prefeasibility report for terminal at dabhol, ratnagiri ... · the lng terminal at dabhol is...
TRANSCRIPT
Prefeasibility Report
For
Construction of Breakwater for LNG
Terminal
At
Dabhol, Ratnagiri
Project Proponent
Konkan LNG Private Limited
April 2019
1. Executive Summary
Erstwhile Dabhol Power Project (DPC) which was promoted by M/s Enron Corporation, General
Electric Corporation, Bechtel and MSEB with a total power plant capacity of 1967 MW along
with the integrated 5 MMTPA LNG terminal. Phase-I of the power plant was commissioned in
May 1999 with Naphtha as fuel. Construction of Phase II was more than 90% completed and that
of associated LNG facility, about 85% complete when the operations of Phase - I and
commissioning activities of phase - II were suspended in May 2001 following various disputes.
The project activities came to a halt followed by appointment of a Court Receiver to undertake
Preservation of the assets. Empowered Group of Ministers (EGOM) was constituted to resolve
all issues for revival of DPC in Nov 2004. The EGOM developed a revival package by formation
of project SPV comprising GAIL, NTPC, and Indian lenders with equity infusion by each party
with a mandate to raise additional finances, complete and operate the project.
As a result, Ratnagiri Gas and Power Private Limited (RGPPL) was formed in July 2005 as a JV
between GAIL, NTPC, IFIs and MSEDCL for taking over and operating erstwhile DPC assets.
The assets were transferred to RGPPL in Oct 2005.
On 28th February 2018 RGPPL demerged into two entities as M/s RGPPL (owns an integrated
Power generation facility of approx 1967 MW capacity) and M/s KLPL (owns LNG Receiving
and Regasification Facility of 5 MMTPA capacity) as a JV of Gail (India) Ltd to handle LNG
Cargos import, Unloading and Re-Gasification Operation. With the approval of demerger of
RGPPL by NCLAT, Konkan LNG Private Limited came into existence as a separate entity
carrying out regasification and LNG related transactions. Currently, the LNG facility is not an
all-weather Terminal owing to the fact that there is no breakwater, because of which, no cargoes
are received during the monsoon period. Construction of Balance Breakwater will make it an all-
weather Terminal.
KLPL has ambitious plan to complete the balance works at the LNG Terminal, construction of
partially completed breakwater, and thereafter, operate the facilities throughout the year. The
balance works of completion at the LNG Terminal are being looked after by M/s GAIL. M/s
KLPL has engaged M/s GAIL as the consultant and M/s GAIL in turn has appointed Engineers
India Limited (M/s EIL) as their primary Project Management Consultant (PMC) for PMC
services for the completion and commissioning of the balance works of LNG Terminal.
The project site is located at village Anjanwel, District Ratnagiri in the state of Maharashtra
(India) nearly 330 km southwards from Mumbai. KLPL has a Captive jetty exclusively for
KLPL Terminal use.
Ministry of Environment and Forest (MOEF) has already accorded Environment Clearance vide
File No, J-16011/19/93-IA.III dated 12th April 1994 for the establishment of port facilities in the
favour of Dabhol Power Company. Further MoEF also granted Environment Clearance vide File
No. J-16011/12/98_IA.III dated 18th January 1999 for Construction of Breakwater and related
Foreshore activities for LNG Import Terminal at Dabhol in favour of M/s. Dabhol Power
Company and subsequently transferred to M/s. Ratnagiri Gas & Power Pvt. Ltd vide File No. 11-
20/2010-IA.III dated 28.05.2010. Further Konkan LNG Private Limited submitted application to
MoEF&CC for the change in the name of the company from RGPPL to KLPL vide letter dated
17.04.2018 and the after discussion in ministry, MoEF&CC vide their letter dated 31st August
2018 clarified that the works on the project were not completed as well as the validity of EC
issued on 18th January 1999 already been expired on 17th January 2004.
Now as such the Construction of Breakwater is partially completed, for the completion of
balance works, proposed project will require fresh Environmental Clearance (EC) and Coastal
Regulation Zone (CRZ) Clearance. Further, Maharashtra Pollution Control Board has granted
Consent to Operate vide letter no. KP-17213-15051FT0353/CR/CAC-180600000012 dated
01/06/2018 and accordingly renewal of CTO valid till 30.06.2020.
Form I, as is prescribed by the said notification is duly filled up and submitted. The Prefeasibility
Report is an accompaniment to the same and prepared as per MoEF guideline dated 27/02/2012.
It generally covers, Introduction, Justification, Location, Resources, Process, Pollution Control,
Background Study, Safety, Benefits, EIA Structure, Scoping & Conclusion.
2. Project Facilities:
The configuration of the entire Dabhol Project consists of a 1967 MW combined cycle power
plant along with an integrated 5 MMTPA LNG Terminal located at Anjanwel, about 340 km by
road to the south of Mumbai (India).
The LNG Terminal at Dabhol is designed to supply 2.1 MMTPA of re-gasified LNG to the
Dabhol Power Plant and the balance 2.9 MMTPA is for re-gasification and transportation to
catchment gas markets through a pipeline network already laid for the purpose.
The facilities at the LNG terminal include a 2.3 km long offshore breakwater, approach channel,
1750 m long approach trestle, jetty head with berthing and mooring dolphins, navigational
dolphins, tug berths, LNG unloading arms, LNG unloading lines, vapour return line, 3 numbers
of LNG storage tanks, boil off gas compressors, re-condenser, vaporizers, low pressure and high
pressure pumps, low pressure and high pressure gas export systems, gas metering arrangements,
utilities and other associated infrastructure.
The Dabhol Project was incomplete when the construction works were stopped in June 2001.
Thereafter, since April 2002 the plant facilities have been kept under preservation and the revival
Process envisages putting the facilities into commercial operations from early 2009 after
completing the balance jobs left in the Power Plant and the LNG Terminal and marine works.
After the health assessment of the berthing facilities, jetty structure and non marine portion of the
LNG terminal and modification completed in Dec 2012, the LNG terminal was successfully
commissioned in January 2013 and approximately 60 LNG cargos have been unloaded the LNG
tanks till April 2018 (nonmonsoon period). However, completion of breakwater is essential for
successful unloading of LNG cargo during monsoon period also.
The proposed project for construction of breakwater at existing LNG terminal falls under S.N No
in the Schedule 7 (e) Ports, harbors, breakwaters, dredging. Hence requires Environmental
Clearance as per EIA Notification 2006 and CRZ Clearance as per CRZ Clearance, 2011
3. Project Description:
Existing LNG Terminal is already in operation which includes facilities like: Approach channel:
1750 m long approach trestle, jetty head with berthing and mooring dolphins, navigational
dolphins, tug berths, LNG unloading arms, LNG unloading lines, vapor return line, 3 numbers of
LNG Storage tanks of 160,000 m3 capacity each, boil off gas compressors, re-condenser,
vaporizers, low pressure and high pressure pumps, low pressure and high pressure gas export
systems, gas metering arrangements, utilities and other associated infrastructure.
LNG terminal has Marine and Non Marine facilities as mentioned below.
Terminal Specifications
Description Details
Marine Facilities Details –
Berthing Side Starboard
Maximum Design Draft 12.0m
Recommended –
Max Arrival Vessel Draft
11.5m
Max Vessel LOA 300m
Max Vessel Beam 50 meter
Max Vessel Displacement (MT) 113150 MT
Max Air Draft N/A
Unloading Arm platform Above Chart
datum (CD)
17.77m
Max Manifold to Waterline 26.0m w.r.t. CD, Departure with HW
Condition
Channel Details Buoy Marked 8.0 Km x 300m, &
700m Turning Circle
Number of Mooring Dolphins/Platforms 04
Number of Breasting Dolphins/Platforms 04
Length of Trestle up to Jetty Head 1.89 Km
Dock Water Density Range 1.018 Kg/m3
Bonding cable N/A
No of Tugs 04
Bollard Pull 60 T each
Fire Fighting Capabilities 02 Tugs each of Fi Fi – 1 Ratings
Pollution Control Facilities 01 Tugs with pollution control
Equipment
Unloading Facilities –
No of Unloading
Arms & arrangement
04 {Liquid(L) + Hybrid(H) + Vapour(V) +
Liquid (L)}
Class 4000
Emergency release PERC
Insulating flanges Yes
Max Unloading Rate m3/hrs 4000 m3 /per unloading arm
Connectors Manual Connection – NO QCDC
Cargo (L & V) Connection
Flange Size
16" ANSI 150 RF Smooth Finish Flange
Max working back Pressure Liquid 4.5 to 5.5 bar
Max working Pressure –
Liquid Line
8.5 barg
Max working Pressure –
Vapour Line
3 barg
Design Temperature -168°C
Working Temperature -159.1 to -161°C
Shore Facilities –
No of Shore Tanks 03 {Two operational ( T-300 & T- 400)
, One (T- 200) yet to be commissioned}
Shore Tanks Capacity Each tank- 1,60,000 m3
LNG Density Range 434 – 470 kg/m3
Distance to Shore Tanks from Unloading Arms Appx 2.3 km
Shore Tank Base Elevation w.r.t.
Unloading platform
T-300 = Appx (-) 7.0 m & T 400 :
Appx (-) 12.0 m
Approximate Elevation of Shore tanks
filling point from tank base & from CD
T-200 60 m from Base, 68.24m from
CD, T-300: 60 m from Base, 68.24m
from CD
T-400: 60 m from Base, 63.24m from
CD,
Approximate Elevation of Shore tanks
filling point w.r.t to Unloading arms
platform.
T- 200 : Appx. : 53m T-300: Appx.:
53m
T-400: Appx.: 48m
BOG Compressor(s) 02
Capacity of BOG Compressor 17 MT/hr
Return Vapour Temperature Min (-) 110 Deg C
Approximate Return Vapour Pressure As per requirement of LNGC
Nitrogen Generation Capacity & Liquid
Nitrogen storage capacity
N2 Generation Capacity: 70 m3 / hr.
and
N2 Liquid nitrogen storage tank of 18
KL
Services at Terminal –
Fresh Water Yes – service water in Limited quantity
Bunkers via Barge Not allowed
Slop Facilities No
Liquid Nitrogen No
Refuse No
Customs Yes
Police Assistance Yes
Garbage Reception No garbage reception at Terminal;
Agent to arrange from Sea side Via
Barge
Crew Change No, KLPL Is a Non Immigration Port,
Except emergency.
Medical Care Yes
Detail Project Layout is attached as Annexure 1
Figure: 1 Facilities of LNG Terminal
Figure 2: Process flow diagram of LNG Terminal
The Breakwater construction is partially completed. The dimension of the original Breakwater to
be constructed is mentioned as below:
Length: 2300 m
Height: 21 m at the center,
Width: 80 m at the bottom and with 8m width at the top surface.
The breakwater has been partially constructed and designed as per applicable codes as under
• BS 6349 Part 7 (UK),
• CIRIA/CUR/CETMEF “The Rock Manual”, 2007 (EU)
• Coastal Engineering Manual, 2003 (US Army Corps of Engineers)
• Overtopping manual 2008– EUROTOP (EU)
The protective breakwater was not fully completed when the project was put on hold with the
breakwater approximately 30% completed. The facility was mothballed for some years before
being partly recommissioned for delivery to recommence in 2012.
The approximate status of the marine works at the time of suspension was:
• Approach channel and manoeuvring area capital dredging completed.
• Core placed over 2300m long breakwater – the most northerly 400 m includes underlayer
and Accropode armour, the remaining 1900 m only core placed.
• Jetty and dolphins for vessels 85000 m3 to 145000 m3 capacity-complete, including
loading arms and fenders.
The status of breakwater construction has been depicted as below.
Figure 3: Dabhol – Present State of the Breakwater Construction (EGS, 2013)
As on date, about 7000 ACCROPODETM units (approx. 6600 units of 9m3 and approx. 400
units of 12 m3) are on the storage area and will be provided as free issue on “as is where is”
basis. Since investigations will be done to check whether these units are suitable (according to
specification no. 8714157–R3–CGL) for the BOQ it has been assumed that 95% of the units of
9m3 (so 6300 over 6600) and 90% of the bigger units of 12m3 (so, 360 over 400) will be
declared as suitable for use in the breakwater.
Approximate Bill of Quantities for the major balance work to be completed is as depicted below.
4. Project Location
The proposed project site is located at village Anjanwel, Dabhol town, District Ratnagiri in state
of Maharashtra (India) at latitude & Longitude 17031.096’N 073008.491’E (SE Point),
17032.047’N 073007.479’E (NW Point). Dabhol, is well connected by road and Mumbai is
around 350kms from the site through motorable road & railways. Dabhol site has its own
helipad. No sanctuary, national park or ecologically sensitive area is situated within 10 km radius
of site.
Figure 4: Project Location Map
Figure 5: LNG Jetty Terminal & Breakwater Construction
Figure 6: 10 km Project Location Google Map
Figure 7: Toposheet of 10 km Project area
5. Climate
Climate of the region is tropical and is characterized by heavy monsoon. The region is influenced
by annually recurring seasons of southwest monsoon, post monsoon winter and summer
Rainfall
Yearly mean rainfall: 3500 mm
Monthly maximum average: 1341 mm
Hourly: 300 mm
Rainfall is generally confined between June and October
Temperature
Average: 27.40C
Extremely Dry bulb: 38.90C/100C
Relative Humidity
Average Relative Humidity is 60 %
Winds
Outside the SW monsoon period (May end to mid-September) the wind speed (10 minutes
average) is in the range of 2 to 9 m/s (4-18 Knots), from SW to NW & to NE direction. The
extreme wind events outside the SW monsoon are more likely to occur in the period
October to December than at any other time of the year. During strong winds, tidal levels may
rise by. Surface currents are seldom of concern.
Cyclone
Severe tropical storms and cyclones can occur on this coast at a frequency of about one every 5
to 10 years. These mostly travel from the East across the Indian continent.
6. Water Requirement
The LNG terminal is already in operation, no additional water will be required for the proposed
breakwater construction.
7. Power Requirement: as such no additional power requirement as the terminal is already in
operation
8. Manpower Requirement
The proposed constructions of Breakwater will require100 no of person during construction
phase.
9. Proposed Infrastructure
The LNG terminal already has infrastructure and facilities, hence no proposed infrastructure
except construction of breakwater.
10. R&R Plan
The LNG terminal is already in operation hence no R&R plan.
11. Waste Management
As such the proposed LNG terminal is already in operation, no additional waste will be
generated.
12. Environment Management
Precautions shall be taken that the site is not polluted due to any oil spills/other pollutants due to
activities during the construction period. Project proponent shall develop an environmental
management plan and take adequate anti-pollution measures during construction. Dredged soft
material and silt will be disposed at location notified by CWPRS (presently 15-18 Kms from
work site) and the disposal location tentatively is Lat 17⁰33’21” and Long 73⁰00’00”.
13. Project Schedule and Cost Estimates
The breakwater construction is partially completed. Further the project will be completed within
time frame of 30 months after receiving statutory clearance
Estimated Cost of the project: