PPG Saudi Arabia Move Monster Evaporator Modules

PPG Saudi Arabia Move Monster Evaporator Modules

PPG Member for Saudi Arabia, Almajdouie Heavy Lift Transport and Engineering (MHL), fully justifies its eminent name in the logistics industry in the region. Totally, Almajdouie Group operates 22 companies under the business sectors of logistics, automotives, manufacturing, real estate and investment. Under logistics itself it has 11 companies. Two of its companies are specialized in transportation and erection of super heavy and oversize loads/cargoes. One is Almajdouie heavy Lift Transport and engineering (MHL) one of the first ISO-9001 certified Heavylift Companies with its head office in Dammam and another is Almajdouie PSC Heavylift (MPSC) a JV company between Almajdouie Group of Saudi Arabia and Fagioli Group of Italy with its head office in Bahrain. Almajdouie Heavy Lift Transport and Engineering (MHL) secured a mega contract for transportation of Super heavy & Oversize Evaporators module from Bilfal Heavy Ind. (Ex-Works Yard ) to Marafiq IWPP Project Site Jubail. The Marafiq Desalination plant will be one of the largest water desalination processing plants in the world. The execution of Project is ongoing where Almajdouie Heavy Lift (MHL) and Almajdouie PSC Heavylift (MPSC) are jointly utilizing their expertise in moving such heaviest units by Self Propelled Module Trailers (SPMT’s) trailers.

a) Project Information – How huge project is Marafiq, what is the importance (role) of Evaporators to this project to make successful & safe delivery.

“The power plant will be comprised of 4 blocks and will be based on Combined Cycle generation Gas Turbines where extraction steam from the turbines supplies process steam to the desalination plant which itself will comprise 27 units that will use Multiple Effect Distillation technology (MED). This project is of national importance and is set for achieving its completion in 2010. This will add 2,750 MW of power and 800,000 cubic meters per day of desalinated water to Jubail Industrial City and the Eastern Province of Saudi Arabia”. In total we handled 18 units and out of these 9 units were locally manufactured by Bilfal of Saudi Arabia and remaining unit were manufactured in Korea and UAE. It is worth to mentioned that we were also engaged in loadout of some unit in UAE

b) Massive Machines – It’s about SPMT,s, how many axle lines, how it build, it features, capabilities.

Huge evaporators are very important for the project. Each evaporator is of 1810 Tons in weight, 65 Meters length, 22 Meters Width & 13 Meters Height. We used 84 axles of latest generation Self Propelled Modular Trailers (SPMT). The General Manager Mr. Mark Brereton Stuart set this in a 42 axle side by side configuration. This type of equipment was the only way to handle such large and heavy loads, along a combination of public and private roads.

c) Heavylift Taskforce – About team work, specialized expertise,

MPSC has a team of specially trained operators for SPMT operation, supported by a highly experienced operations team headed by Ely Coyoca, International Operations Manager, who is in the field for the last 25 years who have been involved in some of the largest moves in the region and the wider World. This team worked seamlessly with the MHL team in Dammam to jointly provide all the services and expertise to carry out the transportations, particularly for the Bilfal units.

d) Hurdles/Obstacles – What barriers we faced to move it, Route survey, compactions, trees removal, backfilling, culvert support, Street Lamp post and Traffic signals.

The major obstacle for the Bilfal units, was that the initial conclusion was that they could not be moved by road. MPSC/MHL were called in by Bilfal to verify on the situation as the responsible wanted to make sure the massive loads reach in time safely. MPSC/MHL carry eminet know-how in such movements and ultimately concluded saying that “it is a highly complex move but it is possible”. Since the project were in the eastern region MHL engineering unit extended their support by conducting thorough studies and by preparing and analyzing stuff right from bidding stage till the final approval of relevant Technical documents. In many areas route modifications were needed, including residential areas from the approach roads to the site. Getting permission for this involved around 3 months of engineering work, including studies and detailed simulations. This was presented to the Royal Commission, who were able to give all the required permissions. Key facts about the route modifications are:

· Hard trimming of more than 400 trees in a residential area that had to be maintained throughout the project duration

· Removal and replacement of 108 light posts, and there replacement within strict time windows dictated by the security police.

· Crossing of TS-1 major highway, twice. The second crossing was at a very rarely used crossing place. We had to survey and simulate this crossing meter by meter in order to verify that the SPMT’s could pass safely across.

· Removal and replacement within the same day of three sets of signal lights for each move.

· Propping of three bridges for the duration of the project.

e) Escort arrangements, Traffic Police, Special Permissions, Industrial Security Services – Idea is how many securities are require to move the cargo?

Each move involved several agencies. The Royal Commission had a vital role in firstly studying and working with us to find the solutions to move by road, this involved very special permissions to carry to the work in the above list, and in general to encroach in residential areas with a cargo of this size. It was essential to obtained written permission from Saudi Electric Company, Saudi Telecom Co. and Marafiq existing underground facilities. At the same time the support of local Police and security greatly lend a hand in regards of the safe crossing of the cargo through the very busy TS-1 highway, and in general providing safety and security where needed. We also used several subcontractors for work to prepare the route and handle the street fixtures stated above.

f) How many days taken to reach the destination, how long the distance?

Operation team along with Mr. Ely and Mr. Asif Batt said on average each delivery would take two days to travel the 9 km to site, which is exactly as planned. However, after several moves arrival at the site was also completed in one day, which is a testament to the organization of all the relevant agencies, the quality of the equipment, and the skill of the operators.

g) What contingencies/experience we have for lifting/moving over-dimensional loads?

MPSC is now at the forefront of the movement of super heavy loads throughout the region. We have been involved in moves of up to 5,000 tons and moved more than 30 items over 1,000 tons in the past two years, in countries all over the Middle East, but particularly KSA and UAE. We have also carried out the Tower lift of several vessels up to 1,100 tons during the same period. We are now one of the leaders in the Middle East in our industry, and we have expanded our equipment fleet and profile in the region, leading to the award of key projects that will allow the companies further growth in the coming years.