Logistics Feasibility Study for Ultra Mega Power Plant (UMPP)

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Ultra Mega Power projects (UMPP) are a series of ambitious power projects planned by the
Government of India. Genex Logistics (Projects Division) which specilizes in
turnkey Logistics Projects in Power and Oil & Gas
industries, undertook the Logistics Feasibility study of
one of these UMPPs and studied the logistics challenges in executing such a mega project.

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Logistics Feasibility Study for Ultra Mega Power Plant (UMPP)

  1. 1. Value Creation through process innovations! Logistics Feasibility Study and Route Survey ForUltra Mega Power Plant at Tilaiya, Jharkhand, India (6X660 MW) Prepared by: Genex Logistics Research & Solutions Team Your Key Contact: Mansingh Jaswal – Director Mobile: +91-9810404438 Email: mj@genexlog.com Date: 6-Aug-2011 Revised: 06 – June-2012 Page 1 of 68
  2. 2. Table of ContentsContents1. Executive Summary .............................................................................................................. 42. Timeline for the Study ......................................................................................................... 63. Constituents of Feasibility Study ....................................................................................... 74. Preface ................................................................................................................................... 85. Synopsis .................................................................................................................................. 85.1.1 The Approach ................................................................................................................. 85.1.2 Equipment Drawing [Generator Stator]................................................................... 115.1.3 Equipment Drawing [Dearator] ................................................................................. 125.1.4 The Methodology ......................................................................................................... 135.1.5 The Route Description ................................................................................................ 135.1.6 Route Stretches and Distances: ................................................................................ 175.1.7 Conclusion ..................................................................................................................... 195.1.8 Disclaimer ..................................................................................................................... 206. Detailed Routes ................................................................................................................... 216.1 Route Maps [Two] & Typical Bypass Details ............................................................... 216.2 Brief Note on River Transportation [Barging] ............................................................ 226.3 DETAILED ROUTE SURVEYS ............................................................................................ 246.3.1 Apendix 1 – Haldia – Tilaiya (Site) – 490 kms (100 Pages) .................................... 246.3.2 Appendix II – Kolkatta – Balanagar – 40 kms (15Pages) ......................................... 246.3.3 Appendix III – Fatwah Bakhtiarpur– Tilaiya (Site) – 177 kms (37 Pages) ............ 246.3.4 Appendix IV – Paradip – Tilaiya (Site) – 787 kms (57 Pages) ................................ 246.4 Civil Estimates for constructing 4-lane Road from NH2 to site. ............................. 247. Water Route from the Port of Discharge to the site:................................................... 257.1 Port Detail ........................................................................................................................ 257.1.1 Kolkatta Port ................................................................................................................ 257.1.2 Haldia Port .................................................................................................................... 277.1.3 Cargo Statistics ............................................................................................................ 317.1.4 Paradip Port.................................................................................................................. 347.1.5 Comparative details of Tariffs at Ports ................................................................... 367.1.6 Safe navigation on National Waterways of India .................................................. 37 Page 2 of 68
  3. 3. 7.1.7 Mid Sea Barging ............................................................................................................ 387.1.8 National Waterway No 1............................................................................................. 397.1.9 Available Draft in NW1 (LAD) .................................................................................... 407.1.10 Dredging & Desilting process & Requirement ..................................................... 427.1.11 Barges and its types, capacity and availability .................................................. 437.1.12 Tug Boat types, capacity and availability ........................................................... 467.1.13 Barge Operators in India ......................................................................................... 477.1.14 Location and Details of Jetty ................................................................................ 477.1.15 Safe Period for Water Transport ........................................................................... 497.1.16 List of Marine Contractors for Dredging / Desilting .......................................... 497.1.17 Risks / benefits of transport and handling in marine Environment................ 507.1.18 Tentative Cost in a marine transportation set up ............................................. 517.1.19 Tentative Cost of Jetty Construction and Route from Jetty to Site: ............. 538. Rail Route Trail ................................................................................................................... 558.1 Loading Station ................................................................................................................ 588.2 Unloading Station ............................................................................................................ 588.3 Route Capacity in terms of weight, height and width ............................................. 598.4 Dedicated Berth at the Port .......................................................................................... 609. Project Specific Logistics Plan ......................................................................................... 609.1 Equipment Handling Plan............................................................................................... 6010. Qualification Criteria for Service Providers for the Project ................................... 6111. Methodology for Track & Trace .................................................................................... 6212. Supervision / Surveillance requirement of equipment handling at all phases. 6313. Authorities involved in the execution of the project ............................................... 6414. Process Flow for imported material ............................................................................ 6615. Project management and Administrative requirement ........................................... 6716. Genex Logistics contact details: .................................................................................. 68 Page 3 of 68
  4. 4. 1. Executive Summary Ultra Mega Power projects (UMPP) are a series of ambitious power projects planned by the Government of India. On account of power deficiency in India, the Government of India has planned to provide power for all by the end of the eleventh plan (may get extended to 12th plan ~ ending 2017). This would require a substantial power generation as this would raise the power demand and may not be fulfilled with the available power supply. The Ultra Mega Power projects, each with a capacity of 4000 megawatts or above, are being developed with the aim of bridging this gap. UMPP plan would entail the creation of an additional capacity of at least 100,000 MW. The UMPPs are seen as an expansion of the MPP (Mega Power Projects) projects that the Government of India undertook in the 1990s, but met with limited success. The Ministry of Power, in association with the Central Electricity Authority and Power Finance Corporation Ltd., has launched an initiative for the development of coal-based UMPPs in India. Based on supercritical technology, these projects are awarded to developers on the basis of competitive bidding. As of Early 2011, 16 UMPPs have been planned in Karnataka, Chattisgarh, Madhya Pradesh, Andhra Pradesh (2), Maharashtra (2), Orissa (3, Tamil Nadu (2), Gujarat (2) and Jharkhand. Of these, the ones planned in Chattisgarh, Madhya Pradesh, Orissa and Jharkhand will come up at pithead locations (near coal mines) and use domestic fuel, while the rest will come up in coastal locations with easy access to imported coal. The ones coming up near Pithead locations (generally a hinterland with minimal infrastructure to access these locations) pose a typical logistics challenge of moving all the equipments ranging from small nut-bolt to a huge 400 tons Generator Stator to these locations or a Dearator (42 M x 7 M x 7M and 150 Tons). Moving such large equipements into the hinterland is a project inself and may decide the very feasibility of the power project. An UMPP would require about 1 million Tons of material & equipments (BTG, Structural Steel, Reinforced Steel etc) and all this material need to be moved from different locations into the site. BTG generally comes from O’seas. Genex Logistics (Projects Division) which specilizes in turnkey Logistics Projects in Power and Oil & Gas industries, undertook the Logistics Feasibility study of one of these UMPPs and studied the logistics challenges Page 4 of 68
  5. 5. in executing such a mega project. The study encompassed the port infrastructure, RoadInfrastructure, Waterways Infrastructure, Regulatory challenges, Technical challenges andcapacity / capability constraints from Logistics perspective. Genex team also studied the trafficflows and concluded the study by sugggesting best ways to bridge the GAPS between theavailable infrastructure and required infrastructure (With Technical and commercial implications).For more details on the report, contact :Genex Logistics (Genex LogiSolutions Pvt. Ltd.)New Delhi -110075, IndiaMobile: +91-9810404438Email: info@genexlog.comEmail: mj@genexlog.comWeb: www.genexlogistics.inFacebook | Twitter | LinkedIn | Slideshare | Blog Page 5 of 68

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