use this file when logo unit is more than 10 cm

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

Use this file when Logo unit is more than 10 cm

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


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


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


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,


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


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.


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


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


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


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

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