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January - March 2009 Vol. No. 31 Issue No. 4


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Editor V.S. rnEditorial tEam K. Sn | aex Benjn | V. res K |

aswn Cn | V. Esw | Sb ann

PhotograPhy V.S. NnvedESigN& layout Ss gpcs desn, Cenn.

ContentsVol. No. 31 Issue No. 4

L&T has played a critical role in the development

of technology & capabilities for the Indian nuclear

power sector from its very beginning. ECC, L&Ts

construction Division has the capability to construct

critical and complex structures for nuclear power plants

to international standard specications. Moreover, it has

the distinction of having participated in the construction

of a majority of nuclear power plants and heavy water

plants in the country.

This has opened several avenues for L&T to sign

cooperation agreements / MoUs and forge alliances

with leaders of nuclear technology across the world,

such as: Westinghouse Electric Company (WEC), USA

for Pressurized Water Nuclear Reactors with modular

construction technology; Atomic Energy of Canada

Limited (AECL) for cooperation on Advanced CANDU

Reactor ACR 1000. Recently it signed the MoU with

Atomstroyexport (ASE) of Russia for cooperation

to supply Russian VVER 1000 type reactors for the

Kudankulam nuclear power project.

L&T has been a partner in the development of Indian

Nuclear power programme and it has been playing

an active role in the construction of major nuclear

plants in different parts of the country. As a part of

the operations of L&Ts Infrastructure OC, we take

pleasure in highlighting our contributions to this sector

along with irrigation projects executed by us.

Kaiga Atomic Power Project (Unit 1 & 2)

L&Ts Track Record

in Nuclear Power 4

Endeavours at

Tarapur Nuclear Power Plant 6

Nuclear Reactor

Containment Test Model 12

Kundankulam Nuclear

Power Project 14

PREFRE-3A Project

or BARC Kalpakkam 22L&T signs MoU with World Leaders

in Nuclear Power Sector 23

Indira Sagar

Right Main Canal Project 24

Jindal Dam - L&Ts Maiden Venture

in to Construction o Full-Fledged Dams 28

Veligonda Dam

the Engineering marvel 30

Kaleidoscope 34


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L&T began its journey in to construction o

Nuclear power projects in a modest way, by

undertaking the construction o oce acilities or

the Atomic Energy Establishment and laboratories

or Bhabha Atomic Research Centre at Trombay

during mid 60s. The construction o Main plant

civil works at Kalpakkam or the 220 MWe Madras

Atomic Power Project Unit 1&2 during 70s was

the rst major project in the nuclear segment.Subsequently, the Main plant civil works or the

220 MWe Kaiga Nuclear Power Project (Unit 1&2)

in Karnataka was executed by L&T. Erection o

almost all heavy water plants in India are executed

by L&T.

Realising the vast potential and business

opportunities in this segment the Nuclear Business

Unit was ormed by L&T in the year 1999-2000

when it secured the 540 MWe Tarapur Atomic

Power Project, Unit 3&4. It should be mentioned

that Tarapur Atomic Power Project was one o themajor projects or L&T, where dierent business

units o L&T were actively involved in the execution

o the project - Nuclear, Electrical & Instrumentation

BUs o ECC Division; Heavy Engineering Division;

Nuclear BU o E&C Division to name a ew.

Acevees

Some o the notable achievements in Nuclear

segment include:

Outofthetotalinstalledcapacityof7280MWe

o nuclear power (both commissioned and

ongoing); L&T is involved in almost all Nuclear

power projects in the country extending up to

5280MW.

Successfulcompletionofmainplantcivilworks

o 2x540 MWe Tarapur Nuclear Power project

in a record 60 months rom the rst pour o

concrete is considered as a great achievement

-Oneamongthesixreactorsintheworldto

achieve this eat.

Successful completion of Primary Piping

Package (the heart o the nuclear plant) on

time including other mechanical packages in

the Countrys maiden 2 x 540 MWe Tarapur

Nuclear Power Project. This helped L&T in

understanding the criticality, stringent qualityrequirements, etc and as a sequel, it secured

major mechanical packages in Kudankulam

Nuclear Power Project 1&2.

L&T is involved in the execution o Indias rst

2x1000 MWe Nuclear Power Project at Kudankulam,

which is one o the most prestigious projects

undertaken by Government o India in collaboration

with Russian Government. Initially, L&Ts

participation in civil works involves construction

o inrastructure acilities and auxillary buildingsonly. However, the scenario changed, when L&T

secured our major mechanical packages which

involve technology certications, being done or

the rst time in India, etc.

This apart, auxiliary systems such as Induced Drat

Cooling Towers, HVAC, Service Water Systems,

etc are being constructed on EPC basis.

L&T is also involved in many Reactor back end

projects, that is construction o uel reprocessing

related acilities such as Additional Waste TankFarm, Spent uel Storage Facilities, Power Reactor

Fuel Reprocessing acilities, etc at various locations

in India. Thus, making L&T an all rounder when it

comes to execution o almost the entire spectrum

o activities involved in the construction o nuclear

power projects.

OnthewholeL&Tisplayingacriticalandsignicant

role in the Indias Nuclear Power sector.

Powering The Nation

With Nuclear Energy

ECC Concord|Jan - Mar 203


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Vol. No. 31 Issue No. 4

Nuclear power projects are considered as

one o the sustainable energy projects o the

uture. The Nuclear Power Corporation o India

Limited (NPCIL) presently operates 17 nuclear

power plants in the country at dierent locations.

India has made a strong beginning in the eld o

Nuclear Power. Today it is quite selsucient

rom technology and resources point o view and

NPCIL has ambitious plans o achieving 20,000

MW by 2020, improving rom the current installedcapacity o 4120 MW.

Overthepastvedecades,ECChasconstructed

many nuclear-related structures and played

a major role in this sector. It has the capability

to construct critical and complex structures or

Nuclear Power generation. ECC has the distinction

o making constructive contribution to almost all

the Nuclear power plants in the country. Some o

the important projects are Madras Atomic Power

Project, Kaiga Atomic Power Project, Tarapur

Atomic Power Project, Rajasthan Atomic Power

Project and Kudankulam Nuclear Power Project.

ECC has also been involved in other nuclear

eld related projects such as heavy water plants,

nuclear waste management, rare materials project,

etc alling under the purview o DAE/ BARC. In

act, ECCs association with DAE started in the

early 60s, when it was awarded with design and

construction works or radiological and modular

laboratories at Trombay.

ECCs major involvement in nuclear power projects

started at MAPP in 1970 when it was entrusted with

the construction o the reactor and turbine buildings

or MAPP. The contract or civil construction

included the reactor building with 40m high and

45m dia structure topped by a dome, sub-structure

or service building, cooling water system and

outall structure, demineralisation plant, central

stores, PHT purication buildings, Fast breeder

test reactor building, radio-metallurgical & radio-

chemistry laboratories, active control uel assembly

building, ree stack (100m) and ventilation stacks

(75 m & 65 m tall). The reactor wall and dome were

o prestressed concrete construction requiring

high accuracy. Another salient eature o MAPP

is the double containment wall with outer random

rubble masonry wall to a height o 34 m, which was

done or the rst time in India. ECC has also been

involved in design, installation and commissioning

o 33kV switchyard catering to the entire power

requirement o the Reactor Research Centre at

Kalpakkam. Subsequently electrical installations

or the two research laboratories RCL & MDL

were done by ECC.

NPCIL once again demonstrated its condence in

L&T by awarding the complete civil works or Units

1 & 2 o Kaiga Atomic Power Project. Kaiga was

literally a greeneld project necessitating, in many

cases, even basic inrastructure development. The

site was a natural bowl-shaped terrain surrounded

by hills with deep lush green orest and the site

was accessible in air weather through a orest

road and access to the site was dicult during

monsoon till all the access roads were ready.

ECCs scope o work included construction o

reactor, turbine, service, control, reactor auxiliary,Induced Drat Cooling Towers at 2 x 210 MW Kaiga Atomic Power Plant (Units 3 & 4)

L&Ts Track Record

in Nuclear Power

C Concord|Jan - Mar 2009 4


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Reactor building at Madras Atomic Power Project, Kalpakkam

diesel generator, spent uel buildings, 140m high

ventilation stack, area drainage, excavation, area

grading and miscellaneous structures. During

execution o main civil works, ECC was awarded

additional works such as construction o circulating

water pump houses, saety related pump house,

re water pump house, de-mineralisation, ltration

and chlorination plants, make-up water pre-

treatment acilities, CW Intake structures and

tunnel, domestic water tank, approach channel

to intake structures and outdoor & indoor piping

works.

Some o the advanced construction methods

used at Kaiga site included climbing ormwork

system or prestressed containment walls,

sliporm or ventilation stack and ormwork or

other structures. A special ormwork supporting

structure was designed to support the ormwork

o inner containment dome o the reactor.

Construction o Kaiga nuclear power project was

highly challenging, considering the remoteness o

the site, unriendly weather conditions and other

complexities. Despite the hardships, ECC met the

challenges and successully completed the project

as per the requirements o NPCIL.

L&T is proud o its association with NPCIL, which

has celebrated its Golden Jubilee Year and wishes

to continue its commitment and contribution or

the development o Nuclear Power Generation in

India.



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Endeavours

at TarapurNuclear Power Plant

B.SundArAmoorthy,Project Manager

ViShVA mohAn ShriVAStAVA,Planning Engineer



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taap Ac Pwe Sa

The Tarapur nuclear power station houses two

200 MW Boiling Water Reactors (BWRs). The new

series o 540 MWe nuclear reactors are developed

indegeneously rom 220 MWe Pressurized Heavy

Water Reactors (PHWR). At present, this power

station has the largest nuclear power reactor in thecountry. It was commissioned seven months ahead

o schedule by the Nuclear Power Corporation o

India.

BArC isallas, taap

The Bhabha Atomic Research Centre (BARC) -

Indias primary nuclear research acility supports

Indias nuclear power and research programme.

BARCs installations at Tarapur support the

operations o Tarapur Atomic Power Station.

L&ts rle

L&T has executed the 2 540 MWe at Tarapur

and was involved in almost all the disciplines o

engineering o a Nuclear Power Project. L&T

was involved in main plant civil works, service

water system, reactor piping, composite chilled

water and HVAC packages, electrical works and

instrumentation works which demonstrated the

capability o L&T in broad spectrum engineering

construction. The heavy engineering division o

L&T had supplied the calandria, steam genertaors

while the Engineering & Construction division

supplied the Primary Steam Piping system. ECC

involved in the mechanical erection o these

structures.

The scope o main civil works package covered

construction o reactor, service, station auxiliary,

reactor auxiliary, control buildings, pipe & cable

bridges, ventilation stack, potable water tank,

roads, site grading, abrication & structural steel

erection, EPs and other miscellaneous structures.

The gestation period or nuclear power projects

today is considerably reduced by commissioning

TAPP 3 & 4 in 60 months. This is an international

benchmark achievement. At TAPP 3&4, the

challenge o completing the total project in 60

months was achieved by deploying innovative

construction methods. Some o them include

pumping o heavy concrete, casting o 7m

high columns in single lit, use o sel climbing

ormwork or inner containment wall, casting o 3.5

mhighwallforOCwall,prefabricationofcalandria

vault liner, use o threaded coupler or reducing

reinorcement congestion and wastage, easy

handling etc.

Design, procurement and construction o service

water system, composite chilled water and

HVAC packages include supply o some critical

equipment such as vertical turbine pumps to work

View o Tarapur Atomic Power Project during construction



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in sub-marine environment, 3050 TR capacity

centralized chillers and 60 lakh CMH capacity

ventilation system.

The primary piping package executed by ECC(in association with E&C division o L&T) at TAPP

3&4 is meant or nuclear steam supply system

(NSSS) which consists o reactor assembly, the

moderator system and the primary heat transer

system. The reactor assembly system is the

most important part o NSSS and it consists o

calandria, end shields, calandria tubes, coolant

tubes, end ttings, uel bundles and reactivity

control devices. The abrication and erection o

primary piping system is to be carried out in dust

ree environment. Extreme care need to be takenor maintaining clean room conditions not only in

the abrication stage, but also during erection.

The order or electrical and instrumentation works

is probably the single largest order awarded to

any contractor by NPCIL. These packages involve

design, manuacture, supply, erection, testing and

commissioning o various critical electrical and

eld instrumentation items required or a nuclear

power plant.

Aal Wase tak F (AWtF)

ie descpo u toal Qy

Excavation cu.m 15695

Concrete cu.m 17168

Rebar abrication t 2150

Formwork sq.m 24770

Fabrication & erection o inserts and

structural works - Stainless Steel t 123

Fabrication & erection o inserts and

structuralworks-CS t 84

Fabrication & installation o SS 304L liners sq.m 2900

Supply and installation o ventilation system cu.m / hr. 215000

Fabricationandinstal lationof300cu.mSS304Ltanks Nos 08

Fabrication o SS piping ID 13000

Erection o SS piping IM 11000

Unit 3 & 4 o Tarapur Atomic Power Project, ater completion



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shielded vaults (V-1 and V-2) with 4 tanks each

andtwocells(Cell-IandCell-O)accommodating

the in-routing, out-routing and sump tanks. Each

sub-vault has a sump in the vault rat. Necessary

sloping was provided in each sub vault with a

channel. The foors at all sub-vaults and its walls

up to height o 1.5m are lined with 5 mm SS 304L

plates.

In between the two corridors above the vaults,

rooms or sampling blisters and transmitter rooms

are accommodated. The corridors also house

the embedment or the services and utilities like

headers, valves, instrument racks, cables or

taking samples remotely and to open the vault

entry. A monorail (10 t capacity) was provided in

each corridor or liting the plug o the vaults to

enable service inspection.

AWtF Aex Blg

The service building, known as the AWTF Annex

is a two foor building. Vault exhaust an room,

ventilation air supply an room, electrical room and

change room are housed in the rst foor. Second

foor accommodates control room or monitoring

and carrying out the operations o the AWTF, waste

cooling water room, waste o-gas equipment and

blower room.

Spe Fel Sage Facl (SFSF)

SFSF was constructed to receive and store the

spent uel rom nuclear power plants under water

beore sending it or urther processing.

The SFSF project demanded partially underground,

high perormance concrete structures (lined with

stainless steel plates) meant to store the spent

uel discharged rom the Nuclear Power Reactors.

SFSF is lled with de-mineralised water, supported

by water-polishing system and a water-cooling

system.

The scope o work covers constructing and

installing all associated utilities like inltration

gallery, DM water plant, pool water polishing

system, cooling water system including cooling

towers, material handling system including

10 & 75-t EOT cranes, 2-t pool bridge crane,

re protection and alarm system, electrical and

instrumentation and control panels, air conditioning

and ventilation system.

Spe Fel Soage Facly (SFSF)

ie descpo u toal Qy

Excavation cu.m 39365

Concrete cu.m 9475

Rebarfabrication t 1892

Formwork sq.m 27026

Waterproong (Terrace) sq.m 3390

Fabrication and installation o SS 304L liners t 62

Supply and installation o ventilation system cu.m/hr. 235000

Supplyandinstallationof75/5tEOTCrane Nos 01

Supplyandinstallationof10tEOTCrane Nos 01

Supply and installation o 2-t pool bridge crane Nos 01

Supply and installation o DM water plant Nos 01

Supply and installation o pool water polishing unit Nos 01

Fabrication o tanks and vessels Nos 6

EOT crane at Spent Fuel Storage Facility



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SFSF pl blg ses

vehicleairlocks

caskdecontamination/storagearea

EOTcranes,poolbridgeandhoists

undergroundfuelpool

spentfueltransferbayalongwithunderground

duct to nearby reprocessing plant or hydraulic

transer o uel bundles as per the requirement

o BARC

leak detection and collection facility for fuel

pool

poolwaterpolishingunit

domesticwatertank

approachroadfortrailerandtruckmovement

localcontrolpanels

The SFSF pool building extension houses pumps

or water cooling system and polishing; ventilation

system in an exhaust an room; disposal system

or regenerate efuent (underground RCC tank

with pump and piping) and stack or exhaust

vent. The utility building houses air conditioning

and ventilation system; DM water plant; electrical

substation; change room, rooms or monitoring,

aircompressor,controlandlaboratory.Otherareas

A view o Polishing Unit o Spent Fuel Storage Facility

include low level efuent storage and pumping

acility, de-mineralised water storage tanks (atop

uel pool building) and security and access control

system. The administrative oce area has a good

training and conerence room with all gadgets.

Excellent quality ratings are achieved in this project,

which enabled it to bag ECC Quality Trophy.

DM plant at

Spent FuelStorage Facility



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The main objective o the test model is to nd out

the behaviour o the Nuclear reactors containment

structure under extreme pressure conditions. The

model is pressurized three times more than the

actual design pressure o the Nuclear Reactor.

The model is also tested to establish and check

the design parameters o the actual containment

structures and to get better understanding o

structural behaviour o the containment structure

or uture.

tes mel a taap

The pre-stressed concrete containment test model

is scaled down to represent the actual Pressurised

Heavy Water Reactor o Tarapur Atomic Power

station 3 & 4 at Tarapur, to a actor o 1:4. This

model is constructed at Tarapur close to the

existing BARC acilities.

Contented by the perormance o L&T in Tarapur

Atomic Power Project 3&4, NPCIL invited L&T to

construct the model on nomination basis.

Ater the construction o the model, the same will

be subjected to a pressure, which is approximately

4.5 to 6 kg/sq.cm or even higher. However, the

actual ailure pressure will be established ater

testing. In any case, it is expected that there will

be nominal leakage at 5 kg/sq.cm.

Sale eaes

All the components o the actual reactor is scaled

down to 1:4 including pre-stressing, critical

openings etc.

ra

The inner containment wall is supported on a rat

having dimensions o:

Diameter-15.60mand Depthof3m

Stressinggalleryofsize1500mmx1800mm

below the inner containment structure with 4

access shats

ie Cae wall

Thickness-188mm

Heightofthewall-12.475maboveraft

Constructedusing9lifts

TheinnerdiameterofICwallis12.40m

rg Bea

Heightofringbeamis1.2m

Averagethicknessis450mm

ICwall,ringbeamanddomearedesignedas

monolithic structures

nclea reac Cae

tes mel 1:4 Scale Pe-sesseCcee Cae

B.SundArAmoorthy,Project Manager

Completed view o the test model. Right: Sectional view



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ie Cae de (iC de)

The IC dome starts at 13.706 m height and springs

up to the crown 15.750m.

AveragethicknessofICdomeis164mm

Centre line diameter of the IC dome is

19.60 m

Two radial Steam Generator (SG) openings

o diameter 1.35m at the centre line are

provided in the IC dome to simulate the Steam

Generator openings o the prototype

Inner containment dome was cast in single

pour

Sess

To monitor the response during prestressing o

containment and dome, ollowing sensors were

used:

727 sensors were installed in concrete

rom rat to crown o the dome at

pre-determined locations

89sensorswereinstalledonHTstrandsand

stressing was analysed

Dierent type o sensors used in test containment

included:

Embedded type of Vibrating Wire Strain

Gauge(VWSG)

PastableSMER10mm

Spotweldable51mm,Weldable203mmand

Earthpressurecell

Weldable type o sensors were installed on

reinorcement bars whereas embedded type in

concrete.

Pe-sessg

Inner containment wall and dome was subjected

to prestressing using prestressing system 1T15.

This involved:

Totalnumberof 313cables, comprisingof

JO&JI,VerticalandHorizontalcables.

15.2mmdiameterhightensilestrandforpre-

stressing works

HDPEsheathingof25mm-OD/20mm-ID.

Maximum load applied on HT strands was

21.20 t on each cable and

Sheathing was cement grouted with

temperature controlled cement grout

Csc Js-Fk Sse

Construction joints in the dome and the inner

containment wall were sealed using Fuko system

i.e. Re-injectable grouting system with injection o

hydro swelling, water based, low viscous, thermo-

setting resin. This is done ater construction to

make the joint leak tight or air and water.

Calleges

te wk vlve seveal calleges lke:

Placement of reinforcement, HDPE sheaths

and tube units, due to congestion in scaled

down thickness o walls and dome having

stringent tolerances o +/- 3 mm.

Installationandprotection of 727sensorsin

IC wall and dome during preparation o pours

and concreting were tough tasks

Utmost care was taken during installation

and 99% o sensors are unctioning well even

today.

Installationof instruments in wall anddome

due toslender section i.e. 188 mmthickof

wall and 164 mm thick o dome.

Formwork

- Nuts were not allowed through ties and coil

- Slender sections

- Complicated tailor made ormwork system

was used with preabricated C shaped MS

rames

Difculty in mounting large number of

instruments in limited space around openings

o Airlock Barrels.

Eorts required or the construction o the test

model involved same amount o work or more

than that required or the proto-type due to the

limitation in scaled down dimensions.

heal Sae aEve

Regular training and orientation programs or

workmen were conducted to keep them alert at all

times.

Projecthasachievedzeroaccident

Achieved1.4millionsafeman-hours

The project was successully completed in

December 2008 to the fullest satisfaction of the

client.



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Indias rst 2 1000 MWe Nuclear power plant

is coming up at Kudankulam. The project is

located on the shores o Gul o Mannar, on the

Southeastern tip o India near Kanyakumari. It is

located at Radhapuram taluk o Tirunelveli district

in Tamilnadu state.

The site experiences a tropical climate with

humidity ranging rom 40% to 90% depending on

the season and is subjected mainly to the winter

monsoonduringthemonthsofOctober,November

and December.

The Kudankulam Nuclear Power Project (KKNPP)

consists o two units o 1000 MWe with two steam

driven turbo generators supplied with turbine

steam rom two pressurized water VVER type

reactors o Russian design. The design o various

equipment, systems and structures are carried out

in accordance with Russian and other International

Standards.

The entire project capacity o 2000 MWe (2 x 1000

MWe) o power will be supplied to three southern

states (Tamil Nadu, Karnataka and Kerala) and the

Union Territory o Pondicherry. NPCIL has divided

the whole project into number o packages and

awarded to dierent contractors. The whole project

cost is about Rs. 13,000 cr.

Packages

L&T has been awarded M2, M4, M5, C5 and E1

packages directly by NPCIL. M3 and I1 have been

awarded to L&T by BHEL & ECIL.

mecacal:

Erection of Nuclear Steam Supply System

(NSSS)and auxiliary systems (equipment,

piping & tubing works) - M2 Package

Seawater system (equipment & piping

erection) - M4 Package

Common service (piping & equipment

erection) - M5 Package

Erectionofturbine-M3Package

Cvl:Radioactive waste processing and storage

buildings - C5 Package

Eleccal: Erection o electrical equipment andsystems - E1 Package

teccal Aspecs

Kudankulam Reactors are Water-cooled Water

moderated Energy Reactor (VVER-1000) o

Pressurized Water Reactor (PWR) technology,

which is worldwide proven concept. VVER-1000

reactors are the most advanced reactors

similar to the PWRs o western design. Nuclear

uel is charged into the reactor where the ssion

takes place and the heat is liberated. The

liberated heat in the reactor is carried away by the

light water rom the reactor to steam generator

by the main coolant pump. De Mineralized

(DM) water acts as reactor coolant. The coolant

water is used in the steam generators to produce

steam. The steam is allowed to pass through

turbine blades with high pressure and velocity.

The turbine then rotates receiving the kinetic

energy o the steam. The generator, which is

mechanically, coupled to the turbine also rotates

and generates power. The back steam o the

turbine is allowed to pass through the surace

type condensers. The condenser will be having

tubes through which sea water is allowed

to fow and over which the steam fows. The

sea water absorbs the heat rom the steam and

condenses the back steam. The condensate is

recycled back to steam generator. The sea water

ater absorbing the heat rom the back steam

is discharged into sea and resh water is drawn

through inlet.

n.P. VArAdhArAJAn & r. BALASuBrAmAniAn, Project Managers

Kudankulam Nuclear

Power ProjectA.u. rAo

Planning Manager



15/48

mecacal wks ias Lages nclea

Pwe Pla

Larsen & Toubro has won all major mechanical

erection and installation. This includes our

mechanical packages and two electrical and

instrumentation packages.

The scope o work in M2 package include handling,

transportation, pre-abrication, welding, erection,

inspection & testing o piping, instrument tubing

and erection o associated equipment along with

accessories or nuclear steam supply systems and

nuclear auxiliary systems or Unit 1 & 2. This main

mechanical package involves heavy erection o

critical nuclear equipment like Reactor Pressure

Vessel, Steam Generators, Reactor Cooling

Pumps, associated piping in reactor and auxiliary

buildings, various saety systems like boron

injection system, passive heat removal system

and containment sprinkler system.

Eec a alge

nSSS Eqpe

In this M2 package, reactor equipment (2 x 316 t

each) was erected in our stages. Being a nuclear

project, high degree tolerances limit (0.01mm) was

maintained. Another challenge during the erection

was the clearance between the inner diameter o

support structure and outer diameter o Reactor

Pressure Vessel (RPV), which is only 10 mm and

large volume o blue matching.

SteamGenerator(8x307teach)waserectedina

conned space with the alignment in the range o

0.4 mm to 0.5 mm.

Pressurizer (2 x 222 t each) was also erected in

conned walls with the tolerance of 8mm w.r.t

containment wall and alignment in the range o

0.4 mm to 0.5 mm.

All the above erections were executed using highly

precision optical tooling survey instruments viz.,

Jig Transit.

MainCoolantPiping(64Jointsof990mmOD)

designed or a pressure o 176 kg/cm2 and

temperature o 320C has our quadrants. It

is connected to reactor pressure vessel (RPV)

assembly, steam generator (SG) and reactor

coolant pump (RCP). The piping is used to re-

circulate the primary coolant thereby removing

heat rom reactor and transer the same to steam

generator.

Pipes are made out o low alloy steel having outside diameter o 990mm and 70mm wall thickness,

cladded inside with austenitic stainless steel. The

total circuit involves 32 weld joints per unit and

the total weight o piping is about 260 t. The pipes

were supplied in pre abricated piping spool. For

the rst time in India, a unique and sophisticated

welding method was adopted or Main Coolant

piping at a nuclear power plant. Controlled and

Induction Heating technique was adopted or the

rst time in India during the welding operation with

Erection o ReactorPressure Vessel in

progress



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hot temperature radiography o weld joint at 200

deg centigrade using special xtures and source

protection measures.

te Scpe wk vlve

ReactorEquipment-13,125t

StationaryEquipment-3,036t

RotaryEquipment-652t

Piping(SS/CS)-3,100t

SS/CSValves-1,180t

InstrumentTubing-CS/SS-1,60,920m

TubeWelding-CS/SS-9,000Nos.

tbe Eec

M3 Package work involves handling at site store/

storage yard, transportation to site o work, erection

testing and commissioning o turbine generator,

eed pumps, piping and its auxiliaries.

AlignmentoftheturbinewasdoneusingOptical

Aligning instrument and Fronius was adopted or

orbital welding.

Sea Wae Sse

M4 Package work covers handling, transportation,

pre-abrication, welding, erection, inspection,

testing and painting o sea water systems

equipment and piping in Sea Water Pump house

and Chlorination plant. The main work in this

package include works in pump house like EP

abrication and erection, anti corrosive painting,

erection o gates and screens, GRP piping, vertical

pump erection. chlorination building works and

tunnel piping. Again, using or the rst time in

India, Coupon Hycote paints was used or the

internal painting o sea water pipes.

Rotatingequipment 1,432t

Stationaryequipment 1,465t

CSpiping 2,108t

SSpiping 8t

Glassreinforcementpiping 35t

Titaniumpiping 16.5t

Excavationandbacklling 56,000cu.m

Structuralsteel 500t

Coldinsulation 1,183sq.m

Anti-corrosivepainting 55,683sq.m

Coatingandwrapping 4,000sq.m

Gritblastingandpainting 9,000sq.m

C Sevce Sse

The scope o work M5 Package covers handling,

transportation, pre-abrication, welding, erection,

inspection, testing o indoor and outdoor piping

and equipment o common service systems.

This consists o all indoor and outdoors piping,which includes HDPE piping or portable water,

re-ghting system (SGA, SGC, SGE), buried

piping (coating and wrapping included), boiler

associated works, DM plant associated tanks and

piping, and all nuclear ancillary building piping

and equipment.

Rotatingequipment-450t

Stationaryequipment-2,612t

CSpiping-2,452t

SSpiping-405t CIpiping-65t

HDPEpiping-150t

ACpiping-255t

RCCpiping-900t

Excavationandbacklling-238000cu.m

Coatingandwrapping-7,000sq.m

Supply,fabricationanderectionofstructural

steel - 500 t

Piping or Passive Heat Removal System



17/48

The 1000MWe turbine, rst o its kind is a steam

condensing, our cylinder conguration (1 HPC +

3 LPC) with intermediate moisture separation and

steam reheat, with rotational speed o 50 s-1 (3000

rpm), designed to drive directly an alternating

current generator, mounted on a joint oundation

with the turbine. The total length o turbine with

out generator is about 40.65m. The turbine is

provided with throttling steam admission. The

steam rom steam generator is supplied to 4

HP valve blocks each HP valve block consist o

one stop valve and one governing valve through

which the steam enters the HP cylinder.

HP rotor is an integrally orged rotor. LP rotors

are also integrally orged rotors (blade lengthis 1200mm). All rotors are provided with rigid

coupling and supported by two journal bearings.

The thrust bearing, mounted between HP cylinder

and LPC 1 serves as a xed point or the rotor.

The steam from 4th stage of each LPC is

extracted by 3 LP heaters 1.

Thesteam from 3rdstage of LPC2 &3 is

extracted by LP heater 2.

The steam from 2nd stage of LPC 1 is

extracted by LP heater 3.

HPCturbineisofdoubleowcylinderhaving

5 stages in each fow.

The steam is extracted from second, third

and ourth stages o each fow or eed water

heating by HP heater 5,6 and deaerator

respectively.

FromHPCexhauststeamisextractedbyLP

heater 4.

The steam from exhaust of HPC enters

moisture separator reheater.

AfterseparatorreheaterthesteamentersLP

cylinder through LP valve blocks which consist

o 1 stop valve and 1 governing valve.

LPCturbinearedoubleowcylindershaving

5 stages in each fow.

MassofheaviestpartofturbineisLProtor

-80.5t Massofturbine-1800t

Sale Feaes tbe

Qa wk

Turbine 4,028t

Generator 1,297 t

Condenser 2,609 t

Feedpump drive Turbine & Aux 402 t

Feedpumps 169 tCondensate Pumps 257 t

CrossoverPipes 283t

OtherAuxiliaryEquipment 200t

OtherPiping 12t

Two views o Stator (345 t) during erection or 1000 MWe Turbine Generator at Unit #2



18/48


Insulation-6,000sq.m

Supplyandxingofhiltybolt-1,000Nos.

Wellerection-824Nos.

Sae

Saety system practiced at the project site is

extremely stringent as it involves several heavy

lits, erection o critical equipment, hot processes

and working in severe conditions like tunnel and

conned space. L&Ts team religiously ollows the

saety norms as per the requirement o the Atomic

Energy Regulatory Board (AERB). L&T has been

awarded the Project Directors rolling trophy or

Best House Keeping by the client.

All the pre-commissioning and commissioning

activities were meticulously planned and

implemented successully. All the erection

sequences and procedures were documented

in 175 volumes. These dierent packages are

progressing well, meeting the quality standards

set by Russian authorities.

Apart rom Mechanical packages Instrument

tubing works in reactor building also in L&Ts

scope which involves 160 km tubing works.

Eleccal Scpe

E1 Package - teccal Aspecs

MainPoweroutputsystem

Auxiliarypowersupplysystem

Classicationofauxiliarypowersupplies GIS

Systemgrounding

ipa eaes e pla

First21000MWepowerplantinIndiaunder

construction with single transormer unit o

capacity 417 MVA

First time in India having 4200m length of

400kV GIBD

Fully inside lined reactor containment, a rst

time eature in India.

SG Pressuriser

erection in progress

Turbine erection



19/48

The tender specications covered electrical

system installation in all the buildings o KKNPP

unit 1 & 2 such as 400kV GIS building, switchyard

control room building, transormer yards, normal

operation power supply building, common station

power supply building, emergency power supply

buildings and other main plant buildings such

as reactor building, turbine building, reactor

auxiliary building, pump house etc. as well as

supply o some electrical equipments, hardware,

accessories required or the installation works.

Sse descp

The electrical system or the two units o

Kudankulam nuclear power plant, each o 1000

MW, mainly consists o power output system and

auxiliary power supply system. The power output

system is designed or evacuation o powergenerated at NPP. The auxiliary power system

provides the power to NPP auxiliaries to carry out

their assigned unctions, in all operating modes o

NPP.

Pwe op Sse

The electrical power generated by the turbine

generators at 24 kV, three phase and 50Hz is

stepped up to 400 kV by the generator transormer

and is evacuated through our 400 kV transmission

lines. For reserve source o power to auxiliaries oNPP, Kudankulam NPP is connected to Tuticorn,

SR Pudur and Kayathar through 230 kV lines.

400 kV and 230 kV lines are connected through

interconnecting transormers. 400 kV and 230 kV

switchgear are o SF6 gas insulated considering

the saline atmosphere at Kudankulam site. 400 kV

is designed as one and hal bus scheme. 230 kV is

designed as two main bus schemes.

Major components o the power output system or

KKNPP include:

24kV1000MWgenerator

24kV31.5KAIsolatedPhaseBusduct(IPDB)

24kV28KAgeneratorcircuitbreaker(GCB)

3X417MVA,24/400kVgeneratortransformer

(GT)

400kV2000Agasinsulatedbusduct(GIDB)

400kVgasinsulatedswitchgear(GIS)

400kVtransmissionlines

315 MVA, 400 kV /230 kV interconnecting

transormer (ICT)

230kVgasinsulatedswitchgear(GIS)

230kVtransmissionlines

1phase26.7MVAshuntreactors(6nos)

Axla Pwe Sppl Sse

The main unction o the auxiliary power system is to

ensure the availability o sucient power supply to

the auxiliary system equipments during all modes

o plant operation i.e. normal plant operation,

shutting down the reactor, maintaining the reactor

in sae shut-down state, containment isolation,

reactor core cooling, preventing signicant release

o radioactive material to the environment and any

other necessary unctions.

For start up as well as or normal shutdown o bothunits o plant, station auxiliary power is drawn rom

the 400kV network through generator transormer

and unit auxiliary transormers with the GCB

open.

During normal plant operation, station auxiliary

power is drawn rom the main generator rom the

tap-o to 24kV bus duct through the UATS.

The reserve power supply is derived rom 230kV

grid through 230/6.3-6.3kV RATS and is used as

backup power during non-availability o powersupply rom UATS.

The common station auxiliary power supply eeding

the common station auxiliary loads is derived rom

230kV grid through 230kV/6.3-6.3kV CSATS and is

backed up by the RATS.

The systemmainly consists of 6kV, 0.38kV and

220 V DC power supply sources to supply to

unit auxiliary loads and common station auxiliary

loads.

Auxiliary power supply system envisaged orKKNPP is categorized as per their unctional

requirements detailed below.

Normal auxiliary power supply for each unit

system including common station auxiliary

supply system or the plant.

Reliable auxiliary power supply of normal

operation or each plant.

Emergency auxiliary power supplies system

or saety systems or each unit.



20/48


Eleccal Wks

isalla, esg a pecssg

Description QTY UOM

24KV,2800ASF6GeneratorCircuitBreaker 2 Nos

420/24 KV 417MVAGenerator Transormer 7 Nos

24KV 31500A single phase Isolated Phase Bus Duct 1120 m

315MVA 400/230/33kV interconnecting transormer 2 Nos

63/31.5-31.5MVA, 24/6.3/6.3kV UAT/RAT/CSAT 9 Nos

27MVA 420kV Single phase Shunt reactors 6 Nos

400kV 3150/2000A Single phase SF6 bus duct 4200 m

230kV, 2000A single phase SF6 bus duct 900 m

6kV 6.3MW Diesel Generator Sets 10 sets

6kV 3150A Isolated phase bus duct 2400 m

6kV 3150/1600A Switchgear Panel 522 Nos

6kV/0.4kV 1000KVA/400KVA Dry Type Aux.

Transormer 107 Nos

0.38kVMCCSingleFrontPanel 444 Nos

0.38kVMCCDoubleFrontPanel 668 Nos

CableTray&Supports 1860 t

Cables 7800 km

HT & LT Termination 129000 Nos

LightFittings 21285 Nos

Sppl, eec, esg a cssg

Line Protection Panels 7 Sets

Lighting /Power Distribution Board 672 Nos

Light Fittings 7331 Nos

GI Conduits 344 km

650/1100VFRLSPVCWire 800 km

Classfca o Axla Pwe Spples

Depending on the degree o reliability or

requirement o saety, the power supplies are

classied into three groups

Gp-1: loads that require uninterruptible power

supply are kept in group-1 class. These can be

interruptible but not more than 20 seconds.

These are supplied from 220 V DC, 380 V and

220 V AC power supplies normally derived rom

group-3 or group-2 power supply sources and

whose back up source o power is rom the battery

banks.

The major components o auxiliary power supply

system are given as below.

63MVA,24/6.3-6.3kVUAT

63MVA,230/6.3-6.3kVRATS

230/6.3-6.3kVCSAT

6.3MW,6kVDG

6kVswitchgear

1000 kVa & 400kVa, 6/0.4kV and 6/0.433kV

auxiliary transormers

0.38kVand0.415kVswitchgear/MCCs

Rectiers

220VDC&110VDCbatteries

Inverters

220VDCdistributionboards

220V/380VACdistributionboards

110VDCdistributionboards

Cabling

Cablepenetrations

Gp-2: AC supply to the loads, which can

tolerate short interruption or a time dened by

the conditions without eecting saety o the

reactor, under all modes o the plant, including the

condition o loss o supply rom all o-site sources,

is called the group-2 loads.

6.6 kV control replay panels



21/48

These are supplied from 6kV, 380V and 220 V

AC, 50Hz supplies normally derived rom group-3

power supply and whose back up source o power

is rom DG sets.

Gp-3: power supply to the plant auxiliary

loads normally required under all modes o plant

but which can tolerate prolonged interruption inthe power supply, without aecting the saety o

the plant, and do not require obligatory availability

o power supply even ater the actuation o the

reactor trip system is called the group-3 power

supply.

Thesearefedfrom6kV,380Vand220VAC,50Hz

supply derived rom UATS, RATS or CSAT.

Pcples Cl, mg a

rela Pec Sse

During operation, a system is understood as a

set o devices o relay protection, control and

monitoring o the electrical equipment, structurally

and unctionally involved. At KudanKulam NPP,

independent system o control, monitoring and

relay protection system are provided or many o

the systems.

Gas islae Sbsa

Here switchgear apparatus or 220kV and 400kV

equipment use the SF6 as dielectric media due tomany o its advantages.

Though SF6 was developed in 1900, it was

used as dielectric medium only ater 1940

Itisapowerfuldielectricmedium

Itsdielectricstrengthis2.35timestothatofair

Itis5timesheavierthanair

Itisnon-toxicinpureform

Its dielectric strength is proportional to the

pressure that it operates

ThisiswellsuitedforHVswitchgearsandGIS.

The gas passing through the isolated bus duct acts

as a powerul insulation media and this compacts

the size o the switchgear.

Gg a Lgg Pec

To achieve the requirements, a grid consisting o

70 sq.mm tinned stranded copper conductor has

been laid by the civil contractors at a depth o not

less than 0.5 m below the oundation, with a mesh

size o 25m 25m in the outdoor area and about

6m 6m mesh size beneath the buildings. GI

earthing conductors run to walls and foors inside

the buildings, which orm the main grounding lines

are connected to the buried copper conductors.

All the metal components inside the building are

connected to the grounding network.

Lightning protection conductors in a mesh

ormation are provided over the building surace,

along outer perimeter walls and on the roo and

are connected to the grounding grid. Lightning

arresters are installed on the stack top.

isea

I1 package involves executing the entire

instrumentation work under the supervision o ECIL.

Scope o work includes calibration and installation

of 18,000 instruments such as Pressure, Flow

and Level transmitters, RTD and Thermo couples,

Pressure and Temperature gauges, Analytical

instruments, Level sensors, Seismic sensors and

Radiation monitors, Installation o 3000 instrument

support stands, abrication and erection o 200 tsteel, 50 km o GI perorated tray or eld routing

and 176 km o cable laying and glanding work

Cvl Wks

C5 package involves 65000 cu.m o concreting

works to construct De-Mineralized Plant (DM Plant),

Boiler House, Solid radioactive waste building,

Chiller units building, Compressor building and

Diesel storage pump House including NPCILs

Main Administration Building.

220 kV gas insulated

substation



22/48


PREFRE-3A ProjectF BArC Kalpakka

L&T-ECC is in the verge o completing, the

procurement, construction contract o civil

structure incl. 75 M High RCC stack and electrication

work or PREFRE-3A project (Power Reactor Fuel

Recycling) in the phase II or BARCs premises at

Kalpakkam on the Chennai Puducherry coastal

highway. Valued at Rs.65 Crore, the scope o work

are as ollows :

Excavation - 67500cu.m

Reinforcement - 5400t

Concrete - 27740cu.m

Formwork - 90290sq.m

Brickwork - 3160cu.m

Plastering - 50000sq.m

Painting - 75311sq.m

Site team has received appreciation letter or

achieving 4 million sae man hours. And has got

excellent customer relation ship, TCE Consulting

Engineers are the consultants or this project. Work

commenced in August 2005 and expected to becompleted by May09 in all respect.

These civil structure and electrical works are used

or Nuclear uel recycling received rom designated

Nuclear plants in India.

PREFRE-3A Facility is being developed as an

expansion to the existing KARP-(Kalpakkam Atomic

Recyclingplant)onthesouthside.Oncompletion

the newly constructed structures will be merged

with KARP or enhance the recycling capacity.

The very objective o Recycling programme is to

get to recover materials like Plutonium ,etc in the

process to reuse in non conventional nuclear Power

generation programme like FBR (Fast Breeder

Reactor).

L&TECC Division is engaged in construction works

at Madras Atomic power station (MAPS) Kalpakkam

rom 70s and has the credit o constructing 40m

high and 45m dia dome reactor, turbine buildings,

100m, 75m & 65m RCC stacks or NPCIL.

Scope coss of as ay as 14 sces a e eals ae as follows:

nae of sces deso reaks

High block 60 x 30 x 25 m high 4 storey mainstructures o the plant

Low Block 60 x 26 x 20 m high 4 storey buildingInter mediate Traner acility 24 x 24 x 10 m high 6m substructure and 3 foors

constructed using 19 Ctemp. concrete

75m high RCC stack 75 m high x 3.6 m dia Ventilation stack

Delay tank 24 x 30 x 6 m below RCC tank o sevenchambers below GL.19 C concrete

Substation C 30 x 24 x 10 m high 2 storey structure

ExhaustFanmainplant 50x18x10mhigh 2storeystructure

Exhaust control Room 19 x 17 x 10 m high 2 storey structure

Connecting corridor 25 x 6 x 25 m high 5 storey structure

Fuel Handling Area extn. 21 x 6 x 7 m high

RCCVentilationDuct 60mlong2X2mbox

CompressorHouse 18x12x7m

Bolier House 15 x 16 x 7 m

FOST(Fueloilstoragetank) 13x11m

h.m. BhAdri

Project Manager

Construction in progress at one o the blocks



23/48

to utilize indigenous capabilities or the Turnkey

Construction o nuclear power plants including

supply o reactor equipment and systems,

valves, electrical & instrumentation products and

abrication o structural, piping and equipment

modules or the Westinghouse AP 1000 plants.

Asexp

For Nuclear Power Reactors, L&T and

Atomstroyexport (ASE) o Russia have signed a

MoU or co-operation between the two companies

or Russian design reactors VVER 1000.

The MoU will orm the basis o co-operation

between the companies and address needs

or equipment & other services arising rom the

agreement signed between India & Russia on 5th

December2008,forfouradditionalreactorsKK3-6

at Kudankulam, Tamil Nadu and other Russian

reactors at new sites in India.

L&T is the only Indian company to be accredited by

ASME (American Society o Mechanical Engineers)

to use its N and NPT stamps or critical nuclear

reactor equipment. L&T played an important role

in construction, piping & erection services or the

KK1-2 VVERs at Kudankulam.

According to the signed document L&T and ASE

will develop co-operation in the construction o

Kudankulam new power units, as well as during

construction o plants under the Russian designs

with VVER reactors at new sites in India, and alsoin other countries.

This MoU with ASE represents a major step or L&T

into VVER component & systems manuacturing &

services. It will enable L&T as well as ASE to utilize

indigenous capabilities or nuclear power plants

including supply o equipment and systems,

valves, electrical & instrumentation products and

abrication o structural and piping and construction

or the Russian VVER plants in India and in other

global locations.

AECL ACr 1000 reacs

L&T and Canadian based Atomic Energy o Canada

Limited (AECL) have signed a Memorandum o

Understanding or co-operation on Advanced

CANDU Reactor ACR1000. This agreement is

subject to nal approval by the governments

o India and Canada, o a bilateral Nuclear Co-

operation Agreement between the two countries.

Pressurized Water Nuclear Reactors (PHWR) designis one o the most highly competitive nuclear

technologies in the world with regard to capital

cost, saety & eciency. The unique design allows

reueling online which eliminates the periodic

reueling outage required by other designs.

The ACR1000 is AECLs generation III+ reactor

design that utilizes the proven concepts o the

PHWR. L&T and AECL have joined hands to

develop a competitive cost model or the ACR

1000. Upon completion o the indicative cost/scope

model AECL and L&T agree to begin discussions

to develop Nuclear Power Plants in India on EPC

basis and utilize the collective expertise o the

Parties in global markets.

Wesgse mla nclea Pwe

reacs

L&T and US-based Westinghouse Electric Company

(WEC) have signed a MoU or co-operation to

eectively address the projected need in India or

Pressurized Water Nuclear Reactors with Modularconstruction technology. Westinghouse technology

is in use in over orty per cent o the operating

nuclear power plants in the world.

Whereas L&T has been playing a lead role

in equipment manuacture, construction and

project management or Pressurized Heavy

Water Reactors in Indias domestic program, this

MoU with Westinghouse represents a major step

orward or L&T in Pressurized Water Reactors o

modular design. It will enable L&T as well as WEC

L&t sgs mu w

World Leaders in

Nuclear Power Sector



24/48


Indira Sagar

Right Main CanalProject

SAJid FArooQ mohAmmEdProject Manager



25/48

The Indira Sagar (Polavaram) project is located

in Andhra Pradesh on the river Godavari

near Polavaram Village above 34km upstream o

Kovvur, Rajahmundry. The Polavaram project is

contemplated as multipurpose project envisaging

irrigation benets or the upland areas o East

Godavari under Let Main Canal and West Godavari

and Krishna District under Right Main Canal.

rg ma Caal

The Indira Sagar (Polavaram) Right Main Canal

project is taking o rom the Godavari River on

the upstream o Indira Sagar Project (Polavaram),

Rajahmundry and runs or a length o 174.000 km

in West Godavari and Krishna Districts o Andhra

Pradesh. The Right main Canal at 174.000 km gets

linked up with Krishna River through the existing

Budameru Diversion Channel. This Right MainCanal is contemplated to irrigate an ayacut area o

129259 hectares (Ha) in the upland area o West

Godavari and Krishna District. This canal provides

for diversion of80TMC ofGodavari water tothe

Krishna River to meet the irrigation requirements

o Krishna Delta.

Cac

As a part o the ambitious and most prestigious

Jalayagnam Projects, the Irrigation & Command

Area Development (I&CAD) Department,Government o Andhra Pradesh divided the

174.000 km length Right Main Canal into 7

Packages and awarded the 7th Package to ECC,

L&Ts Construction Division on EPC turnkey basis

foravalueofRs.181crores.

Lca

Chainage 156.500 km - 174.00 km o package 7

begins at Nunna village, 25 km rom Vijayawada.

The main canal traverses through thick mango

elds, reserve orest, hills, deep cut quarries,ponds, lakes and small villages. The project is

ully surrounded by long stretches o green elds.

The 17.5 km long canal passes through 9 small

villages and terminates on the upstream side o

Budameru regulator at Velagaleru village.

Scpe Wk

Construction o this 17.5 km Right Main Canal

involves detailed investigation, survey, preparation

o land plan schedules, design and engineering,

earthwork excavation, ormation o embankments,

lining o main canal, construction o CM & CD

structures and plantation on both sides o main

canal.

Csc

The construction o main canal involves theollowing important stages.

deale ivesga a Sve

The entire stretch o the 17.5Km was studied in

detail by conducting various other alternative

alignment surveys. To the extent possible, the

alignment was done in FSL Contour to avoid

embankments. For nalizing the alignment and to

mark the route in thick reserve orest, bushes and

mango elds, GPS Navigators and Total Stations

were used.

La Pla Scele a La acqs

The village-wise Land Plan Schedules were

prepared or acquiring about 1000 acres o land

involving Private Lands, Revenue Govt. Lands and

Forest Area. About 3.25 km o main canal passes

throughthereserveforestofareaof120.68acres

and the balance part o the alignment traverses

through mango elds and cultivated lands. Digital

Cadastral drawings showing the boundaries o

each Village, extent o land and area to be acquired

were some o the important issues involved in

preparation o Land Plan Schedule and in Land

acquisition.

desg a Egeeg

The design and engineering or the entire

package was done by ECCs Engineering Design

& Research Centre (EDRC) at HQ, Chennai. The

design scope involved preparation o Bore log

sheet, preparation o Hydraulic particulars o maincanal, km-wise LS & plan o main canal, design

& drawings o cross masonry and cross drainage

structures.

The part o the alignment rom km 163.150 to km

163.700 has been designed as Flumed Section

with a bed width o 65.50 m considering the deep

cut excavation and alignment passing between

the hills. Standard Penetration Test and Plate

Load Tests were conducted at each structure to

ascertain the bearing capacity o soil.



26/48


halc Paclas ma Caal

Length o main canal : 17.50 km

Bed width o main canal : 73.25 m

Topwidthofmaincanal : 88.85m

Full supply depth : 4.2 m

Freeboard : 1.0 mSide slopes : 1.5H : 1V

Bed all : 1 in 20,000

Designeddischarge : 318.48Cumecs

No. o structures as per HPs : 24

Eawk Excava

The 73.25m bed width canal involves about

85 lakh cu.m of earthwork excavation and

10 lakh cu.m o embankment. The soils met with

on the course o the alignment were generally red

earth and hard gravel.

The depth o earthwork excavation in normal

section ranges rom 5-7 m depending upon the

ground level. A 40 m deep cut hard rock excavationat fumed section is one o the most critical and

adventurous one.

Lg ma Caal

Prole Walls shall be laid at8.75m and 17.5 m

intervals in curve portion and straight portion

respectively or ormation o Subgrade beore

laying the Lining Concrete. More than 600 workmen



27/48

were deployed or Subgrade preparation. In

addition, Graders and Rollers were also deployed

or ormation o Subgrade.

The lining or the main canal was done with M10

grade o concrete with 40mm maximum size o

aggregates. 100mm thick lining concrete was laid

or the entire bed width o 73.25m with slopes on

both sides up to a height o 4.95m rom the canal.

Onthewholetheworkinvolved1.8lakhcu.mof

lining concrete.

Contraction Joints at 5m intervals were provided

in both transverse and longitudinal direction.

This apart, suitable construction joints, concrete

sleepers, transverse drains, longitudinal drains,

porous plugs were also provided in lining

Concrete.

Css mas &

Css daage Sces

A number o streams and small village roads cut

across the main canal at dierent locations. Toprovide access to the villagers as well as to allow

the streams to pass across the main canal or

irrigation acilities etc., dierent types o structures

were proposed in the alignment o the main canal.

Thus, 24 dierent structures were constructed

in the canal alignment or meeting various

requirements.

Panoramic view o the canal



28/48


Jindal Dam - L&Tsmaiden venture in to

construction o ull-fedged dams

G. BhASKArA rAoPlanning Manager



29/48

Jindal Power Limited, a leading power generation

company, and a subsidiary o Jindal Steel has

set up a 1,000 MW super thermal power plant at

Tamnar in Raigarh district, o Chhattisgarh. For the

consumptive water use in the power plant, a dam

has been built across river Kurket, near village

Rabo, which is about 33 km rom the power plant.

This200mlong18.5mhighdamsuppliesabout

40 cu.m per minute o water to the power plant

and meet the consumptive and circulating

requirements o the power plant.

Apart rom being the ull fedged dam project

undertaken by ECC, this unique and landmark

project was raught with several social and

environmental problems.

Braving all the odds, L&T successully completed

the project and the food gates were ormallyopened and inaugurated by Mr. Sara, President

Jindal Power Limited on July 13, 2007.

Sale eaes

Main earthen dam in the Riverbed - 200m

long,18.5mmaximumheight

Rightbankdykeof1150mlongand2to15m

height

Leftbankdykeof201mlongand2to6m

height

Spillway dam and energy dissipation

arrangement 145m long with 10 vertical

gatesofsize12mx8.5mand2stoplogswith

operating system

Intake and pump house with stop log and

trash rack o 4m x 11m

Riverdiversionworks

Completehydro-mechanicalequipment

Approach roads to the project with

illumination

maj Scpe Wk

Excavationinordinarysoil-5,80,246cu.m

Excavationinrock(alltypes)-3,42,500cu.m

Concrete(allgrades)-57,772cu.m

Reinforcement-1534t

HMworks(GatesandHoist)-800t

Groutingmaterial(cement)-3,243bags

Bentonitefordiaphragmwall-27t

Excavationofcutofftrench-55,500cu.m

Fillingofcutofftrench-55,500cu.m

Earthworkllinginembankment-

48,2407cu.m

Rip-rapworks-30,917cu.m

Metalledroadatthetopofdamfacilities-

2.60 km

Electricalttingsandillumination

ree Lca

As the site was located at 35 km rom Raigarh,

a 11km approach road to site was strengthened

beore commencement o the work. In addition,

L&T had to establish V-sat connection as there

were no communication networks available in the

vicinity.

dapag wall

Initially, the diaphragm wall or the main dam was

an RCC structure. Ater the work was awarded,

the consultant changed the structure rom a rigid

D-wall to a fexible D-wall using plastic concrete

and doing away with the reinorcement. The

Foundation Engineering Competency Cell o ECC

took this challenge and developed a new design

mix or this type o plastic concrete. The ormula

worked perectly and the work was executed

successully.

Acevees

Major portion o project excavation or spillway,

concrete or spillway, abrication, erection &

commissioning o spillway gates and earthen dam

in the river portion including rip-rap works, were

completed in the stipulated time o 25 months

and handed over to clients. This project received

Prashansha Patra rom National Saety Council

o India (Saety Awards 2007) or achieving 4

million sae man-hours without any lost time due

to injury. Site also received Annual Quality trophy.

View o the dam and

hydro-mechanicalstructures (gates)

in position



30/48


Veligonda Dam

The engineeringmarvel

A. r. nErurKArProject Manager

PAnKAJ KEShAV GurSALEPlanning Manager



31/48

Arid landscapes, barren elds and dusty track

lands dene the upland areas o Prakasam,

Nellore and Kadapa Districts in the State o Andhra

Pradesh, which all under the severe drought

prone zone. With the completion o our ongoing

irrigation projects Veligonda, Gundlakamma,

Ramatheertham and Palair, the scenario is

changing. These our projects increased the

irrigation potential o this region rom the present

7.45 lakh acres (3.01 lakh hectares) to 13.45 lakh

acres (5.44 lakh hectares) in a couple o years.

Thisquantumjumpof80percentwillbeachieved

ater the completion o Rs.4000 crore projects

under the Jalayagnam programme.

A huge reservoir, called the Nallamala Sagar,

is being ormed and three dams are being

constructed at Gottipadia, Sunkesula and Kakarla.

Water is drawn rom Kollamvagu oreshore on

rightbankofSrisailamreservoirthrough18.80km

long tunnel by gravity and thereater diverted to

Nallamala sagar through a 23.36km eeder canal.

The canals are proposed rom Sunkesula gap,

Gottipadia gap and Kakarla gap and envisages to

draw 43.50 TMC o food water rom river Krishna

upstreamofSrisailamreservoirtoirrigate4.38lakh

acres (1.7 lakh hectares) in 29 mandals, mostly in

Prakasam district and marginally in Nellore and

Kadapa districts.

L&T is entrusted with the construction o one o

these dream irrigation projects The Veligonda

Dam. The project will provide irrigation benets

to upland areas o the district besides providing

sae drinking water to 15 lakh people, who have

been consuming groundwater with excess fuoride

content or decades. L&Ts scope o works

comprise construction o dam at Gothipadia

and excavation o Gottipadia Canal including

construction o cross masonry and cross drainage

works, distributory system or 9500 acres. L&Tsecured this contract in 2005 rom Irrigation &

Command Area Development Department o

Andhra Pradesh against sti competition.

Valued at Rs. 395 crore, this is the rst major

concrete dam project executed by L&T on an EPC

(Engineering, Procurement and Construction)

basis. The scheme comprises construction o

dam rom EL 162 to EL 230 having a base width o

57.96m and top width o 12m, canal length 11.40

km and distributory system or 9500 acres.

Sale Feaes

Heightofthedamfromthedeepest

level-87m

Totallengthofthedamatthetop-600m

Slopeofthedownstreamface-1:0.662

Slopeoftheupstreamface-1:0.045

ECCs major scope o work includes 10,00,000

cu.mof excavation,9,21,181cu.mand 1,00,000

cu.m o concreting in two stages, 1600 t o

reinforcement,2,30,000sq.mofformwork,58,000

Rmt drilling or grouting, 51,000 cement bags or

grouting.

Cceg

Totalconcretingis10,21,181cu.mintwo

stages

Totaldurationofconcretepouring

24 months

Averagerateofconcretepouringachieved

1500 cu.m perday

Peakrateofconcretepouringachieved

2903 cu.m per day

The project had a huge requirement o concrete,

which was to be poured at a temperature o 15

degree celsius. The herculean task o achieving

and maintaining the standard o concreting was

managed with meticulous planning. As the height

o dam started increasing, earthen ramps up to

30m height was created or the movement o

concrete. Later, conveyor was used or shiting

concrete rom the batching plant to the top. As

the project required steel ormwork, the entire

shuttering was designed and schemed in-houseat site. Hydra cranes were used or handling the

orms. To reduce the cycle time, the shutters

were combined (4.8 m combined width) with

structural steel channels. The whole sequence

o operations, rom aggregate production to

concreting was mechanized thereby ensuring

accuracy and maximum output. The client

awarded commendation certicates or the highest

concreting (46000 cu.m) in the month o February

2006.



32/48


Egeeg Calleges

Veligonda dam project is the rst dam project

designed by the Engineering Design and Research

Centre (EDRC). EDRC looked at the opportunity

as a challenge and successully completed the

design o concrete dam. The internal arrangements

within the dam body like gallery, adit, shat, and lit

were designed with precision. The dam consists o

around 2 km o gallery within it or inspection and

grouting. Planning and aligning this multi level

gallery and the interconnection o the galleries

with access adits were really brain racking. Like in

any other dam, A holes and B holes or grouting

were designed to improve the impermeability o

dam base. The dam base was grouted with a

total drill length o around 22 km. Dierent types

o instruments were embedded in dam body to

monitor the dam in terms o settlement, plumb

and thermal. The monitoring was reviewed with a

computerized data acquisition system.

resces

Remoteness o the project posed the biggest

challenge as management o materials was

a critical task. Except or the aggregates, the

minimum distance or sourcing o other materials

was around 200 km away rom project site.

Interacting with the vendors and convincing them

to deliver as per the schedule was one o the most

critical activity or the smooth progress o the

project.

Sourcing o aggregates was another major issue.

Markapur is amous or slate rock ormation

which cannot be used as aggregates because

o its hard and sot rock combination. The site

has established a rapport with a local quarry or

uninterrupted supply o aggregates.

Identiying and sourcing the total requirement o

boulders (22 lakh mtp), was a major issue during

the initial phase as the local terrain had anity



33/48

to slate rock. Two crushers with a combined

capacity o 450 tph are installed to cater to the

aggregate production. Sand impactors are used

to enhance the quality o the aggregate output.

This mechanized system o aggregate operations

was instrumental to achieve the planned output.

Sourcing o river sand also was a challenging taskas the nearest supplier was around 220 km away

rom project site.

Pla & mace

The initial review o similar dam sites was

instrumental in planning the machinery

requirement or the project. The methodology

involved in concreting was through dump trucks,

transit mixers and tower cranes. Two 125 tpd

chilling plants, 250t o rerigeration, two ice plants

were installed or getting the required concrete

pour. During summer, the temperature crossed 50

degree celsius and maintaining concrete pour at

15 degree celsius was the most critical challenge

through out the execution.

Specialized major P&M deployed include

120 cu.m/hr concrete batching plants with

aggregate individual weighing system or the best

accuracy.

Qal a Sae

TheprojectsitefollowedthenormsofISO9000

and has been reviewed by various audit systems

at regular intervals. Sae methodology was

incorporated in all activities o the project. Daily

pep talks and regular orientation programmes

ensured the communication o saety issues

and awareness is created down the line across

various departments. A system o automated

house keeping was implemented, where beore

commencement o work, the workmen ensure

appropriate environment is maintained.

Some o the sae methods employed at sites

included three lockwork permit systems or

rotating parts, cordless communication system or

tower cranes, and sensor alarm in hydra cranes.

ivas

Innovations and in-house alternatives are the

hallmarks to the speedy execution o this project.

Buckets o 3 cu.m capacity or concreting andvibrator needles were locally abricated which

resulted in considerable saving o time. Gantry

or handling o Formwork was designed by

Construction Methods and Planning Cell (CMPC).

CSr

As part o the corporate social responsibility, two

additional class rooms or the local government

school was built by L&T. An environment riendly

zone is being nurtured at the project site. About

892saplingswereplantedduringHHLCentenary

Celebrations. Three more class rooms were

constructed or the Government school at

Kaolabhimanipadu village.

The project team maintained cordial relationships

with the locale population, which was instrumental

in the smooth fow o work. Veligonda Project

contributed to reconstruct a temple which had to

be relocated due to the dam construction.

Night view o the Veligonda dam, during construction



34/48

K A L E i d o S C o P En E W o r d E r S

rs. 605 C. oes Wae &Seel Secs

Larsen & Toubro (L&T) has bagged resh orders

worth Rs.605 Crores rom the Water and Steel

Sectors in the last quarter o FY 09. L&T secured

three orders aggregating Rs.416 Crores rom the

WaterSectorandanotherorderofRs.189Crores

rom the Steel Sector. The Metallurgical, Material

Handling& WaterOperating Company ofL&Ts

Construction Division will be executing these

orders.

Wae Sec: The company bagged a Rs.165

Crores order rom the Rural Water Supply &

Sanitation Department, Government o Andhra

Pradesh, or supply o potable water to 152

inhabitations in the Ananthapur district o the

state. The project is to be completed in 15 months.

At present, L&T is already executing water supply

projects worth Rs.319 Crores in Ananthapur

district.

L&T has also won a Rs.133 Crores EPC contractrom Delhi Jal Board or design & laying o MS

pipeline rom the Dwaraka Water Treatment Plant

to various areas o Dwaraka, Nazagarh, Daulatpur,

Ujwa and IGI airport (Package 3). The project is

to be completed in 21 months. At present, L&T

is executing the Dwaraka water supply scheme

(package1A)inDelhiforRs.248Crores.

ThecompanyhasalsosecuredaRs.118Crores

order rom Utkal Alumina International Limited or

design & construction o raw water intake structure,

raw water transmission pipeline & reservoir works

attheirAluminaPlantatRayagadaDistrict,Orissa,

to be completed in 17 months. L&T is already

executing Civil & Structural Works or this Alumina

Plant or Rs.455 Cr.

Seel Sec: In the steel sector, the company has

wonanorderof Rs.189Crores fromSAIL-IISCO

SteelPlantforCivilWorksforRollingMill,BOF,CCP

LDCP Complex, Lime Dolomite Plant at Burnpur,

West Bengal, to be completed in 12 months. L&T is

already executing the Sinter Plant & Raw MaterialHandling plant on EPC basis. Securing this new

order reinorces the condence placed on L&T by

SAIL, one o its major customers.

rs.1,143 C. es tAtA

Seel

L&T has bagged two orders totaling Rs. 1143 Cr.

rom TATA Steel.

ThiscomprisesaRs.689croreorderforturnkey

construction o Dry Crushing & Material PreparationPlant (DCMP) at Joda Mines and Engine-on-Load

(EOL)Scheme atNoamundiMinesand another

Rs.454croreorderforIronOre&PelletHandling

System at Jamshedpur. The Metallurgical, Material

Handling&WaterOperatingCompany(MMH&W)

o L&Ts Construction Division will execute these

orders.

L&Ts scope o work or the projects include basic

& detail engineering; complete civil & structural

works; supply and erection o mechanical,

electrical & instrumentation works including testing

& commissioning.

These turnkey projects are to be executed in

a schedule o 30 months or DCMP Project, 24

monthsforEOLschemeand23monthsforIron

Ore&PelletHandlingSystem.

L&T is already implementing Blast Furnace &

Pellet Plant packages or 3 MTPA expansion

project o TATA Steel at Jamshedpur which is

progressing at a ast pace. With these orders,

L&T has emerged as the major partner o TATA

Steel in the implementation o 3 MTPA expansion

project. Moreover, this covers the complete chain

rom material preparation at mines to receipt &

handling o iron ore & pellet and delivery to the

blast urnace.

rs. 1,100 C. Eleccal oes

L&T has bagged a slew o large-value orders

aggregating Rs.1,100 crores in the electrical

constructionsectorinthefourthquarterof2008-09.

C Concord|Oct-Dec08 34


35/48

The orders have come rom leading public sector

organizations the Power Grid Corporation o

India Limited and the Rail Vikas Nigam Limited

and involves setting up high end transmission

lines and substations as well as a project or the

Indian Railways

Mr K. V. Rangaswami, President (Construction)and Member of the Board said: The 800 kV

HVDC Transmission Line project and the 765

kV substation orders represent technological

breakthroughs and they auger well or our growth

potential in these critical segments.

The order secured rom the Power Grid Corporation

o India (PGCIL) involves construction o a part o

thecountrys rst 800 kVHVDC transmission

system or transmitting power rom the north east to

the northern and western parts o India. Extending

across 190 km, this HVDC bi-pole transmission

line, valued at Rs.169 crores will be executed or

the section between Nidhaura Village to Agra in

Uttar Pradesh on the main line between Biswanath

toChariyali.Thisistherst800kVtransmission

line system o its kind in India and signies a

major step orward in high end electrical project

execution.OtherorderssecuredincludeaRs.190

crores order rom Power Transmission Corporation

o Uttarakhand Limited or 400 kV double circuit

Transmission Line between Loharinagpala to

Koteshwar, a Rs.175 crores order rom Rail Vikas

Nigam Limited or the Bharuch-Dahej Railway

Construction Project., and a Rs. 83crore order

rom PGCIL or the construction o 765 kV single

circuit transmission line rom Agra to Jatikalan.

Meanwhile, in a major oray into the high end 765

kV segment o substations, L&T secured three

majorordersfromPGCILvaluedatRs.480crores

or the construction o 765 kV Substations at

Balia, Lucknow and Satna along with associated

transormer packages.The entire project will be

executed within a tight schedule o 27months. It

involves detailed engineering and construction

o 51 bays o 765kV system including supply

and installation o 35 numbers o 500MVA Auto

Transormers.

The 765 kV orders were secured against sti

international competition, through a consortium

with Areva SA (France) and Hyosung (Korea) or

765kV switchgear and transormers respectively.

These projects will be executed by the Electrical

& Gulf Projects Operating Company of L&Ts

Construction Division.

rs. 1,438 C. Gl oes t&d sec

L&ThasbaggedthreenewordersworthRs1438

crores. Two orders worth Rs 1130 crores werebooked in the Gul Region and a third, worth Rs.

308crore,wasbaggedfromtheWestBengalState

Electricity Distribution Company.

L&ThasbaggedanEPCordervaluedatRs.800

crores (USD 164 million/ AED 600 million) rom

the Al Ain Distribution Company (AADC) or the

construction o 7 electrical substations, associated

MV cabling and overhead transmission line in the

Al Ain city o Abu Dhabi.

This is one o the single largest value orders

received by L&T in the UAE, or Power Transmission

& Distribution Sector.

According to the terms o the contract, L&T

will Design and Build these 33/11kV primary

substations to the specications o the international

consultant PB Power & will be completed within 24

months.

Each substation consists o 33 kV gas insulated

switchgear, 11 kV air insulated switchgear,

15/20 MVA 33/11 kV transormers, Substation

Control and Monitoring System, Protection andtelecommunication system, DC system and

auxiliaries. The contract encompasses design and

construction o civil buildings with complete set

o utilities such as air conditioning, re protection

and lighting systems.

L&T has also received another EPC order or

Augmentation & Expansion o 33 kV Power

Transmission Network with a value o Rs 330 crores

(USD 67 million / AED 247 million) rom Abudhabi

Distribution Company (ADDC). The scope covers

design, supply & construction o 300 km o 33 kV

Transmission line network in the western region

o Abudhabi, with the contract completion o 22

months.

These orders were secured against sti

international competition and will be executed

by the Power Transmission & Distribution Sector

o L&T Abu Dhabi. At present L&T is already

executing 20 substations o various capacities in

Al Ain, Abu Dhabi and Dubai areas o UAE.

ECC Concord|Oct-Dec35


36/48

In another development Larsen & Toubro has

baggedaRs.308croresorderfromWestBengal

State Electricity Distribution Company Limited

(WBSEDCL) or Rural Electrication Works in

Jalpaiguri and North 24 Parganas districts o

West Bengal State. As part o the contract, L&T will

carry the 11 kV distribution lines to electriy 2274

villages in these districts, to benet the citizens

o Below Poverty Line ( BPL).The project will be

completedwithin18months.

rs.1,245 C. hpwe

Pjec e

The Infrastructure Opreating Company of

Construction Division has bagged a contract o

Rs.1245 crores or the construction o the Dam

Package, a part o the 1200 MW Punatsangchhu-I

Hydroelectric Project in Bhutan.

The project is being set up by the Punatsangchhu-I

Hydroelectric Project Authority which has been

constituted through an agreement between the

Government o India and the Royal Government o

Bhutan. It is located across Punatsangchhu River,

about80kmfromThimpu,thecapitalofBhutan.

To be executed in 66 months, the scope o work

involves construction o the diversion tunnel, dam,

intake and desilting arrangement including hydro-

mechanical works. L&T won the order through acompetitive bidding process. WAPCOS Limited

is the engineering and design consultant o the

Project.

This is the rst o a series o 10 hydropower

projects jointly identied by the governments o

India & Bhutan and to be implemented or a total

installed capacity o 11,576 MW by 2020.

For L&T, this is the second hydroelectric power

project in Bhutan - the rst one was the 1020 MW

Tala Hydroelectric Project, which was completedahead o schedule.

rs.1,162 C. oe Blgs & Faces oC

L&TsBuildings&FactoriesOperatingCompany

part o its Construction division has bagged new

orders aggregating around Rs.1162 crores in the

fourth quarter of2008-09for the construction of

actories and residential projects.

L&T has bagged a major design & build order

valued at Rs. 605 crores rom the Andhra Pradesh

Rajiv Swagruha Corporation Limited or the

construction o an integrated thematic township

comprising o 3517 fats (27 blocks) and consisting

o Classic/ Intrinsic/ Basic & Civil type fats

at Bachupally, Hyderabad. This project is to be

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