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S e p t - D e c 2 0 0 7
2 SABICUKPetrochemicalsPolyethyleneProject
4 PunjLloydAbrandnewface
5 ThePune-SolapurPipelineproject
15 CelebratingWorldAIDSDay
16 Accidentshurt-Safetydoesn’t
17 CatchingupwithTengizteam,Kazakhstan
18 FocusedHSEQpracticeswinPunjLloydaccolades
SimonCarves,UKbuildstheworld’slargestSingleStreamLDPEplant
S e p t - D e c 2 0 0 6
T h e P u n j L l o y d M a g a z i n e
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RichardBuckleyProject Engineering Manager
Workiswellunderwayatthe
world’slargestsinglestream
LDPEplantbeingbuiltby
SimonCarves,UK,forSABIC
UKPetrochemicals.TheEPC
contractwasawardedin
February2006.Theplantuses
advancedExxonMobilTubular
Technologyandislocatedat
theWiltonInternationalSiteon
Teesside,northeastofEngland.
SABIC UK Petrochemicals owns
several assets on the Wilton Site,
principally an 865 kta Ethylene
Cracker that will produce the
feedstock for the new plant. Simon
Carves has been working on this
project since early 2005, from the
original concept definition through
front end engineering to detail
design. To maintain the project’s fast
track programme, Simon Carves
helped the client place orders for
critical long lead items (compressors,
extruder and high pressure piping),
during the pre-contract phase, taking
over responsibility for these orders
after the EPC award.
WorldClassTechnologyThis is the largest plant of its kind
in the world, but that is not the only
distinction of this plant. At the heart
of the process is a 20 cylinder hyper
SABICUKPetrochemicals Polyethylene Project
Update> Sept-Dec 2006 2
SomeKeyProjectStatistics
• Major Plant Items ~ 200
(Packages, Vessels and Pumps)
• High Pressure Pipe (3000 bar) ~ 5 km
• Manual Valves ~ 4000
• Cable ~ 250 km
• Home Office Manhours ~ 350,000
compressor driven by the world’s
largest slow speed synchronous 33
MW electric motor. The two stage
hyper compressor compresses
Ethylene Gas at 300 bar-g to
3000 bar-g.
DesignThe whole plant has been designed
in 3D using PDMS and is progressing
well with the first isometrics being
released to the piping fabricators in
recent months. The design has been
led by the Simon Carves Manchester
office with significant inputs in Civil
and Piping design, from its office in
Singapore. The project also afforded
the opportunity for a number of
engineers to be seconded to the
two offices.
ConstructionMuch of the civil construction work
has been completed including the
reaction bay walls that shield the
equipment and facilities located
near the reactor that operate
at pressures over 3000 bar-g.
Installation of pipe on the pipe
bridges is underway and erection
of the main reactor piping is shortly
to begin. Mechanical completion is
scheduled for late 2007. u
Largestplant of its kind in the world
The 20 cylinder hyper compressor is driven by theworld’slargestslowspeedsynchronous33MWelectricmotor
Update> Sept-Dec 20063
PunjLloydhasanewface,a
newlooktoreflectthegroup’s
contemporarypersonainthe
wakeofitsrecentspreeof
activities.The new identity, focused
on creating a powerful EPC brand
that unites the group’s global
operations and diverse service
offerings, was unveiled on the 1st of
December by Chairman, Atul Punj
in the Corporate office at Gurgaon
and on the 4th in group companies –
Simon Carves, UK and Sembawang,
Singapore.
Punj LloydAbrandnewface
Speaking at the occasion, Mr Punj
said, “This new brand identity will
help us to create a strong, unified
branding platform for the group and
all our companies will now be united
under a common identity and vision
framework”. He expressed that we
had always offered uncompromising
commitment to our stakeholders.
“We hope that this new face reflects
our brand values of performance,
passion, teamwork, agility and
reliability. It is living these values
that enable us to make a valuable
difference to our stakeholders”.
The new vibrant blue logo comprises
two links enclosed in a 3 dimensional
ellipse, reflecting synergy - different
entities working together to create a
whole which is larger than the sum of
its parts. The two links represent the
strong relationships - those between
the different companies within the
group, as well as the enduring
ones that Punj Lloyd cherishes with
its many stakeholders - that form
the foundation of the brand. The
ellipse has been carefully crafted
with several different shades of
blue to evoke natural elements of
the environment like air and water
and communicate the brand’s
commitment to the environment.
The blue of the brand cues stability,
safety and scale. The brand’s
logotype, which will be used by
all companies within the group, is
Helvetica Neue, a typeface with
crisp, clear letterforms and modern
character. The entire rendition of
the logo has deliberately been kept
futuristic to create a contemporary
persona for the brand that is relevant
across geographies and cultures.
Punj Lloyd’s impressive list of clients
includes virtually the who’s who of
the construction sector and now
with the legacy of 125 year old
petrochemical major - UK based
Simon Carves and Singapore based
Sembawang, the Group is poised to
offer a huge business landscape to
its clients. u
AlwynBowden,PresidentandCEO,Sembawang(2nd from left)atthebrandlaunchinSingapore
BrianWaltmaier,ManagingDirectorSimonCarves,UK
Update> Sept-Dec 2006 4
ThePune-SolapurPipelineprojectMaharashtra, India
Themountainousterrainnotonlyposeddifficultiesinconstruction but also made hydrotesting of the pipeline extremely challenging
AmitJainAdd. General Manager (Pipelines)
Themultiproductpipelinecrossestheundulatingand
hillyterrain of Western Ghats, a mountain range that runs
along the western edge of the Deccan Plateau
Update> Sept-Dec 2006 6
Workinginthegrapeandpomegranateorchards,created by exported soil on barren land, was very challenging
ThePune-SolapurPipeline
projectwasawardedtoPunj
LloydbyHPCLinOctober2005.
The project involved laying of
cross country pipeline from HPCL
existing terminal at Loni in Pune to
Hazarwadi (Miraj) Maharashtra (14’
OD x 6.4 mm WT, 182 km long) and
from Hazarwadi to Pakni in Solapur
(12.75’ OD x 6.4 mm WT, 161 km
long) with a pumping station at Loni
and a tap off at Hazarwadi.
Punj Lloyd’s scope of work also
included construction of 9
sectionalising valve stations, one
intermediate pumping station at
Hazarwadi, one receiving terminal at
Pakni and laying of optical fiber cable
from Vashi to Loni terminal of HPCL.
ChallengesLandscape
The multiproduct pipeline crosses
the undulating and hilly terrain of
Western Ghats, a mountain range
that runs along the western edge of
Update> Sept-Dec 20067
Theextremedifferenceinelevationsinashortspanofdistancemadeitimperative to break the hydrotesting in 27 sections
the Deccan Plateau, separating the
plateau from a narrow coastal plain
along the Arabian Sea. Hard rock
was encountered on more than 80
per cent of the pipeline route. This
mountainous terrain not only posed
difficulties in construction but also
made hydrotesting of the pipeline
extremely challenging. The extreme
difference in elevations in a short
span of distance made it imperative
to break the hydrotesting in 27
sections. Breaking hydrotesting in
the middle of hill slopes at
KP 9.5 at KP81 was a tough task.
To meet the minimum pressure
Work on Bhima river crossing was carried out by opencutmethoddespiteheavywaterflowwith10’depth
requirement stipulated by HPCL and
EIL, the hydrotesting equipment was
mobilised and a hydrotesting cabin
was set up in the middle of the steep
hill slope.
Restricted Right of Way
Another hurdle was the restricted
right of way (ROW) available to the
pipeline. Working in the grape and
pomegranate orchards, created by
exported soil on barren land, was
very challenging. Trenching had to be
carried out by controlled blasting with
minimum damage to the orchards.
Despite huge quantum of blasting,
Update> Sept-Dec 2006 10
restoration was accomplished with
negligible damage to top soil.
Crossing Obstacles
The pipeline crosses 11 rivers, 228
road crossings, 5 railway crossings,
38 canal crossings enroute. The total
length of rivers crossed was 2063 m
and the maximum cover in the rivers
was 6 m from the river bed in Bhima
river which had a span 350 m. Work
on this river crossing was carried
out by open cut method despite
heavy water flow with 10’ depth. The
national highway, railways and canal
crossings were achieved using auger
boring, which did not disturb the
traffic or canal water flow.
Safety
HSEQ was a constant focus, as in all
our work. Despite steep hill slopes
12
and blasting on more than 250 km
of the pipeline, we achieved 2.87
million accident free man-hours.
This speaks volumes about our
commitment to safety of our people
and projects.
Both spreads I & II were
commissioned in the first week of
November 2006 and February 2007
respectively . u
13
Hardrockwasencounteredonmorethan80percentofthepipelineroute. Despite huge quantum of blasting, restoration was accomplished with negligible damage to top soil
WorldAIDSDay,observed
onDecember1everyyear,is
dedicatedtoraisingawareness
oftheAIDSpandemiccausedby
thespreadofHIVinfection.It is
an opportunity for people worldwide
to unite in the fight against HIV and
AIDS. To fight this cause, all our
sites celebrated the day, creating
awareness about the deadly
epidemic.
We have been conducting
workshops like ‘Train the Trainer’,
where experts from SNS Foundation,
discuss various issues pertaining
to the epidemic, encouraging
participants to join the discussion.
Various policies of ABC (Abstinence,
Be-faithful and use Condoms) are
discussed. Employees who attend
the workshop are certified trainers,
who then train others in their
respective sites. u
CelebratingWorldAIDSDay
16workshopsonHIV/AIDSawarenesshave been conducted so far at sites
The workshop covers fundamental
concepts:
• ABC of HIV/AIDS and availability
of vaccines
• Diagnosis of AIDS and HIV
Testing
• Diagnosis and management of
adult HIV Disease
• Caring for HIV/AIDS patients
• Nutrition management of HIV
• Recognition of HIV Infection
• Attitudes and Responsibilities of
Health Care Professionals
The main objectives of the
workshop are...
• ... to pinpoint priority areas where
the population is heavily affected
by HIV/AIDS,
• ... to sensitize the participants
to the methods and tools of the
cultural approach to HIV/AIDS
prevention and care,
• ... to identify the needs in
the field (in training, in new
methodologies, etc.) and to
formulate recommendations for
further action.
Let HIV be your worst enemy!
Lets Fight against HIV/AIDS
ACPIP E R S Y S S D N B H D
Update> Sept-Dec 200615
HiteshGrover/ShashankSingh/RakeshDesaiQA/QC, Kazakhstan
Oneofthelargestoilfields
inKazakhstan,Tengizhas
acontaminatedtoxicgas
environment.
Installation and hydrostatic pressure
testing of high pressure injection gas
pipeline was a crucial task. H2S gas
is injected at a very high pressure
of 635 bars with the help of turbo
multi stage compressors. This high
pressure gas maintains the earth
pressure.
High pressure gas flow injection
lines are used to carry the sour gas
filtered through the Tengiz plant
and through the reduced pipeline
section to gain maximum increased
pressure before entering into high
pressure compressors. After getting
the required pressure through
the compressors, the sour gas is
driven through 10” dia pressure gas
pipelines of 63 mm thick to the drilled
wells. With the help of perforated
injectors, the pressure of gas
reduces, leading to increased velocity
of flow using throttle action which
in turn increases the oil pressure
below the surface the earth. With the
increased pressure, the oil spurts out
through the connected fuel lines.
‘When the going gets tough, the
tough get going’. The team planned
the operation meticulously, keeping
in view the high working pressure
and wall thickness considerations.
Anticipating the need for special
welding technology and equipment
required to produce high quality
welds, the project team purchased
automatic orbital hot wire TIG
welding machines from Liburdi
Dimetrics, USA. Hot wire TIG welding
preheats the filler wire by running an
electric current through it, thereby
allowing a much higher deposition
rate than conventional cold wire.
The amount of deposition depends
on two basic parameters Wire Feed
Rate & Hot Wire Value.
The planning involved a welders
training camp in Panipat, India over
three weeks, where a welding expert
from Liburdi Dimetrics demonstrated
the operation of the automatic
orbital welding machine. Due to
the health and safety hazards, a
special insulated huts with bottom
forced ventilation was designed and
fabricated to vent 99.999% pure
Argon Gas (50-65 CFH) used for
shielding during welding. Welders
were given special skin ointment to
avoid hyper pigmentation associated
with continuous welding 8 -10 hrs
a day.
All relevant mechanical testing
was conducted by Bodycote, UK.
Production welds under extreme
climatic conditions and stringent
weld acceptance criteria were
carried. No root or internal defects
Accidentshurt-Safetydoesn’tPunjLloydKazakhgetstoughonHSEQ
FirstinthehistoryofPunjLloyd-highpressurehydrotestingonthesamelineatapressureof868barforpipelineandabovegroundpipingof1035barwas
donewithahighdegreeofsuccess.
Update> Sept-Dec 2006 16
CatchingupwiththeTengizteam,KazakhstanPerformingagainstallodds
CKMishraQA/QC, Kazakhstan
TheFirstPrizetotheTengizteamforactiveparticipation
inthefestival‘Zhylyoi-PlaceofFriendship’organizedby
ZhylyoiRegion,RepublicofKazakhstan-isanexcellent
displayofthepositiveenergyandspiritbytheteam,
performingitstaskinthedifficultterrainofTengiz. Lying
on the northeast Caspian shore at the western
edge of the steppes, Tengiz - one of the world’s
‘super-giant’ oil fields - is subject to extreme
temperatures from 44° C (111° F) in summer to
-40° C (-40° F) in winter. This did not however
unnerve Team Tengiz which has been determined
to complete its projects in time. The festival
invited all foreign companies working in the
region to participate. 8 people from the Tengiz Team, dressed
in colourful Punjabi traditional costumes, performed an exciting
Bhangra, dance of Punjab.
As a mark of appreciation for contributing towards the
encouragement of economic growth in Republic of Kazakhstan,
Punj Lloyd received a ‘Letter of Congratulation’ from the Zhylyoi
administration. With this enthusiastic participation, the Indian team
from Punj Lloyd presented a friendly face of their country and
strengthened the ties between Republic of Kazakhstan and India. u
were permitted. Routine quality
surveillance was implemented to
reduce repair rate and advanced
NDT technique TOFD (Time of Flight
Diffraction) was used to identify
defects and its correct location.
A specialized NDT Agency was
employed to carry out the TOFD
examination. After successful
completion of production welding of
4 km, hydro testing was carried out
on the same line at a pressure of 868
bar (for pipeline) and 1035 bar (for
above ground piping).
This was a first in the history of
Punj Lloyd that such high pressure
hydrotesting was ever done with
such a high degree of success. u
Update> Sept-Dec 200617
Historyrepeatingitself-GreentechEnvironmentExcellenceAwardthethirdtimePunj Lloyd continues its focus on
Environmental Management and
is proud to be declared winner of
the Gold Greentech Environmental
Excellence Award for 2006 in the
Engineering sector. This is the third
consecutive Greentech
Environment award
for Punj Lloyd and
goes to establish
its committed focus
on HSEQ. This
coveted award is
presented every year
to various companies
for outstanding
an ambitious target of five million
man-hours without lost time incident.
The Jindal Power project team
has also been awarded a letter of
appreciation for four million hours
without lost time injury during March
7 – June 21, 2006. Vinod Kumar,
Vice President – Jindal Power, has
written in the letter ‘we hope that this
tempo will be maintained in the days
and months to come till the project
comes to its fruition’. Amen!
Further to that, Punj Lloyd also
erected one of the tallest structure
ever for Boiler elevator structure
towering to +65.3 M (214’.8”)
FocusedHSEQpracticeswinPunj Lloyd accolades EvenasPunjLloydtouchesnewheights,thedrivingforcebehindthecompanyisitsintrinsicreverenceforearchandalllifeforms.PunjLloydiscommittedtoprogressivelymaintainingthebest-in-classstandardsofHealth,SafetyandEnvironmentalcareforitspeople,practices,processesandservices.
Theawardsandrecognitionsmentionedbelowarejustanexpressionofthetrustandappreciationthatourclientshaveforus.
achievements in Environmental
Management.
The ceremony was held in Goa on
August 31, 2006. The award was
received by Praveen Puri, Senior
Manager - Environment and T K Roy,
Manager - Instruments, from His
Excellency, S C Jamir, Governor of
Goa. The function was presided over
by Wilfred D Souza, Deputy Chief
Minister of Goa.
4millionman-hourswithoutanylosttimeincidentHorizon Project Team has achieved
four million man-hours without any
lost time incident from October
25, 2005 to September 15, 2006
during the construction of the
Bulk Liquid Products Terminal on
Jurong Island, Singapore. They
attribute their success to the ‘safety
culture’ inculcated by the project
management team. It is also a
reflection of the company’s high
safety standards. The team has set
Update> Sept-Dec 2006 18
5millionwork-hourscompletedwithoutlostworkdaycaseincidentOur project at New Doha
International Airport has completed
five million work-hours without
lost workday case incident. In
an appreciation letter to Project
Manager – N R Das, client Bechtel
and owner NDIA appreciated
our commitment in making zero
accidents a reality.
Punj Lloyd also received the ‘NDIA
Housekeeping Award’ in recognition
of outstanding performance, which
is an important element for better
safety and quality compliance.
7.5millionSafeManhoursPunj Lloyd Kazakhstan has been
awarded with another Safety
Milestone Award for achieving 7.5
million safe manhours without a Day
Away from Work-injury on the SGI/
SGP projects of Parsons Fluor Daniel
(PFD) International for TengizChevroil
(TCO) at Tengiz site, Kazakhstan from
January 31, 2004 to October 27,
2004 (combined three contracts of
Punj Lloyd Kazakhstan).
The certificate was received by
K S Bhat, General Manager-Projects,
Punj Lloyd Kazakhstan from John
Dempsey, Project Director, PFD and
Dave Connel, TCO Site Project
Director at the monthly Site Safety
Leadership Team Meeting on
October 11, 2006. Kudos to Punj
Lloyd Kazakhstan for maintaining one
of the best Industrial Relations & HSE
records at Tengiz.
CertificateofAppreciation
fromEssarOilLimited
Punj Lloyd has received a ‘certificate
of appreciation’ from the refinery
division of Essar Oil Limited for being
one of the best campaigners in the
‘Hand Safety Campaign’ recently
conducted at site. All contractors
were invited to participate and
deliver toolbox talks as a part of the
campaign. They were then rated by
the safety department.
Punj Lloyd’s single minded focus
on Safety at all times has resulted
in adherence to international safety
norms. u
Update> Sept-Dec 200619
Oil & Gas • Petrochemicals • Process Industries • Power
Utilities • Transportation • Hi-spec Buildings • Asset Management
Group Companies
Simon Carves • Sembawang Engineers & Constructors • PLN Construction • Spectra Punj Lloyd
S O U T H A S I A
PunjLloydLtd.Banmore Industrial Area, Banmore District Morena 476444 MP India T +91 7532 243644 F +91 7532 243297
PunjLloydLtd.1 TV Industrial Estate S K Ahire Marg, Worli Mumbai 400 025 T +91 22 66602835 F +91 22 24936861 [email protected]
A S I A PA C I F I C
PT.PunjLloydIndonesiaVentura Building, 4th Flr, Suite 401B Jl. R A Kartini 26 Cilandak, Jakarta 12430 Indonesia T +6221 75 91 4766 F +6221 75 914 241 [email protected]
PunjLloydPte.Ltd.25 International Business Park #04-18/19 German Centre Singapore 609916 T +65 6562 9042 / 43 F +65 6562 9044 [email protected]
PunjLloydLtd.6th Flr., 68 Hoang Dieu Street Ward 12, Distt 4, Ho Chi Min City Vietnam 115 093 T +84902410951 [email protected]
SembawangEngineers&ConstructorsPteLtd460 Alexandra Road PSA Building Unit 27-01 Singapore 119963 T +65 6305 8788 F +65 6305 8568 [email protected]
C E n T R A L A S I A
PunjLloydKazakhstanLLP11 B, Srym Datov Street Atyrau, Kazakhstan Republic of Kazakhstan T +7 3122 35 46 48 / 57 / 58 / 59 F +7 3122 354687 [email protected]
PunjLloydLtd.Office 213, Business - center «M-Style Office» 1/57, 3-rd Pavlovskiy str. Moscow 115 093 Russian Federation T/F +7 495 250 77 69 [email protected]
M I D D L E E A S T
PunjLloydLtd.PO Box 28907 1206 Al Gaith Tower Hamdan Street, Abu Dhabi, UAE T +971 2 6261604 F +971 2 6267789 [email protected]
PunjLloydLtd.PO Box 55174, #6, 2nd Flr., Hussain Fikri and Sons Building C - Ring Road, Doha State of Qatar T/F +974 427 0822 [email protected]
PunjLloydLtd.PO Box 704, Postal Code 133 Al Khuwair, Sultanate of Oman T +968 24 597728 F +968 24 597493 [email protected]
DayimPunjLloydConstructionContractingCo.Ltd.PO Box 7995 Riyadh 11472, KSAT +966 1 480 8853 F +966 1 488 2876 [email protected]
E U R O P E
SimonCarvesLtdSim Chem House, Warren Road Cheadle Hulme, Cheadle Cheshire SK8 5BR UKT +44 161 486 4000 F +44 161 486 [email protected]
A F R I C A
PunjLloydLtd.P O 3119, Goth Ashaal Alwahda Area Tripoli - G.S.P.L.A.J Tripoli, Libya T/F +218 21 438 [email protected]
R E G I S T E R E D O F F I C E
PunjLloydLtd.Punj Lloyd House, 17-18 Nehru Place, New Delhi 110 019 IndiaT +91 11 26466105 F +91 11 [email protected]
C O R P O R AT E O F F I C E I
PunjLloydLtd78 Institutional Area, Sector 32, Gurgaon 122001 India T + 91 124 2620123 F +91 124 2620111
C O R P O R AT E O F F I C E I I
PunjLloydLtd95 Institutional Area, Sector 32, Gurgaon 122001 India T + 91 124 2620123 F +91 124 2620777
Use this file when Logo unit is more than 10 cm