Empowering the power sector with seamless project logistics

The power sector plays an important role in the growth and development of any economy. Whether it’s the different industries contributing to progress or the infrastructure needed to sustain them, both need power to keep going. With experience and expertise in project logistics for both thermal and renewable power plants, Allcargo Logistics is the perfect partner the in the power industry’s forward strides for nation building.

As per statistics published by the International Energy Agency (IEA), India is the third largest producer of electricity in the world. A growing population, along with increasing electrification and per-capita usage will drive growth in power consumption in India to 1894.7 TWh (Terawatt hour) by 2022. India is likely to see huge energy investment of around USD 100 billion by 2024, creating opportunities for the logistics sector too.

Powering through the challenges

Power stations, be they thermal power stations or renewable energy generating power stations, require a lot of complex equipment for their set up and functioning.

In addition, they are often constructed in inaccessible areas that can be very difficult to reach owing to poor connectivity in the country’s hinterlands. Transporting heavy, over-dimensional cargo (ODC) and equipment to such sites can be quite a challenge.

“When it comes to logistics and transportation for power projects, there can never be a one-size-fits-all approach. We understand that each project, each site, is unique with its own specifications and requirements. Our solutions are customised accordingly. That is why leading names in the power sector prefer us for our capabilities of offering end-to-end solutions, our specialised expertise in the power sector, the successful projects and experience we have with industry-leading customers and our glorious legacy of over 25 years”, says Rahul Rai, Head – Business Development & Key Account Management, Project Forwarding and Heavy Engineering Division, Allcargo Logistics.

Energising cargo movement for thermal and renewable energy power plants

For thermal power plants, Allcargo is equipped to carry out the entire set-up and erection, along with transportation of the generator stator, which is one of the key components. Allcargo has completed successful transportation of some of the heaviest generator stators for one of India’s leading public sector engineering and manufacturing companies.

In fact, the company very recently achieved a milestone of sorts by transporting a generator stator from Haridwar, right up to Chennai in the shortest possible time for this customer.

For solar, wind and hydro power plants, the requirements for erection and the components are very different. They could be needing transportation to and from a number of countries. Owing to its expertise across a number of logistics services, Allcargo has devised customised solutions for each of these and is well-equipped to align its processes to the timelines of the customer.

Solar farms, in particular, tend to import a lot of their components from China. The cargo in this case is small in size and is more often than not containerised. However, owing to the documentation and regulatory processes in different countries based on the route of transportation, managing the handling of this cargo is of utmost important. To achieve this, Allcargo relies on its reliable global network operating via more than 300 offices in over 160 countries through its wholly owned global subsidiary ECU Worldwide. Most leading companies in the solar energy sector have enlisted Allcargo’s effective project logistics services for the solar sector.

Components required for power generation using wind energy include the tower (who height can be as high as 120-130 meters and is usually separated into 4-5 sections), wind blades (generally three in number) and the nacelle and hub (the main power generating component). Not only is Allcargo fully capable of transporting these ODC components to and from any part of the country in a timely manner, but can also erect it using its own equipment run by trained operators. It has been a worthy track record of success in this space.

In addition, Allcargo’s expertise and experience also spans to transporting any heavy cargo required for the set-up of hydro power plants, even though this sector has yet to pick-up fully and achieve its potential.

Global ambitions

A report by the McKinsey Global Institute (MGI) suggests that physical infrastructure will require an overall investment of USD 3.7 trillion to keep pace with the projected growth until 2035. While the current trying times may slow down the pace a bit, the need for power stations to fuel this growth will continue to drive logistics requirements.

With its expertise, commitment and end-to-end approach, Allcargo has been foraying into Africa and the Far East to collaborate on key power sector projects.

The team has already completed a successful project by collaborating with ECU Worldwide Philippines for the transportation of a 247T/495MVA transformer from the Manila Port to the Team Energy plant in Pagbilao Quezon.

A challenging project at Bhola, in Bangladesh too, is testimony to Allcargo’s ability to collaborate across borders and bring excellence and ingenuity to projects worldwide.

Set apart by impeccable services

Project logistics for the power sector is driven by one main key factor and that is time. Completing the delivery and set up of the power stations within the stipulated time period is critical to success. During such times, it helps to have own equipment that is maintained regularly and operated by trained professionals who never compromise on safety.

This requires thorough advance planning that is carried out by Allcargo’s team in close collaboration with the customers’ teams involved in the project. Right from transportation timelines, routes, regulatory protocols and procedures, securing permissions from official authorities as required to implementing the project, attention to detail is of utmost importance.

Customers benefit from Allcargo’s end-to-end approach and team of trained experts who monitor operations at each stage, anticipate problem well in advance and come up with innovative solutions to tackle them. Being equipped with high-end and sophisticated equipment like cranes, portable bridges, pontoon ferries, girder bridges, motorized and hydraulic jacking equipment, helps Allcargo increase installation efficiency and site-handling for diverse power sector projects.

Ingenuity in action

Allcargo completed a project at Bhola district in Bangladesh, for a proposed dual fuel (Natural Gas and High Speed Diesel) Combined Cycle Power Plant (CCPP), on the bank of Dehular Khal (Canal) alongside an existing 225 MW CCPP of Bangladesh Power Development Board (BPDB).

The scope of work entailed offering multimodal end-to-end logistics services through sea shipments, air shipments, roads, barges, trailers, trucks or any other mode of transport as deemed necessary for transporting and handling equipment like ODC, Non-Over Dimensional Cargo (Non-ODC) and containerised cargo, from the Port of Export – (Shanghai in China, Antwerp in Europe, as well as Kolkata, Chennai and Mumbai in India) – to the Port of Import in Bangladesh (Mongla).

The material received and delivered included 45,000 FRTs within a span of 3 months and 75 TEUs which included cargo like machinery, structures and containerised cargo.

Constructing ro-ro and lo-lo jetties, using beams and stools and equipment like a 150 ton crane as well as a Demag 600 ton crane, the transportation was completed successfully within the desired timelines.

In 2018, Allcargo set out to deliver three generator stators to be from Mumbai to Lara, Chhattisgarh, for BGR Energy. This has been one of its most challenging movements which took more than one and a half years to deliver the entire project.

The heaviest cargo – a stator weighing 376.5 MT – was moved on the road, on a girder bridge. It went through sea and road, a multimodal transport. The cargo and the girder bridge together weighed 650 MT. The first problem came when the cargo arrived at the port. It had nothing on which it could be brought down due to a flaw in its design. However, Allcargo designed a saddle, which was deployed to bring down the cargo. Another problem was when the cargo reached Chhattisgarh. A bridge on which the cargo was to be moved was very weak. Allcargo’s team then built a bypass, a temporary road on the river to move the cargo. Multiple permissions were taken to build and then dismantle it, in the given stipulated time.

This is a success story that exemplifies how Allcargo goes out of the way to ensure project delivery within timelines to ensure that customers’ projects continue without any problems.

Looking Ahead

As the world including India continues to explore power generation through renewable sources, Allcargo’s experience and expertise in the sector makes it a perfect partner for companies that seek to leverage this thrust for business growth.