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310 M Dry Dock at Cochin Shipyard Ltd.

Cochin Shipyard Limited (CSL), the largest Public Sector shipyard in India in terms of dock capacity, has set the course to construct a larger and more dynamic drydock. The Chief Minister of Kerala & Honble Minister of shipping today conducted the ground breaking for the third drydock of the company to be located in the northern end of the shipyard. The new dock will have a length of 310 m. It is a stepped dock with a width of 75 M at the wider part and 60 M at the narrower part. It will have a depth of 13 M and a drought of 9.5M. This will be the largest and more dynamic dock in terms of vessels that can be docked. The stepped dock concept enables longer vessels to fill the length of dock; and wider, shorter vessels and maritime equipments such as jack up rigs to be repaired /constructed at the wider part of the dock.

Again, in terms of the size of the dock and strength of the dock floor, this will be one of the largest dry docks in India. The new dry dock will be equipped with one gantry crane of capacity 600 T, two LLTT cranes of capacity 75 T each and other allied facilities, with an option to add another 600T gantry crane at a later stage. The estimated cost of total dry dock project is Rs. 1799 crores. The cost of the project is being met through the fund raised by the company through an IPO in August 2017 and partly through internal resources. Through the IPO which was a great success and was oversubscribed by 76 times, the company could raise Rs 941 crores for its two objects viz 310 M Dry dock and International Shiprepair Facility project at Cochin Port trust premises. The

Incorporated in the year 1972, CSL, has today, emerged as a forerunner in the Indian ship building & ship repair industry and also as an emergent player in the international arena. At present, CSL has two dry docks, one predominantly used for ship building of size 255m x 43 x 9m and capacity 1,10,000 DWT and the other one for ship repair of size 270 x 45 x 12m and capacity 1,25,000 DWT.

The new drydock , when commissioned, will help the company to have a more diversified product profile. This , dual purpose dry dock is planned essentially to tap the market potential of repairs/construction of specialized and technologically advanced large vessels such as LNG vessels, Jack up Rigs, Drill ships, large Dredgers, Second Indigenous Aircraft Carrier and repair of offshore platforms and larger vessels. The new dry dock can comfortably handle Aircraft carriers of 70,000T docking displacement and Tankers and merchant vessels of 55,000T docking displacement. The Dock floor is designed to take a loading of 600T/m. The design caters for sufficient safety margins as per international codes.

The new dry dock project is in line with the “Make in India” initiatives of the Govt. of India, and dovetailed into the ‘Sagarmala” programme which promotes creation of additional ship building and repair facilities.

Project Benefits:
• Will contribute towards the target of increasing India’s share from 0.4 to 2% of the global ship building industry.
• Emerge as a prominent ship repair centre on par with Colombo, Dubai , Singapore , Bahrain etc.
• Together with both expansion projects of 310 M Dry Dock & ISRF, Kochi will become a one stop maritime hub for repair needs of all vessels calling at Indian ports
• Creation of facility for construction of complex technology intensive vessels like LNG Carriers, large dredgers, high end research vessels etc. and for construction of the second Indigenous Aircraft Carrier of much larger capacity than the IAC-1 for Indian Navy which is in the National interest.
• Building of ‘Green Ships’ such as LNG Carriers in the country.
• Promotion of skills in shipbuilding by way of adaption of world class technology such as LNG Carriers and training of youth.
• To generate employment opportunities in the core shipbuilding as well as the ancillary and supporting industry sector.
• Employment potential of approx. 2000 (including direct & indirect) during the operation stage.
• Develop a strong ancillary base in the country for ship building.
• Nation building by way of socio-economic development and growth of manufacturing sector in the country

The Detailed Project Report for the Drydock was prepared by M/s Haskoning DHV Consulting Pvt. Ltd., Mumbai who are appointed as the Client Consultant for the project. The Project was presented before Public Investment Board (PIB) on 17th May 2016. PIB recommended the proposal for approval by Cabinet Committee on Economic Affairs (CCEA). CCEA has approved the project in it’s meeting held on 20th July 2016.

Environmental Clearance for the project was received from Ministry of Environment Forest and Climate Change (MoEFCC) on 09 Nov 2016. Ministry of Defence (MoD) has issued Defence Clearance for Dry Dock project on 20 Dec 2016.

While constructing the drydock, Cochin Shipyard has given due care for maintaining the environment and to avoid any environmental damage. CSL has awarded the contract for Green Belt Development, which includes planting of 2000 seedlings in project site and Public areas, to Social Forestry Division, Forest Department on 17 May 2018. Environmental monitoring covering, dust , noise and other parameters has been entrusted to an accredited third party agency.

Turnkey Contract for Construction works has been awarded to M/s Larsen & Toubro Ltd, Construction, Heavy Civil Infrastructure, Chennai on 27 April 2018 for an amount of Rs. 1298.76 Crs. This turnkey work for the development of new dry dock comprising of Civil, Mechanical, Electrical, Controls & networked Systems and building services works (CME works) . The duration of the CME works is 36 months and the tentative date of completion is 31 May 2021. Both supply and erection of Goliath & jib crane are excluded from scope of the CME works and shall be executed through separate tender.
Technical details about the CME works

The dry dock is designed for a design life of 100 years. The dry dock is formed with high modulus steel embedded retaining wall for dock wall system anchored by Tie rods and contiguous bored piles, dock floor resting on Reinforced Cement Concrete (RCC) piles, Dock sill, entrance gates and copes constructed in the dry behind an entrance cofferdam.

Approximate quantities of main items involved in the project
• RCC piles – 5000 Nos with diameters ranging from 600mm to 1200mm are to be installed
• Dock wall Steel sheet pile is about 12000MT
• Coffer Dam steel sheet pile of 3000 MT
• Reinforcement steel is about 40,000MT
• Reinforcement cement Concrete is about 2, 50,000 m3
• Excavation quantity to be disposed to sea is about 5,50,000 m3
• Dredging is about 86,000 m3

A grand assembly area of size 50 m X 60 m has been provided in the south of the new dry dock for the storage and fabrication of elements. Three intermediate gate locations have been provided, enabling the dock to be split into smaller operating sections. A floating caisson entrance gate has been provided.

A pump house with three main dewatering pumps of capacity each 23000m3/Hr is provided in order to empty the dock approximately 3.5 Hrs. Sufficient mechanical, electrical and control systems has been provided which includes four underground electrical substations, distribution networks for ballast water, cooling water, industrial water, potable water and fire-fighting system, distribution network for argon, acetylene, carbon dioxide, oxygen and compressed air.

A contaminated water treatment plant is provided in order to process contaminated water. One goliath crane of 600T is provided running the full length of the dock and extends 45m into the Ernakulum channel. Also two nos of 75 T Level Luffing jib crane is provided on each side of the dock.
Source: Cochin Shipyard

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