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deugro recognizes that the power industry has evolved significantly over the last decade, with a drive to develop technologies for lower carbon emissions and power sourced from renewable energy. We have collaborated with all the major power generation manufacturers to design and develop innovative logistics and supply chain solutions.
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As part of a 1,760-megawatt combined-cycle gas turbine power plant project in Indonesia, on behalf of GE, deugro moved approximately 80,000 freight tons of cargo, including two 435-metric-ton gas turbine 9HA.02 units, two 460-metric-ton generator stators (GEN STATs) units, and 52 heat recovery steam generators (HRSGs) with a length of 30 meters and weights of up to 240 metric tons.
- Ground-leveling works at the airport in Kuala Namu in order to receive the heavy cargo
- Tight time schedule during the holiday season
- Loading in heavy weather conditions
A major customer in Indonesia awarded deugro (Singapore) Pte Ltd an air freight charter from Europe to Indonesia. However, this air freight charter, which at first glance seemed like another daily operation for deugro, actually involved a series of challenges and special transport pre-arrangements. The client made clear from the very beginning that the over 95 tons of cargo had to arrive at the construction site in northern Sumatra, Indonesia in early January, just days after the transformers were expected to be released from the factory in Finland. The shipment consisted of two transformers, weighing 36 tons each, plus accessories out of Vaasa, Finland and two five-ton rectifiers coming out of Baden, Switzerland.
deugro was only able to secure the shipment by working as a team with our air freight office in Singapore and our colleagues in Finland, who worked on the overland freight. After evaluating various options, we proposed to the client that we would consolidate both shipments in Helsinki and arrange for a combined air charter to Kuala Namu, Indonesia. Because of the transformer’s dimensions (4.9m x 2.5m x 3.3 meters each), we needed to use an Antonov AN-124-100 aircraft. The remaining capacity of this open-plan aircraft would fit the five-ton rectifiers from Switzerland perfectly. During planning and execution, this solution proved to be the most cost-effective for our client.
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- Restrictions caused by busy ferry traffic at Upper Bay and East River
- Tide flow restrictions in the East River, affecting transit times and scheduling
- Limited lifting options and positions during offloading
- Placement of load spreading devices on the barges with a tolerance of only 10 millimeters
- High winds, which played a significant role due to the RMG cranes’ unfavorable center of gravity
The project was the first large-scale transportation project that Künz GmbH (Kuenz) had awarded to deugro. It involved the movement of four rail mounted gantry (RMG) cranes. As such, this first-time collaboration experience would set the course for any further working relationship between deugro and Kuenz.
The fact that all RMG cranes were fully assembled during the whole execution enabled the client to save valuable time on assembly and disassembly and to save storage costs in New York. In terms of the transportation, this approach caused some challenges for all project team members and resulted in extensive engineering work.
Mining and Metals
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What makes a project unique? Is it the cargo weight and size, the remote locations involving tight schedules and temporary jetties, or the strict quality, health, safety and environmental and security (QHSES) requirements? What about sophisticated project engineering and the need for an extraordinary number of specialists to coordinate? This project has it all!
deugro was awarded this project from a major engineering, procurement and construction (EPC) company that specializes in manufacturing industrial cranes. The custom-built crane trolley transported by deugro will be utilized in the aluminum industry.
deugro was involved in the project from the very early stages. The first investigations regarding the routing of the last transport leg to the site started two years in advance of the actual project execution. At this time, the design of the crane trolley was still in progress.
Several updates of the trolley design—affecting dimensions and transport weight—required flexible planning and amendment of suitable transport routing as well as of trailer configuration during the production process.
New Caledonia (Nouvelle-Calédonie), a French overseas collectivity, is located about 1,200 kilometers east of Australia. We supported the logistics for a world-class industrial complex, which contributes to making New Caledonia one of the world’s largest nickel producers.
The smelter has an annual production capacity of 60,000 tons, and is located near Koné, the county town of New Caledonia’s North Province. Shipments for the project ran between 2008 and 2012, with an investment worth approximately 4.5 billion USD.
deugro moved Approximately 550,000 FRT during this Project
During this project we shipped material and equipment for the mine, the pyrometallurgical nickel foundry, the power plant and other complementary infrastructure, including the deepwater port at Vavouto, the 11-kilometre land-based conveyor and a seawater desalination plant.
Although there was quite some cargo size and volume on one vessel, the main challenge was timing, as the vessel was loaded in China during the Chinese New Year (CNY) holiday period.
To ensure that the cargo was swiftly loaded without delay due to CNY, everything was loaded in advance onto barges and all cargo was loaded from the barge to the MV while anchored. This helped to avoid the labor shortage and port shutdown during CNY.
In addition, we had to comply with stringent Marine Warranty Surveyor (MWS) requirements, including detailed engineering calculations and drawings to provide for the barges and ocean vessels.
Timely delivery of resupply items, project cargo or standard equipment shipments is critically important to energy operations. deugro understands the demands and risks in this business environment and operates with tailored logistics solutions.
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deugro moved four LNG tanks with a unit weight of 225.4 metric tons and dimensions of 48.93 x 5.8 x 6 meters from the manufacturer’s yard in Decin, Czech Republic via the Port of Hamburg, Germany to the construction site in the Caribbean Sea.
To supply the Donghae-2 gas field, Subsea 7 (Singapore) Pte Ltd awarded deugro the contract to transport three laden reels and accessories to Loyang, Singapore.
- Tight time frame for ocean voyage from Europe to Singapore
- Strict sequence loading order for transpooling operations directly from barges
- Complex pre-setting/dismantling of under roller bases and stand-by operations of barges
- Managing of flexible barge delivery schedules in Singapore
- Stringently sequenced delivery requirements
- Challenging local import requirements
- Restrictive project schedule
- Requirement for dynamic and differing delivery solutions due to delayed ground works
The deugro team managed a rig transportation project by road, including accessories, that required an overall flexible, fast, secure and safe handling.
The rig had to be delivered in sequence, starting with the camp facilities for the rig crew and main rig substructure, followed by components such as draw works, mud pumps, and tanks, before ending with the drill pipes.
In addition to the importance of the sequencing, the transit times needed to be factored to ensure timely collection and uninterrupted arrival of these components at the site in order to support the construction sequence as well as prevent site congestion and waiting time.
deugro Perth was invited by a major customer in Australia to bid on the project of a combined transportation package. This included one 220-metric-ton equipment room and two 650-metric ton pre-assembled gas compression modules and accessories. Transportation was from Batam, Indonesia to the northwest coast of Western Australia.
The deugro Difference
A key driver in deugro being awarded the contract was our proposal to utilize a self-propelled barge or modular carrier. This type of vessel has a low draft, allowing it to berth at the fabricator’s site jetty in Sekupang, Batam, Indonesia (which has a maximum depth of 5 meters at low tide).
To accommodate this jetty depth limitation, deugro Perth sourced the Dongbang Giant 5 from the specialized South Korean vessel operator Dongbang.
With an empty draft of 3.20 meters, the Dongbang Giant 5 could easily berth at the Sekupang jetty where, even after loading the two 650-metric-ton modules with a loaded draft of approximately 4 meters, there would still be sufficient and safe under-keel clearance from the seabed.
- Shipping through the Northern Sea Route
- Cargo weight of 860 MT, with a size of 39 x 18 x 35 m
- Over a period of four years, deugro transported 850,000 FRT in total from all over the world to Russia, China, Indonesia, the Philippines and Belgium.
- More than 17,500 single shipments, shipped by air, ocean and road, to various destinations around the world, including Sabetta in the Arctic North
- Eight sea voyages shipping a total of 98,350 cbm
- Additionally deugro shipped another 227,845 cmb, utilizing 24 sea voyages for other
After several years of intensive planning, engineering and execution, the various teams of deugro have managed one of the largest and most complex liquefied natural gas (LNG) projects ever executed.
More than 17,500 single shipments were shipped by all possible transportation modes, including air and ocean full charters, to various destinations around the world such as Sabetta in the Arctic North. A specialized heavy lift vessel was used together with ice breakers to ensure a safe passage. Along with experience gained dealing with local authorities to receive special permission, we have gained competence and know-how that not every project freight forwarder can offer.
An oil major has awarded Technip the EPC contract for the first tension leg platform phase of the project in Malaysia. Technip and
Malaysia Marine & Heavy Engineering Sdn Bhd (MMHE) formed a joint venture under the name of TMJV to execute the Malikai Project.
Construction of the platform took place at MMHE’s yard in Pasir Gudang, a city in the state of Johor. Once finalized, the platform was
towed to its final destination in the Malikai oil field, about 100 kilometers off of Sabah, Malaysia.
The platform is working in water about 500 meters deep and is moored securely in place by specially coated tendons.
This case study describes the transportation of the abovementioned tendons from the special coating facility in New Iberia, Louisiana, USA to Pasir Gudang, Malaysia.
- HSE Requirements—beyond the strict standard
- Technical Requirements—Transport engineering
- Vast Distance—Teams in multiple time zones
- Critical Move—Tug and barge alongside vessel offshore
- Zero Incidents—No harm to persons and cargo
Parque das Conchas (BC-10) is an energy-producing, deepwater project located in the Campos Basin, off the coast of Brazil. deugro has been awarded the transportation of accommodation modules from UAE to the
BC-10 field. The modules are helping to operate a Rigless Intervention System that serves to facilitate the replacement of worn or failed caisson-based artificial lift systems deployed at the project site.
Whereas the actual transportation of the accommodation modules was rather straight forward and nothing out of the ordinary, the challenge was found by meeting SBM Offshore’s and Shell’s stringent requirements in regard to health, safety and environment (HSE) and engineering.
From the beginning, the petrochemical industry has always been a key sector of success for deugro. deugro has always been and still is perceived as a market leader in innovative project logistics, mainly due to the complexity of the projects we successfully execute.
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For the EGAT Project, deugro Korea was contracted by its client Hyundai Engineering to move 120,000 freight tons (14,000 metric tons) of petrochemical cargo to a project site in Police, Poland. The project encompassed a considerable amount of oversized and heavy lift (OSHL) units, including an 889-metric-ton propylene-propane splitter, with impressive dimensions of 96 x 9.35 x 8.90 meters; five 613.98-metric-ton and over 72-meter-long propylene storage bullets; and a 44-meter-long, 596-metric-ton reactor.
In close and precise cooperation between the offices in Japan, Russia and Korea, deugro transported 35,541 freight tons of cargo simultaneously on two fully chartered heavy lift vessels for an ethylene and polypropylene plant. The cargo was moved from the cargo marshalling yard in Masan, South Korea via Tiksi in the Arctic Ocean to Ust-Kut, Russia. The heavy lift vessels, which have the Finnish/Swedish ice class 1A, were accompanied by the nuclear ice breaker Yamal for the Northern Sea Route (NSR) passage to ensure a safe delivery of the valuable cargo at the Port of Tiksi. The total distance from Masan to Tiksi and the subsequent barge transport across the Lena River to Ust-Kut was over 6,450 nautical miles.
In close collaboration, the deugro Hanau and deugro Moscow teams executed the NKNK03 Olefin Project on behalf of Linde Engineering. After intensive planning and engineering, deugro moved nearly 90,000 freight tons of heavy lift and oversized cargo from various origins in the Far East and Europe to a remote job site in Nizhnekamsk, Republic of Tatarstan, Russia.
For an expansion project of a chemical refinery, deugro moved a C6 column, lights tower, and primary fractionator by vessel and barges from Ulsan, South Korea to Houston, Texas, USA.
- Because the C6 column hung over the barge’s stern by approximately 20 m, the trunnions to be lashed were above water.
- Cargo dimensions of up to 91.9 m in length and unit weights of over 485 MT
- Strict QHSES regulations in times of COVID-19
In direct cooperation, deugro Hanau and deugro Moscow executed deliveries of equipment for two major engineering, procurement and construction companies (EPCs) from Germany and France during the 2016, 2017 and 2018 shipping periods. The equipment was shipped to the biggest integrated complex for the production of polymers in Russia, located in Tobolsk.
Tobolsk is a town in Tyumen Oblast, Russia, located at the confluence of the Tobol and Irtysh Rivers, one of the most remote areas in Russia. It is a large industrial center in the field of gas chemistry, located in Western Siberia. The temperatures in winter fall to as low as minus 40 degrees Celsius and, when combined with icy winds, make working conditions extreme for all involved. In summer, the soil turns wet, which creates obstacles for any work on the ground.
Due to the intense weather conditions, deliveries are very difficult to perform. Heavy plant equipment can only be delivered via the Tobolsk waterways within a short navigational period of approximately 45 days between July and August. A delay of just a few days could result in the delivery being postponed to the next summer. To counteract the weather conditions, deliveries have to be meticulously planned, considering the construction schedule, delivery sequences, cargo readiness, opening of the navigational periods and, of course, the mobilization of the equipment such as barges and tugs.
Complete Set-up of a Fertilizer Plant in a remote Area of Tatarstan
Russia. A territory almost twice the size of the United States, or four times as big as the European Union.
Logistical Concept for a Fertilizer Plant
Scope of Work
The Liwa Plastics Industries Complex (LPIC) Project is a major capital investment project in Oman. The total investment value exceeds USD 6 billion, with financing provided by multiple international Export Credit Agencies (ECAs) from Europe and Asia. Owned by ORPIC (Oman Refineries & Petrochemical Company LLC), it shall increase Oman’s production of petrochemicals and increase fuel production, generating 450 direct jobs and over 1,200 indirect jobs in Oman to have a positive effect on the Omani economy.
Pulp and Paper
deugro (Finland) Oy executed one of the most challenging projects that the company has ever completed in Sweden, delivering 30,000 freight tons of project cargo, including heavy lifts of up to 405 metric tons, to SCA Östrand’s pulp mill site in northern Sweden.
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- 30,000 FRT
- 294,000 MT
- 30,000 CBM
- Max. heavy lift:
- 405 MT
- Total Project Investment:
- SEK 7.8 billion (approx. USD 962.2 million)
deugro’s scope within this project was delivery from Shanghai, China to
the job site in Östrand, Sweden. The SCA Helios Project in Östrand was an
excellent example of teamwork. deugro Finland had the lead on the project
and control tower, with close support from deugro (Sweden) AB for local
operations on-site. With assistance from dteq Transport Engineering
Solutions, a company of the deugro group, for site surveys and lifting
arrangements, and deugro (China) Co., Ltd. for local operations and
coordination, the execution of the project was an astounding success.
deugro’s Breakbulk & Heavy Lift Chartering Division assisted the project
team with their expertise, and all parts were shipped by chartered heavy
lift vessels. Even though the majority of the cargo was not stackable due
to the dimensions, deugro aimed to optimize costs for the ocean
transportation by shipping the cargo in three separate shipments.