Larsen & Toubro’s Hydrocarbon Onshore business vertical (L&T Onshore) reached a major milestone by achieving feed-in at the world’s first LC-Max Residue Upgradation Facility (RUF) at Hindustan Petroleum Corporation Limited’s (HPCL) Visakh Refinery in Andhra Pradesh. The facility has a designed capacity of 3.55 million metric tons per annum (MMTPA).
Successful Commissioning Marks Key Industry Moment
L&T has successfully commissioned the project. The unit is now receiving actual feedstock—vacuum residue from the existing refinery—and producing high-value products. Senior representatives from HPCL, technology licensor CLG, and project management consultant Engineers India Limited (EIL) were present at the milestone event, underlining its significance for India’s refining and energy landscape.
Cornerstone of HPCL’s Refinery Modernisation Programme
Executed by L&T on an EPC turnkey basis, the RUF represents the most complex process unit within HPCL’s Visakh Refinery Modernisation Project. The initiative forms a critical part of the National Energy Self-Reliance Programme, aimed at maximising value extraction from the residue stream of domestic crude oil.
Advanced Technology Enhances Product Value and Compliance
The LC-Max RUF produces fuels that comply with stringent BS-VI emission norms, while significantly improving the value realised from crude oil refining. Notably, the facility integrates several first-of-its-kind technologies for Indian refineries, including ebullating pumps, Grayloc flanges, pressure let-down stations, and a dedicated pitch solidification and handling unit.
Leadership Perspective on the Milestone
Subramanian Sarma, Deputy Managing Director and President, L&T, said that the commissioning of the world’s first LC-Max RUF demonstrates L&T’s ability to deliver highly complex projects with innovation and precision. He added that the project reinforces the company’s leadership in safety, quality, and technological excellence.
Overcoming Complex Execution Challenges
Despite its success, the execution journey was far from straightforward. Critical construction phases coincided with the peak of the COVID-19 pandemic. The project also faced global supply chain disruptions and geopolitical challenges. Additionally, severe constructability constraints arose within the operating brownfield refinery, located in a compact urban site in Visakhapatnam.
Modular Construction and Off-site Fabrication Drive Efficiency
To address these challenges, L&T deployed advanced construction methodologies and maximised off-site fabrication. More than 50 per cent of the structural and piping scope was modularised into 135 plug-and-play modules. Some modules extended up to 35 metres in length and weighed between 100 and 700 metric tonnes. The modules were fabricated at L&T’s manufacturing facilities across India. These facilities are state-of-the-art.
Massive Construction Scale Sets New Benchmarks
As per the press release, the scale of construction was substantial, involving the installation of over 750 equipment items. It includes 230 over-dimensional consignments transported through Visakhapatnam. The project also required extensive piping and cabling works. Over 50 per cent of the civil construction, including all three substation buildings, was executed using precast technology. This marked a first for any refinery project in India.
