Larsen & Toubro Limited

Heavy Engineering Division

Powai Manufacturing

Supervisory Development Program

Mr Laxmesh Hasnabadi

Powai works

PC2
PC1

PC-1
Total Covered Area
Max OH crane Cap
Annual Capacity

DFS
FTC
AMS

14000 Sqm
: 80 T
: 4 lakh Manhrs

E1
E2
E3

E8
E7
E5
E6
W
N

PC-2
Total Covered Area : 22000 Sqm
Max OH crane Cap : 160 T (2 cranes combined)
Annual Capacity : 4 lakh Manhrs
Acid
cleaning

MMS
SFS
Aero Shop

MFS1

MFS1
HMS

HMS

HFS

NFS
HFS
W

RT
Encl.

S/B
Shed

Manufacturing Facilities

Handling
Forming
Cutting & Grinding
Fabrication
Welding & Special Technology Processes
Pressure Testing
Stress Relieving
Surface Preparation
NDT

Handling:
1.

OH Cranes in Bays/ Evener Beams:

Handling with 3 EOT Cranes using Evener Beam

Handling with 2 EOT Cranes

2. Jib Crane/ Cantilever Crane:)

- Capacity= 1 Ton/ 5Tons
- Mounted on shop columns

3. Cross- Bay Wagon:)

- Capacity= 50 to 160 Tons
- Moving on rails

Inter-Dept. movement Wagons

4. Movable Cranes: Columns)

- Capacity= 10 to 250 Tons

Handling with movable Cranes

5. Fork-Lifts:
- Capacity= 1 to 5 Tons

6. Components Trolley:
- Small components, cylinders
movement

Forming:
Hydraulic Presses

3 no. of Presses- BAKER, PEARSON, VPF1000

Capacity= 250 - 1000 Tons
Hot tube sheet
blank

1000 Ton Hydraulic Press:

Column to Column= 5000 mm
Daylight= 1900 mm
Stroke= 700 mm
Table size= 1900 x 1400

HOT forming on Press

Punch
Holder
Punch

Ram travel speed= 65mm/min

Pressing speed= 0 to 6.1mm/min
Use: Plate E/B, petals forming, Tube
sheet forming, Straightening

Die
Petal forming operation

Edge- Breaking of plate on 1000T Press:

Forming
Rolling Machines
a) 3 Roll Plate Bending m/c (SCHAFER)
- Cap.= 2000 D x 4000 W x 30 T- CS plate (cold)
- Smallest dia. to be bend= 745

b) 4 Roll Plate Bending m/c-1 (HAEUSLER)

- Cap.= 2000 D x 3500 W x 50 T- CS plate (cold)
2000 D x 3500 W x 75 T CS plate (warm)
- Smallest dia. to be bend= 745

c) 4 Roll Plate Bending m/c-2 (HAEUSLER)

- Cap.= 2000 D x 3500 W x 90 T- CS plate (cold)
2000 D x 3500 W x 125 T CS plate (warm)
- Smallest dia. to be bend= 960

Cutting & Grinding Facilities:

Plate Cutting
Plate Shearing
Edge Planning
Grinding Machines

CNC Plate Profile cutting m/c

(MESSER)

Size of the bed :24 m X 6.5 m

Thk upto 200 mm

Plasma Cutting (LINDE)

Under Water cutting

Size of tank = 10 m x 3.5 m
Thk: 45mm under water
90mm above water
Sound reduced to 35-40 dB
Complete elimination of fumes

Edge Planing M/c

Used for plate WEP preparation
Plate size = 8 m width x 80 thk

Gas Cutting M/c (TANAKA)

Automatic flame adjustment

Grinding M/c

FAROS BLATTER Grinding m/c 2

nos.
For automatic, fast & accurate
grinding of weld seams, chip-back,
WEP
Can go into 1400 Dia. Shell
Horizontal Stroke= 2200 mm
Vertical stroke= 2500 mm

Fabrication Facilities:

Tank Rotators

Alignment Rollers

Cap 25 Tons to 100 Tons

Turn Tables

Cap.= 5 Tons to 350 Tons

Flat bed and Tilting bed

Capacity= 1 Ton to 50 Tons

Stands and Scaffolding

Tools & Tackles

Welding Facilities:

SAW (Submerged Arc-welding m/c)

SMAW (Shielded Metal Arc Welding m/c)
GTAW (Gas Tungsten Arc Welding m/c)
FCAW (Flux cored Arc welding m/c)

Orbital Welding
Auto Tube to T/S welding m/c
Strip Cladding
Nozzle Welding
Stud Welding

Welding Facilities:

SAW (Submerged Arc-welding)

TANDEM welding

SMAW (Shielded Metal Arc Welding)

Single wire long-seam welding

Welding Facilities:

GTAW (Gas Tungsten Arc Welding)

FCAW (Flux cored Arc welding m/c)

Welding Facilities:
Orbital Welding (TIG)

Automatic Tube to Tube sheet welding (TIG)

Welding Facilities:
ESSC Welding

SAW with Nozzle Welder

Special Technology Processes:

Auto Temp. monitoring System
Thermal Shrink Fitting
Automatic Elbow ID Overlay

Pressure Testing Facilities:

Air Pressure Testing
Hydro Testing
He Leak testing
Vacuum Testing

Stress Relieving Facilities:

Permanent Heat Treatment Furnaces
PNG/LPG Fired
Main Furnace:
Size: 14.5m x 7.4m x 6.2m Ht
Capacity:
200T Bogie capacity
10000C Temperature

PH Furnace:
Size: 13.2m x 4.8m x 3.5m Ht
Capacity:
60T Bogie capacity
10000C Temperature

Bagsvig Furnace:
Size: 700mm x 400mm x 480mm

Stress Relieving Facilities:

Temporary Furnaces

Local Stress Relieving

Surface Preparation Facilities:

Shot Blasting
Outside shop area
Size= 27m x 9.5m x 7.5m Ht

Acid Cleaning
Outside shop area
Cleaning of SS components

Painting & Stenciling

Outside shop area

NDT Facilities:
Radiography Enclosures

Two Enclosures in shop

Size = 13m x 8m
One Enclosure outside shop
Size = 27m x 15m x 10m Ht.

X-Ray Radiography:
- Capacity = 75 thk
Gamma Ray Radiography:
- IR192 and CO-60 Camera
- Capacity = 170 Thk

- UT Testing facility
- PT Testing
- MP Testing
- Other NDT facilities

Manufacturing Processes:
Shell Fabrication
Cone / Dend Fabrication
Tube Bundle Fabrication
Tube bundle insertion
Job Assembly Sequencing
Stud Tightening
Pressure Testing
Supporting for Stress Relieving
Surface Preparation

Shell fabrication:
Plate length calculation
Marking and cutting
WEP preparation OR Edge-Breaking
Rolling- M/c capacity chart
Marking required circumference
Gap closing and set-up
Welding
Re-rolling

Multiwall Fabrication:
Plate length calculation
2nd layer plate length calculation
3rd & subsequent layer plate length calculation
Shrink-fitting

Shrink- Fitting:

Cone fabrication:
Plate layout calculation
Marking and cutting
WEP preparation OR Edge-Breaking
Rolling- M/c capacity chart
Set-up & welding
Re-rolling
Marking required circumference & height

Tube Bundle fabrication:

Tube bundle Assembly sequence

 Special Shops

Special Material
Special Processes

Special Shop (SS Fabrication):

Special enclosed area for SS Fabrication

Thk from 8mm to 90mm SS fabrication
Dia. Upto 6.5 m

Special Shop (DFE):

2 nos. Dust Free Enclosure

Size = 40m long x 10m width x 5m height

under Goliath Crane

Used for special fabrication like Nuclear

Reactors, End Shield, Titanium welding

Provided with air filters to maintain clean

atmospheric condition of Class-A

Positive pressure of 5mm water height

Rolling in enclosed area

Special Shop (Aero-Space Shop):

Manufacturing Maraging Steel Motor Casings & Hard
wares for PSLV/GSLV
Complete Automatic Welding
1 Station for longitudinal seams welding
4 Stations for circumferential seams welding
Welding in controlled temperature & humidity condition

Special Shop (Aero-Space Shop):

Aging Furnace
- Temp. 6000C with +/-5 degree accuracy

Fully Automatic
Pressure Proof Testing:

Hydraulic Oil filled

66 Bar pressure
Depressurizing in 5 sec

.. Its all about imagineering