bbe15 ep5 instar ge power

BreakBulk Antwerp 2015 Case-Study Wloclawek

Poland Combine Cycle Power Plant

INSTAR Projects, Germany:

Maciej Malinowski, Project ManagerHendrik Wagner, Director EngineeringGE Power Generation Products Customer Projects:

Odile Déhu, Logistics Project Manager

GE Picture / Shaftline overview / April 1st 2015

Overview

Content

[1] Overview

[2] Challenges

[3] Preparation

[4] Solution

[5] Conclusion

Slide 2Challenges Preparation Solution Conclusion

3

7

11

26

37

OverviewSlide 3

Challenges Preparation Solution Conclusion

Wloclawek

Project Location

Wloclawek

Gdansk

OverviewSlide 4


PKN Orlen Poland End Customer

GE / SNC Lavalin / Turnkey Project Consortium

INSTAR HL Project Freight Forwarder

Pol-Mare Port Operations

MTD Heavy Transports

Trend L/S/D and HL Rigging

Lastro Heavy Lift Service Provider

Parties Involved

OverviewSlide 5


Cargo Qty Origin Loading PortLength

[cm]

Width

[cm]

Height

[cm]

Weight

[Mg]

Gas Turbine 1 France Antwerp 1095 498 504 302

Generator 1 USA Albany 940 544 411 276

HRSG-Module (a) 6 South Korea Masan 2750 460 340 198

HRSG-Module (b) 9 Vietnam Haiphong 2750 460 270 146

Steam Drum 1 South Korea Masan 1760 280 310 120

Steam Turbine 1 USA Albany 965 307 376 102

Total GE Project Volume: 26’000 m³ / 7’000 tons

OverviewSlide 6


December 2012Q2 2015

First Fire

December 2015, COD

Site Preparation (Przygotowanie Miejsca)

Civil Works(Prace Lądowe)

Q1-Q2 2014Major Equipment

Delivery to Site

Mechanical

Electrical Installations(Prace Elektro-mechaniczne)

Commisioning

(Przekazywanie do eksploatacji)

Project schedule, Key dates

June 6, 2014 Deadline for site delivery of major heavy lifts

OverviewSlide 7


Vistula river (Wisla, Weichsel), Characteristics

Wloclawek

• Unregulated river

• Rapidly fluctuating waterlevel

• Difficult to predict

• Overhead clearance limited by several bridges

• Width limited by river locks

OverviewSlide 8


Huge Amount of Cargo to be Transported Within a Tight Schedule

• No road and rail options for 33 heavy lifts

• Only option:Vistula river

• Limited number ofsuitable pontoons and push boats

• Short and unpredictable navigation time window

OverviewSlide 9


Road Infrastructure from pier to site

Main route

ANWIL

OverviewSlide 10


24 tons of total capacity

Either: Replacement 650K EUR

Or: fly-over for 10 months

Bridge on the route from ramp to site

OverviewSlide 11


Port of Import: Gdansk

Westerplatte (Pier)

- HL cargo

Szczecinskie Pier

- General cargo

- OOG cargo

Szczecinskie Pier

Westerplatte

OverviewSlide 12


Quay Selection Criteria:

• Suitable for Break Bulk vessels

• Starting point for OOG road transports

• Starting point for HL road transports

• Direct access to the Vistula river to avoid the Gdansk Bay passage

• Sufficient space for storage and maneuvers with large pieces

Selection of Potentially Best Pier, depending on Cargo Type

OverviewSlide 13


Routing from Port into Vistula River

Two possible routings:

1 – via Gdansk Bay2 – via Channel

Team decision: Enter Vistula river via channel to avoid Gdansk Bay and to reduce risks of pontoon navigation on sea

OverviewSlide 14


Vistula River = Unpredictable Inland Navigation Periods

• Usual Navigation Periods: - April…June- October…November

• 2012 and 2013 lowest water levels since 200 years

• No rain or snow fall in autumn/winter 2013

Max 5m

Min 3m

Vistula river, Water level in Torun 2003 to 2012

OverviewSlide 15


Typical Cycle for Inland Transport of HL on Vistula river

OverviewSlide 16


First Draft of Project Transport Schedule / Oct. 2013

Even under perfect navigation conditions, with 4 pontoons last HRSG modulewould be 3 weeks to late.

Main Challenge: Optimize the inland waterway schedule

54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121

6th LOT

6th LOT2 st LOT 2nd LOT 4th LOT

3rd LOT 5th LOT 7th LOT

2 st LOT 2nd LOT 4th LOT 8th LOT

5th LOT 7th LOT3rd LOT

April 15, 2014Expected official startof river nav. period

June 6, 2014Deadline

OverviewSlide 17


Opt.16 Pontoons for GT, GEN and HRSG

> Still sensitive to unfavourableclimatic conditions

Optimization of Project Transport Schedule / Dec. 2013



OverviewSlide 18


In Option 1 – Discharging Pier would become Bottleneck

OverviewSlide 19


Opt.16 Pontoons for GT, GEN and HRSG

> Still sensitive to unfavourableclimatic conditions

Opt.24 Pontoons for GT, GEN and HRSGPLUS 220 km Road Transports

> shortest possible cycle times

Optimization of Project Transport Schedule / Dec. 2013



OverviewSlide 20


HRSG Modules 200 tons: Pontoon Barging, Roll-off

OverviewSlide 21


HRSG Modules 150 tons: Road Transport

OverviewSlide 22


Main route

Bridge Bypass over Chemical Plant

OverviewSlide 23


Site Transport and Storage Scenarios of HRSG Modules

OverviewSlide 24


Heaviest Item: Gas Turbine, 302 tons

OverviewSlide 25


Get ready to catch the river transport window

OverviewSlide 26


Arrival and Start of River Transport of HL items in Gdansk

OverviewSlide 27


GT and GEN - Routing from Port into Vistula river

Measurement of bridges overhead clearance:

On channel, passage of cargo over 4.20 m height not possible

Decision:- GEN (4.11m) via Channel- GT (5.05m) via Bay

OverviewSlide 28


April 2 to April 5:GT and Geno

from Gdansk to Korzeniewo

GT + GEN Pontoons Transfer from Gdansk to Wloclawek

April 6 to May 1: low water level

forced a stop

Max 5m

Min 3m

OverviewSlide 29


Parking Position because of Low Water Level

OverviewSlide 30


Sounding of the River Bed

OverviewSlide 31


May 2 to May 6:GEN and Geno

from Korzeniewo to Wloclawek

Max 5m

Min 3m

April 6 to May 1: low water level

forced a stop

April 2 to April 5:GT and Geno

from Gdansk to Korzeniewo

GT + GEN Pontoons from Gdansk to Wloclawek

OverviewSlide 32


Discharging of GT and GEN in Wloclawek

OverviewSlide 33


Heaviest Item: Gas Turbine, 302 tons

OverviewSlide 34


HRSG Modules and Steam Drum, Port Storage Gdansk

OverviewSlide 35


HRSG Modules over 150 tons: Pontoon Barging, Roll-off

OverviewSlide 36


• Team building and cooperative mindset:• Team Building starting from the early project stage• Empower every team member and gain trust

• Concentrate on factors the Team can influence:• Be prepared for favorable weather conditions • Consider as many scenarios as needed

• Jump out of the box to meet project targets:• Shift some HRSG modules strategy transfer from river to road

• Communication plan:• Information direct from the source• To all the Project Team Members

Collaborative thinking

OverviewSlide 37


• Engineering INSTAR capabilities for Heavy Lift transport:• Detailed and documented itinerary surveys• Drawings and Method of statements• ?

• Polish Project Manager:• Knowledge and experience of the:

• Polish authorities• Subcontractors• Local actors including customer

- > FILM

Technical and local expertise

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