Completing the 1500 MW Combined Cycle Gas Turbine (CCGT) power project in Uzbekistan represents a significant achievement in project logistics and heavy lift management. Managed by Globalink, the project necessitated the transportation and delivery of over 100 out-of-gauge/overweight (OOG/OW) items, including gas turbines (GTs), gas turbine generators (GTGs), a stator, transformers, Heat Recovery Steam Generator (HRSG) modules, among others. These components varied in weight from 100 metric tons to 517 metric tons. The logistical execution spanned 13 months, concluding with successfully delivering all critical components to the remote project site in Uzbekistan.
Project Overview
The 1500 MW CCGT power project in Uzbekistan required importing significant machinery and components from multiple countries, including Japan, China, the UAE, Germany, the Netherlands, and the USA. All items were consolidated in Istanbul, from where they were transported to Uzbekistan through a meticulously planned route that included sea, river, and land segments.
Logistical Execution
Consolidation and Chartering: All cargoes were managed end-to-end from all worldwide origins to the project site in Uzbekistan via a specially prepared consolidation hub in Istanbul. All project items were consolidated in Istanbul, following their procurement from various countries. This process involved chartering vessels from points of loading (POLs) to the trans-shipment port in Turkey.
Maritime and River Navigation: Suitable vessels were chartered to navigate from Istanbul to the Caspian Sea port in Kazakhstan. This journey required vessels capable of handling the seas and river canals. There was a contractual condition: vessels were not older than five years old, which posed an additional challenge to find multiple vessels with permission to navigate the Volga-Don channel.
Land Carriage: The most challenging phase involved transporting goods over 2,500 kilometres from the Port of Entry (POE) in the Caspian Sea, Kazakhstan, to the remote project site in Uzbekistan. The terrain presented significant logistical challenges.
Final Mile Delivery: The trans-shipment of five super out-of-gauge (SOOG) units from a girder bridge to the job site involved using an 1100-metric-ton capacity gantry crane and modular trailers.
Preparatory Works
Globalink initiated preparatory works in September 2021, ahead of the project’s major milestones. These included significant civil works to improve over 200 kilometres of roads and the construction of new by-passes in Kazakhstan and Uzbekistan. Additionally, more than 120 bridges were inspected, with 24 strengthened and two new bridges constructed to facilitate the transportation of heavy loads. The civil work involved over 200 men and took nearly a year to complete.
Engagement and Planning
The engagement with the project owner and the Engineering, Procurement, and Construction (EPC) contractor began in 2020, with actual preparations, studies, and route surveys starting at the beginning of that year.
Challenges and Solutions
The project faced several significant challenges:
The Russian-Ukrainian war erupted while vessels carrying cargo were en route to the Black Sea. The maritime and insurance industries declared much of the Black Sea a war zone, presenting a significant challenge. A backup plan involving engineers, handling, and insurance specialists had to be devised, and new routes were planned in record time.
An unforeseen change in the trans-shipment port necessitated a rapid adjustment in logistical plans.
Coordination issues with insurers regarding using the Black Sea route led to developing an alternative route to ensure delivery before the closure of navigation for the winter season in the Volga-Don River channel.
Harsh winter conditions presented additional obstacles, with temperatures dropping below minus 30 degrees centigrade.
There is a shortage of certified heavy-lift equipment capable of handling Super Out Of Gauge (SOOG) items. Globalink had to implement a comprehensive equipment procurement plan to ensure we had the right equipment available at the right time. In addition to acquiring equipment, maintenance workshops were set up along the route to address unforeseen challenges.
Obtaining road permissions and removing obstacles posed significant challenges, as the Super Out Of Gauge (SOOG) items needed to traverse cities, towns, and villages with overhead gas pipelines, electrical lines, and city gates. In several areas along the route, roads had to be blocked for hours, and sometimes days, to ensure the safe passage of cargo. Globalink’s government and public relationship managers worked tirelessly to obtain the necessary permits and permissions and closely collaborated with communities to ensure their understanding and cooperation.
Conclusion
Globalink’s successful execution of the 1500 MW CCGT power project in Uzbekistan demonstrates remarkable logistics and project management expertise under challenging conditions. The project highlights Globalink’s capacity to manage complex international logistics operations and contribute significantly to Uzbekistan’s energy infrastructure development.
