pipavav port project
DESCRIPTION
Pipavav Port is a successful public – private enterprise, and is emerging as an important gateway port on the West Coast of India for containers, bulk and liquid cargo. With less than ten hours steaming time from the Nhava Sheva Port in Mumbai, Port Pipavav provides excellent access to the main trade lines in the North Western region of India.TRANSCRIPT
NCRD’S STERLING INSTITUTE OF MANAGEMENT STUDIES
111
MATERIAL HANDLING
PIPAVAV PORT IN GUJARAT
Submitted To: Prof. Rajiv Wad
Submitted By: Pankaj Shirsat (52)
Mitali Mazgaonkar (87)
Faisal Siddiqui (111)
Specialization: Operations
Date: 29th October 2009
24
INDEX
Sr. No.
Contents Page No.
1 Introduction 3-5
2 Pipavav port-present status
a. Oceanography 6
b. Current Facilities 7-12
c. Operations 13-14
3 Future Developments 15
4 Connectivity 16-17
5 Daily Vessel Positions 18-20
6 Pipavav Shipyard 21
7 Business Strategy 22-25
8 Activities at Shipyard 26-30
24
INTRODUCTION:
Pipavav Port is a successful public – private enterprise, and is emerging as an important
gateway port on the West Coast of India for containers, bulk and liquid cargo. With less than
ten hours steaming time from the Nhava Sheva Port in Mumbai, Port Pipavav provides
excellent access to the main trade lines in the North Western region of India.
Port Pipavav is operated by APM Terminals, part of the A.P. Moller-Maersk Group one of
the largest container terminal operators in the world. APM Terminals has operations spread
over more than 50 terminals in 31 countries, on five continents. With a 54% stake, APM
Terminals is the largest shareholder in Port Pipavav. The other shareholders of the company
include New York Life International India Fund (Mauritius) LLC, IDFC Infrastructure Fund,
The Infrastructure Fund of India, IL&FS Trust Company Ltd., Jacob Ballas Capital India Pvt.
Ltd., Unit Trust of India, Industrial Development Bank of India and India Infrastructure
Fund.
The Waterfront
Port Pipavav offers a total quay length of 1,075m and accepts vessels up to 14.5 metre Draft.
There is an on-dock rail facility with dedicated sidings to handle containers, bulk and break-
bulk cargo. It also offers extensive back – up infrastructure, including warehousing facilities,
open stack yards, weigh bridges and dedicated rail slidings.
Excellent Connectivity
Port Pipavav is well connected by road and rail to the rest of the country. It is directly
connected by the broad gauge rail network of the Indian Railways. Port Pipavav has set up a
joint venture with the Indian Railways – Pipavav Rail Corporation Limited, making it
possible to offer the most competitive rail freight and transit times in the western coast. The
hinterland capabilities have also been augmented with new scheduled services being provided
by the Container Corporation of India (CONCOR).
Port Pipavav has built an 11 km long four-lane expressway connecting the port to the
National Highway. The Government of India has undertaken a project to construct the
Ahmedabad-Dholera central spine road, extending up to Port Pipavav.
24
History:
In 1996, the port was set up by an entrepreneur as India’s first private port. While some
inroads were made in port services, progress was slow. In 2001, APM Terminals
demonstrated its initial interest in the port and in 2004, APM Terminals invested in a 54%
partnership and made substantial investments in machinery and infrastructure expansion.
Within a short period of time, Port Pipavav has enhanced the capability to include 2 modern
container terminals, 2 bulk terminals, eight Quay Gantry cranes, five of which are Post-
panamax Quay Gantry Cranes with an outreach of 18 across and twin lift capacity. The
container yards have 18 Rubber tyred gantries, reefer handling facilities, a CFS and an on-
dock rail facility. A hi-tech fertilizer bagging plant, raising the bagging capacity from 1,000
to 10,000 tones per day, has recently been installed.
Location:
Port Pipavav is located at Latitude 20 54'N and Longitude 71 30'E on the west coast of
India, at a distance of 140 Kms South west of Bhavnagar.
24
Pipava Port Layout:
24
PIPAVAV PORT- Present Status:
OCEANOGRAPHY:
Port Pipavav is protected by islands Shial Bet and Savai Bet, which act as a natural
breakwater making the port safe in all weather conditions. The presence of these islands also
leads to the tranquillity in the harbour as well as ensures the wave height is less than 0.5m
most of the time. Port Pipavav has now increased the Draft to 14.5 metres from 12.5 metres.
Tides:
High High Water Springs (HHWS) +3.92 M
Mean High High Water (MHHW) +3.19 M
Mean Sea Level (MSL) +1.76 M
Mean Low Low Water (MLLW) +0.50 M
Low Low Water Springs (LLWS) -O.O1 M
Note: All levels are with reference to Chart Datum
Currents:
The water currents are between 2.5 to 3 knots during peak tidal conditions. These favourable
oceanographic conditions at Port Pipavav ensure easy and safe navigation of ships round the
year. Thanks to the islands Shial Bet and Savai Bet, Port Pipavav can offer its services
throughout the year, even during the monsoons, which provides an added advantage to its
customers.
24
Current facilities
a. MARINE INFRASTRUCTURE
Draft:
Port Pipavav currently has a vessel acceptance draft of 12.5m, with an outer channel depth of
12.5m and a turning basin depth of 11.5m at chart datum.
The draft at the bulk and container berths is 13.5m and at the LPG berth the draft is 15.5m at
chart datum.
Pilotage & Towage:
Pilotage at Port Pipavav is compulsory. Port Pipavav provides the pilotage and towage
services at the port and has deployed three tugs for this purpose.
Channel:
The channel length at the port is 4,550 meter and due to the favourable oceanographic
conditions, the port offers day and night navigation to all vessels other than LPG vessels
which are berthed or de-berthed during the day only.
24
b. CIVIL INFRASTRUCTURE
Berths:
The port offers 340m of quay length for handling bulk and break-bulk cargo. 735m of quay
length has been dedicated for container handling. The port also has a dedicated LPG cargo
handling berth which measures 65m in length.
Backup Infrastructure:
The port has developed an extensive backup infrastructure in the form of warehouses, open
stack yards and a port users building to accommodate the offices of customs, stevedores
agents and shipping lines.
Storage Infrastructure:
Bulk and Bulk Break Cargo:
The port has constructed 7 warehouses of 600 square meters each and 2 warehouses of 3,657
square meters and 3,252 square meters respectively. These warehouses are located behind the
dry cargo berths. Six additional warehouses of approximately 6,690 square meters each have
been constructed in the warehousing zone, approximately 5 kilometers from the berths.
Central Warehousing Corporation (CWC) operates 4 of these warehouses located in the
warehousing zone. The port has leased three of these warehouses from CWC.
24
The port also has an open stack yard of 148,500 square meters dedicated to the storage of
bulk cargoes such as coal.
Container Cargo:
The port has dedicated container stack yard of 108,100 sq.mts, which is equipped with 1,708
twenty–foot ground slots and 140 forty–foot powered ground slots for reefer container
storage.
CFS Operation:
Port Pipavav operates a Container Freight Station (CFS) within the port limits for the
consolidation of cargo moving from the immediate hinterland of the port. The port has
dedicated 11,000 sq.mts of covered warehousing space and an area of paved stack yards to
handle the CFS operations.
The CFS at the port is currently handling a wide range of cargo ranging from cotton, wood
pulp, sesame seeds, cattle feeds, agricultural products, ceramic tiles to soda ash all generating
from the Saurashtra and other regions of North West India.
24
Liquid Storage:
Land within the port area has been dedicated for the construction and development of tank
farms for the storage of Liquid cargo by the port users.
Port Users Complex:
The port has developed a port user’s complex within the port limits to accommodate the
offices of customs, banks, agents, stevedores, shipping lines and other service providers.
24
c. EQUIPMENT:
Bulk & break bulk cargo handling:
The port has deployed one mobile-harbour Mannesman Gottwald Harbour Crane (HMK
296E) from Germany and two rail mounted Electric Level Luffing (ELL) cranes from B M
Titan of Belgium for the efficient handling of bulk and break-bulk cargo.. The ELL type
cranes are equipped with a built in hopper and a cross conveyor with a rated handling
capacity of 1,000 MT per hour per crane.
The two ELL cranes are supported by a conveyor system, 1,260 meters in length, which
connects the dry cargo berths to the storage areas. The rated handling capacity of this
conveyor system is 2,000 MTs per hour. The port has installed sufficient weighbridges to
support the bulk cargo operations. The port also offers an in-motion weighbridge on rails.
24
Container Handling:
The container berth which measures 735m in length is equipped with six Quay Gantry
Cranes. Three of these quay cranes are post – panamax quay cranes having an outreach of
53m (18 across), total lift of 58m (40m above crane rail) and a capacity of 61 tons under the
spreader with twin-lift capability of handling two twenty – foot containers simultaneously.
The other three quay cranes deployed on the container berth are panamax cranes having a
safe working load (SWL) of 40T and an outreach of 13 containers across on a ship.
The container yard is equipped with 18 RTGs. Ten of these RTGs are environmentally
friendly and is expected to achieve fuel savings of upto 45% as compared to regular RTGs.
Port Pipavav is the first port in India to receive eco-friendly RTGs. The port has also
deployed 5 reach stackers for operations to be carried out at the dedicated container rail
siding.
24
Operations
Bulk operations:
Port Pipavav handles a variety of bulk and break bulk cargo such as Coal, Cement, Clinker,
Fertilizers, Steel, Iron Ore, Agri products, Salt and Soda Ash. The key customers at the port
include IFFCO, Ultra Tech Cement Limited, Essar Steel, Gujarat Heavy Chemicals Limited
etc.
Container Operations:
Container Operations at the port commenced in April 1998. With road and rail connectivity
to its hinterland, Pipavav has emerged as an important gateway port for containers on the
West Coast of India. The port has developed extensive facilities to handle reefer and general
cargo containers. Port Pipavav has dedicated 735m of quay length for container operations
and has deployed six quay cranes to handle ship-to-shore operations. Operations at the
container yards are performed by the 18 RTGs and the rail siding operations are performed
by reach stackers. Port Pipavav has also leased out land in the port to private reefer
technicians, who offer repair, maintenance and pre – trip inspection services.
The port today offers direct weekly mainline services to Europe, US East Coast and the Far
East. Pipavav offers the fastest transit time to Shanghai and the US East Coast from the West
Coast of India. Some of the major shipping lines operating at the port include Maersk Line,
Safmarine, NYK, RCL, United Arab Shipping Company, Hanjin, K - Line, Hyundai
24
Merchant Marine, Mitsui OSK Line, Coastal operators like Shreyas Shipping and Jindal
Waterways are also calling the port.
LPG Berth:
The LPG cargo berth is currently being remodelled and relocated to allow access to off-shore
supply vessels and ensure better berth availability and improved berth utilization.
24
Future Developments:
Vision:
To develop pipavav into a modern container terminal capable of competing with the
best ports in the world.
One of the unique features of Port Pipavav is the availability of large tracts of land. This is
attractive to several customers who wish to set up tank farms or warehouse facilities on site.
2013 - On approval from GMB
Additional dedicated bulk berth of 200m
Additional container cargo berth of 365m
24
Connectivity:
Rail:
Port Pipavav is now connected to its hinterland via Surendranagar by the broad gauge rail
network of Indian Railways. The broad guage rail connectivity project has been undertaken
by Pipavav Rail Corporation Limited (PRCL) promoted by Gujarat Pipavav Port Limited and
the Ministry of Railways. Port Pipavav has an equity stake of 38.8% in PRCL. The Port can
handle incoming and outgoing trains simultaneously and the current capacity of the rail link
is 22 trains per day. At present, the port is handling on an average 2 trains per day.
The station code for the Gujarat Pipavav Port Rail Siding is PPSP - 08424130 and it falls
under the Bhavnagar Division.
Port Pipavav is the first port in India to receive double stacked container trains (March 2006),
which have a capacity of carrying 180TEUs as against 90TEUs carried in a single stack train.
At present, the double stack container trains run between ICD Kanakpura (Jaipur) and the
port.
Railway:
Port Pipavav has been receiving container trains from all the major North India ICD’s. In
November 2003 the port received its first train from ICD Tughlakabad and from February
2004 regular train services between ICD Sabarmati, ICD Dhandarikalan (Ludhiana) and ICD
Kanakpura (Jaipur) to Port Pipavav commenced.
Port Pipavav is now connected by rail to all the major ICD’s in North West India which
include:
ICD Tughlakabad (New Delhi)
ICD Dhandarikalan (Ludhiana)
ICD Sabarmati (Ahmedabad)
24
ICD Kanakpura (Jaipur)
ICD Jodhpur (Jodhpur)
ICD Agra (via ICD TKD)
ICD Moradabad (via ICD TKD)
RCT Vadodra (Vadodra)
Port Pipavav has the most competitive rail freights from North India coupled with excellent
transit times as compared to other gateway ports on the West Coast of India.
Rail Distances
Pipavav
Tughlakabad 1,333
Sabarmati 398
Jaipur 980
Jodhpur 810
Amritsar 1,726
Ludhiana 1,590
Indore 910
All Distances in Kms
Road:
GPPL has developed a four lane expressway which connects the port to the National
Highway 8E. The National Highway 8E was previously Coastal Highway 6 and has
undergone significant up-gradation after conversion.
Road Distances PipavavDelhi 1115RAJASTHANJaipur 873Jodhpur 775Udaipur 506GUJARATRajkot 211Ahmedabad 302Vadodara 321PUNJAB
24
Amritsar 1432All Distances in Kms
Daily Vessel Position:
27/10/2009
Berth No. Vessels Agent Next Port ATB Cargo Qty/Mt
GP-4MV Maersk
KushiroMIPL Salalah
27/10/09 0342
Containers 800 Boxes
Berth No. Vessels Agent Last Port ATB Cargo Qty/Mt
GP-2 MV Vita FaithCompass Shipping
Aqaba23/10/09
2315DAP 23000 MT
GP-4MV Maersk
KushiroMIPL Nhava Sheva
27/10/09 0342
Containers 400 Boxes
GP-1 MV LOK PremParekh Marine
AgenciesMumbai
27/10/09 0524
Steel Plates 622 Plates
Berth No. Vessels Agent Last Port ATB Cargo Qty/Mt
GP-4Tug ASL
Sentosa+Barge Swiber-283
Arya Offshore Mumbai05/06/09
0730Nil For Maintenance Work
Vessels Name Vessel Agent Anchored Cargo Type Import Export
Tug Maritime Chandra 25/10/09 Nil Nil Nil
24
Ratna + Cargo Barge Maritime
HawkShipping 1315
Mv OlympiaMOL India
Pvt. Ltd27/10/09
1200Containers
100 Boxes
150 Boxes
MV Charlotte Bulker
J M Baxi & co27/10/09
1650Urea
28724 MT
Nil
Vessels Name Vessel Agent ETA Cargo Type Remarks
MV Lal Bahadur Shastri
J M Baxi & co27/10/09
1900Containers
Imp 200 Exp 250
MV Hyundai Bridge
Seabridge Maritime
28/10/09 0200
ContainersImp 25 Exp 200 Boxes
MV Jindal TaraSeabridge Maritime
28/10/09 AM
ContainersImp 160 Exp
140
MV AL Mariyah
UASC (I) Pvt Ltd
30/10/09 AM
ContainersImp 75 Exp
120
MV Josco Suzhou
Compass Shipping
30/10/09 0600
CoalImp 47358
MT
MV Target J M Baxi & co30/10/09
2200Nil
For Flag Conversion
MV Maersk Kimi
MIPL03/11/09
0400Containers
Imp-500, Exp-900 Boxes
MV Nedlloyd Asia
MIPL30/10/09
0600Containers
Imp-300, Exp-300 Boxes
MV Nedlloyd Drake
MIPL02/11/09
1300Containers
Imp-800, Exp-600 Boxes
MV SCI Kolkata
J M Baxi & co02/11/09
AMContainers
Imp 100 Exp 100
MV Bunga Raya Satu
Crescent Shipping Agency
03-11-2009
ContainersImp 300 Exp
300
24
MV Hyundai Sprinter
Seabridge Maritime
03-11-2009
ContainersImp 20 Exp
200
MV Thomas Mann
Tai Pan Shipping
03/11/09 PM
ContainersImp 50 Exp
100
MV Al Ihsa'aUASC (I) Pvt
Ltd04/11/09
1100Containers
Imp 47 Exp 190
Vessels Name Date
MV Houma Belle
25/10/09 0900
OSV Pacific Sword
25/10/09 1850
MV Pacific Nickel
25/10/09 1910
MV Nord Mariner
25/10/09 2100
Bei Hai 26/10/09 1045
MV Emirates Marina
26/10/09 1127
MV Nedlloyd Merctor
26/10/09 2145
OSV Pacific Sword
27/10/09 1635
OSV Pacific Nickel
27/10/09 1645
24
Pipavav Shipyard:
Pipavav Shipyard Limited (PSL) is a testimony to the vision and active participation of the
private sector in India’s quest to become a major player in the global maritime industry.
PSL is currently completing the setting up of an integrated shipbuilding facility which, upon
completion, will be the largest in India and among the largest in Asia.
PSL is spread over an aggregate area of 198.92 hectares (approximately 491.53 acres),
comprising an SEZ unit spread over 95 hectares (approximately 234.75 acres) and an EOU
spread over 103.92 hectares (approximately 256.79 acres). The two sites are connected by a
dedicated corridor road of approximately 4.5 km length built by the Company.
Commercial operations at PSL commenced on 1st April 2009
The shipyard complex is located on the South Western coast of Gujarat, about 130
kms from Bhavnagar to its east and Diu, about 90 kms to its west. It is adjacent to Pipavav
Port, the first private sector port in India, which is controlled and operated by the A.P. Møller
Group (Maersk) of Denmark,one of the largest maritime groups in the world.
24
Business Strategy:
PSL’s long-term strategy is to have four pillars to stand on, each capable of supporting the
Shipyard on its own. The Company has engaged in activities in the following business
sectors:
Commercial shipbuilding
Offshore fabrication and servicing
Naval Vessel
And in the next two years, will also add the following:
Ship repair
This strategy will insulate PSL from the the risks of relying on one market segment alone,
and also allow for profitable business opportunities in each segment to be grasped as market
conditions dictate.
PSL has been set up with the in-built flexibility to switch from one product type to another,
without compromising on the efficiency or cost-effectiveness of the yard operations.
24
Accordingly, there will be capability to build and repair (dry dock & afloat) most kinds of commercial
dry and liquid cargo ships such as:
Very Large Crude Carriers ("VLCC")
Capesize bulkcarriers
Suezmax tankers
Aframax tankers
Panamax bulkcarrier and tankers
Handymax and handysize bulkcarriers and tankers
Containerships
Chemical Tankers
Platform Supply Vessels and anchor handling tugs
Dredgers
24
In Naval shipbuilding and repair, PSL has the necessary infrastructure and facility to build all
kinds of naval vessels .
Given the increasing focus on offshore exploration for oil and gas around the coast of India,
and in the Middle East, the Shipyard has been designed to exploit the opportunities that this
sector has to offer. Our capabilities in this regard include fabrication / construction of
offshore platforms, SBM’s, rigs, jackets, vessels, etc. for upstream oil and gas sector /
companies both in India and abroad.
PSL has teamed up with one of India’s leading engineering companies involved in the
offshore sector, Punj Lloyd Limited. This will help the Company fast-track into this growing
sector since Punj Lloyd is pre-qualified with the major exploration and development
companies operating in Indian waters. Punj Lloyd has taken a substantial shareholding in
PSL.
At its site at Pipavav, PSL has installed and commissioned some of the most modern
shipbuilding equipment that can be purchased – inter-alia, from leading companies in
Norway, Japan, Italy and Norway. Two Goliath cranes, each having a lifting capacity of 600
tonnes, the largest in India, are being erected at the site.
This modern plant, when combined with PSL’s highly experienced management team,
comprising Indians and multi-national expatriates and the competitively priced skilled labour
available in India, have enabled PSL to make an impressive beginning in the various business
segments.
24
PSL has teamed up with two world-leading technical associates:
SembCorp Marine, Singapore
SembCorp Marine is a leading global marine engineering and shipyard group, specialising
in a full spectrum of integrated solutions in ship repair, shipbuilding, ship conversion, rig
building, topsides fabrication and offshore engineering. SembCorp been advising PSL on
yard layout and manufacturing processes in relation to the Company’s start-up commercial
shipbuilding operations.
KOMAC, Korea
Korea Maritime Consultants Co., Ltd. (KOMAC) was established in 1969 as Korea’s first
and only private organization of naval architects and marine engineers. KOMAC has
designed more than 1,200 different classes and type of ships. PSL has a technical services
agreement with KOMAC to provide designs as well as assist with procurement of equipment
and materials for the commercial ships being built, thus minimizing potential problems areas
during the start-up phase.
24
Activities Carried:
Dry-docks:
The dry dock and surrounding facilities are located on 103.92 hectares (approximately
256.79 acres) adjoing 800 meters of dedicated waterfront. This entire area has been
approved as an Export Oriented Unit (EOU) by the Government of India.
Workshops and Facilities:
By having located the workshops and fabrication facilities in a SEZ away from the
dockyard site, PSL has the dual advantage of having been able to reserve the maximum
area of water frontage available at the shipyard site for ship assembly, offshore
fabrication and ship repair activities whilst carrying out its fabrication and other
similar activities through a highly tax-efficient SEZ unit.
The blocks manufactured at this site are pre-outfitted to the maximum extent. This is done in
the ideal working conditions offered by covered fabrication shops. When ready, the blocks
The Pipavav Shipyard originally consisted of two wet basins – one approximately 680 meters
long and 65 meters wide, and the other approximately 680 meters long and 60 meters wide.
The first of these has been converted into a dry dock measuring 662 meters longs, and 65
meters wide.
Two Goliath cranes, each having a lifting capacity of 600 tonnes, and two level luffing cranes
are being erected to service this dry dock.
To facilitate afloat fit-out and commissioning of ships, including afloat repairs, a 300–meter
long quay, with the capacity for berthing on both sides, has been constructed with adequate
draft and serviced by a level luffing crane. The entrance of the dry dock will also have a 100
meter extension track for the Goliath cranes for unloading heavy machinery and equipment
weighing up to 1200 tonnes directly from ships and heavy lift barges.
Approximately 4.5 kilometers away from the dry-dock, and located on 95 hectares of land in
a Special Economic Zone approved by the Government of India, a state of the art block-
making facility has been set up for fabrication of hull blocks
24
are moved to the dock-side for pre-erection of mega/giga-blocks followed by lowering them
on the dock floor for final assembly and vessel launching.
The block-making site is equipped with, among others, the following facilities:
Central Steel storage, surface treatment and CNC marking shop
Hull shop comprising of panel line, sub assembly, curved block
assembly, 3D block assembly cells
Pipe fabrication shop
Electrical shop
Shipwright shop
Machine shop
Outfitting shops
Blast cells
Paint cells
Equipment storage shed
Inflammable and paint stores
Transport workshop
24
In addition, the Shipyard’s utility infrastructure includes the following:
2 x 66 KVA power line along with switchyard,
transmission and distribution systems
Water pipeline and fire fighting system along with
pumps, overhead tanks and pumping systems
Low pressure compressed air system
Infrastructure relating to consumable gases such as
O2, CO2, LPG and nitrogen
24
Ship Building:
Potential PSL Product Range:
24
Category Ship type
Tankers VLCC's
Suezmax
Aframax
Panamax
Products
Chemical
Bulkcarriers Capesize
Panamax
Handymax
Handysize
Specialised LNG carriers
LPG carriers
Reefers
Containerships
Offshore support
Ferries
Dredgers
24
24
Offshore Group
Offshore Platforms
Rigs
Jackets
Single Buoy Mooring Systems (SBM)
Naval Vessels:
In Naval shipbuilding and repair, PSL can build all kinds of vessels required by the Indian
Navy and Coast Guard
Ship Repair:
Refit/dry docking
Afloat Repair
Conversions