Case Study JIRAU PRJ 5 Dec 12

4-5 December 2012 Renaissance Hotel Sao Paulo, Brazil

CASE STUDY: UHE JIRAU Transporting an Hydro-Electric Power Plant

from China to the Amazonian Region

by Paulo José Santos


Attendees on this Panel Today present to answer your questions:

Paulo José Alves dos Santos Managing Director Bertling Logistics Brasil Ltda.

Pedro Carelli Diretor de Desenvolvimento, Energia Sustentável do Brasil

Rafael Fonseca da Mota Analista de Logística Sênior, Andritz Hydro Inepar do Brasil S.A.

João Miguel Redondo Gerente Comercial Transportadora Cruz de Malta

Márcio Giannotti Gerente de Suprimentos Energia Sustentável do Brasil


The Challenge

To transport 22 Hydro turbines directly from China to a Job site near the board with Bolivia, at Porto Velho / RO, Brazil, located 15 days navigation into the Amazonas and the Madeira Rivers. During 36 months, transporting more than 150,000 Fr.Ton of special equipments of all sizes, up to 260 mton and 450 m3 per unit.

Transporting an Hydro-Electric Power Plant from China to the Amazonian Region


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Overall Scenario – The Pre-Existing Conditions Sea Transportation: (45 + 5 days) • No regular lines, not familiar with Amazon • Long deviation with high costs • Need for specialized tonnage – self geared, heavy lift and long outreach

Transshipment Ports: (5 days) • Not familiar with the cargo • No equipment suitable to handle H.Lifts • Pontoon piers • Customs not familiar with the operation

River Navigation: (800 nm - 9 days) • No adequate fleet available • Existing River operators not familiar the type of cargo • High river current speed – 7 knots • Shallow drafts during dry season

Discharging Port: (5 days) • No prepared customs for the project • No suitable equipment or infra-structure for discharging • 14 meters water level variation between dry and rain seasons.

Heavy Lift Haulage: (120 Km) • No equipment available • Tight urban areas • Narrow road and bridges in bad conditions • Local road authorities not sufficiently equipped and not familiar with the cargo • Tight maneuvering at job site • Delivery at the opposite river bank – Additional barge crossing.


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Overall Scenario – Existing Madeira River navigation

Pre-Existing Conditions – Transhipment Port in Manaus

There was no exisiting crane capacity to discharge vessel And load barge. Heavy equipment could not be offloaded to pier.


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Pre-Existing Conditions – River Navigation


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Pre-Existing Conditions – River Navigation


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Flotating Pontoon to discharge general cargo and containers

Concrete Ramp to discharge the heavy lift trafo bodies

Pre-Existing Conditions – Discharging Port – Porto Velho


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Usual Discharge Method by an improvised jetty on the river bank

Why doing a different standard? Costs:

Old style is not cheap. We foreseen 20+ operations minimum Needed something quicker, safer, easier. Higher investment on short term but would create the structure for all necessary operations in the port and eventually on the site – where we need to cross the River again.

Risks Environmental problems – placing and removing all material Be questioned by insurance in case… Costs of construction equipment and materials would increase in the area

Pre-Existing Conditions – Discharging Port – Porto Velho


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Overall Scenario – Road Conditions

Pre-Existing Conditions – Road Transportation


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To perform the project, Bertling had to create a transportation system with little dependence on the existing structure and on third party services. That implied on a higher initial investment but on the other hand it would create a system which could be used for other cargo needs.

The necessary tasks included:

The Plan – Creating a Transportation System

1. Establishing a regular line from Shanghai to Manaus with heavy lift vessels capable of lifting the cargoes and discharging directly to barges;

2. Creating an office in Manaus with dedicated technical team and establishing the transshipment in Manaus with the necessary customs arrangements allowing the international voyage to proceed until the final destination;

3. Establishing a River navigation service with reinforced barges specially prepared to transport the heavy lifts even during the shallow draft at dry season and considering the necessary Load Out discharge operation in Porto Velho / RO;

4. Creating an office in Porto Velho with dedicated technical team and building the necessary infra-structure at the port to receive the special barges, discharge and handle the heavy cargoes to the project.

5. Creating a Heavy Haulage service with dedicated park of specialized equipment at Porto Velho / RO, able to transport to the project;

6. Arranging the reinforcement of the bridges on the road and establishing the necessary cooperation with local state, city and road authorities to allow for a proper Heavy Lift road transportation.


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Considering fabrication and transport schedule

we studied and identified possible tonnage to serve the project; Stowage plans analyzed Cranes outreach analyzed Ballast capabilities Size of fleet and current trade patterns

Fixed a long term contract with a Project

specialized ship-owner;

Established a dedicated technical team in China to interface with suppliers, supervise the loading operations and interface with local carrier agents;

Established a dedicated office and technical team in Manaus to support the vessel and perform the transshipment operations in Manaus

The Plan – Establishing Sea Transport from China to Manaus


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Performed a series of technical and rigging studies for all alternatives of transshipments from vessels to barges.

Established a long term contract with 2 port terminals in Manaus

Agreed with customs authorities on a direct discharge to barges.

Agreed with customs authorities on a new regulation to continue international transportation from China until port of Porto Velho / RO;

Insurance issues considered

Fiscal issues considered

International Fleet registration issues

Registered as Legal OTM - Multimodal Transport Operator and changed our internal tax system for the project

The Plan – Establishing the Transhipment at Manaus


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The strategy was not ignore local know-how, but to enhance it with higher standards engineering.

Established a partnership with a local “barge-owner” and operator who has a higher standards of operation and HSE - Health, Safety and Environmental policies.

We jointly analyzed the available fleet and structure and made the necessary investments to adequate the operation to the project.

Barges were reinforced with first class Computer Added Structural analysis software by

Navigability and seasonal drafts analyzed when planning for fleet capacity.

The Plan – Establishing the River Transportation Service With higher standards for the river fleet


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Fleet and Stability calculations made with high technical standards and systems.

Load Out operations calculated and planned, generating proper ballasting, mooring and lashing method statements.

Proper planned stowage plans with related method statements.

Purchase of all accessory equipment such as: Reinforced lashing, cables,

shackles, stoppers, tensioners; Ballast pumps Hydraulic pumps and jacks Specially built steel elephant legs Timbers Structural beams

The Plan – Establishing the River Transportation Service With higher standards for the river fleet

With higher standards for the river fleet


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Planning the Barge LOAD OUT Offloading at Porto Velho


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Planning the Necessary Physical Structure at the Port of Porto Velho


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Cooperation with local Port Administration: Designing and Building the mooring bollards Priority for our heavy lift barges on that ramp Dedicated area in the port for Jirau Bertling office with technical team in the port

Building the Necessary Physical Structure at the Port of Porto Velho


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Designing and Building a Special Equipment for offloading Heavy Lifts

Proper calculation, drawings and “data book”: Computer added Finite Element structural analysis software Control of all material certificates (certified where the good steel purchased was employed) Control of certified manpower – in which piece it was applied (welders) Certified engineer for design and construction


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Designing and Building a Special Equipment for offloading Heavy Lifts


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Planning the Heavy Lift Transportation

Planning City crossing routes


In Practice: Loading in China


In Practice: Transhipment to Barges in Manaus


In Practice: Load Out at Porto Velho


In Practice: Load Out at Porto Velho


In Practice: Crossing the City


In Practice: On the Road


In Practice: At the Site – Crossing the River


UHE JIRAU


THANK YOU!

Case Study JIRAU PRJ 5 Dec 12

Documents

renaissance hotel sao

conditions river navigation

operation river navigation

days navigation

brazil attendees

paulo jos santos

brazil case study

heavy equipment