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IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 1+14 of 30
A
A
A
2
1
2
3
Delay in issue of Process deliverables for engineering for NHT / ISOM due to delay in receipt of Process Package from M/s UOP (Process pkg incl. resolution sheet received on mid Aug'13 against sch of 30-Apr-13) Schedule : 31-Jul-13 Anticipated : mid Nov'13
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
Process
Low
N
N
Y
N
Short term
D
0.2
Open
Delay in Finalisation of balance OSBL distribution P&IDs due to delay in receipt of data from BPCL LAD - 30-Nov-12; Ant - 15-Oct13 Natural gas operating/ design condition information has been received from BPCL during meeting dated 13 & 14.8.13. Steam distribution : Preliminary discussion on BOO steam distribution held with BPCL. BPCL approval on EIL scheme required.
Open
Process
Medium
N
N
Y
N
Short term
D
0.16
Holds, missing information, corrections, changes in PDS / P&IDs - CDU / VDU - DCNs on account of HAZOP recommendations for CDU / VDU
Open
Process
Medium
N
N
N
N
Short term
D
0
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 2+14 of 30
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
4
5
6
7
8
9
10
11
12
Open
Process
Medium
N
N
N
N
Short term
D
0
Close
BPCL / Process
Low
N
N
Y
N
Short term
I
0.4
Delay in "issue for engineering - IFE" PDS / P&IDs Close for DHDT P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
Process
Very High
N
N
Y
N
Short term
D
0.16
Delay in "issue for engineering - IFE" PDS for DCU LAD : 29-Dec-12; Ant : 19-Mar-13
Process
Medium
N
N
Y
N
Short term
D
0.16
Process
Low
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
Status
3
Risk Id
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Holds, missing information, corrections, changes in PDS / P&IDs - DCU A
4
Delay in Process Package for TGTU (M/s CB & INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13 A
A
A
A
5
6
7
8
Agreement signed by BPCL-KR issued to Licensor on 04.04.13
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Close
Close
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 3+14 of 30
A
A
A
4
5
6
7
8
9
10
11
12
Delay in "issue for engineering - IFE" PDS / P&IDs Close for FCC LAD :29-Jan-13; Ant : 08-May-13
Process
Low
N
N
Y
N
Short term
D
0.16
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12
Process
Low
N
N
N
N
Short term
I
0
Delay in "issue for engineering - IFE" PDS / P&IDs Close for VGO-HDT LAD : 29-Jan-13; Ant : 10-May-13
Process
Medium
N
N
Y
N
Short term
D
0.16
-Preparation of Offsite P&ID’s for tankages (LAD - Close 21.01.13) - Delay has been due to delay in receipt of As-built drawings from BPCL-KR (except CEMP-II). All details received now. -Upgradation of Crude oil pipeline system (Inside refinery) to be taken up.
POSD
Very High
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
A
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
9
Close
10
11
12
0.00
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 4+14 of 30
2 13
14
In view of increase in sulphur load PDS & P&IDs for sulphur block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement. Revision in PDS after issue of “Issued for Engineering” after release of MR -Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
A
A
A
A
A
3
4
5
6
7
8
9
10
11
12
Close
Process
Low
N
N
Y
N
Short term
D
0.16
Close
Process/EN GG
Low
N
N
Y
N
Long term
I
0.2
Process
High
N
N
Y
N
Short term
I
0.4
Low
Y
Y
Y
Y
Long term
D
0.2
Y
Y
Y
Y
Long term
D
0.2
Status
1
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
A
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
A
Risk Id
Integrated Refinery Expansion Project
Close
15
Close
16
Revision in PDS after issue of “Issued for Engineering” after Order
Process/EN GG/Procure
Close
17
Revision in PDS after issue of “Issued for Engineering” after Equipment manufacturing
Process/EN Very Low GG/Procure
Close
Process
Low
N
N
Y
N
Long term
I
0.2
18
Updation of estimated utilities on account of revision in process parameters (revision of PDS based on engg comments)
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
19
ISBL Distribution P&IDs for VGO-HDT SCH: 30-Nov-12 ANT: Jun-13
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 5+14 of 30
2
A
20
A
21
A
A
A
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 ANT: 31-May-13
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
Process
Medium
N
N
Y
N
Short term
D
0.16
Close
Utility distribution P&IDs for DCU
Close
Process
Low
N
N
N
N
Long term
I
0
Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 Updation of P&ID as per finalised condensate philosophy to be taken up.
Open
Process
Medium
N
N
Y
N
Short term
D
0.16
Open
Engg
Very High
N
N
N
N
Short term
D
0
23
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed engineering activities.
Open
Power Tech.
High
N
N
Y
N
Short term
D
0.16
24
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new GTG).
22
13
0.00
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 6+14 of 30
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
4
5
6
7
8
9
10
11
12
BPCL confirmation/clarification over datasheets/GAD’s for existing/new raw water intake pump obtained from M/s KBL (LAD for MR for pumps - 07.03.13)
Close
Engg.
Medium
N
N
Y
N
Short term
I
0.4
Identifications of hook-ups on flare lines and finalisation of methodology BPCL Signing of ISBL P&IDs and with battery limiti.e. P&IDs for availability of Shut down / Hot tapping. Units, Utility packages & other packages.
Close Open
Projects Process / POSD
Medium Low
N N
N N
Y Y
N N
Short term Short term
I D
0.4 0.16
Close
Process / POSD
High
N
N
Y
N
Short term
D
0.16
28
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Open
Engg.
Very High
N
N
Y
N
Short term
D
0.16
1
Issue of Equipment layout for engineering for NHT/ISOM Ant - 21-Aug-13) Delay in this activity shall hamper the following: i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation
Key Risk Description
1
2
A
25
A
26
A
27
A
B
Status
3
Risk Id
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 7+14 of 30
B
B
B
B
B
4
5
6
7
8
9
10
11
12
Close
Engg.
Very high
N
N
Y
N
Short term
D
0.16
Close
Engg.
High
N
N
Y
N
Short term
D
0.16
Open
ENGG
High
N
N
Y
N
Short term
D
0.16
Procure/EN GG/CONS.
Medium
Y
N
Y
N
Long term
D
0.12
New requirement of power recovery system Close (FCCU) shall have impact on project cost. 3 Nos PRTs envisaged (FCC-1 Nos ; VGO- 2 Nos)
Project
High
Y
N
Y
N
Short term
I
0.6
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; Ant: Mid Jun'13
Engg.
High
N
N
Y
N
Short term
D
0.16
Key Risk Description
1
2
2
3
4
5
6
7
Issue of Equipment layout for engineering for VGO-HDT LAD - 07-Nov-12 Ant- 26-Dec-12 Delay in this activity shall hamper the following: Issue of Equipment layout for engineering for i) 3 D Modelling FCCU (targeted by ii) Civil/Structural & 27.12.2012) UG Piping Tender preparation Delay in this activity shall hamper the following: i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation NIT for Heater for FCCU LAD -01-Apr-13 ; Ant - 18-Jun-13 a) Cost/time overrun due to rework b) Non completion of critical project activities within time & delay in Project completion c) Poor performance of Sub-contractors and Vendors
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
B
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Close
Open
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 8+14 of 30
B
B
B
C
4
5
6
7
8
9
10
11
12
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant - End Close May 13) Piping preliminary MTO has been released without covering DHDT, VGO FCC& offsite interconnection P&IDs, Flare system & offsite storage P&IDs. Prel. MTO covers 35% for large bore pipes.
Piping
Very High
N
N
Y
Y
Short term
D
0.2
Delay in thermal design for Heat exchangers & Air Close coolers for licensed and non licensed units LAD (DHDT): 02-Feb-13 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
HMTD
Very High
N
N
Y
N
Short term
D
0.16
Issue Overall UG piping layout drawing for the complex
Close
Engg.
High
N
N
N
N
Short term
D
0
Completion of 30 % Model review VGO- LAD: 09-Mar-13 FCCU-LAD : 23-Apr-13
Open
Engg.
High
N
N
Y
N
Short term
D
0.16
NIT for Civil & Strl work for existing Refinery Area LAD: 31-Jan-13 ANT: 18-Jun-13
Open Project/C&P Very High
N
N
Y
N
Short term
D
0.16
Key Risk Description
1
2
8
9
10
11
12
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
B
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 9+14 of 30
B
B
B
B
2
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
N
N
Y
N
Long term
D
0.08
a) Inaccurate assessment of quantum of work
Close
MR issue for MCC (Main combustion Chamber) packages.
Close
4
5
Engg/procur Very High ement
13
14
15
16
Project
Medium
N
N
Y
N
Short term
D
0.16
Timely finalisation of Package Interface Open CDSP-DCU awarded on 22-Aug-13; RR pkg-FCC awarded on 25-Jul-13. (Battery Limit conditions for each package to be frozen within three months of award to ensure time availability for engg, procurement and construction by all the concerned).
Engg.
High
N
N
Y
N
Short term
D
0.16
Unit and offsite interfaces (Elevation termination levels)
Engg.
Medium
N
N
Y
Y
Long term
D
0.1
LAD: 16-Feb-13 Ant: 15-Apr-13
Close
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 10+14 of 30
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
2
3
4
5
6
7
8
9
10
11
12
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule requirements. LAD - 28.02.13; Ant - upto Feb 14.
Open
Projects
High
N
N
Y
N
Short term
D
0.16
NIT for Heater for DCU LAD -15-Feb-13;
Close PROCESS/ Very High ENGG
N
N
Y
N
Short term
I
0.4
Open
Low
N
N
Y
N
Long term
D
0.08
19
CPP: Integration of various packages & BOP Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas Booster compressor.
Open Engg/procur ement
Medium
N
Y
N
N
Long term
I
0.15
B
20
Distributed Control System (DCS) Detailed engg., supply and erection (ordered on M/s Emerson Process on 04.11.13)
B
21
60 % Model review for DCU (LAD:03.07.13 Act:13.09.13)
Close
Very High
N
N
Y
N
Short term
D
0.16
B
B
B
17
Status
Risk Id
Integrated Refinery Expansion Project
18
Engg/Cont.
ENGG
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 11+14 of 30
B
B
B
B
5
6
7
8
9
10
11
12
Package Vendor refuses to submit Instrumentation Open Engg/procur Drawings/ Documentation in Smart Plant ement Instrumentation Database as per Client Requirement
Low
N
Y
Y
N
Long term
D
0.14
Open Engg/procur ement
Low
N
N
Y
N
Long term
I
0.2
23
Delay in Interface Engineering (including control system) due to non availability of Package Vendor Data
Open
ENGG
Medium
N
N
Y
N
Short term
D
0.16
20
60 % Model review for DHDT (LAD:07.08.13 Ant:04.10.13) - Integrated model for RGC, MUG compressor, Feed filter & Heater pkg awaited from vendor. - Vendor drawings for sheds awaited.
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
GC
Medium
N
N
Y
N
Long term
D
0.08
Order of MR for DG set Dely: (12 M FOB + 3 M Site work) Sch: 05.11.13
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
22
24
25
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
B
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
4
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 12+14 of 30
4
5
6
7
8
9
10
11
12
Receipt of Inputs from Process / Vendors for 60 % Close Model review for VGO-HDT required for procurement of piping material (LAD:14.08.13 Ant:25.10.13) - Integrated model for RGC, MUG compressor, Feed filter & Heater pkg awaited from vendor. - Vendor drawings for sheds awaited.
ENGG
Very High
N
N
Y
N
Short term
D
0.16
60 % Model review for Open FCCU (LAD:16.09.13 Ant:25.10.13) - Line size for 300 nos P&IDs under hold -Vendor data needed for coalescer, electric heater, pumps & filters - Review of model by Licensor (Stone & Webster) envisaged.
ENGG
Very High
N
N
Y
N
Short term
D
0.16
60 % Model review for SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), 164 (SRU),15 (SWS) & 60(TGTU) + 155(Utilities -CVs Size Hold as follows: 13 (ARU), 6 (SWS), 125 (SRU). -All Control Valve Face to Face Dimensions are
ENGG
Medium
N
N
Y
N
Short term
D
0.16
Key Risk Description
1
2
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
B
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
26
B
27
B
28
Open
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 13+14 of 30
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
2
3
4
5
6
7
8
9
10
11
12
Delay in release of Intermediate 2nd MTO LAD:30.09.13; Act:31.10.13) Holds: -CDU/VDU: Pump nozzle for 6 nos. pumps under hold), sizes for 256 lines under hold, Control valve matching flange, bypass valve and flanges (21 nos.) & PSV inlet outlet flanges and reducers (37 nos.) -DHDT: By-pass lines for CVs under hold (30nos), PSV's mating flanges and reducers (44 nos), Lines (103 nos.) not considered in MTO.
Open
ENGG
Very High
N
N
Y
N
Short term
I
0.4
Generation of Surplus Piping material
Open
ENGG
Low
N
N
Y
N
Short term
D
0.16
ENGG ENGG
High Low
N N
N N
Y Y
N N
Short term Short term
D D
0.16 0.16
Status
Risk Id
Integrated Refinery Expansion Project
B
29
B
30
B
31
HAZOP for FCCU Close LAD - 23-Sep-13 Completion of 90 % engineering by Mar-14. Open Average progress achieved in last 3 months 3.0 %
B
32
LD Milestone date - Dec'13
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 14+14 of 30
B
C
C
4
5
6
7
8
9
10
11
12
Release of final Piping MTO Sch: Jul'14
Open
ENGG
High
N
N
Y
N
Short term
D
0.16
Finalisation of GTG fuel forwarding scheme for naphtha to day tank when Naphtha tank being under maintenance.
Open
POSD
Medium
N
N
Y
N
Short term
I
0.4
Delay in award of PRT -FCCU(Hot gas expander) LAD: 19.04.13 Ant: 30.12.13 Multiple Bids extensions leading to delay in ordering. 02 Bids recd on 12.08.13 (Dresser Rand ,Elliot Ebara) Org. BDD: 27.06.13 1st extension: 16.07.13 2nd Extension: 01.08.13 3rd extension: 09.08.13 Duration: 16 M FOB
Close
Project
Medium
Y
Y
Y
N
Short term
I
0.9
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 Duration: 18 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
33
34
1
2
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
B
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 15+14 of 30
C
7
8
9
10
11
12
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
Very High
Y
Y
Y
N
Short term
D
0.36
3
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
Close
Project
Very High
Y
N
N
N
Short term
I
0.2
Award of Heater for DHDT LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for DCU LAD -06.06.13 ; Ant - 25.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
Status
6
Risk Id
5
2
4
C
6
C
4
1
5
C
3
Key Risk Description
C
C
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
7
8
9
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 16+14 of 30
C
C
1
2
3
4
5
6
7
8
9
10
11
12
Award of PRT for DHDT & VGO-HDT unit (Pumps centrifugal multistage) Sch: 23.04.13 Ant: 15.03.14 (IV-P-301A/B)
Open
ENGG
Medium
Y
Y
Y
N
Short term
D
0.36
NIT for Composite Works for Offsite DHDS area LAD -22.07.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for Existing refinery area Open LAD -22.07.13 ; Ant - 31.10.13
ENGG
Very High
N
N
Y
N
Short term
D
0.16
Open Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
Status
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
C
Risk Id
Integrated Refinery Expansion Project
10
11
12
13
Award of : Main fractionator for FCCU LAD: 25-Mar-12 Ant: 20-Jul-13
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 17+14 of 30
C
C
C
C
C
C
2
14
15
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
4
5
Issue NIT for Tankage-II LAD: 21-Jan-13 ANT: 31-May-13
Close Project/C&P Very High
N
N
Y
N
Short term
I
0.4
Award for RO-DM LAD:30-Jan-13 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13
Close
Project
High
N
N
Y
N
Short term
I
0.4
Project / Licensor
Very High
Y
Y
Y
N
Short term
I
0.9
Project
Low
N
N
N
N
Short term
I
0
Project
Very High
N
N
Y
N
Short term
I
0.4
16
17
18
19
NIT for Reactor regenerator package for FCCU Close LAD : 01-Jan-13 Ant: 21-Feb-13 Changes in scope of supply led to revision in BQC / tender.
Award for Raw water quarries LAD :03-May-13 ANT: 15-Apr-13 Ordering of Reactor for VGO-HDT LAD: 29-Dec-12 ACT: 08-Apr-13
Close
Close
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 18+14 of 30
2 Award of contract for Piling-II LAD: 31-Dec-12
C
C
C
C
C
20
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
3
4
5
6
7
8
9
10
11
12
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
Status
Risk Id
Integrated Refinery Expansion Project
Ant: 15-Apr-13
21
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 Ant: 30-Mar-13
Close
Engg.
Very High
N
N
Y
N
Short term
I
0.4
22
Award of Crude and Vacuum heaters (LAD 29.12.12) Ant : 07.03.13
Storage of sulphur and related issues with Granulator to be finalised between BPCL / EIL.
Close
Project
Very High
N
Y
Y
N
Short term
I
0.7
NIT for ETP package with WAO (Wet air oxidation) Close LAD: 15-Jan-13 Ant: 16-Apr-13
Project
Very High
N
N
Y
N
Short term
I
0.4
23
24
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 19+14 of 30
2 Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13
C
C
3
4
5
6
7
8
9
10
11
12
Close
Project
High
N
N
Y
N
Short term
D
0.16
Project
Very High
N
N
Y
N
Short term
I
0.4
Strl
High
N
N
Y
N
Short term
D
0.16
25
26
Award of contract for Building incl substations LAD: 07-Feb-13 Ant: 15-Apr-13
Filling of existing part fire water pond required for area preparation. Sch - 28.08.13; Area handed over to M/s L&T C
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
27
Close
Open
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 20+14 of 30
C
6
7
8
9
10
11
12
Delay in ordering of Long Lead Items. Close Engg / C&P Very High Technical / Commercial evaluation of long lead items (compressors & packages) taking more than 2 months.
N
N
Y
N
Short term
D
0.16
Award of Waste heat Boiler package (Waste Heat Boilers along with respective steam drums(un engineered ), Incinerator Combustion Chambers (engineered), Incinerator vent stacks). LAD: 27.04.13 Ant: 30.12.13 Bids extension: 1st extension - from 28.05.13 to 20.06.13. 2nd Extension- from 20.06.13 to 02.07.13. 3rd extension - from 02.07.13 to 08.07.13. Duration: Supply + Erection - 18 M
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
4
5
28
29
Close
Project
Very High
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 21+14 of 30
C
4
5
6
7
8
9
10
11
12
Delay in award of CDSP package Schedule: 02.03.13 Anticipated : 30.08.13 Completion of works Sch: 01.05.15 ( M); RFQ Duration : ( M) Anticipated: 23.11.15 (27 M) Bidders quoted 27 M against schedule of 26 M.
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
Ordering of GTG Pkg (LAD:10-Mar-13; Ant 20.07.13) Bid received on 28.03.13. Multiple extension (4 times) in bid due date on request of M/s Siemens. Duration (Supply) - 15 M FOB /16 M FOT as per RFQ; Sch : 20 M
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
Key Risk Description
1
2
30
31
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 22+14 of 30
C
4
5
6
7
8
9
10
11
12
Delay in Ordering of HRSG Close (Sch Order - 22-May-13; Ant - 20-Dec-13) Initial Change in configuration by BPCL. Multiple extensions (twice) in bid due date due non availability of exhaust data for GTG. Post Enquiry changes in type of Fuel (LSVR) by BPCL. No PTR available for LSVR Fuel Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
Projects / Engg
Very High
Y
N
Y
N
Short term
I
0.6
Ordering of Reactor regenerator package for Close FCCU LAD : 10-Apr-13 Act: 10-Jul-13 Changes in scope of supply led to revision in BQC / tender due to which NIT was delayed. Bidders sought extension in dates.
Project / Licensor
Very High
Y
Y
Y
N
I
0.9
Key Risk Description
1
2
32
33
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Short term
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 23+14 of 30
C
C
4
5
6
7
8
9
10
11
12
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) Duration: 21 M+2 M No bidder could meet the BQC criteria in view of which the tender has been re-floated.
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Open
Process / Engg / constn
Very High
N
N
Y
N
Short term
I
0.4
35
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 Duration: 20 M
Close Project/C&P Very High
N
N
Y
N
Short term
D
0.16
36
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 Duration: 22 M+2 M
Key Risk Description
1
2
34
Anticipated Completion: 29-Jul-15
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 24+14 of 30
5
6
7
8
9
10
11
12
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
Low
N
N
Y
N
Long term
I
0.2
Failure of contractors
Open
Const.
Low
N
N
Y
N
Long term
D
0.08
Ordering of Ejector Pkg (LAD:12-Jan-13; Ant: 15-Jul-13)
Open
Project
Medium
Y
Y
Y
N
Short term
I
0.90
Award of Heater package for DCU (LAD:24-May-13; Ant: 15-Nov-13 Earlier 04 Bids recd on 21.05.13. (Petron, Thermax, Heurtey, Technip). Due to Technical and related commercial issues enquiry re-floated. Duration 20 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.40
1
2
Status
4
Risk Id
3
Key Risk Description
37
C
38
C
39
C
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
40
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 25+14 of 30
C
C
C
4
5
6
7
8
9
10
11
12
Award of Civil & Strl work for DHDS offsite area (LAD: 30-Mar-13; Ant: 20.07.13) Duration: 18 M
Open
Project
High
N
N
Y
N
Short term
I
0.40
Award of Civil & Strl work for refinery area. (LAD:25-Apr-13; Ant: 10.10.13) Duration: 16 M
Close
Project
High
N
N
Y
N
Short term
I
0.40
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) Duration : 16 M
Open
Project
Medium
N
N
Y
N
Short term
D
0.16
Award of work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
Key Risk Description
1
2
41
42
43
44
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 26+14 of 30
C
C
C
4
5
6
7
8
9
10
11
12
Ordering of Main Air blower & wet gas compressor Close for FCCU LAD: 04-Mar-13 Ant: 30-Sep-13 (Total execution duration is 25-27 M : 19 M FOT for delivery of WGC & MAB at site + 6 to 8 M Site installation & pre-comm; Time Available from order to MC OF FCCU - 24 months)
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of Civil & Strl contract for CDU/ VDU & DCU LAD: 15-Dec-12 Ant: 07-Mar-13
Close
Project
Close
N
N
Y
N
Long term
I
0.2
Ordering of wet gas compressor for DCU LAD: 02-Feb-13 Ant: 30-Jun-13
Close
Project
Medium
N
N
Y
N
Short term
I
0.4
Ordering of OFF GAS COMPRESSOR - VGO LAD: 08-Jun-13 Ant: 30-Oct-13 RFQ duration: 17 M FOB
Open
Project
High
N
N
Y
N
Short term
D
0.16
Key Risk Description
1
2
45
46
47
48
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
0.00
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 27+14 of 30
1
2
3
4
5
6
7
8
9
10
11
12
Award of Sulphur Forming LAD: 03.04.13 Ant: 30.01.14 Earlier enquiry re-floated due to changes in MR requirements by BPCL(MR was revised as Evaluation methodology was to be based on NPV and in view of 2 different types of technologies viz., sulphur pelletiser and sulphur granule); refloated again as financial criteria was not met by all the bidders.
Open
Project
Very High
N
Y
Y
N
Short term
D
0.28
Award of contract for Civil & structural for FCCU area (refloated) LAD:15-Mar-13 Ant: 30-Sep-13 Compl: 15 M – Dec'14; Sch: Nov’14 As decided during Management meeting dated 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
Very High
N
Y
Y
N
Short term
D
0.28
49
50
Status
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
C
Risk Id
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 28+14 of 30
C
1
2
3
4
5
6
7
8
9
10
11
12
Award of contract for Civil & structural for DHDT & VGO area (refloated) LAD:15-Mar-13 Ant: 30-Sep-13 Compl: 16 M – Jan’15; Sch: Nov’14 As decided during Management meeting dated 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
Very High
N
Y
Y
N
Short term
D
0.28
Award of contract for Civil & structural for CPP area LAD:28-Jun-13 Ant: end Aug-13 Duration: 16 M
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
Award of MCC package LAD:10.06.13 Ant: 14.08.13 Duration: 12 M despatch and 6 M for site work (ODC)
Open
Project
High
N
N
Y
N
Short term
I
0.4
51
52
53
Status
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
C
Risk Id
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 29+14 of 30
C
C
4
5
6
7
8
9
10
11
12
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
54
Award of contract for RWTP (Refloat case) LAD: 14-Jan-13 Ant: 19-Jul-13 (Execution Duration - 18+2 M)
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
55
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 15.06.14 (Incinerator burner) (Execution Duration - 14 M)
Award of Air blower/compressor for SRU LAD: 29-Mar-13 Ant: 25-Jul-13 (Execution Duration - 17 M FOB/ 18 M FOT)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
56
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 30+14 of 30
2 Delay in Award of contract for Demountable flare (LAD: 08-Apr-13; Ant: 28-Sep-13) Change in type of Flare. Initially as per DFR normal flare was envisaged.
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
3
4
5
6
7
8
9
10
11
12
Close
Project
Very High
Y
Y
Y
N
Short term
I
0.9
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Status
Risk Id
Integrated Refinery Expansion Project
Post enquiry significant changes (received on 15.03.13) in Flare Load/Process Data Sheet due to enormous increase in BOO flare load and non acceptance of mitigation measures by FCCU Licenser. C
57
Change in flare load data due to change in flare height upto 150 M. Completion of works Sch. : 31.01.15 Ant. : 28.02.15
C
58
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 Duration: 12 M
13
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Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 31+14 of 30
C
C
C
C
2
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
4
5
Award for:RGC compressor for VGO-HDT (LAD: 30-Mar-13; Ant: end Jun 13) Dely: 18 M
Open Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
Award of MUG compressor for VGO-HDT (LAD: 08-Apr-13; Ant: 30.11.13) Dely: 16 M FOB
Close Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
Award of Contract for Tankage-III (Crude tank: 02 Close Project/Eng Very High Nos & 1 surge relief tank and crude drain tank) g Outage of existing crude tank from crude to naphtha can be taken up after commissioning of new crude tanks. Shutdown of existing tanks- 17 & 18 depend on commissioning of new crude tanks25/26 under tankage-III. Sch: 01.10.13 Ant: 15-Dec-13
N
N
Y
N
Short term
I
0.4
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: Jun 13)
N
N
Y
N
Short term
I
0.4
59
60
61
62
Close Project/Eng Very High g
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 32+14 of 30
C
C
C
2
63
64
65
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
4
5
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep-13) Duration : 18 M FOB
Close Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) Sch: 30.04.13 Ant: 30-Sep-13 Duration:22 M
Close
BPCL
High
N
N
Y
N
Short term
D
0.16
Award of Tankage-IV (Total 15 Nos Tanks) LAD: Jan14 • Outage for Tank YT-340 depends on readiness of at least one new DCU feed tank which will require 14 M durations. Alternative scheme required to be finalised for outage. • Outage of Tankage YT-18 depends on readiness of new crude tanks (Tankage-III; YT-25/26). Alternative scheme required to be finalised for outage.
Open
BPCL / Projects
Very High
N
N
Y
N
Short term
I
0.4
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 33+14 of 30
2
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of Composite Works for CDU/VDU (06 Bids Open - L&T, Petron, Offshore, Mcnally Bharat, Albana, IOTL recd on 04.09.13) LAD -30.08.13 ; Ant - 31.10.13 C
C
C
66
Duration - 20 M
Award for contract for development of flare area LAD: 01-Nov-13 Ant: end Dec'13
Close
Project
Very High
Y
N
Y
N
Short term
D
0.24
Award of Composite Works for VGO-HDT, DHDT, CPP and Offsites (DHDS) LAD 31.12.13 ; Ant - 30.05.14
Open
ENGG
Very High
N
N
Y
N
Short term
I
0.4
67
68
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 34+14 of 30
C
C
C
C
4
5
6
7
8
9
10
11
12
Award of Heater package for FCCU (LAD:08-Jul-13; Ant: 15-Dec-13 Earlier 05 Bids recd on 23.07.13. (Thermax, Technicas, Petron, B&R, JNK). Duration 20 M
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of Gas Booster Compressor for CPP (Dly: 13 M FOB / 14 M FOT)) (LAD:29.12.13; Ant: 30.07.14)
Open
Project
Medium
Y
N
Y
N
Short term
I
0.6
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 Ant: 10.10.14
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards Piping intermediate MTO-II released on 30.10.13.
Open
Project
Low
N
N
Y
N
Short term
D
0.16
Ordering of Critical Valves Sch: 11.07.14 Ant: 31.01.15 Dely: 06/07 M FOT /FOB
Open
Project
High
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
69
70
71
72
73
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 35+14 of 30
C
C
C
1
2
3
4
5
6
7
8
9
10
11
12
Award of contract for Mechanical works-CPP area LAD: 28.02.14 Ant: 25.05.14
Open
Project
Medium
N
N
Y
N
Short term
D
0.16
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 Ant: 15.05.15
Open
Project
Low
N
N
Y
N
Short term
D
0.16
Award of Composite Works (Structural Works & Mechanical) for NHT/ISOM-Refloated Sch: 08.05.14 Ant: 25.03.15
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of Fuel forwarding Pumps (08 nos) for GTG Open (Dely: 6 M FOB / 7 M FOT) Sch:27.06.14 Ant: 05.08.14
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of Electrical & Instrumentation Works for Units & Offsite Sch: 30.06.14 Ant: 10.11.14 Electrical/Instr. Works: Part A: CDU/VDU, DCU, FCCU, DHDT, VGO-HDT & IREP Offsite: Part B: SRU & DHDS/Refinery Offsite :
Project
Low
N
N
Y
N
Long term
I
0.2
74
75
76
77
78
Status
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
C
Risk Id
Integrated Refinery Expansion Project
Open
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 36+14 of 30
D
D
4
5
6
7
8
9
10
11
12
13
Delay in award of piping material with G2E specification in CPP area.
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
Completion of Reactor regenerator package for FCCU-M/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 93.9% Act: 72.8 % Construction Progress: Sch: 90.24% Front: 95.62% Act: 35.23 %
Open
Project
Very High
Y
Y
Y
N
I
0.9
0.86
Delivery of GTG Pkg at site (LAD:29-Sep-14; Ant - Close 24-Nov-14) Awarded to M/s BHEL Duration (Supply) - 16 M
Project
Very High
Y
Y
N
N
I
0.25
Key Risk Description
1
2 79
1
2
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
C
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Short term
Long term
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 37+14 of 30
D
D
D
4
5
6
7
8
9
10
11
12
13
Completion of UB package LAD : 31.03.15 CCD : 23.03.15 ECD:10.08.15 Awarded to M/s ISGEC on 25.07.13 Construction Progress: Sch:100 % Front: 100 % Act: 58.04 % Manpower : Required 450, Deployed 333 incl 39 welders
Open
Project
Very High
N
N
Y
N
Long term
I
0.2
0.19
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14
Open
Project
Low
N
N
Y
N
Long term
I
0.20
Delivery of wet gas compressor for DCU at Site (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 31.03.15)
Open
Project
Low
N
N
N
N
Long term
I
0
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 28.02.15)
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
3
4
5
6
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
D
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT.
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 38+14 of 30
D
4
5
6
7
8
9
10
11
12
13
Completion of all three site Fabricated Columns for FCCU :Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). LAD: 22.01.15 CCD:14.01.15 ECD: 15.10.15 Overall progress: Sch: 100 % Act: 76.2 % - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach road upto fabrication yard, which affected shifting of sections.
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.67
Completion of MCC pkg for SRU LAD: 23.06.15 CCD:18.02.15 (including Site work) ECD: 30.09.15 site work yet to start Ordered to M/s Thermax on 19.08.13 (18 M incl erection)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Key Risk Description
1
2
7
8
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
D
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 39+14 of 30
D
2
9
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 30.07.16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 92.8 %; Act: 68.4 % Construction Progress: Sch: 87.08% Front: 100% Act: 43 % Strl Steel: Out of total 3210 MT, 2926 MT procured, 1929 MT fabricated & 1716 MT received.
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
3
4
5
6
7
8
9
10
11
12
13
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
Status
Risk Id
Integrated Refinery Expansion Project
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 40+14 of 30
D
D
D
D
2
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
4
Open Project/Eng g
Low
N
N
Y
N
Long term
I
0.2
10
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M Ordered to M/s BHEL on 28.06.13
Open Project/Eng g
Low
N
N
Y
N
Long term
I
0.2
11
Delivery of RGC compressor for DHDT(LAD : 05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
BPCL / Projects / Const.
Medium
N
N
Y
N
Short term
I
0.4
T&CC
Very High
N
N
Y
N
Short term
I
0.4
12
13
Delay in hydrotesting of Vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: 19.03.15 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column.
Open
Logistics of VGO / DHDT reactors & Other ODC Open equipments from Kochi port to BPCL-KR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Jun15 DHDT reactor reached at site VGO reactor dispatched from L&T shop
13
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Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 41+14 of 30
2
14
15
3
4
5
6
7
8
9
10
11
12
13
Projects
High
N
N
Y
N
Long term
D
0.08
0.06
Low
N
N
Y
N
Long term
I
0.2
Close Monitoring of ODC equipment (including site Open fabricated/assembled) up to receipt at site
Delay in delivery at site due to non-availability of transporter / hindrances enroute. D
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
Status
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
D
Risk Id
Integrated Refinery Expansion Project
Close Procure/Co nstr
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 42+14 of 30
2 Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions.
D
D
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
Medium
N
N
Y
N
Short term
I
0.4
Low
Y
Y
Y
N
Long term
I
0.45
4
Open Contract / Inspection
13
16
17
Completion of Demountable Flare works (Awarded Open Project to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Apr-15 Ant: 24-Apr-15 Construction progress Sch: 100 % Act:30.9 %
0.14
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 43+14 of 30
D
D
D
D
2
18
19
20
21
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
4
Addition of 4th Riser in Demountable Flare and identification of additional Equipment to be procured due to the same. (BPCL informed additional of 1 no. riser during meeting dated 16th Oct 13.) - Flare (with 3 risers) awarded to M/s Airoil on 25Sep-13. Completion of Flare work: Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Open Project / Process
Very High
Y
Y
Y
N
Short term
I
0.9
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 31.10.15
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 CDD: 03.04.15 Ant: 30.04.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 EDD: 15.04.15
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
13
0.38
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 44+14 of 30
D
D
D
4
5
6
7
8
9
10
11
12
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 CDD: 07.10.14 Overall Progress: Sch: 98 % Act: 95.0 %
Open
Projects
High
N
N
Y
N
Long term
I
0.2
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
Open
Projects
Low
Y
Y
Y
N
Long term
I
0.45
24
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) LAD ;30.03.15 CDD: 30.04.15
Open
Projects
Medium
N
Y
Y
N
Long term
I
0.35
25
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 CDD: 30.03.15 (Excluding site work)
Key Risk Description
1
2
22
23
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
D
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
0.23
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 45+14 of 30
D
D
D
4
5
6
7
8
9
10
11
12
Delivery of steel plates by M/s Essar to other vendors. CDD: Progressively by 15.01.14.
Open
Projects
Very Low
N
N
Y
N
Short term
I
0.4
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 CDD: 10.03.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) LAD : 26.02.15 CDD: 13.04.15 ECD: 28.05.15 Delay by vendor with respect to CDD due to financial constraint.
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
Key Risk Description
1
2
26
27
28
29
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
D
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
0.10
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 46+14 of 30
D
D
D
D
4
5
6
7
8
9
10
11
12
Non acceptance of PO for DHDT & VGO feed filter Open by M/s Filtrex (MR-4370) Ordered on 21.12.13 to M/s Filtrex ( Dely: 13 M FOB)
Projects
Medium
N
N
Y
N
Short term
I
0.4
Non acceptance of work order by M/s Flowserve for DHDT Centrifugal pumps Ordered on 30.01.14 to M/s Flowserve (MR-5403) (FOA No 550 & 551) CDD: 01.03.15
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) CDD: 18.10.14
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
0.10
Availability of Piping materials to generate adequate piping material front to composite contractors. Sch: (Final MTO): Dec'14-Feb'15 EDD: Jun'15
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
0.20
Delivery Gas Booster Compressor for CPP (Dly: 13 M FOB
Open
Project
Low
N
N
Y
N
Long term
I
0.2
0.06
Key Risk Description
1
2
30
31
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
D
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
13
32
33
34
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 47+14 of 30
D
E
4
5
6
7
8
9
10
11
12
13
Delay in delivery of equipments by: M/s TEMA :CDD: 06.01.14 to 15.01.15; EDD:30.06.15 M/s Nuberg: CDD: 03.07.14 to 03.11.14; EDD: 30.06.15 M/s GR Engg: CDD: 28.01.14 to 31.07.14; EDD: 30.06.15 M/s Fabtech Projects: CDD: Jul’14 to Jan’15; EDD: Aug’15
Open
Project
Medium
N
N
Y
N
Long term
I
0.2
0.10
Delay in submission & finalization of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. CDD: 19.05.15
Open
Project
Low
N
N
Y
N
Short term
I
0.4
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsite) - Awarded on 25.09.12 (Sch - 100 %, Act 91.7%) RCC Piles:4822 / 5307 Nos. Balance for offsite (SS VGO & compound area at FACT). Presently 5 total rigs are operating
Open
Constn.
Medium
N
N
Y
N
Short term
I
0.4
Key Risk Description
1
2
35
36
1
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
D
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 48+14 of 30
E
E
E
2
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
Very High
Y
N
Y
Y
Short term
D
0.28
0.27
2
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
Open Constn.
Medium
N
N
Y
N
Short term
I
0.4
3
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered. Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 12 M available for construction works (excl. Dismantling works) against schedule of 22 M. - Process package was delayed by 2 M due to delay in P&IDs review meeting and delay in award of licensor. - Change in the scope based on health check report has an impact on Project cost and schedule. Physical Progress: Target Sch: 94.4% Catch Up Sch: 86.1 % Act: 59.3%
Open Constn. / Projects
Very High
Y
Y
Y
N
Short term
I
0.9
4
Open
4 Constn.
0.86
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 49+14 of 30
E
2
5
6
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
Status
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
E
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
N
N
Y
N
Long term
I
0.2
N
N
Y
N
Short term
I
0.4
4
Availability of Soil investigation Report for new Crude tankages area. Delay in availability of soil data will affect preparation for piling tender and layouts drawings. Further civil / structural tender will also affected.
Open BPCL / Projects / Const.
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 100% Front: 100 % Act:79.9 % CCD: 20.12.14 Ant: 15.07.15
Open
Const
5 High
Very High
13
0.38
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 50+14 of 30
E
4
5
6
7
8
9
10
11
12
13
Backlog 20.6% as of 15-Apr-15 in Construction activities viz., Civil works and Mechanical works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 35 M Catch Up sch: Const Sch Front Act 73.3 90.1 70.4 52.6 Contractors are facing problem in retaining the labour at site. Approx 13000 labours are available against requirement of 20000 at site.
Open
Const
Very High
N
Y
Y
N
Short term
I
0.7
0.67
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Jun'15)
Open
Constn.
Very High
N
N
N
N
Long term
I
0
0.00
Key Risk Description
1
2
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
E
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
7
8
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 51+14 of 30
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
2
3
4
5
6
7
8
9
10
11
12
Completion of piling work by M/s L&T (Piling-II): CDD- 08.05.14. (Total 12003 Nos piles). (Contr.Sch- 100%, Front-100%, Act-100%) Only 10 nos. hydraulic & 4 nos. conventional rigs are currently operational at site. Total 10124 nos completed out of 12003
Open
Constn.
High
N
N
Y
N
Short term
I
0.4
Payment to contractors
Close
Constn.
Low
N
N
Y
N
Long term
D
0.08
Low
N
N
Y
N
Long term
D
0.08
Medium
N
N
Y
N
Short term
I
0.4
E
9
E
10
Unrealistic project time leading to under quality E
E
Status
Risk Id
Integrated Refinery Expansion Project
Close
11
12
Dismantling of LO CAT SRU and area handing over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. Will affect release of front for tankages.
Open
Project / Engg. / planning BPCL
13
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 52+14 of 30
E
E
2
13
14
15
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
Status
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
E
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Project
Medium
Y
N
Y
N
Long term
I
0.3
0.15
0.57
Completion of Raw water treatment plant Pkg (M/s Open Triveni Engg).(Delayed due to refloating) Overall Progress: Contr. Sch: 99.7 % Act: 83.7% Construction Progress: Sch: 100 % Front: 100 % Act: 83.55 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Slow construction progress of SRU Block due to delayed area handing over - As per present trend 15 months (starting from end Jun’14) are available with respect to schedule of 25 M (As per past experience minimum requirement for SRU is 30 M).
Open Proj. / Constn.
Very High
Y
N
Y
N
Short term
I
0.6
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
Open Proj. / Constn.
Medium
N
N
Y
N
Short term
I
0.4
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 53+14 of 30
E
E
2
16
17
18
19
E
20
E
21
Status
1
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
E
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
E
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
N
N
Y
N
Short term
I
0.4
Very High
N
N
N
N
Short term
I
0
4
5
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Ant - Dec 2013
Close Proj.
Land acquisition for Crude tank (2 nos.) . (LAD Jul 13; Ant - 30-Aug-13)
Close Proj.
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
BPCL
Medium
N
N
Y
N
Short term
I
0.4
Delivery of bought out items by BHEL for GTG package (LAD supply:29.09.14; Ant - Jul'15) Awarded to M/s BHEL on 25.07.13 with CDD for delivery as 24.11.14.
Open
Const. / Projects
Low
N
N
N
N
Long term
I
0
Const.
Low
N
N
Y
N
Long term
I
0.2
EIL
Low
Y
N
Y
N
Long term
D
0.12
HEAVY LIFT Cranes for INTALLATION OF Close REACTORS Finalisation of Erection scheme and capacity the crane, inclusion in scope and timely mobilisation at site
Theft of material from Warehouse
Close
Very High
13
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Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 54+14 of 30
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
2
3
4
5
6
7
8
9
10
11
12
13
Completion of UG piping work due delay in receipt of piping material and monsoon.
Open
Const.
High
Y
N
Y
N
Short term
I
0.6
0.48
Lighting during construction
Open Constn.
Low
N
N
N
Y
Short term
D
0.04
EIL
Low
N
N
Y
N
Long term
I
0.2
Project
Low
Y
N
N
N
Short term
I
0.2
E
22
E
23
E
24
Delay in construction due to monsoon. As work Open progress between Jun to Sep is expected to be hindered due to monsoon, all out effort to be made to release tender as per sch. Generally to manage delays in initial stages of project, constr. Duration are reduced while floating tenders. This needs to be avoided.
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
E
25
Status
Risk Id
Integrated Refinery Expansion Project
Open
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 55+14 of 30
E
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
2
3
4
5
6
7
8
9
10
11
12
13
Construction of Subway on the PWD road including re routing of existing road / existing facilities and necessary liasoning with government department. Construction of culvert got affected
Open
Project
Very Low
N
N
Y
N
Short term
I
0.4
0.04
Slow construction progress in Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 CCD: 08.10.14; ECD: 15.09.15 Progress figures Sch: 100% Front: 99.7% Act.: 55.85% Insufficient mobilisation of manpower: Required: 635 nos Deployed: 216 nos
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
26
27
Status
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
E
Risk Id
Integrated Refinery Expansion Project
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 56+14 of 30
E
4
5
6
7
8
9
10
11
12
13
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 100%; Front: 100%; Act: 84.36% CCD:18.12.14; ECD: 15.06.15
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Slow progress of Civil & Strl Works for SRU block (Awarded to M/s Mcnally Bharat on 04.11.13) LAD: 12.01.15 CCD: 03.03.15 Ant: Oct'15 SCH. FRONT. ACT. 100% 100 % 62.17%
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Key Risk Description
1
2
28
29
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
E
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 57+14 of 30
E
4
5
6
7
8
9
10
11
12
13
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 ECD: 30.10.15 Contr. Sch: 91.29% Front: 86.75% Act: 54.96 %
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Completion of Coke handling work (Awarded to M/s Thyssen on 04.11.13) LAD: 18.04.15 CCD: 03.07.15 EDD: Dec'15 Construction: Sch:85.2 %; Front:100.0%; Act:26.3%
Open
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.29
Key Risk Description
1
2
30
31
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
E
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 58+14 of 30
E
2
32
33
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
Status
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
E
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
Medium
Y
N
Y
N
Long term
I
0.3
0.15
Very High
N
N
Y
N
Long term
I
0.2
4
Completion of DCU Heater works (Awarded to M/s Open Project Heurtey on 04.11.13 (20 M) LAD: May 15 CCD: 03.07.15 Ant: Oct'15 Overall Progress: Sch: 97.1 % Act: 83.7 % Construction work: Sch- 97.09% Front:100% Act:64.85%
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Completion Sch: 30.01.15 (CDD:11.06.15) Awarded to M/s Driplex on 12.06.13. (Duration: 20 M+2 M incl pre commng)
Open
Project
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 59+14 of 30
E
4
5
6
7
8
9
10
11
12
13
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 97.4 % Act: 59.1 % Construction Progress: Sch: 96.7% Front: 100 % Act: 36.9 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 96.68 %; Front:95.39% Act: 50.31 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Completion of works for Tankage-III (Crude Tanks) Open Project (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 Duration: 20 M Sch: 88.70 % Front: 100.0 % Act: 62.15 %
Very High
N
N
Y
N
Short term
I
0.4
0.38
Key Risk Description
1
2
34
35
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
E
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Awarded to M/s B&R on 25-Sep-13
E
36
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 60+14 of 30
E
E
E
2
37
38
39
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
Medium
N
N
Y
N
Short term
I
0.4
0.20
4
Slow progress of FCCU Heater works (Awarded to Open Project M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 100% Act: 72.1 % Construction progress: Sch: 100% Front: 97.55% Act:42.07%
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
Close Project
Very High
N
N
Y
N
Long term
I
0.2
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 CCD: 30.06.15; EDD: 30.09.15 (As per Vendor)
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
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Job No.: A307 Apr'15 Page 61+14 of 30
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5
6
7
8
9
10
11
12
13
Open Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
Slow Construction progress for Civil Works- FCCU Open Project Contr. Sch: 100 %; Front: 100% Act: 83.1 % (M/s SEPC) CCD: 24.12.14 ECD: Oct'15
Very High
N
Y
Y
N
Short term
I
0.7
0.67
Key Risk Description
1
2
40
41
Slow progress of RO-DM works (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 (As per vendor) Overall Progress: Sch: 99 % Act: 74.4% Construction Progress: Sch: 100 %; Front: 100%; Act:49.9%
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
E
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
4
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 62+14 of 30
E
E
2
42
43
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
4
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15 Constr. Progress: Sch: 100 % Front: 100 % Act: 85.6 % -Delay in completion of Radiography and PWHT
Open Project
Very High
Y
N
N
N
Long term
I
0.1
0.10
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
Construction Progress: Sch: 100% Front: 97.4% Act.: 36.4%
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 63+14 of 30
E
E
E
2
44
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
4
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: 30.06.15 Sch: 100 %; Front :99.6 % Act: 89.5 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open Project
Low
N
N
Y
N
Short term
I
0.4
0.12
Completion of Cooling Tower -I & II (Awarded to M/s Paharpur on 01.02.13) LAD: 31.01.15 CCD: 20.10.14 ECD: Jun'15
Open Project
High
N
N
Y
N
Long term
I
0.2
0.16
45
46
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 85.8%
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 64+14 of 30
2 Completion of Cooling Tower -III (Awarded to M/s Paharpur on 11.09.15) LAD: 30.06.15 CCD: 10.01.15 ECD: Aug'15
E
E
E
47
48
49
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
Medium
N
N
Y
N
Long term
I
0.2
0.10
4
Open Project
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 58.33%
Slow construction progress in Offsite-DHDS area. Work stopped by M/s KSS in DHDS area for Civil & Strl work CDD: 24.01.15 ECD:. Dec'15
Open Constructio Very High n
Y
Y
Y
N
Short term
I
0.9
0.86
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 69.38 %; Front: 27.48%; Act.:18.42%
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 65+14 of 30
E
2
50
51
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
Status
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
E
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
High
N
N
Y
N
Short term
I
0.4
0.32
Y
N
Y
N
Short term
I
0.6
0.57
4
Slow progress of work & poor manpower mobilisation by M/s B&R for Composite WorksDCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15 Construction Progress: Sch: 69.2 % Front: 45.75% Act.: 23.9% AG piping fabrication: Only 133333 ID / 406975 ID fabrication completed. AG piping erection: Only 89894 IM / 526435 IM piping erection completed.
Open Constructio n
Slow construction progress for Civil & Strl work for Refinery area: Generation of front for mechanical works affected (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:100%; Front: 98.26%; Act: 47.1% CCD: 25.01.15 ECD: Oct'15
Open Constructio Very High n
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 66+14 of 30
E
E
E
E
2
52
53
54
55
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
13
4
5
Slow progress by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. Awarded on 25.03.14. CCD: 24.09.15. Sch: 76.22% Front : 36.22% Actual : 18.76%
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
Slow construction progress by M/s B&R for Composite works: Offsite Refinery area due to delay in mobilisation. Awarded on 25.03.14. CCD: 24.09.15 Sch:79.1%; Front: 14.5%; Act:10%
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for CDU/VDU. Sch: 04.09.14 CCD: 06.09.14 ECD: 31.03.15 Sch:100% Front: 100% Act: 97.03%
Open Constructio n
Medium
N
N
Y
N
Short term
I
0.4
0.20
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 67+14 of 30
E
2
56
57
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for DCU. Sch: 04.09.14 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 100 % Act: 97.1 %
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
Status
Key Risk Description
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
E
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
13
N
N
Y
N
Short term
I
0.4
0.38
N
N
Y
N
Short term
I
0.4
0.20
4
5
Open Constructio Very High n
Start of work for Tankage-IV by M/s Offshore Open Constructio Awarded on 17.04.14 n CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) Sch : 64.6% Front : 58.4% Actual : 27.5%
Medium
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 68+14 of 30
E
E
E
2
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
4
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 100 % Front: 100 % Act: 68.9 %
Open Constructio n
Medium
N
N
Y
N
Short term
I
0.4
0.20
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 CCD:18.06.15 Sch: 97.4 % Front: 74.7 % Act: 55.1 %
Open Constructio n
High
N
N
Y
N
Short term
I
0.4
0.32
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. Sch : 67.8% Front : 56.6% Actual : 29.1 %
Open Constructio n
Low
N
N
Y
N
Short term
I
0.4
0.12
58
59
60
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 69+14 of 30
E
E
E
2
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
6
7
8
9
10
11
12
13
4
5
Start of Composite works by M/s Offshore for Offsite DHDS area Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15. Sch: 70.97% Front: 14.95% Act: 9.18%
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 78760 / 298905 ID fabricated. 18200 IM / 299780 IM erected. Sch : 58.5% Front : 31.2% Actual : 18%
Open Constructio n
Medium
N
N
Y
N
Short term
I
0.4
0.20
Completion of balance piling work (Covered under Piling-IIII Contract) (Total 2077 Nos piles approx).
Open
Low
N
N
Y
N
Short term
I
0.4
0.12
61
62
63
Constn.
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 70+14 of 30
E
F
F
F
2
64
1
2
3
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
5
6
7
8
9
10
11
12
13
4
Completion of Composite works by M/s Albana for VGO Unit Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15 Sch : 69.1% Front : 30.7% Actual : 22.3 %
Open Constructio n
Low
N
N
Y
N
Short term
I
0.4
0.12
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
High
N
N
Y
N
Long term
I
0.2
0.16
Implementation of Change management system The same affects : - Finalization of basic philosophies - Scope of services - Release of deliverables Various scope changes (as advised by BPCL), resulting in expenditure of extra manhours against control manhours.
Open PROCESS/ ENGG/CON S.
Medium
N
Y
Y
N
Long term
D
0.14
0.07
Timely Commissioning of UB package to meet refinery commissioning schedule. LAD : 31.03.15 (UB 1) 30.06.15 (UB 2)
Open
Medium
N
N
Y
N
Long term
I
0.2
0.10
Projects
Constn.
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 71+14 of 30
G
4
5
6
7
8
9
10
11
12
13
Timely payment to sub contractor by main contractor
Open
Const.
Medium
N
N
Y
Y
Long term
D
0.1
0.05
Infrastructure at Kochi
Open
Const.
Low
N
N
Y
Y
Long term
D
0.1
0.03
Process / Engg.
High
N
Y
Y
N
Long term
D
0.14
Key Risk Description
1
2
1
2 Scope changes & information flow to executing group
G
G
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
G
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Open
3 Non-performing vendors
Open Inspn
Low
N
N
Y
N
Long term
I
0.2
Delay in Approval of Vendor List for various items of the project (specially for Long lead items)
Close
Low
N
N
Y
N
Long term
I
0.2
N
N
Y
N
Short term
D
0.16
4
G
5
G
6
Finalisation of Non plant buildings.
Close
Purch / Contrc.
BPCL
Low
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 72+14 of 30
I
I
J
K
4
5
6
7
8
9
10
11
12
13
Implementation of environmental clearance Open conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Projects
Medium
Y
N
N
N
Short term
D
0.08
0.04
Delay in commencement of site work for dyke wall Close inside TF-3 affected due to non availability of PESO approval for tankage area
Engg. / Proj.
Medium
N
N
Y
N
Long term
I
0.2
Key Risk Description
1
2
7
Status
3
Risk Id
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
G
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
1
2
1
1
Statutory approvals - Factory inspectorate approval - CEA (Central electrical authority) approval -IBR approval (LAD - IBR Package for DCU by end Dec'13; CDU/VDU by 31.12.13)
Open
Projects / BPCL
Low
N
N
Y
N
Long term
I
0.2
0.06
Implementation of Health, Safety and environmental (HSE) system
Open
Const.
Very High
N
N
Y
Y
Short term
I
0.5
0.48
Delay due to Labour strikes (due to labour issue like wage revision, other benefits) during project execution phase
Close
Const.
Low
N
N
Y
N
Long term
I
0.2
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 73+14 of 30
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
4
5
6
7
8
9
10
11
12
13
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
0.40
Constraint in movement & transportation of ODC eqpt.
Open
Project
Low
N
N
Y
N
Long term
I
0.2
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open Project/Eng g
High
N
N
Y
N
Long term
I
0.2
Quarry operator strike : Quarry operator strike in the state from 12.02.15 has affected the concreting work.
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
Costing
High
Y
N
N
N
Short term
D
0.08
Environ.
Very High
Y
N
N
N
Short term
D
0.08
Key Risk Description
1
2
Status
3
Risk Id
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Integrated Refinery Expansion Project
Mobilisation of Skilled workers K
K
K
2
3
4
K
5
M
1
M
2
At present only approx 12000 labours are working against requirement of 15000-18000 labours.
Cost monitoring & control on regular basis Increase in facilities on account of deletion zero liquid discharge
Close Open
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 74+14 of 30
M
2
3
Conditi Impact on ( Score D/I ) => {6+7+8+ Current 9} * 10 * Risk 11 Score -> {5}* {12}
1
(Open / Close) Probabi lity Risk (Very Owner High / High / Medium / Low / Very Low) (95% / Project 80% / Cost 50% / ( Y / N) 30% / EIL 10%) Cost (Y / N) Schedu le ( Y / N) Output Quality Urgenc ( Y / N) y (Long Term / Short Controll term) ability
Key Risk Description
Status
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
Project
Low
Y
N
Y
N
Short term
I
0.6
Variation in foreign exchange rates from Rs 50 per Open USD as on Mar 12 to Rs. 60 per USD as on date and fluctuations in the intermediate period and Scope changes w.r.t. DFR (additional in scope) has significantly impacted on the overall project cost.
Total Risk Score
13
20.78
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 75+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Actions Taken so far: - UOP package received on 08.08.13. - PDS issued for all Columns, Vessels, Air Fin Coolers, Exchangers & Refrigeration pkg, pumps (part balance). - All 30 nos P&IDs issued for engineering Action Plan for balance - 19 nos out of 23 nos pumps datasheet issued for engineering. Balance progressively targeted by 15.11.13.
Projects / Process
0.00
- Meeting held with BPCL on 18-20.09.13.
Process / Projects
0.00
- All P&IDs incorporating DCNs issued.
Process
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 76+14 of 30
14
15 0.00
Action Plan
Action By
16
17
- Design Change Note based on Hazop recommendations issued on 03.01.14. All major process P&IDs released. - Major pumps data received and foundation drawing released.
Projects / Engg Process
0.00
-Process package received on 14.04.13
Projects / Process
0.00
All PDS issued for Engg. All Process P&IDS issued. Utility P&IDs: 15 out of 15 nos issued for engineering.
0.00
Process package from M/s Lummus received on 17-Aug-12. All Equipment PDS issued for engineering. Utility equipment issued for engineering.
Process
0.00
Based on latest information from BOO HGU and SWII (FCC), Revised Design Basis issued.
Projects / Process
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 77+14 of 30
14
0
15
Action Plan
Action By
16
17
0.00
Process P&IDs: All process P&ID issued. PDS: Heat Exch. - 52/52 issued for Engg. Pumps 49/50 issued for Engineering. Vessels 38/38 tags issued for Engg. Air cooler 6/6 issued for Engineering.
Process
0.00
- Common Interconnection P&ID for FCC, VGO and DHDT will be issued (covered under risk A09). Hence clubbed with Risk no. A09.
BPCL / Projects / POSD
0.00
All process P&IDs issued. Pumps PDS issued for engg,. All Vessels PDS issued for engg.
Process
0.00
- All 32 P&ID issued for engineering
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 78+14 of 30
14
15
Action Plan
Action By
16
17
0.00
- All PDS and P&ID revised and issued.
0.00
Revision in PDS to be avoided once same is issued for engineering
0.00
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New facilities) has been issued for engineering. Balance 1 no. BPCL / targeted by 15.03.13 Projects / POSD
0.00
Revision in PDS to be avoided once same is issued for engineering.
Process
0.00
Revision in PDS to be avoided once same is issued for engineering
Process
0.00
In case of revision in process parameters of an equipment the utility estimates furnished by engineering against RED / PED/ older Revision of PDS should not be used until same is got verified/ updated for current revision. PROCESS RED to update all such changes within stipulated time frame as per departmental guidelines and Process to incorporate in the revised PDS. Utility P&IDs: P&IDs (14 / 17 ) issued for engg (except for small bore piping: Pump Seal & Vent Drain). The same Process are targeted by Jun'13.
0.00
Process
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 79+14 of 30
14
0
15
Action Plan
Action By
16
17
0.00
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
Process
0.00
Distribution P&IDs issued for engineering.
0.00
- Revised P&ID for Condensate System issued on 15.05.13.
BPCL
0.00
- Inconsistency related to type of Isolation valve (Ball Vs. gate / globe/check) between instrumentation and process design basis identified during coordination meetings resolved by TSD.
Engg.
0.00
- System configuration including 8 pumps, filters & centrifuge finalised and PDS for pumps issued. Filters & Centrifuge PDS issued for engineering on 22.05.14. - Readiness of the fuel forwarding system to be ensured w.r.t. GTG commg schedule (i.e. in Mar 15).
Projects (CPP group)
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 80+14 of 30
14
Action Plan
Action By
16
17
15 0.00
- PDS for desalting pumps issued on 25.10.13. MR issued on 13.11.13.
Engg
0.00 0.00
- Identification of hook ups for Flare line, FCC flare, PRU flare and NHT / ISOM completed during site visit by EIL Process. Signing of P&IDs completed for: --CDU/VDU Hook sketches prepared and signed by Piping / POSD / BPCL. Marking at site to be taken up on priority. Blocktoonbe24.06.14. -- Finalisation of methodology taking up 22.07.14. works targeted by end Dec 13. DCU unit on 03.07.14 & CR for LPG unit on - VGO unit on 12.07.14. - DHDT unit on 24.07.14 - FCCU unit on 23.07.14 - SRU block on 25.07.14. - Offsite P&IDs issued to BPCL. Signing completed
Projects / Constn. Process / POSD /
0.00
Updated P&IDs released.
Process / POSD /
0.00
- Equipment layout issued for engineering on 23.08.13
Piping
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 81+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Equipment layout issued for engineering
Piping
0.00
Equipment layout issued for engineering
Projects / Piping / BPCL
0.00
NIT issued on 24.06.13, bids due on 23.07.13
Projects / Process / HMTD
0.00
1) Involvement of technical/engineering team and client with vendor where non-standard products are required
Projects
2) Clarification of all doubts prior to beginning of work 3) Procedures for internal review and approval of design/deliverables to be followed
0.00
-Discussions with prospective bidders held seeking details on implementation methodology. -Decision regarding System integration schemes taken during meeting dated 17th & 18th Dec 12. MR issued
Engg (Elec)
0.00
- Layout finalised with licensor. Final layout under study. - Model review for SRU completed on 30th May'13 (except TGTU, incinerator section & downstream of sulphur pit).
Piping
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 82+14 of 30
14
Action Plan
Action By
16
17
15 0.00
Intermediate MTO released on 31.05.13.
Piping
0.00
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
0.00
- Layout for OWS, CRWS, CW & FW lines issued for Offsite.
Gen Civil
0.00
VGO-HDT: 30 % modelling completed on 7th Jun'13 FCCU: 30 % modelling completed on 06.06.13. SRU (excluding TGTU) – completed on 30.05.13.
Piping
0.00
- NIT issued for publishing on 12.06.13 with sale period from 17.06.2013 to 05.07.2013
Project / C&P
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 83+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Wide variation of BOQ and site executed quantities for item rate tenders to be controlled. Past data to be analysed and used for reference purposes.
Engg
0.00
MR issued on 02.05.13.
Engg
0.00
- Management level meetings with package contractors being organised to expedite the works. - Battery limit conditions for CDSP Pkg (awarded to M/s Essar on 22.08.13) submitted by vendor & approved under code 2 on 07.05.14. - Battery limit conditions for R&R Pkg (awarded to M/s Essar on 25.07.13) received from vendor and approved.
Projects / Engg. / Process
0.00
- Clubbed with Risk ID A27
TSD
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 84+14 of 30
14
0.02
15
Action Plan
Action By
16
17
0.00
- Data received from all vendors. All piling drawings for CPP area released. - Foundation drawings for & HRSG under progress and targeted by mid Mar'14.
0.00
- NIT issued on 11.03.13, bids due on 16.04.13. Pre bid meeting targeted on 02.04.13. (Delivery : 18 M for Mechanical Completion including Pre-Commissioning Activities)
ENGG/PLNG
-0.02 - Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. Engg - HAZOP review completed for GTG, HRSG & UB package. Projects / - 90% model review for HRSG completed on 04.02.15. Process -90% model review for UB package held from 18.11.14 to 20.11.14. Process / - GBC ordered to M/s BHEL on 25.07.14. KOM held with M/s BHEL for Gas booster compressor on 12-13 Aug'14. HMTD C&P
0.00
- Preparation of Inst. dwgs./ docs. by the DCS vendor, using Smart Plant Instrumentation (SPI) is already covered in DCS vendor’s scope in DCS
Projects
0.00
- Model review completed on 13.09.13
ENGG
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 85+14 of 30
14
15
Action Plan
Action By
16
17
0.00
- Being taken up with respective package vendors for implementation.
Instn / Projects
0.00
Package vendor inputs being made available by expediting for updation of interface engineering documents.
Projects / Engg.
0.00
Model review completed on 04.10.13
ENGG
0.00
- All P&IDs released
G. Civil
0.00
- Ordered to M/s Powerica Ltd on 29.09.14 (Delivery duration 13 M+ 3 M site works).
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 86+14 of 30
14
15
Action Plan
Action By
16
17
0.00
- Model review completed on 24.10.13. Process to remove holds as per piping Hold up lists released till date by 25th Oct 13. - Piping to release updated hold up lists based on release of holds by process on fortnightly basis to process / project / planning / TSD / Risk Coordinator. - Meeting between Process, Piping, Projects shall be organised within 3 days of issue of hold up lists. - Process to issue Revised P&IDs latest within 4 weeks of HAZOP recommendations.
Process / Projects
0.00
- Model review completed on 25.10.13.
ENGG
0.00
- Model review started on 28.10.13 and under progress. Targeted to complete by 31.10.13.
ENGG
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 87+14 of 30
14
15 0.00
0.05
Action Plan
Action By
16
17
- Intermediate 2nd MTO released on 31.10.13, based on above MR under preparation.
Projects / ENGG
-0.05 - Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
0.00 0.00
ENGG ENGG
- HAZOP study completed on 29.11.13. - As of 15 Aug'14 Engineering progress is 91.4 %.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 88+14 of 30
14
15
Action Plan
Action By
16
17
0.00
- Final MTO released on 11.09.14.
0.00
- Revised P&IDs issued for connecting tank-101 & 102. New pump process datasheet released for piping naphtha from YT-332 to CPP day tank.
Process / Engg.
0.00
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
0.00
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 89+14 of 30
14
Action Plan
Action By
16
17
15 0.00
- BPCL confirmation sought for minimum nos (10.97 MW or 80% of 10.97) for qualifying criteria. Accordingly BQC C&P changed and approved by BPCL. Draft NIT by 25.05.13. Publishing targeted by end May 13.
0.00
- As per latest cost status report the impact of cost variation has been neutralised by savings.
Projects
0.00
Awarded to M/s Technip on 04.09.13 (Duration 18 M)
Projects / HMTD
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 90+14 of 30
14
15
Action Plan
Action By
16
17
0.00
-Ordered on M/s Shin Nippon & M/s Flowserve on 30.01.14 (except Tag IV-P-301 A/B due to poor past performance of PRT supplied under CEMP-II by M/s GENP); - Separate MR released for item tag IV-P-301 A/B. BPCL informed that order expected to be placed as per previous recommendation, ordering expected by mid Mar'14. - As a parallel action MR was issued however RFQ kept under hold in view of BPCL information regarding ordering by mid Mar 14.
EIL
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Projects / HMTD
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Projects / HMTD
0.00
-Ordered to M/s Fabtech on 15.07.13
Engg/Proj
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 91+14 of 30
14
Action Plan
Action By
16
17
15 0.00
NIT issued on 29.05.13, bids due on 18.06.13.
Project / C&P
0.00
- Awarded to M/s Driplex on 12.06.13. duration is 22 M.
Engg / C&P
0.00
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months.
BPCL
0.00
BQC finalised on 15.01.13. Tender under compilation. Draft NIT being issued to BPCL for approval. NIT targeted by 21-Feb-13.
Projects / BPCL
0.00
Ordered to M/s Paulose George (15 M).
BPCL
0.00
Ordered on M/s L&T on 08.04.13.
Proj/Engg
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 92+14 of 30
14
Action Plan
Action By
16
17
15 0.00
Awarded to M/s L&T on 09.04.13 with duration of 12 M.
BPCL
0.00
Awarded to M/s Petron on 09.04.13 with 18 M duration.
BPCL
0.00
Awarded to M/s Technip on 07.03.13 (Duration 23 M)
0.00
- Scheme finalised.
Projects / BPCL
0.00
Tender released on 26.03.13; BQC finalised on 08.04.13. NIT targeted by 16-Apr-13
Engg
Projects / C&P / BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 93+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Award recommendation issued on 11.02.13. Awarded to M/s Howe baker on 07.03.13
Proj/Engg
0.00
Awarded to M/s L&T (duration 20 M)
BPCL
0.00
KB tech completed development of flare area & handed over the area to M/s L&T.for piling.
Projects
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 94+14 of 30
14
Action Plan
Action By
16
17
15 0.00
- Evaluation of LLIs to be ensured with-in 1 month from receipt of bids by Engg. & PBO recommendation with-in 1 Engg / C&P / week by C&P. Projects - Pre tender / Pre enquiry meetings to be conducted with bidders to avoid extensions in bid due date due to lack of clarity in scope / other requirements. - Immediate after issue of Enquiry a firm action plan to be developed by the Project coordinator clearly indicating targets for Issue of TQ / CQ , Post bid meetings, TBA/CBA, PBO reco., Price bid opening and award recommendation dates. - Uploading of bids in eDMS by C&P within 1 - 2 days (Max.) of bid submission by bidders. - Restriction of multiple TQs / CQs. - Rigorous follow up by C&P / Engg. / Projects for receipt of TQ / CQ replies from bidders within cut off dates.
0.00
Awarded to M/s Tecnicas Reunidas S.A. on 31.12.13
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 95+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Awarded to M/s Essar Project on 22.08.13 (Duration: 27 M)
C&P / Engg / Projects
0.00
- Awarded to M/s BHEL on 25.07.13.
Projects / Engg / C&P / BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 96+14 of 30
14
15 0.00
Action Plan
Action By
16
17
- Awarded to M/s Thermax on 20.12.13
Projects / BPCL
It is planned that common facility (incl. common piperack, utility lines etc) shall be taken up as per project schedule requirement. This shall be taken up during KOM with selected bidder.
0.00
- 2 Bids (Essar & L&T) received on 25.04.13. - TBA issued on 21.05.13. - PBO recomn. issued on 30.05.13 and BPCL approval received on 03.06.13 - Price bids opened on 04.06.13. - Award recommendation issued on 25.06.13. - Awarded to M/s Essar on 10.07.13.
Projects / BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 97+14 of 30
14
15
Action Plan
Action By
16
17
0.00
BPCL Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
0.00
- 3 no. bids received on extended date of 02.02.13. - Meeting with bidders held from 19.02.13 to 26.02.13. PBO recomn. issued on 06.05.13. Price bids opened on 09.05.13. - Award recomm issued on 12.06.13. Execution duration as per RFQ - 20 M; Sch - 24-26 M
Projects / C&P / BPCL
0.00
Awarded to M/s Paramount (with 21 M for mechanical completion + 2 M for commissioning). Execution duration as per RFQ was - 22 + 2 M; Sch - 28 M
C&P/Engg/Pr oj
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 98+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Meeting held with EIL & BPCL. Approach paper prepared and signed jointly by EIL / BPCL for limiting single agency getting work orders against more than 2 tenders. (In cases of big agencies with financial capability, one agency can get maximum works order against 3 tenders)
BPCL / C&P
0.00
Limit the number of works being awarded to one Agency so that alternatives can be worked out fast. BPCL/EIL To evolve a System to be implemented to ensure that the maximum number of jobs awarded to single agency is only 2 if NOT to be preferably made ONE only.
C&P BPCL / Projects
0.00
Awarded to M/s GEA on 10.07.13 with delivery period of 13 M.
BPCL
0.00
Awarded to M/s Heurtey, (Duration - 20 M)
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 99+14 of 30
14
Action Plan
Action By
16
17
15 0.00
Awarded to M/s KSS on 25.07.13. (Duration 18 M)
BPCL
0.00
Awarded to Mcnally Bharat on 26.09.13. Duration- 16 Months
Project/C&P
0.00
NIT issued on 01.08.13, bids due on 30.08.13
Gen Civil/Project
0.00
Awarded to M/s McNally Bharat. Duration - 16 M
Gen Civil/Project
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 100+14 of 30
14
0
15
Action Plan
Action By
16
17
0.00
MAB awarded to M/s Elliot Ebara on 04.09.13. WGC awarded to M/s BHEL
C&P/Engg/Pr oj
0.00
Awarded to M/s L&T on 07.03.13. Award recomm sent to BPCL on 01.02.13. Award to be targeted by 07.03.13.
C&P
0.00
Ordered to M/s Eliot Ebara on 28.06.13.
0.00
Ordered on M/s Dresser Rand, Dely - 17 M FOT Dispatch
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 101+14 of 30
14
15
Action Plan
Action By
16
17
0.00
- Ordered to M/s Sandvik.
BPCL
0.00
Awarded to M/s Sriram on 25.09.13
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 102+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Awarded to M/s McNally bharat on 11.09.13 (with 16 M execution period)
BPCL
0.00
Awarded to M/s Essar Projects on 19.08.13
BPCL
0.00
Awarded to M/s Thermax
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 103+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Awarded to M/s Triveni
BPCL
0.00
Ordered to M/s Callidus and M/s UOP India on 20.06.14.
BPCL
0.00
Ordered on M/s Howden Process Compressors
Projects / C&P
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 104+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Awarded to M/s Airoil on 25.09.13 with duration of 18 M.
Projects/ Process/ Engg / C&P/
0.00
- Awarded on M/s Ray Engineering on 23.01.14.
Engg / C&P
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 105+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Awarded to M/s BHEL
Proj/Engg
0.00
Ordered to M/s Neumen & Essar on 14.11.13
BPCL
0.00
Awarded to M/s IOT Anwesha on 04.12.13. (duration: 20 M)
BPCL
0.00
Awarded to M/s BHEL
Proj/Engg
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 106+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Awarded to M/s Dresser Rand
Proj/Engg
0.00
Awarded to M/s B&R
BPCL
0.00
Awarded to M/s Offshore on 17.04.14.
EIL / BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 107+14 of 30
14
15
Action Plan
Action By
16
17
0.00
.Awarded to M/s Offshore (Duration- 20 months)
BPCL
0.00
Contract for development of flare area awarded to M/s KB Tech..
Engg / C&P
0.00
Composite Works for VGO-HDT & DHDT -DHDT- Awarded to M/s Albana on 19.05.14 (16M+2M). -VGO-HDT- Awarded to M/s Albana on 19.05.14 (16M+2M). Composite Works for Offsite Part B (DHDS): Awarded to M/s Offshore on 19.05.14 (16M+2M). Composite Works for CPP: Awarded to M/s Zillion Infra. on 19.05.14 (16M+2M).
Projects / Engg.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 108+14 of 30
14
Action Plan
Action By
16
17
15 0.00
Awarded to M/s Petron on 04.12.13. Duration is 16 M
BPCL
0.00
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
0.00
-Ordered on M/s Asco Filtri Srl ON 17.10.14.
BPCL
0.00
- All pipes, fittings & flanges ordered.
C&P Engg
0.00
-Revised MR (MR-3415): Ordered to M/s Oswal, M/s Shalimar, M/s AV valves and M/s L&T. - New MR-3515 (41 Nos) ordered on 05.02.15
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 109+14 of 30
14
15 0.00
0.05
Action Plan
Action By
16
17
- Awarded to M/s Zillion on 19.05.14.
-0.05 -Total 35526/ 35652 nos (99.7%) isometrics issued for units . Balance ISO's targeted progressively by mid May'15. -All GADs issued released.
Engg.
0.00
-Awarded to M/s OIL on 18.03.15 (Duration 12 M).
EIL/BPCL
0.00
- Ordered to M/s Sulzer.
BPCL
0.00
- Electrical Works: Part A: M/s Technimont Part B: M/s Consilium - Instrumentation Works: Part A: M/s Technimont . Part B: M/s Consilium
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 110+14 of 30
Action Plan
Action By
16
17
14
15
0.20
0.00
Majority ordered, balance targeted by 2nd week of May'15. Deliveries to be expedited in order to timely availability EIL/BPCL of piping material for completion of steam network in CPP area.
0.86
0.00
Management level review meeting held with M/s ESSAR/ GRE on 13.04.15. Following Major targets agreed: - Delivery of all bought out progressively by Jun’15. - Completion of Flue Gas cooler & ESP by Jun’15. - Erection of TSS bottom section executed on 17.04.15 - Steam drum erected on 13.03.2015 & economiser panel erection commenced on 20.03.15, RHS, LHS & economiser modules 3/5 for FGC erected. - 1st lot of fabricated ESP materials received at port. Site to update????
EIL/BPCL
0.00
Clubbed with Risk ID E19
Project
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 111+14 of 30
Action Plan
Action By
16
17
14
15
0.19
0.00
- Balance foundation to be expedited (including FD fan, HP pump drive turbine, blow down tank & other Project / auxillaries). Constn. - Completion of structural erection work to be expedited. Coil erection completed for UB-12 & in progress for UB13. Deaerator tank erection completed.
0.00
-All Indigenous component received at site within CDD. - All Foreign Source Components dispatched.
Project/Inspe ction
0.00
Compressor dispatched on 06.03.15
Project/Inspe ction
0.00
All parts dispatched.
Project/Inspe ction
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 112+14 of 30
14
15
0.67
0.00
Action Plan
Action By
16
17
- Main fractionator column: Top section dispatched to site on 26.04.15. Erection targeted by end May’15. Stripper Project / Column: Hydrotest erection by end Jun’15. Rectifier Column: erection by mid Aug’15. Constn. ????
0.38
0.00
- Erection of second Main combustion chamber (Tag No: IS-F-202) has been successfully & safely completed. - Refractory lining agency expected to mobilise at site by 05.05.15????.
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 113+14 of 30
14
15
0.86
0.00
Action Plan
Action By
16
17
Following commitments have been made by M/s Essar. Constr. -Shift Work: Works in two shifts implemented. - Coke fractionator column delivery by 07.05.15 and coke drums progressively from 13.05.15 till 25.05.15. - Crane (2000 MT): Mobilization & assembly of crane completed and erection of equipments targeted progressively by May’15. -Clear water tank fabrication- Civil tank pad work completed, rolling in progress.- Shell erection of clear water tank commenced. BPCL/EIL - Resource augmentation for Civil & Strl works being expedited. At present 590 nos have been deployed against requirement of 836 nos. - Above ground pipe fabrication commenced at a lower productivity due to non-availability of pipe fittings. EPIL informrd that majority of pipe fittings will be available within one month. ????
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 114+14 of 30
14
0.38
15
Action Plan
Action By
16
17
0.00
- All items received at site.
Project/Inspe ction
0.00
- Received at site and erected.
Project/Inspe ction
0.00
- Vacuum Column : Hydrotesting completed.
Constn. / VTV / Projects
-0.38 - Contract for ODC transportation awarded to M/s Urmila on 26.05.14. - 2 no DHDT Reactor reached at site & erected. - First dumb barge (newly fabricated) launched in the river after IRS certification. - ISGEC Josen (3 nos) Column: expected to receive at Kochi port from upto end May'15. - VGO reactor moved on way to site.
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 115+14 of 30
Action Plan
Action By
16
17
14
15
0.06
0.00
Out of total 57 nos. of ODCs; 25 nos received at site. & 29 nos under dispatch. Balance under close monitoring.
Shipping
0.00
- Transporter philosophy frozen and hindrance enroute has been covered under Risk ID K3.
Shipping
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 116+14 of 30
14
15 0.00
0.23
Action Plan
Action By
16
17
Equipment by Ganson - M/s Ganson agreed to supply balance item of CDU/VDU. Items for SRU and DCU refloated under MR-6560 (DCU): All items relocated to M/s Patel Airtemp, M/s Phils Heavy, M/s Acoustics India ; M/s Beekay Engg ; M/s Fab-Tech, M/s Nuberg Engg.
-0.09 - Erection of Derrick structure up to 40 mtr completed. - Flare tips likely to be reached at site by end Apr'15. 1 no water seal drum and Molecular seal received at site. -Water Seal drum (3 nos) received at Kochi port.
BPCL
Projects/Con str.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 117+14 of 30
14
0.38
15
Action Plan
Action By
16
17
0.00
- BPCL confirmation on the additional flare stack addition received. - Agreed with Air Oil / BPCL for completion of 4th riser within CDD. - Revised PDS & P&IDs released on 15.11.13. - Order placement (change order) issued to M/s Airoil on 14.11.13.
BPCL / EIL
0.00
- Compressor Lube Oil Console : MRT completed for turbine & is under dispatch. LOP Drive Turbine ordered on KEPL is still under manufacturing and likely to be delivered during May 2015. .
Project/Inspe ction
0.00
- MRT of compressor and Steam turbine completed & same is under dispatch.
Project/Inspe ction
0.00
-Reactors reached RORO Jetty at Irumpunam on 28.04.15. Jacking and forecutting work under progress.
Project/Inspe ction
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 118+14 of 30
14
15
Action Plan
Action By
16
17
0.00
- Reactor received at Kochi port and unloaded to barge on 26.12.14.
Project/Inspe ction
0.23
0.00
- 90% model review for HRSG completed. - Balance engineering to be expedited by M/s Thermax. - HRSG #3, 4 & 5: Foundation works completed and handed over to M/s Thermax. Erection in progress for HRSG-4 & HRSG-5 - All column alignment completed for HRSG-3.
Project/Inspe ction
0.14
-0.14 - Generator subordered. - Pedestal fabrication is at final-machining. - Exhaust case assembly, including diffuser and thermal insulation has been completed
Project/Inspe ction
0.18
-0.18 -Silos with structure & Conveyors sub ordered by M/s Sandvik. - Bottom Cones for Silo C ,D, E & F dispatched to site. -Delivery of Semi rolled sections of Silos shall commence from Jan'15 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited. - Foundations for pelletiser shed to be made ready.
Project/Inspe ction
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 119+14 of 30
14
0.10
15
Action Plan
Action By
16
17
0.00
Strl. Steel for R&RMajor portion of steel plates have been delivered by M/s Essar.
Project/Inspe ction
0.00
- Equipment dispatched
EIL/ BPCL
0.00
- Compressor & Accessories have been loaded on ship at Antwerp port & Motor
EIL/ BPCL
0.00
- Following bidders showing slow manufacturing progress: - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:184. Meeting held on 24.04.15. Balance order expected to dispatch by end May'15. - M/s Universal: M/s UHE agreed to deliver balance items progressively upto May’15. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 311, 360, 423 & 444. - M/s HDO (Columns, Heat Exchangers & Vessels): FOA No.: 199, 302, 310, 318, 320, 327, 389 & 395.
EIL/ BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 120+14 of 30
14
15
Action Plan
Action By
16
17
0.00
- M/s Filtrex asking for deviations on commercial terms. Meeting held on 08.07.14 to resolve the issues with M/s Filtrex. Vendor provided all details.
EIL/ BPCL
0.00
- Order has been accepted by M/s Flowserve and amendment issued by BPCL on 11.07.14.
EIL/ BPCL
0.10
0.00
- All part received at Kochi.
EIL/ BPCL
0.20
0.00
- As of now around 90% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Apr'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL. Additional requirement of 20000 m2 area in FACT being taken for piping storage.
EIL/ BPCL
0.06
0.00
Ordered to M/s BHEL on 25.07.14. KOM held on 12-13.08.14. - Compressor Journal Bearings were ordered. Impeller manufacturing is in process
EIL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 121+14 of 30
Action Plan
Action By
16
17
14
15
0.10
0.00
Vendor being pushed for deliveries. Vendor shop visit/meeting being arranged.
Inspection / Project
0.00
-All burner drawings finaised across the table.
HMTD/Projec ts
0.00
Piling completed for CDU/VDU DCU & Offsite (except boundary wall) Constn. Balance piling (479 nos) for GTG, UB & stack area being done by M/s DBM. Job given on 07.10.13 with CCD by 1st week of Dec'13.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 122+14 of 30
Action Plan
Action By
16
17
14
15
0.27
0.00
- During the project review meeting dated 23.01.15, following points discussed and requested with BPCL to provide assistance: - Additional storage space for owner supply items (20,000 Sq. M). - Additional storage space for piping spools. ??? Site to update
BPCL
0.00
-Major rock blasting work completed.
Constn.
0.00
'- Tender splitter into two parts (Structural/ Mechanical works & Civil work). Awarded to M/s OIL. BPCL/EIL Civil work being done by misc. Civil agency (M/s Furnace Fabrica). RCC substructure work commenced (340 m3 out of 2900 m3 RCC work completed). Electrical Work: Awarded to M/s Konstelec on 05.05.15. Instrumentation Work: Awarded to M/s Konstelec on 05.05.15.
0.86
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 123+14 of 30
14
0.38
15
Action Plan
Action By
16
17
0.00
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
BPCL / Projects
0.00
- MCR, CPP control room : Release for panels by Oct'15 & total completion by Dec'15. - Other building works : SRR Completion progressively by end May'15. - L&T also agreed to augment required manpower to 1000 from current deployment of 850 to meet the target completion date. ????
Constn
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 124+14 of 30
Action Plan
Action By
16
17
14
15
0.67
0.00
- Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deens has been lined Constn up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. - Contractors are facing problem in retaining the labour at site. Approx 13000 labours are available at site, though induction programme has been carried out for more than 18000 labours . requirement of manpower at site is approx 19000 nos. - RCC work & structural fabrication/erection work to be expedited to give complete front to mechanical contractor BPCL/EIL progressively upto end May'15. - Lighting of areas to facilitate night shift working. - Provision made for snacks/dinner for labour to facilitate working in extended/night shift - Provision of multiple entries inside plant areas to ease manpower/machinery mobilisation to be explored. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. Site to update?????
0.00
0.00
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Jun'15.
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 125+14 of 30
14
15
Action Plan
Action By
16
17
0.00
L&T has completed all piles in Demountable flare area, Air compressor & DG shed area.
Constr.
0.00
Ensure that 90% payment of the RA bills certified by EIL are released to the contractors within 7 days of receipt by client.
BPCL
0.00
Ensure that realistic dates of availability of inputs(drawings, front and materials) are considered in project/ construction schedule rather than compressing construction schedules alone to meet the completion target.
Project / Planning
0.00
All 5 nos tank area cleared and released. Area handed over to M/s B&R for Tankage-II works on 30.04.2014
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 126+14 of 30
Action Plan
Action By
16
17
14
15
0.15
0.00
- M/s Triveni to augment manpower by mobilizing additional manpower (Manpower required is 300 nos while available manpower is 235 Nos). - Substation building: completion being targeted by Apr'15. - Chemical house works completion being targeted by end Apr'15. Site to update???
0.57
0.00
- All area handed over in SRU. Constn. - Pond Retaining wall construction is in progress. - Piling for SRU : All piling drawing released. To meet Euro-IV compliance, focussed efforts being made for ARU/SWS. Piling for ARU/SWS is completed. Balance piling work completion targeted by end Apr'15. - Civil works completion targeted by end May’15 and handing over of front to mechanical contractor targeted from end Mar'15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
Constr.
EIL/BPCL 0.00
Graded and handed over to tankage-II
Constr.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 127+14 of 30
14
15
Action Plan
Action By
16
17
0.00
Clubbed with Risk ID E33
BPCL
0.00
M/s BPCL Vide mail dated 21.08.2013 has handed over the area for SG-III.
BPCL
0.00
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
0.00
- All 3 GTGs received at site.
Projects
0.00
-Included in mechanical contractor scope. Project / - Based on prel. Erection scheme, 1600 T heavy lift crane with 600 T trailing crane envisaged for erection of both Constn. VGO and DHDT reactors. - Timely mobilization of cranes and preparation of Load Test. - Finalization of erection scheme.
0.00
- Security arrangements in Warehouse in place by BPCL.
Constn.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 128+14 of 30
14
15
0.48
0.00
Action Plan
Action By
16
17 EIL/BPCL
- All balance material deliveries being expedited, subsequently all UG piping work completion targeted by end May'15. 0.00
Area lighting being done.
Constn.
0.00
-During 2013-2014 monsoon following actions were taken - Temporary drains were constructed for draining accumulated rain water. - Pumping arrangements for draining water accumulated in pits were made.
Constn.
0.00
LPG flare - As per EIL study LPG flare is adequate. Report issued to BPCL and clarification received. BPCL / EIL Acid flare - HC flare & Sour flare system P&IDs issued for engineering on 15.06.13. DHDS sour flare replacement: Sour Flare system P&ID (DHDS Area) issued for comments on 17.05.13, this additional requirement of existing structure and replacement of sour stack by higher size (16") being checked for adequacy. New flare components to be procured for revised stack size.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 129+14 of 30
Action Plan
Action By
16
17
14
15
0.04
0.00
After construction of subway road opened on 10.04.15
0.38
0.00
-Management level meeting held with M/s KSSIIPL at site on 24.04.15. EIL/BPCL - M/s AA Erectors being mobilized by KSSPPL for Structural work. - M/s JD Works to be mobilized shortly by KSSPPL for UG piping works. - Additional 80MT crane also shall be mobilized shortly. (Currently one 100MT, one 75MT & one 70MT available). - Rock blasting being expedited for drain on West side of piperack area 104, CW line at East of VGO. - BG already arranges for 400 MT cement, apart from current stock of 100MT. - KSSPPL shall be expediting around 700 MT of strl steel required for completing the currently progressing areas of piperack on priority. Entire fabrication completion targeted by 30.04.15. - Bridge erection at area 117 shall be taken up. Bridge at area 113 nearing completion. -Strl steel painting & repair works shall be expedited with new gang. - Manpower for restarting manhole works shall be additionally deployed. - CW road crossing of 84" pipes shall be expedited. - Area wise handing over of piperack to mechanical agency to be expedited.
Constrn.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 130+14 of 30
14
15
0.38
0.00
0.38
0.00
Action Plan
Action By
16
17
Management review meeting held with M/s Essar on 20.03.15 at site - Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - boiler piperack foundations completed. - GBC fdn completed.
EIL/BPCL
EIL/BPCL - As on date the manpower is 470 Nos against the requirement of 750 Nos. - ARU/SWS : TS-1 & TS-2 being expedited TS Completion committed by MBE -TS-II : 30.04.2015 -TS-III: 30.04.2015 -TS-I : 31.06.2015 -TS-IV: 10.07.2015 -TS-V : 15.07.2015 -TS-VI: 15.04.2015 -MPR : 31.05.2015 -SILO: 20.04.2015
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 131+14 of 30
Action Plan
Action By
16
17
14
15
0.38
0.00
- Management level Meeting held with M/s OIL on 25.03.15 and following action plan has been agreed - M/s OIL has augmented manpower to 1122nos. - Structural fabrication completion targeted for end May '15 - Alloy steel piping fabrication to be expedited.-Fabrication Completion target by End May '15 - Fire proofing of Crude Column completed. - Dehumidification started in Crude Column. Column Internals completed o tray erect - Order placed for fabrication of rain protection shed - 350 out of 358 equipments erected. Completion Plan : 1. SRLPG - Total loop 129 loops -completion by 30.06.2015 2. FO FG Treater 145 loops Completion target by 31.07.2015,3. 400 loops out of 799 loops will be completed by 31..07.2015
0.29
0.00
-Piling work to be completed by 30.04.15 Constr. -TT-3, TT-4, TT-5, Circular stacker cum reclaimer work in progress. - For CSR pit, due to collapse of excavation, revised scheme of excavation is being followed, in consultation with Geotech experts of EIL and Dr. Moza, who visited site and envisaged the problem on 12/01/15. - Pilling rate to enhance considering the upcoming dry period - Structural erection need to be expedite, supply of matching sections need to expedite.
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 132+14 of 30
Action Plan
Action By
16
17
14
15
0.15
0.00
-Heater A: Hot Work 6/6 box completed, Tube support fixing completed. Radiant coil erection completed. Pedestal Constrcution grouting (56/60) in progress. -Heater B:Hot Work 6/6 box completed, Tube support fixing 32/48 nos completed. -Refractory Dry-out for 3/6 nos of convection module completed at shop. Fabrication for Stack in progress at shop. APH- str erection is in progress. Glass APH & Fan erection in progress. Crane-450 MT mobilised at site.
0.00
- Total area handed over on 05.05.14.
Project
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 133+14 of 30
Action Plan
Action By
16
17
14
15
0.57
0.00
- Mobilization of additional 75 nos manpower by end Apr'15 (Presently 190 nos manpower available) - Completion of raft for TWT/SBR/ACT by 30.04.15. - Completion of equalisation tank targeted by Jun'15. - Procurement of BQ plate for Spent caustic tanks to be expedited.
0.38
0.00
- Management level meeting held on 25.03.15 at site. Total tanks: (New tanks 13 nos, work in progress for 12 EIL/BPCL nos. Balance for 1 nos is YT-33 which shall be start after completion of YT-32; Modification tanks: Out of total 16 nos, work in progress for 5 nos, 3 nos handed over to BPCL.) - B&R to augment resources to complete all balance work within agreed target. YT-32 completed.
0.38
0.00
EIL/BPCL
Constr. - Plate erection to be expedited for YT-26/28. - Tank pad completion works to be expedited in YT-25.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 134+14 of 30
Action Plan
Action By
16
17
14
15
0.20
0.00
-Management level meeting held on 24.04.15 - Structural steel: Out of total 217 MT, 217 MT received & 158MT fabricated & 120MT erected. - Erection of radiant section completed. - Coil tubes: Pipes & fittings (part) delivered. Coil fabrication commenced. - Order placed for anchors & refractory blanket & expected at site progressively from 15.05.15
Project
0.00
Clubbed with Risk ID D7
BPCL
0.00
- Vent Stacks: Common Stacks template already fabricated and dispatched to site. Bottom intermediate and top sections and transition cones are being manufactured as scheduled
Projects
0.38
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 135+14 of 30
Action Plan
Action By
16
17
14
15
0.57
0.00
- Sub-station-Completion of RCC super structure completion by 15.06.2015 - DM tanks (2 nos) : Tank -A : All piling completed, pile cap completion by 30.04.2015 - Fabricated structural steel Qty. 80 MT reached site, Balance 40 MT expected to reach site by 10.05.2015 Erection started in R.O. shed. - M/s DWEL being expedited to delivery of balance bought out items.
0.67
0.00
Management level meeting held with M/s Shriram on 22.04.15 at site. - Mobilisation of resources is being expedited. At present only 160 nos, manpower mobilised against requirement of 350 nos. - M/s Shriram to complete balance Civil work by 15.05.15. EIL/BPCL - SEPC to expedite structural erection for Tech str A,E,BPR-2 - 5575m3 offloaded to M/s Tuaman (3374m3 completed) - 2432m3 offloaded to M/s PGC (692m3 completed) - 2025MT structural work offloaded to REL - 1684 MT structural work offloaded to ZIPL - 310 MT Offloaded to TEL
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 136+14 of 30
Action Plan
Action By
16
17
14
15
0.10
0.00
-Erection of stack completed. Balance welding to be expedited. NDT and PWHT to be expedited
Constr.
0.20
0.00
- Procurement completed for structural steel - Radiant panel erection completed for IV-H-101 & IV-H-201. APH Structure & Stack erection in progress - Refractory for radiant section to be expedited. - Delivery of Radiant coil tubes to be expedited.
Projects
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 137+14 of 30
Action Plan
Action By
16
17
14
15
0.38
0.00
- Current manpower is 507 nos. against requirement of 600 nos. MBEL to mobilise 200 nos additional manpower Constrn. for structural works - 6 cranes mobilised in order to carry out structural erection in both VGO & DHDT simultaneously. - In DHDT Unit: MPR, TS 1, TS 2, TS 4 completed and handed over to mechanical agencies for subsequent works. All structural erection to be completed by 15.05.15. In VGO HDT Unit: MPR only handed over for mechanical works. Balance structural shall be handed over progressively and handing over shall be completed by 30.06.15.
0.12
0.00
PEB1: Project Material storage commenced. PEB 2 All works targeted to complete by 30.04.2015 PEB 3: All works targeted to complete by15.05.2015 Buildings to be expedited for storage of material / equipment being received at site.
Constrn.
0.16
0.00
Management level meeting held on 07.01.15 at site and PCTL to expedite to complete all works by Jun'15.
EIL / BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 138+14 of 30
Action Plan
Action By
16
17
14
15
0.10
0.00
- Manpower - Additional manpower to be deployed for civil works. (Required: 150 nos, Available: 87 nos) - Delivery of Bought out item to be expedited. - Mechanical contractor to be finalised. - RCC work for CWPH & CWTP to be expedited. - Early delivery of Pipes and immediate commencement of Piping fabrication work.
EIL / BPCL
0.86
0.00
-Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. Civil/Strl contractor. -Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deen has been lined up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works.
EIL/BPCL
0.38
0.00
Management level meeting held on 24.04.15 at site. - M/s Petron have started with night shift work. - PECL have erected the gantry crane & same made operational. - 10 nos semi automatic welding machines shall be operational by Apr'15 - Gratings & consumables are being ordered. Handrails, wrapping coating mtrls & GI pipes ordering to be expedited. Strl steel partially ordered. Structural steel & support fabrication to be expedited.
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 139+14 of 30
14
15
0.32
0.00
Action Plan
Action By
16
17
Management review meeting held on 25.03.15.
EIL/BPCL
-Insulation/painting agency to be finalised. - Hanger scaffolding to be installed at site.
0.57
0.00
- RCC sub structure work shall be completed by end Apr '15. - 30MT /day shall be fabricated from 01.01.15 onwards.
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 140+14 of 30
Action Plan
Action By
16
17
14
15
0.38
0.00
Piping fabrication & erection work in progress in pipe rack 101-103, 108, 111-114. Fabrication in progress for piperack area 115. CS IBR & SS fabrication also commenced. AG piping fabrication: Scope: 285505 ID; Front: 101111 ID; Completed 56586 ID AG piping erection: Scope: 1214330 IM; Front: 373941 IM; Completed 261447 IM - Release of adequate front for erection to be expedited.
Constr.
0.38
0.00
- Management level meeting held 25.03.15 at site. - B&R to take up compressor erection immediately. - Due to delay in completion of civil work, release of front to composite contractor got affected.
EIL/BPCL
0.20
0.00
Management level meeting held on 20.03.15 -TS I handed over -TS II, III & IV,VI handed over. -TS V by 27.05.15 -TS VII handed over.
Constr.
0.20
0.00
- MRM held on 23.03.15 - Refractory of stack, dryout & erection of stack to be expedited.
Constr.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 141+14 of 30
Action Plan
Action By
16
17
14
15
0.38
0.00
Management level meeting held on 20.03.15 - TS I by 30.04.15 - TS II by 05.05.15. - TS IV & TS-V handed over. - Branch piperack completion targeted by 30.04.15.
0.20
0.00
- Management level Meeting held on 25.03.15, M/s OIl started night shift work in YT-150 from 10.03.2015 EIL/BPCL - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT-383,391 for modification and 150 for new. - YT-150: Tank Pad completed, erection of annular plate completed, welding u/p, bottom plate erection under progress.. - YT-383: Roof structure erection completed, roof plate erection u/p. - YT-391: Hydrotesting completed, blasting and painting under progress. - Ordering of cladding and moisture barriers to be expedited.
EIL/BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 142+14 of 30
Action Plan
Action By
16
17
14
15
0.20
0.00
- Management level meeting held on 25.02.2015 with M/s B&R at site. Start of Hydrotest - YT 341 : hydrotest by 06.05.2015 - YT 342 : Hydro test by 28.06.2015 - YT 343 : hydro test by 12.06.2015 - YT 344 : Hydrotest by 01.05.2015 - YT 112 : Hydrotest by 30.04.2015 - YT 113 : Hydrotest by 05.06.2015 - YT 114 : Hydrotest by 25.06.2015 -Manpower required is 250 nos, available is 161.
EIL/BPCL
0.32
0.00
-These tankages (Amine water and sour water services) are required for commissioning of CDU/VDU. - ISW-T-101 tank: 1st Shell & Bottom plate welding is in progress, Roof structural erection is in progress. - ISW-T-201: Bottom plate & Shell erection is in progress. - ISA-T-101: Annular plate welding completed & Bottom plate laying & Welding is in progress. - IS-T-502 & IS-T-102 A/ B tand pad ready.
Constr.
0.12
0.00
- Piping fabrication & piping erection in MPR in progress. Structural fabrication in progress for reactor structure, piping supports, piping manifold - Equipment erection in progress (50 nos equipment erection completed) AG piping fabrication: Scope: 210605 ID; Front: 110882 ID; Completed 87644 ID AG piping erection: Scope: 301995 IM; Front: 96604 IM; Completed 26364 IM
Constr.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 143+14 of 30
Action Plan
Action By
16
17
14
15
0.38
0.00
- Management level meeting held with M/s OIL on 25.03.15 at site. M/s OIL has been asked to ensure sufficient Constr. manpower mobilization when work front is released to them. - Due to delay in completion of civil work, release of front to composite contractor got affected. site update: site work started on 23/12/2014 the progress is as follows:- 1. 216 and 217 area handed over for pipe laying, work in progress. 2. front release plan for next 3 months prepeared, based on which advance blasting & painting,fabrication of spools, pipe doubling works going on. Monthly plan of fabrication and erection is as follows: a) April,15- 15000 ID, 45190 IM b) May, 15- 20000 ID, 45000 IM c) June, 15- 20000 Id, 45000 IM. 3. Cement lining of 20"pipe 492 running meter completed. 4. one underground vessel, 6 pumps already erected, erection of fire water pumps to commence soon.
0.20
0.00
- Management level meeting held with M/s OIL on 25.03.15 at site. M/s OIL has been asked to mobilise additional Constr. resources, M/s OIL confirmed to increase the resources and achieved 1200 ID/day by Mar'15. - At present only 26 nos welders are available at site with per day rate of 1000 ID, however to achieve the completion schedule minimum 1500 ID/day to be achieved.
0.12
0.00
-Out of 2205 nos piles, 1421 nos piles completed.
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 144+14 of 30
Action Plan
Action By
16
17
14
15
0.12
0.00
- Piping fabrication work & Piping erection work in progress. - Equipment erection in progress (13 nos completed) - Structural fabrication in progress for TS-2
Constr.
0.16
0.00
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
BPCL
0.07
0.00
a. Change management should be in place immediately b. Strict discipline to be maintained else end objective would be difficult to meet.
Projects
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
0.10
0.00
-Strict monitoring required at all stages upto commissioning. -Completeness of supply of all subparts, their assembly and other BOP Items to be ensured. - Both steam drum delivered at site. RCC work for chimney completed, foundation work in progress for UB's. Erection of structure started. - Progress of work affected due to delay in completion of civil foundations.
Constn. / Projects / BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 145+14 of 30
Action Plan
Action By
16
17
14
15
0.05
0.00
Following methodology being taken up for smooth cash flow to contractors: - Issue of comfort letter by BPCL to sub Vendors & subcontractor being implemented. - Provision for direct payments to contractors sub vendors & subcontractor being implemented as per contract provision. - Provision of interest bearing mobilisation advance against equivalent bank guarantee being implemented for future contract of more than 5CR value. - Expeditious processing of RA bills.
Project/BPCL
0.03
0.00
Contractor to identify the proposed areas in and around Project area and BPCL to facilitate by persuading with local authorities for required permission.
Constn. / Projects / BPCL
0.00
All DCN ‘s and change orders, if any to be frozen and incorporated in P&IDs at 60% construction progress stage. Process / POSD / Engg. / Projects
0.00
The vendor list to be carefully selected to avoid overloading of vendors shops. Bulk materials to be distributed on Inspn different vendors.
0.00
- Covered under risk ID C73
BPCL
0.00
- BPCL-KR vide e-mail dated 06-Dec-12 sent a list of Non plant buildings to be located under IREP Project. - The same is reviewed by EIL. Point wise issues targeted to be discussed with BPCL in week starting 15.04.13. - List of buildings finalised between EIL and BPCL. Methodology for execution under finalisation.
Projects
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 146+14 of 30
Action Plan
Action By
16
17
14
15
0.04
0.00
- Meeting held with BPCL on EIL recommendations and action plan finalised. - BPCL to take up with MOEF for approval of changes in system already incorporated. (e.g. configuration for CPP) - Incorporation of EC and RRA recommendations in balance systems under progress.
BPCL / Projects
0.00
- Documents approved from PESO
BPCL
0.06
0.00
- All drawings for F&B approval issued progressively upto 29.09.14. -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
EIL/BPCL
0.48
0.00
- Deployment of skilled manpower for enforcement of safety precautions. - Monitoring of the HSE conditions and maintenance of records ./ reports. - Safety Drills being organised on monthly basis.
Constn.
0.00
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
BPCL
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 147+14 of 30
Action Plan
Action By
16
17
14
15
0.40
0.00
-Utilisation of migrant and skilled labour from outside Kerala needs to be encouraged. However, the same will be Constn / effective only if proper labour colony facilities are arranged by the contractors. BPCL - Slow down in progress of work by Union workmen, inspite of assurance by trade union leaders that workers shall be instructed to improve productivity.
0.00
-A separate contract to be given to agency which will take care by approaching KSEB and telephonic authority. -Fabn / transportation philosophy being finalised.
Shipping
0.00
Closed as no concern as on date.
BPCL
0.00
Quarry strike has been called off.
Constn / BPCL
0.00
Cost engg. to issue cost status report on regular basis
Costing
0.00
Scope of facilities finalised.
Environ.
Previou s Risk Score (Curren t risk Score Previou s Risk score)
Job No.: A307 Apr'15 Page 148+14 of 30
14
15 0.00
21.68
-0.90
Action Plan
Action By
16
17
- BPCL have informed that approval for revised cost received.
EIL/BPCL
Job No.: A307 Apr'15 Page 149+14 of 30
Target Date
Risk Severity
18
19
15-Nov-13
Oct'13
15-Oct-13
sep'13
25/10/13
Oct'13
Job No.: A307 Apr'15 Page 150+14 of 30
Target Date
Risk Severity
18
19
15-Mar-14
Mar'14 & Apr'14
31-Mar-14 30-Apr-14 Apr'13
-
Apr'13
-
Mar'13
-
Mar'13
Job No.: A307 Apr'15 Page 151+14 of 30
Target Date
Risk Severity
18
19 Apr'13
31-Dec-12
Jan'13
Apr'13
Apr'13
Job No.: A307 Apr'15 Page 152+14 of 30
Target Date
Risk Severity
18
19 Apr'13
-
Apr'13
15-Mar-13
Feb'13
-
Apr'13
-
Apr'13
As Required
Apr'13
31-May-13
Apr'13
Job No.: A307 Apr'15 Page 153+14 of 30
Target Date
Risk Severity
18
19
31-May-13
Apr'13
Jan'13
25-May-13
May'13
30-Apr-14
May'14
30-May-14
May'14
Job No.: A307 Apr'15 Page 154+14 of 30
Target Date
Risk Severity
18
19 Nov'13
30-Dec-13 31-Jan-15
Dec'13 Jan'15
Mar'14 & Apr'14
21-Aug-13
JUL'13
Job No.: A307 Apr'15 Page 155+14 of 30
Target Date
Risk Severity
18
19
26-Dec-12
Jan'13
21-Dec-12
Jan'13
18-Jun-13
May'13
As Required
Apr'13
15-Jan-13
Jan'13
15-Jun-13
May'13
Job No.: A307 Apr'15 Page 156+14 of 30
Target Date
Risk Severity
18
19
31-May-13
May'13
Apr'13
31-May-13
May'13
Prog. To Jun 13
May'13
18-Jun-13
May'13
Job No.: A307 Apr'15 Page 157+14 of 30
Target Date
Risk Severity
18
19
As Required
Apr'13
Apr'13
May'14
-
Mar'14 & Apr'14
Job No.: A307 Apr'15 Page 158+14 of 30
Target Date
Risk Severity
18
19
Mid Mar'14
Feb'14
10-Mar-13
Feb'13
30-Apr-15
May'15 & Jun'15
Continuous
Sep'14 & Oct'14
Aug'13
Job No.: A307 Apr'15 Page 159+14 of 30
Target Date
Risk Severity
18
19
Continuous
Sep'14 & Oct'14
Continuous
Mar'15
4-Oct-13
sep'13
25-Jul-13
JUL'13
5-Oct-14
Sep'14 & Oct'14
Job No.: A307 Apr'15 Page 160+14 of 30
Target Date
Risk Severity
18
19
25-Oct-13
sep'13
25-Oct-13
sep'13
31-Oct-13
sep'13
Job No.: A307 Apr'15 Page 161+14 of 30
Target Date
Risk Severity
18
19
31-Oct-13
Progressively
Oct'13
May'15 & Jun'15 Nov'13 Aug'14
Job No.: A307 Apr'15 Page 162+14 of 30
Target Date
Risk Severity
18
19
Sep'14
Sep'14 & Oct'14
Sep'14
Sep'14 & Oct'14
30-Dec-13
Dec'13
30-Aug-13
JUL'13
Job No.: A307 Apr'15 Page 163+14 of 30
Target Date
Risk Severity
18
19
30-May-13
May'13
Continuous
Nov'13
15-Sep-13
Aug'13
25-Oct-13
sep'13
31-Oct-13
sep'13
15-Oct-13
sep'13
15-Oct-13
sep'13
Job No.: A307 Apr'15 Page 164+14 of 30
Target Date
Risk Severity
18
19
15-Mar-14
Mar'14 & Apr'14
15-Oct-13
sep'13
31-Oct-13
sep'13
20-Jul-13
JUL'13
Job No.: A307 Apr'15 Page 165+14 of 30
Target Date
Risk Severity
18
19
31-May-13
May'13
29-Jun-13
May'13
28-Feb-13
Feb'13
21-Feb-13
Feb'13
Apr'13
-
Mar'13
Job No.: A307 Apr'15 Page 166+14 of 30
Target Date
Risk Severity
18
19
-
Mar'13
-
Mar'13
7-Mar-13
Feb'13
Apr'13
Apr'13
Job No.: A307 Apr'15 Page 167+14 of 30
Target Date
Risk Severity
18
19
7-Mar-13
Feb'13
Apr'13
30-Mar-14
Mar'14 & Apr'14
Job No.: A307 Apr'15 Page 168+14 of 30
Target Date
Risk Severity
18
19
TBA - 1 month of bids receipt PBO - 1 week of TBA
Dec'13
30-Dec-13
Dec'13
Job No.: A307 Apr'15 Page 169+14 of 30
Target Date
Risk Severity
18
19
30-Aug-13
20-Jul-13
JUL'13
JUL'13
Job No.: A307 Apr'15 Page 170+14 of 30
Target Date
Risk Severity
18
19
20-Dec-13
Nov'13
Jun'13
Job No.: A307 Apr'15 Page 171+14 of 30
Target Date
Risk Severity
18
19
31-Oct-13
Oct'13
31-Jul-13
JUL'13
Aug'13
Job No.: A307 Apr'15 Page 172+14 of 30
Target Date
Risk Severity
18
19
-
sep'13
-
sep'13
15-Jul-13
Jun'13
15-Nov-13
Oct'13
Job No.: A307 Apr'15 Page 173+14 of 30
Target Date
Risk Severity
18
19
20-Jul-13
JUL'13
sep'13
25-Jul-13
JUL'13
30-Oct-13
Oct'13
Job No.: A307 Apr'15 Page 174+14 of 30
Target Date
Risk Severity
18
19
30-Sep-13
Aug'13
7-Mar-13
Feb'13
Jun'13
30-Oct-13
Oct'13
Job No.: A307 Apr'15 Page 175+14 of 30
Target Date
Risk Severity
18
19
30-Jan-14
Jan'14
30-Sep-13
Aug'13
Job No.: A307 Apr'15 Page 176+14 of 30
Target Date
Risk Severity
18
19 Aug'13
28-Aug-13
JUL'13
14-Aug-13
JUL'13
Job No.: A307 Apr'15 Page 177+14 of 30
Target Date
Risk Severity
18
19
19-Jul-13
JUL'13
Jun'14
19-Jul-13
JUL'13
Job No.: A307 Apr'15 Page 178+14 of 30
Target Date
Risk Severity
18
19
28-Sep-13
Aug'13
Jan'14
Job No.: A307 Apr'15 Page 179+14 of 30
Target Date
Risk Severity
18
19
29-Jun-13
Jun'13
30-Nov-13
Nov'13
15-Dec-13
Nov'13
28-Jun-13
Jun'13
Job No.: A307 Apr'15 Page 180+14 of 30
Target Date
Risk Severity
18
19 Aug'13
30-Sep-13
Aug'13
25-Apr-14
Mar'14 & Apr'14
Job No.: A307 Apr'15 Page 181+14 of 30
Target Date
Risk Severity
18
19
31-Oct-13
Oct'13
30-Dec-13
Nov'13
30-May-14
May'14
Job No.: A307 Apr'15 Page 182+14 of 30
Target Date
Risk Severity
18
19
15-Dec-13
Nov'13
30-Jul-14
Jul'14
Oct'14
Sep'14 & Oct'14
14-Aug-14
Aug'14
30-Apr-15
Feb'15
Job No.: A307 Apr'15 Page 183+14 of 30
Target Date
Risk Severity
18
19
25-May-14
May'14
30-Apr-15
May'15 & Jun'15
Mar'15
5-Aug-14
Jul'14
Nov'14
Nov'14
Job No.: A307 Apr'15 Page 184+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
Jun'15
24-Nov-14
I Nov'13
Job No.: A307 Apr'15 Page 185+14 of 30
Target Date
Risk Severity
18
19
Continuous
III
Sep'14
Sep'14 & Oct'14
31-Mar-15
Mar'15
28-Feb-15
Feb'15
Job No.: A307 Apr'15 Page 186+14 of 30
Target Date
Risk Severity
18
19
As stated
I 15-May-15
II
Job No.: A307 Apr'15 Page 187+14 of 30
Target Date
Risk Severity
18
19
Erection by May'15
I
Job No.: A307 Apr'15 Page 188+14 of 30
Target Date
Risk Severity
18
19
end Dec'14
Dec'14
27-Dec-14
Dec'14
19-Mar-15
Mar'15
May'15
May'15 & Jun'15
Job No.: A307 Apr'15 Page 189+14 of 30
Target Date
Risk Severity
18
19
Continous
As Required
IV
Nov'13
Job No.: A307 Apr'15 Page 190+14 of 30
Target Date
Risk Severity
18
19 Jun'14
As Required
III
Job No.: A307 Apr'15 Page 191+14 of 30
Target Date
Risk Severity
18
19
As Required
Oct'13
Continuous
Continuous
II APR'15
Continuous
APR'15
Job No.: A307 Apr'15 Page 192+14 of 30
Target Date
Risk Severity
18
19
Continuous
Dec'14
Continuous
III
Continuous
May'15 & Jun'15
Continuous
May'15 & Jun'15
Job No.: A307 Apr'15 Page 193+14 of 30
Target Date
Risk Severity
18
19
Continuous
Jun'14
Continuous
APR'15
Progressively
APR'15
30-May-15
III
Job No.: A307 Apr'15 Page 194+14 of 30
Target Date
Risk Severity
18
19
Aug'14
Aug'14
Jul'14
Jul'14
Feb'15
Feb'15
30-May-15
III
1-Jul-15
IV
Job No.: A307 Apr'15 Page 195+14 of 30
Target Date
Risk Severity
18
19
1-Jul-15
III
Feb'15
Mid Oct'13
sep'13
Job No.: A307 Apr'15 Page 196+14 of 30
Target Date
Risk Severity
18
19
30-May-15
sep'14
II Aug'14
30-Apr-15
I
Job No.: A307 Apr'15 Page 197+14 of 30
Target Date
Risk Severity
18
19
15-Jul-13
JUL'13
As Required
II
Job No.: A307 Apr'15 Page 198+14 of 30
Target Date
Risk Severity
18
19
As Required
Jun'15
I IV
Job No.: A307 Apr'15 Page 199+14 of 30
Target Date
Risk Severity
18
19
Immediate
Jul'14
within 7 days of certified RA bills
sep'13
As Required
sep'13
end Apr'14
May'14
Job No.: A307 Apr'15 Page 200+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
30-Apr-15
I Jul'14
Job No.: A307 Apr'15 Page 201+14 of 30
Target Date
Risk Severity
18
19
Dec'13
Nov'13
Aug'13
As Required
sep'13
30-Apr-15
Feb'15
-
Nov'13
-
Mar'13
Job No.: A307 Apr'15 Page 202+14 of 30
Target Date
Risk Severity
18
19
May'15
As Required
II May'13
As Required
sep'13
15-Nov-13
Oct'13
Job No.: A307 Apr'15 Page 203+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
IV
30-Apr-15
II
Job No.: A307 Apr'15 Page 204+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
II Continuous
II
Job No.: A307 Apr'15 Page 205+14 of 30
Target Date
Risk Severity
18
19
Continuous
II Continuous
II
Job No.: A307 Apr'15 Page 206+14 of 30
Target Date
Risk Severity
18
19
As Required
As stated
III
Jun'14
Job No.: A307 Apr'15 Page 207+14 of 30
Target Date
Risk Severity
18
19
As stated
I As stated
II As stated
II
Job No.: A307 Apr'15 Page 208+14 of 30
Target Date
Risk Severity
18
19
As Required
III
As Required
Dec'13
As Required
II
Job No.: A307 Apr'15 Page 209+14 of 30
Target Date
Risk Severity
18
19
As Required
I As Required
I
Job No.: A307 Apr'15 Page 210+14 of 30
Target Date
Risk Severity
18
19
As Required
III
As Required
III
Job No.: A307 Apr'15 Page 211+14 of 30
Target Date
Risk Severity
18
19
As Required
As Required
II III
As Required
III
Job No.: A307 Apr'15 Page 212+14 of 30
Target Date
Risk Severity
18
19
As Required
III
30-Apr-15
I 30-Apr-15
II
Job No.: A307 Apr'15 Page 213+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
II 30-Apr-15
I
Job No.: A307 Apr'15 Page 214+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
II 30-Apr-15
30-Apr-15
II III
As Required
III
Job No.: A307 Apr'15 Page 215+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
30-Apr-15
II III
Job No.: A307 Apr'15 Page 216+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
30-Apr-15
30-Apr-15
II III
Job No.: A307 Apr'15 Page 217+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
30-Apr-15
II III
30-Apr-15
III
Job No.: A307 Apr'15 Page 218+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
1-Jun-15
III
Continuous
IV
as scheduled
III
Job No.: A307 Apr'15 Page 219+14 of 30
Target Date
Risk Severity
18
19
As Required
IV
As Required
IV
All by 60% constn progress
sep'13
As Required
sep'13
within 2 days of request
Nov'13
15-Apr-13
Apr'13
Job No.: A307 Apr'15 Page 220+14 of 30
Target Date
Risk Severity
18
19
As required
IV
Apr'13
30-Apr-15
IV
Continuous
As Required
II Nov'13
Job No.: A307 Apr'15 Page 221+14 of 30
Target Date
Risk Severity
18
19
As Required
As Required
As stated
As Required
II Jun'14
Jun'14
Mar'15
Monthly
Apr'13
15-Oct-13
sep'13
Job No.: A307 Apr'15 Page 222+14 of 30
Target Date
Risk Severity
18
19 Jan'15
Job No.: A307 Apr'15 Page 223+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
A
2
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Delay in Finalisation of balance OSBL distribution P&IDs due to delay in receipt of data from BPCL LAD - 30-Nov-12; Ant - 15-Oct13 Natural gas operating/ design condition information has been received from BPCL during meeting dated 13 & 14.8.13. Steam distribution : Preliminary discussion on BOO steam distribution held with BPCL. BPCL approval on EIL scheme required.
EIL Cost (Y / N)
1
Delay in issue of Process deliverables for engineering for NHT / ISOM due to delay in receipt of Process Package from M/s UOP (Process pkg incl. resolution sheet received on mid Aug'13 against sch of 30-Apr-13) Schedule : 31-Jul-13 Anticipated : mid Nov'13
Project Cost ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
A
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Process
Low
N
N
Y
N
Short term
D
0.2
Process
Medium
N
N
Y
N
Short term
D
0.16
Open
Open
Job No.: A307 Apr'15 Page 224+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
A
Key Risk Description
Status (Open / Close)
A
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Holds, missing information, corrections, changes in PDS / P&IDs - CDU / VDU - DCNs on account of HAZOP recommendations for CDU / VDU
Open
Process
Medium
N
N
N
N
Short term
D
0
Holds, missing information, corrections, changes in PDS / P&IDs - DCU
Open
Process
Medium
N
N
N
N
Short term
D
0
BPCL / Process
Low
N
N
Y
N
Short term
I
0.4
3
4
Delay in Process Package for TGTU (M/s CB & INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13 A
5
Agreement signed by BPCL-KR issued to Licensor on 04.04.13
Close
Job No.: A307 Apr'15 Page 225+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
4
5
6
7
8
9
10
11
12
13
Delay in "issue for engineering - IFE" PDS / P&IDs Close for DHDT P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
Process
Very High
N
N
Y
N
Short term
D
0.16
Delay in "issue for engineering - IFE" PDS for DCU LAD : 29-Dec-12; Ant : 19-Mar-13
Process
Medium
N
N
Y
N
Short term
D
0.16
Process
Low
N
N
Y
N
Short term
I
0.4
Process
Low
N
N
Y
N
Short term
D
0.16
Risk Id
Project Cost ( Y / N)
A
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
A
Risk Owner
A
Status (Open / Close)
Integrated Refinery Expansion Project
Key Risk Description
1
2
6
7
8
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Close
Close
Delay in "issue for engineering - IFE" PDS / P&IDs Close for FCC LAD :29-Jan-13; Ant : 08-May-13 A
9
Job No.: A307 Apr'15 Page 226+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Close
Process
Low
N
N
N
N
Short term
I
0
0.00
Delay in "issue for engineering - IFE" PDS / P&IDs Close for VGO-HDT LAD : 29-Jan-13; Ant : 10-May-13
Process
Medium
N
N
Y
N
Short term
D
0.16
-Preparation of Offsite P&ID’s for tankages (LAD - Close 21.01.13) - Delay has been due to delay in receipt of As-built drawings from BPCL-KR (except CEMP-II). All details received now. -Upgradation of Crude oil pipeline system (Inside refinery) to be taken up.
POSD
Very High
N
N
Y
N
Short term
I
0.4
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A
A
A
10
11
12
Job No.: A307 Apr'15 Page 227+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
A
Controllability Condition (D/I )
A
Urgency (Long Term / Short term)
A
Output Quality ( Y / N)
-Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
Schedule ( Y / N)
14
EIL Cost (Y / N)
13
In view of increase in sulphur load PDS & P&IDs for sulphur block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement. Revision in PDS after issue of “Issued for Engineering” after release of MR
Project Cost ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
A
Key Risk Description
Status (Open / Close)
A
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Close
Process
Low
N
N
Y
N
Short term
D
0.16
Close
Process/EN GG
Low
N
N
Y
N
Long term
I
0.2
Process
High
N
N
Y
N
Short term
I
0.4
Low
Y
Y
Y
Y
Long term
D
0.2
Y
Y
Y
Y
Long term
D
0.2
Close
15
Close
16
Revision in PDS after issue of “Issued for Engineering” after Order
Process/EN GG/Procure
Close
17
Revision in PDS after issue of “Issued for Engineering” after Equipment manufacturing
Process/EN Very Low GG/Procure
Job No.: A307 Apr'15 Page 228+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
A
A
A
A
A
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Close
Process
Low
N
N
Y
N
Long term
I
0.2
18
Updation of estimated utilities on account of revision in process parameters (revision of PDS based on engg comments)
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
19
ISBL Distribution P&IDs for VGO-HDT SCH: 30-Nov-12 ANT: Jun-13 ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 ANT: 31-May-13
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
20
Utility distribution P&IDs for DCU
Close
Process
Low
N
N
N
N
Long term
I
0
Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 Updation of P&ID as per finalised condensate philosophy to be taken up.
Open
Process
Medium
N
N
Y
N
Short term
D
0.16
21
22
0.00
Job No.: A307 Apr'15 Page 229+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Engg
Very High
N
N
N
N
Short term
D
0
23
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed engineering activities.
Open
Power Tech.
High
N
N
Y
N
Short term
D
0.16
24
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new GTG).
Close
Engg.
Medium
N
N
Y
N
Short term
I
0.4
A
25
BPCL confirmation/clarification over datasheets/GAD’s for existing/new raw water intake pump obtained from M/s KBL (LAD for MR for pumps - 07.03.13)
A
26
Identifications of hook-ups on flare lines and finalisation of methodology with BPCL i.e. availability of Shut down / Hot tapping.
Close
Projects
Medium
N
N
Y
N
Short term
I
0.4
A
A
Job No.: A307 Apr'15 Page 230+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
B
Risk Owner
A
Key Risk Description
Status (Open / Close)
A
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Signing of ISBL P&IDs and battery limit P&IDs for Units, Utility packages & other packages.
Open
Process / POSD
Low
N
N
Y
N
Short term
D
0.16
Close
Process / POSD
High
N
N
Y
N
Short term
D
0.16
28
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Open
Engg.
Very High
N
N
Y
N
Short term
D
0.16
1
Issue of Equipment layout for engineering for NHT/ISOM Ant - 21-Aug-13) Delay in this activity shall hamper the following: i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation
27
Job No.: A307 Apr'15 Page 231+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
B
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
B
Risk Owner
B
Key Risk Description
Status (Open / Close)
B
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Close
Engg.
Very high
N
N
Y
N
Short term
D
0.16
Close
Engg.
High
N
N
Y
N
Short term
D
0.16
Open
ENGG
High
N
N
Y
N
Short term
D
0.16
Procure/EN GG/CONS.
Medium
Y
N
Y
N
Long term
D
0.12
2
3
4
5
Issue of Equipment layout for engineering for VGO-HDT LAD - 07-Nov-12 Ant- 26-Dec-12 Delay in this activity shall hamper the following: Issue of Equipment layout for engineering for i) 3 D Modelling FCCU (targeted by ii) Civil/Structural & 27.12.2012) UG Piping Tender preparation Delay in this activity shall hamper the following: i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation NIT for Heater for FCCU LAD -01-Apr-13 ; Ant - 18-Jun-13 a) Cost/time overrun due to rework b) Non completion of critical project activities within time & delay in Project completion c) Poor performance of Sub-contractors and Vendors
Close
Job No.: A307 Apr'15 Page 232+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
4
5
6
7
8
9
10
11
12
13
New requirement of power recovery system Close (FCCU) shall have impact on project cost. 3 Nos PRTs envisaged (FCC-1 Nos ; VGO- 2 Nos)
Project
High
Y
N
Y
N
Short term
I
0.6
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; Ant: Mid Jun'13
Open
Engg.
High
N
N
Y
N
Short term
D
0.16
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant - End Close May 13) Piping preliminary MTO has been released without covering DHDT, VGO FCC& offsite interconnection P&IDs, Flare system & offsite storage P&IDs. Prel. MTO covers 35% for large bore pipes.
Piping
Very High
N
N
Y
Y
Short term
D
0.2
Risk Id
Project Cost ( Y / N)
B
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
B
Risk Owner
B
Status (Open / Close)
Integrated Refinery Expansion Project
Key Risk Description
1
2
6
7
8
Job No.: A307 Apr'15 Page 233+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
4
5
6
7
8
9
10
11
12
13
Delay in thermal design for Heat exchangers & Air Close coolers for licensed and non licensed units LAD (DHDT): 02-Feb-13 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
HMTD
Very High
N
N
Y
N
Short term
D
0.16
Issue Overall UG piping layout drawing for the complex
Close
Engg.
High
N
N
N
N
Short term
D
0
Completion of 30 % Model review VGO- LAD: 09-Mar-13 FCCU-LAD : 23-Apr-13
Open
Engg.
High
N
N
Y
N
Short term
D
0.16
NIT for Civil & Strl work for existing Refinery Area LAD: 31-Jan-13 ANT: 18-Jun-13
Open Project/C&P Very High
N
N
Y
N
Short term
D
0.16
Risk Id
EIL Cost (Y / N)
C
Project Cost ( Y / N)
B
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
B
Risk Owner
B
Status (Open / Close)
Integrated Refinery Expansion Project
Key Risk Description
1
2
9
10
11
12
Job No.: A307 Apr'15 Page 234+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
B
B
B
Close
Current Risk Score -> {5}* {12}
MR issue for MCC (Main combustion Chamber) packages.
Impact Score => {6+7+8+9} * 10 * 11
Close
Controllability Condition (D/I )
a) Inaccurate assessment of quantum of work
Urgency (Long Term / Short term)
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
N
N
Y
N
Long term
D
0.08
Engg/procur Very High ement
13
14
15
Project
Medium
N
N
Y
N
Short term
D
0.16
Engg.
High
N
N
Y
N
Short term
D
0.16
LAD: 16-Feb-13 Ant: 15-Apr-13 Timely finalisation of Package Interface Open CDSP-DCU awarded on 22-Aug-13; RR pkg-FCC awarded on 25-Jul-13. (Battery Limit conditions for each package to be frozen within three months of award to ensure time availability for engg, procurement and construction by all the concerned).
Job No.: A307 Apr'15 Page 235+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
B
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
B
Key Risk Description
Status (Open / Close)
B
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Unit and offsite interfaces (Elevation termination levels)
Close
Engg.
Medium
N
N
Y
Y
Long term
D
0.1
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule requirements. LAD - 28.02.13; Ant - upto Feb 14.
Open
Projects
High
N
N
Y
N
Short term
D
0.16
NIT for Heater for DCU LAD -15-Feb-13;
Close PROCESS/ Very High ENGG
N
N
Y
N
Short term
I
0.4
16
17
18
Job No.: A307 Apr'15 Page 236+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Engg/Cont.
Low
N
N
Y
N
Long term
D
0.08
0.02
19
CPP: Integration of various packages & BOP Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas Booster compressor.
Open Engg/procur ement
Medium
N
Y
N
N
Long term
I
0.15
B
20
Distributed Control System (DCS) Detailed engg., supply and erection (ordered on M/s Emerson Process on 04.11.13)
B
21
N
N Y
Y
N
Short Long term
D
0.16 0.14
B
22
B
60 % Model review for to submit Instrumentation Close ENGG Very High Package Vendor refuses Open Engg/procur Low DCU (LAD:03.07.13 Act:13.09.13) Drawings/ Documentation in Smart Plant ement Instrumentation Database as per Client Requirement
Job No.: A307 Apr'15 Page 237+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
B
B
B
B
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Low
N
N
Y
N
Long term
I
0.2
Open Engg/procur ement
23
Delay in Interface Engineering (including control system) due to non availability of Package Vendor Data
Open
ENGG
Medium
N
N
Y
N
Short term
D
0.16
20
60 % Model review for DHDT (LAD:07.08.13 Ant:04.10.13) - Integrated model for RGC, MUG compressor, Feed filter & Heater pkg awaited from vendor. - Vendor drawings for sheds awaited.
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
GC
Medium
N
N
Y
N
Long term
D
0.08
Order of MR for DG set Dely: (12 M FOB + 3 M Site work) Sch: 05.11.13
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
24
25
Job No.: A307 Apr'15 Page 238+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
ENGG
Very High
N
N
Y
N
Short term
D
0.16
Receipt of Inputs from Process / Vendors for 60 % Close Model review for VGO-HDT required for procurement of piping material (LAD:14.08.13 Ant:25.10.13) - Integrated model for RGC, MUG compressor, Feed filter & Heater pkg awaited from vendor. - Vendor drawings for sheds awaited. B
26
Job No.: A307 Apr'15 Page 239+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
4
5
6
7
8
9
10
11
12
13
60 % Model review for Open FCCU (LAD:16.09.13 Ant:25.10.13) - Line size for 300 nos P&IDs under hold -Vendor data needed for coalescer, electric heater, pumps & filters - Review of model by Licensor (Stone & Webster) envisaged.
ENGG
Very High
N
N
Y
N
Short term
D
0.16
60 % Model review for SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), 164 (SRU),15 (SWS) & 60(TGTU) + 155(Utilities -CVs Size Hold as follows: 13 (ARU), 6 (SWS), 125 (SRU). -All Control Valve Face to Face Dimensions are HOLD. All CVs for TGTU are HOLD.
ENGG
Medium
N
N
Y
N
Short term
D
0.16
Risk Id
Status (Open / Close)
Integrated Refinery Expansion Project
Key Risk Description
1
2
B
27
B
28
Open
Job No.: A307 Apr'15 Page 240+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Delay in release of Intermediate 2nd MTO LAD:30.09.13; Act:31.10.13) Holds: -CDU/VDU: Pump nozzle for 6 nos. pumps under hold), sizes for 256 lines under hold, Control valve matching flange, bypass valve and flanges (21 nos.) & PSV inlet outlet flanges and reducers (37 nos.) -DHDT: By-pass lines for CVs under hold (30nos), PSV's mating flanges and reducers (44 nos), Lines (103 nos.) not considered in MTO.
Open
ENGG
Very High
N
N
Y
N
Short term
I
0.4
Generation of Surplus Piping material
Open
ENGG
Low
N
N
Y
N
Short term
D
0.16
HAZOP for FCCU LAD - 23-Sep-13
Close
ENGG
High
N
N
Y
N
Short term
D
0.16
B
29
B
30
B
31
LD Milestone date - Dec'13
0.05
Job No.: A307 Apr'15 Page 241+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
4
5
6
7
8
9
10
11
12
13
Completion of 90 % engineering by Mar-14. Open Average progress achieved in last 3 months 3.0 %
ENGG
Low
N
N
Y
N
Short term
D
0.16
Release of final Piping MTO Sch: Jul'14
Open
ENGG
High
N
N
Y
N
Short term
D
0.16
Finalisation of GTG fuel forwarding scheme for naphtha to day tank when Naphtha tank being under maintenance.
Open
POSD
Medium
N
N
Y
N
Short term
I
0.4
Risk Id
Project Cost ( Y / N)
B
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
B
Risk Owner
B
Status (Open / Close)
Integrated Refinery Expansion Project
Key Risk Description
1
2
32
33
34
Job No.: A307 Apr'15 Page 242+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Delay in award of PRT -FCCU(Hot gas expander) LAD: 19.04.13 Ant: 30.12.13 Multiple Bids extensions leading to delay in ordering. 02 Bids recd on 12.08.13 (Dresser Rand ,Elliot Ebara) Org. BDD: 27.06.13 1st extension: 16.07.13 2nd Extension: 01.08.13 3rd extension: 09.08.13 Duration: 16 M FOB
Close
Project
Medium
Y
Y
Y
N
Short term
I
0.9
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 Duration: 18 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
Very High
Y
Y
Y
N
Short term
D
0.36
1
2
3
Job No.: A307 Apr'15 Page 243+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Project Cost ( Y / N)
C
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
C
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
Close
Project
Very High
Y
N
N
N
Short term
I
0.2
Award of Heater for DHDT LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for DCU LAD -06.06.13 ; Ant - 25.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
4
5
6
7
8
Job No.: A307 Apr'15 Page 244+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
C
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
Award of PRT for DHDT & VGO-HDT unit (Pumps centrifugal multistage) Sch: 23.04.13 Ant: 15.03.14 (IV-P-301A/B)
Open
ENGG
Medium
Y
Y
Y
N
Short term
D
0.36
NIT for Composite Works for Offsite DHDS area LAD -22.07.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
NIT for Composite Works for Existing refinery area Open LAD -22.07.13 ; Ant - 31.10.13
ENGG
Very High
N
N
Y
N
Short term
D
0.16
9
10
11
12
Job No.: A307 Apr'15 Page 245+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
C
C
C
C
13
14
15
16
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
Award of : Main fractionator for FCCU LAD: 25-Mar-12 Ant: 20-Jul-13
Open Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
Issue NIT for Tankage-II LAD: 21-Jan-13 ANT: 31-May-13
Close Project/C&P Very High
N
N
Y
N
Short term
I
0.4
Award for RO-DM LAD:30-Jan-13 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13
Close
Project
High
N
N
Y
N
Short term
I
0.4
Job No.: A307 Apr'15 Page 246+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
C
C
19
20
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
18
EIL Cost (Y / N)
17
Project Cost ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Project / Licensor
Very High
Y
Y
Y
N
Short term
I
0.9
Project
Low
N
N
N
N
Short term
I
0
NIT for Reactor regenerator package for FCCU Close LAD : 01-Jan-13 Ant: 21-Feb-13 Changes in scope of supply led to revision in BQC / tender.
Award for Raw water quarries LAD :03-May-13 ANT: 15-Apr-13
Close
Ordering of Reactor for VGO-HDT LAD: 29-Dec-12 ACT: 08-Apr-13
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of contract for Piling-II LAD: 31-Dec-12
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
Ant: 15-Apr-13
Job No.: A307 Apr'15 Page 247+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
C
C
C
C
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
21
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 Ant: 30-Mar-13
Close
Engg.
Very High
N
N
Y
N
Short term
I
0.4
22
Award of Crude and Vacuum heaters (LAD 29.12.12) Ant : 07.03.13
Storage of sulphur and related issues with Granulator to be finalised between BPCL / EIL.
Close
Project
Very High
N
Y
Y
N
Short term
I
0.7
NIT for ETP package with WAO (Wet air oxidation) Close LAD: 15-Jan-13 Ant: 16-Apr-13
Project
Very High
N
N
Y
N
Short term
I
0.4
23
24
Job No.: A307 Apr'15 Page 248+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Close
Project
High
N
N
Y
N
Short term
D
0.16
Project
Very High
N
N
Y
N
Short term
I
0.4
Strl
High
N
N
Y
N
Short term
D
0.16
Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13 C
C
25
26
Award of contract for Building incl substations LAD: 07-Feb-13 Ant: 15-Apr-13
Filling of existing part fire water pond required for area preparation. Sch - 28.08.13; Area handed over to M/s L&T C
27
Close
Open
Job No.: A307 Apr'15 Page 249+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
N
N
Y
N
Short term
D
0.16
Delay in ordering of Long Lead Items. Close Engg / C&P Very High Technical / Commercial evaluation of long lead items (compressors & packages) taking more than 2 months.
C
28
Job No.: A307 Apr'15 Page 250+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of Waste heat Boiler package (Waste Heat Boilers along with respective steam drums(un engineered ), Incinerator Combustion Chambers (engineered), Incinerator vent stacks). LAD: 27.04.13 Ant: 30.12.13 Bids extension: 1st extension - from 28.05.13 to 20.06.13. 2nd Extension- from 20.06.13 to 02.07.13. 3rd extension - from 02.07.13 to 08.07.13. Duration: Supply + Erection - 18 M
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
29
Job No.: A307 Apr'15 Page 251+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Delay in award of CDSP package Schedule: 02.03.13 Anticipated : 30.08.13 Completion of works Sch: 01.05.15 ( M); RFQ Duration : ( M) Anticipated: 23.11.15 (27 M) Bidders quoted 27 M against schedule of 26 M.
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
Ordering of GTG Pkg (LAD:10-Mar-13; Ant 20.07.13) Bid received on 28.03.13. Multiple extension (4 times) in bid due date on request of M/s Siemens. Duration (Supply) - 15 M FOB /16 M FOT as per RFQ; Sch : 20 M
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
30
31
Job No.: A307 Apr'15 Page 252+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
C
32
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Projects / Engg
Very High
Y
N
Y
N
Short term
I
0.6
Delay in Ordering of HRSG Close (Sch Order - 22-May-13; Ant - 20-Dec-13) Initial Change in configuration by BPCL. Multiple extensions (twice) in bid due date due non availability of exhaust data for GTG. Post Enquiry changes in type of Fuel (LSVR) by BPCL. No PTR available for LSVR Fuel Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
Job No.: A307 Apr'15 Page 253+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
C
34
6
7
8
9
Project / Licensor
Very High
Y
Y
Y
N
Project
Very High
N
N
Y
N
Ordering of Reactor regenerator package for Close FCCU LAD : 10-Apr-13 Act: 10-Jul-13 Changes in scope of supply led to revision in BQC / tender due to which NIT was delayed. Bidders sought extension in dates.
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) Duration: 21 M+2 M No bidder could meet the BQC criteria in view of which the tender has been re-floated.
Open
Current Risk Score -> {5}* {12}
5
Impact Score => {6+7+8+9} * 10 * 11
Output Quality ( Y / N)
4
Controllability Condition (D/I )
Schedule ( Y / N)
3
Urgency (Long Term / Short term)
EIL Cost (Y / N)
33
Project Cost ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
10
11
12
13
I
0.9
I
0.4
Short term
Short term
Job No.: A307 Apr'15 Page 254+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Process / Engg / constn
Very High
N
N
Y
N
Short term
I
0.4
35
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 Duration: 20 M
Close Project/C&P Very High
N
N
Y
N
Short term
D
0.16
36
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 Duration: 22 M+2 M Anticipated Completion: 29-Jul-15
Job No.: A307 Apr'15 Page 255+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
Low
N
N
Y
N
Long term
I
0.2
Failure of contractors
Open
Const.
Low
N
N
Y
N
Long term
D
0.08
Ordering of Ejector Pkg (LAD:12-Jan-13; Ant: 15-Jul-13)
Open
Project
Medium
Y
Y
Y
N
Short term
I
0.90
37
C
38
C
39
Job No.: A307 Apr'15 Page 256+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
C
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of Heater package for DCU (LAD:24-May-13; Ant: 15-Nov-13 Earlier 04 Bids recd on 21.05.13. (Petron, Thermax, Heurtey, Technip). Due to Technical and related commercial issues enquiry re-floated. Duration 20 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.40
Award of Civil & Strl work for DHDS offsite area (LAD: 30-Mar-13; Ant: 20.07.13) Duration: 18 M
Open
Project
High
N
N
Y
N
Short term
I
0.40
Award of Civil & Strl work for refinery area. (LAD:25-Apr-13; Ant: 10.10.13) Duration: 16 M
Close
Project
High
N
N
Y
N
Short term
I
0.40
40
41
42
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15
Job No.: A307 Apr'15 Page 257+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
C
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) Duration : 16 M
Open
Project
Medium
N
N
Y
N
Short term
D
0.16
Award of work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
43
44
Job No.: A307 Apr'15 Page 258+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
4
5
6
7
8
9
10
11
12
13
Ordering of Main Air blower & wet gas compressor Close for FCCU LAD: 04-Mar-13 Ant: 30-Sep-13 (Total execution duration is 25-27 M : 19 M FOT for delivery of WGC & MAB at site + 6 to 8 M Site installation & pre-comm; Time Available from order to MC OF FCCU - 24 months)
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of Civil & Strl contract for CDU/ VDU & DCU LAD: 15-Dec-12 Ant: 07-Mar-13
Close
Project
Close
N
N
Y
N
Long term
I
0.2
Ordering of wet gas compressor for DCU LAD: 02-Feb-13 Ant: 30-Jun-13
Close
Project
Medium
N
N
Y
N
Short term
I
0.4
Risk Id
Project Cost ( Y / N)
C
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
C
Risk Owner
C
Status (Open / Close)
Integrated Refinery Expansion Project
Key Risk Description
1
2
45
46
47
0.00
C Key Risk Description Status (Open / Close)
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) EIL Cost (Y / N) Schedule ( Y / N) Output Quality ( Y / N) Urgency (Long Term / Short term) Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Ordering of OFF GAS COMPRESSOR - VGO LAD: 08-Jun-13 Ant: 30-Oct-13 RFQ duration: 17 M FOB
Risk Id
Kochi Refinery, BPCL
48
Job No.: A307 Apr'15 Page 259+14 of 30
IV - RISK REGISTER
Integrated Refinery Expansion Project
1 2 3 4 5 6 7 8 9 10 11 12 13
Open Project High N N Y N Short term D 0.16
Job No.: A307 Apr'15 Page 260+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of Sulphur Forming LAD: 03.04.13 Ant: 30.01.14 Earlier enquiry re-floated due to changes in MR requirements by BPCL(MR was revised as Evaluation methodology was to be based on NPV and in view of 2 different types of technologies viz., sulphur pelletiser and sulphur granule); refloated again as financial criteria was not met by all the bidders.
Open
Project
Very High
N
Y
Y
N
Short term
D
0.28
49
Job No.: A307 Apr'15 Page 261+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
C
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Close
Project
Very High
N
Y
Y
N
Short term
D
0.28
50
Award of contract for Civil & structural for FCCU area (refloated) LAD:15-Mar-13 Ant: 30-Sep-13 Compl: 15 M – Dec'14; Sch: Nov’14 As decided during Management meeting dated 19.06.13, based on past Performance of recommended bidder tender refloated.
Job No.: A307 Apr'15 Page 262+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of contract for Civil & structural for DHDT & VGO area (refloated) LAD:15-Mar-13 Ant: 30-Sep-13 Compl: 16 M – Jan’15; Sch: Nov’14 As decided during Management meeting dated 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
Very High
N
Y
Y
N
Short term
D
0.28
Award of contract for Civil & structural for CPP area LAD:28-Jun-13 Ant: end Aug-13 Duration: 16 M
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
51
52
Job No.: A307 Apr'15 Page 263+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of MCC package LAD:10.06.13 Ant: 14.08.13 Duration: 12 M despatch and 6 M for site work (ODC)
Open
Project
High
N
N
Y
N
Short term
I
0.4
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
54
Award of contract for RWTP (Refloat case) LAD: 14-Jan-13 Ant: 19-Jul-13 (Execution Duration - 18+2 M)
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
55
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 15.06.14 (Incinerator burner) (Execution Duration - 14 M)
53
C Risk Id
Key Risk Description Status (Open / Close)
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) EIL Cost (Y / N) Schedule ( Y / N) Output Quality ( Y / N) Urgency (Long Term / Short term) Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Kochi Refinery, BPCL
56
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Integrated Refinery Expansion Project
1 2 3 4 5 6 7 8 9 10 11 12 13
Open Project Very High N N Y N Short term I 0.4
Award of Air blower/compressor for SRU LAD: 29-Mar-13 Ant: 25-Jul-13 (Execution Duration - 17 M FOB/ 18 M FOT)
Job No.: A307 Apr'15 Page 265+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Close
Project
Very High
Y
Y
Y
N
Short term
I
0.9
Delay in Award of contract for Demountable flare (LAD: 08-Apr-13; Ant: 28-Sep-13) Change in type of Flare. Initially as per DFR normal flare was envisaged. Post enquiry significant changes (received on 15.03.13) in Flare Load/Process Data Sheet due to enormous increase in BOO flare load and non acceptance of mitigation measures by FCCU Licenser. C
57
Change in flare load data due to change in flare height upto 150 M. Completion of works Sch. : 31.01.15 Ant. : 28.02.15
Job No.: A307 Apr'15 Page 266+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 Duration: 12 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Award for:RGC compressor for VGO-HDT (LAD: 30-Mar-13; Ant: end Jun 13) Dely: 18 M
Open Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
Award of MUG compressor for VGO-HDT (LAD: 08-Apr-13; Ant: 30.11.13) Dely: 16 M FOB
Close Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
58
59
60
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Kochi Refinery, BPCL
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
7
8
9
10
11
12
13
Award of Contract for Tankage-III (Crude tank: 02 Close Project/Eng Very High Nos & 1 surge relief tank and crude drain tank) g Outage of existing crude tank from crude to naphtha can be taken up after commissioning of new crude tanks. Shutdown of existing tanks- 17 & 18 depend on commissioning of new crude tanks25/26 under tankage-III. Sch: 01.10.13 Ant: 15-Dec-13
N
N
Y
N
Short term
I
0.4
Close Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
62
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: Jun 13)
Close Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
63
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep-13) Duration : 18 M FOB
Risk Owner
6
Key Risk Description
Status (Open / Close)
5
Risk Id
Schedule ( Y / N)
C
EIL Cost (Y / N)
C
Project Cost ( Y / N)
C
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Integrated Refinery Expansion Project
1
2
3
4
61
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Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) Sch: 30.04.13 Ant: 30-Sep-13 Duration:22 M
Close
BPCL
High
N
N
Y
N
Short term
D
0.16
Award of Tankage-IV (Total 15 Nos Tanks) LAD: Jan14 • Outage for Tank YT-340 depends on readiness of at least one new DCU feed tank which will require 14 M durations. Alternative scheme required to be finalised for outage. • Outage of Tankage YT-18 depends on readiness of new crude tanks (Tankage-III; YT-25/26). Alternative scheme required to be finalised for outage.
Open
BPCL / Projects
Very High
N
N
Y
N
Short term
I
0.4
64
65
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Kochi Refinery, BPCL
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Project
Very High
N
N
Y
N
Short term
I
0.4
Project
Very High
Y
N
Y
N
Short term
D
0.24
Award of Composite Works for CDU/VDU (06 Bids Open - L&T, Petron, Offshore, Mcnally Bharat, Albana, IOTL recd on 04.09.13) LAD -30.08.13 ; Ant - 31.10.13 C
66
Duration - 20 M
Award for contract for development of flare area LAD: 01-Nov-13 Ant: end Dec'13 C
67
Close
Job No.: A307 Apr'15 Page 270+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of Composite Works for VGO-HDT, DHDT, CPP and Offsites (DHDS) LAD 31.12.13 ; Ant - 30.05.14
Open
ENGG
Very High
N
N
Y
N
Short term
I
0.4
Award of Heater package for FCCU (LAD:08-Jul-13; Ant: 15-Dec-13 Earlier 05 Bids recd on 23.07.13. (Thermax, Technicas, Petron, B&R, JNK). Duration 20 M
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of Gas Booster Compressor for CPP (Dly: 13 M FOB / 14 M FOT)) (LAD:29.12.13; Ant: 30.07.14)
Open
Project
Medium
Y
N
Y
N
Short term
I
0.6
68
69
70
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Kochi Refinery, BPCL
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
C
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 Ant: 10.10.14
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards Piping intermediate MTO-II released on 30.10.13.
Open
Project
Low
N
N
Y
N
Short term
D
0.16
Ordering of Critical Valves Sch: 11.07.14 Ant: 31.01.15 Dely: 06/07 M FOT /FOB
Open
Project
High
N
N
Y
N
Short term
I
0.4
Award of contract for Mechanical works-CPP area LAD: 28.02.14 Ant: 25.05.14
Open
Project
Medium
N
N
Y
N
Short term
D
0.16
71
72
73
74
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IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Risk Owner
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 Ant: 15.05.15
Open
Project
Low
N
N
Y
N
Short term
D
0.16
0.05
Award of Composite Works (Structural Works & Mechanical) for NHT/ISOM-Refloated Sch: 08.05.14 Ant: 25.03.15
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Award of Fuel forwarding Pumps (08 nos) for GTG Open (Dely: 6 M FOB / 7 M FOT) Sch:27.06.14 Ant: 05.08.14
Project
Very High
N
N
Y
N
Short term
I
0.4
75
76
77
Job No.: A307 Apr'15 Page 273+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
C
Key Risk Description
Status (Open / Close)
C
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Award of Electrical & Instrumentation Works for Units & Offsite Sch: 30.06.14 Ant: 10.11.14 Electrical/Instr. Works: Part A: CDU/VDU, DCU, FCCU, DHDT, VGO-HDT & IREP Offsite: Part B: SRU & DHDS/Refinery Offsite :
Open
Project
Low
N
N
Y
N
Long term
I
0.2
Delay in award of piping material with G2E specification in CPP area.
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
78
79
0.20
Job No.: A307 Apr'15 Page 274+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Schedule ( Y / N)
Output Quality ( Y / N)
4
5
6
7
8
9
Open
Project
Very High
Y
Y
Y
N
Delivery of GTG Pkg at site (LAD:29-Sep-14; Ant - Close 24-Nov-14) Awarded to M/s BHEL Duration (Supply) - 16 M
Project
Very High
Y
Y
N
N
1
2
Completion of Reactor regenerator package for FCCU-M/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 93.9% Act: 72.8 % Construction Progress: Sch: 90.24% Front: 95.62% Act: 35.23 %
Current Risk Score -> {5}* {12}
EIL Cost (Y / N)
3
Impact Score => {6+7+8+9} * 10 * 11
Project Cost ( Y / N)
2
Controllability Condition (D/I )
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Urgency (Long Term / Short term)
Risk Owner
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
10
11
12
13
I
0.9
0.86
I
0.25
Short term
Long term
Job No.: A307 Apr'15 Page 275+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
D
Risk Owner
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Completion of UB package LAD : 31.03.15 CCD : 23.03.15 ECD:10.08.15 Awarded to M/s ISGEC on 25.07.13 Construction Progress: Sch:100 % Front: 100 % Act: 58.04 % Manpower : Required 450, Deployed 333 incl 39 welders
Open
Project
Very High
N
N
Y
N
Long term
I
0.2
0.19
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14
Open
Project
Low
N
N
Y
N
Long term
I
0.20
Open
Project
Low
N
N
N
N
Long term
I
0
3
4
5
Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT. Delivery of wet gas compressor for DCU at Site (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 31.03.15)
Job No.: A307 Apr'15 Page 276+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 28.02.15)
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
Completion of all three site Fabricated Columns for FCCU :Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). LAD: 22.01.15 CCD:14.01.15 ECD: 15.10.15 Overall progress: Sch: 100 % Act: 76.2 % - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach road upto fabrication yard, which affected shifting of sections.
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
6
7
0.67
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IV - RISK REGISTER
Kochi Refinery, BPCL
D
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
8
Completion of MCC pkg for SRU LAD: 23.06.15 CCD:18.02.15 (including Site work) ECD: 30.09.15 site work yet to start Ordered to M/s Thermax on 19.08.13 (18 M incl erection)
Job No.: A307 Apr'15 Page 278+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
D
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
9
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 30.07.16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 92.8 %; Act: 68.4 % Construction Progress: Sch: 87.08% Front: 100% Act: 43 % Strl Steel: Out of total 3210 MT, 2926 MT procured, 1929 MT fabricated & 1716 MT received.
Job No.: A307 Apr'15 Page 279+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
D
D
D
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Open Project/Eng g
Low
N
N
Y
N
Long term
I
0.2
10
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M Ordered to M/s BHEL on 28.06.13
Open Project/Eng g
Low
N
N
Y
N
Long term
I
0.2
11
Delivery of RGC compressor for DHDT(LAD : 05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
Medium
N
N
Y
N
Short term
I
0.4
12
Delay in hydrotesting of Vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: 19.03.15 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column.
Open
BPCL / Projects / Const.
Job No.: A307 Apr'15 Page 280+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
4
5
6
7
8
9
10
11
12
13
Logistics of VGO / DHDT reactors & Other ODC Open equipments from Kochi port to BPCL-KR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Jun15 DHDT reactor reached at site VGO reactor dispatched from L&T shop
T&CC
Very High
N
N
Y
N
Short term
I
0.4
0.38
Close Monitoring of ODC equipment (including site Open fabricated/assembled) up to receipt at site
Projects
High
N
N
Y
N
Long term
D
0.08
0.06
Low
N
N
Y
N
Long term
I
0.2
Risk Id
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
D
Risk Owner
D
Status (Open / Close)
Integrated Refinery Expansion Project
Key Risk Description
1
2
13
14
Delay in delivery at site due to non-availability of transporter / hindrances enroute. D
15
Close Procure/Co nstr
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IV - RISK REGISTER
Kochi Refinery, BPCL
D
16
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions.
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Medium
N
N
Y
N
Short term
I
0.4
Open Contract / Inspection
Job No.: A307 Apr'15 Page 282+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
D
18
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
17
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
D
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
Very High
Y
Y
Y
N
Short term
I
0.9
Completion of Demountable Flare works (Awarded Open Project to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Apr-15 Ant: 24-Apr-15 Construction progress Sch: 100 % Act:30.9 %
Addition of 4th Riser in Demountable Flare and identification of additional Equipment to be procured due to the same. (BPCL informed additional of 1 no. riser during meeting dated 16th Oct 13.) - Flare (with 3 risers) awarded to M/s Airoil on 25Sep-13. Completion of Flare work: Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Open Project / Process
Job No.: A307 Apr'15 Page 283+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
D
Risk Owner
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 31.10.15
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 CDD: 03.04.15 Ant: 30.04.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 EDD: 15.04.15
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
19
20
21
Job No.: A307 Apr'15 Page 284+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
D
Risk Owner
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 CDD: 07.10.14 Overall Progress: Sch: 98 % Act: 95.0 %
Open
Projects
High
N
N
Y
N
Long term
I
0.2
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) LAD ;30.03.15 CDD: 30.04.15
Open
Projects
Low
Y
Y
Y
N
Long term
I
0.45
0.14
22
23
24
Job No.: A307 Apr'15 Page 285+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
D
Risk Owner
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 CDD: 30.03.15 (Excluding site work)
Open
Projects
Medium
N
Y
Y
N
Long term
I
0.35
0.18
Delivery of steel plates by M/s Essar to other vendors. CDD: Progressively by 15.01.14.
Open
Projects
Very Low
N
N
Y
N
Short term
I
0.4
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 CDD: 10.03.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
25
26
27
Job No.: A307 Apr'15 Page 286+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
D
Risk Owner
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
Non acceptance of PO for DHDT & VGO feed filter Open by M/s Filtrex (MR-4370) Ordered on 21.12.13 to M/s Filtrex ( Dely: 13 M FOB)
Projects
Medium
N
N
Y
N
Short term
I
0.4
28
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) LAD : 26.02.15 CDD: 13.04.15 ECD: 28.05.15 Delay by vendor with respect to CDD due to financial constraint.
29
30
0.10
Job No.: A307 Apr'15 Page 287+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
D
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
D
Risk Owner
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Non acceptance of work order by M/s Flowserve for DHDT Centrifugal pumps Ordered on 30.01.14 to M/s Flowserve (MR-5403) (FOA No 550 & 551) CDD: 01.03.15
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) CDD: 18.10.14
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
0.10
Availability of Piping materials to generate adequate piping material front to composite contractors. Sch: (Final MTO): Dec'14-Feb'15 EDD: Mar'15-Jun'15
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
0.20
Delivery Gas Booster Compressor for CPP (Dly: 13 M FOB
Open
Project
Low
N
N
Y
N
Long term
I
0.2
0.06
31
32
33
34
Job No.: A307 Apr'15 Page 288+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
D
Key Risk Description
Status (Open / Close)
D
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Delay in delivery of equipments by: M/s TEMA :CDD: 06.01.14 to 15.01.15; EDD:30.06.15 M/s Nuberg: CDD: 03.07.14 to 03.11.14; EDD: 30.06.15 M/s GR Engg: CDD: 28.01.14 to 31.07.14; EDD: 30.06.15 M/s Fabtech Projects: CDD: Jul’14 to Jan’15; EDD: Aug’15
Open
Project
Medium
N
N
Y
N
Long term
I
0.2
0.10
Delay in submission & finalization of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. CDD: 19.05.15
Open
Project
Low
N
N
Y
N
Short term
I
0.4
35
36
Job No.: A307 Apr'15 Page 289+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
E
Risk Owner
E
Key Risk Description
Status (Open / Close)
E
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Constn.
Medium
N
N
Y
N
Short term
I
0.4
Very High
Y
N
Y
Y
Short term
D
0.28
Medium
N
N
Y
N
Short term
I
0.4
1
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsite) - Awarded on 25.09.12 (Sch - 100 %, Act 91.7%) RCC Piles:4822 / 5307 Nos. Balance for offsite (SS VGO & compound area at FACT). Presently 5 total rigs are operating
2
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
3
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
Open
Constn.
Open Constn.
0.27
Job No.: A307 Apr'15 Page 290+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
4
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 12 M available for construction works (excl. Dismantling works) against schedule of 22 M. - Process package was delayed by 2 M due to delay in P&IDs review meeting and delay in award of licensor. - Change in the scope based on health check report has an impact on Project cost and schedule. Physical Progress: Target Sch: 94.4% Catch Up Sch: 86.1 % Act: 59.3%
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
Open Constn. / Projects
Job No.: A307 Apr'15 Page 291+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
6
Open
Const
Current Risk Score -> {5}* {12}
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 100% Front: 100 % Act:79.9 % CCD: 20.12.14 Ant: 15.07.15
Impact Score => {6+7+8+9} * 10 * 11
Open BPCL / Projects / Const.
Controllability Condition (D/I )
5
Availability of Soil investigation Report for new Crude tankages area. Delay in availability of soil data will affect preparation for piling tender and layouts drawings. Further civil / structural tender will also affected.
Urgency (Long Term / Short term)
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
E
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
N
N
Y
N
Long term
I
0.2
N
N
Y
N
Short term
I
0.4
High
Very High
0.38
Job No.: A307 Apr'15 Page 292+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Const
Very High
N
Y
Y
N
Short term
I
0.7
0.67
Backlog 20.6% as of 15-Apr-15 in Construction activities viz., Civil works and Mechanical works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 35 M Catch Up sch: Const Sch Front Act 73.3 90.1 70.4 52.6 Contractors are facing problem in retaining the labour at site. Approx 12000 labours are available against requirement of 20000 at site. E
7
Job No.: A307 Apr'15 Page 293+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
E
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Jun'15)
Open
Constn.
Very High
N
N
N
N
Long term
I
0
0.00
Completion of piling work by M/s L&T (Piling-II): CDD- 08.05.14. (Total 12003 Nos piles). (Contr.Sch- 100%, Front-100%, Act-100%) Only 10 nos. hydraulic & 4 nos. conventional rigs are currently operational at site. Total 10124 nos completed out of 12003
Open
Constn.
High
N
N
Y
N
Short term
I
0.4
Payment to contractors
Close
Constn.
Low
N
N
Y
N
Long term
D
0.08
8
E
9
E
10
Job No.: A307 Apr'15 Page 294+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
12
Current Risk Score -> {5}* {12}
Open
Impact Score => {6+7+8+9} * 10 * 11
Dismantling of LO CAT SRU and area handing over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. Will affect release of front for tankages.
Controllability Condition (D/I )
11
Urgency (Long Term / Short term)
E
Close
Output Quality ( Y / N)
Unrealistic project time leading to under quality
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Low
N
N
Y
N
Long term
D
0.08
Medium
N
N
Y
N
Short term
I
0.4
Project / Engg. / planning BPCL
Job No.: A307 Apr'15 Page 295+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
14
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
13
Project Cost ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
E
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Project
Medium
Y
N
Y
N
Long term
I
0.3
0.15
Very High
Y
N
Y
N
Short term
I
0.6
0.57
Completion of Raw water treatment plant Pkg (M/s Open Triveni Engg).(Delayed due to refloating) Overall Progress: Contr. Sch: 99.7 % Act: 83.7% Construction Progress: Sch: 100 % Front: 100 % Act: 83.55 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Slow construction progress of SRU Block due to delayed area handing over - As per present trend 15 months (starting from end Jun’14) are available with respect to schedule of 25 M (As per past experience minimum requirement for SRU is 30 M).
Open Proj. / Constn.
Job No.: A307 Apr'15 Page 296+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
E
E
E
15
16
17
18
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
Open Proj. / Constn.
Medium
N
N
Y
N
Short term
I
0.4
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Ant - Dec 2013
Close Proj.
Very High
N
N
Y
N
Short term
I
0.4
Land acquisition for Crude tank (2 nos.) . (LAD Jul 13; Ant - 30-Aug-13)
Close Proj.
Very High
N
N
N
N
Short term
I
0
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
Medium
N
N
Y
N
Short term
I
0.4
BPCL
Job No.: A307 Apr'15 Page 297+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
E
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Const. / Projects
Low
N
N
N
N
Long term
I
0
HEAVY LIFT Cranes for INTALLATION OF Close REACTORS Finalisation of Erection scheme and capacity the crane, inclusion in scope and timely mobilisation at site
Const.
Low
N
N
Y
N
Long term
I
0.2
Theft of material Warehouse Completion of UGfrom piping work due delay in receipt Close Open of piping material and monsoon.
EIL Const.
Low High
Y
N
Y
N
Long Short term
D I
0.12 0.6
Low
N
N
N
Y
Short term
D
0.04
19
E
20
E
21
E
22
E
23
Delivery of bought out items by BHEL for GTG package (LAD supply:29.09.14; Ant - Jul'15) Awarded to M/s BHEL on 25.07.13 with CDD for delivery as 24.11.14.
Lighting during construction
Open Constn.
0.48
Job No.: A307 Apr'15 Page 298+14 of 30
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Kochi Refinery, BPCL
25
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
4
5
6
7
8
9
10
11
12
13
EIL
Low
N
N
Y
N
Long term
I
0.2
Project
Low
Y
N
N
N
Short term
I
0.2
Delay in construction due to monsoon. As work Open progress between Jun to Sep is expected to be hindered due to monsoon, all out effort to be made to release tender as per sch. Generally to manage delays in initial stages of project, constr. Duration are reduced while floating tenders. This needs to be avoided.
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
E
EIL Cost (Y / N)
24
Project Cost ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
E
Risk Id
Integrated Refinery Expansion Project
Open
Job No.: A307 Apr'15 Page 299+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
E
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Construction of Subway on the PWD road including re routing of existing road / existing facilities and necessary liasoning with government department. Construction of culvert got affected
Open
Project
Very Low
N
N
Y
N
Short term
I
0.4
0.04
26
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Kochi Refinery, BPCL
E
27
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Slow construction progress in Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 CCD: 08.10.14; ECD: 15.09.15 Progress figures Sch: 100% Front: 99.7% Act.: 55.85% Insufficient mobilisation of manpower: Required: 635 nos Deployed: 216 nos
Urgency (Long Term / Short term)
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
N
N
Y
N
Short term
I
0.4
0.38
Open Constructio Very High n
Job No.: A307 Apr'15 Page 301+14 of 30
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Kochi Refinery, BPCL
E
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
E
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 100%; Front: 100%; Act: 84.36% CCD:18.12.14; ECD: 15.06.15
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Slow progress of Civil & Strl Works for SRU block (Awarded to M/s Mcnally Bharat on 04.11.13) LAD: 12.01.15 CCD: 03.03.15 Ant: Oct'15 SCH. FRONT. ACT. 100% 100 % 62.17%
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
28
29
Job No.: A307 Apr'15 Page 302+14 of 30
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Kochi Refinery, BPCL
E
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
30
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 ECD: 30.10.15 Contr. Sch: 91.29% Front: 86.75% Act: 54.96 %
Job No.: A307 Apr'15 Page 303+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
E
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Open
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.29
Medium
Y
N
Y
N
Long term
I
0.3
0.15
31
32
Completion of Coke handling work (Awarded to M/s Thyssen on 04.11.13) LAD: 18.04.15 CCD: 03.07.15 EDD: Dec'15 Construction: Sch:85.2 %; Front:100.0%; Act:26.3%
Completion of DCU Heater works (Awarded to M/s Open Project Heurtey on 04.11.13 (20 M) LAD: May 15 CCD: 03.07.15 Ant: Oct'15 Overall Progress: Sch: 97.1 % Act: 83.7 % Construction work: Sch- 97.09% Front:100% Act:64.85%
Job No.: A307 Apr'15 Page 304+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
E
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Completion Sch: 30.01.15 (CDD:11.06.15) Awarded to M/s Driplex on 12.06.13. (Duration: 20 M+2 M incl pre commng)
Open
Project
Very High
N
N
Y
N
Long term
I
0.2
33
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Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
E
Key Risk Description
Status (Open / Close)
E
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 97.4 % Act: 59.1 % Construction Progress: Sch: 96.7% Front: 100 % Act: 36.9 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 96.68 %; Front:95.39% Act: 50.31 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
34
35
Awarded to M/s B&R on 25-Sep-13
Job No.: A307 Apr'15 Page 306+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
5
6
7
8
9
10
11
12
13
Completion of works for Tankage-III (Crude Tanks) Open Project (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 Duration: 20 M Sch: 88.70 % Front: 100.0 % Act: 62.15 %
Very High
N
N
Y
N
Short term
I
0.4
0.38
Slow progress of FCCU Heater works (Awarded to Open Project M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 100% Act: 72.1 % Construction progress: Sch: 100% Front: 97.55% Act:42.07%
Medium
N
N
Y
N
Short term
I
0.4
0.20
Key Risk Description
Status (Open / Close)
4
Risk Id
Project Cost ( Y / N)
E
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
E
Risk Owner
Integrated Refinery Expansion Project
1
2
3
36
37
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Kochi Refinery, BPCL
E
E
38
39
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
Close Project
Very High
N
N
Y
N
Long term
I
0.2
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 CCD: 30.06.15; EDD: 30.09.15 (As per Vendor)
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Job No.: A307 Apr'15 Page 308+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
40
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Slow progress of RO-DM works (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 (As per vendor) Overall Progress: Sch: 99 % Act: 74.4% Construction Progress: Sch: 100 %; Front: 100%; Act:49.9%
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Very High
Y
N
Y
N
Short term
I
0.6
0.57
Open Project
Job No.: A307 Apr'15 Page 309+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
5
6
7
8
9
10
11
12
13
Slow Construction progress for Civil Works- FCCU Open Project Contr. Sch: 100 %; Front: 100% Act: 83.1 % (M/s SEPC) CCD: 24.12.14 ECD: Oct'15
Very High
N
Y
Y
N
Short term
I
0.7
0.67
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15 Constr. Progress: Sch: 100 % Front: 100 % Act: 85.6 % -Delay in completion of Radiography and PWHT
Very High
Y
N
N
N
Long term
I
0.1
0.10
Key Risk Description
Status (Open / Close)
4
Risk Id
Project Cost ( Y / N)
E
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
E
Risk Owner
Integrated Refinery Expansion Project
1
2
3
41
42
Open Project
Job No.: A307 Apr'15 Page 310+14 of 30
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Kochi Refinery, BPCL
E
43
Construction Progress: Sch: 100% Front: 97.4% Act.: 36.4%
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Medium
N
N
Y
N
Short term
I
0.4
0.20
Open Project
Job No.: A307 Apr'15 Page 311+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
E
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: 30.06.15 Sch: 100 %; Front :99.6 % Act: 89.5 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open Project
Low
N
N
Y
N
Short term
I
0.4
0.12
44
45
Job No.: A307 Apr'15 Page 312+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
7
8
9
10
11
12
13
Open Project
High
N
N
Y
N
Long term
I
0.2
0.16
Open Project
Medium
N
N
Y
N
Long term
I
0.2
0.10
Status (Open / Close)
6
Risk Id
5
1
2
3
46
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 85.8%
Completion of Cooling Tower -III (Awarded to M/s Paharpur on 11.09.15) LAD: 30.06.15 CCD: 10.01.15 ECD: Aug'15 E
4
Key Risk Description
Completion of Cooling Tower -I & II (Awarded to M/s Paharpur on 01.02.13) LAD: 31.01.15 CCD: 20.10.14 ECD: Jun'15 E
Risk Owner
Integrated Refinery Expansion Project
47
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 58.33%
Job No.: A307 Apr'15 Page 313+14 of 30
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Kochi Refinery, BPCL
E
E
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
Slow construction progress in Offsite-DHDS area. Work stopped by M/s KSS in DHDS area for Civil & Strl work CDD: 24.01.15 ECD:. Dec'15
Open Constructio Very High n
Y
Y
Y
N
Short term
I
0.9
0.86
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 69.38 %; Front: 27.48%; Act.:18.42%
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
48
49
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Kochi Refinery, BPCL
E
50
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Slow progress of work & poor manpower mobilisation by M/s B&R for Composite WorksDCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15 Construction Progress: Sch: 69.2 % Front: 45.75% Act.: 23.9% AG piping fabrication: Only 133333 ID / 406975 ID fabrication completed. AG piping erection: Only 89894 IM / 526435 IM piping erection completed.
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
High
N
N
Y
N
Short term
I
0.4
0.32
Open Constructio n
Job No.: A307 Apr'15 Page 315+14 of 30
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Kochi Refinery, BPCL
E
E
51
52
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
Slow construction progress for Civil & Strl work for Refinery area: Generation of front for mechanical works affected (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:100%; Front: 98.26%; Act: 47.1% CCD: 25.01.15 ECD: Oct'15
Open Constructio Very High n
Y
N
Y
N
Short term
I
0.6
0.57
Slow progress by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. Awarded on 25.03.14. CCD: 24.09.15. Sch: 76.22% Front : 36.22% Actual : 18.76%
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
Job No.: A307 Apr'15 Page 316+14 of 30
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Kochi Refinery, BPCL
E
E
E
53
54
55
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
Slow construction progress by M/s B&R for Composite works: Offsite Refinery area due to delay in mobilisation. Awarded on 25.03.14. CCD: 24.09.15 Sch:79.1%; Front: 14.5%; Act:10%
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for CDU/VDU. Sch: 04.09.14 CCD: 06.09.14 ECD: 31.03.15 Sch:100% Front: 100% Act: 97.03%
Open Constructio n
Medium
N
N
Y
N
Short term
I
0.4
0.20
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
Job No.: A307 Apr'15 Page 317+14 of 30
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Kochi Refinery, BPCL
E
57
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
56
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for DCU. Sch: 04.09.14 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 100 % Act: 97.1 %
Urgency (Long Term / Short term)
4
Output Quality ( Y / N)
3
Schedule ( Y / N)
Risk Owner
2
EIL Cost (Y / N)
Status (Open / Close)
1
Project Cost ( Y / N)
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
E
Risk Id
Integrated Refinery Expansion Project
5
6
7
8
9
10
11
12
13
N
N
Y
N
Short term
I
0.4
0.38
N
N
Y
N
Short term
I
0.4
0.20
Open Constructio Very High n
Start of work for Tankage-IV by M/s Offshore Open Constructio Awarded on 17.04.14 n CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) Sch : 64.6% Front : 58.4% Actual : 27.5%
Medium
Job No.: A307 Apr'15 Page 318+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
E
E
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 100 % Front: 100 % Act: 68.9 %
Open Constructio n
Medium
N
N
Y
N
Short term
I
0.4
0.20
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 CCD:18.06.15 Sch: 97.4 % Front: 74.7 % Act: 55.1 %
Open Constructio n
High
N
N
Y
N
Short term
I
0.4
0.32
58
59
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Kochi Refinery, BPCL
E
61
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
60
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Key Risk Description
Risk Owner
E
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Low
N
N
Y
N
Short term
I
0.4
0.12
N
N
Y
N
Short term
I
0.4
0.38
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. Sch : 67.8% Front : 56.6% Actual : 29.1 %
Open Constructio n
Start of Composite works by M/s Offshore for Offsite DHDS area Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15. Sch: 70.97% Front: 14.95% Act: 9.18%
Open Constructio Very High n
Job No.: A307 Apr'15 Page 320+14 of 30
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Kochi Refinery, BPCL
E
64
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
63
Output Quality ( Y / N)
62
Schedule ( Y / N)
3
EIL Cost (Y / N)
2
Project Cost ( Y / N)
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
E
Key Risk Description
Risk Owner
E
Risk Id
Integrated Refinery Expansion Project
4
5
6
7
8
9
10
11
12
13
Medium
N
N
Y
N
Short term
I
0.4
0.20
Low
N
N
Y
N
Short term
I
0.4
0.12
Low
N
N
Y
N
Short term
I
0.4
0.12
Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 78760 / 298905 ID fabricated. 18200 IM / 299780 IM erected. Sch : 58.5% Front : 31.2% Actual : 18%
Open Constructio n
Completion of balance piling work (Covered under Piling-IIII Contract) (Total 2077 Nos piles approx).
Open
Completion of Composite works by M/s Albana for VGO Unit Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15 Sch : 69.1% Front : 30.7% Actual : 22.3 %
Open Constructio n
Constn.
Job No.: A307 Apr'15 Page 321+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
F
Risk Owner
F
Key Risk Description
Status (Open / Close)
F
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
High
N
N
Y
N
Long term
I
0.2
0.16
Implementation of Change management system The same affects : - Finalization of basic philosophies - Scope of services - Release of deliverables Various scope changes (as advised by BPCL), resulting in expenditure of extra manhours against control manhours.
Open PROCESS/ ENGG/CON S.
Medium
N
Y
Y
N
Long term
D
0.14
0.07
Timely Commissioning of UB package to meet refinery commissioning schedule. LAD : 31.03.15 (UB 1) 30.06.15 (UB 2)
Open
Medium
N
N
Y
N
Long term
I
0.2
0.10
1
2
3
Constn.
Job No.: A307 Apr'15 Page 322+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
G
Key Risk Description
Status (Open / Close)
G
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Timely payment to sub contractor by main contractor
Open
Const.
Medium
N
N
Y
Y
Long term
D
0.1
0.05
Infrastructure at Kochi
Open
Const.
Low
N
N
Y
Y
Long term
D
0.1
0.03
Process / Engg.
High
N
Y
Y
N
Long term
D
0.14
Low
N
N
Y
N
Long term
I
0.2
1
2 Scope changes & information flow to executing group
G
3 Non-performing vendors
G
Open
4
Open Inspn
Job No.: A307 Apr'15 Page 323+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Id
Key Risk Description
Status (Open / Close)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Close
Purch / Contrc.
Low
N
N
Y
N
Long term
I
0.2
N
N
Y
N
Short term
D
0.16
G
5
G
6
G
I
7
1
Delay in Approval of Vendor List for various items of the project (specially for Long lead items)
Finalisation of Non plant buildings.
Close
BPCL
Low
Implementation of environmental clearance Open conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Projects
Medium
Y
N
N
N
Short term
D
0.08
Delay in commencement of site work for dyke wall Close inside TF-3 affected due to non availability of PESO approval for tankage area
Engg. / Proj.
Medium
N
N
Y
N
Long term
I
0.2
0.04
Job No.: A307 Apr'15 Page 324+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
K
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
K
Risk Owner
J
Key Risk Description
Status (Open / Close)
I
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Statutory approvals - Factory inspectorate approval - CEA (Central electrical authority) approval -IBR approval (LAD - IBR Package for DCU by end Dec'13; CDU/VDU by 31.12.13)
Open
Projects / BPCL
Low
N
N
Y
N
Long term
I
0.2
0.06
Implementation of Health, Safety and environmental (HSE) system
Open
Const.
Very High
N
N
Y
Y
Short term
I
0.5
0.48
Delay due to Labour strikes (due to labour issue like wage revision, other benefits) during project execution phase
Close
Const.
Low
N
N
Y
N
Long term
I
0.2
Mobilisation of Skilled workers
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
2
1
1
2
At present only approx 12000 labours are working against requirement of 15000-18000 labours.
0.40
Job No.: A307 Apr'15 Page 325+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
K
Key Risk Description
Status (Open / Close)
K
Risk Id
Integrated Refinery Expansion Project
1
2
3
4
5
6
7
8
9
10
11
12
13
Constraint in movement & transportation of ODC eqpt.
Open
Project
Low
N
N
Y
N
Long term
I
0.2
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open Project/Eng g
High
N
N
Y
N
Long term
I
0.2
Quarry operator strike : Quarry operator strike in the state from 12.02.15 has affected the concreting work.
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
Costing
High
Y
N
N
N
Short term
D
0.08
Environ.
Very High
Y
N
N
N
Short term
D
0.08
3
4
K
5
M
1
M
2
Cost monitoring & control on regular basis Increase in facilities on account of deletion zero liquid discharge
Close Open
Job No.: A307 Apr'15 Page 326+14 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
M
3
Project Cost ( Y / N)
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
1
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
3
4
5
6
7
8
9
10
11
12
13
Project
Low
Y
N
Y
N
Short term
I
0.6
Variation in foreign exchange rates from Rs 50 per Open USD as on Mar 12 to Rs. 60 per USD as on date and fluctuations in the intermediate period and Scope changes w.r.t. DFR (additional in scope) has significantly impacted on the overall project cost.
Total Risk Score
21.68
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 327+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Actions Taken so far: - UOP package received on 08.08.13. - PDS issued for all Columns, Vessels, Air Fin Coolers, Exchangers & Refrigeration pkg, pumps (part balance). - All 30 nos P&IDs issued for engineering Action Plan for balance - 19 nos out of 23 nos pumps datasheet issued for engineering. Balance progressively targeted by 15.11.13.
Projects / Process
0.00
- Meeting held with BPCL on 18-20.09.13.
Process / Projects
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 328+14 of 30
Action Plan
14
15
16
0.00
- All P&IDs incorporating DCNs issued.
0.00
- Design Change Note based on Hazop recommendations issued on 03.01.14. All major process P&IDs released. - Major pumps data received and foundation drawing released.
0.00
-Process package received on 14.04.13
Action By
17 Process
Projects / Engg Process
Projects / Process
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 329+14 of 30
Action Plan
14
15
16
Action By
17
0.00
All PDS issued for Engg. All Process P&IDS issued. Utility P&IDs: 15 out of 15 nos issued for engineering.
0.00
Process package from M/s Lummus received on 17-Aug-12. All Equipment PDS issued for engineering. Utility equipment issued for engineering.
Process
0.00
Based on latest information from BOO HGU and SWII (FCC), Revised Design Basis issued.
Projects / Process
0.00
Process P&IDs: All process P&ID issued. PDS: Heat Exch. - 52/52 issued for Engg. Pumps 49/50 issued for Engineering. Vessels 38/38 tags issued for Engg. Air cooler 6/6 issued for Engineering.
Process
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 330+14 of 30
Action Plan
14
15
16
0
0.00
- Common Interconnection P&ID for FCC, VGO and DHDT will be issued (covered under risk A09). Hence clubbed with Risk no. A09.
BPCL / Projects / POSD
0.00
All process P&IDs issued. Pumps PDS issued for engg,. All Vessels PDS issued for engg.
Process
0.00
- All 32 P&ID issued for engineering
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 331+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- All PDS and P&ID revised and issued.
0.00
Revision in PDS to be avoided once same is issued for engineering
0.00
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New facilities) has been issued for engineering. Balance 1 no. BPCL / targeted by 15.03.13 Projects / POSD
0.00
Revision in PDS to be avoided once same is issued for engineering.
Process
0.00
Revision in PDS to be avoided once same is issued for engineering
Process
Process
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 332+14 of 30
Action Plan
14
15
16
0.00
0.00
0
Action By
17
In case of revision in process parameters of an equipment the utility estimates furnished by engineering against RED / PED/ older Revision of PDS should not be used until same is got verified/ updated for current revision. PROCESS RED to update all such changes within stipulated time frame as per departmental guidelines and Process to incorporate in the revised PDS. Utility P&IDs: P&IDs (14 / 17 ) issued for engg (except for small bore piping: Pump Seal & Vent Drain). The same Process are targeted by Jun'13.
0.00
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
0.00
Distribution P&IDs issued for engineering.
0.00
- Revised P&ID for Condensate System issued on 15.05.13.
Process
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 333+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- Inconsistency related to type of Isolation valve (Ball Vs. gate / globe/check) between instrumentation and process design basis identified during coordination meetings resolved by TSD.
Engg.
0.00
- System configuration including 8 pumps, filters & centrifuge finalised and PDS for pumps issued. Filters & Centrifuge PDS issued for engineering on 22.05.14. - Readiness of the fuel forwarding system to be ensured w.r.t. GTG commg schedule (i.e. in Mar 15).
Projects (CPP group)
0.00
- PDS for desalting pumps issued on 25.10.13. MR issued on 13.11.13.
Engg
0.00
- Identification of hook ups for Flare line, FCC flare, PRU flare and NHT / ISOM completed during site visit by EIL Projects / Process. Constn. - Hook sketches to be prepared and signed by Piping / POSD / BPCL. Marking at site to be taken up on priority. - Finalisation of methodology for taking up works targeted by end Dec 13.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 334+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Signing of P&IDs completed for: -CDU/VDU Block on 24.06.14. - DCU unit on 03.07.14 & CR LPG unit on 22.07.14. - VGO unit on 12.07.14. - DHDT unit on 24.07.14 - FCCU unit on 23.07.14 - SRU block on 25.07.14. - Offsite P&IDs issued to BPCL. Signing completed
Process / POSD /
0.00
Updated P&IDs released.
Process / POSD /
0.00
- Equipment layout issued for engineering on 23.08.13
Piping
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 335+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Equipment layout issued for engineering
Piping
0.00
Equipment layout issued for engineering
Projects / Piping / BPCL
0.00
NIT issued on 24.06.13, bids due on 23.07.13
Projects / Process / HMTD
0.00
1) Involvement of technical/engineering team and client with vendor where non-standard products are required
Projects
2) Clarification of all doubts prior to beginning of work 3) Procedures for internal review and approval of design/deliverables to be followed
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 336+14 of 30
Action Plan
14
15
16
Action By
17
0.00
-Discussions with prospective bidders held seeking details on implementation methodology. -Decision regarding System integration schemes taken during meeting dated 17th & 18th Dec 12. MR issued
Engg (Elec)
0.00
- Layout finalised with licensor. Final layout under study. - Model review for SRU completed on 30th May'13 (except TGTU, incinerator section & downstream of sulphur pit).
Piping
0.00
Intermediate MTO released on 31.05.13.
Piping
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 337+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
0.00
- Layout for OWS, CRWS, CW & FW lines issued for Offsite.
Gen Civil
0.00
VGO-HDT: 30 % modelling completed on 7th Jun'13 FCCU: 30 % modelling completed on 06.06.13. SRU (excluding TGTU) – completed on 30.05.13.
Piping
0.00
- NIT issued for publishing on 12.06.13 with sale period from 17.06.2013 to 05.07.2013
Project / C&P
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 338+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Wide variation of BOQ and site executed quantities for item rate tenders to be controlled. Past data to be analysed and used for reference purposes.
Engg
0.00
MR issued on 02.05.13.
Engg
0.00
- Management level meetings with package contractors being organised to expedite the works. - Battery limit conditions for CDSP Pkg (awarded to M/s Essar on 22.08.13) submitted by vendor & approved under code 2 on 07.05.14. - Battery limit conditions for R&R Pkg (awarded to M/s Essar on 25.07.13) received from vendor and approved.
Projects / Engg. / Process
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 339+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- Clubbed with Risk ID A27
TSD
0.00
- Data received from all vendors. All piling drawings for CPP area released. - Foundation drawings for & HRSG under progress and targeted by mid Mar'14.
ENGG/PLNG
0.00
- NIT issued on 11.03.13, bids due on 16.04.13. Pre bid meeting targeted on 02.04.13. (Delivery : 18 M for Mechanical Completion including Pre-Commissioning Activities)
Projects / Process Process / HMTD C&P
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 340+14 of 30
Action Plan
14
15
16
0.02
0.00
- Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. Engg - HAZOP review completed for GTG, HRSG & UB package. - 90% model review for HRSG completed on 04.02.15. -90% model review for UB package held from 18.11.14 to 20.11.14. - GBC ordered to M/s BHEL on 25.07.14. KOM held with M/s BHEL for Gas booster compressor on 12-13 Aug'14.
0.00
- Preparation of Inst. dwgs./ docs. by the DCS vendor, using Smart Plant Instrumentation (SPI) is already covered in DCS vendor’s scope in DCS
Projects
0.00
Model taken reviewup completed on 13.09.13 - Being with respective package vendors for implementation.
ENGG/ Instn Projects
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 341+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Package vendor inputs being made available by expediting for updation of interface engineering documents.
Projects / Engg.
0.00
Model review completed on 04.10.13
ENGG
0.00
- All P&IDs released
G. Civil
0.00
- Ordered to M/s Powerica Ltd on 29.09.14 (Delivery duration 13 M+ 3 M site works).
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 342+14 of 30
Action Plan
14
15
16
0.00
- Model review completed on 24.10.13. Process to remove holds as per piping Hold up lists released till date by 25th Oct 13. - Piping to release updated hold up lists based on release of holds by process on fortnightly basis to process / project / planning / TSD / Risk Coordinator. - Meeting between Process, Piping, Projects shall be organised within 3 days of issue of hold up lists. - Process to issue Revised P&IDs latest within 4 weeks of HAZOP recommendations.
Action By
17 Process / Projects
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 343+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- Model review completed on 25.10.13.
ENGG
0.00
- Model review started on 28.10.13 and under progress. Targeted to complete by 31.10.13.
ENGG
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 344+14 of 30
Action Plan
14
15
16
0.05
Action By
17
0.00
- Intermediate 2nd MTO released on 31.10.13, based on above MR under preparation.
Projects / ENGG
0.00
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
0.00
- HAZOP study completed on 29.11.13.
ENGG
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 345+14 of 30
Action Plan
14
15
16
0.00
- As of 15 Aug'14 Engineering progress is 91.4 %.
0.00
- Final MTO released on 11.09.14.
0.00
- Revised P&IDs issued for connecting tank-101 & 102. New pump process datasheet released for piping naphtha from YT-332 to CPP day tank.
Action By
17 ENGG
Process / Engg.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 346+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
0.00
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
0.00
- BPCL confirmation sought for minimum nos (10.97 MW or 80% of 10.97) for qualifying criteria. Accordingly BQC C&P changed and approved by BPCL. Draft NIT by 25.05.13. Publishing targeted by end May 13.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 347+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- As per latest cost status report the impact of cost variation has been neutralised by savings.
Projects
0.00
Awarded to M/s Technip on 04.09.13 (Duration 18 M)
Projects / HMTD
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 348+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
0.00
-Ordered on M/s Shin Nippon & M/s Flowserve on 30.01.14 (except Tag IV-P-301 A/B due to poor past performance of PRT supplied under CEMP-II by M/s GENP); - Separate MR released for item tag IV-P-301 A/B. BPCL informed that order expected to be placed as per previous recommendation, ordering expected by mid Mar'14. - As a parallel action MR was issued however RFQ kept under hold in view of BPCL information regarding ordering by mid Mar 14.
EIL
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Projects / HMTD
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Projects / HMTD
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 349+14 of 30
Action Plan
14
15
16
Action By
17
0.00
-Ordered to M/s Fabtech on 15.07.13
Engg/Proj
0.00
NIT issued on 29.05.13, bids due on 18.06.13.
Project / C&P
0.00
- Awarded to M/s Driplex on 12.06.13. duration is 22 M.
Engg / C&P
0.00
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months.
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 350+14 of 30
Action Plan
14
15
16
Action By
17
0.00
BQC finalised on 15.01.13. Tender under compilation. Draft NIT being issued to BPCL for approval. NIT targeted by 21-Feb-13.
Projects / BPCL
0.00
Ordered to M/s Paulose George (15 M).
BPCL
0.00
Ordered on M/s L&T on 08.04.13.
Proj/Engg
0.00
Awarded to M/s L&T on 09.04.13 with duration of 12 M.
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 351+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Awarded to M/s Petron on 09.04.13 with 18 M duration.
BPCL
0.00
Awarded to M/s Technip on 07.03.13 (Duration 23 M)
0.00
- Scheme finalised.
Projects / BPCL
0.00
Tender released on 26.03.13; BQC finalised on 08.04.13. NIT targeted by 16-Apr-13
Engg
Projects / C&P / BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 352+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Award recommendation issued on 11.02.13. Awarded to M/s Howe baker on 07.03.13
Proj/Engg
0.00
Awarded to M/s L&T (duration 20 M)
BPCL
0.00
KB tech completed development of flare area & handed over the area to M/s L&T.for piling.
Projects
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 353+14 of 30
Action Plan
14
15
16
0.00
Action By
17
- Evaluation of LLIs to be ensured with-in 1 month from receipt of bids by Engg. & PBO recommendation with-in 1 Engg / C&P / week by C&P. Projects - Pre tender / Pre enquiry meetings to be conducted with bidders to avoid extensions in bid due date due to lack of clarity in scope / other requirements. - Immediate after issue of Enquiry a firm action plan to be developed by the Project coordinator clearly indicating targets for Issue of TQ / CQ , Post bid meetings, TBA/CBA, PBO reco., Price bid opening and award recommendation dates. - Uploading of bids in eDMS by C&P within 1 - 2 days (Max.) of bid submission by bidders. - Restriction of multiple TQs / CQs. - Rigorous follow up by C&P / Engg. / Projects for receipt of TQ / CQ replies from bidders within cut off dates.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 354+14 of 30
Action Plan
14
15
16
0.00
Awarded to M/s Tecnicas Reunidas S.A. on 31.12.13
Action By
17 BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 355+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Awarded to M/s Essar Project on 22.08.13 (Duration: 27 M)
C&P / Engg / Projects
0.00
- Awarded to M/s BHEL on 25.07.13.
Projects / Engg / C&P / BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 356+14 of 30
Action Plan
14
15
16
0.00
- Awarded to M/s Thermax on 20.12.13 It is planned that common facility (incl. common piperack, utility lines etc) shall be taken up as per project schedule requirement. This shall be taken up during KOM with selected bidder.
Action By
17 Projects / BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 357+14 of 30
Action Plan
14
15
16
0.00
- 2 Bids (Essar & L&T) received on 25.04.13. - TBA issued on 21.05.13. - PBO recomn. issued on 30.05.13 and BPCL approval received on 03.06.13 - Price bids opened on 04.06.13. - Award recommendation issued on 25.06.13. - Awarded to M/s Essar on 10.07.13.
0.00
Action By
17 Projects / BPCL
BPCL Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 358+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- 3 no. bids received on extended date of 02.02.13. - Meeting with bidders held from 19.02.13 to 26.02.13. PBO recomn. issued on 06.05.13. Price bids opened on 09.05.13. - Award recomm issued on 12.06.13. Execution duration as per RFQ - 20 M; Sch - 24-26 M
Projects / C&P / BPCL
0.00
Awarded to M/s Paramount (with 21 M for mechanical completion + 2 M for commissioning). Execution duration as per RFQ was - 22 + 2 M; Sch - 28 M
C&P/Engg/Pr oj
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 359+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Meeting held with EIL & BPCL. Approach paper prepared and signed jointly by EIL / BPCL for limiting single agency getting work orders against more than 2 tenders. (In cases of big agencies with financial capability, one agency can get maximum works order against 3 tenders)
BPCL / C&P
0.00
Limit the number of works being awarded to one Agency so that alternatives can be worked out fast. BPCL/EIL To evolve a System to be implemented to ensure that the maximum number of jobs awarded to single agency is only 2 if NOT to be preferably made ONE only.
C&P BPCL / Projects
0.00
Awarded to M/s GEA on 10.07.13 with delivery period of 13 M.
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 360+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Awarded to M/s Heurtey, (Duration - 20 M)
BPCL
0.00
Awarded to M/s KSS on 25.07.13. (Duration 18 M)
BPCL
0.00
Awarded to Mcnally Bharat on 26.09.13. Duration- 16 Months
Project/C&P
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 361+14 of 30
Action Plan
14
15
16
Action By
17
0.00
NIT issued on 01.08.13, bids due on 30.08.13
Gen Civil/Project
0.00
Awarded to M/s McNally Bharat. Duration - 16 M
Gen Civil/Project
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 362+14 of 30
Action Plan
14
15
16
0
Action By
17
0.00
MAB awarded to M/s Elliot Ebara on 04.09.13. WGC awarded to M/s BHEL
C&P/Engg/Pr oj
0.00
Awarded to M/s L&T on 07.03.13. Award recomm sent to BPCL on 01.02.13. Award to be targeted by 07.03.13.
C&P
0.00
Ordered to M/s Eliot Ebara on 28.06.13.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 363+14 of 30
Action Plan
14
15
16
0.00
Ordered on M/s Dresser Rand, Dely - 17 M FOT Dispatch
Action By
17 EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 364+14 of 30
Action Plan
14
15
16
0.00
- Ordered to M/s Sandvik.
Action By
17 BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 365+14 of 30
Action Plan
14
15
16
0.00
Awarded to M/s Sriram on 25.09.13
Action By
17 BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 366+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Awarded to M/s McNally bharat on 11.09.13 (with 16 M execution period)
BPCL
0.00
Awarded to M/s Essar Projects on 19.08.13
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 367+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Awarded to M/s Thermax
BPCL
0.00
Awarded to M/s Triveni
BPCL
0.00
Ordered to M/s Callidus and M/s UOP India on 20.06.14.
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 368+14 of 30
Action Plan
14
15
16
0.00
Ordered on M/s Howden Process Compressors
Action By
17 Projects / C&P
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 369+14 of 30
Action Plan
14
15
16
0.00
Awarded to M/s Airoil on 25.09.13 with duration of 18 M.
Action By
17 Projects/ Process/ Engg / C&P/
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 370+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- Awarded on M/s Ray Engineering on 23.01.14.
Engg / C&P
0.00
Awarded to M/s BHEL
Proj/Engg
0.00
Ordered to M/s Neumen & Essar on 14.11.13
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 371+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Awarded to M/s IOT Anwesha on 04.12.13. (duration: 20 M)
BPCL
0.00
Awarded to M/s BHEL
Proj/Engg
0.00
Awarded to M/s Dresser Rand
Proj/Engg
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 372+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Awarded to M/s B&R
BPCL
0.00
Awarded to M/s Offshore on 17.04.14.
EIL / BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 373+14 of 30
Action Plan
14
15
16
Action By
17
0.00
.Awarded to M/s Offshore (Duration- 20 months)
BPCL
0.00
Contract for development of flare area awarded to M/s KB Tech..
Engg / C&P
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 374+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Composite Works for VGO-HDT & DHDT -DHDT- Awarded to M/s Albana on 19.05.14 (16M+2M). -VGO-HDT- Awarded to M/s Albana on 19.05.14 (16M+2M). Composite Works for Offsite Part B (DHDS): Awarded to M/s Offshore on 19.05.14 (16M+2M). Composite Works for CPP: Awarded to M/s Zillion Infra. on 19.05.14 (16M+2M).
Projects / Engg.
0.00
Awarded to M/s Petron on 04.12.13. Duration is 16 M
BPCL
0.00
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 375+14 of 30
Action Plan
14
15
16
Action By
17
0.00
-Ordered on M/s Asco Filtri Srl ON 17.10.14.
BPCL
0.00
- All pipes, fittings & flanges ordered.
C&P Engg
0.00
-Revised MR (MR-3415): Ordered to M/s Oswal, M/s Shalimar, M/s AV valves and M/s L&T. - New MR-3515 (41 Nos) ordered on 05.02.15
0.00
- Awarded to M/s Zillion on 19.05.14.
EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 376+14 of 30
Action Plan
14
15
16
0.15
Action By
17
-0.10 -Total 35526/ 35652 nos (99.7%) isometrics issued for units . Balance ISO's targeted progressively by mid May'15. -All GADs issued released.
Engg.
0.00
-Awarded to M/s OIL on 18.03.15 (Duration 12 M).
EIL/BPCL
0.00
- Ordered to M/s Sulzer.
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 377+14 of 30
Action Plan
14
15
16
0.00
0.38
- Electrical Works: Part A: M/s Technimont Part B: M/s Consilium - Instrumentation Works: Part A: M/s Technimont . Part B: M/s Consilium
Action By
17 EIL/BPCL
-0.18 Majority ordered, balance targeted by 1st week of May'15. Deliveries to be expedited in order to timely availability EIL/BPCL of piping material for completion of steam network in CPP area.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 378+14 of 30
Action Plan
14
15
16
0.86
0.00
Management level review meeting held with M/s ESSAR/ GRE on 13.04.15. Following Major targets agreed: - All strl. steel dispatch by end Apr’15. - Delivery of all bought out progressively by Jun’15. - Completion of Flue Gas cooler & ESP by Jun’15. - Erection of TSS bottom section executed on 17.04.15 - Steam drum erected on 13.03.2015 & economiser panel erection commenced on 20.03.15, RHS, LHS & economiser modules 3/5 for FGC erected. - 1st lot of fabricated ESP materials received at port.
EIL/BPCL
0.00
Clubbed with Risk ID E19
Project
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 379+14 of 30
Action Plan
14
15
16
0.19
0.00
- Balance foundation to be expedited (including FD fan, HP pump drive turbine, blow down tank & other Project / auxillaries). Constn. - Completion of structural erection work to be expedited. Coil erection completed for UB-12 & in progress for UB13. Deaerator tank erection completed.
0.00
-All Indigenous component received at site within CDD. - All Foreign Source Components dispatched.
Project/Inspe ction
0.00
Compressor dispatched on 06.03.15
Project/Inspe ction
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 380+14 of 30
Action Plan
14
15
16
0.67
Action By
17
0.00
All parts dispatched.
Project/Inspe ction
0.00
- Main fractionator column: Top section dispatched to site on 26.04.15. Erection targeted by end May’15. Stripper Project / Column: Hydrotest erection by end Jun’15. Rectifier Column: erection by mid Aug’15. Constn.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 381+14 of 30
Action Plan
14
15
16
0.38
0.00
- Erection of second Main combustion chamber (Tag No: IS-F-202) has been successfully & safely completed. - Refractory lining agency expected to mobilise at site by 05.05.15.
Action By
17 EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 382+14 of 30
Action Plan
14
15
16
0.86
0.00
Action By
17
Following commitments have been made by M/s Essar. Constr. -Shift Work: Works in two shifts implemented. - Coke fractionator column delivery by 07.05.15 and coke drums progressively from 13.05.15 till 25.05.15. - Crane (2000 MT): Mobilization & assembly of crane completed and erection of equipments targeted progressively by May’15. -Clear water tank fabrication- Civil tank pad work completed, rolling in progress.- Shell erection of clear water tank commenced. BPCL/EIL - Resource augmentation for Civil & Strl works being expedited. At present 590 nos have been deployed against requirement of 836 nos. - Above ground pipe fabrication commenced at a lower productivity due to non-availability of pipe fittings. EPIL informrd that majority of pipe fittings will be available within one month.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 383+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- All items received at site.
Project/Inspe ction
0.00
- Received at site and erected.
Project/Inspe ction
0.00
- Vacuum Column : Hydrotesting completed.
Constn. / VTV / Projects
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 384+14 of 30
Action Plan
14
15
16
0.38
0.00
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. - 2 no DHDT Reactor reached at site & erected. - First dumb barge (newly fabricated) launched in the river after IRS certification. - ISGEC Josen (3 nos) Column: expected to receive at Kochi port from upto end May'15. - VGO reactor reached at Koch port.
EIL/BPCL
0.06
0.00
Out of total 57 nos. of ODCs; 25 nos received at site. & 29 nos under dispatch. Balance under close monitoring.
Shipping
0.00
- Transporter philosophy frozen and hindrance enroute has been covered under Risk ID K3.
Shipping
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 385+14 of 30
Action Plan
14
15
16
0.00
Equipment by Ganson - M/s Ganson agreed to supply balance item of CDU/VDU. Items for SRU and DCU refloated under MR-6560 (DCU): All items relocated to M/s Patel Airtemp, M/s Phils Heavy, M/s Acoustics India ; M/s Beekay Engg ; M/s Fab-Tech, M/s Nuberg Engg.
Action By
17 BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 386+14 of 30
Action Plan
14
15
16
0.23
0.00
- Erection of Derrick structure up to 40 mtr completed. - Flare tips likely to be reached at site by end Apr'15. 1 no water seal drum and Molecular seal received at site. All flare riser expected to receive at site from workshop progressively by 30.04.15. -Water Seal drum (3 nos) is under transit.
Projects/Con str.
0.00
- BPCL confirmation on the additional flare stack addition received. - Agreed with Air Oil / BPCL for completion of 4th riser within CDD. - Revised PDS & P&IDs released on 15.11.13. - Order placement (change order) issued to M/s Airoil on 14.11.13.
BPCL / EIL
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 387+14 of 30
Action Plan
14
15
16
0.38
0.00
0.06
-0.06 - MRT of compressor and Steam turbine completed & same is under dispatch.
Project/Inspe ction
0.19
-0.19 -Reactors reached RORO Jetty at Irumpunam on 28.04.15. Jacking and forecutting work under progress.
Project/Inspe ction
- Compressor Lube Oil Console : MRT completed for turbine & is under dispatch. LOP Drive Turbine ordered on KEPL is still under manufacturing and likely to be delivered during May 2015. .
Action By
17 Project/Inspe ction
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 388+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- Reactor received at Kochi port and unloaded to barge on 26.12.14.
Project/Inspe ction
0.23
0.00
- 90% model review for HRSG completed. - Balance engineering to be expedited by M/s Thermax. - HRSG #3, 4 & 5: Foundation works completed and handed over to M/s Thermax. Erection in progress for HRSG-4 & HRSG-5 - All column alignment completed for HRSG-3.
Project/Inspe ction
0.14
0.00
- Generator subordered. - Pedestal fabrication is at final-machining. - Exhaust case assembly, including diffuser and thermal insulation has been completed
Project/Inspe ction
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 389+14 of 30
Action Plan
14
15
16
0.18
0.00
-Silos with structure & Conveyors sub ordered by M/s Sandvik. - Bottom Cones for Silo C ,D, E & F dispatched to site. -Delivery of Semi rolled sections of Silos shall commence from Jan'15 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited. - Foundations for pelletiser shed to be made ready.
Project/Inspe ction
0.00
Strl. Steel for R&RMajor portion of steel plates have been delivered by M/s Essar.
Project/Inspe ction
0.06
-0.06 - Equipment dispatched
Action By
17
EIL/ BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 390+14 of 30
Action Plan
14
15
16
Action By
17
0.06
-0.06 - Compressor & Accessories have been loaded on ship at Antwerp port & Motor
EIL/ BPCL
0.10
0.00
- Following bidders showing slow manufacturing progress: EIL/ BPCL - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:184. Meeting held on 24.04.15. Balance order expected to dispatch from end Apr'15 to May'15. - M/s Universal: M/s UHE agreed to deliver balance items progressively upto May’15. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360, 423 & 444. - M/s HDO (Columns, Heat Exchangers & Vessels): FOA No.: 199, 302, 310, 315, 318, 320, 327, 369, 389 & 395.
0.00
- M/s Filtrex asking for deviations on commercial terms. Meeting held on 08.07.14 to resolve the issues with M/s Filtrex. Vendor provided all details.
EIL/ BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 391+14 of 30
Action Plan
14
15
16
Action By
17
0.00
- Order has been accepted by M/s Flowserve and amendment issued by BPCL on 11.07.14.
EIL/ BPCL
0.10
0.00
- All part received at Kochi.
EIL/ BPCL
0.20
0.00
- As of now around 90% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Apr'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL. Additional requirement of 20000 m2 area in FACT being taken for piping storage.
EIL/ BPCL
0.06
0.00
Ordered to M/s BHEL on 25.07.14. KOM held on 12-13.08.14. - Compressor Journal Bearings were ordered. Impeller manufacturing is in process
EIL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 392+14 of 30
Action Plan
14
15
16
0.16
Action By
17
-0.06 Vendor being pushed for deliveries. Vendor shop visit/meeting being arranged.
Inspection / Project
0.00
HMTD/Projec ts
-All burner drawings finaised across the table.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 393+14 of 30
Action Plan
14
15
16
0.27
Action By
17
0.00
Piling completed for CDU/VDU DCU & Offsite (except boundary wall) Constn. Balance piling (479 nos) for GTG, UB & stack area being done by M/s DBM. Job given on 07.10.13 with CCD by 1st week of Dec'13.
0.00
- During the project review meeting dated 23.01.15, following points discussed and requested with BPCL to provide assistance: - Additional storage space for owner supply items (20,000 Sq. M). - Additional storage space for piping spools.
BPCL
0.00
-Major rock blasting work completed.
Constn.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 394+14 of 30
Action Plan
14
15
16
0.86
0.00
Action By
17
'- Tender splitter into two parts (Structural/ Mechanical works & Civil work). Awarded to M/s OIL. BPCL/EIL Civil work being done by misc. Civil agency (M/s Furnace Fabrica). Rigorous follow up with contractor to be made after award of contract. Electrical Work: Award recommendation issued on 30.03.15. Instrumentation Work: Award recommendation issued on 30.03.15.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 395+14 of 30
Action Plan
14
15
16
0.32
Action By
17
0.00
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
BPCL / Projects
0.06
- MCR, CPP control room : Release for panels by Oct'15 & total completion by Dec'15. - Other building works : SRR Completion progressively between Apr'15 to May'15. - L&T also agreed to augment required manpower to 1000 from current deployment of 850 to meet the target completion date.
Constn
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 396+14 of 30
Action Plan
14
15
16
0.67
0.00
Action By
17
- Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deens has been lined Constn up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. - Contractors are facing problem in retaining the labour at site. Approx 12000 labours are available at site, though induction programme has been carried out for more than 18000 labours . requirement of manpower at site is approx 19000 nos. - RCC work & structural fabrication/erection work to be expedited to give complete front to mechanical contractor BPCL/EIL progressively upto end May'15. - Lighting of areas to facilitate night shift working. - Provision made for snacks/dinner for labour to facilitate working in extended/night shift - Provision of multiple entries inside plant areas to ease manpower/machinery mobilisation to be explored. - Additional mechanical contracts being awarded to supplement existing mechanical contractors.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 397+14 of 30
Action Plan
14
15
16
0.00
0.00
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Jun'15.
BPCL
0.00
L&T has completed all piles in Demountable flare area, Air compressor & DG shed area.
Constr.
0.00
Ensure that 90% payment of the RA bills certified by EIL are released to the contractors within 7 days of receipt by client.
BPCL
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 398+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Ensure that realistic dates of availability of inputs(drawings, front and materials) are considered in project/ construction schedule rather than compressing construction schedules alone to meet the completion target.
Project / Planning
0.00
All 5 nos tank area cleared and released. Area handed over to M/s B&R for Tankage-II works on 30.04.2014
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 399+14 of 30
Action Plan
14
15
16
0.15
0.00
- M/s Triveni to augment manpower by mobilizing additional manpower (Manpower required is 300 nos while available manpower is 235 Nos). - Substation building: completion being targeted by Apr'15. - Chemical house works completion being targeted by end Apr'15.
0.57
0.00
- All area handed over in SRU. Constn. - Pond Retaining wall construction is in progress. - Piling for SRU : All piling drawing released. To meet Euro-IV compliance, focussed efforts being made for ARU/SWS. Piling for ARU/SWS is completed. Balance piling work completion targeted by end Apr'15. - Civil works completion targeted by end May’15 and handing over of front to mechanical contractor targeted from end Mar'15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
Action By
17 Constr.
EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 400+14 of 30
Action Plan
14
15
16
Action By
17
0.00
Graded and handed over to tankage-II
Constr.
0.00
Clubbed with Risk ID E33
BPCL
0.00
M/s BPCL Vide mail dated 21.08.2013 has handed over the area for SG-III.
BPCL
0.00
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 401+14 of 30
Action Plan
14
15
16
0.30
Action By
17
0.00
- All 3 GTGs received at site.
Projects
0.00
-Included in mechanical contractor scope. Project / - Based on prel. Erection scheme, 1600 T heavy lift crane with 600 T trailing crane envisaged for erection of both Constn. VGO and DHDT reactors. - Timely mobilization of cranes and preparation of Load Test. - Finalization of erection scheme.
0.00 0.18
- Security arrangements in Warehouse in place by BPCL. - All balance material deliveries being expedited, subsequently all UG piping work completion targeted by end May'15.
Constn. EIL/BPCL
0.00
Area lighting being done.
Constn.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 402+14 of 30
Action Plan
14
15
16
Action By
17
0.00
-During 2013-2014 monsoon following actions were taken - Temporary drains were constructed for draining accumulated rain water. - Pumping arrangements for draining water accumulated in pits were made.
Constn.
0.00
LPG flare - As per EIL study LPG flare is adequate. Report issued to BPCL and clarification received. BPCL / EIL Acid flare - HC flare & Sour flare system P&IDs issued for engineering on 15.06.13. DHDS sour flare replacement: Sour Flare system P&ID (DHDS Area) issued for comments on 17.05.13, this additional requirement of existing structure and replacement of sour stack by higher size (16") being checked for adequacy. New flare components to be procured for revised stack size.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 403+14 of 30
Action Plan
14
15
16
0.04
0.00
After construction of subway road opened on 10.04.15
Action By
17 Constrn.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 404+14 of 30
Action Plan
14
15
16
0.38
0.00
Action By
17
-Management level meeting held with M/s KSSIIPL at site on 24.04.15. EIL/BPCL - M/s AA Erectors being mobilized by KSSPPL for Structural work. - M/s JD Works to be mobilized shortly by KSSPPL for UG piping works. - Additional 80MT crane also shall be mobilized shortly. (Currently one 100MT, one 75MT & one 70MT available). - Rock blasting being expedited for drain on West side of piperack area 104, CW line at East of VGO. - BG already arranges for 400 MT cement, apart from current stock of 100MT. - KSSPPL shall be expediting around 700 MT of strl steel required for completing the currently progressing areas of piperack on priority. Entire fabrication completion targeted by 30.04.15. - Bridge erection at area 117 shall be taken up. Bridge at area 113 nearing completion. -Strl steel painting & repair works shall be expedited with new gang. - Manpower for restarting manhole works shall be additionally deployed. - CW road crossing of 84" pipes shall be expedited. - Area wise handing over of piperack to mechanical agency to be expedited.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 405+14 of 30
Action Plan
14
15
16
0.38
0.00
0.38
0.00
Management review meeting held with M/s Essar on 20.03.15 at site - Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - boiler piperack foundations completed. - GBC fdn completed.
Action By
17 EIL/BPCL
EIL/BPCL - As on date the manpower is 470 Nos against the requirement of 750 Nos. - ARU/SWS : TS-1 & TS-2 being expedited TS Completion committed by MBE -TS-II : 30.04.2015 -TS-III: 30.04.2015 -TS-I : 31.06.2015 -TS-IV: 10.07.2015 -TS-V : 15.07.2015 -TS-VI: 15.04.2015 -MPR : 31.05.2015 -SILO: 20.04.2015
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 406+14 of 30
Action Plan
14
15
16
0.32
0.06
- Management level Meeting held with M/s OIL on 25.03.15 and following action plan has been agreed - M/s OIL has augmented manpower to 1122nos. - Structural fabrication completion targeted for end May '15 - Alloy steel piping fabrication to be expedited.-Fabrication Completion target by End May '15 - Fire proofing of Crude Column completed. - Dehumidification started in Crude Column. Column Internals completed o tray erect - Order placed for fabrication of rain protection shed - 350 out of 358 equipments erected. Completion Plan : 1. SRLPG - Total loop 129 loops -completion by 30.06.2015 2. FO FG Treater 145 loops Completion target by 31.07.2015,3. 400 loops out of 799 loops will be completed by 31..07.2015
Action By
17 EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 407+14 of 30
Action Plan
14
15
16
0.29
0.00
-Piling work to be completed by 30.04.15 Constr. -TT-3, TT-4, TT-5, Circular stacker cum reclaimer work in progress. - For CSR pit, due to collapse of excavation, revised scheme of excavation is being followed, in consultation with Geotech experts of EIL and Dr. Moza, who visited site and envisaged the problem on 12/01/15. - Pilling rate to enhance considering the upcoming dry period - Structural erection need to be expedite, supply of matching sections need to expedite.
0.15
0.00
-Heater A: Hot Work 6/6 box completed, Tube support fixing completed. Radiant coil erection completed. Pedestal Constrcution grouting (56/60) in progress. -Heater B:Hot Work 6/6 box completed, Tube support fixing 32/48 nos completed. -Refractory Dry-out for 3/6 nos of convection module completed at shop. Fabrication for Stack in progress at shop. APH- str erection is in progress. Glass APH & Fan erection in progress. Crane-450 MT mobilised at site.
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 408+14 of 30
Action Plan
14
15
16
0.00
- Total area handed over on 05.05.14.
Action By
17 Project
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 409+14 of 30
Action Plan
14
15
16
0.57
0.00
- Mobilization of additional 75 nos manpower by end Apr'15 (Presently 190 nos manpower available) - Completion of raft for TWT/SBR/ACT by 30.04.15. - Completion of equalisation tank targeted by Jun'15. - Procurement of BQ plate for Spent caustic tanks to be expedited.
0.32
0.06
- Management level meeting held on 25.03.15 at site. Total tanks: (New tanks 13 nos, work in progress for 12 EIL/BPCL nos. Balance for 1 nos is YT-33 which shall be start after completion of YT-32; Modification tanks: Out of total 16 nos, work in progress for 5 nos, 3 nos handed over to BPCL.) - B&R to augment resources to complete all balance work within agreed target. YT-32 completed.
Action By
17 EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 410+14 of 30
Action Plan
14
15
16
0.32
0.06
Action By
17 Constr.
- Plate erection to be expedited for YT-26/28. - Tank pad completion works to be expedited in YT-25.
0.20
0.00
-Management level meeting held on 24.04.15 - Structural steel: Out of total 217 MT, 217 MT received & 158MT fabricated & 120MT erected. - Erection of radiant section completed. - Coil tubes: Pipes & fittings (part) delivered. Coil fabrication commenced. - Order placed for anchors & refractory blanket & expected at site progressively from 15.05.15
Project
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 411+14 of 30
Action Plan
14
15
16
0.38
Action By
17
0.00
Clubbed with Risk ID D7
BPCL
0.00
- Vent Stacks: Common Stacks template already fabricated and dispatched to site. Bottom intermediate and top sections and transition cones are being manufactured as scheduled
Projects
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 412+14 of 30
Action Plan
14
15
16
0.57
0.00
- Sub-station-Completion of RCC super structure completion by 15.06.2015 - DM tanks (2 nos) : Tank -A : All piling completed, pile cap completion by 30.04.2015 - Fabricated structural steel Qty. 80 MT reached site, Balance 40 MT expected to reach site by 10.05.2015 Erection started in R.O. shed. - M/s DWEL being expedited to delivery of balance bought out items.
Action By
17 EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 413+14 of 30
Action Plan
14
15
16
0.67
0.00
Management level meeting held with M/s Shriram on 22.04.15 at site. - Mobilisation of resources is being expedited. At present only 160 nos, manpower mobilised against requirement of 350 nos. - M/s Shriram to complete balance Civil work by 15.05.15. EIL/BPCL - SEPC to expedite structural erection for Tech str A,E,BPR-2 - 5575m3 offloaded to M/s Tuaman (3374m3 completed) - 2432m3 offloaded to M/s PGC (692m3 completed) - 2025MT structural work offloaded to REL - 1684 MT structural work offloaded to ZIPL - 310 MT Offloaded to TEL
0.10
0.00
-Erection of stack completed. Balance welding to be expedited. NDT and PWHT to be expedited
Action By
17
Constr.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 414+14 of 30
Action Plan
14
15
16
0.20
0.00
- Procurement completed for structural steel - Radiant panel erection completed for IV-H-101 & IV-H-201. APH Structure & Stack erection in progress - Refractory for radiant section to be expedited. - Delivery of Radiant coil tubes to be expedited.
Action By
17 Projects
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 415+14 of 30
Action Plan
14
15
16
0.38
0.00
0.38
-0.26 PEB1: Project Material storage commenced. PEB 2 All works targeted to complete by 30.04.2015 PEB 3: All works targeted to complete by15.05.2015 Buildings to be expedited for storage of material / equipment being received at site.
Action By
17
- Current manpower is 507 nos. against requirement of 600 nos. MBEL to mobilise 200 nos additional manpower Constrn. for structural works - 6 cranes mobilised in order to carry out structural erection in both VGO & DHDT simultaneously. - In DHDT Unit: MPR, TS 1, TS 2, TS 4 completed and handed over to mechanical agencies for subsequent works. All structural erection to be completed by 15.05.15. In VGO HDT Unit: MPR only handed over for mechanical works. Balance structural shall be handed over progressively and handing over shall be completed by 30.06.15.
Constrn.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 416+14 of 30
Action Plan
14
15
16
0.16
0.00
Management level meeting held on 07.01.15 at site and PCTL to expedite to complete all works by Jun'15.
EIL / BPCL
0.10
0.00
- Manpower - Additional manpower to be deployed for civil works. (Required: 150 nos, Available: 87 nos) - Delivery of Bought out item to be expedited. - Mechanical contractor to be finalised. - RCC work for CWPH & CWTP to be expedited. - Early delivery of Pipes and immediate commencement of Piping fabrication work.
EIL / BPCL
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 417+14 of 30
Action Plan
14
15
16
0.86
0.00
-Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. Civil/Strl contractor. -Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deen has been lined up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works.
EIL/BPCL
0.38
0.00
Management level meeting held on 24.04.15 at site. - M/s Petron have started with night shift work. - PECL have erected the gantry crane & same made operational. - 10 nos semi automatic welding machines shall be operational by Apr'15 - Gratings & consumables are being ordered. Handrails, wrapping coating mtrls & GI pipes ordering to be expedited. Strl steel partially ordered. Structural steel & support fabrication to be expedited.
EIL/BPCL
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 418+14 of 30
Action Plan
14
15
16
0.32
0.00
Management review meeting held on 25.03.15. -Insulation/painting agency to be finalised. - Hanger scaffolding to be installed at site.
Action By
17 EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 419+14 of 30
Action Plan
14
15
16
0.48
0.09
- RCC sub structure work shall be completed by end Apr '15. - 30MT /day shall be fabricated from 01.01.15 onwards.
EIL/BPCL
0.38
0.00
Piping fabrication & erection work in progress in pipe rack 101-103, 108, 111-114. Fabrication in progress for piperack area 115. CS IBR & SS fabrication also commenced. AG piping fabrication: Scope: 285505 ID; Front: 101111 ID; Completed 56586 ID AG piping erection: Scope: 1214330 IM; Front: 373941 IM; Completed 261447 IM - Release of adequate front for erection to be expedited.
Constr.
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 420+14 of 30
Action Plan
14
15
16
0.38
0.00
- Management level meeting held 25.03.15 at site. - B&R to take up compressor erection immediately. - Due to delay in completion of civil work, release of front to composite contractor got affected.
EIL/BPCL
0.20
0.00
Management level meeting held on 20.03.15 -TS I handed over -TS II, III & IV,VI handed over. -TS V by 27.05.15 -TS VII handed over.
Constr.
0.20
0.00
- MRM held on 23.03.15 - Refractory of stack, dryout & erection of stack to be expedited.
Constr.
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 421+14 of 30
Action Plan
14
15
16
0.38
0.00
Management level meeting held on 20.03.15 - TS I by 30.04.15 - TS II by 05.05.15. - TS IV & TS-V handed over. - Branch piperack completion targeted by 30.04.15.
0.20
0.00
- Management level Meeting held on 25.03.15, M/s OIl started night shift work in YT-150 from 10.03.2015 EIL/BPCL - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT-383,391 for modification and 150 for new. - YT-150: Tank Pad completed, erection of annular plate completed, welding u/p, bottom plate erection under progress.. - YT-383: Roof structure erection completed, roof plate erection u/p. - YT-391: Hydrotesting completed, blasting and painting under progress. - Ordering of cladding and moisture barriers to be expedited.
Action By
17 EIL/BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 422+14 of 30
Action Plan
14
15
16
0.20
0.00
- Management level meeting held on 25.02.2015 with M/s B&R at site. Start of Hydrotest - YT 341 : hydrotest by 06.05.2015 - YT 342 : Hydro test by 28.06.2015 - YT 343 : hydro test by 12.06.2015 - YT 344 : Hydrotest by 01.05.2015 - YT 112 : Hydrotest by 30.04.2015 - YT 113 : Hydrotest by 05.06.2015 - YT 114 : Hydrotest by 25.06.2015 -Manpower required is 250 nos, available is 161.
EIL/BPCL
0.32
0.00
-These tankages (Amine water and sour water services) are required for commissioning of CDU/VDU. - ISW-T-101 tank: 1st Shell & Bottom plate welding is in progress, Roof structural erection is in progress. - ISW-T-201: Bottom plate & Shell erection is in progress. - ISA-T-101: Annular plate welding completed & Bottom plate laying & Welding is in progress. - IS-T-502 & IS-T-102 A/ B tand pad ready.
Constr.
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 423+14 of 30
Action Plan
14
15
16
0.12
0.00
- Piping fabrication & piping erection in MPR in progress. Structural fabrication in progress for reactor structure, piping supports, piping manifold - Equipment erection in progress (50 nos equipment erection completed) AG piping fabrication: Scope: 210605 ID; Front: 110882 ID; Completed 87644 ID AG piping erection: Scope: 301995 IM; Front: 96604 IM; Completed 26364 IM
0.38
0.00
- Management level meeting held with M/s OIL on 25.03.15 at site. M/s OIL has been asked to ensure sufficient Constr. manpower mobilization when work front is released to them. - Due to delay in completion of civil work, release of front to composite contractor got affected. site update: site work started on 23/12/2014 the progress is as follows:- 1. 216 and 217 area handed over for pipe laying, work in progress. 2. front release plan for next 3 months prepeared, based on which advance blasting & painting,fabrication of spools, pipe doubling works going on. Monthly plan of fabrication and erection is as follows: a) April,15- 15000 ID, 45190 IM b) May, 15- 20000 ID, 45000 IM c) June, 15- 20000 Id, 45000 IM. 3. Cement lining of 20"pipe 492 running meter completed. 4. one underground vessel, 6 pumps already erected, erection of fire water pumps to commence soon.
Action By
17 Constr.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 424+14 of 30
Action Plan
14
15
16
0.20
0.00
- Management level meeting held with M/s OIL on 25.03.15 at site. M/s OIL has been asked to mobilise additional Constr. resources, M/s OIL confirmed to increase the resources and achieved 1200 ID/day by Mar'15. - At present only 26 nos welders are available at site with per day rate of 1000 ID, however to achieve the completion schedule minimum 1500 ID/day to be achieved.
0.12
0.00
-Out of 2205 nos piles, 1421 nos piles completed.
BPCL
0.12
0.00
- Piping fabrication work & Piping erection work in progress. - Equipment erection in progress (13 nos completed) - Structural fabrication in progress for TS-2
Constr.
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 425+14 of 30
Action Plan
14
15
16
0.16
0.00
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
BPCL
0.07
0.00
a. Change management should be in place immediately b. Strict discipline to be maintained else end objective would be difficult to meet.
Projects
Action By
17
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
0.10
0.00
-Strict monitoring required at all stages upto commissioning. -Completeness of supply of all subparts, their assembly and other BOP Items to be ensured. - Both steam drum delivered at site. RCC work for chimney completed, foundation work in progress for UB's. Erection of structure started. - Progress of work affected due to delay in completion of civil foundations.
Constn. / Projects / BPCL
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 426+14 of 30
Action Plan
14
15
16
0.05
0.00
Following methodology being taken up for smooth cash flow to contractors: - Issue of comfort letter by BPCL to sub Vendors & subcontractor being implemented. - Provision for direct payments to contractors sub vendors & subcontractor being implemented as per contract provision. - Provision of interest bearing mobilisation advance against equivalent bank guarantee being implemented for future contract of more than 5CR value. - Expeditious processing of RA bills.
Project/BPCL
0.03
0.00
Contractor to identify the proposed areas in and around Project area and BPCL to facilitate by persuading with local authorities for required permission.
Constn. / Projects / BPCL
0.00
All DCN ‘s and change orders, if any to be frozen and incorporated in P&IDs at 60% construction progress stage. Process / POSD / Engg. / Projects
0.00
The vendor list to be carefully selected to avoid overloading of vendors shops. Bulk materials to be distributed on Inspn different vendors.
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 427+14 of 30
Action Plan
14
15
16
0.04
Action By
17
0.00
- Covered under risk ID C73
BPCL
0.00
Projects
0.00
- BPCL-KR vide e-mail dated 06-Dec-12 sent a list of Non plant buildings to be located under IREP Project. - The same is reviewed by EIL. Point wise issues targeted to be discussed with BPCL in week starting 15.04.13. - List of buildings finalised between EIL and BPCL. Methodology for execution under finalisation. - Meeting held with BPCL on EIL recommendations and action plan finalised. - BPCL to take up with MOEF for approval of changes in system already incorporated. (e.g. configuration for CPP) - Incorporation of EC and RRA recommendations in balance systems under progress.
0.00
- Documents approved from PESO
BPCL
BPCL / Projects
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 428+14 of 30
Action Plan
14
15
16
0.06
0.00
- All drawings for F&B approval issued progressively upto 29.09.14. -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
EIL/BPCL
0.19
0.29
- Deployment of skilled manpower for enforcement of safety precautions. - Monitoring of the HSE conditions and maintenance of records ./ reports. - Safety Drills being organised on monthly basis.
Constn.
0.00
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
BPCL
0.00
-Utilisation of migrant and skilled labour from outside Kerala needs to be encouraged. However, the same will be Constn / effective only if proper labour colony facilities are arranged by the contractors. BPCL - Slow down in progress of work by Union workmen, inspite of assurance by trade union leaders that workers shall be instructed to improve productivity.
0.40
Action By
17
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 429+14 of 30
Action Plan
14
15
16
Action By
17
0.00
-A separate contract to be given to agency which will take care by approaching KSEB and telephonic authority. -Fabn / transportation philosophy being finalised.
Shipping
0.00
Closed as no concern as on date.
BPCL
0.00
Quarry strike has been called off.
Constn / BPCL
0.00
Cost engg. to issue cost status report on regular basis
Costing
0.00
Scope of facilities finalised.
Environ.
Previous Risk Score
(Current risk Score Previous Risk score)
Job No.: A307 Apr'15 Page 430+14 of 30
Action Plan
14
15
16
0.00
21.86
-0.18
- BPCL have informed that approval for revised cost received.
Action By
17 EIL/BPCL
Job No.: A307 Apr'15 Page 431+14 of 30
Target Date
Risk Severity
18
19
15-Nov-13
Oct'13
15-Oct-13
sep'13
Job No.: A307 Apr'15 Page 432+14 of 30
Target Date
Risk Severity
18
19
25/10/13
15-Mar-14
Oct'13
Mar'14 & Apr'14
31-Mar-14 30-Apr-14 Apr'13
Job No.: A307 Apr'15 Page 433+14 of 30
Target Date
Risk Severity
18
19
-
Apr'13
-
Mar'13
-
Mar'13
Apr'13
Job No.: A307 Apr'15 Page 434+14 of 30
Target Date
Risk Severity
18
19
31-Dec-12
Jan'13
Apr'13
Apr'13
Job No.: A307 Apr'15 Page 435+14 of 30
Target Date
Risk Severity
18
19 Apr'13
-
Apr'13
15-Mar-13
Feb'13
-
Apr'13
-
Apr'13
Job No.: A307 Apr'15 Page 436+14 of 30
Target Date
Risk Severity
18
19
As Required
Apr'13
31-May-13
Apr'13
31-May-13
Apr'13
Jan'13
25-May-13
May'13
Job No.: A307 Apr'15 Page 437+14 of 30
Target Date
Risk Severity
18
19
30-Apr-14
May'14
30-May-14
May'14
Nov'13
30-Dec-13
Dec'13
Job No.: A307 Apr'15 Page 438+14 of 30
Target Date
Risk Severity
18
19
31-Jan-15
Jan'15
Mar'14 & Apr'14
21-Aug-13
JUL'13
Job No.: A307 Apr'15 Page 439+14 of 30
Target Date
Risk Severity
18
19
26-Dec-12
Jan'13
21-Dec-12
Jan'13
18-Jun-13
May'13
As Required
Apr'13
Job No.: A307 Apr'15 Page 440+14 of 30
Target Date
Risk Severity
18
19
15-Jan-13
Jan'13
15-Jun-13
May'13
31-May-13
May'13
Job No.: A307 Apr'15 Page 441+14 of 30
Target Date
Risk Severity
18
19 Apr'13
31-May-13
May'13
Prog. To Jun 13
May'13
18-Jun-13
May'13
Job No.: A307 Apr'15 Page 442+14 of 30
Target Date
Risk Severity
18
19
As Required
Apr'13
Apr'13
May'14
Job No.: A307 Apr'15 Page 443+14 of 30
Target Date
Risk Severity
18
19
-
Mar'14 & Apr'14
Mid Mar'14
Feb'14
10-Mar-13
Feb'13
Job No.: A307 Apr'15 Page 444+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
IV
Continuous
Sep'14 & Oct'14
Continuous
Aug'13 Sep'14 & Oct'14
Job No.: A307 Apr'15 Page 445+14 of 30
Target Date
Risk Severity
18
19
Continuous
Mar'15
4-Oct-13
sep'13
25-Jul-13
JUL'13
5-Oct-14
Sep'14 & Oct'14
Job No.: A307 Apr'15 Page 446+14 of 30
Target Date
Risk Severity
18
19
25-Oct-13
sep'13
Job No.: A307 Apr'15 Page 447+14 of 30
Target Date
Risk Severity
18
19
25-Oct-13
sep'13
31-Oct-13
sep'13
Job No.: A307 Apr'15 Page 448+14 of 30
Target Date
Risk Severity
18
19
31-Oct-13
Progressively
Oct'13
IV Nov'13
Job No.: A307 Apr'15 Page 449+14 of 30
Target Date
Risk Severity
18
19 Aug'14
Sep'14
Sep'14 & Oct'14
Sep'14
Sep'14 & Oct'14
Job No.: A307 Apr'15 Page 450+14 of 30
Target Date
Risk Severity
18
19
30-Dec-13
Dec'13
30-Aug-13
JUL'13
30-May-13
May'13
Job No.: A307 Apr'15 Page 451+14 of 30
Target Date
Risk Severity
18
19
Continuous
Nov'13
15-Sep-13
Aug'13
25-Oct-13
sep'13
31-Oct-13
sep'13
15-Oct-13
sep'13
Job No.: A307 Apr'15 Page 452+14 of 30
Target Date
Risk Severity
18
19
15-Oct-13
sep'13
15-Mar-14
Mar'14 & Apr'14
15-Oct-13
sep'13
31-Oct-13
sep'13
Job No.: A307 Apr'15 Page 453+14 of 30
Target Date
Risk Severity
18
19
20-Jul-13
JUL'13
31-May-13
May'13
29-Jun-13
May'13
28-Feb-13
Feb'13
Job No.: A307 Apr'15 Page 454+14 of 30
Target Date
Risk Severity
18
19
21-Feb-13
Feb'13
Apr'13
-
Mar'13
-
Mar'13
Job No.: A307 Apr'15 Page 455+14 of 30
Target Date
Risk Severity
18
19
-
Mar'13
7-Mar-13
Feb'13
Apr'13
Apr'13
Job No.: A307 Apr'15 Page 456+14 of 30
Target Date
Risk Severity
18
19
7-Mar-13
Feb'13
Apr'13
30-Mar-14
Mar'14 & Apr'14
Job No.: A307 Apr'15 Page 457+14 of 30
Target Date
Risk Severity
18
19
TBA - 1 month of bids receipt PBO - 1 week of TBA
Dec'13
Job No.: A307 Apr'15 Page 458+14 of 30
Target Date
Risk Severity
18
19
30-Dec-13
Dec'13
Job No.: A307 Apr'15 Page 459+14 of 30
Target Date
Risk Severity
18
19
30-Aug-13
20-Jul-13
JUL'13
JUL'13
Job No.: A307 Apr'15 Page 460+14 of 30
Target Date
Risk Severity
18
19
20-Dec-13
Nov'13
Job No.: A307 Apr'15 Page 461+14 of 30
Target Date
Risk Severity
18
19 Jun'13
31-Oct-13
Oct'13
Job No.: A307 Apr'15 Page 462+14 of 30
Target Date
Risk Severity
18
19
31-Jul-13
JUL'13
Aug'13
Job No.: A307 Apr'15 Page 463+14 of 30
Target Date
Risk Severity
18
19
-
sep'13
-
sep'13
15-Jul-13
Jun'13
Job No.: A307 Apr'15 Page 464+14 of 30
Target Date
Risk Severity
18
19
15-Nov-13
Oct'13
20-Jul-13
JUL'13
sep'13
Job No.: A307 Apr'15 Page 465+14 of 30
Target Date
Risk Severity
18
19
25-Jul-13
JUL'13
30-Oct-13
Oct'13
Job No.: A307 Apr'15 Page 466+14 of 30
Target Date
Risk Severity
18
19
30-Sep-13
Aug'13
7-Mar-13
Feb'13
Jun'13
Job No.: A307 Apr'15 Page 467+14 of 30
Target Date
Risk Severity
18
19
30-Oct-13
Oct'13
Job No.: A307 Apr'15 Page 468+14 of 30
Target Date
Risk Severity
18
19
30-Jan-14
Jan'14
Job No.: A307 Apr'15 Page 469+14 of 30
Target Date
Risk Severity
18
19
30-Sep-13
Aug'13
Job No.: A307 Apr'15 Page 470+14 of 30
Target Date
Risk Severity
18
19 Aug'13
28-Aug-13
JUL'13
Job No.: A307 Apr'15 Page 471+14 of 30
Target Date
Risk Severity
18
19
14-Aug-13
JUL'13
19-Jul-13
JUL'13
Jun'14
Job No.: A307 Apr'15 Page 472+14 of 30
Target Date
Risk Severity
18
19
19-Jul-13
JUL'13
Job No.: A307 Apr'15 Page 473+14 of 30
Target Date
Risk Severity
18
19
28-Sep-13
Aug'13
Job No.: A307 Apr'15 Page 474+14 of 30
Target Date
Risk Severity
18
19 Jan'14
29-Jun-13
Jun'13
30-Nov-13
Nov'13
Job No.: A307 Apr'15 Page 475+14 of 30
Target Date
Risk Severity
18
19
15-Dec-13
Nov'13
28-Jun-13
Jun'13
Aug'13
Job No.: A307 Apr'15 Page 476+14 of 30
Target Date
Risk Severity
18
19
30-Sep-13
Aug'13
25-Apr-14
Mar'14 & Apr'14
Job No.: A307 Apr'15 Page 477+14 of 30
Target Date
Risk Severity
18
19
31-Oct-13
Oct'13
30-Dec-13
Nov'13
Job No.: A307 Apr'15 Page 478+14 of 30
Target Date
Risk Severity
18
19
30-May-14
May'14
15-Dec-13
Nov'13
30-Jul-14
Jul'14
Job No.: A307 Apr'15 Page 479+14 of 30
Target Date
Risk Severity
18
19
Oct'14
Sep'14 & Oct'14
14-Aug-14
Aug'14
30-Apr-15
Feb'15
25-May-14
May'14
Job No.: A307 Apr'15 Page 480+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
IV
Mar'15
5-Aug-14
Jul'14
Job No.: A307 Apr'15 Page 481+14 of 30
Target Date
Risk Severity
18
19
Nov'14
30-Apr-15
Nov'14
III
Job No.: A307 Apr'15 Page 482+14 of 30
Target Date
Risk Severity
18
19
24-Nov-14
I Nov'13
Jun'15
Job No.: A307 Apr'15 Page 483+14 of 30
Target Date
Risk Severity
18
19
Continuous
III
Sep'14
31-Mar-15
Sep'14 & Oct'14
Mar'15
Job No.: A307 Apr'15 Page 484+14 of 30
Target Date
Risk Severity
18
19
28-Feb-15
Feb'15
As stated
I
Job No.: A307 Apr'15 Page 485+14 of 30
Target Date
Risk Severity
18
19
15-May-15
II
Job No.: A307 Apr'15 Page 486+14 of 30
Target Date
Risk Severity
18
19
Erection by May'15
I
Job No.: A307 Apr'15 Page 487+14 of 30
Target Date
Risk Severity
18
19
end Dec'14
Dec'14
27-Dec-14
Dec'14
19-Mar-15
Mar'15
Job No.: A307 Apr'15 Page 488+14 of 30
Target Date
Risk Severity
18
19
May'15
Continous
As Required
II IV
Nov'13
Job No.: A307 Apr'15 Page 489+14 of 30
Target Date
Risk Severity
18
19 Jun'14
Job No.: A307 Apr'15 Page 490+14 of 30
Target Date
Risk Severity
18
19
As Required
III
As Required
Oct'13
Job No.: A307 Apr'15 Page 491+14 of 30
Target Date
Risk Severity
18
19
Continuous
II Continuous
Continuous
Job No.: A307 Apr'15 Page 492+14 of 30
Target Date
Risk Severity
18
19
Continuous
Dec'14
Continuous
III
Continuous
III
Job No.: A307 Apr'15 Page 493+14 of 30
Target Date
Risk Severity
18
19
Continuous
III
Continuous
Jun'14
Continuous
Job No.: A307 Apr'15 Page 494+14 of 30
Target Date
Risk Severity
18
19
Progressively
30-May-15
Aug'14
III
Aug'14
Job No.: A307 Apr'15 Page 495+14 of 30
Target Date
Risk Severity
18
19
Jul'14
Jul'14
Feb'15
Feb'15
30-Apr-15
III
30-Apr-15
IV
Job No.: A307 Apr'15 Page 496+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
Feb'15
Job No.: A307 Apr'15 Page 497+14 of 30
Target Date
Risk Severity
18
19
Mid Oct'13
sep'13
30-Apr-15
sep'14
II Aug'14
Job No.: A307 Apr'15 Page 498+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
I
Job No.: A307 Apr'15 Page 499+14 of 30
Target Date
Risk Severity
18
19
15-Jul-13
JUL'13
As Required
II
Job No.: A307 Apr'15 Page 500+14 of 30
Target Date
Risk Severity
18
19
As Required
I
Job No.: A307 Apr'15 Page 501+14 of 30
Target Date
Risk Severity
18
19
Jun'15
IV
Immediate
Jul'14
within 7 days of certified RA bills
sep'13
Job No.: A307 Apr'15 Page 502+14 of 30
Target Date
Risk Severity
18
19
As Required
sep'13
end Apr'14
May'14
Job No.: A307 Apr'15 Page 503+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
30-Apr-15
I
Job No.: A307 Apr'15 Page 504+14 of 30
Target Date
Risk Severity
18
19 Jul'14
Dec'13
Nov'13
Aug'13
As Required
sep'13
Job No.: A307 Apr'15 Page 505+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
Feb'15
-
Nov'13
May'15
-
As Required
Mar'13 II May'13
Job No.: A307 Apr'15 Page 506+14 of 30
Target Date
Risk Severity
18
19
As Required
sep'13
15-Nov-13
Oct'13
Job No.: A307 Apr'15 Page 507+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
IV
Job No.: A307 Apr'15 Page 508+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
II
Job No.: A307 Apr'15 Page 509+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
II Continuous
II
Job No.: A307 Apr'15 Page 510+14 of 30
Target Date
Risk Severity
18
19
Continuous
II
Job No.: A307 Apr'15 Page 511+14 of 30
Target Date
Risk Severity
18
19
Continuous
As Required
II III
Job No.: A307 Apr'15 Page 512+14 of 30
Target Date
Risk Severity
18
19
As stated
Jun'14
Job No.: A307 Apr'15 Page 513+14 of 30
Target Date
Risk Severity
18
19
As stated
I As stated
II
Job No.: A307 Apr'15 Page 514+14 of 30
Target Date
Risk Severity
18
19
As stated
As Required
II III
Job No.: A307 Apr'15 Page 515+14 of 30
Target Date
Risk Severity
18
19
As Required
Dec'13
As Required
II
Job No.: A307 Apr'15 Page 516+14 of 30
Target Date
Risk Severity
18
19
As Required
I
Job No.: A307 Apr'15 Page 517+14 of 30
Target Date
Risk Severity
18
19
As Required
As Required
I III
Job No.: A307 Apr'15 Page 518+14 of 30
Target Date
Risk Severity
18
19
As Required
III
Job No.: A307 Apr'15 Page 519+14 of 30
Target Date
Risk Severity
18
19
As Required
As Required
II III
Job No.: A307 Apr'15 Page 520+14 of 30
Target Date
Risk Severity
18
19
As Required
III
As Required
III
Job No.: A307 Apr'15 Page 521+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
I 30-Apr-15
II
Job No.: A307 Apr'15 Page 522+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
II
Job No.: A307 Apr'15 Page 523+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
I 30-Apr-15
II
Job No.: A307 Apr'15 Page 524+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
30-Apr-15
II III
As Required
III
Job No.: A307 Apr'15 Page 525+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
30-Apr-15
II III
Job No.: A307 Apr'15 Page 526+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
30-Apr-15
II
Job No.: A307 Apr'15 Page 527+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
30-Apr-15
II
Job No.: A307 Apr'15 Page 528+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
III
30-Apr-15
III
30-Apr-15
III
Job No.: A307 Apr'15 Page 529+14 of 30
Target Date
Risk Severity
18
19
1-Jun-15
III
Continuous
IV
as scheduled
III
Job No.: A307 Apr'15 Page 530+14 of 30
Target Date
Risk Severity
18
19
As Required
IV
As Required
IV
All by 60% constn progress
sep'13
As Required
sep'13
Job No.: A307 Apr'15 Page 531+14 of 30
Target Date
Risk Severity
18
19
within 2 days of request
Nov'13
15-Apr-13
Apr'13
As required
IV
Apr'13
Job No.: A307 Apr'15 Page 532+14 of 30
Target Date
Risk Severity
18
19
30-Apr-15
IV
Continuous
As Required
II Nov'13
As Required
II
Job No.: A307 Apr'15 Page 533+14 of 30
Target Date
Risk Severity
18
19
As Required
As stated
As Required
Jun'14
Jun'14
Mar'15
Monthly
Apr'13
15-Oct-13
sep'13
Job No.: A307 Apr'15 Page 534+14 of 30
Target Date
Risk Severity
18
19 Jan'15
Job No.: A307 Mar'15 Page 535 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
D
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Completion of Reactor regenerator package for FCCU-M/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 93.9% Act: 70.8 % Construction Progress: Sch: 83.6% Front: 85.8% Act: 30.8 %
Open
Project
Management level meeting held on 20.03.15 at site. - Out of 3842 MT strl steel qty, only 3273 MT fabricated, 3160 MT received at site & 2537 MT erected. - Regenerator bottom section erected on 21.03.15 - Erection of TSS bottom section targeted by mid Apr'15. Balance deliveries comprising of nozzles, insert plates for equipment fabrication of Regenerator (top section), Reactor, TSS to be expedited. - Steam drum erected on 13.03.2015 & economiser panel erection commenced on 20.03.15 - 1st lot of fabricated ESP materials received at port.
Completion of all three site Fabricated Columns for FCCU :Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 100 % Act: 74.0 % - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach road upto fabrication yard, which affected shifting of sections.
Open
Project
- Main fractionator column: Hydrotest targeted by end Apr’15. Stripper Column: EIL/BPCL Hydrotest targeted by mid Jun’15. Rectifier Column: Hydrotest targeted by mid Aug’15
As stated
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 30.07.16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 89.0 %; Act: 65.4 % Construction Progress: Sch: 77.58% Front: 100% Act: 39.08 %
Open
Project
Following commitments have been made by M/s Essar. -Shift Work: Works in two shifts implemented. - M/s Essar have been pressurized to deliver all coke drums progressively and Coke fractionator upto end Apr’15. - Crane (2000 MT): Mobilization & assembly of crane completed and erection of equipments targeted progressively by May’15. -Clear water tank fabrication- Civil tank pad work completed, rolling in progress. - Resource augmentation for Civil & Strl works being expedited. At present 590 nos have been deployed against requirement of 836 nos.
EIL/BPCL
Erection by May'15
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 31.10.15
Open
Projects
- Steam turbine: MRT completed for turbine. Main Compressor: MRT targeted progressively by May’15.
EIL/BPCL
Continuous
Availability of Piping materials to generate adequate piping material front to composite contractors. Sch: (Final MTO): Dec'14-Feb'15 EDD: Apr'15-Jun'15
Open
Projects
- As of now around 90% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Apr'15. -Vendors being expedited to prepone the deliveries.
EIL/ BPCL
15-Apr-15
- During the project review meeting dated 23.01.15, following points discussed and requested with BPCL to provide assistance: - Additional storage space for owner supply items (20,000 Sq. M). - Additional storage space for piping spools.
BPCL
15-Apr-15
Key Risk Description
1
Action Plan
Action By
EIL/BPCL
Target Date
Risk Severity
Apr'15
I
D
7
I
D
9
Strl Steel: Out of total 3210 MT, 2926 MT procured, 1929 MT fabricated & 1716 MT received.
I
D
D
E
19
II III
33
2
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
Open
Constn.
II
Job No.: A307 Mar'15 Page 536 of 749
Integrated Refinery Expansion Project, Kochi
E
4
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Action Plan
Action By
Target Date
Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 12 M available for construction works (excl. Dismantling works) against schedule of 22 M. - Process package was delayed by 2 M due to delay in P&IDs review meeting and delay in award of licensor. - Change in the scope based on health check report has an impact on Project cost and schedule. Physical Progress: Target Sch: 92.5% Catch Up Sch: 75.2 % Act: 55.3%
Open
Constn. / Projects
- Tender splitted into two parts (Structural/ Mechanical works & Civil work). Awarded BPCL/EIL to M/s OIL. Civil work being done by misc. Civil agency (M/s Furnace Fabrica). Rigorous follow up with contractor to be made after award of contract. Electrical Work: Award recommendation issued on 30.03.15. Instrumentation Work: Award recommendation issued on 30.03.15.
15-Apr-15
Backlog 18.2% as of 15-Mar-15 in Construction activities viz., Civil works and Mechanical works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 34 M Catch Up sch: Const Sch Front Act 66.7 85.9 66.4 48.5 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site.
Open
Const
- Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deens has been lined up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. - Contractors are facing problem in retaining the labour at site. Approx 12000 labours are available at site, though induction programme has been carried out for more than 18000 labours . requirement of manpower at site is approx 19000 nos. - RCC work & structural fabrication/erection work to be expedited to give complete BPCL/EIL front to mechanical contractor progressively upto Apr-May'15. - Lighting of areas to facilitate night shift working. - Provision made for snacks/dinner for labour to facilitate working in extended/night shift - Provision of multiple entries inside plant areas to ease manpower/machinery mobilisation to be explored. - Hiring of cranes: Awarded to M/s Ideal movers on 27.03.15 to supplement mechanical works.
As Required
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Jun'15)
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Jun'15.
Jun'15
Slow construction progress in Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 CCD: 08.10.14; ECD: Jun'15 Progress figures Sch: 100% Front: 99.7% Act.: 54.78% Insufficient mobilisation of manpower: Required: 635 nos Deployed: 216 nos
Open
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 94.6 % Act: 55.7 % Construction Progress: Sch: 92.5% Front: 100 % Act: 31.5 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Risk Severity
I
E
E
E
7
8
27
BPCL
Constructio -Management level meeting held with M/s KSSIIPL at site on 25.03.15. EIL/BPCL n - M/s AA Erectors being mobilized by KSSPPL for Structural work. - M/s JD Works to be mobilized shortly by KSSPPL for UG piping works. - Payment released for 150 MT crane by KSSPPL. One 80MT crane also shall be mobilized shortly. (Currently one 100MT, one 75MT & one 70MT available). - Rock blasting being expedited for drain on West side of piperack area 104, CW line at East of VGO. - BG already arranges for 400 MT cement, apart from current stock of 100MT. - KSSPPL shall be expediting around 700 MT of strl steel required for completing the currently progressing areas of piperack on priority. Entire fabrication completion targeted by 30.04.15. - Bridge erection at area 117 shall be taken up. Bridge at area 113 nearing completion. -Strl steel painting & repair works shall be expedited with new gang. - Manpower for restarting manhole works shall be additionally deployed. - CW road crossing of 84" pipes shall be expedited. - Area wise handing over of piperack to mechanical agency to be expedited.
I IV
30-Apr-15
II
E
34
Project
- Mobilization of additional 120 nos manpower by Mar-15(Presently 145 nos manpower available) - Completion of raft for TWT/SBR/ACT by 30.04.15. - Control room slab casting in sub-station by 1st week of Apr'15. - 2nd slab in chemical house under completion stage. - Completion of equalisation tank targeted by Jun'15. - Procurement of BQ plate for Spent caustic tanks being expedited.
EIL/BPCL
As stated
I
Job No.: A307 Mar'15 Page 537 of 749
Integrated Refinery Expansion Project, Kochi
E
40
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Action Plan
Action By
EIL/BPCL
Target Date
Risk Severity
Slow progress of RO-DM works (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 (As per vendor) Overall Progress: Sch: 99 % Act: 72% Construction Progress: Sch: 100 %; Front: 100%; Act:46.41%
Open
Project
- Sub-station-Completion of RCC super structure completion by 15.06.15 - DM tanks (2 nos) : All 160nos piling completed & pile cap expected to complete by 1st week of Apr'15. - Delivery of fabricated structural steel to be expedited to reach at site. Strl steel erection will start by 1st week of Apr'15. - M/s DWEL being expedited to delivery of balance bought out items by Jun'15.
As Required
Slow Construction progress for Civil Works- FCCU Contr. Sch: 100 %; Front: 100% Act: 78.42 % (M/s SEPC) CCD: 24.12.14 ECD: Oct'15
Open
Project
Management level meeting held with M/s Shriram on 19.03.15 at site. - Mobilisation of resources is being expedited. At present only 160 nos, manpower mobilised against requirement of 350 nos. - M/s Shriram to complete balance Civil work by 15.04.15. - SEPC to expedite structural erection for Tech str A,D,BPR-2 - 5575m3 offloaded to M/s Tuaman (3374m3 completed) - 2432m3 offloaded to M/s PGC (692m3 completed) - 2025MT structural work offloaded to REL - 1684 MT structural work offloaded to ZIPL - 310 MT Offloaded to TEL
Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open
Project
Slow construction progress in Offsite-DHDS area. Work stopped by M/s KSS in DHDS area for Civil & Strl work CDD: 24.01.15 ECD:. Dec'15
Open
Constructio -Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. EIL/BPCL n Civil/Strl contractor. -Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deen has been lined up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works.
30-Apr-15
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 54.68 %; Front: 20.95%; Act.:14.61%
Open
Constructio Management level meeting held on 25.03.15 at site. n - M/s Petron have started with night shift work. - PECL have erected the gantry crane & same made operational. - 10 nos semi automatic welding machines shall be operational by Apr'15 - Auto blasting installed to be made operational by Apr'15. - Gratings & consumables are being ordered. Handrails, wrapping coating mtrls & GI pipes ordering to be expedited. Strl steel partially ordered. Structural steel & support fabrication to be expedited.
EIL/BPCL
30-Apr-15
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
BPCL
1-Jun-15
II III
Timely payment to sub contractor by main contractor
Open
Const.
Following methodology being taken up for smooth cash flow to contractors: EIL/BPCL - Issue of comfort letter by BPCL to sub Vendors & subcontractor being implemented on request from contractors. - Provision for direct payments to contractors sub vendors & subcontractor being implemented as per contract provision. - Provision of interest bearing mobilisation advance against equivalent bank guarantee being implemented for future contract of more than 5CR value. - Expeditious processing of RA bills.
As Required
IV
Mobilisation of Skilled workers
Open
Const.
- Slow down in progress of work by Union workmen, inspite of assurance by trade union leaders that workers shall be instructed to improve productivity. - Respective contractors being persued to increase manpower commensurate with site requirement. - Additional entry gate provision being made to facilitate smooth entry inside working area. - Availibilty of permits being made available for inside refinery works.
As Required
I
E
41
As Required EIL/BPCL
I
E
46
PEB1: Project Material storage commenced. PEB 2 All works targeted to complete by 20.04.2015 PEB 3: All works targeted to complete by 1st week of Apr'15. Buildings to be expedited for storage of material / equipment being received at site.
EIL/BPCL
As Required
II
E
49
I
E
F
G
50
1
1
At present only approx 12000 labours are working against requirement of 15000-18000 labours. K
2
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
EIL/BPCL
II
A
A
A
A
1
2
3
5
A
6
(Current risk Score Previous Risk score)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
16
17
5
6
7
8
9
10
11
12
Low
N
N
Y
N
Short term
D
0.2
0.00
Actions Taken so far: Projects / - UOP package received on 08.08.13. Process - PDS issued for all Columns, Vessels, Air Fin Coolers, Exchangers & Refrigeration pkg, pumps (part balance). - All 30 nos P&IDs issued for engineering Action Plan for balance - 19 nos out of 23 nos pumps datasheet issued for engineering. Balance progressively targeted by 15.11.13.
15-Nov-13
Oct'13
Delay in Finalisation of balance OSBL distribution P&IDs due to delay in receipt of data from BPCL LAD - 30-Nov-12; Ant - 15-Oct13 Natural gas operating/ design condition information has been received from BPCL during meeting dated 13 & 14.8.13. Steam distribution : Preliminary discussion on BOO steam distribution held with BPCL. BPCL approval on EIL scheme required.
Open
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
- Meeting held with BPCL on 18-20.09.13.
Process / Projects
15-Oct-13
sep'13
Holds, missing information, corrections, changes in PDS / P&IDs - CDU / VDU - DCNs on account of HAZOP recommendations for CDU / VDU
Open
Process
Medium
N
N
N
N
Short term
D
0
0.00
- All P&IDs incorporating DCNs issued.
Process
25/10/13
Oct'13
Holds, missing information, corrections, changes in PDS / P&IDs - DCU
Open
Process
Medium
N
N
N
N
Short term
D
0
0.00
- Design Change Note based on Hazop recommendations issued on 03.01.14. All major process P&IDs released. - Major pumps data received and foundation drawing released.
7
8
BPCL / Process
Low
N
N
Y
N
Short term
I
0.4
0.00
-Process package received on 14.04.13
15-Mar-14 Projects / Engg Process
19
Mar'14 & Apr'14
31-Mar-14 30-Apr-14
Projects / Process
Apr'13
Agreement signed by BPCL-KR issued to Licensor on 04.04.13 Delay in "issue for engineering - IFE" PDS / P&IDs for DHDT P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
Close
Process
Very High
N
N
Y
N
Short term
D
0.16
0.00
All PDS issued for Engg. All Process P&IDS issued. Utility P&IDs: 15 out of 15 nos issued for engineering.
Delay in "issue for engineering - IFE" PDS for DCU LAD : 29-Dec-12; Ant : 19-Mar-13
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
Process package from M/s Lummus received on 17-Aug-12. All Equipment PDS issued for engineering. Utility equipment issued for engineering.
Process
-
Mar'13
Process
Low
N
N
Y
N
Short term
I
0.4
0.00
Based on latest information from BOO HGU and SWII (FCC), Revised Design Basis issued.
Projects / Process
-
Mar'13
Process
Low
N
N
Y
N
Short term
D
0.16
0.00
Process P&IDs: All process P&ID issued. PDS: Heat Exch. - 52/52 issued for Engg. Pumps 49/50 issued for Engineering. Vessels 38/38 tags issued for Engg. Air cooler 6/6 issued for Engineering.
Process
Process
Low
N
N
N
N
Short term
I
0
0.00
- Common Interconnection P&ID for FCC, VGO and DHDT will be issued (covered under risk A09). Hence clubbed with Risk no. A09.
BPCL / Projects / POSD
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Close
Close
9
10
18
Risk Severity
4
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A
15
Target Date
Process
Delay in "issue for engineering - IFE" PDS / P&IDs for FCC LAD :29-Jan-13; Ant : 08-May-13 A
14
Action By
4
A
A
13
Action Plan
Delay in issue of Process deliverables for Open engineering for NHT / ISOM due to delay in receipt of Process Package from M/s UOP (Process pkg incl. resolution sheet received on mid Aug'13 against sch of 30-Apr-13) Schedule : 31-Jul-13 Anticipated : mid Nov'13
Delay in Process Package for TGTU (M/s CB & Close INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13
A
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Mar'15 Page 538+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Close
0.00
0
-
Apr'13
Apr'13
31-Dec-12
Jan'13
A
2
11
A
12
A
13
A
14
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
15
16
7
8
9
10
11
12
N
Y
N
Short term
D
0.16
0.00
All process P&IDs issued. Pumps PDS issued for engg,. All Vessels PDS issued for engg.
-Preparation of Offsite P&ID’s for tankages Close (LAD - 21.01.13) - Delay has been due to delay in receipt of Asbuilt drawings from BPCL-KR (except CEMP-II). All details received now. -Upgradation of Crude oil pipeline system (Inside refinery) to be taken up.
POSD
Very High
N
N
Y
N
Short term
I
0.4
0.00
- All 32 P&ID issued for engineering
Apr'13
In view of increase in sulphur load PDS & Close P&IDs for sulphur block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement. Revision in PDS after issue of “Issued for Close Engineering” after release of MR
Process
Low
N
N
Y
N
Short term
D
0.16
0.00
- All PDS and P&ID revised and issued.
Apr'13
Process/EN GG
Low
N
N
Y
N
Long term
I
0.2
0.00
Revision in PDS to be avoided once same is issued for engineering
Process
High
N
N
Y
N
Short term
I
0.4
0.00
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New facilities) has been issued for engineering. Balance BPCL / 1 no. targeted by 15.03.13 Projects / POSD
Low
Y
Y
Y
Y
Long term
D
0.2
0.00
Revision in PDS to be avoided once same is issued for engineering.
Y
Y
Y
Y
Long term
D
0.2
0.00
Revision in PDS to be avoided once same is issued for engineering
In case of revision in process parameters of an equipment the utility estimates furnished by engineering RED / PED/ against older Revision of PDS should not be used until same is got verified/ updated for current revision. PROCESS RED to update all such changes within stipulated time frame as per departmental guidelines and Process to incorporate in the revised PDS. Utility P&IDs: P&IDs (14 / 17 ) issued for engg (except for small bore piping: Pump Seal & Vent Drain). The Process same are targeted by Jun'13.
Close
16
Revision in PDS after issue of “Issued for Engineering” after Order
Close
A
Process/EN GG/Procure
17
Revision in PDS after issue of “Issued for Engineering” after Equipment manufacturing
Close
A
Process/EN Very Low GG/Procure Low
N
N
Y
N
Long term
I
0.2
0.00
18
Updation of estimated utilities on account of Close revision in process parameters (revision of PDS based on engg comments)
Process
A
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
19
ISBL Distribution P&IDs for VGO-HDT SCH: 30-Nov-12 ANT: Jun-13
Close
A
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
20
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 ANT: 31-May-13
Close
A
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
0.00
Distribution P&IDs issued for engineering.
A
21
A
18
6 N
15
A
17
Risk Severity
5
A
A
Target Date
Medium
-Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
14
Action By
4
Close
13
Action Plan
Process
Delay in "issue for engineering - IFE" PDS / P&IDs for VGO-HDT LAD : 29-Jan-13; Ant : 10-May-13
3
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 539+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
0
Process
19 Apr'13
-
Apr'13
15-Mar-13
Feb'13
Process
-
Apr'13
Process
-
Apr'13
As Required
Apr'13
Process
31-May-13
Apr'13
31-May-13
Apr'13
Utility distribution P&IDs for DCU
Close
Process
Low
N
N
N
N
Long term
I
0
Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 Updation of P&ID as per finalised condensate philosophy to be taken up.
Open
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
- Revised P&ID for Condensate System issued on 15.05.13.
BPCL
25-May-13
May'13
Open
Engg
Very High
N
N
N
N
Short term
D
0
0.00
- Inconsistency related to type of Isolation valve (Ball Vs. gate / globe/check) between instrumentation and process design basis identified during coordination meetings resolved by TSD.
Engg.
30-Apr-14
May'14
23
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed engineering activities.
Open Power Tech.
High
N
N
Y
N
Short term
D
0.16
0.00
- System configuration including 8 pumps, filters & centrifuge finalised and PDS for pumps issued. Filters & Projects 30-May-14 Centrifuge PDS issued for engineering on 22.05.14. (CPP group) - Readiness of the fuel forwarding system to be ensured w.r.t. GTG commg schedule (i.e. in Mar 15).
May'14
24
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new GTG).
22
0.00
Process
Jan'13
1
2
A
25
A
26
A
27
A
28
B
1
B
2
B
3
B
4
B
5
B
6
B
7
B
B
8
9
(Current risk Score Previous Risk score)
Target Date
17
18
4
5
6
7
8
9
10
11
12
Engg.
Medium
N
N
Y
N
Short term
I
0.4
0.00
- PDS for desalting pumps issued on 25.10.13. MR issued on 13.11.13.
Engg
Identifications of hook-ups on flare lines and finalisation of methodology BPCL Signing of ISBL P&IDs and with battery limiti.e. P&IDs availability of Shut down / Hot tapping. for Units, Utility packages & other packages.
Close Open
Projects Process / POSD
Medium Low
N N
N N
Y Y
N N
Short term Short term
I D
0.4 0.16
0.00 0.00
- Identification of hook ups for Flare line, FCC flare, PRU flare and NHT / ISOM completed during site visit by EIL Process. Signing of P&IDs completed for: - Hook sketches prepared and signed by Piping / POSD / BPCL. Marking at site to be taken up on -CDU/VDU Blocktoonbe24.06.14. priority. - DCU unit on 03.07.14 & CR LPG unit on 22.07.14. Finalisation methodology for taking up works targeted by end Dec 13. -- VGO unit onof12.07.14. - DHDT unit on 24.07.14 - FCCU unit on 23.07.14 - SRU block on 25.07.14. - Offsite P&IDs issued to BPCL. Signing completed
Projects / Constn. Process / POSD /
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Close
Process / POSD
High
N
N
Y
N
Short term
D
0.16
0.00
Updated P&IDs released.
Process / POSD /
Issue of Equipment layout for engineering for Open NHT/ISOM Ant - 21-Aug-13) Delay in this activity shall hamper the following: i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation
Engg.
Very High
N
N
Y
N
Short term
D
0.16
0.00
- Equipment layout issued for engineering on 23.08.13
Piping
21-Aug-13
JUL'13
Issue of Equipment layout for engineering for VGO-HDT LAD - 07-Nov-12 Ant- 26-Dec-12
Engg.
Very high
N
N
Y
N
Short term
D
0.16
0.00
Equipment layout issued for engineering
Piping
26-Dec-12
Jan'13
Engg.
High
N
N
Y
N
Short term
D
0.16
0.00
Equipment layout issued for engineering
Projects / Piping / BPCL
21-Dec-12
Jan'13
ENGG
High
N
N
Y
N
Short term
D
0.16
0.00
NIT issued on 24.06.13, bids due on 23.07.13
Projects / Process / HMTD
18-Jun-13
May'13
Procure/EN GG/CONS.
Medium
Y
N
Y
N
Long term
D
0.12
0.00
1) Involvement of technical/engineering team and client with vendor where non-standard products are required 2) Clarification of all doubts prior to beginning of work 3) Procedures for internal review and approval of design/deliverables to be followed
Projects
As Required
Apr'13
Close
16
Risk Severity
3
a) Cost/time overrun due to rework b) Non completion of critical project activities within time & delay in Project completion c) Poor performance of Sub-contractors and Vendors
15
Action By
Close
Delay in this activity shall hamper the following: Issue of Equipment layout for engineering for Close i) 3 D Modelling FCCU (targeted by ii) Civil/Structural & 27.12.2012) UG Piping Tender Delay in this activity shall hamper the following: preparation i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation NIT for Heater for FCCU Open LAD -01-Apr-13 ; Ant - 18-Jun-13
14
Action Plan
BPCL confirmation/clarification over datasheets/GAD’s for existing/new raw water intake pump obtained from M/s KBL (LAD for MR for pumps - 07.03.13)
Close
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 540+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
19 Nov'13
30-Dec-13 31-Jan-15
Dec'13 Jan'15
Mar'14 & Apr'14
New requirement of power recovery system (FCCU) shall have impact on project cost. 3 Nos PRTs envisaged (FCC-1 Nos ; VGO- 2 Nos)
Close
Project
High
Y
N
Y
N
Short term
I
0.6
0.00
-Discussions with prospective bidders held seeking details on implementation methodology. -Decision regarding System integration schemes taken during meeting dated 17th & 18th Dec 12. MR issued
Engg (Elec)
15-Jan-13
Jan'13
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; Ant: Mid Jun'13
Open
Engg.
High
N
N
Y
N
Short term
D
0.16
0.00
- Layout finalised with licensor. Final layout under study. - Model review for SRU completed on 30th May'13 (except TGTU, incinerator section & downstream of sulphur pit).
Piping
15-Jun-13
May'13
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant Close End May 13) Piping preliminary MTO has been released without covering DHDT, VGO FCC& offsite interconnection P&IDs, Flare system & offsite storage P&IDs. Prel. MTO covers 35% for large bore pipes.
Piping
Very High
N
N
Y
Y
Short term
D
0.2
0.00
Intermediate MTO released on 31.05.13.
Piping
31-May-13
May'13
Delay in thermal design for Heat exchangers & Close Air coolers for licensed and non licensed units LAD (DHDT): 02-Feb-13 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
HMTD
Very High
N
N
Y
N
Short term
D
0.16
0.00
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
Apr'13
2
B
10
B
11
C
12
B
13
B
14
B
B
B
15
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
16
Target Date
4
5
6
7
8
9
10
11
12
Engg.
High
N
N
N
N
Short term
D
0
0.00
- Layout for OWS, CRWS, CW & FW lines issued for Offsite.
Gen Civil
31-May-13
May'13
Completion of 30 % Model review VGO- LAD: 09-Mar-13 FCCU-LAD : 23-Apr-13
Open
Engg.
High
N
N
Y
N
Short term
D
0.16
0.00
VGO-HDT: 30 % modelling completed on 7th Jun'13 FCCU: 30 % modelling completed on 06.06.13. SRU (excluding TGTU) – completed on 30.05.13.
Piping
Prog. To Jun 13
May'13
NIT for Civil & Strl work for existing Refinery Area LAD: 31-Jan-13 ANT: 18-Jun-13
Open Project/C&P Very High
N
N
Y
N
Short term
D
0.16
0.00
- NIT issued for publishing on 12.06.13 with sale period from 17.06.2013 to 05.07.2013
Project / C&P 18-Jun-13
May'13
N
N
Y
N
Long term
D
0.08
0.00
Wide variation of BOQ and site executed quantities for item rate tenders to be controlled. Past data to be analysed and used for reference purposes.
Engg
Apr'13
Engg/procur Very High ement
17
18
Risk Severity
3
MR issue for MCC (Main combustion Chamber) Close packages.
B
15
Action By
Close
Close
14
Action Plan
Issue Overall UG piping layout drawing for the complex
a) Inaccurate assessment of quantum of work
13
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 541+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
As Required
19
Project
Medium
N
N
Y
N
Short term
D
0.16
0.00
MR issued on 02.05.13.
Engg
Apr'13
Timely finalisation of Package Interface Open CDSP-DCU awarded on 22-Aug-13; RR pkg-FCC awarded on 25-Jul-13. (Battery Limit conditions for each package to be frozen within three months of award to ensure time availability for engg, procurement and construction by all the concerned).
Engg.
High
N
N
Y
N
Short term
D
0.16
0.00
- Management level meetings with package contractors being organised to expedite the works. - Battery limit conditions for CDSP Pkg (awarded to M/s Essar on 22.08.13) submitted by vendor & approved under code 2 on 07.05.14. - Battery limit conditions for R&R Pkg (awarded to M/s Essar on 25.07.13) received from vendor and approved.
Projects / Engg. / Process
May'14
Unit and offsite interfaces (Elevation termination Close levels)
Engg.
Medium
N
N
Y
Y
Long term
D
0.1
0.00
- Clubbed with Risk ID A27
TSD
Projects
High
N
N
Y
N
Short term
D
0.16
0.00
- Data received from all vendors. All piling drawings for CPP area released. - Foundation drawings for & HRSG under progress and targeted by mid Mar'14.
ENGG/PLNG Mid Mar'14
Feb'14
N
N
Y
N
Short term
I
0.4
0.00
- NIT issued on 11.03.13, bids due on 16.04.13. Pre bid meeting targeted on 02.04.13. (Delivery : 18 M for Mechanical Completion including Pre-Commissioning Activities)
10-Mar-13
Feb'13
N
N
Y
N
Long term
D
0.08
0.00
- Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. - HAZOP review completed for GTG, HRSG & UB package. - 90% model review for HRSG completed on 04.02.15. -90% model review for UB package held from 18.11.14 to 20.11.14. - GBC ordered to M/s BHEL on 25.07.14. KOM held with M/s BHEL for Gas booster compressor on 12-13 Aug'14.
Engg
30-Apr-15
IV
LAD: 16-Feb-13 Ant: 15-Apr-13
-
Mar'14 & Apr'14
16
17
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule requirements. LAD - 28.02.13; Ant - upto Feb 14.
Open
NIT for Heater for DCU LAD -15-Feb-13;
Close PROCESS/ Very High ENGG
18
B
19
CPP: Integration of various packages & BOP Open Engg/Cont. Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas Booster compressor.
Low
20
Distributed Control System (DCS) Detailed engg., supply and erection (ordered on M/s Emerson Process on 04.11.13)
Open Engg/procur ement
B B
21 22
60 % Model review for to submit Package Vendor refuses DCU (LAD:03.07.13 Act:13.09.13) Instrumentation Drawings/ Documentation in Smart Plant Instrumentation Database as per Client Requirement
Close ENGG Very High Open Engg/procur Low ement
B
Medium
0.02
0.02
Projects / Process Process / HMTD C&P
N
Y
N
N
Long term
I
0.15
0.00
- Preparation of Inst. dwgs./ docs. by the DCS vendor, using Smart Plant Instrumentation (SPI) is already covered in DCS vendor’s scope in DCS
Projects
Continuous
Sep'14 & Oct'14
N
N Y
Y
N
Short Long term
D
0.16 0.14
0.00
Model taken reviewup completed on 13.09.13 - Being with respective package vendors for implementation.
ENGG/ Instn Projects
Continuous
Aug'13 Sep'14 & Oct'14
6
7
8
9
10
11
12
N
N
Y
N
Long term
I
0.2
13
14
Action Plan
Action By
15
16
17
Target Date
Risk Severity
18
19
23
Delay in Interface Engineering (including control Open Engg/procur system) due to non availability of Package ement Vendor Data Open
ENGG
Medium
N
N
Y
N
Short term
D
0.16
0.00
Model review completed on 04.10.13
ENGG
4-Oct-13
sep'13
B
20
60 % Model review for DHDT (LAD:07.08.13 Ant:04.10.13) - Integrated model for RGC, MUG compressor, Feed filter & Heater pkg awaited from vendor. - Vendor drawings for sheds awaited.
GC
Medium
N
N
Y
N
Long term
D
0.08
0.00
- All P&IDs released
G. Civil
25-Jul-13
JUL'13
24
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
B
Project
Medium
N
N
Y
N
Short term
I
0.4
0.00
- Ordered to M/s Powerica Ltd on 29.09.14 (Delivery duration 13 M+ 3 M site works).
BPCL
5-Oct-14
Sep'14 & Oct'14
25
Order of MR for DG set Dely: (12 M FOB + 3 M Site work) Sch: 05.11.13
Open
B
Receipt of Inputs from Process / Vendors for 60 Close % Model review for VGO-HDT required for procurement of piping material (LAD:14.08.13 Ant:25.10.13) - Integrated model for RGC, MUG compressor, Feed filter & Heater pkg awaited from vendor. - Vendor drawings for sheds awaited.
ENGG
Very High
N
N
Y
N
Short term
D
0.16
0.00
- Model review completed on 24.10.13. Process / Process to remove holds as per piping Hold up lists released till date by 25th Oct 13. Projects - Piping to release updated hold up lists based on release of holds by process on fortnightly basis to process / project / planning / TSD / Risk Coordinator. - Meeting between Process, Piping, Projects shall be organised within 3 days of issue of hold up lists. - Process to issue Revised P&IDs latest within 4 weeks of HAZOP recommendations.
25-Oct-13
sep'13
60 % Model review for FCCU (LAD:16.09.13 Ant:25.10.13) - Line size for 300 nos P&IDs under hold -Vendor data needed for coalescer, electric heater, pumps & filters - Review of model by Licensor (Stone & Webster) envisaged.
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
0.00
- Model review completed on 25.10.13.
ENGG
25-Oct-13
sep'13
60 % Model review for Open SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), Delay in release of Intermediate 2nd Open 164 (SRU),15 (SWS) & 60(TGTU) + MTO LAD:30.09.13; 155(Utilities Act:31.10.13) Holds: -CVs Size Hold as follows: 13 (ARU), 6 (SWS), -CDU/VDU: 125 (SRU). Pump nozzle for 6 nos. pumps under hold),Valve sizesFace for 256 lines under hold, are -All Control to Face Dimensions Control valve flange, bypass valve HOLD. All CVsmatching for TGTU are HOLD. and flanges (21 nos.) & PSV inlet outlet flanges and reducers (37 nos.) -DHDT: By-pass lines for CVs under hold (30nos), PSV's mating flanges and reducers (44 nos), Lines (103 nos.) not considered in MTO.
ENGG
Medium
N
N
Y
N
Short term
D
0.16
0.00
- Model review started on 28.10.13 and under progress. Targeted to complete by 31.10.13.
ENGG
31-Oct-13
sep'13
ENGG
Very High
N
N
Y
N
Short term
I
0.4
0.00
- Intermediate 2nd MTO released on 31.10.13, based on above MR under preparation.
Projects / ENGG
31-Oct-13
Oct'13
Generation of Surplus Piping material
Open
ENGG
Low
N
N
Y
N
Short term
D
0.16
0.00
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
Progressively
HAZOP for FCCU LAD - 23-Sep-13
Close
ENGG
High
N
N
Y
N
Short term
D
0.16
0.00
- HAZOP study completed on 29.11.13.
ENGG
B
B
0.06
(Current risk Score Previous Risk score)
5 Low
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
4
Schedule ( Y / N)
3
EIL Cost (Y / N)
Risk Owner
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Status (Open / Close)
Risk Id
Key Risk Description
1
Job No.: A307 Mar'15 Page 542+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
-0.06 Package vendor inputs being made available by expediting for updation of interface engineering documents. Projects / Engg.
Continuous
26
B
27
B
28
B
29
B
30
B
31
LD Milestone date - Dec'13
0.05
0.05
IV
Nov'13
B
32
B
33
B
34
C
1
C
2
C
3
C
4
C
5
C
6
C
7
C
8
C
9
C
10
14
(Current risk Score Previous Risk score)
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Mar'15 Page 543+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
4
5
6
7
8
9
10
11
12
Completion of 90 % engineering by Mar-14. Open Average progress achieved in last 3 months 3.0 %
ENGG
Low
N
N
Y
N
Short term
D
0.16
0.00
- As of 15 Aug'14 Engineering progress is 91.4 %.
Release of final Piping MTO Sch: Jul'14
Open
ENGG
High
N
N
Y
N
Short term
D
0.16
0.00
- Final MTO released on 11.09.14.
Finalisation of GTG fuel forwarding scheme for naphtha to day tank when Naphtha tank being under maintenance.
Open
POSD
Medium
N
N
Y
N
Short term
I
0.4
0.00
- Revised P&IDs issued for connecting tank-101 & 102. New pump process datasheet released for piping naphtha from YT-332 to CPP day tank.
Delay in award of PRT -FCCU(Hot gas expander) LAD: 19.04.13 Ant: 30.12.13 Multiple Bids extensions leading to delay in ordering. 02 Bids recd on 12.08.13 (Dresser Rand ,Elliot Ebara) Org. BDD: 27.06.13 1st extension: 16.07.13 2nd Extension: 01.08.13 3rd extension: 09.08.13 Duration: 16 M FOB
Close
Project
Medium
Y
Y
Y
N
Short term
I
0.9
0.00
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 Duration: 18 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
Very High
Y
Y
Y
N
Short term
D
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
Close
Project
Very High
Y
N
N
N
Short term
Award of Heater for DHDT LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Very High
N
N
Y
N
NIT for Composite Works for DCU LAD -06.06.13 ; Ant - 25.10.13
Open
ENGG
Very High
N
N
Y
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
ENGG
Very High
N
N
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
ENGG
Very High
Award of PRT for DHDT & VGO-HDT unit (Pumps centrifugal multistage) Sch: 23.04.13 Ant: 15.03.14 (IV-P-301A/B)
Open
ENGG
Medium
Action By
Target Date
17
18
ENGG
Risk Severity
19 Aug'14
Sep'14
Sep'14 & Oct'14
Process / Engg.
Sep'14
Sep'14 & Oct'14
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
30-Dec-13
Dec'13
0.00
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
30-Aug-13
JUL'13
0.36
0.00
- BPCL confirmation sought for minimum nos (10.97 MW or 80% of 10.97) for qualifying criteria. Accordingly C&P BQC changed and approved by BPCL. Draft NIT by 25.05.13. Publishing targeted by end May 13.
30-May-13
May'13
I
0.2
0.00
- As per latest cost status report the impact of cost variation has been neutralised by savings.
Projects
Continuous
Nov'13
Short term
D
0.16
0.00
Awarded to M/s Technip on 04.09.13 (Duration 18 M)
Projects / HMTD
15-Sep-13
Aug'13
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
25-Oct-13
sep'13
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
31-Oct-13
sep'13
N
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
N
N
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
Y
Y
Y
N
Short term
D
0.36
0.00
-Ordered on M/s Shin Nippon & M/s Flowserve on 30.01.14 (except Tag IV-P-301 A/B due to poor past EIL performance of PRT supplied under CEMP-II by M/s GENP); - Separate MR released for item tag IV-P-301 A/B. BPCL informed that order expected to be placed as per previous recommendation, ordering expected by mid Mar'14. - As a parallel action MR was issued however RFQ kept under hold in view of BPCL information regarding ordering by mid Mar 14.
15-Mar-14
Mar'14 & Apr'14
C
11
C
12
C
13
C
14
C
15
C
16
(Current risk Score Previous Risk score) 15
16
Action By
Target Date
4
5
6
7
8
9
10
11
12
Very High
N
N
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Projects / HMTD
15-Oct-13
sep'13
NIT for Composite Works for Existing refinery area LAD -22.07.13 ; Ant - 31.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Projects / HMTD
31-Oct-13
sep'13
Award of : Main fractionator for FCCU LAD: 25-Mar-12 Ant: 20-Jul-13
Open Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
0.00
-Ordered to M/s Fabtech on 15.07.13
Engg/Proj
20-Jul-13
JUL'13
Issue NIT for Tankage-II LAD: 21-Jan-13 ANT: 31-May-13
Close Project/C&P Very High
N
N
Y
N
Short term
I
0.4
0.00
NIT issued on 29.05.13, bids due on 18.06.13.
Project / C&P 31-May-13
May'13
Award for RO-DM LAD:30-Jan-13 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
- Awarded to M/s Driplex on 12.06.13. duration is 22 M.
Engg / C&P
29-Jun-13
May'13
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13
Close
Project
High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months.
BPCL
28-Feb-13
Feb'13
NIT for Reactor regenerator package for FCCU LAD : 01-Jan-13 Ant: 21-Feb-13 Changes in scope of supply led to revision in BQC / tender.
Close
Project / Licensor
Very High
Y
Y
Y
N
Short term
I
0.9
0.00
BQC finalised on 15.01.13. Tender under compilation. Draft NIT being issued to BPCL for approval. NIT targeted by 21-Feb-13.
Projects / BPCL
21-Feb-13
Feb'13
Project
Low
N
N
N
N
Short term
I
0
0.00
Ordered to M/s Paulose George (15 M).
BPCL
C
18
C
19
C
20
C
21
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 Ant: 30-Mar-13
C
22
Award of Crude and Vacuum heaters (LAD 29.12.12) Ant : 07.03.13
C
23
C
24
Award for Raw water quarries LAD :03-May-13 ANT: 15-Apr-13
Close
17
Ordering of Reactor for VGO-HDT LAD: 29-Dec-12 ACT: 08-Apr-13
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Ordered on M/s L&T on 08.04.13.
Proj/Engg
Award of contract for Piling-II LAD: 31-Dec-12
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s L&T on 09.04.13 with duration of 12 M.
BPCL
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Petron on 09.04.13 with 18 M duration.
BPCL
Close
Engg.
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Technip on 07.03.13 (Duration 23 M)
Storage of sulphur and related issues with Close Granulator to be finalised between BPCL / EIL.
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.00
- Scheme finalised.
Projects / BPCL
NIT for ETP package with WAO (Wet air oxidation) LAD: 15-Jan-13 Ant: 16-Apr-13
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Tender released on 26.03.13; BQC finalised on 08.04.13. NIT targeted by 16-Apr-13
Engg
18
Risk Severity
ENGG
17
14
Action Plan
NIT for Composite Works for Offsite DHDS area Open LAD -22.07.13 ; Ant - 15.10.13
C
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2
Risk Owner
Status (Open / Close)
Risk Id
Key Risk Description
1
Job No.: A307 Mar'15 Page 544+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
19
Apr'13
-
Mar'13
-
Mar'13
Ant: 15-Apr-13
Close
-
Projects / 7-Mar-13 C&P / BPCL
Mar'13
Feb'13
Apr'13
Apr'13
C
C
Previous Risk Score
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12} 13
14
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 545+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
17
Target Date
18
Risk Severity
2
3
4
5
6
7
8
9
10
11
12
Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13
Close
Project
High
N
N
Y
N
Short term
D
0.16
0.00
Award recommendation issued on 11.02.13. Awarded to M/s Howe baker on 07.03.13
Proj/Engg
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s L&T (duration 20 M)
BPCL
Strl
High
N
N
Y
N
Short term
D
0.16
0.00
KB tech completed development of flare area & handed over the area to M/s L&T.for piling.
Projects
N
N
Y
N
Short term
D
0.16
0.00
- Evaluation of LLIs to be ensured with-in 1 month from receipt of bids by Engg. & PBO recommendation Engg / C&P / with-in 1 week by C&P. Projects - Pre tender / Pre enquiry meetings to be conducted with bidders to avoid extensions in bid due date due to lack of clarity in scope / other requirements. - Immediate after issue of Enquiry a firm action plan to be developed by the Project coordinator clearly indicating targets for Issue of TQ / CQ , Post bid meetings, TBA/CBA, PBO reco., Price bid opening and award recommendation dates. - Uploading of bids in eDMS by C&P within 1 - 2 days (Max.) of bid submission by bidders. - Restriction of multiple TQs / CQs. - Rigorous follow up by C&P / Engg. / Projects for receipt of TQ / CQ replies from bidders within cut off dates.
TBA - 1 month of bids receipt PBO - 1 week of TBA
Dec'13
7-Mar-13
19 Feb'13
25
26
Award of contract for Building incl substations LAD: 07-Feb-13 Ant: 15-Apr-13
Filling of existing part fire water pond required for area preparation.
Close
Open
Apr'13
30-Mar-14
Mar'14 & Apr'14
Sch - 28.08.13; Area handed over to M/s L&T C
27
Delay in ordering of Long Lead Items. Technical / Commercial evaluation of long lead items (compressors & packages) taking more than 2 months.
C
C
C
C
Close Engg / C&P Very High
28
29
30
31
Award of Waste heat Boiler package (Waste Close Heat Boilers along with respective steam drums(un engineered ), Incinerator Combustion Chambers (engineered), Incinerator vent stacks). LAD: 27.04.13 Ant: 30.12.13 Bids extension: 1st extension - from 28.05.13 to 20.06.13. 2nd Extension- from 20.06.13 to 02.07.13. 3rd extension - from 02.07.13 to 08.07.13. Duration: Supply + Erection - 18 M
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Tecnicas Reunidas S.A. on 31.12.13
BPCL
30-Dec-13
Dec'13
Delay in award of CDSP package Open Schedule: 02.03.13 Anticipated : 30.08.13 Completion of works Sch: 01.05.15 ( M); RFQ Duration : ( M) Anticipated: 23.11.15 (27 M) Bidders quoted 27 M against schedule of 26 M.
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.00
Awarded to M/s Essar Project on 22.08.13 (Duration: 27 M)
C&P / Engg / 30-Aug-13 Projects
JUL'13
Ordering of GTG Pkg (LAD:10-Mar-13; Ant 20.07.13) Bid received on 28.03.13. Multiple extension (4 times) in bid due date on request of M/s Siemens. Duration (Supply) - 15 M FOB /16 M FOT as per RFQ; Sch : 20 M
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.00
- Awarded to M/s BHEL on 25.07.13.
Projects / Engg / C&P / BPCL
JUL'13
Open
20-Jul-13
C
C
C
C
C
5
6
7
8
9
10
11
12
Projects / Engg
Very High
Y
N
Y
N
Short term
I
0.6
Ordering of Reactor regenerator package for FCCU LAD : 10-Apr-13 Act: 10-Jul-13 Changes in scope of supply led to revision in BQC / tender due to which NIT was delayed. Bidders sought extension in dates.
Close
Project / Licensor
Very High
Y
Y
Y
N
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) Duration: 21 M+2 M No bidder could meet the BQC criteria in view of which the tender has been re-floated.
Open
Project
Very High
N
N
Y
N
Open
Very High
N
N
Y
35
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 Duration: 20 M
Close Project/C&P Very High
N
N
36
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 Duration: 22 M+2 M
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
Low
N
Failure of contractors
Open
Const.
Low
N
32
33
34
13
14
(Current risk Score Previous Risk score)
4
Delay in Ordering of HRSG Close (Sch Order - 22-May-13; Ant - 20-Dec-13) Initial Change in configuration by BPCL. Multiple extensions (twice) in bid due date due non availability of exhaust data for GTG. Post Enquiry changes in type of Fuel (LSVR) by BPCL. No PTR available for LSVR Fuel Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2
Risk Owner
Status (Open / Close)
Risk Id
Key Risk Description
1
Job No.: A307 Mar'15 Page 546+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
0.00
- Awarded to M/s Thermax on 20.12.13
Action By
17 Projects / BPCL
Target Date
18 20-Dec-13
Risk Severity
19 Nov'13
It is planned that common facility (incl. common piperack, utility lines etc) shall be taken up as per project schedule requirement. This shall be taken up during KOM with selected bidder.
Process / Engg / constn
Short term
I
0.9
0.00
- 2 Bids (Essar & L&T) received on 25.04.13. - TBA issued on 21.05.13. - PBO recomn. issued on 30.05.13 and BPCL approval received on 03.06.13 - Price bids opened on 04.06.13. - Award recommendation issued on 25.06.13. - Awarded to M/s Essar on 10.07.13.
Projects / BPCL
Short term
I
0.4
0.00
N
Short term
I
0.4
0.00
- 3 no. bids received on extended date of 02.02.13. Projects / 31-Jul-13 - Meeting with bidders held from 19.02.13 to 26.02.13. PBO recomn. issued on 06.05.13. Price bids opened C&P / BPCL on 09.05.13. - Award recomm issued on 12.06.13. Execution duration as per RFQ - 20 M; Sch - 24-26 M
JUL'13
Y
N
Short term
D
0.16
0.00
Awarded to M/s Paramount (with 21 M for mechanical completion + 2 M for commissioning). Execution duration as per RFQ was - 22 + 2 M; Sch - 28 M
Aug'13
N
Y
N
Long term
I
0.2
0.00
Meeting held with EIL & BPCL. Approach paper prepared and signed jointly by EIL / BPCL for limiting single BPCL / C&P agency getting work orders against more than 2 tenders. (In cases of big agencies with financial capability, one agency can get maximum works order against 3 tenders)
-
sep'13
N
Y
N
Long term
D
0.08
0.00
Limit the number of works being awarded to one Agency so that alternatives can be worked out fast. BPCL/EIL To evolve a System to be implemented to ensure that the maximum number of jobs awarded to single agency is only 2 if NOT to be preferably made ONE only.
-
sep'13
BPCL
Jun'13
31-Oct-13
Oct'13
Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
C&P/Engg/Pr oj
Anticipated Completion: 29-Jul-15
C
37
C
38
C
39
C
40
C&P BPCL / Projects
Ordering of Ejector Pkg (LAD:12-Jan-13; Ant: 15-Jul-13)
Open
Project
Medium
Y
Y
Y
N
Short term
I
0.90
0.00
Awarded to M/s GEA on 10.07.13 with delivery period of 13 M.
BPCL
15-Jul-13
Jun'13
Award of Heater package for DCU Open (LAD:24-May-13; Ant: 15-Nov-13 Earlier 04 Bids recd on 21.05.13. (Petron, Thermax, Heurtey, Technip). Due to Technical and related commercial issues enquiry re-floated. Duration 20 M
Project
Very High
N
N
Y
N
Short term
I
0.40
0.00
Awarded to M/s Heurtey, (Duration - 20 M)
BPCL
15-Nov-13
Oct'13
C
41
C
42
C
43
C
C
45
46
C
47
C
14
(Current risk Score Previous Risk score)
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
3
Risk Owner
2
Action Plan
15
16
Action By
17
Target Date
18
Risk Severity
4
5
6
7
8
9
10
11
12
Award of Civil & Strl work for DHDS offsite area Open (LAD: 30-Mar-13; Ant: 20.07.13) Duration: 18 M
Project
High
N
N
Y
N
Short term
I
0.40
0.00
Awarded to M/s KSS on 25.07.13. (Duration 18 M)
BPCL
Award of Civil & Strl work for refinery area. (LAD:25-Apr-13; Ant: 10.10.13) Duration: 16 M
Close
Project
High
N
N
Y
N
Short term
I
0.40
0.00
Awarded to Mcnally Bharat on 26.09.13. Duration- 16 Months
Project/C&P
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) Duration : 16 M
Open
Project
Medium
N
N
Y
N
Short term
D
0.16
0.00
NIT issued on 01.08.13, bids due on 30.08.13
Gen Civil/Project
25-Jul-13
JUL'13
Award of work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
0.00
Awarded to M/s McNally Bharat. Duration - 16 M
Gen Civil/Project
30-Oct-13
Oct'13
Ordering of Main Air blower & wet gas compressor for FCCU LAD: 04-Mar-13 Ant: 30-Sep-13 (Total execution duration is 25-27 M : 19 M FOT for delivery of WGC & MAB at site + 6 to 8 M Site installation & pre-comm; Time Available from order to MC OF FCCU - 24 months)
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
MAB awarded to M/s Elliot Ebara on 04.09.13. WGC awarded to M/s BHEL
C&P/Engg/Pr 30-Sep-13 oj
Aug'13
Award of Civil & Strl contract for CDU/ VDU & DCU LAD: 15-Dec-12 Ant: 07-Mar-13
Close
Project
Close
N
N
Y
N
Long term
I
0.2
0.00
Awarded to M/s L&T on 07.03.13. Award recomm sent to BPCL on 01.02.13. Award to be targeted by 07.03.13.
C&P
Feb'13
Ordering of wet gas compressor for DCU LAD: 02-Feb-13 Ant: 30-Jun-13
Close
Project
Medium
N
N
Y
N
Short term
I
0.4
0.00
Ordered to M/s Eliot Ebara on 28.06.13.
Ordering of OFF GAS COMPRESSOR - VGO LAD: 08-Jun-13 Ant: 30-Oct-13 RFQ duration: 17 M FOB
Open
Project
High
N
N
Y
N
Short term
D
0.16
0.00
Ordered on M/s Dresser Rand, Dely - 17 M FOT Dispatch
EIL/BPCL
30-Oct-13
Oct'13
Award of Sulphur Forming LAD: 03.04.13 Ant: 30.01.14 Earlier enquiry re-floated due to changes in MR requirements by BPCL(MR was revised as Evaluation methodology was to be based on NPV and in view of 2 different types of technologies viz., sulphur pelletiser and sulphur granule); refloated again as financial criteria was not met by all the bidders.
Open
Project
Very High
N
Y
Y
N
Short term
D
0.28
0.00
- Ordered to M/s Sandvik.
BPCL
30-Jan-14
Jan'14
20-Jul-13
19 JUL'13
sep'13
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15
44
C
C
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Mar'15 Page 547+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
0.00
0
7-Mar-13
Jun'13
48
49
C
C
C
C
C
C
C
50
51
52
53
54
55
56
14
(Current risk Score Previous Risk score)
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Mar'15 Page 548+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
17
Target Date
18
Risk Severity
4
5
6
7
8
9
10
11
12
Award of contract for Civil & structural for FCCU Close area (refloated) LAD:15-Mar-13 Ant: 30-Sep-13 Compl: 15 M – Dec'14; Sch: Nov’14 As decided during Management meeting dated 19.06.13, based on past Performance of recommended bidder tender refloated.
Project
Very High
N
Y
Y
N
Short term
D
0.28
0.00
Awarded to M/s Sriram on 25.09.13
BPCL
Award of contract for Civil & structural for DHDT Close & VGO area (refloated) LAD:15-Mar-13 Ant: 30-Sep-13 Compl: 16 M – Jan’15; Sch: Nov’14 As decided during Management meeting dated 19.06.13, based on past Performance of recommended bidder tender refloated.
Project
Very High
N
Y
Y
N
Short term
D
0.28
0.00
Awarded to M/s McNally bharat on 11.09.13 (with 16 M execution period)
BPCL
Award of contract for Civil & structural for CPP area LAD:28-Jun-13 Ant: end Aug-13 Duration: 16 M
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Essar Projects on 19.08.13
BPCL
28-Aug-13
JUL'13
Award of MCC package LAD:10.06.13 Ant: 14.08.13 Duration: 12 M despatch and 6 M for site work (ODC)
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Thermax
BPCL
14-Aug-13
JUL'13
Award of contract for RWTP (Refloat case) LAD: 14-Jan-13 Ant: 19-Jul-13 (Execution Duration - 18+2 M)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Triveni
BPCL
19-Jul-13
JUL'13
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 15.06.14 (Incinerator burner) (Execution Duration - 14 M)
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.00
Ordered to M/s Callidus and M/s UOP India on 20.06.14.
BPCL
Award of Air blower/compressor for SRU LAD: 29-Mar-13 Ant: 25-Jul-13 (Execution Duration - 17 M FOB/ 18 M FOT)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Ordered on M/s Howden Process Compressors
Projects / C&P
30-Sep-13
19 Aug'13
Aug'13
Jun'14
19-Jul-13
JUL'13
2
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
Previous Risk Score 14
Action Plan
15
16
Action By
Target Date
17
18
Risk Severity
3
4
5
6
7
8
9
10
11
12
Close
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.00
Awarded to M/s Airoil on 25.09.13 with duration of 18 M.
Projects/ 28-Sep-13 Process/ Engg / C&P/
Aug'13
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 Duration: 12 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
- Awarded on M/s Ray Engineering on 23.01.14.
Engg / C&P
Jan'14
Award for:RGC compressor for VGO-HDT (LAD: 30-Mar-13; Ant: end Jun 13) Dely: 18 M
Open Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s BHEL
Proj/Engg
29-Jun-13
Jun'13
Award of MUG compressor for VGO-HDT (LAD: 08-Apr-13; Ant: 30.11.13) Dely: 16 M FOB
Close Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
0.00
Ordered to M/s Neumen & Essar on 14.11.13
BPCL
30-Nov-13
Nov'13
Award of Contract for Tankage-III (Crude tank: Close Project/Eng Very High 02 Nos & 1 surge relief tank and crude drain g tank) Outage of existing crude tank from crude to naphtha can be taken up after commissioning of new crude tanks. Shutdown of existing tanks17 & 18 depend on commissioning of new crude tanks-25/26 under tankage-III. Sch: 01.10.13 Ant: 15-Dec-13
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s IOT Anwesha on 04.12.13. (duration: 20 M)
BPCL
15-Dec-13
Nov'13
28-Jun-13
Jun'13
Delay in Award of contract for Demountable flare (LAD: 08-Apr-13; Ant: 28-Sep-13) Change in type of Flare. Initially as per DFR normal flare was envisaged.
13
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 549+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
19
Post enquiry significant changes (received on 15.03.13) in Flare Load/Process Data Sheet due to enormous increase in BOO flare load and non acceptance of mitigation measures by FCCU Licenser. C
57
Change in flare load data due to change in flare height upto 150 M. Completion of works Sch. : 31.01.15 Ant. : 28.02.15
C
58
C
59
C
60
C
61
Close Project/Eng Very High g
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s BHEL
Proj/Engg
62
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: Jun 13)
N
C
Close Project/Eng Very High g
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Dresser Rand
Proj/Engg
63
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep-13) Duration : 18 M FOB
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) Sch: 30.04.13 Ant: 30-Sep-13 Duration:22 M
Close
N
N
Y
N
Short term
D
0.16
0.00
Awarded to M/s B&R
BPCL
C
C
64
BPCL
High
Aug'13
30-Sep-13
Aug'13
C
C
C
C
C
2
65
66
Previous Risk Score
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12} 13
14
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 550+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
Target Date
17
18
Risk Severity
3
4
5
6
7
8
9
10
11
12
Award of Tankage-IV (Total 15 Nos Tanks) LAD: Jan14 • Outage for Tank YT-340 depends on readiness of at least one new DCU feed tank which will require 14 M durations. Alternative scheme required to be finalised for outage. • Outage of Tankage YT-18 depends on readiness of new crude tanks (Tankage-III; YT25/26). Alternative scheme required to be finalised for outage.
Open
BPCL / Projects
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Offshore on 17.04.14.
EIL / BPCL
25-Apr-14
Mar'14 & Apr'14
19
Award of Composite Works for CDU/VDU (06 Bids - L&T, Petron, Offshore, Mcnally Bharat, Albana, IOTL recd on 04.09.13) LAD -30.08.13 ; Ant - 31.10.13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
.Awarded to M/s Offshore (Duration- 20 months)
BPCL
31-Oct-13
Oct'13
Award for contract for development of flare area Close LAD: 01-Nov-13 Ant: end Dec'13
Project
Very High
Y
N
Y
N
Short term
D
0.24
0.00
Contract for development of flare area awarded to M/s KB Tech..
Engg / C&P
30-Dec-13
Nov'13
Award of Composite Works for VGO-HDT, DHDT, CPP and Offsites (DHDS) LAD 31.12.13 ; Ant - 30.05.14
Open
ENGG
Very High
N
N
Y
N
Short term
I
0.4
0.00
Composite Works for VGO-HDT & DHDT -DHDT- Awarded to M/s Albana on 19.05.14 (16M+2M). -VGO-HDT- Awarded to M/s Albana on 19.05.14 (16M+2M). Composite Works for Offsite Part B (DHDS): Awarded to M/s Offshore on 19.05.14 (16M+2M). Composite Works for CPP: Awarded to M/s Zillion Infra. on 19.05.14 (16M+2M).
Projects / Engg.
30-May-14
May'14
Award of Heater package for FCCU (LAD:08-Jul-13; Ant: 15-Dec-13 Earlier 05 Bids recd on 23.07.13. (Thermax, Technicas, Petron, B&R, JNK). Duration 20 M
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Petron on 04.12.13. Duration is 16 M
BPCL
15-Dec-13
Nov'13
Award of Gas Booster Compressor for CPP (Dly: 13 M FOB / 14 M FOT)) (LAD:29.12.13; Ant: 30.07.14)
Open
Project
Medium
Y
N
Y
N
Short term
I
0.6
0.00
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
30-Jul-14
Jul'14
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 Ant: 10.10.14
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.00
-Ordered on M/s Asco Filtri Srl ON 17.10.14.
BPCL
Oct'14
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards Piping intermediate MTO-II released on 30.10.13.
Open
Project
Low
N
N
Y
N
Short term
D
0.16
0.00
- All pipes, fittings & flanges ordered.
C&P
14-Aug-14
Aug'14
Ordering of Critical Valves Sch: 11.07.14 Ant: 31.01.15 Dely: 06/07 M FOT /FOB
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.00
-Revised MR (MR-3415): Ordered to M/s Oswal, M/s Shalimar, M/s AV valves and M/s L&T. - New MR-3515 (41 Nos) ordered on 05.02.15
30-Apr-15
Feb'15
Award of contract for Mechanical works-CPP area LAD: 28.02.14 Ant: 25.05.14
Open
Project
Medium
N
N
Y
N
Short term
D
0.16
0.00
- Awarded to M/s Zillion on 19.05.14.
25-May-14
May'14
Duration - 20 M
67
68
69
C
70
C
71
C
72
C
73
C
74
Sep'14 & Oct'14
Engg EIL/BPCL
C
76
C
77
C
78
C
79
7
8
9
10
11
12
13
14
15
16
N
N
Y
N
Short term
D
0.16
0.15
0.15
0.00
Award of Composite Works (Structural Works & Mechanical) for NHT/ISOM-Refloated Sch: 08.05.14 Ant: 25.03.15
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
-0.38 -Awarded to M/s OIL on 18.03.15 (Duration 12 M).
EIL/BPCL
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) Sch:27.06.14 Ant: 05.08.14
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
- Ordered to M/s Sulzer.
Award of Electrical & Instrumentation Works for Units & Offsite Sch: 30.06.14 Ant: 10.11.14 Electrical/Instr. Works: Part A: CDU/VDU, DCU, FCCU, DHDT, VGO-HDT & IREP Offsite: Part B: SRU & DHDS/Refinery Offsite :
Open
Project
Low
N
N
Y
N
Long term
I
0.2
0.00
Delay in award of piping material with G2E specification in CPP area.
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
Completion of Reactor regenerator package for FCCU-M/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 93.9% Act: 70.8 % Construction Progress: Sch: 83.6% Front: 85.8% Act: 30.8 %
Open
Project
Very High
Y
Y
Y
N
I
0.9
0.86
0.86
Delivery of GTG Pkg at site (LAD:29-Sep-14; Ant - 24-Nov-14) Awarded to M/s BHEL Duration (Supply) - 16 M
Close
Project
Very High
Y
Y
N
N
Long term
I
0.25
Completion of UB package LAD : 31.03.15 CCD : 23.03.15 ECD:10.08.15 Awarded to M/s ISGEC on 25.07.13 Construction Progress: Sch:100 % Front: 100 % Act: 54.66 % Manpower : Required 450, Deployed 333 incl 39 welders
Open
Project
Very High
N
N
Y
N
Long term
I
0.2
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14
Open
Project
Low
N
N
Y
N
Long term
I
0.20
Delivery of wet gas compressor for DCU at Site Open (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 31.03.15)
Project
Low
N
N
N
N
Long term
I
0
Urgency (Long Term / Short term)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
6
Very High
Schedule ( Y / N)
5
Project
EIL Cost (Y / N)
(Current risk Score Previous Risk score)
75
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
4
Open
Risk Owner
3
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 Ant: 15.04.15
2
C
Status (Open / Close)
Risk Id
Action Plan
Key Risk Description
1
Job No.: A307 Mar'15 Page 551+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
-Total 35484/ 35618 nos (99%) isometrics issued for units . Balance ISO's targeted progressively by mid Apr'15. -All GADs issued except SRU block 172 nos balance). Same shall be targeted by mid Apr'15.
Action By
Target Date
Risk Severity
18
19
17 Engg.
15-Apr-15
III
BPCL
5-Aug-14
Jul'14
- Electrical Works: Part A: M/s Technimont Part B: M/s Consilium - Instrumentation Works: Part A: M/s Technimont . Part B: M/s Consilium
EIL/BPCL
Nov'14
Nov'14
0.00
All items have been ordered, deliveries to be expedited in order to timely availability of piping material for completion of steam network in CPP area.
EIL/BPCL
Apr'15
0.00
Management level meeting held on 20.03.15 at site. - 1600MT Demag CC-8800 made ready for erection after load test. - Out of 3842 MT strl steel qty, only 3273 MT fabricated, 3160 MT received at site & 2537 MT erected. - Regenerator bottom section erected on 21.03.15 - Erection of TSS bottom section planned on 06.04.15 Balance deliveries comprising of nozzles, lifting trunions, insert plates for equipment fabrication of Regenerator (top section), Reactor, TSS to be expedited. - Steam drum erected on 13.03.2015 & economiser panel erection commenced on 20.03.15 - 1st lot of fabricated ESP materials received at port.
EIL/BPCL
Apr'15
0.00
Clubbed with Risk ID E19
Project
0.00
- 90% model review for UB package completed. Project / - Erection of steam drum-I & II completed. (Sch: 16.09.14: got delayed as 550MT crane could not be Constn. mobilized from M/s.TWC). - Completion of structural erection work to be expedited. Coil erection completed for UB-12 & in progress for UB-13. Deaerator tank erection completed.
0.00
-All Indigenous component received at site within CDD. - All Foreign Source Components dispatched.
Project/Inspe Sep'14 ction
0.00
Compressor dispatched on 06.03.15
Project/Inspe 31-Mar-15 ction
II
D
D
D
1
2
3
D
4
D
5
Short term
0.19
0.19
24-Nov-14
Continuous
Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT. 0.00
I Nov'13
III
Sep'14 & Oct'14
D
D
2
4
5
6
7
8
9
10
11
12
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
Completion of all three site Fabricated Columns for FCCU :Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 100 % Act: 74.0 % - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach road upto fabrication yard, which affected shifting of sections.
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.67
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
8
Completion of MCC pkg for SRU LAD: 23.06.15 CCD:18.02.15 (including Site work) ECD: 30.09.15 site work yet to start Ordered to M/s Thermax on 19.08.13 (18 M incl erection)
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
9
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 30.07.16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 89.0 %; Act: 65.4 % Construction Progress: Sch: 77.58% Front: 100% Act: 39.08 %
6
7
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
3
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 28.02.15)
14
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 552+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
Target Date
17
18
0.00
All parts dispatched.
Project/Inspe 28-Feb-15 ction
0.38
0.29
- Main fractionator column: Hydrotest targeted by end Apr’15. Stripper Column: Hydrotest targeted by mid Jun’15. Rectifier Column: Hydrotest targeted by mid Aug’15
Project / Constn.
As stated
0.38
0.20
0.18
- M/s Thermax seeking extension for duration due to delayed availability of burner data from M/s Aecometric. Letter forwarded on 11.06.14 to BPCL for recommending extension for supply portion to M/s Thermax upto 30.11.14. Further M/s Thermax seeking extension for duration upto 31.03.15 for supply through letter dated 08.10.14. - Refractory lining work in Combustion chamber can be started only after erection of MCC pkg. - Erection of MCC package could not started as MCC foundation yet to be handed over. Delivery of refractory material also deffered due to delay in erection of MCC.
EIL/BPCL
15-May-15
0.86
0.86
0.00
Following commitments have been made by M/s Essar. Constr. -Shift Work: Works in two shifts implemented. - Coke Drum Supporting Structure concreting completed. - EPIL to deliver Coker fractionator by 08.04.15 - Crane (2000 MT): All consignment reached at port. Mobilization & assembly of crane by end of Mar'15 and erection of equipments targeted to commence from Apr’15 to May’15. -Clear water tank fabrication- Civil tank pad work completed, rolling in progress. BPCL/EIL - Resource augmentation for Civil & Strl works being expedited. At present 590 nos have been deployed against requirement of 836 nos.
Risk Severity
19 Feb'15
I
D
II
D
Erection by May'15
Strl Steel: Out of total 3210 MT, 2926 MT procured, 1929 MT fabricated & 1716 MT received.
D
10
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M Ordered to M/s BHEL on 28.06.13
D
11
Delivery of RGC compressor for DHDT(LAD : 05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
D
12
Delay in hydrotesting of Vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: 19.03.15 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column.
Open Project/Eng g
Low
N
N
Y
N
Long term
I
0.2
0.00
- All items received at site.
Project/Inspe end Dec'14 ction
Open Project/Eng g
Low
N
N
Y
N
Long term
I
0.2
0.00
- Received at site and erected.
Project/Inspe 27-Dec-14 ction
Medium
N
N
Y
N
Short term
I
0.4
Open
BPCL / Projects / Const.
0.38
-0.38 - Vacuum Column : Hydrotesting completed.
Constn. / VTV / Projects
19-Mar-15
I Dec'14
Dec'14
D
D
D
D
7
8
9
10
11
12
13
14
15
16
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. - 2 no DHDT Reactor reached at site & erected. - First dumb barge (newly fabricated) launched in the river after IRS certification. - ISGEC Josen (3 nos) Column: expected to receive at Kochi port from upto mid May'15.
EIL/BPCL
May'15
Close Monitoring of ODC equipment (including site fabricated/assembled) up to receipt at site
Open
Projects
High
N
N
Y
N
Long term
D
0.08
0.06
0.06
0.00
Out of total 57 nos. of ODCs; 25 nos received at site. & 29 nos under dispatch. Balance under close monitoring.
Shipping
Continous
Low
N
N
Y
N
Long term
I
0.2
0.00
- Transporter philosophy frozen and hindrance enroute has been covered under Risk ID K3.
Shipping
As Required
0.00
Equipment by Ganson - M/s Ganson agreed to supply balance item of CDU/VDU. Items for SRU and DCU refloated under MR6560 (DCU): All items relocated to M/s Patel Airtemp, M/s Phils Heavy, M/s Acoustics India ; M/s Beekay Engg ; M/s Fab-Tech, M/s Nuberg Engg.
BPCL
0.00
- Erection of Derrick structure up to 40 mtr completed. - Flare tips likely to be reached at site by end Apr'15. 1 no water seal drum and Molecular seal received at site. All flare riser expected to receive at site from workshop progressively by 30.04.15. -Water Seal drum (3 nos) dispatched from Adani port.
Projects/Con As Required str.
0.00
- BPCL confirmation on the additional flare stack addition received. - Agreed with Air Oil / BPCL for completion of 4th riser within CDD. - Revised PDS & P&IDs released on 15.11.13. - Order placement (change order) issued to M/s Airoil on 14.11.13.
BPCL / EIL
0.00
- Steam turbine: MRT completed for turbine. Main Compressor: MRT targeted progressively by May’15.
Project/Inspe Continuous ction
Urgency (Long Term / Short term)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
6
Very High
Schedule ( Y / N)
5
T&CC
EIL Cost (Y / N)
4
Open
2
Action By
Target Date
Risk Severity
18
19
17
13
14
Delay in delivery at site due to non-availability of transporter / hindrances enroute. D
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
3
Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 DHDT reactor reached at site
Risk Owner
(Current risk Score Previous Risk score)
D
Status (Open / Close)
Risk Id D
Action Plan
Key Risk Description
1
Job No.: A307 Mar'15 Page 553+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Close Procure/Co nstr
II IV
Nov'13
15
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions.
Open Contract / Inspection
Medium
N
N
Y
N
Short term
I
0.4
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Apr-15 Ant: 24-Apr-15 Construction progress Sch: 99 % Act: 18.1 %
Open Project
Medium
Y
Y
Y
N
Long term
I
0.45
Addition of 4th Riser in Demountable Flare and identification of additional Equipment to be procured due to the same. (BPCL informed additional of 1 no. riser during meeting dated 16th Oct 13.) - Flare (with 3 risers) awarded to M/s Airoil on 25-Sep-13. Completion of Flare work: Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Open Project / Process
Very High
Y
Y
Y
N
Short term
I
0.9
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 31.10.15
Open
Very High
N
N
Y
N
Short term
I
0.4
Jun'14
16
17
18
19
Projects
0.23
0.38
0.23
0.38
As Required
III
Oct'13
II
D
21
22
D
23
D
24
D
25
D
26
D
27
D
D
28
29
7
8
9
10
11
12
13
14
15
16
18
19
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- MRT of compressor and Steam turbine completed.
Project/Inspe Continuous ction
IV
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 EDD: 09.04.15
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
-Hydrotesting for first reactor completed and second reactor hydrotesting planned in end Mar’15.
Project/Inspe Continuous ction
III
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 CDD: 07.10.14 Overall Progress: Sch: 98 % Act: 95.0 %
Open
Projects
High
N
N
Y
N
Long term
I
0.2
0.00
- Reactor received at Kochi port and unloaded to barge on 26.12.14.
Project/Inspe Continuous ction
Dec'14
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- 90% model review for HRSG completed. - Balance engineering to be expedited by M/s Thermax. - HRSG #3, 4 & 5: Foundation works completed and handed over to M/s Thermax. Erection in progress for HRSG-4 & HRSG-5 - All column alignment completed for HRSG-3.
Project/Inspe Continuous ction
III
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) LAD ;30.03.15 CDD: 30.04.15
Open
Projects
Low
Y
Y
Y
N
Long term
I
0.45
0.14
0.14
0.00
- Generator subordered. - Pedestal fabrication is at final-machining. - Exhaust case assembly, including diffuser and thermal insulation has been completed
Project/Inspe Continuous ction
III
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 CDD: 30.03.15 (Excluding site work)
Open
Projects
Medium
N
Y
Y
N
Long term
I
0.35
0.18
0.18
0.00
-Silos with structure & Conveyors sub ordered by M/s Sandvik. Project/Inspe Continuous - Bottom Cones for Silo C ,D, E & F dispatched to site. ction -Delivery of Semi rolled sections of Silos shall commence from Jan'15 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited. - Foundations for pelletiser shed to be made ready.
III
Delivery of steel plates by M/s Essar to other vendors. CDD: Progressively by 15.01.14.
Open
Projects
Very Low
N
N
Y
N
Short term
I
0.4
0.00
Strl. Steel for R&RMajor portion of steel plates have been delivered by M/s Essar.
Project/Inspe Continuous ction
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 CDD: 10.03.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Synchronous Motor ordered to M/s Toshiba Mitsubishi dispatched. MRT completed for compressor.
EIL/ BPCL
Continuous
IV
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) LAD : 26.02.15 CDD: 13.04.15 ECD: 28.05.15 Delay by vendor with respect to CDD due to financial constraint.
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Main motor ordered. KOM for Motor held on 06-07.05.14 & expected to receive by 13.04.15 (FOB: Germany). MRT completed.
EIL/ BPCL
Progressively
IV
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
0.10
0.10
0.00
- Following bidders showing slow manufacturing progress: EIL/ BPCL - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:184. . Meeting held on 09.02.15. Balance order expected to dispatch from Jan'15 to May'15. - M/s Universal: Meeting held on 25.11.14, M/s UHE agreed to deliver balance items progressively upto May’15. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360, 423 & 444. - M/s HDO (Columns, Heat Exchangers & Vessels): FOA No.: 199, 302, 310, 315, 318, 320, 327, 369, 389 & 395.
15-Apr-15
III
Urgency (Long Term / Short term)
6
Low
Schedule ( Y / N)
5
Projects
EIL Cost (Y / N)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
4
Open
Risk Owner
(Current risk Score Previous Risk score)
D
3
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 CDD: 03.04.15 Ant: 03.04.15
2
20
Status (Open / Close)
Risk Id D
Action Plan
Key Risk Description
1
Job No.: A307 Mar'15 Page 554+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
17
Jun'14
D
30
D
31
D
32
D
33
D
34
D
D
E
E
E
35
36
1
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
Action By
15
16
17
Target Date
3
4
5
6
7
8
9
10
11
12
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
0.00
- M/s Filtrex asking for deviations on commercial terms. Meeting held on 08.07.14 to resolve the issues with EIL/ BPCL M/s Filtrex. Vendor provided all details.
Aug'14
Aug'14
Non acceptance of work order by M/s Flowserve for DHDT Centrifugal pumps Ordered on 30.01.14 to M/s Flowserve (MR5403) (FOA No 550 & 551) CDD: 01.03.15
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
0.00
- Order has been accepted by M/s Flowserve and amendment issued by BPCL on 11.07.14.
EIL/ BPCL
Jul'14
Jul'14
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) CDD: 18.10.14
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
0.10
0.10
0.00
- All part received at Kochi.
EIL/ BPCL
Feb'15
Feb'15
Availability of Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-3): Oct'14 EDD: Mid Feb'15 Sch: (Final MTO): Dec'14-Feb'15 EDD: Mar'15-Jun'15
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.38
-0.18 - As of now around 90% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Apr'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL. Additional requirement of 20000 m2 area in FACT being taken for piping storage.
EIL/ BPCL
15-Apr-15
III
Delivery Gas Booster Compressor for CPP (Dly: Open 13 M FOB
Project
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
Ordered to M/s BHEL on 25.07.14. KOM held on 12-13.08.14. - Compressor Journal Bearings were ordered. Impeller manufacturing is in process
EIL
15-Apr-15
IV
Delay in delivery of equipments by: M/s TEMA :CDD: 06.01.14 to 15.01.15; EDD: end Mar’15 M/s Nuberg: CDD: 03.07.14 to 03.11.14; EDD: Feb'14 to May'15 M/s GR Engg: CDD: 28.01.14 to 31.07.14; EDD: Mar'15 to 30.06.15 M/s Fabtech Projects: CDD: Jul’14 to Jan’15; EDD: Feb'14 to Aug’15
Open
Project
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
Vendor being pushed for deliveries. Vendor shop visit/meeting being arranged.
Inspection / Project
15-Apr-15
III
Delay in submission & finalization of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. CDD: 19.05.15
Open
Project
Low
N
N
Y
N
Short term
I
0.4
0.00
-All burner drawings finaised across the table.
HMTD/Projec ts
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsite) Awarded on 25.09.12 (Sch - 100 %, Act 91.7%) RCC Piles:4822 / 5307 Nos. Balance for offsite (SS VGO & compound area at FACT). Presently 5 total rigs are operating
Open
Constn.
Medium
N
N
Y
N
Short term
I
0.4
0.00
Piling completed for CDU/VDU DCU & Offsite (except boundary wall) Balance piling (479 nos) for GTG, UB & stack area being done by M/s DBM. Job given on 07.10.13 with CCD by 1st week of Dec'13.
Constn.
Very High
Y
N
Y
Y
Short term
D
0.28
0.00
- During the project review meeting dated 23.01.15, following points discussed and requested with BPCL to BPCL provide assistance: - Additional storage space for owner supply items (20,000 Sq. M). - Additional storage space for piping spools.
15-Apr-15
Medium
N
N
Y
N
Short term
I
0.4
0.00
-Major rock blasting work completed.
sep'14
2
3
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
Constn.
Open Constn.
0.27
0.27
Constn.
18
Risk Severity
2
Open
14
Action Plan
Non acceptance of PO for DHDT & VGO feed filter by M/s Filtrex (MR-4370) Ordered on 21.12.13 to M/s Filtrex ( Dely: 13 M FOB)
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
13
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 555+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
19
Feb'15
Mid Oct'13
sep'13
II Aug'14
E
E
4
5
6
Availability of Soil investigation Report for new Open BPCL / Crude tankages area. Projects / Delay in availability of soil data will affect Const. preparation for piling tender and layouts drawings. Further civil / structural tender will also affected.
7
8
9
10
11
12
13
14
15
16
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
'- Tender splitter into two parts (Structural/ Mechanical works & Civil work). Awarded to M/s OIL. BPCL/EIL Civil work being done by misc. Civil agency (M/s Furnace Fabrica). Rigorous follow up with contractor to be made after award of contract. Electrical Work: PBO recommendation issued to BPCL on 20.03.15. Instrumentation Work: PBO recommendation issued on 16.03.15.
15-Apr-15
N
N
Y
N
Long term
I
0.2
0.00
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
BPCL / Projects
15-Jul-13
Constn
As Required
Urgency (Long Term / Short term)
6 Y
High
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
5 Very High
Schedule ( Y / N)
4
Action Plan
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
2
Construction of NHT/ISOM (Revamp) Open Constn. / - Target Schedule : 30.09.15; Only 12 M Projects available for construction works (excl. Dismantling works) against schedule of 22 M. - Process package was delayed by 2 M due to delay in P&IDs review meeting and delay in award of licensor. - Change in the scope based on health check report has an impact on Project cost and schedule. Physical Progress: Target Sch: 92.5% Catch Up Sch: 75.2 % Act: 55.3%
(Current risk Score Previous Risk score)
E
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Mar'15 Page 556+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
17
Target Date
Risk Severity
18
19
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 100% Front: 100 % Act:76.6 % CCD: 20.12.14 Ant: 15.07.15
Open
Const
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- MCR, CPP control room : Release for panels by Oct'15 & total completion by Dec'15. - Other building works : SRR Completion progressively between Mar'15 to May'15. SRR 4 handed over, SS 2 & SRR 6 to be handed over by 31.03.15 - L&T also agreed to augment required manpower to 1000 from current deployment of 850 to meet the target completion date.
Backlog 18.2% as of 15-Mar-15 in Construction activities viz., Civil works and Mechanical works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration 46 M; Time lapsed - 34 M Catch Up sch: Const Sch Front Act 66.7 85.9 66.4 48.5 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site.
Open
Const
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
- Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deens has been Constn lined up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. - Contractors are facing problem in retaining the labour at site. Approx 12000 labours are available at site, though induction programme has been carried out for more than 18000 labours . requirement of manpower at site is approx 19000 nos. - RCC work & structural fabrication/erection work to be expedited to give complete front to mechanical BPCL/EIL contractor progressively upto Apr-May'15. - Lighting of areas to facilitate night shift working. - Provision made for snacks/dinner for labour to facilitate working in extended/night shift - Provision of multiple entries inside plant areas to ease manpower/machinery mobilisation to be explored. - Additional mechanical contracts being awarded to supplement existing mechanical contractors.
As Required
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Jun'15)
Open
Constn.
Very High
N
N
N
N
Long term
I
0
0.00
0.00
0.00
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Jun'15.
Jun'15
I JUL'13
II
E
E
7
8
BPCL
I IV
E
9
E
10
E
11
E
E
E
E
12
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Risk Owner
15
16
E
16
E
17
E
18
Risk Severity
3
4
5
6
7
8
9
10
11
12
18
19
Constn.
High
N
N
Y
N
Short term
I
0.4
0.00
L&T has completed all piles in Demountable flare area, Air compressor & DG shed area.
Constr.
Immediate
Jul'14
Payment to contractors
Close
Constn.
Low
N
N
Y
N
Long term
D
0.08
0.00
Ensure that 90% payment of the RA bills certified by EIL are released to the contractors within 7 days of receipt by client.
BPCL
within 7 days of certified RA bills
sep'13
Low
N
N
Y
N
Long term
D
0.08
0.00
Ensure that realistic dates of availability of inputs(drawings, front and materials) are considered in project/ Project / construction schedule rather than compressing construction schedules alone to meet the completion target. Planning
As Required
sep'13
0.00
All 5 nos tank area cleared and released. Area handed over to M/s B&R for Tankage-II works on 30.04.2014 BPCL
end Apr'14
May'14
30-Apr-15
III
Dismantling of LO CAT SRU and area handing Open over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. Will affect release of front for tankages.
BPCL
Medium
N
N
Y
N
Short term
I
0.4
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating) Overall Progress: Contr. Sch: 99.7 % Act: 83.7% Construction Progress: Sch: 100 % Front: 100 % Act: 77.6 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Open
Project
Medium
Y
N
Y
N
Long term
I
0.3
0.15
0.29
-0.14 - M/s Triveni to augment manpower by mobilizing additional manpower (Manpower required is 300 nos while available manpower is 235 Nos). - Substation building: completion being targeted by Apr'15. - Chemical house works completion being targeted by end Apr'15.
Slow construction progress of SRU Block due to delayed area handing over - As per present trend 15 months (starting from end Jun’14) are available with respect to schedule of 25 M (As per past experience minimum requirement for SRU is 30 M).
Open Proj. / Constn.
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
17
Target Date
Open
Constr.
- All area handed over in SRU. Constn. - Pond Retaining wall construction is in progress. - Piling for SRU : All piling drawing released. To meet Euro-IV compliance, focussed efforts being made for ARU/SWS. Piling for ARU/SWS is completed. Balance piling work completion targeted by mid Apr'15. - Civil works completion targeted by mid May’15 and handing over of front to mechanical contractor targeted from end Mar'15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
30-Apr-15
EIL/BPCL
14
15
Action By
2
Project / Engg. / planning
14
Action Plan
Completion of piling work by M/s L&T (Piling-II): CDD- 08.05.14. (Total 12003 Nos piles). (Contr.Sch- 100%, Front-100%, Act-100%) Only 10 nos. hydraulic & 4 nos. conventional rigs are currently operational at site. Total 10124 nos completed out of 12003
Unrealistic project time leading to under quality Close
13
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 557+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
Open Proj. / Constn.
Medium
N
N
Y
N
Short term
I
0.4
0.00
Graded and handed over to tankage-II
Constr.
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Ant - Dec 2013
Close Proj.
Very High
N
N
Y
N
Short term
I
0.4
0.00
Clubbed with Risk ID E33
BPCL
Very High
N
N
N
N
Short term
I
0
0.00
M/s BPCL Vide mail dated 21.08.2013 has handed over the area for SG-III.
BPCL
Medium
N
N
Y
N
Short term
I
0.4
0.00
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
Land acquisition for Crude tank (2 nos.) . (LAD - Close Proj. Jul 13; Ant - 30-Aug-13) Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
BPCL
I Jul'14
Dec'13
Nov'13
Aug'13
As Required
sep'13
E
19
E
20
E
21
E
22
E
23
E
E
E
E
24
Theft of material Warehouse Completion of UGfrom piping work due delay in receipt of piping material and monsoon.
Lighting during construction
(Current risk Score Previous Risk score)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
15
16
5
6
7
8
9
10
11
12
Low
N
N
N
N
Long term
I
0
0.00
- All 3 GTGs received at site.
Close
Const.
Low
N
N
Y
N
Long term
I
0.2
0.00
-Included in mechanical contractor scope. Project / - Based on prel. Erection scheme, 1600 T heavy lift crane with 600 T trailing crane envisaged for erection of Constn. both VGO and DHDT reactors. - Timely mobilization of cranes and preparation of Load Test. - Finalization of erection scheme.
Close Open
EIL Const.
Low Medium
Y
N
Y
N
Long Short term
DI
0.12 0.6
Low
N
N
N
Y
Short term
D
EIL
Low
N
N
Y
N
Long term
Delay in construction due to monsoon. As work Open progress between Jun to Sep is expected to be hindered due to monsoon, all out effort to be made to release tender as per sch. Generally to manage delays in initial stages of project, constr. Duration are reduced while floating tenders. This needs to be avoided.
14
27
Target Date
17 Projects
18
Risk Severity
19
30-Apr-15
Feb'15
-
Nov'13
0.00 - Security arrangements in Warehouse in place by BPCL. -0.27 - All balance material deliveries being expedited, subsequently all UG piping work completion targeted by end May'15.
Constn. EIL/BPCL
May'15
0.04
0.00
Area lighting being done.
Constn.
As Required
II May'13
I
0.2
0.00
-During 2013-2014 monsoon following actions were taken - Temporary drains were constructed for draining accumulated rain water. - Pumping arrangements for draining water accumulated in pits were made.
Constn.
As Required
sep'13
0.00
LPG flare - As per EIL study LPG flare is adequate. Report issued to BPCL and clarification received. BPCL / EIL Acid flare - HC flare & Sour flare system P&IDs issued for engineering on 15.06.13. DHDS sour flare replacement: Sour Flare system P&ID (DHDS Area) issued for comments on 17.05.13, this additional requirement of existing structure and replacement of sour stack by higher size (16") being checked for adequacy. New flare components to be procured for revised stack size.
15-Nov-13
Oct'13
IV
0.30
0.57
-
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
Open
Project
Low
Y
N
N
N
Short term
I
0.2
Construction of Subway on the PWD road including re routing of existing road / existing facilities and necessary liasoning with government department. Construction of culvert got affected
Open
Project
Very Low
N
N
Y
N
Short term
I
0.4
0.04
0.04
0.00
Management level meeting held with B&R on 25.02.15 at site. Culvert top slab completed, road work in progress. Restoring of diverted KWA water line completed. Road opening by mid Apr'15
Constrn.
31-Mar-15
Slow construction progress in Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 CCD: 08.10.14; ECD: Jun'15 Progress figures Sch: 100% Front: 99.7% Act.: 54.78% Insufficient mobilisation of manpower: Required: 635 nos Deployed: 216 nos
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
-Management level meeting held with M/s KSSIIPL at site on 25.03.15. - M/s AA Erectors being mobilized by KSSPPL for Structural work. - M/s JD Works to be mobilized shortly by KSSPPL for UG piping works. - Payment released for 150 MT crane by KSSPPL. One 80MT crane also shall be mobilized shortly. (Currently one 100MT, one 75MT & one 70MT available). - Rock blasting being expedited for drain on West side of piperack area 104, CW line at East of VGO. - BG already arranges for 400 MT cement, apart from current stock of 100MT. - KSSPPL shall be expediting around 700 MT of strl steel required for completing the currently progressing areas of piperack on priority. Entire fabrication completion targeted by 30.04.15. - Bridge erection at area 117 shall be taken up. Bridge at area 113 nearing completion. -Strl steel painting & repair works shall be expedited with new gang. - Manpower for restarting manhole works shall be additionally deployed. - CW road crossing of 84" pipes shall be expedited. - Area wise handing over of piperack to mechanical agency to be expedited.
EIL/BPCL
30-Apr-15
25
26
Action By
4
Open Constn.
13
Action Plan
Const. / Projects
Delivery of bought out items by BHEL for GTG Open package (LAD supply:29.09.14; Ant - Jul'15) Awarded to M/s BHEL on 25.07.13 with CDD for delivery as 24.11.14. HEAVY LIFT Cranes for INTALLATION OF REACTORS Finalisation of Erection scheme and capacity the crane, inclusion in scope and timely mobilisation at site
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Mar'15 Page 558+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Mar'13
II
5
6
7
8
9
10
11
12
13
14
15
16
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management review meeting held with M/s Essar on 20.02.15 at site - Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - boiler piperack foundations completed. - GBC fdn completed.
EIL/BPCL
30-Apr-15
Slow progress of Civil & Strl Works for SRU block (Awarded to M/s Mcnally Bharat on 04.11.13) LAD: 12.01.15 CCD: 03.03.15 Ant: Oct'15 SCH. FRONT. ACT. 100% 100 % 57.86%
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
EIL/BPCL
Continuous
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 ECD: 30.10.15 Contr. Sch: 83.9% Front: 68.73% Act: 47.5 %
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Management level meeting held at site on 24.02.15. - As on date the manpower is 470 Nos against the requirement of 750 Nos. - ARU/SWS : TS-1 & TS-2 being expedited TS Completion committed by MBE -TS-II : 30.03.2015 -TS-III: 31.03.2015 -TS-I : 31.06.2015 -TS-IV: 10.07.2015 -TS-V : 15.07.2015 -TS-VI: 15.04.2015 -MPR : 31.05.2015 -SILO: 20.03.2015 - Management level Meeting held with M/s OIL on 25.03.15 and following action plan has been agreed
EIL/BPCL
Continuous
Completion of Coke handling work (Awarded to M/s Thyssen on 04.11.13) LAD: 18.04.15 CCD: 03.07.15 EDD: Dec'15 Construction: Sch:73.6 %; Front:100.0%; Act:23.4% Overall Progress: Sch: 84.7 % Act: 59.2%
Open
Completion of DCU Heater works (Awarded to M/s Heurtey on 04.11.13 (20 M) LAD: May 15 CCD: 03.07.15 Ant: Oct'15 Overall Progress: Sch: 97.1 % Act: 83.7 % Construction work: Sch- 92.84% Front:100% Act:57.33%
Open Project
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Completion Sch: 30.01.15 (CDD:11.06.15) Awarded to M/s Driplex on 12.06.13. (Duration: 20 M+2 M incl pre commng)
Open
Urgency (Long Term / Short term)
4 Project
Schedule ( Y / N)
3 Open
EIL Cost (Y / N)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2 Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 100%; Front: 100%; Act: 80.91% CCD:18.12.14; ECD: May'15
Risk Owner
(Current risk Score Previous Risk score)
28
Status (Open / Close)
Risk Id E
Action Plan
Key Risk Description
1
Job No.: A307 Mar'15 Page 559+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
17
Target Date
Risk Severity
18
19
II
E
E
29
30
II
- M/s OIL has augmented manpower to 1122nos. - Structural fabrication completed targeted for end Apr'14 - Alloy steel piping fabrication to be expedited. - Fire proofing of Crude Column completed. - Agency for column dehumidification mobilised - Order placed for fabrication of rain protection shed - 257 out of 318 equipments erected.
II
E
E
E
31
32
33
Project
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.29
0.15
0.14
Medium
Y
N
Y
N
Long term
I
0.3
0.15
0.15
0.00
Long term
I
Very High
N
N
Y
N
-Piling work to be completed by 15.04.15 Constr. -TT-3, TT-4, TT-5, Circular stacker cum reclaimer work in progress. - For CSR pit, due to collapse of excavation, revised scheme of excavation is being followed, in consultation with Geotech experts of EIL and Dr. Moza, who visited site and envisaged the problem on 12/01/15. - Pilling rate to enhance considering the upcoming dry period - Structural erection need to be expedite, supply of matching sections need to expedite.
Continuous
Constrcution As Required
II III
-Heater A: Hot Work 6/6 box completed, Tube support fixing completed. Radiant coil erection completed. Pedestal grouting (56/60) in progress. -Heater B:Hot Work 6/6 box completed, Tube support fixing 32/48 nos completed. -Refractory Dry-out for 3/6 nos of convection module completed at shop. Fabrication for Stack in progress at shop. APH- str erection is in progress. Glass APH & Fan erection in progress. Crane-450 MT mobilised at site.
0.2
0.00
- Total area handed over on 05.05.14.
Project
As stated
Jun'14
5
6
7
8
9
10
11
12
13
14
15
16
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Mobilization of additional 120 nos manpower by Mar-15(Presently 145 nos manpower available) - Completion of raft for TWT/SBR/ACT by 30th Apr-15 - Control room slab casting in sub-station by 31.03.2015 - 2nd slab in chemical house by 25th Mar-2015 - Completion of equalisation tank targeted by Jun'15. - Procurement of BQ plate for Spent caustic tanks to be expedited.
EIL/BPCL
As stated
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 94.47 %; Front:95.39% Act: 45.77 %
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Management level meeting held on 25.03.15 at site. Total tanks: (New tanks 13 nos, work in progress for EIL/BPCL 12 nos. Balance for 1 nos is YT-33 which shall be start after completion of YT-32; Modification tanks: Out of total 16 nos, work in progress for 5 nos, 3 nos handed over to BPCL.) - B&R to augment resources to complete all balance work within agreed target.
As stated
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
Medium
N
N
Y
N
Short term
I
0.4
0.20
Urgency (Long Term / Short term)
4 Project
Schedule ( Y / N)
3 Open
EIL Cost (Y / N)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2 Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 94.6 % Act: 55.7 % Construction Progress: Sch: 92.5% Front: 100 % Act: 31.5 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Risk Owner
(Current risk Score Previous Risk score)
34
Status (Open / Close)
Risk Id E
Action Plan
Key Risk Description
1
Job No.: A307 Mar'15 Page 560+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
17
Target Date
Risk Severity
18
19
I
E
35
Awarded to M/s B&R on 25-Sep-13 II
E
36
E
37
E
38
E
39
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 Duration: 20 M Sch: 86.82 % Front: 100.0 % Act: 57.17 %
Slow progress of FCCU Heater works (Awarded Open Project to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 100% Act: 67.7 % Construction progress: Sch: 94.09% Front: 89.7% Act:39.74%
0.32
0.20
0.00
- Plate erection to be expedited for YT-26/28. - Tank pad completion works to be expedited in YT-25.
Constr.
As stated
0.00
-Management level meeting held on 25.03.15 - Structural steel: Out of total 217 MT, 217 MT received & 158MT fabricated & 60MT erected. - Erection of radiant section completed. - Coil tubes: Pipes & fittings (part) delivered. Coil fabrication commenced. - Delivery of soot blowers and FD fans to be preponed to suit completion of heater by 03.04.15. - Order placed for anchors & refractory blanket & expected at site progressively from 31.03.15
Project
As Required
II III
0.00
Clubbed with Risk ID D7
BPCL
As Required
Dec'13
Projects
As Required
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
Close Project
Very High
N
N
Y
N
Long term
I
0.2
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 CCD: 30.06.15; EDD: 30.09.15 (As per Vendor) Overall Progress: Sch: 82 % Act: 35 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Vent Stacks: Common Stacks template already fabricated and dispatched to site. Bottom intermediate and top sections and transition cones are being manufactured as scheduled
Slow progress of RO-DM works (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 (As per vendor) Overall Progress: Sch: 99 % Act: 72% Construction Progress: Sch: 100 %; Front: 100%; Act:46.41%
Open Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Sub-station-Completion of RCC super structure completion by 15.06.2015 EIL/BPCL - DM tanks (2 nos) : Tank -A : 120/160nos piling completed, expected pile cap by 28.03.2015. - Delivery of fabricated structural steel to be expedited to reach at site by 31.03.2015. Strl steel erection will start by 1st week of Apr'15. - M/s DWEL being expedited to delivery of balance bought out items.
II
E
40
As Required
I
E
E
E
E
41
42
43
6
7
8
9
10
11
12
13
14
15
16
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Urgency (Long Term / Short term)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
5 Very High
Schedule ( Y / N)
Action Plan
EIL Cost (Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
3
(Current risk Score Previous Risk score)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 561+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Management level meeting held with M/s Shriram on 19.03.15 at site. - Mobilisation of resources is being expedited. At present only 160 nos, manpower mobilised against requirement of 350 nos. - M/s Shriram to complete balance Civil work by 15.04.15. - SEPC to expedite structural erection for Tech str A,D,BPR-2 - 5575m3 offloaded to M/s Tuaman (3374m3 completed) - 2432m3 offloaded to M/s PGC (692m3 completed) - 2025MT structural work offloaded to REL - 1684 MT structural work offloaded to ZIPL - 310 MT Offloaded to TEL
Action By
17
Target Date
Risk Severity
18
19
Slow Construction progress for Civil WorksFCCU Contr. Sch: 100 %; Front: 100% Act: 78.42 % (M/s SEPC) CCD: 24.12.14 ECD: Oct'15
Open Project
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15 Constr. Progress: Sch: 100 % Front: 100 % Act: 80.56 %
Open Project
Very High
Y
N
N
N
Long term
I
0.1
0.10
0.10
0.00
-Modification of coils to be completed by end Mar'15.
Constr.
As Required
I III
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 100% Act: 71.7% Construction Progress: Sch: 99% Front: 97.4% Act.: 33.53%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Procurement completed for structural steel - Radiant panel erection completed for IV-H-101 & IV-H-201. APH Structure & Stack erection in progress - Refractory for radiant section to be expedited - Radiant coil tubes in transit and expected to arrive by 31.03.15
Projects
As Required
III
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 Sch: 100 %; Front :99.55 % Act: 86.67 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Current manpower is 436 nos. against requirement of 600 nos. MBEL agreed to mobilise 200 nos additional manpower for structural works - 6 cranes mobilised in order to carry out structural erection in both VGO & DHDT simultaneously. - All structural erection to be completed by 31.03.15
Constrn.
As Required
Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
PEB1: Project Material storage commenced. PEB 2 All works targeted to complete by 20.04.2015 PEB 3: All works targeted to complete by 31.03.2015 Buildings to be expedited for storage of material / equipment being received at site.
Constrn.
As Required
Completion of Cooling Tower -I & II (Awarded to M/s Paharpur on 01.02.13) LAD: 31.01.15 CCD: 20.10.14 ECD: Mar'15
Open Project
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
-Major backlog is due to construction (37%). Management level meeting held on 07.01.15 at site and PCTL EIL / BPCL to expedite to complete all works by Apr'15.
EIL/BPCL
44
II
E
E
45
46
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 84.25%
As Required
II III
E
E
47
48
6
7
8
9
10
11
12
13
14
15
16
N
N
Y
N
Long term
I
0.2
0.10
0.10
0.00
- Manpower - Additional manpower to be deployed for civil works. (Required: 150 nos, Available: 87 nos) EIL / BPCL - Delivery of Bought out item to be expedited. - Mechanical contractor to be finalised. - RCC work for CWPH & CWTP to be expedited. - Early delivery of Pipes and immediate commencement of Piping fabrication work.
As Required
Urgency (Long Term / Short term)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
5 Medium
Schedule ( Y / N)
Action Plan
EIL Cost (Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
3
Open Project
(Current risk Score Previous Risk score)
2 Completion of Cooling Tower -III (Awarded to M/s Paharpur on 11.09.15) LAD: 30.06.15 CCD: 10.01.15 ECD: Aug'15
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 562+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
17
Target Date
Risk Severity
18
19 III
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 54.04%
Slow construction progress in Offsite-DHDS area. Work stopped by M/s KSS in DHDS area for Civil & Strl work CDD: 24.01.15 ECD:. Dec'15
Open Constructio Very High n
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
-Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. Civil/Strl contractor. EIL/BPCL -Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deen has been lined up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works.
30-Apr-15
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 54.68 %; Front: 20.95%; Act.:14.61%
Open Constructio Very High n
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 25.03.15 at site. - M/s Petron have started with night shift work. - PECL have erected the gantry crane & same made operational. - 10 nos semi automatic welding machines shall be operational by Mar'15 - Auto blasting installed to be made operational by Mar'15 - Gratings & consumables are being ordered. Handrails, wrapping coating mtrls & GI pipes ordering to be expedited. Strl steel partially ordered. Structural steel & support fabrication to be expedited.
EIL/BPCL
30-Apr-15
Slow progress of work & poor manpower mobilisation by M/s B&R for Composite WorksDCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15 Construction Progress: Sch: 59 % Front: 33.5% Act.: 17.8% AG piping fabrication: Only 92041 ID / 406975 ID fabrication completed. AG piping erection: Only 66896 IM / 526435 IM piping erection completed.
Open Constructio n
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
Management review meeting held on 25.03.15.
EIL/BPCL
30-Apr-15
Slow construction progress for Civil & Strl work for Refinery area: Generation of front for mechanical works affected (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:100%; Front: 98.3%; Act: 41.4% CCD: 25.01.15 ECD: Oct'15
Open Constructio n
EIL/BPCL
30-Apr-15
Slow progress by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. Awarded on 25.03.14. CCD: 24.09.15. Sch: 64.67% Front : 32.28% Actual : 15.91%
Open Constructio Very High n
I
E
49
II
E
50
High
-Insulation/painting agency to be finalised. - Hanger scaffolding to be installed at site.
II
E
51
High
Y
N
Y
N
Short term
I
0.6
0.48
0.48
0.00
Management level meeting held at Kochi site on 20.01.15 - RCC sub structure work shall be completed by end Mar '15. - 30MT /day shall be fabricated from 01.01.15 onwards.
N
N
Y
N
Short term
I
0.4
0.38
0.19
0.19
Piping fabrication & erection work in progress in pipe rack 101-103, 108, 111-114. Fabrication in progress for Constr. piperack area 115. CS IBR & SS fabrication also commenced. AG piping fabrication: Scope: 285505 ID; Front: 101111 ID; Completed 47154 ID AG piping erection: Scope: 1214330 IM; Front: 373941 IM; Completed 217195 IM - Release of adequate front for erection to be expedited.
II
E
52
30-Apr-15
II
E
E
E
E
E
E
E
E
53
54
55
56
57
5
7
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.38
0.19
0.19
- Management level meeting held 25.03.15 at site. - B&R to take up compressor erection immediately. - Due to delay in completion of civil work, release of front to composite contractor got affected.
EIL/BPCL
30-Apr-15
Urgency (Long Term / Short term)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
6 N
Schedule ( Y / N)
Action Plan
EIL Cost (Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
3
Open Constructio Very High n
(Current risk Score Previous Risk score)
2 Slow construction progress by M/s B&R for Composite works: Offsite Refinery area due to delay in mobilisation. Awarded on 25.03.14. CCD: 24.09.15 Sch:44.1%; Front: 11.1%; Act: 5.3%
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 563+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
60
17
Target Date
Risk Severity
18
19
Completion of Civil & Strl works (incl. UG Piping Open Constructio works) by M/s L&T for CDU/VDU. n Sch: 04.09.14 CCD: 06.09.14 ECD: 31.03.15 Sch:100% Front: 99.44% Act: 88.20%
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
Management level meeting held on 20.03.15 -TS I by 20.03.15 -TS II, III & IV,VI handed over. -TS V by 27.05.15 -TS VII by 15.03.15. - Main piperack 100% completion targeted by 12.03.15
Constr.
30-Apr-15
II III
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- MRM held on 23.03.15 - Refractory of stack, dryout & erection of stack to be expedited.
Constr.
As Required
III
Completion of Civil & Strl works (incl. UG Piping Open Constructio Very High works) by M/s L&T for DCU. n Sch: 04.09.14 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 100 % Act: 96 %
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 20.03.15 -TS I by 25.03.15 -TS II by 10.04.15. - TS IV handed over. -TS V by 31.03.15
EIL/BPCL
30-Apr-15
Start of work for Tankage-IV by M/s Offshore Open Constructio Awarded on 17.04.14 n CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT383/391) Sch : 61.27% Front : 57.56% Actual : 24.19%
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level Meeting held on 25.03.15, M/s OIl started night shift work in YT-150 from 10.03.2015 - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT383,391 for modification and 150 for new. - YT-150: Tank Pad completed, erection of annular plate completed, welding u/p, bottom plate erection under progress.. - YT-383: Roof structure erection completed, roof plate erection u/p. - YT-391: Hydrotesting completed, blasting and painting under progress. - Ordering of cladding and moisture barriers to be expedited.
EIL/BPCL
30-Apr-15
II III
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 100 % Front: 100 % Act: 64.85 %
Open Constructio n
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held on 25.02.2015 with M/s B&R at site. Start of Hydrotest - YT 341 : hydrotest by 06.04.2015 - YT 342 : Hydro test by 28.06.2015 - YT 343 : hydro test by 12.06.2015 - YT 344 : Hydrotest by 01.05.2015 - YT 111 : Hydrotest by 24.03.2015 - YT 112 : Hydrotest by 04.04.2015 - YT 113 : Hydrotest by 05.06.2015 - YT 114 : Hydrotest by 25.06.2015 -Manpower required is 250 nos, available is 161.
EIL/BPCL
30-Apr-15
III
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 CCD:18.06.15 Sch: 92.9 % Front: 74.7 % Act: 49.6 %
Open Constructio n
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
-These tankages (Amine water and sour water services) are required for commissioning of CDU/VDU. - ISW-T-101 tank: 1st Shell & Bottom plate welding is in progress, Roof structural erection is in progress. - ISW-T-201: Bottom plate & Shell erection is in progress. - ISA-T-101: Annular plate welding completed & Bottom plate laying & Welding is in progress. - IS-T-502 & IS-T-102 A/ B tand pad ready.
Constr.
30-Apr-15
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. Sch : 53.18% Front : 38.41% Actual : 22.46 %
Open Constructio n
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Piping fabrication & piping erection in MPR in progress. Structural fabrication in progress for reactor structure, piping supports, piping manifold - Equipment erection in progress (50 nos equipment erection completed) AG piping fabrication: Scope: 210605 ID; Front: 110882 ID; Completed 76965 ID AG piping erection: Scope: 301995 IM; Front: 96604 IM; Completed 22215 IM
Constr.
30-Apr-15
Open Project
58
59
Action By
II III
(Current risk Score Previous Risk score)
10
11
12
13
14
15
16
N
Short term
I
0.4
0.38
0.20
0.18
- Management level meeting held with M/s OIL on 25.03.15 at site. M/s OIL has been asked to ensure sufficient manpower mobilization when work front is released to them. - Due to delay in completion of civil work, release of front to composite contractor got affected.
Constr.
30-Apr-15
Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 42530 / 298905 ID fabricated. 18200 IM / 299780 IM erected. Sch : 48.79% Front : 32.5% Actual : 13%
Open Constructio n
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held with M/s OIL on 25.03.15 at site. M/s OIL has been asked to mobilise additional resources, M/s OIL confirmed to increase the resources and achieved 1200 ID/day by Mar'15.
Constr.
30-Apr-15
II III
Completion of balance piling work (Covered under Piling-IIII Contract) (Total 2077 Nos piles approx).
Open
Completion of Composite works by M/s Albana for VGO Unit Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15 Sch : 56.96% Front : 28.95% Actual : 17.12%
Urgency (Long Term / Short term)
9
Y
Schedule ( Y / N) 8
N
EIL Cost (Y / N) 7
N
5
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Status (Open / Close)
Risk Id
6
Open Constructio Very High n
Action By
17
Target Date
Risk Severity
18
19
61
62
E
63
E
64
F
1
F
4
Start of Composite works by M/s Offshore for Offsite DHDS area Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15. Sch: 60.44% Front: 11.52% Act: 6.82%
2
E
F
3
Action Plan
Key Risk Description
1
E
Job No.: A307 Mar'15 Page 564+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
2
3
G
1
G
2
G
3
Medium
- At present only 26 nos welders are available at site with per day rate of 1000 ID, however to achieve the completion schedule minimum 1500 ID/day to be achieved.
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
-Out of 2205 nos piles, 949 nos piles completed.
BPCL
30-Apr-15
III
Open Constructio n
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Piping fabrication work & Piping erection work in progress. - Equipment erection in progress (13 nos completed) - Structural fabrication in progress for TS-2
Constr.
30-Apr-15
III
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
BPCL
1-Jun-15
III
Implementation of Change management system The same affects : - Finalization of basic philosophies - Scope of services - Release of deliverables Various scope changes (as advised by BPCL), resulting in expenditure of extra manhours against control manhours.
Open PROCESS/ ENGG/CON S.
Medium
N
Y
Y
N
Long term
D
0.14
0.07
0.07
0.00
a. Change management should be in place immediately b. Strict discipline to be maintained else end objective would be difficult to meet.
Projects
Continuous
IV
Timely Commissioning of UB package to meet refinery commissioning schedule. LAD : 31.03.15 (UB 1) 30.06.15 (UB 2)
Open
Constn.
Medium
N
N
Y
N
Long term
I
0.2
0.10
0.10
0.00
-Strict monitoring required at all stages upto commissioning. Constn. / -Completeness of supply of all subparts, their assembly and other BOP Items to be ensured. Projects / - Both steam drum delivered at site. RCC work for chimney completed, foundation work in progress for UB's. BPCL Erection of structure started. - Progress of work affected due to delay in completion of civil foundations.
as scheduled
III
Timely payment to sub contractor by main contractor
Open
Const.
Medium
N
N
Y
Y
Long term
D
0.1
0.05
0.05
0.00
Following methodology being taken up for smooth cash flow to contractors: - Issue of comfort letter by BPCL to sub Vendors & subcontractor being implemented. - Provision for direct payments to contractors sub vendors & subcontractor being implemented as per contract provision. - Provision of interest bearing mobilisation advance against equivalent bank guarantee being implemented for future contract of more than 5CR value. - Expeditious processing of RA bills.
Project/BPCL As Required
IV
Infrastructure at Kochi
Open
Const.
Low
N
N
Y
Y
Long term
D
0.1
0.03
0.03
0.00
Contractor to identify the proposed areas in and around Project area and BPCL to facilitate by persuading with local authorities for required permission.
Constn. / Projects / BPCL
As Required
IV
Process / Engg.
High
N
Y
Y
N
Long term
D
0.14
0.00
All DCN ‘s and change orders, if any to be frozen and incorporated in P&IDs at 60% construction progress stage.
Process / POSD / Engg. / Projects
All by 60% constn progress
Scope changes & information flow to executing Open group
Constn.
Projects
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
sep'13
G
4
G
5
G
6
G
I
7
15
16
Action By
5
6
7
8
9
10
11
12
N
N
Y
N
Long term
I
0.2
0.00
The vendor list to be carefully selected to avoid overloading of vendors shops. Bulk materials to be distributed on different vendors.
Inspn
As Required
sep'13
Delay in Approval of Vendor List for various items of the project (specially for Long lead items)
Close
Low
N
N
Y
N
Long term
I
0.2
0.00
- Covered under risk ID C73
BPCL
within 2 days of request
Nov'13
N
N
Y
N
Short term
D
0.16
0.00
15-Apr-13
Apr'13
0.00
- BPCL-KR vide e-mail dated 06-Dec-12 sent a list of Non plant buildings to be located under IREP Project. Projects - The same is reviewed by EIL. Point wise issues targeted to be discussed with BPCL in week starting 15.04.13. -- Meeting held with BPCL on EIL recommendations and action plan BPCL / List of buildings finalised between EIL and BPCL. Methodology for finalised. execution under finalisation. - BPCL to take up with MOEF for approval of changes in system already incorporated. (e.g. configuration for Projects CPP) - Incorporation of EC and RRA recommendations in balance systems under progress.
0.00
- Documents approved from PESO
BPCL
Close
BPCL
Low
Implementation of environmental clearance conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Open
Projects
Medium
Y
N
N
N
Short term
D
0.08
Delay in commencement of site work for dyke Close wall inside TF-3 affected due to non availability of PESO approval for tankage area
Engg. / Proj.
Medium
N
N
Y
N
Long term
I
0.2
0.04
0.04
17
As required
19
IV
Apr'13
1
Statutory approvals - Factory inspectorate approval - CEA (Central electrical authority) approval -IBR approval (LAD - IBR Package for DCU by end Dec'13; CDU/VDU by 31.12.13)
Open
Projects / BPCL
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- All drawings for F&B approval issued progressively upto 29.09.14. -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
EIL/BPCL
30-Apr-15
IV
0.19
0.19
0.00
- Deployment of skilled manpower for enforcement of safety precautions. - Monitoring of the HSE conditions and maintenance of records ./ reports. - Safety Drills being organised on monthly basis.
Constn.
Continuous
III
0.00
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
BPCL
As Required
Nov'13
0.00
-Utilisation of migrant and skilled labour from outside Kerala needs to be encouraged. However, the same will be effective only if proper labour colony facilities are arranged by the contractors. - Slow down in progress of work by Union workmen, inspite of assurance by trade union leaders that workers shall be instructed to improve productivity.
Constn / BPCL
As Required
As Required
2
Const.
Very High
N
N
Y
Y
Short term
D
0.2
1
Implementation of Health, Safety and environmental (HSE) system
Open
J
Low
N
N
Y
N
Long term
I
0.2
1
Delay due to Labour strikes (due to labour issue Close like wage revision, other benefits) during project execution phase
Const.
K
Mobilisation of Skilled workers
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
K
2
Open
Project
Low
N
N
Y
N
Long term
I
0.2
0.00
-A separate contract to be given to agency which will take care by approaching KSEB and telephonic authority. -Fabn / transportation philosophy being finalised.
Shipping
ODC transportation in view of Kochi Metro Open Project/Eng ODC movement schedule is from Nov'13 to Feb g 15.
High
N
N
Y
N
Long term
I
0.2
0.00
Closed as no concern as on date.
BPCL
Quarry operator strike : Quarry operator strike in the state from 12.02.15 has affected the concreting work.
High
N
N
Y
Y
Short term
I
0.5
Costing
High
Y
N
N
N
Short term
D
Environ.
Very High
Y
N
N
N
Short term
D
3
K
4
K
5
M
1
M
18
Risk Severity
Low
I
K
Target Date
Open Inspn
Finalisation of Non plant buildings.
14
Action Plan
Non-performing vendors
Purch / Contrc.
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
3
(Current risk Score Previous Risk score)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Mar'15 Page 565+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
2
0.40
0.40
At present only approx 12000 labours are working against requirement of 15000-18000 labours. Constraint in movement & transportation of ODC eqpt.
Cost monitoring & control on regular basis Increase in facilities on account of deletion zero liquid discharge
Open
Close Open
Const.
0.40
As stated
II Jun'14
Jun'14
-0.40 Quarry strike has been called off.
Constn / BPCL
As Required
0.08
0.00
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
0.08
0.00
Scope of facilities finalised.
Environ.
15-Oct-13
sep'13
M
3
Total Risk Score
5
6
7
8
9
10
11
12
Low
Y
N
Y
N
Short term
I
0.6
13
14
(Current risk Score Previous Risk score)
4 Project
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
2
Variation in foreign exchange rates from Rs 50 Open per USD as on Mar 12 to Rs. 60 per USD as on date and fluctuations in the intermediate period and Scope changes w.r.t. DFR (additional in scope) has significantly impacted on the overall project cost.
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Mar'15 Page 566+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
0.00
21.86
22.50
-0.65
- BPCL have informed that approval for revised cost received.
Action By
Target Date
17
18
EIL/BPCL
Risk Severity
19 Jan'15
Job No.: A307 Feb'15 Page 567 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
D
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Completion of Reactor regenerator package for FCCU-M/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 90.0% Act: 63.7 % Construction Progress: Sch: 77.2% Front: 85.8% Act: 28.7 %
Open
Project
Management level meeting held on 20.02.15 at site. - 1600MT Demag CC-8800 made ready for erection after load test. EPIL/GRE committed the following : - Regenerator bottom section planned for erection on 15.03.15 - Erection of TSS bottom section planned for erection on 27.03.15 Balance deliveries comprising of nozzles, lifting trunions, insert plates, spreader & lifting beam for equipment fabrication of Regenerator (top section), Reactor, TSS to be expedited. - Steam drum delivery expected in 1st week of Mar'15. - 1st lot of fabricated ESP materials dispatched, dispatch of balance materials to be expedited.
Completion of all three site Fabricated Columns for FCCU :Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 100 % Act: 70.0 % - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach road upto fabrication yard, which affected shifting of sections.
Open
Project
-Vendor being expedited to erect main fractionator by end Mar’15 and ensure balance EIL/BPCL columns by May’15. - Foundation for main fractionator column completed & erection planned by 1st week of Apr'15. - Revised erection scheme approved. - Hard stand readiness to be ensured by end Mar'15.
As stated
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 30.07.16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 84.5 %; Act: 63.1 % Construction Progress: Sch: 69.0% Front: 100% Act: 36.5 %
Open
Project
Following commitments have been made by M/s Essar. EIL/BPCL -Shift Work: Works in two shifts implemented. - Coke Drum Supporting Structure concreting completed on 13.02.15. - Opening of LC for imported items: M/s EPIL informed letter of credit through Bank of India opened. - M/s Essar have been pressurized to deliver all coke drums progressively upto Apr’15 and Coke fractionator by end Mar’15. - Crane (2000 MT): All consignment reached at port. Mobilization & assembly of crane by 3rd week of Mar'15 and erection of equipments targeted to commence from Mar’15 to May’15. -Clear water tank fabrication- Civil tank pad work completed, rolling in progress. - Resource augmentation for Civil & Strl works being expedited. At present 590 nos have been deployed against requirement of 836 nos.
Erection by May'15
Key Risk Description
1
Action Plan
Action By
EIL/BPCL
Target Date
Risk Severity
Mar'15
I
D
7
II
D
9
Strl Steel: Out of total 3210 MT, 2800 MT procured, 1539 MT fabricated & 1296 MT received.
I
D
12
Delay in hydrotesting of Vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: 15.03.15 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column.
Open
BPCL / - Vacuum Column : Vacuum column erected on 19.01.15, welding of mid & top section EIL/BPCL Projects / completed, pickling & passivation in progress hydrotesting targeted by 15.03.15. Const.
15-Mar-15
II
D
13
Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB: unloaded onto barge on 26.12.14) ISGEC Josen (3 nos) Column: expected to receive at Kochi port from upto Mar'15.
Open
T&CC
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - 1st DHDT Reactor rolled off on 26.02.15. 2nd Reactor likely to be rolled off by 2nd week of Mar'15. - Erection of reactor planned with 1000 MT crane by 15.03.15 - First dumb barge (newly fabricated-For VGO reactor) launched in the river after IRS certification and other dumb barge targeted by 15.03.15.
15-Mar-15
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 31.10.15
Open
Projects
- Management level review meeting held at Hydrabad on 10.02.15. M/s BHEL agreed EIL/BPCL to dispatch main compressor by 25.04.15 and completion of MRT for drive turbine targeted progressively by 11.03.15.
Continuous
II
D
19
II
Job No.: A307 Feb'15 Page 568 of 749
Integrated Refinery Expansion Project, Kochi
D
33
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-3): Oct'14 EDD: Mid Feb'15 Sch: (Final MTO): Dec'14-Feb'15 EDD: Mar'15-Jun'15
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Open
Projects
Action Plan
Action By
Target Date
- As of now around 88% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Apr'15. -Vendors being expedited to prepone the deliveries.
EIL/ BPCL
15-Apr-15
Constn.
- During the project review meeting dated 23.01.15, following points discussed and requested with BPCL to provide assistance: - Additional area requirement in FACT being taken up for storage of materials. - Additional storage space for piping spools.
BPCL
15-Mar-15
Risk Severity
II
E
2
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
Open
II
E
4
Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 12 M available for construction works (excl. Dismantling works) against schedule of 22 M. - Process package was delayed by 2 M due to delay in P&IDs review meeting and delay in award of licensor. - Change in the scope based on health check report has an impact on Project cost and schedule. Physical Progress: Target Sch: 90.7% Catch Up Sch: 69.0 % Act: 51.9%
Open
Constn. / Projects
- Tender splitter into two parts (Structural/ Mechanical works & Civil work). Award BPCL/EIL recommendation issued on 17.02.15. Civil work being done by misc. Civil agency (M/s Furnace Fabrica). Rigorous follow up with contractor to be made after award of contract. Electrical Work: Bids received on 10.02.15. Instrumentation Work: 09 nos bids received on 11.02.15. Electrical/Instr. work: PBO recommendation targeted by 3rd week of Mar'15.
15-Mar-15
Backlog 14.8% as of 15-Feb-15 in Construction activities viz., Civil works and Mechanical works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 34 M Catch Up sch: Const Sch Front Act 60.2 81.1 69.0 45.4 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site. -Construction progress for Jan'15 got improved (During the month progress achieved is 3.84 %)
Open
Const
- Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deens has been lined up to supplement Civil works. Further 1 additional Civil & Structural works contracts targeted to award by mid Mar’15. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. Further 1 additional Civil & Structural works contracts targeted to award by mid Mar’15. - Contractors are facing problem in retaining the labour at site. Approx 12000 labours are available at site, though induction programme has been carried out for more than BPCL/EIL 18000 labours . requirement of manpower at site is approx 19000 nos. - RCC work & structural fabrication/erection work to be expedited to give complete front to mechanical contractor progressively upto Apr-May'15. - Lighting of areas to facilitate night shift working. - Provision made for snacks/dinner for labour to facilitate working in extended/night shift - Provision of multiple entries inside plant areas to ease manpower/machinery mobilisation to be explored. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. - In order to boost progress, permission from labour union of Kochi to be taken up for two shift work.
As Required
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Jun'15)
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Jun'15.
Jun'15
Slow construction progress in Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 CCD: 08.10.14; ECD: Jun'15 Progress figures Sch: 100% Front: 99.7% Act.: 53.54% Insufficient mobilisation of manpower: Required: 635 nos Deployed: 216 nos
Open
I
E
E
E
7
8
27
BPCL
Constructio -Management level meeting held with M/s KSSIIPL at site on 19.02.15. EIL/BPCL n - M/s AA Erectors being mobilized by KSSPPL for Structural work. - M/s JD Works to be mobilized shortly by KSSPPL for UG piping works. - Payment released for 150 MT crane by KSSPPL. One 80MT crane also shall be mobilized shortly. (Currently one 100MT, one 75MT & one 70MT available). - Rock blasting being expedited for drain on West side of piperack area 104, CW line at East of VGO. - BG already arranged for 400 MT cement, apart from current stock of 100 MT. - KSSPPL shall be expediting around 700 MT of strl steel required for completing the currently progressing areas of piperack on priority. Entire fabrication completion targeted by 30.04.15. - Bridge erection at area 117 shall be taken up. Bridge at area 113 nearing completion. -Strl steel painting & repair works shall be expedited with new gang. - Manpower for restarting manhole works shall be additionally deployed. - CW road crossing of 84" pipes shall be expedited. - Area wise handing over of piperack to mechanical agency shall be expedited.
I IV
30-Apr-15
II
Job No.: A307 Feb'15 Page 569 of 749
Integrated Refinery Expansion Project, Kochi
E
34
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 91.6 % Act: 49.2 % Construction Progress: Sch: 86.1% Front: 100 % Act: 29.3 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Open
Project
Action Plan
- Mobilization of additional 120 nos manpower by Mar-15(Presently 145 nos manpower available) - Completion of raft for TWT/SBR/ACT by 30th Apr-15 - Control room slab casting in sub-station by 31.03.15 - 2nd slab in chemical house by 25th Mar'15 - Completion of equalisation tank targeted by Jun'15. - Procurement of BQ plate for Spent caustic tanks to be expedited.
Action By
EIL/BPCL
Target Date
Risk Severity
As stated
I
E
Open
Project
- Sub-station-Completion of RCC super structure completion by 15.06.2015 EIL/BPCL - Chemical House- Completion of RCC super structure by 10. 03.2015 - DM tanks (2 nos) : Tank B: all 160 nos pile completed, excavation of PCC completed, pile cap by 10.03.2015. Tank -A : 120/160nos piling completed, expected pile cap by 28.03.2015. - Delivery of fabricated structural steel to be expedited to reach at site by 31.03.2015. Strl steel erection will start by 24.03.2015 - M/s DWEL being expedited to delivery of balance bought out items.
As Required
Slow Construction progress for Civil Works- FCCU Constr. Sch: 100 %; Front: 91.3% Act: 67.1 % CCD: 24.12.14 ECD: Oct'15
Open
Project
- 5575m3 offloaded to M/s Tuaman (3374m3 completed) - 2432m3 offloaded to M/s PGC (692m3 completed) - 2025MT structural work offloaded to REL - 1684 MT structural work offloaded to ZIPL EIL/BPCL - 310 MT Offloaded to TEL Management level meeting held with M/s Shriram on 19.02.15 at site. -Mobilisation of resources is being expedited. At present only 110 nos, manpower mobilised against requirement of 350 nos. M/s Shriram agreed to augment additional 50 nos for civil work by 25.02.15. - M/s Shriram to complete balance Civil work by 30.03.15. - SEPC to expedite structural erection for Tech str A,D,BPR-2
As Required
Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open
Project
PEB1: M/s B&R agreed to complete balance work by 2nd week of Mar'15 except road EIL/BPCL work. Project Material storage commenced. PEB 2 All works targeted to complete by 20.04.15 PEB 3: All works targeted to complete by 20.03.15 Buildings to be expedited for storage of material / equipment being received at site.
As Required
Slow construction progress in Offsite-DHDS area. Work stopped by M/s KSS in DHDS area for Civil & Strl work ?? CDD: 24.01.15 ECD:. Dec'15
Open
Constructio -Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. EIL/BPCL n Civil/Strl contractor. -Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deen has been lined up to supplement Civil works. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. Further 1 additional Civil & Structural works contracts targeted to award by mid Mar'14.
30-Apr-15
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 46.1 %; Front: 17.4%; Act.:11.9% AG Piping fabrication: 74252 ID / 486195 ID completed AG Piping Erection: 21716 IM / 811115 ID completed
Open
Constructio Management level meeting held on 25.02.15 at site. EIL/BPCL n - M/s Petron have started with night shift work. - PECL have erected the gantry crane & same to be made operational by mid Mar'15 - 150MT crane is made operational, 200MT crane to be mobilised by mid Mar'15. Currently 4 crane available at site - 10 nos semi automatic welding machines shall be operational by Mar'15 - Auto blasting installed to be made operational by Mar'15 - Gratings & consumables are being ordered. Handrails, wrapping coating mtrls & GI pipes ordering to be expedited.
30-Apr-15
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
Timely payment to sub contractor by main contractor
Open
Const.
40
I
E
41
I
E
46
II
E
49
I
E
F
G
50
1
1
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
BPCL
Following methodology being taken up for smooth cash flow to contractors: EIL/BPCL - Issue of comfort letter by BPCL to sub Vendors & subcontractor being implemented on request from contractors. - Provision for direct payments to contractors sub vendors & subcontractor being implemented as per contract provision. - Provision of interest bearing mobilisation advance against equivalent bank guarantee being implemented for future contract of more than 5CR value. - Expeditious processing of RA bills.
1-Jun-15
II III
As Required
IV
Job No.: A307 Feb'15 Page 570 of 749
Integrated Refinery Expansion Project, Kochi
Mobilisation of Skilled workers At present only approx 12000 labours are working against requirement of 15000-18000 labours. K
2
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Open
Const.
Action Plan
- Slow down in progress of work by Union workmen, inspite of assurance by trade union leaders that workers shall be instructed to improve productivity. - Respective contractors being persued to increase manpower commensurate with site requirement. - Additional entry gate provision being made to facilitate smooth entry inside working area. - Availibilty of permits being made available for inside refinery works.
Action By
EIL/BPCL
Target Date
Risk Severity
As Required
II
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Risk Owner
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Feb'15 Page 571+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Low
N
N
Y
N
Long term
D
0.08
0.02
0.05
-0.02 - Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. - HAZOP review completed for GTG, HRSG & UB package. - 90% model review for HRSG completed on 04.02.15. -90% model review for UB package held from 18.11.14 to 20.11.14. - GBC ordered to M/s BHEL on 25.07.14. KOM held with M/s BHEL for Gas booster compressor on 12-13 Aug'14.
Engg
Mar'15
IV
Action Plan
Action By
Target Date
Risk Severity
B
19
CPP: Integration of various packages & BOP Open Engg/Cont Items of CPP. . 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas Booster compressor.
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
Package vendor inputs being made available by expediting for updation of interface engineering documents.
Projects / Engg.
Continuous
IV
23
Delay in Interface Engineering (including control Open Engg/proc system) due to non availability of Package urement Vendor Data
Low
B
Generation of Surplus Piping material
Open
ENGG
Low
N
N
Y
N
0.16
0.05
0.05
0.00
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
Progressively
IV
30
Short term
D
B
Project
High
N
N
Y
N
Short term
I
0.4
0.32
-0.32 -Revised MR (MR-3415): Ordered to M/s Oswal, M/s Shalimar, M/s AV valves and M/s L&T. - New MR-3515 (41 Nos) ordered on 05.02.15
EIL/BPCL
Mar'15
73
Ordering of Critical Valves Sch: 11.07.14 Ant: 31.01.15 Dely: 06/07 M FOT /FOB
Open
C
Project
Very High
N
N
Y
N
Short term
D
0.16
0.15
0.15
0.00
-Total 35484/ 35618 nos (99%) isometrics issued for units . Balance ISO's targeted progressively by mid Mar'15. -All GADs issued except SRU block 199 nos balance). Same shall be targeted by mid Mar'15.
Engg.
15-Mar-15
75
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 Ant: 15.03.15
Open
C
Award of Composite Works (Structural Works & Mechanical) for NHT/ISOM-Refloated Sch: 08.05.14 Ant: 15.03.15
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
-Award recommendation issued on 17.02.15.
EIL/BPCL
15-Mar-15
Delay in award of piping material with G2E specification in CPP area.
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
All items have been ordered, deliveries to be expedited in order to timely availability of piping material for completion of steam network in CPP area.
EIL/BPCL
Apr'15
Completion of Reactor regenerator package for FCCU-M/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 90.0% Act: 63.7 % Construction Progress: Sch: 77.2% Front: 85.8% Act: 28.7 %
Open
Project
Very High
Y
Y
Y
N
I
0.9
0.86
0.86
0.00
Management level meeting held on 20.02.15 at site. EIL/BPCL - 1600MT Demag CC-8800 made ready for erection after load test. EPIL/GRE committed the following : - Regenerator bottom section planned for erection on 02.03.15 - Erection of TSS bottom section planned for erection on 27.03.15 Balance deliveries comprising of nozzles, lifting trunions, insert plates, spreader & lifting beam for equipment fabrication of Regenerator (top section), Reactor, TSS to be expedited. - Steam drum delivery expected in 1st week of Mar'15. - 1st lot of fabricated ESP materials dispatched, dispatch of balance materials to be expedited.
Mar'15
Completion of UB package LAD : 31.03.15 CCD : 23.03.15 ECD:10.08.15 Awarded to M/s ISGEC on 25.07.13 Overall progress: Sch: 99.8 % Act: 81.8 % Construction Progress: Sch:100 % Front: 100 % Act: 50.2 % Manpower : Required 450, Deployed 333 incl 39 welders
Open
Project
Very High
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
- 90% model review for UB package completed. - Erection of steam drum-I & II completed. (Sch: 16.09.14: got delayed as 550MT crane could not be mobilized from M/s.TWC). - Completion of structural erection work to be expedited. Piping erection work in progress for UB-1 & UB-2. Deaerator tank erection completed.
Project / Constn.
Continuous
Delivery of wet gas compressor for DCU at Site Open (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 15.03.15)
Project
Low
N
N
N
N
Long term
I
0
0.00
0.00
0.00
MRT completed on 10.11.14. Dispatch expected by mid Mar'15 due to Change order for additional requirement of NRT sizing and LC amendment
Project/Inspe 15-Mar-15 ction
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 28.02.15)
Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
-0.20 All parts dispatched.
C
76
III
II C
79
II
D
1
D
3
D
5
D
6
Open
Short term
Project/Inspe 28-Feb-15 ction
I III
IV
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
-Meeting held on 30.01.15, vendor agreed to erect main fractionator by end Feb’15 and balance columns by Project / Apr’15. Constn. - Foundation for main fractionator column : substructure work completed by L&T and super structure work being expedited through by M/s Tuaman and curing period of 28 days. - Revised erection scheme approved. - Stripper & rectifier Column: Erection of bottom section for stripper expected to commence from end Mar'15. Preparation of Hard stand to commence. Erection of bottom section for rectifier expected to commence from end Mar'15.
As stated
Completion of MCC pkg for SRU Open LAD: 23.06.15 CCD:18.02.15 (including Site work) ECD: 18.05.15 Ordered to M/s Thermax on 19.08.13 (18 M incl erection)
Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- M/s Thermax seeking extension for duration due to delayed availability of burner data from M/s Aecometric. Letter forwarded on 11.06.14 to BPCL for recommending extension for supply portion to M/s Thermax upto 30.11.14. Further M/s Thermax seeking extension for duration upto 31.03.15 for supply through letter dated 08.10.14. - Foundation work completed for 1st train. 2nd train foundation targeted by mid Mar'15. Bidder has requested for providing space for storage of MCC equipment & Refractory Materials. - Refractory lining work in Combustion chamber can be started only after erection of MCC pkg.
15-May-15
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 30.07.16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 84.5 %; Act: 63.1 % Construction Progress: Sch: 69.0% Front: 100% Act: 36.5 %
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
Following commitments have been made by M/s Essar. Constr. -Shift Work: Works in two shifts implemented. - Coke Drum Supporting Structure concreting completed on 13.02.15. - Opening of LC for imported items: M/s EPIL informed letter of credit through Bank of India opened. - M/s Essar have been pressurized to deliver all coke drums progressively upto Apr’15 and Coke fractionator by end Mar’15. - Crane (2000 MT): All consignment reached at port. Mobilization & assembly of crane by 3rd week of BPCL/EIL Mar'15 and erection of equipments targeted to commence from Mar’15 to May’15. -Clear water tank fabrication- Civil tank pad work completed, rolling in progress. - Resource augmentation for Civil & Strl works being expedited. At present 590 nos have been deployed against requirement of 836 nos.
Erection by May'15
BPCL / Very High Projects / Const.
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Vacuum Column : Vacuum column erected on 19.01.15, welding of mid & top section completed, pickling & Constn. / passivation in progress hydrotesting planned in 1st week of Mar'15 VTV / Projects
15-Mar-15
Key Risk Description
7
8
9
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
EIL Cost (Y / N)
D
Risk Owner
D
Status (Open / Close)
Risk Id D
Job No.: A307 Feb'15 Page 572+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Completion of all three site Fabricated Columns for FCCU :Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 100 % Act: 70.0 % - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach road upto fabrication yard, which affected shifting of sections.
Open
Strl Steel: Out of total 3210 MT, 2800 MT procured, 1539 MT fabricated & 1296 MT received.
Action Plan
Action By
BPCL / EIL
Target Date
Risk Severity
II III
I
D
12
Delay in hydrotesting of Vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: 15.03.15 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column.
Open
II
D
D
13
14
Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB: unloaded onto barge on 26.12.14) ISGEC Josen (3 nos) Column: expected to receive at Kochi port from upto Mar'15.
Open
T&CC
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. - 1st DHDT Reactor rolled off on 26.02.15. 2nd Reactor likely to be rolled off on 08.03.15 - Erection of reactor planned with 1000 MT crane by 15.03.15 - First dumb barge (newly fabricated) launched in the river after IRS certification.
EIL/BPCL
Mar'15
Close Monitoring of ODC equipment (including site fabricated/assembled) up to receipt at site
Open
Projects
High
N
N
Y
N
Long term
D
0.08
0.06
0.06
0.00
Out of total 57 nos. of ODCs; 22 nos received at site. & 6 nos under dispatch. Balance under close monitoring.
Shipping
Continous
II IV
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
D
D
D
D
D
D
D
D
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- 840 out of 850 MT Derrick structure received at site. - Erection of Derrick structure up to 40 mtr completed. - Erection of Derrick up to 133 mtr by 14.04.2015 - 1 no water seal drum and Molecular seal received at site. All flare riser expected to receive at site from workshop progressively by21.03.15. - Flare tip and Water Seal drum(3 nos) under transit.
Projects/Con As Required str.
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Management level review meeting held at Hydrabad on 10.02.15. M/s BHEL agreed to dispatch main compressor by 25.04.15 and completion of MRT for drive turbine by 28.02.15. - M/s BHEL to prepone the delivery of CEP turbine (from Oct'15 to Apr'15).
Project/Inspe Continuous ction
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- MRT of compressor and Steam turbine completed.
Project/Inspe Continuous ction
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 EDD: 09.04.15
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
-All four sections released for hydro testing progressively on 30.01.15. Hydrotesting targeted by end Mar’15. Project/Inspe Continuous - M/s L&T being monitored continuously to deliver Reactors by Mar’15. ction
III
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13 Overall Progress: Sch: 92 % Act: 67 %
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- 90% model review for HRSG completed. - Balance engineering to be expedited by M/s Thermax. - HRSG #3, 4 & 5: Foundation works completed and handed over to M/s Thermax. Erection work commenced for HRSG-4 & HRSG-5 - All column alignment completed for HRSG-3.
Project/Inspe Continuous ction
III
Open
Projects
Low
Y
Y
Y
N
Long term
I
0.45
0.14
0.14
0.00
- Generator subordered. - Pedestal fabrication is at final-machining. - Exhaust case assembly, including diffuser and thermal insulation has been completed
Project/Inspe Continuous ction
III
24
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) LAD ;30.03.15 CDD: 30.04.15
Open
Projects
Medium
N
Y
Y
N
Long term
I
0.35
0.18
0.18
0.00
-Silos with structure & Conveyors sub ordered by M/s Sandvik. Project/Inspe Continuous - Bottom Cones for Silo C ,D, E & F dispatched to site. ction -Delivery of Semi rolled sections of Silos shall commence from Jan'15 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited. - Foundations for pelletiser shed to be made ready.
III
25
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 CDD: 30.03.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Synchronous Motor ordered to M/s Toshiba Mitsubishi dispatched. MRT completed for compressor.
EIL/ BPCL
Continuous
IV
27
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 CDD: 10.03.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Main motor ordered. KOM for Motor held on 06-07.05.14 & expected to receive by 13.04.15 (FOB: Germany). MRT completed.
EIL/ BPCL
Progressively
IV
28
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) LAD : 26.02.15 CDD: 13.04.15 ECD: 28.05.15
17
19
20
21
23
Risk Owner
Y
Key Risk Description
Status (Open / Close)
Medium
Risk Id D
Job No.: A307 Feb'15 Page 573+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Apr-15 Ant: 24-Apr-15 Overall Progress Sch: 99 % Act: 78.3 %
Open Project
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 31.10.15
Open
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 CDD: 03.04.15 Ant: 03.04.15
Action Plan
Action By
Target Date
Risk Severity
III
II IV
E
Previous Risk Score
(Current risk Score - Previous Risk score)
0.38
0.00
- As of now around 88% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Apr'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL. Additional requirement of 20000 m2 area in FACT being taken for piping storage.
EIL/ BPCL
15-Apr-15
0.06
0.06
0.00
Ordered to M/s BHEL on 25.07.14. KOM held on 12-13.08.14. - Compressor Journal Bearings were ordered. Impeller manufacturing is in process
EIL
15-Apr-15
II IV
0.16
0.16
0.00
Vendor being pushed for deliveries. Vendor shop visit/meeting being arranged.
Inspection / Project
15-Apr-15
III
0.32
-0.32 -All burner drawings finaised across the table.
0.14
0.13
Current Risk Score -> {5}* {12}
Feb'15
Impact Score => {6+7+8+9} * 10 * 11
EIL/ BPCL
Controllability Condition (D/I )
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
- All part received at Kochi.
Urgency (Long Term / Short term)
D
0.10
Output Quality ( Y / N)
D
15-Mar-15
Schedule ( Y / N)
D
- Following bidders showing slow manufacturing progress: EIL/ BPCL - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:134, 184. . Meeting held on 09.02.15. Balance orders expected to dispatch from Jan'15 to May'15. - M/s Universal: Meeting held on 25.11.14, M/s UHE agreed to deliver balance items progressively upto May’15. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360, 423 & 444. - M/s HDO (Columns, Heat Exchangers & Vessels): FOA No.: 199, 302, 310, 315, 318, 320, 327, 369, 389 & 395.
EIL Cost (Y / N)
D
0.00
Risk Owner
D
0.10
Status (Open / Close)
Risk Id D
Job No.: A307 Feb'15 Page 574+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Delay by vendor with respect to CDD due to financial constraint.
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
0.10
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) CDD: 18.10.14
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
0.10
Availability of 90 % Piping materials to generate Open adequate piping material front to composite contractors. Sch: (Intermediate MTO-3): Oct'14 EDD: Mid Feb'15 Sch: (Final MTO): Dec'14-Feb'15 EDD: Mar'15-Jun'15
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
Delivery Gas Booster Compressor for CPP (Dly: Open 13 M FOB
Project
Low
N
N
Y
N
Long term
I
0.2
Delay in delivery of equipments by: M/s TEMA :CDD: 06.01.14 to 15.01.15; EDD:Dec’14 to Mar’15 M/s Nuberg: CDD: 03.07.14 to 03.11.14; EDD: Dec'14 to May'15 M/s GR Engg: CDD: 28.01.14 to 31.07.14; EDD: Dec'14 to 31.01.15 M/s Fabtech Projects: CDD: Jul’14 to Jan’15; EDD: Dec'14 to Jul’15
Open
Project
High
N
N
Y
N
Long term
I
0.2
Delay in submission & finalization of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. CDD: 19.05.15
Open
Project
Low
N
N
Y
N
Short term
I
0.4
Very High
Y
N
Y
Y
Short term
D
0.28
Key Risk Description
29
32
33
34
35
36
2
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
Open
Constn.
0.27
Action Plan
Action By
Target Date
Risk Severity
III
HMTD/Projec ts
- During the project review meeting dated 23.01.15, following points discussed and requested with BPCL to BPCL provide assistance: - Additional storage space for owner supply items (20,000 Sq. M). - Additional storage space for piping spools.
15-Mar-15
II
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Risk Owner
Construction of NHT/ISOM (Revamp) Open Constn. / - Target Schedule : 30.09.15; Only 12 M Projects available for construction works (excl. Dismantling works) against schedule of 22 M. - Process package was delayed by 2 M due to delay in P&IDs review meeting and delay in award of licensor. - Change in the scope based on health check report has an impact on Project cost and schedule. Physical Progress: Target Sch: 90.7% Catch Up Sch: 69.0 % Act: 51.9%
EIL Cost (Y / N)
4
Status (Open / Close)
Risk Id E
Key Risk Description
Job No.: A307 Feb'15 Page 575+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
- Tender splitter into two parts (Structural/ Mechanical works & Civil work). 3 nos bids received on 21.01.15 BPCL/EIL for Structural/mechanical work. Award recommendation issued on 17.02.15. Civil work being done by misc. Civil agency (M/s Furnace Fabrica). Rigorous follow up with contractor to be made after award of contract. Electrical Work: Bids received on 10.02.15. Instrumentation Work: 09 nos bids received on 11.02.15.
15-Mar-15
As Required
Action Plan
Action By
Target Date
Risk Severity
I
E
6
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 100% Front: 100 % Act:74.0 % CCD: 20.12.14 Ant: 15.07.15
Open
Const
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- MCR, CPP control room : Release for panels by Oct'15 & total completion by Dec'15. - Other building works : SRR Completion progressively between Mar'15 to May'15. - L&T also agreed to augment required manpower to 1000 from current deployment of 850 to meet the target completion date.
Constn
Backlog 14.8% as of 15-Feb-15 in Construction Open activities viz., Civil works and Mechanical works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration 46 M; Time lapsed - 34 M Catch Up sch: Const Sch Front Act 60.2 81.1 69.0 45.4 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site. -Construction progress for Jan'15 got improved (During the month progress achieved is 3.84 %)
Const
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
- Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deens has been Constn lined up to supplement Civil works. Further 1 additional Civil & Structural works contracts targeted to award by mid Mar’15. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. Further 1 additional Civil & Structural works contracts targeted to award by mid Mar’15. - Contractors are facing problem in retaining the labour at site. Approx 12000 labours are available at site, though induction programme has been carried out for more than 18000 labours . requirement of manpower BPCL/EIL at site is approx 19000 nos. - RCC work & structural fabrication/erection work to be expedited to give complete front to mechanical contractor progressively upto Apr-May'15. - Lighting of areas to facilitate night shift working. - Provision made for snacks/dinner for labour to facilitate working in extended/night shift - Provision of multiple entries inside plant areas to ease manpower/machinery mobilisation to be explored. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. - In order to boost progress, permission from labour union of Kochi to be taken up for two shift work.
As Required
II
E
E
E
7
8
13
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Jun'15)
Open
Constn.
Very High
N
N
N
N
Long term
I
0
0.00
0.00
0.00
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Jun'15.
BPCL
Jun'15
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating) Overall Progress: Contr. Sch: 99.5 % Act: 81% Construction Progress: Sch: 100 % Front: 100 % Act: 75.5 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Open
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.29
0.29
0.00
- M/s Triveni to augment manpower by mobilizing additional manpower (Manpower required is 300 nos while available manpower is 235 Nos). - Substation building: completion being targeted by Apr'15. - Chemical house works completion being targeted by end Apr'15.
Constr.
30-Apr-15
I IV
II
E
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
Y
Output Quality ( Y / N)
Very High
Schedule ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Risk Owner
Open Proj. / Constn.
EIL Cost (Y / N)
Slow construction progress of SRU Block due to delayed area handing over - As per present trend 15 months (starting from end Jun’14) are available with respect to schedule of 25 M (As per past experience minimum requirement for SRU is 30 M).
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Feb'15 Page 576+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
Action Plan
Action By
- All area handed over in SRU. Constn. - Pond Retaining wall construction is in progress. - Piling for SRU : All piling drawing released. To meet Euro-IV compliance, focussed efforts being made for ARU/SWS. Piling for ARU/SWS is completed. Balance piling work completion targeted by mid Mar'15. - Civil works completion targeted by mid May’15 and handing over of front to mechanical contractor targeted from end Mid Mar'15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
Target Date
Risk Severity
30-Apr-15
EIL/BPCL
14
I
E
E
E
E
19
Delivery of bought out items by BHEL for GTG Open package (LAD supply:29.09.14; Ant - Jul'15) Awarded to M/s BHEL on 25.07.13 with CDD for delivery as 24.11.14.
Const. / Projects
Low
N
N
N
N
Long term
I
0
Const.
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.00
0.00
0.57
0.00
27
Projects
30-Apr-15
EIL/BPCL
Mar'15
Completion of UG piping work due delay in receipt of piping material and monsoon.
Open
Construction of Subway on the PWD road including re routing of existing road / existing facilities and necessary liasoning with government department. Construction of culvert got affected
Open
Very Low
N
N
Y
N
Short term
I
0.4
0.04
0.04
0.00
Management level meeting held with B&R on 25.02.15 at site. Culvert top slab completed, road work in progress. Road opening by 10.03.2015
Constrn.
10-Mar-15
Slow construction progress in Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 CCD: 08.10.14; ECD: Jun'15 Progress figures Sch: 100% Front: 99.7% Act.: 53.54% Insufficient mobilisation of manpower: Required: 635 nos Deployed: 216 nos
Open Constructi Very High on
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
-Management level meeting held with M/s KSSIIPL at site on 19.02.15. - M/s AA Erectors being mobilized by KSSPPL for Structural work. - M/s JD Works to be mobilized shortly by KSSPPL for UG piping works. - Payment released for 150 MT crane by KSSPPL. One 80MT crane also shall be mobilized shortly. (Currently one 100MT, one 75MT & one 70MT available). - Rock blasting being expedited for drain on West side of piperack area 104, CW line at East of VGO. - BG already arranges for 400 MT cement, apart from current stock of 100MT. - KSSPPL shall be expediting around 700 MT of strl steel required for completing the currently progressing areas of piperack on priority. Entire fabrication completion targeted by 30.04.15. - Bridge erection at area 117 shall be taken up. Bridge at area 113 nearing completion. -Strl steel painting & repair works shall be expedited with new gang. - Manpower for restarting manhole works shall be additionally deployed. - CW road crossing of 84" pipes shall be expedited. - Area wise handing over of piperack to mechanical agency shall be expedited.
EIL/BPCL
30-Apr-15
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 100%; Front: 100%; Act: 68.1% CCD:18.12.14; ECD: May'15
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management review meeting held with M/s Essar on 20.01.15 at site - Foundation work completed for HRSG-3. - Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - boiler piperack foundations completed.
EIL/BPCL
30-Apr-15
Slow progress of Civil & Strl Works for SRU block (Awarded to M/s Mcnally Bharat on 04.11.13) LAD: 12.01.15 CCD: 03.03.15 Ant: Oct'15 SCH. FRONT. ACT. 99.83% 99.69 % 55.85%
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Management level meeting held at site on 24.02.15. - As on date the manpower is 470 Nos against the requirement of 750 Nos. - ARU/SWS : TS-1 & TS-2 being expedited. TS Completion committed by MBE -TS-II : 10.03.2015 -TS-III: 31.03.2015 -TS-I : 31.06.2015 -TS-IV: 10.07.2015 -TS-V : 15.07.2015 -TS-VI: 15.04.2015 -MPR : 31.05.2015 -SILO: 20.03.2015
EIL/BPCL
Continuous
- All balance material deliveries being expedited, subsequently all UG piping work completion targeted by end May'15.
22
26
- All 3 GTGs received at site.
Project
I IV
II
E
28
II
E
29
II
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 ECD: 30.10.15 Contr. Sch: 75.0% Front: 66.3% Act: 40.1 %
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Management level Meeting held with M/s OIL on 24.02.15 and following action plan has been agreed - M/s OIL was advised to augment welders to 52 nos. against 45 nos available to increase productivity. - Structural fabrication & erection to be expedited. - Piping productivity has increased with release of erection front. - Alloy steel piping fabrication to be expedited. - Fire proofing of columns commenced - Agency for column dehumidification mobilised - Order placed for fabrication of rain protection shed
EIL/BPCL
Continuous
Completion of Coke handling work (Awarded to M/s Thyssen on 04.11.13) LAD: 18.04.15 CCD: 03.07.15 EDD: Dec'15 Construction: Sch:61.3 %; Front:100.0%; Act:22.7% Overall Progress: Sch: 78.3 % Act: 54.5%
Open
Project
Medium
Y
N
Y
N
Long term
I
0.3
0.15
0.15
0.00
-Meeting held at site on 09.01.15. - Piling work in progress (1136 out of 1642 nos piles completed: 7-8 piles/day) -TT-3, TT-4, TT-5, Circular stacker cum reclaimer work in progress.
Constr.
Continuous
Completion of DCU Heater works (Awarded to M/s Heurtey on 04.11.13 (20 M) LAD: May 15 CCD: 03.07.15 Ant: Oct'15 Overall Progress: Sch: 94.1 % Act: 81.2 % Construction work: Sch- 85.5% Front:100% Act:51.8%
Open Project
Medium
Y
N
Y
N
Long term
I
0.3
0.15
0.15
0.00
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 91.6 % Act: 49.2 % Construction Progress: Sch: 86.1% Front: 100 % Act: 29.3 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 92.05 %; Front:95.35% Act: 43.56 %
Key Risk Description
30
31
32
34
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Schedule ( Y / N)
E
EIL Cost (Y / N)
E
Risk Owner
E
Status (Open / Close)
Risk Id E
Job No.: A307 Feb'15 Page 577+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Project
Action Plan
Action By
Target Date
Constrcution As Required
Risk Severity
II III
III
-Heater A: Hot Work 6/6 box completed, Tube support fixing completed. Radiant coil erection completed. Pedestal grouting (56/60) in progress. -Heater B:Hot Work 6/6 box completed, Tube support fixing 32/48 nos completed. -Refractory Dry-out for 3/6 nos of convection module completed at shop. Fabrication for Stack in progress at shop. APH- str erection is in progress. Glass APH & Fan erection in progress. Crane-450 MT mobilised at site.
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Mobilization of additional 120 nos manpower by Mar-15(Presently 145 nos manpower available) - Completion of raft for TWT/SBR/ACT by 30th Apr-15 - Control room slab casting in sub-station by 31.03.2015 - 2nd slab in chemical house by 25th Mar-2015 - Completion of equalisation tank targeted by Jun'15. - Procurement of BQ plate for Spent caustic tanks to be expedited.
EIL/BPCL
As stated
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Management level meeting held on 25.02.15 at site. Total tanks: (New tanks 13 nos, work in progress for EIL/BPCL 12 nos. Balance for 1 nos is YT-33 which shall be start after completion of YT-32; Modification tanks: Out of total 16 nos, work in progress for 5 nos, 3 nos handed over to BPCL.) - B&R to augment resources to complete all balance work within agreed target.
As stated
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
I
E
35
Awarded to M/s B&R on 25-Sep-13 II
E
36
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 Duration: 20 M Sch: 80.9 % Front: 100.0 % Act: 52.5 %
0.32
0.00
Constr.
As stated
- Plate erection to be expedited for YT-26/28. - Tank pad completion works to be expedited in YT-25.
II
E
39
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Risk Owner
Slow progress of FCCU Heater works (Awarded Open Project to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 100% Act: 67.7 % Construction progress: Sch: 72.7% Front: 89.7% Act:38.3%
EIL Cost (Y / N)
37
Status (Open / Close)
Risk Id E
Key Risk Description
Job No.: A307 Feb'15 Page 578+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
-Management level meeting held on 25.02.15 - Structural steel: Out of total 217 MT, 200 MT received. - Erection of radiant section completed. - Coil tubes: Pipes & fittings (part) delivered. PECL to take up radiant coil fabrication. - Delivery of soot blowers and FD fans to be preponed to suit completion of heater by 03.04.15. - Procurement of refractory anchors & refractory blanket has been inordinately delayed & has cast sequential hold on further site erection work, finalisation of refractory blanket details to be expedited
Project
As Required
Projects
As Required
Action Plan
Action By
Target Date
Risk Severity
III
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 CCD: 30.06.15; EDD: 30.09.15 (As per Vendor) Overall Progress: Sch: 81 % Act: 29 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- PO amendment issued on 15.12.14. - Finalisation of subvendor for expansion bellows to be expedited.
Slow progress of RO-DM works (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 (As per vendor) Overall Progress: Sch: 98 % Act: 68.1% Construction Progress: Sch: 100 %; Front: 100%; Act:43.15%
Open Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Sub-station-Completion of RCC super structure completion by 15.06.2015 EIL/BPCL - Chemical House- Completion of RCC super structure by 10. 03.2015 - DM tanks (2 nos) : Tank B: all 160 nos pile completed, excavation of PCC completed, pile cap by 10.03.2015. Tank -A : 120/160nos piling completed, expected pile cap by 28.03.2015. - Delivery of fabricated structural steel to be expedited to reach at site by 31.03.2015. Strl steel erection will start by 24.03.2015 - M/s DWEL being expedited to delivery of balance bought out items.
As Required
Slow Construction progress for Civil WorksFCCU Contr. Sch: 100 %; Front: 100% Act: 73.1 % (M/s SEPC) CCD: 24.12.14 ECD: Oct'15
Open Project
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Management level meeting held with M/s Shriram on 19.02.15 at site. - Mobilisation of resources is being expedited. At present only 110 nos, manpower mobilised against requirement of 350 nos. M/s Shriram agreed to augment additional 50 nos for civil work by 25.02.15. - M/s Shriram to complete balance Civil work by 30.03.15. - SEPC to expedite structural erection for Tech str A,D,BPR-2 - 5575m3 offloaded to M/s Tuaman (3374m3 completed) - 2432m3 offloaded to M/s PGC (692m3 completed) - 2025MT structural work offloaded to REL - 1684 MT structural work offloaded to ZIPL - 310 MT Offloaded to TEL
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15 Constr. Progress: Sch: 99.3 % Front: 100 % Act: 78.5 %
Open Project
Very High
Y
N
N
N
Long term
I
0.1
0.10
0.10
0.00
-Modification of coils to be completed by 10.03.15 - Duct & Stack erection to be completed by 20.03.15 - Hydrotesting of coil loops to be completed by 20.03.15
Constr.
As Required
I III
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 100% Act: 71.7% Construction Progress: Sch: 99% Front: 97.4% Act.: 30.30%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Procurement completed for structural steel - Radiant panel erection completed for IV-H-101 & IV-H-201. APH Structure & Stack erection in progress - Refractory for radiant section to be expedited - Radiant coil tubes in transit and expected to arrive by 31.03.15
Projects
As Required
III
II
E
40
I
E
E
E
41
42
43
EIL/BPCL
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
44
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Current manpower is 436 nos. against requirement of 600 nos. MBEL agreed to mobilise 200 nos additional manpower for structural works - 6 cranes mobilised in order to carry out structural erection in both VGO & DHDT simultaneously. - All structural erection to be completed by 31.03.15
Constrn.
As Required
Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
PEB1: M/s B&R agreed to complete balance work by 07.03.2015 except road work. Project Material storage Constrn. commenced. PEB 2 All works targeted to complete by 20.04.2015 PEB 3: All works targeted to complete by 20.03.2015 Buildings to be expedited for storage of material / equipment being received at site.
As Required
Completion of Cooling Tower -I & II (Awarded to M/s Paharpur on 01.02.13) LAD: 31.01.15 CCD: 20.10.14 ECD: Mar'15
Open Project
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
-Major backlog is due to construction (37%). Management level meeting held on 07.01.15 at site and PCTL EIL / BPCL to expedite to complete all works by Apr'15.
As Required
II III
Open Project
Medium
N
N
Y
N
Long term
I
0.2
0.10
0.10
0.00
- Manpower - Additional manpower to be deployed for civil works. (Required: 150 nos, Available: 87 nos) EIL / BPCL - Delivery of Bought out item to be expedited. - Mechanical contractor to be finalised. - RCC work for CWPH & CWTP to be expedited. - Early delivery of Pipes and immediate commencement of Piping fabrication work.
As Required
III
Risk Owner
Slow Construction progress for Civil Works by Open Project M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 Sch: 100 %; Front :99.55 % Act: 83.41 % - Structural erection: DHDT: 1920 MT / 2600 MT completed.; VGO: 1652 MT / 3065 MT completed. -UG Piping Laying: DHDT: 25009 IM / 25400 IM completed; VGO: 27260 IM / 42000 IM completed.
Key Risk Description
Status (Open / Close)
Risk Id E
Job No.: A307 Feb'15 Page 579+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
II
E
E
45
46
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 80.6%
Completion of Cooling Tower -III (Awarded to M/s Paharpur on 11.09.15) LAD: 30.06.15 CCD: 10.01.15 ECD: Aug'15 E
E
47
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 52.1%
Open Constructi Very High on
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
-Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. Civil/Strl contractor. EIL/BPCL -Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deen has been lined up to supplement Civil works. Further 1 additional Civil & Structural works contracts targeted to award by mid Mar’15. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. Further 1 additional Civil & Structural works contracts targeted to award by mid Mar'14.
30-Apr-15
48
Slow construction progress in Offsite-DHDS area. Work stopped by M/s KSS in DHDS area for Civil & Strl work CDD: 24.01.15 ECD:. Dec'15
Open Constructi Very High on
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 25.02.15 at site. - M/s Petron have started with night shift work. - PECL have erected the gantry crane & same to be made operational by mid Mar'15 - 150MT crane is made operational, 200MT crane to be mobilised by mid Mar'15. Currently 4 crane available at site) - 10 nos semi automatic welding machines shall be operational by Mar'15 - Auto blasting installed to be made operational by Mar'15 - Gratings & consumables are being ordered. Handrails, wrapping coating mtrls & GI pipes ordering to be expedited. Strl steel partially ordered.
30-Apr-15
49
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 46.1 %; Front: 17.4%; Act.:11.9% AG Piping fabrication: 74252 ID / 486195 ID completed AG Piping Erection: 21716 IM / 811115 ID completed
I
E
EIL/BPCL
II
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
50
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Open Constructi on
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
Management review meeting held on 08.01.15. -30 fitters, 40 welders & the required machineries shall be deployed by 30.01.15. -Insulation/painting agency to be finalised. - Hanger scaffolding to be introduced at site.
EIL/BPCL
30-Apr-15
Slow construction progress for Civil & Strl work for Refinery area: Generation of front for mechanical works affected (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:100%; Front: 98.3%; Act: 36.9% CCD: 25.01.15 ECD: Oct'15
Open Constructi on
High
Y
N
Y
N
Short term
I
0.6
0.48
0.48
0.00
Management level meeting held at Kochi site on 20.01.15 - RCC sub structure work shall be completed by Mar '15. - 30MT /day shall be fabricated from 01.01.15 onwards.
EIL/BPCL
30-Apr-15
Slow progress by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. Awarded on 25.03.14. CCD: 24.09.15. Sch: 52.1% Front : 31.3% Actual : 13.3% 39836/ 285505 ID fabricated & 180402 / 1214330 IM erected.
Open Constructi Very High on
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
Piping fabrication & erection work in progress in pipe rack 101-103, 108, 111-114. Fabrication in progress for Constr. piperack area 115. CS IBR & SS fabrication also commenced. Pipe support fabrication in progress.
30-Apr-15
II III
Slow construction progress by M/s B&R for Composite works: Offsite Refinery area due to delay in mobilisation. Awarded on 25.03.14. CCD: 24.09.15 Sch:44.1%; Front: 11.1%; Act: 5.3%
Open Constructi Very High on
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
- Management level meeting held 08.01.15 at site. -Piping management system shall be installed by Jan'15 - B&R to take up compressor erection immediately.
EIL/BPCL
30-Apr-15
III
Risk Owner
Slow progress of work & poor manpower mobilisation by M/s B&R for Composite WorksDCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15 Construction Progress: Sch: 48.8 % Front: 27.1% Act.: 10.6% AG piping fabrication: Only 92041 ID / 406975 ID fabrication completed. AG piping erection: Only 66896 IM / 526435 IM piping erection completed.
Key Risk Description
Status (Open / Close)
Risk Id E
Job No.: A307 Feb'15 Page 580+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
II
E
E
E
E
E
E
51
52
53
54
55
56
Completion of Civil & Strl works (incl. UG Piping Open Constructi works) by M/s L&T for CDU/VDU. on Sch: 04.09.14 CCD: 06.09.14 ECD: 31.03.15 Sch:100% Front: 99.44% Act: 88.20%
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
Management level meeting held on 20.02.15 -TS I by 20.03.15 -TS II, III & IV,VI handed over. -TS V by 27.05.15 -TS VII by 15.03.15. - Main piperack 100% completion targeted by 12.03.15
Constr.
30-Apr-15
III
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- MRM held on 16.01.15 Major backlog is due to manufacturing & Delivery and construction. - Additional resources to be mobilised to recover construction backlogs All convection modules erected, APH & Burners for VDU Heater erected. CDU APH foundations handed over in Dec'14
Constr.
As Required
III
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 20.02.15 -TS I by 25.03.15 -TS II by 10.04.15. - TS III by 17.03.15. - TS IV handed over. -TS V by 08.03.15 - Main piperack completion targeted by 10.03.15
EIL/BPCL
30-Apr-15
Open Project
Completion of Civil & Strl works (incl. UG Piping Open Constructi Very High works) by M/s L&T for DCU. on Sch: 04.09.14 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 100 % Act: 94.3 %
II
EIL Cost (Y / N)
Schedule ( Y / N)
Output Quality ( Y / N)
Urgency (Long Term / Short term)
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
E
E
E
E
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level Meeting held on 24.02.15, M/s OIl committed to start night shift work in YT-150 from 10.03.2015 - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT383,391 for modification and 150 for new. - YT-150: Tank Pad completed, erection of annular plate completed, welding u/p, bottom plate erection under progress.. - YT-383: Roof structure erection completed, roof plate erection u/p. - YT-391: Hydrotesting completed, blasting and painting under progress. - Ordering of cladding and moisture barriers to be expedited.
EIL/BPCL
30-Apr-15
III
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 99.41 % Front: 100 % Act: 62.13 %
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held on 25.02.2015 with M/s B&R at site. Start of Hydrotest - YT 341 : hydrotest by 06.04.2015 - YT 342 : Hydro test by 28.06.2015 - YT 343 : hydro test by 12.06.2015 - YT 344 : Hydrotest by 01.05.2015 - YT 111 : Hydrotest by 24.03.2015 - YT 112 : Hydrotest by 04.04.2015 - YT 113 : Hydrotest by 05.06.2015 - YT 114 : Hydrotest by 25.06.2015 -Manpower required is 250 nos, available is 161.
EIL/BPCL
30-Apr-15
III
Open Constructi on
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
-These tankages (Amine water and sour water services) are required for commissioning of CDU/VDU. - ISW-T-101 tank: 1st Shell & Bottom plate welding is in progress, Roof structural erection is in progress. - ISW-T-201: Bottom plate & Shell erection is in progress. - ISA-T-101: Annular plate welding completed & Bottom plate laying & Welding is in progress. - IS-T-502 & IS-T-102 A/ B tand pad ready.
Constr.
30-Apr-15
59
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 CCD:18.06.15 Sch: 88 % Front: 74.7 % Act: 41.7 %
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Piping fabrication & piping erection in MPR in progress. Structural fabrication in progress for reactor structure, piping supports, piping manifold - Equipment erection in progress (50 nos equipment erection completed)
Constr.
30-Apr-15
II III
60
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. Sch : 44.5% Front : 36.4% Actual : 18.2% 64907 ID / 210605 ID piping fabrication completed. 17543 IM / 301995 IM erected.
Start of Composite works by M/s Offshore for Offsite DHDS area Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15. Sch: 50.2% Front: 10.9% Act: 5.1% 5138 ID / 232725 ID piping fabrication completed. 3078 IM / 1084540 IM erected.
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held with M/s OIL on 23.01.15 at site. M/s OIL has been asked to ensure sufficient manpower mobilization when work front is released to them. - Qualified 9 Welders are available at site. Additional 6 Nos Welders by to be mobilized by 05.03.2015
Constr.
30-Apr-15
III
Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 42530 / 298905 ID fabricated. 18200 IM / 299780 IM erected. Sch : 39% Front : 31.8% Actual : 10.3%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held with M/s OIL on 23.01.15 at site. M/s OIL has been asked to mobilise additional resources, M/s OIL confirmed to increase the resources and achieved 1200 ID/day by Mar'15.
Constr.
30-Apr-15
III
Completion of balance piling work (Covered under Piling-IIII Contract) (Total 2077 Nos piles approx).
Open
BPCL
30-Apr-15
III
57
Risk Owner
Medium
Key Risk Description
Status (Open / Close)
Start of work for Tankage-IV by M/s Offshore Open Constructi Awarded on 17.04.14 on CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT383/391) Sch : 57.46% Front : 57.56% Actual : 21.51%
Risk Id E
Job No.: A307 Feb'15 Page 581+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
58
61
E
62
E
63
Action Plan
Action By
Target Date
Risk Severity
- At present only 26 nos welders are available at site with per day rate of 1000 ID, however to achieve the completion schedule minimum 1500 ID/day to be achieved.
Constn.
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
-Out of 2205 nos piles, 833 nos piles completed.
Controllability Condition (D/I )
Impact Score => {6+7+8+9} * 10 * 11
Current Risk Score -> {5}* {12}
Previous Risk Score
(Current risk Score - Previous Risk score)
G
2
7
I
2
J
1
2
5
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Piping fabrication work & Piping erection work in progress. - Equipment erection in progress (13 nos completed) - Structural fabrication in progress for TS-2
Constr.
30-Apr-15
III
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
BPCL
1-Jun-15
III
Implementation of Change management system The same affects : - Finalization of basic philosophies - Scope of services - Release of deliverables Various scope changes (as advised by BPCL), resulting in expenditure of extra manhours against control manhours.
Open
PROCES S/ENGG/ CONS.
Medium
N
Y
Y
N
Long term
D
0.14
0.07
0.07
0.00
a. Change management should be in place immediately b. Strict discipline to be maintained else end objective would be difficult to meet.
Projects
Continuous
IV
Timely Commissioning of UB package to meet refinery commissioning schedule. LAD : 31.03.15 (UB 1) 30.06.15 (UB 2)
Open
Constn.
Medium
N
N
Y
N
Long term
I
0.2
0.10
0.10
0.00
-Strict monitoring required at all stages upto commissioning. Constn. / -Completeness of supply of all subparts, their assembly and other BOP Items to be ensured. Projects / - Both steam drum delivered at site. RCC work for chimney completed, foundation work in progress for UB's. BPCL Erection of structure started. - Progress of work affected due to delay in completion of civil foundations.
as scheduled
III
Timely payment to sub contractor by main contractor
Open
Const.
Medium
N
N
Y
Y
Long term
D
0.1
0.05
0.05
0.00
Following methodology being taken up for smooth cash flow to contractors: - Issue of comfort letter by BPCL to sub Vendors & subcontractor being implemented. - Provision for direct payments to contractors sub vendors & subcontractor being implemented as per contract provision. - Provision of interest bearing mobilisation advance against equivalent bank guarantee being implemented for future contract of more than 5CR value. - Expeditious processing of RA bills.
Project/BPCL As Required
IV
Infrastructure at Kochi
Open
Const.
Low
N
N
Y
Y
Long term
D
0.1
0.03
0.03
0.00
Contractor to identify the proposed areas in and around Project area and BPCL to facilitate by persuading with local authorities for required permission.
Constn. / Projects / BPCL
As Required
IV
Projects
Medium
Y
N
N
N
Short term
D
0.08
0.04
0.04
0.00
- Meeting held with BPCL on EIL recommendations and action plan finalised. BPCL / - BPCL to take up with MOEF for approval of changes in system already incorporated. (e.g. configuration for Projects CPP) - Incorporation of EC and RRA recommendations in balance systems under progress.
As required
IV
Implementation of environmental clearance conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Risk Owner
Urgency (Long Term / Short term)
3
1
K
Output Quality ( Y / N)
2
G
K
Schedule ( Y / N)
1
G
EIL Cost (Y / N)
F
F
Open Constructi on
Status (Open / Close)
Risk Id 64
F
Completion of Composite works by M/s Albana for VGO Unit Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15 Sch : 31.1% Front : 28.6% Actual : 13.8% 53608 ID / 145080 ID piping fabrication & 26678 / 248080 IM completed.
Key Risk Description
E
Job No.: A307 Feb'15 Page 582+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Open
Statutory approvals - Factory inspectorate approval - CEA (Central electrical authority) approval -IBR approval (LAD - IBR Package for DCU by end Dec'13; CDU/VDU by 31.12.13)
Open
Projects / BPCL
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- All drawings for F&B approval issued progressively upto 29.09.14. -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
EIL/BPCL
30-Apr-15
IV
Implementation of Health, Safety and environmental (HSE) system
Open
Const.
Very High
N
N
Y
Y
Short term
D
0.2
0.19
0.19
0.00
- Deployment of skilled manpower for enforcement of safety precautions. - Monitoring of the HSE conditions and maintenance of records ./ reports. - Safety Drills being organised on monthly basis.
Constn.
Continuous
III
Mobilisation of Skilled workers
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
0.40
0.40
0.00
-Utilisation of migrant and skilled labour from outside Kerala needs to be encouraged. However, the same will be effective only if proper labour colony facilities are arranged by the contractors. - Slow down in progress of work by Union workmen, inspite of assurance by trade union leaders that workers shall be instructed to improve productivity.
Constn / BPCL
As Required
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
0.40
0.40
Being taken up through BPCL at District Collector & Chief Ministers office for early settlement.
Constn / BPCL
As Required
At present only approx 12000 labours are working against requirement of 15000-18000 labours. Quarry operator strike : Quarry operator strike in the state from 12.02.15 has affected the concreting work.
II
II
Risk Id
Key Risk Description Previous Risk Score (Current risk Score - Previous Risk score)
Impact Score => {6+7+8+9} * 10 * 11
Controllability Condition (D/I )
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Risk Owner
Current Risk Score -> {5}* {12}
Total Risk Score
Status (Open / Close)
Kochi Refinery, BPCL Integrated Refinery Expansion Project
IV - RISK REGISTER Job No.: A307 Feb'15 Page 583+15 of 32
22.50 23.06 -0.56
Action Plan Action By Target Date Risk Severity
Job No.: A307 Jan'15 Page 584 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
D
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Completion of Reactor regenerator package for FCCU-M/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 90.0% Act: 63.7 % Construction Progress: Sch: 66.1% Front: 85.8% Act: 25.6 %
Open
Project
Management level meeting held on 20.01.15 at site. EIL/BPCL - Hard stand construction completed. - Crane (1600 MT): Load test and readiness targeted by end Feb'15. EPIL/GRE to arrange another crane (1000 MT-from M/s VTV) for Regenerator bottom section erection. - 1st lot & 2nd lot cyclones for reactor & regenerator dispatched progressively on 21.01.15, balance shipment targeted by end Feb'15. M/s Emtrol is being expedited. - Erection of TSS bottom and top section targeted by end Feb'15. - Erection of regenerator bottom section targeted from end Feb'15. - Erection of external riser targeted by end Mar'15. - Erection of reactor bottom section targeted by end Mar'15. - Agencies being pressurized to expedite completion of balance works by Dec’15 and requested to submit Catchup plan. - ESP structures are under despatch.
Feb'15-Mar'15
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 30.07.16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 79.2 %; Act: 60.0 % Construction Progress: Sch: 61.5% Front: 100% Act: 32.7 %
Open
Project
Following commitments have been made by M/s Essar. -Shift Work: Works in two shifts implemented. - Structural erection upto 127 m completed. Cage erection completed on 19.12.14. - Opening of LC for imported items: M/s EPIL informed letter of credit through Bank of India opened. - M/s Essar have been pressurized to deliver all coke drums progressively upto Apr’15 and Coke fractionator by end Mar’15. BPCL/EIL - Crane (2000 MT): All consignment reached at port. Mobilization targeted by Feb’15 and erection of equipments targeted to commence from Mar’15 to May’15. -Clear water tank fabrication- Agency being finalised, Civil tank pad work commenced. - Resource augmentation for Civil & Strl works being expedited. At present 457 nos have been deployed against requirement of 607 nos.
Erection by May'15
Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 12 M available for construction works (excl. Dismantling works) against schedule of 22 M. - Process package was delayed by 2 M due to delay in P&IDs review meeting and delay in award of licensor. - Change in the scope based on health check report has an impact on Project cost and schedule. Physical Progress: Target Sch: 88.4% Catch Up Sch: 62.3 % Act: 48.3%
Open
Constn. / Projects
- Tender splited into two parts (Structural/ Mechanical works & Civil work). 3 nos bids EIL/BPCL received on 21.01.15 for Structural/mechanical work. Civil work being done by misc. Civil agency (M/s Furnace Fabrica). Rigorous follow up with contractor to be made after award of contract. Electrical Work: Bids due on 03.02.15. Instrumentation Work: Bids due on 04.02.15. .
Feb'15
Backlog 18.4% as of 15-Jan-15 in Construction activities viz., Civil works and Mechanical works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 33 M Catch Up sch: Const Sch Front Act 53.5 76.0 62.9 41.4 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site. -Construction progress for Jan'15 got improved (During the month progress achieved is 3.84 %)
Open
Const
- Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & EIL M/s Deens has been lined up to supplement Civil works. Further 1 additional Civil & Structural works contracts targeted to award by mid Feb’15. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. Further 1 additional Civil & Structural works contracts targeted to award by mid Feb’15. - Contractors are facing problem in retaining the labour at site. Approx 11000 labours are available at site, though induction programme has been carried out for more than EIL/BPCL 18000 labours . requirement of manpower at site is approx 19000 nos. - RCC work & structural fabrication/erection work to be expedited to give complete front to mechanical contractor progressively upto Apr-May'15. - Lighting of areas to facilitate night shift working. - Provision made for snacks/dinner for labour to facilitate working in extended/night shift - Provision of multiple entries inside plant areas to ease manpower/machinery mobilisation to be explored. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. - In order to boost progress, permission from labour union of Kochi to be taken up for two shift work.
As Required
Key Risk Description
1
Action Plan
Action By
Target Date
Risk Severity
I
D
9
Strl Steel: Out of total 3210 MT, 2138 MT procured, 1207 MT fabricated & 793 MT received.
I
E
4
I
E
7
I
Job No.: A307 Jan'15 Page 585 of 749
Integrated Refinery Expansion Project, Kochi
E
Slow construction progress of SRU Block due to delayed area handing over - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by Jan'15. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) - As per present trend 15 months (starting from end Jun’14) are available with respect to schedule of 25 M (As per past experience minimum requirement for SRU is 30 M).
Open
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 86.6 % Act: 39.6 % Construction Progress: Sch: 75.6% Front: 100 % Act: 23.2 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Slow progress of RO-DM works (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 (As per vendor) Overall Progress: Sch: 98 % Act: 62.9% Construction Progress: Sch: 100 %; Front: 100%; Act:36.0%
Open
Slow Construction progress for Civil Works- FCCU Contr. Sch: 100 %; Front: 100% Act: 68.2 % (M/s SEPC) CCD: 24.12.14 ECD: Oct'15
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Proj. / Constn.
14
Action Plan
- Management level meeting held with M/s B&R on 08.01.15 at EIL site and augmentation of manpower by min. 100 nos to be expedited for concreting work progress. All area handed over in SRU. - Retaining wall completed for the available front. Balance piling being carried out through Piling III to take up further retaining wall work. - Piling for SRU : All piling drawing released. To meet Euro-IV compliance, focussed efforts being made for ARU/SWS. Piling for ARU/SWS is completed. Balance piling work completion targeted by mid Feb'15. - Civil works completion targeted by mid May’15 and handing over of front to mechanical contractor targeted from end Feb’15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
Action By
EIL
Target Date
Risk Severity
Feb'15
EIL/BPCL
I
E
34
Project
Management level meeting held on 09.01.15. EIL/BPCL - Completion of equalisation tank targeted by Mar'15. - Chemical house super strl work completion targeted by mid Mar’15. - During the meeting on 05.12.14, M/s Paramount informed that ETP plant can be made ready by Dec’15. - Substation Building: Slab completion for switch gear room targeted by end Feb'15. - Night shift work being implemented. Additional manpower of 30 nos being planned to mobilise by end Jan'15.
As stated
Project
- M/s Driplex informed that DM water can be provided by Sep’15 for CPP and EIL/BPCL accordingly have been asked to submit completion plan. -M/s Driplex to mobilise additional resources for completion as per catch-up plan. - DM tanks (2 nos) : Piling rig mobilised and piling work commenced. Tank B: (76/160 nos piling completed). Tank -A : (20/160nos piling completed).
As Required
Open
Project
Management level meeting held with M/s Shriram on 19.01.15 at site. - Mobilisation of resources is being expedited. At present only 110 nos, manpower mobilised against requirement of 350 nos. M/s Shriram agreed to augment additional 98 nos manpower by Feb'15. EIL/BPCL - M/s Shriram agreed to complete foundation for Tech structure F & Tech structure D by 07.02.15. Structural fabrication/erection for tech structure A/E/D targeted progressively by end Feb’15. Management level meeting held with M/s Zillion on 13.01.15 at site. - M/s Zillion agreed to complete all fabrication drawings by end Jan’15. - M/s Zillion agreed to fabricate 500 MT structural steel by 31.01.15 & additional 500 MT by 15.02.15.
As Required
Slow construction progress in Offsite-DHDS area. Work stopped by M/s KSS in DHDS area for Civil & Strl work CDD: 24.01.15 ECD:. Dec'15
Open
Constructio -Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. EIL/BPCL n Civil/Strl contractor. -Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deen has been lined up to supplement Civil works. Further 1 additional Civil & Structural works contracts targeted to award by mid Feb’15. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. Further 1 additional Civil & Structural works contracts targeted to award by mid Feb’15.
Ordering of Critical Valves Sch: 11.07.14 Ant: 07.02.15 Dely: 06/07 M FOT /FOB
Open
I
E
40
I
E
41
I
E
49
Feb'15
I
C
73
Project
-Revised MR (MR-3415): Ordered to M/s Oswal, M/s Shalimar, M/s AV valves and M/s BPCL L&T. - New MR-3515 (41 Nos) floated, Award recomn issued on 09.01.15.
Feb'15
II
Job No.: A307 Jan'15 Page 586 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
D
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB: unloaded onto barge on 26.12.14) ISGEC Josen (3 nos) Column: expected to receive at Kochi port from Feb'15 to mid Mar'15.
Open
T&CC
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 31.10.15
Open
Projects
Slow progress of work & poor manpower mobilisation by M/s B&R for Composite Works-DCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15 Construction Progress: Sch: 38.6 % Front: 27.1% Act.: 10.6% AG piping fabrication: Only 55911 ID / 406975 ID fabrication completed. AG piping erection: Only 39904 IM / 526435 IM piping erection completed.
Open
Constructio Management review meeting held on 08.01.15. n -30 fitters, 40 welders & the required machineries shall be deployed by 30.01.15. -Insulation/painting agency finalization by 31.01.15. - Hanger scaffolding to be introduced at site.
Slow construction progress for Civil & Strl work for Refinery area: Generation of front for mechanical works affected (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:98.9%; Front: 95.9%; Act: 29.9% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held at Kochi site on 20.01.15 EIL/BPCL n - RCC sub structure work shall be completed by Mar '15. - 30MT /day shall be fabricated from Jan'15 onwards. - 1500 MT each fabrication shall be done during Feb'15. Bal 600 MT fabrication to be done by 28.02.15.
As Required
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for DCU. Sch: 04.09.14 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 98.7 % Act: 90.6 %
Open
Constructio Management level meeting held on 14.01.15 n - Handing over of complete branch piperack targeted by 28.02.15. - TS-I : completion by 20.02.15. -TS-II : completion by 25.03.15. - TS-III : Structural erection targeted by 31.01.15. Completion by 28.02.15.
As Required
Mobilisation of Skilled workers
Open
Const.
-Utilisation of migrant and skilled labour from outside Kerala needs to be encouraged. Constn / However, the same will be effective only if proper labour colony facilities are arranged BPCL by the contractors. - Slow down in progress of work by Union workmen, inspite of assurance by trade union leaders that workers shall be instructed to improve productivity.
As Required
Completion of MCC pkg for SRU LAD: 23.06.15 CCD:18.02.15 (including Site work) ECD: 18.05.15 Ordered to M/s Thermax on 19.08.13 (18 M incl erection)
Open
Project
- M/s Thermax seeking extension for duration due to delayed availability of burner BPCL / EIL data from M/s Aecometric. Letter forwarded on 11.06.14 to BPCL for recommending extension for supply portion to M/s Thermax upto 30.11.14. Further M/s Thermax seeking extension for duration upto 31.03.15 for supply through letter dated 08.10.14. - Foundation work completed for 1st train. 2nd train foundation targeted by mid Feb'15. Bidder has requested for providing space for storage of MCC equipment & Refractory Materials. - Refractory lining work in Combustion chamber can be started only after erection of MCC pkg.
15-May-15
II III
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
1-Jun-15
III
Key Risk Description
13
Action Plan
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. - DHDT reactor unloaded into barge on 26.12.14 and anchored at BPCL's jetty. - Construction of jetty work for unloading is being expedited to be ready by Feb'15. - Erection of reactor planned with 1000 MT crane by mid Feb'15. - M/s Urmila to carry out strengthening of the Chitrapuzha bridge. - Management level meeting with M/s Urmila planned in 1st week of Feb'15 at EIL Delhi.
Action By
EIL/BPCL
Target Date
Risk Severity
Feb'15
II
D
19
- Compressor casing dispatched from M/s NP Italy workshop on 17.09.14.(Received EIL/BPCL at BHEL workshop). - Compressor casing received at BHEL workshop on 28.10.14 and is under machining. Further delivery of compressor takes normally 10-11 month after receipt of casing. - M/s BHEL to prepone the delivery of CEP turbine (from Oct'15 to Apr'15). - Meeting with M/s BHEL planned on 10.02.15.
Continuous
II
E
20
EIL/BPCL
Continuous
II
E
49
II
E
EIL/BPCL
51
II At present only approx 11000 labours are working against requirement of 15000-18000 labours. K
2
D
8
F
1
BPCL
Job No.: A307 Jan'15 Page 587 of 749
Integrated Refinery Expansion Project, Kochi
G
G
Risk Owner
E
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Mar'15)
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
Timely payment to sub contractor by main contractor
Open
Const.
Following methodology being taken up for smooth cash flow to contractors: Project/BPCL As Required - Issue of comfort letter by BPCL to sub Vendors & subcontractor being implemented. - Provision for direct payments to contractors sub vendors & subcontractor being implemented as per contract provision. - Provision of interest bearing mobilisation advance against equivalent bank guarantee being implemented for future contract of more than 5CR value. - Expeditious processing of RA bills.
IV
Infrastructure at Kochi
Open
Const.
Contractor to identify the proposed areas in and around Project area and BPCL to facilitate by persuading with local authorities for required permission.
IV
Key Risk Description
8
1
2
Action Plan
Action By
BPCL
Constn. / Projects / BPCL
Target Date
Mar'15
As Required
Risk Severity IV
A
A
A
A
1
2
3
14
(Current risk Score Previous Risk score)
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Jan'15 Page 588+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
15
16
17
Target Date
4
5
6
7
8
9
10
11
12
Delay in issue of Process deliverables for Open engineering for NHT / ISOM due to delay in receipt of Process Package from M/s UOP (Process pkg incl. resolution sheet received on mid Aug'13 against sch of 30-Apr-13) Schedule : 31-Jul-13 Anticipated : mid Nov'13
Process
Low
N
N
Y
N
Short term
D
0.2
0.00
Actions Taken so far: Projects / - UOP package received on 08.08.13. Process - PDS issued for all Columns, Vessels, Air Fin Coolers, Exchangers & Refrigeration pkg, pumps (part balance). - All 30 nos P&IDs issued for engineering Action Plan for balance - 19 nos out of 23 nos pumps datasheet issued for engineering. Balance progressively targeted by 15.11.13.
15-Nov-13
Oct'13
Delay in Finalisation of balance OSBL distribution P&IDs due to delay in receipt of data from BPCL LAD - 30-Nov-12; Ant - 15-Oct13 Natural gas operating/ design condition information has been received from BPCL during meeting dated 13 & 14.8.13. Steam distribution : Preliminary discussion on BOO steam distribution held with BPCL. BPCL approval on EIL scheme required.
Open
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
- Meeting held with BPCL on 18-20.09.13.
Process / Projects
15-Oct-13
sep'13
Holds, missing information, corrections, changes in PDS / P&IDs - CDU / VDU - DCNs on account of HAZOP recommendations for CDU / VDU
Open
Process
Medium
N
N
N
N
Short term
D
0
0.00
- All P&IDs incorporating DCNs issued.
Process
25/10/13
Oct'13
Holds, missing information, corrections, changes in PDS / P&IDs - DCU
Open
Process
Medium
N
N
N
N
Short term
D
0
0.00
- Design Change Note based on Hazop recommendations issued on 03.01.14. All major process P&IDs released. - Major pumps data received and foundation drawing released.
4
18
Risk Severity
15-Mar-14 Projects / Engg Process
19
Mar'14 & Apr'14
31-Mar-14 30-Apr-14
Delay in Process Package for TGTU (M/s CB & Close INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13 A
5
A
6
A
7
A
8
N
N
Y
N
Short term
I
0.4
0.00
-Process package received on 14.04.13
Apr'13
Close
Process
Very High
N
N
Y
N
Short term
D
0.16
0.00
All PDS issued for Engg. All Process P&IDS issued. Utility P&IDs: 15 out of 15 nos issued for engineering.
Delay in "issue for engineering - IFE" PDS for DCU LAD : 29-Dec-12; Ant : 19-Mar-13
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
Process package from M/s Lummus received on 17-Aug-12. All Equipment PDS issued for engineering. Utility equipment issued for engineering.
Process
-
Mar'13
Process
Low
N
N
Y
N
Short term
I
0.4
0.00
Based on latest information from BOO HGU and SWII (FCC), Revised Design Basis issued.
Projects / Process
-
Mar'13
Process
Low
N
N
Y
N
Short term
D
0.16
0.00
Process P&IDs: All process P&ID issued. PDS: Heat Exch. - 52/52 issued for Engg. Pumps 49/50 issued for Engineering. Vessels 38/38 tags issued for Engg. Air cooler 6/6 issued for Engineering.
Process
Process
Low
N
N
N
N
Short term
I
0
0.00
- Common Interconnection P&ID for FCC, VGO and DHDT will be issued (covered under risk A09). Hence clubbed with Risk no. A09.
BPCL / Projects / POSD
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Close
Close
9
10
Projects / Process
Delay in "issue for engineering - IFE" PDS / P&IDs for DHDT P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A
Low
Agreement signed by BPCL-KR issued to Licensor on 04.04.13
Delay in "issue for engineering - IFE" PDS / P&IDs for FCC LAD :29-Jan-13; Ant : 08-May-13 A
BPCL / Process
Close
0.00
0
-
Apr'13
Apr'13
31-Dec-12
Jan'13
A
2
11
A
12
A
13
A
14
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
15
16
7
8
9
10
11
12
N
Y
N
Short term
D
0.16
0.00
All process P&IDs issued. Pumps PDS issued for engg,. All Vessels PDS issued for engg.
-Preparation of Offsite P&ID’s for tankages Close (LAD - 21.01.13) - Delay has been due to delay in receipt of Asbuilt drawings from BPCL-KR (except CEMP-II). All details received now. -Upgradation of Crude oil pipeline system (Inside refinery) to be taken up.
POSD
Very High
N
N
Y
N
Short term
I
0.4
0.00
- All 32 P&ID issued for engineering
Apr'13
In view of increase in sulphur load PDS & Close P&IDs for sulphur block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement. Revision in PDS after issue of “Issued for Close Engineering” after release of MR
Process
Low
N
N
Y
N
Short term
D
0.16
0.00
- All PDS and P&ID revised and issued.
Apr'13
Process/E NGG
Low
N
N
Y
N
Long term
I
0.2
0.00
Revision in PDS to be avoided once same is issued for engineering
Process
High
N
N
Y
N
Short term
I
0.4
0.00
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New facilities) has been issued for engineering. Balance BPCL / 1 no. targeted by 15.03.13 Projects / POSD
Low
Y
Y
Y
Y
Long term
D
0.2
0.00
Revision in PDS to be avoided once same is issued for engineering.
Y
Y
Y
Y
Long term
D
0.2
0.00
Revision in PDS to be avoided once same is issued for engineering
In case of revision in process parameters of an equipment the utility estimates furnished by engineering RED / PED/ against older Revision of PDS should not be used until same is got verified/ updated for current revision. PROCESS RED to update all such changes within stipulated time frame as per departmental guidelines and Process to incorporate in the revised PDS. Utility P&IDs: P&IDs (14 / 17 ) issued for engg (except for small bore piping: Pump Seal & Vent Drain). The Process same are targeted by Jun'13.
Close
16
Revision in PDS after issue of “Issued for Engineering” after Order
Close
A
Process/E NGG/Proc ure
17
Revision in PDS after issue of “Issued for Engineering” after Equipment manufacturing
Close
A
Process/E Very Low NGG/Proc ure Low
N
N
Y
N
Long term
I
0.2
0.00
18
Updation of estimated utilities on account of Close revision in process parameters (revision of PDS based on engg comments)
Process
A
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
19
ISBL Distribution P&IDs for VGO-HDT SCH: 30-Nov-12 ANT: Jun-13
Close
A
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
20
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 ANT: 31-May-13
Close
A
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
0.00
Distribution P&IDs issued for engineering.
A
21
A
18
6 N
15
A
17
Risk Severity
5
A
A
Target Date
Medium
-Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
14
Action By
4
Close
13
Action Plan
Process
Delay in "issue for engineering - IFE" PDS / P&IDs for VGO-HDT LAD : 29-Jan-13; Ant : 10-May-13
3
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 589+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
0
Process
19 Apr'13
-
Apr'13
15-Mar-13
Feb'13
Process
-
Apr'13
Process
-
Apr'13
As Required
Apr'13
Process
31-May-13
Apr'13
31-May-13
Apr'13
Utility distribution P&IDs for DCU
Close
Process
Low
N
N
N
N
Long term
I
0
Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 Updation of P&ID as per finalised condensate philosophy to be taken up.
Open
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
- Revised P&ID for Condensate System issued on 15.05.13.
BPCL
25-May-13
May'13
Open
Engg
Very High
N
N
N
N
Short term
D
0
0.00
- Inconsistency related to type of Isolation valve (Ball Vs. gate / globe/check) between instrumentation and process design basis identified during coordination meetings resolved by TSD.
Engg.
30-Apr-14
May'14
23
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed engineering activities.
Open
Power Tech.
High
N
N
Y
N
Short term
D
0.16
0.00
- System configuration including 8 pumps, filters & centrifuge finalised and PDS for pumps issued. Filters & Projects 30-May-14 Centrifuge PDS issued for engineering on 22.05.14. (CPP group) - Readiness of the fuel forwarding system to be ensured w.r.t. GTG commg schedule (i.e. in Mar 15).
24
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new GTG).
22
0.00
Process
Jan'13
May'14
1
2
A
25
A
26
A
27
A
28
B
B
1
2
B
3
B
4
B
5
B
6
B
7
B
8
3
4
5
6
7
8
9
10
11
12
BPCL confirmation/clarification over datasheets/GAD’s for existing/new raw water intake pump obtained from M/s KBL (LAD for MR for pumps - 07.03.13)
Close
Engg.
Medium
N
N
Y
N
Short term
I
0.4
Identifications of hook-ups on flare lines and finalisation of methodology BPCL Signing of ISBL P&IDs and with battery limiti.e. P&IDs availability of Shut down / Hot tapping. for Units, Utility packages & other packages.
Close Open
Projects Process / POSD
Medium Low
N N
N N
Y Y
N N
Short term Short term
I D
0.4 0.16
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Close
Process / POSD
High
N
N
Y
N
Short term
D
Issue of Equipment layout for engineering for Open NHT/ISOM Ant - 21-Aug-13) Delay in this activity shall hamper the following: i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation
Engg.
Very High
N
N
Y
N
Short term
Issue of Equipment layout for engineering for VGO-HDT LAD - 07-Nov-12 Ant- 26-Dec-12
Engg.
Very high
N
N
Y
N
Engg.
High
N
N
Y
ENGG
High
N
N
Procure/E NGG/CON S.
Medium
Y
Close
Delay in this activity shall hamper the following: Issue of Equipment layout for engineering for Close i) 3 D Modelling FCCU (targeted by ii) Civil/Structural & 27.12.2012) UG Piping Tender Delay in this activity shall hamper the following: preparation i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation NIT for Heater for FCCU Open LAD -01-Apr-13 ; Ant - 18-Jun-13 a) Cost/time overrun due to rework b) Non completion of critical project activities within time & delay in Project completion c) Poor performance of Sub-contractors and Vendors
Close
13
14
(Current risk Score Previous Risk score)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 590+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15 0.00
Action By
Target Date
17
18
16 - PDS for desalting pumps issued on 25.10.13. MR issued on 13.11.13.
Engg
Risk Severity
19 Nov'13
0.00 - Identification of hook ups for Flare line, FCC flare, PRU flare and NHT / ISOM completed during site visit EIL Process. -0.05 by Signing of P&IDs completed for: - Hook sketches prepared and signed by Piping / POSD / BPCL. Marking at site to be taken up on -CDU/VDU Blocktoonbe24.06.14. priority. - DCU unit on 03.07.14 & CR LPG unit on 22.07.14. Finalisation methodology for taking up works targeted by end Dec 13. -- VGO unit onof12.07.14. - DHDT unit on 24.07.14 - FCCU unit on 23.07.14 - SRU block on 25.07.14. - Offsite P&IDs issued to BPCL. Signing completed
Projects / Constn. Process / POSD /
0.16
0.00
Updated P&IDs released.
Process / POSD /
D
0.16
0.00
- Equipment layout issued for engineering on 23.08.13
Piping
21-Aug-13
JUL'13
Short term
D
0.16
0.00
Equipment layout issued for engineering
Piping
26-Dec-12
Jan'13
N
Short term
D
0.16
0.00
Equipment layout issued for engineering
Projects / Piping / BPCL
21-Dec-12
Jan'13
Y
N
Short term
D
0.16
0.00
NIT issued on 24.06.13, bids due on 23.07.13
Projects / Process / HMTD
18-Jun-13
May'13
N
Y
N
Long term
D
0.12
0.00
1) Involvement of technical/engineering team and client with vendor where non-standard products are required 2) Clarification of all doubts prior to beginning of work 3) Procedures for internal review and approval of design/deliverables to be followed
Projects
As Required
Apr'13
0.05
30-Dec-13 31-Jan-15
Dec'13
Mar'14 & Apr'14
New requirement of power recovery system (FCCU) shall have impact on project cost. 3 Nos PRTs envisaged (FCC-1 Nos ; VGO- 2 Nos)
Close
Project
High
Y
N
Y
N
Short term
I
0.6
0.00
-Discussions with prospective bidders held seeking details on implementation methodology. -Decision regarding System integration schemes taken during meeting dated 17th & 18th Dec 12. MR issued
Engg (Elec)
15-Jan-13
Jan'13
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; Ant: Mid Jun'13
Open
Engg.
High
N
N
Y
N
Short term
D
0.16
0.00
- Layout finalised with licensor. Final layout under study. - Model review for SRU completed on 30th May'13 (except TGTU, incinerator section & downstream of sulphur pit).
Piping
15-Jun-13
May'13
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant Close End May 13) Piping preliminary MTO has been released without covering DHDT, VGO FCC& offsite interconnection P&IDs, Flare system & offsite storage P&IDs. Prel. MTO covers 35% for large bore pipes.
Piping
Very High
N
N
Y
Y
Short term
D
0.2
0.00
Intermediate MTO released on 31.05.13.
Piping
31-May-13
May'13
B
9
B
10
B
11
C
12
B
B
(Current risk Score Previous Risk score)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
16
17
18
Risk Severity
5
6
7
8
9
10
11
12
Very High
N
N
Y
N
Short term
D
0.16
0.00
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
Issue Overall UG piping layout drawing for the complex
Close
Engg.
High
N
N
N
N
Short term
D
0
0.00
- Layout for OWS, CRWS, CW & FW lines issued for Offsite.
Gen Civil
31-May-13
May'13
Completion of 30 % Model review VGO- LAD: 09-Mar-13 FCCU-LAD : 23-Apr-13
Open
Engg.
High
N
N
Y
N
Short term
D
0.16
0.00
VGO-HDT: 30 % modelling completed on 7th Jun'13 FCCU: 30 % modelling completed on 06.06.13. SRU (excluding TGTU) – completed on 30.05.13.
Piping
Prog. To Jun 13
May'13
NIT for Civil & Strl work for existing Refinery Area LAD: 31-Jan-13 ANT: 18-Jun-13
Open Project/C& Very High P
N
N
Y
N
Short term
D
0.16
0.00
- NIT issued for publishing on 12.06.13 with sale period from 17.06.2013 to 05.07.2013
Project / C&P 18-Jun-13
May'13
N
N
Y
N
Long term
D
0.08
0.00
Wide variation of BOQ and site executed quantities for item rate tenders to be controlled. Past data to be analysed and used for reference purposes.
Engg
Apr'13
19 Apr'13
As Required
13
MR issue for MCC (Main combustion Chamber) Close packages. B
15
Target Date
4
Engg/proc Very High urement
14
Action By
HMTD
Close
13
Action Plan
Delay in thermal design for Heat exchangers & Close Air coolers for licensed and non licensed units LAD (DHDT): 02-Feb-13 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
a) Inaccurate assessment of quantum of work B
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
Status (Open / Close)
Risk Id
Key Risk Description
1
Job No.: A307 Jan'15 Page 591+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
14
15
Project
Medium
N
N
Y
N
Short term
D
0.16
0.00
MR issued on 02.05.13.
Engg
Apr'13
Timely finalisation of Package Interface Open CDSP-DCU awarded on 22-Aug-13; RR pkg-FCC awarded on 25-Jul-13. (Battery Limit conditions for each package to be frozen within three months of award to ensure time availability for engg, procurement and construction by all the concerned).
Engg.
High
N
N
Y
N
Short term
D
0.16
0.00
- Management level meetings with package contractors being organised to expedite the works. - Battery limit conditions for CDSP Pkg (awarded to M/s Essar on 22.08.13) submitted by vendor & approved under code 2 on 07.05.14. - Battery limit conditions for R&R Pkg (awarded to M/s Essar on 25.07.13) received from vendor and approved.
Projects / Engg. / Process
May'14
Unit and offsite interfaces (Elevation termination Close levels)
Engg.
Medium
N
N
Y
Y
Long term
D
0.1
0.00
- Clubbed with Risk ID A27
TSD
High
N
N
Y
N
Short term
D
0.16
0.00
- Data received from all vendors. All piling drawings for CPP area released. - Foundation drawings for & HRSG under progress and targeted by mid Mar'14.
ENGG/PLNG Mid Mar'14
N
N
Y
N
Short term
I
0.4
0.00
- NIT issued on 11.03.13, bids due on 16.04.13. Pre bid meeting targeted on 02.04.13. (Delivery : 18 M for Mechanical Completion including Pre-Commissioning Activities)
N
N
Y
N
Short term
D
0.16
0.00
- Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. - HAZOP review completed for GTG, HRSG & UB package. - 90% model review for HRSG planned in end Jan'15. -90% model review for UB package held from 18.11.14 to 20.11.14. - GBC ordered to M/s BHEL on 25.07.14. KOM held with M/s BHEL for Gas booster compressor on 12-13 Aug'14.
Engg
LAD: 16-Feb-13 Ant: 15-Apr-13
-
Mar'14 & Apr'14
16
B
17
B
18
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule requirements. LAD - 28.02.13; Ant - upto Feb 14.
Open
Projects
NIT for Heater for DCU LAD -15-Feb-13;
Close
PROCES Very High S/ENGG
B
19
CPP: Integration of various packages & BOP Open Engg/Cont Items of CPP. . 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas Booster compressor.
20
Distributed Control System (DCS) Detailed engg., supply and erection (ordered on M/s Emerson Process on 04.11.13)
Open Engg/proc urement
B B
21
60 % Model review for DCU (LAD:03.07.13 Act:13.09.13)
Close
ENGG
Low
0.05
0.05
10-Mar-13
Feb'15
Feb'14
Feb'13
IV
Projects / Process Process / HMTD C&P
Medium
N
Y
N
N
Long term
I
0.15
0.00
- Preparation of Inst. dwgs./ docs. by the DCS vendor, using Smart Plant Instrumentation (SPI) is already covered in DCS vendor’s scope in DCS
Projects
Very High
N
N
Y
N
Short term
D
0.16
0.00
- Model review completed on 13.09.13
ENGG
Continuous
Sep'14 & Oct'14
Aug'13
5
6
7
8
9
10
11
12
Low
N
Y
Y
N
Long term
D
0.14
Low
N
N
Y
N
Long term
I
0.2
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
Open Engg/proc urement
14
(Current risk Score Previous Risk score)
2 Package Vendor refuses to submit Instrumentation Drawings/ Documentation in Smart Plant Instrumentation Database as per Client Requirement
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 592+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
Target Date
Risk Severity
17
18
0.00
- Being taken up with respective package vendors for implementation.
Instn / Projects
Continuous
Sep'14 & Oct'14
19
0.00
Package vendor inputs being made available by expediting for updation of interface engineering documents.
Projects / Engg.
Continuous
IV
B
22
B
23
Delay in Interface Engineering (including control Open Engg/proc system) due to non availability of Package urement Vendor Data Open
ENGG
Medium
N
N
Y
N
Short term
D
0.16
0.00
Model review completed on 04.10.13
ENGG
4-Oct-13
sep'13
B
20
60 % Model review for DHDT (LAD:07.08.13 Ant:04.10.13) - Integrated model for RGC, MUG compressor, Feed filter & Heater pkg awaited from vendor. - Vendor drawings for sheds awaited.
GC
Medium
N
N
Y
N
Long term
D
0.08
0.00
- All P&IDs released
G. Civil
25-Jul-13
JUL'13
24
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
B
Project
Medium
N
N
Y
N
Short term
I
0.4
0.00
- Ordered to M/s Powerica Ltd on 29.09.14 (Delivery duration 13 M+ 3 M site works).
BPCL
5-Oct-14
Sep'14 & Oct'14
25
Order of MR for DG set Dely: (12 M FOB + 3 M Site work) Sch: 05.11.13
Open
B
Receipt of Inputs from Process / Vendors for 60 Close % Model review for VGO-HDT required for procurement of piping material (LAD:14.08.13 Ant:25.10.13) - Integrated model for RGC, MUG compressor, Feed filter & Heater pkg awaited from vendor. - Vendor drawings for sheds awaited.
ENGG
Very High
N
N
Y
N
Short term
D
0.16
0.00
- Model review completed on 24.10.13. Process / Process to remove holds as per piping Hold up lists released till date by 25th Oct 13. Projects - Piping to release updated hold up lists based on release of holds by process on fortnightly basis to process / project / planning / TSD / Risk Coordinator. - Meeting between Process, Piping, Projects shall be organised within 3 days of issue of hold up lists. - Process to issue Revised P&IDs latest within 4 weeks of HAZOP recommendations.
25-Oct-13
sep'13
60 % Model review for FCCU (LAD:16.09.13 Ant:25.10.13) - Line size for 300 nos P&IDs under hold -Vendor data needed for coalescer, electric heater, pumps & filters - Review of model by Licensor (Stone & Webster) envisaged.
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
0.00
- Model review completed on 25.10.13.
ENGG
25-Oct-13
sep'13
60 % Model review for Open SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), Delay in release of Intermediate 2nd Open 164 (SRU),15 (SWS) & 60(TGTU) + MTO LAD:30.09.13; 155(Utilities Act:31.10.13) Holds: -CVs Size Hold as follows: 13 (ARU), 6 (SWS), -CDU/VDU: 125 (SRU). Pump nozzle for 6 nos. pumps under hold),Valve sizes Face for 256 lines under hold, are -All Control to Face Dimensions Control All valve flange, bypass valve HOLD. CVsmatching for TGTU are HOLD. and flanges (21 nos.) & PSV inlet outlet flanges and reducers (37 nos.) -DHDT: By-pass lines for CVs under hold (30nos), PSV's mating flanges and reducers (44 nos), Lines (103 nos.) not considered in MTO.
ENGG
Medium
N
N
Y
N
Short term
D
0.16
0.00
- Model review started on 28.10.13 and under progress. Targeted to complete by 31.10.13.
ENGG
31-Oct-13
sep'13
ENGG
Very High
N
N
Y
N
Short term
I
0.4
0.00
- Intermediate 2nd MTO released on 31.10.13, based on above MR under preparation.
Projects / ENGG
31-Oct-13
Oct'13
B
0.06
26
B
27
B
28
B
0.06
29
B
31
B
32
B
33
B
34
C
1
C
2
C
3
C
4
C
5
C
6
C
7
C
8
C
9
7
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
D
0.16
0.05
0.05
0.00
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
HAZOP for FCCU Close LAD - 23-Sep-13 Completion of 90 % engineering by Mar-14. Open Average progress achieved in last 3 months 3.0 % LD Milestone date - Dec'13
ENGG ENGG
High Low
N N
N N
Y Y
N N
Short term Short term
D D
0.16 0.16
0.00 0.00
- HAZOP study completed on 29.11.13. - As of 15 Aug'14 Engineering progress is 91.4 %.
ENGG ENGG
Release of final Piping MTO Sch: Jul'14
Open
ENGG
High
N
N
Y
N
Short term
D
0.16
0.00
- Final MTO released on 11.09.14.
Finalisation of GTG fuel forwarding scheme for naphtha to day tank when Naphtha tank being under maintenance.
Open
POSD
Medium
N
N
Y
N
Short term
I
0.4
0.00
- Revised P&IDs issued for connecting tank-101 & 102. New pump process datasheet released for piping naphtha from YT-332 to CPP day tank.
Delay in award of PRT -FCCU(Hot gas expander) LAD: 19.04.13 Ant: 30.12.13 Multiple Bids extensions leading to delay in ordering. 02 Bids recd on 12.08.13 (Dresser Rand ,Elliot Ebara) Org. BDD: 27.06.13 1st extension: 16.07.13 2nd Extension: 01.08.13 3rd extension: 09.08.13 Duration: 16 M FOB
Close
Project
Medium
Y
Y
Y
N
Short term
I
0.9
0.00
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 Duration: 18 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
Very High
Y
Y
Y
N
Short term
D
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
Close
Project
Very High
Y
N
N
N
Short term
Award of Heater for DHDT LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Very High
N
N
Y
N
NIT for Composite Works for DCU LAD -06.06.13 ; Ant - 25.10.13
Open
ENGG
Very High
N
N
Y
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
ENGG
Very High
N
N
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
ENGG
Very High
N
Urgency (Long Term / Short term)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
6 N
Schedule ( Y / N)
5 Low
EIL Cost (Y / N)
(Current risk Score Previous Risk score)
30
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
4 ENGG
Risk Owner
3 Open
2 Generation of Surplus Piping material
B
Status (Open / Close)
Risk Id
Action Plan
Key Risk Description
1
Job No.: A307 Jan'15 Page 593+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
Progressively
IV
Nov'13 Aug'14
Sep'14
Sep'14 & Oct'14
Process / Engg.
Sep'14
Sep'14 & Oct'14
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
30-Dec-13
Dec'13
0.00
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
30-Aug-13
JUL'13
0.36
0.00
- BPCL confirmation sought for minimum nos (10.97 MW or 80% of 10.97) for qualifying criteria. Accordingly C&P BQC changed and approved by BPCL. Draft NIT by 25.05.13. Publishing targeted by end May 13.
30-May-13
May'13
I
0.2
0.00
- As per latest cost status report the impact of cost variation has been neutralised by savings.
Projects
Continuous
Nov'13
Short term
D
0.16
0.00
Awarded to M/s Technip on 04.09.13 (Duration 18 M)
Projects / HMTD
15-Sep-13
Aug'13
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
25-Oct-13
sep'13
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
31-Oct-13
sep'13
N
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
N
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
2
C
10
C
11
C
12
C
13
C
14
C
15
C
16
C
17
C
18
C
19
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
15
16
17
Target Date
4
5
6
7
8
9
10
11
12
Medium
Y
Y
Y
N
Short term
D
0.36
0.00
-Ordered on M/s Shin Nippon & M/s Flowserve on 30.01.14 (except Tag IV-P-301 A/B due to poor past EIL performance of PRT supplied under CEMP-II by M/s GENP); - Separate MR released for item tag IV-P-301 A/B. BPCL informed that order expected to be placed as per previous recommendation, ordering expected by mid Mar'14. - As a parallel action MR was issued however RFQ kept under hold in view of BPCL information regarding ordering by mid Mar 14.
15-Mar-14
Mar'14 & Apr'14
NIT for Composite Works for Offsite DHDS area Open LAD -22.07.13 ; Ant - 15.10.13
ENGG
Very High
N
N
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Projects / HMTD
15-Oct-13
sep'13
NIT for Composite Works for Existing refinery area LAD -22.07.13 ; Ant - 31.10.13
Open
ENGG
Very High
N
N
Y
N
Short term
D
0.16
0.00
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Projects / HMTD
31-Oct-13
sep'13
Award of : Main fractionator for FCCU LAD: 25-Mar-12 Ant: 20-Jul-13
Open Project/En Very High gg
N
N
Y
N
Short term
I
0.4
0.00
-Ordered to M/s Fabtech on 15.07.13
Engg/Proj
20-Jul-13
JUL'13
Issue NIT for Tankage-II LAD: 21-Jan-13 ANT: 31-May-13
Close Project/C& Very High P
N
N
Y
N
Short term
I
0.4
0.00
NIT issued on 29.05.13, bids due on 18.06.13.
Project / C&P 31-May-13
May'13
Award for RO-DM LAD:30-Jan-13 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
- Awarded to M/s Driplex on 12.06.13. duration is 22 M.
Engg / C&P
29-Jun-13
May'13
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13
Close
Project
High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months.
BPCL
28-Feb-13
Feb'13
NIT for Reactor regenerator package for FCCU LAD : 01-Jan-13 Ant: 21-Feb-13 Changes in scope of supply led to revision in BQC / tender.
Close
Project / Licensor
Very High
Y
Y
Y
N
Short term
I
0.9
0.00
BQC finalised on 15.01.13. Tender under compilation. Draft NIT being issued to BPCL for approval. NIT targeted by 21-Feb-13.
Projects / BPCL
21-Feb-13
Feb'13
Project
Low
N
N
N
N
Short term
I
0
0.00
Ordered to M/s Paulose George (15 M).
BPCL
Close
Ordering of Reactor for VGO-HDT LAD: 29-Dec-12 ACT: 08-Apr-13
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Ordered on M/s L&T on 08.04.13.
Proj/Engg
Award of contract for Piling-II LAD: 31-Dec-12
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s L&T on 09.04.13 with duration of 12 M.
BPCL
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Petron on 09.04.13 with 18 M duration.
BPCL
Engg.
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Technip on 07.03.13 (Duration 23 M)
20
C
21
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 Ant: 30-Mar-13
22
Award of Crude and Vacuum heaters (LAD 29.12.12) Ant : 07.03.13
18
Risk Severity
ENGG
C
C
Action By
3
Award for Raw water quarries LAD :03-May-13 ANT: 15-Apr-13
14
Action Plan
Open
Award of PRT for DHDT & VGO-HDT unit (Pumps centrifugal multistage) Sch: 23.04.13 Ant: 15.03.14 (IV-P-301A/B)
13
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 594+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
19
Apr'13
-
Mar'13
-
Mar'13
Ant: 15-Apr-13
Close
-
Projects / 7-Mar-13 C&P / BPCL
Mar'13
Feb'13
C
23
C
24
C
C
14
(Current risk Score Previous Risk score)
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Jan'15 Page 595+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
Target Date
17
18
Risk Severity
4
5
6
7
8
9
10
11
12
Storage of sulphur and related issues with Close Granulator to be finalised between BPCL / EIL.
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.00
- Scheme finalised.
Projects / BPCL
19
NIT for ETP package with WAO (Wet air Close oxidation) LAD: 15-Jan-13 Ant: 16-Apr-13 Ordering of Desalter Internals (LAD:03-Dec-12) Close Ant: 07-Mar-13
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Tender released on 26.03.13; BQC finalised on 08.04.13. NIT targeted by 16-Apr-13
Engg
Project
High
N
N
Y
N
Short term
D
0.16
0.00
Award recommendation issued on 11.02.13. Awarded to M/s Howe baker on 07.03.13
Proj/Engg
Award of contract for Building incl substations LAD: 07-Feb-13 Ant: 15-Apr-13
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s L&T (duration 20 M)
BPCL
Open
Strl
High
N
N
Y
N
Short term
D
0.16
0.00
KB tech completed development of flare area & handed over the area to M/s L&T.for piling.
Projects
Close
Engg / C&P
Very High
N
N
Y
N
Short term
D
0.16
0.00
- Evaluation of LLIs to be ensured with-in 1 month from receipt of bids by Engg. & PBO recommendation Engg / C&P / with-in 1 week by C&P. Projects - Pre tender / Pre enquiry meetings to be conducted with bidders to avoid extensions in bid due date due to lack of clarity in scope / other requirements. - Immediate after issue of Enquiry a firm action plan to be developed by the Project coordinator clearly indicating targets for Issue of TQ / CQ , Post bid meetings, TBA/CBA, PBO reco., Price bid opening and award recommendation dates. - Uploading of bids in eDMS by C&P within 1 - 2 days (Max.) of bid submission by bidders. - Restriction of multiple TQs / CQs. - Rigorous follow up by C&P / Engg. / Projects for receipt of TQ / CQ replies from bidders within cut off dates.
TBA - 1 month of bids receipt PBO - 1 week of TBA
Dec'13
Award of Waste heat Boiler package (Waste Close Heat Boilers along with respective steam drums(un engineered ), Incinerator Combustion Chambers (engineered), Incinerator vent stacks). LAD: 27.04.13 Ant: 30.12.13 Bids extension: 1st extension - from 28.05.13 to 20.06.13. 2nd Extension- from 20.06.13 to 02.07.13. 3rd extension - from 02.07.13 to 08.07.13. Duration: Supply + Erection - 18 M
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Tecnicas Reunidas S.A. on 31.12.13
BPCL
30-Dec-13
Dec'13
Delay in award of CDSP package Open Schedule: 02.03.13 Anticipated : 30.08.13 Completion of works Sch: 01.05.15 ( M); RFQ Duration : ( M) Anticipated: 23.11.15 (27 M) Bidders quoted 27 M against schedule of 26 M.
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.00
Awarded to M/s Essar Project on 22.08.13 (Duration: 27 M)
C&P / Engg / 30-Aug-13 Projects
JUL'13
Apr'13
Apr'13
7-Mar-13
Feb'13
25
26
Filling of existing part fire water pond required for area preparation.
Close
Apr'13
30-Mar-14
Mar'14 & Apr'14
Sch - 28.08.13; Area handed over to M/s L&T C
27
Delay in ordering of Long Lead Items. Technical / Commercial evaluation of long lead items (compressors & packages) taking more than 2 months.
C
C
C
28
29
30
C
C
C
C
C
C
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
15
16
Action By
Target Date
Risk Severity
2
3
4
5
6
7
8
9
10
11
12
17
18
19
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.00
- Awarded to M/s BHEL on 25.07.13.
Projects / Engg / C&P / BPCL
20-Jul-13
JUL'13
Delay in Ordering of HRSG Close (Sch Order - 22-May-13; Ant - 20-Dec-13) Initial Change in configuration by BPCL. Multiple extensions (twice) in bid due date due non availability of exhaust data for GTG. Post Enquiry changes in type of Fuel (LSVR) by BPCL. No PTR available for LSVR Fuel Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
Projects / Very High Engg
Y
N
Y
N
Short term
I
0.6
0.00
- Awarded to M/s Thermax on 20.12.13
Projects / BPCL
Ordering of Reactor regenerator package for FCCU LAD : 10-Apr-13 Act: 10-Jul-13 Changes in scope of supply led to revision in BQC / tender due to which NIT was delayed. Bidders sought extension in dates.
Close
Project / Licensor
Very High
Y
Y
Y
N
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) Duration: 21 M+2 M No bidder could meet the BQC criteria in view of which the tender has been re-floated.
Open
Project
Very High
N
N
Y
N
Open
Process / Very High Engg / constn
N
N
Y
35
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 Duration: 20 M
Close Project/C& Very High P
N
N
36
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 Duration: 22 M+2 M
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
Low
N
Failure of contractors
Open
Const.
Low
N
32
33
34
14
Action Plan
Ordering of GTG Pkg (LAD:10-Mar-13; Ant 20.07.13) Bid received on 28.03.13. Multiple extension (4 times) in bid due date on request of M/s Siemens. Duration (Supply) - 15 M FOB /16 M FOT as per RFQ; Sch : 20 M
31
13
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 596+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
20-Dec-13
Nov'13
It is planned that common facility (incl. common piperack, utility lines etc) shall be taken up as per project schedule requirement. This shall be taken up during KOM with selected bidder.
Short term
I
0.9
0.00
Short term
I
0.4
0.00
N
Short term
I
0.4
Y
N
Short term
D
N
Y
N
Long term
N
Y
N
Long term
- 2 Bids (Essar & L&T) received on 25.04.13. - TBA issued on 21.05.13. - PBO recomn. issued on 30.05.13 and BPCL approval received on 03.06.13 - Price bids opened on 04.06.13. - Award recommendation issued on 25.06.13. - Awarded to M/s Essar on 10.07.13.
Projects / BPCL
BPCL
Jun'13
31-Oct-13
Oct'13
0.00
- 3 no. bids received on extended date of 02.02.13. Projects / 31-Jul-13 - Meeting with bidders held from 19.02.13 to 26.02.13. PBO recomn. issued on 06.05.13. Price bids opened C&P / BPCL on 09.05.13. - Award recomm issued on 12.06.13. Execution duration as per RFQ - 20 M; Sch - 24-26 M
JUL'13
0.16
0.00
Awarded to M/s Paramount (with 21 M for mechanical completion + 2 M for commissioning). Execution duration as per RFQ was - 22 + 2 M; Sch - 28 M
Aug'13
I
0.2
0.00
Meeting held with EIL & BPCL. Approach paper prepared and signed jointly by EIL / BPCL for limiting single BPCL / C&P agency getting work orders against more than 2 tenders. (In cases of big agencies with financial capability, one agency can get maximum works order against 3 tenders)
-
sep'13
D
0.08
0.00
Limit the number of works being awarded to one Agency so that alternatives can be worked out fast. BPCL/EIL To evolve a System to be implemented to ensure that the maximum number of jobs awarded to single agency is only 2 if NOT to be preferably made ONE only.
-
sep'13
Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
C&P/Engg/Pr oj
Anticipated Completion: 29-Jul-15
C
C
37
38
C&P BPCL / Projects
C
2 39
C
40
C
41
C
42
C
43
C
C
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
15
16
Action By
17
Target Date
18
Risk Severity
3
4
5
6
7
8
9
10
11
12
Project
Medium
Y
Y
Y
N
Short term
I
0.90
0.00
Awarded to M/s GEA on 10.07.13 with delivery period of 13 M.
BPCL
15-Jul-13
Jun'13
19
Award of Heater package for DCU Open (LAD:24-May-13; Ant: 15-Nov-13 Earlier 04 Bids recd on 21.05.13. (Petron, Thermax, Heurtey, Technip). Due to Technical and related commercial issues enquiry re-floated. Duration 20 M
Project
Very High
N
N
Y
N
Short term
I
0.40
0.00
Awarded to M/s Heurtey, (Duration - 20 M)
BPCL
15-Nov-13
Oct'13
Award of Civil & Strl work for DHDS offsite area Open (LAD: 30-Mar-13; Ant: 20.07.13) Duration: 18 M
Project
High
N
N
Y
N
Short term
I
0.40
0.00
Awarded to M/s KSS on 25.07.13. (Duration 18 M)
BPCL
20-Jul-13
JUL'13
Award of Civil & Strl work for refinery area. (LAD:25-Apr-13; Ant: 10.10.13) Duration: 16 M
Close
Project
High
N
N
Y
N
Short term
I
0.40
0.00
Awarded to Mcnally Bharat on 26.09.13. Duration- 16 Months
Project/C&P
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) Duration : 16 M
Open
Project
Medium
N
N
Y
N
Short term
D
0.16
0.00
NIT issued on 01.08.13, bids due on 30.08.13
Gen Civil/Project
25-Jul-13
JUL'13
Award of work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
0.00
Awarded to M/s McNally Bharat. Duration - 16 M
Gen Civil/Project
30-Oct-13
Oct'13
Ordering of Main Air blower & wet gas compressor for FCCU LAD: 04-Mar-13 Ant: 30-Sep-13 (Total execution duration is 25-27 M : 19 M FOT for delivery of WGC & MAB at site + 6 to 8 M Site installation & pre-comm; Time Available from order to MC OF FCCU - 24 months)
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
MAB awarded to M/s Elliot Ebara on 04.09.13. WGC awarded to M/s BHEL
C&P/Engg/Pr 30-Sep-13 oj
Aug'13
Award of Civil & Strl contract for CDU/ VDU & DCU LAD: 15-Dec-12 Ant: 07-Mar-13
Close
Project
Close
N
N
Y
N
Long term
I
0.2
0.00
Awarded to M/s L&T on 07.03.13. Award recomm sent to BPCL on 01.02.13. Award to be targeted by 07.03.13.
C&P
Feb'13
Ordering of wet gas compressor for DCU LAD: 02-Feb-13 Ant: 30-Jun-13
Close
Project
Medium
N
N
Y
N
Short term
I
0.4
0.00
Ordered to M/s Eliot Ebara on 28.06.13.
Ordering of OFF GAS COMPRESSOR - VGO LAD: 08-Jun-13 Ant: 30-Oct-13 RFQ duration: 17 M FOB
Open
Project
High
N
N
Y
N
Short term
D
0.16
0.00
Ordered on M/s Dresser Rand, Dely - 17 M FOT Dispatch
sep'13
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15
44
45
C
46
C
47
C
14
Action Plan
Open
Ordering of Ejector Pkg (LAD:12-Jan-13; Ant: 15-Jul-13)
13
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 597+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
48
0.00
0
7-Mar-13
Jun'13
EIL/BPCL
30-Oct-13
Oct'13
C
C
C
C
C
C
C
49
50
51
52
53
54
55
Previous Risk Score
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12} 13
14
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 598+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
17
Target Date
18
Risk Severity
2
3
4
5
6
7
8
9
10
11
12
Award of Sulphur Forming LAD: 03.04.13 Ant: 30.01.14 Earlier enquiry re-floated due to changes in MR requirements by BPCL(MR was revised as Evaluation methodology was to be based on NPV and in view of 2 different types of technologies viz., sulphur pelletiser and sulphur granule); refloated again as financial criteria was not met by all the bidders.
Open
Project
Very High
N
Y
Y
N
Short term
D
0.28
0.00
- Ordered to M/s Sandvik.
BPCL
30-Jan-14
Jan'14
19
Award of contract for Civil & structural for FCCU Close area (refloated) LAD:15-Mar-13 Ant: 30-Sep-13 Compl: 15 M – Dec'14; Sch: Nov’14 As decided during Management meeting dated 19.06.13, based on past Performance of recommended bidder tender refloated.
Project
Very High
N
Y
Y
N
Short term
D
0.28
0.00
Awarded to M/s Sriram on 25.09.13
BPCL
30-Sep-13
Aug'13
Award of contract for Civil & structural for DHDT Close & VGO area (refloated) LAD:15-Mar-13 Ant: 30-Sep-13 Compl: 16 M – Jan’15; Sch: Nov’14 As decided during Management meeting dated 19.06.13, based on past Performance of recommended bidder tender refloated.
Project
Very High
N
Y
Y
N
Short term
D
0.28
0.00
Awarded to M/s McNally bharat on 11.09.13 (with 16 M execution period)
BPCL
Award of contract for Civil & structural for CPP area LAD:28-Jun-13 Ant: end Aug-13 Duration: 16 M
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Essar Projects on 19.08.13
BPCL
28-Aug-13
JUL'13
Award of MCC package LAD:10.06.13 Ant: 14.08.13 Duration: 12 M despatch and 6 M for site work (ODC)
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Thermax
BPCL
14-Aug-13
JUL'13
Award of contract for RWTP (Refloat case) LAD: 14-Jan-13 Ant: 19-Jul-13 (Execution Duration - 18+2 M)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Triveni
BPCL
19-Jul-13
JUL'13
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 15.06.14 (Incinerator burner) (Execution Duration - 14 M)
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.00
Ordered to M/s Callidus and M/s UOP India on 20.06.14.
BPCL
Aug'13
Jun'14
C
2
56
Previous Risk Score
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12} 13
14
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 599+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
17
Target Date
18
Risk Severity
3
4
5
6
7
8
9
10
11
12
Award of Air blower/compressor for SRU LAD: 29-Mar-13 Ant: 25-Jul-13 (Execution Duration - 17 M FOB/ 18 M FOT)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Ordered on M/s Howden Process Compressors
Projects / C&P
Delay in Award of contract for Demountable flare (LAD: 08-Apr-13; Ant: 28-Sep-13) Change in type of Flare. Initially as per DFR normal flare was envisaged.
Close
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.00
Awarded to M/s Airoil on 25.09.13 with duration of 18 M.
Projects/ 28-Sep-13 Process/ Engg / C&P/
Aug'13
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 Duration: 12 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
- Awarded on M/s Ray Engineering on 23.01.14.
Engg / C&P
Jan'14
Award for:RGC compressor for VGO-HDT (LAD: 30-Mar-13; Ant: end Jun 13) Dely: 18 M
Open Project/En Very High gg
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s BHEL
Proj/Engg
29-Jun-13
Jun'13
Award of MUG compressor for VGO-HDT (LAD: 08-Apr-13; Ant: 30.11.13) Dely: 16 M FOB
Close Project/En Very High gg
N
N
Y
N
Short term
I
0.4
0.00
Ordered to M/s Neumen & Essar on 14.11.13
BPCL
30-Nov-13
Nov'13
Award of Contract for Tankage-III (Crude tank: Close Project/En Very High 02 Nos & 1 surge relief tank and crude drain gg tank) Outage of existing crude tank from crude to naphtha can be taken up after commissioning of new crude tanks. Shutdown of existing tanks17 & 18 depend on commissioning of new crude tanks-25/26 under tankage-III. Sch: 01.10.13 Ant: 15-Dec-13
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s IOT Anwesha on 04.12.13. (duration: 20 M)
BPCL
15-Dec-13
Nov'13
28-Jun-13
Jun'13
19-Jul-13
19 JUL'13
Post enquiry significant changes (received on 15.03.13) in Flare Load/Process Data Sheet due to enormous increase in BOO flare load and non acceptance of mitigation measures by FCCU Licenser. C
57
Change in flare load data due to change in flare height upto 150 M. Completion of works Sch. : 31.01.15 Ant. : 28.02.15
C
58
C
59
C
60
C
61
Close Project/En Very High gg
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s BHEL
Proj/Engg
62
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: Jun 13)
N
C
Close Project/En Very High gg
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Dresser Rand
Proj/Engg
63
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep-13) Duration : 18 M FOB
C
Aug'13
C
C
C
C
C
C
64
65
66
Previous Risk Score
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12} 13
14
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 600+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
Target Date
17
18
Risk Severity
2
3
4
5
6
7
8
9
10
11
12
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) Sch: 30.04.13 Ant: 30-Sep-13 Duration:22 M
Close
BPCL
High
N
N
Y
N
Short term
D
0.16
0.00
Awarded to M/s B&R
BPCL
30-Sep-13
Aug'13
19
Award of Tankage-IV (Total 15 Nos Tanks) LAD: Jan14 • Outage for Tank YT-340 depends on readiness of at least one new DCU feed tank which will require 14 M durations. Alternative scheme required to be finalised for outage. • Outage of Tankage YT-18 depends on readiness of new crude tanks (Tankage-III; YT25/26). Alternative scheme required to be finalised for outage.
Open
BPCL / Projects
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Offshore on 17.04.14.
EIL / BPCL
25-Apr-14
Mar'14 & Apr'14
Award of Composite Works for CDU/VDU (06 Bids - L&T, Petron, Offshore, Mcnally Bharat, Albana, IOTL recd on 04.09.13) LAD -30.08.13 ; Ant - 31.10.13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
.Awarded to M/s Offshore (Duration- 20 months)
BPCL
31-Oct-13
Oct'13
Award for contract for development of flare area Close LAD: 01-Nov-13 Ant: end Dec'13
Project
Very High
Y
N
Y
N
Short term
D
0.24
0.00
Contract for development of flare area awarded to M/s KB Tech..
Engg / C&P
30-Dec-13
Nov'13
Award of Composite Works for VGO-HDT, DHDT, CPP and Offsites (DHDS) LAD 31.12.13 ; Ant - 30.05.14
Open
ENGG
Very High
N
N
Y
N
Short term
I
0.4
0.00
Composite Works for VGO-HDT & DHDT -DHDT- Awarded to M/s Albana on 19.05.14 (16M+2M). -VGO-HDT- Awarded to M/s Albana on 19.05.14 (16M+2M). Composite Works for Offsite Part B (DHDS): Awarded to M/s Offshore on 19.05.14 (16M+2M). Composite Works for CPP: Awarded to M/s Zillion Infra. on 19.05.14 (16M+2M).
Projects / Engg.
30-May-14
May'14
Award of Heater package for FCCU (LAD:08-Jul-13; Ant: 15-Dec-13 Earlier 05 Bids recd on 23.07.13. (Thermax, Technicas, Petron, B&R, JNK). Duration 20 M
Close
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Petron on 04.12.13. Duration is 16 M
BPCL
15-Dec-13
Nov'13
Award of Gas Booster Compressor for CPP (Dly: 13 M FOB / 14 M FOT)) (LAD:29.12.13; Ant: 30.07.14)
Open
Project
Medium
Y
N
Y
N
Short term
I
0.6
0.00
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
30-Jul-14
Jul'14
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 Ant: 10.10.14
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.00
-Ordered on M/s Asco Filtri Srl ON 17.10.14.
BPCL
Oct'14
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards Piping intermediate MTO-II released on 30.10.13.
Open
Project
Low
N
N
Y
N
Short term
D
0.16
0.00
- All pipes, fittings & flanges ordered.
C&P
14-Aug-14
Duration - 20 M
67
68
69
C
70
C
71
C
72
Engg
Sep'14 & Oct'14
Aug'14
74
C
75
C
76
77
C
78
C
79
D
D
D
1
2
3
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
-Revised MR (MR-3415): Ordered to M/s Oswal, M/s Shalimar, M/s AV valves and M/s L&T. - New MR-3515 (41 Nos) floated, Award recomn issued on 09.01.15.
Award of contract for Mechanical works-CPP area LAD: 28.02.14 Ant: 25.05.14
Open
Project
Medium
N
N
Y
N
Short term
D
0.16
0.00
- Awarded to M/s Zillion on 19.05.14.
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 Ant: 31.01.15
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
0.15
0.15
0.00
-Total 34393 / 35337 nos (98%) isometrics issued for units . Balance ISO's targeted progressively by end Jan'15. -All GADs issued except SRU block (235 nos). Same shall be targeted by end Jan'15.
Engg.
Feb'15
Award of Composite Works (Structural Works & Mechanical) for NHT/ISOM-Refloated Sch: 08.05.14 Ant: 15.02.15
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
-Tender splited into two parts (Structural/ Mechanical works & Civil work). 3 nos bids received on 21.01.15 for Structural/mechanical work. Civil work being done by misc. Civil agency (M/s Furnace Fabrica).
EIL/BPCL
15-Feb-15
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) Sch:27.06.14 Ant: 05.08.14
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
- Ordered to M/s Sulzer.
BPCL
5-Aug-14
II Jul'14
Award of Electrical & Instrumentation Works for Units & Offsite Sch: 30.06.14 Ant: 10.11.14 Electrical/Instr. Works: Part A: CDU/VDU, DCU, FCCU, DHDT, VGO-HDT & IREP Offsite: Part B: SRU & DHDS/Refinery Offsite :
Open
Project
Low
N
N
Y
N
Long term
I
0.2
0.00
- Electrical Works: Part A: M/s Technimont Part B: M/s Consilium - Instrumentation Works: Part A: M/s Technimont . Part B: M/s Consilium
EIL/BPCL
Nov'14
Nov'14
Delay in award of piping material with G2E specification in CPP area.
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
All items have been ordered, deliveries to be expedited in order to timely availability of piping material for completion of steam network in CPP area.
EIL/BPCL
Feb'15-Apr'15
Completion of Reactor regenerator package for FCCU-M/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 90.0% Act: 63.7 % Construction Progress: Sch: 66.1% Front: 85.8% Act: 25.6 %
Open
Project
Very High
Y
Y
Y
N
I
0.9
0.86
0.86
0.00
Management level meeting held on 20.01.15 at site. - Hard stand construction completed. - Crane (1600 MT): Load test and readiness targeted by end Feb'15. EPIL/GRE to arrange another crane (1000 MT-from M/s VTV) for Regenerator bottom section erection. - 1st lot & 2nd lot cyclones for reactor & regenerator dispatched progressively on 21.01.15, balance shipment targeted by end Feb'15. M/s Emtrol is being expedited. - Erection of TSS bottom and top section targeted by end Feb'15. - Erection of regenerator bottom section targeted from end Feb'15. - Erection of external riser targeted by end Mar'15. - Erection of reactor bottom section targeted by end Mar'15. - Agencies being pressurized to expedite completion of balance works by Dec’15 and requested to submit Catchup plan. - ESP structures are under despatch.
EIL/BPCL
Feb'15-Mar'15
Delivery of GTG Pkg at site (LAD:29-Sep-14; Ant - 24-Nov-14) Awarded to M/s BHEL Duration (Supply) - 16 M
Close
Project
Very High
Y
Y
N
N
Long term
I
0.25
0.00
Clubbed with Risk ID E19
Project
Completion of UB package LAD : 31.03.15 CCD : 23.03.15 ECD:10.08.15 Awarded to M/s ISGEC on 25.07.13 Overall progress: Sch: 99.0 % Act: 76.5 % Construction Progress: Sch:99.6 % Front: 100 % Act: 43.7 %
Open
Project
Very High
N
N
Y
N
Long term
I
0.2
0.00
- 90% model review for UB package completed. - Erection of steam drum-I & II completed. (Sch: 16.09.14: got delayed as 550MT crane could not be mobilized from M/s.TWC). - Completion of structural erection work to be expedited. Piping erection work in progress for UB-1 & UB-2.
Project / Constn.
Urgency (Long Term / Short term)
7
N
Schedule ( Y / N)
6
High
EIL Cost (Y / N)
5
Project
Short term
0.19
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
4
Open
Risk Owner
(Current risk Score Previous Risk score)
C
C
3
Ordering of Critical Valves Sch: 11.07.14 Ant: 31.01.15 Dely: 06/07 M FOT /FOB
2
73
Status (Open / Close)
Risk Id C
Action Plan
Key Risk Description
1
Job No.: A307 Jan'15 Page 601+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
0.19
Action By
Target Date
Risk Severity
18
19
17 EIL/BPCL
Feb'15
25-May-14
II May'14
III
II
24-Nov-14
Continuous
I Nov'13
III
2
D
4
D
5
D
D
D
D
6
7
8
9
4
5
6
7
8
9
10
11
12
Project
Low
N
N
Y
N
Long term
I
0.20
13
Delivery of wet gas compressor for DCU at Site Open (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 15.02.15)
Project
Low
N
N
N
N
Long term
I
0
0.00
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 28.02.15)
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
Completion of all three site Fabricated Columns for FCCU :Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 100 % Act: 66.6 % - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach road upto fabrication yard, which affected shifting of sections.
Open
Project
Very High
N
N
Y
N
Short term
I
Completion of MCC pkg for SRU Open LAD: 23.06.15 CCD:18.02.15 (including Site work) ECD: 18.05.15 Ordered to M/s Thermax on 19.08.13 (18 M incl erection)
Project
Medium
N
N
Y
N
Short term
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 30.07.16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 79.2 %; Act: 60.0 % Construction Progress: Sch: 61.5% Front: 100% Act: 32.7 %
Project
Very High
Y
Y
Y
N
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
3 Open
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14
14
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 602+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
Target Date
17
18
Risk Severity
19
0.00
-All Indigenous component received at site within CDD. - All Foreign Source Components dispatched.
Project/Inspe Sep'14 ction
Sep'14 & Oct'14
0.00
0.00
MRT completed on 10.11.14. Dispatch expected by Mid Feb'15 due to Change order for additional requirement of NRT sizing and LC amendment
Project/Inspe 15-Feb-15 ction
IV
0.20
0.06
0.14
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Lube oil system under final testing. Further the final testing getting delayed as confirmed by M/s Howden due to delayed delivery by M/s Enpro (1st shift testing targeted by 25.02.15 & 2nd shift testing targeted by 30.03.15). Close monitoring to be done to ensure delivery on CDD.
Project/Inspe 28-Feb-15 ction
III
0.4
0.38
0.38
0.00
-Meeting held on 22.11.14, vendor agreed to deliver main fractionator by Jan'15 and balance columns by Project / Mar/Apr'15. Constn. - Foundation for main fractionator column (by M/s L&T): Only raft work completed and super structural work being expedited by M/s Tuaman and targeted by end Jan'15 and curing period of 28 days. - Erection for main fractionator targeted by end of Feb'15. Crane 1250 MT and 550 MT mobilised, erection scheme approved. - Stripper & rectifier Column: Erection of bottom section for stripper expected to commence from end Mar'15. Preparation of Hard stand to commence. Erection of bottom section for rectifier expected to commence from end Mar'15.
As stated
I
0.4
0.20
0.20
0.00
- M/s Thermax seeking extension for duration due to delayed availability of burner data from M/s Aecometric. Letter forwarded on 11.06.14 to BPCL for recommending extension for supply portion to M/s Thermax upto 30.11.14. Further M/s Thermax seeking extension for duration upto 31.03.15 for supply through letter dated 08.10.14. - Foundation work completed for 1st train. 2nd train foundation targeted by mid Feb'15. Bidder has requested for providing space for storage of MCC equipment & Refractory Materials. - Refractory lining work in Combustion chamber can be started only after erection of MCC pkg.
15-May-15
Short term
I
0.9
0.86
0.86
0.00
Following commitments have been made by M/s Essar. Constr. -Shift Work: Works in two shifts implemented. - Structural erection upto 127 m completed. Cage erection completed on 19.12.14. - Opening of LC for imported items: M/s EPIL informed letter of credit through Bank of India opened. - M/s Essar have been pressurized to deliver all coke drums progressively upto Apr’15 and Coke fractionator by end Mar’15. Additional manpower (75 nos) by M/s VTV shall available at site by 3rd week of Jan'15. - Crane (2000 MT): All consignment reached at port. Mobilization targeted by Feb’15 and erection of BPCL/EIL equipments targeted to commence from Mar’15 to May’15. -Clear water tank fabrication- Agency being finalised, Civil tank pad work commenced. - Resource augmentation for Civil & Strl works being expedited. At present 457 nos have been deployed against requirement of 607 nos. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT.
Open
Strl Steel: Out of total 3210 MT, 2138 MT procured, 1207 MT fabricated & 793 MT received.
D
10
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M Ordered to M/s BHEL on 28.06.13
D
11
Delivery of RGC compressor for DHDT(LAD : 05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
BPCL / EIL
II III
Erection by May'15
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.00
- All items received at site.
Project/Inspe end Dec'14 ction
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.00
- Received at site and erected.
Project/Inspe 27-Dec-14 ction
I Dec'14
Dec'14
D
2
12
Delay in hydrotesting of Vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: 15.02.15 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column.
3 Open
5
7
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Vacuum Column : Vacuum column erected on 19.01.15, hydrotesting planned in Mid Feb'15.
Constn. / VTV / Projects
15-Feb-15
Urgency (Long Term / Short term)
6 N
Schedule ( Y / N)
Action Plan
EIL Cost (Y / N)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner 4
BPCL / Very High Projects / Const.
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 603+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
II
D
D
13
14
Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB: unloaded onto barge on 26.12.14) ISGEC Josen (3 nos) Column: expected to receive at Kochi port from Feb'15 to mid Mar'15.
Open
T&CC
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. - DHDT reactor unloaded into barge on 26.12.14 and anchored at BPCL's jetty. - Construction of jetty work for unloading is being expedited to be ready by Feb'15. - Erection of reactor planned with 1000 MT crane by mid Feb'15. - M/s Urmila to carry out strengthening of the Chitrapuzha bridge. - Management level meeting with M/s Urmila planned in 1st week of Feb'15 at EIL Delhi.
EIL/BPCL
Feb'15
Close Monitoring of ODC equipment (including site fabricated/assembled) up to receipt at site
Open
Projects
High
N
N
Y
N
Long term
D
0.08
0.06
0.06
0.00
Out of total 57 nos. of ODCs; 22 nos received at site. & 6 nos under dispatch. Balance under close monitoring.
Shipping
Continous
Close Procure/C onstr
Low
N
N
Y
N
Long term
I
0.2
0.00
- Transporter philosophy frozen and hindrance enroute has been covered under Risk ID K3.
Shipping
As Required
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions.
Open Contract / Inspection
Medium
N
N
Y
N
Short term
I
0.4
0.00
Equipment by Ganson - M/s Ganson agreed to supply balance item of CDU/VDU. Items for SRU and DCU refloated under MR6560 (DCU): All items relocated to M/s Patel Airtemp, M/s Phils Heavy, M/s Acoustics India ; M/s Beekay Engg ; M/s Fab-Tech, M/s Nuberg Engg.
BPCL
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Apr-15 Ant: 24-Apr-15 Overall Progress Sch: 93.7 % Act: 63.1 %
Open Project
Medium
Y
Y
Y
N
Long term
I
0.45
0.00
- Flare foundation work completed. Projects/Con As Required - Erection scheme finalised. str. - Flare tip & molecular seal drum under dispatch. Molecular seal received at site. All flare riser expected to receive at site from workshop progressively by end Feb'15. Derrick structure: parts received at site, balance targeted by mid Feb'15.
Delay in delivery at site due to non-availability of transporter / hindrances enroute. D
D
D
II IV
Nov'13
15
Jun'14
16
17
0.23
0.23
III
D
D
D
D
D
D
D
D
D
18
19
20
21
22
23
24
25
26
5
6
7
8
9
10
11
12
Open Project / Process
Very High
Y
Y
Y
N
Short term
I
0.9
13
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 31.10.15
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 CDD: 03.04.15 Ant: 03.04.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 EDD: 05.04.15
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 CDD: 07.10.14 Overall Progress: Sch: 98 % Act: 95.0 %
Open
Projects
High
N
N
Y
N
Long term
I
0.2
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13 Overall Progress: Sch: 91 % Act: 66 %
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) LAD ;30.03.15 CDD: 30.04.15
Open
Projects
Low
Y
Y
Y
N
Long term
I
0.45
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 CDD: 30.03.15
Open
Projects
Medium
N
Y
Y
N
Long term
I
0.35
Delivery of steel plates by M/s Essar to other vendors. CDD: Progressively by 15.01.14.
Open
Projects
Very Low
N
N
Y
N
Short term
I
0.4
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
Addition of 4th Riser in Demountable Flare and identification of additional Equipment to be procured due to the same. (BPCL informed additional of 1 no. riser during meeting dated 16th Oct 13.) - Flare (with 3 risers) awarded to M/s Airoil on 25-Sep-13. Completion of Flare work: Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
14
(Current risk Score Previous Risk score)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 604+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
17
Target Date
18 As Required
Risk Severity
19
0.00
- BPCL confirmation on the additional flare stack addition received. - Agreed with Air Oil / BPCL for completion of 4th riser within CDD. - Revised PDS & P&IDs released on 15.11.13. - Order placement (change order) issued to M/s Airoil on 14.11.13.
BPCL / EIL
0.38
0.00
- Compressor casing dispatched from M/s NP Italy workshop on 17.09.14.(Received at BHEL workshop). - Compressor casing received at BHEL workshop on 28.10.14 and is under machining. Further delivery of compressor takes normally 10-11 month after receipt of casing. - M/s BHEL to prepone the delivery of CEP turbine (from Oct'15 to Apr'15). - Meeting with M/s BHEL planned on 10.02.15.
Project/Inspe Continuous ction
0.06
0.06
0.00
- MRT of compressor and Steam turbine completed.
Project/Inspe Continuous ction
0.19
0.19
0.00
-Ordered to M/s L&T on 08.04.13; Dly 21M FOT. Close monitoring to be done to ensure delivery on CDD. -Skirt fabrication completed. - Strike has been called off with effect from 12.05.14 at L&T Hazira workshop. Vendor being followed up continuously to deliver reactor before Feb'15.
Project/Inspe Continuous ction
III
0.00
- Reactor received at Kochi port and unloaded to barge on 26.12.14.
Project/Inspe Continuous ction
Dec'14
0.23
0.00
- 90% model review for HRSG planned in end Jan'15. - Balance engineering to be expedited by M/s Thermax. - HRSG #3, 4 & 5: Foundation works completed and handed over to M/s Thermax. Erection work commenced for HRSG-4. - Column erection started for 1st HRSG.
Project/Inspe Continuous ction
III
0.14
0.14
0.00
- Generator subordered. - Pedestal fabrication is at final-machining. - Exhaust case assembly, including diffuser and thermal insulation has been completed
Project/Inspe Continuous ction
III
0.18
0.18
0.00
-Silos with structure & Conveyors sub ordered by M/s Sandvik. Project/Inspe Continuous - Bottom Cones for Silo C ,D, E & F dispatched to site. ction -Delivery of Semi rolled sections of Silos shall commence from Jan'15 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited. - Foundations for pelletiser shed to be made ready.
III
0.00
Strl. Steel for R&RMajor portion of steel plates have been delivered by M/s Essar.
Project/Inspe Continuous ction
Oct'13
II IV
Jun'14
2
5
6
7
8
9
10
11
12
13
14
15
16
18
19
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Synchronous Motor ordered to M/s Toshiba Mitsubishi. Expected to receive at M/s Dresser shop by 03.02.15.
EIL/ BPCL
Continuous
IV
EIL/ BPCL
Progressively
IV
Urgency (Long Term / Short term)
4 Projects
Schedule ( Y / N)
3 Open
EIL Cost (Y / N)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Action Plan
Risk Owner
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 605+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
17
D
27
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 CDD: 10.03.15
Projects
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Main motor ordered. KOM for Motor held on 06-07.05.14 & expected to receive by 13.04.15 (FOB: Germany).
28
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) LAD : 26.02.15 CDD: 13.04.15
Open
D
Delay by vendor with respect to CDD due to financial constraint.
Open
Projects
Medium
N
N
Y
N
Long term
I
0.2
0.10
0.10
0.00
- Following bidders showing slow manufacturing progress: EIL/ BPCL - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:134, 184. . Balance orders expected to dispatch from Jan'15 to May'15. - M/s Universal: Meeting held on 25.11.14, M/s UHE agreed to deliver balance items progressively upto May’15. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360, 423 & 444. - M/s HDO (Columns, Heat Exchangers & Vessels): FOA No.: 199, 302, 310, 315, 318, 320, 327, 369, 389 & 395.
Feb'15
III
Non acceptance of PO for DHDT & VGO feed filter by M/s Filtrex (MR-4370) Ordered on 21.12.13 to M/s Filtrex ( Dely: 13 M FOB)
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
0.00
- M/s Filtrex asking for deviations on commercial terms. Meeting held on 08.07.14 to resolve the issues with EIL/ BPCL M/s Filtrex. Vendor provided all details.
Aug'14
Aug'14
Non acceptance of work order by M/s Flowserve for DHDT Centrifugal pumps Ordered on 30.01.14 to M/s Flowserve (MR5403) (FOA No 550 & 551) CDD: 01.03.15
Open
Projects
Medium
N
N
Y
N
Short term
I
0.4
0.00
- Order has been accepted by M/s Flowserve and amendment issued by BPCL on 11.07.14.
Jul'14
Jul'14
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) CDD: 18.10.14 EDD: 31.03.15
Open
Projects
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Order got delayed due to delay in manufacturing works. At present EIL/ BPCL fabrication of Stripper column going beyond Jan’15 due to which there will be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD. - Vendor being continuously followed up to expedite manufacturing progress. Debutanizer and Depropanizer already dispatched in sections to site.
Feb'15
Availability of 90 % Piping materials to generate Open adequate piping material front to composite contractors. Sch: (Intermediate MTO-3): Oct'14 EDD: Mid Feb'15 Sch: (Final MTO): Dec'14-Feb'15 EDD: Mar'15-Jun'15
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- As of now around 81% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Feb'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL. Additional requirement of 20000 m2 area in FACT being taken for piping storage.
EIL/ BPCL
Feb'15
Delivery Gas Booster Compressor for CPP (Dly: Open 13 M FOB
Project
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
Ordered to M/s BHEL on 25.07.14. KOM held on 12-13.08.14. - Compressor Journal Bearings were ordered. Impeller manufacturing is in process
EIL
Feb'15
II IV
Delay in delivery of equipments by: M/s TEMA :CDD: 06.01.14 to 15.01.15; EDD:Dec’14 to Mar’15 M/s Nuberg: CDD: 03.07.14 to 03.11.14; EDD: Dec'14 to May'15 M/s GR Engg: CDD: 28.01.14 to 31.07.14; EDD: Dec'14 to 31.01.15 M/s Fabtech Projects: CDD: Jul’14 to Jan’15; EDD: Dec'14 to Jul’15
Open
Project
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
Vendor being pushed for deliveries. Vendor shop visit/meeting being arranged.
Inspection / Project
Feb'15
III
Delay in submission & finalization of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. CDD: 19.05.15
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
-Submission of drawing by vendor & approval by HMTD to be expedited.
HMTD/Projec Feb'15 ts
D
D
D
D
29
30
31
32
EIL/ BPCL
II
D
D
D
D
33
34
35
36
II
E
1
E
2
E
3
E
E
E
4
5
6
3
4
5
6
7
8
9
10
11
12
Open
Constn.
Medium
N
N
Y
N
Short term
I
0.4
Constn.
Medium
Y
N
Y
Y
Short term
D
0.28
Open Constn.
Medium
N
N
Y
N
Short term
I
0.4
Very High
Y
Y
Y
N
Short term
I
0.9
Availability of Soil investigation Report for new Open BPCL / High Crude tankages area. Projects / Delay in availability of soil data will affect Const. preparation for piling tender and layouts drawings. Further civil / structural tender will also affected.
N
N
Y
N
Long term
I
0.2
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 100% Front: 100 % Act:69.9 % CCD: 20.12.14 Ant: 15.07.15
N
N
Y
N
Short term
I
0.4
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
Open
Construction of NHT/ISOM (Revamp) Open Constn. / - Target Schedule : 30.09.15; Only 12 M Projects available for construction works (excl. Dismantling works) against schedule of 22 M. - Process package was delayed by 2 M due to delay in P&IDs review meeting and delay in award of licensor. - Change in the scope based on health check report has an impact on Project cost and schedule. Physical Progress: Target Sch: 88.4% Catch Up Sch: 62.3 % Act: 48.3%
Open
Const
High
13
0.14
0.86
0.32
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
2 Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsite) Awarded on 25.09.12 (Sch - 100 %, Act 91.7%) RCC Piles:4822 / 5307 Nos. Balance for offsite (SS VGO & compound area at FACT). Presently 5 total rigs are operating
14
0.14
0.86
0.32
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 606+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
Action By
Target Date
Risk Severity
17
18
0.00
Piling completed for CDU/VDU DCU & Offsite (except boundary wall) Balance piling (479 nos) for GTG, UB & stack area being done by M/s DBM. Job given on 07.10.13 with CCD by 1st week of Dec'13.
Constn.
Mid Oct'13
19
0.00
- During the project review meeting dated 28.08.14 following points discussed and BPCL agreed: - Area for spool storage handed over to Mechanical contractors. - FACT area arranged for storage of materials of owner and package contractors. Storage in FACT area commenced.
BPCL
Feb'15
III
0.00
-Major rock blasting work completed.
Constn.
sep'14
Aug'14
0.00
- Tender splited into two parts (Structural/ Mechanical works & Civil work). 3 nos bids received on 21.01.15 BPCL/EIL for Structural/mechanical work. Civil work being done by misc. Civil agency (M/s Furnace Fabrica). Rigorous follow up with contractor to be made after award of contract. Electrical Work: Bids due on 03.02.15. Instrumentation Work: Bids due on 04.02.15. .
Feb'15
0.00
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
BPCL / Projects
15-Jul-13
0.00
- MCR, CPP control room : Release for panels by Oct'15 & total completion by Dec'15. - Other building works : SRR Completion progressively between Jan'15 to May'15. - L&T also agreed to augment required manpower to 1000 from current deployment of 900 to meet the target completion date.
Constn
As Required
sep'13
I JUL'13
II
E
7
8
E
9
E
10
E
11
E
12
13
7
8
9
10
11
12
13
14
15
16
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
- Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deens has been Constn lined up to supplement Civil works. Further 1 additional Civil & Structural works contracts targeted to award by mid Feb’15. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. Further 1 additional Civil & Structural works contracts targeted to award by mid Feb’15. - Contractors are facing problem in retaining the labour at site. Approx 11000 labours are available at site, though induction programme has been carried out for more than 18000 labours . requirement of manpower BPCL/EIL at site is approx 19000 nos. - RCC work & structural fabrication/erection work to be expedited to give complete front to mechanical contractor progressively upto Apr-May'15. - Lighting of areas to facilitate night shift working. - Provision made for snacks/dinner for labour to facilitate working in extended/night shift - Provision of multiple entries inside plant areas to ease manpower/machinery mobilisation to be explored. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. - In order to boost progress, permission from labour union of Kochi to be taken up for two shift work.
As Required
0.00
0.00
0.00
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
BPCL
Mar'15
Urgency (Long Term / Short term)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
6 N
Schedule ( Y / N)
5 Very High
Action By
17
Target Date
Risk Severity
18
19
I IV
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Mar'15)
Open
Constn.
Very High
N
N
N
N
Long term
I
0
Completion of piling work by M/s L&T (Piling-II): CDD- 08.05.14. (Total 12003 Nos piles). (Contr.Sch- 100%, Front-100%, Act-100%) Only 10 nos. hydraulic & 4 nos. conventional rigs are currently operational at site. Total 10124 nos completed out of 12003
Open
Constn.
High
N
N
Y
N
Short term
I
0.4
0.00
L&T has completed all piles in Demountable flare area, Air compressor & DG shed area.
Constr.
Immediate
Jul'14
Payment to contractors
Close
Constn.
Low
N
N
Y
N
Long term
D
0.08
0.00
Ensure that 90% payment of the RA bills certified by EIL are released to the contractors within 7 days of receipt by client.
BPCL
within 7 days of certified RA bills
sep'13
Low
N
N
Y
N
Long term
D
0.08
0.00
Ensure that realistic dates of availability of inputs(drawings, front and materials) are considered in project/ Project / construction schedule rather than compressing construction schedules alone to meet the completion target. Planning
As Required
sep'13
0.00
All 5 nos tank area cleared and released. Area handed over to M/s B&R for Tankage-II works on 30.04.2014 BPCL
end Apr'14
May'14
0.00
- M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barbendors (Manpower required is 359 nos while available manpower is 166 Nos). - Substation building: completion being targeted by Mar'15. - Chemical house works completion being targeted by end Mar'15. - 90 % Model review held on 03.11.14.
Feb'15
Unrealistic project time leading to under quality Close
E
(Current risk Score Previous Risk score)
E
4 Const
EIL Cost (Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Backlog 18.4% as of 15-Jan-15 in Construction Open activities viz., Civil works and Mechanical works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration 46 M; Time lapsed - 33 M Catch Up sch: Const Sch Front Act 53.5 76.0 62.9 41.4 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site. -Construction progress for Jan'15 got improved (During the month progress achieved is 3.84 %)
Action Plan
Risk Owner
Status (Open / Close)
Risk Id
Key Risk Description
1
Job No.: A307 Jan'15 Page 607+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Project / Engg. / planning
Dismantling of LO CAT SRU and area handing Open over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. Will affect release of front for tankages.
BPCL
Medium
N
N
Y
N
Short term
I
0.4
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating) Overall Progress: Contr. Sch: 98.4 % Act: 76.6% Construction Progress: Sch: 99.7 % Front: 100 % Act: 71.3 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Project
Very High
Y
N
Y
N
Long term
I
0.3
Open
0.29
0.29
Constr.
II
E
14
15
E
16
E
17
E
18
E
19
E
20
E
21
E
22
E
23
E
24
8
9
10
11
12
13
14
15
16
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Management level meeting held with M/s B&R on 08.01.15 at EIL site and augmentation of manpower by Constn. min. 100 nos to be expedited for concreting work progress. All area handed over in SRU. - Retaining wall completed for the available front. Balance piling being carried out through Piling III to take up further retaining wall work. - Piling for SRU : All piling drawing released. To meet Euro-IV compliance, focussed efforts being made for ARU/SWS. Piling for ARU/SWS is completed. Balance piling work completion targeted by mid Feb'15. - Civil works completion targeted by mid May’15 and handing over of front to mechanical contractor targeted from end Feb’15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15. EIL/BPCL
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
Open Proj. / Constn.
Medium
N
N
Y
N
Short term
I
0.4
0.00
Graded and handed over to tankage-II
Constr.
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Ant - Dec 2013
Close Proj.
Very High
N
N
Y
N
Short term
I
0.4
0.00
Clubbed with Risk ID E33
BPCL
Very High
N
N
N
N
Short term
I
0
0.00
M/s BPCL Vide mail dated 21.08.2013 has handed over the area for SG-III.
BPCL
BPCL
Medium
N
N
Y
N
Short term
I
0.4
0.00
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
As Required
Const. / Projects
Low
N
N
N
N
Long term
I
0
Projects
Feb'15
Close
Const.
Low
N
N
Y
N
Long term
I
0.2
Close Open
EIL Const.
Low Very High
Y
N
Y
N
Long Short term
DI
0.12 0.6
Low
N
N
N
Y
Short term
D
Low
N
N
Y
N
Long term
I
Land acquisition for Crude tank (2 nos.) . (LAD - Close Proj. Jul 13; Ant - 30-Aug-13) Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
Delivery of bought out items by BHEL for GTG Open package (LAD supply:29.09.14; Ant - Jul'15) Awarded to M/s BHEL on 25.07.13 with CDD for delivery as 24.11.14. HEAVY LIFT Cranes for INTALLATION OF REACTORS Finalisation of Erection scheme and capacity the crane, inclusion in scope and timely mobilisation at site
Theft of material Warehouse Completion of UGfrom piping work due delay in receipt of piping material and monsoon.
Lighting during construction
Open Constn.
Delay in construction due to monsoon. As work Open progress between Jun to Sep is expected to be hindered due to monsoon, all out effort to be made to release tender as per sch. Generally to manage delays in initial stages of project, constr. Duration are reduced while floating tenders. This needs to be avoided.
EIL
Urgency (Long Term / Short term)
7
Very High
Schedule ( Y / N)
6
Slow construction progress of SRU Block due to Open Proj. / delayed area handing over Constn. - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by Jan'15. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) - As per present trend 15 months (starting from end Jun’14) are available with respect to schedule of 25 M (As per past experience minimum requirement for SRU is 30 M).
EIL Cost (Y / N)
Action Plan
5
0.00
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
4
Output Quality ( Y / N)
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
2
(Current risk Score Previous Risk score)
E
Key Risk Description
Status (Open / Close)
Risk Id 1
Job No.: A307 Jan'15 Page 608+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
0.23
-0.23 - All 3 GTGs received at site. - Extension sought by M/s BHEL. - Contractor for Mechanical works for CPP awarded to M/s Zillion.
Action By
17
Target Date
Risk Severity
18
19
Feb'15
I Jul'14
Dec'13
Nov'13
Aug'13
sep'13
IV
0.00
-Included in mechanical contractor scope. Project / - Based on prel. Erection scheme, 1600 T heavy lift crane with 600 T trailing crane envisaged for erection of Constn. both VGO and DHDT reactors. - Timely mobilization of cranes and preparation of Load Test. - Finalization of erection scheme.
-
0.00
- Security arrangements in Warehouse in place by BPCL. - All balance material deliveries being expedited by Feb'15, subsequently all UG piping work completion targeted by end Feb'15.
Constn. EIL/BPCL
Feb'15
0.04
0.00
Area lighting being done.
Constn.
As Required
I May'13
0.2
0.00
-During 2013-2014 monsoon following actions were taken - Temporary drains were constructed for draining accumulated rain water. - Pumping arrangements for draining water accumulated in pits were made.
Constn.
As Required
sep'13
0.57
0.57
Nov'13
-
Mar'13
E
E
E
3
4
5
6
7
8
9
10
11
12
Open
Project
Low
Y
N
N
N
Short term
I
0.2
13
Construction of Subway on the PWD road including re routing of existing road / existing facilities and necessary liasoning with government department. Construction of culvert got affected
Open
Project
Very Low
N
N
Y
N
Short term
I
0.4
0.04
Slow construction progress in Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 CCD: 08.10.14; ECD: Jun'15 Progress figures Sch: 100% Front: 99.7% Act.: 52.2%
Open Constructi Very High on
N
N
Y
N
Short term
I
0.4
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 100%; Front: 100%; Act: 68.1% CCD:18.12.14; ECD: May'15
Open
Project
Very High
N
N
Y
N
Short term
I
Slow progress of Civil & Strl Works for SRU block (Awarded to M/s Mcnally Bharat on 04.11.13) LAD: 12.01.15 CCD: 03.03.15 Ant: Oct'15 SCH. FRONT. ACT. 98.3% 85.3 % 43.5%
Open
Project
Very High
N
N
Y
N
Short term
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 ECD: 30.10.15 Contr. Sch: 65.2% Front: 63.3% Act: 33.9 %
Open
Project
High
N
N
Y
N
Completion of Coke handling work (Awarded to M/s Thyssen on 04.11.13) LAD: 18.04.15 CCD: 03.07.15 EDD: Dec'15 Construction: Sch:49.1 %; Front:100.0%; Act:19.6% Overall Progress: Sch: 51.3 % Act: 37.9%
Open
Project
Medium
Y
N
Y
N
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
EIL Cost (Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
2 Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
14
(Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 609+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
15
16
17
18
Risk Severity
19
0.00
LPG flare - As per EIL study LPG flare is adequate. Report issued to BPCL and clarification received. BPCL / EIL Acid flare - HC flare & Sour flare system P&IDs issued for engineering on 15.06.13. DHDS sour flare replacement: Sour Flare system P&ID (DHDS Area) issued for comments on 17.05.13, this additional requirement of existing structure and replacement of sour stack by higher size (16") being checked for adequacy. New flare components to be procured for revised stack size.
15-Nov-13
Oct'13
0.04
0.00
Management level meeting held with B&R on 08.01.15 at site. Culvert top slab completed, road work in progress.
Constrn.
end Jan'15
IV
0.38
0.38
0.00
-Management level meeting held with M/s KSSIIPL at site on 12.01.15. - Additional gangs to be deployed to complete cable trenches work. - M/s KSS has been asked to deploy additional 50 nos civil manpower. Manpower for UG piping work has been increased up to 38 nos. Additional manpower to be deployed to carry out work for OWS/ CRWS. - Rock blasting in progress in balance areas. -Cable trench cast in situ offloaded to PGC (Misc Civil contract) - M/s KSS has been asked to complete one manhole per day - TMT bars: Out of ordered 500 MT qty 150 MT qty received, balance being delivered progressively. - Additional agencies including M/s Tuaman & M/s PGC have been lined up to supplement Civil/Structural works.
EIL/BPCL
Feb'15
0.4
0.38
0.38
0.00
Management review meeting held with M/s Essar on 20.01.15 at site - Foundation work completed for HRSG-3. - Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - boiler piperack foundations completed.
EIL/BPCL
Feb'15
I
0.4
0.38
0.38
0.00
- Management level meeting held at site on 20.01.15. - As on date the manpower is 180 Nos against the requirement of 400 Nos. - ARU/SWS : TS-1 & TS-2 being expedited.
EIL/BPCL
Continuous
Short term
I
0.4
0.32
0.32
0.00
- Management level Meeting held with M/s OIL on 14.01.15 and following action plan has been agreed - M/s OIL was advised to augment welders to 52 nos. against 39 nos available to increase productivity. - Structural fabrication & erection to be expedited. - Auto blasting m/c received, being installed.
EIL/BPCL
Continuous
Long term
I
0.3
0.15
0.15
0.00
-Meeting held at site on 09.01.15. - Piling work in progress (1136 out of 1642 nos piles completed: 7-8 piles/day) -TT-3, TT-4, TT-5, Circular stacker cum reclaimer work in progress.
Constr.
Continuous
25
26
Target Date
27
II
E
28
II
E
29
II
E
E
30
31
II III
E
E
32
33
34
7
8
9
10
11
12
13
14
15
16
N
Y
N
Long term
I
0.3
0.15
0.15
0.00
Review meeting held at site on 26.09.14. -Heater A: All radiant panels erected. -Heater B: All radiant panels erected. Shop fabrication of coil, convection modules, APH structure and duct to be expedited. -Crane 150 MT mobilised. - M/s Heurtey has been asked to increase number of welders and start works round the clock.
Constrcution As Required
Project
Very High
N
N
Y
N
Long term
I
0.2
0.00
- Total area handed over on 05.05.14.
Project
As stated
Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
Management level meeting held on 09.01.15. - Completion of equalisation tank targeted by Mar'15. - Chemical house super strl work completion targeted by mid Mar’15. - During the meeting on 05.12.14, M/s Paramount informed that ETP plant can be made ready by Dec’15. - Night shift work being implemented. Additional manpower of 30 nos being planned to mobilise by end Jan'15.
EIL/BPCL
As stated
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Management level meeting held on 08.01.15 at site. Total tanks: (New tanks 13 nos, work in progress for EIL/BPCL 12 nos. Balance for 1 nos is YT-33 which shall be start after completion of YT-32; Modification tanks: Out of total 16 nos, work in progress for 5 nos, 3 nos handed over to BPCL.) - B&R to augment resources to complete all balance work within agreed target. - Plates: 375 MT (SA 516 Grade 70) - not yet delivered.
As stated
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Completion Sch: 30.01.15 (CDD:11.06.15) Awarded to M/s Driplex on 12.06.13. (Duration: 20 M+2 M incl pre commng)
Open
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 86.6 % Act: 39.6 % Construction Progress: Sch: 75.6% Front: 100 % Act: 23.2 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 84.6 %; Front:87.3% Act: 38.3 %
Urgency (Long Term / Short term)
6 Y
Schedule ( Y / N)
5 Medium
Open Project
EIL Cost (Y / N)
Action Plan
Completion of DCU Heater works (Awarded to M/s Heurtey on 04.11.13 (20 M) LAD: May 15 CCD: 03.07.15 Ant: Oct'15 Overall Progress: Sch: 88.5 % Act: 77.5 % Construction work: Sch- 76.9% Front:100% Act:45.8%
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
(Current risk Score Previous Risk score)
E
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 610+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
17
18
19 III
Jun'14
I
E
35
Awarded to M/s B&R on 25-Sep-13 II
E
36
E
37
E
38
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 Duration: 20 M Sch: 71.10 % Front: 100.0 % Act: 45.9 %
Slow progress of FCCU Heater works (Awarded Open Project to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 98.4% Act: 58.5 % Construction progress: Sch: 71.2% Front: 89.7% Act:32.5%
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
Close Project
0.32
0.00
Constr.
As stated
- Plate erection to be expedited for YT-26/28. - Tank pad completion works to be expedited in YT-25.
Medium
N
N
Y
N
Short term
I
0.4
Very High
N
N
Y
N
Long term
I
0.2
0.20
0.20
0.00
-Management level meeting held on 07.01.15 - Structural steel: Out of total 217 MT, 200 MT received. - Erection of radiant section completed. - Coil tubes: Delivery held up due to financial constraints. - Delivery of soot blowers and FD fans to be preponed to suit completion heater by 03.04.15. - Procurement of refractory anchors & refractory blanket to be expedited.
Project
As Required
II III
0.00
Clubbed with Risk ID D7
BPCL
As Required
Dec'13
(Current risk Score Previous Risk score)
7
8
9
10
11
12
13
14
15
16
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- PO amendment issued on 15.12.14. - Finalisation of subvendor for expansion bellows to be expedited.
Slow progress of RO-DM works (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 (As per vendor) Overall Progress: Sch: 98 % Act: 62.9% Construction Progress: Sch: 100 %; Front: 100%; Act:36.0%
Open Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- During the meeting on 05.12.14, M/s Driplex informed that DM water can be provided by Sep’15 for CPP EIL/BPCL and accordingly have been asked to submit completion plan. -In view of delay in handing over of areas and various site related issues and soil problem encountered during execution, progress of construction badly affected. Letter issued on 05.09.14 to submit revised catch up plan for mitigating backlogs in construction & manufacturing. M/s Driplex to mobilise additional resources for completion as per catch-up plan. - DM tanks (2 nos) : Piling rig mobilised and piling work commenced. Tank B: (76/160 nos piling completed). Tank -A : (20/160nos piling completed).
As Required
Slow Construction progress for Civil WorksFCCU Contr. Sch: 100 %; Front: 100% Act: 68.2 % (M/s SEPC) CCD: 24.12.14 ECD: Oct'15
Open Project
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Management level meeting held with M/s Shriram on 19.01.15 at site. - Mobilisation of resources is being expedited. At present only 110 nos, manpower mobilised against requirement of 350 nos. M/s Shriram agreed to augment additional 98 nos manpower by end Jan’15. - M/s Shriram agreed to complete foundation for Tech structure F by 28.01.15 & Tech structure D by 07.02.15. Structural fabrication/erection for tech structure A/E/D targeted progressively by end Feb’15. Management level meeting held with M/s Zillion on 13.01.15 at site. - M/s Zillion agreed to complete all fabrication drawings by end Jan’15. - M/s Zillion agreed to fabricate 500 MT structural steel by 31.01.15 & additional 500 MT by 15.02.15.
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15 Constr. Progress: Sch: 95.0 % Front: 100 % Act: 67.7 %
Open Project
Very High
Y
N
N
N
Long term
I
0.1
0.10
0.10
0.00
- Fabrication of Convection Modules for IG-H-101 is in progress. - Convection modules for IG-H-102 despatched. - Radiant Refractory blanket works completed for IG-H-102 & in progress for IG-H-101. - Radiant coil erection for IG-H-102 done. Alignment and welding in progress.
Constr.
As Required
I III
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 100% Act: 63.4% Construction Progress: Sch: 97.1% Front: 97.4% Act.: 27.5%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
-Management level meeting held on 14.11.14. Order has been placed for all bought out items. - Procurement completed for 600 MT out of 935 MT steel. - Fabrication in progress at Coimbatore Yard for both heaters (IV-H-101 & IV-H-201) - Radiant panel erection completed for IV-H-101 & IV-H-201.
Projects
As Required
III
Slow Construction progress for Civil Works by Open Project M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 Sch: 100 %; Front :99.55 % Act: 79.8 % - Structural erection: DHDT: 1530 MT / 2600 MT completed.; VGO: 1285 MT / 3065 MT completed. -UG Piping Laying: DHDT: 17790 IM / 25400 IM completed; VGO: 18798 IM / 42000 IM completed.
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
-Management level meeting held with M/s MBEL on 13.11.14 at site. M/s MBEL agreed: Constrn. - Current manpower is 436 nos. against requirement of 570 nos. MBEL agreed to mobilise 4 separate gangs for UG piping. - 4 cranes mobilised and Additional 2 nos cranes to be mobilized in order to carry out structural erection in both VGO & DHDT simultaneously. - Delivery of balance anchor bolts to be expedited. -TS-4 for DHDT targeted by 15.01.15
As Required
Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
PEB1: M/s B&R agreed to complete balance work by end Dec'14. Project Material storage commenced. PEB 2 All works targeted to complete by Feb'15 PEB 3: All works targeted to complete by Feb'15 Buildings to be expedited for storage of material / equipment being received at site.
As Required
Urgency (Long Term / Short term)
6
Very High
Schedule ( Y / N)
5
Open Project
EIL Cost (Y / N)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner 4
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 CCD: 30.06.15; EDD: 30.09.15 (As per Vendor) Overall Progress: Sch: 78 % Act: 25 %
2
39
Status (Open / Close)
Risk Id E
3
Action Plan
Key Risk Description
1
Job No.: A307 Jan'15 Page 611+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
17 Projects
Target Date
Risk Severity
18
19
As Required
II
E
40
I
E
E
E
E
41
42
43
44
EIL/BPCL
II
E
45
Open Project
Constrn.
II
E
46
E
47
7
8
9
10
11
12
13
14
15
16
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
-Major backlog is due to construction (37%). Management level meeting held on 07.01.15 at site and PCTL EIL / BPCL to expedite to complete all works by Apr'15.
As Required
III
Open Project
Medium
N
N
Y
N
Long term
I
0.2
0.10
0.10
0.00
-Major backlog is due to engineering & construction. Last management level meeting held on 14.10.14 at site. Commitment made by M/s PCT has again slipped. - Balance Area for CWTP handed over after completion of grading by M/s PEL. - Manpower - Additional manpower to be deployed for civil works. (Required: 151 nos, Available: 99 nos) - Delivery of Bought out item to be expedited. - Mechanical contractor to be finalised.RCC work for CWPH & CWTP to be expedited. Backfilling to be expedited.
As Required
III
Urgency (Long Term / Short term)
6
High
Schedule ( Y / N)
5
Open Project
EIL Cost (Y / N)
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
4
Action Plan
Action By
17
Target Date
Risk Severity
18
19
Construction progress: Cum Sch: 100% Front: 100% Cum Act: 76.4%
Completion of Cooling Tower -III (Awarded to M/s Paharpur on 11.09.15) LAD: 30.06.15 CCD: 10.01.15 ECD: Aug'15 E
3
(Current risk Score Previous Risk score)
2 Completion of Cooling Tower -I & II (Awarded to M/s Paharpur on 01.02.13) LAD: 31.01.15 CCD: 20.10.14 ECD: Mar'15
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jan'15 Page 612+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Construction progress: Cum Sch: 98.8% Front: 100% Cum Act: 48.3%
EIL / BPCL
Open Constructi Very High on
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
-Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. Civil/Strl contractor. EIL/BPCL -Civil works: Additional agencies including M/s Ray, M/s PGC, M/s Furnace Fabrica & M/s Deen has been lined up to supplement Civil works. Further 1 additional Civil & Structural works contracts targeted to award by mid Feb’15. - Structural works: Additional agencies including M/s Ray, M/s MNB Nair & M/s Zillion have been lined up to supplement structural works. Further 1 additional Civil & Structural works contracts targeted to award by mid Feb’15.
Feb'15
48
Slow construction progress in Offsite-DHDS area. Work stopped by M/s KSS in DHDS area for Civil & Strl work CDD: 24.01.15 ECD:. Dec'15
Open Constructi Very High on
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 07.01.15 at site. - M/s Petron agreed to start night shift. - 150MT crane is mobilised. 80MT crane shall be shortly deployed. 200MT crane to be despatched soon. The 150MT & 200 MT cranes shall be operational by end Jan'15. - 10 nos semi automatic welding machines shall be operational by Jan'15. - Auto blasting shall start by Jan'15. - Gratings & consumables are being ordered. Handrails, wrapping coating mtrls & GI pipes ordering to be expedited. Strl steel partially ordered. - Gantry crane shall be despatched by third week & received by end of Jan'15.
EIL/BPCL
Feb'15
49
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 35.2 %; Front: 15.5%; Act.: 8.4% AG Piping fabrication: 42564 ID / 486195 ID completed AG Piping Erection: 12032 ID / 811115 ID completed
Slow progress of work & poor manpower mobilisation by M/s B&R for Composite WorksDCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15 Construction Progress: Sch: 38.6 % Front: 27.1% Act.: 10.6% AG piping fabrication: Only 55911 ID / 406975 ID fabrication completed. AG piping erection: Only 39904 IM / 526435 IM piping erection completed.
Open Constructi on
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
Management review meeting held on 08.01.15. -30 fitters, 40 welders & the required machineries shall be deployed by 30.01.15. -Insulation/painting agency finalization by 31.01.15. - Hanger scaffolding to be introduced at site.
EIL/BPCL
Feb'15
Slow construction progress for Civil & Strl work for Refinery area: Generation of front for mechanical works affected (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:98.9%; Front: 95.9%; Act: 29.9% CCD: 25.01.15 ECD: Oct'15
Open Constructi on
High
Y
N
Y
N
Short term
I
0.6
0.48
0.48
0.00
Management level meeting held at Kochi site on 20.01.15 EIL/BPCL - RCC sub structure work shall be completed by Mar '15. - 30MT /day shall be fabricated from 01.01.15 onwards. - 1500 MT each fabrication shall be don