EXECUTIVE SUMMARY
1.0 BACKGROUND
As a part of the National Gas Grid, GAIL had got the Detail Feasibility Report (DFR) prepared for
Kochi-Kanjirkkod-Bangalore-Mangalore pipelines. The DFR These report was prepared during
2002 and were covering only the main trunk lines, based on the demand-supply situation at that
time. Now GAIL had received the Authorization from MoP&NG in July 2007 to lay Kochi-
Kanjirkkod-Bangalore-Mangalore Pipeline (KKBMPL) for a capacity of 16 MMSCMD (12.0
MMSCMD for GAIL and its Associates and 4.0 MMSCMD for common carrier) on common carrier
basis. DFR was prepared long back and since then market dynamics has considerably changed
thereby GAIL has decided to update DFR in house in line with the authorization received in 2007.
M/s Petronet LNG Limited (PLL) is constructing the LNG regasification terminal at Vyapeen,
Kochi for 2.5MMTPA capacity and as per the information received from PLL it is expected to be
completed by 2011-12. Regasified LNG (R-LNG) from M/s PLL at Vyapeen has been considered
as source for KKBMPL. Pipeline network considered for DFR preparation is shown in Sketch -
1.0.
Kochi → Alwaye → Kanjirkkod → Palghat/Pallakad → Coimbatore → Trippur → Bangalore →
Kanjirkod → Kasargod → Mangalore
PLL is constructing the regasification facility for 2.5 MMTPA (9.0 MMSCMD) and in near future it
will be upgraded to 5.0 MMTPA, therefore it is proposed that pipeline should also be executed in
phases. Synchronizing with the commissioning/Availability of R-LNG from PLL terminal.
Demand: Phase wise Demand of KKBMPL is given below:
(As provided by Mktg. Group)
Phase-I (2010-11)
Sr. Consumer Location Volume
No. (MMSCMD)
1 NEST, SEZ Kochi. 300 MW plant Vyapin Kochi 1.2
2 GTN Textiles. Alwaye, Ernakulam. Always 0.048
3 Premier Tyres Limited:Kalamassery,Kochi. Kalamassery 0.014
4 REL, Udyogruandal Kochi. Udyogmandal 0.9
5 FACT Udyogmandal (FACT-I) Udyogmandal 1
6 Sudchemie, Udyogmandal Udyogmandal 0.006
7 Travancore Cochin Chemicals, Udyogmandal 0.012
Udyogmandal
8 Cochin Minerals & Rutiles, Binanipuram Binaniparam 0.012
9 Binani Zinc Limited: Binanipuram, Kochi Binanipuram 0.1
10 Kerala Chemicals & Proteins Ltd: Kakkanad 0.022
Kakkanad, Kochi.
11 FACT Ambalamedu(FACT-II) Ambalamedu 1.21
12 BPCL, Refinery, Ambalamedu, Kochi Ambalamedu 1.6
13 Hindustan Organics Limited, Ambalamedu 0.11
Ambalamedu
14 Philips Carbon, Ambalamedu Ambalamedu 0.026
15 MILMA Ernakulam Ambalamedu 0.0096
Total 6.2696
Phase-II (2011-12)
No. Consumer Location Volume
(MMSCMD)
1. Apollo Tyres Limited: Perambra, Thrissur. Thrissur 0.042
2. Arya Vaidya Sala, Kottakal. Kottakal 0.014
3. KSEB Diesel Plant, Nallalam, Kozhikode Kozhikode 0.78
4. Western India Plywoods, Kannur Kannur 0.04
5. Kannur Power Projects Limited Kannur 2.25
6. Kasargod Power Corporation: Kasarpod Kasargod 0.5
7. MCF, Mangalore Mangalore 0.9
8. Indsil Electrosmelts limited:Pallakkad. Pallakkad 0.24
9. Precot Mills Limited: Walayar, Pallakkad Pallakkad 0.05
10. Steel Industries in Palakkad Pallakkad 0.02
Total 4.836
Phase-III (2012-13)
Sr. Consumer Location Volume
No. (MMSCMD)
1. Sri Kannapan Mills Ltd Coimbatore 0.0825
2 Flow Link Systems (P) Ltd Coimbatore 0.0275
3 CPC Pvt Ltd Coimbatore 0.0165
4 Kovai Auto Products Coimbatore 0.001
5 K.G.Denim Ltd Coimbatore 0385
6 Van Tex Ltd Coimbatore 0.0053
7. Texmo Precision Castings Coimbatore 0.005
8.
Texmo Industries(Pump Division) Coimbatore 0.02
9
Texmo Industries(Motor Division) Coimbatore 0.01
10
Super Spinning Mills Ltd Coimbatore 0.022
11.
Premier Mills P Ltd Coimbatore 0.1686
12 L.G Balakrishnan & Bros Ltd Coimbatore 0.0127
13. S A Textile Pvt Ltd Tirupur 0.0165
14. Gomuki Spinning Mills Pvt Ltd Tirupur 0.0165
15. Agni Steels Pvt Ltd Erode 0.01
16. Pavai Alloys and Steels Pvt Ltd Tiruchengode 0.075
17 Ran India Steels P Ltd Tiruchengode 0.01
18. Jansons Industries Ltd Tiruchengode 0.075
19. Micro-Tech CNG Pvt Ltd. Hosur 0.01
20. NGA Steels Pvt Ltd Salem 0.1
21. Sri Krishna Alloys Salem 0.015
Total 0.8731
Grand Total: 12 MMSCMD
Pipeline Design Throughput: 16 MMSCMD - (As per Authorization from MoP&NG)
Note: 12 MMSCMD for GAIL and its associates, 4.0 MMSCMD for common carrier as per
the authorization received from MoP& NG
1.1 PROJECT PROPOSAL
Based on the demand provided by the Marketing Department and authorization received from
MoP&NG, updation of the DFR has been carried in house by Project Development Pipeline (PD-
PL) group. Pipeline route as shown in sketch 1.0 is considered for updation of DFR.
The flow rate of re-gasified gas (R-LNG) considered is 16.0 MMSCMD starting from Kochi
Despatch Terminal. Distribution of gas in various segments of the pipeline network shall be as
follows:
Kochi - Alwaye - 16.0 MMSCMD
Alwaye FACT-1 / BSES/FACT-11 - 6.0 MMSCMD
Alwaye — Kanjirkkod - 10.0 MMSCMD
Kanjirkkod -- Mangalore - 6.0 MMSCMD
Kanjirkkod — Bangalore - 4.0 MMSCMD
Distribution of gas shall preferably be without the aid of compression facilities anywhere. Pipeline
segment shall be designed as per following design conditions:
Normal Inlet Pressure (i.e. custody transfer of regasified LNG : 87 kg/cm2g
By PLL to GAIL at Kochi Despatch Terminal)
Normal Inlet Temperature : 0O C
Pipeline Design Pressure : 92.0 kg/cm2g
Pipeline Design Temperature : -28oC to 65o C
Number of stream days / year : 365
Arrival Pressure at Receipt Terminals: Mangalore - 45 kg/cm2g, Banglore-45 kg/cm2 g
Pipeline length : As per Pipeline section details
Mainline and Spur line details are provided in the pipeline section details below:
Summary of Pipeline Length
Pipeline Size Length (Km)
24 862
12 38
8 214
Main Pipeline
Description: Kochi-Alwaye-Thrissur-Kanjirkkod-Palakkad-Bangalore Ch 0.0 Km at Kochi
Dispatch terminal near PLL
Pipeline Section Length (Km.) Pipe Size (Inch) Execution
Kochi Alwaye (TOP for FACT) 27 24 Phase-I
Alwaye Thrissur 18 Phase-II
Thrissur Kanjirkkod 62
Kanjirkkod Palghat/Pallakkad 50
Palghat/Pallakkad Coimbatore 53 Phase-III
Coimbatore Trippur 57
Trippur Erode/Trichengede 18
Erode/Trichengede Salem 77
Salem Bangalore 178
Mangalore Spurline
Description: Kanjirkkod-Mangalore Pipeline
Ch 0.0 Km at Ch 107 in Kanjirkkod- Palghat section of KKBMPL Mainline
Pipeline Section Length (Km.) Pipe Size (Inch) Execution
Kanjirkkod Kottakal 30 24 Phase-II
Kottakal Kozhikode 55 Phase-II
Kozhikode Kannur 100 Phase-II
Kannur Kasargod 27 24 Phase-II
Kasargod Mangalore 110 Phase-II
Total 322
FACT Spurline
Description Alwaye - FACT Pipeline
Ch 0.0 Km at Ch 27 in Kochi-Alwaye Section of KKBMPL Mainline
Pipeline Section Length (Km.) Pipe Size (Inch) Execution
Alwaye (FACT TOP) TOP of FACT-I 10 12 Phase-I
TOP of FACT-I FACT-II 18 12 Phase-I
Other Spur Pipeline and Consumer connections
Pipeline Section Length Pipe Execution
(Km.) Size
(Inch)
Kochi Teminal to NEST SEZ 5 8 Phase-I
FACT-1 TOP to REL 4 8
REL to FACT-I 1 8
FACT- I TOP to GTN textile 3 8
Grid for Consumers in Udyogmandal, ,Binanipuram,Kakkanad, 20 8
Alwaye
FACT-II to BPCL refinery Ambalamedu 4 8
BPCL refinery Ambalamedu to HOL & other consumers 4 8
Appolo tyres Thrissur 14 8 Phase-II
Aryavaidsala , Kottakal 8
KSEB Power Plant, Kozhikode 7 8
Western plywood, Kannur 20 8
Kannur Power Projects Limited 4 8
Power plant, Kasargod 4 8
MCF, Mangalore 2 8 Phase-II
Indosil, Pallakkad 18 8
Precot and others ,Pallakkad 5 8
TOP to Coimbatore Despatch Terminal 10 12 Phase-III
Grid for Consumers in Coimbatore 40 8
Grid for Consumers in Trippur 10 8
TOP to Erode Despatch Terminal Agni Steel 2 8
Grid for Consumers in Trichengede 15 8
Grid for Consumers in Salem 30 8
Summary of Pipeline - Phase- I
Pipeline Size Length (Km)
24 27
12 28
8 41
Summary of Pipeline - Phase-II
Pipeline Length(Km)
Size
24 452
8 76
Summary of Pipeline- Phase-III
Pipeline Length(Km)
Size
24 383
12 10
8 97
1.2 Pipeline Route, Environment Impact Assessment and Risk Analysis Study Detailed
Route Survey, Soil Resistivity Survey, Soil Investigation Studies and topographical surveys of
proposed pipeline route and terminals were carried out in the past , now in view of the changes in
consumer bases, fresh survey will be carried out. This DFR therefore is based on desk top study
of available maps and reconnaissance survey of critical accessible locations along the proposed
pipeline route.
Similarly. Environment Impact Assessment and Risk Analysis Studies of the proposed pipeline
are yet to be established. Thus. environment management plan and disaster management plan
are yet to be finalized and established. However, design. construction and operation of the
proposed pipeline network is being conceived and planned in a manner that impact on base
values of air quality, water quality, noise quality, soil quality, laud use, ecology, Flora / Fauna and
Socio economic aspects is minimal and temporary in nature.
1.3 OPTIMISATION STUDY
Following three alternatives have been considered for determination of optimum pipeline size and
configuration.
Alternative - 1
Pipeline Size : Kochi to Kanjirkkod (Trichur) - 22" O.D. (107 km long)
Kanjirkkod to Mangalore - 22" O.D. (322 km long)
Kanjirkkod to Bangalore - 22" O.D. (440 km long)
Compression facilities: NIL
Alternative-2
Pipeline Size: Kochi to Kanjirkkod (Trichur) 24" O.D. (107 km long)
Kanjirkkod to Mangalore 24" O.D. (322 km long)
Kanjirkkod to Bangalore - 24" O.D. (440 km long)
Compression facilities: NIL
Alternative-3
Pipeline Size : Kochi to Kanjirkkod (Trichur) -- 26" O.D. (107 km long)
Kanjirkkod to Mangalore 26" O.D. (322 km long)
Kanjirkkod to Bangalore 26" O.D. (440 km long)
Compression facilities: NIL
Summary of results of the optimization study are tabulated below:
Alternative Pipe Size Pressure at Pressure at
(Inch) Manglore Manglore (Kg/cm2)
(Kg/cm2)
1 22 43 48
2 24 62 64
3 26 70 72
TABLE
ALTERNATIVE COST IN Rs. LAKHS
Direct Capital cost without
common facilities (Rs.
Lakhs)
2 170055
3 190611
**Minimum pressure requirement of 45 Kg/cm2 is not achieved by pipe size selected in
alternative-1; therefore Costing has been carried out for Alternative-2 &3 only.
NOTE: 1. Cost of the common facilities in the above three alternatives has been excluded.
2. Capital cost estimates mentioned above are not to be considered for investment purposes.
From above Table, it can be observed that Alternative - 2 has the least Capex.
Therefore Alternative -2 is selected for preparation of this DFR.
Total Project cost including all the facilities is Rs. 2817.40 Crores including a Foreign Exchange
(FE) component of Rs. 18.59 Crores.
1.4 PROJECT FACILITIES
Facilities proposed for the pipeline system at various terminals and along the cross country
portions of the pipelines are as follows:
1.4.1 Pipeline
Details. of pipeline. segments such as pipeline size, material, length and location etc. of the
pipeline configuration considered in the DFR is indicated in Annexure-III (Ch. Process Design
basis)
The proposed pipeline shall have following features:
External surface of the Buried portion of the pipeline shall be coated with 3 layer PE ,
internal coating shall be done by Epoxy. Supplemented by Impressed current type
cathodic protection system.
Only mainline(24") shall be internally coated
Continuous concrete weight coating shall be provided for anti-buoyancy. wherever
required.
For monitoring the health of the pipeline, the pipeline and its associated fittings including
scraper traps, shall be designed to allow passage of online inspection (OLI) tools like
intelligent pigs.
1.4.2 Pipeline Associated Facilities
Sectionalizing Valve Stations (SV), Intermediated Pigging Stations (IPS), Tap-off stations (TOP),
Consumer Receipt Terminals (CRT), Cathodic Protection Stations (CP) and repeater stations
(RS) provided along the pipeline route are as follows:
Pipeline TOTAL NUMBER
Segment SV IPS TOP CRT CP RS
Kochi -
16 3 7 32 19 19
Bangalore
Kanjirkkod
11 1 4 17 10 10
Mangalore
SV: Sectionalizing Valve
IPS: Intermediate Pigging Station
TOP: tap off point
CRT Consumer receipt terminal
CP Cathodic protection
RS Remote Station
NOTE: Stations at FACT -I/II, Kanjirkkod. Kasargod, Mangalore, Coimbatore, Trippur, and Salem
shall be manned and shall also serve as maintenance basis.
Quantities of SVs, IPS, TOP, CRT, CP, RS are tentative only, they have been considered on the
basis of desk top study. Actual quantity shall be worked out during detail engineering based on
the detail route survey.
1.4.3 Facilities envisaged at other terminals are as follows:
1 .4.3.1 Kochi Dispatch Terminal
Gas chromatograph and Analyser for H2S, moisture content
Gas Filters
Scraper Launcher for 24" O.D. pipeline section from Kochi to Kanjirkkod
Flow meters for Kochi-Kanjirkkod sections of the pipeline.
Control room building cum administrative building
All utilities like instrument air, plant air, nitrogen, service water and drinking water, Fire
water Network etc. shall be drawn from R-LNG plant of PLL.
DG Set
Pipeline of NEST SEZ from Kochi dispatch terminal is non piggable (Line length is 5 Km
only).
1.4.3.2 Kanjirkkod Dispatch Terminal
Gas chromatograph and .Analyser for H2S, moisture content
Scraper Launcher for 24" O.D. pipeline section from Kanjirkkod to Mangalore
Scraper Launcher/Receiver for 24" O.D. pipeline section from Kanjirkkod to Bangalore.
Pipeline section has been considered bidirectional.
Flow meters for Kanjirkkod - Bangalore sections of the pipeline.
Flow meters for Kanjirkkod- Mangalore sections of the pipeline.
Control room building cum administrative building
DG Set.
1.4.3.3 Receipt Terminals
a) FACT-II
Scraper Receiver for 12.75" O.D. pipeline section from Alwaye to FACT-II.
Cartridge type gas filters
Flow meters
Control room-cum -office
b) MCF (Mangalore)
Scraper receiver
Cartridge type gas filters
Flow meters
Control room-cum-administrative building
DG set
c) Bidadi (Bangalore)
Scraper launcher/ receiver *
Cartridge type gas filters
Flow meters
Control room-cum-administrative building
DG set
* Assumed that in future GAIL may flow the gas from Bangalore to Kanjirkkod therefore
Kanjirkkod Bangalore section of the pipeline is considered Bidirectional)
c) Receipt terminal for consumer clusters in Palakkad, Coimbatore,Trippur, Erode, Salem -
Facilities as above
1.4.3.4 Intermediate Pigging Station-cum-tap off's and maintenance base
a) Kanjirkkod, Kasargod, Coimbatore and Salem etc.
Scraper launcher and receiver
Cartridge type gas filters
Flow meters
Control room-cum-office
DG Set
1 .4.3.5 Intermediate Pigging Station
Scraper launcher and receiver
Cartridge type gas filters
Flow meters
Control room
1.4.3.6 Consumer Terminals:
Cartridge type gas filters
Flow Meters
Letdown system (PRS) -if required
Field mounted flow computers for Consumer upto 0.8 MMSCMD
Metering Data for all the consumers 0.8 MMSCMD
Data for consumers > = 0.8 MMSCMD shall be collected thru SCADA
Power supply for metering will be fulfilled through solar system however for other
applications power shall be taken from consumer on chargeable basis.
1.4.4 POWER SUPPLY AT TERMINALS
1.4.4.1 Kochi Dispatch Terminal
415V, 3 Phase supply from R-LNG plant of Petronet Ltd is considered available. 1 No. DG set of
125 KVA capacity shall also be provided to cater to Auxiliary/Emergency load.
1.4.4.2 Receipt Terminals
1.4.4.2.1 Bangalore (Bidadi) and MCF (Mangalore)
Two feeders of 11 kv/415 V supply from KSEB grid is considered available to meet the power
demand of the terminal. In addition a DG set of 125 KVA capacity to cater to Auxiliary /
Emergency load of the terminal shall also be provided.
1.4.4.2.2 Intermediate Pigging Stations at Kanjirkkod, Kannur and Salem
11 kv / 415 V power supply from the grid of State Electricity Boards of the states in 'which these
stations are located is considered to be available. In additional a DG set of 30-45 KVA capacity
shall be provided to cater to Auxiliary / emergency load of the terminal.
1.4.4.3 Other Stations
At all other stations, electricity load demand shall be met by Grid with solar system/CCVT /TEG
1.4.5 SCADA & TELECOMMUNICATION SYSTEM
The complete system shall be monitored and controlled by Supervisory Control and Data
Acquisition (SCADA) system for which Master Control Stations (MCS) will be provided at Kochi
and Kanjirkkod (Trichur). The inter-master stations communication shall be through high speed
data channels provided by OFC based communication system. A satellite communication system
(SCPC) connecting Kochi, Kayamkulam, Bangalore, Mangalore, and GAIL Noida is proposed for
back up and connectivity for essential voice and data traffic. To facilitate the operations personnel
at the manned stations for being able to view the entire pipeline date, remote work stations shall
be extended from the SMCS's to all manned Stations.
APPS system for leak detection envisaged shall be provided with following modules:
a) Predicitive00.
Module
b) Inventory analysis
c) Survival time analysis
d) Pipeline Transportation Efficiency Scrapers tracking module
e) Contingency Analysis
f) Operator learning.
1.4.6 CAPITAL COSTS
The total capital cost for the project is estimated at Rs. 2817.40 Crores including a Foreign
Exchange (FE) component of Rs. 18.59 Crores. The cost estimates have been prepared based
on desk top study.
1.4.7 PROJECT SCHEDULE
The proposed project facilities up to mechanical completion (including pre-project activities) are
expected to be completed in 36 months from the zero date i.e. the date of go-ahead clearance by
GAIL. It is assumed that the detail route survey and environment clearance shall be made
available prior to award of work. Pipeline is proposed to be executed in three phases.
Phase I (2010-11) - Kochi to Alwaye and spurline to FACT-I/FACT-II and Other Consumers in
Alwaye
Phase II (2011-12) - Alwaye to Kanjirkkod- Pallakkad,
Kanjirkkod to Mangalore and
Spurlines to consumer in Kottakal, Kannur, Kozhikode, Kasargod and Mangalore
Phase III (2012-13) -Pallakkad to Bangalore and
Spurlines to Consumer in Trippur, Coimbatore, Erode and Salem