Lift & Shift (LSPL) Delivers Biggest, Heaviest Boiler & HRSG Modules For The Largest Refinery In Nigeria

  05. October 2020
 Lift & Shift (LSPL) Delivers Biggest, Heaviest Boiler & HRSG Modules For The Largest Refinery In Nigeria

Lift and Shift India Pvt. Ltd., representing India in the Project Logistics Alliance, is looking back over a project they completed for Thermax. Thermax was awarded one of its largest export orders for a large Refinery Project in Nigeria. Plug & Play Modules were assembled by Thermax in their modularization yard at Mundra SEZ & delivered these between Mar’19 to Nov’19. The consignment delivered by Thermax included 8 x HRSGs, 4 x UBs and 2 x FGSG modules. These modules are amongst the biggest, heaviest Boiler & HRSG modules delivered anywhere in the world.

LSPL was involved with Thermax since the bidding stage for the study of transport engineering of the modules from their yard in Mundra to the port of Mundra and then to be rolled on to RORO ships.

The equipment which was transported and shipped was:

Sr. No. Module Qty. Axle Configuration L (M) W (M) H (M) Weight (MT)
1 UB Module 4 24 + 24 x 1.5 38 14 15 1,000
2 HRSG module 1 8 16 + 16 + 16 24 14 22 750
3 HRSG module 2 8 16 + 16 24 10 20 100
4 FGSG module 1 2 30 + 30 28 9 15 1200
5 FGSG module 2 2 28 + 28 43 11 21 800
6 Heater 1 1 12 + 12 15 9 11 330
7 Heater 2 1 12 + 12 19 8 10 290
The equipment fabrication plan was such that work at site in Nigeria would be kept minimum.

  1. The engineering involved a study of arrangements to limit modification to the minimum.
  2. The road width at Adani Mundra port was lower than the maximum width of the modules to be transported. This implied that when transport of the modules would take place total traffic to the ports on roads would need to stop (all truck/ trailer/ car) movements of Import / Export cargo containers / breakbulk.
  3. The heaviest equipment weighed 1200 tons and would be the heaviest modules to be transported from Mundra port and requiring crossing the Nevinal canal.
  4. The tallest equipment for transport stood at 22 m, that meant the removal of 1 high tension tower line on no of occasions as and when the crossing was required, the tower line was permanently taken underground, this led reduction of downtime of power and hence less trouble to the Public due to power outage.
  5. Finally, the discussion revolved around the management of traffic during the transport of modules. It was agreed by all parties to plan transport in 2 or 3 stages thereby causing limited port work stoppage and eliminating traffic jams.
  6. The client nominated a ship suitable to carry the cargo and operate at Adani Mundra port where the tidal range is 6 m. For Adani Mundra port this was going to be its first-ever RORO operation since the port inception.
  7. It was finally concluded that the loadout would be done at 2 different jetty/ terminals - The Multipurpose terminal for the side on operations and the container terminal for stern on operations.
  8. The next requirement was to stow the equipment at 1.5 m height suitable for the receiver trailers in Nigeria, so wooden blocks that were kept between the trailer and modules to achieve the height of 1.5 m which was 1.2 m of LSPL axles and 300 mm of wooden blocks.
  9. Since the load out was to happen with stools the modules were first transported to port about 10 days in advance where the cargo was stored on stools, stools were welded for stowing on the barge. This would help the ship to achieve a faster turnaround and more safety for continuous operation.
The transport arrangement was unique for each equipment taking into account the various safety modalities of wind force due to module heights, the stability of the modules, route per axle load, and the port per deck load. During the transport, LSPL mobilized a total of 120 self-propelled axles with 5 PPU as the transport required axles in various configurations as seen in the chart above.

The FGSG modules were the heaviest ever to be transported in Mundra weighing at 1200 tons over the Nevinal canal. For the first time in India, 5 files trailers (2½ axles) were used for transport of cargo in India as the UB modules were heavy in the center and required to spread the load for safe transport. The HRSG modules the tallest ever were very slender the height of the modules was 22m requiring an extension of the transport beam such that the width of the module was increased for safe transport.

The client nominated 3 vessels first in April and Second in October 2019. For the first vessel, a total of 7 modules were to be loaded out. The second Vessel was to carry 5 modules and the third vessel was to carry 6 modules. The operation was planned such that each day 1 module would be loaded in the stern on position and then for the few modules the ship would wait for the CB berth to load the equipment.

This was a first in all aspects for Adani port, Thermax, and LSPL. Thank you Lift and Shift for sharing this video with us!

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