, this interconnector project is expected to take about five years to get commissioned. The project will have two broad components, HVDC – High Voltage Direct Current (of which the Biswanath-Agra line is a part) and the AC (alternating current) segment. The Interconnector-I project is part of PGCIL’s overall objective

of attaining 37,500 MW of inter-regional grid transfer capacity with an investment of Rs.55,000 crore.

The +/- 800kV bipole Biswanath-Agra line, of around 1,800 km will handle a capacity of 6,000 MW traversing four Indian states right from Assam, West Bengal,

Bihar up to Uttar Pradesh. The packages will have demarcation points at Tangla, Borabisa (both in Assam), Islampur (West Bengal), Saharsa, Gopalganj (both in Bihar), Gorakhpur, Gomti river and Nidhuara (all in Uttar Pradesh).

The 800kV HVDC bipole Biswanath Chariyali – Agra lineis divided into nine tower packages and L&T was awarded package A1, the construction of 800kV HVDC Biswanath Chariyali – Tangla transmission line that includes:

y Approximately 166 km of 800 kV (Hexa Bundle) HVDC Biswanath Chariyali – Tangla transmission line.

y Approximately 74 km of 110/132 kV (Twin Bundle) Earth Electrode Line from Biswanath Chariyali – Thagiabari

Envisaged with an investment of

over Rs 11,130 crore, this interconnector

project is expected to take about five

years to get commissioned.

View of Tower Erection in progress using Gin Pole


Description UnitHVDC Earth Electrode

As per LOA Revised As per LOA Revised

Check Survey km 159 166 72 74

Detail Survey km 20 55 10 22

Earth Work cu.m 190539 196239 24778 21195

Concreting cu.m 29794 30031 3008 2502

Supply, Fabrication & placement of Steel t 2256 2209 159 138

Supply & Erection of Towers t 17019 20591 1627 1680

Hoisting of Insulators nos. 185988 223688 1035 1219

Installation of Hardware fittings sets 1141 1319 659 742

Conductor Stringing km 159 166 72 74

Protection of Tower Footing cu.m 3710 3710 - -

Scope of work y Detailed survey, profiling, tower

spotting and optimization of tower locations, soil resistivity measurement, geotechnical investigation and check survey

y Fabrication and supply of all types of transmission line towers as per client’s design

y Supply of earth wire for HVDC Line and hardware fittings along with insulator (90kN and

120 kN) for Earth Electrode Line y Selecting the type of foundation

for different types of tower and casting of foundation as per client’s drawing

y Erection of towers, fixing of insulator strings, stringing of conductor and earth wire along with accessories

y Providing protection of tower footing

y Testing and commissioning of all erected transmission lines

The +/- 800kV bipole Biswanath-

Agra line, of around 1,800 km will handle a capacity of 6,000 MW traversing four

Indian states

Rescue Kit Demonstration


AC technology has proved very effective in the field of generation, transmission and distribution of electrical energy. They are a useful supplement or in certain situations the only alternative for traditional High Voltage Alternating Current (HVAC) systems.

HVDC transmission systems connect two separate high voltage AC systems via a DC link. The basic principle of operation of an HVDC system is based on the conversion of AC to DC and vice-versa by means of converter valves comprising power thyristors, which are the heart of a converter station.

These HVDC transmission systems are specifically used to:

y Economically transmit electrical energy over long

distances via overhead lines or cable,

y Connect asynchronous grids or grids with different frequencies.

India has been a pioneer developer of HVDC since 1990 with the 1000 MW Rihand – Dadri line in Uttar Pradesh. The Talcher - Kolar link is considered the biggest commissioned so far and also spans four states in the country.

The Direct Advantage

HVDC transmission systems connect

two separate high voltage AC systems

via a DC link.

Challenges Faced

The Biswanath Chariyali – Tangla HVDC towers are not only the first in India but also has earned the status of being the first-of-its-kind in Asia. A project of such complexity and dimension has therefore posed several challenges during the execution phase of the project. Since the project was technically superior, the availability of skilled manpower was very scarce. Staff and workmen who were taken aboard were given extensive induction training before they were deployed to the actual project site.

The terrain and climatic conditions were one of the most challenging factors. The soil condition had poor strata as a resultant of constant rainfall in the region making foundation planning very difficult. With the towers weighing anywhere between 30 to 124 t, foundation pits were of varying dimensions

View of HVDC Hexa Conductor Stringing in progress


and several advanced geotechnical innovations were implemented to counter this challenge.

The conductors passing through the towers are hexagonal in nature (total 12 nos. through two cross arms).The activity of stringing was most challenging and hence the team resorted to the use of Tensioner and Pullers of 160Kn pulling capacity to string the conductors. L&T commissioned two TSE machines synchronising both at the same speeds for paying out 6 conductors in tandem for both puller and tensioner. Hexagonal stringing is carried out using Tensioner and Puller machines, where the bull wheel of the puller pulls the pilot wire connected to the conductor and tensioner releases the conductor from the conductor drum. The puller and tensioner are placed

at two different angle points between the stretches.

Working in the Assam region posed several social issues such as insurgency, militancy and work stoppages at regular intervals. Due to such reasons, retention of workmen to work at remote job locations was a very difficult task. Constantly looking into their various needs and keeping the workmen morale high helped counter this challenge.

Construction Methodology

Gin pole work methodology was extensively used for the effortless erection of towers. The project had the towers categorized in four different design specifications depending on the angle of deviation. Tower nomenclature was as A, B, C, and D having different weight, where B, C, D type towers exceeded a weight of 50 t per tower. L&T’s scope included construction of 20000 t which was done by introduced Gin Pole methodology. The gin-pole is a rigid pole, with a pulley or Block and Tackle on the end, used for the purpose of lifting. The lower portion of the gin-pole is set in a shallow hole in the ground and the top secured with three or more guy-wires with strong anchoring points. The wires can be manipulated to position the

Gin pole work methodology was extensively used for the effortless

erection of towers.

Use of Horizontal Life Line and safety net


object being lifted or attached to the upper exterior of an existing tower or structure. The gin-pole’s free end extends above the location with an angle of 10 degrees when the object is to be lifted. Once the process is completed, the gin-pole can be detached, raised and re-attached to the just completed segment for the purpose of lifting the next segment. The process is repeated until the top most portion of the tower is completed.

Safety

Significant safety initiatives included implementation of hard barricading for foundation work, horizontal life line for proper access during erection, use of tools bags for fitters working at height and use of safety nets to arrest falling of material from height.

Contract Management

There were several operational constraints prevailing in Assam in the form of insurgency,agitation and prolonged rainy seasons. The project team made it imperative to maintain the data on loss of time due to such factors which were beyond control. Accordingly, all activities that affected work were

noted down on a regular basis and the same was duly signed by the client. Due to this sincere and effective data management system, time extension for another one year was approved. This rigorous and effective documentation also made L&T a trustworthy partner of PGCIL.

Achievements

The 800 kV HVDC Biswanath Chariyali – Tangla transmission line project won prestigious awards such as Quality Trophy and EHS Rolling Trophy. The project had also won RoSPA Gold Award 2013 and achieved 3 million safe man hours.

Debashis Mukhopadhyay Project Manager

Rigorous and effective

documentation made L&T a trustworthy partner of

PGCIL.

View of completed stringing stretch.


Hogenakkal Water Supply Project


Dharmapuri and Krishnagiri have long been declared as water starving districts

in Tamil Nadu. The ground water in this region is affected by fluoride that ranges from 1.5mg/l to 12.4mg/l, which is in excess to the permissible limits of 1.5mg/l as specified in the CPHEEO manual. Due to the consumption of fluoride contaminated water over a prolonged period of time, people in these two districts are known to be suffering from skeleton fluorosis, dental fluorosis, non-skeleton fluorosis manifestation and/or combinations of the above.

At present water supply is provided through various combined water supply schemes and individual power pumps. The client, Tamil Nadu Water Supply and Drainage Board has been working fervently on the prestigious Hogenakkal Water Supply and Fluorosis Mitigation

Project, which when completed will become a fifty year ‘dream come true’ project for the water starved people of this region.

The project envisages overcoming the water issues of the two districts by bringing water from river Cauvery near Hogenakkal which is located 60 and 100 km from Dharmapuri and Krishnagiri districts respectively. The state government has taken up this Rs. 1929 crore project

with the assistance of JICA (Japan International Co-Operation Agency) covering both the districts for 9500 sq.km and 8000 villages. Around 30 lakh people are expected to be benefitted from this ambitious project.

In order to facilitate prompt implementation, this project has been divided into five packages by the state government. It is matter of great pride that L&T’s Water and Effluent Treatment business is executing almost 30% of the project under package III and package V covering 4500 sq.km, 3500 villages and a population of 13.40 lakh.

Package III – consists of branch trunk main to Harur, Branch Pipelines to a length of 1405 km covering 5 town Panchayats including construction of various union reservoirs, panchayat reservoirs, sumps, overhead tanks, chlorination stations, booster

People in these two districts are

known to be suffering from

skeleton fluorosis

Overall view of the MS pipe manufacturing plant


pumping stations, instrumentation, electrical and mechanical works.

Package V – consists of trunk main from master balancing reservoir at Madam to Moongilpatti sump and then Moongilpatti sump to Krishnagiri feeder main etc., to a length of 2950 km. covering Krishnagiri Municipality, 7 town Panchayats and 2299 habitants in 5 unions including construction of various union reservoirs, panchayat reservoirs, sumps, overhead tanks, chlorination stations, booster pumping stations, instrumentation, electrical and mechanical works

Scope of work

L&T’s scope in both the packages includes 82 km pipe line work of MS pipe, 971 km of DI Pipe, 3302 km of HDPE Pipe and construction of 612 elevated reservoir, 226 ground level sump, 236 pump houses, pumping

machineries, electro mechanical works, Rechlorination etc., to provide water to 3500 villages in Krishnagiri & Dharmapuri districts.

In both the packages, the total distribution network pipe line of

around 3000 km is designed to feed water supply by gravity which entirely eliminates the need for power source. Suitably the master balancing reservoirs are located and constructed at a commanding level to take care of water supply through gravity.

The scope of work is inclusive of structural and piping design engineering. L&T secured this job amidst stiff competition by considering several value engineering proposals at the bid stage itself. Therefore, design optimization without compromising on any facilities or quality was constantly done throughout the project progress.

The project on both the packages commenced in the month of January 2011 with contract duration of 24 months and along with a marginal time extension of up to June 2013 the project was officially inaugurated

Prestigious Hogenakkal Water

Supply and Fluorosis Mitigation Project, when completed

will become a fifty year ‘dream come

true’ project for the water starved people

of this region.

Edge preparation of MS Pipe in progress


by the Honorable Chief Minister of Tamil Nadu on 29th May 2013.

Pipe Line

Mild Steel = 82 km (1500 mm dia to 700 mm dia)

Ductile Iron = 971 km (450 mm dia to 100 mm dia)

HDPE Pipe = 3302 km (315 mm dia to 63 mm dia)

Elevated Reservoirs

20 M Height = 259 nos. (10000 Ltr to 12 Lakh litre capacity)

09 M Height = 353 nos. (10000 Ltr to 30000 litre capacity)

Underground Sumps = 226 nos.

Pump Room & Re-Chlorination Building = 236 nos.

Supply & Installation of Pump Sets = 226 sets

Supply & Installation of Valves = 19545 nos.

All associated Electrical and Instrumentation works

In total, 4355 km of pipeline including 82 km of mild steel pipe from 1500 mm dia to 700 mm, 971 km of ductile iron pipe from 450 mm dia to 100 mm dia and 3302 km of HDPE pipes ranging from

315 mm dia to 63 mm dia were laid. Around 259 MBRs (Master Balancing Reservoir) of 20 m height with varying capacity of 10000 to 12 lakh liter capacity were built and 353 overhead tanks of 06 m height ranging from 10000 to 30000 liter capacity were also constructed. The scope also included construction of 226 underground sumps of various capacities.

Major Quantities

Excavation = 472415 cu.m

Shuttering = 311522 sq.m

Reinforcement = 5000 t

Concreting = 62532 cu.m

Pipe Line

MS Pipe = 82 km

DI Pipe = 971 km

HDPE Pipe = 3302 km

Considering several value engineering proposals at the bid stage itself - L&T secured this job amidst stiff

competition.

Interior view of the Common Booster Pumping Station (CBPS)


The enabling structures in the form of buildings were of 236 numbers including pump room and re-chlorination buildings. A total of 226 sets of pumps and 19545 valves were installed during the entire project. With such huge scope of works and limited schedule for execution, the planning team at L&T worked hard to execute the project from design to reality with the L&T stamp of quality.

Construction methodology

The widespread nature of the job made it impractical to set-up any batching plant for the concrete needs. Besides, one of the contract requirement stated that the only measured concrete were to be poured. In order to tackle this situation, six self-loaders were commissioned for the project. This sophisticated

machine comes along with a digital weighing batcher and can load and produce concrete with a capability to travel at a speed of 20 kmph. The usage of this innovative machine saved a lot of time and cost for the project.

The project called for more than 14000 valve chambers of different sizes at various locations. To overcome the construction problem and at the same time to set a quality standard, the project team adopted precast technology for valve chambers. Based on the load distance method, precast yards were established at 3 locations and precast chambers were constructed ensuring better quality control.

In any pipeline project, crossing of railway tracks and major roads would result in huge delays. In this project, trenchless pipe pushing method was adopted and this resulted in very quick execution and minimal hindrances to flow of traffic.

L&T established a full-fledged plant for the manufacturing of spirally welded mild steel pipes, complying

Major Structures

75 lakh liter capacity sump




07 lakh liter capacity sump cum 06 lakh liter capacity MBR

12 lakh liter capacity BPT with 25 m height

06 lakh liter capacity MBR with 20 m height = 3 nos

04 lakh liter capacity MBR with 20 m height = 3 nos

View of the precast valve chambers


with all the statutory requirements. L&T produced and rolled out 82 km of spirally welded MS pipes from 1500 mm dia to 700 mm dia with BIS certification.

Challenges

Like in any other pipeline project that traverses such long distances, the encountering of underground utilities were a very big challenge. It was impossible to avoid damages to local utilities that had no authentic records. The local administration was taken into full confidence and damages were avoided as far as possible.

Being a cross country job, the first and foremost hurdle was workmen movement and arranging for their accommodation. Activities such as shuttering, reinforcement and concreting had to be done by the same agency or at the most two agencies. Hence the workmen were trained in multi-tasking construction activities under supervision. Centralised workmen camps were organized to facilitate movement of

workmen and temporary sheds or in some cases, rented houses in the villages were arranged for enabling comfortable accommodation. In order to facilitate smooth transportation, two passenger vehicles were allotted for each zone by dividing the entire project into five zones.

The task of laying about 3300 km of HDPE pipeline called for a lot of planning and precision in execution. A daily target of 12 to 15 km was fixed and was consistently achieved with a progress of 300 km per month. Prior survey, Right Of Way clearance, and necessary permission form local bodies were arranged well in advance to enable faster completion.

The terrains of Dharmapuri and Krishnagiri districts were both very rocky and undulating. Covering about 4500 sq.km for laying pipeline was a highly challenging task. In several places throughout the pipeline alignment, controlled blasting was done to carry out excavation.

The pipeline also covered several urban areas such as markets and road junctions. Working

The task of laying about

3300 km of HDPE pipeline called for a lot of planning and precision in

execution.

View of 11kV / 3.3 kV substation

Illuminated view of 7 lakh litre capacity sump and 6 lakh litre capacity BPT


The public in general were very

supportive and extended all possible

help and support to the project

team

adjacent to live traffic and taking care of existing utilities was a big challenge. In certain densely populated areas, the entire activity of excavation, pipeline laying and back filling was done in a single day to minimize inconvenience to public. In some stretches, the project team was allowed to do pipe laying only during the night hours. Special permission from the respective district Collectors was taken in advance to carry out controlled blasting in urban areas.

Quality

y Work method statements were made for each and every activity and were approved by both the consultants and the clients.

y All material used were sourced from client approved vendors only

y All items are supplied with specific project quality assurance plan and inspected by consultants, clients and third party inspection agency

y Client appointed Project Management Consultant representatives conducted regular inspection and compliances along with L&T’s engineering staff

y L&T’s project team conducting periodic quality audits

During the execution phase, the project team was happy to note that the public in general were very supportive and extended all possible help and support to the project team to expedite the process. For the public, the completion of this project meant a lot in terms of access to quality potable water. The project was executed to the fullest satisfaction of the client and was officially inaugurated by the Honorable Chief Minister of Tamil Nadu on May 29, 2013.

V. S Sridhar Project Manager

75.2 lakh litre capacity sump and CBPS


NEW ORDERS

L&T Construction Secures AED 943.11 Mn Abu Dhabi Airport Order The Transportation Infrastructure Business of L&T Construction has won an order worth AED 943.11 Mn for the development of the prestigious Midfield Terminal Complex - an airside construction project for Abu Dhabi Airports Company PJSC, UAE.

Work on the Midfield Terminal Complex (MTC) is part of the major expansion programme of Abu Dhabi International Airport. It consists of a Midfield Terminal Building (MTB) and related airside and landside work. The MTB will serve as the new gateway to Abu Dhabi.

L&T will build concrete hardstands for aircraft parking around the new Midfield Terminal Building, including contact and remote stands. The airside works also include taxi lanes along the apron parking stands and link taxiway connections to the existing airside infrastructure with a tunnel on the airside. The major item of works for the airside include earthwork, concrete pavement, asphalt pavement with markings, drainage, general utilities, airfield ground lighting, gate services such as flood lighting, visual dock guidance system and structural works/systems for airside tunnel. The project also includes Aircraft fuel hydrant system, storm & portable water distribution line, chilled water distribution system, medium voltage distribution Sub-Stations, communication network and fire main distribution system on the major utility segments.

The Project will commence in April 2013 with a construction period of 28 months. The Airport Terminal Complex is expected to be commissioned by 2017.

`6700 Cr Western Dedicated Freight Corridor ProjectThe Railways Strategic Business Unit of L&T Construction’s Transportation Infrastructure Business has won a major order worth ` 6699.50 Crore from the Dedicated Freight Corridor Corporation of India Ltd. (DFCCIL). This prestigious order has been secured by a consortium of Larsen and Toubro Ltd and Sojitz Corp., Japan. The EPC order involves construction of 626 km of a double track corridor from Rewari in Haryana to Iqbalgarh in Gujarat, via Rajasthan, spanning three states. This is the country’s largest project awarded so far in rail sector and the first of its kind in India.

DFCCIL is a special purpose vehicle of the Indian Railways, mandated to build dedicated freight corridors. This project will be funded by Japan International Cooperation Agency

(JICA) and is part of the 1,490 km western corridor proposed between Dadri (near Delhi) and Jawaharlal Nehru Port Trust (near Mumbai).

The track will be designed for 25 MT axle load to run double stack containers dedicated for freight. Around 1.5 lacs MT of rails will be imported from Japan for this project. The scope of work includes construction of 1400 track km of railway line, 50 major & 1250 minor bridges, 20 stations along with supply of all associated equipment.

The project has been planned to be executed using completely mechanized means of track linking using the latest technology in railway construction. The project is expected to be completed in four years. The successful award of this Design and Build contract by DFCCIL will pave way for finalization of other DFCC packages which are in various stages of the bidding process.

Orders Valued `3057 CrsL&T Construction has won new orders worth ` 3057 crores across various business segments in June 2013.

The Building & Factories Business has secured orders worth `1808 crores for the construction of an office space, residential building and a hospital from customers across the country.

The Water & Renewable Energy Business has bagged orders worth ` 628 crores. A major order is from the Water Resource Department, Jharkhand for construction of the Kharkai barrage with gates and allied works including civil, mechanical, and electrical systems. Another turnkey order is from West Bengal Power Development Corporation Limited for supply of equipment, material, erection and services for plant water systems of the Sagardighi Thermal Power extension project units 3 & 4 (2x500MW). The Company also received orders for various utility development works at Gurgaon from a private developer, including an additional order on operating projects.

In the Power Transmission & Distribution Business, orders worth ` 442 crores have been received from the Delhi Metro Rail Corporation Limited for design verification, detailed engineering, manufacture, supply, installation, testing and commissioning of electrical and mechanical system including fire and hydraulic system for underground stations of Delhi Mass Rapid Transport System project phase-3. Additional orders have also been received in domestic and international markets of ongoing projects.

New orders worth ` 179 crores have been secured in Heavy Civil infrastructure and Metallurgical & Material Handling Businesses from various ongoing projects.


PROJECT NEWS

L&T’s Solar Projects team has commissioned a 17 MW (AC) solar power plant in Phalodi, Rajasthan, in a record time of just 60 days. Since its formation, the project team has earned the reputation of commissioning solar projects within very stringent time frames. This project joins the list as the 10th such project in a row to get commissioned under the 150 day mark with earlier records set at 40 MW in 129 days and 6 MW in 80 days!

As of date, L&T has commissioned around 155 MW of solar photovoltaic (PV) power plants across various states in India. Each project executed by L&T employs different module technologies such as Thin Film / C-Si / Trackers, etc. L&T Solar is also integrating a 125MWe CSP Power Project using Compact Linear Fresnel Reflector technology in Rajasthan, which has gained the status of being Asia’s largest Solar CSP Power Project. Apart from this, the 6 MW PV Project for M/s. Sun Clean using thin film technology, has been rated as the best performing plant of the year with an average PLF of 19.10% among the other plants at Charanka Solar Park, Gujarat

L&T commissions 17 MW Solar plant in record 60 days

Today, L&T is the only pure play Indian EPC to be present in Solar PV as well as Solar CSP arena with a dedicated in-house team for Standalone CSP Plants, Solar Steam Augmentation Projects & Solar Direct Steam Application such as industrial/process heat applications. L&T is also active in the Micro-grids and Rooftop PV systems, with multiple projects across various states.

New facilities inaugurated at BIAL The NEC (New Energy Centre) and NCP (New Chiller Plant) at Bengaluru International Airport Terminal 1 Expansion Project was inaugurated on 14th May. Dr. G V K Reddy, Founder Chairman and Managing Director BIAL, Mrs. G Indira Krishna Reddy, Director BIAL and Mr. Sanjay Reddy, Chairman (GVK GROUP) inaugurated the Energy Centre by switching on DG set and the Chiller Plant by turning on the Chillers. Mr. G V K Reddy & Sanjay Reddy were accompanied by Mr. Sanjeev Gupta- Project Director BIAL-T1E, Bangalore. Mr. Reddy appreciated the site time for the new facilities.


Baggage Handling System at MIAL achieves milestone The Baggage Handling System rightly known as the ‘Back bone’ of Mumbai International Airport Project is an optimized mechanical layout designed to automatically sort 10,800 bags/hr to the destination. The system consists of 6.2 km conveyor, inline screening process as per IATA standard where all bags are tracked by Programmable Logic Control and are routed to the relevant direction as per screening decisions. Baggage sorting system verifies the processed bag status and sorts the bag to the right destination to facilitate passenger processing within set time parameters. The BHS at MIAL has achieved a major milestone on 15th April 2013 by commencing full system load test.

The full system load test of BHS was inaugurated by Mr. Karthi Gajendran, President of GVK Airport Development, in the august presence of Mr. J. Gopalakrishna Pillai, General Manager & Deputy Project Director (L&T – B&F), Mr. John Whitehead, Regional Director, BNP Associates and Mr. Oon Chong Howe, CEO of Pteris Global Ltd.

Both domestic and international baggage are handled and dispatched through common user check-in counter. The system is programmed to automatically identify bags and deliver it to its destination carousal.

Departure System:

y 14 Check-in-Row

y 200 nos. Check-in conveyor.

y Separate Line for large baggage.

y 2 Line for Transfer Baggage

y 2 Tilt tray sorter.

y 6.2 km Conveyor.

y Check-in capacity 10,800 bags /hr

y Automatic Sortation 10800 bags/hr.

y 8 No. Level-1 in line screening machine.

y 4 No. Level-3 CT class (TSA certified) in line screening machine.

y 40 no. multiplexed HBS level-2 workstation.

y 18 Make-up carousels.

y 2 no. Manual Encoding station.

y 8no. Automatic Tag reader.

y 4 No. Baggage Dimension Device.

Arrival System:

y 10 Arriving Baggage Reclaim carousel divided into International and domestic flights associated with 26 off loading and delivery conveyor.

y 10 inline custom X-ray machine.

y Separate line for oversize bag feed

11,200 cu.m Concreting in a month

Omkar Worli Sales Team has completed 11,200 cu.m concreting (Avg. Daily concrete = 431 cu.m) in the month of April’13. This is the maximum concreting achieved in a month by any residential buildings site in Mumbai Cluster.

Considering the congested site location and local issues, this is a great feat achieved by the site team. 5490 cu.m was done using the existing M1 batching plant and 5710 cu.m was done using external RMCs. All concrete pours were done with accurate front-end planning and logistics management.

This site also sets another unique record by being one of the first to implement GGBS (Ground Granulated Blast Furnace Slag) in the mix design along with temperature control by inserting ‘Thermocouplers’. The concrete pours were done in conformance to all safety standards and temperature mapping was also done for all the pours.

Tower 2 - Top Reinforcement work in progress


6 MTPA - Phase II CHP, inaugurated at Northern Coal Fields A 6 MTPA Coal Handing Plant commissioned by L&T at Amlohri for Northern Coal Field (NCL) was inaugurated on 1st May 2013, by Shri. Tapas Kumar Lahiry, Chairman cum Managing Director (NCL) in the presence of other directors from NCL. This is the first project that L&T has undertaken for Northern Coalfields Limited. During their inaugural speech, the directors appreciated and congratulated L&T’s project team, headed by Mr. B.K. Singh, Project Manager, for completing the project within the scheduled time, with high standards of quality and safety.

Amlohri OCP (Open Cast Project) located in the Singrauli District of Madhya Pradesh forms a part of Singrauli Coalfields. This project is owned and run by Northern Coalfields Limited, NCL. The existing Amlohri CHP Phase – I is having a capacity of 4 MTPA while the newly constructed Amlohri CHP Phase – II has a capacity of 6 MTPA. Both the units are expected to produce 10 MTPA of power grade coal for dispatch to various thermal power houses through Indian railway and through Merry-Go-Round of NTPC.

Godrej BKC project Tower crane erected in record time

The in-house P&M team have set a benchmark in erection of a 5 t Potain MCi 85 tower crane measuring

35 m high in just 7 hours! The length of main jib is 50 m with the counter jib measures 12.7 m in length. The erection and assembling was done with the help of 150 t telescopic mobile crane of height 55m and radius 19m. The entire process was done with precision and conformance to all safety standards due to perfect planning prior to the actual execution. A third party testing certification was also done and the client greatly appreciated the entire team on this achievement.

Record time concreting

The project team at Godrej BKC, Mumbai has done record time concreting using high volume flyash, temperature controlled concrete of M 40 grade. 2650 cu.m of concreting was done in just 25 hours using about 350 t of reinforcement. The process was ably backed by the P&M team operating through 4 RMC plants, a boom placer and two concrete pumps. The concrete was temperature controlled at 28 ± 2˚C during placing with core temperature ≤ 70˚C and differential temperature of core and surface ≤ 20˚C. Crushed ice was used to maintain the temperature of concrete within the specified limit by structural consultant. Before pouring of concrete, thermocouples was installed at three locations at three different levels viz. bottom, middle and top to check the temperature.

Vaishnavi Terraces residential project team sets benchmark in completion of Transverse Plate SlabVaishnavi terraces Bangalore site team has achieved a unique feat of 7 pours in 7 days in the month of April 2013. This feat recorded a total of 3151 cu.m with 450 cu.m/day of M40 grade, temperature controlled concrete spread over 70 hrs with 600+t of rebar scope.

The massive slab, known as transverse plate slab (1200 mm thick) with beams of 1500 mm thickness at 3rd floor level (height of 14.65 m from foundation level) acts as a raft for the upper 24 floors.

Batching plant was located 12 km away from the Project Site and challenges of peak traffic in Bangalore were mitigated with proper planning of logistics. With restricted concreting hours at site,


the entire pouring was completed between 6 a.m to 6 p.m.

The team executed the works with safe methods and ensured highest quality standards.

Kohinoor Square P&M team sets benchmark with derrick based dismantling of tower crane The Kohinoor Square P&M team set a benchmark with derrick based dismantling of Potain MC-205 tower crane from a height of 235 m using a 10 t capacity

Liebherr Derrick - 200DR 5/100. Though this method is quite common in the Middle East and other parts of the world, this is the first time in India that a tower crane has been dismantled using sophisticated derrick system which has resulted in completion of entire dismantling in less than 5 days.

Initially, the critical dismantling was planned by conventional method, (using heavy erection winches supported by structural elements and staging) considering the criticality due to restricted site logistics and façade work which was in progress. A detailed study was made by the P&M team at HQ Chennai, in consultation with CMPC and the possibility of derrick based dismantling was explored. After convincing the management on this trustworthy mechanisation, the derrick was imported from Germany and was successfully installed at a height of 218 m within 03 days in conformance to all safety standards.

Meticulous micro planning and coordination was ensured, so as to take up the process at par with international standards. The excellent cooperation from the site team helped the in-house P&M team to exhibit a flawless erection as per the plan with utmost caution in all perspectives.

With the introduction of derrick, P&M department of B&F-IC has entered a new epoch of safe and faster dismantling of tower cranes from high-rise structures. This initiative not only elevates the working standards, but also proves to be an effective solution for many such critical dismantling in the future.

Substations for Jaipur Metro inaugurated 132kV GIS Substation for JMRC Jaipur was inaugurated by Shri. Shanti Dhariwal (Hon. Minister for Urban Development & Housing) on 21st May.

Mr. Mangu Singh (MD-DMRC), Mr. N.C. Goel (CMD-JMRC), Mr. G.S. Sandhu (Additional Chief Secretary, Urban development) and other dignitaries graced the occasion.

DMRC complimented the L&T team for completing the entire works and feeding both 33kV & 25kV supply to the Depot for operation in a record time of 1 year starting from Bhoomi Pooja.


L&T commissions 100 kWp Solar Rooftop Power Plant at Tirumala Tirupati Devasthanams

L&T’s Solar Projects team has commissioned a 100kWp grid connected rooftop solar power plant at Tirumala Tirupati Devasthanams (TTD), Tirupati, Andhra Pradesh.

It was a unique privilege and a great honour for L&T to work with TTD and seek the blessings of Lord Venkateswara. The 100kWp plant was commissioned on 19th June, 2013. Mr. Subramanyam L. V. (Executive Officer, TTD) along with Mr. S. Rajavel (Executive Vice President & Head - Water & Renewable Energy IC), Mr. R. Srinivasan (Vice President & Head - Renewable Energy BU), Ms. Harshita S. Kumar (Head - Microgrid & Rooftop PV Systems) and the project team inaugurated the solar power plant.

The grid connected solar power plant will cater to the electricity needs of TTD, along with their existing wind power facility. The project has been completed in a commendable span of two and half months. This eco-friendly initiative will save more than 100 tonnes of carbon dioxide emission annually. In month of

Dan Hotel Project achieves 1600 cu.m of concreting in 28 hoursThe project team at Dan Hotel, Bangalore completed the first pour of 1600 cu.m of temperature controlled concreting within 28 hours by deploying 3 concrete pumps and 24 transit mixers. The entire activity was planned with proper logistics for the delivery of concrete from external batching plant located 10 km from the site.

The placing temperature was maintained at 24 degrees C at the time of pouring by adding ice to the water used at the batching plant. To maintain the said temperature even during the day time, continuous monitoring was

April this year, L&T Solar commissioned a 100kWp pilot Micro Grid Solar Plant in Patna, Bihar. Recently, it has also bagged the order for India’s largest Rooftop Solar PV.


done and quality was also maintained right from

the batching plant. The lowering of post concrete

temperature was achieved by curing compound

treatment followed by covering up with PVC sheets laid

over Thermocol.

Working at a depth of 16 m below ground level,

the team executed the works with safe methods and

ensured highest quality standards, which satisfied the

requirements of the international client.

CM inaugurates Hogenakkal Water Supply & Fluorosis Mitigation Project

Delhi One achieves 10,000 cu.m of concreting

The project team of Delhi One, Noida has

achieved more than 10,000 cu.m of concreting

over the last 4 months (Feb-2013 to May-

2013). This achievement was done by deploying

7 boom placers, 5 concrete pumps and 23

transit mixers. The entire activity was planned

with proper logistics for the delivery of concrete

from the external batching plant located 10 km

from the site.

Considering the congested site location and

local issues, this is considered a great feat

achieved by the site team. The concrete production

was done using the CP30 and M1 plant of

capacity 30cu.m/hr and 56 cu.m/hr respectively.

Considering the varying requirement of concrete

grades and conditions, the proper scheduling of

pours for all the 9 towers and non-towers were

harmonized with precision and targets were met

month on month.

The Address project achieves 1.5 lakh cu.m of concreting

‘The Address’ project team received a certificate of

appreciation from the client for successfully pouring

1.50 Lakh cu.m of concrete of different grades

through a single operated CP-30 Batching Plant since

March-2010.

This certificate was presented by Mr. Sanjay Shah,

General Manager -Projects along with Mr. Dipesh

Joshi, QA/QC Head of Wadhwa Group and was

received by Mr. P Dhananjaya, Project Manager

and Mr. A Sekar, Quality Manager on behalf

of the entire L&T project team. “The Address

Project” team was appreciated for maintaining an

exceptional standard deviation below 1.5N/sq.mm

in this project.

Hogenakkal Water Supply and Fluorosis Mitigation

Project was inaugurated by the Chief Minister of Tamil

Nadu Ms. J Jayalalithaa on 29th May.

The project consists of five packages and L&T’s

Water & Effluent Treatment Business executed

Package III & Package V. This includes pipeline work

- 82 km of MS Pipe, 949 km of DI Pipe, 3490 km

of HDPE Pipe and construction of 627 Elevated

reservoirs, 221 ground level sumps and 221 pump

houses, pumping machineries, electromechanical

works, re-chlorination etc., to provide water to 3396

villages in Krishnagiri, Dharmapuri and surrounding

areas.


CORPORATE

Performance for the year ended March 31, 2013 Larsen & Toubro recorded Gross Revenue of ` 61471 crore for the year ended March 31, 2013, registering an increase of 14.4% on a y-o-y basis over the corresponding previous year. International Revenue at ` 12110 crore doubled as compared to the previous year. The Gross Revenue for the quarter ended March 31, 2013 at ` 20485 crore recorded 10% growth over the corresponding quarter of the previous year, as certain sectoral bottlenecks moderated the pace of execution.

The Company successfully garnered fresh orders worth ` 88035 crore during the year 2012-13, recording a healthy y-o-y growth of 25%. The order Inflow during the quarter January-March 2013 was ` 27929 crore and recorded an impressive increase of 32%, despite challenging economic environment. International order inflow constituted 17% of the total order inflow for the year 2012-13. The major orders during the year came from Building & Factories, Power Transmission & Distribution, Transportation Infrastructure and Power sectors.

The Order Book is ` 153604 crore as at March 31, 2013. International Order Book constituted 13% of the total Order Book. Profit after Tax (PAT) for the year April-March 2013 stood at ` 4911 crore, recording an increase of 10.2% over the corresponding previous year. The Board of Directors has recommended a dividend of ` 18.50 per equity share. The Board of Directors has recommended for the approval of shareholders, the issue of bonus equity shares in the ratio of 1:2 [one bonus equity share of ` 2 each for every two equity shares of ` 2 each held].

Engineering & Construction (E&C) Segment The E&C Segment achieved Segment Revenue of ` 54378 crore for the year ended March 31, 2013 registering a y-o-y growth of 16%. International sales constituted 19% of the total revenue as compared to 10% in the corresponding previous year.

The businesses of the E&C Segment secured fresh orders of ` 79766 crore, during the year ended March 31, 2013 registering a y-o-y growth of 25% on the back of the proven track record and international forays. International orders

constituted 16% of the total order inflow of the segment during the year ended March 31, 2013. The Order Book of the Segment is ` 150346 crore as at March 31, 2013.

The EBIDTA margin of the segment is 11.5% for the year 2012-13 vis-à-vis 12.7% recorded in the previous year reflects the cost and pricing pressures prevalent in the sector.

Sad demise of Mr. V.Y. GaitondeMr. V.Y. Gaitonde, who was part of the core-team that built many milestone projects in the early days of erstwhile ECC (Engineering Construction Corporation, which was incorporated in 1944 and presently known as L&T Construction) passed away on July 2, 2013 at his residence in Chennai.

Mr. Gaitonde joined ECC in 1958 as a junior engineer and retired as Commercial Manager, EWL in 1989. In his early days, the management recognized Mr. Gaitonde’s work by sending him to Leeds, U.K., where he was trained for a year and a half in the area of construction. He closely worked with Mr. John Hover and Mr. P.H. Mortensen, the architects of the ECC and contributed a lot in building a unique discipline, integrity, culture and making the company’s name synonymous with quality.

His contribution to Bangalore Water Supply Project, Ambasamudhram Cement Plant, Bangalore Works, ECC Workshops and as a Head of Central Procurement Department is commendable.

After retirement, he along with his wife Mrs. Maya Gaitonde have been spending lot of time and energy in running a charitable NGO “Bala Mandir Kamaraj Trust”, which is serving the cause of children, especially orphans, destitute and those from the economically deprived strata for the past 63 years. Under VYGs watchful eyes and dedication, the institution has expanded its welfare activities and is providing care, protection, education, medical service, vocational training and rehabilitation for children.

He is survived by his wife and two sons. The management and staff of L&T mourn VYG’s demise and expresses heartfelt condolences to the bereaved family members.


EVENTS

PT&D IC showcases superior capabilities in GRIDTECH 2013Power Transmission and Distribution Independent Company (PT&D IC) put up an impressive stall at GRIDTECH 2013, the fourth International Exhibition cum Conference on power transmission and distribution, held at New Delhi from April 3 to 5, 2013.

L&T projected its multi-dimensional capabilities in power transmission and distribution through its 66 sqm stall displaying signature projects through eye catching LED panels. Prominent among the displays were many of India’s first’s in power transmission and distribution – 800 kV HVDC Nidhaura - Agra Transmission Line (256 Km),

1200kV Substation at Bina in Madhya Pradesh, 765 kV AIS and GIS Substation. The entire capability spectrum was presented through 10 LED panels which highlighted PT&D’s Global/Domestic footprints and milestone projects. CCD- Chennai designed the stall and supported in delivering marketing and branding collaterals.

RENERGY 2013 L&T displayed its multi-dimensional capabilities in Solar Power & Renewable Energy at RENERGY 2013, India’s most acclaimed renewable energy event which is being organised by Tamil Nadu Energy Development Agency during May 9-11, in Chennai Trade Centre.

As the largest EPC player in Indian solar power, L&T highlighted its leading position at this EXPO in a 24 sq.m stall. This year, the exhibition had over 200 companies showcasing their capabilities in solar, wind, bio-energy, waste-to-energy, energy efficiency and green buildings.

Project Qatar 2013L&T Construction and other Operating Divisions in Qatar such as Valves and Infotech, participated in Project Qatar 2013 – The 10th International Construction, Building Environmental Technology and Materials Exhibition held during May 6-9, 2013 at Doha in Qatar.

The Associated Chambers of Commerce and Industry of India (ASSOCHAM) in association with Ministry of Commerce & Industries, Government of India organized “India Pavilion” in Project Qatar 2013. India’s Ambassador – Mr. Sanjiv Arora visited L&T’s stall and appreciated the success of L&T in Qatar

Project Qatar – 2013 is a prestigious exhibition in which 2083 exhibitors from 48 countries participated in Construction, Building, Infrastructure, Utilities and Materials sectors.


Best Management Award for Hyderabad Metro Rail ProjectL&T Construction – Hyderabad Metro Rail Project was awarded the Best Management Award by Shri Danam Nagender, Honourable Minister for Labour, Employment, Training & Factories, and Industrial Training Institutes, Government of Andhra Pradesh on the occasion of May Day official Government celebrations on 1st May 2013.

Mr. C.Sankaralingam, Task Force Leader, Hyderabad Metro Rail Project along with Mr. A. Mohandas, Head – Admin & IR, Divisional Corporate and Mr. C. Vasudev, Head – Commercial Services, Hyderabad Metro Rail Project received the award.

L&T Ranks High In International Emission Disclosure RankingsL&T has been ranked first in the industrial category in India in a study conducted by the UK-based organization – Environment Investment Organization (EIO). Further, the report ranked L&T second in the industrial category among BRICS (Brazil, Russia, India, China and South Africa) countries, 12th amid BRICS 300 companies and 84th globally.

Carbon ranking is a measure of an organization’s transparency, and provides the investment community with a tool to appraise levels of disclosure. The Environmental Tracking Carbon Ranking series is a public database and includes companies based on their market size. This examines the Green House Gas (GHG) emissions and transparency of the world’s 800 largest companies.

The EIO placed firms in four categories based on their disclosure and verification mechanisms for carbon emissions. Firms in each category were then ranked in terms of their carbon intensity. L&T featured in the top category of firms whose disclosures on Green House Gas emissions met the highest criteria of being ‘Public, Complete and Independently Verified’. L&T has been consistently reporting all aspects of governance, economic, social and environmental performance as per GRI (Global Reporting Initiatives) guidelines and all reports are ‘GRI Checked A+’, demonstrating highest level of disclosure. The ranking validates L&T’s support to a low carbon economy.

Hyderabad Metro Rail Project has been providing safe work environment and the most Hygienic labour colonies for the workforce with state of art facilities of recreation, sports, house-keeping, cooking, utilities etc. An exclusive Construction Skills Training Institute (CSTI) was setup at multiple locations of Viaduct and Stations & Depot works at the Project level to empower the labour & to increase productivity by honing skills and enhancing workmanship – all these initiatives received many laurels from various internal and external stakeholders of the project. There has been a recognizable change in the living standards of our beloved workmen. The “Best Management” Award is a testimony for the continued initiatives of our Hyderabad Metro Rail Project in Labour Welfare and Empowerment.

AWARDS

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.

For the complete list of key visitors, their impressions and more information on HHL centre, please visit: - http://www.lntecc.com/homepage/common/museum.htm

Holck-Larsen CentreVisitors’ Impressions

“Amazing and fantastic..truly world-class” Senior Officials - Mr. David Joynt, Mr.Prakul Kaushiva and Dan Fetter. Canada Pension Plan Investment Board on April 18, 2013

“A very special and fascinating tour of a great company started by 2 visionaries and followed up by a dynamic team of leaders” Mr.KEITH A DIAS - Sr. Director Workplace Resources Mr.MURALI NAIDU - Senior Manager, WPR Project Management on April 23, 2013

“Very Impressive - Thank you!!” Mr.Daniel Pryar - CEO Lennox International, Mr. Jiri Kula - Managing Director & Mr. P Ravi Kumar-Head Marketing. M/s ESAB INDIA LIMITED accompanied by Mr. V K Magapu (L&T Infotech) on April 24, 2013

“Absolutely fabulous - the way the Museum has been created and been showcased by Shamala. No words to express my sincere appreciation for the splendid work” Mrs. Vijaya Lakshmi Iyer, Chairperson & Senior Officials Bank of India on July 7, 2013

“Visiting this museum has been a fascinating experience!! I don’t have words to say how overwhelmed i am by the achievements of L&T” “Thank You for hosting us and it is interesting to see how dreams can become real... Very Impressive!! ” Dr. Chithra Madhavan Author and an eminent research scholar in the fields of History and Archeology on April 8, 2013

“You have displayed great engineering in an inspirational way with great Imagineering. Congratulations L&T” Dr.Pradeep Mathur- Director & Professor of Chemistry Indian Institute of Technology-Indore on April 11, 2013

Documents

INDIA’S BUSIEST - L&T Construction Journal of L&T Construction April - June 2013 • Volume-36 • Issue-2 Six-laning of one of INDIA’S BUSIEST Highways Water project catering