Executive Summary - DPR
Executive Summary - DPR
Executive Summary - DPR
Executive Summary
Vadhavan Port
Executive Summary
1. Background
India has an approximately 7,500 km long peninsular coastline and is located close to major shipping routes
linking East Asia, Europe and the Middle East. Presently, there are 12 Major Ports and 200 Non-Major ports
in India. The 12 major ports carry about 54% of the total port traffic of the country. The share of non-major
ports in cargo traffic has increased from 7% in 1990 to the current levels of 46%.
Maharashtra with a coastline of 720 km stretching
along the Arabian sea has two major ports. Mumbai
and JNPA which cater to the hinterland of
Maharashtra, North Karnataka, Telangana, Gujarat
and secondary hinterland of NCR, Punjab,
Rajasthan and Uttar Pradesh. JNPA was developed
as a satellite port of Mumbai port and has coped well
in becoming the largest container port of the country.
The development of Phase 2 of 4th container terminal
is underway and after its full development there is
little space for further expansion. Apart from that due
to the presence of bed rock at or very close the
existing bed level, JNPA cannot be deepened further
economically to handle the future generation of
mega container ships drawing draft of 16 m or more.
There is a need for a deep draft port that will cater to
the spill over traffic from JNPA port once its expanded capacity of 10.4 million TEUs is fully utilized.
As the projected demand for containers to go up, it is necessary to locate a new mega port site which can
cater to increased requirement of capacity and could be developed to handle the future deep draft ships.
Considering the above it has been decided to develop Vadhavan port as a satellite port for JNPA and for
this purpose the present report has been prepared to assess its technical suitability and cost economics.
Port
Site Site Specific Operations & Port
Traffic Study
Appreciation Surveys Functional Masterplan
Requirements
Mathematical
Land Financial Project Implementati
Model
Acquisition Viability Benefits on Schedule
Studies
2. Site Appreciation
Vadhavan Port is planned to be developed by Jawaharlal Nehru Port Authority (JNPA) and Maharashtra
Maritime Board (MMB) to handle the additional traffic. Vadhavan is a Greenfield site located along the west
coast of India, at the North tip of Maharashtra which is about 150 km north of JN Port. The port limits is as
shown in below figure.
A natural water depth of around 20.0 m below CD is available at 10 km from Vadhavan point and 15 m
contour is available at a distance of 6 km which will allow safe voyage and mooring for the new generation
vessels. As deep-water depth is available from 6 to 10 km, new generation vessels calling for deep draft
can be planned with minimal cost on dredging.
2.1. Metrological & Oceanographic Information
The metrological data has been extracted from previous/ historical studies for the project as well as from
the West Coast of India Pilot (WCIP) climatological table applicable for the area and the project site. The
average annual rainfall is 1163 mm with the total number of rainy days of 51 per year. The mean daily
maximum temperature is 31°C and with 34°C the highest occurring in April. Mean daily minimum
temperature is 24°C and with 18°C the lowest occurring in December.
Relative humidity is generally high and rises to about 85% during the monsoons in the month of August.
Visibility is good throughout the year as the region has zero fog days. However, during rains and squalls,
the visibility deteriorates. In general, the cyclones in the Arabian Sea from 1877 to 2012 that only 10 storms
endangering the Mumbai coast have occurred in the above said period i.e., at a frequency of once in 12
years.
Based on the ship observed offshore wind data from India Meteorological Department (IMD) wind speed is
less than 10 m/s for 88% of the time. A maximum wind speed of 22.7 m/s has been reported, under normal
conditions.
The ship observed wave data were collected from the India Meteorological Department (IMD). The waves
are less than 1 m, 2 m and 3 m in height for 77%, 94% and 98% of the time respectively. Based on UKMO
data, Wave heights were found to be less than 3 m for about 93% of the time.
Tide levels in the Vadhavan Port region as per the NHO Chart No. 210 Umargam to Satpati are summarised
below.
Table 1 Tide levels in Vadhavan (NHO Chart No. 210)
Description Tide Levels (m CD)
Mean High Water Spring +4.7
Mean High Water Neap +3.7
Mean Sea Level +2.8
Mean Low Water Neap +2.0
Mean Low Water Level Spring +1.2
The currents in the region are mainly of monsoon origin and sets in south-westerly and north-easterly
direction with a strength of about 2.5 knots (1.25 m/s). Vadhavan Port site is in Zone III of Indian Map of
Seismic zones (IS-1893 Part-1 2002) which is a moderate risk seismic intensity zone. However, considering
the Palghar earthquake sequence, whose largest magnitude was 4.5 till now and considering the project of
national importance and vital installations, it was advised by CSIR - National Geophysical Research Institute
to consider the seismic zone IV in design parameters.
Wave climate in the area is dominated during SW monsoon period (June to September). The maximum
significant wave height observed in the entire period is 1.19 m and the minimum of 0.14 m. Currents are
significant in the project area.
The current speeds in general are observed within the range of 0.00 knots to 2.60 knots with the dominant
speeds observed in the range of 0.20 knots to 1.60 knots.
Site specific tide measurements were carried out for the proposed development. The observed tidal range
was about 3.5 m during spring tide and 1.7 m during neap tide.
Side Scan Sonar Survey classifies the seabed into following categories such as Soft silty clay, Highly
weathered rock /sand /gravel and Basalt rock. The seafloor appeared to be clear of any debris other objects
which are likely to be hazardous or otherwise obstruct anchoring and operations in the port.
4. Traffic Study
The summary of the traffic projection for the proposed Vadhavan port is as below:
Gate capacity analysis is essential feature to get essence of seamless inward and outward traffic movement
including major share of trucks having containers. The number of exit lanes required for Phase 1 is 6 lanes
and in Master plan 26 lanes.
Based on the Level of Services (LOS) grade as per the HCM, it is proposed to provide the approach trestle
with 4 lanes each way for the approach trestle to cater the truck movements in and out of the Vadhavan
port.
For the initial stage development, the port would require 6 tugs (4 operational + 2 standby) with a capacity
of 65 T and 100 T bollard pull, 1 pilot cum survey launches and 2 mooring launches. Berth of 200 m is
proposed for berthing of port crafts.
5.5. Buildings
The terminal administration building will be required to house the terminal operator’s management, security,
admin, and customer service personnel. Typical users/uses of the administration building shall include
Terminal Administration, Customer Service, Gate Equipment Control, IT/Server, Gate Control Clerks,
Offices, Shipping Lines Offices, and Terminal Security and Communications Hub.
Maintenance and Repair Building shall provide maintenance, repair, and related activities for RTGs, yard
tractors, top-picks, side-picks, truck chassis, and other container terminal operating equipment. It also
supports other service areas such as tire changing, and equipment steam cleaning activities.
A separate JNPA Administration building, and land area will be required to provide for functioning of JNPA
in managing the port operations. This will include but not limited to office building for the JNPA management
and administration staff, office for government officials, security staff and customs and border protection
officers. This will also include the facilities for port maintenance and engineering staff.
A centralized fire station with special firefighting equipment such as foam and gas extinguishers will also be
provided for chemical and electrical fires. Fire detection, monitoring and control system will be provided in
all vulnerable area of the port. In addition to it a separate building will be required to provide for functioning
of rail operations within the terminal. This building will house the rail master and associated staff managing
the rail operations within the port. This building will also house a small workshop for minor maintenance
functions.
Based on the above, almost 13,441 trucks (71,661 PCUs) are expected in the year 2030, increasing to
about 34,284 truck (186,348 PCUs) movements in 2040. It is proposed to provide an 8-lane road with a
capacity of 173,000 PCU.
The port will be supplied through a 220 KV Main Receiving Substation. Based on the requirements of berths
over the master plan horizon, it is expected that the power demand at the port shall increase from 50 MVA
in the Phase 1 development to about 80 MVA over the master plan horizon.
The model studies were carried out for the proposed master plan and Phase 1 layout to ascertain the flow
conditions within the harbour.
Based on mathematical model studies maximum velocities at harbour entrance, stopping distance and
turning circle are 2.6 m/s, 1.2 m/s and 0.3 m/s respectively. The maximum current strength at berths is about
0.05 m/s. The annual siltation in the dredged areas will be about 6.45 M cum during Phase 1 and 8.65 M
cum for Master Plan development.
The estimated berths and the total quay length for the various phases of development is provided below.
Table 7 Vadhavan Port berths & terminal requirements established from the market study
Berth/ Quay Ship max.
Berths/terminals Phase 1 Phase 2 Total
length (m) draught (m)
Container quay (1,000 m each) 1,000 16.5 4 5 9
Multi-purpose berths (250 m each) 250 10.5 3 1 4
Liquid bulk berths 200 9.5 2 0 2
Bulk Liquid berth 280 10.5 1 0 1
Other liquid berth 400 12.0 1 0 1
Ro-Ro berth 250 11.3 1 0 1
Coastguard berth 1 0 1
A water depth of - 22.0 m CD is required in the approach channel and -19.5 m CD in the basins and at the
container berths. The development will essentially be a large deep-water container port for the largest
deep-draught container ships.
The depth of the approach channel is a very important parameter in approach channel design. Water depth
in the channel is around 17 to 18 m depth below CD. +2.0 m tidal advantage has been considered as the
MSL is about +2.8 m CD. The dredged depths with tidal advantage at different parts of the harbour for the
design ships are provided below.
Table 9 Dredged Levels at Port for the Design Ships - With Tidal Advantage
Approach Inner channel
Tidal channel and
At Berths
Ship Category Ship Size Draft (m) Advantage outside manoeuvring
(m CD)
(m) breakwater area
(m CD) (m CD)
Containers 24,000 TEUs 16.5 2 20.0 17.5 19.5
Other Liquid 2,67,000 m3 12 2 14.1 12.3 14.3
Bulk Liquid 45,000 DWT 12.5 2 14.8 12.9 14.9
Multipurpose 40,000 DWT 10.5 2 12.2 10.6 12.6
Liquid bulk 20,000 DWT 9.5 2 10.9 9.4 11.4
RORO 8000 units 11.3 2 13.2 11.5 13.5
The diameter of the sheltered turning circle with tug assistance is 700 m.
The main emphasis while developing the port layout is given to balance the cost of dredging and reclamation
land area developed. It is estimated that approximately 200 million cum of reclamation material would be
required for the proposed port development.
7.1. Equipment
Based on the Phase-1 and Master plan development certain equipment’s will be required to effectively
support the turnaround time of the vessel.
Phase 1 development will have 4 container terminals each can cater minimum of 3 container ships at any
time. It is proposed to provide 12 Rail Mounted Quay Cranes (RMQCs) on each of these terminals. 36
electric Rubber Tyred Gantry Cranes (e-RTGCs) are provided for each container yard. Similarly, 5 Rail
Mounted Gantry Cranes (RMGCs) are provided to handle containers being moved by rails. ITV’s are
provided for movement of containers between quay, container yard and rail yard. The flow diagram for the
container handling system for import and export containers are as presented below.
Similarly, the equipment’s required for other bulk cargo are Mobile harbour cranes etc. Liquid terminal is
planned to handle Chemicals & Edible oil and Bulk Liquid. The liquid bulk, received in tanker will be unloaded
at berth using the marine unloading arms and transferred to the tank farms by means of pipeline. The
cargo
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is pumped directly from the vessel’s pump later based on requirements, the cargo will be dispatched to the
destinations by loading into trucks or through pipelines.
7.2. Utilities
MSEDCL has assured that 80 MVA will be available from PGCIL/ Tarapur-Borivali station through a tapping
from double circuit line. The required electrical system for the project will consist of incoming electrical supply
at 220 kV level, 220/33 kV substations, switchboards, control equipment, etc. to supply the electrical power
to various parts of the site at the required voltage levels of 11kV or 6.6 kV & 0.415 kV, Control and Monitoring
systems, 11 or 6.6 kV underground cabling system for medium voltage supply like for quay cranes, Fibre
optic communications from the substation to the quay cranes. 0.415 kV cabling system from the 11 or 6.6
/0.415 kV substations to the reefer area. The cables should be run in cable trenches, Provision of
underground power cabling to the buildings and gate complex shall be provided, Provision of underground
power cabling to terminal light towers. In addition, consideration of future electrical requirements of the
terminal all necessary provisions shall be made in the design and installation of the electrical system, to
take account of future requirements. This applies to switchboards, transformers, underground cabling
system etc.
The water requirement for the port shall be fulfilled from Surya River 22 km away from the port location.
Drainage systems are also planned for the port. A drainage system will be provided below the stacking area,
with buried perforated drain lines. It is proposed to lay the RCC trench drain parallel to the proposed internal
road. The storm water from the berths, administrative offices, all terminal operator facility buildings, transit
sheds and all other buildings from the different areas of the terminals will also be connected to the storm
water drain. The wastewater collected from the workshop will be treated in an oil skimmer before disposing
off to the storm water drain.
The sewerage system is provided for the buildings such as office buildings, canteens, and other operational
buildings. For isolated buildings and berths portable sanitary cabins are proposed. As per MARPOL
convention, the ships are now required to have STP on board. Sewage and sullage generated from various
buildings with-in a terminal shall be disposed to a Sewage treatment plant (STP) proposed near each
terminal operator facility building / administration building. A separate sewage treatment plant is required to
be provided for township and the type of treatment will be as per the population and township conditions.
Navigation aids for the port are required to ensure safe and efficient navigation of ships entering and leaving
the port through the approach channel as well as berthing / un-berthing requirements inside the harbour.
The navigational aids shall include Buoys - a total of 11 buoys, which include 4 channel buoys i.e., 2 port
side buoys (3m dia.) & 2 starboard buoys (3 m dia.), BEACONS and Vessel traffic management information
system (VTMIS) would be required for the navigational purpose.
Design conditions consist of tide levels, 2 m high storm sure for 100-year return period, 0.2 m od sea level
rise in next 50-years, maximum and minimum design water levels with 100-year extreme are +6.9 m CD
and +0.00 m CD. Design wave conditions at breakwater for 1 in 1 year design wave: i.e., Significant wave
height (Hs) is 3.0m and wave period (Tp) of 10s
The details type and size of armour units in various layers are provided in below tables.
Table 10 Proposed Primary Armour Layers on seaside slope of the Offshore Breakwater
Breakwater Breakwater Breakwater Breakwater
Seaside
Roundhead Trunk Roundhead Trunk
Armour Type Accropode IITM Accropode IITM Accropode IITM Accropode IITM
Slope (V:H) 3:4 3:4 3:4 3:4
Critical Condition 100 year at LAT 100 year at LAT 100 year at LAT 100 year at LAT
Recommended Toe
4,000-6,000 kg 4,000-6,000 kg 3,000-6,000 kg 3000-6000 kg
Armour Size
The revetments protecting the land reclamation can be built as a series of small rock bunds to form a
compact core which minimise the volume of quarry run rock required. This approach is sometimes referred
to as the “Christmas tree” concept.
Design cross sections have been developed for the trunk and roundhead locations along the offshore
breakwater and revetments.
The development of port facilities at Vadhavan would require huge quantity of rock and aggregates for
construction of various port structures. About 73.55 MT of rock quarry is required which shall suffice the
requirements for Breakwater, shore protection, murrum and aggregates for construction of various facilities
including rail and road. The required quarry shall be procured from various quarry site such as Gargaon,
Khanivade, Nanivali, Borsheti, Kirat, Nagzari, Girnoli and Mahagaon.
Geotechnical design of piles shall be done with the factor of safety of 2.5 for end bearing and skin friction
on compression piles, 3.0 skin friction on tension piles and 2.0 for lateral load. Termination criteria shall
correspond to PPR of 100 Tm/m2/cm corresponding to safe end bearing resistance of 500 T/m2. The loads
such as dead load, live load, vehicle & crane load, seismic load, wind loads, current load, wave load, mooring
loads, berthing loads shall be considered based on structural requirements.
Berth details are based on functional requirements geotechnical conditions construction methodology and
structural arrangements for container berth, multipurpose berth, Ro-Ro, Bulk liquid jetty and other liquid jetty
has been provided.
Based on the mathematical model studies on siltation, the estimate the likely rate of annual siltation for
Phase 1 reveal that, the average rate of siltation in the dredged areas will be about 6.45 million cum. The
siltation rates are not uniform over the area under consideration and seems to vary based on the prevailing
hydrodynamic conditions. The dredged material in channel and harbour basin would be disposed at the
designated dumping site offshore.
The location of the disposal site which is in deep water (beyond 25 m contour). The disposal site is spread
over an area of about 20 sq. km and the depth of dumping will be restricted to only 0.5 m.
8.4. Reclamation
Emphasis was given to balance the cost of dredging and reclamation land while developing the port layout.
Based on the stakeholder consultation, the capital investment required for Private entity and mitigate the
risk of basic development cost, the reclamation of 1,227 Ha +5.0 m CD by VPPL while upto the FFL shall
be carried out by the concessionaire, is planned in the offshore of the coast on a seabed ranging from -6.00
m to -15.00 m below the CD and an area of 221 ha nearshore on the seabed from 0 m CD to -1 m CD.
About 227 million cum of reclamation material would be required for the proposed port development.
Internal roads shall be developed for improved internal connectivity. 204 ha. of area to be developed for
Container yard storage in Phase 1. The stack areas shall be developed using concrete block paving.
Considering the various terminals to be developed by various operators and the number of truck movements
within the port, it is required to provide a centralised truck parking space close to the respective terminals.
49 ha. of parking space shall be required over the master plan.
Two step entry/exit gate complex has been planned. Initially in Phase-1 there shall be 6 lanes increasing to
26 lanes in Master plan. The gate complex shall consist of controls access to and from the container handling
and storage areas and facilitates the transfer of responsibility for the cargo from one party to another.
The administration building is planned for offices of key personnel engaged in managerial and departmental
activities. The building will have provision to accommodate custom office building, CISF office and police
station. Port operation building to be developed for providing space for engineering department, terminal
operations, marine operations, and vessel traffic control room. Port user building to provide working space
for general store, dispensary, restaurants, canteen, recreational area such as theatre and shops.
Maintenance workshops for foremen, mechanics, electricians, technicians and the storekeepers and rooms
for off duty operational personnel and maintenance labour. Substation building for transformer and other
electrical equipment.
It is proposed to have a road connecting Vadhavan port with NH-48 and Mumbai-Vadodara expressway.
The entire 34 km. of road is split in to three sections i.e., first 12 km. is from Vadhavan to Western railway
line, next section is from Western railway line at 12 km. upto Surya river 21 km. and third section starting
from Surya river at 21 km. upto NH-48 junction at 34 km. All roads will be merging with the road connecting
port to the NH-48 and Mumbai Vadodara expressway. Road from custom gate to container terminals will be
of 8 lane wide road and the other roads from gate complex to JNPA Port Administration Building will be of
two-lane wide road. The 4-lane road from the gate complex bifurcate to the multipurpose/ liquid/terminal.
approximately 22 km where only road connectivity is required. The Socio-Economic Assessment (SEIA)
was conducted as part of the DPR for the people whose agricultural land / partial agriculture land needs to
be acquired by the Government for the public interest and to study the impact of the development of the port
on 21 affected villages.
Various mitigation measures are adopted to reduce the effect of socio-economic impact assessment. The
project affected people and families may be encouraged to participate in the development of the port and to
have a positive view towards port development. The project affected people shall be clearly informed
regarding the development of the port and benefit to the society and same to be conveyed through personal
meeting printed literature, audio visual presentation and videos. JNPAA may arrange meetings and
discussions with project affected people and apprehensions to be cleared. Focused group interactions shall
be required to be carried out. Statutory meetings of Gram panchayat to be participated and brief on project
and its overall benefits to be discussed. The misconception of the people should be removed through public
meetings with locals in association of Gram panchayat, NGOs and promoting authorities of governments.
571.06 (Acquisition)
Total
100.00 (Long Term Lease)
Table 16 Total Land acquisition for Road and Rail
571.05 (Aq)
Grand Total 462.19 108.86
100.00 (L)
The wave modelling software MIKE21 SW was used to transform the offshore wave conditions nearshore
to a point at depth -24 m CD outside the port. The results from the modelling are reproduced below.
Table 17 Annual Wave Frequency Offshore outside Vadhavan Port (-24m water depth)
Wave Height
0.5-1.0 1.0-1.5 1.5-2.0 2.0-2.5 2.5-3.0 3.0-3.5 3.5-4.0 4.0-4.5 Total
(m)
Calm
Direction (°)
54.49%
180 (S) 0.35 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.35
202.5 (SSW) 1.11 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.11
225 (SW) 5.28 0.21 0.63 0.35 0.00 0.00 0.00 0.00 6.47
247.5 (WSW) 2.13 7.61 13.27 5.35 0.35 0.00 0.00 0.00 28.71
270 (W) 3.27 1.9 0.49 0.00 0.00 0.00 0.00 0.00 5.66
292.5 WNW) 3.07 0.07 0.00 0.00 0.00 0.00 0.00 0.00 3.14
315 (NW) 0.07 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.0.7
Total 40.92 26.53 9.61 3.01 0.97 0.38 0.14 0.06 100
The wave modelling software MIKE21 BW has been used to assess the shelter provided by the breakwater
and conditions within the port. The model has been used to assess a range of layouts which were rejected
in favour of the final layout. The final layout provides good protection to all berths from waves from SW,
WSW, and W with conditions within the limits set earlier. At the container berths waves conditions are also
less than 0.5 m for these directions. The berths are less well protected for waves from the NW with the
limiting criteria of 0.8 m exceeded at the coal berth which is now replaced by additional container terminals.
Wave conditions at the container berths are less than the limit of 0.8 m but exceed 0.5 m. It is expected
that
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the proposed breakwater layout will provide adequate protection to the port with low downtime at the berths
as the assessment has been completed using 1-year storm conditions.
Results show that due to the development of proposed port the current strength on the seaward side of the
intake channels at TAPS reduce by 9%. At the outfall channel, the change in current magnitude is around
11% on the north side and by 2% on the south side of the outfall channel. In the guided portion of the intake
and outfalls, the impact on the current is negligible i.e., less than 2%. As per the model study, difference
between water depth before and after construction of Vadhavan port at all the observation locations in and
around TAPS were found to be negligible.
For estimation of change in the coastline, the breakwater is introduced into the LITLINE model and
comparison is made with the existing scenario to estimate the changes in the coastline. The construction of
port for a period of 1,2,4 and 6 years after the construction of breakwater and the results show that the
change in the shoreline due to the construction of Vadhavan is negligible. Model output for shoreline
evolution after construction of breakwater is shown in below figure.
Studies for simulation of shoreline changes indicated that the construction of proposed offshore breakwater
of 10.1 km length will result in negligible deposition of sand behind the breakwater and will have negligible
impact on the adjacent shoreline as well.
CT-2, Manoeuvring near and at the approach channel during maximum flood and ebb with wind speed of
20 knots was on the high side.
Figure 13 Annual siltation pattern for the recommended Master plan and Phase 1 layout
6 Berths/ Terminals
6.1 Container Terminal 1 (CT1) - - 2,689 - - 2,689 2,689
6.2 Container Terminal 2 (CT2) - - 2,693 - - 2,693 2,693
12 Landscaping 90 - - - 90 90
(A) Total (1+2+3+4+5+6+7+8+9+10+11+12) 22,296 6,353 13,849 14,560 28,648 28,410 57,058
(B) GST (@18%) on infra Cost 4,013 1,143 2,493 2,621 5,157 5,114 10,270
(C) Total Infra Cost (including GST) (A+B) 26,309 7,496 16,342 17,181 33,805 33,523 67,328
(F) Financial Cost for Debt syndication 125 25 1,651 150 - 150
1,735
(G) PMC charges 150 25 175 - 175
(G) Interest During Construction Period (IDC Cost of Borrowing) 2,503 500 3,003 - 3,003