Quality Bulletin Issue 7-22110

INDEX
Sponsors Desk 3
Convener Message 4
Events 5 to 12
Process Improvement 13 to 19
Quality Improvement 20 to 31
Milestones/Benchmarks 32 to 37
Certifications 37 to 38
Competence Development 39 to 41
Scholarly articles 42 to 50
Awards & Accolades 51 to 58
Certificate of Appreciations 58 to 61
Lessons Learnt 62 to 63
P a g e |2 Quality Bulletin, Jul to Sep 2023

SPONSORS DESK
Kickstarted Business Excellence Model journey in L&T
My Dear Readers,
Through the organizational journey of more than eight decades, L&T pursued and managed sustained growth and stands out
as an organization to have achieved unmatched success in sustaining growth. This has been made possible by adopting unique
business models to stay ahead of the competition, being agile, targeting and converting opportunities in less-known domains,
taking on challenges, putting in hard work, commitment to manage risks to achieve successes. Quest for top-class quality hand
in hand with execution speed enabled L&T in setting up unique benchmarks and attaining distinction in execution of
technologically advanced projects, products, and Solutions.
In today’s faster changing business environment, Innovation, agility, and Business Excellence have globally assumed necessary
ingredients of business success. Enriching action orientation, establishing dynamism, developing highly competitive culture with
a special emphasis on creativity, Talent Development and pursue unstinted commitment to Quality, have become necessary
ingredients to Excellence, sustaining success and long-term growth.
History was made on 20th Nov’23, when our CMD launched uniquely crafted L&T Business Excellence Model (LTBEM) at the
Quality Summit organized at AMN Heavy Engineering Complex, Hazira. Launching the L&T Business Excellence Model is just the
beginning of the unstinted pursuit to excellence across L&T and integrate the organization seamlessly and measuring
performance on a common scale.
With institutionalization of L&T Business Excellence model (LTBEM), we all must shed complacency, embrace challenges, grab
opportunities to drive competitiveness, demonstrate capabilities and track record to deliver unique enriching experience to our
customers and enable them to succeed in their business as also enhance shareholders value.
Competition brings out the best. Our businesses can’t be exceptions. The L&T Business Excellence model, based on its Self-
Assessment criteria, will exhort Businesses to think, strategize, act and achieve to march ahead. Dispassionate Self-
measurement alone will assure us success in the rapidly changing future. It is LTBEM’s earnest endeavor to acknowledge and
appreciate the achievements of well performing businesses and directionally achieving desired success.
I would like to compliment the Leadership team at the helm of businesses for their continuous zeal in driving the LTBEM
initiative as an organizational process to assess process maturity, learning from each other and internal benchmarking.
Towards capacity and capability building, multiple awareness sessions on LTBEM viz, BE Assessor program, Train-The-Trainers
(TTT) program and ATL course on LTBEM for various stakeholders are in implementation pipeline.
I’m confident LTBEM will serve as a guiding light to L&T wide businesses embarking on a journey of fostering culture of
continuous learning, caring, exceeding customer expectations, shareholder value, achievement imagery employees, and other
stakeholders in the ecosystem to become an ever-excelling organization as a global benchmark.
As we unveil ISSUE 07 of our Quarterly Quality Magazine, I express heartfelt gratitude to all contributors of articles for having
made this periodical exciting and complete by sharing their valuable experiences.
J. D. Patil
Sponsor - Quality Council
Member of Executive Council and Advisor to the CMD, Defence and Smart Technologies

CONVENER MESSAGE
Dear Colleagues,
We are delighted to present the seventh edition of the Quality Bulletin

Magazine, showcasing advancements in process improvement, significant
milestones, competency development, valuable lessons learned, and the latest
developments and activities spearheaded by the Quality Council.
Our commitment to the Quality Council remains unwavering as we persist in

cultivating a pervasive culture of quality across diverse business verticals. Our
overarching goal is to drive continual improvement, facilitating the exchange of
best practices, experiences, and lessons learned from various businesses.
L&T Business Excellence Model (LTBEM) was formally launched by our beloved CMD along with senior dignitaries at the
7th Annual Quality Summit, held on 20th & 21st of Nov’23 at L&T’s A M Naik Heavy Engineering Complex, Hazira, Surat.
L&T BE Model is poised to be a pivotal force in elevating L&T's position within the value chain of its operations.
The following outlines the strategic direction that will establish the roadmap for upcoming initiatives led by the Quality
Council:
Refining Behavior-based Quality (BBQ) to foster a culture of excellence and reinforce positive behaviors, thereby driving
ongoing improvement throughout the organization. This endeavor will be supported by our HC IC, leveraging the valuable
insights derived from the successful execution of the "PRATHAM" initiative. Detailed roadmap will be unveiled during the
upcoming Quality Council Meeting to outline the strategy for implementation.
Rollout of Quality Equalizer (Sanyog) and a range of Analytics dashboards to enhance action-based performance
improvement. The release will occur gradually until April 2024, with plans for customization and tailored launches for
Manufacturing businesses thereafter.
Usage of AI and data analytics through Quality digital platform for predictive measures. support will be taken from
Corporate Digital Team through “Sanyog” for study and analysis. Data integration with “Sanyog” for development of New-
gen AI modules.
Enhancing Supplier Quality through Standardization Mechanisms. Implementation of expert-led processes for internal
and external coating applications. Elevating the competence of skilled workmen through video-based Quality Training.
Capability Building Initiative: Aim for a 20% increase in the coverage of high-quality staff through the "Academy of
Excellence" certification program, fostering the development of leaders equipped to tackle complex projects in the
future.
I wish to extend my sincere appreciation to all members of the Quality Council and the dedicated editorial team for
contributing significantly to the success of this Quarterly Quality Bulletin.
We believe you will find this edition to be both enlightening and engaging.
P. Sivasankaran
Convener - Quality Council
Head - QMS, WET(WWW)

1. EVENTS
7 T H QUALITY SUMMIT & LAUNCH OF L&T

BUSINESS EXCELLENCE MODEL

•

DEFENCE: WON PAR EXCELLENCE AWARD IN
QCFI
Topic: 5S Implementation in Manufacturing & Assembly
integration shop at Quality Circle Forum of India (QCFI)
Team members: Bhavik Desai, Rutul Solanki, Yug Guna
HCI: PRESETNTED ARTICLE ON

“DISTORTION CONTROL IN ORTHOTROPIC
DEFENCE: L&T’S CONTRIBUTION IN STEEL DECK (OSD) WELDING” AT NWM
CHANDRAYAAN 3 LAUNCH Mr. P Raja Rethinam (Head Quality) & Mr. Sampath
Kumar S (Asst. manger Quality of MTHL package-1
project of HCI IC) presented an article on “Distortion
control in Orthotropic Steel Deck (OSD) welding” at the
National Welding Meet (NWM) organized by Indian
Institute of Welding (IIW) at Bhubaneswar on 1st to 2nd
September 2023.
IIW invited MTHL package-1 to present the Case Study

article: Distortion Control in Orthotropic Steel Deck
Welding” in the theme of “Welding stresses and
distortion”.
DEFENCE: PI AWARD FOR PRODUCTIVITY
ENHANCEMENT FOR SARVATRA PROJECT Mr. P Raja Rethinam & Mr. Sampath Kumar S presented
TO ENSURE DELIVERY AHEAD OF SCHEDULE the case study article on 01st September 2023. Being
first of its kind, he espoused L&T’s capabilities in
successfully handling the challenges in construction this
OSD bridge. Challenges associated with welding
shrinkage estimation, maintaining bridge camber,
handling thermal expansion & angular deformation, and

accordingly sequencing welding and fasteners were a plant for Perdaman Chemicals and Fertilisers Pty Ltd to
few of the topics covered in presentation. LTEH, MFFK. The plant will be constructed on the Burrup
Peninsula, approximately 20km north of Karratha,
Glimpse of National welding Seminar Western Australia. On completion, this state-of-the-art
facility will be the largest urea plant in Australia and one
of the largest in the world.
The scope of largest project for MFFK comprises about

50,000 MT of modules and to be fabricated in just 24
months. The project is unique on its own way.
Team Saipem, Perdaman & MFFK
Kick-Off meeting with Saipem Perdaman held on 28th

August’ 2023 at LTEH MFFK premises. Top management
of Saipem & Perdaman were present to make the kick-
off meeting a great success.
Discussion on project readiness went well. Clients were

delighted to hear out quality & preservation initiatives
taken for the project.
During discussion in kick-off meeting

MFF KATTUPPALLI: KICK-OFF MEETING –
SAIPEM PERDAMAN Highlights of the event was the launch of Australian
handbook in the presence of Mrs. Sarojini Rambal,
SCJV has awarded supply and fabrication of modules
Director (Perdaman), Vikas Rambal Chairman
on LTEH, MFFK
(Perdaman), Peter Bennet CEO (Clough), Mr.
The very first time Australian project has been awarded Subramanian Sarma, Whole Time Director & Senior
to LTEH. It is a contract for fabrication and supply of Executive Vice President (LTEH), Anil Bontadka Vice
process and pipe rack modules for a 2.3 MMTPA urea President & Head (LTEH-MFB) along with all senior

management of Perdaman, Saipem, SCJV & LTEH MFFK.
The handbook compiles the framework of Australian
compliances so that anyone can refer it easily. The
handbook was very much appreciated by client.
Pledge taken by L&T & AP employees
The event marked a significant milestone in the project's

Australian Handbook Launch journey, signaling the commencement of construction
for a groundbreaking venture that promised to redefine
standards in its domain. Amidst an atmosphere charged
with enthusiasm and optimism, the ceremony
commenced with a solemn yet celebratory tone. The
first steel cut, a symbolic act, was performed, signifying
the birth of the project and the commencement of its
physical manifestation.
Australian Handbook front page
MFF KATTUPPALLI: THE FIRST STEEL

CEREMONY OF AP NEOM PROJECT
Air Products in conjunction with NEOM awarded a green Prayer for the beginning
hydrogen-based ammonia production project to The ceremony intertwined customary rituals with
Modular Fabrication facility, Kattupalli. The project modern practices, bridging the gap between heritage
marked its commencement with a grand ceremony – and contemporary progress. The ceremony inaugurated
the first steel cut. The ceremony held on 25th June’2023 by taking oath. Then it followed with traditional rituals.
with traditional arrangement. Inspiring address by Mr. K Kumar (Unit Head LTEH –
MFFK) made stakeholders motivated. The event served
as a catalyst, igniting enthusiasm and unity among all
involved
P a g e | 10 Quality Bulletin, Jul to Sep 2023

RUBBER PROCSSING MACHINERY: QUALITY
MONTH CELEBRATION
Mrs. Rita (AP) performing traditional ritual
In the presence of Mrs Rita (Project Sponsor), Mr Ajit

Kadam (Head Construction India) Mr Nishant Singh
(Project Manager) Air Products and Mr Kannan Kumar
(Head MFFK), S Prasad (Project Manager), L&T MFFK
Top management first steel cut held successfully. As the
event concluded with applause and camaraderie, it left
an indelible mark on the project’s narrative. The first
steel cut ceremony not only signified a pivotal moment
but also set the stage for a promising future, symbolizing
not just the start of construction but the dawn of a
transformative endeavour.
Quality Flag Hoisting and Quality Pledge
First Steel Cut
TI: EQP MEET (27TH JULY -29TH JULY)

Purpose of the EQP meet was: -
• to synergize 3-key functions (EHS, Quality and

P&M) and create action plans for achieving
strategic goals derived during RBF conclave-
2022.
• to enhance the role of the support functions as
a strategic partner of operations.

Supplier Engagement
POWERSPEAKS - A QUALITY THOUGHT

SERIES
QUALITY TALK - BUSINESS ASSOCIATE KE

SAATH
•
•
MANTHAN: SESSION ON SHARING GOOD

PRACTICES, LEARNINGS, AND IDEAS

• Jack hammer weighs more than 30kgs with
2. PROCESS IMPROVEMENT Pneumatic hoses connection, which slower
production cycle.
GEOSTRUCTURE: PROCESS IMPROVEMENT • Production cycle time is more
• Maintenance of Jack hammer and compressor
IN DIAPHRAGM WALL AND PILE HEAD
adds cost
DRESSING WORKS: • Fuel consumption is comparatively more with
At one of our projects “Kamarajar Port Limited (KPL) respect to time cycle
• Works effects due to monsoon
RORO Berth construction at Ennore”, we had a total
• Number of days for breaking one d ‘wall
scope of Diaphragm wall dressing of 405 running meters
(6.25mtr long) = 6 days
with width 1.2 meter and height of 2 Meter also having
280 numbers of BCIS pile chipping with 1.2-meter
diameter and 2.6-meter length. Diaphragm wall and pile
casted with M40 grade of concrete, approximate of
1845 m3 of M40 concrete need to be dressed in a
timeline of 2 months. Site team has implemented
alternate method to reduce the time and cost involved
in this activity by introducing Axis cutter application.
AXIAL CUTTER APPLICATION:

HCI: ACCURATE CHECKS FOR SEGMENTS
• Ideal for grinding of Concrete in D ’wall RCC AND MOULDS USING 3D LASER METER –
structure and hard rocks
RVNL04
• Three to five times faster than hammers when
working on hard concrete. Moreover, the Measurement of dimensions of moulds and segments
resulting gravel-sized material is more used in tunneling projects is traditionally carried out by
manageable and can be removed in cost- means of measuring tape. This method is time-
effective manner and may be reused for other
consuming and leaves room for errors in measurement.
applications.
• Lower vibration and lower noise
At RVNL 4 project, for the first time in HCI projects,
• No impact of productivity in monsoon
dimension checks for moulds and segments are being
• Fuel Savings as equipment uses pressure load
regulator carried out using 3D laser technology - VMT laser tracker
• Huge reduction in time cycle. 120Hrs saving industrial measurement system, using the German–
when compared with breaking with hammers made equipment : FARO. Using this technology, the
• Economical cost of bullets (8nos of 19mm dimensions of both moulds and segments can be
Bullet – 970/- 24nos of 28mm Bullets – 1470/- measured with sub-millimetre precision and their
each) geometry checked (distances, angles and torsion). The
• Number of hours for breaking one d ’wall
integrated reporting system forwards the measurement
(6.25mtr long) = 5hours
logs to the segment documentation system and
provides information as to whether the required
tolerances have been observed.
JACK HAMMER APPLICATION:
The main advantages of using this technology are
ADVANTAGES:
• Meeting the tolerance demand;
• Ideal for medium hard materials breaking
• Reduced measurement time due to optimized
• Good for less quantity of breaking
measurement routines and
DISADVANTAGES: • Simple handling (2 operators).
So far, 336 moulds and 592 segments have been tested
• Required Manpower is more for breaking
using this technology at the RVNL 4 project as per the
application
frequency set in the contract. This has resulted in the
achievement of ‘zero deviation’ in both mould and

segment dimensions which is not possible with manual comparison of the mould geometry under different
checks. This article covers the principle of working and conditions. The automatic report is generated by the
usage of this technology for dimension checks by the help of the software.
RVNL 4 project team.
Dimension checking
Retroreflector Before starting the measurements, a precision check is

performed to verify the system specifications after the
setup of the laser tracker system. The laser tracker is
positioned into the centre of the mould using the
magnetic base. The correct Spatial Analyzer (SA)
template for the actual mould, which includes pre-
defined instruments, point groups for storage of
measured points, design planes and surfaces, is
selected. Then, the laser beam is initialized and locked
with focus to the reflector.
For the calculation of the mould’s geometry, the four

contact joint planes (front, back, left & right) and the
two cylinders (inside & outside) as well as the gasket
groove (up & down) are measured in the dynamic
measurement mode. The spherically mounted
retroreflector is moved over the plane or cylinder while
the laser beam follows, and the software registers a
point after a pre-defined distance increment (generally,
20 mm). With this, hundreds of points are measured on
3D check of moulds using the 3D measurement system each plane and cylinder, which guarantees to cover each
Working principle contact joint and cylinder arc sufficiently. After all
measurements are completed, the analysis and
A laser tracker is a measuring device that works by reporting commences.
projecting a laser beam onto an optical target in contact
with an object being measured. The device then During the analysis, the four planes and two cylinders
determines the three-dimensional position of the are intersected to derive the corner points and all
target. The Faro 3D laser tracker system comprises of relevant geometries, further to which all required
the sensor head, controller, motor & sensor cable, a distances, angles and deviations are generated and
computer with LAN cable and a triple-mirror reflector. reported automatically. As per the agreed frequency,
The sensor head rotates around two orthogonal axes the moulds are tested initially, after re-using 30 times
and reads the angle and distance information. Each axis and after re-using 200 times.
has an encoder for angle measuring and a directly
The Project Quality team has now gained experience
powered DC motor to permit remotely controlled
with the 3D-measurement controls and have well-
movement. The sensor head contains an absolute
trained staff to assess the segments and mould
distance measurement laser to measure distances. A
dimensions as per the contract specifications. Casting of
two-axis photo sensor (PSD), next to the laser, receives
5025 rings has been completed as on date. The well-
part of the reflected beam, enabling the tracker to
controlled dimensions of mould and segments has
follow the reflector.
helped to maintain the lips, steps and gaps during
The laser tracker system includes a weather station to erection of segments inside the tunnel without any
measure air temperature, pressure and humidity. The deviation.
measurement results are compensated with the
coefficient of thermal expansion for steel to a required
reference temperature of 20º C for an appropriate

LMB: TECHNICAL NDT PAPER
PRESENTATION BY LMB QUALITY HAZIRA.
LMB Quality had presented a technical paper in NDE
2023 Conference and Exhibition held in Pune,
Maharashtra during December 7-9, 2023 at The Orchid
Hotel, Pune organized by Indian Society for Non-
destructive Testing (ISNT).
Title of the paper was “Optimizing Radiographic Testing

for Tubular Products: A Comprehensive study on DWDI
Technique” and the author of the paper were Mr.
Hitendra Gohil, Mr. Satish Tilva, Mr. Suraj Yadav and Mr. LMB conducted numerous practical tests and
Ajay Saraswat. examinations on test pieces, revealing that depending
solely on two spots in DWDI radiography is insufficient
This technical paper illustrates a detailed case study for achieving comprehensive coverage. This limitation is
focusing on radiographic testing techniques for tubular especially pronounced in tubular joints with a specific
products, with an emphasis on the Double wall double diameter-to-thickness ratio, significantly increasing the
Image (DWDI) technique. In the technical paper, we risk of missing defects.
highlighted the critical importance of the Diameter-to-
thickness ratio in radiographic testing when using the This paper sheds light on the limitation of the
DWDI technique with only two spots. conventional DWDI approach in such scenarios and
emphasis the necessity for a more comprehensive
testing methodology to ensure defect detection in
tubular products.
This is one example, provided in detail:
• OD – 50.8mm
• Thickness – 11.2mm (excluding reinforcement)
• DWDI – Elliptical technique
• SFD – 350mm
• kV – 285 kV
• mA – 5
• RT – Digital Radiography (RTR)
After conducting Radiographic Testing (RT) on two
spots, the defect was not detected in both images.
Recognizing the necessity for comprehensive coverage,

we proceeded to take additional shots at a 45-degree
angle, successfully revealing the previously undetected
defect.

The solution implemented will improve the welding
productivity upto 3X w.r.t conventional system.
Significant benefits.
• Improved Productivity by 3 times.

• Less wastage
• Improved welding quality
Based on our experimentation, we have concluded that

when the diameter-to-thickness ratio is 4.5 or below,
additional shots are required to achieve full coverage in
radiography.
LTEH ONSHORE: WELDING AUTOMATION IN

SUPPORT FABRICATION THRU ROBOTIC
WELDING SYSTEM @HRRL FABRICATION Robotic welding system installed at HRRL shop
SHOP.
Need for Automation
Support fabrication is a major activity during piping

fabrication which involves equivalent amount of
welding as similar to circumferential joints. However,
there is constraint to use existing welding automation
systems for support fabrication due to its geometry.
Currently SMAW, FCAW & GMAW processes are being
used for support fabrication. Productivity with these Robotic welding system for support fabrication.
conventional methods is significantly low when
compared to productivity of automated welding TI: ZERO REWORK” THROUGH “FIRST TIME
deployed for circumferential joints.
RIGHT” INITIATIVE LAUNCHED IN 3 PILOT
Welding Automation in Support Fabrication PROJECTS.
The Objective of zero rework is aimed to be achieved by
Identified Robotic Welding System with M/s Panasonic
adopting the following approach: -
for support welding and decided to perform trials to
verify the suitability for our application. Subsequently, • to develop proactive approach for adopting
various trials have been conducted at their facility under “First Time Right”
simulated conditions by providing sample supports and • to approach everyone to become facilitators for
validated the process successfully and the system has the execution team.
been deployed at HRRL Project Fabrication Shop. • to develop growth mindset-focus on process
over product
• to adopt the system as a habit

To facilitate this objective a user-friendly mobile app
consisting of 4 modules (Pep-talk, Findings, Activity
Update, WMS) was created by in-house Digital Team.
Mobile pop-up notifications and e-mail notifications
help the users to be proactive and take swift actions.
Live Dashboards present real-time data and analysis.
Here are few images of real-time dashboards of

Findings, Peptalk and Activity Update app, along with
analysis of Findings:-
WET: SLIPFORM WORK ADOPTED FOR

INTAKE WELL CONSTRUCTION AT GOND
DEVSAR MVS PROJECT
The GDMVS Project team adopted Slipform work for
INTAKE Well construction to achieve the target set for
construction as well as to maintain utmost product
quality in entire Structure height. The Circular shape
INTAKE wall is having height of 25.00 mtr., wall thickness
1.00 mtr. & having the Internal dia. of 10 mtr.
Slipform is a construction technique used for reinforced

concrete walls, construction of lift & stair core walls.
This technique of construction is often found
economical for multistoried buildings. Slipform
construction involves the formwork for the walls being
raised in a continuous process as the wall concrete is
poured.
Slip formwork is one of the best techniques which

carried out fast and rapid construction in an unusual
structure like cooling towers, chimneys, Cement silos &
also in roadway bridge construction. Slipform work
technique carried out with more than 16 m height
structure and its very rapid and time-saving erection
techniques & also economical.
In Gond Devsar Project the concreting of full staging

height of INTAKE Well took Place in <1 month by
maintaining all the Quality standard. The concreting was
taking place in combination of Boom Placer Concrete
Pump & Ajax Fiori. With the help of Boom placer the
concrete was placed up to required depth & on final
setting of concrete of bottom layer the hydraulic Jacks
was used to slipped the formwork upward and fix for
next lift for pouring. A total concrete Qty of 865 Cum
poured in 25 days to construct 25 mtr. Full height
INTAKE Well.

To overcome and tackle this specific sensitive issue, the
Project team deployed an initiative in our project that
complies with the technical requirements with cost &
time benefits. Necessary prerequisites and assurances
regarding this product were demonstrated to the Client
and achieved the objective of "Operational Excellence
by innovating cost-effective practices".
The project team find an opportunity to introduce this

new technique i.e. Connecting FHTC at the same time
while laying and close the end of FHTC pipe by using of
20 mm CPVC nipple at the threaded portion of adaptor
socket which bring down the time of hydrostatic test
Initial setup of Intake well
and as well as reduced the rework, while ensuring
Quality & Customer requirements are well met.
The new technique has set a benchmark in the RWSS

project in Odisha and will serve as a reference for
various water supply projects in upcoming years around
the Country. The approval provides an excellent
opportunity for the organization during future
tendering.
Concrete Pouring on slipform with help of Boom placer
Photos of adapter fixing at 20mm HDPE pipe.

Final Product with help of Intake well
WET: WWW SBG: HDPE PIPES HYDROTEST

DOING ALONG WITH FHTC CONNECTIONS IN
JAGATSINGHPUR WATER SUPPLY PROJECT
Generally, in a water supply project the sequence of
activity from pipe laying to fixing of FHTC is done in four
stages i.e.- 1. Pipe laying & joining. 2.Backfilling. 3.
Hydrostatic test with testing m/c & apparatus. 4. FHTC
Field Testing of FHTC Connections During HT.
connection.
The entire sequence of activity involves time, cost & loss

of productivity, which directly impacted on timely
completion of project.

WELDING AUTOMATION IN CLAD PLATE
WELDING

practices as per the work methodology are briefed to all
3. QUALITY IMPROVEMENT
the workmen and engineers through various training
activities. Also, experts from outside - either expert
GEOSTRUCTURE: STRUCTURED subcontractors or associated vendors are invited to
ORIENTATION PROGRAM FOR EXECUTION conduct training programs in their specialized filed of
STAFF IN QA/QC FUNCTIONS works. These training initiatives ensures the application
of the same standardized work procedure at all sites in
This is an activity-based orientation program to train the
the project and enabling work progression in harmony.
execution staff in Quality functions by acquainting them
with technical specifications of a project, as well as how Attention to details
to carry out stage wise inspections and make sure that
it meets product quality standards. Since every step/task, no matter how small it is,
contributes to the final output, giving attention to
This orientation program has been launched and details during work execution at site as well as
covered for Three of our project sites and continuing to continuous inspection of works is a critical step towards
cover other balance LTGS project sites. impacting the first-time right mindset This ensures
minimization of errors and most importantly, helps to
HCI: CULTIVATING PRATHAM (QUALITY identify the need for further improvements in processes
CONSCIOUS) MINDSET: A PATH TO SUCCESS or work methods. This is achieved by frequent
AND EXCELLENCE AT RRTS P7 inspections of site activities by site quality engineers
during various stages of construction of a structure and
In a world that thrives on rapid advancements and
also by getting the feedback from the site engineers and
constant change, the ability to perform tasks accurately
client representatives on areas of improvements based
and effectively on the first attempt is a valuable skill. The
on site observations.
aim of creating the ‘first-time right’ mindset is to
emphasize the importance of delivering high-quality
results from the outset, minimizing errors, and
maximizing efficiency. This goes beyond simply aiming
for perfection; it involves instilling a culture of
accountability, strategic planning, and continuous
learning.
Delhi-Meerut Rapid Rail transit system (RRTS) line is the

first of its kind semi high-speed regional rail system in
India aimed to enable fast and reliable transportation in
the National capital Region. At Package 7 of RRTS, HCI IC
is constructing 11 km of elevated viaduct including 5
elevated stations in the Meerut City. With the PRATHAM
mindset, the project team has deployed various
interconnected processes, methodologies, and best
practices meticulously orchestrated to elevate finished
Training programs conducted on post-tensioning works and precast
products and operations to attain and sustain the high-
segmental gluing works by Industry experts before the
quality standards. This article presents an overview of commencement of erection works in the project
the steps taken in this direction.
Thorough preparation & process standardization
Before commencement of a particular works at site, the

standardized working methodology is prepared by
incorporating all the industry best practices and lessons
learnt from similar projects. The instructions and best

passage of <1000 Coulombs has been consistently
attained in the rapid chloride penetration test and water
penetration of <15 mm has been consistently achieved
without the use of Microsilica. Further, Tunneling
activities have been carried out in unpredictable
geologies without deviation of standards. For instance,
the Heading Breakthrough of Tunnel Cross Passage CP03
was completed within the stipulated time. Similarly, the
concreting work for collar section of Tunnel Cross
passage of CP01 was completed without any concern.
In-house training on common deficiencies in the precast girders, pier
& per cap and preventive measures
These successes are well-connected to the belief that
Feedback integration & continuous learning “Quality means doing it right when no one is looking (Qt.
Henry Ford)”. With this thought, the project team has
The first-time-right mindset recognizes that learning is a encouraged each other to accomplish the job assigned
never-ending journey and feedback is a valuable tool for to them flawlessly; regardless of whether any internal or
identifying the areas for improvement. Feedback from third-party supervision is impending.
site engineers and observation through client play a vital
role in identifying and rectifying the common defects The first step towards meeting high-quality standards
observed. For such observations or non-conformities for unique activities is sensitizing the workmen on the
identified, necessary rectification measures and importance of having a “first time right mindset”. To
investigation to identify the root cause are carried out facilitate this, a comprehensive training program
and further corrective measures are deployed to covering all aspects of construction process, was
prevent their recurrence. developed. The program primarily covers topics such as
quality control, quality assurance, as well as specific
This cycle of timely addressing observations and defects skills related to the work that they will be performing on
is crucial to reduce the future lapses and reworks. It also site. Each training module is designed to provide
helps in improving customer satisfaction and to prevent knowledge and skills to the workmen to do their jobs
the non-conformities raised by the customer. effectively and efficiently. Industrial / technical experts
from different companies like Hilti, Bosch, Normet, BASF
However, the most important step in the process is to
etc., are brought to our site for developing knowledge
ensure that the correct corrective measures are devised
on machineries used in site and construction materials
and deployed to prevent the recurrence of such
to our engineers and foreman. A structured framework
observations at site. This is possible through frequent
for training is prepared in collaboration with the
training programs conducted in view of continuous
planning team based the site progress.
improvement of workmanship and practices to address
the common defects observed at site and corrective Some of the features of the training programme at RT03
measures to prevent them. are as follows:
• Precise identification of target Workmen and

Engineers ensures that the right individuals
HCI: PROMOTING ‘FIRST-TIME RIGHT receive the necessary training.
MINDSET’ AT BMRL RT03 • A blend of classroom (theoretical) and on-site
(practical) – based training is designed for the
Bangalore metro package RT03 involves construction of participants to provide a holistic knowledge
tunnel of length 2.884 km using the tunnel boring development platform – which is a key for
machine (TBM) in addition to two underground metro effective learning.
• Elaboration on specific topics with quality
stations. 6400 precast tunnel lining segments made of
constraints address real-world challenges and
M50 grade concrete have been cast with ordinary
possible solutions
Portland Cement (OPC) and ground granulated blast
furnace slag (GGBS) combination. With this, a charge

• Technical and Strategic Improvements in streamlining the processes and has ensured easy access
Quality is kept as the core target of the training to crucial information.
approach.
• It is ensured that a roadmap for Our commitment to fostering a 'first-time right mindset'
implementation is made available for the has yielded remarkable results. Through continuous
discussed topics so that they can translate into
monitoring, training, feedback discussions with our
actionable plans.
teams, we've achieved a staggering 90% reduction in
• Every participant is encouraged to commit to
the declarations in the Quality Pledge and non-conformance of activities performed on-site. Our
uphold the highest standards. overall Project Quality rating has surged from 75% to an
• Quiz competitions, quality pep talk meetings outstanding 90%.
and interactions with site in-charges is regularly
done to assess the effectiveness of training and Our journey towards quality excellence doesn't stop
maintain a focus on quality. here. We are committed to maintaining a non-
conformance-free project in the future. By training and
motivating our workmen, front-line supervisors,
foremen, engineer and site in-charges, we
strive to set a standard that inspires everyone to
maintain the highest quality of work at site.
LMTG : CAPACITY ENHANCEMENT &

ACHIEVEMENT OF OVERSEAS DISPATCH
MILESTONES WITH ACCELERATED DELIVERY
SCHEDULE
1. Introduction:
As the Power industry has transformed from sellers to
buyer’s market, we need to improve the product in
terms of quality, cost, delivery & performance. To meet
the requirements of changing market conditions, LMTG
introduced the most effective equipment in power
generation “Ultra Super Critical Turbine”. These
turbines operate at very high temperature of 620°C &
steam pressure 670 Kg/cm².
Classroom training
The Turbine Blade is the most critical part of Turbine.
The accuracy in the manufacturing of Blade gives direct
impact on operating efficiency of power plant. Aerofoil
or profile part of the blade plays vital role in smooth flow
of steam. To achieve the required accuracy, turbine
blades are manufactured on the most accurate 5-Axis
machines. Including our technology provider & our
competitors manufacture blades on 5-axis machines.
2. Trigger for the Project:

LMTG Blade manufacturing facility was designed to
On-site training
manufacture around 37,000 of Blades. Switching over
We are also quick to adopting new initiatives. Since the to a new design of ultra-super critical Turbine,
inception of digital application for Monthly Quality requirement of the blades is increased to 58,000. To
Report (MQR), we have been recording site quality meet the new requirement, it called for additional
activities using that platform. It has helped with investment of approx. 20-25 Cr. for machinery &
accessories. The revised requirement of Blades

prompted us to take a project that delivers 60,000 Environmental issues are disruptions in the usual
blades/annum with the same set of manufacturing function of ecosystems. Further, these issues can be
facility. caused by humans impact on the environment or they
can be natural
3. Improvements:
We, in the Blade manufacturing division, have Environmental protection is the practice of protecting
undergone continual improvements in process, tooling, the natural environment on the individual,
Fixturing & CNC programming. This resulted in organizational or governmental levels Environment
enhancement of manufacturing capacity, reduction in damage caused by humans is a global, ongoing problem.
rejection & deviations. After the implementation of the
From previous 4 ~ 5 years the environmental norms are
improvements and other Kaizen initiatives, we plotted
getting more strengthen. Impact of the same,
the following graph. The YOY Average has increased to
Installation of coal-based power plants are becoming
5066 nos of blades per month.
harder & harder. LMTG as OEM of coal-based Turbine
Generators, started starving with the domestic orders
and also, Blade manufacturing division,
6. Breakthrough:
To utilise the enhanced capacity, we started to
manufacture & export the Blades for Mitsubishi Heavy
Industries Japan, with desired quality, Cost & stimulated
delivery schedule.
Customer delight is the one of the parameters that

Blade Manufacturing Year on Year 2019 to 2023
every manufacturing industry seeks for. This can be
done by offering a quality product, improving the
delivery standards, reducing the cost.
4. Quality Improvement:
Along with the productivity enhancement, we have From past 2 ~ 2.5 years, along with domestic orders, we
implemented systematic plan to quality are now supplying blades for overseas customers
Improvements.Blade shop has significantly reduced the through our technological partner MHI & has no
rejection ratio over the years. To reduce rejection customer complaint in any form either in quality or in
percentage, we kept the aim for First Time Right delivery schedule. This is achieved by doing meticulous
approach & implemented a program verification using planning. Continuously anticipating customer needs has
VERICUT software & develop fool proof process, helped us to understand their requirement and meet
automation to minimise the man handling of the their expectation.
process. The trend below shows the improvement in the
quality by reducing the rejection rate.
Blade Rejection Year on Year 2019 to 2023

5. Set back: Mr. Alok Sarkar, CE & WTD receiving the Appreciation certificate
from MHI Delegates

Valve Stand Fabricated Using Scrap Material
Improper preservation / handling of valves can also have

a wide range of negative consequences, including major
cost of poor quality, safety hazards, environmental
damages, and operational damage.
Valve stand has been fabricated to deal with the issues

Certificate of Appreciation related to valve preservation. It is fabricated in such a
7. Appreciation: way that valves can be kept in the racks appropriately
Energy Transition & Power Headquarters, Mitsubishi and thus we can reduce the cost of poor quality as well
Heavy Industries Limited has appreciated LMTG- Blade as all other issues related valve preservation.
shop for supplying more than 50000 Steam Turbine
Blade with highest quality & as per scheduled delivery
date.
MFF KATUPALLI: PRESERVATION PRACTICE

IMPROVEMENT USING INHOUSE
FABRICATED VALVE STAND.
Valve preservation in the oil and gas industry is of
paramount importance due to the critical role valves
play in controlling the flow of hazardous fluids and
ensuring safety in high-pressure and high temperature
environments.
Preservation plays a major role to prevent the corrosion,

maintain the integrity of the system and ensure the
valves are in their adequate condition.
Valve Stand Placed in Yard for Awareness on Valve Handling.
Valve stand would be beneficial in preserving the valves Valve stand helps to preserve valves leading many
through the shop floors and yard. In addition to that it benefits as below:
would be very helpful during the handling or
transferring the valves to other locations without • Extended Valve Life: Effective preservation
causing any damages. There is a provision for valve techniques prevent valve corrosion, and
damage which may result in operational leakage, valve damage. This extends the lifespan of valves.
• Cost Savings: By avoiding emergency repairs
damage, corrosion, paint damage etc.
and replacements, companies can significantly
reduce maintenance and operational costs
associated with valves. Additionally, extended

equipment life reduces the capital expenditure their connections shall be the responsibility of the
needed for new valves. engineering design department (EDD). The design shall
• Improved Safety: Properly preserved valves be performed by a qualified and competent structural
minimize safety hazards.
engineer of the precast company.
• Enhanced Reliability: Well-preserved valves
are more reliable and less prone to failures.
The precast structure design shall be in accordance with
This reliability can lead to increased customer
ACI 318/318M, PCI Design Handbook (MNL-120) and PCI
satisfaction and trust in the quality of products
or services. Manual (MNL-122). Prior to precast concrete
• Reuse of scrap: Scrap materials has been used fabrication, structural design calculations, design
instead of discarding. drawings and shop drawings including lifting details and
Apart from these benefits, usage of valve stands also capacities (Safe Working Load – SWL) shall be submitted
helps to meet the compliance requirements which to customer review and approval.
results in customer satisfaction which was our ultimate
The Prestressed Concrete Institute (PCI) Design
goal. This results in building Operational Confidence and
Handbook shall be the basis for analysis and design of
Building Customer Trust.
precast and prestressed concrete structures. Precast
This method of fabrication of valve stands using scrap concrete work shall be designed to carry all dead and
material was the first time in L&T Modular Fabrication superimpose loads indicated, including hanging loads
Business. We also planned to spread this ideology to our and lateral loads, including loads arising from storage,
other units of LTEH MFB across the world. handling and transportation.
In future, we have planned to fabricate more Valve Precast substation construction offers several
stands as per project requirements and keep in place to advantages, such as speed, durability, and cost-
improve the preservation practices to next level. effectiveness. In this approach architectural finishing
tasks such as CMU wall construction, plastering,
PT&D: L&T SAUDI ARABIA (LTSA) PRECAST installing gypsum board in accordance with fire safety
regulations, and painting scope has been eliminated.
SUPERSTRUCTURES FOR SUBSTATION
PROJECTS.
Electrical substations are the backbone of our power
distribution network, ensuring a reliable and continuous
supply of electricity to homes and industries. To
enhance the efficiency and resilience of these critical
facilities, many utilities are turning to precast concrete
for their construction. The previous approach to
substation construction in KSA by traditional method up
to roof. Whereas roof deck slab installation was in
practice till 2011. Considering geographical remote
location challenges and to minimize the project time Substation Elevation
cycle LTSA project team proposed entire superstructure Advantages of Precast Concrete in Substation
building and outdoor foundation construction with Construction:
precast elements.
1.Speed of Construction: Precast concrete components
Customer requirements of design of precast and are manufactured in a controlled environment, enabling
prestressed concrete structures for use in the concurrent on-site work. This approach reduces
substation building and other building facilities in construction time significantly, making it an ideal choice
Transmission System of Saudi Electricity Company (SEC), for utilities looking to expedite substation projects.
Kingdom of Saudi Arabia cover under SEC Transmission
Construction Standard for Precast Concrete TES-Q- 2.Quality, Durability and Strength: Precast elements are
113.01, Rev. 0, which also specified in respective project made in the factory under controlled conditions and
specifications. Structural design of all members and hence the best Quality including finish is ensured.

Precast concrete is known for its resilience to harsh Key Considerations for Precast Substation
environmental conditions, including extreme Construction:
temperatures, moisture, and seismic activity.
Substations need to withstand these challenges, and 1.Design Precision: Precise design and planning are
precast concrete provides a robust solution. crucial for successful precast construction. Any changes
or modifications can be costly and time-consuming once
3.Customization: Precast concrete allows for a high components are in production.
degree of customization. Substation designs can be
tailored to meet specific needs, accommodating various Very detailed shop drawings to be prepared with
configurations and equipment requirements. marking, lifting, transportation arrangement,
assembly/erection details based on Contractual
4.Cost-Effective: While the initial cost of precast drawings.
components may be slightly higher than traditional
construction materials, the time savings and long-term
durability offset these costs. The reduced maintenance
needs further enhance cost-effectiveness.
Substation building - Precast Super structure
Precast building inside- Double-T slab formworks 2.Quality Control: Maintaining strict quality control
5.Environmental Benefits: Precast concrete production during precast production is essential to ensure the
is energy-efficient, and the materials are typically components meet required specifications, dimensional
sourced locally, reducing transportation-related tolerances which are highly essential for ensuring
emissions. This aligns with sustainability goals and erections without any hindrances. High-quality precast
reduces the carbon footprint of substation projects. components are critical for substation longevity.
Environmental Impact: The production of precast 3.Transportation and Installation: Precast components
concrete can have a significant environmental impact can be large and heavy, necessitating careful planning
due to the energy consumption and carbon emissions for transportation and installation. Proper equipment
associated with cement production. However, advances for transportation with safety measures are essential to
in sustainable precast production methods are avoid accidents during transportation & installation.
mitigating some of these issues.
4.Foundation Considerations: The substation's
foundation design and preparation must be compatible
with precast components. Load-bearing capabilities and
soil conditions must be factored in.
5.Maintenance: While precast concrete is durable,

routine maintenance is still necessary to ensure the
longevity of the substation.
Precast buildings have numerous advantages, such as

Hollow core slab production at factory speed of construction, High quality and sustainability.
However, they also come with certain disadvantages,
which include:

Initial Cost: The upfront cost of precast concrete can be
higher than traditional construction methods. The
manufacturing of precast components, transportation,
and on-site assembly can all contribute to increased
initial expenses.
Transportation Challenges: Precast concrete elements

are often large and heavy, which can lead to
transportation challenges. Specialized equipment is
often required, and transportation costs can be high,
especially for long distances.
Crane Dependency: The installation of precast

components usually relies on cranes or heavy
machinery. This can be problematic in tight urban
spaces or in areas with limited access.
On-Site Labor: While precast construction can be faster,

it still requires skilled labor for assembly, which can be
challenging to find in some regions and may add to labor
costs.
Precast Building finishing. -Al-Uwayqilah 380kV BSP
Maintenance and Repairs: Over time, precast concrete
can suffer from wear and tear, and repairs can be more
challenging compared to traditional construction,
especially in terms of matching color and texture.
Limited Adaptability: Once precast components are in

place, making modifications or alterations to the
building can be difficult and expensive. This can be a
drawback if future changes are anticipated.
Quality Product: While precast construction is often

praised for its best quality, errors in manufacturing or Precast Building Installation. - Al-Uwayqilah BSP
transportation can result in defects that are difficult to
Handling & Storage: The handling process mainly
rectify once the components are on-site.
involves the removal of the precast elements from the
mold, transportation to the storage yard, loading and
unloading operation and erection of these elements at
the job sites. Different sets of lifting points and cast-in
devices will have to be used for various handling stages.
Precast elements shall be handled and transported in a

position consistent with their shape, weight and design
to avoid excessive handling, stress or damage and shall
be in accordance with concrete demoulding strength of
minimum 13.8 Mpa & 70% for prestressed elements was
reached prior to stripping and demoulding. (PCI-116,
117 Chapter 4.20.3).
Substation building – Precast super inside view-Uthamaniya-SS

to ensure maximum utilization of the time, equipment
and all other resources, and to avoid site stocking which
lead to double work, but in case where concrete panels
and elements are not be lifted directly into position, we
will store it at site, the stored items must be stable even
in windy conditions. Panels are stored using concrete
panel racks. Traffic Management Plan shall be
formulated by respective team to coordinate material
and element deliveries, identify trailer vehicular
movements, the anticipated entry and travel path of
trailers within the Site.
Installation of Precast elements:
The precast units shall be erected in conformance with

PCI - MNL -135 (Tolerances for Precast and Pre-stressed
Construction unless the client has alternative
specifications for compliance. The tolerances ought to
GIS Building Precast Column installation works - Al-Uwayqilah BSP be employed as reference points for determining
Precast concrete elements will be transported to site in acceptability, rather than as strict thresholds for
a safe manner and loaded on trucks by using Crane so outright rejection.
that it will not fall off the truck.
The panels are loaded in trucks with A-Frame where the

panels are supported. During loading
load to be distributed approximately equal for each side

of A-frame to balance trailer. They are attached with
steel wires to the frame and respect the maximum load
of the truck.
Elements will be restrained on the trailer by a system

that ensures the load is evenly distributed and
withstands movement of the elements during transport.
Column erection, showing lifting pin inserted in sleeve.
Elements will also be loaded and secured such that they
will not become unstable when the restraint system is
released on site.
Storage of precast wall elements at site
A proper delivery sequence will be established based

on-site erection requirement by the Site team in order

requirements. It is imperative to ensure the provision of
skilled workers who have received comprehensive and
effective training in the loading, delivery, and erection
of various precast elements. This is crucial in order to
attain a project outcome that is entirely satisfied.
During the process of erection, precast components and

structures are appropriately supported and braced to
maintain their stability and structural integrity.
Pre-cast Building Internal View
The alignment and structural integrity shall be

maintained until the permanent connections have been
finalized.
380kV Marjan BSP
Care shall be taken to ensure no damage to precast

members erected during other activities which includes
MEP, finishing, fixing accessories etc. Any damage may
create challenges to rectify the precast members
already erected. Any painting works if involved to be
done very carefully to avoid damage to precast texture
finish.
In no situations, the elements erected partially shall be

unstable which needs the correct sequence of erection PT&D: PT&D IC HAS INTRODUCED “NEW
as well as the right method of supporting the members QUALITY PYRAMID.”
till completion of erection and grouting the joints as per Quality is a differentiator in the competitive business
approved drawing. The members are fastened to world. Walking a step ahead through innovative ideas
supporting bearing elements as per drawings and adds value to organization. All of us know the pyramid
method of installation. The structural recommendation or triangle established while setting QMS Document
is that members be secured together at regular intervals framework for ISO 9001: QMS which is as below:
along their length as well suitable bracings. The lifting
plan shall be submitted for each of the elements, taking
into consideration their weight and placement

grouped as Lag indicators (Reactive measures) shown
with yellow color.
Within the framework of the Quality Pyramid,

meticulous data recording plays a pivotal role in
overseeing and managing the quality of a product. This
comprehensive approach involves tracking Training
sessions, induction processes, Inspections & Tests
conducted, potential incidents, Subcontractor
assessments, SOPs, Mockups conducted, Audits &
findings, quality incidents, induction processes, Cost of
What is that “New Quality Pyramid” or Quality Triangle?
poor quality, non-conformance reports (NCRs) and
The main reason behind selecting pyramid is the shape customer complaints. Each of these components serves
which has max stability. Now the “New Quality Pyramid” as a crucial data point in the quality control process,
idea generated by Renewable domestic BU team to contributing to a robust system that ensures adherence
present the Result also in the similar Pyramid / to standards, continuous improvement, and effective
Triangular structure. resolution of issues that may arise throughout the
product lifecycle.
Why, What and How do these New Quality Pyramid
questions arise automatically. Let us see the answer to
each one of these questions.
There are 2 Quality indicators we are referring viz. Lead

indicator and Lag indicator. These 2 types of indicators
cover many parameters of fitness of quality as
presented in the New Quality Pyramid. To improve
Quality fitness what all the parameters, are they
adequate/insufficient can be assessed very quickly. This
will help to sensitize the team on matter of concern and
needs immediate action. In fact, going ahead the range
of ratios also can be arrived.
Conclusion:
Various key parameters under these 2 Quality indicators
are thoroughly checked and selected and the measuring Quality pyramid helps in quick monitoring of quality
unit for the same also arrived to quantify the same. performance result of a project. Going ahead it is
Pyramid clearly represent these indicators and units of possible to find out a range of values to achieve the best
measurements. This helps a lot in quick and periodical results. Since it is a monthly monitoring, it also helps in
monitoring of QMS performance. So, the “New Quality taking timely corrective actions for improvement.
Pyramid” shows QMS performance result of the project.
REALTY: LAUNCH OF QUALITY HANDBOOK
The last part of the question is how? Every month, every
project shall update this Quality Pyramid and check Creating a Quality handbook for finishing process for a
Quality Performance result and at the same time take residential building involves compiling comprehensive
improvement action where it is found inadequate. It will information and guidelines for the construction team to
have monthly statistics and also cumulative quantities achieve zero snags while handing over to the customer.
from the beginning of the project.
Quality pyramid built in 2 parts. The first part is base,

includes various parameters grouped as Lead indicators
(Proactive measures) and shown in green color. The
second part is a crown, includes various parameters

• Mandatory floor Benchmark Activity
Quality Handbook on • Stage Certification
• Benchmark approval by Design, Quality, MEP,
• Material Selection and Finishes and Project Head.
Specifications • Approved Project specific Benchmark to be
• Using Tools, Technology printed and circulated among the team.
Integration, and trainings
• Construction stages and Stage 5 & Stage 6 (Flat Handing over process activated)
sequence
• Pre-Handing over process in • Robust Finishing team members includes
construction. (Project head, Design, Quality Finishes and
• Post-occupancy Customer MEP)
feedback/complaints Stage Checklist
Evaluation
• The activity in red indicates mandatory signoff
and auto trigger of sequence jump.
Stage 1 & Stage 2 (Mandatory activities)
• First Activity Mock-up/ Benchmark sign off.

• Stage Certification at each stage
• Monthly Quality Audit
• Robust finishing includes booklet with
benchmark
Stage 3 & Stage 4 (Mandatory activities)

LTEH ONSHORE: ON-TIME COMPLETION OF
4. MILESTONES/BENCHMARKS
HIGHLY ACCELERATED PROJECT - REROUTE
GAS & CONDENSATE PIPELINES, MIDYAN
GEOSTRUCTURE: RAISING THE PQR
DUBA, KSA
BENCHMARK
LTEH team was honored to contribute to NEOM's
This financial year, PQA benchmark has been set at 90% ambitious projects, including 'The Line' and 'The Spine',
against last year 85%. The PQA rating observed in the which are the flagship projects of Saudi Arabia's Neom’s
Second quarter from 11 operational sites is 92.61% megacity. Saudi Aramco Senior Management
appreciated & congratulated project team for successful
LTEH ONSHORE: “IN BREAKING Mechanical Completion of Midyan Reroute Gas &
BOUNDARIES, WE REDEFINE WHAT'S Condensate Pipelines. After Mechanical Completion,
POSSIBLE” - NEW RECORD SET AT JAFURAH Commissioning & start-up activities are also completed,
EXPORT PIPELINE PROJECT, KSA - 201 Hydrocarbon (Gas & Condensate liquid) introduced
JOINTS OF 36” DIA. WELDED IN A SINGLE flawlessly and Plant restarted, 7 days ahead of target.
DAY WITHOUT ANY REPAIR.
A new record has been set at Jafurah Export Pipeline
Projects by completing 201 joints (equivalent to 5 km
linear pipeline length) of 36” diameter in a single day.
This has been achieved by meticulous Planning and
executed by extended hours of working (15 Hours). 10
welders & 5 nos. of Automatic welding machine were
used for achieving this milestone. 2 Nos. AUT crew with
additional calibration setup was also available at site for
conducting AUT at a time after completion of weld
joints. Saudi Aramco Project Manager Mr. Fahad and
other ARAMCO Project team appreciated the LTEH
Project team for this remarkable achievement.
Project team received certificate of appreciation from

Saudi Aramco for distinguished performance and
commitment during execution and completion of the
project.

The SMP#3 project team at Hazira received immense
appreciation from the AMNSI team for achieving this
milestone despite challenging site conditions, while
adhering to the highest standards of safety & quality
and adopting innovative work methodologies. The
AMNSI and L&T management appreciated the efforts of
the team members and motivated everyone to keep
their spirits high to achieve further upcoming
milestones.
Converter and High bay Area
M&M: STEEL MELTING PLANT #3, HAZIRA,

ACHIEVES MILESTONE BY COMPLETING
1,034 PILES AND 10,203 CUM. OF
CONCRETING IN AUGUST 2023:
Caster Area
Minerals & Metals SBG has been entrusted with the
supply, erection, and commissioning of the 6 MTPA
Steel Melting Plant (SMP) by M/s ArcelorMittal Nippon PT&D: PRIME MINISTER OF NEPAL
Steel India (AMNSI) at their Hazira Works, Gujarat, as a INAUGURATES 220 KV GIS BHARATPUR
part of their ambitious expansion plan from the existing SUBSTATION
8.7 MTPA to 14.2 MTPA. PT&D IC has added one more benchmark to its list of
vital power infrastructure projects with the
The SMP#3 project is to be completed in a stringent
inauguration of the 220 kV Gas Insulated Substation
timeframe of 38 months. A major challenge in the
(GIS) at Bharatpur, Nepal, which is L&T’s first GIS project
construction of the 6 MTPA Steel Melting Plant is its
and the 4th substation overall in Nepal.
huge scope of concreting 2,13,400 cum. and around
11,700 of piling works. Out of the total scope, the site The Rt. Hon’ble Prime Minister of Nepal Mr. Pushpa
team has remarkably achieved more than half of its Kamal Dahal inaugurated the substation on 22 August
piling scope and 25,000+ cum. of concreting. In the 2023 in the presence of Mr. Shakti Bahadur, Nepal
month of August 2023 alone, the team achieved a Energy Minister, and senior ministry officials. The
benchmark by casting 1,034 piles and 10,203 cum. of occasion was graced by Mr. Kulman Ghising, Managing
concrete. Director, Nepal Electricity Authority (NEA), and Mr. Tara
Pradhan, Deputy Managing Director, NEA.
The major part in the concrete quantity achieved for the
month came from the mass concrete pourings of the
BOF Converter 2, Caster 6 raft, and high-bay building
foundation columns. The team has also achieved a
milestone by casting more than 50 piles on a single day
in the same month.

The Hon’ble Prime Minister and other government
PT&D: INSTALLED MALAYSIA’S TALLEST
officials appreciated the efforts of the project team with
POWER TRANSMISSION TOWER
a Certificate for Appreciation for successful completion
and welcomed for further association towards nation- PT&D IC’s ASEAN BU, Project team has completed
building in Nepal. installing of Malaysia’s tallest transmission line tower,
standing at 147.7metres. The project scope of works
involved engineering, manufacturing, supplying,
installing, testing, and commissioning the 37 km long
500 kV double circuit overhead transmission line,

connecting the
Pulau Indah 1,200 MW Power Plant to the Olak Lempit

500 kV Substation in West Malaysia. This involved
crossing straits span length of 810 metres, with towers
weighing 217 MT.
This substation paves the way for success in upcoming

projects from NEA in the region. The project involved
procurement of plant design, supply, installation,
testing, and commissioning of 220 kV GIS substations at
Udaipur and Bharatpur towns located in the hilly area of
Northern-Central Nepal.
The gigantic tower is located on the edges of Selat

Lumut (Straits) and within the confines of a dense
mangrove swamp. To install the tower, the project team
constructed 45 m × 45 m platforms at 5.07 m above sea
level to overcome the high-tide water level. The
installation of the tower at this unique location posed
significant challenges due to location constraints,
limited access, and intricate guy rope arrangements
within the mangrove swamp. Due to these constraints,
heavy machinery couldn't be mobilized, and hence the
tower had to be manually installed, which poses a high-
risk and challenging environment for the installation

team. However, with stringent safety measures, the
aforesaid risk was mitigated.
The tower installation was completed with full safety

and quality. With this achievement, the project has
surpassed Malaysia's previous record for the tallest
power transmission tower, which stood at 109.79
meters.
The same has been listed in The Malaysia Book of

Records.
Flag-off ceremony in a traditional way
The modular fabrication for the project was kick-started

in December 2021 as the first steel cut has been carried
out. From which the project takes a big hit with the
global pandemic and due to which the execution phase
of the project has been re-scheduled. After various n
number of hindrance crossed during the course such as
with the availability of raw materials in the global
market and the recruitment of the workforce and their
safety. With lot of pre-cautions & conviction all the
efforts have been taken to complete the fabrication
successfully.
MFF KATTUPPALLI: MILESTONES OF LINDE-

ROTTERDAM PROJECT LOT-2: : FLAG OFF OF Largest Module of LTEH MFFK 1A2010A Syn Gas –2871 MT Pic:
1A5010A Off Gas Module – 345.8MT
LARGEST MODULE AND PROJECT
Execution: To execute all the modules with CE marking
COMPLETION WITH CE MARKING.
in accordance the European Directives & EN standards,
The project scope consists of 5 PAR PAU+ modules and awareness and necessary training given to the entire
to be delivered to Netherlands. The largest module project team to understand and to enhance their
which was ever fabricated in our MFFK which weighs operational capability for the completion of the project.
over 3000MT has been fabricated and sailed away from The control measures put in place in all stages of
this project. In the month of September, lot 2 consisting Engineering, raw materials , welding and execution.
of 2 modules and 1 Pre-Dressed Column were High supervision and thorough stage inspections were
dispatched successfully to Netherlands. performed at every stage of the fabrication activities to
ensure that the activity is completed in accordance with
the EN standard.

Detailed progress of the modules are maintained (Check Significant achievement was done by the project crews
records, Punch Points status) which helped for the with all the hard work, dedication, and perseverance
completion of project on time. This resulted in the helped deliver this milestone safely and the Upstream
successful completion of the modules with “ZERO side of the Tunnel having structures- Intake Well
PUNCH POINTS WITH CE COMPLAINCE” and dispatched (capacity of 206 MLD), WTP (Capacity of 166 MLD) and
successfully. OHMBR (Capacity 5410 KL) commissioned.
We’ve received heartwarming feedback from satisfied The upstream side of the tunnel was inaugurated by
customers praising the product quality, communication Honourable Minister of MP Govt. for Backward Classes
system, work environment and personnel competence and Minorities Welfare | Panchayat & Rural
related to our dispatched modules. Their satisfaction Development Shri Ramkhelawan Patel & Honourable
motivates us to continue deliver excellence. Member of Parliament of Satna Shri Ganesh Singh on
7th Oct 2023 with approved procedure and contractual
specification within stipulated time and made it
successful. It is possible because of all coordination,
cooperation, and collaboration of IC, SBG, BU, Accounts
& Admin and Quality dept with first time right theme.
Drone shot of Fully Loaded Barge – Ready for Sail Out
TI : QMS
RBF SBG of TI IC has taken a significant step towards
total quality management. Each department is
preparing their own quality manual in accordance of ISO
9001:2015, which shall be overarched by the
organizational manual.
WET: WWW SBG: SUCCESSFUL

COMMISSIONING OF THE UPSTREAM SIDE
OF THE TUNNEL HAVING STRUCTURES -
INTAKE WELL (CAPACITY OF 206 MLD) ,
WTP (CAPACITY OF 166 MLD) AND OHMBR
( CAPACITY 5410 KL)
Satna MVRWSS: Engineering, procurement,
construction, testing, commissioning, trial run and
operation & maintenance of various components of
"Satna - Bansagar Multi Village Rural Water Supply
Scheme, Distt. Satna" for ultimate capacity of bringing
166.00 mld treated water (23 hours of pumping) from
the Bansagar Dam on river Sone to 1019 villages.

The Honourable Minister of MP Govt. for Backward
5. CERTIFICATIONS
Classes and Minorities Welfare | Panchayat & Rural
Development Shri Ramkhelawan Patel & Honourable
Member of Parliament has inaugurated the WTP 166 GEOSTRUCTURE
MLD up to the upstream portion of tunnel.
28nos. QA/QC Staff completed structured module
training on “Certified Quality Engineers” in ATL NEXT. In
continuation to this 11nos. Staff oriented by classroom
session and received a certificates for the same.
ATL Certificate:
MFF KATTUPPALLI: ENHANCEMENT

EN1090-2:2018 CERTIFICATE WITH HIGHEST
GRADE S690
The EN 1090 series comprises a set of European
standards that define the requirements for the
execution of steel and aluminum structures in the
European Union. Compliance with EN 1090 standards
involves a thorough assessment of production
processes, materials, and the competence of personnel
involved in manufacturing these structural elements.
What is EN 1090?
EN 1090 is a European standard that outlines the

requirements for the execution of steel and aluminum
structures. It defines the technical specifications and
procedures for fabrication, welding, and assembly to
ensure these structures meet the necessary safety and
quality standards within the European Union.
Compliance with EN 1090 is necessary for
manufacturers and suppliers of structural components
to affix the CE marking, demonstrating conformity with
EU regulations.
EN 1090 consists of several parts, with the most notable

ones being:
EN 1090-1: This part specifies the requirements for

conformity assessment of structural components made
from steel. It covers fabrication and assembly

requirements and mandates the CE marking for
products meeting these standards.
EN 1090-2: This part addresses the requirements for

aluminum structural components, outlining similar
guidelines to EN 1090-1 but specific to aluminum
materials.
The EN 1090 standard introduces the concept of

Execution Classes (EXC) and Material Grades (or steel
grades) to ensure the proper fabrication and use of
structural components within the European Union.
Execution Classes (EXC): Execution Classes are

categories that specify the level of technical
requirements and quality control needed during the
fabrication and construction process. They range from
EXC1 to EXC4, with EXC1 representing the lowest and
EXC4 the highest level of stringency in terms of
production control and quality assurance
• EXC1: Basic fabrication requirements, typically

for simpler structures with minimal
consequences in case of failure.
• EXC2: Standard fabrication requirements for
most common structures.
• EXC3: Increased control measures and quality
assurance, suitable for more complex or critical
structures.
• EXC4: The most rigorous requirements for
structures with high consequences in case of
failure or structures subjected to exceptional
conditions.
Facility must implement an efficient system that
meets the requirements of the EN 1090 standard to
En 1090-1,2 latest certificates
achieve EN 1090-1,2 certificate. MFFK yard went
through several audits to achieve the highest
Execution class for EN 1090-1,2 previously. Until
August’2023 MFFK owned EN 1090-1,2 EXC4 up to
S550.
S690 being the highest class in EN 1090certification,

it strives several requirements to acquire. In
August’2023 L&T Modular Fabrication Facility,
Kattupalli obtained EN 1090- 1,2 EXC4 up to S690
certificate.

given by the Quality team to Workmen, Supervisors for
6. COMPETENCE DEVELOPMENT
the ASME and METI changes and METI requirement
during manufacturing & Inspection.
LMB: NEW MARKET SEGMENT
ESTABLISHMENT AS PER METI (MINISTRY Second Phase: METI deployment Gap Analysis,
Standardization: LMB’s Current QC system ASME
OF ECONOMY, TRADE & INDUSTRY) AND
COMPLIANCE OF JAPANESE ELECTRICITY
BUSINESS ACT (ARTICLE 39) BY DELIVERING
QUALITY BOILER PRESSURE PARTS AS PER
CUSTOMER’S QUALITY REQUIREMENTS
Business need & Strategy: As the market opportunities
dried due to limited tenders floated for fossil fuel-based
power plant in India as government’s policy are inclined studied, and comparison prepared (Gap analysis) for
towards green energy. LMB management started difference between ASME & METI requirements. METI-
looking at all the avenues of creating business. As one of Project specific SOPs, standardized formats, Internal
the ideas of creating biomass boiler business though QAPs/ITP were prepared with detailed information in
Andrtiz enquiries for Japanese market. L&T-MHI Power order to give maximum METI project related
Boilers Private Limited (LMB) is familiar with ASME, information for execution of the project. The idea
ASNT, IBR code as these standards are published in behind preparing detailed SOPs with METI requirement
English and LMB has experience of following these is that contractual METI requirement should not be
standards/codes. skipped.
Limitation / constraint: METI guideline, JIS & JSME are

only available only in Japanese language and limited
scope resources available for study and understanding
METI requirements and application
Third Phase: Welding Control Initiatives: Welding

control in METI welds is the strictest of attributes. LMB
deployed Welder skill test, welder arm bands-for visual
control, WDL (Welding Detail List) & Digital Kiosk and
welding applications for welding activities control.
LMB followed following phases and deployment

strategy for successful implementation for METI
qualification to meet customer(stakeholder’s)
expectation:
Benefits from New Qualification & new product: LMB

has transitioned from a domestic manufacturer to a
global supplier of Boiler Pressure Parts and entered in
First Phase: Upskilling of human resources: During the new market segment establishment i.e. METI (Ministry
Pre-ordering stage, the Quality team thoroughly studied of Economy, Trade & Industry) as per Japanese
the METI requirements from Customer specification. Electricity business act (Article 39) for scope Boiler
Post-ordering, extensive training and awareness was pressure parts export to Japan. LMB has executed 1st

METI project independently. Upon successful
demonstration of quality system, skill, Toyo along with
Andrtiz qualify LMB for METI scope.
Business growth due to METI Qualification: This has not

only improved LMB’s credentials in meeting
international benchmarks but has also set up our global
footprint for supply references. which has resulted in
new back-to-back orders from the same customer which
has benefitted in Business growth.
Participants and Organizers of Lead Auditor Training Program
PT&D: INITIATES FRONT LINE SUPERVISORY

(FLS) TRAINING AT CSTI-PILKHUWA, DELHI
REGION
PT&D IC (Renewable Business & Utility Power
Distribution) is implementing a comprehensive training
L&T-MHI Power Boilers Private Limited (LMB) Quality program for first line supervisors at project sites, with a
team won METI –Q-Success story paper presentation in focus on enhancing man management skills, particularly
Quality fest organized by CoE, corporate HR-L&D & at the site level. This initiative addresses the imperative
Quality council during World Quality Month celebration. of strengthening site coordination activities and
improving the interface between workmen and project
engineers.
PT&D: ARRANGED ISO 9001:2015 LEAD The top management of PT&D IC, in collaboration with
AUDITOR COURSE THROUGH BUREAU CSTD-HQ, has devised a plan to design a specialized
VERITAS. course and select the best talent from CSTIs to undergo
training at CSTI-Pilkhuwa, specifically tailored for
PT&D IC arranged ISO 9001:2015 QMS Lead Auditor
advanced Solar and UPD systems. To kickstart this
Course through Bureau Veritas from Sep 12-16, 2023.
program, the PT&D IC HR team conducted a rigorous
Program was arranged as a classroom schedule in HQ
selection drive across CSTIs, resulting in the
Campus, Chennai. The course was arranged for 12
identification of the top fifty candidates for the
participants.
inaugural batch.
Objectives of the program:
CSTD-HQ and CSTI teams collaborated closely to
• To Strengthen the Auditing Team of PT&D IC understand project requirements and swiftly developed
with Certified Lead Auditors for ISO 9001: 2015 a comprehensive training curriculum, plans, assessment
QMS. procedures, and study material.
• To Enhance the effectiveness of Auditing
conducted across the organization and train
the team for effective implementation of ISO
9001:2015 QMS.
• To provide requisite knowledge and skills to
plan, conduct and report a QMS audit
according to the applicable audit principles,
procedures, and techniques.
The 5-day training course is a blend of training sessions,
exercises and group discussions coupled with learning
to achieve its set objectives.
During the inauguration, senior project officials from
PT&D IC interacted with trainees, congratulated them,

shared expectations for Front-Line Supervisors, and
emphasized their crucial role in project success.
TI
Series of training programs were conducted in the
month of July and August for technical competency
development of site teams : -
• Training on Concrete Production & Placement

related Issues (8th July & 15th July) -The
program provided an overview of seven steps
in the manufacturing of concrete as well as
diagnosis and prevention strategies of various
issues pertaining to each step.
• Training on Precast Segmental Construction of
Bridges (28th July-29th July)-The program
aimed to strengthen the knowledge and skill of
employees in execution and QA/QC involved in
the intensive structure work and enhance their
understanding of technical concepts and
construction methodology.
• Training on Bridge Construction (1ST August to
5th August)- The program provided in-depth
understanding of the construction techniques
and QA/QC aspects of various components of
bridges and address issues that can arise during
construction.

related performance attributes such as rate and degree
7. SCHOLARLY ARTICLES
of cure, sound absorption and impact resistance, and
morphology.
DEFENCE: DYNAMIC MECHANICAL
ANALYSIS (DMA) – AN OVERVIEW 3. What is Storage Modulus, Loss Modulus and Tan
delta of a Viscoelastic material?
1. What is Dynamic Mechanical Analysis (DMA)?
The Modulus: Measure of materials overall resistance to
Dynamic Mechanical Analysis, otherwise known as
deformation
DMA, is a thermomechanical analysis technique that
measures the properties of materials as they are The Storage (Elastic) Modulus (E’): Measure of elasticity
deformed under periodic stress. of material. The ability of the material to store energy.
2. How Does a DMA Work? The Loss (Viscous) Modulus (E’’): Measure of viscosity of
DMA works by applying a sinusoidal deformation to a material. The ability of the material to dissipate energy.
sample of known geometry.
Tan Delta (tan δ) or Loss Factor: Measure of material
The sample can be subjected by a controlled stress or a damping. It is the ratio between the loss modulus and
controlled strain. For a known stress, the sample will the storage modulus (tanδ = E’’/E’).
then deform a certain amount.
If the material being evaluated is purely elastic, the

phase difference between the stress and strain sine
waves is 0°. If the material is purely viscous, the phase
difference is 90°. However, most real-world materials
including polymers are viscoelastic and exhibit a phase
difference between those extremes.
4. Practical Applications and Interpretation of DMA

in Composites:
Application 1: Young’s Modulus and Glass Transition
Temperature of a CFRP
DMA measurement on very stiff, carbon fibre-

reinforced epoxy resin tested with single cantilever
bending sample holder with measurement parameters
DMA Measurement - Principle
of dynamic temperature ranges from 35°C to 230°C at a
heating rate of 3°C/min with frequency 10Hz and
amplitude ±40µm is shown below
This phase difference, together with the amplitudes of

the stress and strain waves, is used to determine a
variety of fundamental material parameters, including
storage and loss modulus, tan d, complex and dynamic
viscosity, storage and loss compliance, transition The results of DMA measurements on a carbon fiber-
temperatures, creep, and stress relaxation, as well as reinforced epoxy resin indicated that high storage

modulus at 50°C (approx. 145,000 MPa) indicates that becoming a necessary component of characterizing the
this material is even stiffer than metallic titanium. The viscoelastic properties of polymers.
drop in the curve at 159°C (onset temperature), related
to the maxima in the loss modulus and loss factor (tan --Contributed by S Gokul Raj, Coimbatore
δ) curves at 171°C and 176°C, marks the glass transition
of the epoxy matrix. DEFENCE: DIVERSIFICATION GOING AN
EXTRA MILE IN CONSTRUCTION OF NEW
Application 2: Curing of a Liquid Epoxy Adhesive FACILITY
DMA measurement on liquid epoxy adhesive tested In the realm of naval warfare, submariners play a pivotal
with compression sample holder with measurement role in maintaining maritime security. Aspiring
parameters as isothermal temperature at 30°C with submariners undergo rigorous training to ensure their
frequency 1Hz and amplitude ±20μm is shown below readiness for the challenges that lie beneath the waves.
At the heart of this preparation stands the Escape
Training Tower (ETT) at INS Satavahana-a remarkable
new facility that simulates real-world scenarios and
equips trainees with the skills needed to navigate
emergency situations in a submarine environment. This
article delves into the Diversification………. Going an
Extra mile in construction of new facility
This facility is a three-story building (with a design

capacity of five floors) with an integrated facility of
structural chambers encompassing engineering and
electrical systems. This necessitates interdisciplinary
The results of DMA measurements on a liquid epoxy competence in Civil, Mechanical, Electrical, and
adhesive indicated that the increase in storage modulus structures.
after 140 minutes (time onset) results from the curing
reaction. It is related to a peak at 151 minutes in the tan As the first person responsible for QA & QC operations
δ curve. The further increase of the storage modulus at the ETT facility, I took the challenge to diversify in
value after approximately 500 minutes at 30°C civil, mechanical, and electrical domains.
isothermal run indicates that the curing has not been
The journey began with understanding the civil
finished.
nomenclature, Process and Civil inspection
5. Why DMA is better than DSC in evaluating Glass methodology, and approval of the Civil QAPs for L&T,
Transition (Tg) temperature? which was followed by IRS and Indian Navy approval.
DMA easily recognizes small transition regions that are 1. Civil QAPs generally are classified as Material testing
beyond the resolution of DSC (Differential Scanning & Inspection test plans. The topics covered are
Calorimetry). DMA provides higher sensitivity to Tg than mentioned below
DSC, because it directly measures changes in mechanical
and Viscoelastic properties as a function of
temperature. Some materials Tg cannot be resolved by
DSC can often be measured easily in DMA.
6. Summary
DMA is a versatile technique that complements the
information provided by the more traditional thermal
analysis techniques Differential Scanning Calorimeter
(DSC), Thermogravimetric Analysis (TGA), and
QAP-Material Testing QAP-Inspection Test Plan
Thermomechanical Analysis (TMA). Hence, it is rapidly

2. The experience and knowledge gained on the Process Diagram:
engineering & technical documents of SUP projects
extended an opportunity to explore on these standards,
• ASME SEC-8: Requirements applicable to the

design, fabrication, inspection, testing, and
certification of pressure vessels
• ASME-PVHO-1: Safety Standard for Pressure
Vessels for Human Occupancy (Requirements
for the design, fabrication, inspection, testing)
• ASME-PVHO-2: Safety Standard for Pressure
Vessels for Human Occupancy-In-service guide
lines (Technical criteria and guidelines for the
operation and maintenance of PVHOs and
PVHO systems
• AWS D1.1: Structural Welding Code--Steel
• Several Indian Standard Codes 1. Pour Plan preparation:
3.Using the information gathered from these standards, • Prepare Pour plan as per site condition
the QAPs for Mechanical and Structural domains such as Considering site condition, we have each pour size of
Fabrication Structural Chambers, Installation of approx. 300 sqm. We have prepared pour plan such that
Structural Chambers, and Installation of Out fitting each pour CJ will be always at 4X4m panel where groove
Components (Engineering & Electrical) have been cutting and sealant filling will be done, due to which we
approved. can avoid any future crack at CJ location.
4. As the ETT is combination of Civil, Mechanical and

structural works adjusting the time lines to manage the
works at three different locations. Understanding the
criticality of Civil and mechanical works, various
inspections at different locations of vendor premises
across India, managing and undertaking civil inspections
during absence of civil inspector (Civil inspections are at
VDF Pour Plan
base Location-Visakhapatnam). In spite of challenges 2. Preparation works for VDF flooring:
going an extra mile to support for all the Factory • Remove/chip dead concrete
Acceptance tests such as Compressors, Valves, • Grind/clean existing concrete surface
Actuators, PT Doors & Hatches and also expeditor for • Soak base slab with water
Structural Fabrication.
Contributed by R James Sunil Kumar, Vizag
GEOSTRUCTURE : VACUUM DEWATERED

FLOORING WORKS @ CMRL-CENTRAL
SQUARE BUILDING PROJECT:
Vacuum dewatered flooring (VDF) is a construction
technique that uses a vacuum to remove excess water
and air from concrete immediately after placing thereby
reducing the water: cement ratio to the optimum level.
It helps to create high strength, durable and smooth
finish floor, resistant to crack and other damages. This 3. Placing flooring concrete:
type of flooring is ideal for heavy traffic movement and • Thickness of floor concreting should be 100
high abrasion. mm
• Fix level bulls at every 2-3 sqm

• Fix strips as per CJ pour plan • Use Power Floater until the surface is
• Place M25 grade concrete and compact with sufficiently compacted and required finish is
needle vibrator achieved
• Ensure concrete is with 10 mm down aggregate
4. Vacuum Dewatering:
• Vacuum Dewatering process must start within
30 minutes of concrete placing
• Place filter pads on fresh concrete and it should
be overlapped with each other by at least
250mm.
• Suction pads are rolled over filter pads and
connect suction hose with vacuum pump
• After starting pump, vacuum is created
between top cover and suction pads 6. Groove Cutting & filling:
• Excess water from concrete is taken and • To avoid cracks in concrete due to expansion
discharged through pipe and contraction grooves are made
• Dewatering time takes approx. 1.5-2 min per sq • Cut Groove (size: 3 mm wide & 6mm thickness)
meter of floor within 48 hrs of concrete placing.
• Fill groove with polysulphide sealant (Fosroc –
Thioflex 600 or equivalent material).
• Curing of VDF Floor concrete must be carried

out for 14 days by water curing.
HCI: HIGH QUALITY CONSTRUCTION

THROUGH MODULARIZATION OF ENABLING
STRUCTURES
“Modularization combines the benefits of
standardization and customization by enabling the
right product for each requirement”
5. Floor Hardener application and finishing: Modular fabrication refers to the process of building or
• Concrete is left to stiffen to the point when foot producing individual modules off-site in a fabrication
traffic leaves an imprint maxm about 3-6 mm. facility. This is often corelated with building blocks –
• Apply Floor Hardener at an even application
Blocks (modules) fabricated in distinct yard is delivered
rate of 5 kg/sqm after concrete has stiffened
to the worksite and integrated into field operations.
Modular fabrication offers significant benefits over field

construction like time saving due to parallelized
construction, cost efficiency due to standardization,
improved safety and quality, component variant
customization. This differs from on-site construction in
which the component is fully built at the worksite.
While many industries like automotives, fabrication

facilities have shined in modularization and assembly
system with automated robotics, IOT, Industry 4.O, 3D
manufacturing, etc., construction industry deals with
various challenges to achieve high levels of HCI’s zealous determination led to development of
modularization in terms of the percentage of stick-built distinctive approach for fabricating temporary /
work hours being exported offsite. enabling structures cross IC, that is handled through HCI
IC’s Competency Cell for Temporary Works and Precast
Infrastructure construction often consists of large
Works.
modular components and involves fabrication of heavy
machineries and enabling structures to integrate it with Construction on-site and modularization off-site in HCI
main product on-site. Our HCI IC projects involve a range has not only brought significant benefits over field
of such modular fabrication and construction demand construction, but also opportunities to exploit strategic
that required extensive front-end planning, capital and advantages as described below:
resource for operations, increased engineering and
coordination, transportation and handling. Some of • Safety & optimum planning of works: Since
these are I-girder & U-girder mould, pier & pier cap fabrication shops are designed explicitly to
handle fabrication operations and workers are
shutters, launching girder, pier arm erector, inspection
not exposed to unanticipated hazards,
platforms, long line mould (LLM), form traveler, etc. modularization approach is safer. Also, here
routine construction operations are not
interrupted by fabrication and assembly works.
E.g., fabrication and preassembly of moulds are
done offsite, while foundations are poured
onsite, thereby not only acquiring time saving
at large but also enables us addressing
constraints independently without
compromising the schedule of other.
• Improved quality: Fabricating components
away from the site allows higher quality control
due to controlled fabricating conditions and
allows explicit planning, testing and inspections
of raw materials as per specification/ IS & ASME
codes, quality checks for discrete activities
during all stages of fabrication like, welder
qualifications, fit-up of members, hassle-free
welding activities, non-destructive testing of
weld joints, trial assembly facilities, dedicated
paint shop, etc., thereby achieving high quality
product with required tolerances attained and
reduced rework by first-time-right.
• Opportunity for Innovations: There is a wide
scope for innovation in such dedicated
modularized fabrication wherein customization
can be explored.
This was demonstrated during an extensive
requirement for fillet weld of built-up sections,
encompassing a total weld length of ~4 km at KKNPP

3&4. A suitable semi-automatic machine (MAG – Arc grinding wheels, welding machines, welding
rover 22 with power source TPS 500i) was identified and consumables, etc. were established by the team.
in order to attain optimal results, multiple trial mock-
ups were conducted by meticulously adjusting the During fabrication: To avoid distortion in web plates,
welding parameters to meet the required standards. butt joint welding was carried out post installation of
Further, to ensure the quality and soundness of welds, stiffeners on both the sides of the plates and welding
inspections including visual examination, dye penetrant was done in symmetrical sequence welding method.
testing (DPT), and macro etching analysis was Control of distortion / deflection was achieved by step
performed. Consequently, WPS approval was obtained back welding techniques without using any positive
from client, signifying adherence to the specified anchors.
guidelines as per GOST 14771-76. Adopting Arc Rover
During Assembly of box girder: Horizontal / vertical axis
welding technique resulted in the following:
marking of boxes were done that enabled match drilling
• High-quality weld finish by Seamless and and bolting of splice holes for the entire span to join the
uninterrupted welding boxes eliminating realignment/ rework. The following
• Increased deposition of weld metal instruments were used for fabrication & inspection of
• Minimization of weld distortion LG Box Girder:
• Cost savings through timely completion
• Reduction in post-weld grinding for improved • Auto level to ensure the levels,
visual appearance • Theodolite for axis control
• Substitution of manual welders with alternative • Laser Distance Meter (LDM) for dimensional
Another example for achievements of modularization is inspections & recording for analysis
• Total Station for checking the diagonals of box
a ‘Massive Fabrication for Massive Job’. A 1000 MT
girder
massive component fabricated at our L&T’s TWCC
facility for High-Speed Rail project.
A launching girder (LG) itself is a design-and-built

machine used in bridge construction. The requirement
of a double-girder type LG of 995 MT of 144m long
consists of 16 individual boxes per side of dimensions L
9m x W 2.8m x H 4.3m. Other than Main Box Girder, it
also comprises of, Front Support, Middle Support, Rear
Support and Slider Beam. Fabrication of such intricate
component was done at Kanchipuram, Tamil Nadu while
the project is executed at Surat, Gujarat. Following are
the details of extra-mile steps adopted for achieving the
completion of fabrication:
LG Box Girder – Double box assembly
Modernization of Fabrication Techniques in LG Box

Prefabrication: A detailed plan for managing raw Girder
materials, logistics, full set of drawings, BOQ, cutting
plan, nesting plan, equipment, tools, grinding machines,

Reduction in the number of butt weld joints in web productivity. Ideally, every day, all the activities at the
plates to avoid distortion: Zig zag welding of seams were construction site must run smoothly with no issues with
proposed in the web plates as per initial plan. However, machines, staff, or suppliers, and concrete must be
location of butt joints were altered that reduced one poured as per plan without any defects. However, this
welding joint per web. The proposed single butt weld may not be the case everyday. This is indicated by a term
joint instead of 2 joints & straight weld seams instead of called “non-conformance”(NC). ISO 9000:2015 defines
zig zag layout not only controlled distortions but also nonconformity as a non-fulfilment of a requirement.
reduced welding consumables and effective NDT Non-conformance is a sign that something went wrong
procedure. The same was technically approved by prime in a construction activity, process, or in the system itself
customer. and certain set of specifications were not met.
~25,000 nos. of splice holes were required to be drilled During the course of the project, some NCs such as
for connecting the boxes. Usually, the drilling process honeycomb, cracks, offset & water seepages, deviation
will be done using CNC cutting or radial drilling process. from drawings, specification etc. occur, which adversely
Instead, we completed all splice drilling and drilling in affect the product quality. NCs can lead to rework, and
one side of the web and flange before the job reached delay. The specification deviation or work that fails to
the assembly shop. This method had reduced the lead meet the quality standards can be identified and
time, efforts of drilling at assembly, also reducing the assessed through internal and external audits, customer
rework during assembly of boxes. complaints and training effectiveness.
Post Fabrication: By Using Airless – Air Assisted Preventive action is taken to

Electrostatic Painting Guns & Machines, a 15% saving of prevent occurrence whereas
paint consumption is achieved compared to airless corrective action is taken to
spray-painting technique which was used earlier. This prevent recurrence. ISO
technique has better finishing, more automized, 9001:2015 clearly emphasizes
improved transfer efficiency, lower material viscosity that problem prevention should
and provides aesthetic coating. Additionally, this be prioritized. However, when non-conformances
method enabled effortless overhead & vertical painting. occur, corrective action needs to be carried out. A
robust corrective action process shall ensure
compliance. This article presents a case study on the
effect of training on preventing occurrence and re-
occurrence of NCs.
Evaluation of Non-Conformances
In the selected project site, the defects and NCs were

identified in the construction activities from the
following sources:
Painted surface • Customer feedback comments including

customer complaints
HCI: ‘TRAINING WILL REDUCE NON- • Internal and external auditing of projects and
systems
CONFORMANCE’ – MYTH OR FACT?
• Inspections
The Quality Management System (QMS) in any project • Management reviews
ensures that the construction quality meets the
customer requirements with improvement in

All the defects and non-conformities were documented Evaluation of Training
and maintained in a log register.
Training was provided onsite and offsite for all levels of
The Quality Team identified these nonconformities and workmen on their skill and workmanship based on the
issued an observation (OBS) to the responsible section defects observed in the construction activities for
engineer. The receiver of the OBS was required to process improvement. A significant portion (40%) of the
address and resolve the issues within a 7-day training program focused on addressing the root cause
timeframe. In the event of failure to resolve the OBS, the of improper concrete pouring and compaction,
QA Manager re-issued it as an NC. specifically to prevent honeycombing in concrete.
During the training, the workmen were educated about
the proper usage of immersion vibrators for
consolidating concrete. They gained knowledge about
the appropriate frequency, suitability, performance,
and application of the vibrator to ensure effective
compaction. Emphasis was placed on the critical
importance of preventing free fall of concrete pouring,
ensuring it does not exceed a height of 1.5 meters.
12% of training focused on addressing the root cause of

Process of NC addressal
offset occurrences between subsequent lifts in
It is imperative that the root cause of a NC/OBS is permanent RCC wall structures. It centered around
identified during the analysis period. This involves imparting knowledge on proper alignment, firm fixing
utilizing problem solving skills to answer questions such with required lateral supports & ties by nurturing a
as ‘what has happened’, ‘why it happened’, ‘who is culture of attentiveness and responsibility
affected’ and ‘how it happened’?
23% of training was dedicated to prevent common
Possible solutions were defined and the most suitable mistakes in various aspects of reinforcement works.
one was chosen among them. In case the solution was Knowledge was imparted on avoiding errors in bending,
ineffective, the actioner re-evaluates the root cause binding & fixing of bars. Emphasis was on the
before determining another solution and the proposed importance of correct placement of reinforcement,
corrective action was updated accordingly. including ensuring proper cover, appropriate overlaps,
accurate placement at designated locations,
Training
embedment lengths, creating proper shapes for stirrups
Tailored to address these specific needs and root cause and shear links, maintaining appropriate spacing as per
areas, a comprehensive training schedule was devised the structural drawings.
for each quarter for workers, supervisors and
The remainder of the training was through frequent pep
technicians. The effectiveness of the training process
talks.
was systematically assessed and reviewed during the
Management Review Meeting (MRM). As the year progressed, a notable improvement in the
training effectiveness in subsequent quarters was
noted. This targeted training programs played a pivotal
role in addressing the root causes of various issues,
thereby resulting in a gradual reduction of critical non-
conformities.

The impact of the training on reducing Critical
Nonconformities was clearly evident.
By investing more effort in providing comprehensive

training sessions that tackled underlying problems, the
project site observed a positive impact on its overall
performance. This synergy between increased training
and decreased non-conformances demonstrated the
value of a proactive and knowledge-driven approach,
fostering a culture of continuous improvement and
excellence.
PRATHAM – Quality First, First Time Right
The cornerstone of achieving high-quality standards lies

in the prevention of non-conformities. Proactive
measures and a preventive mindset are essential to
maintain a "FIRST TIME RIGHT" approach as an ongoing
process. In uncertain conditions, deviations may occur.
But, swift corrective actions based on root causes can
overcome challenges.
Mandating training to ensure compliance with both

standard and contractual specifications is imperative for
maintaining product quality. Critical activities in the
project site should be identified and training to prevent
NCs should be provided. Apart from this, key areas for
training can be identified through management Review,
site-level reviews, internal audits, and customer
feedback on potential non-conformities.
The training's primary aim is to raise awareness about

the processes, ensuring clear instructions are followed
meticulously, thereby producing FIRST TIME RIGHT
product. By instilling a quality-conscious behavior in all
stakeholders, the training emphasizes that maintaining
product quality is a collective responsibility. This
approach is vital in effectively implementing QMS and
exercising robust control over both processes and
product quality.

digitalisation & latest cutting edge technologies etc.
8. AWARDS & ACCOLADES
[Refer Appendix 1 for the list of projects
DEFENCE: L&T DEFENCE AMASSED AWARDS The judges were impressed by the diverse range of
IN THE ‘CHAPTER CONVENTION ON projects, the thoroughness of data analysis, and the
creativity of implemented solutions. They were
QUALITY CIRCLES’ (QCFI COMPETITIONS)
astonished by the L&T Defence’s contribution to the
HELD ACROSS INDIA
Indian Defence sector. Till recent, we didn’t participate
A wave of innovation and continuous improvement has in the industry competitions to protect our IP and
swept through L&T Defence, culminating in a glorious information to the external world. Lately we have
haul of awards at the recent Quality Circle competitions started participating in such events keeping the ILDC
organised by Quality Circle Forum of India. guidelines.
List of Teams, their presentations & Results
Total 19 teams from D&A SBG had participated in the The competition wasn't just about winning; it was a
various chapter level QCFI events held at different cities platform for cross-learning and sharing best practices.
this year 2023. Out of the 19 teams, D&A won 17 Golds This knowledge exchange fostered a culture of
and 2 Silvers in the events. This is a testimony of our continuous improvement, enriching the entire
strong orientation to be a process driven organisation, organization.
continually improve the Quality systems and empower
the employees to bring change and implement Way forward, Teams will further participate in National
innovations. Convention on Quality Circles and the International
Convention.
Quality Circles, small groups of employees who identify
and solve workplace problems, are the driving force The success of L&T Defence in the Quality Circle
behind this outstanding achievement. The dedication competitions extends beyond accolades. It signifies a
and ingenuity of these teams were evident in their commitment to quality, empowers employees, and
presentations, tackling issues ranging from streamlining fosters a vibrant atmosphere of innovation. This
production processes, increasing productivity, out of achievement sets a benchmark for other organizations
box approach to remove bottlenecks, embracing and paves the way for a future driven by quality
excellence.

HCI: RRTS P3 LOT-2 TEAM RECEIVES ICI HCI: MAHSR C4 PACKAGE RECEIVES TOP
AWARD FOR OUTSTANDING CONCRETE HONOUR AT THE ANNUAL GREENTECH
STRUCTURE-2023 QUALITY & INNOVATION AWARDS
L&T RRTS team (P3 Lot 2) have won the prestigious The Mumbai–Ahmedabad High Speed Rail (MAHSR) C4
Indian Concrete Institute (ICI) award for Outstanding Package has received the most admired top honour at
Concrete Structure 2023, in the category of tee 2nd Annual Greentech Quality & Innovation Award
Infrastructure Project. The award was presented by Er. under the category ‘Quality Improvement’ for various
G K Sahu (Chairman ICI- Ghaziabad) on ‘Concrete Day’ initiatives taken for quality improvement in concrete
September 9, 2023 to Mr. S S Gangwar (Project being used in the project.
Director) & Mr. Sitaram Tarai (Quality Head) at ICI
Ghaziabad. Indian Concrete Institute (ICI) - a registered
professional body dedicated to the cause of concrete
construction, design & research in India.
The award ceremony was held at New Delhi on 21

August 2023 in the presence of Mr. K. Sharan, Chairman
& CEO, Greentech Foundation, and Mr. Mahabal
Mishra, former MP, Lok Sabha. The award was received
on behalf of the MAHSR C4 Package project team by Mr.
S. Ramesh, Head – QA/QC, MAHSR C4, who was also
invited as a keynote speaker in the summit and award
function.

HCI: HEAVY CIVIL INFRASTRUCTURE IC Machinery, HCI IC), and Mr. T. S. Thiruvenghadam (JGM
BAGS THE FIRST FICCI AWARDS FOR & Head - Plant & Machinery [Heavy Structures BU], HCI
EXCELLENCE IN PLANT MAINTENANCE IC) received the award on behalf of HCI IC. Following
this, Mr. T. S. Thiruvenghadam outlined the salient
SYSTEMS-2023
features of the Resilient Maintenance Systems
L&T’s Heavy Civil Infrastructure (HCI) IC was bestowed implemented by HCI IC despite the complexities
with the Gold Prize of the 1st FICCI Awards for associated with execution of massive Infrastructure
Excellence in Plant Maintenance Systems – being the projects across the country.
only company in the construction sector to be awarded
this recognition.
HEAVY ENGINEERING: L&T HEAVY
ENGINEERING BECOMES THE FIRST
COMPANY INCLUDED IN ASL OF WESTING
HOUSE FROM INDIA
One More Feather to L&T’s Crown!!!
L&T Heavy Engineering (HE) has become the first

company, included in ASL of US reputed customer
Westing House.
Westing House: Westinghouse Electric Company is the

The jury declared HCI IC as the winner of the 1st FICCI world's leading supplier of safe, innovative nuclear
Awards for Excellence in Plant Maintenance Systems on technology and is shaping the future of carbon-free
3rd June 2023 after a rigorous process involving energy.
application evaluation, site audit and finally Jury
presentation since October 2022. The famed Awards Assessment Team: Raj Bhan, Ted Andersen, Nathan
Trophy was presented to HCI IC during the 1st National Hansen, Alok Mishra, Ray Montgomery & Vittorio Murer
Conference on Efficient Maintenance Systems for
Strengths identified during Audit:
Sustainable Industrial Growth at the FICCI Federation
House, New Delhi on 7th July 2023, in the presence of • Significant digitalization campaign
Industry leaders. • Impressive capability and capacity
• Strong Nuclear Safety and "First Time Right
“Culture
• Consistency in communication across all levels
of the organization
• Depth of knowledge
Opportunities for Improvement
• Global recognition within the nuclear industry

• Absence of significant ASME stamping
experience
• Minor safety and housekeeping concerns
within the facility have been noted.
The award was presented by Dr. Hanif Qureshi, Joint

Secretary, Ministry of Heavy Industries, Govt. of India.
Mr. T. Srinivasan (General Manager & Head – Quality,
HCI IC), Mr. Prasanta Kumar Ray (JGM & Head - Plant &

LMB
Certification handover ceremony was arranged at L&T

Heavy Engineering, A. M Naik Heavy Engineering
Complex on 8th January 2024, Mr. Anil Parav (Whole-
Time Director & Sr.
Executive Vice President, (Heavy Engineering & L&T

Valves) PP&N, MFG. CLUSTERS, MKTG (NCLR&PIPING)
Mr. Falgun Chokshi (Vice President & Head - Hazira and
Vadodara Manufacturing Cluster) & Mr. Praveen Bhatt
(Vice President & Head – Nuclear BU) along with entire
Nuclear Team received the ASL Certificate from Mr.
Pavan Pattada (Executive Vice President, Global
Operations Services), Mr. Alok Mishra (India Director,
Westing House) & Luca Oriani (Global Chief Engineering
Officer and Senior Vice President, Engineering Services).
Some Glimpses of ASL ceremony
Commenting on this, Mr. Anil Parab said: “that L&T and

Westinghouse are made for each other. L&T and
Westinghouse will together make many Global bench
mark in the nuclear energy sector and also works for
humanity for green energy.

PT&D: PT&D IC’S DISTINCTIVE MIDDLE EAST
PROJECT EARNS HIGH PRAISE
PT&D IC's Middle East Business Unit has recently earned
recognition for its exemplary execution of a distinctive
STATCOM project from TAQA, the Energy & Water
company of Abu Dhabi. The project involves the supply
and installation of a state-of-the-art Dynamic Reactive
Power Compensation (DRPC) system at the New 220kV
Zakher Grid Station. DRPC enables real-time
management and control of reactive power, using
advanced power electronics devices, to enhance voltage
stability and overall system efficiency.
The scope of the project also encompasses the

installation of a 300MVA Power Transformer, IGBT
modules, a sophisticated water-cooling system, and
Phase reactors, among other components.
The appreciation certificate acknowledges the project

team's efforts and commitment to adhering to the
highest standards of safety and quality.
TAQA and the Government of Abu Dhabi have

expressed their satisfaction and conveyed their wishes
for PT&D to maintain the same spirit and enthusiasm

throughout the project's completion. They also
recognized PT&D as one of the best contractors in the
Abu Dhabi Transmission network.
PT&D: TLT MANUFACTURING UNIT,

PITHAMPUR, WINS CII DX (DIGITAL
PT&D: TLT PITHAMPUR WINS GREENTECH TRANSFORMATION) AWARD 2023
QUALITY & INNOVATION AWARD 2023 PT&D IC’s Transmission Line Tower (TLT) Manufacturing
PT&D IC's Transmission Line Tower (TLT) Unit in Pithampur has received an award for the best
Manufacturing, Pithampur Unit, clinched the practice in digital transformation at the 5th CII DX
distinguished 2nd Annual Greentech Quality & (Digital Transformation) Awards 2023, in the
Innovation Award 2023. ‘Innovative’ category for ‘Digitally Enabled CBG Based
Hot Dip Galvanizing’.
This prestigious recognition illuminates the unit's
remarkable advancements in the realm of quality The judges and reviewers were impressed by the
improvement. following aspects of TLT Pithampur’s digital system:
• Real-time monitoring of energy use through a

mobile dashboard
• Online monitoring of crucial factors like
temperature, pressure, flow rate, and water
level
• Automation of the entire manufacturing
process
• Reducing carbon footprint by switching from
LPG to CBG
• Aligning with the Hon’ble Prime Minister's goal
of achieving net-zero emissions
• inception of a cutting-edge Laboratory

Management System (ISO/IEC 17025)
• significantly leveraged investments in state-of-
the-art equipment and comprehensive
employee capacitation
• unwavering adherence to a regimen of
meticulous audits and comprehensive reviews
• cultivation of an ecosystem perpetually driven
by enhancement

TI
Mumbai Ahmedabad High Speed Rail (MAHSR) C6
Package bagged the prestigious 10th EPC World Award
under “Innovation and Excellence in Quality” category
and was felicitated by Shri Nitin Gadkari.
Various innovations made in MAHSR C6 were-

mobilization of skin friction in test piles, construction of
India’s first shinso pile, casting technique of Full span
Box Girder (FSBG), R&D in FSBG concrete like
autogenous shrinkage, real time monitoring of strain
during stressing in prestressed concrete, digitalization
techniques to cut down cycle time and improvement in
efficiency.
L&T ENERGY-POWER WINS TRIPLE GOLD AT

QCFI’S ANNUAL CONVENTION ON QUALITY
HEAD-POWER IC FELICITATES ‘L&T ENERGY -
CONCEPTS
POWER QUALITY SHIELD AWARD’ WINNERS

9. CERTIFICATE OF APPRECIATIONS
DEFENCE
Coimbatore
Hazira
GEOSTRUCTURE
NRL project - MSB Unit received Certificate of
Appreciation by Customer for completing the MSB unit
with utmost Quality and safety standards.

HCI
Heavy Civil Infrastructure (HCI) IC's 120 MW Lower
Kopili Hydroelectric Project team achieved a major
milestone on 16 September 2023 by completing
underground excavation of the 3.6-kilometre-long Head
Race Tunnel 2 months ahead of schedule.
The Hon’ble Chief Minister of Assam Dr. Himanta Biswa Appreciation from HRRL
Sarma congratulated the project teams from APGCL &
L&T for achieving this important milestone. The Assam
Chief Minister’s Office (CMO), in a post on ‘X’ (formerly
known as Twitter), lauded the achievement and the
Project Director appreciated the team for the best
quality standard.
Appreciation from EIL
Appreciation from Saudi Aramco - Low Repair rate –

Jafurah Export Pipeline Projects
Jafurah Export Pipelines Project team received

appreciation from SAUDI ARAMCO (through ARAMCO
EPM logbook) for maintaining lower repair rate
consistently in Mainline automatic welding. Current
Repair level - 0.30% in 200 Km of Pipeline welding.
LTEH ONSHORE EPC Appreciation received during Aug’23:

Appreciation from HRRL & EIL : World Quality Month
“ Jafurah Field Development Project Export Pipeline. The
celebration 2023- PFCCU & PRU, HRRL, Rajasthan
SAPID assessed that contractor submitted the weekly
World Quality month-2023 was celebrated across Project Weld Status Report JEPL-LTHSC-PWS-090 from
offices and project sites at domestic and international Aug 19 2023 to Aug 25,2023, for the Welder Repair Rate
locations. Goal of the campaign was to emphasis the Report on SATR-W-2019 and SATR-W-2013, respectively
thrust on “Customer Delight through Quality Excellence, in accordance with SAEP-1160 para.5.4, it was found
First Time Right and on-Time Delivery” across all that the percentage of linear repair rate and joint repair
stakeholders. Appreciation received from HRRL rate for the week were both 0.00, that the cumulative
(Hindustan Rajasthan Refinery limited) & EIL for linear repair rate was 0.0321, that the joint repair rate
extensive & innovative Quality month celebration at was 0.34, and that there was a 4 joint RT or UT backlog.
one of our project site, PFCCU & PRU Project, HRRL SAPID would like to appreciate to the Contractors LTHSC
Rajasthan for keeping the weld rejection rate under control for the
weekly basis and cumulative basis as well and found to
be acceptable. This logbook entry has been recorded in
the EPM for information and records.”

LTEP: CUSTOMER APPRECIATIONS
RECEIVED FROM VARIOUS SITES
M&M: NTPC COAL HANDLING PLANT,

KERANDARI, RECEIVES APPRECIATION
CERTIFICATE:
M&M SBG’s Coal Handling Plant, Kerandari, Part ‘A’
Project has received an Appreciation Certificate from
M/s. NTPC for implementation of Quality Management
System and maintaining the best work methodologies
while carrying out the construction of CHP work at the
Kerandari Coal Mining Project.
The certificate was presented by Mr. Faiz Taiyab,

General Manger (HOD-Kerendari), to Mr. Mukesh
Kumar, Project Director, and team. The officials from
NTPC appreciated the collective efforts made by the
entire project team for maintaining quality at all
stretches of the project.

WET: WWW SBG: SUCCESSFULLY
COMMISSIONING OF THE UPSTREAM SIDE
OF THE TUNNEL.
WET IC – WWW SBG- RWS-Central MP Segment – Satna
MVRWSS Project received the appreciation certificate
on successful commissioning of the Upstream side of
the Tunnel having structures- Intake Well (capacity of
206 MLD), WTP (capacity of 166 MLD) and OHMBR
(Capacity 5410 KL)
The Upstream side of the tunnel will provide the

portable drinking water to 235 number of villages
having 39,000 Number of house service connections)
The Certificate was presented to Mr. Elango A (Project
Manager – Satna MVRWSS) and team by Mr. Neerav
Agrawal (General Manager – PIU Satna, Madhya
Pradesh Jal Nigam Mayardit).

MFF KATTUPPALLI: LESSONS LEARNT AND
10. LESSONS LEARNT
COUNTER STEPS FOR IMPROVEMENT
Preservation of Instruments and Exotic Materials Using
LTEH ONSHORE EPC : PROJECT: PFCCU &
Heat Shrink Method.
PRU, HRRL, RAJASTHAN
Problem description: In accordance with EIL's standard We LTEH MFFK always strives to improve our
specification, Radiographic examination of Radiant coil's Preservation practices continuously to as it plays a key
bottom return bend after Erection was supposed to be role in keeping the fabrication activities streamlined and
performed at Manufacturer’s premises. Since it was gains customer satisfaction and builds trust. We
missed at Manufacturer’s premises, subject continuously organize lessons learnt sessions in
Radiography was performed at site and during RT film
presence of top management to highlight the lapses in
interpretation, foreign material (i.e. Grinding Disc) and
other debris was observed within the examined area in the ongoing and previous projects and the key areas &
one of the bends. counter steps to overcome them.
Analysis: The presence of foreign material in the radiant As a part of the counter steps to improve the
coil's bottom return bend can be attributed to a preservation of Junction Boxes (JB’s), Valves and other
combination of factors, including potential lapses in critical components in our yard, Heat Shrink method
vendor quality control, material preservation
was commenced in place.
methodologies (Eg. Internal Cleaning)
Solution adopted: Implemented routine internal

cleaning schedule and maintained thorough
documentation (Internal Cleaning Register) for
monitoring and addressing any gaps in the process.
Employed appropriate protective measures, such as
covers and seals, to prevent foreign material ingress
over time.
Learnings: Radiographic examination of bottom return

bend to be performed at shop, since coils are assembled
and tested in shop & potential contamination shall be
eliminated at the source.
Heat Shrink of Junction Box Installed on Module
Radiant coil's bottom return bend
Benefits of Heat Shrink Method for Preserving

Instruments and Piping Components were considered
for better usage. Below were some of the advantages
we considered which increases the quality and
preservation of components:
Trace of foreign material observed in Radiographic film for bottom
return bend

• Corrosion Protection: Heat shrink creates a Pedestal bed of I-Girder settled due to rain-cut beneath
protective barrier, guarding against corrosion, pedestal at casting yard
moisture, and environmental damage, extending
the lifespan of instruments and piping Root Cause Analysis
components.
• Enhanced Insulation: It provides excellent Preparation of pedestal beds in the low-line area of the
electrical insulation, safeguarding sensitive hillock so during rain the water of the hillock catchment
equipment from electrical interference or short flows towards the girder's bed, and rain cuts from
circuits.
beneath the pedestal bed, leading to settlement of the
• Custom Fit: Heat shrink conforms to various
pedestal bed in addition to delays in casting of the girder
shapes and sizes, ensuring a snug fit, which is
crucial for maintaining the integrity of the
Lesson Learned Description
components.
• Chemical Resistance: Offers resistance to
A thorough study of rainwater flow and soil compaction
chemicals, oils, and solvents, preserving the
functionality and durability of instruments and conditions should be conducted prior to finalizing
pipes even in harsh environments. casting bed area of precast elements, to avoid
• Easy Application: The heat shrink process is interruptions in production due to heavy rainfalls.
relatively simple and quick, reducing installation
time and labour costs. 2. Failure of vendor to execute foundation work
Utilizing the heat shrink method provides Problem Statement
comprehensive protection, extends component life, and
Delay in Construction of foundation for the gantry and
simplifies maintenance for instruments and piping
high mast work due to the failure of the vendor or
systems.
agency to execute foundation works at site.
The usage of Heat Shrink not only reduces the damages
Root Cause Analysis
during operation but also during transportation (Sail
Away). This reduces the back charges on LTEH MFFK and No methodical way to monitor the vendor's or agency's
time to rework /repair if any problem arises during commitment to the contract
modules erection at on site. agreement's requirements. The failure of foundation
work for these road furniture results in delays in project
TI completion.
A lesson learned app is created by in-house digital team
Lesson Learned Description
in coordination with the Quality team to capture best
practices/Problems from projects to: - Vendor and agency compliance with the contract
agreement should be assessed and monitored to avoid
• Improve future/ongoing projects performance
construction delays and the loss of products or services.
• Create a culture of learning
• Share knowledge
The lesson learned app plays a crucial role in
• Providing inputs for risk assessment

• Contributing to minimize the cost/duration of
future projects
• Supporting decision making
• Preventing repetitions of same problems in
different projects
Here are few examples of lessons learned along with
dashboard from different projects:
1. Settlement of Pedestal Bed of I-Girder

Problem Statement

QUALITY COUNCIL MEMBERS
Business Council Member Business Council Member

1. WET Mr. P Sivasankaran - Convener 13. MFF Kattupalli Mr. Selvaraj Duraisami
2. HCI Mr. T. Srinivasan 14. LMB Mr. Asutosh Khandelwal
3. M&M Mr. Ram Kishore 15. LMTG Mr. Mahipal S. Rawat
Mr. S. N. Rajan
4. PT&D Mr. Shripad Hegde 16. GeoStructure
Mr. G Shettar
Mr. Claudio Trupiano
5. TI 17. Howden Mr. Sandeep Singh
Mr. Ajay Kumar
Mr. Dinesh Kumar
6. B&F Mr.P.S.Suresh 18. S&L Mr. Rajarsi Ray
Dr. M.V. Venkatesan
7. Defence Mr. Mohit Ekbote 19. Shipbuilding Dr. Shrirang Kulkarni
8. Heavy Engineering Mr. V Chinnasamy 20. SW&C Mr. D. P. Shinde
9. LTEP Mr. G Kannappan 21. Realty Mr. Anil Sharma
Mr. Raja Chacko
10. LTEH Onshore Mr. Harshil Shah 22. Valves
Mr. Vijayaranjan M
11. LTEH- CS Mr. D. U. Rama Krishnan 23.Construction Equipment Mr. H. N. Shivashankar
24. Rubber Processing
12. LTHE- Offshore Mr. Alok Khare Mr. V Selvan Athishtaraj
Machinery
Please send your valuable suggestions & comments on this issue to Quality council editorial team
Ms. Poongothai Arunachalam Mr. Saravanan Pazhanivel Pillai

Manager- QA&QC, HCI IC Sr. Manager- QA&QC, WET IC
poongsarun@lntecc.com saravananpp@lntecc.com
+91 9488066123 +91 9597941731
Mr. Subash S Mr. Raghavendra Shenoy

Manager - QA&QC, WET IC AGM - QMCC, Energy Power
s.subash@lntecc.com
+91 7004171897 +91 9724986346
Conceptualized, Desig ned, Executed & Publi shed by
Quality Council Team – L&T

Quality Bulletin Issue 7-22110

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INDEX

Awards & Accolades 51 to 58

P a g e |2 Quality Bulletin, Jul to Sep 2023

Kickstarted Business Excellence Model journey in L&T

P a g e |3 Quality Bulletin, Jul to Sep 2023

We are delighted to present the seventh edition of the Quality Bulletin

Our commitment to the Quality Council remains unwavering as we persist in

P a g e |4 Quality Bulletin, Jul to Sep 2023

7 T H QUALITY SUMMIT & LAUNCH OF L&T

P a g e |5 Quality Bulletin, Jul to Sep 2023

P a g e |7 Quality Bulletin, Jul to Sep 2023

Team members: Bhavik Desai, Rutul Solanki, Yug Guna

HCI: PRESETNTED ARTICLE ON

IIW invited MTHL package-1 to present the Case Study

P a g e |8 Quality Bulletin, Jul to Sep 2023

The scope of largest project for MFFK comprises about

Team Saipem, Perdaman & MFFK

Kick-Off meeting with Saipem Perdaman held on 28th

Discussion on project readiness went well. Clients were

During discussion in kick-off meeting

P a g e |9 Quality Bulletin, Jul to Sep 2023

Pledge taken by L&T & AP employees

The event marked a significant milestone in the project's

Australian Handbook front page

MFF KATTUPPALLI: THE FIRST STEEL

P a g e | 10 Quality Bulletin, Jul to Sep 2023

In the presence of Mrs Rita (Project Sponsor), Mr Ajit

First Steel Cut

TI: EQP MEET (27TH JULY -29TH JULY)

• to synergize 3-key functions (EHS, Quality and

P a g e | 11 Quality Bulletin, Jul to Sep 2023

POWERSPEAKS - A QUALITY THOUGHT

QUALITY TALK - BUSINESS ASSOCIATE KE

MANTHAN: SESSION ON SHARING GOOD

P a g e | 12 Quality Bulletin, Jul to Sep 2023

AXIAL CUTTER APPLICATION:

P a g e | 13 Quality Bulletin, Jul to Sep 2023

Retroreflector Before starting the measurements, a precision check is

For the calculation of the mould’s geometry, the four

P a g e | 14 Quality Bulletin, Jul to Sep 2023

Title of the paper was “Optimizing Radiographic Testing

This is one example, provided in detail:

Recognizing the necessity for comprehensive coverage,

P a g e | 15 Quality Bulletin, Jul to Sep 2023

• Improved Productivity by 3 times.

Based on our experimentation, we have concluded that

LTEH ONSHORE: WELDING AUTOMATION IN

Support fabrication is a major activity during piping

P a g e | 16 Quality Bulletin, Jul to Sep 2023

Here are few images of real-time dashboards of

WET: SLIPFORM WORK ADOPTED FOR

Slipform is a construction technique used for reinforced

Slip formwork is one of the best techniques which

In Gond Devsar Project the concreting of full staging

P a g e | 17 Quality Bulletin, Jul to Sep 2023

The project team find an opportunity to introduce this

The new technique has set a benchmark in the RWSS

Concrete Pouring on slipform with help of Boom placer

Photos of adapter fixing at 20mm HDPE pipe.

WET: WWW SBG: HDPE PIPES HYDROTEST

The entire sequence of activity involves time, cost & loss

P a g e | 18 Quality Bulletin, Jul to Sep 2023

P a g e | 19 Quality Bulletin, Jul to Sep 2023

Delhi-Meerut Rapid Rail transit system (RRTS) line is the