May - Jun 2004 - Punj Lloyd

The Punj Lloyd Magazine | MAY-JUN 2004updateSGP Offsite and Utilitiesmechanical work for AssetDevelopment Project byParsons/Fluor Daniel JV (PFD)for Tengizchevroil (TCO) inKazakhstan.updateSulphur Recovery Unit andTail Gas Units for AssetDevelopment Project byParsons/Fluor Daniel JV (PFD)for Tengizchevroil (TCO)in Kazakhstan.38,230 m 3 Capacity LPGStorage Tank Project bythe Reliance Industries,JamnagarEPC Project forConstruction andCommissioning of aProtection Facility(BeAAT) by Takreer,Abu DhabiMechanical PX2Panipat RefineryProject by Indian OilCorporation, Panipat31.50 km. long Silcharto Balachera Sectionof NH 54 Project bythe National HighwaysAuthority of India

updatepanipat refineryexpansion projectupdateeach reactorweighed 590 MTthe fractionatorwas 73 m high

Project Funded by State Bank of HyderabadEnabling Heavy LiftingInstallation of heavyand critical equipmentfor the hydrocracker unitof Indian Oil’s PanipatRefi nery Expansion projectin Haryana, India. PunjLloyd was chosen as asub contractor to Daelim,Korea. We bagged thisproject based on our pastsuccessful completion ofthe hydrocracker unit forIndian Oil at Mathura. Theequipment which was tobe installed, consistedof two reactors, eachweighing 590 MT, witha diameter of 5.96 mand height of 24 m andone product fractionatorweighing 253 MT, witha diameter of 5 m andheight of 73 m.The foremost challengewas to strengthen thesoil to bear the combinedweight of cranes andequipment, totalling 1500MT. While the existingload bearing capacity ofsoil was a mere 5 t/m 2 ata depth of one meter, itneeded to withstand theweight of 95 t/m 2 . A soilanalysis was conductedand the topsoil of selectedareas was strengthenedupto a depth of 3 mwith an engineered mix ofstone and soil. To ensureproper distribution of load,36 mm and 25 mm thicksteel plates wereplaced under the bodyof the main craneand its counterweighttrolley, respectively.The complexity of thechallenge increasedmanifold because theequipment had to belifted in a single piece.Since the hydrocrackerunit was congested, itallowed very little spacefor accommodatingthe cranes and otherlifting accessories.To install the tworeactors, a 1000 MTAmerican crane wasused as the main craneand a 450 MT Liebherrcrane was deployedas the tailing crane.Each reactor had atotal lifting weight of628 MT including liftingaccessories. To lift thefractionator, a 350 MTManitowoc crane alongwith a 208 MT tailingcrane were utilised.The fractionator hada total lifting weightof 284 MT, includinglifting accessories.On April 12, the fi rstreactor was installed.It took just an hour toachieve the heaviestinstallation in Punj Lloydhistory. After a gap oftwo days, the secondreactor was successfullyinstalled using thesame technique.To install the fractionator,a special 300 MT capacitylifting beam was designedin-house, fabricated andtested at site. On April22, the fractionator wasinstalled in two and ahalf hours. The mostchallenging part of thisoperation was the useof the longest boommeasuring 99 m of themain crane and operatingthis within the restrictedarea of the site.Team Punj Lloydheaved a sigh of reliefwhen the single pieceinstallation of these threeheavy equipment wascompleted successfully.With this accomplishment,Punj Lloyd has brokennew ground and hasestablished itself fi rmly inthe fi eld of Heavy Lifting.◆ Amitava Bose

updatedelhi metro rail projectAs a vital componentof its expansion plans,when the Delhi MetroRail Corporation Ltd.(DMRC) decided to laya new 23.19 km longsubterranean as well aselevated track to connectDwarka to ConnaughtPlace, Punj Lloyd wasawarded the mostchallenging task ofconstructing a 6.3 kmlong elevated trackbetween Kirti Nagarand Tilak Nagar.Apart from the enormityof the work involved, thebiggest challenge facedby the Punj Lloyd teamwas to manage andcarry out the entire jobwithin a narrow 8 m widesanitised corridor, madeeven more congesteddue to the presence ofa 5 m wide piling rig.Scope of workThe project includes castingof 253 spans by segmentalconstruction method, andtheir subsequent launch atthe site by an auto-launchinggirder. The substructureconsists of 260 piers restingon about 1200 large diametrepiles (1500 mm) bored withthe help of hydraulic andmechanical piling rigs. Thedepth of the piles range from25 to 30 metres.Project Funded by ICICI BankThe Delhi MetroAccomplishing an impossible taskSince the proposedmetro track runs throughthe heart of the city,passing through someof the most denselypopulated areas havingan intricate subterraneannetwork of sewerage,water pipelines, electricalcables and OFClines, the team facedsevere constraints.Managing themovement of material,equipment and manpoweramidst the heavy traffi c ofDelhi was another majorchallenge. As the 40 to70 tonne segmentsrequired to construct thesuper structure were castin a factory located 25 kmaway from the site, theyhad to be transported tothe site on trailers, whichcould move only duringthe night due to heavydaytime traffi c. To dealwith this situation, wehad to use the “Traffi cManagement Plan”.Moreover, besidesovercoming the oddsof space and incrediblyheavy Delhi traffi c, theteam is required tocomplete this projectwithin a challengingtimeframe. The projectis scheduled to becompleted in January2005 and we areconfi dent of completingthe project on schedulein spite of all the hurdles.◆ Ranjan Wazir

updategolden quadrilateralprojectsBridging the GapThe “Golden Quadrilateral Project”, conceived under the widerRs 54,000 crore National Highways Development Project (NHDP)

The “National Highways Authorityof India” (NHAI) is the nodalbody responsible for the overallsupervision and execution of thisproject. Amidst stiff competition,Punj Lloyd was awarded thecontract of constructing the 77 kmlong Belgaum–Maharashtra BorderRoad (km 515 to km 592 of NH–4).The Belgaum–MaharashtraBorder RoadThis annuity project isa joint venture involvingPunj Lloyd, IL&FS andCTNL controlled througha Special PurposeVehicle (SPV), the NorthKarnataka ExpresswayLtd that was establishedspecifi cally for this project.It sets the foundation ofa trend by displaying thesuccess of a partnershipbetween Governmentand the private sector inrealising the infrastructuraldreams of India.Initiated in June2002, this project wascompleted fi ve monthsahead of its schedule. Outof the annuity projects ofthe “Golden Quadrilateral”,this Punj Lloyd project hasthe distinction of being thefi rst and only one to becompleted so far, therebyrecording the fastestcompletion of a roadproject of such magnitudeand complexity in India.updatesuccessful partnershipbetween Government andthe private sector inrealising the infrastructuraldreams of India

Punj Lloyd used stateof the art plant, machineryand equipment toimplement this prestigiousproject. In order tocoordinate a plethoraof complex engineeringactivities at each stage,four construction campswere built along the77 km road toaccommodate offi ce,laboratory, central store,mechanical workshop,weigh-bridge,reinforcement andshuttering yard, castingScope of WorkThe scope of the work involved in the project was enormous.It has been detailed concisely in the following table:Facility Type/Size UOM Qty.Road Length Dual Carriageway km 78Rigid Pavement 2 Lane/3 Lane km 92Flexible Pavement 2 Lane km 64Service Roads 4 – 7 m wide km 144Major Bridges 90 – 200 m length Nos. 6Minor Bridges < 60 m Length Nos. 12Grade Separators 24.5 m x 21.4 m x 7.5 m Nos. 7Vehicular Underpasses 24.5 m x 11.1 m x 7.5 m Nos. 6Pedestrian Subway/Underpasses 24.5 m x 7.5 m x 4.7m Nos. 7Cattle Walk cum Cattle Tracks 27.5 m x 3.5 m x 3.5 m Nos. 19Culverts Box/Pipe Nos. 128At Grade Junctions ‘T’ & ‘X’ shaped Nos. 14The “Golden Quadrilateral Project” interlink four majormetros, namely Delhi, Kolkata, Mumbai and Chennaiby constructing 5,952 km of new roads to interconnectexisting national highways.

updateQuantitiesEarthwork 3,000,000 m 3QuantitiesGSB 295,000 m 3Earthwork WMM 3,000,000 253,000 m 3m 3GSB DBM 295,000 141,000 m 3m 3WMMBC 253,000 47,500 m 3m 3DBMSTONE PITCHING 141,000 74,000 m 3m 3BC Concrete work 47,500 160,000 m 3m 3Stone KERB Pitching 74,000 70,000 m 3RMConcrete METAL work CRASH BARRIER 160,000 26,000 m 3RMKerbACCESS CONTROL FENCING70,000 43,000 RM RMMetal Crash Barrier 26,000 RMAccess Control Fencing 43,000 RM

yard for pre-castelements, hot mix plant,concrete batching plant,material stacking area,cement godown as wellas residential area.One of our specialachievements was thecomplete rehabilitationof the 200 m long GhatPrabha River bridgein only 90 days.During the course ofthis project, Punj Lloydalso created several jobopportunities for the localpeople and employedlocal engineers includingseven lady civil engineers,thereby defying genderprejudices associatedwith the male dominatedconstruction industry. Atotal of 14.5 million manhoursof work went intocompleting this project.At Belgaum, theprogress of the projectwas hindered due toinordinate delay in gettinga municipal clearance toshift the water pipelineof Nepani town. Theincessant rain during themonsoon of last yearalso made execution ofwork extremely diffi cult.With sustained efforts,meticulous, detailedplanning and hard work,we completed theproject and received thecompletion certifi catewith the opening of thehighway to traffi c.Thus, by completingthe project ahead ofschedule, the Punj Lloydteam has once againproved its prowess inhighway engineeringand construction.updatecreatingemployment forthe local people

Another crucial road projectbagged by the Punj Lloydteam under the GoldenQuadrilateral Project was theconstruction of a section ofthe NH 8, the Jaipur bypassScope of Work4 lane divided carriageway 35 kmService Roads32 kmGrade Separators2 NosUnderpasses11 NosBox Culverts12 NosCamel Crossings5 NosPipe Culverts24 NosThe Jaipur BypassThis project involves theconstruction of the 35 kmlong, 4-lane carriagewaythat connects NH-8(Delhi-Jaipur Road) atChandwaji, bypassesJaipur city and fi nally joinsNH-11 (Jaipur-Sikar Road)at Harmara. As a part ofthis project, Punj Lloyd isconstructing service roadsat strategic locations withfl exible pavements, gradeseparators, underpasses,retaining walls and severalother related structures.Numerous elevatedstructures wereconstructed; two gradeseparators at eitherend of the highway;11 vehicular underpasses,two separate 7 m highbox cell structures

to facilitate two-waymovement on the roadunderneath and fi ve camelcrossings to enable localmovement on small roads.These structures coveralmost half of the lengthof this elevated road.The most striking featureof the project is the factthat this high-speedcorridor is completelyaccess-controlled withguardrails and fencingon both sides. Due tohigh speed traffi c on thehighway, this fencingis important to preventpedestrian movement.Because of theconstruction of elevatedstructures and crossings,a substantial amount ofearthwork was involvedin this project, whichmeasured 3,000,000m 3 and concrete workof 160,000 m 3 . Basedon per km standards,this is very high whencompared to conventionalroad projects.We also constructednumerous drainagestructures, extremelylong retaining walls30 km long and morethan 32 km of serviceroads on either side atimportant locations.

Our major achievementwas pouring 1080 m 3 ofconcrete in a non-stopoperation of 12 hoursover the entire length ofthe project at scatteredlocations, by utilising theoptimum effi ciency ofConcrete Batching Plants.The bypass oncecompleted will enablevehicles to travel atuninterrupted speedsupto 120 kph along theentire stretch, thus savingtwo hours of travel-timebetween Delhi - Mumbaiand Delhi - Sikar - Bikaner.Jaipur Bypass NH-8 Project Funded by ICICI BankBelgaum - Maharashtra NH-4 Project Funded by ILFS and Rabo Bank◆ Akhil Gupta and S Ansariupdatevehicles can travel atuninterrupted speedsupto 120 kph alongthe entire stretch

Health, Safety and EnvironmentTurkeyEnvironmentThe Baku-Tbilisi-Ceyhan(BTC) pipeline widelyreferred to as the“Pipeline of the Century”will connect Baku inAzerbaijan throughTbilisi in Georgia to theport of Ceyhan in Turkey.Punj Lloyd Limak - JV ofTurkey has been awardedthe prestigious contractof LOT-C in the Turkishsection, covering alength of 334 km.The environmental andsocial considerationsare paramount in thisproject along with healthand safety.To undertake theenvironmental complianceactivities, Punj Lloyd Limakhas appointed the reputedenvironmental consultingfi rm EnvironmentalResource Management.We have also establishedour EnvironmentalManagement Systemsin compliance withISO : 14001 and havebeen certifi ed by DetNorske Veritas (DNV).Before beginningconstruction Punj LloydLimak - JV has conducteddetailed vegetationmapping along thepipeline Right Of Way(ROW) and identifi edthe threatened and rarespecies found in the area.The surveys were followedwith documentation,compilation ofenvironmental manuals,setting up of procedures,formulation of plans,establishing of special areareinstatement methods,preparation of reports andmobilisation of resources.During the constructionphase, important areaswere barricaded, erosionwas controlled, ROW andrivers were protected andenvironmental training wasimparted to all concerned.In the post constructionphase, reinstatementand bio restoration werethe most importantactivities carried out.Our specialachievements at thissite were successfulreinstatement of theZamanti River andthe innovative wastemanagement activitiescarried out by us. TheZamanti River and itsfl oodplain is home to fi sh,eel, aquatic and exoticplants and migratory birds.Between the periods oftheir migration, breedingand ecological constraints,we had only two monthsin the entire year toexecute this importantriver crossing. Care wastaken to preserve the topsoil from the ROW andduring mobilisation ofequipment, reinstatementof river and its tributaries,re-contouring the landwith re-growth of fl ora.Waste disposal isdone only by recyclerscomplying with the EUstandards. They areaudited quarterly for theirEnvironment ManagementSystem (EMS) andenvironmental compliance.Health and SafetyPunj Lloyd Limak - JVhas achieved the bestcontractors status asmeasured under a seriesof key performanceindicators. Superiorperformance has led toPunj Lloyd Limak - JVbeing awarded a secondsection of the pipeline inGeorgia as part of therecovery plan.Distance travelled byus till now is 12.69 millionkm which is equivalent to16.5 times the distancebetween earth and

moon, without injury toany project personnel.We have achieved4.14 million working hourswithout a day away fromwork till May 2004.IndonesiaEnvironmentTo protect the environmentat TOTAL’s Tunu FieldDevelopment Phase 9,PT Punj Lloyd Indonesiafollowed the guidingprinciples listed below:• Minimal use ofraw material• Conservation ofenergy and water• Promotion of the 3Rprinciple i.e. Reduce,Reuse and Recycle.Effective monitoringand implementation ofEnvironment ManagementPlan during constructionin the restricted ROW hassaved the adjoining aquaculture ponds, fi shnets,vegetation, fl ora and faunain the Mahakam Delta.Continuous analysisof seawater to maintainits natural qualitywas undertaken. Thisactivity also ensuredthere was no negativeimpact on fi shingand shrimp farming,which are importanteconomic activities ofthe Mahakam Delta.For blocking theswamp area PT PunjLloyd Indonesia usedjute sand bags in placeof plastic bags to protectthe environment.To ensure minimumenvironmental damagein the Mahakam Delta,the Horizontal DirectionalDrilling procedureSafe Man-hoursTunu Phase 4 & 50.85 million in 1996-97Tunu Phase 71.31 million in 1999-2001Tunu phase 81.12 million in 2001-03Caltex1.25 million in 1999-2001Panaran Pemping1.89 million in 2002-03PECIKO1.35 million in 2002*Tunu Phase 91.50 million in 2003**till june 2004was used to traversea 2 km length of the20” gas pipeline.1 million mangroveshave been planted byus in the swamp areaof ROW at Batam torestore the environmentand to prevent erosion.Health and SafetyPT Punj Lloyd Indonesiahas imparted exhaustivehealth and safety trainingto all its employees. Wehave received appreciationletters for outstandingsafety performanceconsecutively for 5projects from TOTAL.We were awarded arating of 86 per centwhich is not only thehighest score on Tunu 9project by any contractorbut is also the best safetyperformance in TOTALhistory in a high riskcategory. Our successfulinstallation of the pipelinein the NPU with livegas plants, without anylost time incident wasappreciated by our client,TOTAL Indonesie.IndiaPanipatHealth and SafetyAt the Hydrocrackerproject at Indian Oil’srefi nery in Panipat wehave completed 2.2million man-hours withoutany accidents and themonthly safety award hasbeen awarded to us sixtimes consecutively foroutstanding contribution insafety supervision at site.Two reactors eachweighing 590 MT andone fractionator of 73 Mheight were installed byus without any incident.Dust suppressionwas ensured by regularsprinkling of water.Health Monitoring isregularly conducted byDr S Mudgil, a leadingIndian occupationalhealth specialist forworkers and staff.BelgaumEnvironmentTo maintain our ISO :14001 we undertookan exercise to monitorthe consumption ofpaper, high speed dieseland lubrication oil, perpercentage progressof project work at ourBelgaum - Maharashtraproject site. The exercisewas initiated in 2001 andwill be concluded shortly.The results would giveus a benchmark againstwhich we can measureour future performance.A similar exercise isbeing undertaken at ourother sites.The benefi t of ourupdatehealth, safety andenvironment at sitesmonitoring activity isalready evident in thereduced usage of HSD,Paper and Lubricant oil.Oil has reduced from103 KL to 15.16 KL,HSD from 170 KL to120 KL and paper from68 to 12.9 packets.The stress on ourenvironment has reducedthrough conservationof natural resourcesand source reductionin hazardous waste.BanmoreEnvironmentAt our equipmentmaintenance and repairfacility in Banmore atreatment plant to handlewaste water has beencommissioned. A gardenof 2,400 sq mtr with40 different varieties offl owers has been nurturedand 600 trees of differentvarieties have beenplanted. A horticulturisthas joined our team toensure that our garden isalways in full bloom.◆ K K Saha, P Kolwalkar,P K Tripathi and Col. R K Mehta

5A1 ratingassignedDun & Bradstreet is the leadingprovider of business-to-businesscredit, marketing, purchasing,receivables management anddecision-support servicesworldwide.Punj Lloyd has been assigneda rating of 5A1 based onFinancial Strength and CompositeAppraisal/Condition.Financial Strength of 5A isan indicator of a company’stangible networth.The Composite CreditAppraisal/Condition of ‘1’ isthe highest rating of D&B.The rating of 5A1 is assignedon a business’s undoubtedstanding, where there is minimalrisk associated with it. ◆Founder’s day CelebrationOn June 26, Punj Lloyd celebrated its proud legacy andhonoured those who have worked tirelessly to give shape to itsfounder’s dreams, Pandit Kanahya Lal Punj. It is also the time whenthe Punj Lloyd 1400 strong family gets together. The ceremony thisyear was inaugurated by S N P Punj. He took this opportunity toenlighten the gathering about his father, the visionary who dreamtof creating one of the most respected organisations in India.Atul Punj, the Chairman, updated the entire team about thephenomenal growth that Punj Lloyd has achieved duringthe last year.This occasion is also special as the long service award goesout to many veterans. Irrespective of the grade or level,long years of hard work are rewarded by the managementwith the distribution of 10, 15, 20, 25 and 30 yearawards to the employees. This year 67 proud employeesreceived their awards from the gracious Indu Punj.Punj Lloyd is one of the few companies in the present age andtime, which can boast of many recruitsqualifying for these awards every year.This proves the high level ofsatisfaction that people working inPunj Lloyd draw from their jobs. ◆Corporate Office Punj Lloyd Ltd. Punj Lloyd House, 17-18 Nehru Place, New Delhi 110019 India Tel +91 11 26200123 Fax +91 11 26200111 Email info@punjlloyd.comOther Offices Punj Lloyd Ltd. PO Box 28907, 202 Al Otaiba Building Khalifa Street Abu Dhabi UAE Tel +971 2 6261604 Fax +971 2 6267789 Email pllad@emirates.net.aePunj Lloyd Ltd. PO Box 704, Postal Code 133, Al Khuwair, Sultanate of Oman Tel +968 597728 Fax +968 597493 | Punj Lloyd Kazakhstan LLP Astana International Hote l,113 Baitursynov Str. 480072 Almaty, Republic of Kazakhstan Tel +7 3272 501233, 507258 Fax +7 3272 501223 Email punjlloyd@nursat.kz Punj Lloyd - LIMAK JV 74 MahatmaGandhi Road, GOP 06700 Ankara, Turkey Tel +90 312 4466364, 4469714 Fax +90 312 4466794 Email plljv@plljv.com Punj Lloyd Ltd. Banmore Industrial Area, Banmore, DistrictMorena 476444 Madhya Pradesh, India Tel +91 7532 243644, 243534 Fax +91 7532 243297 | Punj Lloyd (Malaysia) Sdn. Bhd. Cosmos Centre, 69/1 New Circular Road Dhaka1217, Bangladesh Tel +880 2 9330859, 8312024 Fax +880 2 8314602 | Punj Lloyd Ltd. Bin Yousef Group Companies WLL, 9th Floor, Almana Tower, Old Airport Road, PO Box3264 Doha, Qatar Tel +974 4622127, 4626172 Fax +974 4626180 Email pbali@punjlloyd.com | Pt. Punj Lloyd Indonesia Ventura Building, 4th Floor, Suite 401B Jl. R A Kartini26, Jakarta 12430 Indonesia Tel +6221 7591 4766, 7591 4762 Fax +6221 7591 4241 Email svyas@ptpli.com | Mr. Erich Niedermeyr Area Manager Kutterlingerweg 383059Kolbermoor, Germany Tel +49 8061 5616 Fax +49 8061 370450 Email e.niecons@t-online.de Punj Lloyd Ltd. 32 Harley House Marylebone Road, London NW1 5HF UKTel +44 20 7486 6009 Fax +44 20 7935 5086 Email info@punjlloyd.com | Punj Lloyd Ltd. 1 TV Industrial Estate, SK Ahire Marg, Worli, Mumbai 400025 Tel +91 22 24924421,56602835 Fax +91 22 24936861 Email dmankame@punjlloyd.comwww.punjlloyd.comStrategic Business UnitsCivil Construction | Pipelines | Tankage & Terminals | Telecom | Process Plants | Plant and Facility Management | Power PlantsHigh Value Engineering | Broadband Convergent Services