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

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

Our member Lift & Shift, representing the Project Logistics Alliance in India, was involved in the execution of another groundbreaking project. Thermax was awarded one of its largest export orders for a large Refinery Project coming up in Nigeria. Thermax assembled all the Plug & Play Modules in its Modularization Yard at Mundra SEZ & delivered all the modules from Mar’19 to Nov’19. Thermax delivered 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 a 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 that was to be transported and shipped were:

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 to the 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 ton and would be the heaviest modules to be transported from Mundra port and requiring to cross 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 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 outrage.
  5. Finally, the discussion revolved to 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 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 its first-ever RORO operation since port inception.
  7. It was finally concluded that the loadout would be done at 2 different jetty/ terminal - The Multipurpose terminal for side on operations and 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 at Nigeria, so wooden blocks which 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 is unique for each equipment taking account of 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 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 stern on position and then for the few modules the ship would wait for the CB berth to load the equipment.

A first in all aspects for Adani port, Thermax and LSPL. Congratulations to our member Lift & Shift for mastering this challenge.

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