in-house journal of l&t construction april - june 2012

April - June 2012 • Volume-35 • Issue-2In-house Journal of L&T Construction

FocusThe stature of L&T, as a nation builder is constantly

growing with the number of far reaching projects

that it has completed and commissioned. L&T

recently completed the construction of JIPMER Phase

2 which was open to the public by Hon’ble Prime

Minister of India, Dr.Manmohan Singhon 30th of

June 2012. After adding the speciality block for

Women and child healthcare, JIPMER has become

an important health care destination in South India

providing world-class medical care to the needy

and deserving.

Power crises has been looming large in the country

and the Central Government is taking all measures

to ensure uninterrupted power to the increasingly

power hungry states. As a major step to alleviate

the power crises, the Central Government will

very shortly start production in the 2 x 1000 MWe

Kudankulam Nuclear Power Plant which is also

India’s first light water reactor. Once commissioned,

this plant is expected to ease the power shortages

in the southern states of peninsular India. L&T has

done civil, mechanical and electrical packages in

this very significant nuclear power project.

With the emphasis laid on clean and green energy,

many state governments have started promoting

investments in solar power, the forerunners being

Gujarat and Rajasthan. Recently, L&T commissioned

India’s largest solar photo voltaic based power

plant (40 MWp) owned by Reliance Power Limited

at the Jaisalmer district of Rajasthan. With the

commissioning of this plant, L&T Construction has

installed 114MW of utility scale solar PV power

plants over the last fiscal – a benchmark in India’s

solar EPC industry.

The Kaliedoscope section, as usual, covers a

gamut of corporate events and new initiatives on

the project front.

Wish you a happy reading!

- Editor

In this issueApril - June 2012 • Volume - 35 • Issue - 2

Editor : V. S. Ramana

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

V. Eswar | Ashwin Chand | Mayura. K

Subha Anand | Shamala Nadendla

Photography : V. S. Natanavelu

Design & layout : Global Print Design, Chennai

Kudankulam India’s first large-size imported nuclear reactor project

Plant Electrical System works at Kudankulam

JIPMER Phase 2

40 MW of solar power project in just 129 days! Reliance Pokhran

Coal Handling Plant at Anpara Stage - D

Kaliedoscope

Inauguration .............................43New Orders .............................47Project News ............................49Corporate ................................. 51

315

2921

37

ECC CONCORD April - June 2012 3

Kudankulam India’s first large-size imported nuclear reactor project


Kudankulam Nuclear Power Project (KKNPP), India’s first 2 X 1000 MWe Nuclear

power project also enjoys the status of being the first Light Water Reactor constructed in India.

Being put up by NPCIL, the site was chosen way back in 1987 – 88 by the Site Selection Committee (SSC) of the Department of Atomic Energy (DAE). The SSC considered several aspects including the guidelines set by International Atomic Energy Agency (IAEA). Several factors related to nuclear safety, social, economic and environmental were considered by the committee before finalising Kudankulam.

The project is located in a low seismic area zone II as per Indian Standard of classification. The project site is free from severe cyclonic activities though it lies along the coast of Gulf of Mannar, which also provides ample water for the condenser cooling.

The Kudankulam site is also well connected by road, railways and by sea. The National Hgihway-7, broad-gauge rail head at Kanyakumari and the Tuticorin sea port located about 100km, will be used by the project authorities to transport large equipment and components to the site.

Scope of work

Of the two units being set up at Kudankulam with a gross capacity

of 1000 MWe, the reactors belong to Pressurised Water Reactor (PWR) family - the dominant type of reactors in use the world over. This type of water cooled water moderated reactor, called VVER in Russian nomenclature uses slightly enriched uranium. The Kudankulam Reactors are of Russian design and the majority of the comments are supplied from Russia.

L&T’s contribution started with the construction of Administration

Major quantities – Nuclear steam supply system

Erection of 300 t equipment : 10 nos

Erection of 100 t equipment : 26 nos

Erection of Reactor Coolant Pump (RCP) : 8nos

Erection and welding of Main Coolant Piping (MCP) : 64 joints (460 t)

Erection and welding of Critical Piping systems : 2900 t (5.99 LakhID)

Instrument tubing works (SS) : 156 km

View of Turbine Building after errection


building in the year 2000. From doing just simple civil works, L&T started executing all the complex mechanical works for labour component only as all the materials were supplied by Russian Federation. L&T also played a major role in the execution of all the mechanical packages including electrical and instrumentation works.

L&T executed the project in six separate contracts secured amidst high global competition. The package includes Reactor, Reactor Aux. building, Turbine erection, Sea Water package, Common Services packages, Electrical and Instrumentation.

KKNPP project mechanical systems can be divided into six main systems such as:

Nuclear Steam Supply system y

Safety System y

Fuel Handling systems y

Auxiliary systems y

Common service systems y

Waste management system y

Nuclear Steam Supply System

Power is generated with the help of Steam Turbine and power generation is achieved by both Primary and Secondary cycle processes. Primary

Work in progress for pressurizer errection

View of erected chlorination plant tanks


cycle consists of Reactor Pressure Vessel with four Steam Generators and Reactor Coolant Pumps interconnected by Main Coolant Piping. Heat generated in the Reactor by the fission process is transported by the coolant through Main coolant piping to the Steam Generator. Here heat is exchanged to the shell side of the Steam Generator and the coolant water is pumped back to Reactor through Reactor Coolant Pump. This is a Primary cycle and the entire process takes place within the reactor containment.

In the secondary cycle, the Steam Generator shell side water turns into steam and is transported to Turbo Generator for generating power. As this process is not directly connected to reactor this becomes the secondary process. The equipment involved for both Primary and Secondary cycles have been erected by L&T.

Safety Systems

Complete safety systems were provided to mitigate the consequences of likely accident situations. These systems actuate on the basis of signals from primary side or secondary side. All systems are provided with a redundancy of 4 X 100%. In both the reactors design care has been taken to mitigate the Loss of Coolant Accident (LOCA) situation. In KKNPP, 4 x 100% DG sets are provided as a back-up for power and in the event

of DG sets failure, 4 X 100% battery sets have been provided as a tertiary contingency measure.

In the remotest event of all the power supply to safety systems failing, the shut-off rods provided in the reactor which are held by the electromagnetic clutches will fall automatically in the absence of power which will thereby shut-off the unit. After shutdown, in order to control the residual heat, the coolant water is pumped by both active and passive emergency cooling systems. L&T has erected 12 emergency cooling system tanks each weighing 86 t.

Passive Heat Removal System

Passive Heat Removal System (PHRS) considered as major enhancing safety feature of KKNPP, was one of the firsts in the world and has

View of demineralised water plant pumps

Major Quantities

Reactor Equipments : 13175 t

Static & Rotary Equipments : 2050 t

SS / CS Piping : 3100 t

SS / CS Valves : 1180 t

Erection of Supports : 950 t

Instrument Tubing :168820 rm


been strongly etched as one of the major achievements of L&T. As per this system, it can function as heat removal system of the reactor even when there is no power supply to site (Total loss of power) and DGs are not available.

Hydrogen Recombiner – When coolant in the reactor is lost or reactor core is not cooled, the core becomes hot and at high temperature zirconium tube in the fuel assembly reacts with water and generates hydrogen. When there is presence of hydrogen more than 24% in the air, it is highly inflammable. To prevent any explosion such as that of Fukushima, there are 152 hydrogen recombiners that have been tested and installed.

Auxiliary systems

There are several systems that are provided to maintain the normal operation of the reactor such as to

maintain water chemistry of reactor coolant, provide cooling media to various heat exchangers, pumps and tanks and to maintain other related functions of reactor system. This entire auxiliary system including piping was erected successfully by L&T for KKNPP.

Fuelling handling system

During shut down refuelling of reactor which happens once a year, the spent fuel is removed from the reactor core and stored in the storage racks of fuel storage pond

View of errected sea water cooling pumps

Internal veiw of demineralised water plant


located within the containment. Fresh fuels are temporarily stored in a separate section of the fuel pond and subsequently placed into the reactor core. The refuelling machine and associated tooling carries out the operation of handling of

individual fuel assemblies and absorber assemblies within the containment. The refuelling machine with associated tools, fuel racks in the pond and new fuel storage building were erected by L&T with close tolerances to suit the stringent specifications.

Common services systems

L&T’s scope of work also included erecting all the equipment, tanks, pumps and piping required for the auxiliary systems like steam, chilled water, compressed air, fire water, De-mineralized water, hydrogen and nitrogen etc.

Waste Management system

In a nuclear power project, waste management is considered as a very important aspect and a lot of focus is given on the safe handling of all types of wastes such as solid, liquid and gases. These wastes are processed and monitored before discharge to the environment or long term storage. Solid wastes are processed, packed and stored in the storage facility while liquid waste from active systems are collected,

Cooling water piping at Pump House

View of Transport Air Lock


monitored and processed. Liquid wastes are later evaporated in special evaporators and the condensate is recycled while the wet residue is further processed and stored as solid waste. Specialized equipment such as high efficiency filters, evaporators and pumps have been erected by L&T to serve this very significant purpose. Other than the equipment required for the process, L&T has also erected three types of air locks which are the entries for the operators during the operation / shut down period.

Construction Methodology and Achievements

L&T had successfully erected over ten major equipment weighing about 300 t and had them aligned in very close tolerances inside the reactor building. The alignment of Reactor Pressure Vessel (RPV) seating’s support

ring was aligned to the accuracy of 0.1mm which is considered a remarkable achievement. Both Steam Generator (SG) and Reactor Coolant Pumps (RCP) have been aligned with an accuracy of + 0.5 mm in liner dimension between the equipment.

All the heavy equipment were erected in three stages such as:

Lifting them from the ground yand placing them on the trolley specially designed, fabricated and erected on the trolley beam

Steam generator lifted by crane for errection

Closer view of intake pump


Leading the equipment inside ythe reactor building with the help of trolley

Lifting with help of polar crane yand erected in location.

Reactor pressure vessel was lifted and placed over the inspection cavity in a

horizontal position. After changing the hooking arrangement and position, RPV was made vertical, again lifted and lowered in the reactor cavity with the help of polar crane.

In the case of Steam Generator (SG), the equipment was lifted horizontally and positioned at a slanting position

of 600 to accommodate the length of the SG. The SG was lowered completely through the hatch opening and tilted horizontally. After nearing the location, it was placed on the saddle/rollers and aligned to the required position.

Reactor Coolant Pump casing was placed in position with the help of 650 t crane before the erection of the dome and after completion of the dome, the internal parts of the pump and rollers were also erected and aligned to perfection.

TRANSPORT AIR LOCK (TAL)WEIGHT : 280 t.

DIMENSION : DIA 8.95 m X 13.21 m in length.

There are three air locks available to provide access to the reactor building. During operation the air locks will

View of piping in Chiller plant

View of Chiller plant building


be in a closed position and help to maintain negative pressure in the reactor building. One of the openings is Transport Air lock (TAL) which has provision of rail arrangement. Any shifting of heavy materials will be taken inside with help of trolley mounted on the rail. The fuel for powering the reactor also will be transported through this air lock only. TAL is a huge barrel with rail arrangement and having two doors for both inner and outer containment walls.

During the period of construction, L&T has erected temporary trolley beams with trolley of 400 t capacity. This trolley was dismantled after erecting all heavy equipment’s. The TAL was a massive structure with a large diameter. Due to the sheer massiveness, logistics to the site location was real challenge. TAL was shifted in five parts from Russia and the erection was done in three parts after completing the assembly at site.

The assembly was done at ground level in two parts. After completion of ground assembly, with LR650 DEMAG crane the Inner section/adaptor section assembly weighing 60 t was lifted and rested over the fabricated saddle support mounted over rail arrangements specially

erected for shifting the assembled section inside reactor building. After moving the inner/adaptor section, central/outer assembly section, the next assembly of outer gate weighing 123 t was lifted and placed over the fabricated saddle support and shifted to location.

Reactor components during reactor assembly

View of Compressor House


Once at location the adaptor section and central section were aligned, welding and NDT (UT) was done. After completion of welding total assembly was aligned with help of 96 wedges in inner containment wall embedded parts. Alignment was done using optical instrument with an accuracy of 1mm. Locking and sequential welding of wedges with inner section and I/C wall EP were subsequently completed. Necessary arresting arrangements were made to avoid disturbing of alignment. After completion of assembly, permanent rail erection was done inside the TAL with bellow supports. Rail alignment was done with an accuracy of 0.5mm. Before erection of inner gate, sector plate erection and welding with I/C wall EP was done and leak test at a pressure of 0.3MPA was carried out. Inner gate weighing 51 t was erected inside the reactor building by proving support beam and resting the inner

slide gate over the beam. The gate is provided with hydraulic arrangement for opening and closing. The gates are later sealed and leak test was carried out at a pressure of 0.25MPA by hydraulic drive station erected at +29 m.

Main Coolant Piping

In reactor construction, Main Coolant Piping is considered one of the most challenging works, other than heavy equipment erection. The main coolant piping (MCP) has four quadrants connected to reactor pressure vessel (RPV) assembly; steam generator (SG) and reactor coolant pump (RCP).

The piping is used to recirculate ythe primary coolant thereby removing heat from the reactor and transport the same to steam generator

Pipeline is made from low alloy ysteel having outside diameter

of 990mm and 70mm wall thickness, clad inside with austenitic stainless steel

The pipes are supplied in pre- yfabricated piping spool

The total circuit involves 32 weld yjoints per unit

Total weight of the piping is yabout 230 t

MCP system is designed for a ypressure of 176 kg/cm2 and temperature of 350 deg. C

The Main Coolant Pipe (MCP) supplied in spools was cut to the exact lengths based on the physical dimension between the nozzles of RPV, SG and RCP. For considering the spool length, separate mockup was conducted by welding two similar (70mm) thickness pieces to construe the shrinkage. After the measurement, the excess length of the spool was cut and bevelled by using bevelling m/c. MCP joint fit up

Erected view of Auxiliary Boiler


was given a gap of 1.5 mm to 2.0 mm accuracy. Even a minor error in any of the operation would lead to spool rejection and alternate spool was not available. L&T took up the MCP welding task as a challenge to prove to the Russian

Specialists the capability of an Indian construction major. Initially the Russian team was skeptical about an Indian team doing the MCP welding, but later on seeing the precision with which L&T did the job, the Russian specialist team was highly satisfied. This aspect made KKNPP a prestigious project for both L&T and NPCIL as well.

Tube welding

The scope of the project involved tubing to a tune of about 156 km. L&T has already completed close to 110 km of tubing work that involved tube welding of 60,000

joints which was carried out using Auto tube welding machine with radiography quality.

Sea Water systemThe scope of works under this package includes mechanical

cleaning devices-Coarse Screens, Secondary Screens, including repair slide gates and embedded parts in Main pump house, Essential load pump house, Intake structure, fish protection facility, siphon wells etc.

Components cooling system

Closer view of sea water pump


Common Services SystemHandling, Transportation, Pre-Fabrication, Welding, Erection, Inspection, Testing of Indoor and Outdoor piping and equipment of common service systems for KKNPP Unit-I and II.

Auxiliary Steam system yStarting Air / Compressed Air ySystemsDiesel Oil Systems yOil Systems Acid receipt yand preparation system and Hydrogen feed systems

Refrigerant/Chilled water supply ysystemsDemineralization plant systems yFirefighting systems yDistilled water systems yDecontamination solution ypreparation systemsMakeup water treatment ysystemsSludge removal systems yWater and sewerage systems y

Turbine systemOne of the major work involved the erection, alignment and testing of

1000 MW Steam condensing Turbine of Four cylinder configuration (1HPC and 3LPC) with rotation speeds of 3000 rpm. Total length of the turbine without generator is 40.65 m. The entire operation was carried out by the approved erection procedures, QAPs, safety procedures which were in conformance to Russian Codes and Standards.

A team of 120 engineers and 3000 workmen worked with dedication to provide the nation one of the world’s most advanced and safe Nuclear Power plant which is expected to get commissioned very shortly. Once commissioned, this unit is expected to alleviate the power crises faced by the southern states of peninsular India. Following the successful commissioning of KKNP Unit 1 and 2, L&T has presently started its work on Unit 3 and 4 with packages on civil works.

N.P. Varadharajan Project Manager

View of the first-of its-kind Passive Heat Removal System above the reactor building

View of demineralised water storage tanks


Plant Electrical System works at

Kudankulam


Apart from doing the civil and mechanical packages at the 2 x 1000 MWe

Kudankulam nuclear power plant, L&T is also involved in the main plant electrical system works. Once completed and with all the 6 units fully operational, KKNPP is poised to be the largest nuclear power complex in India.

Power output system

The electrical power generated by the turbine generators at 24 kV, three phase and 50Hz is stepped up to 400kV by the generator transformer and is evacuated through four 400kV Transmission lines.

For start-up source of power to auxiliaries of the plant, KKNPP is connected to Tuticorin, SR Pudur and Kayathar through 230kV lines. 400kV and 230kV lines are connected through 315MVA interconnecting transformers.

Major components of the power output system for KKNPP

24kV, 1000MW generator y

24kV, 31.5KA Isolated Phase yBus duct (IPDB)

24kV, 28KA generator circuit ybreaker (GCB)

3 x 417 MVA, 24/400kV ygenerator transformer (GT)

400kV, 2000A gas insulated bus yduct (GIDB)

400kV gas insulated switchgear y(GIS)

400kV transmission lines y

315 MVA, 400kV/230kV yinterconnecting transformer (ICT)

230kV gas insulated switchgear y(GIS)

230kV transmission lines y

1 phase 27 MVA shunt reactors y

Scope of works

A). Design, Supply, Erection, Testing & Pre-Commissioning of

1) 400 kV, 230 kV Outdoor Switchyards : 2 lots

B). Installation, Testing & Pre-Commissioning of

1. 24kV, 28000A SF6 Generator Circuit Breakers : 2 nos

2. 420/24 kV 417MVA Generator Transformers : 7 nos

3. 24kV 31500A single phase Isolated Phase Bus duct : 1236 m

4. 315MVA 400/230/33kV interconnecting Transformer : 2 nos

5. 63/31.5-31.5MVA,24/6.3/6.3kV UAT/RAT/CSAT : 9 nos

6. 27MVA, 420kV Single phase Shunt reactors : 6 nos

7. 400kV 3150/2000A Single phase SF6 bus duct : 3,980 m

8. 230kV,2000A single phase SF6 bus duct : 1,800 m

9. 6kV 6.3MW Diesel Generator Sets : 10

10. 6kV 3150A Isolated phase bus duct : 2,567 m

11. 6kV 3150/1600A Switchgear Panel : 492 nos

12. 6kV/0.4kV 1.0MVA/0.4MVA Dry type Aux. Transformer : 113 nos

13. LV Switchgears (MCC/ACDB/DCDB) : 2,113nos

14. Cable Tray, Supports & Steel Structures : 5,705 t

15. Cables ( HV/LV/C&I ) : 12,546 km

16. HT / LT / C&I – Termination : 3,90,800nos

17. Lighting fixtures : 47,500nos

18. Indoor/Outdoor earthing for entire main plant With (40/25 x4 mm G.I.Flat / 70sq.mm Cu. condutor) : 298 km

220kV Gas Insulated Substation


Auxiliary Power Supply System

During normal plant operation, station auxiliary power is drawn from the main generator by tapping-off from 24kV bus duct through the 63MVA UATS (Unit Auxiliary Transformers). For start-up as well as for normal shutdown of both units of plant, station auxiliary power is drawn from the 24kV/400kV network through generator transformer and unit auxiliary transformers with the GCB (Generator Circuit Breaker) open.

The main function of the auxiliary power system is to ensure the availability of sufficient power supply to the auxiliary system equipment during all modes of plant operation such as normal plant operation, shutting down the reactor, maintaining the

reactor in safe shut-down state, containment isolation, reactor core cooling, preventing significant release of radioactive material to the environment and any other necessary function.

The reserve power supply is derived from 230kV grid through 230/6.3-6.3kV RATS (Reserve Auxiliary Transformers) and is used as backup power during non-availability of power supply from the station through UATS.

View of 6 kV Switch Gear

400 kV Gas Insulated Substation


The common station auxiliary power supply feeding the common station auxiliary loads is derived from 230kV grid through 230kV/6.3-6.3kV CSATS (Common Station Auxiliary Power Supply Transformers) and is backed up by the RATS.

The system mainly consists of 6kV, 0.38kV and 220 V/110V DC power supply sources to supply to the unit auxiliary loads and common station auxiliary loads.

Auxiliary power supply system

Normal auxiliary power supply yfor each unit system including common station auxiliary supply system for the plant

Reliable auxiliary power supply yof normal operation for each plant

Emergency auxiliary power ysupplies system for safety systems for each unit

Classification of auxiliary power supplies

Depending on the degree of reliability for requirement of safety, the power supplies are classified into three groups

The power supply to the plant auxiliary loads normally required under all modes of plant operation but which can tolerate prolonged

interruption in the power supply, without affecting the safety of the plant, and do not require obligatory availability of power supply even after the actuation of the reactor trip system is called the group-3 power supply. These are fed from 6kV, 380V and 220V AC, 50Hz supply derived from UATS, RATS or CSAT.

AC supply to the loads, which can tolerate short interruption for a time defined by the conditions without affecting safety of the reactor, under all modes of the plant operation, including the condition of loss of supply from all off-site sources, is called the group-2 loads. These are supplied from 6kV, 380V and 220V AC, 50hz supplies normally derived from group-3 power supply and whose back up source of power is from DG sets.

Loads that require uninterruptible power supply are classified as group-1 class. These can be interruptible but not for more than 20s.

These are supplied from 220V DC, 380V and 220V AC power supplies normally derived from group-3 or group-2 power supply sources and whose back up source of power is from the battery banks.

GT-1φ Zaporozh Transformer - (417 MVA 24/400kV) (Ukraine)

Laying of HT/LT/C&I cables


Major components of auxiliary power supply system

63 MVA, 24/6.3-6.3kv UAT y

63 MVA, 230/6.3-6.3KV RATS y

230/6.3-6.3kV CSAT y

6.3 MW, 6kV DG y

6kv switch gear y

1000 kVA & 400kVA, 6/0.4kV yand 6/0.433kV auxiliary transformers

0.38kV and 0.415 kV yswitchgear/ MCCs

Rectifiers y

220V DC & 110V DC batteries y

Inverters y

220V DC distribution boards y

220V/380V AC distribution yboards

110V DC distribution boards y

HV/LV/C&I - Cabling y

Hermetically sealed Cable ypenetrations

Major Quantities

220 kV Outdoor Switchyard –EPC (L&T) : 1 lot

220 kV GIS of Make Elagaz Konversia- Russia ( 9 bays in Double main Bus with bus coupler scheme) : 1 lot

6kV 3150A IPBD : 2597 m

400 kV Outdoor Switchyard–EPC (L&T) : 1 lot

400kV GIS of Make-VAtech – France (12 bays in one and a half breaker scheme) : 1 lot

400 kV/3150A GIBD connecting the GT & GIS ( VATech-France) : 3980 m

220 kV GIBD connecting the ICT to 220 kV System. (CGIT-USA) : 1815 m

6kV 6.3MW Diesel Generator Set : 6 sets

417 MVA 24/ 400 kV Generator Transformer : 7nos

24kV, 31500/20000A IPBD : 1236 m

Cabling for Unit-1& common : 6500 km

Lighting system for Unit-1 & common entirely commissioned : 1 lot

Cabling for Unit-2 : 5500 km

6.3 MW - 6kV Diesel Generator


Principles of control, monitoring and relay protection system

During operation, a system is understood as a set of devices of relay protection, control and monitoring of the electrical equipment, structurally and functionally involved. At KKNPP, independent system of control, monitoring and relay protection system are provided for many of the systems.

Challenges faced

In the year 2007, two single phase generator transformer of capacity 417MVA was received in a damaged condition due to transit. Having approaching many

Indian transformer manufacturing companies for rectification of the damage, officials at KKNPP could find nobody to take up the challenge. The main reason was that it was not possible to make a factory setup and testing facility at the site while it was even more difficult to transport the transformer to any manufacturing unit. Under this situation, the client approached the PT&D IC of L&T Construction to rectify the damage. L&T took it up as a challenge, had dismantled the entire parts of the transformer, rectified, re-assembled and Tested it without compromising the Russian manufacturer’s quality and safety standards. This initiative by L&T was highly appreciated by the Russian delegates.

The L&T project team faced a lot of interface and design issues while doing the huge quantities of cables and cable trays. This was due to the hindrances with other mechanical piping/HVAC systems. In order to mitigate this issue, on the client’s concurrence, L&T engaged its in-house engineering team to clear customer’s design related constraints especially in the Reactor and Turbine buildings. L&T has now successfully completed the entire cable metal structure and huge volume of cabling works of about 6500 km in unit-1 and common areas, while unit-2 is under progress. This proactive support from L&T was highly appreciated by the client.

Future bright

Going in line with its nation building commitment, L&T has reaffirmed its leadership position strongly as the only construction company in India that can mobilize massive resources within a short time period to complete any complex project. With its rich experience at Kudankulam, L&T has become the 1st company in India that has the qualification in the erection of 1000 MWe Nuclear power plant electrical equipment. This experience will certainly help L&T gain a strong foothold in the nascent nuclear field in the coming years, and play a nation building role yet again in India’s ambitious nuclear development program 2032.

G. Gurujanarthan Project Manager

220/6.3, 6.3 kV 63 MVA Reserve Auxiliary Transformers


JIPMER

Phase 2


Located at Puducherry, Jawaharlal Institute of Postgraduate Medical Education

& Research (JIPMER) is one of the top five medical schools in India. Being a Central Government of India funded institute with autonomy to run its internal administration, JIPMER is both an educational institute that imparts undergraduate and postgraduate medical training and a working hospital that provides inexpensive medical care to a large number of patients. JIPMER is also a tertiary care referral hospital that is under the direct administrative control of Directorate General of Health Services (DGHS), Ministry of Health and Family Welfare, Government of India.

Spread over 195 acres, JIPMER, is a residential medical institution with about 200 faculty and 360 resident physicians and over

3,000 nursing, administrative and support staff. Every year it admits 100 undergraduate students and 75 postgraduate students. With a view to increasing capacity,

especially in the areas of women and child care, JIPMER initiated Phase II which involved the setting up of a teaching block, 400 bed Women and Children Hospital,

Building DescriptionNo. of

Storey’sBldg. Height

M

Women & Children Hospital B+G+4 22.9

Teaching Block G+4 22.6

Ladies Hostel G+3 13.6

Resident Doctor’s Hostel 1 G+5 20.6

Resident Doctor’s Hostel-2 G+5 20.6

Lady Doctor’s Hostel G+4 15.9

UG Hostel Boys / Girls G+5 22.8

Sr. Resident Dr’s Quarters G+3 13.6

Common Facility G+1 9.7

Service Building - (Sub Station-1, UG Sump & Pump Room)

B+G

Substation -2 G

Total Area

View of Teaching Block


Hostel Complex and augmentation of existing specialties.

Scope of works

The scope consists of a multi-specialty women and children hospital consisting of 400 beds, equipped with modern gadgets with a mission to provide world-class health care services efficiently to the needy.

Construction methodology

Temperature controlled concreting was done in LINAC (Linear Accelerator) radiation room at the Regional Cancer Center Block.

During the concreting process, Thermocouple sensor was used for measuring the internal concrete temperature and for continuous monitoring to ensure quality. While doing the structure for LINAC, shuttering insulated with 40mm

ActivityTotal Scope

UOM

Shuttering 2,16,818

sq.m

Reinforcement 5,288 t

PCC 2,400 cu.m

RCC 37,421 cu.m

Backfilling 60,300 cu.m

Brickwork 18,110 cu.m

Plastering 2,70,000 sq.m

Flooring 71,785 sq.m

View of Lecture Hall in Teaching Block

View of a Demonstration room in Teaching block


thickness thermocole used to control the heat of hydration in concrete.

Unique shuttering arrangement was planned and implemented for concreting the intersection

area between column and beam. The implementation of this methodology ensured honeycomb free finishes on the beams and columns in all blocks.

During the course of the project,

there was a crisis in the supply of river sand. The project team sought an alternative of using crusher sand for the masonry works. This proposal was submitted to client and after subsequent approval, was implemented successfully.

The project team implemented SPICE (Site Productivity Improvement and Construction Excellence) for all activities such as shuttering, reinforcement, concrete and finishes which greatly increased labour productivity.

Challenges faced

Logistics

All the medical equipment in the women and children’s hospital, were to be imported from various countries such as USA, Switzerland, Germany, Austria etc. Shipment of equipment was

View of Disection Hall in Teaching Block

View of Super Speciality block completed under Phase 1


both airlifted as well as through waterways. In order to ensure timely receipt (after completion of structures) of the equipment precise planning was done and the orders were executed through Indian representative. On arrival, each equipment was verified and approved by JIPMER technical committee, following which it was commissioned.

Due to delay in receiving the environmental statutory approval from Personal Protective Equipment, the work front suffered at Women and Children Hospital for over three months. Accordingly appropriate modifications in planning were implemented and manpower was increased along with additional material deployment to overcome the delay in time.

Thane cyclone

The project faced a major natural calamity in the form of Thane cyclone which hit Puducherry on 30th of

December 2011. This strong cyclone rendered heavy damages to places in and around the project site. L&T project team with its spirited efforts worked tirelessly as a team and

View of Histology Lab in Teaching Block

Interior view of Women’s and Children Hospital


cleared the project site within three days to make it ready for progress. Partnering with JIPMER, L&T also provided food and potable water for the workmen during the cyclone affected period.

Proximity to Phase I

The proximity of phase-2 from Phase -1 is very close. The challenges of undertaking construction activities close to a fully functional hospital and medical institution were many.

In order to fully minimise the possible inconvenience to public in JIPMER Phase I, the phase II area was fully isolated and cordoned off. The safety team were also very vigilant about the construction

View of LINAC Radiation Room

An Overall view of Hostel Complex


activities to ensure safety of public and workmen.

Power availability

During the initial stages of the project, there was no power

supply provided for commencing the construction activities. In order to prevent wastage of time, the project team initiated activities using additional DG without causing any delay in schedule.

Service & Utility lines

During initial excavation for foundations, the project encountered numerous underground service and utility lines which were meant for highly sophisticated medical

View of Massive Attrium in Teaching Block


infrastructure and gadgets. The project engineers carefully carried out construction work without causing any damages to these lines.

LaurelsBased o y n the quality of construction, housekeeping, safety and environment consciousness, etc., the client presented a “Customer Satisfaction” report. The director of JIPMER also personally lauded the initiatives and professional practices followed by L&T.JIPMER phase II project had ya well-planned and properly maintained workmen colony which drew a lot of appreciation from the client.L&T received a safety certificate yfor achieving 10 million safe manhours from JIPMER.L&T actively partnered with JIPMER yfor corporate social responsibility programs such as blood donation camps and world environmental day celebrations.

S. V. Narayanan Project Manager

Another view of Hostel Complex

JIPMER Hospital (Phase II) constructed by L&T at Puducherry was inaugurated by Hon’ble Prime Minister of India Dr. Manmohan Singh on June 30, 2012. L&T designed and built this 400 Bed Women and Children’s Hospital,

Teaching Block and Hostel Complex including supplying and commissioning of medical equipment. JIMPER Phase 1, also built by L&T is one of the leading hospitals in the south providing quality healthcare solutions to the public.

JIPMER Phase 2 inaugurated by Dr. Manmohan Singh


40 MW of solar power in 129 days!

Reliance PokhranIndia’s largest solar photo voltaic based power plant


View of 33 kV Transmission Line at 40 MW Reliance solar project, Pokhran

Pokhran, a non-descript village in the arid regions of Rajasthan has been permanently etched

in the world map following India’s testing of its nuclear prowess. Once considered a dry and blazing desert region with very limited scope for economic development, this place is now gaining prominence for its geographical advantages of offering itself excellently for solar farms of very large scale.

Dhursar, a village located in the country’s largest but very thinly populated district of Jaislamer is only 25 km from Pokhran. This village has been identified by Reliance for locating a 40MW solar power plant. Dhursar was chosen based on the good levels of heat irradiation suitable for generating the highest possible amount of solar power. The geographical location suits Solar Power plants also due to the ready and easy availability of ample space.

L&T was awarded the construction of 40 MW solar power plant by Dahanu Solar Power Pvt. Ltd. (DSPPL), a 100% subsidiary of Reliance Power Limited. The job includes design, engineering, manufacturing, procurement, supply, erection, testing & commissioning of 40MW solar power plant including associated civil and electrical materials and equipment along with necessary works for evacuating power to the utility grid.

Scope of works

L&T, an industry leader in providing comprehensive and cutting edge solutions in the solar industry is giving EPC solution to DSPPL with the following scope of works:

1. Power generation area (Direct current Solar Power)

Geo-survey, leveling & foundation works

Structure installation works

Photo voltaic module installation works

DC cabling works from modules to junction boxes to the inverters

Complete earthing works

2. AC Power Evacuation scheme

Inverter rooms supplied and erected with all necessary electrical panels like LT panels, Auxiliary transformer, HT panels, Load break switch, Distribution boards, Bus ducts, etc including the necessary AC cabling works.

Major Quantities

Total area covered : 260 acres

Galvanised Steel structures : 7500 t

Solar PV modules : 5 lakh +

DC solar graded cable : 1200 km


Step up Power Transformers installation works

Control room to collect the power from the inverters/ Power rooms and export the power through transmission lines

3. Transmission Line works

To evacuate 33 kV power from the Control room to a 220 kV Switchyard with a line length of 5 kms and also inclusive of H pole terminations and associated protection schemes.

4. Data communication system

Implemented SCADA systems for tracking the main electrical parameters of the plant the controlling mechanism to operate remotely from the control room.

Weather station installation

works are also a part of the SCADA control.

5. General Civil cum Infrastructure works

Internal roads works

Storm water drain works

Civil works for foundation of inverter rooms and control rooms

Prefab installation works

Module cleaning works with water tanks/sumps and pipeline.

View of Solar PV panels at 20 MW Kiran Energy, Patan

Metallic Driven Pile works at Pokhran achieving an average rate of 240 stubs per day / machine


25 MW project at Charanka - Gujarat

Project: 25MW Solar Photo-Voltaic Power Project, Charanka. For Sun Edison

Location: Charanka. Patan, Gujarat The site falls under the hotspots of India receiving 5KWh/m2/day.

Land Area: 123 acres

Nature of Job: Engineering, Procurement, Construction, Testing & commissioning of the solar PV power plant

Scope of work

Design, documentation, procurement and levelling of ground - around 123 acre land including tree cutting, grading and compaction. Control room, road works, fencing and drain works

DC scope of work (25 MW)

Foundation (20874 nos. including ramming yand concrete foundation)

Structure erection (1491 nos. including hot yrolled and cold formed structures)

Module mounting (89460 nos. comprising yCHINT and Trina Solar Modules)

DC cabling (approx. 505 km comprising 4 ysq.mm, 10sq.mm and 120 sq.mm cable)

Inverter room

Foundation (8 foundations per inverter room) y

Plinth Beam, Cable Trench and Prefab Structure y

Panel Erection ( 2 LT panel and 3HT panel / y1Load Break Switch)

Installation of Inverters (Total of 45 Inverters) y

Installation of Inverter Duty Transformer (12 ynos in total)

Cabling & Termination y

SwitchyardInstallation of Power Transformer (2 nos) y

Cabling & Termination (Approx. LT power cable y– 570 m, LT control cable – 6800 m)

Testing & Commissioning y

10 MW project at Dhama - Gujarat

Project:10 MWp Millenium PV power Plant project based on Ideematec tracker technology for Sun Edison Energy India Pvt. Ltd.

Location: Dhama in Surendranagar district of Gujarat

Land Area: 70 acres

Nature of Job: Engineering, Procurement, Construction, Testing & commissioning of the solar PV power plant

Scope of work

Civil Works

Includes pile foundation of trackers, inverter room, control room, switch yard, main drainage, plant internal road and fencing was the major civil works.

Structural Work

Ideematec tracker technology was the major structural work involved. These structures involved movement of the entire structure member along 1 vertical tube axis and hence involved high level of erection practice to achieve proper balancing. The structural members were supplied by L&T other than the motors.

Electrical Work

Major work involved DC cabling, AC cabling and communication cabling for the tracker technology in solar field. The other major electrical work was the development of 66kV

substation facility.

Other major solar power projects done by L&T


Construction Methodology

Foundation

The foundation works involved ramming of stubs into the ground to a depth of 1.3 m. A group of eight stubs were clubbed to form a single structure which accommodated about 60 modules (15 modules in one row comprising 4 rows). The scope called for 70,000 stubs to be rammed within a very short period. Since the progress of all other activity depended on the foundation, L&T mobilized about 10 special ramming machines and achieved a whopping rate of 2000 stub ramming per day.

Structure

The project schedule called for erecting of 180 structures per day. With each structure weighing about 800 kg, the project team faced a target of having to erect

7000 t of structure per day, which was a staggering demand. Through swift mobilisation of workforce from local villages under subcontractors, this demanding task was achieved as per schedule. During the progress of the project, L&T’s design team

came out with cold form structure which were not only weighing lesser (540 kg) but also had increased productivity and better finish. On confirmation, fabrication started in quick succession and 50% of the structures were arranged from different sources all over India.

PV Area,40 MW Reliance project, Pokhran

LT Panels in Inverter Room,40 MW Reliance project Pokhran


Conduiting of DC cables in PV area, 40 MW Relaince project, Pokhran

220kV Switchyard - 40MW Reliance project, Pokhran

Modules

The project timelines forced the erection or installation of 14000 module per day as there were only 100 days for completion. The scope also included DC cabling works which had a target of over 45 km per day. Through the implementation of cable pulling pits and HDPE conduits, this challenge was mitigated.

Transmission Line

The commissioning of 5 km of 33 kV double circuit transmission line right from the project site without obstruction to modules was also challenging. 29 km of transmission line conductor was stringed to the transmission tower which was 30 m in height and weighing about 80 t including all accessories.

Resource

Since most of the activities were carried out in tandem, there was a huge demand for manpower. During the peak period of operations, the project site had about 1000 workmen

on the site. This demand was met by employing local youth which in turn gave a fillip to the earlier backward and rural economy.

To ensure timely receipt of material, GPS system based


trucks were only used and were monitored on a frequent basis. This data provided adequate logistic planning to formulate the unloading procedures at various locations within the 260 acre site. High capacity hydra cranes were stationed at various blocks of the solar field area to enable easy unloading.

Challenges

Over 2.4 lakh units of power was expected to be generated out of the 40 MW plant. Hence any delay of commissioning would have caused generation losses to the client. Through its meticulous planning and seamless implementation, L&T had successfully met these challenges head-on.

Changes of the design drawings were forced at an advanced stage of design due to the ambiguity issues over finalization of the site layout (2 distinct boundaries).

25MW Sun Edison Project, Charanka, Patan

L&T Construction Commissions India’s Largest Solar PV Power Plant

L&T Construction has commissioned India’s largest solar photo voltaic based power plant (40 MWp) owned by Reliance Power Limited at Dhursar Village, Jaisalmer district of Rajasthan. As the largest EPC player in solar power, L&T Construction executed the solar power plant from concept (including detailed design) to commissioning in 129 days. With the commissioning of this plant, L&T Construction has installed 114MW of utility scale solar PV power plants over the last fiscal – a benchmark in India’s solar EPC industry.

The solar PV power plant, equipped to supply more than 70 million units of clean and green energy to 75,000 households, was commissioned in the presence of Mr.Farooq Abdullah, Minister for New and Renewable Energy, Mr. Ashok Gehlot, Chief

Minister of Rajasthan, Mr.Jitendra Singh, Energy Minister, Mr. Anil Dhirubhai Ambani, Chairman of Reliance Power and senior officials from L&T. The clean energy generated by the plant is expected to displace nearly 70,000 t of CO2 annually.

The Solar PV power plant, which comprises more than 5,00,000 high output generating thin film technology based Solar PV modules and thirteen 3.5 MVA power transformers to generate 40MWp, is spread across 350 acres. The thin film Solar PV modules for the project were procured by Reliance; while L&T’s scope of work included complete design, engineering, procurement and construction including a 5 km 33 kV double circuit transmission line.


The project covered a total area of 260 acres, therefore, 7500t of galvanized steel structures were used to accommodate and support the Cadmium telluride technology based thin film Solar PV Modules that numbered over 5 lakhs.

Almost all the cabling was done underground in trenches and there was almost 1200 km of DC Solar graded cables apart from drain crossing, communication cable crossing, HT power cable crossing and Hume pipe crossings. Identifying these underground utility crossings was a major challenge.

The project suffered frequent hindrances by local people for want of employment and other demands. All these hindrances delayed the work activities. L&T had extended all

possible support by employing local youth as workmen.

The project site boundary marking for the 260 acre area was changed after project initiation. This forced the project team to re-design the structure/module placing. This also had a bearing on procurement of the cables apart from their routing which also had to be revised.

The project site being an arid region, had dusty terrain which was not in a position to bear heavy loads of trailers that carried solar module pallets. One of the first priorities for the project team was to lay internal roads to enable smooth movement of containers.

The earlier piling design was not feasible at site as there were

frequent breakage of drilling bits of the pneumatic piling machines. This was immediately changed to a lesser dia pile which was designed to run deeper. This methodology provided the leverage of mobilizing more machines and achieving piles in a quicker time frame.

The scope for periphery fencing of plant boundary was with the client and this work was delayed. During the initial period of the project, the project team had to increase security systems considerably as there was a lot of pilferage and theft issues.

Rajiv Kumar Cluster Project Manager

View of project site with a section of border fencing of 20 MW Kiran Energy, Patan


Coal Handling Plant at

Anpara Stage - D


Uttar Pradesh Rajya Vidyut Utpadan Nigam Limited (UPRVUNL) is a wholly

owned state thermal power utility with a present generating capacity of 4277 MW, operating 5 Thermal Power Stations within the state of Uttar Pradesh. The company is fully poised to contribute further towards the nation’s power generation and is in the process of adding 1750 MW capacity to its existing fleet by the year 2013.

As part of its ongoing capacity addition plans, UPRVUNL is setting up a thermal power plant near the Anpara village at Sonebhadra District of Uttar Pradesh. Located 190 km from Varanasi, at the coal pit head of NCL at NH-51, the project site is an abandoned ash disposal area of the existing Anpara thermal power project. This project site was identified for locating the 2X500 MW units of Anpara stage-D.

Scope of work

L&T was awarded UPRVUNL’s Coal Handling Plant (CHP) Package for 2x500 MW Anpara Thermal

Power Project, stage ‘D’. The scope of work includes design, engineering, procurement, civil, structural, equipment installation,

Name of the Equipment/Structure Quantity Specification

RCC Track Hopper 1 No. 210 m long, 3500 t capacity

Paddle Feeder (L&T make) 4 Nos 1240 TPH

Crusher (L&T make) 4 Nos 907.5 TPH (Ring granulator type)

Reversible stacker cum re-claimer (L&T make)

2 Nos 1650 TPH

Travelling Trippers (L&T make)

4 Nos 1650 TPH

Coal Conveyors 28 Nos 1650 TPH

Crusher House 1 No. 34mX35mX42m, 7 RCC Floors

Transfer Points/ Drive House

6 Nos Up to 69 m Height

MCC Building 3 Nos

Pump House 1 No.

Pent House 2 Nos

Under Ground RCC Tunnels

3 Nos

Structural erection getting completed in a section of CHP at Anpara


commissioning and performance guarantee test of 1650 TPH coal handling plant. The scope of work also includes dust suppression system, dust extraction system, ventilation system, packaged air conditioning system, service water, potable water, cooling water system, CCTV and Public announcement system etc., for the CHP.

The project commenced from May 2009 with a 31 month completion period schedule and faced a delay due to non-availability of erection front at bunker floors by BTG agency of UPRVUNL.

Finishing works

The scope also included finishing works such as sheeting works, aluminium door and windows, plastering, POP, decorative painting, tiling, false ceiling apart from sanitary fittings and plumbing for restrooms.

Construction Methodology

Ground Improvement by stone column

The Anpara project stage - D is India’s first thermal power plant which is being constructed at an

abandoned ash disposal area. The entire construction area was filled with flyash (from the existing power plant) to a depth of 13 meters. This lowered the lateral load bearing capacity (Ncd Value 5 to 10 only) posing a geotechnical challenge which called for implementation of

Work description Quantity

Earthworks, Area grading & leveling 20,50,000 cu.m

Ground Improvement- Stone column driving

98,712 Linear Meter

Bored cast in situ RCC Piling 31,724 Linear Meter

Concreting 50,534 cu.m

Formwork 1,42,000 sq.m

Drains 6.1 km

Structural Fabrication & Erection 5,052 t

Sand Blasting & painting 5,052 t

Sheeting 31,600 sq.m

Equipment Installation 7,150 t

Utility Piping 62,000 Inch m

Ironite flooring 25,000 sq.m

Work in progress at the underground section of tunnel for 1650 tph double stream coal conveyor


some innovative construction methodology in the area of ground improvement.

The client, UPRVUNL, proposed conventional stone columns in-order to improve the lateral capacity of the ash filled area. Since this methodology was time

consuming (productivity was only 5 stone columns/ day/ machine) and was expensive considering the number of stone columns per combination. L&T started to explore alternative options that were effective as well as cost efficient.

With an objective to optimize the design for the number of stone columns per combination and to minimize the stone column driving time, several tests and experiments were conducted by the L&T project team.

The outcome of these tests proved that by driving the stone columns with the help of fully automated Vibro CAT equipment, a high productivity of 30 stone columns/day/machine could be achieved. The team also worked tirelessly to arrive at the best combination with minimum number of stone columns having better test results than conventional methods. After arriving at the most optimal solution, this innovative construction methodology was proposed to NTPC (project consultants) and the same was approved for implementation.Interior view of 210 m long track hopper of 3500 t capacity

MCC panels for CHP control room


MIG welding

In order to have better quality of welding, Metal Inert Gas (MIG) welding was employed for the fabrication of built-up and star sections. This welding methodology not only resulted in consistent quality of fabrication but also helped increase productivity.

Challenges faced

BCIS RCC Piling

Since the entire construction zone was filled with 13 meter fly ash, the following were some of the challenges faced by L&T

Collapse of pile bore in the ash yfilled depth during initial pile installation

Necking / bulging of pile yconcrete in ash filled depth

Loss of moisture from the pile yconcrete which had the possibility to affect the strength of the concrete

In order to overcome the above issues, trials were conducted using temporary

MS liner measuring 13 m up to the ash filled depth. This process was monitored closely and subsequently after the test results were found in conformance to the high quality requirements, it was presented to the project consultants and the client.

View of elevated portion of the conveyor just before the transfer point

Above ground view of track hopper


Workmen

Since the project site of Anpara – stage D was located over ash disposal area, even minor construction work resulted in a lot of dust. Due to the ash filled air in the project site, many migrant workmen faced sickness during the initial stages itself. In order to mitigate this health related hazard, the project site safety team arranged for very frequent water sprinkling system with the help of water tanker and sprinklers for suppressing the dust.

B. K. Singh Project Manager

View of stack yard with 1650 tph reversible stacker cum reclaimer

Resources

Plant and Machinery during peak period of construction

Excavator / poclain : 4 Nos

Dumper - 16 cu.m :12 Nos.

Area Grader : 1 No.

Dozer : 1 No.

Vibromax Roller - 9 t : 1 No.

BCIS Piling Rig : 4 Nos.

Crawler Crane - 40 t : 2 Nos.

Vibro Hammer : 1 No

Stone column Rig-Vibro CAT : 2 Nos.

DG set 200KVA : 2 Nos.

Computerized Batching Plant- 30 cu.m/hr. : 1 No.

Transit Mixture - 6 cu.m : 4 Nos.

Concrete Pump - 30 cu.m/hr. : 2 Nos.

Excavator/JCB : 1 No.



Hydraulic Crane - 40 t : 1 Nos.

Hydra Crane - 12 t : 5 Nos.

Rail mounted Gantry crane -10 t : 2 Nos.

Truck/ Trailor - 20 t : 1 No.

Welding machine : 80 Nos.

MIG welding machine : 4 Nos.

Lathe Machine : 1 No.

Manpower during peak period of construction

Staff : 37

Workmen : 1300


I N A U G U R AT I O N

Towards fulfilling the demands of the new vistas in rail construction and the development of rail infrastructure, L&T has established the Competency Development Centre (CDC), a first-of-its-kind training centre for rail construction in the country at Kanchipuram, near Chennai. The facility was inaugurated on 24th May 2012 by Mr. A.P. Mishra, Member Engineering, Railway Board in the presence of Mr. Deepak Krishan, General Manager, Southern Railway, Mr. S C Agnihotri, Managing Director, RVNL, Mr. K.V. Rangaswami, Advisor to Chairman, L&T, Mr. Rajeev Jyoti, Chief Executive, Railway Business, L&T and Mr.P.John Rajkumar, VP & Head - Railway Construction, L&T.

Other dignitaries present during the event included L&T veterans Mr.L.E.D’Cruz, Mr. A.H. Memon and Mr. K.U. Warrier, officials from Railways, CMRL and RVNL.

Mr. Rajeev Jyoti, Chief Executive, Railway Business, L&T, welcomed the Senior Executives from Railways

and RVNL. He elucidated on the need for setting up such an institution for the development of the infrastructure and nation. He called for active participation to make CDC a great institution.

Mr.P.John Rajkumar, VP & Head, Railway Construction, L&T set the context for the event giving a brief on the training centre. This was followed by a flash presentation on Competency Development Centre.

Focusing on industrial demands in the current scenario, Mr. S C Agnihotri, Managing Director, RVNL, expressed that bright prospects await corporates such as L&T that offer integrated railway construction solutions.

Mr. Deepak Krishan, General Manager, Southern Railway, complemented L&T for taking the lead in establishing a diversified training centre concerning the railways in India.

L&T inaugurates India’s first Rail Construction Training Centre

Mr. A.P. Mishra, Member Engineering, Railway Board (Fourth from Left) releasing the brochure


Mr. K. V. Rangaswami, Advisor to Chairman, L&T, emphasized that L&T had always believed in training its workforce professionally to ensure quality construction solutions. L&T’s Competency Development Centre is one such initiative that is sure to become a beacon in providing quality workforce for the railway construction industry.

Stressing on the importance of imparting structured training, Mr. A.P. Mishra, Member Engineering, Railway Board, lauded L&T for having set up a first-of-its-kind comprehensive training centre dedicated to skill development in the Railway construction industry.

The training centre, set up in a 6 acre area is equipped with excellent infrastructure for practical and classroom sessions. It has the facility to impart on-site training to 300 technicians and 180 middle level managers/engineers in a year. Specialized training is provided in various rail construction trades which include permanent way works, overhead electrification, signalling and telecommunication, platform and buildings.

View of platform structure and track


CSTI Inaugurated at Cuttack & Chhindwara

L&T Construction as part of its skills building strategy has established its 8th Construction Skills Training Institute (CSTI) at Gopalpur, Cuttack in the state of Odisha and one more at Chhindwara under CII.

Honourable Chief Minister of Odisha, Mr. Naveen Patnaik inaugurated the Cuttack facility on June 14, 2012 in the presence of Mr. S.N Roy, Member of the Board & Sr. Executive Vice President, L&T, MP’s, MLA’s and bureaucrats from the state along with senior executives of L&T Construction.

The training institute is a joint initiative between the Government of Odisha and L&T. The building and land infrastructure is provided by the State and L&T will be the knowledge provider and training partner. L&T is also establishing 4 sub centres at Baripada, Koraput, Bolangir and Bhulpani for sourcing and imparting initial one month training to the candidates. 5 Government ITI’s have been identified at Cuttack, Berhampur, Rourkela, Pattamundai and Bargarh to conduct skills training as per L&T’s syllabus and standards. Subsequent to the training, L&T shall facilitate the placement through subcontractors at project sites for the willing candidates.

Mr. Kamal Nath, Honorable Minister for Urban Development, Govt. of India, inaugurated the Construction Skills Training Centre at Chhindwara. Mr S. Ramadurai, Adviser to Prime Minister on Skill Development, Mr.Adi Godrej, Chairman-CII along with senior CII officials were present during the function.

The Chhindwara center will operate under CSTI – Jadcherla in the 1+2 module (1 month training at Chhindwara and 2 months at CSTI – Jadcherla).

Mr. Naveen Patnaik inaugurated the Cuttack facility

Mr. Kamal Nath, Hon’ble Minister for Urban Development, CSTI at Chhindwara


First concreting commences at Jaypee-Orchards project after bhoomipooja

Superstructure Works at Lodha Wadala Project Commences with a Pooja

The L&T project team at Lodha Wadala project, Mumbai conducted a pooja on May 30, 2012 for starting the superstructure works. Present during the auspicious occasion were Mr. S.N. Subrahmanyan, Member of the Board and Senior Executive Vice President (Construction), along with Mr.Tidke, CEO – Lodha, Mr. Vijay Chugh and other members from the client side. Mr.Sushant Shah Deo, Project Director commenced the proceedings by doing the inaugural Pooja. Later, Mr.Tidke inaugurated L&T’s site office in the presence of SNS. The project team and senior executives and expressed their support and commitment towards achieving the objectives.

The first concreting activity at Jaypee-Orchards project, Noida, commenced after the bhoomipooja on June 11, 2012. Mr. V.J Ravindra Kumar, Head - Elite Housing, graced the occasion along with Mr. A.K Singh (CPM Delhi Cluster) and Mr.Sankalp Misra (Project Manager). From Jaypee, Mr.Bipin Chand-Joint President, Real Estate Projects and Mr. Rajeev Datt, Vice President, Orchards Site also participated in the ceremony.

Mr.Tidke inaugurating L&T’s site office in the presence of SNS


N E W O R D E R S

Solar BU signs contract with Areva to construct Asia’s largest solar thermal power project L&T’s Solar BU has recently signed a Solar Field Construction Contract with M/s. Areva Solar India for Reliance Infrastructure Limited’s 1 X 125 MW Solar Thermal Power Project at Pokhran, Rajasthan, which is Asia’s largest solar thermal power plant project. The power plant is using Compact Linear Fresnel Technology (CLFR) which can generate steam at 400oC and 96 bar using heat from solar radiation. The other prominent technologies include Parabolic Trough and Power Tower.

This is a first-of-its-kind contract for L&T which includes erection of solar steam generator units, piping, electrical, instrumentation and civil construction works. The construction works has to be completed within 13 months.

This project is one among the 470 MW of solar thermal power projects allocated under the Jawaharlal Nehru National Solar Mission (JNNSM). The National Solar Mission is a major initiative of the Government of India to promote ecologically sustainable growth while addressing India’s energy security challenge. It will also constitute a major contribution by India to the global effort to meet the challenges of climate change. It enables a policy framework for deployment of 20,000 MW of solar power by 2022.

L&T Construction Secures Orders Valued Over ` 2592 CroreL&T Construction’s Building & Factories IC has won new orders valued ` 2592 crore. In

the residential buildings segment, new orders worth ` 1206 crore have been secured from leading developers for the construction of multistoried residential towers in Bangalore and Gurgaon including additional work in on-going projects.

The commercial buildings segment has bagged orders worth ` 1165 crore for the construction of a mixed use development, hospital building and other institutional buildings in major cities across India. In yet another development, new orders worth ̀ 221 crore have been secured from leading automobile players for the construction of factories.

` 744 Crore OrdersThe Power Transmission & Distribution IC has secured new orders worth ` 479 crore from key customers. These include orders for electrical, instrumentation and automation works for 4506 cu.m blast furnace project for National Mineral Development Corporation at Nagarnar, Chhattisgarh from Tata projects, 400 KV switchyard and plant electrics for Jindal Power Limited at Tamnar, Chhattisgarh and electrical works at Mauda and Solapur for a Super Thermal project from The National Thermal Power Corporation.

An order has been secured from Power Grid Corporation of India Limited for the construction of 400 kV overhead transmission lines from Barh in Bihar to Gorakhpur in Uttar Pradesh.

In the Water & Solar Business, L&T Construction has secured orders worth ` 265 crore from various customers for the construction of a Solar thermal plant at Rajasthan and also an EPC contract for the construction of a pumping station and allied works at Botad Branch Canal from Paliyad to Goma in Bhavnagar district, Gujarat.


` 2410 Crore orders in Infra and B&FThe Buildings & Factories IC has secured new orders worth `1821 crore from leading developers for the construction of major residential towers across various cities in the northern part of the country.

The Infrastructure IC has won orders aggregating `345 crore for the design & construction of viaducts and three elevated stations from Delhi Metro Rail Corporation (DMRC) which also includes additional orders from various on-going projects.

In yet another development, the Water Effluent and Treatment business has bagged new orders worth `244 crore from Bangalore Water Supply & Sewerage Board for upgrading the existing water distribution systems including additional orders from various on-going projects.

` 1076 Crore ordersThe Metallurgical & Material Handling IC has bagged an order worth ` 407 crore from Bajaj Infrastructure Development Corporation Limited (BIDCO) to set up a coal handling system on turnkey basis for their green field 3 x 660 MW Super Thermal Power Project in Lalitpur, Uttar Pradesh. This coal handling plant package will be completed on a fast track schedule of 22 months. L&T’s scope of work includes design, engineering, supply and erection of mechanical, electrical & instrumentation works, covering associated civil, structural works, testing and commissioning.

The Power Transmission & Distribution IC has secured new orders worth ` 669 crore in domestic and international markets. A major order has been bagged for the construction of 132/33 kV substations and other modification works in the Middle East. On the domestic front, a new order has been secured for executing electrical works under Restructured Accelerated Power Development Reforms Programme for the Hubli Electricity Supply Company Limited and a few additional orders from various on-going projects.

Infra Orders Valued over ` 2040 CroreInfrastructure IC has won a major order valued at ` 2040 crore from a leading infrastructure developer. The highway will be executed on EPC (Engineering, Procurement & Construction) mode. The scope of work involves six laning of the existing road including construction of rail over bridges, underpasses, flyovers, major bridges and viaducts.

The mega project is a part of National Highway system being developed under the National Highways Development Programme (NHDP).

` 1002 Crore orders in PT&DThe Power Transmission & Distribution IC has won new orders valued over ` 1002 Crore across various business segments in June 2012.

The Power Transmission & Distribution IC has secured new orders in both domestic and international markets.

A major order worth ` 846 Crore has been bagged from West Bengal State Electricity Distribution Company Limited for Rural Electricity Infrastructure in villages in Jalpaiguri, East Midnapur, West Midnapur and Malda districts of West Bengal under the Backward Region Grant Fund Scheme (BRGF).

On the international front, new orders worth ` 156 crore has been secured from reputed customers in Qatar for electrical network power quality improvement work including additional orders in ongoing projects in Middle East.


P R O J E C T N E W S

In a bid towards mechanisation of construction activities, the project team at Aermid Healthcare Hospital, Kalamboli, Navi Mumbai, have successfully implemented mechanised plastering to cover a 220 sq.ft area in two hours using only 3 workmen.

A special machine is used to mix the plaster material which is supplied through a pressurized pipeline. Plastering is done using the pressurised pipeline and finishing is done later manually thereby covering a large area in a relatively lesser time.

Mechanised plastering for speedier and better finish

Steel Lintels for masonry works and the mortar. The steel lintels are also phosphated for surface treatment and powder coated to a thickness of 60 to 80 microns for corrosion prevention.

Advantages of steel lintels

Helps in reducing cycle time, as it is readily yavailable to cut to size and could be installed once masonry reaches lintel level

Does not require the skills of carpenter or fitter. A ysingle mason can do the installation thereby saving on labour cost

Offers high tensile strength while being ylightweight

Has excellent load bearing capacity of up to 400 kg yincorporating efficient load bearing performance

It is designed to carry the full load of the masonry yeven when it is wet

Perforated holes in the lintels and expanded mesh ymake it effective for plastering with the cement mortar

The lintels are protected against corrosion by ythe addition of powder coating. The process of corrosion control creates a very durable surface, which is highly resistant to the impact and abrasion that occurs during site handling.

This system of using prefabricated GI lintels instead of precast RCC lintels has been successfully implemented at the Aermid Healthcare India Pvt Limited, project site at Kalamboli, Navi Mumbai.

In masonry construction, installation of lintel over door or window openings is a vital and critical activity. In case of cast in-situ construction for cut lintels, it is a laborious task and requires a lot of attention on formwork, rebar and concreting. In the conventional method, the continuous construction activity above lintel level is stalled resulting in increased cycle time. Besides, there is also a possibility for errors in line and level, which affects the allied finishes also.

To help ease the construction process and to overcome the aforesaid issues in cast in-situ lintel construction, prefabricated lintels are now available in the market in the form of C channel sections in different widths to suit the required wall thicknesses. The steel lintels are made of 3 mm cold rolled sheet which are perforated with 12.5 mm dia holes that help in good mortar penetration for a strong bond between the steel lintel


The Sahar Elevated Road Project team has achieved a remarkable benchmark by completing the concreting of the superstructure using 800 cu.m of concrete in a single pour within 35 hours. The concreting of the superstructure with 77 t of reinforcement, void form of 2200 mm dia is considered as a first-of-its-kind feat in bridge construction in India.

The Gujarat International Finance Tech (GIFT) City project at Gandhinagar, Gujarat, has achieved a slab cycle time of 6 days for a plan area of 2400 sq.m in the 20th and 21st floors. The slab cycle time indicates time taken from the staging activity to the shuttering, reinforcement, post tensioning works including ducting and cable laying, below floor stressing and grouting, removal of shuttering of the lower floors, reproping and final floor concreting. This is the first time that the project team has set a milestone in cycle time though they had come close to this achievement during the execution of various other floors. The client - Infrastructure Leasing & Financial Services (IL&FS) appreciated the project team for this stupendous achievement.

The GIFT City QC1 Building project scope of work includes Design & Construction of high rise commercial building rising to a height of 122m (Ground plus 29 Floors with Single Basement).

GIFT CITY Project Achieves a Slab Cycle Time of Six Days

Sahar Elevated project achieves 800 cu.m superstructure concreting in a single pour

The superstructure is of 35 m span, prestressed, post tensioned with deck width varying from 14.7 m on one side to 9 m on the other. The superstructure is supported with conventional L&T Formwork staging and curved wallers and plywood shuttering.

The pour sequencing was timed in such a manner as to avoid deformation of void form and cold joints. High Performance Concrete (HPC) of M 60 grade with 3rd generation admixture was used to have a better flow. Similar superstructure with 712 cu.m was recently completed at the same project. It is a matter of highlight that the current achievement was made possible despite bad weather conditions prevailing at the project site.


C O R P O R AT E

L&T’s Contribution to Capacity Building Initiatives Honoured

The Laboratory for Innovative Technology and Engineering Education (LITEE) is an innovative, collaborative effort between Auburn University’s College of Business and Samuel Ginn College of Engineering that disseminates cutting-edge instructional materials and strategies in order to bring real-world issues into classrooms. The materials developed by LITEE are based partially upon work supported by the National Science Foundation, USA through International Research Experiences for Students (IRESS) program.

Since winter 2006, several batches of Auburn University students have worked with L&T to study and document various real world problems and solutions in the construction industry with specific focus on some of L&T’s projects across India. Six multi-media education materials relating to technical as well as problem solving methods have been developed which are now ready for use and can be utilized for L&T’s internal training and capacity building.

The case studies and the curriculum built around them are currently being used at over twenty colleges and universities in the United States. Additionally, the translation of a case study into Spanish and its use in a workshop held in

Santiago, Chile, show the international capacity the case studies have.

A felicitation function was organized at the conference hall of Centre for Industrial Consultancy and Sponsored Research, IIT Madras on 28thMay 2012 between 10:00 a.m and 12:00 noon as an appreciation to the contributions made by L&T and IIT Madras for this program. A presentation session was held, in which the students from Auburn University showcased the work that has been performed between 2006 and 2012 and it was followed by a feedback session.

The list of dignitaries include Dr. Chetan Sankar, Principal Investigator, NSF IRES Program and Professor at Auburn University and Dr. Barbara Kawulich, Professor at Georgia University and reviewer of the IRES program, Mr. K.P. Raghavan, Advisor, L&T Construction, Mr. Rajan Venkateswaran, Chief Architect and Head CEFD, L&T Construction, Dr. Ramachandraiah, Professor, Department of Civil Engineering, IIT Madras and Dr. Krishnan Balasubramaniam, Dean Industrial Consultancy and Sponsored Research, IIT Madras.

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

L&T’s Chairman & Managing Director, Mr. A.M.Naik ranks in the top ten in corporate India’s definitive power listing published by India’s leading business daily, The Economic Times (ET).

Mr.Naik’s high impact and outstanding accomplishments have seen him ascend a listing that is among the most coveted in the Indian industry. His ranking is specially

remarkable as he is one of only two non - promoter CEOs in the top 10 list.

The Economic Times publishes India’s Most Powerful CEOs survey every year, in which 500 senior executives from India Inc. are asked to rate CEOs on leadership, strategy and innovation, performance, stature, social contribution and governance.

Mr. A.M. Naik Ranks in Top Ten of The Economic Times India’s ‘Most Powerful CEOs’ List

in-house journal of l&t construction april - june 2012

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