Heavy-Lift Installation Completed For India’s Dahej Liquid Cargo Berth Expansion
Our take
The completion of heavy-lift installation for the Dahej Liquid Cargo Berth expansion in India represents a significant advancement in logistical infrastructure, particularly crucial for a nation increasingly reliant on imported liquified natural gas (LNG) and other bulk liquids. The JSI Alliance’s successful execution underscores the growing sophistication of engineering and construction capabilities within the region. This development aligns with broader trends of maritime infrastructure investment globally, driven by escalating trade volumes and the need for optimized port operations. It’s worth noting the recent unveiling of the University of Rhode Island’s Ocean Robotics Laboratory URI Unveils Ocean Robotics Laboratory With An Underwater Ribbon Cutting Ceremony, demonstrating a parallel focus on leveraging advanced technologies to improve maritime operations and data collection – a vital component in understanding the environmental impact of expanded shipping activities. Furthermore, the ongoing efforts to strengthen cooperation against piracy and sea robbery between the ReCAAP ISC and the Philippine Coast Guard ReCAAP ISC And Philippine Coast Guard Strengthen Cooperation Against Piracy And Sea Robbery highlight the importance of maritime security in facilitating these expansions.
The expansion of Dahej, one of India’s primary LNG import terminals, directly addresses the nation’s rising energy demands and its transition towards cleaner fuels. LNG, while not a zero-emission solution, offers a lower-carbon alternative to coal and oil, and the increased import capacity facilitated by this infrastructure development is therefore a measurable step towards India's climate goals. The need for such expansions is validated by projections of continued economic growth and urbanization, both of which contribute to increased energy consumption. The success of this heavy-lift operation speaks to the meticulous planning and calibrated execution required in such projects, demanding precise engineering and a deep understanding of maritime physics. The integrated data ecosystem required to manage such a complex undertaking highlights the shift towards digitally-driven port management, a trend World Data Ocean tracks closely through its own integrated data solutions.
Beyond the immediate logistical benefits, the Dahej expansion serves as an indicator of India’s commitment to becoming a global maritime hub. Investment in port infrastructure, coupled with advancements in oceanographic research, like those showcased in WhaleScope Looking for feedback on WhaleScope: combining cetacean observations with oceanographic data, contribute to a more robust and sustainable maritime environment. The empirical data gathered from these developments – regarding cargo throughput, environmental impacts, and operational efficiencies – will be invaluable for future port expansions and for optimizing existing infrastructure. Longitudinal studies of the area surrounding Dahej, tracking water quality, marine life, and sediment deposition, will be critical in assessing the long-term ecological consequences of increased shipping activity.
Looking ahead, the real-time monitoring of operational performance at Dahej – leveraging sensors, data analytics, and potentially even autonomous systems – will be crucial for maximizing efficiency and minimizing environmental impact. The integration of climate indicators into port management strategies, such as sea-level rise projections and extreme weather forecasts, will become increasingly vital for ensuring the long-term resilience of this critical infrastructure. A key question is whether similar expansions across India’s coastline will be accompanied by sufficient investment in comprehensive ocean monitoring programs, ensuring that economic growth doesn’t come at the expense of marine ecosystem health and that data-driven decision-making remains at the core of these developments.
The JSI Alliance is proud to have successfully completed a major project in India for client Afcons Infrastructure Limited. Afcons was contracted to construct a new liquid cargo berth for Gujarat Chemical Port Ltd. (GCPL).
The JSI Alliance was contracted for the execution of critical heavy lifting operations for the development.
Complex and challenging environment
The project scope was complex, requiring extensive heavy-lift capabilities for the installation of eight jackets and fifteen berthing dolphins weighing between 500 and 600 t, at an outreach of 10 m.
Work took place in an extremely challenging environment. The location is subject to a 10 m tidal rise, resulting in currents of up to 5 kn. To compound matters, the seabed is comprised of sand, rendering many conventional mooring solutions unsuitable.
A further factor was that the location was operational at the time of installation – all activities had to be undertaken without interrupting two live, frequently used berths. This resulted in severe space restrictions, leading to further mooring complexities.
Tailored solution
Calling upon the expertise of a wide range of internal disciplines, the JSI Alliance developed a solution fully aligned with the requirements of the project. The Alliance mobilised the heavy-lift vessel (HLV) Jumbo Javelin.
The heavy-lift vessel enabled safe and efficient execution by providing a single platform for the transport and installation of prefabricated structures.
Mobilization commenced on 3 November and took place over a period of fifteen days. During this time, the JSI Alliance equipped the Jumbo Javelin with a flyjib that enabled her to perform the necessary lifting scope.
Heavy-duty mooring solution
The vessel was also outfitted with an eight-point mooring spread tailored to the seabed and tidal conditions of the project location.
Creating sufficient holding force in such a restricted area required utilization of 17 t anchors and 64 and 52 mm mooring lines with a Minimum Breaking Load of approximately 300 t per line.
The Jumbo Javelin was equipped with custom-made 250 t winches. It was determined that eight, in place of four, winches should be installed to provide a back-up wire, ensuring safety and redundancy.
Significant forces
To absorb the significant forces involved, it was necessary to strengthen the vessel with additional steel. Installation of the spread called upon anchor handling support vessels with sufficient capacity for the heavy-duty components employed.
The vessels were required to perform the mooring installation during a four-hour tidal window, when the current was at its lowest speed.
Once connected to the mooring spread, the Jumbo Javelin remained in position for several days at a time, thereby avoiding interruption to berthing operations.
Efficient demobilisation and discharge
The first loadout commenced on 3 December at Dighi Port. In total, the Jumbo Javelin made six voyages. The last item was installed on 14 March, before the vessel departed for Dighi Port for demobilisation, which took place over just seven and a half days.
Following this, the Jumbo Javelin sailed on to Singapore to return equipment to suppliers. Discharge was completed in two days and, on 6 April, the project was fully completed.
“The successful completion of this project is a testament to the teamwork, expertise and commitment of everyone involved. By drawing on the shared resources and capabilities of the JSI Alliance, we were able to develop a solution tailored to the complex site conditions and deliver the project safely and efficiently. ”-Robert de Waard, Project Manager at the JSI Alliance
He said, “I would like to thank all those involved for their efforts, including my colleagues from all departments, as well as our suppliers, including Franklin Offshore International and Moor east Asia, for their support with the anchor handling equipment. I would also like to extend my appreciation to Sea contractors, who supported Afcons with the provision of two vessels for anchor handling and contributed to the successful execution of the project.”
“Of course, we are also extremely grateful to Afcons for placing its trust in the JSI Alliance. Our two teams have worked together closely throughout the project, with Afcons being involved, and providing expert guidance, in all aspects. We have enjoyed the collaboration and look forward to working together again in the future.”
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