GANGAVARAM PORT LIMITED

GREATER VISAKHAPATNAM

BULK CARGO HANDLING FACILITY (HOPPERS)

ON BERTH

FOR CONTROLLED / FILLING OF VARIOUS TYPES OF (POWDER /

GRANULES / LUMPS) MATERIALS INTO TRUCKS / BULK CARRIERS

LINK FASTNERS & FABRICATORS

AUTONAGAR
GREATER VISAKHAPATNAM
 TECHNICAL INDEX
 SYNOPSIS.
 MATERIAL CARGO TO BE HANDLED.
 PROPERTIES OF VARIOUS POWDER / GRANULES /
LUMPS CARGO.
 VOLUMES & WEIGHTS.
 LOAD DATA.
 MECHANISM FOR FACILITY TO MOVE ON BERTH.
 MECHANISM TO HOLD & RELEASE OF MATERIALS.
 STRUCTURAL DRAWINGS.
ANIMATION OF STRUCTURAL HOPPER.
 SYNOPSIS

GENERALLY THE CARGO IS HANDLED AS MENTIONED BELOW :

ALL CARGO

CONTAINERISED NON - CONTAINERISED

BREAK BULK DRY BULK LIQUID BULK

PAPER COAL PETROLEUM
STEEL COKE CHEMICALS
GRAIN
VEHICLES ORES LIQUID EDIBLES
LUMBER CEMENT
OTH FERTILISER
SLAG
FOOD
PRODUCTS
POWDERS
 FOR HANDLING THE ABOVE MENTIONED DRY BULK CARGO USUALLY CRANES
WITH BULK HANDLING GRABS AND CONTROLLED FILLING & DISCHARGING
MOVABLE HOPPERS ARE EQUIPPED.
1. Standard Procedures For Processing Bulk Cargo

Descriptions of the standard procedures for the processing of

bulk cargo submitted by the respondents are generally brief and
telegraphic. What could be deduced is the following pattern:

a. Application for berth

b. Clearances from the Customs agency
c. Payment of permits
d. Performance of actual bulk handling
e. Billing
f. Payment of charges
g. Documentation at each step

For comparison, various descriptions are presented below as

gathered from responses.
For Dry Bulk (various practices):

a. Grab buckets are positioned and fitted to the vessel. Hoppers are
positioned with spouts. Cargo is bagged and bags are stitched. In the
case of
palletized cargo, cargo is piled onto pallets which are stacked in sheds or
stockpiling areas. In the case of fertilizers, stevedores unload from the
vessel by ship’s crane onto hopper with baggers at the dockside to put into
sacks, sewn and piled onto trucks.
b. Cargo on vessel is transferred to hoppers and the arrester group places bags
at mouth of the hoppers to catch cargo. Another group headed by a gang
boss does the bagging and sewing.
c. Rubber pipe is aligned and attached to the vessel. Air is blown through the
pipes from vessel transferring bulk cement from vessel to silo.
d. Pertinent documents like Bill of Loading and manifests are submitted. Cargo
entry/withdrawal permit is filled up and wharf age is paid. The port
authority the approves the workers schedule and cargo operation begins
upon approval.
e. Cargo handler operates pay loader, brings cargo to vessel, discharges cargo
and trims/levels cargo.
f. Submission of manifest; Preparation of logistics and manpower
requirements; Application for mooring of equipment to port (excavator).
g. Berth planning; Submission of documents including ISPS checklist;
Discharging/loading.
h. Dump trucks roll on board the LCT or barge. Pay loader operator
loads cargo on dump trucks. Workers trim cargoes on board with
dump trucks which are covered with tarpaulin. Dump trucks roll off
the vessel.
i. For copra, cargo is loaded in buckets inside trucks, lifted by crane
to the hatch of vessel.
j. Incoming cargo: Pneumatic ship unloading is used and transported
through the pier intake mechanical conveyor. Bulk weighing and
pre-cleaning are done and cargo is mechanically conveyed to silos
or warehouse.
k. Outgoing cargo: Cargo is discharged from the silo/warehouse and
mechanically conveyed to the scale.
l. Consignee submits the Notice of Arrival and receives approved
berth assignment. He then prepares safety equipment with gears
for discharging. He then pays the wharf age dues.
2. Port Operations Standards For Bulk Handling

Some respondents submitted complete information on the operations standards that

they have adopted in their respective bulk terminals presumably based on the
requirements of their clients. Samples are shown below.

(1) Dry Bulk - Operations Standards

Dry Bulk Handling Standards

1 Superintendent
1Supv./12 operators
Labor Complement
Equipment Complement 4-hydraulic grabs
3-hoppers
conveyor belts
Productivity 450T/H
Safety Devices alarms & helmets
 Dry Bulk Handling Standards

Labor Complement 4 foremen/24 workers

6 portable conveyors
Equipment Complement
1 pneumatic conveyor
Productivity 800T/S/H
Safety Devices 50 safety,50 helmets
50 masks, 50 gloves
8 fire extinguishers
3 fire brigades

Dry Bulk Handling Standards

Labor Complement 3 foremen/16 workers

Equipment Complement 3 portable conveyors
2 fixed conveyors
Productivity 300T/S/H
Safety Devices 20 helmets
20 masks, 20 gloves
4 fire extinguishers
 Dry Bulk Handling Standards
Labor Complement 4 foremen/24 workers
Equipment Complement 6 portable conveyors
2 fixed conveyors
1 pneumatic conveyor
Productivity 800T/S/H
Safety Devices 50 helmets
50 masks, 60 gloves
8 fire extinguishers
3 fire brigades

Dry Bulk Handling Standards

Labor Complement 1 foreman,1checker,

1 tallyman
Equipment Complement conveyor, grab
bagging machine
Productivity 300 T/H
Safety Devices 1-helmet, 1-shoes
 Dry Bulk Handling Standards

Labor Complement 50 stevedores/100 baggers

Equipment Complement 4 hoppers
1 un loader
125 mt-bulk wheat/50 mt
Productivity for bulk fertilizer
safety shoes/boots & mask
Safety Devices per worker

Dry Bulk Handling Standards

1 gang of arrester &
Labor Complement stevedores per hatch

Equipment Complement 3 ship's cranes, 3 forklifts

1 hopper / hatch
1 clamshell/ship's crane
Productivity 1,000 mt. per day

Safety Devices gloves/worker

 Dry Bulk Handling Standards

operations personnel-
Labor Complement 13/shift,
stevedores-15/shift
Equipment Complement 2-3 TCM 45 pay loaders
Productivity 4,000-6,000 mt. /day
hard hat, safety sheet,
Safety Devices gloves,
dusk mask, safety goggles,
working clothes

Dry Bulk Handling Standards

Labor Complement 20 persons

Equipment Complement Un loader /Loader / Pay loader
Productivity 4000-5000 mt. /day
goggles, mask, gloves, hard
Safety Devices hat
SOME OF THE BULK HANDLING FACILITIES
BERTH OPERATED CRANE

GRAB

HOPPER
TRUCK / BULK
ROAD CARRIER
SMALL CAPACITY SINGLE PRODUCT CARGO HOPPER
SMALL CAPACITY SINGLE PRODUCT CARGO MOVABLE HOPPER
FIXED TYPE PREFABRICATED CARGO HANDLING HOPPERS
MATERIAL CARGO TO BE HANDLED
 COKE
 COAL
 LIMESTONE DUST
 LIME STONE
 ARTIFICIAL MANURE
 FURNACE SLAG CRUSHED
 FERTILIZER
 CLINKER / SLAG
 FOOD GRAINS
 RICE
 SOYA BEANS
 WHEAT
 WHEAT FLOOR
 CORN
 OTHER POWDER / GRANULES / LUMP SIZE MATERIALS
PROPERTIES OF VARIOUS POWDER /
GRANULES / LUMPS CARGO.
CHARACTERISTICS OF BULK MATERIALS
VOLUMES & WEIGHTS
 HOPPER VOLUME & WEIGHT CALCULATIONS

O/O
HEIGHT DOOR DOOR DEDUCT. WEIGHT
OF LENGTH NET
S. ANGLE OF LENGTH WIDTH OPEN OPEN TOP FOR DENSITY OF
CARGO BOT. TOP CENTER WISE CORNERS TOTAL VOLUME
N OF HOPPER OF OF IN IN PORTION INSIDE OF CARGO
MATERIAL DOO PORTION CORE SLOPE PORTION VOLUME OF
o. REPOSE TROUG HOPPER HOPPER LEN. WIDTH HEIGHT PARTION CARGO IN
R PORTION HOPPER
H WISE WISE PLATES HOPPER
OPEN

1 COKE 35 2.5 7 14.14 8.34 1.00 1.20 0.60 70.77 26.43 62.48 10.62 170.30 14.19 156.11 0.61 95.22

27 2.5 7 16.81 11.01 1.00 1.20 0.60 111.10 29.77 85.86 20.06 246.79 7.27 239.52 0.78 186.83

28 2.5 7 16.40 10.60 1.00 1.20 0.60 104.36 29.25 82.28 18.42 234.32 7.90 226.42 0.78 176.61

2 F.GRAIN 29 2.5 7 16.02 10.22 1.00 1.20 0.60 98.24 28.78 78.93 16.95 222.89 8.59 214.30 0.78 167.15

30 2.5 7 15.66 9.86 1.00 1.20 0.60 92.65 28.33 75.78 15.63 212.38 9.34 203.03 0.78 158.37

33 2.5 7 14.70 8.90 1.00 1.20 0.60 78.49 27.12 67.37 12.35 185.33 12.00 173.33 0.78 135.20

3 COAL 35 2.5 7 14.14 8.34 1.00 1.20 0.60 70.77 26.43 62.48 10.62 170.30 14.19 156.11 0.85 132.69

24 2.5 7 18.23 12.43 1.00 1.20 0.60 135.96 31.54 98.26 26.27 292.04 5.64 286.40 0.85 243.44

26 2.5 7 17.25 11.45 1.00 1.20 0.60 118.53 30.31 89.70 21.89 260.44 6.68 253.76 0.85 215.70
FERTILIS
4
ER
28 2.5 7 16.40 10.60 1.00 1.20 0.60 104.36 29.25 82.28 18.42 234.32 7.90 226.42 1.20 271.70

30 2.5 7 15.66 9.86 1.00 1.20 0.60 92.65 28.33 75.78 15.63 212.38 9.34 203.03 1.20 243.64

35 2 7 12.71 6.91 1.00 1.20 0.60 52.73 19.71 39.99 5.44 117.87 10.97 106.89 1.52 162.48
CLINKER
5
/SLAG
35 2.5 7 14.14 8.34 1.00 1.20 0.60 70.77 26.43 62.48 10.62 170.30 14.19 156.11 1.80 280.99

30 2.5 7 15.66 9.86 1.00 1.20 0.60 92.65 28.33 75.78 15.63 212.38 9.34 203.03 0.88 178.67

35 2.5 7 14.14 8.34 1.00 1.20 0.60 70.77 26.43 62.48 10.62 170.30 14.19 156.11 1.35 210.74

LIME 40 2.5 7 12.96 7.16 1.00 1.20 0.60 55.66 24.95 52.14 7.40 140.15 21.68 118.47 1.44 170.59
6
STONE

45 2.5 7 12.00 6.20 1.00 1.20 0.50 37.20 23.75 43.75 5.21 109.91 33.54 76.37 1.52 116.08

45 2 7 11.00 5.20 1.00 1.20 0.60 34.32 18.00 28.00 2.67 82.99 24.17 58.82 1.80 105.88

40 2.5 7 12.96 7.16 1.00 1.20 0.50 46.38 24.95 52.14 7.40 130.87 21.68 109.19 0.61 66.61

35 2.5 0 7.14 8.14 1.00 1.00 0.60 34.88 8.93 0.00 10.62 54.43 -2.88 57.30 0.61 34.96

36 2.5 0 7.88 8.08 1.00 1.20 0.60 38.22 9.85 0.00 9.87 57.94 -3.12 61.06 0.61 37.25
 LOAD DATA

AVG. BULK DENSITY OF VARIOUS CARGO

TO BE HANDLED ARE TAKEN FROM IS:9178 PART – 1.

LIVE LOAD / IMPOSED LOADS ON

THE STRUCTURE AS PER IS:875 PART – 2.

WIND LOADS AS PER IS:875 PART – 3.

DESIGN OF STEEL BINS FOR STORAGE OF

BULK MATERIAL AS PER IS:9178 PART – 2.

DESIGN OF HOPPER SUPPORTING

STEEL STRUCTURE AS PER IS:800.
MECHANISM FOR FACILITY TO MOVE ON BERTH
POLY ON STEEL WHEELS FOR MOVING HOPPER ON BERTH
TWIN WHEELS FOR HOPPER STRUCTURE ROTATIONAL MOVEMENT
ULTRA HIGH MOLECULAR WEIGHT HDPE LINING MATERIAL
LINING MATERIAL FIXING ARRANGEMENT
ROTATIONAL WHEELS FIXED WHEELS
MECHANISM TO HOLD & RELEASE OF MATERIALS
 PNEUMATIC
CYLINDERS HOPPER DOORS

PNEUMATIC MECHANISM FOR DISCHARGE DOOR OPERATION OF HOPPER

4Nos. PNEUMATIC CYLINDERS OF STROKE LENGTH
BETWEEN 400MM TO 500MM FOR OPENING /
CLOSING OF HOPPER BOT. DISCHARGE DOORS
STRUCTURAL DRAWINGS
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ISOMETRIC VIEW
ANIMATION OF STRUCTURAL HOPPER