BreakBulk Africa 2015

Transcription

1 BreakBulk Africa 2015 Presentation 6, Case Study: Three 149t Transformers for the Cahora Bassa Hydro-Electric Power Plant Sub-Station, Songo/Mozambique Hendrik Wagner Engineering Director INSTAR s, Germany Johann van Zyl Manager East Africa ALE, South Africa

2 Content: [1] General slide [2] Process slide [3] s in RZA & ZW slide [4] s in MOZ, Assembly slide [5] s in MOZ slide [6] and final positioning slide [7] Challenges and Lessons Learned slide Slide 2

3 1 General HCB ABB INSTAR ALE Client: Initiator and buyer of the transformer replacement project. Contractor: Engineering, production and installation of the HVDC unit (three transformers). Forwarder: Sea shipment and on-carriage to site. Heavy Lift Service Provider ARC Route Clearance and Consultancy (for route sections RZA and ZW). Parties Involved Slide 3

4 1 General Three old transformers, to be replaced Slide 4

5 1 General New Transformer, 143 tons (149 tons) Slide 5

6 1 General POL: Norrköping, SWE Job Site: Songo, MOZ POD: Richards Bay, ZA Route Slide 6

7 1 General Entire Route: 2200km Slide 7

8 1 General Mozambique 3 2 Zimbabwe 1 Critical Part: Route Section in MOZ, 200 km Slide 8

9 2 Process In total 45 bridges to cross: Typical spans 15/18/20/25/27 m In acceptable reps. good condition Is locally availble transport equipment sufficient? Is it worth to mobilise equipent from abroad? Is it worth to develop and build project specific transport solutions? Critical Part: Route Section in MOZ, 200 km Slide 9

10 2 Process Key Question: How can we balance transport equipment costs and road infrastructure inprovement costs to an optimum? To find a satisfying answer, we require: - A detailed knowledge and analysis of the road infrastructure, - Expertise of capable local partners, - A long-term and thorough planning process. Our general strategy: Integrative and iterative planning process for transport combinations and and bridges. Critical Part: Route Section in MOZ, 200 km Slide 10

11 2 Process 2014: 143 tons 2012: 133 tons Load Distribution on Bridge Superstructures Slide 11

12 2 Process Final Combination MOZ Slide 12

13 2 Process Frame, 30 m x 4.5 m, 29 tons Slide 13

14 2 Process Segments of Frame Slide 14

15 2 Process Load Test of the Frame (in Germany) Slide 15

16 2 Process Front Bolster, 6 m x 3 m, 5 tons Slide 16

17 2 Process Rear Bolster, 6 m x 3 m, 5 tons Slide 17

18 2 Process Packing of Frame (in Germany) Slide 18

19 2 Process Packing of Frame (in Germany) Slide 19

20 2 Process Packing of Frame (in Germany) Slide 20

21 2 Process Packing of Frame (in Germany) Slide 21

22 2 Process Mazoe Bridge Bypass Slide 22

23 2 Process Bypass Design, Bridge B317 Slide 23

24 2 Process Propping Design, Bridge B120 Slide 24

25 2 Process Bending moments and shear forces of beam Structural Analysis of Propping Effects, by FEM Slide 25

26 3 Through ZA & ZW 1. 3x combinations for road transport through South Africa and Zimbabwe. 143t Transformer 1. 1x Type of trailer: 3x 9 Axle-line, 2 file Cometto Trailers (Italian built) 149t Transformer 1. 2x Different type of trailers: 1x 11 Axle-line, 2 file Cometto Trailer (Italian built) 2x 14 Ale-line, 2 file Goldhofer Trailers (German built) 2x 9 Axle-line, 2 file Cometto trailers were required for the transport combination through Mozambique. Slide 26

27 3 Through ZA & ZW Receiving in Port of Richards Bay Slide 27

28 3 Through ZA & ZW 08 Sep - Receive transformers 09 Sep - Weighing of laden transport combinations and permit application 15 Sep - Receive permits for 2x 14 axle-line Goldhofer trailers 16 Sep - Receive permit for 1x 11 axle-line Cometto trailer 17 Sep - Start transport at 09:45 6 working days from permit application to start of transport. Weighing and Permit Application Slide 28

29 3 Through ZA & ZW Combination 1: 11 Axle-line Cometto Slide 29

30 3 Through ZA & ZW Axle-spacing : 1.9m Wheelbase : 19m Trailer Width : 4.275m Trailer Height : 1.075m ± 0.3m Geometric Stability : 14.7 Hydraulic Stability : 15 Av. Load per Axle : 15.66t Total Load : 172.3t GCM : t Combination 1: 11 Axle-line Cometto Slide 30

31 3 Through ZA & ZW Combination 1: Tractor Arrangement Details Slide 31

32 3 s in RZA & ZW Combination 2 & 3: 14 Axle-line Goldhofer Slide 32

33 3 s in RZA & ZW Axle-spacing : 1.5m Wheelbase : 19.5m Trailer Width : 3m Trailer Height : 1.175m ± 0.3m Geometric Stability : 10.7 Hydraulic Stability : Av. Load per Axle : 12.76t Total Load : t GCM : t Combination 2 & 3: 14 Axle-line Goldhofer Slide 33

34 3 Through ZA & ZW Combination 2 & 3: Tractor Arrangement Details Slide 34

35 4 s in MOZ, Assembly Construction Works, Mazoe Bridge Bypass Slide 35

36 4 s in MOZ, Assembly Installation of Bridge Propping Slide 36

37 4 s in MOZ, Assembly Construction of Laydown Area Slide 37

38 4 s in MOZ, Assembly Staging and Reloading at Laydown Area Slide 38

39 4 s in MOZ, Assembly Frame Assembly Slide 39

40 4 s in MOZ, Assembly Frame Assembling Slide 40

41 5 s Through MZ Combination 4: 2x 9 Axle-line Cometto s Slide 41

42 5 s Through MZ Axle-spacing : 1.9m Wheelbase : 15.2m m Trailer Width : 4.275m Trailer Height : 1.075m ± 0.3m Geometric Stability : 8.1 Hydraulic Stability : 8.8 Av. Load per Axle : t Total Load : 240.6t GCM : 349.5t Combination 4: 2x 9 Axle-line Cometto s Slide 42

43 5 s Through MZ Combination 4: 2x 9 Axle-line Cometto s Slide 43

44 5 s Through MZ Combination 4: Tractor Arrangement Details Slide 44

45 5 s Through MZ Combination 4: Tractor Arrangement Details Slide 45

46 6 and Final Position H = 897 m ab. NN The Songo pass - The distance from the check point to the substation is 9.8 km. The gradient varies from 9% to 16.0%. The road width is approximately 7 m at its widest point, and there are numerous very tight bends with cross fall cambers en route of up to 10%. View of the pass from about ¼ of the way up - The gradients and slopes are extreme and it will not be possible to transport the load (143 ton) up this pass using a conventional trailer especially the 2x 9 axle girder bridge required to be used from Zimbabwe border. Hier könnte auch etwas geschrieben werden H = 483 m ab. NN Typical road condition on the pass Slide 46

47 6 and Final Positioning Combination 5: 6 Axle-line, 4 File Scheuerle SPMT Slide 47

48 6 and Final Positioning Axle-spacing : 1.4m Wheelbase : 7m Trailer Width : 5.33m Trailer Height : 1.5m ± 0.35m Geometric Stability : 12.5 Hydraulic Stability : 23.8 Av. Load per Axle : 34.58t Total Load : 207.5t GCM : N. A. Combination 5: 6 Axle-line, 4 File Scheuerle SPMT Slide 48

49 6 and Final Positioning Slide 49

50 6 and Final Positioning Final positioning was executed using jacking and skidding techniques. Equipment used for final positioning: Hydraulic PPU (Power Pack Unit) 4x Hydraulic Climbing Jacks 2x Hydraulic Push-pull Cylinders Skidding Tracks with Teflon Pads 1x Staging Set (Loadspreading Mats, Stools & Jacking Beams) 1x Hydraulic Correction System (for Precise Final Positioning) Azobe Jacking/Packing/Shimming Timbers Final Positioning: Slide 50

51 6 and Final Positioning Final Positioning: Hydraulic Climbing Jacks Slide 51

52 6 and Final Positioning Final Positioning: Hydraulic Climbing Jacks Slide 52

53 6 and Final Positioning old out new in Final Positioning Slide 53

54 7 Challenges and Lessons Learned 1. Looming rainy season. 2. Long distance, over 2 200km. 3. Two notoriously difficult border crossings, namely Beitbridge and Nyamapanda km Gravel bypass had to be negotiated due to a rock fall that damaged the Chivake Bridge in Zimbabwe. Challenges Slide 54

55 7 Challenges and Lessons Learned Challenges Slide 55

56 7 Challenges and Lessons Learned 1. Looming rainy season. 2. Long distance, over 2 200km. 3. Three different transport combinations needed, in order to adopt to the different conditions on the route. 4. Two notoriously difficult border crossings, namely Beitbridge and Nyamapanda km Gravel bypass had to be negotiated due to a rock fall that damaged the Chivake Bridge in Zimbabwe. 6. Tough conditions for heavy transport: Extreme heat, Poor roads (thin asphalt wearing course and potholes), Lack of mechanics and spare parts, High risk of theft during overnight stops, Public interference during operations, etc. Challenges Slide 56

57 7 Challenges and Lessons Learned Challenges Slide 57

58 7 Challenges and Lessons Learned 1. Times recorded from past experience allowed for an accurate schedule. 2. Communication plan. 3. There is no plastic substitute for hard cash in Africa. 4. Selecting a lead driver who can cope with typical cross-border issues such as cash/cash passports/credit cards, bookkeeping of expenditure, communicating with agents/runners and government officials, reporting back to office etc. 5. Selecting operational personal who is team players and enjoys cross-border work. 6. Keeping moral of the operational personnel high. 7. Roaming and local simcards as well as access to instant messaging and Malaria prevention and emergency treatment. 9. Engaging authorities and community involvement!!! Lessons Learned Slide 58

59 7 Challenges and Lessons Learned Play football with the police and Slide 59

60 7 Challenges and Lessons Learned Involve the local communities! Slide 60