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               Logistics Feasibility Study and Route Survey

                                   For

Ultra 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
Table of Contents


Contents
1. Executive Summary .............................................................................................................. 4
2. Timeline for the Study ......................................................................................................... 6
3. Constituents of Feasibility Study ....................................................................................... 7
4. Preface ................................................................................................................................... 8
5. Synopsis .................................................................................................................................. 8
5.1.1        The Approach ................................................................................................................. 8
5.1.2        Equipment Drawing [Generator Stator]................................................................... 11
5.1.3        Equipment Drawing [Dearator] ................................................................................. 12
5.1.4        The Methodology ......................................................................................................... 13
5.1.5        The Route Description ................................................................................................ 13
5.1.6        Route Stretches and Distances: ................................................................................ 17
5.1.7        Conclusion ..................................................................................................................... 19
5.1.8        Disclaimer ..................................................................................................................... 20
6. Detailed Routes ................................................................................................................... 21
6.1       Route Maps [Two] & Typical Bypass Details ............................................................... 21
6.2       Brief Note on River Transportation [Barging] ............................................................ 22
6.3       DETAILED ROUTE SURVEYS ............................................................................................ 24
6.3.1        Apendix 1 – Haldia – Tilaiya (Site) – 490 kms (100 Pages) .................................... 24
6.3.2        Appendix II – Kolkatta – Balanagar – 40 kms (15Pages) ......................................... 24
6.3.3        Appendix III – Fatwah Bakhtiarpur– Tilaiya (Site) – 177 kms (37 Pages) ............ 24
6.3.4        Appendix IV – Paradip – Tilaiya (Site) – 787 kms (57 Pages) ................................ 24
6.4       Civil Estimates for constructing 4-lane Road from NH2 to site. ............................. 24
7. Water Route from the Port of Discharge to the site:................................................... 25
7.1       Port Detail ........................................................................................................................ 25
7.1.1        Kolkatta Port ................................................................................................................ 25
7.1.2        Haldia Port .................................................................................................................... 27
7.1.3        Cargo Statistics ............................................................................................................ 31
7.1.4        Paradip Port.................................................................................................................. 34
7.1.5        Comparative details of Tariffs at Ports ................................................................... 36
7.1.6        Safe navigation on National Waterways of India .................................................. 37


                                                                                                                              Page 2 of 68
7.1.7       Mid Sea Barging ............................................................................................................ 38
7.1.8       National Waterway No 1............................................................................................. 39
7.1.9       Available Draft in NW1 (LAD) .................................................................................... 40
7.1.10          Dredging & Desilting process & Requirement ..................................................... 42
7.1.11          Barges and its types, capacity and availability .................................................. 43
7.1.12          Tug Boat types, capacity and availability ........................................................... 46
7.1.13          Barge Operators in India ......................................................................................... 47
7.1.14          Location and Details of Jetty ................................................................................ 47
7.1.15          Safe Period for Water Transport ........................................................................... 49
7.1.16          List of Marine Contractors for Dredging / Desilting .......................................... 49
7.1.17          Risks / benefits of transport and handling in marine Environment................ 50
7.1.18          Tentative Cost in a marine transportation set up ............................................. 51
7.1.19          Tentative Cost of Jetty Construction and Route from Jetty to Site: ............. 53
8. Rail Route Trail ................................................................................................................... 55
8.1      Loading Station ................................................................................................................ 58
8.2      Unloading Station ............................................................................................................ 58
8.3      Route Capacity in terms of weight, height and width ............................................. 59
8.4      Dedicated Berth at the Port .......................................................................................... 60
9. Project Specific Logistics Plan ......................................................................................... 60
9.1      Equipment Handling Plan............................................................................................... 60
10.      Qualification Criteria for Service Providers for the Project ................................... 61
11.      Methodology for Track & Trace .................................................................................... 62
12.      Supervision / Surveillance requirement of equipment                                       handling at all phases. 63
13.      Authorities involved in the execution of the project ............................................... 64
14.      Process Flow for imported material ............................................................................ 66
15.      Project management and Administrative requirement ........................................... 67
16.      Genex Logistics contact details: .................................................................................. 68




                                                                                                                         Page 3 of 68
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 UMPP's 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
in executing such a mega project. The study encompassed the port infrastructure, Road
Infrastructure, Waterways Infrastructure, Regulatory challenges, Technical challenges and
capacity / capability constraints from Logistics perspective. Genex team also studied the traffic
flows and concluded the study by sugggesting best ways to bridge the GAPS between the
available 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, India

Mobile: +91-9810404438

Email: info@genexlog.com
Email: mj@genexlog.com

Web: www.genexlogistics.in

Facebook | Twitter | LinkedIn | Slideshare | Blog




                                                                                   Page 5 of 68

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Logistics Feasibility Study for Ultra Mega Power Plant (UMPP)

  • 1. Value Creation through process innovations! Logistics Feasibility Study and Route Survey For Ultra 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. Table of Contents Contents 1. Executive Summary .............................................................................................................. 4 2. Timeline for the Study ......................................................................................................... 6 3. Constituents of Feasibility Study ....................................................................................... 7 4. Preface ................................................................................................................................... 8 5. Synopsis .................................................................................................................................. 8 5.1.1 The Approach ................................................................................................................. 8 5.1.2 Equipment Drawing [Generator Stator]................................................................... 11 5.1.3 Equipment Drawing [Dearator] ................................................................................. 12 5.1.4 The Methodology ......................................................................................................... 13 5.1.5 The Route Description ................................................................................................ 13 5.1.6 Route Stretches and Distances: ................................................................................ 17 5.1.7 Conclusion ..................................................................................................................... 19 5.1.8 Disclaimer ..................................................................................................................... 20 6. Detailed Routes ................................................................................................................... 21 6.1 Route Maps [Two] & Typical Bypass Details ............................................................... 21 6.2 Brief Note on River Transportation [Barging] ............................................................ 22 6.3 DETAILED ROUTE SURVEYS ............................................................................................ 24 6.3.1 Apendix 1 – Haldia – Tilaiya (Site) – 490 kms (100 Pages) .................................... 24 6.3.2 Appendix II – Kolkatta – Balanagar – 40 kms (15Pages) ......................................... 24 6.3.3 Appendix III – Fatwah Bakhtiarpur– Tilaiya (Site) – 177 kms (37 Pages) ............ 24 6.3.4 Appendix IV – Paradip – Tilaiya (Site) – 787 kms (57 Pages) ................................ 24 6.4 Civil Estimates for constructing 4-lane Road from NH2 to site. ............................. 24 7. Water Route from the Port of Discharge to the site:................................................... 25 7.1 Port Detail ........................................................................................................................ 25 7.1.1 Kolkatta Port ................................................................................................................ 25 7.1.2 Haldia Port .................................................................................................................... 27 7.1.3 Cargo Statistics ............................................................................................................ 31 7.1.4 Paradip Port.................................................................................................................. 34 7.1.5 Comparative details of Tariffs at Ports ................................................................... 36 7.1.6 Safe navigation on National Waterways of India .................................................. 37 Page 2 of 68
  • 3. 7.1.7 Mid Sea Barging ............................................................................................................ 38 7.1.8 National Waterway No 1............................................................................................. 39 7.1.9 Available Draft in NW1 (LAD) .................................................................................... 40 7.1.10 Dredging & Desilting process & Requirement ..................................................... 42 7.1.11 Barges and its types, capacity and availability .................................................. 43 7.1.12 Tug Boat types, capacity and availability ........................................................... 46 7.1.13 Barge Operators in India ......................................................................................... 47 7.1.14 Location and Details of Jetty ................................................................................ 47 7.1.15 Safe Period for Water Transport ........................................................................... 49 7.1.16 List of Marine Contractors for Dredging / Desilting .......................................... 49 7.1.17 Risks / benefits of transport and handling in marine Environment................ 50 7.1.18 Tentative Cost in a marine transportation set up ............................................. 51 7.1.19 Tentative Cost of Jetty Construction and Route from Jetty to Site: ............. 53 8. Rail Route Trail ................................................................................................................... 55 8.1 Loading Station ................................................................................................................ 58 8.2 Unloading Station ............................................................................................................ 58 8.3 Route Capacity in terms of weight, height and width ............................................. 59 8.4 Dedicated Berth at the Port .......................................................................................... 60 9. Project Specific Logistics Plan ......................................................................................... 60 9.1 Equipment Handling Plan............................................................................................... 60 10. Qualification Criteria for Service Providers for the Project ................................... 61 11. Methodology for Track & Trace .................................................................................... 62 12. Supervision / Surveillance requirement of equipment handling at all phases. 63 13. Authorities involved in the execution of the project ............................................... 64 14. Process Flow for imported material ............................................................................ 66 15. Project management and Administrative requirement ........................................... 67 16. Genex Logistics contact details: .................................................................................. 68 Page 3 of 68
  • 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 UMPP's 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. in executing such a mega project. The study encompassed the port infrastructure, Road Infrastructure, Waterways Infrastructure, Regulatory challenges, Technical challenges and capacity / capability constraints from Logistics perspective. Genex team also studied the traffic flows and concluded the study by sugggesting best ways to bridge the GAPS between the available 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, India Mobile: +91-9810404438 Email: info@genexlog.com Email: mj@genexlog.com Web: www.genexlogistics.in Facebook | Twitter | LinkedIn | Slideshare | Blog Page 5 of 68