INPLANT TRAINING REPORT

HEAVY ENGINEERING DIVISION

 INTRODUCTION :-

Heavy Engineering Unit Equipment deals with the

marketing, designing, engineering and manufacturing of “one off”
equipment and machinery required for basic industries in the core
sector, such as Fertilizer, Chemical, Petrol Chemical Power, Cement,
Nuclear, Aerospace, Defense, Oil, etc. The unit is headed by a Vice
President and has manpower of over 3000 personnel, including 1000
at Hazira works near Surat.

L & T’s operations are organized under several business

units, of which ‘Heavy Engineering’ specializes in engineering,
manufacturing, supply, erection, and commissioning of unit
equipment and process plants for basic industries in the core-sector.

 CORE INDUSTRIES SERVED:-

Heavy Engineering caters to the core sector industry like

petroleum and petrochemicals, fertilizers, heavy chemicals, cement,
oil and gas exploration, food processing, nuclear, power generation,
co - generation/captive power plants, aerospace, defense and marine
related industries.

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 RANGE OF PRODUCTS:-

Typical products manufactured include pressure vessels,

ultra high pressure vessels, columns & towers, multi-wall converters,
high pressure heat exchanger, reactor vessels, surface condensers,
water heaters, end shields, steam generators, halides, test
separators, inlet manifold, propeller shafting, stern gears, missile
launchers, cement machinery, mineral processing kilns all of which
involve high technology and intricacies of manufacture.

 SUPPLY OF PLANT AND SYSTEMS:-

Process plants including fertilizers, petrochemicals, heavy

chemicals and supply of systems involving rious equipment’s such as
evaporators, crystallizes, dryers and waste heat recovery units.
Offshore structures such as oil well head platforms and skid mounted
systems. Co-generation and captive power plant.

 FABRICATION AND WELDING TECHNOLOGY

ORIENTED PRODUCTS:-

The range of equipment, machinery and plants covered by

this business unit demand a high degree of expertise and skills over
and above the capacity and capabilities of the installed plants and
machinery. The product applications are in high temperature and
high pressure requiring special material for construction and
manufacturing operations.

 STRATEGIC BUSINESS UNITS:-

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Business activities of Unit Equipment are overseen by three

self reliant Strategic Business Units (SBUs). These three SBUs are
formed on the basis of following sub-divisions:

 FUNCTIONS OF SBU’s:-

Each of these Strategic Business Units is self-reliant & covers

the following major functional areas such as:

o Marketing.
o Deign & Product Engineering.
o Material procurement.
o Manufacturing.

 TECHNICAL SERVICES:-

In view of the diverse nature of operations and the wide

product range in Group II (UE) area, there is considerable
interdependence and interaction between areas of manufacturing
services with design, manufacturing shops and marketing. The major
support facilities received from the Technical service departments
are:-

o Welding Engineering.
o Industrial Engineering.
o TQM Facilitation cell.
o Computer systems
o Training and Personnel.
o Plant Engineering.
o Works Accounts & Costing.

 RESEARCH AND DEVELOPMENT: -

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Research and Development Department of Heavy

Engineering was established in 1974 to assimilate and adapt
technology & to develop expertise in design, engineering and
fabrication of plants.

The main objectives are:

• Applied Research Projects.

• Design and advanced engineering.
• Technology assimilation/adaptation.
• New developments & improvements in products and
process.
• Computer Aided Design/Software development.
• Commissioning, process plant optimization and guaranteed
performance.
 MANUFACTURING CAPABILITIES OF HED :-

 HEAT TRANSFER EQUIPMENT :-

Heat exchangers for chemical, petrochemical, refinery and

fertilizer industries and complete range of equipment for man-made
fiber industries.

• Shell and tube heat exchangers for high pressure & high
temperature applications.
• Plate & spiral heat exchangers.
• Air-cooled exchangers.
• High pressure heat exchangers for refineries carbonate
condensers and urea strippers for the fertilizer industry.

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• Specialized multi-tubular reactors.

• Transfer line exchangers.
• Ultra-sensitive exchangers for petrochemical applications.
• Continuous polymerization reactors/finishers.

 PRESSURE VESSELS:-

• Pressure vessels.
• Multi-wall vessels.
• Cryogenic vessels.
• Ultra-high pressure vessels.
• Columns & towers for petrochemical (except cracker plants).
• Polypropylene & polyethylene reactors.
• Process gas waste heat boiler systems, ammonia converters.
SUPPLY OF PLANT AND SYSTEMS:-

• Process plants including fertilizers, petrochemicals, heavy

chemicals and supply of systems involving various equipment’s such as
evaporators, crystallizers, dryers and waste heat recovery units.
• Offshore structures such as oil well head platforms and skid
mounted systems.
• Co-generation and captive power plant.

 SERVICE GROUP :-

To provide various supporting services several service

groups have been formed. These service groups handle Finance and
Accounts, TQM and Industrial engineering. IT and ERP, Training

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personal and HRD, Plant Engineering, Procurement, Stores and

Dispatch, auxiliary services like Heat Treatment, Maintenance, and
Non Destructive Testing etc.

 HEAVY ENGINEERING PRODUCT RANGE :-

• Manufacturers Heat Transfer Equipment for Chemical,

Petrochemical, Refinery and Fertilizer Industries, Fertilizer and Synthetic
Fiber.
• Pressure Vessels, Multiwall Vessels, Cryogenic Vessels, Ultra-High
Pressure Vessels, Columns and Towers for Petrochemical, Chemical &
Fertilizer Industries.
• Equipment & System for Power Plants Like Water Heater,
Deaerators, Condensate And Feed Water Pumps; Inter Connecting
Piping, Valves, Instruments, Controls And Auxiliary Sub-Systems.
• Industrial Machinery & Foundry Products Like Equipment For
Minerals & Metals Industry, Mineral Dressing Equipment, Bulk Material
Handling Equipment, Pulp & Paper Equipment, Rubber Processing
Machinery, Plastics Processing Machinery, Valves & Equipment.

 LOCATION OF HED PLANTS :-

o Powai.
o Hazira (Surat).
o Kansbahal.
o Chennai.
o Ankaleshwar.
o Vadodara.

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 POWAI ENGINEERING WORKS (PEW) :-

The manufacturing complex at Powai works is spread

over 46000 sq. m. area and equipped with sophisticated facilities for
fabrication, machining, handling and quality control, over 1000 highly
trained professionals, including more than 200 qualified welders from
the core strength of the shop.

Specialized fabrication facilities includes a CNC controlled

gas/plasma profile cutting machine, edge planning/milling machine,
dust free enclosure with an area of 400sq m., 1000 ton hydraulic
press, heavy duty plate bending & rolling capacity 125 mm thickness
in cold conditions & 250 mm in hot conditions, deep hole drilling
capabilities of up to 700mm thickness, CNC vertical boring machines
of up to 8500mm dia., CNC horizontal boring machine with 200mm
spindle dia., and 60 ton load, facing and turning lathe of diameter
6000mm and 100ton between centers, welding machines for wide
variety of process like MIG, TIG, Automatic pulse TIG, tube to tube
sheet welding like POLYSOUDE, AMI, Strip cladding, FCAW overlay,
internal bore welding etc. the shops are provided with EOT cranes ,
Large furnace for plate heating as well as X-ray enclosures.

HAZIRA WORKS (HZW):-

This modern heavy engineering complex is situated on a

200- acre plot near Surat in Gujrat. The factory building covers an
area of 35000 sq.m. It is a coastal facility with a loading jetty on the
banks of river Tapi close to the Arebian Sea. The complex has been
an open fabrication yard of 200000 sq. m, which is being further,
expanded this is equipped with material handling equipments for a
125 ton plate heating furnace, radiography up to 500mm thickness,
closed loop flux recovery system etc.

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