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Larsen & Toubro Limited

Bldg. ā€˜Cā€™, Powai Campus, Gate No. 1 Saki Vihar Road, Mumbai 400072, India .
Tel : 1800 2094545 ā€“ Toll Free (India)

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Core Competencies

L&T Hydrocarbon Home > About Us > Core Competencies > Modular Fabrication

Modular Fabrication

L&T has world-class heavy engineering workshops at Powai (Mumbai), Hazira, Kansbahal, Chennai, Vadodara, Kattupalli and in Oman. These state-of-the-art modular fabrication facilities have a combined fabrication area in excess of 1.2 million sq.m with total fabrication capacity in excess of 150,000 MT. Facilities at Oman and Kattupalli are strategically located to cater to international markets. In addition to the logistical advantage, L&T’s fabrication facilities offer round-the-year delivery to customers in India, the Middle East, South East Asia, Australia and North Sea besides other markets.
 
Modular Fabrication Facility – Hazira, India
 
L&T’s Hazira Modular Fabrication Facility (MFF) is geared to meet exacting quality standards within compressed delivery schedules for sophisticated plants. Located at Hazira in Gujarat, 295 km north of Mumbai and 21 km from Surat on the banks of river Tapti, L&T’s MFF has unimpeded passage to the Arabian Sea 8 km away.
 
One of the largest of its kind in South Asia, the MFF is capable of manufacturing several large modules simultaneously with an annual fabrication capacity of 50,000 MT. Fabricated modules are tested and pre-commissioned on shore to ensure rapid and trouble-free hook-up at site. MFF is certified to various international standards such as ISO 9001, 14001, ISO/TS 29001 and OHSAS 18001 and also has Certificate of Authority to use API monogram for products manufactured as per specifications API 5L and API 2B. The facility is also authorised to use ASME ‘U’ & ‘S’ stamps and NBBI’s ‘R’ stamp.
 
It is part of L&T’s Hazira works complex spread over 300 hectares incorporating several state-of-the-art units for manufacture of latest generation refinery, petrochemical, power, nuclear, aerospace and defence equipment and specialized vessels.
 
Infrastructure
 
Modular Fabrication Area: 475,000 Sq.m.
Piping Spool Shops: 8,000 Sq.m Covered Warehouse : 5,000 Sq.m
Pre Fabrication Shops: 6,000 Sq.m Open Warehouse : 20,000 Sq.m
Vessels & Skid Shops: 4,500 Sq.m
Brace Shops: 600 Sq.m Office Space : 3,000 Sq.m
Blast & Paint Shops: 8,000 Sq.m Client Offices: 1,000 Sq.m
 
Jetty / Wharf:
 
Main Jetty: 200m X 18m
Heavy Load-out Facility: 80m X 42m
Roll-on-Roll-off Jetty: 100m X 40m
 
Range
 
  • Offshore platforms & modules
  • Process modules and skid-mounted equipment
  • Fired heaters
  • Modular process plants
  • Heat recovery steam generators
  • Desalination plant and equipment
  • Refinery & gas processing modules
  • Modular furnace & reformer package
 
Design & Engineering
 
Backed by L&T’s Engineering Centres, MFF is equipped to undertake mechanical design of modules including structure, piping, pressure vessels, fabrication and construction engineering.
 
Material of construction
 
  • Duplex stainless steel / super duplex stainless steel
  • C.S. (NACE) / S.S. (NACE)
  • Cupro-nickel
  • GRE/ GRP
  • Solid incoloy / cladded incoloy
 
Track record - Indian projects
 
  • Track record - Indian projects
  • 31 production platforms for ONGC
  • 13 jackets
  • 5 process platforms for ONGC and 1 platform for Enron Oil & Gas India Limited
  • 7 compressor modules for ONGC
  • 5 living quarter modules for ONGC
  • 7 CCR modules for RIL, Jamnagar
  • Convection modules for different refineries & chemical plants as well as HRSG modules for power plants.
  • Vessels, columns & reactors for different refineries & petrochemical plants
 
Track record - Overseas projects
 
  • 3500 MT onshore process modules for Technip for ADGAS-OAG, Abu Dhabi
  • 2 Process-cum-wellhead platforms for MAERSK OIL Qatar
  • Gas injection platform for Bunduq Company Ltd., Abu Dhabi
  • Living quarters platforms for QP - PS2 and PS3 Qatar Offshore
  • Primary reformer modules for Chiyoda Corporation - Japan, for SIPC Methanol Plant in Al-Jubail, Saudi Arabia
  • Test separator skids for Kuwait Oil Company, Kuwait, KOC
  • HRSGs for 168 MW power plant in Sri Lanka for AES Kelanitissa (Pvt.) Limited
  • Flexible pipe reels for Wellstream, UK
 
Modular Fabrication Yard – Sohar, Oman
 
 
L&T Modular Fabrication Yard LLC is a joint venture of L&T and the Zubair Corporation, Oman. This yard possesses the capability to fabricate and Load out, a range of complex structures for Oil & Gas industry like large offshore Process Platforms, Jack up drill Rigs, SPAR/TLP & Modular Process Plants.
 
With an annual fabrication capacity of 50,000 MT, it caters primarily to projects in the Middle East and North Africa region.
 
Located in Sohar Industrial Port Area, L&T-MFY is an all weather yard. It is the first of its kind in Oman, and has significantly augmented Oman's industrial capability since 2007. The yard has state-of-the-art facilities for heavy fabrication, sophisticated equipment for testing and load-out of ultra-large structures.
 
L&T-MFY is certified to various international standards such as ISO 9001, ISO 14001, OHSAS 18001 and also has Certificate of Authority to use the API monogram for products manufactured as per specifications API 5L and API 2B. The yard is also authorised to use ASME 'U' & 'S' stamps and NBBI's ‘R‘ stamp.
 
The yard has been adjudged as the “Best offshore Construction Yard” in GCC region at the Marine International Maritime Awards ceremony in 2011.
L&T MFY has given tremendous thrust in institutionalisation of HSE in every activity performed. To achieve this goal, various strict measures , policies are adopted. L&T MFY has also adapted various productivity improvement measures & improvised welding processes for achieving better productivity as well as well desired quality of finished goods.
 
L&T MFY have pledged to put its expertise in the service of the Oman economy and the local people. The facility has emerged as a key platform contributing to the progress , prosperity & technology development of Oman. L&T MFY is also committed to raising the skill levels of Omani personnel to the world standard.
 
Infrastructure
 
This 500,000 sqm fabrication yard has well-equipped fabrication and pipe shops, having automatic plate & pipe profile cutting machines, plate bending machines and other equipment for pipe spool fabrication. The yard has the automatic shot blasting and painting facilities, covered warehouses, in-house testing laboratories, welder-training centre etc. The yard has its own heavy duty crawler cranes, Goliath cranes and a range of other material handling equipment.
 
Jetty / Quay Wall
 
Waterfront : 450 m
Level : +4.6 m w.r.t. CD
Heavy load-out facility : 20,000 MT
Minimum water depth : 10 m w.r.t. CD
 
Products
 
  • Large Offshore Process Platforms- Jackets, Integrated Decks and Living Quarter Modules
  • Jack up Rigs
  • Compressor Modules, Building Modules, Power Generation Modules , FPSO Modules for fixed & floating production systems
  • Integration of FPSO
  • Skid Mounted Equipment, Modular Process Plants,
  • Pressure Vessels etc., for Mid & Downstream Plants
 
Track Record:
 
  • HB Offshore Platform Project for Maersk Oil Qatar.
  • MHSRP-II well head platform project for ONGC, India.
  • FD-VII Jack-Up Rig major repair & upgradation project for Foresight Drilling, UK.
  • 8-Legged, 13,000 MT of MNP Process Platform Jacket ( fabrication completed in less that 11 months duration).
  • Living Quarter Platform Project for ONGC, India.
  • MHNRD-II Well-Head Platform Project of ONGC, India.
 
Ongoing Projects:
  • Major refurbishment & Layup of Jack up Rig Sagar Uday for ONGC, India.
  • Zawtika Field Development Project Phase 1A consisting of three Well-Head Platforms for PTTEPI, Thailand.
  • Umm Lulu & Umm Nasr – Phase I Field Development Project of ADMA-OPCO, Abu Dhabi; which includes five platforms.
 
Modular Fabrication Yard – Kattupalli, India
 
 
L&T’s export-oriented Modular Fabrication Facility (MFF) offers offshore platform and floating production-cum-storage units and similar products/systems for oil & gas sector as per the intended operations of the approved SEZ. L&T has a controlling interest in its joint venture L&T Shipbuilding Limited (LTSB) with Tamil Nadu Industrial Development Corporation Ltd. (TIDCO). MFF yard at Kattupalli is in Tamil Nadu on India’s east coast, near Chennai.
 
The 400,000 sq.m. yard has a modular fabrication facility with a heavy load-out jetty and an initial dredged channel of 6 metres below chart datum (upgradeable to 12 metres below chart datum). The future development plan will address construction facilities for deep-water floating and modular units. The length of the quay (jetty) is 84 km. Since tidal variation is minimal, it allows for year-round load-out and sail-out.
 
  • Yard area: 400,000 Sq m (approx.)
  • Waterfront: 450 m (approx.)
  • Dredged depth at the jetty: (-12m) below CD
  • Dredged depth at the approach channel: (-14m) below CD
  • Load out capacity, when fully developed:
  • for modules/ decks : up to 24,000 MT
  • for jackets : up to 15,000 MT
 
Product Range
 
  • FPSOs
  • Topsides & Jackets
  • TLPs
  • SPARs
  • Drilling semi-submersibles
  • Drill Ships