Transporting 1,100 mt stators for a thermal plant in interior India is a challenge because of the magnitude as well as logistical bottlenecks. Allcargo Global Logistics innovated the process. Adarsh Hegde writes about the experience.
On 27 July 2007, the contract for the NTPC Barh 3x660 MW stator transportation project was awarded to Allcargo Global Logistics by Power Machine, for the transportation of three generator stators and their accessories from Haldia Port/Kolkata Port to NTPC Barh, Bihar. The first stator arrived in August and was delivered to the jobsite in October 2009. The second stator arrived at Kolkata in June 2010 and was delivered by August 2010, which was finally followed by the third stator, which arrived at Kolkata in December 2010, and is currently making its way to the Barh site.
The dimensions for each of the generator stators were 9.98x5.11x4.73 m, consisting of an enormous weight of 378 mt. Considering the severe constraints in road transportation to the project site directly from Haldia Port, Allcargo opted for multi-modal transportation while executing the operations, using waterways for 904 km and roadways for the remaining 46 km.
The generator stator was initially transported via waterways up the Ganga on a flat top barge from Haldia port to Kiroderpur jetty near Fatwah. The barge was constructed by Allcargo, after which the consignment was undertaken via road transportation from Kiroderpur jetty to NTPC’s Barh super thermal project site.
Allcargo deployed a flat top barge of 60 m length x 15 m width x 2.8 m depth with a carrying capacity of 1,000 tonne and loaded draft of 1.2 m along with two tug boats of 900 BHP each for towing the generator stators from Haldia port to Kiroderpur jetty. We deployed our 12 axle goldhofer hydraulic modular trailer in a one and a half (18 axles, 36 suspensions) combination for the transportation of generator stators by road from Kiroderpur jetty to the NTPC project site.
The generator stators were received on steel beams and stools pre-positioned on the barge. The beams and stools were especially fabricated and arranged on the barge in a specific manner that enabled distribution of the entire load of the generator, and kept in mind the deck-loading factor of five mt per sq m of the barge. The beams were fabricated after calculating the bending movement of the generator’s load.
The package was lashed and secured using tested wire ropes having 19 mm diameter with five tonne bottle screws and D-shackles, as per the insurance surveyor’s recommendations.
We selected the Kiroderpur jetty for the construction of the RORO jetty, just 46 km away from the site. The site was most suitable since there were no bridges en route. Except for a few overhead low-tension electrical lines, tree branches and traffic congestions, the route was considered safe for transportation.
We obtained the required permissions from local administrations: the police, electricity board, forest and other government departments.
Post-monsoon, the roads are prone to being bumpy, and in order to ensure smooth and uninterrupted movement, all the potholes on the road were filled and levelled. The cargo was escorted by our own staff as well as designated police officers, who assisted us in controlling the traffic during the operation. The state police officers also provided us with parking slots during the movement.
The increased precautionary steps and strategic and systematic planning helped the logistics movement of the generator stator and its accessories, and ensured successful delivery which was carried out in an efficient and effective manner.
The author is Executive Director and Corporate Marketing Chief, Allcargo Global Logistics, and spearheaded the above project. He may be contacted at firstname.lastname@example.org.