Moving Heavy Metals

Construction of the mega greenfield petrochemical complex for Oil and Natural Gas Corporation at Dahej Special Economic Zone involved critical challenges for transporting the plant machinery on the job site through multimodal transportation system. P.P.Basistha present the details.

Moving Heavy Metals
Discharging from Vessels on to Barge at Mumbai Anchorage

Oil and Natural Gas Corporation's new petrochemical complex at Dahej Special Economic Zone is one of the mega industrial constr- uction projects, independent India has ever witnessed. Being set up through a huge capital investment of Rs.13,000 crore, the project is a total integrated petrochemical complex in itself. The infrastructure component of the project consists of setting up of dual feed ethylene cracker along with associated units and polymer plants. The petrochemical project is being set up by Petro Additions Limited, a subsidiary of ONGC of India.

However, constructing the mammoth, integrated, state-of-the- art petrochemical complex involved its own multiple challenges. According to Mr. S .K. Misra, Head, Logistics India, Samsung Engineering Company, International Procurement Team, "Challenge for transporting the critical equipments were on two fronts. The first one was an existing shortfall in the available multimodal infrastructure at port and road infrastructure levels. The second one were number of deterring natural factors that restricted the usage of the multimodal transportation infrastructure which we customized at our end to transport the cargo. Samsung Engineering and Linde consortium was awarded the work for building the dual feeder cracker unit and associated units for the petrochemical project. The tender component involved transportation and erection of the equipments for the dual feeder unit."

Moving Heavy Metals Moving Heavy Metals
Discharged on to Barge at Mumbai Anchorage from Jumbo Vessels Barge approaching to Temporary Dahej Jetty made for DFCU & AUProject In India

The major deterrent was deficient unloading facility at Mumbai Port for the over dimensional cargos as bigger barges of 27 mtrs wide which cannot come inside the port, therefore this operation was carried out in mid sea. "Owing to the shortages of unloading facility at Mumbai port and added deficiency of space in road infrastructure needed, to transport the over dimensional cargo, connecting Mumbai to Dahej, we undertook a feasible study to explore the different options for transporting the heavy and over dimensional equipments to Dahej," says Mr. Misra.

The consignment was directly shipped from Massan in South Korea to Mumbai anchorage by Jumbo Heavy Lift Vessels. Following the arrival of the vessel, the equipments were unloaded on flat top dumb barges, provided by logistics solutions provider, Lift and Shift. Mr. Misra informed, "one of the consignments, longest and heavy required for dual feeder cracking unit."

However, transporting the equipments, through the barge was the second set of big challenge for Samsung. As per Mr. Misra, "there was heavy sea current en-route from Mumbai anchorage to Dahej. To neutralize the impact of the high tidal movements, the barge was supported by heavy duty tugs. A main tug was placed to pull the barge. Additional tugs were attached to the barge to control its extra transport during transportation from Dahej anchorage to Dahej Jetty via Narmada River, created by the sea wave.

Moving Heavy Metals
Barge Berthing on to Jetty along with C3 Splitter which is the longest package ever transported in India

The shipment following its arrival to Dahej was unloaded on a temporary roll on-roll off basin for facilitating the roro operation. The roro basin was constructed on Narmada river Mr.Misra, informed, "getting the requisite level of draft to bring the barge near the roro basin to unload the cargo was the third set of challenge. We had to wait for the river tide to come to a high level of 8.9-9 metres to enter basin to unload the cargo from the barge."

Followed by unloading of the equipments from the barge, they were rolled off in beaching conditions connecting the temporary roro basin to the approach road connecting the plant. Followed by unloading of the equipments for the dual feeder cracking units and associated units, they were transported through self-propelled axle trailers. Followed by arrival at the job site, the equipments were unloaded and erected with the help of strand jacks and tower cranes. The total dimension and weight of the equipments for the feeder cracking units comprised 124.65x9.00x9.00m = 1350tons.

Moving Heavy Metals Moving Heavy Metals
Roll off From the Barge to Connecting approach road Such Mammoth equipment finally delivered at Erection foundation where this will be erected by tower Crane.

The heavy haulage operation for the project was carried out under the supervision of S.K.Misra and J H lee of Logistics Team.

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