Heavy Lift Installation at GCPL: A Testament to Engineering Excellence

The JSI Alliance has recently completed a significant project for Afcons Infrastructure Limited at the Gujarat Chemical Port Ltd. (GCPL), where an impressive liquid cargo berth was constructed. This intricate project involved sophisticated heavy lifting operations that not only tested the limits of engineering but also showcased the collaborative spirit of all involved.

Bridging Challenges in Complex Environments

This endeavor presented unique challenges right from the beginning. The installation of eight jackets and fifteen berthing dolphins, each weighing between 500 and 600 tons, demanded exceptional heavy-lift capabilities. The location itself posed obstacles, with a tidal rise of up to 10 meters and powerful currents reaching 5 knots making the working conditions particularly daunting.

Moreover, the project site was operational throughout the installation process, necessitating work done around two live berths. This created severe space restrictions and complicated the mooring solutions, requiring creative and innovative approaches to the design and execution.

A Tailored Solution for Unique Needs

To meet the rigorous demands of the project, the JSI Alliance harnessed its diverse internal resources to develop a customized heavy-lift strategy. Central to this strategy was the mobilization of the heavy-lift vessel (HLV) Jumbo Javelin, which served as a single platform for the safe transport and installation of prefabricated structures.

Mobilization commenced on November 3, taking 15 days to prepare the Jumbo Javelin, including equipping it with a flyjib that would facilitate the lifting operations.

Heavy-Duty Mooring Solution

A key aspect of ensuring stability during heavy lifting operations was the implementation of a durable eight-point mooring system. Given the sandy seabed and tidal conditions, traditional mooring solutions were unsuitable, and the project team engineered a bespoke mooring setup utilizing 17-ton anchors and high-strength mooring lines capable of handling a minimum breaking load of approximately 300 tons per line.

The Jumbo Javelin was outfitted with customized 250-ton winches, and a decision was made to install eight winches, rather than the standard four. This enhancement provided backup systems, boosting safety and operational redundancy as the project progressed.

Managing Forces in a Limited Timeframe

The magnitude of the project required additional steel reinforcements on the vessel to safely absorb the enormous forces during lifting operations. Anchor handling support vessels played a crucial role in the installation of the mooring spread, as they offered the required capacity for the heavy-duty components.

Due to the site constraints, mooring installations had to be executed during a narrow four-hour tidal window when currents were significantly reduced. Once moored, the Jumbo Javelin maintained its position for extended periods, ensuring that operations at the nearby berths could proceed without interruption.

Streamlined Demobilization and Discharge

Following the successful installation, the first loadout occurred on December 3 at Dighi Port, marking the start of a series of six voyages by the Jumbo Javelin. The culmination of the installation process took place on March 14, after which the vessel set off for Dighi Port to demobilize, completing this phase in just seven and a half days.

The Jumbo Javelin then traveled to Singapore to return equipment to suppliers, finishing the entire discharge process within two days. By April 6, the project was declared fully completed.

A Collaborative Success

The successful execution of this complex project is a testament to the deep collaboration and dedication of all participants. Robert de Waard, Project Manager at the JSI Alliance, expressed gratitude to the team, noting, “The shared resources and capabilities of the JSI Alliance enabled us to craft a solution tailored to the challenging site conditions.”

Additionally, he emphasized the essential partnerships formed throughout the project. The collaboration with companies like Franklin Offshore International and Moor East Asia for anchor handling equipment was crucial, as was the support from Sea Contractors for anchor handling vessels.

De Waard thanked Afcons for their trust and collaborative spirit, recognizing their crucial role in guiding the project and ensuring every aspect proceeded smoothly.

This endeavor not only highlights the engineering innovations involved but also underscores the importance of teamwork and strategic partnerships in tackling complex maritime projects. The work undertaken at GCPL stands as a benchmark for future heavy-lift operations and exemplifies the heights that can be achieved through collective effort and ingenuity.