ENGINEERING FOR EFFICIENT PROJECTS & PLANTS · ENGINEERING FOR EFFICIENT PROJECTS & PLANTS ......

www.lnttechservices.com

ENGINEERING FOR EFFICIENT PROJECTS & PLANTS

PROCESS INDUSTRY

Current global trends have created significant pressure on businesses thereby demanding wiser capital allocation and focus on emerging technologies in order to meet Cost Pressure, Enhanced Productivity, Shorter Manufacturing Cycle, Regulatory and Quality compliance.

Process Industry is the most sought after practice at L&T Technology Services with a business objective to provide "Engineering services for efficient projects and plants". We create a strong market differentiation with our offerings on efficient, safe, and sustainable production facilities for our clients to improve their plant productivity, efficiency and safety.

Through these offerings we cater to diverse industries, from Owner Operators to EPC Companies and Original Equipment Package Suppliers in the domains such as Consumer Packaged Goods, Chemicals, and Energy & Utilities.

Industry Overview: Winning in the New Normal

L&T TECHNOLOGY SERVICES

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PROCESS INDUSTRY IS THE MOST SOUGHT AFTER PRACTICE AT L&T TECHNOLOGY SERVICES THAT CREATES A STRONG MARKET DIFFERENTIATION WITH ITS OFFERINGS FOR EFFICIENT, SAFE, AND SUSTAINABLE PRODUCTION FACILITIES.


Partner in Your Success: L&T Technology Services

L&T Technology Services integrates leading edge technology for plant design and ensures your investment is profitable. As your Engineering/EPCM partner, we support each phase of plant development. We provide asset services that creates systems and work processes to deliver these projects effectively. We identify, evaluate, define and execute the projects with best practices and the latest proven technologies.

CAPEX/OPEX Plant Engineering E/EPCM Services

Engineering Re-application and Global Rollouts

Services for Digital Makeover of Manufacturing Sites

Operational Excellence & WAGES program

Plant Reliability through AMS

Regulatory and Compliance Engineering services

Preparing for the Future:

To overcome the current market challenges, Process industry practice has tuned its offerings to deliver efficient project & plants.

Our Industry Span and Services are broadly for:

Consumer Packaged Goods (CPG/FMCG)

Chemical

Energy & Utility

In a continuous hunt of lower COGP (cost of goods produced), Process Industry is heading towards newer ways of engineering to optimize capital cost, improve operational efficiency and meet customer demands.

We bring excellence in engineering and operation through our following service portfolios:


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STRUCTURE OF PROCESS INDUSTRY

The Process Industry, with its experienced technical domain experts, programmers and designers, provides Engineering Services for multi industry domains.

Industry VerticalsCh

emic

als

Ener

gy &

Util

ities

Hom

e &

Per

sona

l Car

e

Food

, Bev

erag

es &

Dai

ry

Phar

mac

eutic

als

Dis

cret

e M

anuf

actu

ring

Engi

neer

ing

Dis

cipl

ines

Project Controls & Cost Estimation

Process Engineering (HSE Included)

Mechanical Engineering

Civil & Structural Engineering

Architectural Engineering

Electrical Engineering

Instrumentation & Controls Engineering

Procurement & Construction Support

Asset Integrity Services

Our Industry Vertical Focus & Engineering

Capabilities


PROCESS INDUSTRY SERVICE PORTFOLIO

CAPEX Project E/EPCM Services

Plant Sustenance & Management

Engineering Reapplication & Global Roll-outs

Operational Excellence

Digital Manufacturing

Regulatory Compliance Engineering

Concept Design

Front End Engineering Design

Detail Design

3D Modelling

Cost Engineering

Procurement Support Services

Modularization Engineering

Document Control and Project Planning

Construction Management including Commissioning Support and Overall Project Management Support

Engineering support to construction phase (Vendor Drawing reviews and As-Built)

Process Safety Management

Master Planning & Remediation Programs

Machine Risk Assessment & Safety Solution

Electrical Safety Study

Structural Stability Study

Engineering Information Management (EIM) Document & Data Management Engineering Tools & Data warehouse Process Safety Information

Enterprise Asset Management (EAM) Maintenance Strategy & Optimization EAM rollout Material Cataloguing & BoM preparation

Asset Performance Management (APM) Asset Integrity Management APM Rollout and Integration IT-OT Integration

Digitalization of Asset Register

Integration of Engineering Spares with Material Management Modules and Inventory Management

Digitalization of Maintenance Manuals

Document Control and Management Services (DCMS)

Asset DATA Management Services (ADMS)

Engineering Tools and Data Warehousing Services (ETDWS)

Maintenance Management Services (MMS)

Application of Lean Management & Six Sigma to improve plant efficiencies

Operational Excellence in Supply Chain Management

Packaging & Warehouse Optimization

Plant Overall Equipment Effectiveness Improvement

Intelligent Industrial Automation

Industrial Internet of Things

Augmented Reality

Plant Controls Mobility Solutions

Engineering Analytics

Packaging Machine Design

Services towards Manufacturing Operation Management

Connectivity Solutions

Data Digitalization and Mobility

Laser Scanning

Plant OPEX Programs

WAGES (Water, Air, Gas, Electricity, Steam) Services

Water Management

Energy Management

Productivity Improvement Programs

Shutdown Management

Modularization Engineering

Procurement Support Services

Standardization & Harmonization

Skid Design & Modularization

Cost Engineering and technology transfer

Core Design

Process Safety Management Program

Master Planning & Remediation

Asset Integrity & Design


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Engineering and Design Integrity Services for an Oil & Gas Major

The Oil & Gas facilities that were established more than 3 decades ago are facing pressing challenges on availability of technical information of the plant that steers the direction of the industry to focus upon existing assets. The inability to afford long term unplanned downtime and the trend of migrating existing plants to intelligent 3D platform triggers a need of design integrity and smart tool based support. This case study is an example of our support to the client in providing integration of as-built data over past years into a single platform, site verification of assets and its conversion to a smart plant model.

Energy Audit & Energy Monitoring Services for a CPG Major

This case study is an example of identifying potential savings of $18.2 Million by Energy auditing at various customer's plants under WAGES program. The main challenge for customer was to cut down OPEX costs by 3% reduction in plant energy consumption & also to develop a system (EMMS) for monitoring & targeting Energy.

The Program covered 35 Sites on a Global scale. The solution covered

Identification of OPEX opportunity to bring in the Operational Cost reduction

Calculation of potential savings & investment required to realize the opportunities along with payback period

Aligning the identified opportunities with plant management team & preparing CAR (CAPEX Appropriation request) for the aligned opportunities.

Proposing EMMS system including infrastructure (Servers, Energy Meters, Instrumentation) required for Energy monitoring and targeting

Hosting Energy Monitoring information on cloud at enterprise level

PLANT SIMULATION SERVICES

We offer advanced modelling and simulation services across processes and plants to help you move quickly from the design to production stage. We also help you curb cost by de-bottlenecking/testing processes without resource commitment and simplify comprehension of systems and operations.

PLANT SIMULATION WORKFLOW

Input Gathering

Prepare Document of Understanding

Constraint Analysis

Build Simulation Model

Analyse

Findings and Improvement Suggestions

CASE STUDIES

When every success story is unique

Dedicated Design Center for a Global Home & Personal Care Major

This is a case study of an example having 10 year long standing engagement wherein we are the Global Engineering partners to the client with our engineering footprints for their 50+ production facilities across the world. 30% of the engineering team strength is at these global facilities and rest deliver projects from India. The engagement comprises of Engineering re-application & global rollout, CAPEX/OPEX project engineering, smart manufacturing, process/machine safety, asset management services and product/machine design services. We enabled the customer to expand their market by doing the modular design of one of their fast moving product and participating in the global rollout in partnership with a fabrication shop.

Plant Sustainability & Remediation Global Roll-out for an International Food & Beverage Brand

This case study is an example of our leading clients sustainability improvement program of reducing the energy consumption by 2% y-o-y across their 80 facilities in 25 plus countries. The energy conservation scope involves our SMEs auditing the global sites, identification of energy saving opportunities with monetary benefit, capital requirements & payback period.

Dedicated Engineering Value Center for a Chemical & Petrochemical Global Major

Our Global Engineering value center with a phased out engagement plan to execute Plant Sustenance Engineering Projects (CAPEX range $15 Mn- $ 200 Mn) for existing plant facility with lean Onsite satellite team supported with offshore dedicated engineering value centre is an ongoing engagement with 17 affiliates of the client where we are providing pre-identified category based support for brownfield/site based sustenance

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projects. We provide support under small projects category in areas of existing equipment modifications, upgradations, replacements, installations of new equipment etc. Sizeable project support includes the ones that also require technology licensors involvement.

We provide flexible delivery models suiting project requirements with our satellite team based at client locations for close coordination and faster turn-around time.

Dedicated Design Center for CAPEX/OPEX Project Efficiency for a Specialty Chemical Global Major

This case study is an example of dedicated design center engagement model with an objective of realignment of the clients engineering organization to enhance the execution of capital projects. Through this partnership, the client was able to further drive engineering excellence and reduce the cost of engineering and design, thereby, gaining a substantial increase in efficiency. We have proven to be a competent and experienced engineering partner with a global presence and presently serving in countries like Netherlands, Sweden, Germany, United States, UK and India, so that clients can execute their capital projects safely, reliably and more efficiently.

Dedicated Design Center for a Fortune 500 Oil & Gas Major

This case study is of a 15-years journey in the area of Asset Management Services for the client who had an explicit focus on building a partner across the globe to support their optimization requirements.

The asset management scope involved supporting 22 countries with best practices and lessons. In this engagement, we deployed a team of 200+ people, which kept growing multi-fold year-on-year.












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Packing Line Integration for a Global Home & personal care major.

This case study is an example of digital services (Connected Machines) provided for increasing the productivity and standardizing Development, Simulation and Validation Process to deliver packaging line integration.

In todays challenging environment, integration of packaging lines PLC Program is expected to be a Plug & Play process - reliable and accurate. Many existing packaging machines are supplied by different vendors, these machines along with the stand-alone machines are expected to work together in sync and deliver. However, lack of integration creates unnecessary downtimes, complicates efficient diagnostics and reduces the efficiency. Today, PackML Standards are being adopted by many of the OEMs to standardize their programming style and structures. We integrated multiple packaging equipment for packing a liquid product. Each individual PLC of the equipment was integrated to a central line PLC, where overall line central parameters (down time, line emergency central, OEE etc.) were monitored & controlled. The line central software was developed & tested in a simulated lab step-up, where all equipment communication was established before the software being deployed at site. This off-line simulation resulted in 50% reduction in software deployment time. We enabled the customer to simulate and validate the PLC & HMI program of Integration PLC & HMI through this tool without the presence of individual machines and simulated up to 20 equipment and checked the reliability of the integration PLC/HMI program. Also customer can integrate large amount of Alarms & Warnings listed in Excel Sheet in PLC/HMI program through OPC communication based on specific set of rules written in algorithm. This gives accurate, reliable and huge time saving PLC/HMI program which provides Plug & Play solution.












QUALITY

Our comprehensive Quality Management System (QMS) provides a robust framework for global delivery. It factors in the varied nature of our engagements across industries and domains including engineering solutions for CAD/CAM/CAE/PDM and other customization services, plant engineering solutions, design and engineering services, product engineering and application software services, independent testing & test automation services, and test systems development.

Our process improvement initiatives are driven with the help of a measurement framework and the support of our compliance testing labs across various industry verticals. Process performance models govern our key delivery processes, which helps us predict performance and proactively take actions on our projects. An independent and dedicated quality team, supported by senior management, is focused on driving the quality movement throughout the organization. A cross-functional task force focuses on continuously improving the efficacy of our quality systems.

ISO 9001:2008 certified delivery centres: Only companies that demonstrate its ability to consistently provide product that meets customer and applicable statutory and regulatory requirements get this certification.

Our Aerospace and Medical Devices practices are AS 9100C and ISO 13485:2003 certified. The certification upholds the quality and system requirements that L&T Technology Services incorporates in its management systems.

Embedded systems and software activities are assessed at Maturity Level 5 of SEI's CMMi Development Ver. 1.3. signifying

high standard of consistency in performance and delivery.

We have bagged the Quality Excellence Award for Planning, Processes & Systems at the World Quality Congress in 2014/15.


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INNOVATIONOur Culture of Innovation has enabled us to grow and retain our customer relationships and successfully achieve process and productivity improvement for customers.

Deeply passionate and perennially curious, the need to create is a true phenomenon at L&T Technology Services. Innovation as a practice dominates both our value-centric and customer-centric approach to solutions. We continuously innovate to make engineering solutions leaner and less complex.

Our presence across multiple industry segments enables cross-pollination of ideas that lead to product, process, and technology innovations. This innovation culture is further nurtured through investments in a dedicated innovation lab to incubate ideas and transform them into reality. We understand the role of continuous improvement and thus make innovation a practice to deliver distinguished engineering solutions.

We focus on innovation driven technology leadership and have set up research and test laboratories that are specific to industry verticals. Our 31 laboratories replicate our customers work environment.

We also work closely with international and national scientific institutions to continually source ideas for engineering solutions. Our events such as Tech Panorama, which is an initiative by the Technology Solutions and Innovation Centre within our company, serve as a platform for our employees to showcase their skill and demonstrate ideas.

Own Patents 37

Co-Authored Patents 137


TESTIMONIALS

Team LTTS has delighted us with on-time project deliverables and we are very satisfied with their responsiveness to problems and overall working relationship. Would very likely recommend LTTS to a business friend or colleague.

- CPG company with global operations

This is good work. Congratulations to the whole team. We are now set for the next big game changing step.

- Global snacking powerhouse

We are very happy with the amount of work and effort that was put in to the SOP, OPL and PMs. They turned around great and will be used for many years to come.

- Global food and beverage company

The cooperation with LTTS enabled us to structure the Asset Technical Data in an efficient and effective manner. LTTS was quick in resource ramp up, turnaround time, availability of SMEs, quality and on time deliverables.

- Leading provider of FPSO systems

We appreciate team LTTSs training methodology and instructors knowledge for making the SmartPlant instrumentation training successful...

- JV between the largest private LNG suppliers

...sincere Appreciation for the exceptional work demonstrated by LTTS site team. While our site was starving for adequate skilled manpower for utility services in the stringent time line, team LTTS personally took the responsibility and gave direction for successfully achieving the objective of PLT permanent Utility services.

- Global Tire Manufacturing Major

OUR ENGINEERING PARTNERS

Corporate member of Institute of Asset

Management (IAM)

Corporate member of Institute of Asset

Global System Integrator (SI) alliance with Dassault

Systems

Global System Integrator (SI) alliance with Dassault

Alliance with Wonderware as System Integration of

Enterprise & Manufacturing Systems

Alliance with Wonderware as System Integration of

The L&T Technology Services' Process Industry vertical provides end to end engineering services for leading plant operators across the globe. The vertical works across the life cycle of the project covering concept & basic engineering to detail engineering and start-up support.

L&T Technology Services Process Industry Vertical

For External Distribution Copyright 2016 L&T Technology ServicesDate of creation: 19/01/2017

Valid Until: 19/01/2018

Reach us at [email protected]

L&T TECHNOLOGY SERVICESThe important thing is not to stop questioning. Curiosity has

its own reason for existing, said Albert Einstein.We couldnt agree more

Thats what we do:IMAGINE: Possibilities for enriched products, services and life

EXPLORE: Ingenious and innovative ways for a sustainable futureDELIVER: Top quality solutions leveraging the 75-year old rich legacy and engineering heritage of our parent company Larsen & Toubro

We offer design and development solutions throughout the entire product development chain across various industries such as Industrial Products, Medical Devices, Transportation, Telecom, Consumer Electronics and Semiconductors and Process Engineering, besides Mechanical Engineering Services, Embedded System Services, Product Life Cycle Management (PLM), Engineering Analytics and Power

Electronics and Machine-to-Machine (M2M) and the Internet of Things (IoT).

Today, 37 own and 137 co-authored patents later, our 8000+ engineering specialists continue to solve business problems for 170+ customers, including 50+ Fortune 500 companies. With presence in 16 countries, 12 Global Delivery Centers and 27 Sales Offices, we continue to dominate the Engineering,

Research and Development (ER&D) space, globally.

ENGINEERING FOR EFFICIENT PROJECTS & PLANTS · ENGINEERING FOR EFFICIENT PROJECTS & PLANTS ......

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