L&T Energy Hydrocarbon Onshore achieved twin milestones on a major project
L&T’s Energy Hydrocarbon (LTEH) Onshore has achieved two major mechanical completion milestones at Indian Oil Corporation Limited’s (IOCL) Panipat Refinery Expansion Project in Haryana, i.e.
• The 5 Million Metric Tonnes Per Annum (MMTPA) Diesel Hydrotreater (DHDT) Unit on 29 May
• The 2.5 MMTPA Reactor-Regenerator (Rx-Rg) System Package of the INDMAX Fluid Catalytic Cracking (FCC) Unit on 11 June
These achievements reinforce L&T’s capability to deliver complex refinery projects through engineering excellence, innovation and flawless execution while contributing significantly to India’s energy security and cleaner fuel aspirations.
Awarded by IOCL, both projects were executed on a comprehensive Engineering, Procurement and Construction basis.
The scope encompassed project management, process engineering, detailed engineering, procurement, fabrication, inspection and testing, transportation, construction, pre-commissioning, commissioning support, performance guarantee testing and successful handover.
While the DHDT Unit is licensed by Shell, the Rx-Rg package is based on Lummus Technology’s globally licensed INDMAX process developed by IOCL’s R&D Centre.
The DHDT Unit is designed to produce premium-quality Bharat Stage VI (BS-VI) compliant diesel through advanced hydrotreating technology, helping reduce vehicular emissions while meeting India’s growing demand for cleaner fuels. The diesel produced will be suitable for use in extreme climatic conditions, including temperatures as low as -15°C, enabling uninterrupted fuel supply to India’s armed forces deployed in challenging terrains such as Siachen Glacier, Ladakh and Jammu & Kashmir. The unit is India’s largest single-train Diesel Hydrotreater licensed by Shell.
The Rx-Rg System Package converts heavy crude fractions into higher-value products, using advanced catalytic cracking technology. Based on IOCL’s indigenous INDMAX technology, licensed globally by Lummus Technology, the unit is designed to maximise LPG production, aligning with India’s rapidly increasing LPG demand and supporting the Government of India’s Pradhan Mantri Ujjwala Yojana, which provides deposit-free LPG connections to women from poor and deprived households.
Delivering these projects demanded exceptional planning, coordination and innovation. The DHDT team executed a complex 1,350 km multimodal transportation operation involving sea and road movement of oversized equipment from Hazira to Panipat, overcoming challenging terrain and infrastructure constraints. The largest consignment was 36 metres long, 8 metres wide and weighed 626 metric tonnes. The team erected the Hydro Desulphurisation Reactor within just 36 hours of its arrival at site and pioneered the implementation of the Free Issue Material philosophy for critical equipment. Proactive pre-commissioning activities accelerated overall project readiness.
The Rx-Rg project presented an equally demanding execution landscape. Procurement involved complex imports under the Manufacturing and Other Operations in Warehouse Regulations scheme, while construction was carried out within a highly congested plot with multiple contractors working simultaneously. Six Over Dimensional Cargo (ODC) equipment weighing over 500 metric tonnes each were fabricated and erected within five months. The project achieved the first-ever site fabrication of ODC equipment for IOCL.
Innovation and digitalisation played a critical role across both projects. L&T leveraged integrated digital platforms to improve productivity, enhance quality and strengthen project control. The Rx-Rg project also introduced sustainable construction practices by adopting pneumatic testing instead of conventional hydrotesting for refractory-lined piping, conserving approximately 26.8 lakh litres of water. Robotic arc welding and Leica laser tracker-enabled bolt matching further enhanced precision and construction efficiency.
Safety and quality remained at the core of execution. The DHDT project recorded 9.6 million safe workhours, while the Rx-Rg project achieved over 5.85 million safe workhours, reflecting L&T’s uncompromising commitment to Health, Safety and Environment.
Both projects earned multiple prestigious recognitions from the Confederation of Indian Industry, the World Safety Organisation and other industry bodies for excellence in safety performance. The projects maintained outstanding quality standards, achieving excellent customer satisfaction scores, industry-leading audit ratings and exceptionally low weld repair percentages.
A defining aspect of these achievements was the leadership demonstrated by L&T’s young workforce. With an average team age of approximately 33 years and 13% women representation at the frontline, both projects showcased the capability of L&T’s emerging leaders in executing some of India’s most complex refining infrastructure.
The projects exemplified the strength of L&T’s integrated ecosystem, bringing together expertise from L&T Onshore EPC, AdVENT (Advanced Value Engineering & Technology), Heavy Engineering, L&T Valves, CarbonLite Solutions and specialised lifting teams to deliver world-class outcomes.
The mechanical completion of these two strategic refinery units marks an important milestone in the project, strengthening L&T’s position as a trusted engineering, procurement and construction partner for India’s most critical energy infrastructure. This will result in the production of cleaner fuels, increase LPG availability and contribute significantly to India’s long-term energy security and sustainability goals.
