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: