Larsen & Toubro (L&T) has completed the fabrication and delivery of 110 modules for Project CERES, Australia’s largest urea manufacturing plant, marking a significant milestone in the execution of the 2.3 MTPA facility. The project is being developed by Perdaman Chemicals & Fertilisers in Karratha, Western Australia, under the Saipem-Clough Joint Venture. 

L&T’s scope comprised 47 Pre-assembled Units and 63 Pre-assembled Racks, with the modules weighing approximately 64,000 metric tonnes. Fabricated at the company’s Modular Fabrication Facility at Kattupalli near Chennai, the modules were transported from India to Karratha through 23 marine shipments in fully tested, pre-commissioned and ready-to-install condition. 

The project demonstrates the use of modularisation to shift substantial construction and integration activities away from the final project site. Fabrication, equipment installation, integration, testing and pre-commissioning were undertaken in a controlled environment, enabling parallel execution while supporting safety and quality oversight, predictability and reduced site interfaces. 

Commenting on the milestone, S N Subrahmanyan, Chairman & Managing Director, Larsen & Toubro, said, “Project CERES reflects how L&T is elevating India’s role in the global project-delivery ecosystem, from a manufacturing base to a source of integrated engineering, technology and execution capabilities.” He added that the achievement demonstrates the depth of India’s industrial ecosystem and its ability to meet demanding international standards. 

Subramanian Sarma, Deputy Managing Director & President, Larsen & Toubro, described modularisation as a “game changer” for large and complex energy projects. According to him, moving construction, integration, testing and pre-commissioning to a controlled fabrication environment enables parallel execution, strengthens safety and quality oversight, improves predictability and reduces complexity at the project site. 

The project achieved 37 million safe workhours and met Australian biosecurity and Electrical Equipment in Hazardous Areas requirements. Rigorous dimensional, quality and interface controls supported the integration of the modules at the Karratha project site. Several complex equipment packages incorporated into the modules were fabricated at L&T’s advanced manufacturing facility at Hazira, Gujarat. 

Executed from L&T’s Modular Fabrication Facility at Kattupalli, the project further demonstrates the facility’s role in large-scale modular fabrication. Spread across 900,000 sq m, the waterfront facility has dedicated marine load-out infrastructure and an annual fabrication capacity exceeding 70,000 metric tonnes. 

The completion of Project CERES demonstrates the scale at which modular fabrication can be deployed for complex projects across geographies. With 110 modules fabricated, tested, pre-commissioned and transported from India to Australia, the project brings engineering, fabrication, integration and international logistics together within a single delivery model. L&T said the experience has relevance across LNG, gas processing, refining, petrochemicals, chemicals, hydrogen, low-carbon fuels and other energy projects where remote locations, constrained construction environments, skilled-labour availability and schedule certainty are critical considerations.