T h e P u n j L l o y d M a g a z i n e | N O V - D E C 2 0 0 4
updateovercoming logistical diffi culties of construction
New Equipment at the BTC-Pipeline Project, Georgia
The Georgian section encountered the steep mountains of the Caucasian range, with a rise from 1000 m to 1800 m within a distance of 54 km, between the Turkish border and Bakuriani.
NOV-DEC 20042
Our success in
overcoming the steep
slopes and logistical
diffi culties were due to
the use of• Caterpillar excavators
with vacuum lift attachments
• Galotrax mulcher for breaking boulders, backfi lling of soil
• Tatra truck and tippers with 6 x 6 drive
• Tatra trucks with Hiab cranes
• PIH pipe coating machine
• Mercedes Astros trailers with 6 X 6 Drive
• Caterpillar excavators with screener crusher bucket of Allu make
• Pulling winches on rear of heavy equipment
• Trench box/Trench shield used to prevent trench failures from injuring workers.
• Bomag vibratory compactors
• Ingersoll Rand air compressors ranging from 260 to 600 cfm
Safety and Environment
measures adopted at
Georgia Site• Passenger vehicles are
provided with roll over protection system, anti lock braking system, safety belts, off-road duty tyres, towing wInches and reverse horns
• Oil absorber pads and oil containment booms used during maintenance and in case of oil seepage
• Geo textile sheet used while servicing equipment
• Pulling winches fi tted on rear of heavy equipment
• Light and heavy
updatebtc pipeline project equipment
NOV-DEC 20043
equipment fi tted ‘Black Box’ (Drive Right Monitors)
• Light vehicle tyres equipped with snow chains
• Vehicles/equipment fi tted with fuel heater
• Anti-freeze coolant in vehicle/equipment inthe ratio 1:2
• Tyre infl ation cage used during repair
• Effl uent Treatment Plant (ETP) used for treating of all wastes
• Mobile vacuum emptier for collecting and further disposing wastes to ETP
• Potable water treatment plant for supply of water to the camp
◆ Baldev Saini
NOV-DEC 20044
Reaching for the Sky
updateheavy lifting cranes
updatewith this specialised equipment the job was completed with
speed and effi ciency
NOV-DEC 20045
1000 T Crane
It was used for the erection of two Reactors and a Fractionator at Panipat Refi nery Project on April, 2004. Each of the reactors were 590 MT with 5.96 m dia and 24 m height. The fractionator weighed 253 MT, with 5 m dia and 73 m height. The successful completion of this project fi rmly established us in the fi eld of heavy lifting.
The crane used for this purpose was an American 11320 SSH crawler crane called ‘The Super Sky Horse’. It is equipped with a 152.4 m boom and 60.9 m jib. The Super Sky Horse can travel with rated loads “straight forward and reverse” in a low range. All ratings allow full 360º wing with load.
The Q&HSE aspect is paramount with the crane as it is with all other equipment. Load ratings for Super Sky Horse are fully compliant with international safety regulations.
This was a complex job as the equipment had to be lifted in a single piece within the restricted space of the refi nery. With this specialised equipment however the job was completed with speed and effi ciency.
◆ Amitava Bose and Amit Nagpal
300 T Crane
As Punj Lloyd ventures into increasingly diffi cult terrain, requiring expansion of high-end equipment, the acquisition of a 300 T crane, model LT1300 is the latest addition to the huge equipment base.
25 storeys high, when raised to its full capacity and capable of lifting 300 T. The eight-axle mobile crane 1300 LT can be operated in an extensive range of applications due to its fi ve sections, 68 m telescopic boom and 63 m jib.
We are utilising the 300 T crane to lift vessels for the SGP Offsite and Utilities mechanical work at Tengizchevroil site, Kazakhstan.
Very few cranes of such high capacity have been put to use in the region. Adding this to our fl eet has made heavy lifting much easier and augmented the expertise of Punj Lloyd in taking upcoming challenges.
◆ Amit Nagpal
Plant & Equipment Division
Equipment are the workhorses behind the success of
an engineering construction company. Equipment
asset management is a critical element in delivering
projects on time. Punj Lloyd’s vast equipment base is
managed and maintained by the Plant & Equipment
division ‘P&E’. Our equipment asset is one of the most
outstanding in Asia
updateover $100
million
worth of
equipment
NOV-DEC 20046
Site Million Hrs Available Uptime Per centage
Sasaram 1.2 95.2
Tuni 1.0 97.7
Jaipur 0.9 97.6
DMRC, Delhi 0.1 96.0
updateplant & equipment division - punj lloyd
updatemore than 160 categories of equipment
NOV-DEC 20047
P&E division acquires, operates, maintains, repairs the entire range of equipment such as earthmoving, material handling, pipeline laying, road construction, amphibian equipment and general construction machinery for our projects.
Our endeavour is to deliver quality service and add value through our effi cient operational skills without compromising on Safety and Environmental protection.
The fl eet of equipment are constantly updated to ensure speedy mobilisation and demobilisation of equipment, attributes that give us our competitive edge.
To drive P&E division our team of experienced and trained personnel, ensure the best utilisation
of equipment, always available to diagnose problems and provide solutions on all equipment related issues. Our personnel work in harsh conditions ranging from scorching desert sun, fi erce monsoons and temperatures between -40º C to +45º C.
We follow a strict routine of training. Each employee is trained for 6 days in a year, backed by in-house programmes in innovative thinking and multi-skilling. Our technical team ensures that equipment are audited and laboratory checks carried out.
Safety is the fi rst priority at Punj Lloyd. We conform to interna-tionally benchmarked standards of Q&HSE and comprehensive preventive maintenance.
Maximo is the asset
management package for the P&E Division, which logs the location and condition of equipment, complete maintenance history, technical specifi cations of each machine and their attachments, at the click of a button.
◆ Sandeep Garg
The backbone of Plant & Equipment
NOV-DEC 20048
Central Workshop
The centralised repair facility in Banmore, central India, spread over an area of 20,000 m2 with technical manpower, is capable of handling all types of equipment.
Our undercarriage repair workshop is reputed to be among the best in Asia.
Main functions of the workshop
• Major overhauling• Modifi cation as per
requirement• Upkeep of equipment
during idle time• Centralised material
management system supporting all sites
Features of the Workshop
• Suffi cient and centralised stock of spare parts
• Skilled and technically trained manpower
• Tool room with latest diagnostic tools for precision repairs of hydraulic and pneumatic equipment
Workshop Sections
For operational ease and quality service the shop is
divided into eight sections:• Undercarriage• Engine• Side Boom/Dozer• Excavator• Crane• General Machinery • Light and Heavy Vehicle• Electrical repairs
Features of important sections
Undercarriage Section
For repair and maintenance of all types of undercarriage • Twin Ram Hydraulic
Track Press (300 T)• Welding Machines• Track link welding
machine• Hard facing welding
machine• Bore welder• Roller Idler
Re-builder (RIR)• Roller Buffer• Roller Idler Press (RIP)• Flux Crusher
Engine Section
Caters to rebuilding of engines from 50 to 350 HP with Dynamometer for repaired engine testing to ensure trouble free performance.
INDIA
NOV-DEC 20049
Sungaipurun Base Camp
The 45,000 m2 base camp of PT Punj Lloyd Indonesia was set up to propel new business initiatives. As PT Punj Lloyd Indonesia are near shore and offshore specialists, a yard with a jetty for maintenance of amphibian equipment was an absolute necessity. The yard built within a record time of ten months at the Mahakam River, East Kalimantan, has a concrete jetty and is accessible by road and river, thus ideal for amphibious transportation.The key features of the base camp include:
Repair and maintenance facilities
The base camp has a 1,200 m2 repair and maintenance shop with a 10 T monorail gantry. It undertakes the maintenance of all types of heavy amphibian and construction equipment. This workshop is capable of stripping, repairing and reconditioning all types equipment and is maintained in dust free conditions. Some of the features of repair and maintenance facilities at the base camp:• Engine repair room • Generator repair room • Machine shop • Testing room • Manpower
Fabrication shop facilities
Base camp has a fabrication shop certifi ed by MIGAS. It is supported by two sandblasting and painting sheds, NDT room and open space of 4100 m2 for storage of raw and fabricated material.
Loading and unloading Jetty
A concrete jetty 70 m x 10 m equipped with 300 T and 150 T cranes.
Warehouse
Two separate warehouses are available at the base camp. Both are built in an area of 18 m x 40 m.
An Oracle-based ERP system is used to maintain and update inventory.
Open storage facilities
9,000 m2 area is located near the jetty and is used for the storage of material ready for load out.
Skid way for platform launching
A skid way of 1,000 T capacity, 120 m long for fabrication, assembling and launching of 275 T weight offshore production platform is underway.
Offi ce and accommodation area
The base camp also houses offi ce, residential accommodation, messing and recreational facilities for PT Punj Lloyd Indonesia and TOTAL E&P Indonesie personnel and is spreadover an area of 8,000 mß.
INDONESIA
NOV-DEC 200410
Marine Equipment
Punj Lloyd’s investment in its fl eet of marine and amphibian equipment is a refl ection of its expertise in offshore pipelaying.
Pipelay Barge POE 2303
Rigged with a variety of pipe laying equipment including:• 40 T pipe tensioner• Ready rack and pipe
transfer system • Electric welding
machines• Hydraulically operated
line up station • NDT station with
overhead monorail controlled lead shield
• Pipe stinger with hydraulic winch adjustment
• 150 and 200 T crawler crane
• 4 x 50 T Davits • Three welding stations • Tensioner and anchor
winches control room • Constant tension A/R
40 T winch • Field joint coating station • 8 point mooring,
8 hydraulically operated deck mounted Anchor winches, pull (max) 40 T
• Anchor wire – 8 x 15/8” x 1,200 M
• Anchors – 8 x 5 T, Stevpris
• Integral below deck fuel and fresh water tanks
Yuheti 180 – Swamp Push / Pull Pipelay Barge
• 3 x 30 T davit • 50 T link belt crane with
boom of 15.4 m• 2 x CAT 583 pipelayers • 750 cfm compressor • 3 welding stations• 8 x 500 amps Lincoln
welding machines • 2 Power generators
75 – 100 kva • Filter and drying units for
fi eld joint coating• Non – destructive
testing facility and dark room
• Buoyancy drums fi xing pontoon attachment
• Integral below deck fuel and fresh water tanks
Platform Riser and Hook-up Barge
• 3.37 m moulded draught • 4 x 30 T davits • 4 PIH mooring winches• 4 x 3 T fl ipper delta
anchors• 150 T link belt crane
with boom of 36.5 m• 50 T link belt crane with
boom of 15.4 m
NOV-DEC 200411
updateP&E division
acquires, operates,
maintains, repairs the
entire range
of equipment
NOV-DEC 200412
NOV-DEC 200413
Some Prized Possessions
Punj Lloyd has state-of-the-art equipment for civil and road construction, material handling, mining
and soil improvement.
Cold Milling Machine
Wirtgen W1900 cold milling machine effi ciently strips and removes damaged paving. It is mechanically driven with milling drums and two discharge conveyors slewing from ends of variable heights. An electronic level control system controls milling depth from 0-300 mm and width of 2,000 mm.
Cranes
Wide range of cranes including crawler, mobile, rough terrain and tower cranes.
300 T Manitowoc Model 4100W Series II Crawler Crane with 36 feet dia ringer attachment. This can lift maximum weight of 300 T with the Ringer attachment.
300 MT Liebherr
Model LTM 1300 hydraulically operated all terrain crane with 68 m boom and 63 m jib.
Pipelayers
72 pipelayers ranging from capacity 20 T to 90 T.
Trenchers
Capable of trenching upto a depth of 2 m and width 1.65 m
Plant & Equipment Division
update
achieved maximum
output from
equipment
NOV-DEC 200417
updatetotal crossing executed 23,000 mtr through horizontal directional drilling
NOV-DEC 200418
Horizontal Directional Drilling Machine
250 T capacity Horizontal Directional Drilling rig gives unmatched capability for laying pipelines below obstacles.
Vibratory Driver / Extractor
We are one of the few companies using hydraulic vibratory hammers for driving piles of dia ranging from 450 to 600 mm. We possess Hydraquip 7 T and 10 T capacity hydraulic hammers mounted on Nippon Sharyo leader cranes capable of driving piles upto 30 m. We also own hydraulic extractor, MGF RBH320 used in combination with the above, for sheet piling.
NOV-DEC 200419
Concrete Pavers
Wirtgen SP1600 can lay pavements upto 450 mm thickness and is equipped with automatic dowel bar and central tie bar inserter.
Bore Piling rigs
Bauer BG 15 and Soilmec R518 hydraulic rigs with capacity to bore from 500 to 2,500 mm dia and depths of 42 m.
Investments in hardware, software, people and training ensure maximum utilisation of equipment. As a result men and machines work in complete synergy.
◆ S K Vasishat
NOV-DEC 200420
NOV-DEC 200421
update
men and machines
work in complete
synergy
An extended arm of
P&E division, Spectra
Punj Lloyd ‘SPLL’ is an
exclusive equipment
rental company, which
operates independently
to lease out equipment
to external clients. SPLL
also arranges equipment
on hire for Punj Lloyd
projects.
SPLL believes in
providing the best services
to their customers.
Backed by Punj Lloyd’s
equipment bank of
over $100 million, it has
Spectra Punj Lloyd
NOV-DEC 200422
experienced operational and maintenance staff. While offering high quality service SPLL upholds safety and environmental protection parameters. Time bound performance and optimum effi ciency are watchwords of SPLL.
SPLL has now diversifi ed into supply of Ready Mix Concrete (RMC) with the installation of 120 m2 per hr batching plant near Gurgaon.
◆ Sandeep Garg
updatebtc pipeline project equipment
updatespectra punj lloydequipment rental company
updateSPLL has diversifi ed into
supply of Ready Mix
Concrete (RMC) of 120 m2
per hr batching plant
at gurgaon
NOV-DEC 200423
one of the wonders of the pipeline industry
506 km, 42” Dia, in 270 days
updatemen and machine worked wonders in
laying the Dahej-Vijaipur pipeline
NOV-DEC 200424
updatedahej-vijaipur pipeline project
This amazing feat was achieved by the huge fl eet including 155 excavators, 109 side booms, 300 trailers, two trenchers, automatic welding and ultrasonic testing machines and 162 categories of 4,100 items of equipment. Organised and commissioned within 40 days, it was nothing short of a logistical miracle.
The project was divided in four spreads with
equipment planning done individually. Punj Lloyd had other important projects running simultaneously and some of our machines were tied up in these efforts.
Certain pipeline equipment was not available in India for a 42” dia pipeline. A worldwide search was conducted in record time and we mobilised equipment from nine countries to keep to the
Total machine hours available 2 million
Uptime in Percentage 97.5%
NOV-DEC 200425
update it was nothing short
of a logistical miracle
NOV-DEC 200426
impossible time frame. The equipment was
planned phase-wise depending on the requirement of each spread. Manpower planning too played an important role in this whole exercise as we hired from 11 countries.
We set up one main workshop at each spread with all the facilities including tool shop, hose crimping shop with two small workshops cum stockyards at convenient locations along the pipeline and a central spare parts store at Vadodara, where sub assemblies of equipment were kept to expedite repair work and minimise downtime. All repairs were undertaken at the site workshop.
Demobilising the equipment was a task no less daunting. It required meticulous planning and execution.
Men and machine worked wonders in laying the Dahej-Vijaipur Pipeline in 270 days.
◆ Pradeep Kathuria
updategolden quadrilateralroad project
New equipment acquired for this project
4 x 120 m3/hr Schwing Stetter Batching Plants
3 x 200 – 250 T/hr Metso Stone Crushers
2 x 30 m3/hr Schwing Stetter Batching Plants
2 Wirtgen Slip Form Concrete Pavers of 16 m width
with curing machine
2 x 160 T/hr Parker Hot Mix Plant
2 x 9 m wide DBM Pavers
2 x 9 m wide Asphalt Pavers
2 m wide Wirtgen Cold Milling machine
update the project has the
distinction of being the
fi rst completed “Golden
Quadrilateral” project
NOV-DEC 200427
The project was awarded to Punj Lloyd for constructing the 77 km long concrete road between Belgaum and the Maharashtra Border. Some of our road construction equipment were engaged at other sites. Mobilising equipment on such a large scale at short notice was a challenge.
We overcame this challenge by investing in four spreads of equipment. This helped us achieve our target of completing the project fi ve months ahead of schedule.
Some of the equipment acquired by us was used for the fi rst time in one of our road projects.
Mechanical workshops were built to take care of maintenance and keep the downtime to a minimum. This resulted in the total equipment hours available for the project being seven million and an
uptime of 94.5 per cent.The scope of work
involved in this project included completion of eight lane roads. Some of the major quantities are earthwork of 30,000,00 m3 and concrete work of 1,60,000 m3. In addition, 135 km of asphalt service road was constructed. A total of 16 million safe man-hours went into completing the project.
High uptime performance of the equipment contributed to the completion of the project fi ve months before schedule.
The project has the distinction of being the fi rst completed “Golden Quadrilateral” project.
◆ Amit Nagpal
Belgaum Maharashtra Road Project
update250 t chain trencher
in oman
NOV-DEC 200428
The Big Mamma250 T Chain Trencher
The 1860 HD, 250 T Trencor Chain Trencher, that is being used at our Oman site is affectionately referred to as the ‘Big Mamma’. There are only eight other such machines in the world. This trencher is designed to have additional power and strength for making unusually deep and wide cuts in rock and hard soil. The mechanical drive Two-Speed Crawler has a maximum speed of 1.2 kmph with a digging width of 36” through 96” and a depth of 12”. It is powered by two engines one of 1200 HP to drive the digging chain and the other of 300 HP to drive the tracks, conveyors and hydraulics.
This Trencher creates a perfectly rectangular trench and crushes the rock into small pieces. The trenched material is, after screening, used for padding, making the process an environment friendly one.
Punj Lloyd’s philosophy is to be ahead of the times and we believe in making the greatest technological advancements work for us. This trencher has added signifi cantly to our effi ciency quotient.
◆ TP Mukhopadhyay
Normally “Big Mamma” brings to mind a jazz singer from New Orleans and the
haunting melody of the saxophone but not so in Oman! “The Big Mamma” is the
pride and joy of the site personnel there. Not only for her size but also the volume
of work that she easily accomplishes.
updatetrencher creates a perfectly rectangular
trench and crushes the rock into small pieces
NOV-DEC 200429
updatequality, health, safety and environment
When man curved out
a wheel from a piece of
stone the fi rst engineer of
this world gave shape to
the fi rst machine. When
he told his child not to
play with the heavy stone
wheel the fi rst safety
standard was established. Then on began the twofold story of using machines to make our job simpler and putting necessary measures in place to avoid accidents.In the present day scenario the greatest manifestation of this story is in the engineering construction industry. In Punj Lloyd we use extremely heavy, automated equipment for work. A 300 T crane, and a 250 T chain trencher are few examples. We have
HSE Perspective of Equipment
procedures and standards in place to safeguard our personnel.
Mandatory to Punj Lloyd’s success has been the inculcation of a zero-defect approach all through the company. Regular trainings are imparted to personnel at all levels. Comprehensive training programs educate Punj Lloyd fi eld personnel on safety procedures for equipment.
The ‘tool box talk’ is imparted to all execution fi eld personnel on a
daily basis. Need-based training is also provided regularly. Consequently, there is an established culture of Q&HSE awareness and adherence at all levels. ◆
Civil Construction | Pipelines | Tankage & Terminals | Telecom | Process Plants | Plant and Facility Management | Power High Value Engineering | Broadband Services
Strategic Business Units
Punj Lloyd Ltd. PO Box 28907, 202 Al Otaiba Building, Khalifa Street Abu Dhabi UAE Tel +971 2 6261604 Fax +971 2 6267789 [email protected]
Punj Lloyd Ltd. PO Box 704, Postal Code 133Al Khuwair, Sultanate of Oman Tel +968 597728 Fax +968 597493 [email protected]
Punj Lloyd Kazakhstan LLP Astana International Hotel113 Baitursynov Str. 480072 Almaty Republic of Kazakhstan Tel +7 3272 501233 Fax +7 3272 501223 [email protected]
Punj Lloyd - LIMAK JV 74 Mahatma Gandhi Road, GOP 06700 Ankara Turkey Tel +90 312 4466364 Fax +90 312 4466794 Email [email protected]
Punj Lloyd (Malaysia) Sdn. Bhd. Cosmos Centre69/1 New Circular Road Dhaka 1217 Bangladesh Tel +880 2 9330859 Fax +880 2 8314602
Punj Lloyd Ltd. Bin Yousef Group Companies WLL, 9th Flr,, Almana TowerOld Airport Road, PO Box 3264 Doha Qatar Tel +974 4622127 Fax +974 4626180 [email protected]
Pt. Punj Lloyd Indonesia Ventura Building, 4th Flr., Suite 401B Jl. R A Kartini 26 Jakarta 12430 Indonesia Tel +6221 7591 4766 Fax +6221 7591 4241 [email protected]
Punj Lloyd Ltd. 32 Harley House Marylebone Road London NW1 5HF UK Tel +44 20 7486 6009 Fax +44 20 7935 5086 [email protected]
Mr. Erich Niedermeyr Area Manager Kutterlingerweg 383059 Kolbermoor Germany Tel +49 8061 5616 Fax +49 8061 [email protected]
Punj Lloyd Ltd. PO Box 115, Bis-Sidi Abbes Sfax 3062 Tunisia Tel +216 74264514 Fax ++216 74615191 [email protected]
Punj Lloyd Ltd. 1 TV Industrial Estate, S K Ahire Marg, Worli Mumbai 400025 Tel +91 22 24924421 Fax +91 22 24936861 [email protected]
Punj Lloyd Ltd. Banmore Industrial Area, Banmore District Morena 476444 Madhya Pradesh, India Tel +91 7532 243644 Fax +91 7532 243297
Punj Lloyd Ltd. C/o Al Rushaid Trading Co. PO Box 31684, Al Khobar 31952, Saudi ArabiaTel +9663 8933 333 Extn. 221 Fax +9663 8647 320 [email protected]
Corporate Offi ce
Punj Lloyd Ltd. Punj Lloyd House, 17-18 Nehru Place New Delhi 110019 India Tel +91 11 26200123 Fax +91 11 26200111 [email protected]
www.punjlloyd.com
Other Offi ces
