Risk Register Project
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Risk Register Project as PDF for free.
More details
- Words: 228,722
- Pages: 749
Loading documents preview...
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 61+14 of 30
E
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
Job No.: A307 Apr'15 Page 264+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 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
Job No.: A307 Apr'15 Page 267+14 of 30
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 268+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 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
Job No.: A307 Apr'15 Page 269+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
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
Job No.: A307 Apr'15 Page 271+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
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
Job No.: A307 Apr'15 Page 272+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
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
Job No.: A307 Apr'15 Page 277+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
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
Job No.: A307 Apr'15 Page 281+14 of 30
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
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 300+14 of 30
IV - RISK REGISTER
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
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
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
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 305+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}
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
Job No.: A307 Apr'15 Page 307+14 of 30
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 314+14 of 30
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 319+14 of 30
IV - RISK REGISTER
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
IV - RISK REGISTER
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 done during Feb 2015. Bal 600 MT fabrication to be done by 28.02.15.
Feb'15
I
E
II
E
50
II
E
51
II
E
E
E
E
E
E
53
54
55
56
57
9
10
11
12
13
14
15
16
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.
Feb'15
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
Feb'15
III
Urgency (Long Term / Short term)
8
N
Schedule ( Y / N)
7
N
EIL Cost (Y / N)
6
Open Constructi Very High on
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
(Current risk Score Previous Risk score)
E
4
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: 39.6% Front : 24.7% Actual : 11.3% 29040 / 285505 ID fabricated & 139484 / 1214330 IM erected.
2
52
Status (Open / Close)
Risk Id E
3
Action Plan
Key Risk Description
1
Job No.: A307 Jan'15 Page 613+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
17
Target Date
Risk Severity
18
19
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 14.01.15 -TS I by 28.02.15 -TS II, III & IV,VI handed over. -TS V by 27.04.15 -TS VII by 28.02.15. - Main piperack completion targeted by 31.01.15
Constr.
Feb'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
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: 98.7 % Act: 90.6 %
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 14.01.15 - 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.
EIL/BPCL
Feb'15
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT383/391) Sch : 44.3% Front : 48.2% Actual : 13.7%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level Meeting held on 14.01.15 - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT383/391/150. - Annular plate erection for tanks YT-26&YT-28 started. - YT-150: Dismantling activities in progress. - YT-383: Dismantling activities in progress. Plate material ordered. - YT-391: tank cleaning under progress. - Ordering of plate material to be expedited. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement.
EIL/BPCL
Feb'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: 96.4 % Front: 100 % Act: 56.8 %
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held on 08.01.2015 with M/s B&R at site. - Round the clock work to commence from 26.12.14. - YT 341 : hydrotest in Mar'15 - YT 342 : Annular plate erection from 03.02.15 - YT 343 : First jacking on 05.02.15. - YT 344 : First jacking on 03.02.15. - YT 111 : 4 / 8 shells completed - YT 112 : 4 / 8 shells completed - YT 113 : 2 / 8 shells completed - YT 114 : 2 / 8 shells completed -Manpower required is 250 nos, available is 186.
EIL/BPCL
Feb'15
III
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 CCD:18.06.15 Sch: 81.7 % Front: 68.5 % Act: 31.5 %
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. -Agency has been pressurised to mobilise resources and start work. - SWS-1 Sour water tank & sour water storage tank pads handed over. 2 tanks fdn handed over , 1 tank fdn by mid Jan & balance fdn by end Jan'15.
Constr.
Feb'15
Open Project
58
59
Action By
II
61
E
62
E
63
E
64
F
1
F
F
G
2
3
1
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected. Piping fabrication work in progress. Structural fabrication yet to commence.
Constr.
Feb'15
III
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: 39.0% Front: 9.1% Act: 4.4% 500 ID / 232725 ID piping fabrication completed. 2304 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 12.11.14 at site. M/s OIL has been asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Mobilisation for 20 nos auto welding machine to be expedited.
Constr.
Feb'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. 16415 / 298905 ID fabricated. 339 IM / 299780 IM erected. Sch : 29.6% Front : 31.4% Actual : 7.9%
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 09.12.14 at site. M/s OIL has been asked to mobilise resources, fabrication yard in progress - 600 MT crane mobilised - At present only 13 nos welders are available at site with per day rate of 220 ID, however to achieve the completion schedule minimum 1000 ID/day to be achieved.
Constr.
Feb'15
III
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
0.20
-0.08 -Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. Piping III contract awarded BPCL to M/s Keller Ground Engineering & work commenced. 435 piles completed.
Feb'15
III
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 : 13.6% Actual : 11.0% 38734 ID / 145080 ID piping fabrication & 10410 / 248080 IM completed.
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected, side cladding in progress. Piping fabrication work in progress. Piping erection work commenced on the main pipe rack.
Constr.
Feb'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.
Urgency (Long Term / Short term)
7
N
Schedule ( Y / N)
6
Low
EIL Cost (Y / N)
5
Open Constructi on
Constn.
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
(Current risk Score Previous Risk score)
E
4
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. Sch : 33.6% Front : 22.5% Actual : 14.7% 48160 ID / 210605 ID piping fabrication completed. 10352 IM / 301995 IM erected.
2
60
Status (Open / Close)
Risk Id E
3
Action Plan
Key Risk Description
1
Job No.: A307 Jan'15 Page 614+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Project/BPCL As Required
IV
2 Infrastructure at Kochi
G
2
G
3
G
4
G
5
G
6
G
7
7
8
9
10
11
12
13
14
15
16
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.
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 Process / stage. POSD / Engg. / Projects
All by 60% constn progress
sep'13
Urgency (Long Term / Short term)
6 N
Process / Engg.
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 Low
Schedule ( Y / N)
4 Const.
EIL Cost (Y / N)
3 Open
Scope changes & information flow to executing Open group
Action By
Target Date
Risk Severity
18
19
17 Constn. / Projects / BPCL
As Required
IV
Non-performing vendors
Open Inspn
Low
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 Y
N N
Y N
N N
Short Short term term
D D
0.16 0.08
0.00 0.00
-- BPCL-KR videwith e-mail dated 06-Dec-12 sent a list of Non plantplan buildings to be located under IREP Project. Projects Meeting held BPCL on EIL recommendations and action finalised. BPCL / The same is reviewed by EIL.for Point wise issues targeted to be discussed with BPCL in week starting -- BPCL to take up with MOEF approval of changes in system already incorporated. (e.g. configuration for Projects 15.04.13. CPP) List of buildings between EIL and BPCL.inMethodology for execution under finalisation. -- Incorporation of finalised EC and RRA recommendations balance systems under progress.
15-Apr-13 As required
Apr'13 IV
0.00
- Documents approved from PESO
BPCL
Finalisation of Non plant buildings.clearance Implementation of environmental conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Close Open
Delay in commencement of site work for dyke Close wall inside TF-3 affected due to non availability of PESO approval for tankage area I
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 615+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Purch / Contrc.
BPCL Projects Low Medium
Engg. / Proj.
Medium
N
N
Y
N
Long term
I
0.2
0.04
0.04
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
Feb'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
I
2
Const.
Very High
N
N
Y
Y
Short term
D
0.2
1
Implementation of Health, Safety and environmental (HSE) system
Open
J
Const.
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 Mobilisation of Skilled workers
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
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/En ODC movement schedule is from Nov'13 to Feb gg 15.
High
N
N
Y
N
Long term
I
0.2
0.00
Closed as no concern as on date.
BPCL
Cost monitoring & control on regular basis
Costing
High
Y
N
N
N
Short term
D
0.08
0.00
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
Environ.
Very High
Y
N
N
N
Short term
D
0.08
0.00
Scope of facilities finalised.
Environ.
15-Oct-13
sep'13
K
K
K
2
3
K
4
M
1
M
2
0.40
0.40
At present only approx 11000 labours are working against requirement of 15000-18000 labours. Constraint in movement & transportation of ODC eqpt.
Increase in facilities on account of deletion zero liquid discharge
Close Open
As stated
II Jun'14
Jun'14
M
3
Total Risk Score
5
6
7
8
9
10
11
12
Low
Y
N
Y
N
Short term
I
0.6
13
23.06
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% / 10%)Cost Project ( 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 Jan'15 Page 616+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
0.18
-0.18 - BPCL have informed that approval for revised cost received.
23.46
-0.39
Action By
Target Date
Risk Severity
17
18
19
EIL/BPCL
Job No.: A307 Dec'14 Page 617 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: 86.4% Act: 58.4 % Construction Progress: Sch: 53.8% Front: 85.2% Act: 21.6 %
Open
Project
Management level meeting held on 14.11.14 at site. EIL/BPCL - Hard stand construction completed. - Crane (1600 MT): mobilisation by 15.02.15. EPIL/GRE to arrange another crane (1000 MT-from M/s VTV) for Regenerator bottom section erection. - EPIL-GRE informed to dispatch cyclones for reactors by 30.12.14 and regenerator cyclones by Feb'15. M/s Emtrol is being expedited. - Erection of TSS bottom and top section targeted by end Jan'15. - Hydrotesting for Regenrator & TSS targeted by Mar'15. - Erection of regenerator bottom section targeted from end Jan'15. - Erection of external riser targeted by end Feb'15. - Erection of reactor bottom section targeted by end Jan'15. - Agencies being pressurized to expedite completion of balance works by Dec’15 and requested to submit Catchup plan. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Jan'15-Mar'15
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: 99.6 % Act: 63.2 % - 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
-Meeting held on 22.11.14, vendor agreed to deliver main fractionator by Jan'15 and EIL/BPCL balance columns by Mar/Apr'15. - 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 10-15 days. - Erection for main fractionator targeted by 2nd week 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 Feb'15. Preparation of Hard stand to commence. Erection of bottom section for rectifier expected to commence from end Mar'15. - Approach road work completed. Area improvement to be expedited for crane movement.
As stated
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 EIL/BPCL data from M/s Accometric. 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 end Jan'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. 73.4 %; Act: 56.5 % Construction Progress: Sch: 54.4% Front: 97.9 % Act: 29.4 %
Open
Project
Weekly review meeting held on 19.12.14. Constr. Following commitments have been made by M/s Essar. -Shift Work: M/s EPIL has been asked to start works in two shifts. - 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 being opened. - M/s Essar have been pressurized to deliver all coke drums progressively upto Apr’15 EIL/BPCL and Coke fractionator by end Mar’15. - Crane (2000 MT): Shipment work started from 05.12.14. 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. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Erection by May'15
Key Risk Description
1
Action Plan
Action By
Target Date
Risk Severity
I
D
D
D
7
8
9
II III
I
D
12
Delay in erection & hydrotesting of Vacuum column Open Sch: Jun 14 CCD: 21.08.14 Ant: end Jan'15 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 80%
BPCL / - Erection of Crude Column : Crude column erection & hydrotesting completed. Projects / - Erection of Vacuum Column : Vacuum column bottom section erected on 13.12.14. Const. Middle section planned on 05.01.15 & top section erection planned on 20.01.15.
VTV/EIL/ BPCL
end Jan'15
II
Job No.: A307 Dec'14 Page 618 of 749
Integrated Refinery Expansion Project, Kochi
Status (Open / Close)
Risk Owner
Risk Id
RISKS REQUIRING ATTENTION
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
- 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).
Continuous
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
- Order got delayed due to delay in manufacturing works. At present fabrication of Stripper column going beyond Dec’14 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.
EIL/ BPCL
Dec'14
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Jan'15 Sch: (Intermediate MTO-3): Oct'14 EDD: Jan'15 to Feb'15
Open
Projects
- As of now around 66% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Jan'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
EIL/ BPCL
Jan'15
Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 7-8 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: 85.4% Catch Up Sch: 55.1 % Act: 42.7%
Open
Constn. / Projects
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued on EIL/ BPCL 30.10.14, BPCL comments received on 04.11.14. As per BPCL email dated 01.12.14, Tender splits into two parts & draft NIT for mechanical/strl works forwarded to BPCL.
end Dec'14
Backlog 9.2% as of 15-Dec-14 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 46.7 70.7 61.6 37.5 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site.
Open
Const
- In order to supplement progress of failing civil contractors, 4 separate contracts EIL/ BPCL have been awarded (M/s Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray Eng-Misc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works awarded on 23.12.14 & are under mobilisation. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 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 of 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. - Management level meeting being planned with various misc.Civil/Strl contractors in Jan'15. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. - All agencies being pressurised to mobilise additional resources and recover the backlog. - In order to boost progress, permission from labour union of Kochi to be taken up for two shift work.
As Required
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
Mar'15
Key Risk Description Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site
D
13
(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)
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 expected to arrive at jetty by 06.01.15. - Construction of jetty work to be expedited. - Erection of reactor planned with 1000 MT crane by mid Feb'15. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at Kochi-Port.
Action By EIL/BPCL
Target Date
Risk Severity
Delivery of DHDT reactor at site by Jan'15
ISGEC Josen (3 nos) Column: expected to receive at Kochi port from end Jan'15 to mid Mar'15.
II
D
19
II
D
32
II
D
33
II
E
4
I
E
E
7
8
Completion of Civil & Strl. works: RCC Qty: 1, 87,386 m3 out of 3, 05,066 m3 completed; Steel Qty: cum. 27,767 MT out of 53344 MT fabricated & cum. 17,643 MT erected.
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)
BPCL
I IV
Job No.: A307 Dec'14 Page 619 of 749
Integrated Refinery Expansion Project, Kochi
E
14
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION Action Plan
Action By
- Management level meeting held with M/s B&R on 17.11.14 at EIL site and Constn. augmentation of manpower by min. 100 nos to be expedited for concreting work progress. All area handed over in SRU block except for peripheral road. - 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 (120 nos) targeted to complete by end Jan'15. Balance piling work completion targeted by mid Feb'15. - Civil works completion targeted by mid May’15 and handing over of front to EIL/BPCL mechanical contractor targeted from end Feb’15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
Target Date
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
Proj. / Constn.
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Constr. Sch:100%; Front:99.7%; Act: 50.1% CCD: 08.10.14; ECD: Jun'15
Open
Constructio -Management level meeting held with M/s KSSIIPL at site on 02.12.14. EIL/BPCL n - 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.
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. 94.9% 76.8 % 35.6%
Open
Project
- Management level meeting held at site on 13.11.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - TS-06 : Raft work completed. Structural steel erection targeted by 30.12.14. - Structural Erection commenced for TS-2 and for TS-03 targeted by 30.12.14. - Out of total 1800 nos piles, 1140 nos completed. Pile cutting completed for 547 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by 15.01.15. - Out of total structural work of 4290 MT, only 1085 MT fabrication completed & 251 MT erection works completed. UG piping erection work yet to commence.
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: 55.4% Front: 57.55% Act: 28.4 %
Open
Project
- Management level Meeting held with M/s OIL on 12.11.14 and following action plan EIL/BPCL has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Auto blasting m/c received, being installed.
Continuous
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 80.6 % Act: 29.9 % Construction Progress: Sch: 64.3% Front: 100 % Act: 16.9 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Management level meeting held on 05.12.14. - Completion of engineering by M/s Paramount targeted by end Dec’14. - Completion of equalisation tank targeted by Mar'15. - Chemical house super strl work completion targeted by mid Mar’15. - M/s Paramount has been asked to start night shift work with immediate effect to boost construction progress. - During the meeting on 05.12.14, M/s Paramount informed that ETP plant can be made ready by Dec’15.
EIL/BPCL
As stated
Completion of works for Tankage-II (Awarded to M/s B&R on 25-Sep-13) Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 78.2 %; Front:86.6% Act: 32.4 %
Open
Project
- Management level meeting held on 17.11.14 at site. Total tanks: (New tanks 13 nos, EIL/BPCL work in progress for 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) - Delivery to be expedited.
As stated
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: 97.4 % Act: 61.9% Construction Progress: Sch: 98.2 %; Front: 100%; Act:29.5 %
Open
Project
- During the meeting on 05.12.14, M/s Driplex informed that DM water can be EIL/BPCL provided by Sep’15 for CPP 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 (72/160 nos piling completed).
As Required
Risk Severity
15-Feb-15
I
E
27
Jan'15
II
E
29
II
E
30
II
E
34
I
E
35
II
E
40
I
Job No.: A307 Dec'14 Page 620 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION Action Plan
Action By
-Mobilisation of resources is being expedited. At present only 187 nos manpower mobilised against a requirement of 700 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -5300 m3 RCC work has been already withdrawn from SEPC scope to M/s Tuaman EIL/BPCL scope. Additional 1500 m3 RCC work being offloaded from SEPC scope to M/s PGC. 2495 MT strl works offloaded to M/s Tuaman, M/s Zillion & M/s Ray engg.
Target Date
Risk Severity
Open
Project
41
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 99.5%; Front: 100% Act: 55.3 % CCD: 24.12.14 ECD: Oct'15
As Required
Open
Constructio -Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. EIL/BPCL n Civil/Strl contractor. -Cable trench cast in situ offloaded to PGC (Misc Civil contract) - Additional agencies including M/s Ray Engg. & M/s Zillion have been lined up to supplement Structural works. Another misc Civil/Strl work contract floated, award targeted by end Jan'15. - Additional agencies including M/s Deens, M/s Furnace fabrica & M/s KSS have been lined up to supplement Structural works. Another misc Civil/Strl work contract floated, award targeted by end Jan'15.
Jan'15
49
Slow construction progress by M/s KSSIIPL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:98.5%; Front: 77.3%; Act: 18.4%
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: 30.68 % Front: 23.30% Act.: 7.42% AG piping fabrication: Only 35316 ID / 406975 ID fabrication completed. AG piping erection: Only 31039 IM / 526435 IM piping erection completed.
Open
Constructio Management review meeting held on 11.12.14. n -30 fitters, 40 welders & the required machineries shall be deployed by 25.12.14 -M/s B&R has been asked to expedite1200 ID/day by end Dec '14. - Finalisation of 2 more piping/eqpt agencies at site by third week of Dec'14. -Insulation/painting agency finalization by 31.01.15. - Hanger scaffolding to be introduced at site.
31-Jan-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:95.2%; Front: 95.9%; Act: 25.4% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held at Kochi site on 09.12.14. EIL/BPCL n - 2500 m3 of RCC shall be targeted to cast by Jan'15. - 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 done during Jan & Feb'15. Bal 600 MT fabrication to be done by 28.02.15. - Strl detailing completion by 31.12.14. -600MT & 1000 MT erection targeted by Jan & Feb 15 respectively. - 125 MT crane to be deployed by 12.12.14 & 150 MT by 15.01.15.
Feb'15
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:32.1%; Front: 8.5%; Act: 4.3%
Open
Constructio Management level meeting held 11.12.14 at site. n -Piping management system shall be installed by 10.01.15. - B&R to take up compressor erection immediately.
EIL/BPCL
10-Jan-14
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: 86.1 %
Open
Constructio Management level meeting held on 05.11.14. 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.
EIL/BPCL
Feb'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. - 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.
-Utilisation of migrant and skilled labour from outside Kerala needs to be encouraged. EIL / BPCL 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.
As Required
I
E
I
E
51
EIL/BPCL
II
E
E
E
F
G
K
52
54
57
1
1
2
At present only approx 9000 labours are working against requirement of 15000-18000 labours.
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
II III
II
Job No.: A307 Dec'14 Page 621+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
Y
N
Short term
D
0.16
0.05
0.05
0.00
Open Engg/Cont .
Low
N
N
Y
N
Short term
D
0.16
0.05
0.08
-0.03 - 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 Dec'14. -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.
Delay in Interface Engineering (including control system) due to non availability of Package Vendor Data
Open Engg/proc urement
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
Generation of Surplus Piping material
Open
ENGG
Low
N
N
Y
N
Short term
D
0.16
0.05
0.05
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N)
N
Open
EIL Cost (Y / N)
Low
Signing of ISBL P&IDs and battery limit P&IDs for Units, Utility packages & other packages.
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) Process / POSD
Key Risk Description
Status (Open / Close)
Risk Id
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
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 targeted by end Dec'14.
Action By
Target Date
Process / POSD /
30-Dec-14
IV
Engg
30-Dec-14
IV
Package vendor inputs being made available by expediting for updation of interface engineering documents. Projects / Engg.
Continuous
IV
0.00
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
Progressively
IV
EIL/BPCL
15-Jan-15
A
27
B
CPP: Integration of various packages & BOP Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas 19 Booster compressor.
B
23
B
30 Ordering of Critical Valves Sch: 11.07.14 73 Ant: 15.01.15 Dely: 06/07 M FOT /FOB
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
C
-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, TBA issued on 29.12.14.
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 75 Ant: 15.01.15
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
0.15
0.15
0.00
-Total 32819 / 34373 nos (95%) isometrics issued for units . Balance ISO's targeted progressively by mid Engg. Jan'15. -Total 1576 / 2298 nos (69%) GAD's issued for units . Balance GAD's targeted progressively by mid Jan'15.
15-Jan-15
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM-Refloated 76 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
- 4 nos bids received on 30.09.14. PBO recommendation issued on 30.10.14, BPCL comments received on EIL/BPCL 04.11.14. As per BPCL email dated 01.12.14, Tender being split into two parts. Draft NIT targeted by 31.12.14
15-Feb-15
Delay in award of piping material with G2E specification 79 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 FCCUM/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 86.4% Act: 58.4 % Construction Progress: Sch: 53.8% Front: 85.2% Act: 21.6 %
Open
Project
Very High
Y
Y
Y
N
I
0.9
0.86
0.86
0.00
Management level meeting held on 14.11.14 at site. EIL/BPCL - Hard stand construction completed. - Crane (1600 MT): mobilisation by 15.02.15. EPIL/GRE to arrange another crane (1000 MT-from M/s VTV) for Regenerator bottom section erection. - EPIL-GRE informed to dispatch cyclones for reactors by 30.12.14 and regenerator cyclones by Feb'15. M/s Emtrol is being expedited. - Erection of TSS bottom and top section targeted by end Jan'15. - Hydrotesting for Regenrator & TSS targeted by Mar'15. - Erection of regenerator bottom section targeted from end Jan'15. - Erection of external riser targeted by end Feb'15. - Erection of reactor bottom section targeted by end Jan'15. - Agencies being pressurized to expedite completion of balance works by Dec’15 and requested to submit Catchup plan. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Jan'15-Mar'15
Open
Project
Very High
N
N
Y
N
I
0.2
0.19
0.19
0.00
Management review held on 13.11.14 to pressurised M/s ISGEC for completing within CCD. - 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 commenced for UB-1.
Continuous
C
C
Risk Severity
II III
II C
D
D
1
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 3 Overall progress: Sch: 99.0 % Act: 73.7 % Construction Progress: Sch:98.7 % Front: 100 % Act: 35.6 %
Short term
Long term
II
Project / Constn.
I III
Job No.: A307 Dec'14 Page 622+15 of 30
(Current risk Score Previous Risk score)
N
N
N
Long term
I
0
0.00
0.00
0.00
MRT completed on 10.11.14. Dispatch expected by Jan'15. - Condensate pump subordered to M/s Flowserve targeted to receive at shop by mid Jan'15.
Project/Inspe 27-Jan-15 ction
IV
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 6 (CDD: 24.12.14; EDD: 28.02.15)
Open
Project
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Project/Inspe 28-Feb-15 Lube oil system under final testing. Further the final testing likely get delayed due to delayed delivery by M/s ction Enpro. Close monitoring to be done to ensure delivery on CDD.
IV
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: 7 Sch: 99.6 % Act: 63.2 % - 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
N
Y
N
Short term
I
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 10-15 days. - Erection for main fractionator targeted by 2nd week 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 Feb'15. Preparation of Hard stand to commence. Erection of bottom section for rectifier expected to commence from end Mar'15. - Approach road work completed. Area improvement to be expedited for crane movement.
As stated
Open
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 Accometric. BPCL / EIL 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 end Jan'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
D
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 8 erection)
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
Weekly review meeting held on 19.12.14. Constr. Following commitments have been made by M/s Essar. -Shift Work: M/s EPIL has been asked to start works in two shifts. - 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 being 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): Shipment work started from 05.12.14. 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. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Erection by May'15
D
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. 73.4 %; Act: 56.5 % Construction Progress: 9 Sch: 54.4% Front: 97.9 % Act: 29.4 %
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.06
-0.06 - All items received at site.
D
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) 10 Dely: 18 M Ordered to M/s BHEL on 28.06.13
Project/Inspe end Dec'14 ction
Delivery of RGC compressor for DHDT(LAD :05.02.15; 11 Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.06
-0.06 - Received at site and erected.
D
Project/Inspe 27-Dec-14 ction
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.00
D
D
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N)
Low
EIL Cost (Y / N)
Project
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Open
D
Key Risk Description
Status (Open / Close)
Delivery of wet gas compressor for DCU at Site (M/s Eliot Ebara) 5 LAD: 05.12.14 (CDD: 27.01.15; EDD: 27.01.15)
Risk Id
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
II III
I
D
Delay in erection & hydrotesting of Vacuum column Open Sch: Jun 14 CCD: 21.08.14 Ant: end Jan'15 (Vacuum column) Normally 12-14 Months are required for Unit Mechanical 12 Compln after erection of Crude & Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 80%
BPCL / Projects / Const.
0.38
- Erection of Crude Column : Crude column erection & hydrotesting completed. Constn. / - Erection of Vacuum Column : Vacuum column bottom section erected on 13.12.14. Middle section planned VTV / on 05.01.15 & top section erection planned on 20.01.15. Projects
Jan'15
II
Job No.: A307 Dec'14 Page 623+15 of 30
D
D
D
D
D
D
D
N
N
Y
N
Short term
I
0.4
0.38
0.32
0.06
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - DHDT reactor unloaded into barge on 26.12.14 and expected to arrive at jetty by 06.01.15. - Construction of jetty work to be expedited. - Erection of reactor planned with 1000 MT crane by mid Feb'15. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at KochiPort.
Jan'15
Close Monitoring of ODC equipment (including site 14 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; 20 nos received at site. & 4 nos under dispatch. Balance under close monitoring and are expected at site from Nov'14.
Continous
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Apr-15 17 Ant: 24-Mar-15 Overall Progress Sch: 55.9 % Act: 47.4 % Construction work likely to start from Oct'14.
Open Project
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- Flare foundation work completed. Projects/Con As Required - Fabrication of flare structure is in progress and delivery expected from Dec'14 onwards. Construction work str. to be started from Dec'14 onwards.
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 19 CCD: 25.04.15 EDD: 31.10.15
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
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).
Project/Inspe Continuous ction
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 20 CDD: 03.04.15 Ant: 03.04.15
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 21 EDD: 30.03.15 Overall Progress: Sch: 95.0 % Act: 90 %
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
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 is 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 within CDD.
Project/Inspe Continuous ction
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 CDD: 07.10.14 22 Overall Progress: Sch: 98 % Act: 95.0 %
Open
Projects
High
N
N
Y
N
Long term
I
0.2
0.16
-0.16 - Reactor received at Kochi port and unloaded to barge on 26.12.14.
Project/Inspe Continuous ction
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 23 Awarded to M/s Thermax on 20.12.13 Overall Progress: Sch: 64 % Act: 53 %
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- 90% model review for HRSG planned in end Dec'14. - 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
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) 24 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 25 CDD: 30.03.15 Overall progress: Sch: 51 %; Act: 46 %
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 Dec'14 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 by end Dec'14.
III
Urgency (Long Term / Short term)
Very High
Schedule ( Y / N) Output Quality ( Y / N)
T&CC
EIL Cost (Y / N)
Open
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
(Current risk Score Previous Risk score)
D
Previous Risk Score
D
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: 13 unloaded onto barge on 26.12.14) ISGEC Josen (3 nos) Column: expected to receive at Kochi port from end Jan'15 to mid Mar'15.
Key Risk Description
Status (Open / Close)
Risk Id D
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Shipping
Target Date
Risk Severity
II IV
III
II IV
III
Job No.: A307 Dec'14 Page 624+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
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
D
Delivery of Make up Gas Compressor -VGO( Ordered to Open M/s Nueman & Essar on 14.11.13 ) 28 LAD : 26.02.15 CDD: 13.04.15
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).
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.: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.
Jan'15
III
Delay by vendor with respect to CDD due to financial constraint.
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N)
N
EIL Cost (Y / N)
Low
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) 27 LAD: 29.01.15 CDD: 10.03.15
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) Projects
Key Risk Description
Status (Open / Close) Open
Risk Id D
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
D
29
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 Dec’14 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.
Dec'14
D
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) CDD: 18.10.14 32 EDD: 31.03.15
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Jan'15 33 Sch: (Intermediate MTO-3): Oct'14 EDD: Jan'15 to Feb'15
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- As of now around 66% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Jan'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
EIL/ BPCL
Jan'15
Delivery Gas Booster Compressor for CPP (Dly: 13 M 34 FOB
Open
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
Dec'14
II IV
Delay in delivery of equipments by: Open 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 35 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
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
Dec'14
III
Delay in submission & finalisation of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. 36 CDD: 19.05.15
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
-Reduction furnace layout drawing to be finalised in order to give front for release of piling drawings. - Submission of drawing by vendor & approval by HMTD to be expedited.
HMTD/Projec Dec'14 ts
Medium
Y
N
Y
Y
Short term
D
0.28
0.14
0.14
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
II
D
D
D
D
E
Open
Space constraints: Open i) Area for Storage of materials for project and package 2 contractors ii) Area for Spool storage
Constn.
Dec'14
II III
Job No.: A307 Dec'14 Page 625+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
N
Short term
I
0.9
0.86
0.86
0.00
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued on 30.10.14, BPCL comments received on 04.11.14. As per BPCL email dated 01.12.14, Tender splits into two parts & draft NIT for mechanical/strl works forwarded to BPCL.
BPCL/EIL
Dec'14
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 Jan'15 to May'15. - L&T also agreed to augment required manpower to meet the target completion date.
Constn
As Required
Const
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
- In order to supplement progress of failing civil contractors, 4 separate contracts have been awarded (M/s Constn Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray Eng-Misc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works awarded on 23.12.14 & are under mobilisation. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 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 of 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. - Management level meeting being planned with various misc.Civil/Strl contractors in Jan'15. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. - All agencies being pressurised to mobilise additional resources and recover the backlog. - In order to boost progress, permission from labour union of Kochi to be taken up for two shift work.
As Required
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 Mar'15.
BPCL
Mar'15
Open
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.29
0.29
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 end Dec'14. - Chemical house works completion being targeted by end Dec'14 - 90 % Model review held on 03.11.14.
Constr.
Dec'14
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 99.7 % Front: 100 % 6 Act:66.2 % CCD: 20.12.14 Ant: 15.07.15
Open
Backlog 9.2% as of 15-Dec-14 in Construction activities Open 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 46.7 70.7 61.6 37.5 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site.
Urgency (Long Term / Short term)
Y
Open Constn. / Projects
Schedule ( Y / N) Output Quality ( Y / N)
Y
Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 14 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. 4 Physical Progress: Target Sch: 85.4% Catch Up Sch: 55.1 % Act: 42.7%
EIL Cost (Y / N)
Y
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) Very High
Status (Open / Close)
Risk Id E
Key Risk Description
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
I
E
II
E
E
7 Completion of Civil & Strl. works: RCC Qty: 1, 87,386 m3 out of 3, 05,066 m3 completed; Steel Qty: cum. 27,767 MT out of 53344 MT fabricated & cum. 17,643 MT erected.
Relocation of existing facility (PRU Flare) for clearance for BOO area. 8 Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Mar'15) Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
E
Overall Progress: Contr. Sch: 94.1 % Act: 66.4% 13 Construction Progress: Sch: 92.3 % Front: 100 % Act: 61.1 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
I IV
II
Job No.: A307 Dec'14 Page 626+15 of 30
E
E
E
E
(Current risk Score Previous Risk score)
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Management level meeting held with M/s B&R on 17.11.14 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 block except for peripheral road. - 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 (120 nos) targeted to complete by end Jan'15. 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 EIL/BPCL from end Feb’15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
Dec'14
Urgency (Long Term / Short term)
Y
Schedule ( Y / N) Output Quality ( Y / N)
Previous Risk Score
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) 14 - 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)
Very High
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Status (Open / Close)
Risk Id E
Key Risk Description
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
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 19 delivery as 24.11.14.
Open
Const. / Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- All 3 GTGs received at site. - Extension sought by M/s BHEL. - Contractor for Mechanical works for CPP awarded to M/s Zillion. - N2 compressor (Delivery period is approx 6-8 M) : Ordered on 01.08.14, delivery going upto beyond Dec 2014.
Projects
Dec'14
Completion of UG piping work due delay in receipt of piping material and monsoon.
Open
Const.
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Pipes under shortage (IS pipes of 30", 40", 48") delivery to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team. - All balance material deliveries being expedited by Jan'15, subsequently all UG piping work completion targeted by Feb'15.
EIL/BPCL
Feb'15
Open
Project
Very Low
N
N
Y
N
Short term
I
0.4
0.04
0.20
-0.16 Management level meeting held with B&R on 17.11.14 at site. Culvert top slab completed, rerouting of existing KWA drinking water supply line completed.
Constrn.
end Dec'14
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Constr. Sch:100%; Front:99.70%; Act: 50.11% CCD: 08.10.14; ECD: Jun'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 with M/s KSSIIPL at site on 02.12.14. - 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
Jan'15
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 99.8%; Front: 100%; Act: 58.0% 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 19.09.14 at site & 25.09.14 at EIL HO. - Foundation work completed for HRSG-3. - Completion of Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - Completion of boiler piperack foundations targeted by 30.12.14 (20/21 nos raft completed).
EIL/BPCL
Dec'14
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 FRONT. ACT. 29 SCH. 94.9% 76.8 % 35.6%
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 13.11.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - TS-06 : Raft work completed. Structural steel erection targeted by 30.12.14. - Structural Erection commenced for TS-2 and for TS-03 targeted by 30.12.14. - Out of total 1800 nos piles, 1140 nos completed. Pile cutting completed for 547 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by 15.01.15. - Out of total structural work of 4290 MT, only 1085 MT fabrication completed & 251 MT erection works completed. UG piping erection work yet to commence.
Continuous
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 30 ECD: 30.10.15 Contr. Sch: 55.4% Front: 57.55% Act: 28.4 %
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 12.11.14 and following action plan has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Auto blasting m/c received, being installed.
Continuous
22
Construction of Subway on the PWD road including re routing of existing road / existing facilities and necessary liasoning with government department. 26 Construction of culvert got affected (Ant. Compln-end Dec'14)
27
Risk Severity
I III
I IV
II
E
28
II
E
II
E
EIL/BPCL
II
Job No.: A307 Dec'14 Page 627+15 of 30
N
Long term
I
0.3
0.15
0.15
0.00
-Meeting held at site on 10.09.14. - Piling work commenced (929 out of 1642 nos piles completed: 7-8 piles/day) M/s TKII to augment piling rigs immediately. -TKII has been advised to commence work in all work fronts to achieve min. 5% construction progress.
Constr.
Medium
Y
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 str 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
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
Management level meeting held on 05.12.14. - Completion of engineering by M/s Paramount targeted by end Dec’14. - Completion of equalisation tank targeted by Mar'15. - Chemical house super strl work completion targeted by mid Mar’15. - M/s Paramount has been asked to start night shift work with immediate effect to boost construction progress. - During the meeting on 05.12.14, M/s Paramount informed that ETP plant can be made ready by Dec’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 17.11.14 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
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 59.9 % Front: 100.0 % Act: 41.4 %
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 37 Overall Progress: Sch: 88.9% Act: 44.6 % Construction progress: Sch: 63.2% Front: 60.65% Act:30.3%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 39 CCD: 30.06.15; EDD: 30.09.15 (As per Vendor) Overall Progress: Sch: 70 % Act: 19 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Project
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 32 Overall Progress: Sch: 77.8 % Act: 70.8 % Construction work: Sch- 67.5% Front:97.2% Act:39.6%
Open Project
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 80.6 % Act: 29.9 % 34 Construction Progress: Sch: 64.3% Front: 100 % Act: 16.9 % 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 35 Sch: 78.2 %; Front:86.6% Act: 32.4 %
Project
Urgency (Long Term / Short term)
Y
Open
Schedule ( Y / N) Output Quality ( Y / N)
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 31 Construction: Sch:37.2 %; Front:100.0%; Act:14.56% Overall Progress: Sch: 51.3 % Act: 37.9%
EIL Cost (Y / N)
Y
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
(Current risk Score Previous Risk score)
E
Previous Risk Score
E
Medium
Key Risk Description
Status (Open / Close)
Risk Id E
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Continuous
Risk Severity III
III
I
E
Awarded to M/s B&R on 25-Sep-13 II
E
E
E
0.32
0.00
Constr.
As stated
-Management level meeting held on 14.11.14 - Structural steel: Out of total 217 MT, 200 MT received. - Fabrication 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.
Project
As Required
- PO amendment issued on 15.12.14. - Finalisation of subvendor for expansion bellows to be expedited.
Projects
As Required
- Plate erection to be expedited for YT-26/28. - Sand filling works to be expedited in YT-25.
II III
II
Job No.: A307 Dec'14 Page 628+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
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 (72/160 nos piling completed).
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 99.5%; Front: 100% Act: 55.3 % 41 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 at Kochi on 18.09.14. -Mobilisation of resources is being expedited. At present only 187 nos , manpower mobilised, against a requirement of 700 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). EIL/BPCL -5300 m3 RCC work has been already withdrawn from SEPC scope to M/s Tuaman scope. Additional 1500 m3 RCC work being offloaded from SEPC scope to M/s PGC. 2495 MT strl works offloaded to M/s Tuaman, M/s Zillion & M/s Ray engg.
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15 42 Constr. Progress: Sch: 87.9 % Front: 100 % Act: 62.7 %
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: 43 Sch: 97.7 % Act: 53.6 % Construction Progress: Sch: 80.6% Front: 96.1% Act.: 17.4%
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 M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 Sch: 97.27 %; Front :99.55 % Act: 63.71 % - Structural erection: DHDT: 825 MT / 2600 MT 44 completed.; VGO: 746 MT / 3065 MT completed. -UG Piping Laying: DHDT: 11089 IM / 25400 IM completed; VGO: 11038 IM / 42000 IM completed.
Open Project
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
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 end Dec'14. Project Material storage commenced. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. Buildings to be expedited for storage of material / equipment being received at site.
Constrn.
As Required
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 14.10.14 at site. Commitment made by M/s PCT has again slipped. Manpower at site is 392 nos instead of committed 670 nos. Supply of balance U/G and A/G Piping Material by PCTL to be expedited. Shortage of TMT steel (540 MT) to be expedited. PCTL to target to complete all Civil work by Dec'14.
EIL / BPCL
As Required
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N)
Y
EIL Cost (Y / N)
Very High
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Open Project
Key Risk Description
Status (Open / Close)
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: Act: 61.9% 40 Sch: 97.4 % Construction Progress: Sch: 98.2 %; Front: 100%; Act:29.5 %
Risk Id E
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
I
E
E
E
E
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E
E
45
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 46 Overall Progress: Sch: 100 % Act: 77.3 % Construction progress: Cum Sch: 100% Front: 100% Cum Act: 71.2%
II III
Job No.: A307 Dec'14 Page 629+15 of 30
(Current risk Score Previous Risk score)
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.
EIL / BPCL
As Required
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. -Cable trench cast in situ offloaded to PGC (Misc Civil contract) - Additional agencies including M/s Ray Engg. & M/s Zillion have been lined up to supplement Structural works. Another misc Civil/Strl work contract floated, award targeted by end Jan'15. - Additional agencies including M/s Deens, M/s Furnace fabrica & M/s KSS have been lined up to supplement Structural works. Another misc Civil/Strl work contract floated, award targeted by end Jan'15.
EIL/BPCL
Dec'14
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 12.12.14 at site. EIL/BPCL - M/s Petron agreed to start night shift. - 150MT crane is under transit. 80MT crane shall be shortly deployed. 200MT crane to be despatched soon. The 150MT & 200 MT cranes shall be operational by end Dec'14. - 10 nos semi automatic welding machines shall be operational by third week of Dec 14. 26 nos welding machines are under transit. - Auto blasting shall start by end Dec '14. - 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 Dec '14. - Second RT agency to start work by end Dec'14. Source pit & concrete bunker to be prepared by PECL. - 1000 ID/day to be achieved from 3rd week of Dec 14. - SS welder qualification to start by end Dec 14. - Welding of site joints to commence from third week of Dec '14.
Dec'14
Slow construction progress by M/s KSSIIPL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 48 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:98.5%; Front: 77.3%; Act: 18.4%
Slow mobilisation by M/s Petron for Composite WorksFCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 27.09 %; Front: 12.73%; Act.: 6.52% AG Piping fabrication: 24857 ID / 486195 ID completed AG Piping Erection: 4944 ID / 811115 ID completed
Medium
Urgency (Long Term / Short term)
N
Open Project
Schedule ( Y / N) Output Quality ( Y / N) Y
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 47 Overall Progress: Sch: 90.2 % Act: 46.3 % Construction progress: Cum Sch: 91.5% Front: 100% Cum Act: 45.7%
EIL Cost (Y / N) N
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Previous Risk Score
E
N
Status (Open / Close)
Risk Id E
Key Risk Description
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity III
I
E
49
II
E
Slow progress of work & poor manpower mobilisation by Open Constructi M/s B&R for Composite Works-DCU on Awarded to M/s B&R on 12.03.14 CCD: 11.11.15 Construction Progress: Sch: 30.68 % Front: 23.30% Act.: 7.42% 50 AG piping fabrication: Only 35316 ID / 406975 ID fabrication completed. AG piping erection: Only 31039 IM / 526435 IM piping erection completed.
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
Management review meeting held on 11.12.14. -30 fitters, 40 welders & the required machineries shall be deployed by 25.12.14 -M/s B&R has been asked to expedite1200 ID/day by end Dec '14. - Finalisation of 2 more piping/eqpt agencies at site by third week of Dec'14. -Insulation/painting agency finalization by 31.01.15. - Hanger scaffolding to be introduced at site.
EIL/BPCL
Dec'14
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:95.2%; Front: 95.9%; Act: 25.4% CCD: 25.01.15 51 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 09.12.14. EIL/BPCL - 2500 m3 of RCC shall be cast during Jan'15 & the supervisory staff reqd for this shall be deployed by later half of Dec'14. - 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 done during Jan & Feb 2015. Bal 600 MT fabrication to be done by 28.02.15. - Strl detailing completion by 31.12.14. -600MT & 1000 MT erection targeted by Jan & Feb 15 respectively. - 125 MT crane to be deployed by 12.12.14 & 150 MT by 15.01.15.
Dec'14
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. 52 Sch: 29.46% Front : 23.41% Actual : 7.76% 20632 / 285505 ID fabricated & 99337 / 1214330 IM erected.
Open Constructi Very High on
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
Pping fabrication & erection work in progress in pipe rack 101-103, 108, 111-114. Fabrication in progress for Constr. piperack area 115.
Dec'14
II
E
E
II III
Job No.: A307 Dec'14 Page 630+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
Long term
I
0.2
0.19
0.19
0.00
- Management level meeting held 11.12.14 at site. -Piping management system shall be installed by 10.01.15. - B&R to take up compressor erection immediately.
EIL/BPCL
Dec'14
III
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for CDU/VDU. Sch: 04.09.14 54 CCD: 06.09.14 ECD: 31.03.15 Sch:100% Front: 99.44% Act: 88.20%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
Management level meeting held on 05.11.14. -TS I by 28.02.15 -TS II, III & IV handed over. -TS V by 27.04.15 -TS VII by 28.02.15. - Main piperack completion targeted by 13.01.15
Constr.
Dec'14
III
E
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15 Overall Progress: 55 Sch: 97.8 % Act: 89.4 % Constr. Progress: Sch: 98.1 % Front: 92.6.0% Act: 69.6 %
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- MRM held on 14.11.14 Constr. Major backlog is due to manufacturing & Delivery and construction. Erection of APH, Hot air ducts for VDU Heater is in progress. - Additional resources to be mobilised to recover construction backlogs Convection module 4/5 erected for Crude Heater A & 3/5 erected for Crude Heater B. CDU APH foundations to be handed over by Dec'14
As Required
III
E
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for DCU. Sch: 04.09.14 56 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 98.7 % Act: 86.1 %
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 05.11.14. - 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.
EIL/BPCL
Jan'15
E
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) Sch : 35.80% Front : 41.86% Actual : 9.85%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level Meeting held on 12.11.14. - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT383/391/150. - Annular plate erection for tanks YT-26&YT-28 started. - YT-150: Dismantling activities in progress. - YT-383: Dismantling activities in progress. Plate material ordered. - YT-391: tank cleaning under progress. - Ordering of plate material to be expedited. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement.
EIL/BPCL
Dec'14
II III
E
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 92.97 % Front: 100 % Act: 50.31 %
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held on 11.12.14 with M/s B&R at site. - Round the clock work to commence from 26.12.14. - YT 341 : First jacking on 18.12.14. - YT 342 : Annular plate erection from 24.12.14. Shell plate erection from 30.12.14. First jacking on 05.02.15. - YT 343 : Shell plate erection from 17.12.14. First jacking on 05.02.15. - YT 344 : First jacking on 05.01.15. - YT 111 : first jacking on 17.12.14. - YT 112 : First jacking on 27.12.14. - YT 113 : First jacking on 05.01.15. - YT 114 : First jacking on 14.01.15. - Entire fire bricks shall be at site by 22.12.14. - Additional 45 nos manpower by 25.12.14. - Receipt of balance MS plates by 26.12.14.
EIL/BPCL
Dec'14
III
E
E
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 59 CCD:18.06.15 Sch: 74.3 % Front: 68.5 % Act: 21.0 %
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. -Agency has been pressurised to mobilise resources and start work. - SWS-1 Sour water tank & sour water storage tank pads handed over.
Constr.
Dec'14
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. Sch : 25.61% Front : 21.82% Actual : 11.92% 60 38810 ID / 210605 ID piping fabrication completed. 6746 IM / 301995 IM erected.
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected. Piping fabrication work in progress.
Constr.
Dec'14
E
57
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N) Y
EIL Cost (Y / N) N
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) N
Key Risk Description
Status (Open / Close)
Slow construction progress by M/s B&R for Composite Open Constructi Very High works: Offsite Refinery area due to delay in mobilisation. on Awarded on 25.03.14. 53 CCD: 24.09.15 Sch:32.1%; Front: 8.5%; Act: 4.3%
Risk Id E
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
58
Action Plan
Action By
Target Date
Risk Severity
II III
Job No.: A307 Dec'14 Page 631+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held with M/s OIL on 12.11.14 at site. M/s OIL has been asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Mobilisation for 20 nos auto welding machine to be expedited.
Constr.
Dec'14
III
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 09.12.14 at site. M/s OIL has been asked to mobilise resources, fabrication yard in progress - 600 MT crane mobilised - At present only 4 nos welders are available at site with per day rate of 120 ID, however to achieve the completion schedule minimum 1000 ID/day to be achieved.
Constr.
Dec'14
III
Completion of balance piling work (Covered under Open Constn. 63 Piling-IIII Contract) (Total 2077 Nos piles approx). Completion of Composite works by M/s Albana for VGO Open Constructi Unit on Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15 64 31124 ID / 203790 ID piping fabrication & 6826 / 336280 IM completed.
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.32
-0.12 -Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. Piping III contract awarded BPCL to M/s Keller Ground Engineering & work commenced.
Dec'14
III
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected, side cladding in progress. Piping fabrication work in progress. Piping erection work commenced on the main pipe rack.
Constr.
Dec'14
III
Start of Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 11163 / 298905 ID fabricated. Erection not yet started. Sch : 22.80% Front : 28.63% Actual : 6.68% E
E
E
F
F
F
Urgency (Long Term / Short term)
Y
Schedule ( Y / N) Output Quality ( Y / N)
N
EIL Cost (Y / N)
N
Start of Composite works by M/s Offshore for Offsite DHDS area 61 Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15. Sch: 28.7% Front: 9.1% Act: 4.1%
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) Medium
Key Risk Description
Status (Open / Close)
Open Constructi on
Risk Id E
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
62
Action Plan
Action By
Target Date
Risk Severity
Availability of Hydrogen and Nitrogen for Pre1 commissioning 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’2015 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 2 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) 3 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.
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.
Implementation of environmental clearance conditions Open by EIL (received from MoEF vide Letter dated 22.11.12)
Projects
Medium
Y
N
N
N
Short term
D
0.08
0.04
0.04
0.00
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
Open
Const.
Very High
N
N
Y
Y
Short term
D
0.2
0.19
0.19
G
1
G
2
G
7
I
2
J
Implementation of Health, Safety and environmental 1 (HSE) system
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Project/BPCL As Required
IV
Constn. / Projects / BPCL - 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
As required
IV
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
Dec'14
IV
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
Job No.: A307 Dec'14 Page 632+15 of 30
M
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
Project
Low
Y
N
Y
N
Short term
I
0.6
0.18
0.18
0.00
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
EIL/BPCL
Dec'14
23.46
23.99
-0.53
Urgency (Long Term / Short term)
High
Schedule ( Y / N) Output Quality ( Y / N)
Const.
EIL Cost (Y / N)
Open
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
(Current risk Score Previous Risk score)
K
Previous Risk Score
Mobilisation of Skilled workers
Status (Open / Close)
Risk Id
Key Risk Description
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
At present only approx 9000 labours are working 2 against requirement of 15000-18000 labours. Variation in foreign exchange rates from Rs 50 per USD as on Mar 12 to Rs. 60 per USD as on date and fluctuations in the intermediate period and Scope 3 changes w.r.t. DFR (additional in scope) has significantly impacted on the overall project cost.
Total Risk Score
Action Plan
Action By
Target Date
Risk Severity
II III
Job No.: A307 Dec'14 Page 633 of 749
Integrated Refinery Expansion Project, Kochi
D
Risk Owner
C
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
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 Offsites: Part B: SRU & DHDS/Refinery Offsites :
Open
Project
- Electrical Works: Part A: M/s Technimont Part B: M/s Consilium - Instrumentation Works: Part A: M/s Technimont . Part B: M/s Consilium
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: 81.8% Act: 53.8 % Construction Progress: Sch: 42.8% Front: 84.4% Act: 17.9 %
Open
Project
Management level meeting held on 14.11.14 at site. - Hard stand construction completed. EIL / BPCL - Crane (1600 MT): Mobilisation by 15.02.15. EPIL/GRE to arrange alternate crane for erection of Regenerator bottom section. - EPIL-GRE informed to dispatch cyclones for reactors by 30.12.14 and regenerator cyclones by Feb'15. M/s Emtrol is being expedited. - Fdn for flue gas area and ESP handed over - M/s EPIL has commenced structural erection for FGC. - TSS Vessel: Assembly for skirt, shell 1 & 2 commenced. TSS assembly and erection of bottom section targeted by 30.12.14. - Essar being followed up for submission of catch up plan. Next management level meeting planned on 12.12.14.
30-Dec-14
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: 78.2 % Act: 59.9 % - 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
-Meeting held on 12.11.14, vendor agreed to complete erection of main fractionator by EIL/BPCL Jan'15 and balance columns by Mar/Apr'15. - Foundation for main fractionator column (by M/s L&T) completed and super structural work being expedited by M/s Tuaman. -1250 MT and 550 MT crane mobilised at site, erection scheme approved. - Stripper & rectifier Column: Erection of bottom section expected to commence from Jan'15. Preparation of Hard stand being expedited for readiness by Jan'15. - Approach road work completed. Area improvement to be expedited for crane movement.
As stated
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) Overall progress: Sch: 80.0 % Act: 71.3 %
Open
Project
- M/s Thermax seeking extension for duration due to delayed availability of burner BPCL / EIL data from M/s Accometric. 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 readiness targeted by end Dec'14. Bidder has requested for providing space for storage of MCC equipment & Refractory Materials.
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. 67.5 %; Act: 53.2 % Construction Progress: Sch: 47.4% Front: 97.9 % Act: 26.7 %
Open
Project
Management review meeting held on 14.11.14. Constr. -Shift Work: M/s EPIL has been asked to start works in two shifts. - Meeting held with M/s Essar for financial issues on 01.09.14. Financial help sought by M/s Essar, being addressed by BPCL to enable opening of LC. - Strl. Steel works offloaded from MK Engg. (580 MT / 650 MT fabrication completed, all dispatch expected by mid Dec'14) to M/s UHE (For derrick structure-1073 MT), M/s SP Infraprojects (Coke drum str-737 MT) & M/s Essar steel (200MT) BPCL/EIL - M/s EPIL to ensure the availability of Coke Fractionator & 2 coke drums by 31.03.15 & balance by 15.04.15. - The first shipment sail on 05.12.14. The second shipment targeted by 12.12.14 and ETA Kochi targeted by 14 Jan 215. Mobilisation of 2000 MT crane targeted in Feb'15 and erection to be targeted 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, while requirement is 607. - Next management level meeting planned on 12.12.14.
Dec'14
Key Risk Description
78
1
Action Plan
Action By EIL/BPCL
Target Date
Risk Severity
Nov'14
I
D
D
D
7
8
9
II III
I
D
12
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Dec'14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 62%
Open
BPCL / Director level meeting held with M/s VTV. Projects / - Crude column erection completed on 24.09.14. Hydrotesting targeted by end Const. Dec'14. - Erection of Vacuum Column : Delayed due to delay in receipt of bottom section. Erection of sections expected from mid Dec'14 to end Dec'14.
Constn. / VTV Dec'14 / BPCL
II
Job No.: A307 Dec'14 Page 634 of 749
Integrated Refinery Expansion Project, Kochi
D
D
D
Risk Owner
D
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
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
- Compressor casing dispatched from M/s NP Italy workshop on 17.09.14.(Received EIL/BHEL/BP Continuous at BHEL workshop). CL - 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 pump (from May'15 to Apr'15).
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 EDD: 30.03.15 Overall Progress: Sch: 95.0 % Act: 90 % Labour Strike: From 16.12.13 to 12.05.14.Equipment delivery affected.
Open
Projects
-Ordered to M/s L&T on 08.04.13; Dly 21M FOT. - Hydrotesting at vendor shop for all sections targeted by mid Jan'15. - Shop activities being expedited by regular visit and status being monitored on weekely basis to avoid further delay.
Delay by vendors with respect to CDD due to financial constraint.
Open
Projects
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Dec'14 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14-Jan'15.
Open
Projects
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 14 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: 81.5% Catch Up Sch: 47.1 % Act: 37.3%
Open
Backlog 31.4 (% wrt target sch) as of 15-Nov-14 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 - 30 M; Remaining Duration - 16 M CatchUp sch Const Sch Front Act 40.5 65.8 58.0 34.4 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU ,DCU, FCCU, VGO,DHDT & Offsite).
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)
Key Risk Description
19
21
Action By
Target Date
Risk Severity
Continuous
II III
- Following bidders showing slow manufacturing progress: EIL/ BPCL - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:134, 184. Meeting held on 04.11.14. Balance orders expected to dispatch from Dec'14 to Mar'15. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 189: As a parallel action separate MR-6122 released and ordered. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360,& 444. Meeting held on 06.09.14 with M/s BP&CL. Vendor confirmed subordering of raw materials on 09.09.14. - M/s HDO (Columns, Heat Exchangers & Vessels): Foa No.: 199, 302, 310, 315, 318, 320, 369, 389 & 395.
Dec'14
III
- As of now around 60% piping material has been received at site. Around 92-95 % EIL/ BPCL material has been ordered upto intermediate IIIrd MTO. Ordering of balance 5-8% material is expected by end Dec14. Delivery of ordered material against intermediate -II MTO expected by Dec'14 to Jan'15 -Vendors being expedited to prepone the deliveries.
Dec'14
Constn. / Projects
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued on EIL/BPCL 30.10.14, BPCL comments received on 04.11.14. As per BPCL email dated 01.12.14, Tender being split into two parts & SOR targeted by 15.12.14. - MR for compressors (BHEL & DR: Adequacy and health check completed): Adequacy check report from BHEL and from D-R received. Execution philosophy finalized on 17.10.14 for compressor (Dresser Rand make). MR issued on 23.10.14, RFQ under preparation. MR for BHEL make compressor targeted by mid Dec'14.
Dec'14
Open
Const
- In order to supplement progress of failing civil contractors, 4 separate contracts have been awarded (M/s Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray Eng-Misc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works being lined up and targeted to award by end Dec'14. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than EIL/BPCL 15000 labours . requirement of manpower at site is approx 15000 nos. BPCL/EIL have introduced reward schemes based on attendance, performance to enhance labour retention. - Work in shifts being implemented for all construction works at site.
As Required
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
Mar'15
29
33
Action Plan
EIL/BPCL
II
E
4
I
E
E
7
8
BPCL
I IV
Job No.: A307 Dec'14 Page 635 of 749
Integrated Refinery Expansion Project, Kochi
E
14
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Proj. / Constn.
Action Plan - Management level meeting held with M/s B&R on 17.11.14 at EIL site and augmentation of manpower by min. 100 nos to be expedited for concreting work progress. All area handed over in SRU block except for peripheral road. - 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 : At present 1140 nos piles completed against scope of 1800 nos. at site by M/s MBEL. Balance piling targeted by mid Jan'15.
Action By
Target Date
Balance availability of area for SRU Block - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by mid Dec'14. (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 construction progress by M/s KSSIIPL for Civil & Strl work in Offsite IREP area. Constr. Sch:100%; Front:99.7%; Act: 48.1% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 97.1%; Front: 100%; Act:54.1% CCD:18.12.14; ECD: May'15
Open
Project
Management review meeting held with M/s Essar on 19.09.14 at site & 25.09.14 at EIL HO. - Foundation work completed for HRSG-3. - Completion of Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - Completion of boiler piperack foundations targeted by 15.12.14 (20/21 nos raft completed).
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. 88.5% 68.4 % 30.5%
Open
Project
- Management level meeting held at site on 13.11.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - TS-06 : Raft work completed. Structural steel erection targeted by 15.12.14. - Structural Erection commenced for TS-2 and for TS-03 targeted by 15.12.14. - Out of total 1800 nos piles, 1140 nos completed. Pile cutting completed for 547 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by 15.01.15. - Out of total structural work of 4290 MT, only 1085 MT fabrication completed & 251 MT erection works completed. UG piping erection work yet to commence.
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: 46.56% Front: 54.19% Act: 25.34 %
Open
Project
- Management level Meeting held with M/s OIL on 12.11.14 and following action plan EIL/BPCL has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Auto blasting m/c received, being installed.
Continuous
Progress of ETP Works LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 73.5 % Act: 24.5 % Construction Progress: Sch: 53.48% Front: 90.20 % Act: 13.18 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Management level meeting held on 12.11.14 at site and on 05.12.14 at EIL Delhi. EIL/BPCL - Augmentation of 100 manpower to be expedited. - Chemical house completion by Mar'15 - Piling work commenced in ACT/SBR/TWT area (17/612 nos completed). Completion of Piling by Dec'14 - Completion of equalisation tank by Mar'15. - M/s Paramount shall submit action plan for completion of ETP by Dec'15.
As stated
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: 70 % Act: 19 %
Open
- Meeting held with vendor on 29.08.14. Recommendation for PO amendment forwarded to BPCL on 11.09.14. BPCL to issue PO amendment. - Finalisation of subvendor for expansion bellows being expedited.
As Required
Risk Severity
Dec'14 EIL/BPCL
I
E
27
Constructio Management level meeting held with M/s KSSIIPL at site on 14.11.14. EIL/BPCL n - 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. - M/s KSS agreed to complete all balance piperack foundations by mid Dec'14. 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.
Dec'14
II
E
28
EIL/BPCL
Dec'14
II
E
29
II
E
30
II
E
34
I
E
39
Project
BPCL
II
Job No.: A307 Dec'14 Page 636 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Progress of RO-DM Plant (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: 96.5 % Act: 60.7% Construction Progress: Sch: 94.93 %; Front: 100%; Act:26.46 % Area handed over, part of area is water logged due to plant drain which is under completion.
Open
Project
Management level meeting held on 05.12.14 at EIL Delhi. EIL/BPCL 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. M/s Driplex has been asked to prepare a catch-up plan to expedite construction activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. 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 (42/160 nos completed).
As Required
Open
Project
-Management level meeting held at Kochi on 18.09.14. -Mobilisation of resources is being expedited. At present only 170 nos , manpower mobilised, against a requirement of 700 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -7917 m3 RCC work has been already withdrawn from SEPC scope to M/s Tuaman (5300 m3) & M/s Paulose George (2617 m3). 3215 MT strl works offloaded to M/s Tuaman, M/s Zillion & M/s Ray engg.
As Required
41
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 94.67%; Front: 98.34% Act: 51.39 % CCD: 24.12.14 ECD: Oct'15
Open
Project
-Management level meeting held with M/s MBEL on 13.11.14 at site. M/s MBEL EIL/BPCL agreed: - 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
44
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 Sch: 97.27 %; Front :99.55 % Act: 63.71 % - Structural erection: DHDT: 825 MT / 2600 MT completed.; VGO: 746 MT / 3065 MT completed. -UG Piping Laying: DHDT: 11089 IM / 25400 IM completed; VGO: 11038 IM / 42000 IM completed.
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 Dec'14. Project Material storage EIL/BPCL commenced. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. Buildings to be expedited for storage of material / equipment being received at site.
As Required
Slow construction progress by M/s KSSIIPL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:95.19%; Front: 72.67%; Act: 17.59%
Open
Constructio Management level Meeting held with M/s KSSIIPL on 14.11.14 at site. EIL/BPCL n - M/s KSS agreed to deploy additional 50 nos manpower by mid Dec'14. Agencies for structural erection have been finalised and started mobilising at site. - M/s KSS has been asked to deploy additional manpower to complete all equipment fdns. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: M/s Ray Engineering, M/s Deens. 4117 m3 RCC work has been already withdrawn from KSSIIPL scope to M/s Ray Engg. (2800 m3), M/s Paulose George (800 m3) & M/s Deens (517 m3). 2431 MT strl works offloaded to M/s Ray Engg. - Futher new tender under preparation to offload M/s KSSIIPL works.
Dec'14
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:85.3%; Front: 89.74%; Act: 21.28% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held at Kochi site on 13.11.14. EIL/BPCL n -MBEL asked to explore the methodology to reduce attrition of present labour. MBEL to augment additional resources (from 210 nos to 400 nos) MBEL committed to increase manpower upto 300 nos by mid Dec'14. - Availability of front to mechanical contractor to be expedited by completing all piperack foundations by 30.12.14 and structural erection by Dec'14. Works offloaded to M/s Ray & M/s Deens to supplement Civil & Strl works. Further 2 additional Civil &Structural works contracts being lined up and expected to award by mid Dec'14.
Dec'14
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:21.3%; Front: 5.8%; Act: 3.6%
Open
Constructio - Management level meeting held 17.11.14 at site. n -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works commenced.
EIL/BPCL
Dec'14
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: 98.51 % Act: 82.77 %
Open
Constructio Management level meeting held on 05.11.14. n - Handing over of complete branch piperack targeted by 28.02.15. - TS-III : Structural erection targeted by 31.01.15. - TS-IV: Complete hand over targeted by 05.12.14. - TS-V: Start of structural erection targeted by 25.12.14.
EIL/BPCL
Jan'15
40
Risk Severity
I
E
EIL/BPCL
I
E
II
E
45
II
E
47
I
E
E
E
50
52
55
II III
II
Job No.: A307 Dec'14 Page 637 of 749
Integrated Refinery Expansion Project, Kochi
E
56
F
1
G
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) Sch: 24.9% Front: 44.2 % Act: 6.1 %
Open
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
Timely payment to sub contractor by main contractor
Open
Const.
Mobilisation of Skilled workers
Open
Const.
2
Action Plan
Constructio - Management level Meeting held on 12.11.14. n - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT-383/391/150. - Annular plate erection for tanks YT-26&YT-28 started. - YT-150: Dismantling activities in progress. - YT-383: Dismantling activities in progress. Plate material ordered. - YT-391: tank cleaning under progress. - Ordering of plate material to be expedited. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement.
1
At present only approx 9000 labours are working against requirement of 20000-25000 labours.
K
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action By
Target Date
Risk Severity
EIL/BPCL
Dec'14
III
BPCL
1-Jun-15
III
Following methodology being taken up for smooth cash flow to contractors: BPCL/EIL - 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.
As Required
IV
-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. -BPCL/EIL to jointly introduce some incentive system for workers to reach manpower upto 12000 by Dec'14. - Work in shifts to be implemented for all construction works at site.
As Required
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015 for CDU/VDU commissioning.
II
Job No.: A307 Nov'14 Page 638+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Total Risk Score
N
Long term
I
0.2
23.99
(Current risk Score - Previous Risk score)
Impact Score => {6+7+8+9} * 10 * 11
Y
Previous Risk Score
Controllability Condition (D/I )
N
Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
N
Output Quality ( Y / N)
Low
Schedule ( Y / N)
Project
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Open
EIL Cost (Y / N)
Award of Electrical & Instrumentation Works for Units & Offsite Sch: 30.06.14 Ant: 10.11.14 C 78 Electrical/Instr. Works: Part A: CDU/VDU, DCU, FCCU, DHDT, VGO-HDT & IREP Offsites: Part B: SRU & DHDS/Refinery Offsites :
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
0.10
-0.10 - Electrical Works: Part A: M/s Technimont Part B: M/s Consilium - Instrumentation Works: Part A: M/s Technimont . Part B: M/s Consilium
24.42
-0.43
Action Plan
Action By
EIL/BPCL
Target Date
Nov'14
Risk Severity
Job No.: A307 Nov'14 Page 639 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Ordering of Critical Valves Sch: 11.07.14 73 Ant: 10.11.14 Dely: 06/07 M FOT /FOB
Open
Project
Revised MR (MR-3415) issued covering all critical valves along with all critical valves BPCL of MR-3211 floated. Award recommendation issued on 08.10.14.
10-Nov-14
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM-Refloated 76 Sch: 08.05.14 Ant: 15.11.14
Open
Project
- 4 nos bids received on 30.09.14. PBO recommednation issued to BPCL on 31.10.14.
15-Nov-14
Completion of Reactor regenerator package for FCCU-M/s Esaar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 76.7 % Act: 51.7 % Construction Progress: Sch: 32.5% Front: 79.9% Act: 14.6 %
Open
Project
Management level meeting held on 16.10.14 at site. - Completion of hard stand targeted by 09.11.14. - Crane (1600 MT): Ship movement started, assembly targeted by 10.11.14 & load test by 30.11.14. Final erection scheme submitted on 15.09.14. Readiness of crane for erection targeted by Dec'14. - EPIL-GRE informed to dispatch cyclones for reactors by 30.11.14 and regenerator cyclones by 31.12.14. M/s Emtrol has been asked to pre pone the deliveries upto Dec’14 during meeting dated 25.08.14. EIL/BPCL - Fdn for flue gas area, stack fdns and ESP fdn to be expedited (Excavation already completed). - M/s EPIL has been asked to commence area development around FGC equipments & commence hard stand work from 07.10.14 and to be ready by 09.11.14. - TSS srection: Assembly for skirt, sheel 1 & 2 commenced. TSS assembly and complete erection targeted by 15.11.14. Area for storage of fabricated materials to be identified and allocated. Issues being followed up.
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) Overall progress: Sch: 80.0 % Act: 69.8 %
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 readiness to be delayed till Dec'14. Bidders has requested for providing space for storage of MCC equipment & Refractory Materials. - Refractory liining 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. 62.9 %; Act: 49.5 % Construction Progress: Sch: 40.5 % Front: 94.1 % Act: 24.1 %
Open
Project
-Management review meeting held on 19.09.14 and 12.09.14. Weekly review meeting Constr. held at site on 10.10.14. Following commitments have been made by M/s Essar. -Shift Work: M/s EPIL asked to start works in two shifts. - Meeting held with M/s Essar for financial issues on 01.09.14. Proposal from M/s Essar for financial support forwarded to BPCL for review / approval. - Strl. Steel works offloaded from MK Engg. to M/s UHE (For derrick structure-1073 MT), M/s SP Infraprojects (Coke drum str-737 MT) & ESSAR steel (200MT) BPCL/EIL - M/s EPIL to ensure the availability of Coke Fractionator by end Dec’14 and all the four Coke Drums progressively by Apr’15. - Mobilisation of 2000 MT crane targeted in Feb'15 and erection to be targeted from Mar'15 to May'15. -Crane (200 MT): Crane parts started arriving at site. Crane readiness by mid Nov’14. -Clear water tank fabrication- Agency finalization by Nov'14. - Resource augmentation for Civil & Strl works being expedited. At present 457 nos have been deployed, while requirement is 607.
Continuous
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
II EIL/BPCL
II
D
D
D
1
8
9
09.11.14 Dec'14
I III
I
D
Delay in erection of Crude & vacuum column Sch: Jun 14; CCD: 21.08.14 Ant: Dec'14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 57%
Open
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Dec'14 Projects / - Erection of Crude Column : Crude column erection completed on 24.09.14. / BPCL Const. Hydrotesting targeted by 07.11.14. - Erection of Vacuum Column : Delayed due to delay in receipt of bottom section. Erection of sections expected from mid Nov'14 to end Nov'14 and hydrotesting by mid Dec'14.
II
Job No.: A307 Nov'14 Page 640 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
T&CC
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - Agency confirmed availability of Barge/Trailer at the time of delivery of Reactors. Out of 2 nos modified barge, 1 no completed and balance one 1 no by 1st week of Nov'14. Drawings for new barge submitted to IRS for approval. 1 nos new barge fabrication by 24.12.14. - Construction of jetty not yet started as land for jetty is yet to be finalised. M/s Urmila agreed to finalise and hire the IOCL land for jetty. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at Kochi-Port.
Nov'14
Delay by vendor with respect to CDD due to financial constraint.
Open
Projects
- Following bidders showing slow manufacturing progress: EIL/ BPCL - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:184. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 189: As a parallel action separate MR-6122 released. Award recommendation issued to BPCL. Cancellation request forwarded to BPCL on 13.10.14. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360,& 444. Meeting held on 06.09.14 with M/s BP&CL. Vendor confirmed subordering of raw materials on 09.09.14. - M/s HDO (Columns, Heat Exchangers & Vessels): Foa No.: 199, 302, 315, 318, 327, 369, 389 & 395.
Nov'14
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) 32 CDD: 18.10.14 EDD: 31.03.15
Open
Projects
- Order got delayed due to delay in manufacturing works. At present fabrication of Stripper column going beyond Nov’14 due to which there will be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
EIL/ BPCL
Nov'14
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 33 EDD: Nov'14 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
Open
Projects
- As of now around 42-45% piping material has been received at site. Around 90-95 EIL/ BPCL % material has been ordered upto intermediate IIIrd MTO. Ordering of balance 5-10% material is in progress and expected progressively upto mid Nov'14. Delivery of ordered material against intermediate -II expected by mid Nov'14. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
Nov'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION Key Risk Description 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)
D
D
D
DHDT Reactor (M/s Doosan) expected to receive at Kochi port by Nov'14. 13 ISGEC Josen (3 nos) Column: expected to receive at Kochi port from Nov'14 to Jan'15.
29
Action Plan
Action By
Target Date
Risk Severity
II III
II
D
E
4
II
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 77.1% Catch Up Sch: 39.6 % Act: 32.3%
Open
Constn. / Projects
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued on BPCL/EIL 31.10.14. Award targeted by Nov'14. - MR for compressors (BHEL & DR: Adequacy and health check under progress): Adequacy check report from BHEL expected by end Oct’14 and from D-R received on 19.09.14. Execution philosophy finalized on 17.10.14 for compressor ( Dressar Rand make ). MR targeted by mid Nov'14.
Nov'14
Backlog 29.6 (% wrt target sch) as of 15-Oct-14 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 - 30 M; Remaining Duration - 16 M Desc. Catch Up sch: Const Sch Front Act Overall 34.9 61.0 58.0 31.4 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU ,DCU, FCCU, VGO,DHDT & Offsite).
Open
Const
- In order to supplement progress of failing civil contractors, 4 separate agencies has Constn been lined up (M/s Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray EngMisc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works being lined up. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 nos. BPCL/EIL to jointly introduce some incentive system for workers to reach manpower upto 12000 by BPCL/EIL Nov'14. - Work in shifts to be implemented for all construction works at site.
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 Mar'15)
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
BPCL
Mar'15
- Management level meeting held with M/s B&R on 19.09.14 at EIL site & on 25.09.14 at EIL HO and augmentation of manpower by min. 100 nos to be expedited for concreting work progress. M/s B&R has been asked to expedite complete SRU filling by 10.11.14. All area handed over in SRU block except for peripheral road. - Retaining wall completed for the available front. Piling to be carried out through Piling III to take up further retaining wall work. - Piling for SRU : At present 989 nos piles completed against front of 1700 nos & scope of 1800 nos. at site by M/s MBEL.
Constn.
Nov'14
I
E
E
E
7
8
Delay in balance area availability for SRU Block - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by 2nd week of Nov'14. (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 14 M (As per Past experience minimum requirement for SRU is 30 M).
Open
Proj. / Constn.
I IV
EIL/BPCL
I
Job No.: A307 Nov'14 Page 641 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Constr. Sch:100%; Front:94.3%; Act: 45.0% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 93.4%; Front: 94.5%; Act:47.3% CCD:18.12.14; ECD: May'15
Open
Project
Management review meeting held with M/s Essar on 19.09.14 at site & 25.09.14 at EIL HO. - Foundation work completed for HRSG-3. - Completion of Structural works for GTG shed targeted by mid Nov'14. - Stack foundation : Only HRSG#3 fdn completed. - Completion of boiler piperack targeted by 30.10.14. - All balance drawings for which data is available shall be targeted for issue by 30.10.14.
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. 80.6% 59.7 % 26.9%
Open
Project
- Management level meeting held at site on 15.10.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - Foundation work: TS-06 by 30.10.14. - Structural Erection commenced for TS-2 & TS-03 and for TS-06 start of strl erection targeted by end Oct'14. - Out of total 1800 nos piles, 989 nos completed. Pile cutting completed for 504 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by end Nov'14. - Out of total structural work of 4290 MT, only 852 MT fabrication completed & 176 MT erection works completed. UG piping erection work yet to commence.
Continuous
27
Constructio Management level meeting held with M/s KSSIIPL at site on 15.10.14. EIL/BPCL n - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - 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 and targeted to complete by 31.10.14. - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. Cable trench work to be commence in Oct’14. - 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.
Target Date
Risk Severity
Nov'14
II
E
28
EIL/BPCL
Nov'14
II
E
29
Open
Project
- Management level Meeting held with M/s OIL on 08.10.14 and following action plan EIL/BPCL has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. -M/s OIL confirmed to cover pipe rack for rain protection modular shed, for which order has been placed & expected to receive at site by end Oct'14.. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Piping fabrication rate of 1500 ID / day from current 800 ID/Day targeted to achieved from 15.10.14. - OIL to deploy their auto blasting machine.
Continuous
E
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: 37.9% Front: 47.3% 30 Act: 21.5 %
Open
Project
-Management level meeting held on 14.10.14. EIL/BPCL - Physical handing over of balance area for treated water tank, API/TPI, ex TPI sump completed. Signing protocol to be expedited. - M/s Paramount has been asked to mobilise additional 60 nos manpower progressively by 30.10.14 -Piling drawing for ACT & SBR area approved vide across the table review meeting dated 05.09.14. - Work in progress in substation area, equalisation tank, treated water tank, sludge thickener, spent caustic tank, chemical handling areas. - Completion of foundation work for chemical house to be expedited by augmenting manpower & resources. -Piling work being executed by M/s Simplex. 2 nos rigs targeted to be mobilised by 30.10.14. Start of work targeted from 01.11.14 to be completed by 31.12.14.
As stated
E
Progress of ETP Works LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 65.7 % Act: 22.3 % Construction Progress: Sch: 42.6 % Front: 90.0 % Act: 11.4 % Awarded to M/s Paramount on 11.09.13. (Duration: 34 21 M+2 M incl pre commng)
Progress of RO-DM Plant (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: 94.3 % Act: 57.9% Construction Progress: Sch: 87.8 %; Front: 100%; Act:22.9 % Area handed over, part of area is water logged due to plant drain which is under completion.
Open
-In view of delay in handing over of areas and various site related issues and soil EIL/BPCL problem encountred during execution, progress of construction badly affected. M/s Driplex has been asked to prepare a catch-up plan to expedite construction activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. 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) : Filling in area targeted to complete by end Oct'14. Piling drawing received from M/s driplex and is under review. Piling work targeted to commence from end Oct'14. -90 % model review completed. - Meeting held with M/s Driplex at site on 14.10.14 & M/s Driplex has been asked to mobilse addln. 45 nos manpower for civil works by 31.10.14 & another 50 nos by 20.11.14.
As Required
II
II
I
E
40
Project
I
Job No.: A307 Nov'14 Page 642 of 749
Integrated Refinery Expansion Project, Kochi
E
41
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
-Management level meeting held at Kochi on 18.09.14. -Mobilisation of resources is being expedited. At present only 187 nos , manpower mobilised,against a requirement of 700 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). EIL/BPCL -5300 m3 RCC work has been already withdrawn from SEPC scope to M/s Tuaman scope. Additional 1500 m3 RCC work being offloaded from SEPC scope to M/s PGC. 2495 MT strl works offloaded to M/s Tuaman, M/s Zillion & M/s Ray engg.
Target Date
Risk Severity
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 85.0%; Front: 95.4% Act: 45.3 % CCD: 24.12.14 ECD: Oct'15
Open
Project
As Required
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:90.1%; Front: 72.2%; Act: 15.9%
Open
Constructio Management level Meeting held with M/s KSSIIPL on 15.10.14 at site. EIL/BPCL n - M/s KSS agreed to deploy additional 50 nos manpower by end Oct’14. Agencies for structural erection have been finalised and started mobilising at site. - M/s KSS has been asked to deploy additional manpower to complete all equipment fdns. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: M/s Ray Engineering, M/s Deens. Others contracts being lined up are: Misc. Strl Works-II: 4 nos bids received on 30.09.14. PBO targeted by 31.10.14. Misc. Civil & Strl-II: 5 Bids received on 07.10.14. PBO targeted by 31.10.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
Nov'14
Open
Constructio Management level meeting held on 16.10.14 at site. n - M/s Petron agreed to increase nos of welders to 30 nos & fitters to 20 nos by 30.10.14. - Semi automatic welding machine shall be in operational by 05.11.14 - M/s Petron has been asked to commence min. 1000-1500 ID / day to complete entire job. Present rate is 160 ID / day.
EIL/BPCL
Nov'14
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: 12.3 % Front: 20.2% Act.: 2.8%
Open
Constructio Management review meeting held on 19.09.14. EIL/BPCL n -Subcontracting agency finalised and 30 nos addln. manpower targeted to be available at site by end Oct'14. Agency for heavy equipment erection has been finalised and mobilisation schedule under submission. -Semi automatic welding machine - 3 nos recd at site. Commissioning yet to be done. AG piping fabrication: Only 12108 ID / 304970 ID fabrication completed. AG piping erection: Only 1078 IM / 412580 IM piping erection completed.
Nov'14
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:76.4%; Front: 82.6%; Act: 18.8% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held at Kochi site on 15.10.14. EIL/BPCL n -MBEL asked to explore the methodology to reduce attrition of present labour. MBEL to augment additional resources (from 210 nos to 400 nos) MBEL committed to increase manpower upto 300 nos by end Oct’14. - Availability of front to mechanical contractor to be expedited by completing all piperack foundations by 30.10.14 and structural erection by mid Nov’14. Works offloaded to M/s Ray &M/s Deens to supplement Civil & Strlworks. Further 2 additional Civil &Structural works contracts being lined upand expected to award by end Nov’14.
Nov'14
Open
Constructio - Management level meeting held 19.09.14 at site. n -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works commenced.
EIL/BPCL
Nov'14
I III
BPCL
1-Jun-15
III
I
E
49
I
E
E
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 50 Construction Progress: Sch: 8.6 %; Front: 9.8%; Act.: 2.3% AG Piping fabrication: 1980 ID / 500000 ID completed
II
51
II
E
E
F
52
Slow construction progress by M/s B&R for Composite works: Offsite Refinery area due to delay in mobilisation. 54 Awarded on 25.03.14. CCD: 24.09.15
1
G
1
G
2
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015 for CDU/VDU commissioning.
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
Constn. / Projects / BPCL
As Required
Job No.: A307 Nov'14 Page 643 of 749
Integrated Refinery Expansion Project, Kochi
Mobilisation of Skilled workers At present only approx 9000 labours are working against requirement of 15000 labours.
K
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Const.
Action Plan
Action By
-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. -BPCL/EIL to jointly introduce some incentive system for workers to reach manpower upto 12000 by Dec'14. - Work in shifts to be implemented for all construction works at site.
Target Date
Risk Severity
As Required
2
II
Kochi Refinery, BPCL
A
A
A
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)
Job No.: A307 Aug'14 Page 644+15 of 32
Action Plan
Action By
15
16
17
Target Date
4
5
6
7
8
9
10
11
12
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 2 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 / 3 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
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
Delay in issue of Process deliverables for engineering for Open 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 1 Anticipated : mid Nov'13
Holds, missing information, corrections, changes in PDS / P&IDs - DCU A
Output Quality ( Y / N)
3
Schedule ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
1
Risk Owner
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
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 & INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13
Close
BPCL / Process
Low
N
N
Y
N
Short term
I
0.4
0.00
-Process package received on 14.04.13
Delay in "issue for engineering - IFE" PDS / P&IDs for DHDT Close P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
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
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
A
5 Agreement signed by BPCL-KR issued to Licensor on 04.04.13
A
6
A
7
A
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly 8 from estimated values.
Delay in "issue for engineering - IFE" PDS / P&IDs for FCC LAD :29-Jan-13; Ant : 08-May-13 A
Close
Close
Close
9
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A 10
Close
0.00
0
Projects / Process
Apr'13
-
Apr'13
Apr'13
31-Dec-12
Jan'13
Kochi Refinery, BPCL
(Current risk Score Previous Risk score) 15
16
Action By
Target Date
17
18
Risk Severity
4
5
6
7
8
9
10
11
12
Process
Medium
N
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 Offsites P&ID’s for tankages (LAD - 21.01.13) Close - 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 A 12 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
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.
In view of increase in sulphur load PDS & P&IDs for sulphur Close block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement.
Revision in PDS after issue of “Issued for Engineering” after A 14 release of MR -Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
Close
Close
14
Action Plan
Delay in "issue for engineering - IFE" PDS / P&IDs for VGO- Close HDT A 11 LAD : 29-Jan-13; Ant : 10-May-13
A 13
13
Previous Risk Score
Job No.: A307 Aug'14 Page 645+15 of 32
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)
3
Schedule ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
1
Risk Owner
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Process
Process
19 Apr'13
-
Apr'13
15-Mar-13
Feb'13
Process
-
Apr'13
Process
-
Apr'13
As Required
Apr'13
A 15
Revision in PDS after issue of “Issued for Engineering” after A 16 Order
Close
Process/E NGG/Proc ure
Revision in PDS after issue of “Issued for Engineering” after A 17 Equipment manufacturing
Close
Process/E Very Low NGG/Proc ure
Updation of estimated utilities on account of revision in A 18 process parameters (revision of PDS based on engg comments)
Close
Process
Low
N
N
Y
N
Long term
I
0.2
0.00
ISBL Distribution P&IDs for VGO-HDT A 19 SCH: 30-Nov-12 ANT: Jun-13
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 A 20 ANT: 31-May-13
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
Close
Process
Low
N
N
N
N
Long term
I
0
0.00
Distribution P&IDs issued for engineering.
Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 A 22 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
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed engineering activities.
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
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new GTG).
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
Utility distribution P&IDs for DCU A 21
A 23
A 24
0.00
0
Process
31-May-13
Apr'13
31-May-13
Apr'13
Jan'13
Kochi Refinery, BPCL
2
3
4
5
6
7
8
9
10
11
12
Close
Engg.
Medium
N
N
Y
N
Short term
I
0.4
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
Open
Engg.
Very High
N
N
Y
N
Short term
B
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 1 ii) Civil/Structural & UG Piping Tender preparation
Issue of Equipment layout for engineering for VGO-HDT LAD - 07-Nov-12 2 Ant- 26-Dec-12
Close
Engg.
Very high
N
N
Y
N
B
Engg.
High
N
N
Y
ENGG
High
N
N
Procure/E NGG/CON S.
Medium
Y
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 BPCLand i.e.battery availability Shut for down / Hot Signing of ISBL P&IDs limit of P&IDs Units, tapping. Utility packages & other packages.
13
14
(Current risk Score Previous Risk score)
Previous Risk Score
Job No.: A307 Aug'14 Page 646+15 of 32
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
15
B
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Delay in this activity shall hamper the following: i) 3 D Modelling Issue of Equipment layout for engineering for FCCU (targeted Close ii) Civil/Structural & UG Piping Tender preparation by 27.12.2012) 3 Delay in this activity shall hamper the following: i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation
Target Date
17
18
16
Risk Severity
19
- 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: - 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 signing by end week of Oct'14.
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
0.05
Nov'13
30-Dec-13 30-Oct-14
Dec'13 IV
Mar'14 & Apr'14
B
NIT for Heater for FCCU 4 LAD -01-Apr-13 ; Ant - 18-Jun-13
B
a) Cost/time overrun due to rework b) Non completion of critical project activities within time & delay in Project completion 5 c) Poor performance of Sub-contractors and Vendors
New requirement of power recovery system (FCCU) shall have impact on project cost. 6 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
B
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; 7 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
B
Close
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
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant - 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 8 large bore pipes.
HMTD
Very High
N
N
Y
N
Short term
D
0.16
0.00
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
B
Open
Action By
0.00
A 27
A 28
Action Plan
Close
Delay in thermal design for Heat exchangers & Air coolers for Close licensed and non licensed units LAD (DHDT): 02-Feb-13 9 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
Apr'13
Kochi Refinery, BPCL
2
15
16
Action By
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 B 11 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 C 12 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
a) Inaccurate assessment of quantum of work
Close
MR issue for MCC (Main combustion Chamber) packages.
Close
Engg/proc Very High urement
17
18
Risk Severity
3
B 10
14
Action Plan
Close
Issue Overall UG piping layout drawing for the complex
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Job No.: A307 Aug'14 Page 647+15 of 32 (Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
As Required
19
B 13
Project
Medium
N
N
Y
N
Short term
D
0.16
0.00
MR issued on 02.05.13.
Engg
Apr'13
May'14
B 14 LAD: 16-Feb-13 Ant: 15-Apr-13
B 15
Timely finalisation of Package Interface 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).
Open
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
Unit and offsite interfaces (Elevation termination levels)
Close
Engg.
Medium
N
N
Y
Y
Long term
D
0.1
0.00
- Clubbed with Risk ID A27
TSD
Open
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
NIT for Heater for DCU LAD -15-Feb-13;
Close
PROCES Very High S/ENGG
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
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/Cont .
Medium
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. - 60% model review for HRSG targeted by end Oct'14. -90% model review for GTG & UB package targeted by end Oct'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.
30-Oct-14
III
Open Engg/proc urement
Medium
-
Mar'14 & Apr'14
B 16
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule requirements. B 17 LAD - 28.02.13; Ant - upto Feb 14.
B 18
B 19
Distributed Control System (DCS) Detailed engg., supply and erection B 20 (ordered on M/s Emerson Process on 04.11.13) B 21
60 % Model review for to submit Instrumentation Drawings/ Close ENGG Very High Package Vendor refuses Open Engg/proc Low DCU (LAD:03.07.13 Act:13.09.13) Documentation in Smart Plant Instrumentation Database as urement B 22 per Client Requirement
B 23
Delay in Interface Engineering (including control system) due to non availability of Package Vendor Data
Open Engg/proc urement
Low
0.08
0.08
Engg Projects / Process Process / HMTD C&P
N
Y
N
N
Long term
I
0.15
0.08
-0.08 - 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
N
N Y
Y
N
Short Long term
D
0.16 0.14
0.04
0.00 - Being Model taken reviewup completed on 13.09.13 -0.04 with respective package vendors for implementation.
ENGG/ Instn Projects
Continuous
Aug'13
N
N
Y
N
Long term
I
0.2
0.06
0.00
Continuous
IV
0.06
Package vendor inputs being made available by expediting for updation of interface engineering documents. Projects / Engg.
Kochi Refinery, BPCL
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Previous Risk Score 14
15
16
Action By
4
5
6
7
8
9
10
11
12
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
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) B 24 LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
GC
Medium
N
N
Y
N
Long term
D
0.08
0.00
- All P&IDs released
G. Civil
25-Jul-13
JUL'13
Order of MR for DG set Dely: (12 M FOB + 3 M Site work) B 25 Sch: 05.11.13
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
BPCL
5-Oct-14
Receipt of Inputs from Process / Vendors for 60 % 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.
Close
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 B 28 SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), 164 (SRU),15 Delay of Intermediate 2nd MTO Open (SWS)in&release 60(TGTU) + 155(Utilities LAD:30.09.13; -CVs Size HoldAct:31.10.13) as follows: 13 (ARU), 6 (SWS), 125 (SRU). Holds: -All Control Valve Face to Face Dimensions are HOLD. All -CDU/VDU: Pump CVs for TGTU are nozzle HOLD. 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 B 29 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
Open
ENGG
Low
N
N
Y
N
Short term
D
0.16
0.05
0.00
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
Progressively
Close Open
ENGG ENGG
High Low
N N
N N
Y Y
N N
Short term Short term
D D
0.16 0.16
0.05
0.00 - HAZOP study completed on 29.11.13. -0.05 - As of 15 Aug'14 Engineering progress is 91.4 %.
-0.20 - Ordered to M/s Powerica Ltd on 29.09.14 (Delivery duration 13 M+ 3 M site works).
18
Risk Severity
ENGG
0.20
17
Target Date
3
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.
13
Action Plan
Open
B 20
2
Job No.: A307 Aug'14 Page 648+15 of 32 (Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19
B 26
B 27
Generation of Surplus Piping material B 30 B 31 HAZOP for FCCU LAD - 23-Sep-13 Completion of 90 % engineering by Mar-14. Average progress achieved in last 3 months 3.0 % B 32 LD Milestone date - Dec'13
0.05
ENGG ENGG
IV
Nov'13 Aug'14
Kochi Refinery, BPCL
2
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
15
16
17
Target Date
Risk Severity
18
19
3
4
5
6
7
8
9
10
11
12
ENGG
High
N
N
Y
N
Short term
D
0.16
0.13
-0.13 - 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
0.20
-0.20 - 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.
Sep'14
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 1 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
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
30-Dec-13
Dec'13
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 2 Duration: 18 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
30-Aug-13
JUL'13
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 3 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
Very High
Y
Y
Y
N
Short term
D
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
Close
Project
Very High
Y
N
N
N
Short term
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
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
14
Action By
Open
B 34
13
Action Plan
Release of final Piping MTO Sch: Jul'14
B 33
C
Job No.: A307 Aug'14 Page 649+15 of 32 (Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Sep'14
C
4
Award of Heater for DHDT 5 LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Very High
N
N
Y
N
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
C
NIT for Composite Works for DCU 6 LAD -06.06.13 ; Ant - 25.10.13
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
Piping
25-Oct-13
sep'13
C
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
Piping
31-Oct-13
sep'13
7
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
C
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
Piping
15-Oct-13
sep'13
8
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
C
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
Piping
15-Oct-13
sep'13
9
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
C
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
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 LAD -22.07.13 ; Ant - 15.10.13
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
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
C 10
C 11
C 12
Kochi Refinery, BPCL
(Current 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)
Previous Risk Score 14
15
16
Action By
Target Date
17
18
Risk Severity
6
7
8
9
10
11
12
N
Y
N
Short term
I
0.4
0.00
-Ordered to M/s Fabtech on 15.07.13
Engg/Proj
Issue NIT for Tankage-II LAD: 21-Jan-13 C 14 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 C 15 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
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
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
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13
13
Action Plan
N
Award of : Main fractionator for FCCU LAD: 25-Mar-12 Ant: 20-Jul-13
5
Schedule ( Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
Job No.: A307 Aug'14 Page 650+15 of 32
Open Project/En Very High gg
C 13
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
20-Jul-13
19 JUL'13
C 16
NIT for Reactor regenerator package for FCCU LAD : 01-Jan-13 Ant: 21-Feb-13 C 17 Changes in scope of supply led to revision in BQC / tender.
C 18
C 19
C 20
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
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
Apr'13
-
Mar'13
-
Mar'13
Ant: 15-Apr-13
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 C 21 Ant: 30-Mar-13
Award of Crude and Vacuum heaters (LAD 29.12.12) Ant : 07.03.13
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 Granulator to be finalised between BPCL / EIL.
Close
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.00
- Scheme finalised.
Projects / BPCL
Close
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
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s L&T (duration 20 M)
BPCL
-
Projects / 7-Mar-13 C&P / BPCL
Mar'13
Feb'13
C 22
Apr'13
C 23
NIT for ETP package with WAO (Wet air oxidation) C 24 LAD: 15-Jan-13 Ant: 16-Apr-13 Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13
Close
Apr'13
7-Mar-13
Feb'13
C 25
Award of contract for Building incl substations LAD: 07-Feb-13 C 26 Ant: 15-Apr-13
Close
Apr'13
Kochi Refinery, BPCL
14
Action Plan
15
16
Action By
17
Target Date
3
4
5
6
7
8
9
10
11
12
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.
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 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: C 29 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
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 Schedule: 02.03.13 Anticipated : 30.08.13 Completion of works Sch: 01.05.15 ( M); RFQ Duration : ( M) C 30 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
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 : C 31 20 M
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
JUL'13
Projects / Engg
Very High
Y
N
Y
N
Short term
I
0.6
0.00
- Awarded to M/s Thermax on 20.12.13
Projects / BPCL
Projects
18
Risk Severity
Open
Filling of existing part fire water pond required for area preparation.
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Job No.: A307 Aug'14 Page 651+15 of 32 (Current risk Score Previous Risk score)
2
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
30-Mar-14
19 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 28
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 C 32 Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
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.
20-Jul-13
20-Dec-13
Nov'13
Kochi Refinery, BPCL
4
5
6
7
8
9
Close
Project / Licensor
Very High
Y
Y
Y
N
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) C 34 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
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 C 35 Duration: 20 M
Open
Process / Engg / constn
Very High
N
N
Y
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 C 36 Duration: 22 M+2 M
Close Project/C& Very High P
N
N
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
Low
N
Failure of contractors
Open
Const.
Low
N
10
14
Action Plan
15
16
Action By
Target Date
17
18
Risk Severity
11
12
I
0.9
0.00
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
Short term
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Job No.: A307 Aug'14 Page 652+15 of 32 (Current risk Score Previous Risk score)
3
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. C 33 Bidders sought extension in dates.
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
- 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 Esaar on 10.07.13.
Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
Projects / BPCL
BPCL
19 Jun'13
31-Oct-13
C&P/Engg/Pr oj
Oct'13
Anticipated Completion: 29-Jul-15
C 37
C 38
C&P BPCL / Projects
Ordering of Ejector Pkg C 39 (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 (LAD:24-May-13; Ant: 15-Nov-13 Earlier 04 Bids recd on 21.05.13. (Petron, Thermax, Heurtey, Technip). C 40 Due to Technical and related commercial issues enquiry refloated. Duration 20 M
Open
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 (LAD: 30-Mar-13; Ant: 20.07.13) C 41 Duration: 18 M
Open
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
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
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
Award of Civil & Strl work for refinery area. (LAD:25-Apr-13; Ant: 10.10.13) Duration: 16 M C 42
sep'13
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) C 43 Duration : 16 M
25-Jul-13
JUL'13
Kochi Refinery, BPCL
14
Action Plan
15
16
Action By
17
Target Date
18
Risk Severity
3
4
5
6
7
8
9
10
11
12
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 & precomm; Time Available from order to MC OF FCCU - 24 C 45 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 C 46 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 C 47 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.
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); C 49 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
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, C 50 based on past Performance of recommended bidder tender refloated.
Close
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 work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Job No.: A307 Aug'14 Page 653+15 of 32 (Current risk Score Previous Risk score)
2
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19
C 44
Ordering of OFF GAS COMPRESSOR - VGO LAD: 08-Jun-13 Ant: 30-Oct-13 RFQ duration: 17 M FOB
0.00
0
7-Mar-13
Jun'13
C 48
Kochi Refinery, BPCL
(Current risk Score 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
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, C 51 based on past Performance of recommended bidder tender refloated.
Close
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 C 52 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 C 53 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 C 54 (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) C 55 (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
Delay in Award of contract for Demountable flare (LAD: 08Apr-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
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
C 56
13
Previous Risk Score
Job No.: A307 Aug'14 Page 654+15 of 32
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19 Aug'13
Jun'14
19-Jul-13
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. Change in flare load data due to change in flare height upto C 57 150 M. Completion of works Sch. : 31.01.15 Ant. : 28.02.15
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 C 58 Duration: 12 M
Kochi Refinery, BPCL
Previous Risk Score
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12} 13
14
Action Plan
15
16
Action By
17
Target Date
Risk Severity
6
7
8
9
10
11
12
18
19
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) C 60 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: 02 Nos & 1 surge relief tank and crude drain tank) 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 tanks-25/26 under tankage-III. C 61 Sch: 01.10.13 Ant: 15-Dec-13
Close Project/En Very High gg
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
Close Project/En Very High gg
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s BHEL
Proj/Engg
28-Jun-13
Jun'13
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep13) C 63 Duration : 18 M FOB
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
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) Sch: 30.04.13 C 64 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
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 C 65 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
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
Close
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 for:RGC compressor for VGO-HDT (LAD: 30-Mar-13; Ant: end Jun 13) Dely: 18 M
5
Schedule ( Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
Job No.: A307 Aug'14 Page 655+15 of 32 (Current risk Score Previous Risk score)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
C 59
C 62
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: Jun 13)
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 C 66
Duration - 20 M
Award for contract for development of flare area LAD: 01-Nov-13 Ant: end Dec'13 C 67
Aug'13
Kochi Refinery, BPCL
2
14
Action Plan
15
16
Action By
Target Date
3
4
5
6
7
8
9
10
11
12
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, C 69 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)) C 70 (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) C 71 LAD:09.05.13 Ant: 10.10.14
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.32
-0.32 -Ordered on M/s Asco Filtri Srl ON 17.10.14.
BPCL
Oct'14
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards C 72 Piping intermediate MTO-II released on 30.10.13.
Open
Project
Low
N
N
Y
N
Short term
D
0.16
0.05
-0.05 - All pipes, fittings & flanges ordered.
C&P
14-Aug-14
Ordering of Critical Valves Sch: 11.07.14 C 73 Ant: 20.10.14 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 C 74 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 C 75 Ant: Nov'14
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
0.15
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM-Refloated C 76 Sch: 08.05.14 Ant: 15.11.14
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M Open FOB / 7 M FOT) C 77 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 C 78 Electrical/Instr. Works: Part A: CDU/VDU, DCU, FCCU, DHDT, VGO-HDT & IREP Offsites: Part B: SRU & DHDS/Refinery Offsites :
Open
Project
Medium
N
N
Y
N
Long term
I
0.2
Delay in award of piping material with G2E specification in C 79 CPP area.
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
C 68
17
18
Risk Severity
Open
Award of Composite Works for VGO-HDT, DHDT, CPP and Offsites (DHDS) LAD 31.12.13 ; Ant - 30.05.14
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Job No.: A307 Aug'14 Page 656+15 of 32 (Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19
Aug'14
Engg 0.32
0.32
0.00
Revised MR (MR-3415) issued covering all critical valves along with all critical valves of MR-3211 floated. Award recommendation issued on 08.10.14.
EIL/BPCL
30-Oct-14
0.00
- Awarded to M/s Zillion on 19.05.14.
0.15
0.00
-Total 29529/ 32638 nos (90%) isometrics issued for units . Balance ISO's targeted progressively by mid Nov'14. - Piping items has been ordered for Intermediate MTO-II, delivery expected by Oct'14 to Nov'14.
Engg.
Oct'14
0.38
0.00
- 4 nos bids received on 30.09.14. PBO recommednation issued to BPCL on 21.10.14.
EIL/BPCL
15-Nov-14
0.00
- Ordered to M/s Sulzer.
BPCL
5-Aug-14
II Jul'14
0.10
0.10
- Award recommendation for both the tenders issued to BPCL on 27.10.14. Electrical Works: Bids received on 26.09.14. Part A: M/s Technimont & M/s Kazmunai Services Part B: M/s Technimont, M/s Consilium & M/s Kazmunai Services. - Instrumentation Works: Bids received on 29.09.14. Part A: M/s Technimont & M/s Eternity Petroleum. Part B: M/s Technimont, M/s Consilium & M/s Kazmunai Services, M/s Eternity Petroleum.
EIL/BPCL
30-Oct-14
III
0.38
0.38
Procurement to be expedited in order to timely availability of piping material for completion of steam network EIL/BPCL in CPP area.
30-Oct-14
25-May-14
II May'14
III
II
Kochi Refinery, BPCL
4
5
6
7
8
9
Project
Very High
Y
Y
Y
N
10 Short term
Action Plan
11
12
13
14
15
16
I
0.9
0.86
0.86
0.00
D
1
Close
Project
Very High
Y
Y
N
N
Long term
I
0.25
D
Delivery of GTG Pkg at site (LAD:29-Sep-14; Ant - 24-Nov14) Awarded to M/s BHEL 2 Duration (Supply) - 16 M
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 3 Overall progress: Sch: 91.7 % Act: 66.1 % Construction Progress: Sch: 86.2 % Front: 100 % Act: 23.2 %
Open
Project
Very High
N
N
Y
N
Long term
I
0.2
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) 5 LAD: 05.12.14 (CDD: 27.01.15; EDD: 27.01.15) Sch: 69.2%; Act: 67%
Open
Project
Low
N
N
Y
N
Long term
I
0.2
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 6 (CDD: 24.12.14; EDD: 24.12.14)
Open
Project
Low
N
N
Y
N
Long term
I
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: 78.2 % Act: 56.5 % 7 - 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
D
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14 D
D
D
D
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
3 Open
Job No.: A307 Aug'14 Page 657+15 of 32 (Current risk Score Previous Risk score)
2 Completion of Reactor regenerator package for FCCU-M/s Esaar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 76.7 % Act: 51.7 % Construction Progress: Sch: 32.5% Front: 79.9% Act: 14.6 %
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Management level meeting held on 16.10.14 at site. - Completion of hard stand targeted by 09.11.14. - Crane (1600 MT): Shipment movement started and expected to arrive at Kochi by end Oct'14, assembly targeted by 10.11.14 & load test by 30.11.14. Final erection scheme submitted on 15.09.14. Readiness of crane for erection targeted by Dec'14. - EPIL-GRE informed to dispatch cyclones for reactors by 30.11.14 and regenerator cyclones by 31.12.14. M/s Emtrol has been asked to pre pone the deliveries upto Dec’14 during meeting dated 25.08.14. - Fdn for flue gas area, stack fdns and ESP fdn targeted to complete by end Oct'14 (Excavation already completed). - M/s EPIL has been asked to commence area development around FGC equipments & commence hard stand work from 07.10.14 and to be ready by 09.11.14. - TSS srection: Assembly for skirt, sheel 1 & 2 commenced. TSS assembly and complete erection targeted by 15.11.14. Area for storage of fabricated materials to be identified and allocated. Issues being followed up.
Action By
Target Date
Risk Severity
17
18
19
Projects Constn
09.11.14 Dec'14
30.10.14 BPCL
Clubbed with Risk ID E19
Project
0.19
0.00
Management review held on 09.09.14 to pressurised M/s ISGEC for completing within CCD. Weekely meeting held at site on 08.10.14. - 90% model review planned at Kochi by end Oct'14. - Erection of steam drum-I targeted by end Oct'14. - Completion of balance foundations being progressively targeted by end Oct'14.
Project / Constn.
0.06
-0.06 -All Indigenous component received at site within CDD. - All Foreign Source Components dispatched.
Project/Inspe Sep'14 ction
0.06
0.06
0.00
Material against all suborders received. Casing for compressor and turbine received at shop. Machining of components of both main compressor and steam turbine under progress.
Project/Inspe 27-Jan-15 ction
IV
0.2
0.06
0.06
0.00
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Project/Inspe 24-Dec-14 Order placed for Motor, turbines, Casings, forgings, impellers, gear box. Part castings and forgings received. ction Close monitoring to be done to ensure delivery on CDD.
IV
0.4
0.38
0.38
0.00
-Meeting held on 09.09.14, 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) completed and super structural work being expedited by M/s Tuaman. - Erection for main fractionator targeted by Jan'15. Crane 1250 MT and 550 MT mobilised, erection scheme approved. - Stripper & rectifier Column: Erection of bottom section expected to commence from Jan'15. Preparation of Hard stand to commence. - Approach road work completed. Area improvement to be expedited.
0.19
24-Nov-14
I Nov'13
0.00
Oct'14
III
4 Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT.
As stated
II
Kochi Refinery, BPCL
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. 62.9 %; Act: 49.5 % Construction Progress: Sch: 40.5 % Front: 94.1 % Act: 24.1 % D
5
6
7
8
9
10
11
12
13
14
15
16
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 readiness to be delayed till Dec'14. Bidders has requested for providing space for storage of MCC equipment & Refractory Materials. - Refractory liining work in Combustion chamber can be started only after erection of MCC pkg.
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
-Management review meeting held on 19.09.14 and 12.09.14. Weekly review meeting held at site on Constr. 10.10.14. Following commitments have been made by M/s Essar. -Shift Work: M/s EPIL asked to start works in two shifts. - Meeting held with M/s Essar for financial issues on 01.09.14. Proposal from M/s Essar for financial support forwarded to BPCL for review / approval. - Strl. Steel works offloaded from MK Engg. to M/s UHE (For derrick structure-1073 MT), M/s SP Infraprojects (Coke drum str-737 MT) & ESSAR steel (200MT) BPCL/EIL - M/s EPIL to ensure the availability of Coke Fractionator by end Dec’14 and all the four Coke Drums progressively by Apr’15. - Mobilisation of 2000 MT crane targeted in Feb'15 and erection to be targeted from Mar'15 to May'15. -Crane (200 MT): Crane parts started arriving at site. All parts expected to arrive by end Oct’14 and crane readiness by mid Nov’14. -Clear water tank fabrication- Agency finalization by Oct'14. - Resource augmentation for Civil & Strl works being expedited. At present 457 nos have been deployed, while requirement is 607.
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Turbine and compressor MRT completed. Compressor train under dispatch. Transfer oil pump and lube oil accumulator already dispatched.
Project/Inspe 27-Dec-14 ction
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Compressor MRT completed. Performance test completed successfully. Turbine rotors ready and casing under assembly. Dispatch expected by end Oct'14. Steam turbine: All components except inner casing ready for assembly. Casing inner (steam chamber) got rejected in hydrotesting. Inner casing to be expedited at BHEL Haridwar shop.
Project/Inspe 27-Dec-14 ction
BPCL / Projects / Const.
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Director level meeting held with M/s VTV. - Erection of Crude Column : Crude column erection completed on 24.09.14. Hydrotesting targeted by 31.10.14. - Erection of Vacuum Column : Delayed due to delay in receipt of bottom section. Erection of sections expected from end Oct'14 to end Nov'14 and hydrotesting by mid Dec'14.
Constn. / VTV / Projects
Open
T&CC
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - Agency confirmed availability of Barge/Trailer at the time of delivery of Reactors. Barge will be ready with reqd modification by Oct'14. - Barge readiness targeted as follows: 2 nos Ammonia Barges modifications by 15.10.14. & 31.10.14. Drawings for new barge submitted to IRS for approval. 1 nos new barge fabrication by 24.12.14. - Construction of jetty not yet started as land for jetty is yet to be finalised. M/s Urmila agreed to finalise and hire the IOCL land for jetty. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at KochiPort.
Oct'14
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; 20 nos received at site. & 4 nos under dispatch. Balance under close monitoring and are expected at site from Oct'14.
Continous
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}
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Action Plan
Risk Owner
2 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) 8 Overall progress: Sch: 80.0 % Act: 69.8 %
Status (Open / Close)
Risk Id 1
Job No.: A307 Aug'14 Page 658+15 of 32 (Current risk Score Previous Risk score)
D
Key Risk Description
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
9
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M D 10 Ordered to M/s BHEL on 28.06.13
Delivery of RGC compressor for DHDT(LAD :05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13 D 11
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Dec'14 Normally 12-14 Months are required for Unit Mechanical D 12 Compln after erection of Crude & Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 57%
Open
Action By
Target Date
Risk Severity
18
19
15-May-15
III
17 BPCL / EIL
Oct'14
I IV
IV
Dec'14
II Logistics of VGO & DHDT reactors from Kochi port to BPCLKR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB) DHDT Reactor (M/s Doosan) expected to receive at Kochi D 13 port by Nov'14. ISGEC Josen (3 nos) Column: expected to receive at Kochi port from Nov'14 to Jan'15.
Close Monitoring of ODC equipment (including site D 14 fabricated/assembled) up to receipt at site
Shipping
II IV
Kochi Refinery, BPCL
Delay in delivery at site due to non-availability of transporter / hindrances enroute.
14
(Current risk Score Previous Risk score)
13
Previous Risk Score
Job No.: A307 Aug'14 Page 659+15 of 32
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
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action Plan
15
16
Action By
17
Target Date
5
6
7
8
9
10
11
12
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
18
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
Open Project
Medium
Y
Y
Y
N
Long term
I
0.45
0.00
- Flare foundation work completed. - Construction work to be started from Oct'14. Fabrication of flare structure is in progress and delivery expected from Oct'14 onwards.
Projects/Con As Required str.
Very High
Y
Y
Y
N
Short term
I
0.9
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
As Required
Risk Severity
19 Nov'13
D 15
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions.
Jun'14
D 16
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Mar-15 D 17 Ant: 24-Mar-15 Overall Progress Sch: 55.9 % Act: 47.4 % Construction work likely to start from Oct'14.
Addition of 4th Riser in Demountable Flare and identification Open Project / of additional Equipment to be procured due to the same. Process (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: D 18 Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15
0.23
0.23
As Required
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Compressor casing dispatched from M/s NP Italy workshop on 17.09.14.(Expected to arrive at BHEL Project/Inspe Continuous workshop by end Oct'14). ction - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. However close monitoring being done.
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 D 20 CDD: 03.04.15 Ant: 03.04.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- All major items has been subordered. Air Blower: Main casing received at workshop. Main coupling received on 25.08.14. Steam Turbine: Casing received at shop. Bearing also received .
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 D 21 EDD: 06.03.15 Overall Progress: Sch: 95.0 % Act: 89.5 %
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
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 is 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 within CDD.
Project/Inspe Continuous ction
D 19
III
Oct'13
II IV
III
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
7
8
9
10
11
12
13
14
15
16
18
19
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
- Hydrotesting completed on 09-10 Oct'14. Change order related to shipment is in finalisation with BPCL and Project/Inspe Continuous vendor. ction
III
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 D 23 Awarded to M/s Thermax on 20.12.13 Overall Progress: Sch: 64 % Act: 53 %
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- Review meeting held with M/s Thermax on 08.10.14. - Balance engineering to be expedited by M/s Thermax. - HRSG #3, 4 & 5: Foundation works completed and handed over to M/s Thermax. - Column erection started for 1st HRSG.
Project/Inspe Continuous ction
III
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) D 24 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. - Fabrication of exhaust diffuser and inner exhaust case targeted by end Oct'14
Project/Inspe Continuous ction
III
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 D 25 CDD: 30.03.15 Overall progress: Sch: 44 %; Act: 40.5 %
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. - Delivery of Semi rolled sections of Silos shall commence from Nov'14 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited as material expected to receive at site by Oct'14. - Foundations for pelletiser shed to be made ready by end Nov'14.
Project/Inspe Continuous ction
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
Jun'14
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. Expected to receive at M/s Dresser shop by 03.02.15.
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
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).
EIL/ BPCL
Progressively
IV
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: - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:184. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 189: As a parallel action separate MR-6122 released. Award recommendation issued to BPCL. Cancellation request forwarded to BPCL on 13.10.14. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360,& 444. Meeting held on 06.09.14 with M/s BP&CL. Vendor confirmed subordering of raw materials on 09.09.14. - M/s HDO (Columns, Heat Exchangers & Vessels): Foa No.: 199, 302, 315, 318, 327, 369, 389 & 395.
EIL/ BPCL
Oct'14
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
0.20
-0.20 - 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 (MR-5403) (FOA No D 31 550 & 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) and Debutaniser Column (IF-V-302) by M/s Uttam Value Steel D 32 (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
0.00
- Order got delayed due to delay in manufacturing works. At present fabrication of Stripper column going beyond Nov’14 due to which there will be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
EIL/ BPCL
Oct'14
Urgency (Long Term / Short term)
6
High
Schedule ( Y / N)
5
Projects
2
EIL Cost (Y / N)
4
Open
1
Risk Owner
3
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 CDD: 07.10.14 D 22 Overall Progress: Sch: 95 % Act: 92.0 %
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Job No.: A307 Aug'14 Page 660+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
17
D 26
D 27
D 28
D 29
D 30
0.32
0.32
II
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
7
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- As of now around 42-45% piping material has been received at site. Around 90-95 % material has been ordered upto intermediate IIIrd MTO. Ordering of balance 5-10% material is in progress and expected progressively upto end Oct'14. Delivery of ordered material against intermediate -II expected by Oct'14. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
EIL/ BPCL
Oct'14
Open
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
Oct'14
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: 31.10.14 to 15.01.15 D 35 M/s GR Engg: CDD: 28.01.14 to 31.07.14; EDD: 30.11.14 to 31.01.15 M/s Fabtech Projects: CDD: Jul’14 to Jan’15; EDD: Oct’14 to Jul’15
Open
Project
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
Vendor being pushed for deliveries. Vendor shop visit/meeting being arranged.
Inspection / Project
Oct'14
III
Delay in submission & finalisation of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. D 36 CDD: 19.05.15
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
-Reduction furncae layout drawing to finalised in order to give front for release piling drawings - Submission of drawing by vendor & approval by HMTD to be expedited.
HMTD/Projec Oct'14 ts
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.
Mid Oct'13
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
N
N
Y
N
Long term
I
0.2
Delivery Gas Booster Compressor for CPP (Dly: 13 M FOB D 34
E
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsites) - Awarded on 25.09.12 (Sch 100 %, Act 91.7%) RCC Piles:4822 / 5307 Nos. Balance for offsite (SS VGO & compound area at FACT). 1 Presently 5 total rigs are operating
E
Space constraints: i) Area for Storage of materials for project and package contractors 2 ii) Area for Spool storage
E
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock 3 encountered.
E
E
Open
Completion duration for NHT/ISOM (Revamp) Open Constn. / Mechanical completion of NHT/ISOM - Target Schedule : Projects 30.09.15; Only 15 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. 4 Physical Progress: Target Sch: 77.1% Catch Up Sch: 39.6 % Act: 32.3%
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.
Open BPCL / High Projects / Const.
Urgency (Long Term / Short term)
6 N
Schedule ( Y / N)
5 Very High
2
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Oct'14 D 33 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
EIL Cost (Y / N)
4 Projects
1
Risk Owner
3 Open
Risk Id
Action Plan
Key Risk Description
0.14
0.86
Previous Risk Score
Job No.: A307 Aug'14 Page 661+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
II sep'13
0.67
-0.53 - 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. Development of the area with fence is in progress.
BPCL
Oct'14
III
0.20
-0.20 -Major rock blasting work completed.
Constn.
sep'14
Aug'14
0.86
0.00
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued to BPCL on 21.10.14. 4 nos bids BPCL/EIL received on 30.09.14. Award targeted by Nov'14. - MR for compressors (BHEL & DR: Adequacy and health check under progress): Adequacy check report from BHEL expected by end Oct’14 and from D-R received on 19.09.14. Execution philosophy finalized on 17.10.14 for compressor ( Dressar Rand make ). MR targeted by end Oct'14.
Nov'14
0.00
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
15-Jul-13
BPCL / Projects
I JUL'13
Kochi Refinery, BPCL
7
8
9
10
11
12
13
14
15
16
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- MCR area, CPP control room area : It has been decided to complete balance strl work by Dec'14 & finishing by Mar'15. - Other building works : Finishing work to be completed by Dec'14. - L&T also agreed to augment required manpower to meet the target completion date.
Backlog 29.6 (% wrt target sch) as of 15-Oct-14 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 - 30 M; Remaining Duration - 16 M Desc. Catch Up sch: Const Sch Front Act Overall 34.9 61.0 58.0 31.4 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU ,DCU, FCCU, 7 VGO,DHDT & Offsite).
Open
Const
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
- In order to supplement progress of failing civil contractors, 4 separate agencies has been lined up (M/s Constn Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray Eng-Misc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works being lined up. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 nos. BPCL/EIL to jointly introduce some incentive system for workers to reach manpower upto 12000 by end Oct'14. BPCL/EIL - Work in shifts to be implemented for all construction works at site.
As Required
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of 8 Demountable flare (Commissioning expected by end Mar'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 Mar'15.
BPCL
Mar'15
Completion of piling work by M/s L&T (Piling-II): CDD08.05.14. (Total 12003 Nos piles). (Contr.Sch- 100%, Front-100%, Act-100%) Only 10 nos. hydraulic & 4 nos. conventional rigs are 9 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
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
Oct'14
Urgency (Long Term / Short term)
6
High
Schedule ( Y / N)
5
Const
2
EIL Cost (Y / N)
4
Open
1
Risk Owner
3
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 96.0 % Front: 100 % 6 Act:58.8% CCD: 20.12.14 Ant: 15.05.15
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
Job No.: A307 Aug'14 Page 662+15 of 32 (Current risk Score Previous Risk score)
E
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17 Constn
As Required
II
E
E
E
E 10
Payment to contractors Unrealistic project time leading to under quality
Close
E 11 Dismantling of LO CAT SRU and area handing over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. E 12 Will affect release of front for tankages.
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
Project / Engg. / planning
Open
BPCL
Medium
N
N
Y
N
Short term
I
0.4
Open
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.29
0.29
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: Foundation works commenced, completion to be targeted by Dec'14. - Chemical house works commenced. - 90 % Model review planned in 1st week of Nov'14..
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 19.09.14 at EIL site & on 25.09.14 at EIL HO and Constn. augmentation of manpower by min. 100 nos to be expedited for concreting work progress. M/s B&R has been asked to expedite complete SRU filling by 10.11.14. All area handed over in SRU block except for peripheral road. - Retaining wall completed for the available front. Piling to be carried out through Piling III to take up further retaining wall work. - Piling for SRU : At present 989 nos piles completed against front of 1700 nos & scope of 1800 nos. at site by M/s MBEL. EIL/BPCL
Overall Progress: Contr. Sch: 91.7 % Act: 61.7% E 13 Construction Progress: Sch: 87.3 % Front: 100 % Act: 55.4 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Constr.
I IV
II Area availability for SRU Block - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by 2nd week of Nov'14. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) E 14 - 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
Oct'14
I
Kochi Refinery, BPCL
(Current 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)
Previous Risk Score 14
15
16
Action By
Target Date
17
18
6
7
8
9
10
11
12
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
Land acquisition for Crude tank (2 nos.) . (LAD - Jul 13; Ant E 17 30-Aug-13)
Close Proj.
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
0.00
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
As Required
0.00
- All 3 GTGs received at site. - Contractor for Mechanical works for CPP awarded to M/s Zillion. - N2 compressor (Delivery period is approx 6-8 M) : Ordered on 01.08.14, delivery going upto Dec 2014, However BHEL confirm that they expect supply to be completed within CDD of GTG package.
Projects
Dec'14
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 0.19
Security arrangements in Warehouse place by48") BPCL. - Pipes under shortage (IS pipes of 30",in36", 40", ordered to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team. - All deliveries to be expedited by end Oct'14, subsequently all UG piping work completion to be expedited by Dec'14.
Constn. EIL/BPCL
Oct'14
Risk Severity
19 Jul'14
Dec'13
Nov'13
Aug'13
OPEN
BPCL
Medium
N
N
Y
N
Short term
I
0.4
Open
Const. / Projects
Medium
Y
Y
Y
N
Long term
I
0.45
Close
Const.
Low
N
N
Y
N
Long term
I
0.2
Theft of from Delay in material completion ofWarehouse UG piping work due delay in receipt of Close Open piping material required at site and due to monsoon
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
0.04
0.00
Area lighting being done.
Constn.
As Required
I May'13
EIL
Low
N
N
Y
N
Long term
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
Open
Project
Low
Y
N
N
N
Short term
I
0.2
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
Construction of Subway on the PWD road including re routing Open of existing road / existing facilities and necessary liasoning with government department. Construction of culvert got affected (Ant. Compln-Nov'14, E 26 Compl date Committed by B&R – 13.11.14)
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Management level meeting held with B&R on 19.09.14 at site & on 25.09.14 at EIL HO. B&R agreed to execute work on extended hours to complete balance works in all respect by 13.11.14. Raft completed, wall work in progress.
13-Nov-14
E 18
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
13
Action Plan
Open Proj. / Constn.
E 16
5
Schedule ( Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
Job No.: A307 Aug'14 Page 663+15 of 32
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
E 15
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
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 E 19 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
0.23
0.23
E 20
E 21
0.57
0.38
E 22
E 23
Lighting during construction
Delay in construction due to monsoon. As work 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 E 24 needs to be avoided.
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
Open Constn. Open
E 25
0.38
0.38
Constrn.
sep'13
III
Nov'13
-
Mar'13
II
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
9
10
11
12
13
14
15
16
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 15.10.14. - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - 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 and targeted to complete by 31.10.14. - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. Cable trench work to be commence in Oct’14. - 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
Oct'14
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 93.4%; Front: 94.5%; Act:47.3% 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 19.09.14 at site & 25.09.14 at EIL HO. - Foundation work completed for HRSG-3. - Completion of Structural works for GTG shed targeted by mid Nov'14. - Stack foundation : Only HRSG#3 fdn completed. - Completion of boiler piperack targeted by 30.10.14. - All balance drawings for which data is available shall be targeted for issue by 30.10.14.
EIL/BPCL
Oct'14
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 FRONT. ACT. E 29 SCH. 80.6% 59.7 % 26.9%
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 15.10.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - Foundation work: TS-06 by 30.10.14. - Structural Erection commenced for TS-2 & TS-03 and for TS-06 start of strl erection targeted by end Oct'14. - Out of total 1800 nos piles, 989 nos completed. Pile cutting completed for 504 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by end Nov'14. - Out of total structural work of 4290 MT, only 852 MT fabrication completed & 176 MT erection works completed. UG piping erection work yet to commence.
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: 37.9% E 30 Front: 47.3% Act: 21.5 %
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 08.10.14 and following action plan has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. -M/s OIL confirmed to cover pipe rack for rain protection modular shed, for which order has been placed & expected to receive at site by end Oct'14.. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Piping fabrication rate of 1500 ID / day from current 800 ID/Day targeted to achieved from 15.10.14. - OIL to deploy their auto blasting machine.
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 E 31 EDD: Dec'15 Construction: Sch:17.2 %; Act:11.5% Overall Progress: Sch: 42.4 % Act: 33.5%
Open
Project
Medium
Y
N
Y
N
Long term
I
0.3
0.15
0.15
0.00
-Meeting held at site on 10.09.14. - Piling work commenced (802 out of 1642 nos piles completed: 7-8 piles/day) M/s TKII to augment piling rigs immediately. -TKII has been advised to commence work in all work fronts to achieve min. 5% construction progress during Oct'14.
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 E 32 Overall Progress: Sch: 71.5 % Act: 65.0 % Construction work: Sch- 49.1% Front:79.7% Act:28.9%
Open Project
Medium
Y
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 panels received at site. 20/24 nos arch panels erected. -Heater B: Out of 66 nos panels, 63 nos received at site, 3 panels dispatched by end Oct'14. 50/66 panels erected. Shop fabrication of coil, convection modules, APH str 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
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 E 33 incl pre commng)
Open
Very High
N
N
Y
N
Long term
I
0.2
0.00
- Total area handed over on 05.05.14.
Project
5
Urgency (Long Term / Short term)
8
N
2
Schedule ( Y / N)
7
Open Constructi Very High on
1
EIL Cost (Y / N)
6
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Constr. Sch:100%; Front:94.3%; Act: 45.0% CCD: 08.10.14; ECD: Jun'15
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Job No.: A307 Aug'14 Page 664+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Risk Owner 4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close) 3
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
E 27
Action By
Target Date
Risk Severity
18
19
17
II
E 28
II
II
Project
As stated
II III
III
Jun'14
Kochi Refinery, BPCL
7
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.6
0.57
0.29
0.29
-Management level meeting held on 14.10.14.. EIL/BPCL - Physical handing over of balance area for treated water tank, API/TPI, ex TPI sump completed. Signing protocol to be expedited. - M/s Paramount has been asked to mobilise additional 60 nos manpower progressively by 30.10.14 - Revised piling drawing for API being submitted by 10.09.14. Piling drawing for ACT & SBR area approved vide across the table review meeting dated 05.09.14. - Work in progress in substation area, equalisation tank, treated water tank, sludge thickener, spent caustic tank, chemical handling areas. - Completion of foundation work for chemical house to be expedited by augmenting manpower & resources. -Piling work being executed by M/s Simplex. 2 nos rigs targeted to be mobilised by 30.10.14. Start of work targeted from 01.11.14 to be completed by 31.12.14.
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 19.09.14 at site and on 25.09.14 at EIL Delhi. Total tanks: (New tanks 13 nos, work in progress for 12 nos. Balance for 1 nos is YT-33 which shall be start after completion of YT32; 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) - Subordered on 16.09.14. 200 MT (IS 2062 GR B): All material received.
EIL/BPCL
As stated
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 E 36 Duration: 20 M Sch: 38.2 % Front: 93.1 % Act: 29.0 %
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.00
- Front for YT-29 is likely to be released by 30.10.14 - Plate erection to be expedited for YT-26/28. - Sand filling works to be expedited in YT-25.
Constr.
As stated
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 E 37 Overall Progress: Sch: 86.6 % Act: 39.1 % Construction progress: Sch: 32.1% Front: 60.7% Act:11.3%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.00
-Management level meeting held on 25.09.14 - Structural steel: Out of total 217 MT, 200 MT sub ordered & 98 MT received at shop. Balance being targeted by end Oct'14. - Fabrication of radiant section targeted to complete by 07.11.14. - Coil tubes: Expected to receive at site by 07.11.14. - Delivery of soot blowers and FD fans to be preponed to suit completion heater by 03.04.15.
Project
As Required
II III
Close Project
Very High
N
N
Y
N
Long term
I
0.2
0.00
Clubbed with Risk ID D7
BPCL
As Required
Dec'13
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) E 39 Overall Progress: Sch: 63 % Act: 18 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Meeting held with vendor on 29.08.14. Recommendation for PO amendment forwarded to BPCL on 11.09.14. BPCL to issue PO amendment. - Nozzle (N1 & N10) size of thermal incinerator on hold, same shall be finalised immediately.
Projects
As Required
Progress of RO-DM Plant (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: 94.3 % Act: 57.9% Construction Progress: Sch: 87.8 %; Front: 100%; Act:22.9 % E 40 Area handed over, part of area is water logged due to plant drain which is under completion.
Open Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.29
0.29
-In view of delay in handing over of areas and various site related issues and soil problem encountred during EIL/BPCL execution, progress of construction badly affected. M/s Driplex has been asked to prepare a catch-up plan to expedite construction activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. 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) : Filling in area targeted to complete by end Oct'14. Piling work targeted to commence from end Oct'14. -90 % model review completed. - Meeting held with M/s Driplex at site on 14.10.14 & M/s Driplex has been asked to mobilse addln. 45 nos manpower for civil works by 31.10.14 & another 50 nos by 20.11.14. - DM tanks: Piling drawing received from M/s driplex and is under review.
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 85.0%; Front: 95.4% Act: 45.3 % E 41 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 at Kochi on 18.09.14. -Mobilisation of resources is being expedited. At present only 140 nos , manpower mobilised,against a requirement of 400 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). EIL/BPCL -part Civil work offloaded to M/s Tuaman, M/s PGC & part structural work offloaded to M/s Zillion & M/s Ray Engineering
As Required
Urgency (Long Term / Short term)
6 Y
Schedule ( Y / N)
5 Very High
EIL Cost (Y / N)
4 Project
Risk Owner
(Current risk Score Previous Risk score)
3
Action Plan
Progress of ETP Works Open LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 65.7 % Act: 22.3 % Construction Progress: E 34 Sch: 42.6 % Front: 90.0 % Act: 11.4 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Previous Risk Score
2
Job No.: A307 Aug'14 Page 665+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Id
Key Risk Description
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
17
Target Date
Risk Severity
18
19
I
E 35
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 63.1 %; Front:84.4% Act: 21.8 % Awarded to M/s B&R on 25-Sep-13
II
E 38
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
0.32
0.20
II
I
I
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
8
9
10
11
12
13
14
15
16
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
III
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: E 43 Sch: 92.3 % Act: 49.8 % Construction Progress: Sch: 63.9% Front: 96.2% Act.: 14.3%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
-Management level meeting held on 16.09.14. 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 in progress for IV-H-101 & IV-H-201
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: 93.9 %; Front :95.6 % Act: 62.7 % - Structural erection: DHDT: 722 MT / 2600 MT completed.; E 44 VGO: 658 MT / 3065 MT completed. -UG Piping Laying: DHDT: 8696 IM / 25400 IM completed; VGO: 9030 IM / 42000 IM completed.
Open Project
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 15.10.14 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. - VGO/DHDT: Completion of main piperack targeted by 31.10.14 -TS-4 for DHDT targeted by 31.10.14.
As Required
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 Oct'14. Project Material storage commenced. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. 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 E 46 Overall Progress: Sch: 99.5 % Act: 74.8 % Construction progress: Cum Sch: 100% Front: 100% Cum Act: 63.3%
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 14.10.14 at site. Commitment made by M/s PCT has again slipped. Manpower at site is 392 nos instead of committed 670 nos. Supply of balance U/G and A/G Piping Material by PCTL to be expedited. Shortage of TMT steel (540 MT) to be expedited. PCTL to target to complete all Civil work by Dec'14.
EIL / BPCL
As Required
II III
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 47 Overall Progress: Sch: 81.5 % Act: 40.7 % Construction progress: Cum Sch: 71.7% Front: 100% Cum Act: 37.1%
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.
EIL / BPCL
As Required
III
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area E 48 Sch:90.1%; Front: 72.2%; Act: 15.9%
Open Constructi Very High on
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
Management level Meeting held with M/s KSSIIPL on 15.10.14 at site. - M/s KSS agreed to deploy additional 50 nos manpower by end Oct’14. Agencies for structural erection have been finalised and started mobilising at site. - M/s KSS has been asked to deploy additional manpower to complete all equipment fdns. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: M/s Ray Engineering, M/s Tuaman & M/s Zillion. Others contracts being lined up are: Misc. Civil Works-I: Awarded to M/s PGCC on 06.10.14. Misc. Strl Works-II: 4 nos bids received on 30.09.14. PBO targeted by 31.10.14. Misc. Civil & Strl-II: 5 Bids received on 07.10.14. PBO targeted by 31.10.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
EIL/BPCL
Oct'14
E 42 Constr. Progress: Sch: 66.6 % Front: 100 %
Urgency (Long Term / Short term)
7
Y
2 Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15
Schedule ( Y / N)
6
Very High
1
EIL Cost (Y / N)
5
Open Project
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Job No.: A307 Aug'14 Page 666+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Risk Owner 4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close) 3
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
Act: 49.3 %
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E 45
I
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 16.10.14 at site. - M/s Petron agreed to increase nos of welders to 30 nos & fitters to 20 nos by 30.10.14. - Semi automatic welding machine shall be in operational by 05.11.14 - M/s Petron has been asked to commence min. 1000-1500 ID / day to complete entire job. Present rate is 160 ID / day.
EIL/BPCL
30-Oct-14
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 E 50 Construction Progress: Sch: 12.3 % Front: 20.2% Act.: 2.8%
Open Constructi on
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
Management review meeting held on 19.09.14. EIL/BPCL -Subcontracting agency finalised and 30 nos addln. manpower targeted to be available at site by end Oct'14. Agency for heavy equipment erection has been finalised and mobilisation schedule under submission. -Semi automatic welding machine - 3 nos recd at site. Commissioning yet to be done. AG piping fabrication: Only 12108 ID / 304970 ID fabrication completed. AG piping erection: Only 1078 IM / 412580 IM piping erection completed.
30-Oct-14
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:76.4%; Front: 82.6%; Act: 18.8% CCD: 25.01.15 E 51 ECD: Oct'15
Open Constructi Very High on
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
Management level meeting held at Kochi site on 15.10.14. EIL/BPCL -MBEL asked to explore the methodology to reduce attrition of present labour. MBEL to augment additional resources (from 210 nos to 400 nos) MBEL committed to increase manpower upto 300 nos by end Oct’14. - Availability of front to mechanical contractor to be expedited by completing all piperack foundations by 30.10.14 and structural erection by mid Nov’14. Works offloaded to M/s Ray &M/s Deens to supplement Civil & Strlworks. Further 2 additional Civil &Structural works contracts being lined upand expected to award by end Nov’14.
Oct'14
Slow progress by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. Awarded on E 52 25.03.14. CCD: 24.09.15
Open Constructi Very High on
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
Mobilisation started. Against requirement of 12 nos welders only six number welders are available at site. Resources to be expedited to commence work. Piping fabrication work commenced.
Constr.
Oct'14
I III
Slow construction progress by M/s B&R for Composite works: Open Constructi Very High Offsite Refinery area due to delay in mobilisation. on Awarded on 25.03.14. E 53 CCD: 24.09.15
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
- Management level meeting held 19.09.14 at site. -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works commenced.
EIL/BPCL
Oct'14
III
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for CDU/VDU. Sch: 04.09.14 E 54 CCD: 06.09.14 ECD: 06.03.15 Sch:100% Front: 99.3% Act: 82.5%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
-TS-1 by Dec'14; TS-2, TS-3, TS-4 , TS-6: handed over. TS V : Beam & slab completion : 31.10.14. -TS VII : Civil completed. Erection to start after piperack erection completion, from this area.
Constr.
Oct'14
III
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15 Overall Progress: E 55 Sch: 95.2 % Act: 86.3 % Constr. Progress: Sch: 85.4 % Front: 88.0% Act: 61.8 %
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Major backlog is due to manufacturing & Delivery (3%) and construction (30%). Erection of APH, Hot air ducts for VDU Heater is in progress. - Additional resources to be mobilised to recover construction backlogs Convection module 4/5 erected for Crude Heater A & 3/5 erected for Crude Heater B. CDU APH foundations to be handed over by mid Nov-14
Constr.
As Required
III
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for DCU. Sch: 04.09.14 E 56 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 98.3 % Act: 78.3 %
Open Constructi Very High on
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Handing over of balance equipment foundation targeted progressively by Oct’14. - Handing over of complete branch piperack targeted by 30.10.14. TS-III : Start of structural erection in TS-III targeted by end Oct'14.
EIL/BPCL
Oct'14
Open Constructi on
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level Meeting held on18.09.14. - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT383/391/150. - Annular plate erection for tanks YT-26&YT-28 started. - YT-150: Dismantling activities in progress. - YT-383: Dismantling activities in progress. Plate material ordered. - YT-391: tank cleaning under progress. - Ordering of plate material to be expedited. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement.
EIL/BPCL
Oct'14
5
Urgency (Long Term / Short term)
8
N
2
Schedule ( Y / N)
7
Open Constructi Very High on
1
EIL Cost (Y / N)
6
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: E 49 Sch: 8.6 %; Front: 9.8%; Act.: 2.3% AG Piping fabrication: 1980 ID / 500000 ID completed
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Job No.: A307 Aug'14 Page 667+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Risk Owner 4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close) 3
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
II High
II
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) E 57
Medium
II III
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
6
7
8
9
10
11
12
13
14
15
16
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held on 19.09.14 with M/s B&R at site. M/s B&R agreed to increase manpower from 96 nos to 180 nos. B&R agreed to complete the civil works as per below targets: 1. YT-341 : Tank pad completed, annular plate laying & welding is in progress. 2. YT-342: 20.08.14 Revised date: 02.11.14. Sand filling is in progress. 3. YT-343: 10.08.14 Revised date: 20.10.14. PCC & fire brick work is in progress. 4. YT-344: 30.07.14 Revised date: 04.11.14 5. YT-111: 15.07.14 Annular & Bottom plate welding completed & 3 nos Shell plate erection completed & welding is in progress. 6. YT-112: 20.07.14 Annular plate laying & welding is in progress. 7. YT-113: 14.08.14 RCC wall done :revised date : 20.10.14. Sand filling is in progress. 8. YT-114: 08.08.14 Revised date: 17.10.14.Sand filling is in progress. - Procurement of Balance Quantity of Plates (890 MT out of 1650 MT) to be expedited.
EIL/BPCL
Oct'14
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. -Agency has been pressurised to mobilise resources and start work. - Tank pads to be handed over from Sep'14 onwards. - SWS-1 Sour water tank & sour water storage tank pads handed over.
Constr.
Oct'14
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected. Piping fabrication work in progress.
Constr.
Oct'14
II III
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 18.09.14 at site. M/s OIL has been asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Mobilisation for 20 nos auto welding machine to be expedited.
Constr.
Oct'14
III
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 18.09.14 at site. M/s OIL has been asked to mobilise resources, fabrication yard in progress - 600 MT crane to be mobilised - At present only 4 nos welders are available at site with per day rate of 120 ID, however to achieve the completion schedule minimum 1000 ID/day to be achieved.
Constr.
Oct'14
III
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
-Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. Piping III contract awarded BPCL to M/s Keller Ground Engineering.
Oct'14
Urgency (Long Term / Short term)
5
Open Constructi on
Schedule ( Y / N)
Action Plan
EIL Cost (Y / N)
Previous Risk Score
4
Job No.: A307 Aug'14 Page 668+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
2 Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 85.6 % Front: 100 % Act: 39.9 %
Status (Open / Close)
Risk Id 1
Key Risk Description
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
E 58
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 CCD:18.06.15 E 59 Work yet to start
E 60
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. 5711 ID / 210605 ID piping fabrication completed.
Start of Composite works by M/s Offshore for Offsite DHDS area E 61 Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15.
E 62
Start of Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 2614 ID / 298914 ID piping fabrication completed. Piping erection work yet to commence
Completion of balance piling work (Covered under Piling-IIII Contract) E 63 (Total 2077 Nos piles approx).
Open
Constn.
Action By
Target Date
Risk Severity
18
19
17
III
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 7114 ID / 203790 ID piping fabrication completed
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected, side cladding in progress. Piping fabrication work in progress. Piping erection work commenced on the main pipe rack.
Constr.
Oct'14
II III
Availability of Hydrogen and Nitrogen for Pre-commissioning 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’2015 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 2 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) 3
Open
as scheduled
III
E 64
F
F
F
1
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
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.
Kochi Refinery, BPCL
2
G
3
G
4
G
5
10
11
12
13
14
15
16
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.
As Required
IV
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.
Constn. / Projects / BPCL Process / POSD / Engg. / Projects
All by 60% constn progress
sep'13
I
I
Action By
Target Date
Risk Severity
17
18
19
Non-performing vendors
Open Inspn
Low
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
- 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. - List of buildings finalised between EIL and BPCL. Methodology for execution under finalisation.
15-Apr-13
Apr'13
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
0.00
- Documents approved from PESO
BPCL
Close
Purch / Contrc.
BPCL
Low
Implementation of environmental clearance conditions by EIL Open (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 inside TF- Close 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
7
IV
Apr'13
1
Statutory approvals - Factory inspectorate approval - CEA (Central electrical authority) approval 2 -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
Oct'14
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
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
0.00
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
BPCL
As Required
Nov'13
Mobilisation of Skilled workers
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
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
Constraint in movement & transportation of ODC eqpt.
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
As Required
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open Project/En gg
High
N
N
Y
N
Long term
I
0.2
0.00
Closed as no concern as on date.
BPCL
1
K
1
K
2
K
Process / Engg.
6
J
K
Open
Previous Risk Score
9
Y
Finalisation of Non plant buildings.
G
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
8
N
Urgency (Long Term / Short term)
7
N
Schedule ( Y / N)
6
Medium
EIL Cost (Y / N)
5
Const.
Scope changes & information flow to executing group
G
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)
G
Status (Open / Close)
Risk Id
3
Timely payment to sub contractor by main contractor
2
1
Job No.: A307 Aug'14 Page 669+15 of 32
Action Plan
Key Risk Description
1
G
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
3
4
0.40
0.40
At present only approx 9000 labours are working against requirement of 15000 labours.
As stated
II Jun'14
Jun'14
Kochi Refinery, BPCL
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
16
6
7
8
9
10
11
12
Y
N
N
N
Short term
D
0.08
0.00
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
Open
Environ.
Very High
Y
N
N
N
Short term
D
0.08
0.00
Scope of facilities finalised.
Environ.
15-Oct-13
sep'13
Variation in foreign exchange rates from Rs 50 per USD as Open on Mar 12 to Rs. 60 per USD as on date and fluctuations in the intermediate period and Scope changes w.r.t. DFR 3 (additional in scope) has significantly impacted on the overall project cost.
Project
Low
Y
N
Y
N
Short term
I
0.6
EIL/BPCL
Oct'14
M
Increase in facilities on account of deletion zero liquid 2 discharge
Total Risk Score
0.18
0.48
-0.30 - BPCL to put up Revised cost in BPCL Board and seek approval on the same.
24.42
24.55
-0.13
17
18
Risk Severity
5
1
M
15
Target Date
High
M
14
Action By
4
Close
13
Action Plan
Costing
Cost monitoring & control on regular basis
3
Job No.: A307 Aug'14 Page 670+15 of 32 (Current risk Score Previous Risk score)
2
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19
III
Job No.: A307 AUG'14 Page 671 of 749
Integrated Refinery Expansion Project, Kochi
A
A
A
A
1
2
3
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
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
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
- 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
- All P&IDs incorporating DCNs issued.
Process
25/10/13
Oct'13
Holds, missing information, corrections, changes in PDS / P&IDs - DCU
Open
Process
- 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
15-Mar-14 Projects / Engg Process
Mar'14 & Apr'14
31-Mar-14 30-Apr-14
Delay in Process Package for TGTU (M/s CB & INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13 A
5
A
6
A
A
Close
BPCL / Process
-Process package received on 14.04.13
Close
Process
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 Close LAD : 29-Dec-12; Ant : 19-Mar-13
Process
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
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Process
Based on latest information from BOO HGU and SWII (FCC), Revised Design Basis issued.
Projects / Process
-
Mar'13
Process
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
- 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
Process
All process P&IDs issued. Pumps PDS issued for engg,. All Vessels PDS issued for engg.
Process
Delay in "issue for engineering - IFE" PDS / P&IDs for DHDT P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
-
Apr'13
7
8
Close
Close
9
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A
10
A
Delay in "issue for engineering - IFE" PDS / P&IDs for VGO-HDT 11 LAD : 29-Jan-13; Ant : 10-May-13
A
Apr'13
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
Projects / Process
Close
Close
-Preparation of Offsites 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 12 details received now. -Upgradation of Crude oil pipeline system (Inside refinery) to be taken up.
POSD
- All 32 P&ID issued for engineering
Apr'13
31-Dec-12
Jan'13
Apr'13
Apr'13
Job No.: A307 AUG'14 Page 672 of 749
Integrated Refinery Expansion Project, Kochi
In view of increase in sulphur load PDS & P&IDs for Close sulphur block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement.
A
13
A
Revision in PDS after issue of “Issued for 14 Engineering” after release of MR -Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
Close
Close
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Process
Action Plan
Target Date
- All PDS and P&ID revised and issued.
Process/EN Revision in PDS to be avoided once same is issued for engineering GG Process
Action By
Risk Severity Apr'13
Process
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New facilities) has been issued for BPCL / engineering. Balance 1 no. targeted by 15.03.13 Projects / POSD
-
15-Mar-13
Apr'13
Feb'13
A
15
Revision in PDS after issue of “Issued for 16 Engineering” after Order
Close
Process/EN Revision in PDS to be avoided once same is issued for engineering. GG/Procure
Process
-
Apr'13
A
Revision in PDS after issue of “Issued for 17 Engineering” after Equipment manufacturing
Close
Process/EN Revision in PDS to be avoided once same is issued for engineering GG/Procure
Process
-
Apr'13
A
As Required
Apr'13
Updation of estimated utilities on account of revision Close 18 in process parameters (revision of PDS based on engg comments)
Process
A
ISBL Distribution P&IDs for VGO-HDT 19 SCH: 30-Nov-12 ANT: Jun-13
Close
Process
A
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 20 ANT: 31-May-13
Close
Process
A
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
Close
Process
Distribution P&IDs issued for engineering.
A
21 Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 22 Updation of P&ID as per finalised condensate philosophy to be taken up.
Open
Process
- Revised P&ID for Condensate System issued on 15.05.13.
Open
Engg
- Inconsistency related to type of Isolation valve (Ball Vs. gate / globe/check) between Engg. instrumentation and process design basis identified during coordination meetings resolved by TSD.
A
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed 23 engineering activities.
Open
Power Tech.
- System configuration including 8 pumps, filters & centrifuge finalised and PDS for Projects (CPP 30-May-14 pumps issued. Filters & Centrifuge PDS issued for engineering on 22.05.14. group) - Readiness of the fuel forwarding system to be ensured w.r.t. GTG commg schedule (i.e. in Mar 15).
May'14
A
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new 24 GTG).
Close
Engg.
- PDS for desalting pumps issued on 25.10.13. MR issued on 13.11.13.
Engg
Nov'13
A
BPCL confirmation/clarification over datasheets/GAD’s for existing/new raw water intake pump obtained from M/s KBL 25 (LAD for MR for pumps - 07.03.13)
A
26 Identifications of hook-ups on flare lines and finalisation of methodology BPCL availability Signing of ISBL P&IDs and with battery limiti.e. P&IDs for of ShutUtility downpackages / Hot tapping. Units, & other packages.
Close Open
Projects Process / POSD
Projects / Constn. Process / POSD /
A
27
- Identification of hook ups for Flare line, FCC flare, PRU flare and NHT / ISOM completed during completed site visit byfor: EIL Process. Signing of P&IDs - Hook sketches prepared and signed by Piping / POSD / BPCL. Marking at site -CDU/VDU Blocktoonbe24.06.14. to be taken up on 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 signing to be expedited.
28
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Close
A
Process / Updated P&IDs released. POSD
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
Open
Engg.
- Equipment layout issued for engineering on 23.08.13
Piping
21-Aug-13
JUL'13
Issue of Equipment layout for engineering for VGOHDT LAD - 07-Nov-12 Ant- 26-Dec-12
Close
Engg.
Equipment layout issued for engineering
Piping
26-Dec-12
Jan'13
Close
Engg.
Equipment layout issued for engineering
Projects / 21-Dec-12 Piping / BPCL
Jan'13
Open
ENGG
NIT issued on 24.06.13, bids due on 23.07.13
Projects / Process / HMTD
May'13
Utility distribution P&IDs for DCU
A
B
B
1
2
B
3
B
4
Delay in this activity shall hamper the following: Issue Equipment layout for engineering for FCCU i) 3 D of Modelling (targeted by 27.12.2012) ii) Civil/Structural & 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
In case of revision in process parameters of an equipment the utility estimates RED / PED/ furnished by engineering against older Revision of PDS should not be used until same PROCESS is got verified/ updated for current revision. RED to update all such changes within stipulated time frame as per departmental Utility P&IDs: (14to/ incorporate 17 ) issued for engg (except for small bore piping: Pump Process guidelines andP&IDs Process in the revised PDS. Seal & Vent Drain). The same are targeted by Jun'13. Process
31-May-13
Apr'13
31-May-13
Apr'13
Jan'13
BPCL
25-May-13
May'13
30-Apr-14
May'14
30-Dec-13 15-Sep-14
Process / POSD /
Dec'13 IV
Mar'14 & Apr'14
18-Jun-13
Job No.: A307 AUG'14 Page 673 of 749
Integrated Refinery Expansion Project, Kochi
B
5
B
6
B
7
B
8
a) Cost/time overrun due to rework Close b) Non completion of critical project activities within time & delay in Project completion c) Poor performance of Sub-contractors and Vendors
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Procure/EN 1) Involvement of technical/engineering team and client with vendor where nonGG/CONS. 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
Action By
Target Date
Risk Severity
Projects
As Required
Apr'13
Engg (Elec)
15-Jan-13
Jan'13
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
-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
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; Ant: Mid Jun'13
Open
Engg.
- Layout finalised with licensor. Final layout under study. Piping - Model review for SRU completed on 30th May'13 (except TGTU, incinerator section & downstream of sulphur pit).
15-Jun-13
May'13
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant - 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.
Close
Piping
Intermediate MTO released on 31.05.13.
Piping
31-May-13
May'13
HMTD
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
Delay in thermal design for Heat exchangers & Air coolers for licensed and non licensed units LAD (DHDT): 02-Feb-13 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
Close
Apr'13
B
9
Issue Overall UG piping layout drawing for the 10 complex
Close
Engg.
- Layout for OWS, CRWS, CW & FW lines issued for Offsite.
Gen Civil
31-May-13
May'13
B
Completion of 30 % Model review 11 VGO- LAD: 09-Mar-13 FCCU-LAD : 23-Apr-13
Open
Engg.
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 12 ANT: 18-Jun-13
Open
B
C
B
a) Inaccurate assessment of quantum of work
Close
MR issue for MCC (Main combustion Chamber) packages.
Close
13
May'13
Engg/procur Wide variation of BOQ and site executed quantities for item rate tenders to be ement controlled. Past data to be analysed and used for reference purposes.
Engg
Apr'13
As Required
MR issued on 02.05.13.
Open
Engg.
- Management level meetings with package contractors being organised to expedite Projects / the works. Engg. / - Battery limit conditions for CDSP Pkg (awarded to M/s Essar on 22.08.13) submitted Process 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.
Unit and offsite interfaces (Elevation termination levels)
Close
Engg.
- Clubbed with Risk ID A27
TSD
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule 17 requirements. LAD - 28.02.13; Ant - upto Feb 14.
Open
Projects
- 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
10-Mar-13
Feb'13
15-Sep-14
III
Continuous
IV
14
B
Timely finalisation of Package Interface 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 15 by all the concerned).
B
Project / C&P 18-Jun-13
Project
B
B
Project/C&P - NIT issued for publishing on 12.06.13 with sale period from 17.06.2013 to 05.07.2013
Engg
Apr'13
LAD: 16-Feb-13 Ant: 15-Apr-13 May'14
-
Mar'14 & Apr'14
16
NIT for Heater for DCU LAD -15-Feb-13;
Close
PROCESS/ - NIT issued on 11.03.13, bids due on 16.04.13. Pre bid meeting targeted on ENGG 02.04.13. (Delivery : 18 M for Mechanical Completion including Pre-Commissioning Activities)
Open
Engg/Cont. - Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. - HAZOP review completed for GTG, HRSG & UB package. - 60% model review for HRSG targeted by mid Sep'14. -90% model review for GTG & UB package targeted by mid Sep'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
B
CPP: Integration of various packages & BOP Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas 19 Booster compressor.
Open
Engg/procur - Preparation of Inst. dwgs./ docs. by the DCS vendor, using Smart Plant ement Instrumentation (SPI) is already covered in DCS vendor’s scope in DCS
Projects
B
Distributed Control System (DCS) Detailed engg., supply and erection 20 (ordered on M/s Emerson Process on 04.11.13)
B
21
B
18
60 % Model review for DCU (LAD:03.07.13 Act:13.09.13)
Close
ENGG
- Model review completed on 13.09.13
Projects / Process Process / HMTD C&P
ENGG
Aug'13
Job No.: A307 AUG'14 Page 674 of 749
Integrated Refinery Expansion Project, Kochi
Action Plan
Action By
Target Date
Risk Severity
Open
Engg/procur - Being taken up with respective package vendors for implementation. ement
Instn / Projects
Continuous
IV
Open
Engg/procur Package vendor inputs being made available by expediting for updation of interface ement engineering documents.
Projects / Engg.
Continuous
IV
B
Delay in Interface Engineering (including control system) due to non availability of Package Vendor 23 Data
Open
ENGG
Model review completed on 04.10.13
ENGG
4-Oct-13
sep'13
B
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. 20 - Vendor drawings for sheds awaited.
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) 24 LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
GC
- All P&IDs released
G. Civil
25-Jul-13
JUL'13
Order for DG set Dely: (12 M FOB + 3 M Site work) 25 Sch: 05.11.13 Ant: 30.09.14
Open
Project
- Award recommendation issued on 07.08.14. BPCL to award.
BPCL
30-Sep-14
III
Close
ENGG
- 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
B
22
B
B
Package Vendor refuses to submit Instrumentation Drawings/ Documentation in Smart Plant Instrumentation Database as per Client Requirement
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Receipt of Inputs from Process / Vendors for 60 % 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
Open
ENGG
- Model review completed on 25.10.13.
ENGG
25-Oct-13
sep'13
B
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) 27 envisaged.
Open
ENGG
- Model review started on 28.10.13 and under progress. Targeted to complete by 31.10.13.
ENGG
31-Oct-13
sep'13
Open
ENGG
- Intermediate 2nd MTO released on 31.10.13, based on above MR under preparation.
Projects / ENGG
31-Oct-13
Oct'13
B
60 % Model review for 28 SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), 164 Delay in release 2nd MTO (SRU),15 (SWS)of & Intermediate 60(TGTU) + 155(Utilities LAD:30.09.13; -CVs Size HoldAct:31.10.13) as follows: 13 (ARU), 6 (SWS), 125 Holds: (SRU). -CDU/VDU: PumpFace nozzle 6 nos. pumps under -All Control Valve to for Face Dimensions are hold), for 256 lines under hold, Control valve HOLD.sizes All CVs for TGTU are HOLD. 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 29 (103 nos.) not considered in MTO.
Open
ENGG
Progressively
30
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
B B
31 HAZOP for FCCU LAD - 23-Sep-13 Completion of 90 % engineering by Mar-14. Average progress achieved in last 3 months 3.0 %
Close Open
ENGG ENGG
- HAZOP study completed on 29.11.13. - As of 15 Aug'14 Engineering progress is 91.4 %.
ENGG ENGG
B
32 LD Milestone date - Dec'13
Open
ENGG
- MTO expected by 10.09.14.
ENGG
B
33
Finalisation of GTG fuel forwarding scheme for naptha to day tank when Naptha tank being under 34 maintenance.
Open
POSD
B
- Revised P&IDs issued for connecting tank-101 & 102. Process / As per BPCL mail dated 25.08.14, requirement of connecting tank YT-332 is under Engg. review where in procurement of additional pumps is required. Process datasheet and P&IDs expected to release by 15.09.14.
B
Generation of Surplus Piping material
Release of final Piping MTO Sch: Jul'14 Ant: Sep'14
IV
Nov'13 Aug'14
Sep'14
III
Sep'14
III
Job No.: A307 AUG'14 Page 675 of 749
Integrated Refinery Expansion Project, Kochi
Status (Open / Close)
Risk Owner
Risk Id
RISKS REQUIRING BPCL ATTENTION
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
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
30-Dec-13
Dec'13
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 Duration: 18 M
Open
Project
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
30-Aug-13
JUL'13
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
- BPCL confirmation sought for minimum nos (10.97 MW or 80% of 10.97) for qualifying criteria. Accordingly BQC changed and approved by BPCL. Draft NIT by 25.05.13. Publishing targeted by end May 13.
C&P
30-May-13
May'13
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
Close
Project
- As per latest cost status report the impact of cost variation has been neutralised by savings.
Projects
Continuous
Nov'13
Award of Heater for DHDT LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Awarded to M/s Technip on 04.09.13 (Duration 18 M)
Projects / HMTD
15-Sep-13
Aug'13
NIT for Composite Works for DCU LAD -06.06.13 ; Ant - 25.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
25-Oct-13
sep'13
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
31-Oct-13
sep'13
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
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
-Ordered on M/s Shin Nippon & M/s Flowserve on 30.01.14 (except Tag IV-P-301 A/B EIL 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.
15-Mar-14
Mar'14 & Apr'14
NIT for Composite Works for Offsite DHDS area LAD -22.07.13 ; Ant - 15.10.13
Open
ENGG
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
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 -Ordered to M/s Fabtech on 15.07.13 g
Engg/Proj
20-Jul-13
JUL'13
Project/C&P NIT issued on 29.05.13, bids due on 18.06.13.
Project / C&P 31-May-13
May'13
Key Risk Description
C
1
C
2
C
3
C
4
C
5
C
6
C
7
C
8
C
9
C
10
C
11
C
12
Action Plan
Action By
Target Date
Risk Severity
C
13
Issue NIT for Tankage-II LAD: 21-Jan-13 14 ANT: 31-May-13
Close
C
Award for RO-DM LAD:30-Jan-13 15 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Open
Project
- Awarded to M/s Driplex on 12.06.13. duration is 22 M.
Engg / C&P
29-Jun-13
May'13
Close
Project
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months.
BPCL
28-Feb-13
Feb'13
Close
Project / Licensor
21-Feb-13
Feb'13
C
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13 C
C
C
16
NIT for Reactor regenerator package for FCCU LAD : 01-Jan-13 Ant: 21-Feb-13 17 Changes in scope of supply led to revision in BQC / tender.
18
Award for Raw water quarries LAD :03-May-13 ANT: 15-Apr-13
Close
Project
BQC finalised on 15.01.13. Tender under compilation. Draft NIT being issued to BPCL Projects / for approval. BPCL NIT targeted by 21-Feb-13.
Ordered to M/s Paulose George (15 M).
BPCL
Apr'13
Job No.: A307 AUG'14 Page 676 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Ordering of Reactor for VGO-HDT LAD: 29-Dec-12 ACT: 08-Apr-13
Close
Project
Ordered on M/s L&T on 08.04.13.
Proj/Engg
Award of contract for Piling-II LAD: 31-Dec-12
Close
Project
Awarded to M/s L&T on 09.04.13 with duration of 12 M.
BPCL
Close
Project
Awarded to M/s Petron on 09.04.13 with 18 M duration.
BPCL
Close
Engg.
Awarded to M/s Technip on 07.03.13 (Duration 23 M)
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
19
Key Risk Description
Action Plan
Action By
C
20
C
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 21 Ant: 30-Mar-13
C
Award of Crude and Vacuum heaters (LAD 29.12.12) 22 Ant : 07.03.13
Storage of sulphur and related issues with Granulator to be finalised between BPCL / EIL.
Close
Project
- Scheme finalised.
Projects / BPCL
C
23
NIT for ETP package with WAO (Wet air oxidation) 24 LAD: 15-Jan-13 Ant: 16-Apr-13
Close
Project
Tender released on 26.03.13; BQC finalised on 08.04.13. NIT targeted by 16-Apr-13
Engg
C
Project
Award recommendation issued on 11.02.13. Awarded to M/s Howe baker on 07.03.13 Proj/Engg
Project
Awarded to M/s L&T (duration 20 M)
BPCL
KB tech completed development of flare area & handed over the area to M/s L&T.for piling.
Projects
Risk Severity
Target Date -
Mar'13
-
Mar'13
Ant: 15-Apr-13
Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13 C
25
C
Award of contract for Building incl substations LAD: 07-Feb-13 26 Ant: 15-Apr-13
Filling of existing part fire water pond required for area preparation.
Close
Close
Open
Strl
-
Mar'13
Projects / 7-Mar-13 C&P / BPCL
Feb'13
Apr'13
Apr'13
7-Mar-13
Feb'13
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
28
Engg / C&P - Evaluation of LLIs to be ensured with-in 1 month from receipt of bids by Engg. & Engg / C&P / PBO recommendation 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 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: 29 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
Awarded to M/s Tecnicas Reunidas S.A. on 31.12.13
BPCL
30-Dec-13
Dec'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) 30 Anticipated: 23.11.15 (27 M) Bidders quoted 27 M against schedule of 26 M.
Open
Project
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. 31 Duration (Supply) - 15 M FOB /16 M FOT as per RFQ; Sch : 20 M
Open
Project
- Awarded to M/s BHEL on 25.07.13.
Projects / Engg / C&P / BPCL
JUL'13
20-Jul-13
Job No.: A307 AUG'14 Page 677 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Delay in Ordering of HRSG (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. 32 No PTR available for LSVR Fuel Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
Close
Projects / - Awarded to M/s Thermax on 20.12.13 Projects / Engg 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.
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. 33 Bidders sought extension in dates.
Close
Project / Licensor
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) 34 Duration: 21 M+2 M No bidder could meet the BQC criteria in view of which the tender has been re-floated.
Open
Project
Open
C
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 35 Duration: 20 M
Close
C
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 36 Duration: 22 M+2 M
C
C
C
- 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 Esaar on 10.07.13.
Target Date 20-Dec-13
Projects / BPCL
BPCL
Risk Severity Nov'13
Jun'13
31-Oct-13
Oct'13
Projects / 31-Jul-13 C&P / BPCL
JUL'13
C&P/Engg/Pr oj
Aug'13
Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
Process / - 3 no. bids received on extended date of 02.02.13. Engg / - Meeting with bidders held from 19.02.13 to 26.02.13. PBO recomn. issued on constn 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 Project/C&P 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
Anticipated Completion: 29-Jul-15
C
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
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
Failure of contractors
Open
Const.
Limit the number of works being awarded to one Agency so that alternatives can be C&P 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 BPCL / only. Projects
-
sep'13
-
sep'13
37
C
38
Ordering of Ejector Pkg 39 (LAD:12-Jan-13; Ant: 15-Jul-13)
Open
Project
Awarded to M/s GEA on 10.07.13 with delivery period of 13 M.
BPCL
15-Jul-13
Jun'13
C
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). 40 Due to Technical and related commercial issues enquiry re-floated. Duration 20 M
Open
Project
Awarded to M/s Heurtey, (Duration - 20 M)
BPCL
15-Nov-13
Oct'13
Award of Civil & Strl work for DHDS offsite area (LAD: 30-Mar-13; Ant: 20.07.13) 41 Duration: 18 M
Open
Project
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
Awarded to Mcnally Bharat on 26.09.13. Duration- 16 Months
Project/C&P
Open
Project
NIT issued on 01.08.13, bids due on 30.08.13
Gen Civil/Project
25-Jul-13
JUL'13
Open
Project
Awarded to M/s McNally Bharat. Duration - 16 M
Gen Civil/Project
30-Oct-13
Oct'13
C
C
C
42
C
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) 43 Duration : 16 M
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15
Award of work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M C
44
sep'13
Job No.: A307 AUG'14 Page 678 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
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 45 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
MAB awarded to M/s Elliot Ebara on 04.09.13. WGC awarded to M/s BHEL
Award of Civil & Strl contract for CDU/ VDU & DCU LAD: 15-Dec-12 46 Ant: 07-Mar-13
Close
Project
Awarded to M/s L&T on 07.03.13. Award recomm sent to BPCL on 01.02.13. Award to C&P be targeted by 07.03.13.
Ordering of wet gas compressor for DCU 47 LAD: 02-Feb-13 Ant: 30-Jun-13
Close
Project
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
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., 49 sulphur pelletiser and sulphur granule); refloated again as financial criteria was not met by all the bidders.
Open
Project
- Ordered to M/s Sandvik.
BPCL
30-Jan-14
Jan'14
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 50 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
Awarded to M/s Sriram on 25.09.13
BPCL
30-Sep-13
Aug'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 51 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
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 52 Duration: 16 M
Open
Project
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 53 Duration: 12 M despatch and 6 M for site work (ODC)
Open
Project
Awarded to M/s Thermax
BPCL
14-Aug-13
JUL'13
Open
Project
Awarded to M/s Triveni
BPCL
19-Jul-13
JUL'13
C
Award of contract for RWTP (Refloat case) LAD: 14-Jan-13 Ant: 19-Jul-13 54 (Execution Duration - 18+2 M)
Open
Project
Ordered to M/s Callidus and M/s UOP India on 20.06.14.
BPCL
C
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 15.06.14 (Incinerator burner) 55 (Execution Duration - 14 M)
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
C
C
C
C
C
C
C
Key Risk Description
Action Plan
Action By
Target Date
C&P/Engg/Pr 30-Sep-13 oj
7-Mar-13
Risk Severity Aug'13
Feb'13
Jun'13
48
Aug'13
Jun'14
Job No.: A307 AUG'14 Page 679 of 749
Integrated Refinery Expansion Project, Kochi
56
Risk Owner
C
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
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
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
Awarded to M/s Airoil on 25.09.13 with duration of 18 M.
Projects/ 28-Sep-13 Process/ Engg / C&P/
Aug'13
Open
Project
- Awarded on M/s Ray Engineering on 23.01.14.
Engg / C&P
Jan'14
Key Risk Description
Action Plan
Action By
Target Date 19-Jul-13
Risk Severity 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
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 58 Duration: 12 M
Award for:RGC compressor for VGO-HDT (LAD: 30Mar-13; Ant: end Jun 13) Dely: 18 M
Open
Project/Eng Awarded to M/s BHEL g
Proj/Engg
29-Jun-13
Jun'13
C
59
Award of MUG compressor for VGO-HDT (LAD: 08-Apr-13; Ant: 30.11.13) 60 Dely: 16 M FOB
Close
Project/Eng Ordered to M/s Neumen & Essar on 14.11.13 g
BPCL
30-Nov-13
Nov'13
C
Award of Contract for Tankage-III (Crude tank: 02 Nos & 1 surge relief tank and crude drain tank) 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 tanks-25/26 under 61 tankage-III. Sch: 01.10.13 Ant: 15-Dec-13
Close
Project/Eng Awarded to M/s IOT Anwesha on 04.12.13. (duration: 20 M) g
BPCL
15-Dec-13
Nov'13
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: 62 Jun 13)
Close
Project/Eng Awarded to M/s BHEL g
Proj/Engg
28-Jun-13
Jun'13
C
Close
Project/Eng Awarded to M/s Dresser Rand g
Proj/Engg
C
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep-13) 63 Duration : 18 M FOB
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) 64 Sch: 30.04.13 Ant: 30-Sep-13 Duration:22 M
Close
BPCL
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 65 new crude tanks (Tankage-III; YT-25/26). Alternative scheme required to be finalised for outage.
Open
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
C
C
C
C
66
Duration - 20 M
Aug'13
Awarded to M/s B&R
BPCL
30-Sep-13
Aug'13
BPCL / Projects
Awarded to M/s Offshore on 17.04.14.
EIL / BPCL
25-Apr-14
Mar'14 & Apr'14
Project
.Awarded to M/s Offshore (Duration- 20 months)
BPCL
31-Oct-13
Oct'13
Job No.: A307 AUG'14 Page 680 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award for contract for development of flare area LAD: 01-Nov-13 Ant: end Dec'13
Close
Project
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
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, 69 Technicas, Petron, B&R, JNK). Duration 20 M
Close
Project
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)) 70 (LAD:29.12.13; Ant: 30.07.14)
Open
Project
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) 71 LAD:09.05.13 Ant: 30.09.14
Open
Project
-Award recomn. issued on 08.08.14. BPCL to award.
BPCL
30-Sep-14
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards 72 Piping intermediate MTO-II released on 30.10.13.
Open
Project
- All pipes, fittings & flanges ordered.
C&P
14-Aug-14
Ordering of Critical Valves Sch: 11.07.14 73 Ant: 30.09.14 Dely: 06/07 M FOT /FOB
Open
Project
Revised MR (MR-3415) issued covering all critical valves along with all critical valves EIL/BPCL of MR-3211 floated. Price bid opened on 09.09.14. Award recommendation targeted by 12.09.14.
30-Sep-14
Award of contract for Mechanical works-CPP area LAD: 28.02.14 74 Ant: 25.05.14
Open
Project
- Awarded to M/s Zillion on 19.05.14.
25-May-14
Release of balance piping Isometrics drawings and GAD's. 75 Target Sch: Jul'14 Ant: Sep'14
Open
Project
-Total 24054/ 30154 nos (81%) isometrics issued for units . Balance ISO's targeted progressively by Sep'14. - Piping items has been ordered for Intermediate MTO-II, delivery expected by Sep'14-Oct'14.
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM-Refloated 76 Sch: 08.05.14 Ant: 15.10.14
Open
Project
- Tender on sale from 28.08.14 to 17.09.14.
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) 77 Sch:27.06.14 Ant: 05.08.14
Open
Project
- Ordered to M/s Sulzer.
Completion of Reactor regenerator package for FCCU-M/s Esaar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 59.8 % Act: 47.3 % Construction Progress: Sch: 16.4 % Front: 71.1% Act: 11.1 %
Open
Project
Management level meeting held on 08.08.14 at site. - Completion of hard stand targeted by 15.10.14. Projects - M/s EPIL has been pressurised to complete construction of hard stand by 15.10.14. Submission of final erection scheme targeted by mid Sep'14 and approval by EIL Constn targeted by 20.09.14. (Preliminary erection scheme discussed with EIL). - Work for assembly of hoppers and TSS to be commenced from 15.09.14. - Fdn for flue gas area, stack fdns and ESP fdn targeted to complete by end Oct'14(Excavation already completed). - Refractory lining to commence from 11.09.14 at Tarapur. - M/s EPIL asked to commence area development around FGC equipments & hard stand immediately and to be ready by 15.10.14. - M/s EPIL agreed to mobilise 1600 MT crane by end Oct'14 and will ready for erection by Dec'14. Shipment movement already started. - Delivery of Cyclones expected at site from Nov’14 to Feb’15. M/s Emtrol has been asked to pre pone the deliveries upto Dec’14 during meeting dated 25.08.14. Plennum fabrication status to be obtained from M/s GRE. - Readiness for TSS erection targeted by 2nd week of Sep'14 to Feb'15. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. - Next Management review meeting with M/s Essar planned at site on 12.09.14.
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
C
C
C
C
C
C
C
C
C
D
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
67
68
1
II Aug'14
Engg
Engg.
Sep'14
II May'14
III
15-Oct-14
BPCL
5-Aug-14
II Jul'14
Progressively upto Sep'14
EIL/BPCL
I
Job No.: A307 AUG'14 Page 681 of 749
Integrated Refinery Expansion Project, Kochi
D
D
D
D
D
D
Risk Owner
D
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
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
Clubbed with Risk ID E19
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: 78.1 % Act: 57.8 % Construction Progress: Sch: 63.3 % Front: 100 % Act: 16.6 %
Open
Project
Management review held on 01.08.14 to pressurised M/s ISGEC for completing within Project / CCD. Constn. - M/s ISGEC to expedite modelling work to carry out 90% modelling by Sep'14. - Completion of balance foundations being progressively targeted by end Oct'14. -Erection of UB-1 & UB-2 to be expedited. - Project review meeting planned with M/s ISGEC on 09.09.14 at EIL HO.
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14 Ant : 30.09.14 Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT.
Open
Project
Delivery of wet gas compressor for DCU at Site (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 27.01.15) Sch: 50.7%; Act: 48.2%
Open
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 24.12.14)
Key Risk Description
2
3
4
5
6
7
8
Action Plan
Action By Project
Target Date
Risk Severity
24-Nov-14
Nov'13
Sep'14
III
-All Indigenous component received at site within CDD. - Foreign Source Components: Delivery of ejector and LRVP pkg dispatched.
Project/Inspe Sep'14 ction
IV
Project
Material against all suborders received. Casing for compressor and turbine received at shop. Machining of components of both main compressor and steam turbine under progress.
Project/Inspe 27-Jan-15 ction
IV
Open
Project
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Order placed for Motor, turbines, Casings, forgings, impellers, gear box. Hazop and modelling in progress from 26.08.14. Close monitoring to be done to ensure delivery on CDD.
Project/Inspe 24-Dec-14 ction
IV
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: 73.0 % Act: 50.8 % - 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
-All 3685 MT Plates received at Chakan Shop, plate cutting & welding in progress. Project / - Staggered delivery of columns is required from Sep'14 onwards as major piping Constn. works is held up due to hold for crane movement for these columns. - Foundation for main fractionator column (by M/s L&T) completed and superstructural work being expedited by M/s Tuaman. - Erection for main fractionator targeted by Dec'14. Crane 1250 MT and 550 MT mobilised, erection scheme approved. - Stripper & rectifier Column: Erection expected to commence from Dec'14. Preparation of Hard stand commence from 3rd week of Sep'14. - Approach road work completed. Area improvement to be expedited.
As stated
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) Overall progress: Sch: 71.0 % Act: 63.2 %
Open
Project
- M/s Thermax seeking extension for duration due to delayed availability of burner BPCL / EIL data from M/s Aecometric. Letter issued to BPCL for recommending extension for supply portion to M/s Thermax upto 30.11.14. - Foundation readiness to be delayed till Dec'14. Bidders has requested for providing space for stoarge of MCC equipment & Refractory Materials.
15-May-15
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 49.0 %; Act: 37.0 % Construction Progress: Sch: 27.0 % Front: 92.2 % Act: 18.1 %
Open
Project
-Management review meeting held on 08.08.14 and 14.08.14 at site. Weekely review Constr. meeting held at site on 22.08.14. Following commitments have been made by M/s Essar. -Fabrication for Derrick structure agreed by Dec'14. - Meeting held with M/s Essar for financial issues on 01.09.14. - Derrick and coke drum structure offload from M/s MK Engg scope to M/s Infraprojects and M/s Universal respectively. Status to be obtained for structure BPCL/EIL readiness. - Balance fabrication (for Switch Deck 250 MT) targeted by 30.09.14. - M/s Esaar agreed for readiness of Fractionator column and coke drum for erection by 28.02.15. -Supply of balance Plates (33/38 plates received) targeted by 14.09.14. - Ordering of 2000 MT crane targeted by mid Sep'14 and Crane availability agreed from Feb'15 to May'15. - Resource augmentation for Civil & Strl works being expedited. At present 227 nos have been deployed, while requirement is 328.
Continuously
D
9
Open
Project/Eng - Drive turbine for LOP (Lube oil Pump) sub ordered to M/s KEPL on 22.03.14 & g targeted to receive at shop by Dec'14. Impeller manufacturing is in process. Turbine casings reached at BHEL workshop. - Compressor: MRT expected to complete by mid Sep'14.
Project/Inspe 27-Dec-14 ction
D
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M 10 Ordered to M/s BHEL on 28.06.13
Delivery of RGC compressor for DHDT(LAD : 05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
Open
Project/Eng - Drive turbine for LOP (Lube oil Pump) subordered to M/s KEPL on 22.03.14 & g targeted to receive at shop by Dec'14. Turbine rotors and casings reached at BHEL workshop. Steam turbine: All components except inner casing ready for assembly. Casing inner (steam chamber) got rejected in hydrotesting. Inner casing to be expedited at BHEL Haridwar shop.
Project/Inspe 27-Dec-14 ction
D
11
II III
I IV
IV
Job No.: A307 AUG'14 Page 682 of 749
Integrated Refinery Expansion Project, Kochi
D
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Oct 14 Normally 12-14 Months are required for Unit 12 Mechanical Compln after erection of Crude & Vacuum column. VTV progress Sch ( 100 %); Act (88.5%)
Open
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Oct'14 Projects / - Erection of Crude Column : Top section erection planned on 12.09.14 and / Projects Const. hydrotesting planned on 15.10.14. Middle section erected on 19.08.14 and Bottom section erected on 07.08.14. - Erection of Vacuum Column : Erection of sections expected from end Sep'14 to end Oct'14 and hydrotesting by mid nov'14.
II Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site
Open
T&CC
Open
Projects
(VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB)
D
DHDT Reactor (M/s Doosan) expected to receive at Kochi port by Nov'14. ISGEC Josen (3 nos) Column: expected to receive 13 at Kochi port from Nov'14 to Jan'15.
Close Monitoring of ODC equipment (including site fabricated/assembled) up to receipt at site D
D
D
D
Out of total 57 nos. of ODCs; 16 nos received at site. & 3 nos under dispatch. Balance under close monitoring and are expected at site from Sep'14.
Continous
Shipping
Close
Procure/Co - Transporter philosophy frozen and hindrance enroute has been covered under Risk Shipping nstr ID K3.
II IV
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
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.
BPCL
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Mar-15 Ant: 24-Mar-15 17 Overall Progress Sch: 48.2 % Act: 36.5 % Construction work likely to start from Oct'14.
Open
Project
- Hazop review covered in offsite Hazop. - Foundation drawing released. - Flare foundation work completed. - Construction work to be started from Oct'14. Fabrication of flare structure is in progress and delivery expected from Sep'14 onwards.
Projects/Cons As Required tr.
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. 18 Completion of Flare work: Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Open
Project / Process
- 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
Nov'13
15
Jun'14
16
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15 D
Sep'14
14
Delay in delivery at site due to non-availability of transporter / hindrances enroute. D
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - Agency confirmed availability of Barge/Trailer at the time of delivery of Reactors. Barge will be ready with reqd modification by Sep'14. - KOM held on 02.06.14 & follow up meeting held on 16.07.14. Barge readiness targeted as follows: 2 nos Ammonia Barges modifications by 30.09.14. Drawings for new barge submitted to IRS for approval. 1 nos new barge fabrication by 24.12.14. - M/s Urmila informed construction of jetty targeted by 30.09.14 (approval by 30.08.14), Construction of jetty not yet started as land for jetty is yet to be finalised. Meeting with M/s Urmila planned in 2nd week of Sep'14 to finalise modalities. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at Kochi-Port.
19
Open
Projects
As Required
III
Oct'13
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. However close monitoring being done. Meeting held on 06.08.14. Casing delivery expected within CDD.
II
Job No.: A307 AUG'14 Page 683 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 20 CDD: 03.04.15 Ant: 03.04.15
Open
Projects
- All major items has been subordered. Air Blower: Main casing received at workshop. Main coupling expected to receive at shop by Sep'14. Steam Turbine: Casing received at shop. Bearing expected to receive by Oct'14.
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 21 EDD: 02.03.15 Overall Progress: Sch: 85.0 % Act: 80.0 %
Open
Projects
-Ordered to M/s L&T on 08.04.13; Dly 21M FOT. Close monitoring to be done to Project/Inspe Continuous ensure delivery on CDD. ction - Strike has been called off with effect from 12.05.14 at L&T Hazira workshop. Vendor being followed up continuously to deliver reactor within CDD.
III
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 22 CDD: 07.10.14 Overall Progress: Sch: 83.9 % Act: 82.9 %
Open
Projects
- Follow up visit held, though no delay anticipated as per CDD, however close monitoring to be maintained.
Project/Inspe Continuous ction
III
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13 23 Overall Progress: Sch: 46 % Act: 38.8%
Open
Projects
- Management review meeting held with M/s Thermax on 31.07.14. - Balance engineering to be expedited by m/s Thermax. - HRSG #4 & 5: Foundation works completed and handed over to M/s Thermax. Foundations works for HRSG#3 along with Stack, Pumps(10 nos) and cable trench works are planned for completion during the mid Sep'14. - 30 % model review completed & 60 % model review targeted by mid sep'14.
Project/Inspe Continuous ction
III
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) 24 LAD ;30.03.15 CDD: 30.04.15
Open
Projects
- Generator subordered - Pedestal fabrication is at final-machining. - Fabrication of exhaust diffuser and inner exhaust case targeted by Sep'14
Project/Inspe Continuous ction
III
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 25 CDD: 30.03.15 Overall progress: Sch: 30 %; Act: 26.5 %
Open
Projects
-Silos with structure & Conveyors sub ordered by M/s Sandvik. - Delivery of Semi rolled sections of Silos shall commence from Nov'14 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited as material expected to receive at site by Sep'14. - Foundations for pelletiser shed to be made ready by end Nov'14.
Project/Inspe Continuous ction
III
Delivery of steel plates by M/s Essar to other vendors. CDD: Progressively by 15.01.14.
Open
Projects
Strl. Steel for R&RMajor portion of steel plates have been delivered by M/s Essar.
Project/Inspe Continuous ction
Jun'14
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 27 CDD: 10.03.15
Open
Projects
- Synchronous Motor ordered to M/s Toshiba Mitsubishi. Expected to receive at M/s Dresser shop by 03.02.15. - HAZOP review completed on 20.06.14.
Continuous
IV
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) 28 LAD : 26.02.15 CDD: 13.04.15
Open
Projects
- Main motor ordered. KOM for Motor held on 06-07.05.14 & expected to receive by 13.04.15 (FOB: Germany). - HAZOP completed on 19.06.14.
Progressively
IV
Open
Projects
- Following bidders showing slow manufacturing progress: - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.: 133, 144 & 184. Expediting meeting held at shop on 04.07.14. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 116, 189: As a parallel action separate MR-6122 released. 30 nos bids received on 25.08.14. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360 & 444. Continuous expediting being made by visiting vendor workshop for all critical orders in respective regions.
Sep'14
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 30 FOB)
Open
Projects
- 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
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 (MR-5403) 31 (FOA No 550 & 551) CDD: 01.03.15
Open
Projects
- 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) and Debutaniser Column (IF-V-302) by M/s Uttam Value Steel (Ordered on 19.08.13) 32 CDD: 18.10.14 EDD: 31.03.15
Open
Projects
- Order got delayed due to delay in manufacturing works. At present only 7 shell course rolled out of 17 nos due to which there be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
sep'14
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Sep'14 33 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
Open
Projects
- As of now around 40-45% piping material has been received at site. Around 90-95 EIL/ BPCL % material has been ordered. Ordering of balance 5-10% material is in progress and expected progressively upto end Sep'14. Delivery of ordered material against intermediate -II expected by Sep-Oct'14. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL. Unit specific items: - MR for VGO (4 nos) targeted to issue by 10.09.14.
Sep'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
D
D
D
D
D
D
D
D
D
26
Key Risk Description
Delay by vendor with respect to CDD due to financial constraint.
D
D
D
D
29
Action Plan
Action By
Target Date
Risk Severity
II
D
II
Job No.: A307 AUG'14 Page 684 of 749
Integrated Refinery Expansion Project, Kochi
E
Delivery Gas Booster Compressor for CPP (Dly: 13 34 M FOB
1
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsites) - 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
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage E
E
E
E
E
Risk Owner
D
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
EIL
sep'14
Open
Constn.
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
Constn.
- During the project review meeting dated 28.08.14 following points discussed and BPCL agreed: - Balance 6 nos units in the township to be handed over for grading by M/s Ray (SGIII). - FACT area to be arranged for storage of materials of owner and package contractors. FACT area being arranged by BPCL by mid Sep'14. -A separate meeting shall be planned with BPCL for identification of storage area for package contractors by mid Sep'14.
BPCL
Sep'14
Open
2
3
4
5
6
Action Plan
Action By
Target Date
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
Open
Constn.
-Major rock blasting work completed.
Constn.
sep'14
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 65.9% Catch Up Sch: 27.2 % Act: 24.1 %
Open
Constn. / Projects
- Composite Works (Civil Strl. & Mechanical) on 03.07.14: NIT on sale 28.08.14 to 17.09.14. Award targeted by Oct'14.
EIL/BPCL
Sep'14
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.
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
BPCL / Projects
15-Jul-13
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 87.2 % Front: 100 % Act:49.3% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Management level meeting held on 18.07.14, Constn - MCR area, CPP control room area : It has been decided to complete balance strl work by Dec'14 & finishing by Mar'15. - Other building works : Finishing work to be completed by Dec'14. - L&T also agreed to augment required manpower to meet the target completion date. - Management review meeting planned at site on 17.09.14.
As Required
Backlog 27.8 (% wrt target sch) as of 15-Aug-14 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 - 29M; Remaining Duration - 17 M Desc. Catch Up sch: Const Sch Front Act Overall 26.9 53.2 51.4 25.3 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
- In order to supplement progress by failing civil contractors, 2 separate agencies has Constn been lined up (M/s Tuaman-Civil & Strl works & M/s Zillion-Strl. works). Further additional two agencies for Civil & Structural works being lined up. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the sub vendors against Performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and boost progress. - Contractors are facing problem in retaining the labour at site.Approx 7000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 nos.
As Required
Risk Severity IV
sep'13
I Aug'14
I JUL'13
II
E
7
BPCL/EIL
E
8
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.
EIL/BPCL
Mar'15
I IV
Job No.: A307 AUG'14 Page 685 of 749
Integrated Refinery Expansion Project, Kochi
Status (Open / Close)
Risk Owner
Risk Id
RISKS REQUIRING BPCL ATTENTION
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.
L&T has completed all piles in Demountable flare area, Air compressor & DG shed area.
Constr.
Immediate
Jul'14
Payment to contractors
Close
Constn.
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
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
Key Risk Description
E
9
E
10
E
11
E
Dismantling of LO CAT SRU and area handing over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. 12 Will affect release of front for tankages.
Unrealistic project time leading to under quality
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
E
Close
Project / Engg. / planning
Action Plan
Action By
Target Date
Risk Severity
As Required
sep'13
May'14
Open
BPCL
All 5 nos tank area cleared and released. Area handed over to M/s B&R for Tankage- BPCL II works on 30.04.2014
end Apr'14
Open
Project
- Project review meeting held on 23.08.14 with M/s Triveni. Constr. -M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barbendors (Manpower required is 300 nos while available manpower is 152 Nos). - Substation building: Foundation works commenced, completion to be targeted by Dec'14. - Chemical house works commenced. - Meeting planned in mid Sep'14 with M/s Triveni.
Sep'14
Sep'14
Overall Progress: Contr. Sch: 78.4 % Act: 48.1% Construction Progress: Sch: 72.0 % Front: 100 % Act: 42.8 % 13 Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
II
E
E
Area availability for SRU Block - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by end Sep'14. (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 14 M (As per Past experience minimum requirement for SRU is 30 M).
Open
Proj. / Constn.
- Management level meeting held with M/s B&R on 06.08.14 & 19.08.14 and Constn. augmentation of manpower by min. 100 nos to be expedited for concreting work progress. M/s B&R has been asked to expedite complete SRU filling. - Retaining wall in progress. B&R agreed to complete wall by 31.08.14 for which front is available and balance shall be completed by 30.09.14. B&R shall mobilize shuttering materials & manpower accordingly to meet above targets. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 964 nos piles completed against front of 1150 nos at site by M/s MBEL.Total nos of piles is 1800 EIL/BPCL nos piles
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
Open
Proj. / Constn.
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.
Clubbed with Risk ID E33
BPCL
Land acquisition for Crude tank (2 nos.) . (LAD - Jul 13; Ant - 30-Aug-13)
Close
Proj.
M/s BPCL Vide mail dated 21.08.2013 has handed over the area for SG-III.
BPCL
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
15
E
16
E
17
BPCL
18
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
E
Open
Const. / Projects
E
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 19 delivery as 24.11.14.
Close
E
HEAVY LIFT Cranes for INTALLATION OF REACTORS Finalisation of Erection scheme and capacity the crane, inclusion in scope and timely mobilisation at 20 site
E
21
Close Open
E
22
E
23
Theft of Delay in material delivery from of UGWarehouse piping material Material required at site for Civil & strl contractor.
Lighting during construction
Open
I Jul'14
Dec'13
Nov'13
Aug'13
As Required
sep'13
- All 3 GTGs received at site. Projects - Contractor for Mechanical works for CPP awarded to M/s Zillion. - N2 compressor (Delivery period is approx 6-8 M) : Ordered on 01.08.14, delivery going upto Dec 2014, However BHEL confirm that they expect supply to be completed within CDD of GTG package.
Sep'14
Const.
-Included in mechanical contractor scope. - Based on prel. Erection scheme, 1600 T heavy lift crane with 600 T trailing crane envisaged for erection of both VGO and DHDT reactors. - Timely mobilization of cranes and preparation of Load Test. - Finalization of erection scheme.
-
Nov'13
EIL Const.
Security arrangements in Warehouse in place byordered BPCL. under FOA 769, 826, 0013, Constn. - Total 3 KM pipe under shortage (IS pipes of 24") 655,652, 593 to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team.
Sep'14 -
Mar'13
Area lighting being done.
As Required
II May'13
Constn.
Project / Constn.
Constn.
III
Job No.: A307 AUG'14 Page 686 of 749
Integrated Refinery Expansion Project, Kochi
E
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 24 are reduced while floating tenders. This needs to be avoided.
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
EIL
Action Plan
Action By
Target Date
Risk Severity
-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
LPG flare - As per EIL study LPG flare is adequate. Report issued to BPCL and clarification received. 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.
BPCL / EIL
15-Nov-13
Oct'13
Constrn.
Sep'14
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
Open
Project
E
25
Open
Project
E
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 (Ant. Compln26 Nov'14, Compl date Committed by B&R – 13.11.14)
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Civil & Strl work-offsite IREP Area: Constr. Sch:97.3%; Front:78.0%; Act: 32.9% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 83.2%; Front: 90.7%; Act:35.0% CCD:18.12.14; ECD: Apr'15
Open
Project
Management review meeting held with M/s Essar on 08.08.14 at site. - Foundation completion for HRSG-3 targeted by 15.09.14. - Completion of Structural works for GTG shed targeted by 10.10.14. - Stack foundation targeted to complete for HRSG-3 by 07.09.14, HRSG-4 by 20.09.14 & HRSG-5 by 05.10.14. - All balance drawings for which data is available shall be targeted for issue by 15.09.14. - Next Management review meeting planned at site on 12.09.14.
EIL/BPCL
Sep'14
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 29 SCH. FRONT. ACT. 64.0% 57.8 % 20.1%
Open
Project
- Management level meeting held at site on 07.08.14. - As on date the manpower is 123 Nos against the requirement of 200 Nos. - Strl work at fabrication yard: Strl steel for TS-2 & TS-3 targeted by 15.09.14 & 30.09.14 respectively. - Breaking of Pile cap to be expedited. - Next Management review meeting planned at site on 17.09.14.
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 Cum. Sch: 25.3% 30 Front: 34.8% Act: 14.2 %
Open
Project
- Management level Meeting held with M/s OIL on 06.08.14 and following action plan EIL/BPCL has been agreed - M/s OIL advised to to augment welders to 50 nos. against 39 nos available. - Piping fabrication rate of 1500 ID / day from current 660 ID/Day targeted to achieve from 01.09.14. Concrete bunker to be constructed at fabrication yard to facilitate radiography work. - OIL to deploy their own auto blasting & priming machine. - Next Management review meeting planned at site on 17.09.14.
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 31 Construction: Sch:7.2 %; Act:7.9% Overall Progress: Sch: 32.8 % Act: 26.0%
Open
Project
-Major backlog is due to engineering (23 %), ordering (40%) & mfg.delivery (5.8 %) due to delayed finalisation of layout. - Piling work commenced (542 out of 1642 nos piles completed as on date) M/s TKII to augment piling rigs immediately. -TKII to augment manpower for Civil works as well.
Continuous
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Management level meeting held with B&R on 08.07.14. B&R agreed to execute work on extended hours to complete balance works in all respect by 13.11.14.
II
E
27
Constructio Management level meeting held with M/s KSSIIPL on 07.08.14. EIL/BPCL n - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - Additional gangs to be deployed to complete cable trenches work. - 100 MT crane assembled and testing under progress. - Additional manpower being expedited by M/s KSSIIPL. - M/s KSS informed that agency for rock blasting has been deployed since 04.08.14. - TMT bars: Out of ordered 500 MT qty only 94 MT qty received, balance expected by 12.09.14. - Next Management review meeting planned at site on 17.09.14.
Sep'14
II
E
28
II
E
II
E
E
Constr.
II III
Job No.: A307 AUG'14 Page 687 of 749
Integrated Refinery Expansion Project, Kochi
E
E
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Project
Action Plan
Action By
Target Date
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: 57.6 % Act: 53.5 % Construction work: Sch-33.6% Front:63.1% 32 Act:13.8% As of end Jul'14 Heater A: Total 66 nos panels; Received: 66 nos; Erected: 56 nos. Heater B: Total 66 nos panels; Received: 25 nos; Fabrication: 5 nos completed
Open
Review meeting held at site on 22.08.14. Constrcution As Required -Heater A: All panels received at site. Out of balance 10 nos panels for erection, 3 nos erection planned by 23.08.14 & balance 7 nos planned by 29.08.14. -Heater B: Out of 66 nos panels, 25 nos received at site. Balance panels being expedited. - 2032 MT / 2300 MT structural steel received, balance 200 MT for stack is being expedited. -Crane (150 MT) assembled and ready for testing.
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 33 M+2 M incl pre commng)
Open
Project
- Total area handed over on 05.05.14.
Progress of ETP Works LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 48.1 % Act: 15.7 % Construction Progress: Sch: 24.8 % Front: 81.1 % Act: 8.4 % Awarded to M/s Paramount on 11.09.13. (Duration: 34 21 M+2 M incl pre commng)
Open
Project
-60 % model review completed on 12.08.14. EIL/BPCL - Physical handing over of balance area for treated water tank, API/TPI, ex TPI sump completed. Signing protocall to be expedited. - In order to recover the construction backlog, paramount has agreed to mobilse resource immediately & submit catchup plan. Letter issued on 05.09.14 to submit catch up plan for mitigating backlogs in construction & manufacturing. - Revised piling drawing for API being submitted by 10.09.14. Piling drawing for ACT & SBR area approved vide across the table review meeting dated 05.09.14. - Work in progress in substation area, equalisation tank, treated water tank, sludge thickner, spent caustic tank, chemical handling areas. - Next Management review meeting planned at site on 12.09.14.
As stated
Project
As stated
Risk Severity III
Jun'14
II Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 48.1 %; Front:84.4% Act: 14.9 %
Open
Project
- Management level meeting held on 06.08.14 at site and on 19.08.14 at EIL Delhi. EIL/BPCL Total tanks: (New tanks 13 nos, work in progress for 12 nos. Balance for 1 nos is YT33 which shall be start after completion of YT-32; Modification tanks: Out of total 16 nos, work in progress for 4 nos, 3 nos handed over to BPCL.) - B&R to augment resources to complete all balance work within agreed target. - All modification work for YT-80 (MS Tank) completed by M/s B&R on 19.08.14. - PO acceptance copy from M/s B&R awaited for 375 MT Plates ( SA 516 Grade 70) & delivery for 200 MT: IS 2062 GR B to be expedited. - Next Management review meeting planned at site on 16.09.14.
As stated
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 23.9 % Front: 91.4 % Act: 19.2 %
Open
Project
- Front for YT-29 is likely to be released by 25.08.2014 - Tank Pad foundations for YT-26 & YT-28 planned for completion during the Sep’14 month. - Area graded and handed over for 2nd Crude tank.
Constr.
As stated
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 37 Overall Progress: Sch: 66.6 % Act: 13.3 % Constrcution yet to start
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. - Structural steel: Out of 190 MT, 68 MT received at Coimbatore fabrication yard. Balance being expedited by M/s Petron. - Blasting and painting at Coimbatore is in completion stage. - Fabrication started for radiant section, erection planned by last week of Sep'14. - All radiant coils have been ordered to M/s MSL - Further as directed during director level meeting with BPCL dated 13.08.14, new tenders for M/s Petron's work not to be floated.
Project
As Required
II III
Close
Project
Clubbed with Risk ID D7
BPCL
As Required
Dec'13
Open
Project
-Nozzle size for 42" finalised, M/s Callidus to expedite balance data based on 42" nozzle size. - Burner details not yet finalised affecting progress of engineering and completion of package.
Projects
As Required
Awarded to M/s B&R on 25-Sep-13 E
35
II
E
E
E
E
38
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 39 CCD: 30.06.15 Overall Progress: Sch: 31 % Act: 14 %
II
Job No.: A307 AUG'14 Page 688 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 Overall Progress: Sch: 87.1 % Act: 52.6% Construction Progress: Sch: 71.5 %; Front: 100%; Act:18.7 % Area handed over, part of area is water logged due to plant drain which is under completion.
Open
Project
-Management level meeting held on 21.07.14 at EIL Delhi. M/s Driplex has been asked to prepare a catchup plan to expedite constr. activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. 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 catchup plan. - Piling work nearly in completion for Substation area (112 nos out of 131 nos piles casted). - DM tanks (2 nos) piling drawing under approval. Piling yet to commenced at site. -90 % model review completed. - M/s Driplex has been asked to mobilse 200 labours against present 128 nos. - DM tanks: Piling drawing received from M/s driplex and is under review. - Next Management review meeting planned at site on 12.09.14.
EIL/BPCL
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 67.2%; Front: 94.0% Act: 25.1 % CCD: 24.12.14 ECD: Oct'15
Open
Project
-Due to continuous poor progress of work and repeated slippages in commitments made by M/s SEPC, Management review meeting held on 04.09.14 at EIL Delhi. -M/s SEPC asked to take immediate action to mobilise 100 manpower and take up work on multi fronts and ensure extended hours / night shift working. M/s SEPC EIL/BPCL agreed to mobilize additional 50 nos manpower by 15.09.14. At present only 140 nos manpowers available. - In addition to 2151 m3 RCC work which has been already withdrawn from SEPC scope, additional 1500 m3 RCC work being offloaded from SEPC scope to be executed through misc. civil agencies. - Tech Structure A targeted to complete by mid Sep'14. - Next Management review meeting planned at site on 16.09.14.
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15
Open
Project
-Prefabrication of radiant coils for IG-H-101, fabrication of stack and fabrication of Constr. convection module to be expedited. - Platform erection are in progress for IG-H-102. Refractory works of Radiant Section in progress for IG-H-102. - Refractory works to be taken up in both the heaters simultaneously.
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: 78.7 % Act: 14.9 % Construction work yet to start
Open
Project
Projects
As Required
III
E
43
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. - Blasting and painting at Coimbatore is in completion stage. - Fabrication for 6 panels out of 30 panels for radiant section completed, balance 20 panels under dispatch and targeted progressively by 20.08.14. VGO Heater : Erection of radiant section started on 20.08.14 by M/s Petron. - All radiant coils have been ordered to M/s Tubocex Spain. - Structural erection work agreed to start by 16.08.14. - Further as directed during director level meeting with BPCL dated 13.08.14, new tenders for M/s Petron's work not to be floated.
Open
Project
-Management level meeting held with M/s MBEL on 07.08.14 at site. M/s MBEL Constrn. agreed: - Current manpower is 410 nos. MBEL agreed to mobilise 2 separate gangs for UG piping. - 2 cranes mobilised and Additional 2 nos cranes to be mobilized in order to carry out structural erection in both VGO & DHDT simultaneously. - Management review meeting planned at site on 17.09.14.
As Required
E
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 44 Sch: 84.0 %; Front :86.1 % Act: 46.1 %
Open
Project
Management level Meeting held with B&R on 06.08.14 and 19.08.14 PEB1: M/s B&R agreed to complete balance work by end Sep'14. Material storage commenced. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. 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 47 Overall Progress: Sch: 96.1 % Act: 65.2 % Construction progress: Cum Sch: 98.5% Front: 100% Cum Act: 51.7%
Open
Project
-Major backlog is due to construction (46%). Last management level meeting held on 23.07.14 at Site. Commitment made by M/s PCT has again slipped. Manpower at site is 439 nos instead of committed 670 nos. Supply of balance U/G and A/G Piping Material by PCTL to be expedited. Shortage of TMT steel to be expedited. PCTL to target to complete all Civil work by Dec'14.
As Required
II III
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 Site to confirm 48 Overall Progress: Sch: 70.1 % Act: 31.0 % Construction progress: Cum Sch: 55.0% Front: 100% Cum Act: 27.7%
Open
Project
-Major backlog is due to engineering & construction. Last management level meeting held on 28.05.14 at Kolkata. Commitment made by M/s PCT has again slipped. - Balance Area for CWTP handed over after completion of grading by M/s PEL. - Manpower to be augmented urgently - Delivery of Boughtout item to be expedited. -Uninterrupted RMC supply to be ensured.
As Required
III
E
40
II
E
E
41
Constr. Progress: 42 Sch: 52.5 % front: 100 %
Act: 34.1 %
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E
E
E
46
Constrn.
Job No.: A307 AUG'14 Page 689 of 749
Integrated Refinery Expansion Project, Kochi
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:76.0%; Front: 71.9%; Act: 12.9%
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Open
Constructio Management level Meeting held with M/s KSSIIPL on 07.08.14 at site. n - M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 82 nos deployed only. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: Misc Strl Work (for 1800 MT): Awarded to M/s Zillion on 26.08.14. • Misc. Civil works-2 (approx 3000 m3 RCC) : (DHDS Pipe rack or other areas of IREP)-Award recommendation issued on 29.08.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - Award recommendation issued on 06.08.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor. - Next Management review meeting planned at site on 17.09.14.
EIL/BPCL
sep'14
Open
Constructio -Management level meeting held on 08.08.14 at site. n - Welders: 3 welders qualified and welding to be start by mid Sep'14. - Further as directed during director level meeting with BPCL dated 13.08.14, new tenders for M/s Petron's work not to be floated.
EIL/BPCL
Sep'14
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 AG piping fabrication: Only 5724 ID / 304970 ID 51 fabrication completed. AG piping erection: Only 552 IM / 412580 IM piping erection completed.
Open
Constructio Management level meeting held on 06.08.14 at site. n - B&R to mobilize 750 MT crane for erection of heavy lift. - B&R to expedite work for completion of fabrication shed. - Next Management review meeting planned at site on 16.09.14.
EIL/BPCL
Sep'14
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.) 52 Sch:59.3%; Front: 84.4%; Act: 13.4% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 07.08.14 at site. EIL/BPCL n -Manpower: As on date only 130 Nos against the requirement of 300 Nos reported to site. MBEL committed to increase manpower upto 220 nos. - In view of slow progress and delay in release of construction front to mechanical contractor, new tender under preparation and likely to be awarded by mid Sep'14. - Next Management review meeting planned at site on 17.09.14.
Sep'14
Start of work by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. 53 Awarded on 25.03.14. CCD: 24.09.15
Open
Constructio KOM held on 17.05.14. Mobilisation work initiated by M/s techsharp. Constr. n Against requirement of 10 nos welders only four number welders are available at site. Resources to be expedited to commence work. Piping fabrication work commenced.
Sep'14
I 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. 54 CCD: 24.09.15 Work yet to start at site.
Open
Constructio - Management level meeting held 06.08.14 at site and on 19.08.14. n -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works commenced. - Management review meeting planned at site on 16.09.14.
Sep'14
III
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for CDU/VDU. Sch: 04.09.14 55 CCD: 06.09.14 ECD: 15.02.15 Sch:99.8% Front: 97.8% Act: 80.3%
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete Constr. n balance civil & strl works by end Oct'14 & TS-5 strl by Nov'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. - Management review meeting planned at site on 17.09.14.
Sep'14
III
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15 56 Overall Progress: Sch: 89.8 % Act: 79.9 % Constr. Progress: Sch: 70.2 % Front: 88.0% Act: 50.5 %
Open
Project
As Required
III
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: 99.7% Front: 98.7 % Act: 69.9 %
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete EIL/BPCL n balance civil & strl works progressively by Dec'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. -MPR : 1st tier for total length handed over, grids 25-30 expected to handed over by Sep'14. TS-IV : total handing over by 15.09.14 TS-III : total handing over by 10.09.14 - Next Management review meeting planned at site on 17.09.14.
Sep'14
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391)
Open
Constructio - Management level Meeting held on 07.07.14 n - OIL started to dismantle YT-150 Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT-383/391/150. -B&R has been informed that 2 tanks YT-383 & 391 have been handed over for taking up construction work and since these are to be made operational before taking outage of next tanks, the completion of these tanks is most critical. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement. - Management review meeting planned at site on 17.09.14.
Sep'14
E
49
E
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 50 CCD: 25.10.15
I
Construction work yet to start at site II
E
II
E
E
E
E
E
E
E
57
58
- Major backlog is due to manufacturing & Delivery (8%) and construction (20%). Erection of APH for VDU Heater is in progress. - Additional resources to be mobilised to recover construction backlogs Convection module erection for CDU Heaters commenced. CDU APH foundations to be handed over by end Sept-14
Constr.
II III
Job No.: A307 AUG'14 Page 690 of 749
Integrated Refinery Expansion Project, Kochi
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 81.0 % Front: 100 % Act: 34.1 %
E
E
E
E
E
E
E
F
F
F
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Open
Constructio - Management level meeting held on 06.08.14 with M/s B&R at site. n M/s B&R agreed to increase manpower from 90 nos to 150 nos. B&R agreed to complete the civil works as per below targets: 1. YT-341 : tank pad completed, annular plate laying commenced 2. YT-342: 20.08.14 Revised date: 15.09.14 3. YT-343: 10.08.14 Revised date: 15.09.14 4. YT-344: 30.07.14 Revised date: 10.09.14 5. YT-111: 15.07.14 tank pad completed 6. YT-112: 20.07.14 Revised date: 08.09.14 7. YT-113: 14.08.14 Revised date: 10.09.14 8. YT-114: 08.08.14 Revised date: 10.09.14 - Procurement of Balance Quantity of Plates (890 MT out of 1650 MT) to be expedited. - Management review meeting planned at site on 16.09.14.
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 60 CCD:18.06.15 Work yet to start
Open
Constructio -These tankages (Amine water and sour water services) are required for n commissioning of CDU/VDU. -Agency has been pressurised to mobilise resources and start work. - Tank pads to be handed over from Sep'14 onwards.
Constr.
Sep'14
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. 61 10 ID / 210605 ID piping fabrication completed.
Open
Constructio - Fabrication shed in progress and expected to be completed by 10.09.14 n Piping erection work to be expedited.
Constr.
Sep'14
II III
Start of Composite works by M/s Offshore for Offsite DHDS area Awarded to M/s OIL on 19.05.14 with CCD: 62 18.11.15.
Open
Constructio - Management level meeting held with M/s OIL on 06.08.14 at site. M/s OIL has been Constr. n asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Fabrication yard hand over targeted by 16.08.14. - Mobilisation for 20 nos auto welding machine to be expedited. - Management review meeting planned at site on 17.09.14.
Sep'14
III
Start of Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 63 1450 ID / 298914 ID piping fabrication completed. Piping erection work yet to commence
Open
Constructio - Management level meeting held with M/s OIL on 06.08.14 at site. M/s OIL has been Constr. n asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - 600 MT crane mobilisation targeted by 15.09.14. - Management review meeting planned at site on 17.09.14.
Sep'14
III
Completion of balance piling work (Covered under Piling-IIII Contract) 64 (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: 65 18.11.15 88 ID / 203790 ID piping fabrication completed
Open
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
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
Timely Commissioning of UB package to meet refinery commissioning schedule. Contr. Sch: 69.1%; Act: 52.4% LAD : 31.03.15 (UB 1) 30.06.15 (UB 2) Constr. Progress: Sch: 63.3%; Act: 16.6%
Open
Constn.
-Strict monitoring required at all stages upto commisioning. -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.
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.
Constn. / Projects / BPCL
As Required
IV
Process / Engg.
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
sep'13
Inspn
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
59
1
2
3
G
1
G
2
G
3
G
4
Scope changes & information flow to executing group
Non-performing vendors
Open
Open
Constn.
-Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. Award recommendation issued on 02.09.14.
Constructio - Fabrication shed in progress and expected to be completed by 10.09.14. Piping n fabrication work started. Piping erection work to be expedited.
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015 for CDU/VDU commissioning.
PROCESS/ a. Change management should be in place immediately ENGG/CON b. Strict discipline to be maintained else end objective would be difficult to meet. S. All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Sep'14
Risk Severity III
BPCL
Sep'14
Constr.
Sep'14
II III
BPCL
1-Jun-15
III
Projects
Continuous
IV
as scheduled
III
Job No.: A307 AUG'14 Page 691 of 749
Integrated Refinery Expansion Project, Kochi
G
G
I
5
7
J
1
K
1
BPCL
- Covered under risk ID C73
Action By
Risk Severity Nov'13
- BPCL-KR vide e-mail dated 06-Dec-12 sent a list of Non plant buildings to be Projects 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.
15-Apr-13
Apr'13
As required
Close
Implementation of environmental clearance conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Open
Projects
- 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.
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.
- Documents approved from PESO
BPCL
Target Date within 2 days of request
Finalisation of Non plant buildings.
BPCL
IV
Apr'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 / - IBR package for DCU targeted after 90 % model review. BPCL - List of all the buildings in IREP along with the plinth area details for taking approvals from F&B as well as Panchayath issued to BPCL on 12.04.14. Approval for tall strl/stacks: Signed documents with 6 sets handed over on 13.05.14. -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
Implementation of Health, Safety and environmental (HSE) system
Open
Const.
- 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.
Delay due to Labour strikes (due to labour issue like wage revision, other benefits) during project execution phase
Close
Const.
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
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
Constraint in movement & transportation of ODC eqpt.
Open
Project
-A separate contract to be given to agency which will take care by approaching KSEB Shipping and telephonic authority. -Fabn / transportation philosophy being finalised.
As Required
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open
2
3
K
4
M
1
M
2
M
Purch / Contrc.
Action Plan
1
2
K
Close
6
I
K
Delay in Approval of Vendor List for various items of the project (specially for Long lead items)
Risk Owner
G
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
3
Cost monitoring & control on regular basis
Close
Project/Eng Closed as no concern as on date. g
Sep'14
IV
Constn.
Continuous
III
BPCL
As Required
Nov'13
BPCL
As stated
II Jun'14
Jun'14
Costing
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
Environ.
15-Oct-13
sep'13
Increase in facilities on account of deletion zero liquid discharge
Open
Environ.
Scope of facilities finalised.
Variation in foreign exchange rates from Rs 50 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.
Open
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
Sep'14
II
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 Overall Progress: Sch: 87.1 % Act: 52.6% Construction Progress: Sch: 71.5 %; Front: 100%; Act:18.7 % Area handed over, part of area is water logged due to plant E 40 drain which is under completion.
Open Project
(Current risk Score - Previous Risk score)
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
N
N
Y
N
Short term
I
0.4
0.00
Clubbed with Risk ID E33
BPCL
Very High
N
N
Y
N
Long term
I
0.2
0.00
- Total area handed over on 05.05.14.
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.00
-Management level meeting held on 21.07.14 at EIL Delhi. M/s Driplex has been asked to prepare a catchup EIL/BPCL plan to expedite constr. activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. 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 catchup plan. - Piling work nearly in completion for Substation area (112 nos out of 131 nos piles casted). - DM tanks (2 nos) piling drawing under approval. Piling yet to commenced at site. -90 % model review completed. - M/s Driplex has been asked to mobilse 200 labours against present 128 nos. - DM tanks: Piling drawing received from M/s driplex and is under review. - Management review meeting planned at site on 12.09.14.
Very High
0.29
Previous Risk Score
N
Very High
Current Risk Score -> {5}* {12}
Impact Score => {6+7+8+9} * 10 * 11
Project
Controllability Condition (D/I )
Open
Urgency (Long Term / Short term)
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 E 33 incl pre commng)
Output Quality ( Y / N)
Close Proj.
Schedule ( Y / N)
Project
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Open
EIL Cost (Y / N)
E 16
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Ant - Dec 2013
Risk Owner
Award for RO-DM LAD:30-Jan-13 C 15 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Aug'14 Page 692+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
0.29
Action Plan
Action By
Target Date
29-Jun-13
Dec'13
As stated
Risk Severity
May'13
Nov'13
Jun'14
As Required
II
Job No.: A307 JUL'14 Page 693 of 749
Integrated Refinery Expansion Project, Kochi
A
A
A
A
1
2
3
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
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
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
- 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
- All P&IDs incorporating DCNs issued.
Process
25/10/13
Oct'13
Holds, missing information, corrections, changes in PDS / P&IDs - DCU
Open
Process
- 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
15-Mar-14 Projects / Engg Process
Mar'14 & Apr'14
31-Mar-14 30-Apr-14
Delay in Process Package for TGTU (M/s CB & INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13 A
5
A
6
A
A
Close
BPCL / Process
-Process package received on 14.04.13
Close
Process
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 Close LAD : 29-Dec-12; Ant : 19-Mar-13
Process
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
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Process
Based on latest information from BOO HGU and SWII (FCC), Revised Design Basis issued.
Projects / Process
-
Mar'13
Process
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
- 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
Process
All process P&IDs issued. Pumps PDS issued for engg,. All Vessels PDS issued for engg.
Process
Delay in "issue for engineering - IFE" PDS / P&IDs for DHDT P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
-
Apr'13
7
8
Close
Close
9
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A
10
A
Delay in "issue for engineering - IFE" PDS / P&IDs for VGO-HDT 11 LAD : 29-Jan-13; Ant : 10-May-13
A
Apr'13
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
Projects / Process
Close
Close
-Preparation of Offsites 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 12 details received now. -Upgradation of Crude oil pipeline system (Inside refinery) to be taken up.
POSD
- All 32 P&ID issued for engineering
Apr'13
31-Dec-12
Jan'13
Apr'13
Apr'13
Job No.: A307 JUL'14 Page 694 of 749
Integrated Refinery Expansion Project, Kochi
In view of increase in sulphur load PDS & P&IDs for Close sulphur block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement.
A
13
A
Revision in PDS after issue of “Issued for 14 Engineering” after release of MR -Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
Close
Close
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Process
Action Plan
Target Date
- All PDS and P&ID revised and issued.
Process/EN Revision in PDS to be avoided once same is issued for engineering GG Process
Action By
Risk Severity Apr'13
Process
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New facilities) has been issued for BPCL / engineering. Balance 1 no. targeted by 15.03.13 Projects / POSD
-
15-Mar-13
Apr'13
Feb'13
A
15
Revision in PDS after issue of “Issued for 16 Engineering” after Order
Close
Process/EN Revision in PDS to be avoided once same is issued for engineering. GG/Procure
Process
-
Apr'13
A
Revision in PDS after issue of “Issued for 17 Engineering” after Equipment manufacturing
Close
Process/EN Revision in PDS to be avoided once same is issued for engineering GG/Procure
Process
-
Apr'13
A
As Required
Apr'13
Updation of estimated utilities on account of revision Close 18 in process parameters (revision of PDS based on engg comments)
Process
A
ISBL Distribution P&IDs for VGO-HDT 19 SCH: 30-Nov-12 ANT: Jun-13
Close
Process
A
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 20 ANT: 31-May-13
Close
Process
A
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
Close
Process
Distribution P&IDs issued for engineering.
A
21 Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 22 Updation of P&ID as per finalised condensate philosophy to be taken up.
Open
Process
- Revised P&ID for Condensate System issued on 15.05.13.
Open
Engg
- Inconsistency related to type of Isolation valve (Ball Vs. gate / globe/check) between Engg. instrumentation and process design basis identified during coordination meetings resolved by TSD.
A
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed 23 engineering activities.
Open
Power Tech.
- System configuration including 8 pumps, filters & centrifuge finalised and PDS for Projects (CPP 30-May-14 pumps issued. Filters & Centrifuge PDS issued for engineering on 22.05.14. group) - Readiness of the fuel forwarding system to be ensured w.r.t. GTG commg schedule (i.e. in Mar 15).
May'14
A
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new 24 GTG).
Close
Engg.
- PDS for desalting pumps issued on 25.10.13. MR issued on 13.11.13.
Engg
Nov'13
A
BPCL confirmation/clarification over datasheets/GAD’s for existing/new raw water intake pump obtained from M/s KBL 25 (LAD for MR for pumps - 07.03.13)
A
26 Identifications of hook-ups on flare lines and finalisation of methodology BPCL availability Signing of ISBL P&IDs and with battery limiti.e. P&IDs for of ShutUtility downpackages / Hot tapping. Units, & other packages.
Close Open
Projects Process / POSD
Projects / Constn. Process / POSD /
A
27
- Identification of hook ups for Flare line, FCC flare, PRU flare and NHT / ISOM completed during completed site visit byfor: EIL Process. Signing of P&IDs - Hook sketches prepared and signed by Piping / POSD / BPCL. Marking at site -CDU/VDU Blocktoonbe24.06.14. to be taken up on 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 signing to be expedited.
28
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Close
A
Process / Updated P&IDs released. POSD
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
Open
Engg.
- Equipment layout issued for engineering on 23.08.13
Piping
21-Aug-13
JUL'13
Issue of Equipment layout for engineering for VGOHDT LAD - 07-Nov-12 Ant- 26-Dec-12
Close
Engg.
Equipment layout issued for engineering
Piping
26-Dec-12
Jan'13
Close
Engg.
Equipment layout issued for engineering
Projects / 21-Dec-12 Piping / BPCL
Jan'13
Open
ENGG
NIT issued on 24.06.13, bids due on 23.07.13
Projects / Process / HMTD
May'13
Utility distribution P&IDs for DCU
A
B
B
1
2
B
3
B
4
Delay in this activity shall hamper the following: Issue Equipment layout for engineering for FCCU i) 3 D of Modelling (targeted by 27.12.2012) ii) Civil/Structural & 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
In case of revision in process parameters of an equipment the utility estimates RED / PED/ furnished by engineering against older Revision of PDS should not be used until same PROCESS is got verified/ updated for current revision. RED to update all such changes within stipulated time frame as per departmental Utility P&IDs: (14to/ incorporate 17 ) issued for engg (except for small bore piping: Pump Process guidelines andP&IDs Process in the revised PDS. Seal & Vent Drain). The same are targeted by Jun'13. Process
31-May-13
Apr'13
31-May-13
Apr'13
Jan'13
BPCL
25-May-13
May'13
30-Apr-14
May'14
30-Dec-13 08-Aug-14
Process / POSD /
Dec'13 IV
Mar'14 & Apr'14
18-Jun-13
Job No.: A307 JUL'14 Page 695 of 749
Integrated Refinery Expansion Project, Kochi
B
5
B
6
B
7
B
8
a) Cost/time overrun due to rework Close b) Non completion of critical project activities within time & delay in Project completion c) Poor performance of Sub-contractors and Vendors
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Procure/EN 1) Involvement of technical/engineering team and client with vendor where nonGG/CONS. 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
Action By
Target Date
Risk Severity
Projects
As Required
Apr'13
Engg (Elec)
15-Jan-13
Jan'13
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
-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
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; Ant: Mid Jun'13
Open
Engg.
- Layout finalised with licensor. Final layout under study. Piping - Model review for SRU completed on 30th May'13 (except TGTU, incinerator section & downstream of sulphur pit).
15-Jun-13
May'13
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant - 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.
Close
Piping
Intermediate MTO released on 31.05.13.
Piping
31-May-13
May'13
HMTD
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
Delay in thermal design for Heat exchangers & Air coolers for licensed and non licensed units LAD (DHDT): 02-Feb-13 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
Close
Apr'13
B
9
Issue Overall UG piping layout drawing for the 10 complex
Close
Engg.
- Layout for OWS, CRWS, CW & FW lines issued for Offsite.
Gen Civil
31-May-13
May'13
B
Completion of 30 % Model review 11 VGO- LAD: 09-Mar-13 FCCU-LAD : 23-Apr-13
Open
Engg.
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 12 ANT: 18-Jun-13
Open
B
C
B
a) Inaccurate assessment of quantum of work
Close
MR issue for MCC (Main combustion Chamber) packages.
Close
13
May'13
Engg/procur Wide variation of BOQ and site executed quantities for item rate tenders to be ement controlled. Past data to be analysed and used for reference purposes.
Engg
Apr'13
As Required
MR issued on 02.05.13.
Open
Engg.
- Management level meetings with package contractors being organised to expedite Projects / the works. Engg. / - Battery limit conditions for CDSP Pkg (awarded to M/s Essar on 22.08.13) submitted Process 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.
Unit and offsite interfaces (Elevation termination levels)
Close
Engg.
- Clubbed with Risk ID A27
TSD
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule 17 requirements. LAD - 28.02.13; Ant - upto Feb 14.
Open
Projects
- 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
10-Mar-13
Feb'13
13-Aug-14
III
14
B
Timely finalisation of Package Interface 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 15 by all the concerned).
B
Project / C&P 18-Jun-13
Project
B
B
Project/C&P - NIT issued for publishing on 12.06.13 with sale period from 17.06.2013 to 05.07.2013
Engg
Apr'13
LAD: 16-Feb-13 Ant: 15-Apr-13 May'14
-
Mar'14 & Apr'14
16
NIT for Heater for DCU LAD -15-Feb-13;
Close
PROCESS/ - NIT issued on 11.03.13, bids due on 16.04.13. Pre bid meeting targeted on ENGG 02.04.13. (Delivery : 18 M for Mechanical Completion including Pre-Commissioning Activities)
Open
Engg/Cont. - Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. - HAZOP review completed for GTG, HRSG & UB package. - 60% model review for HRSG targeted by 12-13th Aug'14. -90% model review for GTG & UB package targeted by mid Aug'14. - GBC ordered to M/s BHEL on 25.07.14. KOM planned with M/s BHEL for Gas booster compressor on 12-13 Aug'14.
Engg
B
CPP: Integration of various packages & BOP Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas 19 Booster compressor.
Distributed Control System (DCS) Detailed engg., supply and erection 20 (ordered on M/s Emerson Process on 04.11.13)
Open
Engg/procur - Preparation of Inst. dwgs./ docs. by the DCS vendor, using Smart Plant ement Instrumentation (SPI) is already covered in DCS vendor’s scope in DCS - Resolution of NDA issues for NHT to be resolved by Aug'14.
Projects
B B
21
B
18
60 % Model review for DCU (LAD:03.07.13 Act:13.09.13)
Close
ENGG
- Model review completed on 13.09.13
Projects / Process Process / HMTD C&P
ENGG
Aug'14
IV
Aug'13
Job No.: A307 JUL'14 Page 696 of 749
Integrated Refinery Expansion Project, Kochi
Action Plan
Action By
Target Date
Risk Severity
Open
Engg/procur - Being taken up with respective package vendors for implementation. ement
Instn / Projects
Continuous
IV
Open
Engg/procur Package vendor inputs being made available by expediting for updation of interface ement engineering documents.
Projects / Engg.
Continuous
IV
B
Delay in Interface Engineering (including control system) due to non availability of Package Vendor 23 Data
Open
ENGG
Model review completed on 04.10.13
ENGG
4-Oct-13
sep'13
B
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. 20 - Vendor drawings for sheds awaited.
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) 24 LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
GC
- All P&IDs released
G. Civil
25-Jul-13
JUL'13
Order of MR for DG set Dely: (12 M FOB + 3 M Site work) 25 Sch: 05.11.13 Ant: 20.08.14
Open
Project
- Award recommendation issued on 07.08.14. BPCL to award.
BPCL
20-Aug-14
III
Close
ENGG
- 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
B
22
B
B
Package Vendor refuses to submit Instrumentation Drawings/ Documentation in Smart Plant Instrumentation Database as per Client Requirement
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Receipt of Inputs from Process / Vendors for 60 % 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
Open
ENGG
- Model review completed on 25.10.13.
ENGG
25-Oct-13
sep'13
B
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) 27 envisaged.
60 % Model review for 28 SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), 164 Delay in release 2nd MTO (SRU),15 (SWS)of & Intermediate 60(TGTU) + 155(Utilities LAD:30.09.13; -CVs Size HoldAct:31.10.13) as follows: 13 (ARU), 6 (SWS), 125 Holds: (SRU). -CDU/VDU: PumpFace nozzle 6 nos. pumps under -All Control Valve to for Face Dimensions are hold), for 256 lines under hold, Control valve HOLD.sizes All CVs for TGTU are HOLD. 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 29 (103 nos.) not considered in MTO.
Open
ENGG
- Model review started on 28.10.13 and under progress. Targeted to complete by 31.10.13.
ENGG
31-Oct-13
sep'13
Open
ENGG
- Intermediate 2nd MTO released on 31.10.13, based on above MR under preparation.
Projects / ENGG
31-Oct-13
Oct'13
Open
ENGG
- Surplus material to be salvaged with effective substitution. ENGG - Letter to be written to BPCL with backup details on reasons of Surplus generation on account of changes by them :- Process & POSD to consolidate changes in P&IDs on account of BPCL and forward to piping for attribution of surplus material to owner. Based on the report, projects to take up the issue with BPCL.
Close Open
ENGG ENGG
- HAZOP study completed on 29.11.13. - Catch up plan has been prepared as per discussion held on 18th Apr’14. 90 % completion of engineering targeted by Aug'14.
ENGG ENGG
Aug'14
Nov'13 IV
Open
ENGG
- HAZOP for all packages targeted to complete by end Aug'14. Revised process package targeted by 26.08.14. Accordingly MTO expected by mid Sep'14.
ENGG
Aug'14 to Sep'14
III
B
B
Generation of Surplus Piping material
B
30
B
31 HAZOP for FCCU LAD - 23-Sep-13 Completion of 90 % engineering by Mar-14. As of 15.07.14 engineering progress is 89.2 %. Average progress achieved in last 3 months 3.0 % 32 LD Milestone date - Dec'13
B
Release of final Piping MTO Sch: Jul'14 Ant: Sep'14 B
33
Progressively
IV
Job No.: A307 JUL'14 Page 697 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
B
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Finalisation of GTG fuel forwarding scheme for naptha to day tank when Naptha tank being under maintenance.
Open
POSD
- Scheme forwarded to BPCL on 17.07.14, BPCL to review.
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
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
30-Dec-13
Dec'13
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 Duration: 18 M
Open
Project
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
30-Aug-13
JUL'13
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
- BPCL confirmation sought for minimum nos (10.97 MW or 80% of 10.97) for qualifying criteria. Accordingly BQC changed and approved by BPCL. Draft NIT by 25.05.13. Publishing targeted by end May 13.
C&P
30-May-13
May'13
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
Close
Project
- As per latest cost status report the impact of cost variation has been neutralised by savings.
Projects
Continuous
Nov'13
Award of Heater for DHDT LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Awarded to M/s Technip on 04.09.13 (Duration 18 M)
Projects / HMTD
15-Sep-13
Aug'13
NIT for Composite Works for DCU LAD -06.06.13 ; Ant - 25.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
25-Oct-13
sep'13
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
31-Oct-13
sep'13
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
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
-Ordered on M/s Shin Nippon & M/s Flowserve on 30.01.14 (except Tag IV-P-301 A/B EIL 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.
15-Mar-14
Mar'14 & Apr'14
NIT for Composite Works for Offsite DHDS area LAD -22.07.13 ; Ant - 15.10.13
Open
ENGG
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
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 -Ordered to M/s Fabtech on 15.07.13 g
Engg/Proj
20-Jul-13
JUL'13
Project/C&P NIT issued on 29.05.13, bids due on 18.06.13.
Project / C&P 31-May-13
May'13
Key Risk Description
Action Plan
Action By
Target Date Aug'14
Risk Severity III
34
C
1
C
2
C
3
C
4
C
5
C
6
C
7
C
8
C
9
C
10
C
11
C
12
C
13
Issue NIT for Tankage-II LAD: 21-Jan-13 14 ANT: 31-May-13
Close
C
Award for RO-DM LAD:30-Jan-13 15 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Open
Project
- Awarded to M/s Driplex on 12.06.13. duration is 22 M.
Engg / C&P
29-Jun-13
May'13
Close
Project
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months.
BPCL
28-Feb-13
Feb'13
Close
Project / Licensor
21-Feb-13
Feb'13
C
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13 C
C
16
NIT for Reactor regenerator package for FCCU LAD : 01-Jan-13 Ant: 21-Feb-13 17 Changes in scope of supply led to revision in BQC / tender.
BQC finalised on 15.01.13. Tender under compilation. Draft NIT being issued to BPCL Projects / for approval. BPCL NIT targeted by 21-Feb-13.
Job No.: A307 JUL'14 Page 698 of 749
Integrated Refinery Expansion Project, Kochi
C
18
C
19
Award for Raw water quarries LAD :03-May-13 ANT: 15-Apr-13
Close
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Project
Ordered to M/s Paulose George (15 M).
BPCL
Ordering of Reactor for VGO-HDT LAD: 29-Dec-12 ACT: 08-Apr-13
Close
Project
Ordered on M/s L&T on 08.04.13.
Proj/Engg
Award of contract for Piling-II LAD: 31-Dec-12
Close
Project
Awarded to M/s L&T on 09.04.13 with duration of 12 M.
BPCL
Close
Project
Awarded to M/s Petron on 09.04.13 with 18 M duration.
BPCL
Close
Engg.
Awarded to M/s Technip on 07.03.13 (Duration 23 M)
Storage of sulphur and related issues with Granulator to be finalised between BPCL / EIL.
Close
Project
- Scheme finalised.
Projects / BPCL
C
23
NIT for ETP package with WAO (Wet air oxidation) 24 LAD: 15-Jan-13 Ant: 16-Apr-13
Close
Project
Tender released on 26.03.13; BQC finalised on 08.04.13. NIT targeted by 16-Apr-13
Engg
C
Project
Award recommendation issued on 11.02.13. Awarded to M/s Howe baker on 07.03.13 Proj/Engg
Project
Awarded to M/s L&T (duration 20 M)
BPCL
KB tech completed development of flare area & handed over the area to M/s L&T.for piling.
Projects
C
20
C
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 21 Ant: 30-Mar-13
C
Award of Crude and Vacuum heaters (LAD 29.12.12) 22 Ant : 07.03.13
Risk Severity
Target Date
Apr'13
-
Mar'13
-
Mar'13
Ant: 15-Apr-13
Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13 C
25
C
Award of contract for Building incl substations LAD: 07-Feb-13 26 Ant: 15-Apr-13
Filling of existing part fire water pond required for area preparation.
Close
Close
Open
Strl
-
Mar'13
Projects / 7-Mar-13 C&P / BPCL
Feb'13
Apr'13
Apr'13
7-Mar-13
Feb'13
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
Close
28
Engg / C&P - Evaluation of LLIs to be ensured with-in 1 month from receipt of bids by Engg. & Engg / C&P / PBO recommendation 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 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: 29 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
Awarded to M/s Tecnicas Reunidas S.A. on 31.12.13
BPCL
30-Dec-13
Dec'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) 30 Anticipated: 23.11.15 (27 M) Bidders quoted 27 M against schedule of 26 M.
Open
Project
Awarded to M/s Essar Project on 22.08.13 (Duration: 27 M)
C&P / Engg / 30-Aug-13 Projects
JUL'13
Job No.: A307 JUL'14 Page 699 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
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. 31 Duration (Supply) - 15 M FOB /16 M FOT as per RFQ; Sch : 20 M
Open
Project
Delay in Ordering of HRSG (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. 32 No PTR available for LSVR Fuel Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
Close
Projects / - Awarded to M/s Thermax on 20.12.13 Projects / Engg 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.
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. 33 Bidders sought extension in dates.
Close
Project / Licensor
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) 34 Duration: 21 M+2 M No bidder could meet the BQC criteria in view of which the tender has been re-floated.
Open
Project
Open
C
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 35 Duration: 20 M
Close
C
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 36 Duration: 22 M+2 M
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
C
C
Key Risk Description
Action Plan - Awarded to M/s BHEL on 25.07.13.
- 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 Esaar on 10.07.13.
Action By
Target Date
Risk Severity
Projects / Engg / C&P / BPCL
20-Jul-13
JUL'13
20-Dec-13
Projects / BPCL
BPCL
Nov'13
Jun'13
31-Oct-13
Oct'13
Projects / 31-Jul-13 C&P / BPCL
JUL'13
C&P/Engg/Pr oj
Aug'13
Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
Process / - 3 no. bids received on extended date of 02.02.13. Engg / - Meeting with bidders held from 19.02.13 to 26.02.13. PBO recomn. issued on constn 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 Project/C&P 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
Anticipated Completion: 29-Jul-15
C
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
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
Failure of contractors
Open
Const.
Limit the number of works being awarded to one Agency so that alternatives can be C&P 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 BPCL / only. Projects
-
sep'13
-
sep'13
37
C
38
Ordering of Ejector Pkg 39 (LAD:12-Jan-13; Ant: 15-Jul-13)
Open
Project
Awarded to M/s GEA on 10.07.13 with delivery period of 13 M.
BPCL
15-Jul-13
Jun'13
C
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). 40 Due to Technical and related commercial issues enquiry re-floated. Duration 20 M
Open
Project
Awarded to M/s Heurtey, (Duration - 20 M)
BPCL
15-Nov-13
Oct'13
Award of Civil & Strl work for DHDS offsite area (LAD: 30-Mar-13; Ant: 20.07.13) 41 Duration: 18 M
Open
Project
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
Awarded to Mcnally Bharat on 26.09.13. Duration- 16 Months
Project/C&P
Open
Project
NIT issued on 01.08.13, bids due on 30.08.13
Gen Civil/Project
C
C
C
42
C
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) 43 Duration : 16 M
sep'13
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15 25-Jul-13
JUL'13
Job No.: A307 JUL'14 Page 700 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
Project
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 45 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
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 46 Ant: 07-Mar-13
Close
Project
Awarded to M/s L&T on 07.03.13. Award recomm sent to BPCL on 01.02.13. Award to C&P be targeted by 07.03.13.
Ordering of wet gas compressor for DCU 47 LAD: 02-Feb-13 Ant: 30-Jun-13
Close
Project
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
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., 49 sulphur pelletiser and sulphur granule); refloated again as financial criteria was not met by all the bidders.
Open
Project
- Ordered to M/s Sandvik.
BPCL
30-Jan-14
Jan'14
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 50 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
Awarded to M/s Sriram on 25.09.13
BPCL
30-Sep-13
Aug'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 51 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
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 52 Duration: 16 M
Open
Project
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 53 Duration: 12 M despatch and 6 M for site work (ODC)
Open
Project
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 54 (Execution Duration - 18+2 M)
Open
Project
Awarded to M/s Triveni
BPCL
19-Jul-13
JUL'13
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION Key Risk Description Award of work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M C
C
C
C
C
C
C
C
C
C
C
Action Plan
Action By
Target Date
Risk Severity
44
7-Mar-13
Feb'13
Jun'13
48
Aug'13
Job No.: A307 JUL'14 Page 701 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 15.06.14 (Incinerator burner) 55 (Execution Duration - 14 M)
Open
Project
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
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
Awarded to M/s Airoil on 25.09.13 with duration of 18 M.
Projects/ 28-Sep-13 Process/ Engg / C&P/
Aug'13
Open
Project
- Awarded on M/s Ray Engineering on 23.01.14.
Engg / C&P
Jan'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
56
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity Jun'14
19-Jul-13
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
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 58 Duration: 12 M
Award for:RGC compressor for VGO-HDT (LAD: 30Mar-13; Ant: end Jun 13) Dely: 18 M
Open
Project/Eng Awarded to M/s BHEL g
Proj/Engg
29-Jun-13
Jun'13
C
59
Award of MUG compressor for VGO-HDT (LAD: 08-Apr-13; Ant: 30.11.13) 60 Dely: 16 M FOB
Close
Project/Eng Ordered to M/s Neumen & Essar on 14.11.13 g
BPCL
30-Nov-13
Nov'13
C
Award of Contract for Tankage-III (Crude tank: 02 Nos & 1 surge relief tank and crude drain tank) 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 tanks-25/26 under 61 tankage-III. Sch: 01.10.13 Ant: 15-Dec-13
Close
Project/Eng Awarded to M/s IOT Anwesha on 04.12.13. (duration: 20 M) g
BPCL
15-Dec-13
Nov'13
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: 62 Jun 13)
Close
Project/Eng Awarded to M/s BHEL g
Proj/Engg
28-Jun-13
Jun'13
C
Close
Project/Eng Awarded to M/s Dresser Rand g
Proj/Engg
C
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep-13) 63 Duration : 18 M FOB
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) 64 Sch: 30.04.13 Ant: 30-Sep-13 Duration:22 M
Close
BPCL
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 65 new crude tanks (Tankage-III; YT-25/26). Alternative scheme required to be finalised for outage.
Open
BPCL / Projects
C
C
C
Aug'13
Awarded to M/s B&R
BPCL
30-Sep-13
Aug'13
Awarded to M/s Offshore on 17.04.14.
EIL / BPCL
25-Apr-14
Mar'14 & Apr'14
Job No.: A307 JUL'14 Page 702 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
Project
.Awarded to M/s Offshore (Duration- 20 months)
BPCL
31-Oct-13
Oct'13
Award for contract for development of flare area LAD: 01-Nov-13 Ant: end Dec'13
Close
Project
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
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, 69 Technicas, Petron, B&R, JNK). Duration 20 M
Close
Project
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)) 70 (LAD:29.12.13; Ant: 30.07.14)
Open
Project
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 71 Ant: 18.08.14
Open
Project
-Award recommendation issued on 08.08.14.
BPCL
18-Aug-14
Open
Project
- All pipes, fittings & flanges ordered, balance for valves. Ordering progressively targeted by end Aug'14.
C&P
14-Aug-14
C
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards 72 Piping intermediate MTO-II released on 30.10.13.
Open
Project
Revised MR (MR-3415) issued covering all critical valves along with all critical valves Engg. of MR-3211 floated. 10 nos bids received on 24.07.14. TBA targeted by 16.08.14.
30-Aug-14
C
Ordering of Critical Valves Sch: 11.07.14 Ant: 30.08.14 73 Dely: 06/07 M FOT /FOB
Open
Project
- Awarded to M/s Zillion on 19.05.14.
25-May-14
C
Award of contract for Mechanical works-CPP area LAD: 28.02.14 74 Ant: 25.05.14
Open
Project
-Total 22190/ 30154 nos (72%) isometrics issued for units . Balance ISO's targeted progressively by progressively upto Sep'14. - Piping items has been ordered for Intermediate MTO-II, delivery expected by Aug'14-Sep'14.
Engg.
Aug'14-Sep'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION Key Risk Description 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 C
C
C
C
C
C
66
Action Plan
Action By
Target Date
Risk Severity
Duration - 20 M
67
68
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 Ant: Sep'14
30-Jul-14
II IV
Engg
C
75
Open
Project
- Award recommendation issued to BPCL on 03.07.14. Sole bidder has not ready to give any discounts during negotiation, Being refloated. Draft NIT targeted by 18.08.14.
EIL/BPCL
18-Aug-14
C
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM Sch: 08.05.14 76 Ant: 10.10.14
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) 77 Sch:27.06.14 Ant: 05.08.14
Open
Project
- Ordered to M/s Sulzer.
BPCL
5-Aug-14
II May'14
III
II
C
Job No.: A307 JUL'14 Page 703 of 749
Integrated Refinery Expansion Project, Kochi
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 57.62 % Act: 41.41 % Construction Progress: Sch: 12.4 % Front: 65.5% Act: 10.6 % D
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
1
Action Plan
Action By
Management level meeting held on 08.08.14 at site. -M/s EPIL has been asked to start site work by 26.08.14. Projects - M/s EPIL has been pressurised to complete construction of hard stand by 15.10.14. Submission of erection scheme targeted by 18.08.14. Constn - Deliveries of balance materials being expedited. (Nozzle for regenerator by end Aug'14, Reactor torricone by end Aug'14 and TSS torricone by mid Sep'14). - Work for assembly of hoppers and TSS to be commenced form 21.08.14 & 15.09.14 respectively. - M/s EPIL asked to commence area development around FGC equipments & hard stand immediately and to be ready by 15.10.14. - M/s EPIL agreed to mobilise 1600 MT crane by 1st week of Oct'14 and will ready for erection by 05.11.14. - Readiness for TSS erection targeted by 2nd week of Sep'14 to Feb'15. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up.
Target Date
Risk Severity
Progressively upto Aug'14
BPCL
D
D
D
D
D
D
D
2
3
4
5
6
7
8
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
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: 69.1 % Act: 52.4 % Construction Progress: Sch: 53.5 % Front: 63.66 % Act: 14.12 %
Open
Project
Management review held on 01.08.14 to pressurised M/s ISGEC for completing within Project CCD. - M/s ISGEC to expedite modelling work to carry out 90% modelling by end Aug'14. -Erection of UB-1 targeted by mid Aug'14. - M/s ISGEC to expedite shed drawings for equipments.
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14 Ant : 09.08.14 Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT.
Open
Project
Delivery of wet gas compressor for DCU at Site (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 27.01.15) Sch: 45.0%; Act: 42.2%
Open
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 24.12.14)
24-Nov-14
I Nov'13
Aug'14
III
-All Indigenous component received at site within CDD. - Foreign Source Components: Delivery of ejector and LRVP pkg targeted to be dispatch from Aug'14 onwards. - HAZOP & 3D model review held on 10th-11th Jul'14
Project/Inspe Aug'14 ction
IV
Project
Sub-orders of Casing, Nozzle, end plate, end wall, shaft of rotor completed. Bearing expected to receive from Aug'14 to Sep'14 progressively. Casing for compressor and turbine received at shop.
Project/Inspe 27-Jan-15 ction
IV
Open
Project
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Order placed for Motor, turbines, Casings, forgings, impellers, gear box. Close monitoring to be done to ensure delivery on CDD.
Project/Inspe 24-Dec-14 ction
IV
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: 68.8 % Act: 46.6 %
Open
Project
-All 3685 MT Plates received at Chakan Shop, plate cutting & welding in progress. Project - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority assigned to complete main fractionator (IF-V-104) by Oct'14. - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach roach upto fabrication yard, which affected shifting of sections. - Approach road work completed. - Crane under mobilisation.
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) Overall progress: Sch: 71.0 % Act: 63.2 %
Open
Project
- M/s Thermax seeking extension for duration due to delayed availability of burner data from M/s Accometric. Letter issued to BPCL for recommending extension for supply portion to M/s Thermax upto 30.11.14. -MCC: Shell Rolling is completed. - Foundation readiness targeted by Sep'14
BPCL
As stated
15-May-15
II III
Job No.: A307 JUL'14 Page 704 of 749
Integrated Refinery Expansion Project, Kochi
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 49.0 %; Act: 37.0 % Construction Progress: Sch: 27.0 % Front: 92.2 % Act: 18.1 %
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Action Plan
Action By
-Management review meeting held on 08.08.14 at site. Following commitments have been made by M/s Essar. -Fabrication for Derrick structure agreed to complete by Dec'14. - 500 MT qty out of total 1800 MT qty planned to offload from M/s MK Engg by 12.08.14. - Balance fabrication for Switch Deck 250 MT) targeted by 30.09.14. - Structural drawing for balance 1600 MT out of 3500 MT targeted to complete by EIL/BPCL 31.08.14. - M/s Esaar has been asked the readiness of Fractionator Column and Coke Drum for erection by 28.02.15. -Supply of balance Plates (33/38 plates received) targeted by 10.09.14. - Ordering of 2000 MT crane targeted by mid Aug'14 and Crane availability agreed from Feb'15 to May'15. - Completion of Coke drum structure upto 113 level by 10.09.14. - Resource augmentation for Civil & Strl works being expedited. At present 236 nos have been deployed, balance 14 nos by 14.08.14.
Target Date
Risk Severity
Aug'14
D
9
Open
Project/Eng - Drive turbine for LOP (Lube oil Pump) sub ordered to M/s KEPL on 22.03.14 & g targeted to receive at shop by Dec'14. Impeller manufacturing is in process. Turbine casings reached at BHEL workshop. - MRT targeted by 20.08.14.
Project/Inspe ction
27-Dec-14
I IV
D
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M 10 Ordered to M/s BHEL on 28.06.13
Delivery of RGC compressor for DHDT(LAD : 05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
Open
Project/Eng - Drive turbine for LOP (Lube oil Pump) subordered to M/s KEPL on 22.03.14 & g targeted to receive at shop by Dec'14. Turbine rotors and casings reached at BHEL workshop. Compressor MRT-1 conducted successfully. MRT-2 targeted by 30.08.14.
Project/Inspe ction
27-Dec-14
IV
D
D
11
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Oct 14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV progress Sch ( 98.5 %); Act (85.6%)
Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site
Open
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Oct'14 Projects / - Due to weld crack in all 4 nos bottom shell likely to be delayed by 2 month w.r.t CDD. / Projects Const. Revised target for erection and hydrotesting of column finalised. Root cause and rectification completed. Detailed report issued to BPCL on 28.07.14. - Crude Column: Bottom section erected on 07.08.14. Erection other sections planned from 16.08.14 to 31.08.14. - Erection of Vacuum Column targeted from 30.08.14 to 30.09.14.
Open
T&CC
Open
Projects
(VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Feb'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB) D
D
13
Close Monitoring of ODC equipment (including site fabricated/assembled) up to receipt at site - Preflash drum, Crude Column reflux drum, Flare 14 KOD for CDU / VDU - HP Air Receiver received for U/O
Shipping
Procure/Co - Transporter philosophy frozen and hindrance enroute has been covered under Risk Shipping nstr ID K3.
Open
Contract / Inspection
Sep'14
II IV
Aug'14-Sep'14
IV
As Required
Nov'13
15
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions.
D
Out of total 57 nos. of ODCs; 14 nos received at site. & 5 nos under dispatch. Balance under close monitoring and are expected at site from Jul'14 to Aug'15.
Close Delay in delivery at site due to non-availability of transporter / hindrances enroute. D
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. - Agency confirmed availability of Barge/Trailer at the time of delivery of Reactors. Barge will be ready with reqrd modification by Sep'14. - KOM held on 02.06.14 & follow up meeting held on 16.07.14. Barge readiness targeted as follows: 2 nos Ammonia Barges modifications by 30.09.14 drawings for new barge submitted to IRS for approval. 1 nos new barge fabrication by 24.12.14 - M/s Urmila informed construction of jetty targeted by 30.09.14 (approval by 30.08.14). - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at Kochi-Port.
16
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.
BPCL
Jun'14
Job No.: A307 JUL'14 Page 705 of 749
Integrated Refinery Expansion Project, Kochi
D
D
D
D
D
D
D
D
D
D
D
Action Plan
Action By
Target Date
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Mar-15 Ant: 24-Mar-15 17 Overall Progress Sch: 42.8 % Act: 34.9 % Construction work likely to start from Oct'14.
Open
Project
- Hazop review covered in offsite Hazop. - Foundation drawing released. - Filling of area & piling work completed, excavation commenced. Delivery of foundation bolts from Airoil being expedited. - Foundation to be handed over by Aug'14. - Construction work to be started from Oct'14. Fabrication of flare structure is in progress and being delivered from Aug'14 onwards.
Projects/Cons As Required tr.
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. 18 Completion of Flare work: Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Open
Project / Process
- 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
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15 D
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
As Required
Risk Severity III
Oct'13
Open
Projects
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. However close monitoring being done. Meeting held on 06.08.14. Casing delivery expected within CDD i.e
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 20 CDD: 03.04.15 Ant: 03.04.15
Open
Projects
- All major items has been subordered. Air Blower: Main casing received at workshop. Steam Turbine: Casing received at shop
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 21 EDD: 16.02.15 Overall Progress: Sch: 79.0 % Act: 75.0 %
Open
Projects
-Ordered to M/s L&T on 08.04.13; Dly 21M FOT. Close monitoring to be done to Project/Inspe Continuous ensure delivery on CDD. ction - Strike has been called off with effect from 12.05.14 at L&T Hazira workshop. Vendor being followed up continuously to deliver reactor within CDD.
III
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 22 CDD: 07.10.14 Overall Progress: Sch: 77.1 % Act: 73.8 %
Open
Projects
- Follow up visit held, though no delay anticipated as per CDD, however close monitoring to be maintained.
Project/Inspe Continuous ction
III
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 23 Awarded to M/s Thermax on 20.12.13 Overall Progress: Sch: 34.7 % Act: 24.0%
Open
Projects
- Management review meeting held with M/s Thermax on 31.07.14. - Balance engineering to be expedited by m/s Thermax by end Aug'14. - Tharmax has been asked to submit the foundations details of auxiliaries by 20.08.14. - 30 % model review completed & 60 % model review targeted by 11-14Aug'14
Project/Inspe Continuous ction
III
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) 24 LAD ;30.03.15 CDD: 30.04.15
Open
Projects
- Generator subordered - Pedestal fabrication is at final-machining. - Fabrication of exhaust diffuser and inner exhaust case targeted by mid Aug'14.
Project/Inspe Continuous ction
III
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 25 CDD: 30.03.15
Open
Projects
-Silos with structure & Conveyors sub ordered by M/s Sandvik. - Delivery of Semi rolled sections of Silos shall commence from Nov'14 onwards. Structure to be made ready for installation work to proceed. - Space for SILO's to be expedited as material expected to receive at site by end Aug'14. - Foundations for pelletiser shed to be made ready by end Nov'14.
Project/Inspe Continuous ction
III
Delivery of steel plates by M/s Essar to other vendors. CDD: Progressively by 15.01.14.
Open
Projects
Strl. Steel for R&RMajor portion of steel plates have been delivered by M/s Essar.
Project/Inspe Continuous ction
Jun'14
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 27 CDD: 10.03.15
Open
Projects
- Synchronous Motor ordered to M/s Toshiba Mitsubishi. Expected to receive at M/s Dresser shop by 03.02.15. - HAZOP review completed on 20.06.14.
Continuous
IV
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) 28 LAD : 26.02.15 CDD: 13.04.15
Open
Projects
- Main motor ordered. KOM for Motor held on 06-07.05.14 & expected to receive by 13.04.15 (FOB: Germany). - HAZOP completed on 19.06.14.
Progressively
IV
19
26
Project/Inspe Continuous ction
II IV
Job No.: A307 JUL'14 Page 706 of 749
Integrated Refinery Expansion Project, Kochi
Delay by vendor with respect to CDD due to financial constraint.
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Projects
- Following bidders showing slow manufacturing progress: - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.: 133, 144 & 184. Expediting meeting held at shop on 04.07.14, vendor agreed to dispatch balance orders of FOA 133 progressively upto 30.08.14 for FOA 144 upto 02.08.14. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 116, 189: As a parallel action separate MR-6122 released. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311 & 444. Continuous expediting being made by visiting vendor workshop for all critical orders in respective regions.
Aug'14
III
Aug'14
III
Action Plan
Action By
D
29
Open
Projects
- M/s Filtrex asking for deviations on commercial terms. Meeting held on 08.07.14 to resolve the issues with M/s Filtrex. Proposed letter has been not accepted. Vendor has been asked to submit revised request.
D
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 30 FOB)
Non acceptance of work order by M/s Flowserve for DHDT Centrifugal pumps Ordered on 30.01.14 to M/s Flowserve (MR-5403) 31 (FOA No 550 & 551) CDD: 01.03.15
Open
Projects
- Order has been accepted by M/s Flowserve and amendment issued by BPCL on 11.07.14.
Delay in delivery of Stripper column (IF-V-206) and Debutaniser Column (IF-V-302) by M/s Uttam Value Steel (Ordered on 19.08.13) 32 CDD: 18.10.14 EDD: 31.03.15
Open
Projects
- Order got delayed due to delay in manufacturing works. At present only 4 shell course rolled out of 17 nos due to which there be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 33 EDD: Sep'14 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
Open
Projects
- As of now around 35-40% piping material has been received at site. Around 85-90 EIL/ BPCL % material has been ordered. Ordering of balance 5-10% material is in progress and expected by Aug'14. Delivery of ordered material against intermediate -II expected by Aug-Sep'14. -Vendors to be expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
Delivery Gas Booster Compressor for CPP (Dly: 13 34 M FOB
Open
Project
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
Open
Constn.
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.
D
D
EIL/ BPCL
Target Date
Risk Severity
Jul'14
Aug'14
II
D
D
E
1
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsites) - 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
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage E
E
E
E
E
Open
3
4
5
6
Aug'14
Constn.
Constn.
- Balance 16 nos units in the township handed over for grading by M/s Ray (SG-III) on BPCL 21.07.14 - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material.
2
Sep'14
Mid Oct'13
Open
Constn.
-Rock breaking in VGO area 200 cum. balance targeted by 08.08.14
Engg./Constn. 8-Aug-14
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 59.8% Catch Up Sch: 21.7 % Act: 20.9 %
Open
Constn. / Projects
- All long delivery equipments (incl. Compressors) to be awarded progressively by end EIL/BPCL Aug'14. Columns ordered to M/s Fabtech on 03.07.14 (CDD: 02.07.15) Award recommendation issued for - Refrigeration package on 29.05.14: - Composite Works (Civil Strl. & Mechanical) on 03.07.14: Being refloated.
Aug'14
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.
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
15-Jul-13
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch:79.4 % Front: 100 % Act:46.2% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Management level meeting held on 18.07.14, Constn - MCR area, CPP control room area : It has been decided to complete balance strl work by Dec'14 & finishing by Mar'15. - Other building works : Finishing work to be completed by Dec'14. - L&T also agreed to augment required manpower to meet the target completion date.
sep'13
Aug'14
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
BPCL / Projects
II III
I III
I JUL'13
As Required
II
Job No.: A307 JUL'14 Page 707 of 749
Integrated Refinery Expansion Project, Kochi
E
E
7
8
Backlog 26.1 (% wrt target sch) as of 15-Jul-14 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 - 28M; Remaining Duration - 18 M Desc. Catch Up sch: Const Sch Front Act Overall 23.9 49.4 48.6 23.3 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Action Plan Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, contract for 2 additional Structural works & 1 civil work under evaluation and likely to awarded by mid Aug'14. Additional 1 tender for offsite refinery area is under preparation. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the sub vendors against Performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and boost progress. - Contractors are facing problem in retaining the labour at site.Approx 7000 labours are available at site, though induction programme has been carried out for 15000 labours . requirement of manpower at site is approx 15000 nos.
Action By
Target Date
EIL/BPCL
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
BPCL
Mar'15
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.
L&T has completed all piles in Demountable flare area, Air compressor & DG shed area.
Constr.
Immediate
Payment to contractors
Close
Constn.
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
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
9
E
10
E
11
E
Dismantling of LO CAT SRU and area handing over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. 12 Will affect release of front for tankages.
Unrealistic project time leading to under quality
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
Close
Project / Engg. / planning
Open
BPCL
All 5 nos tank area cleared and released. Area handed over to M/s B&R for Tankage- BPCL II works on 30.04.2014
Open
Project
- Project review meeting held on 26.06.14 with M/s Triveni. -Balance engineering and complete ordering progressively by Aug'14. -M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barvendors and take up chemical house construction work. (Manpower required is 300 nos & Available manpower is 136 Nos). - Substation building: Foundation works commenced , completion to be targeted by Dec'14. - Chemical house work yet to start.
Overall Progress: Contr. Sch: 68.2 % Act: 41.2% Construction Progress: Sch: 63.8 % Front: 100 % Act: 39.5 % 13 Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Risk Severity
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 Mar'15)
E
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Constr.
I IV
sep'13
As Required
sep'13
end Apr'14
May'14
Aug'14
II Area availability for SRU Block - At present only 91 % area given to M/s MBEL, balance Site for SRU block shall be available by end Aug'14. (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). E
Open
Proj. / Constn.
- Meeting held with M/s B&R management on 06.08.14 at site and resources have been augmented. M/s B&R has been asked to expedite completion of balance area by end Aug'14 by augmenting additional dumpers. - Retaining wall in progress. B&R agreed to complete wall by 31.08.14 for which front is available and balance shall be completed by 30.09.14. B&R shall mobilize shuttering materials & manpower accordingly to meet above targets. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 952 nos piles EIL/BPCL completed against front of 1150 nos at site by M/s MBEL. Release of balance piling front at site progressively by mid Aug'14.Total nos of piles is 1800 nos piles
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
Open
Proj. / Constn.
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.
Clubbed with Risk ID E33
BPCL
Land acquisition for Crude tank (2 nos.) . (LAD - Jul 13; Ant - 30-Aug-13)
Close
Proj.
M/s BPCL Vide mail dated 21.08.2013 has handed over the area for SG-III.
BPCL
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
Aug'14
14 Front for balance piling 918 nos will released progressively upto end Jul'14 on completion of site grading by M/s B&R.
I E
15
E
16
E
17
E
18
BPCL
Dec'13
Nov'13
Aug'13
As Required
sep'13
Job No.: A307 JUL'14 Page 708 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
Const. / Projects
E
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 19 delivery as 24.11.14.
Close
Const.
E
HEAVY LIFT Cranes for INTALLATION OF REACTORS Finalisation of Erection scheme and capacity the crane, inclusion in scope and timely mobilisation at 20 site
-Included in mechanical contractor scope. - Based on prel. Erection scheme, 1600 T heavy lift crane with 600 T trailing crane envisaged for erection of both VGO and DHDT reactors. - Timely mobilization of cranes and preparation of Load Test. - Finalization of erection scheme.
E
21
Close Open
EIL Const.
E
22
- Security arrangements in Warehouse in place Total 2 KM pipe under shortage (IS 3589 pipesby of BPCL. 32", 36", 44" & 48") ordered under Constn. FOA 592, 593, 652, 655 to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team.
E
23
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
E
Key Risk Description
Theft Delayof in material delivery from of UGWarehouse piping material Material required at site for Civil & strl contractor.
Lighting during construction
Open
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 24 are reduced while floating tenders. This needs to be avoided.
Constn. EIL
Action Plan
Action By
- All 3 GTGs received at site. Projects - Contractor for Mechanical works for CPP awarded to M/s Zillion. - Subordering: MCC ordered. - N2 compressor (Delivery period is approx 6-8 M) : Ordered on 01.08.14, delivery going upto Dec 2014, However BHEL confirm that they expect supply to be completed within CDD of GTG package.
Project / Constn.
Target Date
Risk Severity
Aug'14
III
-
Nov'13
Aug'14
Mar'13
Area lighting being done.
Constn.
As Required
II May'13
-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
LPG flare - As per EIL study LPG flare is adequate. Report issued to BPCL and clarification received. 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.
BPCL / EIL
15-Nov-13
Oct'13
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
Open
Project
E
25
Open
Project
E
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 (Ant. Compln26 May'14, Compl date Committed by B&R – 13.11.13)
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 Civil & Strl work-offsite IREP Area: Constr. Sch:94.3%; Front:75.8%; Act: 31.1% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 76.6%; Front: 87.1%; Act:31.1% CCD:18.12.14; ECD: Apr'15
Open
Project
Management review meeting held with M/s Essar on 08.08.14 at site. - Foundation completion for HRSG-3 targeted by 22.08.14. - Completion of Structural works for GTG shed targeted by 10.10.14. - Stack foundation targeted to complete for HRSG-3 by 07.09.14, HRSG-4 by 20.09.14 & HRSG-5 by 05.10.14.
EIL/BPCL
Aug'14
31-Aug-14 Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Management level meeting held with B&R on 08.07.14. B&R agreed to execute work on extended hours to complete balance works in all respect by 31.08.14.
II
E
27
Constructio Management level meeting held with M/s KSSPPL on 07.08.14. EIL/BPCL n - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - Additional gangs to be deployed to complete cable trenches work. - KSS agreed to assemble the 100 MT crane from from 16.08.14. - Additional manpower being expedited by M/s KSS. - M/s KSS informed that agency for rock blasting has been deployed since 04.08.14. - TMT bars: Out of ordered 500 MT qty only 94 MT qty received, balance expected by 31.08.14.
Aug'14
II
E
28
Open
Project
- Management level meeting held at site on 07.08.14. - As on date the manpower is 123 nos against the requirement of 200 nos. 100 nos civil labour expected to join site by 12.08.14. - Strl work at fabrication yard: Strl steel for TS-2 & TS-3 targeted by 15.09.14 & 30.09.14 respectively. - Breaking of Pile cap to be expedited.
EIL/BPCL
Continuous
E
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. 17.7% 29 56.2% 52.9 %
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 ECD: 03.07.15 30 Cum. Sch: 20.7% Front: 26.1% Act: 11.4 %
Open
Project
- Management level Meeting held with M/s OIL on 06.08.14 and following action plan EIL/BPCL has been agreed - M/s OIL advised to to augment welders to 50 nos. against 39 nos available. - Piping fabrication rate of 1500 ID / day from current 660 ID/Day targeted to achieve from 01.09.14. - Additional radiography source to be deployed immediately to clear the backlog approx 700 joints by carrying out 50-60 joints per day by mid Aug'14. Concrete bunker to be constructed at fabrication yard to facilitate radiography work.
Continuous
II
E
II III
Job No.: A307 JUL'14 Page 709 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
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 31 Construction: Sch:12.1 %; Act:8.5% Overall Progress: Sch: 25.9 % Act: 18.0%
Open
Project
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: 54.2 % Act: 51.1 % Construction work: Sch-26.6% Front:56.7% 32 Act:10.5% As of end Jul'14 Heater A: Total 66 nos pannels; Received: 62 nos; Erected: 45 nos. Heater B: Total 66 nos pannels; Received: 18 nos; Fabrication: 20 nos in progress.
Open
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 33 M+2 M incl pre commng)
Open
Progress of ETP Works (Handing over of graded area for ETP & dismantling of existing Oil Catcher) LAD: 30.09.15 CCD:10.08.15 ECD: Dec'15 Overall progress: Sch: 47.6 % Act: 14.5 % Construction Progress: 34 Sch: 19.1 % Front: 61.5 % Act: 7.2 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
E
E
E
E
Key Risk Description
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 40.3 %; Front:84.3% Act: 12.4 % E
E
Action Plan
Action By
Target Date
-Major backlog is due to engineering (29 %), ordering (49.2%) & mfg.delivery (13.3 %) due to delayed finalisation of layout. - Piling work commenced (510 out of 1642 nos piles completed as on date) M/s TKII to augment piling rigs immediately. -TKII to augment manpower for Civil works as well.
Continuous
III
- 1312 MT steel received & Radiant Section fabrication in progress at Coimbatore Project fabrication yard. Welding completed for Panel frame of radiant end Panel for Heater 101B. Mobilization of work force & crane for erection work commenced. Procurement of steel to be augmented - Handing over of Heater-B foundation handed over. -Crane (150 MT) expected to reach at site from 1st week of Aug'14.
As Required
III
Project
- Total area handed over on 05.05.14.
As stated
Project
Management level meeting held on 21.07.14. EIL/BPCL - M/s Paramount to complete major engineering by mid Aug'14. -60 % model review being in progress from 11th Aug'14. Work commenced in substation (5 out of 42 fdns cast) and equalisation tank. - Handing over of balance area for treated water tank, API/TPI, ex TPI sump targeted by end Aug'14. Area handing over geeting delayed due to rain & U/G structure present in areas. - In order to recover the construction backlog, paramount has agreed to mobilse resource immediately & submit catsup plan. - To be followed up with M/s Paramount.
As stated
As stated
Project
Project
Open
Project
- Management level meeting held on 06.08.14. Total tanks: 27 nos (New tanks 19 nos, work in progress for 11 nos;. Modification tanks: 18 nos work in progress for 8 nos.) - B&R to augment resources to complete all balance work within agreed target. Additional manpower to be increased by 30.08.14. - B&R to complete the modification work for YT-80 (MS Tank) by 10.08.14. - Anchor bolts: 112 nos out of 206 nos expected to be available by 25.08.14.
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 14.7 % Front: 67.8 % Act: 15 %
Open
Project
- Tank pad area handed over for 3 nos out of 4 nos tank. Excavation for tank pad YT-25/26/28 completed. - Area grading in progress for 2nd Crude tank and area to be handed over by mid Aug14.
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 47.1 % Act: 12.1 %
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. - Structural steel: Out of 190 MT, 68 MT received at Coimbatore fabrication yard. Balance being expedited by M/s Petron. - Blasting and painting at Coimbatore is in completion stage. - Fabrication started for radiant section, erection planned by last week of Sep'14. EIL - All radiant coils have been ordered to M/s MSL - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited. BPCL
As Required
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
Close
Project
Clubbed with Risk ID D7
BPCL
As Required
Open
Project
-PO amendment: Letter issued to BPCL on 31.07.14. BPCL confirmation awaited.
BPCL
As Required
35
Risk Severity
Awarded to M/s B&R on 25-Sep-13
Constr.
Jun'14
II III
As stated
II
E
E
E
37
38
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 39 Overall Progress: Sch: 20 % Act: 12 %
II Dec'13
II
Job No.: A307 JUL'14 Page 710 of 749
Integrated Refinery Expansion Project, Kochi
E
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: Dec'15 Overall Progress: Sch: 77.0 % Act: 49.5% Construction Progress: Sch: 63.2 %; Front: 100%; Act:17.7 % 40 Area handed over, part of area is water logged due to plant drain which is under completion.
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Open
Project
-Management level meeting held on 21.07.14 at EIL Delhi. M/s Driplex has been EIL/BPCL asked to prepare a catchup plan to expedite constr. activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. M/s Driplex to mobilise additional resources for completion as per catchup plan. -90 % model review expected in Sep'14. - M/s Driplex has been asked to mobilse 200 labours against present 107 nos. - DM tanks: Soil strengthen to be carried out by additional work of Stone Column. Further tanks work held up.
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC Contr. Sch: 59.9%; Front: 92.7% Act: 21.7 % CCD: 24.12.14 ECD: Oct'15
Open
Project
-Management review meeting held on 06.08.14 at site. M/s SEPC has been informed that their performance to be evaluated for next one month, additional agency to be lined to supplement progress (if required). -Resource Deployment of skilled workmen to be increased (Carpenters, bar benders EIL/BPCL to be increased). -Manpower shall be increased to 400 nos. from present 135 nos. 50 nos being planned to mobilise from 30.08.14. - Tech Structure A targeted to complete by 13.08.14. -Part Civil Work in FCCU offloaded to M/s Tauman. M/s Tuaman started mobilising. Additional 2 nos Strl. work contract being lined up to offload above contracts (if required). Award recommendation issued on 25.07.14. For other structural contract 5 nos bids received on 08.07.14.
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15
Open
Project
Ordering of damper completed Reactor Charge Heater - Radiant Panels erection completed Fractionator Reboiler Heater - Radiant Panel erection completed Fabrication of convections section, ducts and stack in progress
As Required
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 74.7 % Act: 13.9 %
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all Projects bought out items. - Structural steel: Out of 935 MT, 677 MT ordered, 437 MT received. 67 MT expected to receive by 17.08.14. - Blasting and painting at Coimbatore is in completion stage. EIL/BPCL - Fabrication for 6 panels out of 30 panels for radiant section completed, balance 20 panels under dispatch and targeted progressively by 20.08.14. - All radiant coils have been ordered to M/s Tubocex Spain. - Structural erection work agreed to start by 16.08.14. - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited. BPCL
As Required
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 44 ECD: 31.03.15 Sch: 78.3 %; Front :86.1 % Act: 42.6 %
Open
Project
-Management level meeting held with M/s MBEL on 07.08.14 at site. M/s MBEL agreed: - Current manpower is 410 nos. MBEL agreed to mobilise 2 separate gangs for UG piping by 25.08.14. - 2 cranes mobilised and balance 2 cranes targeted to mobilised by 25.08.14.
Projects
As Required
Open
Project
Management level Meeting held with B&R on 06.08.14 at site. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. Buildings to be expedited for storage of material / equipment being received at site.
Projects
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 45 Overall Progress: Sch: 92.0 % Act: 62.0 % Construction progress: Cum Sch: 93.9% Front: 100% Cum Act: 47.3%
Open
Project
-Major backlog is due to construction (45.2%). Last management level meeting held on 23.07.14 at Site. Commitment made by M/s PCT has again slipped. Manpower at site is 439 nos instead of committed 670 nos. Against a requirement of 2045 MT reinforcement steel only 1372 MT is received. PCTL to target to complete all Civil work by Dec'14.
As Required
II III
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 Site to confirm 46 Overall Progress: Sch: 59 % Act: 27.0 % Construction progress: Cum Sch: 50.0% Front: 100% Cum Act: 24.6%
Open
Project
-Major backlog is due to engineering (33.4%) & construction (30%). Last management level meeting held on 28.05.14 at Kolkata. Commitment made by M/s PCT has again slipped. - Balance Area for CWTP handed over after completion of grading by M/s PEL. - Manpower to be augmented urgently -Dedicated transit mixers to be arranged to ensure prompt supply of RMC. -Uninterrupted RMC supply to be ensured.
As Required
III
II
E
E
E
41
Constr. Progress: 42 Sch: 44.6 % front: 100 %
Projects
I III
Act: 24.7 %
43
I
E
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E
E
E
44
Job No.: A307 JUL'14 Page 711 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area 47 Sch:68.5%; Front: 71.9%; Act: 11.2%
Open
Constructio Management level Meeting held with M/s KSSIIPL on 07.08.14 at site. EIL/BPCL n - M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 82 nos deployed only. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-05 nos bids received on 08.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - Award recommendation issued on 06.08.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15
Open
Constructio -Management level meeting held on 08.08.14 at site. EIL/BPCL n - Piping fabrication shed: Foundations work completed, fabrication shed targeted to complete by 31.08.14. - In view of delay in start of works (5 Month elapsed) by M/s Petron, separate tender for refloating is under progress.
Open
Constructio Management level meeting held on 06.08.14 at site. n - B&R to mobilize 750 MT crane for erection of heavy lift from Aug’14 onwards. - B&R agreed to complete fabrication shed by 25.08.14. - Semi welding m/c ordered on 31.07.14.
EIL/BPCL
Aug'14
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:52.7%; Front: 67.9%; Act: 11.7% 50 CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 07.08.14 at site. n -Manpower: As on date only 110 Nos against the requirement of 300 Nos reported to site. MBEL committed to increase manpower upto 220 nos by 21.08.14. - TMT bars: 40 MT targeted to receive at site by 18.08.14. - In view of slow progress and delay in release of construction front to mechanical contractor, new tender under preparation and likely to be awarded by Sep'14.
EIL/BPCL
Aug'14
Start of work by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. 51 Awarded on 25.03.14. CCD: 24.09.15 Work yet to start at site.
Open
Constructio KOM held on 17.05.14. Mobilisation work initiated by M/s techsharp. n Pooja held on 22.07.14, WQT commenced.
Constr.
Aug'14
I III
Open
Constructio - Management level meeting held 06.08.14 at site. n -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works to commence by 16.08.14.
Aug'14
III
E
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 52 Work yet to start at site.
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete Constr. n balance civil & strl works by end Oct'14 & TS-4 strl by Nov'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. TS-2 total handover by 08.08.14 - TS-3 total handover by 31.08.14 - TS-6 total handover by 15.08.14 - MPR Grids 1 to 4 handing over by 22.08.14 49 welders deployed (further 3 welders by Mid Aug'14)
Aug'14
III
E
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: 15.02.15 53 Sch:98.8% Front: 97.7% Act: 77.1%
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15 54 Overall Progress: Sch: 85.3 % Act: 77.2 % Constr. Progress: Sch: 60.5 % Front: 87.4% Act: 45.8 %
Open
Project
As Required
III
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 55 Sch: 98.9% Front: 98.7 % Act: 66.2 %
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete EIL/BPCL n balance civil & strl works progressively by Dec'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. -MPR : 1st tier for total length handed over, grids 25-30 shall be handed over by Aug'14. TS-IV : total handing over by 31.08.14
Aug'14
Open
Constructio - Management level Meeting held on 07.07.14 n - OIL started to dismantle YT-150 Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT-383/391/150. -B&R has been informed that 2 tanks YT-383 & 391 have been handed over for taking up construction work and since these are to be made operational before taking outage of next tanks, the completion of these tanks is most critical. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement. - Next Management review meeting with M/s OIL planned on 06.08.14.
Aug'14
E
Aug'14
I
E
48
Aug'14
Construction work yet to start at site II 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 E
49
II
E
E
E
E
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) E
56
- Major backlog is due to manufacturing & Delivery (9.8%) and construction (13.3%). Erection of APH for VDU Heater is in progress. - Additional resources to be mobilised to recover construction backlogs by Aug'14. Convection module erection for CDU Heaters to commence from Aug'14. CDU APH foundations to be handed over by end Sept-14
Constr.
II III
Job No.: A307 JUL'14 Page 712 of 749
Integrated Refinery Expansion Project, Kochi
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 77.1 % Front: 100 % Act: 31.5 %
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Aug'14
III
Open
Constructio - Management level meeting held on 06.08.14 with M/s B&R at site. n M/s B&R agreed to increase manpower from 90 nos to 150 nos. B&R agreed to complete the civil works as per below targets: 1. YT-341 : 25.07.14 Revised date: 12.08.14 2. YT-342: 20.08.14 Revised date: 20.08.14 3. YT-343: 10.08.14 Revised date: 10.08.14 4. YT-344: 30.07.14 Revised date: 10.08.14 5. YT-111: 15.07.14 Revised date: 29.08.14 6. YT-112: 20.07.14 Revised date: 18.08.14 7. YT-113: 14.08.14 Revised date: 22.08.14 8. YT-114: 08.08.14 Revised date: 14.08.14 - Procurement of Balance Quantity of Plates (890 MT out of 1650 MT) to be expedited.
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 58 CCD:18.06.15 Work yet to start
Open
Constructio -These tankages (Amine water and sour water services) are required for n commissioning of CDU/VDU. -Agency has been pressurised to mobilise resources and start work. - Tank pads to be handed over from Aug'14 onwards.
Constr.
Aug'14
III
Start of Composite works by M/s Albana for DHDT & VGO Unit DHDT: Awarded to M/s Albana on 19.05.14 with 59 CCD: 18.11.15. VGO: Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15
Open
Constructio - KOM held on 27.05.14. n - Fabrication shed in progress and expected to be completed by 14.08.14 - WPS/PQR in progress
Constr.
Aug'14
III
Start of Composite works by M/offshore for Offsite DHDS area Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15.
Open
Constructio - Management level meeting held with M/s OIL on 06.08.14 at site. M/s OIL has been Constr. n asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Fabrication yard hand over targeted by 16.08.14. - Mobilisation for 20 nos auto welding machine to be expedited.
Aug'14
III
Start of Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15.
Open
E
61
Constructio - Management level meeting held with M/s OIL on 06.08.14 at site. M/s OIL has been Constr. n asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - M/s OIL agreed to establish complete fabrication yard by end Aug'14. - 600 MT crane mobilisation targeted by 25.08.14.
Completion of balance piling work (Covered under Piling-IIII Contract) 62 (Total 2077 Nos piles approx).
Open
Constn.
-Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. 08 nos bids received on 22.07.14. PBO recommendation targeted by 18.08.14
Engg./C&P
E
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015 for CDU/VDU commissioning.
BPCL
1-Jun-15
III
F
1
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
Projects
Continuous
III
Timely Commissioning of UB package to meet refinery commissioning schedule. Contr. Sch: 69.1%; Act: 52.4% LAD : 31.03.15 (UB 1) 30.06.15 (UB 2)
Open
Constn.
-Strict monitoring required at all stages till award of UB Tender and further during execution. -Completeness of supply of all subparts, their assembly and other BOP Items to be ensured. - Special attention to be given to multi flue chimney.
as scheduled
IV
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. - 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 for more than 5CR value. - Expeditious processing of RA bills.
As Required
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.
EIL/BPCL
As Required
IV
Process / Engg.
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
sep'13
Inspn
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
- Covered under risk ID C73
BPCL
within 2 days of request
Nov'13
E
E
E
E
F
F
57
60
2
3
G
1
G
2 Scope changes & information flow to executing group
G
3
G
4
G
5
Open
Non-performing vendors
Open
Delay in Approval of Vendor List for various items of the project (specially for Long lead items)
Close
PROCESS/ a. Change management should be in place immediately ENGG/CON b. Strict discipline to be maintained else end objective would be difficult to meet. S. All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Purch / Contrc.
Aug'14
18-Aug-14
III
IV
Job No.: A307 JUL'14 Page 713 of 749
Integrated Refinery Expansion Project, Kochi
G
G
I
I
Finalisation of Non plant buildings.
Close
Implementation of environmental clearance conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Open
Delay in commencement of site work for dyke wall Close inside TF-3 affected due to non availability of PESO approval for tankage area
BPCL
Action Plan
Action By
Target Date
- BPCL-KR vide e-mail dated 06-Dec-12 sent a list of Non plant buildings to be Projects 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.
15-Apr-13
Projects
- 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.
As required
Engg. / Proj.
- Documents approved from PESO
6
7
BPCL
Risk Severity Apr'13
IV
Apr'13
1
2
J
1
K
1
K
2
K
3
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
Implementation of Health, Safety and environmental (HSE) system
Open
Const.
- Deployment of skilled manpower for enforcement of safety precautions. - Monitoring of the HSE conditions and maintenance of records ./ reports. - Safety Drills being organised monthly basis.
Constn.
Continuous
III
Delay due to Labour strikes (due to labour issue like wage revision, other benefits) during project execution phase
Close
Const.
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
BPCL
As Required
Nov'13
Non availability of Skilled workers
Open
Const.
-Utilisation of migrant labour and skilled labour from outside the state needs to be EIL/BPCL 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 of trade union leaders that workers shall be instructed to improve productivity.
As Required
III
Constraint in movement & transportation of ODC eqpt.
Open
Project
-A separate contract to be given to agency which will take care by approaching KSEB Shipping and telephonic authority. -Fabn / transportation philosophy being finalised.
As Required
Jun'14
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open
K
4
M
1
M
2
Increase in facilities on account of deletion zero liquid discharge
3
Variation in foreign exchange rates from Rs 50 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.
M
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Cost monitoring & control on regular basis
Close
Projects / - IBR package for DCU targeted after 90 % model review. BPCL - List of all the buildings in IREP along with the plinth area details for taking approvals from F&B as well as Panchayath issued to BPCL on 12.04.14. Approval for tall strl/stacks: Signed documents with 6 sets handed over on 13.05.14. -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
Project/Eng Closed as no concern as on date. g
Aug'14
BPCL
As stated
IV
Jun'14
Costing
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
Open
Environ.
Scope of facilities finalised.
Environ.
15-Oct-13
sep'13
Open
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
Aug'14
II
Job No.: A307 JUL'14 Page 714 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 71 Ant: 18.08.14
Open
Project
-Award recommendation issued on 08.08.14.
BPCL
18-Aug-14
Open
Project
Revised MR (MR-3415) issued covering all critical valves along with all critical valves Engg. of MR-3211 floated. 10 nos bids received on 24.07.14. TBA targeted by 16.08.14.
30-Aug-14
C
Ordering of Critical Valves Sch: 11.07.14 Ant: 30.08.14 73 Dely: 06/07 M FOT /FOB
Open
Project
- Award recommendation issued to BPCL on 03.07.14. Sole bidder has not ready to give any discounts during negotiation, Being refloated. Draft NIT targeted by 18.08.14.
18-Aug-14
C
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM Sch: 08.05.14 76 Ant: 10.10.14
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 57.62 % Act: 41.41 % Construction Progress: Sch: 12.4 % Front: 65.5% Act: 10.6 %
Open
Project
Management level meeting held on 08.08.14 at site. -M/s EPIL has been asked to start site work by 26.08.14. Projects - M/s EPIL has been pressurised to complete construction of hard stand by 15.10.14. Submission of erection scheme targeted by 18.08.14. Constn - Deliveries of balance materials being expedited. (Nozzle for regenerator by end Aug'14, Reactor torricone by end Aug'14 and TSS torricone by mid Sep'14). - Work for assembly of hoppers and TSS to be commenced form 21.08.14 & 15.09.14 respectively. - M/s EPIL asked to commence area development around FGC equipments & hard stand immediately and to be ready by 15.10.14. - M/s EPIL agreed to mobilise 1600 MT crane by 1st week of Oct'14 and will ready for erection by 05.11.14. - Readiness for TSS erection targeted by 2nd week of Sep'14 to Feb'15. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. BPCL
Progressively upto Aug'14
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: 68.8 % Act: 46.6 %
Open
Project
-All 3685 MT Plates received at Chakan Shop, plate cutting & welding in progress. Project - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority assigned to complete main fractionator (IF-V-104) by Oct'14. - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach roach upto fabrication yard, which affected shifting of sections. - Approach road work completed. - Crane under mobilisation.
As stated
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 49.0 %; Act: 37.0 % Construction Progress: Sch: 27.0 % Front: 92.2 % Act: 18.1 %
Open
Project
-Management review meeting held on 08.08.14 at site. Following commitments have Constr. been made by M/s Essar. -Fabrication for Derrick structure agreed to complete by Dec'14. - 500 MT qty out of total 1800 MT qty planned to offload from M/s MK Engg by 12.08.14. - Balance fabrication for Switch Deck 250 MT) targeted by 30.09.14. - Structural drawing for balance 1600 MT out of 3500 MT targeted to complete by BPCL/EIL 31.08.14. - M/s Esaar has been asked the readiness of Fractionator Column and Coke Drum for erection by 28.02.15. -Supply of balance Plates (33/38 plates received) targeted by 10.09.14. - Ordering of 2000 MT crane targeted by mid Aug'14 and Crane availability agreed from Feb'15 to May'15. - Completion of Coke drum structure upto 113 level by 10.09.14. - Resource augmentation for Civil & Strl works being expedited. At present 236 nos have been deployed, balance 14 nos by 14.08.14.
Aug'14
Risk Id
Status (Open / Close)
RISKS REQUIRING ATTENTION
C
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
II
II BPCL/EIL
II
D
1
I
D
7
II
D
9
I
D
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Oct 14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV progress Sch ( 98.5 %); Act (85.6%)
Open
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Oct'14 Projects / - Due to weld crack in all 4 nos bottom shell likely to be delayed by 2 month w.r.t CDD. / Projects Const. Revised target for erection and hydrotesting of column finalised. Root cause and rectification completed. Detailed report issued to BPCL on 28.07.14. - Crude Column: Bottom section erected on 07.08.14. Erection other sections planned from 16.08.14 to 31.08.14. - Erection of Vacuum Column targeted from 30.08.14 to 30.09.14.
II
Job No.: A307 JUL'14 Page 715 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
Projects
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. However close monitoring being done. Meeting held on 06.08.14. Casing delivery expected within CDD i.e
Delay in delivery of Stripper column (IF-V-206) and Debutaniser Column (IF-V-302) by M/s Uttam Value Steel (Ordered on 19.08.13) 32 CDD: 18.10.14 EDD: 31.03.15
Open
Projects
- Order got delayed due to delay in manufacturing works. At present only 4 shell EIL/ BPCL course rolled out of 17 nos due to which there be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 33 EDD: Sep'14 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
Open
Projects
- As of now around 35-40% piping material has been received at site. Around 85-90 EIL/ BPCL % material has been ordered. Ordering of balance 5-10% material is in progress and expected by Aug'14. Delivery of ordered material against intermediate -II expected by Aug-Sep'14. -Vendors to be expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
Risk Id
Status (Open / Close)
RISKS REQUIRING ATTENTION Key Risk Description Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15 D
19
Action Plan
Action By
Target Date
Risk Severity
II
D
Aug'14
II
D
Sep'14
II Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage E
Open
Constn.
- Balance 16 nos units in the township handed over for grading by M/s Ray (SG-III) on BPCL 21.07.14 - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material.
- All long delivery equipments (incl. Compressors) to be awarded progressively by end BPCL/EIL Aug'14. Columns ordered to M/s Fabtech on 03.07.14 (CDD: 02.07.15) Award recommendation issued for - Refrigeration package on 29.05.14: - Composite Works (Civil Strl. & Mechanical) on 03.07.14: Being refloated.
Aug'14
2
Aug'14
I
E
4
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 59.8% Catch Up Sch: 21.7 % Act: 20.9 %
Open
Constn. / Projects
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch:79.4 % Front: 100 % Act:46.2% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Management level meeting held on 18.07.14, Constn - MCR area, CPP control room area : It has been decided to complete balance strl work by Dec'14 & finishing by Mar'15. - Other building works : Finishing work to be completed by Dec'14. - L&T also agreed to augment required manpower to meet the target completion date.
As Required
Backlog 26.1 (% wrt target sch) as of 15-Jul-14 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 - 28M; Remaining Duration - 18 M Desc. Catch Up sch: Const Sch Front Act Overall 23.9 49.4 48.6 23.3 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, contract for 2 additional Structural works & 1 civil work under evaluation and likely to awarded by mid Aug'14. Additional 1 tender for offsite refinery area is under preparation. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the sub vendors against Performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and boost progress. - Contractors are facing problem in retaining the labour at site.Approx 5000 labours are available at site, though induction programme has been carried out for 15000 labours . requirement of manpower at site is approx 15000 nos.
Constn
As Required
- Project review meeting held on 26.06.14 with M/s Triveni. -Balance engineering and complete ordering progressively by Aug'14. -M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barvendors and take up chemical house construction work. (Manpower required is 300 nos & Available manpower is 136 Nos). - Substation building: Foundation works commenced , completion to be targeted by Dec'14. - Chemical house work yet to start.
Constr.
I
E
6
II
E
7
BPCL/EIL
I Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
E
Overall Progress: Contr. Sch: 68.2 % Act: 41.2% Construction Progress: Sch: 63.8 % Front: 100 % Act: 39.5 % 13 Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Open
Project
Aug'14
II
Job No.: A307 JUL'14 Page 716 of 749
Integrated Refinery Expansion Project, Kochi
Area availability for SRU Block - At present only 91 % area given to M/s MBEL, balance Site for SRU block shall be available by end Aug'14. (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). E
Open
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Proj. / Constn.
14 Front for balance piling 918 nos will released progressively upto end Jul'14 on completion of site grading by M/s B&R.
Action Plan
Action By
- Meeting held with M/s B&R management on 06.08.14 at site and resources have Constn. been augmented. M/s B&R has been asked to expedite completion of balance area by end Aug'14 by augmenting additional dumpers. - Retaining wall in progress. B&R agreed to complete wall by 31.08.14 for which front is available and balance shall be completed by 30.09.14. B&R shall mobilize shuttering materials & manpower accordingly to meet above targets. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 952 nos piles completed against front of 1150 nos at site by M/s MBEL. Release of balance piling BPCL/EIL front at site progressively by mid Aug'14.Total nos of piles is 1800 nos piles - Next Management review meeting with M/s B&R planned on 06.08.14.
Target Date
Risk Severity
Aug'14
I Delay in delivery of UG piping material Material required at site for Civil & strl contractor.
Open
Const.
- Total 2 KM pipe under shortage (IS 3589 pipes of 32", 36", 44" & 48") ordered under BPCL FOA 592, 593, 652, 655 to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team.
Aug'14
E
22
Open
Project
E
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 (Ant. Compln26 May'14, Compl date Committed by B&R – 13.11.13)
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 Civil & Strl work-offsite IREP Area: Constr. Sch:94.3%; Front:75.8%; Act: 31.1% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 76.6%; Front: 87.1%; Act:31.1% CCD:18.12.14; ECD: Apr'15
Open
Project
Management review meeting held with M/s Essar on 08.08.14 at site. - Foundation completion for HRSG-3 targeted by 22.08.14. - Completion of Structural works for GTG shed targeted by 10.10.14. - Stack foundation targeted to complete for HRSG-3 by 07.09.14, HRSG-4 by 20.09.14 & HRSG-5 by 05.10.14.
BPCL / EIL
Aug'14
BPCL / EIL
Continuous
II BPCL / EIL
31-Aug-14
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Management level meeting held with B&R on 08.07.14. B&R agreed to execute work on extended hours to complete balance works in all respect by 31.08.14.
II
E
27
Constructio Management level meeting held with M/s KSSPPL on 07.08.14. BPCL / EIL n - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - Additional gangs to be deployed to complete cable trenches work. - KSS agreed to assemble the 100 MT crane from from 16.08.14. - Additional manpower being expedited by M/s KSS. - M/s KSS informed that agency for rock blasting has been deployed since 04.08.14. - TMT bars: Out of ordered 500 MT qty only 94 MT qty received, balance expected by 31.08.14.
Aug'14
II
E
28
Open
Project
E
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. 17.7% 29 56.2% 52.9 %
- Management level meeting held at site on 07.08.14. - As on date the manpower is 123 nos against the requirement of 200 nos. 100 nos civil labour expected to join site by 12.08.14. - Strl work at fabrication yard: Strl steel for TS-2 & TS-3 targeted by 15.09.14 & 30.09.14 respectively. - Breaking of Pile cap to be expedited. - Next Management review meeting with M/s Mcnally planned on 07.08.14.
Progress of ETP Works (Handing over of graded area for ETP & dismantling of existing Oil Catcher) LAD: 30.09.15 CCD:10.08.15 ECD: Dec'15 Overall progress: Sch: 47.6 % Act: 14.5 % Construction Progress: 34 Sch: 19.1 % Front: 61.5 % Act: 7.2 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Management level meeting held on 21.07.14. Eil - M/s Paramount to complete major engineering by mid Aug'14. -60 % model review being in progress from 11th Aug'14. Work commenced in substation (5 out of 42 fdns cast) and equalisation tank. BPCL - Handing over of balance area for treated water tank, API/TPI, ex TPI sump targeted by end Aug'14. Area handing over geeting delayed due to rain & U/G structure present in areas. - In order to recover the construction backlog, paramount has agreed to mobilse resource immediately & submit catsup plan. - To be followed up with M/s Paramount.
As stated
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 14.7 % Front: 67.8 % Act: 15 %
Open
- Tank pad area handed over for 3 nos out of 4 nos tank. Excavation for tank pad YT-25/26/28 completed. - Area grading in progress for 2nd Crude tank and area to be handed over by mid Aug14.
As stated
II
II
E
II
E
Project
Constr.
II
Job No.: A307 JUL'14 Page 717 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION Action Plan
Action By
Target Date
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 47.1 % Act: 12.1 %
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. - Structural steel: Out of 190 MT, 68 MT received at Coimbatore fabrication yard. BPCL Balance being expedited by M/s Petron. - Blasting and painting at Coimbatore is in completion stage. - Fabrication started for radiant section, erection planned by last week of Sep'14. EIL - All radiant coils have been ordered to M/s MSL - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited.
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 39 Overall Progress: Sch: 20 % Act: 12 %
Open
Project
-PO amendment: Letter issued to BPCL on 31.07.14. BPCL confirmation awaited.
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: Dec'15 Overall Progress: Sch: 77.0 % Act: 49.5% Construction Progress: Sch: 63.2 %; Front: 100%; Act:17.7 % 40 Area handed over, part of area is water logged due to plant drain which is under completion.
Open
Project
-Management level meeting held on 21.07.14 at EIL Delhi. M/s Driplex has been EIL asked to prepare a catchup plan to expedite constr. activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up BPCL plan has been discussed & reviewed and issued on 26.07.14. M/s Driplex to mobilise additional resources for completion as per catchup plan. -90 % model review expected in Sep'14. - M/s Driplex has been asked to mobilse 200 labours against present 107 nos. - DM tanks: Soil strengthen to be carried out by additional work of Stone Column. Further tanks work held up.
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC Contr. Sch: 59.9%; Front: 92.7% Act: 21.7 % CCD: 24.12.14 ECD: Oct'15
Open
Project
-Management review meeting held on 06.08.14 at site. M/s SEPC has been informed Constr. that their performance to be evaluated for next one month, additional agency to be lined to supplement progress (if required). -Resource Deployment of skilled workmen to be increased (Carpenters, bar benders EIL/BPCL to be increased). -Manpower shall be increased to 400 nos. from present 135 nos. 50 nos being planned to mobilise from 30.08.14. - Tech Structure A targeted to complete by 13.08.14. -Part Civil Work in FCCU offloaded to M/s Tauman. M/s Tuaman started mobilising. Additional 2 nos Strl. work contract being lined up to offload above contracts (if required). Award recommendation issued on 25.07.14. For other structural contract 5 nos bids received on 08.07.14.
As Required
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 74.7 % Act: 13.9 %
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all Projects bought out items. - Structural steel: Out of 935 MT, 677 MT ordered, 437 MT received. 67 MT expected to receive by 17.08.14. - Blasting and painting at Coimbatore is in completion stage. BPCL/EIL - Fabrication for 6 panels out of 30 panels for radiant section completed, balance 20 panels under dispatch and targeted progressively by 20.08.14. - All radiant coils have been ordered to M/s Tubocex Spain. - Structural erection work agreed to start by 16.08.14. - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited.
As Required
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 44 ECD: 31.03.15 Sch: 78.3 %; Front :86.1 % Act: 42.6 %
Open
Project
-Management level meeting held with M/s MBEL on 07.08.14 at site. M/s MBEL agreed: - Current manpower is 410 nos. MBEL agreed to mobilise 2 separate gangs for UG piping by 25.08.14. - 2 cranes mobilised and balance 2 cranes targeted to mobilised by 25.08.14.
Projects
As Required
Open
Project
Management level Meeting held with B&R on 06.08.14 at site. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. Buildings to be expedited for storage of material / equipment being received at site.
Projects
As Required
37
Risk Severity
As Required
II
E
Projects/BPC As Required L
II
E
II
E
41
I
E
43
I
E
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E
44
II
Job No.: A307 JUL'14 Page 718 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION Action Plan
Action By
Target Date
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area 47 Sch:68.5%; Front: 71.9%; Act: 11.2%
Open
Constructio Management level Meeting held with M/s KSSIIPL on 07.08.14 at site. BPCL / EIL n - M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 82 nos deployed only. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-05 nos bids received on 08.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - Award recommendation issued on 06.08.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15
Open
Constructio -Management level meeting held on 08.08.14 at site. BPCL / EIL n - Piping fabrication shed: Foundations work completed, fabrication shed targeted to complete by 31.08.14. - In view of delay in start of works (5 Month elapsed) by M/s Petron, separate tender for refloating is under progress.
Open
Constructio Management level meeting held on 06.08.14 at site. n - B&R to mobilize 750 MT crane for erection of heavy lift from Aug’14 onwards. - B&R agreed to complete fabrication shed by 25.08.14. - Semi welding m/c ordered on 31.07.14.
BPCL / EIL
Aug'14
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:52.7%; Front: 67.9%; Act: 11.7% 50 CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 07.08.14 at site. n -Manpower: As on date only 110 Nos against the requirement of 300 Nos reported to site. MBEL committed to increase manpower upto 220 nos by 21.08.14. - TMT bars: 40 MT targeted to receive at site by 18.08.14. - In view of slow progress and delay in release of construction front to mechanical contractor, new tender under preparation and likely to be awarded by Sep'14.
BPCL / EIL
Aug'14
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 55 Sch: 98.9% Front: 98.7 % Act: 66.2 %
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete BPCL / EIL n balance civil & strl works progressively by Dec'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. -MPR : 1st tier for total length handed over, grids 25-30 shall be handed over by Aug'14. TS-IV : total handing over by 31.08.14
Aug'14
Risk Severity
Aug'14
I
E
48
Aug'14
Construction work yet to start at site II 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 E
49
II
E
I
E
II
M
3
Variation in foreign exchange rates from Rs 50 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.
Open
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
EIL/BPCL
Aug'14
II
Y
N
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 49.0 %; Act: 37.0 % Construction Progress: Sch: 27.0 % Front: 92.2 % Act: 18.1 %
Open
Project
Very High
Y
Y
Y
N
Short term
(Current risk Score - Previous Risk score)
Y
Previous Risk Score
Y
Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Very High
Impact Score => {6+7+8+9} * 10 * 11
Schedule ( Y / N)
Project
Controllability Condition (D/I )
EIL Cost (Y / N)
Open
Urgency (Long Term / Short term)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Status (Open / Close)
Risk Id D
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 57.62 % Act: 41.41 % Construction Progress: Sch: 12.4 % Front: 65.5% Act: 10.6 %
Key Risk Description
Job No.: A307 Jul'14 Page 719+15 of 34
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
I
0.9
0.86
0.86
0.00
Management level meeting held on 08.08.14 at site. -M/s EPIL has been asked to start site work by 26.08.14. Projects - M/s EPIL has been pressurised to complete construction of hard stand by 15.10.14. Submission of erection scheme targeted by 18.08.14. Constn - Deliveries of balance materials being expedited. (Nozzle for regenerator by end Aug'14, Reactor tricone by end Aug'14 and TSS torricone by mid Sep'14). - Work for assembly of hoppers and TSS to be commenced form 21.08.14 & 15.09.14 respectively. - M/s EPIL asked to commence area development around FGC equipments & hard stand immediately and to be ready by 15.10.14. - M/s EPIL agreed to mobilise 1600 MT crane by 1st week of Oct'14 and will ready for erection by 05.11.14. - Readiness for TSS erection targeted by 2nd week of Sep'14 to Feb'15. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. BPCL
Progressively upto Aug'14
I
0.9
0.86
0.86
0.00
-Management review meeting held on 08.08.14 at site. Following commitments have been made by M/s Essar. -Fabrication for Derrick structure agreed by Dec'14. - 500 MT qty out of total 1800 MT qty planned to offload from M/s MK Engg by 12.08.14. - Balance fabrication for Switch Deck 250 MT) targeted by 30.09.14. - Structural drawing for balance 1600 MT out of 3500 MT targeted to complete by 31.08.14. - M/s Esaar asked to ready Fractionator column and coke drum for erection by 28.02.15. -Supply of balance Plates (33/38 plates received) targeted by 10.09.14. - Ordering of 2000 MT crane targeted by mid Aug'14 and Crane availability agreed from Feb'15 to May'15. - Completion of Coke drum structure upto 113 level by 10.09.14. - Resource augmentation for Civil & Strl works being expedited. At present 236 nos have been deployed, balance 14 nos by 14.08.14.
Constr.
Aug'14
1
Action Plan
Action By
Target Date
Risk Severity
I
D
Short term
9
BPCL/EIL
I Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage E
Open
Constn.
Very High
Y
N
Y
Y
Short term
I
0.7
0.67
0.67
0.00
- During the project review meeting dated 26.06.14 following points discussed and BPCL agreed: - Balance 16 nos units in the township handed over for grading by M/s Ray (SG-III) on 21.07.14 - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material.
BPCL
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
- All long delivery equipments (incl. Compressors) to be awarded progressively by end Aug'14. Columns ordered to M/s Fabtech on 03.07.14 (CDD: 02.07.15) Award recommendation issued for - Refrigeration package on 29.05.14: Being refloated. - Composite Works (Civil Strl. & Mechanical) on 03.07.14: Being refloated.
BPCL/EIL
Aug'14
2
I
E
Completion duration for NHT/ISOM (Revamp) Open Constn. / Mechanical completion of NHT/ISOM - Target Schedule : Projects 30.09.15; Only 15 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. 4 Physical Progress: Target Sch: 59.8% Catch Up Sch: 21.7 % Act: 20.9 %
Aug'14
I
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)
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU Constn completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, contract for 2 additional Structural works & 1 civil work under evaluation and likely to awarded by mid Aug'14. Additional 1 tender for offsite refinery area is under preparation. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the sub vendors against Performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and boost progress. - Contractors are facing problem in retaining the labour at site.Approx 5000 labours are available at site, though induction programme has been carried out for 15000 labours . requirement of manpower at site is approx 15000 nos. BPCL/EIL
As Required
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Meeting held with M/s B&R management on 06.08.14 at site and resources have been augmented. Constn. M/s B&R has been asked to expedite completion of balance area by end Aug'14 by augmenting additional dumpers. - Retaining wall in progress. B&R agreed to complete wall by 31.08.14 for which front is available and balance shall be completed by 30.09.14. B&R shall mobilize shuttering materials & manpower accordingly to meet above targets. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 952 nos piles completed against front of 1150 nos at site by M/s MBEL. Release of balance piling front at site progressively by mid Aug'14.Total nos of BPCL/EIL piles is 1800 nos piles - Next Management review meeting with M/s B&R planned on 06.08.14.
Aug'14
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
-Management review meeting held on 06.08.14 at site. M/s SEPC has been informed that their Constr. performance to be evaluated for next one month, additional agency to be lined to supplement progress (if required). -Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be EIL/BPCL increased). -Manpower shall be increased to 400 nos. from present 135 nos. 50 nos being planned to mobilise from 30.08.14. - Tech Structure A targeted to complete by 13.08.14. -Part Civil Work in FCCU offloaded to M/s Tauman. M/s Tuaman started mobilising. Additional 2 nos Strl. work contract being lined up to offload above contracts (if required). Award recommendation issued on 25.07.14. For other structural contract 5 nos bids received on 08.07.14.
As Required
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Schedule ( Y / N)
Const
EIL Cost (Y / N)
Backlog 26.1 (% wrt target sch) as of 15-Jul-14 in Open 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 - 28M; Remaining Duration - 18 M Desc. Catch Up sch: Const Sch Front Act Overall 23.9 49.4 48.6 23.3 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, 7 VGO/DHDT & Offsite).
Risk Owner
Status (Open / Close)
Risk Id E
Key Risk Description
Job No.: A307 Jul'14 Page 720+15 of 34
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Very High
Action Plan
Action By
Target Date
Risk Severity
I Area availability for SRU Block - At present only 91 % area given to M/s MBEL, balance Site for SRU block shall be available by end Aug'14. (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 Proj. / Constn.
Very High
Front for balance piling 918 nos will released progressively E 14 upto end Jul'14 on completion of site grading by M/s B&R.
I Slow Construction progress for Civil Works by M/s Shriram EPC Contr. Sch: 59.9%; Front: 92.7% Act: 21.7 % CCD: 24.12.14 ECD: Oct'15
E 41
Open Project
Very High
I
Output Quality ( Y / N)
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)
Urgency (Long Term / Short term)
Schedule ( Y / N)
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. Projects - Structural steel: Out of 935 MT, 677 MT ordered, 437 MT received. 67 MT expected to receive by 17.08.14. - Blasting and painting at Coimbatore is in completion stage. - Fabrication for 6 panels out of 30 panels for radiant section completed, balance 20 panels under BPCL/EIL dispatch and targeted progressively by 20.08.14. - All radiant coils have been ordered to M/s Tubocex Spain. - Structural erection work agreed to start by 16.08.14. - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited.
Open Constructi Very High on
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
Management level Meeting held with M/s KSSIIPL on 07.08.14 at site. BPCL / EIL - M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 82 nos deployed only. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-05 nos bids received on 08.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - Award recommendation issued on 06.08.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
Aug'14
Open Constructi Very High on
Y
N
Y
N
Short term
I
0.6
0.57
0.38
0.19
Management level meeting held on 07.08.14 at site. -Manpower: As on date only 110 Nos against the requirement of 300 Nos reported to site. MBEL committed to increase manpower upto 220 nos by 21.08.14. - TMT bars: 40 MT targeted to receive at site by 18.08.14. - In view of slow progress and delay in release of construction front to mechanical contractor, new tender under preparation and likely to be awarded by Sep'14.
Aug'14
Open Project
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) Very High
Risk Owner
EIL Cost (Y / N)
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 74.7 % Act: 13.9 %
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jul'14 Page 721+15 of 34
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
E 43
Action Plan
Action By
Target Date
Risk Severity
As Required
I Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 E 48 Civil & Strl work-offsite DHDS Area Sch:68.5%; Front: 71.9%; Act: 11.2%
I
E 51
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:52.7%; Front: 67.9%; Act: 11.7% CCD: 25.01.15 ECD: Oct'15
BPCL / EIL
I
Job No.: A307 JUN'14 Page 722 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award of Gas Booster Compressor for CPP (Dly: 13 M FOB / 14 M FOT)) 70 (LAD:29.12.13; Ant: 11.07.14)
Open
Project
Award recommendation issued on 27.05.14. Award expected by 11.07.14. BPCL has recommended to negotiate with BHEL on the reduction in delivery time by 2 months.
BPCL
11-Jul-14
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 71 Ant: 25.07.14
Open
Project
-TBA issued on 10.06.14, PBO recommendation issued on 23.06.14. Award recommendation targeted by 10.07.14
Projects / C&P/BPCL
10-Jul-14
Open
Project
New MR (MR-3415) issued covering all critical valves along with all critical valves of MR-3211 floated. Bids due on 21.07.14.
Engg.
21-Jul-14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
II
C
II Ordering of Critical Valves Sch: 11.07.14 Ant: 20.08.14 C
73
Open
Project
- 04 bids received on 02.04.14. PBO recommendation issued on 16.05.14. Price bids BPCL/EIL opened on 17.06.14. Award recommendation targeted by 04.07.14.
4-Jul-14
C
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM Sch: 08.05.14 76 Ant: 15.07.14
Open
Project
- Award recommendation issued on 01.07.14. BPCL to order.
15-Jul-14
C
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) Sch:27.06.14 77 Ant: 15.07.14
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 50.78 % Act: 37.58 % Construction Progress: Sch: 23.0 % Front: 85.0% Act: 9.3 %
Open
Project
- 90 % model review & HAZOP review completed. - All R&R foundation along with TSS foundation completed. Handing over of TSS fdn Projects targeted by 08.07.14. Strl. Steel fabrication for R&R along with TSS: 3600 MT out of 3803 MT completed. Constn Strl. Steel erection for R&R- 645 MT out of 2300 (2300 MT for R&R & for TSS 1300 MT) MT erection completed. Flue gas, ESP & Stack fdn etc: Strl. material is ready for dispatch for flue gas cooler. Foundation work to be expedited. Strl. Steel erection for TSS - Work yet to be commence. Additional resource for assembly of modules, simultaneous erections of structures and delivery of cyclones to be expedited. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up.
II
II BPCL
II
D
1
Progressively upto Aug'14
BPCL
I
D
Open
Project
- Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). 3685 MT out of 3747 MT Project Plates received at Chakan Shop, plate cutting & welding in progress. - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority to be assigned to main fractionator (IF-V-104). Taken up with M/s Fabtech. - Progress of works is affected due to delay in handing over of fabrication yards and completion of approach roach upto fabrication yard, which affected shifting of sections.
As stated
7
Completion of all three site Fabricated Columns for FCCU (M/s Fabtech) LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 65.5 % Act: 43.1 %
Open
Project
-M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. -Coke Drum (4 nos) & Main Fractionator : Subordered on M/s VTV (for site fabricated works). SS Clad (2231 MT) plates received at VTV shop. All fabrication yard area released. Approach road cleared on 09.06.14. Site fabrication to start. Mobilisation of 2000 MT crane targeted in Jan'15 and erection to be targeted from Mar'15 to May'15. - Strl. Fabr.: 169 MT out of 3560 MT completed. Sch for strl. erection is from 04.08.14 BPCL/EIL to 16.07.15. Strl. Fabrication Site to be visited in 1st week of Jul'14 and accordingly to review the performance and take decision for offloading (if required). - Manpower to be increased from present 227 to 505 for Civil work.
Jul'14
9
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 44.5 %; Act: 34.21 % Construction Progress: Sch: 24.2 % Front: 92.2 % Act: 16.6 %
II
D
I
D
Delay in erection of Crude & vacuum column due to Open delayed ordering. Sch: Jun 14 CCD: 21.08.14 Ant: Oct 14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV progress Sch ( 96.9 %); Act (84.9%)
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Oct'14 Projects / - Due to weld crack in all 4 nos bottom shell likely to be delayed by 2 month w.r.t CDD. / Projects Const. Revised target for erection and hydrotesting of column to be finalised after resolution of welding crack issue. - Erection of Vacuum Column targeted from 06.08.14 to 28.08.14 & hydrotest planned in Sept'14. -1000 MT Crane : Load test completed and is ready for use. -500 MT Crane : Load test completed and is ready for use.
II
Job No.: A307 JUN'14 Page 723 of 749
Integrated Refinery Expansion Project, Kochi
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15 D
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Projects
19
Action Plan
Action By
Target Date
Risk Severity
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. 90% model review completed.. Hazop review completed on 19.06.14.
II Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
E
Open
Constn.
- During the project review meeting following points discussed and BPCL agreed: BPCL - Balance 16 nos units in the township to be handed over for grading by M/s Ray (SGIII). - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material. -Part of PEB1 new ware house handed over for material storage total warehouse handover after completion of work by Jul'14.
2
Jul'14
I
E
3
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
Open
Constn.
- M/s Mcnally to mobilise adequate resources & expedite rock breaking in VGO area. Engg./Constn.13-Jul-14 - Commitment made by Mcnally to complete balance blasting work by 31.07.14
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 51.6% Catch Up Sch: 18.1 % Act: 17.8 %
Open
Constn. / Projects
- All long delivery equipments (incl.compressors) to be awarded progressively by mid BPCL/EIL Jul'14. Reactor ordered on M/s Phills Heavy (CDD: 21.12.14) - Award recommendation issued for Columns on 05.06.14. Health check compressor (BHEL make) on 05.06.14 New Compressor on 23.06.14 Refrigeration package on 29.05.14 - Composite Works (Civil Strl. & Mechanical) : Award recommendation targeted by 04.07.14.
Jul'14
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch:73.8 % Front: 100 % Act:43% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Front available for all 11 buildings . Constn - MCR area, CPP control room area : MCR foundation completed and grade slab part 1 out of 3 completed. SS-10 grade slab part 1 out of 3 nos completed. - Manpower being augmented to 700 nos from present 550 nos. - Engineering for Packages like HVAC and Pressurization & Ventilation system in progress - Clean agent system: Drawings awaited from L&T. - Casting of foundations up to first expansion joint in MCR to be expedited. Strl. dwg. for Roof structures for MCR, SRR & substation to be cleared. - Lifts: Orders placed, drawings received and under review.
As Required
Backlog 24.6 (% wrt target sch) as of 15-Jun-14 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 - 26M; Remaining Duration - 20 M Desc. Catch Up sch: Const Sch Front Act Overall 21.1 45.3 45.3 20.7 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Director level meeting held with contractors from May'14 to Jun'14. order to complete Constn the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, additional 1 tender for civil works already awarded (M/s Tuaman) and 2 additional civil & Strl works under tendering and likely to awarded by end Jul'14.. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the subvendors against performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and expedite progress. BPCL/EIL
As Required
Completion of piling work by M/s L&T (Piling-II): CDD- 08.05.14. (Total 12003 Nos piles). (Contr.Sch- 100%, Front-89.8%, Act-84.9%) Only 10 nos. hydraulic & 4 nos. conventional rigs are currently operational at site. Total 10124 nos completed out of 12003
Open
Constn.
II
E
4
I
E
6
II
E
7
I
E
9
L&T has completed nearly 10124 pile. Piling completed in Demountable flare area, Air Constr. compressor & DG shed area. Piling balance in Chitrapuzha area, Offsite Refinery area, new tender being prepared. Tender on sale from 30.06.14 to 21.07.14, bids due on 22.07.14.
Immediate
II
Job No.: A307 JUN'14 Page 724 of 749
Integrated Refinery Expansion Project, Kochi
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Overall Progress: Contr. Sch: 58.6 % Act: 36.7% Construction Progress: Sch: 55.6 % Front: 100 % Act: 31.7 % 13 Sch: 15.11.14 CCD: 24.03.15 ECD: Oct'15 Compl: 18 M+2M
Action Plan
Action By
Target Date
- Project review meeting held on 26.06.14 with M/s Triveni. Constr. -Balance engineering targeted to complete by 15.07.14 and complete ordering progressively by mid Jul'14. -M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barvendors by 1st week of July 14 and take up chemical house construction work by 1st week of July 14. (Manpower required is 300 nos & Available manpower is 136 Nos). - Substation building: Foundation works commenced , completion to be targeted by Dec'14.
Jul'14
- Retaining wall in progress. Reservoir wall dismantling & grade slab dismantling completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 28.05.14. and resources have been augmented. M/s B&R agreed to complete SRU earth filling work by 15.07.14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 905 nos piles completed against front of 910 nos at site by M/s MBEL. Release of balance piling front at site progressively by end Jul'14.Total nos of piles is 1828 nos piles
Jul'14
Risk Severity
II
E
14
Area availability for SRU Block - At present only 85 % area given to M/s MBEL, balance Site for SRU block shall be available by end Jul'14. (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
Proj. / Constn.
Constn.
BPCL/EIL
Front for balance piling 918 nos will released progressively upto end Jul'14 on completion of site grading by M/s B&R.
I Delay in delivery of UG piping material Material required at site for Civil & strl contractor.
Open
Const.
E
22
Open
Project
E
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 (Ant. Compln26 May'14, Compl date Committed by B&R – 13.11.13)
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 27 Civil & Strl work-offsite IREP Area: Constr. Sch:90.5%; Front:73.0%; Act: 28% CCD: 08.10.14; ECD: Jun'15
Open
- Total 2 KM pipe under shortage (IS 3589 pipes of 32", 36", 44" & 48") ordered under BPCL FOA 592, 593, 652, 655 to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team.
Jul'14
II BPCL / EIL
Jul'14
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Balance work to be expedited.
II
E
Constructio Meetings held with M/s KSSPPL on 12.06.14 M/s KSSIPL to deploy cumulative 200 BPCL / EIL n Manpower for Civil fdn work alone (Inside DHDS area) & 250 Manpower for Civil Fdn (IREP area) . As on date 83 and 112 nos deployed resp. Rock Blasting in IREP area being expedited & targeted to completed by 1st week of Jul'14. M/s Tuaman being deployed to supplement KSSPPL for trenches.
30-Jul-14
II Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 66.9%; Front: 69.5%; Act:24.6% CCD:18.12.14; ECD: Apr'15
E
Open
Project
-Meeting held M/s Essar on 12.06.14 at EIL HO. M/s Essar has been asked to deploy BPCL / EIL additional manpower and machinery to recover the backlog and submit catchup plan. Structural steel fabrication works: 490 MT received for GTG shed. 295MT fabrication completed. Release of balance AFC drawings for UG piping works, Earthing layout , precast works etc. to be expedited. - RCC drawings released 8522 Cum out of 9990 Cum & steel quantity released 1173 MT out of total 1262 MT.
15-Jul-14
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. 29 48.4% 42.3 % 14.6%
Open
Project
- During management review at Kolkata in 28.05.14, M/s B&R has committed site BPCL / EIL grading works for SRU block by 06.07.14. Balance front of 58 % will be released progressively by Aug'14 on completion of site grading by M/s B&R - Manpower for all works to be increased to 150 from present 60 nos. As on date the manpower is 123Nos against the requirement of 200Nos. 25Nos reported to site and shall join. - 1018/1450MT TMT steel received at site .Non availability of sections (16/28MM) of TMT still an area of concern . MBECL informed to place orders by mid Jul'14.
Continuous
Progress of ETP Works (Handing over of graded area for ETP & dismantling of existing Oil Catcher) LAD: 30.09.15 CCD:10.08.15 ECD: Dec'15 Overall progress: Sch: 39.1 % Act: 12.9 % Construction Progress: 34 Sch: 13.6 % Front: 20 % Act: 5.6 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Meeting held with with M/s Paramount on 15.05.14 Project Work commenced in substation (5 out of 42 fdns cast) and equalisation tank. - Area handing over for RL-7 to M/s Paramount targeted by 10.07.14. Engineering issues to be resolved for SBR/ACT area (relating to soil bore logs based on recent testing) targeted by 15.07.14. Based on above revised drawings to be targeted by end Jul'14. - 30 % model review targeted by mid Jul'14. -API, TPI Ex TPI area handing over targeted by 10.07.14. Chemical house & DAF (Dissolved air floatation) area already handed over. Works started in Chemical house area and sludge thickner area. Dismantling of under ground structures observed while carried out foundation works to be expedited.
As stated
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 5.0 % Front: 25 % Act: 4.8 %
Open
- Tank pad area handed over for 1 tank. Excavation for tank pad YT-26 completed - Area grading in progress for 2nd Crude tank and area to be handed over by Jul'14.
As stated
28
II
E
II
E
II
E
Project
Constr.
II
Job No.: A307 JUN'14 Page 725 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 37 Overall Progress: Sch: 45.3 % Act: 8.33 %
Open
Project
-Parallel action being initiated to supplement the works of M/s Petron. Final decision shall be taken after reviewing the performance of M/s Petron for next 1 month, i.e upto mid Jul'14 based on milestones upto end Jun'14. - Radiant section fabrication drawings to be finalised across the table on fast track. - Vendor being pressurised to mobilised at site immediately. - Strl. Steel: Total 193 MT. Ordering targeted by mid Jul'14 progressively. To be followed up with M/s Petron.
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 39 Overall Progress: Sch: 11 % Act: 10 %
Open
Project
- Burner / reduction furnace data from Incinerator burner vendor required (M/s Projects/BPC As Required Callidus). Input expected to receive by end Aug'14. KOM planned with M/s Callidus on L 22.07.14. - Chamber (M/s Techno Process) & stack (M/s Loyd Steel) ordered on Indian Vendors, whereas order delivery is on FOB basis. -Vendor has submitted revised proposal on 17.06.14 for splitting of supply into offshore and onshore portion. Note for the same is under internal approval and targeted by 15.07.14.
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: Dec'15 Overall Progress: Sch: 68.26 % Act: 43.88% Construction Progress: Sch: 55.5 %; Front: 100%; Act:15.2 %
Open
Project
- Director level meeting held on 20.06.14 at EIL Delhi. Following points agreed: Projects - M/s Driplex has sub ordered piling works to local agency. Agency to mobilise resources and start work from Mid Jul'14 and complete by Sep'14 for substation area. - Completion of balance civil works including chemical house expected by Mar'15. - Driplex started foundation pedestals for RO shed and targeted to complete the same by mid Aug'14. The fabrication of structural steel for shed is also to be expedited and material receipt at site by Sep’14 for starting of erection work and completing the shed at the earliest. - 90 % model review targeted by mid Jul'14. Ordering of piping material after 90 % model review. - Ordering of steam turbine to be finalised.
As Required
Slow Construction progress for Civil Works by M/s Shiram EPC Contr. Sch: 52.7%; Front: 69.4% Act: 17.6 % CCD: 24.12.14 ECD: Oct'15
Open
Project
As Required
E
41
-Director review meeting held on 13.05.14 Constr. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including approx EIL/BPCL 50 nos in fabrication yard). Manpower as on 10.06.14 is 151 nos -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. 387MT progressively by 30.06.14. Required qty. of reinforcement still not available at site. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). 06 nos bids received on 24.06.14.
Open
Project
- Mobilisation work stated. -Parallel action being initiated to supplement the works of M/s Petron. Final decision shall be taken after reviewing the performance of M/s Petron for next 1 month, i.e upto mid Jul'14 based on milestones upto end Jun'14. - Shop fabrication work started. - Strl. Steel: 400 MT out of 800 MT ordered, balance ordering targeted by end Jul'14 progressively. To be followed up with M/s Petron.
Projects
As Required
E
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: 43 Sch: 51.6 % Act: 10.1 %
Slow Construction progress for Civil Works by M/s Mcnally Bharat for DHDT & VGO CCD: 10.01.15 ECD: 31.03.15 Sch: 70 %; Front :75 % Act: 34.6 %
Open
Project
-Director level meeting held with M/s MBEL on 28.05.14. M/s MBEL agreed: -Out of indent for procurement of 4200MT of structural steel, delivery of 30MT is balance. -Balance 1480 bolts are expected at site by 15.06.14 -Strl. detailing: 5035MT out of 5630MT completed, balance by end Jul'14. - During meeting dated 28.05.14 M/s MBEL agreed to increase manpower from 320 nos to 400 nos, however at present only 320 nos have been augmented.
Constr
As Required
Completion of PreEngineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open
Project
Work under progress by M/s B&R. 85 % work completed balance targeted by mid Jul'14 for PEB1. PEB 2 structural work in progress. Buildings to be expedited for storage of material / equipment being received at site.
Constr
As Required
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 47 Civil & Strl work-offsite DHDS Area Sch:60.7%; Front: 71.9%; Act: 8.4%
Open
Constructio Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 n Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)Tender on sale from 13 06.14, BDD- 07.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - NIT issued on 12.06.14, bids due on 04.07.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
BPCL / EIL
7-Jul-14
E
Project
Target Date
Risk Severity
As Required
II
E
II
E
40
II
I
BPCL/EIL
I
E
44
II
E
44
II
E
I
Job No.: A307 JUN'14 Page 726 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By BPCL / EIL
Target Date
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15
Open
Constructio -KOM held on 21.04.14. Meeting held with M/s Petron on 06.06.14. Due to delay in n mobilisation and financial crunch. It has been decided to float parallel tender for composite works to supplement progress of composite works and decision to be taken based on performance upto mid Jul'14. - Fabrication shed work under construction and targeted to complete by mid Jul'14. - 70 MT and 273 MT crane under mobilisation.
Delay in mobilisation and start of work by M/s B&R for Composite Works-DCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15
Open
Constructio KOM held on 08.04.14. Mobilisation work initiated by M/s B&R. BPCL / EIL n - Fabrication yard work under progress. B&R is arranging crane to commence erection of Eqpts. from July'14 onwards. Already 3 month has past, work not started at site.
Jul'14
Slow construction progress for Civil & Strl work for Refinery area (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:45.9%; Front: 58.3%; Act: 9.7% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 28.05.14. n -MBECL informed that manpower available at site is 49 nos and assured to augment manpower by 100 nos. by 10.06.2014, however as on date only 64 Nos against the requirement of 200 Nos reported to site. - Anchor bolts being expedited (as on date 1189/3438Nos available at site). - Strl. Detailing: Detailing for 3129MT completed against the AFC drawing release of 5785MT.(Scope :6010MT). Balance detailing to be completed by 05.07.2014.
BPCL / EIL
Jul'14
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: 15.02.15 Sch: 95.68% Front: 95.59 % Act: 63.12 %
Open
Constructio - Management level meeting held on 13.05.14, M/s L&T to augment manpower and n additional machineries for completion of balance works to generate front to mechanical contractor.
BPCL / EIL
Jul'14
Variation in foreign exchange rates from Rs 50 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 (additionals in scope) has significantly impacted on the overall project cost.
Open
EIL/BPCL
Jul'14
Risk Severity
15-Jul-14
48
II
E
49
II
E
50
II
E
55
II
M
3
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
II
Job No.: A307 JUN'14 Page 727 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award of Gas Booster Compressor for CPP (Dly: 13 M FOB / 14 M FOT)) 70 (LAD:29.12.13; Ant: 11.07.14)
Open
Project
Award recommendation issued on 27.05.14. Award expected by 11.07.14. BPCL has recommended to negotiate with BHEL on the reduction in delivery time by 2 months.
BPCL
11-Jul-14
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 71 Ant: 25.07.14
Open
Project
-TBA issued on 10.06.14, PBO recommendation issued on 23.06.14. BPCL to provide PBO approval. Award recommendation targeted by 10.07.14
Projects / C&P/BPCL
10-Jul-14
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) Sch:27.06.14 77 Ant: 15.07.14
Open
Project
- Award recommendation issued on 01.07.14. BPCL to order.
BPCL
15-Jul-14
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 50.78 % Act: 37.58 % Construction Progress: Sch: 23.0 % Front: 85.0% Act: 9.3 %
Open
Project
- Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. - Handing over of TSS fdn targeted by 08.07.14.
Projects
Progressively upto Aug'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
II
C
II
C
II
D
Constn Flue gas, ESP & Stack fdn etc: Strl. material is ready for dispatch for flue gas cooler. Foundation work to be expedited. Strl. Steel erection for TSS - Work yet to be commence. Additional resource for assembly of modules, simultaneous erections of structures and delivery of cyclones to be expedited.
1
BPCL
I
D
7
Completion of all three site Fabricated Columns for FCCU (M/s Fabtech) LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 65.5 % Act: 43.1 %
Open
Project
- Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). 3685 MT out of 3747 MT Project Plates received at Chakan Shop, plate cutting & welding in progress. - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority to be assigned to main fractionator (IF-V-104). Taken up with M/s Fabtech. - Progress of works is affected due to delay in handing over of fabrication yards and completion of approach roach upto fabrication yard, which affected shifting of sections.
As stated
BPCL II
D
D
D
D
9
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 44.5 %; Act: 34.21 % Construction Progress: Sch: 24.2 % Front: 92.2 % Act: 16.6 %
Open
Project
-M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. -Coke Drum (4 nos) & Main Fractionator : Subordered on M/s VTV (for site fabricated works). SS Clad (2231 MT) plates received at VTV shop. All fabrication yard area released. Approach road cleared on 09.06.14. Site fabrication to start. Mobilisation of 2000 MT crane targeted in Jan'15 and erection to be targeted from Mar'15 to May'15. - Strl. Fabr.: 169 MT out of 3560 MT completed. Sch for strl. erection is from 04.08.14 BPCL/EIL to 16.07.15. Strl. Fabrication Site to be visited in 1st week of Jul'14 and accordingly to review the performance and take decision for offloading (if required). - Manpower to be increased from present 227 to 505 for Civil work.
Jul'14
Delay by vendor with respect to CDD due to slow progress of manufacturing works and financial constraint.
Open
Projects
- Following bidders showing slow manufacturing progress: M/s Arjun Technologies EIL/ BPCL (Pressure Vessel supplier): FOA No.: 133, 144 & 184. M/s Reynold Chem. (Heat Exchangers): FOA No.: 116, 189 M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311 & 444. Continuous expediting being made by visiting vendor workshop for all critical orders in respective regions.
Jul'14
I 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
- M/s Filtrex asking for deviations on commercial terms. Meeting being called on 08.07.14 to resolve the issues with M/s Filtrex.
EIL/ BPCL
Jul'14
III
Non acceptance of work order by M/s Flowserve for DHDT Centrifugal pumps Ordered on 30.01.14 to M/s Flowserve (MR-5403)
Open
Projects
- Order not accepted by vendor. Meeting with vendor held on 17.06.14.
EIL/ BPCL
Jul'14
III
29
30
31
Job No.: A307 JUN'14 Page 728 of 749
Integrated Refinery Expansion Project, Kochi
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
E
Open
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Constn.
- During the project review meeting following points discussed and BPCL agreed: BPCL - Balance 16 nos units in the township to be handed over for grading by M/s Ray (SGIII). - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material. -Part of PEB1 new ware house handed over for material storage total warehouse handover after completion of work by Jul'14.
Jul'14
2
Risk Severity
I
E
4
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 51.6% Catch Up Sch: 18.1 % Act: 17.8 %
Open
Constn. / Projects
- All long delivery equipments (incl.compressors) to be awarded progressively by mid BPCL/EIL Jul'14. Reactor ordered on M/s Phills Heavy (CDD: 21.12.14) - Award recommendation issued for Health check compressor (BHEL make) on 05.06.14 New Compressor on 23.06.14 Refrigeration package on 29.05.14 Composite Works (Civil Strl. & Mechanical) on 03.07.14.
Jul'14
Backlog 24.6 (% wrt target sch) as of 15-Jun-14 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 - 26M; Remaining Duration - 20 M Desc. Catch Up sch: Const Sch Front Act Overall 21.1 45.3 45.3 20.7 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Director level meeting held with contractors from May'14 to Jun'14. order to complete Constn the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, additional 1 tender for civil works already awarded (M/s Tuaman) and 2 additional civil & Strl works under tendering and likely to awarded by end Jul'14. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the subvendors against performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and expedite progress. BPCL/EIL
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 Mar'15)
Open
Constn.
Area availability for SRU Block - At present only 85 % area given to M/s MBEL, balance Site for SRU block shall be available by end Jul'14. (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
I
E
E
E
7
8
Proj. / Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
BPCL
- Retaining wall in progress. Reservoir wall dismantling & grade slab dismantling completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 28.05.14. and resources have been augmented. M/s B&R agreed to complete SRU earth filling work and targeted by 15.07.14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 905 nos piles completed against front of 910 nos at site by M/s MBEL. Release of balance piling front at site progressively by end Jul'14.Total nos of piles is 1828 nos piles
Constn.
Mar'15
I IV
Jul'14
BPCL/EIL
14 Front for balance piling 918 nos will released progressively upto end Jul'14 on completion of site grading by M/s B&R.
I
E
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 (Ant. Compln26 May'14, Compl date Committed by B&R – 13.11.13)
Open
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 27 Civil & Strl work-offsite IREP Area: Constr. Sch:90.5%; Front:73.0%; Act: 28% CCD: 08.10.14; ECD: Jun'15
Open
Project
BPCL / EIL
Jul'14
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Balance work to be expedited.
II
E
Constructio Meetings held with M/s KSSPPL on 12.06.14 M/s KSSIPL to deploy cumulative 200 BPCL / EIL n Manpower for Civil fdn work alone (Inside DHDS area) & 250 Manpower for Civil Fdn (IREP area) . As on date 83 and 112 nos deployed resp. Rock Blasting in IREP area being expedited & targeted to completed by 1st week of Jul'14. M/s Tuaman being deployed to supplement KSSPPL for trenches.
30-Jul-14
II Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 66.9%; Front: 69.5%; Act:24.6% CCD:18.12.14; ECD: Apr'15
E
28
Open
Project
-Meeting held M/s Essar on 12.06.14 at EIL HO. M/s Essar has been asked to deploy BPCL / EIL additional manpower and machinery to recover the backlog and submit catchup plan. Structural steel fabrication works: 490 MT received for GTG shed. 295MT fabrication completed. Release of balance AFC drawings for UG piping works, Earthing layout , precast works etc. to be expedited. - RCC drawings released 8522 Cum out of 9990 Cum & steel quantity released 1173 MT out of total 1262 MT.
15-Jul-14
II
Job No.: A307 JUN'14 Page 729 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
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 29 SCH. FRONT. ACT. 48.4% 42.3 % 14.6%
Open
Project
Slow Construction progress for Civil Works by M/s Shiram EPC Contr. Sch: 52.7%; Front: 69.4% Act: 17.6 % CCD: 24.12.14 ECD: Oct'15
Open
E
41
Open
E
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: 43 Sch: 51.6 % Act: 10.1 %
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 47 Civil & Strl work-offsite DHDS Area Sch:60.7%; Front: 71.9%; Act: 8.4%
Open
Constructio Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 n Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)Tender on sale from 13 06.14, BDD- 07.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - NIT issued on 12.06.14, bids due on 04.07.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
BPCL / EIL
7-Jul-14
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15
Open
Constructio -KOM held on 21.04.14. Meeting held with M/s Petron on 06.06.14. Due to delay in n mobilisation and financial crunch. It has been decided to float parallel tender for composite works to supplement progress of composite works and decision to be taken based on performance upto mid Jul'14. - Fabrication shed work under construction and targeted to complete by mid Jul'14. - 70 MT and 273 MT crane under mobilisation.
BPCL / EIL
15-Jul-14
Delay in mobilisation and start of work by M/s B&R for Composite Works-DCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15
Open
Constructio KOM held on 08.04.14. Mobilisation work initiated by M/s B&R. BPCL / EIL n - Fabrication yard work under progress. B&R is arranging crane to commence erection of Eqpts. from July'14 onwards. Already 3 month has past, work not started at site.
Jul'14
Slow construction progress for Civil & Strl work for Refinery area (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:45.9%; Front: 58.3%; Act: 9.7% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 28.05.14. n -MBECL informed that manpower available at site is 49 nos and assured to augment manpower by 100 nos. by 10.06.2014, however as on date only 64 Nos against the requirement of 200 Nos reported to site. - Anchor bolts being expedited (as on date 1189/3438Nos available at site). - Strl. Detailing: Detailing for 3129MT completed against the AFC drawing release of 5785MT.(Scope :6010MT). Balance detailing to be completed by 05.07.2014.
BPCL / EIL
Jul'14
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: 15.02.15 Sch: 95.68% Front: 95.59 % Act: 63.12 %
Open
Constructio - Management level meeting held on 13.05.14, M/s L&T to augment manpower and n additional machineries for completion of balance works to generate front to mechanical contractor.
BPCL / EIL
Jul'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
E
Key Risk Description
Action Plan
Action By
Target Date
- During management review at Kolkata in 28.05.14, M/s B&R has committed site BPCL / EIL grading works for SRU block by 06.07.14. Balance front of 58 % will be released progressively by Aug'14 on completion of site grading by M/s B&R - Manpower for all works to be increased to 150 from present 60 nos. As on date the manpower is 123Nos against the requirement of 200Nos. 25Nos reported to site and shall join. - 1018/1450MT TMT steel received at site .Non availability of sections (16/28MM) of TMT still an area of concern . MBECL informed to place orders by mid Jul'14.
Continuous
Project
-Director review meeting held on 13.05.14 Constr. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including approx EIL/BPCL 50 nos in fabrication yard). Manpower as on 10.06.14 is 151 nos -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. 387MT progressively by 30.06.14. Required qty. of reinforcement still not available at site. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). 06 nos bids received on 24.06.14.
As Required
Project
- Mobilisation commenced. -Parallel action being initiated to supplement the works of M/s Petron. Final decision shall be taken after reviewing the performance of M/s Petron for next 1 month, i.e upto mid Jul'14 based on milestones upto end Jun'14. - Shop fabrication work started. - Strl. Steel: 400 MT out of 800 MT ordered, balance ordering targeted by end Jul'14 progressively. To be followed up with M/s Petron.
As Required
Risk Severity
II
I Projects
BPCL/EIL
I
E
I
E
48
II
E
49
II
E
50
II
E
55
II
Job No.: A307 JUN'14 Page 730 of 749
Integrated Refinery Expansion Project, Kochi
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 E
E
E
F
F
58
1
3
G
2
Target Date
Risk Severity
Constructio - Management level meeting held on 28.05.14 with M/s B&R at KolKata. n Agency being asked to start work immediately.
BPCL / EIL
Jul'14
III
Open
Constructio - Management level meeting held on 28.05.14 with M/s B&R at KolKata. n M/s B&R agreed to increase manpower from 90 nos to 150 nos. Agency being asked to start work immediately.
BPCL / EIL
Jul'14
III
Start of work for SRU Tankage works (Ordered to M/s Tuaman on19.02.14 CCD:18.06.15
Open
Constructio - Agency has been pressurised to mobilise resources and start work. n - Tank pads to be handed over from Aug'14 onwards.
BPCL / EIL
Jul'14
III
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project : Works to be awarded by BPCL
Open
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015.
BPCL
1-Jun-15
III
Timely Commissioning of UB package to meet refinery commissioning schedule. Contr. Sch: 42.9%; Act: 34.1% LAD : 31.03.15 (UB 1) 30.06.15 (UB 2)
Open
Constn.
-Strict monitoring required at all stages till award of UB Tender and further during execution. -Completeness of supply of all subparts, their assembly and other BOP Items to be ensured. - Special attention to be given to multi flue chimney.
Constn. / Projects / BPCL
as scheduled
IV
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 for 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.
As Required
IV
Implementation of environmental clearance conditions by EIL (received from MoEF vide Letter dated 22.11.12)
M
Action By
Open
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 57 ECD:Aug'15 Sch: 70.6 % Front: 100 % Act: 27.9 %
1
K
Action Plan
56
G
G
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Projects
- 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. Projects (e.g. configuration for CPP) - Incorporation of EC and RRA recommendations in balance systems under progress.
As required
IV
III
7
Non availability of Skilled workers
Open
Const.
-Utilisation of migrant labour and skilled labour from outside the state needs to be Constn / encouraged. However, the same will be effective only if proper labour colony facilities BPCL are arranged by the contractors. - Slow down in progress of work by Union workmen, inspite of assurance of trade union leaders that workers shall be instructed to improve productivity.
As Required
Variation in foreign exchange rates from Rs 50 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 (additionals in scope) has significantly impacted on the overall project cost.
Open
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
Jul'14
2
3
Constn. / Projects / BPCL
EIL/BPCL
II
Job No.: A307 Jun'14 Page 731+15 of 38
Y
Y
N
Open
Project
Very High
Y
Y
Y
N
Very High
Y
N
Y
Y
(Current risk Score Previous Risk score)
Y
Previous Risk Score
Very High
Current Risk Score -> {5}* {12}
Project
Impact Score => {6+7+8+9} * 10 * 11
Open
I
0.9
0.86
0.43
0.43
- 90 % model review & HAZOP review completed. - All R&R foundation along with TSS foundation completed. Handing over of TSS Projects fdn targeted by 08.07.14. Strl. Steel fabrication for R&R along with TSS: 3600 MT out of 3803 MT Constn completed. Strl. Steel erection for R&R- 645 MT out of 2300 (2300 MT for R&R & for TSS 1300 MT) MT erection completed. Flue gas, ESP & Stack fdn etc: Strl. material is ready for dispatch for flue gas cooler. Foundation work to be expedited. Strl. Steel erection for TSS - Work yet to be commence. Additional resource for assembly of modules, simultaneous erections of structures and delivery of cyclones to be expedited. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. BPCL
Progressively upto Aug'14
Short term
I
0.9
0.86
0.86
0.00
-M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. -Coke Drum (4 nos) & Main Fractionator : Subordered on M/s VTV (for site fabricated works). SS Clad (2231 MT) plates received at VTV shop. All fabrication yard area released. Approach road cleared on 09.06.14. Site fabrication to start. Mobilisation of 2000 MT crane targeted in Jan'15 and erection to be targeted from Mar'15 to May'15. BPCL/EIL - Strl. Fabr.: 169 MT out of 3560 MT completed. Sch for strl. erection is from 04.08.14 to 16.07.15. Strl. Fabrication Site to be visited in 1st week of Jul'14 and accordingly to review the performance and take decision for offloading (if required). - Manpower to be increased from present 227 to 505 for Civil work.
Jul'14
Short term
I
0.7
0.67
0.16
0.51
- During the project review meeting following points discussed and BPCL agreed: BPCL - Balance 16 nos units in the township to be handed over for grading by M/s Ray (SG-III). - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material. -Part of PEB1 new ware house handed over for material storage total warehouse handover after completion of work by Jul'14.
Jul'14
Urgency (Long Term / Short term)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Output Quality ( Y / N)
D
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 44.5 %; Act: 34.21 % Construction Progress: 9 Sch: 24.2 % Front: 92.2 % Act: 16.6 %
Schedule ( Y / N)
1
EIL Cost (Y / N)
D
Risk Owner
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 50.78 % Act: 37.58 % Construction Progress: Sch: 23.0 % Front: 85.0% Act: 9.3 %
Status (Open / Close)
Risk Id
Key Risk Description
Controllability Condition (D/I )
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Short term
Action Plan
Action By
Target Date
Risk Severity
I
I Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
E
2
Open
Constn.
I
Job No.: A307 Jun'14 Page 732+15 of 38
IV - RISK REGISTER
Output Quality ( Y / N)
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
N
Short term
I
0.9
0.86
0.86
0.00
- All long delivery equipments (incl.compressors) to be awarded progressively by BPCL/EIL mid Jul'14. Reactor ordered on M/s Phills Heavy (CDD: 21.12.14) - Award recommendation issued for Columns on 05.06.14. Health check compressor (BHEL make) on 05.06.14 New Compressor on 23.06.14 Refrigeration package on 29.05.14 - Composite Works (Civil Strl. & Mechanical) : Award recommendation targeted by 04.07.14.
Jul'14
E
Backlog 24.6 (% wrt target sch) as of 15-Jun-14 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 - 26M; Remaining Duration - 20 M Desc. Catch Up sch: Const Sch Front Act Overall 21.1 45.3 45.3 20.7 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, 7 VGO/DHDT & Offsite).
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Director level meeting held with contractors from May'14 to Jun'14. order to Constn complete the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, additional 1 tender for civil works already awarded (M/s Tuaman) and 2 additional civil & Strl works under tendering and likely to awarded by end Jul'14.. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the subvendors against performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and expedite progress. BPCL/EIL
As Required
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Retaining wall in progress. Reservoir wall dismantling & grade slab dismantling Constn. completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 28.05.14. and resources have been augmented. M/s B&R agreed to complete SRU earth filling work by 15.07.14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 905 nos piles completed against front of 910 nos at site by M/s MBEL. Release of balance piling front at site progressively by end Jul'14.Total nos of piles is 1828 nos piles BPCL/EIL
Jul'14
Urgency (Long Term / Short term)
Schedule ( Y / N)
Y
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) Y
Risk Owner
Very High
Key Risk Description
Status (Open / Close)
Completion duration for NHT/ISOM (Revamp) Open Constn. / Mechanical completion of NHT/ISOM - Target Schedule : Projects 30.09.15; Only 15 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. 4 Physical Progress: Target Sch: 51.6% Catch Up Sch: 18.1 % Act: 17.8 %
Risk Id
EIL Cost (Y / N)
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
I
E
Open
Const
I Area availability for SRU Block - At present only 85 % area given to M/s MBEL, balance Site for SRU block shall be available by end Jul'14. (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 Proj. / Constn.
Very High
Front for balance piling 918 nos will released progressively E 14 upto end Jul'14 on completion of site grading by M/s B&R.
I
Job No.: A307 Jun'14 Page 733+15 of 38
IV - RISK REGISTER
Output Quality ( Y / N)
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
N
Short term
I
0.7
0.67
0.67
0.00
-Director review meeting held on 13.05.14 Constr. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including EIL/BPCL approx 50 nos in fabrication yard). Manpower as on 10.06.14 is 151 nos -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. 387MT progressively by 30.06.14. Required qty. of reinforcement still not available at site. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). 06 nos bids received on 24.06.14.
As Required
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: E 43 Sch: 51.6 % Act: 10.1 %
Open Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.48
0.09
- Mobilisation work stated. -Parallel action being initiated to supplement the works of M/s Petron. Final decision shall be taken after reviewing the performance of M/s Petron for next 1 month, i.e upto mid Jul'14 based on milestones upto end Jun'14. - Shop fabrication work started. - Strl. Steel: 400 MT out of 800 MT ordered, balance ordering targeted by end Jul'14 progressively. To be followed up with M/s Petron.
Projects
As Required
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 E 48 Civil & Strl work-offsite DHDS Area Sch:60.7%; Front: 71.9%; Act: 8.4%
Open Constructi Very High on
Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-Tender on sale from 13 06.14, BDD- 07.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - NIT issued on 12.06.14, bids due on 04.07.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
BPCL / EIL
Urgency (Long Term / Short term)
Schedule ( Y / N)
Y
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) N
Slow Construction progress for Civil Works by M/s Shiram EPC Contr. Sch: 52.7%; Front: 69.4% Act: 17.6 % CCD: 24.12.14 ECD: Oct'15
Risk Owner
Very High
Key Risk Description
Status (Open / Close)
Open Project
Risk Id
EIL Cost (Y / N)
Kochi Refinery, BPCL Integrated Refinery Expansion Project
E 41
Action Plan
Action By
Target Date
Risk Severity
I
BPCL/EIL
I Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
7-Jul-14
I
Job No.: A307 MAY'14 Page 734 of 749
Integrated Refinery Expansion Project, Kochi
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 30.05.14 (Incinerator burner) 55 (Execution Duration - 14 M)
Risk Owner
C
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Incinerator burner:MR 7582: Price bids opened on 09.05.14. Award recommendation BPCL issued on 16.05.14. Delivery of waste heat boiler is affected due to burner data.
30-May-14
Open
Project
Award recommendation issued on 27.05.14. Award targeted by 05.06.14.
BPCL
5-Jun-14
Action Plan
Action By
Target Date
Risk Severity
I Award of Gas Booster Compressor for CPP (LAD:29.12.13; Ant: 05.06.14)
C
70
Open
Project
- 04 bids received on 02.04.14 (Petron, KSS, Techsharp & Bilfinger). PBO recommendation issued on 16.05.14, BPCL approval targeted by 30.05.14.
BPCL
20-Jun-14
C
Award of Composite Works (Mechanical & Civil /Strl. Works) for NHT/ISOM Sch: 08.05.14 76 Ant: 20.06.14
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 Ant: Sep'15 (Upto pre commissioning)
Open
Project
- 90 % model review completed on 20.03.14. - All R&R foundation work completed, TSS foundation targeted by 30.05.14. Strl. Steel fabrication drawingsTotal Qty: 2444 MT; Drawings released.: 2436 MT, balance targeted by end May’14. Strl. Fabr. workFabricated Qty.: 1644 MT; Dispatched Qty: 966 MT; Under Fabrication: 721 MT - Strl. Fabr. & erection for TSSTotal Qty.:1388 MT; under Fabrication.: 211 MT
Inspection
end May'14
II
II
D
1
Projects Constn
II
D
Completion of all three site Fabricated Columns for FCCU (M/s Fabtech) LAD: 22.01.15 CDD:14.01.15 ECD: 15.05.15
Open
Project
- Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). Order placed for Plates Project (BQ + LAS) on M/s Essar. 3685 MT out of 3747 MT Plates received at Chakan Shop, plate cutting & welding in progress. - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority to be assigned to main fractionator (IF-V-104). Taken up with M/s Fabtech.
Completion of MCC pkg for SRU LAD: 23.06.15 CDD:18.02.15 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 vendor from M/s Accometric. Meeting held with M/s Accometric on 28.05.14. Burner Flange details from burner vendor targeted by end May'14. -MCC: Shell Rolling is completed, C-seam welding is in process
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 21.11.15 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Bidder facing Financial crunch. Cum. Sch. 42.6; Act: 29.3 %
Open
Project
• M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. • Main Fractionator: 265 MT out of 290 MT clad plates received at VTV site & is under rolling, balance targeted by end May’14. Coke Drum: SS Clad (177 MT) plates received at VTV shop, balance 2054 MT expected to receive at VTV shop progressively by mid Jun’14. • The fabrication area to be cleared of rock and handed over by end May’14. Temporarily fabrication works panned near canteen area. Area marked for Coke drum A has been handed over to EPIL on 27.05.14.
7
As stated
II
D
8
EIL/BPCL
30-May-14
II
D
9
Area handing over by endMay'14
I
D
Delay in erection of Crude & vacuum column due to Open delayed ordering. Sch: Jun 14 Ant: Sep 14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV progress Sch ( 94.2 %); Act (83.5%)
BPCL / Director level meeting held with M/s VTV. M/s VTV agreed: Constn. / VTV 5-Sep-14 Projects / - Erection for crude column targeted from Jun'14 & hydro testing targeted by / Projects Const. 25.08.14. - Erection of Vacuum Column targeted from 07.07.14 to 02.08.14 & hydrotest planned in 05.09.14. -1000 MT Crane : Assembly work started. -500 MT Crane : Assembly work & Load test completed. II
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions. - M/s Tema due to financial constraint.
D
Open
Contract / Inspection
Equipment by Ganson Inspection - M/s Ganson agreed to supply balance item of CDU/VDU. Items for SRU and DCU refloated under MR-6560 (DCU) & MR-6120 (SRU): All items ordered. Projects -Slow progress by M/s Tema due to financial constraint. Meeting held on 06.05.14 with M/s TEMA.
30-May-14
16
II
Job No.: A307 MAY'14 Page 735 of 749
Integrated Refinery Expansion Project, Kochi
D
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Project
Action Plan - Hazop review completed. - Foundation drawing released. - 30 % model review targeted by mid Jun'14. - Filling of area & piling work completed, excavation commenced. Delivery of foundation bolts from Airoil being expedited. - Foundation to be handed over by Aug'14.
Action By
Target Date
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 Duration: 18 M 17 Ant: 24-Mar-15
Open
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15
Open
Projects
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held with M/s BHEL & M/s GE NP on 19.02.14, M/s BHEL to submit detailed catch-up plan. Meeting held on 26.05.14 with BHEL. BHEL has committed to deliver within CDD. 60% model review completed.
Open
Projects
- All load data and layout received from M/s Thermax. - Fan subordered to M/s Andrew Yule. -HRSG casing engineering targeted to complete by 25-June-14
Project/Inspe Continuous ction
- Target sch for completion by Sep'15 finalized and issued. All long delivery equipments (incl.compressors) to be awarded progressively by May'14. Reactor ordered on M/s Phills Heavy. - Unit shut down held from 04th May'14 to 14th May'14 all shutdown hook ups, blinding and dismantling of 7 equipments identified for shut down & is completed. - 70 % ISO's targeted to release by Jun'14, At present only 200/1296 nos ISOs released.
Project
Risk Severity
Projects/Cons As Required tr.
II
D
19
II
D
Delivery of HRSG Package LAD : 30.03.15 23 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13
II
E
4
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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.
Open
Constn. / Projects
May'14
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 67.9% Front: 100 % Act: 39.7% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Front available for all 11 buildings . Constn - MCR area, CPP control room area : all substructure RCC work targeted for completion by end May'14. - Manpower being augmented to 700 nos from present 550 nos. - Engineering for Packages like HVAC and Pressurization & Ventilation system in progress - Clean agent system: Drawings awaited from L&T. - Casting of foundations up to first expansion joint in MCR to be expedited. Strl. dwg. for Roof structures for MCR, SRR & substation to be cleared. - Lifts: Orders placed, drawings awaited.
As Required
Backlog 22.6 (% wrt sch) as of 15-May-14 in Construction activities viz., Piling work & Civil works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 26M; Remaining Duration - 20 M Desc. Const Sch Front Act Overall 40.8 37.1 18.6 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Director level meeting held with contractors from Apr'14 to May'14. rder to complete Constn the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - Civil Works-CDU/VDU & DCU : Structural work being expedited. -Civil Works -FCCU/VGO/DHDT/IREP/DHDS/Refinery area : Requirement for adequate mobilisation of resources being taken up with higher management of respective contractors. All agencies being expedited to submit catch-up plan for accumulating backlogs. - Misc. Civil & Strl works floated and awarded to M/s Tuaman.
As Required
Open
Project
- Project review meeting held on 15.04.14 with M/s Triveni at EIL HO. Huge backlog seen in detailed engg.Slow construction progress due to inadequate mobilization (asking rate has now gone up to 9-10% Per month). (Manpower Req 284 nos. Avl 118 Nos)
As stated
I
E
6
II
E
7
E
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating) Contr. Sch: 47.7 % Front: 100 % Act: 25.4% Sch: 15.11.14 CCD: 24.03.15 ECD: 24.03.15 13 Compl: 18 M+2M
I Constr.
II Area availability for SRU Block - At present only 75 % area given to M/s MBEL, balance Site for SRU block shall be available by mid Jun'14. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) - As per present trend 17 months (starting from end Apr’14) are available with respect to schedule of 25 M (As per Past experience minimum requirement for SRU is 30 M). E
Open
Proj. / Constn.
- Retaining wall in progress. Reservoir wall dismantling & 70& grade slab dismantling Constn. completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 26.04.14. and resources have been augmented. - At present only 313 nos manpower deployed at site. M/s B&R agreed to increase manpower upto 375 nos. Along with 3 excavators & dumper to be increased upto 40 nos from present of 20 nos by end May'14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 608 / 1828 nos piles completed at site by M/s MBEL.
End May'14
14
I
Job No.: A307 MAY'14 Page 736 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Constructio Meeting held with M/s KSSPPL on 05.05.14. M/s KSSIPL to deploy cumulative 200 Constr. n Manpower for Civil fdn work alone (Inside DHDS area) & 250 Manpower for Civil Fdn (IREP area) . As on date 83 & 216 nos deployed resp. Rock Blasting in IREP area being expedited for completion by end May'14. M/s Tuaman shall be deployed to supplement KSSPPL for trenches.
Target Date
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 27 Civil & Strl work-offsite IREP Area: Constr. Sch:84.8%; Front:70.2%; Act: 24.0% CCD: 08.10.14; ECD: 15.05.15
Open
Release of balance front to M/s Essar to start civil & Strl. work for CPP Contr. Sch: 56.3%; Front: 57.2%; Act:18.2% CCD:18.12.14; ECD: 18.02.15
Open
Project
- M/s Essar agreed to deploy additional manpower and machinery. Constr. Structural steel fabrication works: 490 MT received for GTG shed. 295MT fabrication completed. Release of balance Arc drawings for UG piping works, Earthing layout , precast works etc. to be expedited.
30-May-14
Open
Project
Director level meeting held with M/s Mcnally on 23.04.14 . - Manpower for all works to be increased to 150 from present 60 nos. - Strl Steel works: 370 MT shall be delivered progressively by 05-May-14. 170 MT of structural steel fabrication for TS-2 shall be done by 30-May-14
Continous
Progress of ETP Works (Handing over of graded area for ETP & dismantling of existing Oil Catcher. ) LAD: 30.09.15 (CDD:10.08.15) Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Meeting held with with M/s Paramount on 15.05.14 Project Work commenced in substation (5 out of 42 fdns cast) and equalisation tank. - Area handing over for RL-7 to M/s Paramount targeted progressively from 15.05.14. - Area for chemical house by 25.05.14 - area for TPI/API by 31.05.14
As stated
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 Ant: 03.04.15
Open
Project
KOM held at site on 29.01.14 BPCL - Radiant section fabrication drawings to be finalised across the table on fast track. - Vendor being pressurised to mobilised at site immediately. - Strl. Steel: Total 193 MT. Ordering targeted by mid Jun'14 progressively. To be followed up with M/s Petron. - Management meeting held with M/s Petron on 07.05.14. Action for slow progress to be taken against PETRON based on EIL’s CCEC decision, tender under preparation.
As Required
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
Open
Project
-KOM held on 28-29Jan'14 at EIL Delhi. Projects/BPC As Required - Burner data from Incinerator burner vendor required and same under ordering. L Input expected to receive by Jun'14. - Chamber (M/s Techno Process) & stack (M/s Loyd Steel) ordered on Indian Vendors, whereas order delivery is on FOB basis. Vendor has requested to amend free trade warehouse zone requirement to enable dispatch of materials. Matter taken up with BPCL.
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 Sch: 47.6 %; Front: 93.3%; Act:11.6 %
Open
Project
- Director level meeting held on 06.05.14 at EIL Delhi. Following points agreed: - Balance engineering including piping targeted to complete by mid Jun'14. - 90 % model review targeted by 15.06.14. - M/s Driplex advised to complete soil investigation substation building & RO-DM Shed areas.
Projects
As Required
Slow Construction progress for Civil Works by M/s ShriRam EPC Contr. Sch: 45.4%; Front: 56.7% Act: 12.8 % CCD: 24.12.14 ECD:31.05.15
Open
Project
-Director review meeting held on 13.05.14 Projects Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including approx 50 nos in fabrication yard) -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). NIT issued on 26.05.14, bids due on 17.06.14.
As Required
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15
Open
Project
- M/s Petron yet to mobilise at site to start work. BPCL - Shop fabrication work started. - Fans ordered. Load data expected by end May'14. - Strl. Steel: 160 MT out of 800 MT ordered, balance ordering targeted by mid Jun'14 progressively. To be followed up with M/s Petron. - Management meeting held with M/s Petron on 07.05.14. Action for slow progress to be taken against PETRON based on EIL’s CCEC decision, tender under preparation.
As Required
Risk Severity
30-May-14
II
E
28
E
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: 03.07.15 SCH. FRONT. ACT. 10.8% 29 40.7% 39.9 %
II Constr.
II
E
34
II
E
37
II
E
39
II
E
40
II
E
41
I
E
43
II
Job No.: A307 MAY'14 Page 737 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Slow Construction progress for Civil Works by M/s Mcnally Bharat for DHDT & VGO Sch: 61 %; Front :71.7 % Act: 28.9 %
Open
Project
-Director level meeting held with M/s MBEL on 23.04.14. M/s MBEL agreed: 323 MT of matching steel urgently required – shall be delivered progressively by 05May-14. All rock blasting targeted for completion by end May'14
Projects
As Required
Completion of PreEngineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open
Project
As Required
E
44
Work under progress by M/s B&R. 50 % work completed balance targeted by end Projects May'14 for PEB1. Buildings to be expedited for storage of material / equipment being received at site.
Open
E
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13. Civil & Strl work-offsite DHDS Area 47 Sch:54.2%; Front: 33.9%; Act: 5.4%
Constructio Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 n Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)SOR issued on 20.05.14. NIT targeted by 05.06.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - SOR issued on 20.05.14. NIT targeted by 05.06.14.
E
Risk Severity
44
II
II BPCL / EIL
5-Jun-14
I
Job No.: A307 MAY'14 Page 738 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
C
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Incinerator burner:MR 7582: Price bids opened on 09.05.14. Award recommendation BPCL issued on 16.05.14. Delivery of waste heat boiler is affected due to burner data.
30-May-14
Award of Gas Booster Compressor for CPP (LAD:29.12.13; Ant: 05.06.14)
Open
Project
Award recommendation issued on 27.05.14. Award targeted by 05.06.14.
BPCL
5-Jun-14
Ordering of additional Critical Valves
Open
Project
MR-3211 (417 nos): Award recommendation issued on 08.05.14. Award targeted by 30.05.14 Balance MR under preparation.
BPCL
30-May-14
20-Jun-14
Key Risk Description
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 30.05.14 (Incinerator burner) 55 (Execution Duration - 14 M)
Action Plan
Action By
Target Date
Risk Severity
I C
70
II III
C
73 Open
Project
- 04 bids received on 02.04.14 (Petron, KSS, Techsharp & Bilfinger). PBO recommendation issued on 16.05.14, BPCL approval targeted by 30.05.14.
BPCL
C
Award of Composite Works (Mechanical & Civil /Strl. Works) for NHT/ISOM Sch: 08.05.14 76 Ant: 20.06.14
Completion of MCC pkg for SRU LAD: 23.06.15 CDD:18.02.15 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 vendor from M/s Accometric. Meeting held with M/s Accometric on 28.05.14. Burner Flange details from burner vendor targeted by end May'14. -MCC: Shell Rolling is completed, C-seam welding is in process
EIL/BPCL
- Part Township area handed over by BPCL, 6 out of 19 buildings in colony handed over for dismantling, balance to be expedited by May'14 so as to ready for allocating to mechanical agencies by Jul/Aug'14.
BPCL
30-May-14
II III
BPCL / EIL
May'14
III
II
D
8
Space constraints: i) Area for Storage of Client materials ii) Area for Spool storage
E
Open
Constn.
30-May-14
'-Part of PEB1 new ware house handed over for material storage total warehouse handover after completion of work by end May'14. (Fabrication area handing over: R&R -90 % fabrication area handed over, CDSP (8500 out of 1000 sq.m handed over) balance by end May'14.
2
Meeting held with FACT authorities to lease out some land from FACT.
E
E
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 (Ant. Compln26 May- June'14, Compl date Committed by B&R – 13.11.13)
Open
Project
Culvert part I covering 8 m out of 13 m shal be completed by first week of June 14. further the balance stretch shall be taken up.
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 Ant: 03.04.15
Open
Project
KOM held at site on 29.01.14 BPCL - Radiant section fabrication drawings to be finalised across the table on fast track. - Vendor being pressurised to mobilised at site immediately. - Strl. Steel: Total 193 MT. Ordering targeted by mid Jun'14 progressively. To be followed up with M/s Petron. - Management meeting held with M/s Petron on 07.05.14. Action for slow progress to be taken against PETRON based on EIL’s CCEC decision, tender under preparation.
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
Open
Project
-KOM held on 28-29Jan'14 at EIL Delhi. Projects/BPC As Required - Burner data from Incinerator burner vendor required and same under ordering. L Input expected to receive by Jun'14. - Chamber (M/s Techno Process) & stack (M/s Loyd Steel) ordered on Indian Vendors, whereas order delivery is on FOB basis. Vendor has requested to amend free trade warehouse zone requirement to enable dispatch of materials. Matter taken up with BPCL.
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15
Open
Project
- M/s Petron yet to mobilise at site to start work. BPCL - Shop fabrication work started. - Fans ordered. Load data expected by end May'14. - Strl. Steel: 160 MT out of 800 MT ordered, balance ordering targeted by mid Jun'14 progressively. To be followed up with M/s Petron. - Management meeting held with M/s Petron on 07.05.14. Action for slow progress to be taken against PETRON based on EIL’s CCEC decision, tender under preparation.
Open
Constructio Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 n Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)SOR issued on 20.05.14. NIT targeted by 05.06.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - SOR issued on 20.05.14. NIT targeted by 05.06.14.
37
As Required
II
E
39
II
E
43
E
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13. Civil & Strl work-offsite DHDS Area 47 Sch:54.2%; Front: 33.9%; Act: 5.4%
As Required
II BPCL / EIL
5-Jun-14
I
Job No.: A307 MAY'14 Page 739 of 749
Integrated Refinery Expansion Project, Kochi
1
1
G
2
I
2
K
2
M
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project : Works to be awarded by BPCL
Open
Projects
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 for 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.
As Required
IV
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
30-May-14
III
Non availability of Skilled workers
Open
As Required
IV
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open
Variation in foreign exchange rates from Rs 50 per USD as on Mar 12 to Rs. 59 per USD as on date and fluctuations in the intermediate period and Scope changes w.r.t. DFR (additionals in scope) has significantly impacted on the overall project cost.
Open
Key Risk Description
G
K
Risk Owner
F
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
4
3
Action Plan BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015.
Action By BPCL
Constn. / Projects / BPCL
Projects / - IBR package for DCU targeted after 90 % model review. EIL/BPCL BPCL - List of all the buildings in IREP along with the plinth area details for taking approvals from F&B as well as Panchayath issued to BPCL on 12.04.14, BPCL to take approval Approval for tall strl/stacks: Signed documents with 6 sets handed over on 13.05.14, BPCL to take approval -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
Const.
Utilisation of migrant labour and skilled labour from outside the state needs to be Constn / encouraged. However, the same will be effective only if proper labour colony facilities BPCL are arranged by the contractors.
Project/Eng - BPCL to inform the probable date of commencement of metro work. g - Alternate route for ODC movement to be checked. - RCM issued letter to BPCL . Issue has been put to the notice of Kochi metro & District Collector.
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
BPCL
EIL/BPCL
Target Date 1-Jun-15
As stated
30-May-14
Risk Severity III
III
III
Job No.: A307 May'14 Page 740+13 of 36
IV - RISK REGISTER
Schedule ( Y / N)
Output Quality ( Y / N)
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)
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Incinerator burner:MR 7582: Price bids opened on 09.05.14. Award BPCL recommendation issued on 16.05.14. Delivery of waste heat boiler is affected due to burner data.
30-May-14
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 21.11.15 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Bidder facing Financial crunch. 9 Cum. Sch. 42.6; Act: 29.3 %
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
• M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. • Main Fractionator: 265 MT out of 290 MT clad plates received at VTV site & is under rolling, balance targeted by end May’14. Coke Drum: SS Clad (177 MT) plates received at VTV shop, balance 2054 MT expected to receive at VTV shop progressively by mid Jun’14. • The fabrication area to be cleared of rock and handed over by end May’14. Temporarily fabrication works panned near canteen area. Area marked for Coke drum A has been handed over to EPIL on 27.05.14.
Area handing over by endMay'14
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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. 4 - Change in the scope based on health check report has an impact on Project cost and schedule.
Open Constn. / Projects
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
- Target sch for completion by Sep'15 finalized and issued. Project All long delivery equipments (incl.compressors) to be awarded progressively by May'14. Reactor ordered on M/s Phills Heavy. - Unit shut down held from 04th May'14 to 14th May'14 all shutdown hook ups, blinding and dismantling of 7 equipments identified for shut down & is completed. - 70 % ISO's targeted to release by Jun'14, At present only 200/1296 nos ISOs released.
May'14
Backlog 22.6 (% wrt sch) as of 15-May-14 in Construction activities viz., Piling work & Civil works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 26M; Remaining Duration - 20 M Desc. Const Sch Front Act Overall 40.8 37.1 18.6 Backlog in Civil / strl works will affect 7 availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Director level meeting held with contractors from Apr'14 to May'14. rder to Constn complete the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - Civil Works-CDU/VDU & DCU : Structural work being expedited. -Civil Works -FCCU/VGO/DHDT/IREP/DHDS/Refinery area : Requirement for adequate mobilisation of resources being taken up with higher management of respective contractors. All agencies being expedited to submit catch-up plan for accumulating backlogs. - Misc. Civil & Strl works floated and awarded to M/s Tuaman.
As Required
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 30.05.14 (Incinerator burner) C 55 (Execution Duration - 14 M)
Urgency (Long Term / Short term)
EIL Cost (Y / N)
Project
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Risk Owner
Open
Risk Id
Status (Open / Close)
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
I
D
I
E
I
E
Const
I
IV - RISK REGISTER
Schedule ( Y / N)
Output Quality ( Y / N)
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)
N
Short term
I
0.6
0.57
0.57
0.00
- Retaining wall in progress. Reservoir wall dismantling & 70& grade slab Constn. dismantling completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 26.04.14. and resources have been augmented. - At present only 313 nos manpower deployed at site. M/s B&R agreed to increase manpower upto 375 nos. Along with 3 excavators & dumper to be increased upto 40 nos from present of 20 nos by end May'14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 608 / 1828 nos piles completed at site by M/s MBEL.
End May'14
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
-Director review meeting held on 13.05.14 Projects Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including approx 50 nos in fabrication yard) -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). NIT issued on 26.05.14, bids due on 17.06.14.
As Required
Open Constructi Very High on
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative BPCL / EIL 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-SOR issued on 20.05.14. NIT targeted by 05.06.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - SOR issued on 20.05.14. NIT targeted by 05.06.14.
5-Jun-14
Open Proj. / Constn.
Slow Construction progress for Civil Works by M/s ShriRam EPC Contr. Sch: 45.4%; Front: 56.7% Act: 12.8 % CCD: 24.12.14 ECD:31.05.15
Open Project
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13. Civil & Strl work-offsite DHDS Area Sch:54.2%; Front: 33.9%; Act: 5.4%
Very High
Urgency (Long Term / Short term)
EIL Cost (Y / N)
Y
Area availability for SRU Block - At present only 75 % area given to M/s MBEL, balance Site for SRU block shall be available by mid Jun'14. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) - As per present trend 17 months (starting from end Apr’14) are available with respect to schedule of 25 M (As per Past experience minimum requirement for SRU is 30 M).
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
N
Risk Owner
Y
Status (Open / Close)
Risk Id
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Key Risk Description
Job No.: A307 May'14 Page 741+13 of 36
E 14
Action Plan
Action By
Target Date
Risk Severity
I
E 41
I
E 48
I
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 742+12 of 749+12 As of 08-Mar-13
13
14
15
0.4
0.38
0.38
0.00
- Awarded to M/s UOP on 22-Nov-12. - Agreement singed with M/s UOP on 15.02.13 - PFD review held from 25th to 27th Feb’13. - P&ID submission from Licensor expected by 04-Apr-13 and review targeted from 22-Apr-13 at USA.
Projects / Process
24-May-13
Delay in Process Package for TGTU (M/s CB & Open INC) LAD : 31-Dec-12 ; Ant : 15-Apr-13
BPCL / Process
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
-P&ID review meeting held from 25 Feb 13 to 06 Mar 13 at Texas. Final Process package targeted by 15.04.13.
Projects / Process
15-Apr-13
Projects / POSD
22-Mar-13
(Current risk Score Previous Risk score)
12
I
Previous Risk Score
11
Short term
Current Risk Score -> {5}* {12}
10
N
Impact Score => {6+7+8+9} * 10 * 11
Controllability Condition ( D / I ) ((40% / 100%)
9
Y
Output Quality ( Y / N) (10% / 0%)
8
N
Schedule ( Y / N) (40% / 0%)
7
N
EIL Cost (Y / N) (30% / 0%)
6
Very High
3
Project Cost ( Y / N) (20% / 0%)
5
BPCL / Process
2 Delay in Process Package for NHT / ISOM LAD : 30-Apr-13 ; Ant : 24-May-13
A
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Urgency (Long Term / Short term) (50% / 100%)
1
Risk Owner 4
Open
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
1
Action Plan
16
Action By
17
Target Date
Risk Severity
18
19
II
A
2
II
A
-Preparation of Offsites P&ID’s for tankages (LAD - 21.01.13) - Delay has been due to delay in receipt of Asbuilt drawings from BPCL-KR (except CEMP#REF! II). All details recieved now. -Upgradation of Crude oil pipeline system (Inside refinery)
Open
POSD
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Out of 32 P&IDs, 29 nos. issued for engineering and 3 nos. issued for comments. Balance P&ID-1142 & 1143 (Fuel Oil), and 1140 (ATF) issue for engineering targeted by 22-Mar-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.
Open
Process
Very High
Y
Y
Y
Y
Short term
D
0.4
0.38
0.38
0.00
- All PDS for ARU & SWS revised. P&IDs for ARU (part) Process / R&D 31-Mar-13 issued. All Revised P&IDs (ARU & SWS) targeted to issue by 16.03.13. -Major PDS for SRU revised and balance PDS / P&IDs targeted for issue by 19.03.13. Utility distribution P&IDs Issued for engineering - ARU/SWS/SRU from 20.03.13 onwards. ' - Rev.A issued for CW, N2 , Air , Steam and BFW/Service water/DM water (7 / 15 issued).
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Open
Process
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
Based on latest information from BOO HGU and SWII (FCC), Projects / Revised Design Basis targeted by 04.03.13. Process Approval from BPCL targeted by 18.03.13.
II
A
A
18-Mar-13
II III
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 743+12 of 749+12 As of 08-Mar-13
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
12
13
14
15
I
0.4
0.20
0.152
0.05
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New BPCL facilities) has been issued for engineering. Balance 1 no. targeted by 15.03.13 -During PRM dated 28.02.13 and 01.03.13, EIL informed that pending information (for CPP, FCCU, NSU-I, SRU and HGU) is required from BPCL on priority to clear the OSBL distribution drawings.
31-Mar-13
Finalisation of tender for Civil works including piling in demountable Flare area (Delay in award of Flare adversely affecting the sch.) Sch - 20-May-13; Ant - 31-Jul-13
Open
Strl
Very High
Y
Y
Y
N
Long term
I
0.45
0.43
0.4275
0.00
Load details required from Flare vendor for finalisation of piling Projects tender and drawings. Load data from demountable flare vendor to be obtained at offer stage and tender to be finalised based on recomnended vendors data (load data is likely by end Jun'13).
31-Jul-13
Timely availability of piling and load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule requirements. LAD - 28-Feb-13; Ant - from Mid Apr 13 to Sep 13.
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Firm layout and other relevant data for piling to be asked ENGG/PLNG from Package Vendors at offer stage. -Award of GTG package targeted by 15.06.13. -Award of UB package targeted by 15.04.13. -Award of HRSG package targeted by Aug'13 - Issue piling layout targeted progressively from Apr to Sep'13. - Any balance piling left to be taken up through additional piling tender III.
Sep'13
HRSG package on critical path since the HRSG PDS can be finalised after receipt of GTG exhaust data. Sch Order - 22-May-13; Ant - Aug 13 Tender prepared & uploaded in eDMS, BQC approved by BPCL on 05.03.13, further BQC being revised.
Open
Engg
Very High
Y
N
Y
N
Long term
I
0.3
0.29
0.285
0.00
- To finalise PDS for HRSG based on GTG exhaust data of selected vendor (data received with offers) and issue amendment. The same is expected by end May 13. - Based on the above Award of HRSG targeted by Aug 13. - Strict monitoring of HRSG Tender at various stages preaward and during execution.
ENGG
Aug'13
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 31-Mar-13 Duration: 16 M FOB
Open
Project
High
Y
Y
N
N
Short term
I
0.5
0.40
0.40
-Licensor’s reply (for flow, temp & pressure related issues) recd on 06.03.13. Revised MR targeted to be issued by 18.03.13.
Engg (Elec)
31-Mar-13
(Current risk Score Previous Risk score)
11
Short term
Previous Risk Score
10
N
Current Risk Score -> {5}* {12}
9
Y
Impact Score => {6+7+8+9} * 10 * 11
8
N
Output Quality ( Y / N) (10% / 0%)
7
N
Schedule ( Y / N) (40% / 0%)
6
Medium
EIL Cost (Y / N) (30% / 0%)
5
Process
Project Cost ( Y / N) (20% / 0%)
4
Open
2
Risk Owner
Controllability Condition ( D / I ) ((40% / 100%)
B
Urgency (Long Term / Short term) (50% / 100%)
1
A
3
Final issue for OSBL distribution P&IDs LAD: 30-Nov-12 ANT: 31-Mar-13
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
###
#REF!
Action Plan
Action By
16
17
Target Date
Risk Severity
18
19 III
II
B
II
B
II
C
1
II
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 744+12 of 749+12 As of 08-Mar-13
13
14
15
0.9
0.86
0.3325
0.52
- NIT issued on 11.02.13 and NDA signed upto 19.02.13.BDD C&P / Engg / extended upto 04.04.13, original BDD- 19.03.13. Projects -Post bid receipt, Techno/commercial evaluation to be done across the table within 1 month
15-Jun-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
0.32
-0.32
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months. BPCL
28-Feb-13
Ordering of GTG Pkg (LAD:10-Mar-13; Ant 15-Jun-13) Bid due date further extended to 22.03.13. (Earlier BDD - 11.02.13, 08.03.13) 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
0.86
0.855
0.00
- Technical evaluation targeted by 30.04.13. Projects / BPCL - Task force from concerned disciplines will be centrally located for evaluation of bids and action plan will be issued for adherence to the above target.
Ordering of Reactor regenerator package for FCCU LAD : 10-Apr-13 Ant: 15-Jun-13 Changes in scope of supply led to revision in BQC / tender due to which NIT was delayed.
Open
Project / Licensor
Very High
Y
Y
Y
N
0.9
0.86
0.86
-Tender on sale from 19.02.13 to 25.03.13. Pre bid meeting Projects / BPCL 15-Jun-13 held on 11.03.13. Amendment targeted by 15,03.13. Bid due date being extended to 16.04.2013. -Techno/commercial evaluation by task force will done across the table within 1 month i.e. by . An action plan for evaluation will be issued for adherence by the team. - Bidders seeking extension in execution duration (30-36 months against RFQ duration of 24 months). Proposed to extend to 27 Months.
Award of UB package LAD : 19-Jan-13 Ant : 21-Apr-13
Open
Process / Engg / constn
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
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. targeted by 25.03.13.. Award targeted by 21.04.13.
Engg. / Projects 21-Apr-13 / Process / C&P / BPCL
Ordering of Ejector Pkg (LAD:12-Jan-13) Ant: 30-Apr-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
02 Bids received on 11.01.13. Meeting held with bidders. TBA under preparation.
Proj/Engg
30-Apr-13
Award of Sulphur Pelletiser LAD: 03-Apr-13 Ant; 15-Jul-13 Enquiry being re-floated due to changes in MR requirements by BPCL.
Open
Project
Very High
N
Y
Y
N
Short term
D
0.28
0.27
0.06
0.21
-Evaluation Process of original MR stalled based on BPCL mail dated 12.03.13. - Revised MR targeted by 15.04.13. - Award targeted by mid Jul 13.
C&P
15-Jul-13
(Current risk Score Previous Risk score)
12
I
Previous Risk Score
11
Current Risk Score -> {5}* {12}
10 Short term
Impact Score => {6+7+8+9} * 10 * 11
Controllability Condition ( D / I ) ((40% / 100%)
9 N
Output Quality ( Y / N) (10% / 0%)
8 Y
Schedule ( Y / N) (40% / 0%)
7 Y
EIL Cost (Y / N) (30% / 0%)
6 Y
2
Delay in award of CDSP package Sch: 02-Mar-13 Ant:15-Jun-13 Earlier PQ was envisaged as NDA agreement was to be signed with prospective bidders. Now #REF! Bidders has to sign NDA before downloading the tender.
Project Cost ( Y / N) (20% / 0%)
5 Very High
1
Risk Owner 4 Project
Key Risk Description
Status (Open / Close) 3 Open
Risk Id
Urgency (Long Term / Short term) (50% / 100%)
C
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Integrated Refinery Expansion Project
Action Plan
Action By
16
17
Target Date
Risk Severity
18
19
I
C
C
###
15-Jun-13
I
C
Short term
I
#REF!
I
C
II
C II
C
II
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 745+12 of 749+12 As of 08-Mar-13
12
13
14
15
I
0.4
0.38
0.38
0.00
Award recommendation sent on 08.03.13. Award targeted by BPCL 31.03.13. BPCL response on L1 bidders under holiday, under review by C&P
31-Mar-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Bids due date extended upto 26.03.13 Orginal: BDD:26.02.2013
31-May-13
###
Award for RO-DM LAD:30-Jan-13 Ant: 31-May-13
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.855
0.00
Projects/ '- The revised design basis issued to BPCL-KR for their Process/ approval on 06.03.13 Engg / C&P/ - Process data sheet (IFE) targeted by 16-03-13 and layout by 16-03-13. - Due to significant Technical and commercial changes (consortium bids is acceptable) tender to be refloated. Same is targeted by end Mar'13. Award targeted by end Jul'13.
31-Jul-13
###
Delay in Award of contract for Demountable flare (LAD: 08-Apr-13; Ant: 31-Jul-13) - Change in type of Flare. Initially as per DFR normal flare was envisaged. - Post enquiry significant changes in Flare Load/Process Data Sheet due to enormous increase in BOO flare load and non acceptance of mitigation measures by FCCU Licenser.
NIT for ETP package with WAO (Wet air oxidation)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Tender under preparation, readiness by 18.03.13. BQC to BPCL by 18.03.13. NIT publishing targeted by 22.03.13
Engg
22-Mar-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Price bids opened on 11.03.13. Award recommendation targeted by 18.03.13.
C&P
31-Mar-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Award recommendation sent on 07.03.13. Award targeted by 31.03.13.
C&P
31-Mar-13
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 Ant: 30-Mar-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.475
-0.10
Price bids opened on 19.02.13. Award Recommendation issued on 05.03.13. Award of works by end Mar'13.
C&P
30-Mar-13
Handing over of Land for project usage
Open
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
Client to be followed up to acquire the allocated land and hand BPCL over to the project usage at the earliest.
Risk Owner
(Current risk Score Previous Risk score)
11
Previous Risk Score
10 Short term
Current Risk Score -> {5}* {12}
9 N
Impact Score => {6+7+8+9} * 10 * 11
Controllability Condition ( D / I ) ((40% / 100%)
8 Y
Output Quality ( Y / N) (10% / 0%)
7 N
Schedule ( Y / N) (40% / 0%)
6 N
2 Award of contract for RWTP
EIL Cost (Y / N) (30% / 0%)
5 Very High
1
Project Cost ( Y / N) (20% / 0%)
4 Project
Key Risk Description
Status (Open / Close) 3 Open
Risk Id
Urgency (Long Term / Short term) (50% / 100%)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Integrated Refinery Expansion Project
LAD: 14-Jan-13
C
Action Plan
Action By
16
17
Target Date
Risk Severity
18
19
Ant: 31-Mar-13 (Execution Duration - 22 M)
C
II Engg
II
C
I
C
###
LAD: 15-Jan-13 Ant: 22-Mar-13 II Award of contract for Building incl substations LAD: 07-Feb-13
C
###
Ant: 31-Mar-13
II Award of contract for Piling-II LAD: 31-Dec-12 C
###
Ant: 31-Mar-13 II
C
E
###
#REF!
Proj.
Continuous
II III
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 746+12 of 749+12 As of 08-Mar-13
E
E
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
10
11
12
13
14
15
Y
Long term
D
0.1
0.03
0.03
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.
Dismantling of LO CAT SRU (Required for New tankagesTF-4) by BPCL : will affect release of front for tankages.
Open
BPCL
Medium
N
N
Y
Y
Long term
D
0.1
0.05
0.05
0.00
Relocation of existing FWPH (Constn. / Commng.) and site grading of area for handing over for SRU. (Ant - Aug'13) Site for SRU block shall be available only after dismantling of existing FWPH & reservoir. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) As per present trend 25 months are available with respect to requirement of minimum 30 M.
Open
Proj. / Constn.
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
Area for MCR and FCC Feed Tanks: Diversion of ETP II to ETP III and development of area reqd. by Apr.13 Ant: Jun'13
Open
Proj. / Constn.
Very High
N
N
Y
N
Short term
I
0.4
0.38
Land acquisition for Crude tank (2 nos.) . (LAD - Jul 13; Ant - Apr 13)
Open
Proj.
Very High
N
N
N
N
Short term
I
0
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
Medium
Y
N
Y
Y
Long term
I
0.35
Risk Owner
(Current risk Score Previous Risk score)
9
Y
Previous Risk Score
8
N
Current Risk Score -> {5}* {12}
7
N
Impact Score => {6+7+8+9} * 10 * 11
6
Low
Output Quality ( Y / N) (10% / 0%)
5
Constn.
Schedule ( Y / N) (40% / 0%)
4
Open
2
EIL Cost (Y / N) (30% / 0%)
3
Payment to contractors
Project Cost ( Y / N) (20% / 0%)
Controllability Condition ( D / I ) ((40% / 100%)
E
Urgency (Long Term / Short term) (50% / 100%)
1
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
Action Plan
Action By
16
Target Date
Risk Severity
17
18
19
within 7 days of certified RA bills
IV
Tender being floated by BPCL-KR and site will be available by BPCL Apr 13
30-Apr-13
IV
0.00
- Relocation of FWPH and reservoir (including civil works and Constn. grading of area) targeted by end Aug 13. (Contractual milestone of SG II contractor M/s B&R for civil works is July 13) - Award of Composite works (by ROC) for relocated pump house targeted by end May 13. Award to local agency for rerouting of piping works to be taken up by RCM, if works can be taken up parallely. - Engineering / Procurement activities for Sulphur block to be expedited parallely. - Award for Piling II (which includes piling of reatining wall) by -Mar-13. - Construction Execution Philosophy for award of Piling / Civil under review/ finalisation. Award of works being targeted by end Aug 13.
30-Aug-13
0.38
0.00
- Scheme for re-routing of ETP-II to ETP-III finalised. - Routing to be completed by end Apr 13 so that dismantling of ETP-II can be commenced. Constn. - All MR's (for pumps & piping materials) have been floated. Availability of OWS & CRWS pumps to be ensured within 4 Projects months of order i.e. by Jun 13. - Electrical procurement initiated, Cables (part) ordered. BPCL to confirm the availability of cables (For connection with ETPIV) by May 13. - Readiness of CRWS / OWS sump by Apr 13 to be monitored. Micro schedule for completion of works under preparation by EIL site for rigorous monitoring. Constn
0.00
0.38
-0.38
During meeting held on 28/29.01.13, BPCL-KR informed that BPCL land shall be made available by Mar/Apr’13. EIL requested BPCL to provide survey/ coordinate details and bore hole data details of land area for preparation of site grading work tender
Apr-13
II IV
0.18
0.175
0.00
BPCL to expedite
As Required
III
BPCL
#REF!
#REF!
#REF!
I
E
E
#REF!
E
#REF!
BPCL
BPCL
1-Jun-13
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 747+12 of 749+12 As of 08-Mar-13
I
13
14
15
0.2
0.19
0.19
0.00
- Adequacy report for CDU II issued on 11.03.13. - Adeauqcy report for CEMP II targeted after finalisation of IREP flare design.
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project : Works to be awarded by BPCL
Open
Projects
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
1
Statutory approvals - PESO Approval for IREP complex - DGCA approval
Open
Projects / BPCL
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
12.09
10.86
1.24
(Current risk Score Previous Risk score)
12
I
Previous Risk Score
11
Current Risk Score -> {5}* {12}
10 Short term
Impact Score => {6+7+8+9} * 10 * 11
9 N
Output Quality ( Y / N) (10% / 0%)
8 N
Schedule ( Y / N) (40% / 0%)
7 N
EIL Cost (Y / N) (30% / 0%)
6 Y
2
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and #REF! CEMP-II flare
Project Cost ( Y / N) (20% / 0%)
5 Very High
1
Risk Owner 4 Project
Key Risk Description
Status (Open / Close) 3 Open
Risk Id
Controllability Condition ( D / I ) ((40% / 100%)
F
Urgency (Long Term / Short term) (50% / 100%)
E
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Integrated Refinery Expansion Project
1
Action Plan
Action By
16
17 BPCL / EIL
Target Date
Risk Severity
18
19
31-Mar-13
III
BPCL-KR to ensure that Hydrogen & Nitrogen are available by BPCL Jun’2015.
1-Jun-15
III
- Documents for submission to PESO authorities for approval BPCL sent to BPCL-KR on 25.01.13. Meeting with PESO authorities scheduled on 13.03.13 at Nagpur. - BPCL to obtain DGCA approval on priority (in any case before award of flare).
18-Mar-13
II Total Risk Score
7718
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
Kochi Refinery, BPCL
Job No.: A307 Apr'15 Page 61+14 of 30
E
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
Job No.: A307 Apr'15 Page 264+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 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
Job No.: A307 Apr'15 Page 267+14 of 30
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 268+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 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
Job No.: A307 Apr'15 Page 269+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
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
Job No.: A307 Apr'15 Page 271+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
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
Job No.: A307 Apr'15 Page 272+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
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
Job No.: A307 Apr'15 Page 277+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
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
Job No.: A307 Apr'15 Page 281+14 of 30
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
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 300+14 of 30
IV - RISK REGISTER
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
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
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
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 305+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}
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
Job No.: A307 Apr'15 Page 307+14 of 30
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 314+14 of 30
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
IV - RISK REGISTER
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
Job No.: A307 Apr'15 Page 319+14 of 30
IV - RISK REGISTER
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
IV - RISK REGISTER
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 done during Feb 2015. Bal 600 MT fabrication to be done by 28.02.15.
Feb'15
I
E
II
E
50
II
E
51
II
E
E
E
E
E
E
53
54
55
56
57
9
10
11
12
13
14
15
16
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.
Feb'15
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
Feb'15
III
Urgency (Long Term / Short term)
8
N
Schedule ( Y / N)
7
N
EIL Cost (Y / N)
6
Open Constructi Very High on
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
(Current risk Score Previous Risk score)
E
4
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: 39.6% Front : 24.7% Actual : 11.3% 29040 / 285505 ID fabricated & 139484 / 1214330 IM erected.
2
52
Status (Open / Close)
Risk Id E
3
Action Plan
Key Risk Description
1
Job No.: A307 Jan'15 Page 613+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
17
Target Date
Risk Severity
18
19
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 14.01.15 -TS I by 28.02.15 -TS II, III & IV,VI handed over. -TS V by 27.04.15 -TS VII by 28.02.15. - Main piperack completion targeted by 31.01.15
Constr.
Feb'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
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: 98.7 % Act: 90.6 %
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 14.01.15 - 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.
EIL/BPCL
Feb'15
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT383/391) Sch : 44.3% Front : 48.2% Actual : 13.7%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level Meeting held on 14.01.15 - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT383/391/150. - Annular plate erection for tanks YT-26&YT-28 started. - YT-150: Dismantling activities in progress. - YT-383: Dismantling activities in progress. Plate material ordered. - YT-391: tank cleaning under progress. - Ordering of plate material to be expedited. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement.
EIL/BPCL
Feb'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: 96.4 % Front: 100 % Act: 56.8 %
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held on 08.01.2015 with M/s B&R at site. - Round the clock work to commence from 26.12.14. - YT 341 : hydrotest in Mar'15 - YT 342 : Annular plate erection from 03.02.15 - YT 343 : First jacking on 05.02.15. - YT 344 : First jacking on 03.02.15. - YT 111 : 4 / 8 shells completed - YT 112 : 4 / 8 shells completed - YT 113 : 2 / 8 shells completed - YT 114 : 2 / 8 shells completed -Manpower required is 250 nos, available is 186.
EIL/BPCL
Feb'15
III
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 CCD:18.06.15 Sch: 81.7 % Front: 68.5 % Act: 31.5 %
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. -Agency has been pressurised to mobilise resources and start work. - SWS-1 Sour water tank & sour water storage tank pads handed over. 2 tanks fdn handed over , 1 tank fdn by mid Jan & balance fdn by end Jan'15.
Constr.
Feb'15
Open Project
58
59
Action By
II
61
E
62
E
63
E
64
F
1
F
F
G
2
3
1
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected. Piping fabrication work in progress. Structural fabrication yet to commence.
Constr.
Feb'15
III
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: 39.0% Front: 9.1% Act: 4.4% 500 ID / 232725 ID piping fabrication completed. 2304 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 12.11.14 at site. M/s OIL has been asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Mobilisation for 20 nos auto welding machine to be expedited.
Constr.
Feb'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. 16415 / 298905 ID fabricated. 339 IM / 299780 IM erected. Sch : 29.6% Front : 31.4% Actual : 7.9%
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 09.12.14 at site. M/s OIL has been asked to mobilise resources, fabrication yard in progress - 600 MT crane mobilised - At present only 13 nos welders are available at site with per day rate of 220 ID, however to achieve the completion schedule minimum 1000 ID/day to be achieved.
Constr.
Feb'15
III
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
0.20
-0.08 -Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. Piping III contract awarded BPCL to M/s Keller Ground Engineering & work commenced. 435 piles completed.
Feb'15
III
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 : 13.6% Actual : 11.0% 38734 ID / 145080 ID piping fabrication & 10410 / 248080 IM completed.
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected, side cladding in progress. Piping fabrication work in progress. Piping erection work commenced on the main pipe rack.
Constr.
Feb'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.
Urgency (Long Term / Short term)
7
N
Schedule ( Y / N)
6
Low
EIL Cost (Y / N)
5
Open Constructi on
Constn.
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
(Current risk Score Previous Risk score)
E
4
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. Sch : 33.6% Front : 22.5% Actual : 14.7% 48160 ID / 210605 ID piping fabrication completed. 10352 IM / 301995 IM erected.
2
60
Status (Open / Close)
Risk Id E
3
Action Plan
Key Risk Description
1
Job No.: A307 Jan'15 Page 614+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Project/BPCL As Required
IV
2 Infrastructure at Kochi
G
2
G
3
G
4
G
5
G
6
G
7
7
8
9
10
11
12
13
14
15
16
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.
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 Process / stage. POSD / Engg. / Projects
All by 60% constn progress
sep'13
Urgency (Long Term / Short term)
6 N
Process / Engg.
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 Low
Schedule ( Y / N)
4 Const.
EIL Cost (Y / N)
3 Open
Scope changes & information flow to executing Open group
Action By
Target Date
Risk Severity
18
19
17 Constn. / Projects / BPCL
As Required
IV
Non-performing vendors
Open Inspn
Low
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 Y
N N
Y N
N N
Short Short term term
D D
0.16 0.08
0.00 0.00
-- BPCL-KR videwith e-mail dated 06-Dec-12 sent a list of Non plantplan buildings to be located under IREP Project. Projects Meeting held BPCL on EIL recommendations and action finalised. BPCL / The same is reviewed by EIL.for Point wise issues targeted to be discussed with BPCL in week starting -- BPCL to take up with MOEF approval of changes in system already incorporated. (e.g. configuration for Projects 15.04.13. CPP) List of buildings between EIL and BPCL.inMethodology for execution under finalisation. -- Incorporation of finalised EC and RRA recommendations balance systems under progress.
15-Apr-13 As required
Apr'13 IV
0.00
- Documents approved from PESO
BPCL
Finalisation of Non plant buildings.clearance Implementation of environmental conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Close Open
Delay in commencement of site work for dyke Close wall inside TF-3 affected due to non availability of PESO approval for tankage area I
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 615+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Purch / Contrc.
BPCL Projects Low Medium
Engg. / Proj.
Medium
N
N
Y
N
Long term
I
0.2
0.04
0.04
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
Feb'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
I
2
Const.
Very High
N
N
Y
Y
Short term
D
0.2
1
Implementation of Health, Safety and environmental (HSE) system
Open
J
Const.
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 Mobilisation of Skilled workers
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
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/En ODC movement schedule is from Nov'13 to Feb gg 15.
High
N
N
Y
N
Long term
I
0.2
0.00
Closed as no concern as on date.
BPCL
Cost monitoring & control on regular basis
Costing
High
Y
N
N
N
Short term
D
0.08
0.00
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
Environ.
Very High
Y
N
N
N
Short term
D
0.08
0.00
Scope of facilities finalised.
Environ.
15-Oct-13
sep'13
K
K
K
2
3
K
4
M
1
M
2
0.40
0.40
At present only approx 11000 labours are working against requirement of 15000-18000 labours. Constraint in movement & transportation of ODC eqpt.
Increase in facilities on account of deletion zero liquid discharge
Close Open
As stated
II Jun'14
Jun'14
M
3
Total Risk Score
5
6
7
8
9
10
11
12
Low
Y
N
Y
N
Short term
I
0.6
13
23.06
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% / 10%)Cost Project ( 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 Jan'15 Page 616+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
15
16
0.18
-0.18 - BPCL have informed that approval for revised cost received.
23.46
-0.39
Action By
Target Date
Risk Severity
17
18
19
EIL/BPCL
Job No.: A307 Dec'14 Page 617 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: 86.4% Act: 58.4 % Construction Progress: Sch: 53.8% Front: 85.2% Act: 21.6 %
Open
Project
Management level meeting held on 14.11.14 at site. EIL/BPCL - Hard stand construction completed. - Crane (1600 MT): mobilisation by 15.02.15. EPIL/GRE to arrange another crane (1000 MT-from M/s VTV) for Regenerator bottom section erection. - EPIL-GRE informed to dispatch cyclones for reactors by 30.12.14 and regenerator cyclones by Feb'15. M/s Emtrol is being expedited. - Erection of TSS bottom and top section targeted by end Jan'15. - Hydrotesting for Regenrator & TSS targeted by Mar'15. - Erection of regenerator bottom section targeted from end Jan'15. - Erection of external riser targeted by end Feb'15. - Erection of reactor bottom section targeted by end Jan'15. - Agencies being pressurized to expedite completion of balance works by Dec’15 and requested to submit Catchup plan. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Jan'15-Mar'15
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: 99.6 % Act: 63.2 % - 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
-Meeting held on 22.11.14, vendor agreed to deliver main fractionator by Jan'15 and EIL/BPCL balance columns by Mar/Apr'15. - 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 10-15 days. - Erection for main fractionator targeted by 2nd week 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 Feb'15. Preparation of Hard stand to commence. Erection of bottom section for rectifier expected to commence from end Mar'15. - Approach road work completed. Area improvement to be expedited for crane movement.
As stated
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 EIL/BPCL data from M/s Accometric. 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 end Jan'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. 73.4 %; Act: 56.5 % Construction Progress: Sch: 54.4% Front: 97.9 % Act: 29.4 %
Open
Project
Weekly review meeting held on 19.12.14. Constr. Following commitments have been made by M/s Essar. -Shift Work: M/s EPIL has been asked to start works in two shifts. - 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 being opened. - M/s Essar have been pressurized to deliver all coke drums progressively upto Apr’15 EIL/BPCL and Coke fractionator by end Mar’15. - Crane (2000 MT): Shipment work started from 05.12.14. 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. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Erection by May'15
Key Risk Description
1
Action Plan
Action By
Target Date
Risk Severity
I
D
D
D
7
8
9
II III
I
D
12
Delay in erection & hydrotesting of Vacuum column Open Sch: Jun 14 CCD: 21.08.14 Ant: end Jan'15 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 80%
BPCL / - Erection of Crude Column : Crude column erection & hydrotesting completed. Projects / - Erection of Vacuum Column : Vacuum column bottom section erected on 13.12.14. Const. Middle section planned on 05.01.15 & top section erection planned on 20.01.15.
VTV/EIL/ BPCL
end Jan'15
II
Job No.: A307 Dec'14 Page 618 of 749
Integrated Refinery Expansion Project, Kochi
Status (Open / Close)
Risk Owner
Risk Id
RISKS REQUIRING ATTENTION
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
- 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).
Continuous
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
- Order got delayed due to delay in manufacturing works. At present fabrication of Stripper column going beyond Dec’14 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.
EIL/ BPCL
Dec'14
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Jan'15 Sch: (Intermediate MTO-3): Oct'14 EDD: Jan'15 to Feb'15
Open
Projects
- As of now around 66% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Jan'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
EIL/ BPCL
Jan'15
Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 7-8 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: 85.4% Catch Up Sch: 55.1 % Act: 42.7%
Open
Constn. / Projects
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued on EIL/ BPCL 30.10.14, BPCL comments received on 04.11.14. As per BPCL email dated 01.12.14, Tender splits into two parts & draft NIT for mechanical/strl works forwarded to BPCL.
end Dec'14
Backlog 9.2% as of 15-Dec-14 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 46.7 70.7 61.6 37.5 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site.
Open
Const
- In order to supplement progress of failing civil contractors, 4 separate contracts EIL/ BPCL have been awarded (M/s Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray Eng-Misc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works awarded on 23.12.14 & are under mobilisation. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 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 of 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. - Management level meeting being planned with various misc.Civil/Strl contractors in Jan'15. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. - All agencies being pressurised to mobilise additional resources and recover the backlog. - In order to boost progress, permission from labour union of Kochi to be taken up for two shift work.
As Required
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
Mar'15
Key Risk Description Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site
D
13
(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)
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 expected to arrive at jetty by 06.01.15. - Construction of jetty work to be expedited. - Erection of reactor planned with 1000 MT crane by mid Feb'15. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at Kochi-Port.
Action By EIL/BPCL
Target Date
Risk Severity
Delivery of DHDT reactor at site by Jan'15
ISGEC Josen (3 nos) Column: expected to receive at Kochi port from end Jan'15 to mid Mar'15.
II
D
19
II
D
32
II
D
33
II
E
4
I
E
E
7
8
Completion of Civil & Strl. works: RCC Qty: 1, 87,386 m3 out of 3, 05,066 m3 completed; Steel Qty: cum. 27,767 MT out of 53344 MT fabricated & cum. 17,643 MT erected.
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)
BPCL
I IV
Job No.: A307 Dec'14 Page 619 of 749
Integrated Refinery Expansion Project, Kochi
E
14
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION Action Plan
Action By
- Management level meeting held with M/s B&R on 17.11.14 at EIL site and Constn. augmentation of manpower by min. 100 nos to be expedited for concreting work progress. All area handed over in SRU block except for peripheral road. - 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 (120 nos) targeted to complete by end Jan'15. Balance piling work completion targeted by mid Feb'15. - Civil works completion targeted by mid May’15 and handing over of front to EIL/BPCL mechanical contractor targeted from end Feb’15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
Target Date
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
Proj. / Constn.
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Constr. Sch:100%; Front:99.7%; Act: 50.1% CCD: 08.10.14; ECD: Jun'15
Open
Constructio -Management level meeting held with M/s KSSIIPL at site on 02.12.14. EIL/BPCL n - 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.
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. 94.9% 76.8 % 35.6%
Open
Project
- Management level meeting held at site on 13.11.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - TS-06 : Raft work completed. Structural steel erection targeted by 30.12.14. - Structural Erection commenced for TS-2 and for TS-03 targeted by 30.12.14. - Out of total 1800 nos piles, 1140 nos completed. Pile cutting completed for 547 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by 15.01.15. - Out of total structural work of 4290 MT, only 1085 MT fabrication completed & 251 MT erection works completed. UG piping erection work yet to commence.
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: 55.4% Front: 57.55% Act: 28.4 %
Open
Project
- Management level Meeting held with M/s OIL on 12.11.14 and following action plan EIL/BPCL has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Auto blasting m/c received, being installed.
Continuous
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 80.6 % Act: 29.9 % Construction Progress: Sch: 64.3% Front: 100 % Act: 16.9 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Management level meeting held on 05.12.14. - Completion of engineering by M/s Paramount targeted by end Dec’14. - Completion of equalisation tank targeted by Mar'15. - Chemical house super strl work completion targeted by mid Mar’15. - M/s Paramount has been asked to start night shift work with immediate effect to boost construction progress. - During the meeting on 05.12.14, M/s Paramount informed that ETP plant can be made ready by Dec’15.
EIL/BPCL
As stated
Completion of works for Tankage-II (Awarded to M/s B&R on 25-Sep-13) Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 78.2 %; Front:86.6% Act: 32.4 %
Open
Project
- Management level meeting held on 17.11.14 at site. Total tanks: (New tanks 13 nos, EIL/BPCL work in progress for 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) - Delivery to be expedited.
As stated
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: 97.4 % Act: 61.9% Construction Progress: Sch: 98.2 %; Front: 100%; Act:29.5 %
Open
Project
- During the meeting on 05.12.14, M/s Driplex informed that DM water can be EIL/BPCL provided by Sep’15 for CPP 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 (72/160 nos piling completed).
As Required
Risk Severity
15-Feb-15
I
E
27
Jan'15
II
E
29
II
E
30
II
E
34
I
E
35
II
E
40
I
Job No.: A307 Dec'14 Page 620 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION Action Plan
Action By
-Mobilisation of resources is being expedited. At present only 187 nos manpower mobilised against a requirement of 700 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -5300 m3 RCC work has been already withdrawn from SEPC scope to M/s Tuaman EIL/BPCL scope. Additional 1500 m3 RCC work being offloaded from SEPC scope to M/s PGC. 2495 MT strl works offloaded to M/s Tuaman, M/s Zillion & M/s Ray engg.
Target Date
Risk Severity
Open
Project
41
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 99.5%; Front: 100% Act: 55.3 % CCD: 24.12.14 ECD: Oct'15
As Required
Open
Constructio -Work stopped by M/s KSSIIPL. Balance work being expedited by additional Misc. EIL/BPCL n Civil/Strl contractor. -Cable trench cast in situ offloaded to PGC (Misc Civil contract) - Additional agencies including M/s Ray Engg. & M/s Zillion have been lined up to supplement Structural works. Another misc Civil/Strl work contract floated, award targeted by end Jan'15. - Additional agencies including M/s Deens, M/s Furnace fabrica & M/s KSS have been lined up to supplement Structural works. Another misc Civil/Strl work contract floated, award targeted by end Jan'15.
Jan'15
49
Slow construction progress by M/s KSSIIPL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:98.5%; Front: 77.3%; Act: 18.4%
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: 30.68 % Front: 23.30% Act.: 7.42% AG piping fabrication: Only 35316 ID / 406975 ID fabrication completed. AG piping erection: Only 31039 IM / 526435 IM piping erection completed.
Open
Constructio Management review meeting held on 11.12.14. n -30 fitters, 40 welders & the required machineries shall be deployed by 25.12.14 -M/s B&R has been asked to expedite1200 ID/day by end Dec '14. - Finalisation of 2 more piping/eqpt agencies at site by third week of Dec'14. -Insulation/painting agency finalization by 31.01.15. - Hanger scaffolding to be introduced at site.
31-Jan-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:95.2%; Front: 95.9%; Act: 25.4% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held at Kochi site on 09.12.14. EIL/BPCL n - 2500 m3 of RCC shall be targeted to cast by Jan'15. - 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 done during Jan & Feb'15. Bal 600 MT fabrication to be done by 28.02.15. - Strl detailing completion by 31.12.14. -600MT & 1000 MT erection targeted by Jan & Feb 15 respectively. - 125 MT crane to be deployed by 12.12.14 & 150 MT by 15.01.15.
Feb'15
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:32.1%; Front: 8.5%; Act: 4.3%
Open
Constructio Management level meeting held 11.12.14 at site. n -Piping management system shall be installed by 10.01.15. - B&R to take up compressor erection immediately.
EIL/BPCL
10-Jan-14
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: 86.1 %
Open
Constructio Management level meeting held on 05.11.14. 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.
EIL/BPCL
Feb'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. - 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.
-Utilisation of migrant and skilled labour from outside Kerala needs to be encouraged. EIL / BPCL 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.
As Required
I
E
I
E
51
EIL/BPCL
II
E
E
E
F
G
K
52
54
57
1
1
2
At present only approx 9000 labours are working against requirement of 15000-18000 labours.
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’15 for CDU/VDU commissioning.
II III
II
Job No.: A307 Dec'14 Page 621+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
Y
N
Short term
D
0.16
0.05
0.05
0.00
Open Engg/Cont .
Low
N
N
Y
N
Short term
D
0.16
0.05
0.08
-0.03 - 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 Dec'14. -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.
Delay in Interface Engineering (including control system) due to non availability of Package Vendor Data
Open Engg/proc urement
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
Generation of Surplus Piping material
Open
ENGG
Low
N
N
Y
N
Short term
D
0.16
0.05
0.05
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N)
N
Open
EIL Cost (Y / N)
Low
Signing of ISBL P&IDs and battery limit P&IDs for Units, Utility packages & other packages.
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) Process / POSD
Key Risk Description
Status (Open / Close)
Risk Id
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
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 targeted by end Dec'14.
Action By
Target Date
Process / POSD /
30-Dec-14
IV
Engg
30-Dec-14
IV
Package vendor inputs being made available by expediting for updation of interface engineering documents. Projects / Engg.
Continuous
IV
0.00
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
Progressively
IV
EIL/BPCL
15-Jan-15
A
27
B
CPP: Integration of various packages & BOP Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas 19 Booster compressor.
B
23
B
30 Ordering of Critical Valves Sch: 11.07.14 73 Ant: 15.01.15 Dely: 06/07 M FOT /FOB
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
C
-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, TBA issued on 29.12.14.
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 75 Ant: 15.01.15
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
0.15
0.15
0.00
-Total 32819 / 34373 nos (95%) isometrics issued for units . Balance ISO's targeted progressively by mid Engg. Jan'15. -Total 1576 / 2298 nos (69%) GAD's issued for units . Balance GAD's targeted progressively by mid Jan'15.
15-Jan-15
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM-Refloated 76 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
- 4 nos bids received on 30.09.14. PBO recommendation issued on 30.10.14, BPCL comments received on EIL/BPCL 04.11.14. As per BPCL email dated 01.12.14, Tender being split into two parts. Draft NIT targeted by 31.12.14
15-Feb-15
Delay in award of piping material with G2E specification 79 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 FCCUM/s Essar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 86.4% Act: 58.4 % Construction Progress: Sch: 53.8% Front: 85.2% Act: 21.6 %
Open
Project
Very High
Y
Y
Y
N
I
0.9
0.86
0.86
0.00
Management level meeting held on 14.11.14 at site. EIL/BPCL - Hard stand construction completed. - Crane (1600 MT): mobilisation by 15.02.15. EPIL/GRE to arrange another crane (1000 MT-from M/s VTV) for Regenerator bottom section erection. - EPIL-GRE informed to dispatch cyclones for reactors by 30.12.14 and regenerator cyclones by Feb'15. M/s Emtrol is being expedited. - Erection of TSS bottom and top section targeted by end Jan'15. - Hydrotesting for Regenrator & TSS targeted by Mar'15. - Erection of regenerator bottom section targeted from end Jan'15. - Erection of external riser targeted by end Feb'15. - Erection of reactor bottom section targeted by end Jan'15. - Agencies being pressurized to expedite completion of balance works by Dec’15 and requested to submit Catchup plan. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Jan'15-Mar'15
Open
Project
Very High
N
N
Y
N
I
0.2
0.19
0.19
0.00
Management review held on 13.11.14 to pressurised M/s ISGEC for completing within CCD. - 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 commenced for UB-1.
Continuous
C
C
Risk Severity
II III
II C
D
D
1
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 3 Overall progress: Sch: 99.0 % Act: 73.7 % Construction Progress: Sch:98.7 % Front: 100 % Act: 35.6 %
Short term
Long term
II
Project / Constn.
I III
Job No.: A307 Dec'14 Page 622+15 of 30
(Current risk Score Previous Risk score)
N
N
N
Long term
I
0
0.00
0.00
0.00
MRT completed on 10.11.14. Dispatch expected by Jan'15. - Condensate pump subordered to M/s Flowserve targeted to receive at shop by mid Jan'15.
Project/Inspe 27-Jan-15 ction
IV
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 6 (CDD: 24.12.14; EDD: 28.02.15)
Open
Project
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Project/Inspe 28-Feb-15 Lube oil system under final testing. Further the final testing likely get delayed due to delayed delivery by M/s ction Enpro. Close monitoring to be done to ensure delivery on CDD.
IV
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: 7 Sch: 99.6 % Act: 63.2 % - 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
N
Y
N
Short term
I
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 10-15 days. - Erection for main fractionator targeted by 2nd week 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 Feb'15. Preparation of Hard stand to commence. Erection of bottom section for rectifier expected to commence from end Mar'15. - Approach road work completed. Area improvement to be expedited for crane movement.
As stated
Open
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 Accometric. BPCL / EIL 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 end Jan'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
D
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 8 erection)
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
Weekly review meeting held on 19.12.14. Constr. Following commitments have been made by M/s Essar. -Shift Work: M/s EPIL has been asked to start works in two shifts. - 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 being 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): Shipment work started from 05.12.14. 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. - Management level review meeting being planned with M/s Essar by 2nd week of Jan'15.
Erection by May'15
D
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. 73.4 %; Act: 56.5 % Construction Progress: 9 Sch: 54.4% Front: 97.9 % Act: 29.4 %
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.06
-0.06 - All items received at site.
D
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) 10 Dely: 18 M Ordered to M/s BHEL on 28.06.13
Project/Inspe end Dec'14 ction
Delivery of RGC compressor for DHDT(LAD :05.02.15; 11 Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.06
-0.06 - Received at site and erected.
D
Project/Inspe 27-Dec-14 ction
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.00
D
D
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N)
Low
EIL Cost (Y / N)
Project
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Open
D
Key Risk Description
Status (Open / Close)
Delivery of wet gas compressor for DCU at Site (M/s Eliot Ebara) 5 LAD: 05.12.14 (CDD: 27.01.15; EDD: 27.01.15)
Risk Id
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
II III
I
D
Delay in erection & hydrotesting of Vacuum column Open Sch: Jun 14 CCD: 21.08.14 Ant: end Jan'15 (Vacuum column) Normally 12-14 Months are required for Unit Mechanical 12 Compln after erection of Crude & Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 80%
BPCL / Projects / Const.
0.38
- Erection of Crude Column : Crude column erection & hydrotesting completed. Constn. / - Erection of Vacuum Column : Vacuum column bottom section erected on 13.12.14. Middle section planned VTV / on 05.01.15 & top section erection planned on 20.01.15. Projects
Jan'15
II
Job No.: A307 Dec'14 Page 623+15 of 30
D
D
D
D
D
D
D
N
N
Y
N
Short term
I
0.4
0.38
0.32
0.06
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - DHDT reactor unloaded into barge on 26.12.14 and expected to arrive at jetty by 06.01.15. - Construction of jetty work to be expedited. - Erection of reactor planned with 1000 MT crane by mid Feb'15. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at KochiPort.
Jan'15
Close Monitoring of ODC equipment (including site 14 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; 20 nos received at site. & 4 nos under dispatch. Balance under close monitoring and are expected at site from Nov'14.
Continous
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Apr-15 17 Ant: 24-Mar-15 Overall Progress Sch: 55.9 % Act: 47.4 % Construction work likely to start from Oct'14.
Open Project
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- Flare foundation work completed. Projects/Con As Required - Fabrication of flare structure is in progress and delivery expected from Dec'14 onwards. Construction work str. to be started from Dec'14 onwards.
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 19 CCD: 25.04.15 EDD: 31.10.15
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
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).
Project/Inspe Continuous ction
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 20 CDD: 03.04.15 Ant: 03.04.15
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 21 EDD: 30.03.15 Overall Progress: Sch: 95.0 % Act: 90 %
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
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 is 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 within CDD.
Project/Inspe Continuous ction
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 CDD: 07.10.14 22 Overall Progress: Sch: 98 % Act: 95.0 %
Open
Projects
High
N
N
Y
N
Long term
I
0.2
0.16
-0.16 - Reactor received at Kochi port and unloaded to barge on 26.12.14.
Project/Inspe Continuous ction
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 23 Awarded to M/s Thermax on 20.12.13 Overall Progress: Sch: 64 % Act: 53 %
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- 90% model review for HRSG planned in end Dec'14. - 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
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) 24 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 25 CDD: 30.03.15 Overall progress: Sch: 51 %; Act: 46 %
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 Dec'14 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 by end Dec'14.
III
Urgency (Long Term / Short term)
Very High
Schedule ( Y / N) Output Quality ( Y / N)
T&CC
EIL Cost (Y / N)
Open
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
(Current risk Score Previous Risk score)
D
Previous Risk Score
D
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: 13 unloaded onto barge on 26.12.14) ISGEC Josen (3 nos) Column: expected to receive at Kochi port from end Jan'15 to mid Mar'15.
Key Risk Description
Status (Open / Close)
Risk Id D
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Shipping
Target Date
Risk Severity
II IV
III
II IV
III
Job No.: A307 Dec'14 Page 624+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
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
D
Delivery of Make up Gas Compressor -VGO( Ordered to Open M/s Nueman & Essar on 14.11.13 ) 28 LAD : 26.02.15 CDD: 13.04.15
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).
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.: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.
Jan'15
III
Delay by vendor with respect to CDD due to financial constraint.
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N)
N
EIL Cost (Y / N)
Low
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) 27 LAD: 29.01.15 CDD: 10.03.15
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) Projects
Key Risk Description
Status (Open / Close) Open
Risk Id D
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
D
29
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 Dec’14 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.
Dec'14
D
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) CDD: 18.10.14 32 EDD: 31.03.15
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Jan'15 33 Sch: (Intermediate MTO-3): Oct'14 EDD: Jan'15 to Feb'15
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- As of now around 66% piping material has been received at site. Ordering of balance material is in progress and expected progressively upto Jan'15. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
EIL/ BPCL
Jan'15
Delivery Gas Booster Compressor for CPP (Dly: 13 M 34 FOB
Open
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
Dec'14
II IV
Delay in delivery of equipments by: Open 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 35 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
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
Dec'14
III
Delay in submission & finalisation of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. 36 CDD: 19.05.15
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
-Reduction furnace layout drawing to be finalised in order to give front for release of piling drawings. - Submission of drawing by vendor & approval by HMTD to be expedited.
HMTD/Projec Dec'14 ts
Medium
Y
N
Y
Y
Short term
D
0.28
0.14
0.14
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
II
D
D
D
D
E
Open
Space constraints: Open i) Area for Storage of materials for project and package 2 contractors ii) Area for Spool storage
Constn.
Dec'14
II III
Job No.: A307 Dec'14 Page 625+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
N
Short term
I
0.9
0.86
0.86
0.00
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued on 30.10.14, BPCL comments received on 04.11.14. As per BPCL email dated 01.12.14, Tender splits into two parts & draft NIT for mechanical/strl works forwarded to BPCL.
BPCL/EIL
Dec'14
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 Jan'15 to May'15. - L&T also agreed to augment required manpower to meet the target completion date.
Constn
As Required
Const
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
- In order to supplement progress of failing civil contractors, 4 separate contracts have been awarded (M/s Constn Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray Eng-Misc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works awarded on 23.12.14 & are under mobilisation. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 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 of 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. - Management level meeting being planned with various misc.Civil/Strl contractors in Jan'15. - Additional mechanical contracts being awarded to supplement existing mechanical contractors. - All agencies being pressurised to mobilise additional resources and recover the backlog. - In order to boost progress, permission from labour union of Kochi to be taken up for two shift work.
As Required
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 Mar'15.
BPCL
Mar'15
Open
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.29
0.29
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 end Dec'14. - Chemical house works completion being targeted by end Dec'14 - 90 % Model review held on 03.11.14.
Constr.
Dec'14
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 99.7 % Front: 100 % 6 Act:66.2 % CCD: 20.12.14 Ant: 15.07.15
Open
Backlog 9.2% as of 15-Dec-14 in Construction activities Open 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 46.7 70.7 61.6 37.5 Contractors are facing problem in retaining the labour at site. Approx 10000 labours are available against requirement of 20000 at site.
Urgency (Long Term / Short term)
Y
Open Constn. / Projects
Schedule ( Y / N) Output Quality ( Y / N)
Y
Construction of NHT/ISOM (Revamp) - Target Schedule : 30.09.15; Only 14 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. 4 Physical Progress: Target Sch: 85.4% Catch Up Sch: 55.1 % Act: 42.7%
EIL Cost (Y / N)
Y
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) Very High
Status (Open / Close)
Risk Id E
Key Risk Description
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
I
E
II
E
E
7 Completion of Civil & Strl. works: RCC Qty: 1, 87,386 m3 out of 3, 05,066 m3 completed; Steel Qty: cum. 27,767 MT out of 53344 MT fabricated & cum. 17,643 MT erected.
Relocation of existing facility (PRU Flare) for clearance for BOO area. 8 Dismantling of PRU flare can start after commissioning of Demountable flare (Commissioning expected by end Mar'15) Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
E
Overall Progress: Contr. Sch: 94.1 % Act: 66.4% 13 Construction Progress: Sch: 92.3 % Front: 100 % Act: 61.1 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
I IV
II
Job No.: A307 Dec'14 Page 626+15 of 30
E
E
E
E
(Current risk Score Previous Risk score)
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Management level meeting held with M/s B&R on 17.11.14 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 block except for peripheral road. - 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 (120 nos) targeted to complete by end Jan'15. 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 EIL/BPCL from end Feb’15 onwards. - To meet Euro-IV compliance, readiness of ARU/SWS targeted by Dec’15.
Dec'14
Urgency (Long Term / Short term)
Y
Schedule ( Y / N) Output Quality ( Y / N)
Previous Risk Score
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) 14 - 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)
Very High
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Status (Open / Close)
Risk Id E
Key Risk Description
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
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 19 delivery as 24.11.14.
Open
Const. / Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- All 3 GTGs received at site. - Extension sought by M/s BHEL. - Contractor for Mechanical works for CPP awarded to M/s Zillion. - N2 compressor (Delivery period is approx 6-8 M) : Ordered on 01.08.14, delivery going upto beyond Dec 2014.
Projects
Dec'14
Completion of UG piping work due delay in receipt of piping material and monsoon.
Open
Const.
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Pipes under shortage (IS pipes of 30", 40", 48") delivery to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team. - All balance material deliveries being expedited by Jan'15, subsequently all UG piping work completion targeted by Feb'15.
EIL/BPCL
Feb'15
Open
Project
Very Low
N
N
Y
N
Short term
I
0.4
0.04
0.20
-0.16 Management level meeting held with B&R on 17.11.14 at site. Culvert top slab completed, rerouting of existing KWA drinking water supply line completed.
Constrn.
end Dec'14
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Constr. Sch:100%; Front:99.70%; Act: 50.11% CCD: 08.10.14; ECD: Jun'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 with M/s KSSIIPL at site on 02.12.14. - 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
Jan'15
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 99.8%; Front: 100%; Act: 58.0% 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 19.09.14 at site & 25.09.14 at EIL HO. - Foundation work completed for HRSG-3. - Completion of Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - Completion of boiler piperack foundations targeted by 30.12.14 (20/21 nos raft completed).
EIL/BPCL
Dec'14
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 FRONT. ACT. 29 SCH. 94.9% 76.8 % 35.6%
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 13.11.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - TS-06 : Raft work completed. Structural steel erection targeted by 30.12.14. - Structural Erection commenced for TS-2 and for TS-03 targeted by 30.12.14. - Out of total 1800 nos piles, 1140 nos completed. Pile cutting completed for 547 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by 15.01.15. - Out of total structural work of 4290 MT, only 1085 MT fabrication completed & 251 MT erection works completed. UG piping erection work yet to commence.
Continuous
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 30 ECD: 30.10.15 Contr. Sch: 55.4% Front: 57.55% Act: 28.4 %
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 12.11.14 and following action plan has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Auto blasting m/c received, being installed.
Continuous
22
Construction of Subway on the PWD road including re routing of existing road / existing facilities and necessary liasoning with government department. 26 Construction of culvert got affected (Ant. Compln-end Dec'14)
27
Risk Severity
I III
I IV
II
E
28
II
E
II
E
EIL/BPCL
II
Job No.: A307 Dec'14 Page 627+15 of 30
N
Long term
I
0.3
0.15
0.15
0.00
-Meeting held at site on 10.09.14. - Piling work commenced (929 out of 1642 nos piles completed: 7-8 piles/day) M/s TKII to augment piling rigs immediately. -TKII has been advised to commence work in all work fronts to achieve min. 5% construction progress.
Constr.
Medium
Y
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 str 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
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
Management level meeting held on 05.12.14. - Completion of engineering by M/s Paramount targeted by end Dec’14. - Completion of equalisation tank targeted by Mar'15. - Chemical house super strl work completion targeted by mid Mar’15. - M/s Paramount has been asked to start night shift work with immediate effect to boost construction progress. - During the meeting on 05.12.14, M/s Paramount informed that ETP plant can be made ready by Dec’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 17.11.14 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
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 59.9 % Front: 100.0 % Act: 41.4 %
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 37 Overall Progress: Sch: 88.9% Act: 44.6 % Construction progress: Sch: 63.2% Front: 60.65% Act:30.3%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 39 CCD: 30.06.15; EDD: 30.09.15 (As per Vendor) Overall Progress: Sch: 70 % Act: 19 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Project
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 32 Overall Progress: Sch: 77.8 % Act: 70.8 % Construction work: Sch- 67.5% Front:97.2% Act:39.6%
Open Project
Slow progress of ETP works by M/s Paramount LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 80.6 % Act: 29.9 % 34 Construction Progress: Sch: 64.3% Front: 100 % Act: 16.9 % 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 35 Sch: 78.2 %; Front:86.6% Act: 32.4 %
Project
Urgency (Long Term / Short term)
Y
Open
Schedule ( Y / N) Output Quality ( Y / N)
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 31 Construction: Sch:37.2 %; Front:100.0%; Act:14.56% Overall Progress: Sch: 51.3 % Act: 37.9%
EIL Cost (Y / N)
Y
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
(Current risk Score Previous Risk score)
E
Previous Risk Score
E
Medium
Key Risk Description
Status (Open / Close)
Risk Id E
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Continuous
Risk Severity III
III
I
E
Awarded to M/s B&R on 25-Sep-13 II
E
E
E
0.32
0.00
Constr.
As stated
-Management level meeting held on 14.11.14 - Structural steel: Out of total 217 MT, 200 MT received. - Fabrication 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.
Project
As Required
- PO amendment issued on 15.12.14. - Finalisation of subvendor for expansion bellows to be expedited.
Projects
As Required
- Plate erection to be expedited for YT-26/28. - Sand filling works to be expedited in YT-25.
II III
II
Job No.: A307 Dec'14 Page 628+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
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 (72/160 nos piling completed).
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 99.5%; Front: 100% Act: 55.3 % 41 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 at Kochi on 18.09.14. -Mobilisation of resources is being expedited. At present only 187 nos , manpower mobilised, against a requirement of 700 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). EIL/BPCL -5300 m3 RCC work has been already withdrawn from SEPC scope to M/s Tuaman scope. Additional 1500 m3 RCC work being offloaded from SEPC scope to M/s PGC. 2495 MT strl works offloaded to M/s Tuaman, M/s Zillion & M/s Ray engg.
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15 42 Constr. Progress: Sch: 87.9 % Front: 100 % Act: 62.7 %
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: 43 Sch: 97.7 % Act: 53.6 % Construction Progress: Sch: 80.6% Front: 96.1% Act.: 17.4%
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 M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 Sch: 97.27 %; Front :99.55 % Act: 63.71 % - Structural erection: DHDT: 825 MT / 2600 MT 44 completed.; VGO: 746 MT / 3065 MT completed. -UG Piping Laying: DHDT: 11089 IM / 25400 IM completed; VGO: 11038 IM / 42000 IM completed.
Open Project
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
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 end Dec'14. Project Material storage commenced. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. Buildings to be expedited for storage of material / equipment being received at site.
Constrn.
As Required
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 14.10.14 at site. Commitment made by M/s PCT has again slipped. Manpower at site is 392 nos instead of committed 670 nos. Supply of balance U/G and A/G Piping Material by PCTL to be expedited. Shortage of TMT steel (540 MT) to be expedited. PCTL to target to complete all Civil work by Dec'14.
EIL / BPCL
As Required
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N)
Y
EIL Cost (Y / N)
Very High
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Open Project
Key Risk Description
Status (Open / Close)
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: Act: 61.9% 40 Sch: 97.4 % Construction Progress: Sch: 98.2 %; Front: 100%; Act:29.5 %
Risk Id E
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
I
E
E
E
E
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E
E
45
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 46 Overall Progress: Sch: 100 % Act: 77.3 % Construction progress: Cum Sch: 100% Front: 100% Cum Act: 71.2%
II III
Job No.: A307 Dec'14 Page 629+15 of 30
(Current risk Score Previous Risk score)
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.
EIL / BPCL
As Required
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. -Cable trench cast in situ offloaded to PGC (Misc Civil contract) - Additional agencies including M/s Ray Engg. & M/s Zillion have been lined up to supplement Structural works. Another misc Civil/Strl work contract floated, award targeted by end Jan'15. - Additional agencies including M/s Deens, M/s Furnace fabrica & M/s KSS have been lined up to supplement Structural works. Another misc Civil/Strl work contract floated, award targeted by end Jan'15.
EIL/BPCL
Dec'14
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 12.12.14 at site. EIL/BPCL - M/s Petron agreed to start night shift. - 150MT crane is under transit. 80MT crane shall be shortly deployed. 200MT crane to be despatched soon. The 150MT & 200 MT cranes shall be operational by end Dec'14. - 10 nos semi automatic welding machines shall be operational by third week of Dec 14. 26 nos welding machines are under transit. - Auto blasting shall start by end Dec '14. - 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 Dec '14. - Second RT agency to start work by end Dec'14. Source pit & concrete bunker to be prepared by PECL. - 1000 ID/day to be achieved from 3rd week of Dec 14. - SS welder qualification to start by end Dec 14. - Welding of site joints to commence from third week of Dec '14.
Dec'14
Slow construction progress by M/s KSSIIPL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 48 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:98.5%; Front: 77.3%; Act: 18.4%
Slow mobilisation by M/s Petron for Composite WorksFCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 Construction Progress: Sch: 27.09 %; Front: 12.73%; Act.: 6.52% AG Piping fabrication: 24857 ID / 486195 ID completed AG Piping Erection: 4944 ID / 811115 ID completed
Medium
Urgency (Long Term / Short term)
N
Open Project
Schedule ( Y / N) Output Quality ( Y / N) Y
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 47 Overall Progress: Sch: 90.2 % Act: 46.3 % Construction progress: Cum Sch: 91.5% Front: 100% Cum Act: 45.7%
EIL Cost (Y / N) N
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
Previous Risk Score
E
N
Status (Open / Close)
Risk Id E
Key Risk Description
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity III
I
E
49
II
E
Slow progress of work & poor manpower mobilisation by Open Constructi M/s B&R for Composite Works-DCU on Awarded to M/s B&R on 12.03.14 CCD: 11.11.15 Construction Progress: Sch: 30.68 % Front: 23.30% Act.: 7.42% 50 AG piping fabrication: Only 35316 ID / 406975 ID fabrication completed. AG piping erection: Only 31039 IM / 526435 IM piping erection completed.
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
Management review meeting held on 11.12.14. -30 fitters, 40 welders & the required machineries shall be deployed by 25.12.14 -M/s B&R has been asked to expedite1200 ID/day by end Dec '14. - Finalisation of 2 more piping/eqpt agencies at site by third week of Dec'14. -Insulation/painting agency finalization by 31.01.15. - Hanger scaffolding to be introduced at site.
EIL/BPCL
Dec'14
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:95.2%; Front: 95.9%; Act: 25.4% CCD: 25.01.15 51 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 09.12.14. EIL/BPCL - 2500 m3 of RCC shall be cast during Jan'15 & the supervisory staff reqd for this shall be deployed by later half of Dec'14. - 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 done during Jan & Feb 2015. Bal 600 MT fabrication to be done by 28.02.15. - Strl detailing completion by 31.12.14. -600MT & 1000 MT erection targeted by Jan & Feb 15 respectively. - 125 MT crane to be deployed by 12.12.14 & 150 MT by 15.01.15.
Dec'14
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. 52 Sch: 29.46% Front : 23.41% Actual : 7.76% 20632 / 285505 ID fabricated & 99337 / 1214330 IM erected.
Open Constructi Very High on
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
Pping fabrication & erection work in progress in pipe rack 101-103, 108, 111-114. Fabrication in progress for Constr. piperack area 115.
Dec'14
II
E
E
II III
Job No.: A307 Dec'14 Page 630+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
Long term
I
0.2
0.19
0.19
0.00
- Management level meeting held 11.12.14 at site. -Piping management system shall be installed by 10.01.15. - B&R to take up compressor erection immediately.
EIL/BPCL
Dec'14
III
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for CDU/VDU. Sch: 04.09.14 54 CCD: 06.09.14 ECD: 31.03.15 Sch:100% Front: 99.44% Act: 88.20%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
Management level meeting held on 05.11.14. -TS I by 28.02.15 -TS II, III & IV handed over. -TS V by 27.04.15 -TS VII by 28.02.15. - Main piperack completion targeted by 13.01.15
Constr.
Dec'14
III
E
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15 Overall Progress: 55 Sch: 97.8 % Act: 89.4 % Constr. Progress: Sch: 98.1 % Front: 92.6.0% Act: 69.6 %
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- MRM held on 14.11.14 Constr. Major backlog is due to manufacturing & Delivery and construction. Erection of APH, Hot air ducts for VDU Heater is in progress. - Additional resources to be mobilised to recover construction backlogs Convection module 4/5 erected for Crude Heater A & 3/5 erected for Crude Heater B. CDU APH foundations to be handed over by Dec'14
As Required
III
E
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for DCU. Sch: 04.09.14 56 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 98.7 % Act: 86.1 %
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 05.11.14. - 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.
EIL/BPCL
Jan'15
E
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) Sch : 35.80% Front : 41.86% Actual : 9.85%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level Meeting held on 12.11.14. - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT383/391/150. - Annular plate erection for tanks YT-26&YT-28 started. - YT-150: Dismantling activities in progress. - YT-383: Dismantling activities in progress. Plate material ordered. - YT-391: tank cleaning under progress. - Ordering of plate material to be expedited. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement.
EIL/BPCL
Dec'14
II III
E
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 92.97 % Front: 100 % Act: 50.31 %
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held on 11.12.14 with M/s B&R at site. - Round the clock work to commence from 26.12.14. - YT 341 : First jacking on 18.12.14. - YT 342 : Annular plate erection from 24.12.14. Shell plate erection from 30.12.14. First jacking on 05.02.15. - YT 343 : Shell plate erection from 17.12.14. First jacking on 05.02.15. - YT 344 : First jacking on 05.01.15. - YT 111 : first jacking on 17.12.14. - YT 112 : First jacking on 27.12.14. - YT 113 : First jacking on 05.01.15. - YT 114 : First jacking on 14.01.15. - Entire fire bricks shall be at site by 22.12.14. - Additional 45 nos manpower by 25.12.14. - Receipt of balance MS plates by 26.12.14.
EIL/BPCL
Dec'14
III
E
E
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 59 CCD:18.06.15 Sch: 74.3 % Front: 68.5 % Act: 21.0 %
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. -Agency has been pressurised to mobilise resources and start work. - SWS-1 Sour water tank & sour water storage tank pads handed over.
Constr.
Dec'14
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. Sch : 25.61% Front : 21.82% Actual : 11.92% 60 38810 ID / 210605 ID piping fabrication completed. 6746 IM / 301995 IM erected.
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected. Piping fabrication work in progress.
Constr.
Dec'14
E
57
Urgency (Long Term / Short term)
N
Schedule ( Y / N) Output Quality ( Y / N) Y
EIL Cost (Y / N) N
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) N
Key Risk Description
Status (Open / Close)
Slow construction progress by M/s B&R for Composite Open Constructi Very High works: Offsite Refinery area due to delay in mobilisation. on Awarded on 25.03.14. 53 CCD: 24.09.15 Sch:32.1%; Front: 8.5%; Act: 4.3%
Risk Id E
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
58
Action Plan
Action By
Target Date
Risk Severity
II III
Job No.: A307 Dec'14 Page 631+15 of 30
Previous Risk Score
(Current risk Score Previous Risk score)
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held with M/s OIL on 12.11.14 at site. M/s OIL has been asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Mobilisation for 20 nos auto welding machine to be expedited.
Constr.
Dec'14
III
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 09.12.14 at site. M/s OIL has been asked to mobilise resources, fabrication yard in progress - 600 MT crane mobilised - At present only 4 nos welders are available at site with per day rate of 120 ID, however to achieve the completion schedule minimum 1000 ID/day to be achieved.
Constr.
Dec'14
III
Completion of balance piling work (Covered under Open Constn. 63 Piling-IIII Contract) (Total 2077 Nos piles approx). Completion of Composite works by M/s Albana for VGO Open Constructi Unit on Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15 64 31124 ID / 203790 ID piping fabrication & 6826 / 336280 IM completed.
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.32
-0.12 -Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. Piping III contract awarded BPCL to M/s Keller Ground Engineering & work commenced.
Dec'14
III
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected, side cladding in progress. Piping fabrication work in progress. Piping erection work commenced on the main pipe rack.
Constr.
Dec'14
III
Start of Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 11163 / 298905 ID fabricated. Erection not yet started. Sch : 22.80% Front : 28.63% Actual : 6.68% E
E
E
F
F
F
Urgency (Long Term / Short term)
Y
Schedule ( Y / N) Output Quality ( Y / N)
N
EIL Cost (Y / N)
N
Start of Composite works by M/s Offshore for Offsite DHDS area 61 Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15. Sch: 28.7% Front: 9.1% Act: 4.1%
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N) Medium
Key Risk Description
Status (Open / Close)
Open Constructi on
Risk Id E
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
62
Action Plan
Action By
Target Date
Risk Severity
Availability of Hydrogen and Nitrogen for Pre1 commissioning 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’2015 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 2 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) 3 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.
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.
Implementation of environmental clearance conditions Open by EIL (received from MoEF vide Letter dated 22.11.12)
Projects
Medium
Y
N
N
N
Short term
D
0.08
0.04
0.04
0.00
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
Open
Const.
Very High
N
N
Y
Y
Short term
D
0.2
0.19
0.19
G
1
G
2
G
7
I
2
J
Implementation of Health, Safety and environmental 1 (HSE) system
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Project/BPCL As Required
IV
Constn. / Projects / BPCL - 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
As required
IV
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
Dec'14
IV
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
Job No.: A307 Dec'14 Page 632+15 of 30
M
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
Project
Low
Y
N
Y
N
Short term
I
0.6
0.18
0.18
0.00
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
EIL/BPCL
Dec'14
23.46
23.99
-0.53
Urgency (Long Term / Short term)
High
Schedule ( Y / N) Output Quality ( Y / N)
Const.
EIL Cost (Y / N)
Open
Risk Owner Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / Project 10%)Cost ( Y / N)
(Current risk Score Previous Risk score)
K
Previous Risk Score
Mobilisation of Skilled workers
Status (Open / Close)
Risk Id
Key Risk Description
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
At present only approx 9000 labours are working 2 against requirement of 15000-18000 labours. Variation in foreign exchange rates from Rs 50 per USD as on Mar 12 to Rs. 60 per USD as on date and fluctuations in the intermediate period and Scope 3 changes w.r.t. DFR (additional in scope) has significantly impacted on the overall project cost.
Total Risk Score
Action Plan
Action By
Target Date
Risk Severity
II III
Job No.: A307 Dec'14 Page 633 of 749
Integrated Refinery Expansion Project, Kochi
D
Risk Owner
C
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
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 Offsites: Part B: SRU & DHDS/Refinery Offsites :
Open
Project
- Electrical Works: Part A: M/s Technimont Part B: M/s Consilium - Instrumentation Works: Part A: M/s Technimont . Part B: M/s Consilium
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: 81.8% Act: 53.8 % Construction Progress: Sch: 42.8% Front: 84.4% Act: 17.9 %
Open
Project
Management level meeting held on 14.11.14 at site. - Hard stand construction completed. EIL / BPCL - Crane (1600 MT): Mobilisation by 15.02.15. EPIL/GRE to arrange alternate crane for erection of Regenerator bottom section. - EPIL-GRE informed to dispatch cyclones for reactors by 30.12.14 and regenerator cyclones by Feb'15. M/s Emtrol is being expedited. - Fdn for flue gas area and ESP handed over - M/s EPIL has commenced structural erection for FGC. - TSS Vessel: Assembly for skirt, shell 1 & 2 commenced. TSS assembly and erection of bottom section targeted by 30.12.14. - Essar being followed up for submission of catch up plan. Next management level meeting planned on 12.12.14.
30-Dec-14
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: 78.2 % Act: 59.9 % - 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
-Meeting held on 12.11.14, vendor agreed to complete erection of main fractionator by EIL/BPCL Jan'15 and balance columns by Mar/Apr'15. - Foundation for main fractionator column (by M/s L&T) completed and super structural work being expedited by M/s Tuaman. -1250 MT and 550 MT crane mobilised at site, erection scheme approved. - Stripper & rectifier Column: Erection of bottom section expected to commence from Jan'15. Preparation of Hard stand being expedited for readiness by Jan'15. - Approach road work completed. Area improvement to be expedited for crane movement.
As stated
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) Overall progress: Sch: 80.0 % Act: 71.3 %
Open
Project
- M/s Thermax seeking extension for duration due to delayed availability of burner BPCL / EIL data from M/s Accometric. 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 readiness targeted by end Dec'14. Bidder has requested for providing space for storage of MCC equipment & Refractory Materials.
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. 67.5 %; Act: 53.2 % Construction Progress: Sch: 47.4% Front: 97.9 % Act: 26.7 %
Open
Project
Management review meeting held on 14.11.14. Constr. -Shift Work: M/s EPIL has been asked to start works in two shifts. - Meeting held with M/s Essar for financial issues on 01.09.14. Financial help sought by M/s Essar, being addressed by BPCL to enable opening of LC. - Strl. Steel works offloaded from MK Engg. (580 MT / 650 MT fabrication completed, all dispatch expected by mid Dec'14) to M/s UHE (For derrick structure-1073 MT), M/s SP Infraprojects (Coke drum str-737 MT) & M/s Essar steel (200MT) BPCL/EIL - M/s EPIL to ensure the availability of Coke Fractionator & 2 coke drums by 31.03.15 & balance by 15.04.15. - The first shipment sail on 05.12.14. The second shipment targeted by 12.12.14 and ETA Kochi targeted by 14 Jan 215. Mobilisation of 2000 MT crane targeted in Feb'15 and erection to be targeted 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, while requirement is 607. - Next management level meeting planned on 12.12.14.
Dec'14
Key Risk Description
78
1
Action Plan
Action By EIL/BPCL
Target Date
Risk Severity
Nov'14
I
D
D
D
7
8
9
II III
I
D
12
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Dec'14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 62%
Open
BPCL / Director level meeting held with M/s VTV. Projects / - Crude column erection completed on 24.09.14. Hydrotesting targeted by end Const. Dec'14. - Erection of Vacuum Column : Delayed due to delay in receipt of bottom section. Erection of sections expected from mid Dec'14 to end Dec'14.
Constn. / VTV Dec'14 / BPCL
II
Job No.: A307 Dec'14 Page 634 of 749
Integrated Refinery Expansion Project, Kochi
D
D
D
Risk Owner
D
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
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
- Compressor casing dispatched from M/s NP Italy workshop on 17.09.14.(Received EIL/BHEL/BP Continuous at BHEL workshop). CL - 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 pump (from May'15 to Apr'15).
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 EDD: 30.03.15 Overall Progress: Sch: 95.0 % Act: 90 % Labour Strike: From 16.12.13 to 12.05.14.Equipment delivery affected.
Open
Projects
-Ordered to M/s L&T on 08.04.13; Dly 21M FOT. - Hydrotesting at vendor shop for all sections targeted by mid Jan'15. - Shop activities being expedited by regular visit and status being monitored on weekely basis to avoid further delay.
Delay by vendors with respect to CDD due to financial constraint.
Open
Projects
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Dec'14 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14-Jan'15.
Open
Projects
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 14 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: 81.5% Catch Up Sch: 47.1 % Act: 37.3%
Open
Backlog 31.4 (% wrt target sch) as of 15-Nov-14 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 - 30 M; Remaining Duration - 16 M CatchUp sch Const Sch Front Act 40.5 65.8 58.0 34.4 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU ,DCU, FCCU, VGO,DHDT & Offsite).
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)
Key Risk Description
19
21
Action By
Target Date
Risk Severity
Continuous
II III
- Following bidders showing slow manufacturing progress: EIL/ BPCL - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:134, 184. Meeting held on 04.11.14. Balance orders expected to dispatch from Dec'14 to Mar'15. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 189: As a parallel action separate MR-6122 released and ordered. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360,& 444. Meeting held on 06.09.14 with M/s BP&CL. Vendor confirmed subordering of raw materials on 09.09.14. - M/s HDO (Columns, Heat Exchangers & Vessels): Foa No.: 199, 302, 310, 315, 318, 320, 369, 389 & 395.
Dec'14
III
- As of now around 60% piping material has been received at site. Around 92-95 % EIL/ BPCL material has been ordered upto intermediate IIIrd MTO. Ordering of balance 5-8% material is expected by end Dec14. Delivery of ordered material against intermediate -II MTO expected by Dec'14 to Jan'15 -Vendors being expedited to prepone the deliveries.
Dec'14
Constn. / Projects
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued on EIL/BPCL 30.10.14, BPCL comments received on 04.11.14. As per BPCL email dated 01.12.14, Tender being split into two parts & SOR targeted by 15.12.14. - MR for compressors (BHEL & DR: Adequacy and health check completed): Adequacy check report from BHEL and from D-R received. Execution philosophy finalized on 17.10.14 for compressor (Dresser Rand make). MR issued on 23.10.14, RFQ under preparation. MR for BHEL make compressor targeted by mid Dec'14.
Dec'14
Open
Const
- In order to supplement progress of failing civil contractors, 4 separate contracts have been awarded (M/s Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray Eng-Misc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works being lined up and targeted to award by end Dec'14. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than EIL/BPCL 15000 labours . requirement of manpower at site is approx 15000 nos. BPCL/EIL have introduced reward schemes based on attendance, performance to enhance labour retention. - Work in shifts being implemented for all construction works at site.
As Required
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
Mar'15
29
33
Action Plan
EIL/BPCL
II
E
4
I
E
E
7
8
BPCL
I IV
Job No.: A307 Dec'14 Page 635 of 749
Integrated Refinery Expansion Project, Kochi
E
14
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Proj. / Constn.
Action Plan - Management level meeting held with M/s B&R on 17.11.14 at EIL site and augmentation of manpower by min. 100 nos to be expedited for concreting work progress. All area handed over in SRU block except for peripheral road. - 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 : At present 1140 nos piles completed against scope of 1800 nos. at site by M/s MBEL. Balance piling targeted by mid Jan'15.
Action By
Target Date
Balance availability of area for SRU Block - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by mid Dec'14. (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 construction progress by M/s KSSIIPL for Civil & Strl work in Offsite IREP area. Constr. Sch:100%; Front:99.7%; Act: 48.1% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 97.1%; Front: 100%; Act:54.1% CCD:18.12.14; ECD: May'15
Open
Project
Management review meeting held with M/s Essar on 19.09.14 at site & 25.09.14 at EIL HO. - Foundation work completed for HRSG-3. - Completion of Structural works for GTG shed under completion. - Stack foundation : Only HRSG#3 fdn completed. - Completion of boiler piperack foundations targeted by 15.12.14 (20/21 nos raft completed).
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. 88.5% 68.4 % 30.5%
Open
Project
- Management level meeting held at site on 13.11.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - TS-06 : Raft work completed. Structural steel erection targeted by 15.12.14. - Structural Erection commenced for TS-2 and for TS-03 targeted by 15.12.14. - Out of total 1800 nos piles, 1140 nos completed. Pile cutting completed for 547 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by 15.01.15. - Out of total structural work of 4290 MT, only 1085 MT fabrication completed & 251 MT erection works completed. UG piping erection work yet to commence.
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: 46.56% Front: 54.19% Act: 25.34 %
Open
Project
- Management level Meeting held with M/s OIL on 12.11.14 and following action plan EIL/BPCL has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Auto blasting m/c received, being installed.
Continuous
Progress of ETP Works LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 73.5 % Act: 24.5 % Construction Progress: Sch: 53.48% Front: 90.20 % Act: 13.18 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Management level meeting held on 12.11.14 at site and on 05.12.14 at EIL Delhi. EIL/BPCL - Augmentation of 100 manpower to be expedited. - Chemical house completion by Mar'15 - Piling work commenced in ACT/SBR/TWT area (17/612 nos completed). Completion of Piling by Dec'14 - Completion of equalisation tank by Mar'15. - M/s Paramount shall submit action plan for completion of ETP by Dec'15.
As stated
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: 70 % Act: 19 %
Open
- Meeting held with vendor on 29.08.14. Recommendation for PO amendment forwarded to BPCL on 11.09.14. BPCL to issue PO amendment. - Finalisation of subvendor for expansion bellows being expedited.
As Required
Risk Severity
Dec'14 EIL/BPCL
I
E
27
Constructio Management level meeting held with M/s KSSIIPL at site on 14.11.14. EIL/BPCL n - 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. - M/s KSS agreed to complete all balance piperack foundations by mid Dec'14. 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.
Dec'14
II
E
28
EIL/BPCL
Dec'14
II
E
29
II
E
30
II
E
34
I
E
39
Project
BPCL
II
Job No.: A307 Dec'14 Page 636 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Progress of RO-DM Plant (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: 96.5 % Act: 60.7% Construction Progress: Sch: 94.93 %; Front: 100%; Act:26.46 % Area handed over, part of area is water logged due to plant drain which is under completion.
Open
Project
Management level meeting held on 05.12.14 at EIL Delhi. EIL/BPCL 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. M/s Driplex has been asked to prepare a catch-up plan to expedite construction activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. 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 (42/160 nos completed).
As Required
Open
Project
-Management level meeting held at Kochi on 18.09.14. -Mobilisation of resources is being expedited. At present only 170 nos , manpower mobilised, against a requirement of 700 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -7917 m3 RCC work has been already withdrawn from SEPC scope to M/s Tuaman (5300 m3) & M/s Paulose George (2617 m3). 3215 MT strl works offloaded to M/s Tuaman, M/s Zillion & M/s Ray engg.
As Required
41
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 94.67%; Front: 98.34% Act: 51.39 % CCD: 24.12.14 ECD: Oct'15
Open
Project
-Management level meeting held with M/s MBEL on 13.11.14 at site. M/s MBEL EIL/BPCL agreed: - 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
44
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 Sch: 97.27 %; Front :99.55 % Act: 63.71 % - Structural erection: DHDT: 825 MT / 2600 MT completed.; VGO: 746 MT / 3065 MT completed. -UG Piping Laying: DHDT: 11089 IM / 25400 IM completed; VGO: 11038 IM / 42000 IM completed.
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 Dec'14. Project Material storage EIL/BPCL commenced. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. Buildings to be expedited for storage of material / equipment being received at site.
As Required
Slow construction progress by M/s KSSIIPL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:95.19%; Front: 72.67%; Act: 17.59%
Open
Constructio Management level Meeting held with M/s KSSIIPL on 14.11.14 at site. EIL/BPCL n - M/s KSS agreed to deploy additional 50 nos manpower by mid Dec'14. Agencies for structural erection have been finalised and started mobilising at site. - M/s KSS has been asked to deploy additional manpower to complete all equipment fdns. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: M/s Ray Engineering, M/s Deens. 4117 m3 RCC work has been already withdrawn from KSSIIPL scope to M/s Ray Engg. (2800 m3), M/s Paulose George (800 m3) & M/s Deens (517 m3). 2431 MT strl works offloaded to M/s Ray Engg. - Futher new tender under preparation to offload M/s KSSIIPL works.
Dec'14
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:85.3%; Front: 89.74%; Act: 21.28% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held at Kochi site on 13.11.14. EIL/BPCL n -MBEL asked to explore the methodology to reduce attrition of present labour. MBEL to augment additional resources (from 210 nos to 400 nos) MBEL committed to increase manpower upto 300 nos by mid Dec'14. - Availability of front to mechanical contractor to be expedited by completing all piperack foundations by 30.12.14 and structural erection by Dec'14. Works offloaded to M/s Ray & M/s Deens to supplement Civil & Strl works. Further 2 additional Civil &Structural works contracts being lined up and expected to award by mid Dec'14.
Dec'14
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:21.3%; Front: 5.8%; Act: 3.6%
Open
Constructio - Management level meeting held 17.11.14 at site. n -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works commenced.
EIL/BPCL
Dec'14
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: 98.51 % Act: 82.77 %
Open
Constructio Management level meeting held on 05.11.14. n - Handing over of complete branch piperack targeted by 28.02.15. - TS-III : Structural erection targeted by 31.01.15. - TS-IV: Complete hand over targeted by 05.12.14. - TS-V: Start of structural erection targeted by 25.12.14.
EIL/BPCL
Jan'15
40
Risk Severity
I
E
EIL/BPCL
I
E
II
E
45
II
E
47
I
E
E
E
50
52
55
II III
II
Job No.: A307 Dec'14 Page 637 of 749
Integrated Refinery Expansion Project, Kochi
E
56
F
1
G
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) Sch: 24.9% Front: 44.2 % Act: 6.1 %
Open
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
Timely payment to sub contractor by main contractor
Open
Const.
Mobilisation of Skilled workers
Open
Const.
2
Action Plan
Constructio - Management level Meeting held on 12.11.14. n - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT-383/391/150. - Annular plate erection for tanks YT-26&YT-28 started. - YT-150: Dismantling activities in progress. - YT-383: Dismantling activities in progress. Plate material ordered. - YT-391: tank cleaning under progress. - Ordering of plate material to be expedited. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement.
1
At present only approx 9000 labours are working against requirement of 20000-25000 labours.
K
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action By
Target Date
Risk Severity
EIL/BPCL
Dec'14
III
BPCL
1-Jun-15
III
Following methodology being taken up for smooth cash flow to contractors: BPCL/EIL - 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.
As Required
IV
-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. -BPCL/EIL to jointly introduce some incentive system for workers to reach manpower upto 12000 by Dec'14. - Work in shifts to be implemented for all construction works at site.
As Required
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015 for CDU/VDU commissioning.
II
Job No.: A307 Nov'14 Page 638+15 of 30
IV - RISK REGISTER
Kochi Refinery, BPCL
Total Risk Score
N
Long term
I
0.2
23.99
(Current risk Score - Previous Risk score)
Impact Score => {6+7+8+9} * 10 * 11
Y
Previous Risk Score
Controllability Condition (D/I )
N
Current Risk Score -> {5}* {12}
Urgency (Long Term / Short term)
N
Output Quality ( Y / N)
Low
Schedule ( Y / N)
Project
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Open
EIL Cost (Y / N)
Award of Electrical & Instrumentation Works for Units & Offsite Sch: 30.06.14 Ant: 10.11.14 C 78 Electrical/Instr. Works: Part A: CDU/VDU, DCU, FCCU, DHDT, VGO-HDT & IREP Offsites: Part B: SRU & DHDS/Refinery Offsites :
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
0.10
-0.10 - Electrical Works: Part A: M/s Technimont Part B: M/s Consilium - Instrumentation Works: Part A: M/s Technimont . Part B: M/s Consilium
24.42
-0.43
Action Plan
Action By
EIL/BPCL
Target Date
Nov'14
Risk Severity
Job No.: A307 Nov'14 Page 639 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Ordering of Critical Valves Sch: 11.07.14 73 Ant: 10.11.14 Dely: 06/07 M FOT /FOB
Open
Project
Revised MR (MR-3415) issued covering all critical valves along with all critical valves BPCL of MR-3211 floated. Award recommendation issued on 08.10.14.
10-Nov-14
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM-Refloated 76 Sch: 08.05.14 Ant: 15.11.14
Open
Project
- 4 nos bids received on 30.09.14. PBO recommednation issued to BPCL on 31.10.14.
15-Nov-14
Completion of Reactor regenerator package for FCCU-M/s Esaar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 76.7 % Act: 51.7 % Construction Progress: Sch: 32.5% Front: 79.9% Act: 14.6 %
Open
Project
Management level meeting held on 16.10.14 at site. - Completion of hard stand targeted by 09.11.14. - Crane (1600 MT): Ship movement started, assembly targeted by 10.11.14 & load test by 30.11.14. Final erection scheme submitted on 15.09.14. Readiness of crane for erection targeted by Dec'14. - EPIL-GRE informed to dispatch cyclones for reactors by 30.11.14 and regenerator cyclones by 31.12.14. M/s Emtrol has been asked to pre pone the deliveries upto Dec’14 during meeting dated 25.08.14. EIL/BPCL - Fdn for flue gas area, stack fdns and ESP fdn to be expedited (Excavation already completed). - M/s EPIL has been asked to commence area development around FGC equipments & commence hard stand work from 07.10.14 and to be ready by 09.11.14. - TSS srection: Assembly for skirt, sheel 1 & 2 commenced. TSS assembly and complete erection targeted by 15.11.14. Area for storage of fabricated materials to be identified and allocated. Issues being followed up.
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) Overall progress: Sch: 80.0 % Act: 69.8 %
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 readiness to be delayed till Dec'14. Bidders has requested for providing space for storage of MCC equipment & Refractory Materials. - Refractory liining 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. 62.9 %; Act: 49.5 % Construction Progress: Sch: 40.5 % Front: 94.1 % Act: 24.1 %
Open
Project
-Management review meeting held on 19.09.14 and 12.09.14. Weekly review meeting Constr. held at site on 10.10.14. Following commitments have been made by M/s Essar. -Shift Work: M/s EPIL asked to start works in two shifts. - Meeting held with M/s Essar for financial issues on 01.09.14. Proposal from M/s Essar for financial support forwarded to BPCL for review / approval. - Strl. Steel works offloaded from MK Engg. to M/s UHE (For derrick structure-1073 MT), M/s SP Infraprojects (Coke drum str-737 MT) & ESSAR steel (200MT) BPCL/EIL - M/s EPIL to ensure the availability of Coke Fractionator by end Dec’14 and all the four Coke Drums progressively by Apr’15. - Mobilisation of 2000 MT crane targeted in Feb'15 and erection to be targeted from Mar'15 to May'15. -Crane (200 MT): Crane parts started arriving at site. Crane readiness by mid Nov’14. -Clear water tank fabrication- Agency finalization by Nov'14. - Resource augmentation for Civil & Strl works being expedited. At present 457 nos have been deployed, while requirement is 607.
Continuous
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
II EIL/BPCL
II
D
D
D
1
8
9
09.11.14 Dec'14
I III
I
D
Delay in erection of Crude & vacuum column Sch: Jun 14; CCD: 21.08.14 Ant: Dec'14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 57%
Open
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Dec'14 Projects / - Erection of Crude Column : Crude column erection completed on 24.09.14. / BPCL Const. Hydrotesting targeted by 07.11.14. - Erection of Vacuum Column : Delayed due to delay in receipt of bottom section. Erection of sections expected from mid Nov'14 to end Nov'14 and hydrotesting by mid Dec'14.
II
Job No.: A307 Nov'14 Page 640 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
T&CC
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - Agency confirmed availability of Barge/Trailer at the time of delivery of Reactors. Out of 2 nos modified barge, 1 no completed and balance one 1 no by 1st week of Nov'14. Drawings for new barge submitted to IRS for approval. 1 nos new barge fabrication by 24.12.14. - Construction of jetty not yet started as land for jetty is yet to be finalised. M/s Urmila agreed to finalise and hire the IOCL land for jetty. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at Kochi-Port.
Nov'14
Delay by vendor with respect to CDD due to financial constraint.
Open
Projects
- Following bidders showing slow manufacturing progress: EIL/ BPCL - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:184. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 189: As a parallel action separate MR-6122 released. Award recommendation issued to BPCL. Cancellation request forwarded to BPCL on 13.10.14. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360,& 444. Meeting held on 06.09.14 with M/s BP&CL. Vendor confirmed subordering of raw materials on 09.09.14. - M/s HDO (Columns, Heat Exchangers & Vessels): Foa No.: 199, 302, 315, 318, 327, 369, 389 & 395.
Nov'14
Delay in delivery of Stripper column (IF-V-206) by M/s Uttam Value Steel (Ordered on 19.08.13) 32 CDD: 18.10.14 EDD: 31.03.15
Open
Projects
- Order got delayed due to delay in manufacturing works. At present fabrication of Stripper column going beyond Nov’14 due to which there will be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
EIL/ BPCL
Nov'14
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 33 EDD: Nov'14 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
Open
Projects
- As of now around 42-45% piping material has been received at site. Around 90-95 EIL/ BPCL % material has been ordered upto intermediate IIIrd MTO. Ordering of balance 5-10% material is in progress and expected progressively upto mid Nov'14. Delivery of ordered material against intermediate -II expected by mid Nov'14. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
Nov'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION Key Risk Description 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)
D
D
D
DHDT Reactor (M/s Doosan) expected to receive at Kochi port by Nov'14. 13 ISGEC Josen (3 nos) Column: expected to receive at Kochi port from Nov'14 to Jan'15.
29
Action Plan
Action By
Target Date
Risk Severity
II III
II
D
E
4
II
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 77.1% Catch Up Sch: 39.6 % Act: 32.3%
Open
Constn. / Projects
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued on BPCL/EIL 31.10.14. Award targeted by Nov'14. - MR for compressors (BHEL & DR: Adequacy and health check under progress): Adequacy check report from BHEL expected by end Oct’14 and from D-R received on 19.09.14. Execution philosophy finalized on 17.10.14 for compressor ( Dressar Rand make ). MR targeted by mid Nov'14.
Nov'14
Backlog 29.6 (% wrt target sch) as of 15-Oct-14 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 - 30 M; Remaining Duration - 16 M Desc. Catch Up sch: Const Sch Front Act Overall 34.9 61.0 58.0 31.4 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU ,DCU, FCCU, VGO,DHDT & Offsite).
Open
Const
- In order to supplement progress of failing civil contractors, 4 separate agencies has Constn been lined up (M/s Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray EngMisc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works being lined up. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 nos. BPCL/EIL to jointly introduce some incentive system for workers to reach manpower upto 12000 by BPCL/EIL Nov'14. - Work in shifts to be implemented for all construction works at site.
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 Mar'15)
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
BPCL
Mar'15
- Management level meeting held with M/s B&R on 19.09.14 at EIL site & on 25.09.14 at EIL HO and augmentation of manpower by min. 100 nos to be expedited for concreting work progress. M/s B&R has been asked to expedite complete SRU filling by 10.11.14. All area handed over in SRU block except for peripheral road. - Retaining wall completed for the available front. Piling to be carried out through Piling III to take up further retaining wall work. - Piling for SRU : At present 989 nos piles completed against front of 1700 nos & scope of 1800 nos. at site by M/s MBEL.
Constn.
Nov'14
I
E
E
E
7
8
Delay in balance area availability for SRU Block - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by 2nd week of Nov'14. (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 14 M (As per Past experience minimum requirement for SRU is 30 M).
Open
Proj. / Constn.
I IV
EIL/BPCL
I
Job No.: A307 Nov'14 Page 641 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Constr. Sch:100%; Front:94.3%; Act: 45.0% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 93.4%; Front: 94.5%; Act:47.3% CCD:18.12.14; ECD: May'15
Open
Project
Management review meeting held with M/s Essar on 19.09.14 at site & 25.09.14 at EIL HO. - Foundation work completed for HRSG-3. - Completion of Structural works for GTG shed targeted by mid Nov'14. - Stack foundation : Only HRSG#3 fdn completed. - Completion of boiler piperack targeted by 30.10.14. - All balance drawings for which data is available shall be targeted for issue by 30.10.14.
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. 80.6% 59.7 % 26.9%
Open
Project
- Management level meeting held at site on 15.10.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - Foundation work: TS-06 by 30.10.14. - Structural Erection commenced for TS-2 & TS-03 and for TS-06 start of strl erection targeted by end Oct'14. - Out of total 1800 nos piles, 989 nos completed. Pile cutting completed for 504 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by end Nov'14. - Out of total structural work of 4290 MT, only 852 MT fabrication completed & 176 MT erection works completed. UG piping erection work yet to commence.
Continuous
27
Constructio Management level meeting held with M/s KSSIIPL at site on 15.10.14. EIL/BPCL n - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - 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 and targeted to complete by 31.10.14. - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. Cable trench work to be commence in Oct’14. - 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.
Target Date
Risk Severity
Nov'14
II
E
28
EIL/BPCL
Nov'14
II
E
29
Open
Project
- Management level Meeting held with M/s OIL on 08.10.14 and following action plan EIL/BPCL has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. -M/s OIL confirmed to cover pipe rack for rain protection modular shed, for which order has been placed & expected to receive at site by end Oct'14.. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Piping fabrication rate of 1500 ID / day from current 800 ID/Day targeted to achieved from 15.10.14. - OIL to deploy their auto blasting machine.
Continuous
E
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: 37.9% Front: 47.3% 30 Act: 21.5 %
Open
Project
-Management level meeting held on 14.10.14. EIL/BPCL - Physical handing over of balance area for treated water tank, API/TPI, ex TPI sump completed. Signing protocol to be expedited. - M/s Paramount has been asked to mobilise additional 60 nos manpower progressively by 30.10.14 -Piling drawing for ACT & SBR area approved vide across the table review meeting dated 05.09.14. - Work in progress in substation area, equalisation tank, treated water tank, sludge thickener, spent caustic tank, chemical handling areas. - Completion of foundation work for chemical house to be expedited by augmenting manpower & resources. -Piling work being executed by M/s Simplex. 2 nos rigs targeted to be mobilised by 30.10.14. Start of work targeted from 01.11.14 to be completed by 31.12.14.
As stated
E
Progress of ETP Works LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 65.7 % Act: 22.3 % Construction Progress: Sch: 42.6 % Front: 90.0 % Act: 11.4 % Awarded to M/s Paramount on 11.09.13. (Duration: 34 21 M+2 M incl pre commng)
Progress of RO-DM Plant (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: 94.3 % Act: 57.9% Construction Progress: Sch: 87.8 %; Front: 100%; Act:22.9 % Area handed over, part of area is water logged due to plant drain which is under completion.
Open
-In view of delay in handing over of areas and various site related issues and soil EIL/BPCL problem encountred during execution, progress of construction badly affected. M/s Driplex has been asked to prepare a catch-up plan to expedite construction activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. 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) : Filling in area targeted to complete by end Oct'14. Piling drawing received from M/s driplex and is under review. Piling work targeted to commence from end Oct'14. -90 % model review completed. - Meeting held with M/s Driplex at site on 14.10.14 & M/s Driplex has been asked to mobilse addln. 45 nos manpower for civil works by 31.10.14 & another 50 nos by 20.11.14.
As Required
II
II
I
E
40
Project
I
Job No.: A307 Nov'14 Page 642 of 749
Integrated Refinery Expansion Project, Kochi
E
41
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
-Management level meeting held at Kochi on 18.09.14. -Mobilisation of resources is being expedited. At present only 187 nos , manpower mobilised,against a requirement of 700 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). EIL/BPCL -5300 m3 RCC work has been already withdrawn from SEPC scope to M/s Tuaman scope. Additional 1500 m3 RCC work being offloaded from SEPC scope to M/s PGC. 2495 MT strl works offloaded to M/s Tuaman, M/s Zillion & M/s Ray engg.
Target Date
Risk Severity
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 85.0%; Front: 95.4% Act: 45.3 % CCD: 24.12.14 ECD: Oct'15
Open
Project
As Required
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:90.1%; Front: 72.2%; Act: 15.9%
Open
Constructio Management level Meeting held with M/s KSSIIPL on 15.10.14 at site. EIL/BPCL n - M/s KSS agreed to deploy additional 50 nos manpower by end Oct’14. Agencies for structural erection have been finalised and started mobilising at site. - M/s KSS has been asked to deploy additional manpower to complete all equipment fdns. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: M/s Ray Engineering, M/s Deens. Others contracts being lined up are: Misc. Strl Works-II: 4 nos bids received on 30.09.14. PBO targeted by 31.10.14. Misc. Civil & Strl-II: 5 Bids received on 07.10.14. PBO targeted by 31.10.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
Nov'14
Open
Constructio Management level meeting held on 16.10.14 at site. n - M/s Petron agreed to increase nos of welders to 30 nos & fitters to 20 nos by 30.10.14. - Semi automatic welding machine shall be in operational by 05.11.14 - M/s Petron has been asked to commence min. 1000-1500 ID / day to complete entire job. Present rate is 160 ID / day.
EIL/BPCL
Nov'14
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: 12.3 % Front: 20.2% Act.: 2.8%
Open
Constructio Management review meeting held on 19.09.14. EIL/BPCL n -Subcontracting agency finalised and 30 nos addln. manpower targeted to be available at site by end Oct'14. Agency for heavy equipment erection has been finalised and mobilisation schedule under submission. -Semi automatic welding machine - 3 nos recd at site. Commissioning yet to be done. AG piping fabrication: Only 12108 ID / 304970 ID fabrication completed. AG piping erection: Only 1078 IM / 412580 IM piping erection completed.
Nov'14
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:76.4%; Front: 82.6%; Act: 18.8% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held at Kochi site on 15.10.14. EIL/BPCL n -MBEL asked to explore the methodology to reduce attrition of present labour. MBEL to augment additional resources (from 210 nos to 400 nos) MBEL committed to increase manpower upto 300 nos by end Oct’14. - Availability of front to mechanical contractor to be expedited by completing all piperack foundations by 30.10.14 and structural erection by mid Nov’14. Works offloaded to M/s Ray &M/s Deens to supplement Civil & Strlworks. Further 2 additional Civil &Structural works contracts being lined upand expected to award by end Nov’14.
Nov'14
Open
Constructio - Management level meeting held 19.09.14 at site. n -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works commenced.
EIL/BPCL
Nov'14
I III
BPCL
1-Jun-15
III
I
E
49
I
E
E
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15 50 Construction Progress: Sch: 8.6 %; Front: 9.8%; Act.: 2.3% AG Piping fabrication: 1980 ID / 500000 ID completed
II
51
II
E
E
F
52
Slow construction progress by M/s B&R for Composite works: Offsite Refinery area due to delay in mobilisation. 54 Awarded on 25.03.14. CCD: 24.09.15
1
G
1
G
2
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015 for CDU/VDU commissioning.
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
Constn. / Projects / BPCL
As Required
Job No.: A307 Nov'14 Page 643 of 749
Integrated Refinery Expansion Project, Kochi
Mobilisation of Skilled workers At present only approx 9000 labours are working against requirement of 15000 labours.
K
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Const.
Action Plan
Action By
-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. -BPCL/EIL to jointly introduce some incentive system for workers to reach manpower upto 12000 by Dec'14. - Work in shifts to be implemented for all construction works at site.
Target Date
Risk Severity
As Required
2
II
Kochi Refinery, BPCL
A
A
A
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)
Job No.: A307 Aug'14 Page 644+15 of 32
Action Plan
Action By
15
16
17
Target Date
4
5
6
7
8
9
10
11
12
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 2 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 / 3 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
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
Delay in issue of Process deliverables for engineering for Open 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 1 Anticipated : mid Nov'13
Holds, missing information, corrections, changes in PDS / P&IDs - DCU A
Output Quality ( Y / N)
3
Schedule ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
1
Risk Owner
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
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 & INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13
Close
BPCL / Process
Low
N
N
Y
N
Short term
I
0.4
0.00
-Process package received on 14.04.13
Delay in "issue for engineering - IFE" PDS / P&IDs for DHDT Close P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
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
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
A
5 Agreement signed by BPCL-KR issued to Licensor on 04.04.13
A
6
A
7
A
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly 8 from estimated values.
Delay in "issue for engineering - IFE" PDS / P&IDs for FCC LAD :29-Jan-13; Ant : 08-May-13 A
Close
Close
Close
9
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A 10
Close
0.00
0
Projects / Process
Apr'13
-
Apr'13
Apr'13
31-Dec-12
Jan'13
Kochi Refinery, BPCL
(Current risk Score Previous Risk score) 15
16
Action By
Target Date
17
18
Risk Severity
4
5
6
7
8
9
10
11
12
Process
Medium
N
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 Offsites P&ID’s for tankages (LAD - 21.01.13) Close - 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 A 12 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
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.
In view of increase in sulphur load PDS & P&IDs for sulphur Close block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement.
Revision in PDS after issue of “Issued for Engineering” after A 14 release of MR -Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
Close
Close
14
Action Plan
Delay in "issue for engineering - IFE" PDS / P&IDs for VGO- Close HDT A 11 LAD : 29-Jan-13; Ant : 10-May-13
A 13
13
Previous Risk Score
Job No.: A307 Aug'14 Page 645+15 of 32
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)
3
Schedule ( Y / N)
2
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
1
Risk Owner
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Process
Process
19 Apr'13
-
Apr'13
15-Mar-13
Feb'13
Process
-
Apr'13
Process
-
Apr'13
As Required
Apr'13
A 15
Revision in PDS after issue of “Issued for Engineering” after A 16 Order
Close
Process/E NGG/Proc ure
Revision in PDS after issue of “Issued for Engineering” after A 17 Equipment manufacturing
Close
Process/E Very Low NGG/Proc ure
Updation of estimated utilities on account of revision in A 18 process parameters (revision of PDS based on engg comments)
Close
Process
Low
N
N
Y
N
Long term
I
0.2
0.00
ISBL Distribution P&IDs for VGO-HDT A 19 SCH: 30-Nov-12 ANT: Jun-13
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 A 20 ANT: 31-May-13
Close
Process
Medium
N
N
Y
N
Short term
D
0.16
0.00
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
Close
Process
Low
N
N
N
N
Long term
I
0
0.00
Distribution P&IDs issued for engineering.
Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 A 22 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
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed engineering activities.
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
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new GTG).
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
Utility distribution P&IDs for DCU A 21
A 23
A 24
0.00
0
Process
31-May-13
Apr'13
31-May-13
Apr'13
Jan'13
Kochi Refinery, BPCL
2
3
4
5
6
7
8
9
10
11
12
Close
Engg.
Medium
N
N
Y
N
Short term
I
0.4
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
Open
Engg.
Very High
N
N
Y
N
Short term
B
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 1 ii) Civil/Structural & UG Piping Tender preparation
Issue of Equipment layout for engineering for VGO-HDT LAD - 07-Nov-12 2 Ant- 26-Dec-12
Close
Engg.
Very high
N
N
Y
N
B
Engg.
High
N
N
Y
ENGG
High
N
N
Procure/E NGG/CON S.
Medium
Y
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 BPCLand i.e.battery availability Shut for down / Hot Signing of ISBL P&IDs limit of P&IDs Units, tapping. Utility packages & other packages.
13
14
(Current risk Score Previous Risk score)
Previous Risk Score
Job No.: A307 Aug'14 Page 646+15 of 32
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
15
B
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Delay in this activity shall hamper the following: i) 3 D Modelling Issue of Equipment layout for engineering for FCCU (targeted Close ii) Civil/Structural & UG Piping Tender preparation by 27.12.2012) 3 Delay in this activity shall hamper the following: i) 3 D Modelling ii) Civil/Structural & UG Piping Tender preparation
Target Date
17
18
16
Risk Severity
19
- 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: - 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 signing by end week of Oct'14.
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
0.05
Nov'13
30-Dec-13 30-Oct-14
Dec'13 IV
Mar'14 & Apr'14
B
NIT for Heater for FCCU 4 LAD -01-Apr-13 ; Ant - 18-Jun-13
B
a) Cost/time overrun due to rework b) Non completion of critical project activities within time & delay in Project completion 5 c) Poor performance of Sub-contractors and Vendors
New requirement of power recovery system (FCCU) shall have impact on project cost. 6 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
B
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; 7 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
B
Close
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
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant - 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 8 large bore pipes.
HMTD
Very High
N
N
Y
N
Short term
D
0.16
0.00
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
B
Open
Action By
0.00
A 27
A 28
Action Plan
Close
Delay in thermal design for Heat exchangers & Air coolers for Close licensed and non licensed units LAD (DHDT): 02-Feb-13 9 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
Apr'13
Kochi Refinery, BPCL
2
15
16
Action By
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 B 11 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 C 12 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
a) Inaccurate assessment of quantum of work
Close
MR issue for MCC (Main combustion Chamber) packages.
Close
Engg/proc Very High urement
17
18
Risk Severity
3
B 10
14
Action Plan
Close
Issue Overall UG piping layout drawing for the complex
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Job No.: A307 Aug'14 Page 647+15 of 32 (Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
As Required
19
B 13
Project
Medium
N
N
Y
N
Short term
D
0.16
0.00
MR issued on 02.05.13.
Engg
Apr'13
May'14
B 14 LAD: 16-Feb-13 Ant: 15-Apr-13
B 15
Timely finalisation of Package Interface 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).
Open
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
Unit and offsite interfaces (Elevation termination levels)
Close
Engg.
Medium
N
N
Y
Y
Long term
D
0.1
0.00
- Clubbed with Risk ID A27
TSD
Open
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
NIT for Heater for DCU LAD -15-Feb-13;
Close
PROCES Very High S/ENGG
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
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/Cont .
Medium
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. - 60% model review for HRSG targeted by end Oct'14. -90% model review for GTG & UB package targeted by end Oct'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.
30-Oct-14
III
Open Engg/proc urement
Medium
-
Mar'14 & Apr'14
B 16
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule requirements. B 17 LAD - 28.02.13; Ant - upto Feb 14.
B 18
B 19
Distributed Control System (DCS) Detailed engg., supply and erection B 20 (ordered on M/s Emerson Process on 04.11.13) B 21
60 % Model review for to submit Instrumentation Drawings/ Close ENGG Very High Package Vendor refuses Open Engg/proc Low DCU (LAD:03.07.13 Act:13.09.13) Documentation in Smart Plant Instrumentation Database as urement B 22 per Client Requirement
B 23
Delay in Interface Engineering (including control system) due to non availability of Package Vendor Data
Open Engg/proc urement
Low
0.08
0.08
Engg Projects / Process Process / HMTD C&P
N
Y
N
N
Long term
I
0.15
0.08
-0.08 - 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
N
N Y
Y
N
Short Long term
D
0.16 0.14
0.04
0.00 - Being Model taken reviewup completed on 13.09.13 -0.04 with respective package vendors for implementation.
ENGG/ Instn Projects
Continuous
Aug'13
N
N
Y
N
Long term
I
0.2
0.06
0.00
Continuous
IV
0.06
Package vendor inputs being made available by expediting for updation of interface engineering documents. Projects / Engg.
Kochi Refinery, BPCL
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Previous Risk Score 14
15
16
Action By
4
5
6
7
8
9
10
11
12
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
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) B 24 LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
GC
Medium
N
N
Y
N
Long term
D
0.08
0.00
- All P&IDs released
G. Civil
25-Jul-13
JUL'13
Order of MR for DG set Dely: (12 M FOB + 3 M Site work) B 25 Sch: 05.11.13
Open
Project
Medium
N
N
Y
N
Short term
I
0.4
BPCL
5-Oct-14
Receipt of Inputs from Process / Vendors for 60 % 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.
Close
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 B 28 SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), 164 (SRU),15 Delay of Intermediate 2nd MTO Open (SWS)in&release 60(TGTU) + 155(Utilities LAD:30.09.13; -CVs Size HoldAct:31.10.13) as follows: 13 (ARU), 6 (SWS), 125 (SRU). Holds: -All Control Valve Face to Face Dimensions are HOLD. All -CDU/VDU: Pump CVs for TGTU are nozzle HOLD. 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 B 29 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
Open
ENGG
Low
N
N
Y
N
Short term
D
0.16
0.05
0.00
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
Progressively
Close Open
ENGG ENGG
High Low
N N
N N
Y Y
N N
Short term Short term
D D
0.16 0.16
0.05
0.00 - HAZOP study completed on 29.11.13. -0.05 - As of 15 Aug'14 Engineering progress is 91.4 %.
-0.20 - Ordered to M/s Powerica Ltd on 29.09.14 (Delivery duration 13 M+ 3 M site works).
18
Risk Severity
ENGG
0.20
17
Target Date
3
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.
13
Action Plan
Open
B 20
2
Job No.: A307 Aug'14 Page 648+15 of 32 (Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19
B 26
B 27
Generation of Surplus Piping material B 30 B 31 HAZOP for FCCU LAD - 23-Sep-13 Completion of 90 % engineering by Mar-14. Average progress achieved in last 3 months 3.0 % B 32 LD Milestone date - Dec'13
0.05
ENGG ENGG
IV
Nov'13 Aug'14
Kochi Refinery, BPCL
2
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
15
16
17
Target Date
Risk Severity
18
19
3
4
5
6
7
8
9
10
11
12
ENGG
High
N
N
Y
N
Short term
D
0.16
0.13
-0.13 - 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
0.20
-0.20 - 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.
Sep'14
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 1 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
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
30-Dec-13
Dec'13
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 2 Duration: 18 M
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
30-Aug-13
JUL'13
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 3 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
Very High
Y
Y
Y
N
Short term
D
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
Close
Project
Very High
Y
N
N
N
Short term
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
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
14
Action By
Open
B 34
13
Action Plan
Release of final Piping MTO Sch: Jul'14
B 33
C
Job No.: A307 Aug'14 Page 649+15 of 32 (Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Sep'14
C
4
Award of Heater for DHDT 5 LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Very High
N
N
Y
N
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
C
NIT for Composite Works for DCU 6 LAD -06.06.13 ; Ant - 25.10.13
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
Piping
25-Oct-13
sep'13
C
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
Piping
31-Oct-13
sep'13
7
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
C
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
Piping
15-Oct-13
sep'13
8
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
C
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
Piping
15-Oct-13
sep'13
9
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
C
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
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 LAD -22.07.13 ; Ant - 15.10.13
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
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
C 10
C 11
C 12
Kochi Refinery, BPCL
(Current 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)
Previous Risk Score 14
15
16
Action By
Target Date
17
18
Risk Severity
6
7
8
9
10
11
12
N
Y
N
Short term
I
0.4
0.00
-Ordered to M/s Fabtech on 15.07.13
Engg/Proj
Issue NIT for Tankage-II LAD: 21-Jan-13 C 14 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 C 15 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
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
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
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13
13
Action Plan
N
Award of : Main fractionator for FCCU LAD: 25-Mar-12 Ant: 20-Jul-13
5
Schedule ( Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
Job No.: A307 Aug'14 Page 650+15 of 32
Open Project/En Very High gg
C 13
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
20-Jul-13
19 JUL'13
C 16
NIT for Reactor regenerator package for FCCU LAD : 01-Jan-13 Ant: 21-Feb-13 C 17 Changes in scope of supply led to revision in BQC / tender.
C 18
C 19
C 20
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
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
Apr'13
-
Mar'13
-
Mar'13
Ant: 15-Apr-13
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 C 21 Ant: 30-Mar-13
Award of Crude and Vacuum heaters (LAD 29.12.12) Ant : 07.03.13
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 Granulator to be finalised between BPCL / EIL.
Close
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.00
- Scheme finalised.
Projects / BPCL
Close
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
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s L&T (duration 20 M)
BPCL
-
Projects / 7-Mar-13 C&P / BPCL
Mar'13
Feb'13
C 22
Apr'13
C 23
NIT for ETP package with WAO (Wet air oxidation) C 24 LAD: 15-Jan-13 Ant: 16-Apr-13 Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13
Close
Apr'13
7-Mar-13
Feb'13
C 25
Award of contract for Building incl substations LAD: 07-Feb-13 C 26 Ant: 15-Apr-13
Close
Apr'13
Kochi Refinery, BPCL
14
Action Plan
15
16
Action By
17
Target Date
3
4
5
6
7
8
9
10
11
12
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.
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 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: C 29 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
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 Schedule: 02.03.13 Anticipated : 30.08.13 Completion of works Sch: 01.05.15 ( M); RFQ Duration : ( M) C 30 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
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 : C 31 20 M
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
JUL'13
Projects / Engg
Very High
Y
N
Y
N
Short term
I
0.6
0.00
- Awarded to M/s Thermax on 20.12.13
Projects / BPCL
Projects
18
Risk Severity
Open
Filling of existing part fire water pond required for area preparation.
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Job No.: A307 Aug'14 Page 651+15 of 32 (Current risk Score Previous Risk score)
2
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
30-Mar-14
19 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 28
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 C 32 Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
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.
20-Jul-13
20-Dec-13
Nov'13
Kochi Refinery, BPCL
4
5
6
7
8
9
Close
Project / Licensor
Very High
Y
Y
Y
N
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) C 34 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
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 C 35 Duration: 20 M
Open
Process / Engg / constn
Very High
N
N
Y
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 C 36 Duration: 22 M+2 M
Close Project/C& Very High P
N
N
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
Low
N
Failure of contractors
Open
Const.
Low
N
10
14
Action Plan
15
16
Action By
Target Date
17
18
Risk Severity
11
12
I
0.9
0.00
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
Short term
13
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Job No.: A307 Aug'14 Page 652+15 of 32 (Current risk Score Previous Risk score)
3
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. C 33 Bidders sought extension in dates.
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Schedule ( Y / N)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
- 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 Esaar on 10.07.13.
Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
Projects / BPCL
BPCL
19 Jun'13
31-Oct-13
C&P/Engg/Pr oj
Oct'13
Anticipated Completion: 29-Jul-15
C 37
C 38
C&P BPCL / Projects
Ordering of Ejector Pkg C 39 (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 (LAD:24-May-13; Ant: 15-Nov-13 Earlier 04 Bids recd on 21.05.13. (Petron, Thermax, Heurtey, Technip). C 40 Due to Technical and related commercial issues enquiry refloated. Duration 20 M
Open
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 (LAD: 30-Mar-13; Ant: 20.07.13) C 41 Duration: 18 M
Open
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
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
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
Award of Civil & Strl work for refinery area. (LAD:25-Apr-13; Ant: 10.10.13) Duration: 16 M C 42
sep'13
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) C 43 Duration : 16 M
25-Jul-13
JUL'13
Kochi Refinery, BPCL
14
Action Plan
15
16
Action By
17
Target Date
18
Risk Severity
3
4
5
6
7
8
9
10
11
12
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 & precomm; Time Available from order to MC OF FCCU - 24 C 45 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 C 46 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 C 47 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.
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); C 49 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
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, C 50 based on past Performance of recommended bidder tender refloated.
Close
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 work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Job No.: A307 Aug'14 Page 653+15 of 32 (Current risk Score Previous Risk score)
2
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19
C 44
Ordering of OFF GAS COMPRESSOR - VGO LAD: 08-Jun-13 Ant: 30-Oct-13 RFQ duration: 17 M FOB
0.00
0
7-Mar-13
Jun'13
C 48
Kochi Refinery, BPCL
(Current risk Score 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
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, C 51 based on past Performance of recommended bidder tender refloated.
Close
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 C 52 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 C 53 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 C 54 (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) C 55 (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
Delay in Award of contract for Demountable flare (LAD: 08Apr-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
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
C 56
13
Previous Risk Score
Job No.: A307 Aug'14 Page 654+15 of 32
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19 Aug'13
Jun'14
19-Jul-13
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. Change in flare load data due to change in flare height upto C 57 150 M. Completion of works Sch. : 31.01.15 Ant. : 28.02.15
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 C 58 Duration: 12 M
Kochi Refinery, BPCL
Previous Risk Score
Urgency (Long Term / Short term)
Output Quality ( Y / N)
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12} 13
14
Action Plan
15
16
Action By
17
Target Date
Risk Severity
6
7
8
9
10
11
12
18
19
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) C 60 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: 02 Nos & 1 surge relief tank and crude drain tank) 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 tanks-25/26 under tankage-III. C 61 Sch: 01.10.13 Ant: 15-Dec-13
Close Project/En Very High gg
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
Close Project/En Very High gg
N
N
Y
N
Short term
I
0.4
0.00
Awarded to M/s BHEL
Proj/Engg
28-Jun-13
Jun'13
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep13) C 63 Duration : 18 M FOB
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
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) Sch: 30.04.13 C 64 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
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 C 65 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
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
Close
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 for:RGC compressor for VGO-HDT (LAD: 30-Mar-13; Ant: end Jun 13) Dely: 18 M
5
Schedule ( Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
Job No.: A307 Aug'14 Page 655+15 of 32 (Current risk Score Previous Risk score)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
C 59
C 62
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: Jun 13)
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 C 66
Duration - 20 M
Award for contract for development of flare area LAD: 01-Nov-13 Ant: end Dec'13 C 67
Aug'13
Kochi Refinery, BPCL
2
14
Action Plan
15
16
Action By
Target Date
3
4
5
6
7
8
9
10
11
12
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, C 69 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)) C 70 (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) C 71 LAD:09.05.13 Ant: 10.10.14
Open
Project
Very High
N
Y
Y
N
Short term
I
0.7
0.32
-0.32 -Ordered on M/s Asco Filtri Srl ON 17.10.14.
BPCL
Oct'14
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards C 72 Piping intermediate MTO-II released on 30.10.13.
Open
Project
Low
N
N
Y
N
Short term
D
0.16
0.05
-0.05 - All pipes, fittings & flanges ordered.
C&P
14-Aug-14
Ordering of Critical Valves Sch: 11.07.14 C 73 Ant: 20.10.14 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 C 74 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 C 75 Ant: Nov'14
Open
Project
Very High
N
N
Y
N
Short term
D
0.16
0.15
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM-Refloated C 76 Sch: 08.05.14 Ant: 15.11.14
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M Open FOB / 7 M FOT) C 77 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 C 78 Electrical/Instr. Works: Part A: CDU/VDU, DCU, FCCU, DHDT, VGO-HDT & IREP Offsites: Part B: SRU & DHDS/Refinery Offsites :
Open
Project
Medium
N
N
Y
N
Long term
I
0.2
Delay in award of piping material with G2E specification in C 79 CPP area.
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
C 68
17
18
Risk Severity
Open
Award of Composite Works for VGO-HDT, DHDT, CPP and Offsites (DHDS) LAD 31.12.13 ; Ant - 30.05.14
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
Job No.: A307 Aug'14 Page 656+15 of 32 (Current risk Score Previous Risk score)
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19
Aug'14
Engg 0.32
0.32
0.00
Revised MR (MR-3415) issued covering all critical valves along with all critical valves of MR-3211 floated. Award recommendation issued on 08.10.14.
EIL/BPCL
30-Oct-14
0.00
- Awarded to M/s Zillion on 19.05.14.
0.15
0.00
-Total 29529/ 32638 nos (90%) isometrics issued for units . Balance ISO's targeted progressively by mid Nov'14. - Piping items has been ordered for Intermediate MTO-II, delivery expected by Oct'14 to Nov'14.
Engg.
Oct'14
0.38
0.00
- 4 nos bids received on 30.09.14. PBO recommednation issued to BPCL on 21.10.14.
EIL/BPCL
15-Nov-14
0.00
- Ordered to M/s Sulzer.
BPCL
5-Aug-14
II Jul'14
0.10
0.10
- Award recommendation for both the tenders issued to BPCL on 27.10.14. Electrical Works: Bids received on 26.09.14. Part A: M/s Technimont & M/s Kazmunai Services Part B: M/s Technimont, M/s Consilium & M/s Kazmunai Services. - Instrumentation Works: Bids received on 29.09.14. Part A: M/s Technimont & M/s Eternity Petroleum. Part B: M/s Technimont, M/s Consilium & M/s Kazmunai Services, M/s Eternity Petroleum.
EIL/BPCL
30-Oct-14
III
0.38
0.38
Procurement to be expedited in order to timely availability of piping material for completion of steam network EIL/BPCL in CPP area.
30-Oct-14
25-May-14
II May'14
III
II
Kochi Refinery, BPCL
4
5
6
7
8
9
Project
Very High
Y
Y
Y
N
10 Short term
Action Plan
11
12
13
14
15
16
I
0.9
0.86
0.86
0.00
D
1
Close
Project
Very High
Y
Y
N
N
Long term
I
0.25
D
Delivery of GTG Pkg at site (LAD:29-Sep-14; Ant - 24-Nov14) Awarded to M/s BHEL 2 Duration (Supply) - 16 M
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 3 Overall progress: Sch: 91.7 % Act: 66.1 % Construction Progress: Sch: 86.2 % Front: 100 % Act: 23.2 %
Open
Project
Very High
N
N
Y
N
Long term
I
0.2
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) 5 LAD: 05.12.14 (CDD: 27.01.15; EDD: 27.01.15) Sch: 69.2%; Act: 67%
Open
Project
Low
N
N
Y
N
Long term
I
0.2
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 6 (CDD: 24.12.14; EDD: 24.12.14)
Open
Project
Low
N
N
Y
N
Long term
I
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: 78.2 % Act: 56.5 % 7 - 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
D
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14 D
D
D
D
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
3 Open
Job No.: A307 Aug'14 Page 657+15 of 32 (Current risk Score Previous Risk score)
2 Completion of Reactor regenerator package for FCCU-M/s Esaar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 76.7 % Act: 51.7 % Construction Progress: Sch: 32.5% Front: 79.9% Act: 14.6 %
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Management level meeting held on 16.10.14 at site. - Completion of hard stand targeted by 09.11.14. - Crane (1600 MT): Shipment movement started and expected to arrive at Kochi by end Oct'14, assembly targeted by 10.11.14 & load test by 30.11.14. Final erection scheme submitted on 15.09.14. Readiness of crane for erection targeted by Dec'14. - EPIL-GRE informed to dispatch cyclones for reactors by 30.11.14 and regenerator cyclones by 31.12.14. M/s Emtrol has been asked to pre pone the deliveries upto Dec’14 during meeting dated 25.08.14. - Fdn for flue gas area, stack fdns and ESP fdn targeted to complete by end Oct'14 (Excavation already completed). - M/s EPIL has been asked to commence area development around FGC equipments & commence hard stand work from 07.10.14 and to be ready by 09.11.14. - TSS srection: Assembly for skirt, sheel 1 & 2 commenced. TSS assembly and complete erection targeted by 15.11.14. Area for storage of fabricated materials to be identified and allocated. Issues being followed up.
Action By
Target Date
Risk Severity
17
18
19
Projects Constn
09.11.14 Dec'14
30.10.14 BPCL
Clubbed with Risk ID E19
Project
0.19
0.00
Management review held on 09.09.14 to pressurised M/s ISGEC for completing within CCD. Weekely meeting held at site on 08.10.14. - 90% model review planned at Kochi by end Oct'14. - Erection of steam drum-I targeted by end Oct'14. - Completion of balance foundations being progressively targeted by end Oct'14.
Project / Constn.
0.06
-0.06 -All Indigenous component received at site within CDD. - All Foreign Source Components dispatched.
Project/Inspe Sep'14 ction
0.06
0.06
0.00
Material against all suborders received. Casing for compressor and turbine received at shop. Machining of components of both main compressor and steam turbine under progress.
Project/Inspe 27-Jan-15 ction
IV
0.2
0.06
0.06
0.00
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Project/Inspe 24-Dec-14 Order placed for Motor, turbines, Casings, forgings, impellers, gear box. Part castings and forgings received. ction Close monitoring to be done to ensure delivery on CDD.
IV
0.4
0.38
0.38
0.00
-Meeting held on 09.09.14, 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) completed and super structural work being expedited by M/s Tuaman. - Erection for main fractionator targeted by Jan'15. Crane 1250 MT and 550 MT mobilised, erection scheme approved. - Stripper & rectifier Column: Erection of bottom section expected to commence from Jan'15. Preparation of Hard stand to commence. - Approach road work completed. Area improvement to be expedited.
0.19
24-Nov-14
I Nov'13
0.00
Oct'14
III
4 Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT.
As stated
II
Kochi Refinery, BPCL
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. 62.9 %; Act: 49.5 % Construction Progress: Sch: 40.5 % Front: 94.1 % Act: 24.1 % D
5
6
7
8
9
10
11
12
13
14
15
16
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 readiness to be delayed till Dec'14. Bidders has requested for providing space for storage of MCC equipment & Refractory Materials. - Refractory liining work in Combustion chamber can be started only after erection of MCC pkg.
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
-Management review meeting held on 19.09.14 and 12.09.14. Weekly review meeting held at site on Constr. 10.10.14. Following commitments have been made by M/s Essar. -Shift Work: M/s EPIL asked to start works in two shifts. - Meeting held with M/s Essar for financial issues on 01.09.14. Proposal from M/s Essar for financial support forwarded to BPCL for review / approval. - Strl. Steel works offloaded from MK Engg. to M/s UHE (For derrick structure-1073 MT), M/s SP Infraprojects (Coke drum str-737 MT) & ESSAR steel (200MT) BPCL/EIL - M/s EPIL to ensure the availability of Coke Fractionator by end Dec’14 and all the four Coke Drums progressively by Apr’15. - Mobilisation of 2000 MT crane targeted in Feb'15 and erection to be targeted from Mar'15 to May'15. -Crane (200 MT): Crane parts started arriving at site. All parts expected to arrive by end Oct’14 and crane readiness by mid Nov’14. -Clear water tank fabrication- Agency finalization by Oct'14. - Resource augmentation for Civil & Strl works being expedited. At present 457 nos have been deployed, while requirement is 607.
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Turbine and compressor MRT completed. Compressor train under dispatch. Transfer oil pump and lube oil accumulator already dispatched.
Project/Inspe 27-Dec-14 ction
Open Project/En gg
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- Compressor MRT completed. Performance test completed successfully. Turbine rotors ready and casing under assembly. Dispatch expected by end Oct'14. Steam turbine: All components except inner casing ready for assembly. Casing inner (steam chamber) got rejected in hydrotesting. Inner casing to be expedited at BHEL Haridwar shop.
Project/Inspe 27-Dec-14 ction
BPCL / Projects / Const.
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Director level meeting held with M/s VTV. - Erection of Crude Column : Crude column erection completed on 24.09.14. Hydrotesting targeted by 31.10.14. - Erection of Vacuum Column : Delayed due to delay in receipt of bottom section. Erection of sections expected from end Oct'14 to end Nov'14 and hydrotesting by mid Dec'14.
Constn. / VTV / Projects
Open
T&CC
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - Agency confirmed availability of Barge/Trailer at the time of delivery of Reactors. Barge will be ready with reqd modification by Oct'14. - Barge readiness targeted as follows: 2 nos Ammonia Barges modifications by 15.10.14. & 31.10.14. Drawings for new barge submitted to IRS for approval. 1 nos new barge fabrication by 24.12.14. - Construction of jetty not yet started as land for jetty is yet to be finalised. M/s Urmila agreed to finalise and hire the IOCL land for jetty. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at KochiPort.
Oct'14
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; 20 nos received at site. & 4 nos under dispatch. Balance under close monitoring and are expected at site from Oct'14.
Continous
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}
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Action Plan
Risk Owner
2 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) 8 Overall progress: Sch: 80.0 % Act: 69.8 %
Status (Open / Close)
Risk Id 1
Job No.: A307 Aug'14 Page 658+15 of 32 (Current risk Score Previous Risk score)
D
Key Risk Description
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
9
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M D 10 Ordered to M/s BHEL on 28.06.13
Delivery of RGC compressor for DHDT(LAD :05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13 D 11
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Dec'14 Normally 12-14 Months are required for Unit Mechanical D 12 Compln after erection of Crude & Vacuum column. VTV Construction Progress: Sch: 100.0% Front: 100% Act: 57%
Open
Action By
Target Date
Risk Severity
18
19
15-May-15
III
17 BPCL / EIL
Oct'14
I IV
IV
Dec'14
II Logistics of VGO & DHDT reactors from Kochi port to BPCLKR site (VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB) DHDT Reactor (M/s Doosan) expected to receive at Kochi D 13 port by Nov'14. ISGEC Josen (3 nos) Column: expected to receive at Kochi port from Nov'14 to Jan'15.
Close Monitoring of ODC equipment (including site D 14 fabricated/assembled) up to receipt at site
Shipping
II IV
Kochi Refinery, BPCL
Delay in delivery at site due to non-availability of transporter / hindrances enroute.
14
(Current risk Score Previous Risk score)
13
Previous Risk Score
Job No.: A307 Aug'14 Page 659+15 of 32
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
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action Plan
15
16
Action By
17
Target Date
5
6
7
8
9
10
11
12
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
18
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
Open Project
Medium
Y
Y
Y
N
Long term
I
0.45
0.00
- Flare foundation work completed. - Construction work to be started from Oct'14. Fabrication of flare structure is in progress and delivery expected from Oct'14 onwards.
Projects/Con As Required str.
Very High
Y
Y
Y
N
Short term
I
0.9
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
As Required
Risk Severity
19 Nov'13
D 15
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions.
Jun'14
D 16
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Mar-15 D 17 Ant: 24-Mar-15 Overall Progress Sch: 55.9 % Act: 47.4 % Construction work likely to start from Oct'14.
Addition of 4th Riser in Demountable Flare and identification Open Project / of additional Equipment to be procured due to the same. Process (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: D 18 Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15
0.23
0.23
As Required
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Compressor casing dispatched from M/s NP Italy workshop on 17.09.14.(Expected to arrive at BHEL Project/Inspe Continuous workshop by end Oct'14). ction - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. However close monitoring being done.
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 D 20 CDD: 03.04.15 Ant: 03.04.15
Open
Projects
Low
N
N
Y
N
Long term
I
0.2
0.06
0.06
0.00
- All major items has been subordered. Air Blower: Main casing received at workshop. Main coupling received on 25.08.14. Steam Turbine: Casing received at shop. Bearing also received .
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 D 21 EDD: 06.03.15 Overall Progress: Sch: 95.0 % Act: 89.5 %
Open
Projects
Very High
N
N
Y
N
Long term
I
0.2
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 is 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 within CDD.
Project/Inspe Continuous ction
D 19
III
Oct'13
II IV
III
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
7
8
9
10
11
12
13
14
15
16
18
19
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
- Hydrotesting completed on 09-10 Oct'14. Change order related to shipment is in finalisation with BPCL and Project/Inspe Continuous vendor. ction
III
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 D 23 Awarded to M/s Thermax on 20.12.13 Overall Progress: Sch: 64 % Act: 53 %
Open
Projects
Medium
Y
Y
Y
N
Long term
I
0.45
0.23
0.23
0.00
- Review meeting held with M/s Thermax on 08.10.14. - Balance engineering to be expedited by M/s Thermax. - HRSG #3, 4 & 5: Foundation works completed and handed over to M/s Thermax. - Column erection started for 1st HRSG.
Project/Inspe Continuous ction
III
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) D 24 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. - Fabrication of exhaust diffuser and inner exhaust case targeted by end Oct'14
Project/Inspe Continuous ction
III
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 D 25 CDD: 30.03.15 Overall progress: Sch: 44 %; Act: 40.5 %
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. - Delivery of Semi rolled sections of Silos shall commence from Nov'14 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited as material expected to receive at site by Oct'14. - Foundations for pelletiser shed to be made ready by end Nov'14.
Project/Inspe Continuous ction
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
Jun'14
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. Expected to receive at M/s Dresser shop by 03.02.15.
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
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).
EIL/ BPCL
Progressively
IV
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: - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.:184. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 189: As a parallel action separate MR-6122 released. Award recommendation issued to BPCL. Cancellation request forwarded to BPCL on 13.10.14. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360,& 444. Meeting held on 06.09.14 with M/s BP&CL. Vendor confirmed subordering of raw materials on 09.09.14. - M/s HDO (Columns, Heat Exchangers & Vessels): Foa No.: 199, 302, 315, 318, 327, 369, 389 & 395.
EIL/ BPCL
Oct'14
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
0.20
-0.20 - 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 (MR-5403) (FOA No D 31 550 & 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) and Debutaniser Column (IF-V-302) by M/s Uttam Value Steel D 32 (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
0.00
- Order got delayed due to delay in manufacturing works. At present fabrication of Stripper column going beyond Nov’14 due to which there will be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
EIL/ BPCL
Oct'14
Urgency (Long Term / Short term)
6
High
Schedule ( Y / N)
5
Projects
2
EIL Cost (Y / N)
4
Open
1
Risk Owner
3
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 CDD: 07.10.14 D 22 Overall Progress: Sch: 95 % Act: 92.0 %
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Job No.: A307 Aug'14 Page 660+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
17
D 26
D 27
D 28
D 29
D 30
0.32
0.32
II
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
7
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- As of now around 42-45% piping material has been received at site. Around 90-95 % material has been ordered upto intermediate IIIrd MTO. Ordering of balance 5-10% material is in progress and expected progressively upto end Oct'14. Delivery of ordered material against intermediate -II expected by Oct'14. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
EIL/ BPCL
Oct'14
Open
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
Oct'14
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: 31.10.14 to 15.01.15 D 35 M/s GR Engg: CDD: 28.01.14 to 31.07.14; EDD: 30.11.14 to 31.01.15 M/s Fabtech Projects: CDD: Jul’14 to Jan’15; EDD: Oct’14 to Jul’15
Open
Project
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
Vendor being pushed for deliveries. Vendor shop visit/meeting being arranged.
Inspection / Project
Oct'14
III
Delay in submission & finalisation of vendor drawings for SRU burners & reduction burner package. Ordered to M/s UOP Callidus on 20.06.14. D 36 CDD: 19.05.15
Open
Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
-Reduction furncae layout drawing to finalised in order to give front for release piling drawings - Submission of drawing by vendor & approval by HMTD to be expedited.
HMTD/Projec Oct'14 ts
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.
Mid Oct'13
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
N
N
Y
N
Long term
I
0.2
Delivery Gas Booster Compressor for CPP (Dly: 13 M FOB D 34
E
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsites) - Awarded on 25.09.12 (Sch 100 %, Act 91.7%) RCC Piles:4822 / 5307 Nos. Balance for offsite (SS VGO & compound area at FACT). 1 Presently 5 total rigs are operating
E
Space constraints: i) Area for Storage of materials for project and package contractors 2 ii) Area for Spool storage
E
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock 3 encountered.
E
E
Open
Completion duration for NHT/ISOM (Revamp) Open Constn. / Mechanical completion of NHT/ISOM - Target Schedule : Projects 30.09.15; Only 15 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. 4 Physical Progress: Target Sch: 77.1% Catch Up Sch: 39.6 % Act: 32.3%
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.
Open BPCL / High Projects / Const.
Urgency (Long Term / Short term)
6 N
Schedule ( Y / N)
5 Very High
2
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Oct'14 D 33 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
EIL Cost (Y / N)
4 Projects
1
Risk Owner
3 Open
Risk Id
Action Plan
Key Risk Description
0.14
0.86
Previous Risk Score
Job No.: A307 Aug'14 Page 661+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
II sep'13
0.67
-0.53 - 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. Development of the area with fence is in progress.
BPCL
Oct'14
III
0.20
-0.20 -Major rock blasting work completed.
Constn.
sep'14
Aug'14
0.86
0.00
- Composite Works (Civil Strl. & Mechanical) PBO recommendation issued to BPCL on 21.10.14. 4 nos bids BPCL/EIL received on 30.09.14. Award targeted by Nov'14. - MR for compressors (BHEL & DR: Adequacy and health check under progress): Adequacy check report from BHEL expected by end Oct’14 and from D-R received on 19.09.14. Execution philosophy finalized on 17.10.14 for compressor ( Dressar Rand make ). MR targeted by end Oct'14.
Nov'14
0.00
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
15-Jul-13
BPCL / Projects
I JUL'13
Kochi Refinery, BPCL
7
8
9
10
11
12
13
14
15
16
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- MCR area, CPP control room area : It has been decided to complete balance strl work by Dec'14 & finishing by Mar'15. - Other building works : Finishing work to be completed by Dec'14. - L&T also agreed to augment required manpower to meet the target completion date.
Backlog 29.6 (% wrt target sch) as of 15-Oct-14 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 - 30 M; Remaining Duration - 16 M Desc. Catch Up sch: Const Sch Front Act Overall 34.9 61.0 58.0 31.4 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU ,DCU, FCCU, 7 VGO,DHDT & Offsite).
Open
Const
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
- In order to supplement progress of failing civil contractors, 4 separate agencies has been lined up (M/s Constn Tuaman-Civil & Strl works, M/s Zillion-Strl. works, M/s Ray Eng-Misc Strl. works & M/s Paulose George-Misc Civil works- I for IREP unit & offsite). Further additional two agencies for Civil & Structural works being lined up. - Contractors are facing problem in retaining the labour at site. Approx 9000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 nos. BPCL/EIL to jointly introduce some incentive system for workers to reach manpower upto 12000 by end Oct'14. BPCL/EIL - Work in shifts to be implemented for all construction works at site.
As Required
Relocation of existing facility (PRU Flare) for clearance for BOO area. Dismantling of PRU flare can start after commissioning of 8 Demountable flare (Commissioning expected by end Mar'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 Mar'15.
BPCL
Mar'15
Completion of piling work by M/s L&T (Piling-II): CDD08.05.14. (Total 12003 Nos piles). (Contr.Sch- 100%, Front-100%, Act-100%) Only 10 nos. hydraulic & 4 nos. conventional rigs are 9 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
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
Oct'14
Urgency (Long Term / Short term)
6
High
Schedule ( Y / N)
5
Const
2
EIL Cost (Y / N)
4
Open
1
Risk Owner
3
Delay in completion of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 96.0 % Front: 100 % 6 Act:58.8% CCD: 20.12.14 Ant: 15.05.15
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close)
Job No.: A307 Aug'14 Page 662+15 of 32 (Current risk Score Previous Risk score)
E
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17 Constn
As Required
II
E
E
E
E 10
Payment to contractors Unrealistic project time leading to under quality
Close
E 11 Dismantling of LO CAT SRU and area handing over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. E 12 Will affect release of front for tankages.
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
Project / Engg. / planning
Open
BPCL
Medium
N
N
Y
N
Short term
I
0.4
Open
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.29
0.29
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: Foundation works commenced, completion to be targeted by Dec'14. - Chemical house works commenced. - 90 % Model review planned in 1st week of Nov'14..
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 19.09.14 at EIL site & on 25.09.14 at EIL HO and Constn. augmentation of manpower by min. 100 nos to be expedited for concreting work progress. M/s B&R has been asked to expedite complete SRU filling by 10.11.14. All area handed over in SRU block except for peripheral road. - Retaining wall completed for the available front. Piling to be carried out through Piling III to take up further retaining wall work. - Piling for SRU : At present 989 nos piles completed against front of 1700 nos & scope of 1800 nos. at site by M/s MBEL. EIL/BPCL
Overall Progress: Contr. Sch: 91.7 % Act: 61.7% E 13 Construction Progress: Sch: 87.3 % Front: 100 % Act: 55.4 % Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Constr.
I IV
II Area availability for SRU Block - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by 2nd week of Nov'14. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) E 14 - 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
Oct'14
I
Kochi Refinery, BPCL
(Current 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)
Previous Risk Score 14
15
16
Action By
Target Date
17
18
6
7
8
9
10
11
12
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
Land acquisition for Crude tank (2 nos.) . (LAD - Jul 13; Ant E 17 30-Aug-13)
Close Proj.
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
0.00
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
As Required
0.00
- All 3 GTGs received at site. - Contractor for Mechanical works for CPP awarded to M/s Zillion. - N2 compressor (Delivery period is approx 6-8 M) : Ordered on 01.08.14, delivery going upto Dec 2014, However BHEL confirm that they expect supply to be completed within CDD of GTG package.
Projects
Dec'14
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 0.19
Security arrangements in Warehouse place by48") BPCL. - Pipes under shortage (IS pipes of 30",in36", 40", ordered to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team. - All deliveries to be expedited by end Oct'14, subsequently all UG piping work completion to be expedited by Dec'14.
Constn. EIL/BPCL
Oct'14
Risk Severity
19 Jul'14
Dec'13
Nov'13
Aug'13
OPEN
BPCL
Medium
N
N
Y
N
Short term
I
0.4
Open
Const. / Projects
Medium
Y
Y
Y
N
Long term
I
0.45
Close
Const.
Low
N
N
Y
N
Long term
I
0.2
Theft of from Delay in material completion ofWarehouse UG piping work due delay in receipt of Close Open piping material required at site and due to monsoon
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
0.04
0.00
Area lighting being done.
Constn.
As Required
I May'13
EIL
Low
N
N
Y
N
Long term
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
Open
Project
Low
Y
N
N
N
Short term
I
0.2
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
Construction of Subway on the PWD road including re routing Open of existing road / existing facilities and necessary liasoning with government department. Construction of culvert got affected (Ant. Compln-Nov'14, E 26 Compl date Committed by B&R – 13.11.14)
Project
Very High
N
N
Y
N
Short term
I
0.4
0.00
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Management level meeting held with B&R on 19.09.14 at site & on 25.09.14 at EIL HO. B&R agreed to execute work on extended hours to complete balance works in all respect by 13.11.14. Raft completed, wall work in progress.
13-Nov-14
E 18
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
13
Action Plan
Open Proj. / Constn.
E 16
5
Schedule ( Y / N)
4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
3
Job No.: A307 Aug'14 Page 663+15 of 32
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
E 15
2
Risk Owner
1
Status (Open / Close)
Risk Id
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
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 E 19 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
0.23
0.23
E 20
E 21
0.57
0.38
E 22
E 23
Lighting during construction
Delay in construction due to monsoon. As work 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 E 24 needs to be avoided.
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
Open Constn. Open
E 25
0.38
0.38
Constrn.
sep'13
III
Nov'13
-
Mar'13
II
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
9
10
11
12
13
14
15
16
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 15.10.14. - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - 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 and targeted to complete by 31.10.14. - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. Cable trench work to be commence in Oct’14. - 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
Oct'14
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 93.4%; Front: 94.5%; Act:47.3% 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 19.09.14 at site & 25.09.14 at EIL HO. - Foundation work completed for HRSG-3. - Completion of Structural works for GTG shed targeted by mid Nov'14. - Stack foundation : Only HRSG#3 fdn completed. - Completion of boiler piperack targeted by 30.10.14. - All balance drawings for which data is available shall be targeted for issue by 30.10.14.
EIL/BPCL
Oct'14
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 FRONT. ACT. E 29 SCH. 80.6% 59.7 % 26.9%
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 15.10.14. EIL/BPCL - As on date the manpower is 172 Nos against the requirement of 300 Nos. - Foundation work: TS-06 by 30.10.14. - Structural Erection commenced for TS-2 & TS-03 and for TS-06 start of strl erection targeted by end Oct'14. - Out of total 1800 nos piles, 989 nos completed. Pile cutting completed for 504 nos. Delay in completion of piling works affecting progress of civil works. - Balance pile completion including pile breaking targeted by end Nov'14. - Out of total structural work of 4290 MT, only 852 MT fabrication completed & 176 MT erection works completed. UG piping erection work yet to commence.
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: 37.9% E 30 Front: 47.3% Act: 21.5 %
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 08.10.14 and following action plan has been agreed - M/s OIL was advised to augment welders to 50 nos. against 39 nos available to increase productivity. -M/s OIL confirmed to cover pipe rack for rain protection modular shed, for which order has been placed & expected to receive at site by end Oct'14.. - Additional gamma ray source has been mobilised. Backlog in RT work has reduced. - Piping fabrication rate of 1500 ID / day from current 800 ID/Day targeted to achieved from 15.10.14. - OIL to deploy their auto blasting machine.
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 E 31 EDD: Dec'15 Construction: Sch:17.2 %; Act:11.5% Overall Progress: Sch: 42.4 % Act: 33.5%
Open
Project
Medium
Y
N
Y
N
Long term
I
0.3
0.15
0.15
0.00
-Meeting held at site on 10.09.14. - Piling work commenced (802 out of 1642 nos piles completed: 7-8 piles/day) M/s TKII to augment piling rigs immediately. -TKII has been advised to commence work in all work fronts to achieve min. 5% construction progress during Oct'14.
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 E 32 Overall Progress: Sch: 71.5 % Act: 65.0 % Construction work: Sch- 49.1% Front:79.7% Act:28.9%
Open Project
Medium
Y
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 panels received at site. 20/24 nos arch panels erected. -Heater B: Out of 66 nos panels, 63 nos received at site, 3 panels dispatched by end Oct'14. 50/66 panels erected. Shop fabrication of coil, convection modules, APH str 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
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 E 33 incl pre commng)
Open
Very High
N
N
Y
N
Long term
I
0.2
0.00
- Total area handed over on 05.05.14.
Project
5
Urgency (Long Term / Short term)
8
N
2
Schedule ( Y / N)
7
Open Constructi Very High on
1
EIL Cost (Y / N)
6
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Constr. Sch:100%; Front:94.3%; Act: 45.0% CCD: 08.10.14; ECD: Jun'15
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Job No.: A307 Aug'14 Page 664+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Risk Owner 4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close) 3
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
E 27
Action By
Target Date
Risk Severity
18
19
17
II
E 28
II
II
Project
As stated
II III
III
Jun'14
Kochi Refinery, BPCL
7
8
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.6
0.57
0.29
0.29
-Management level meeting held on 14.10.14.. EIL/BPCL - Physical handing over of balance area for treated water tank, API/TPI, ex TPI sump completed. Signing protocol to be expedited. - M/s Paramount has been asked to mobilise additional 60 nos manpower progressively by 30.10.14 - Revised piling drawing for API being submitted by 10.09.14. Piling drawing for ACT & SBR area approved vide across the table review meeting dated 05.09.14. - Work in progress in substation area, equalisation tank, treated water tank, sludge thickener, spent caustic tank, chemical handling areas. - Completion of foundation work for chemical house to be expedited by augmenting manpower & resources. -Piling work being executed by M/s Simplex. 2 nos rigs targeted to be mobilised by 30.10.14. Start of work targeted from 01.11.14 to be completed by 31.12.14.
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 19.09.14 at site and on 25.09.14 at EIL Delhi. Total tanks: (New tanks 13 nos, work in progress for 12 nos. Balance for 1 nos is YT-33 which shall be start after completion of YT32; 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) - Subordered on 16.09.14. 200 MT (IS 2062 GR B): All material received.
EIL/BPCL
As stated
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 E 36 Duration: 20 M Sch: 38.2 % Front: 93.1 % Act: 29.0 %
Open Project
High
N
N
Y
N
Short term
I
0.4
0.32
0.00
- Front for YT-29 is likely to be released by 30.10.14 - Plate erection to be expedited for YT-26/28. - Sand filling works to be expedited in YT-25.
Constr.
As stated
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 E 37 Overall Progress: Sch: 86.6 % Act: 39.1 % Construction progress: Sch: 32.1% Front: 60.7% Act:11.3%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.00
-Management level meeting held on 25.09.14 - Structural steel: Out of total 217 MT, 200 MT sub ordered & 98 MT received at shop. Balance being targeted by end Oct'14. - Fabrication of radiant section targeted to complete by 07.11.14. - Coil tubes: Expected to receive at site by 07.11.14. - Delivery of soot blowers and FD fans to be preponed to suit completion heater by 03.04.15.
Project
As Required
II III
Close Project
Very High
N
N
Y
N
Long term
I
0.2
0.00
Clubbed with Risk ID D7
BPCL
As Required
Dec'13
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) E 39 Overall Progress: Sch: 63 % Act: 18 %
Open Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Meeting held with vendor on 29.08.14. Recommendation for PO amendment forwarded to BPCL on 11.09.14. BPCL to issue PO amendment. - Nozzle (N1 & N10) size of thermal incinerator on hold, same shall be finalised immediately.
Projects
As Required
Progress of RO-DM Plant (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: 94.3 % Act: 57.9% Construction Progress: Sch: 87.8 %; Front: 100%; Act:22.9 % E 40 Area handed over, part of area is water logged due to plant drain which is under completion.
Open Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.29
0.29
-In view of delay in handing over of areas and various site related issues and soil problem encountred during EIL/BPCL execution, progress of construction badly affected. M/s Driplex has been asked to prepare a catch-up plan to expedite construction activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. 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) : Filling in area targeted to complete by end Oct'14. Piling work targeted to commence from end Oct'14. -90 % model review completed. - Meeting held with M/s Driplex at site on 14.10.14 & M/s Driplex has been asked to mobilse addln. 45 nos manpower for civil works by 31.10.14 & another 50 nos by 20.11.14. - DM tanks: Piling drawing received from M/s driplex and is under review.
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 85.0%; Front: 95.4% Act: 45.3 % E 41 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 at Kochi on 18.09.14. -Mobilisation of resources is being expedited. At present only 140 nos , manpower mobilised,against a requirement of 400 nos. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). EIL/BPCL -part Civil work offloaded to M/s Tuaman, M/s PGC & part structural work offloaded to M/s Zillion & M/s Ray Engineering
As Required
Urgency (Long Term / Short term)
6 Y
Schedule ( Y / N)
5 Very High
EIL Cost (Y / N)
4 Project
Risk Owner
(Current risk Score Previous Risk score)
3
Action Plan
Progress of ETP Works Open LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 65.7 % Act: 22.3 % Construction Progress: E 34 Sch: 42.6 % Front: 90.0 % Act: 11.4 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Previous Risk Score
2
Job No.: A307 Aug'14 Page 665+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Status (Open / Close)
1
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Id
Key Risk Description
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
17
Target Date
Risk Severity
18
19
I
E 35
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 63.1 %; Front:84.4% Act: 21.8 % Awarded to M/s B&R on 25-Sep-13
II
E 38
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
0.32
0.20
II
I
I
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
8
9
10
11
12
13
14
15
16
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
III
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: E 43 Sch: 92.3 % Act: 49.8 % Construction Progress: Sch: 63.9% Front: 96.2% Act.: 14.3%
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
-Management level meeting held on 16.09.14. 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 in progress for IV-H-101 & IV-H-201
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: 93.9 %; Front :95.6 % Act: 62.7 % - Structural erection: DHDT: 722 MT / 2600 MT completed.; E 44 VGO: 658 MT / 3065 MT completed. -UG Piping Laying: DHDT: 8696 IM / 25400 IM completed; VGO: 9030 IM / 42000 IM completed.
Open Project
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 15.10.14 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. - VGO/DHDT: Completion of main piperack targeted by 31.10.14 -TS-4 for DHDT targeted by 31.10.14.
As Required
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 Oct'14. Project Material storage commenced. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. 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 E 46 Overall Progress: Sch: 99.5 % Act: 74.8 % Construction progress: Cum Sch: 100% Front: 100% Cum Act: 63.3%
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 14.10.14 at site. Commitment made by M/s PCT has again slipped. Manpower at site is 392 nos instead of committed 670 nos. Supply of balance U/G and A/G Piping Material by PCTL to be expedited. Shortage of TMT steel (540 MT) to be expedited. PCTL to target to complete all Civil work by Dec'14.
EIL / BPCL
As Required
II III
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 47 Overall Progress: Sch: 81.5 % Act: 40.7 % Construction progress: Cum Sch: 71.7% Front: 100% Cum Act: 37.1%
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.
EIL / BPCL
As Required
III
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area E 48 Sch:90.1%; Front: 72.2%; Act: 15.9%
Open Constructi Very High on
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
Management level Meeting held with M/s KSSIIPL on 15.10.14 at site. - M/s KSS agreed to deploy additional 50 nos manpower by end Oct’14. Agencies for structural erection have been finalised and started mobilising at site. - M/s KSS has been asked to deploy additional manpower to complete all equipment fdns. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: M/s Ray Engineering, M/s Tuaman & M/s Zillion. Others contracts being lined up are: Misc. Civil Works-I: Awarded to M/s PGCC on 06.10.14. Misc. Strl Works-II: 4 nos bids received on 30.09.14. PBO targeted by 31.10.14. Misc. Civil & Strl-II: 5 Bids received on 07.10.14. PBO targeted by 31.10.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
EIL/BPCL
Oct'14
E 42 Constr. Progress: Sch: 66.6 % Front: 100 %
Urgency (Long Term / Short term)
7
Y
2 Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15
Schedule ( Y / N)
6
Very High
1
EIL Cost (Y / N)
5
Open Project
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Job No.: A307 Aug'14 Page 666+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Risk Owner 4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close) 3
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
Act: 49.3 %
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E 45
I
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
9
10
11
12
13
14
15
16
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Management level meeting held on 16.10.14 at site. - M/s Petron agreed to increase nos of welders to 30 nos & fitters to 20 nos by 30.10.14. - Semi automatic welding machine shall be in operational by 05.11.14 - M/s Petron has been asked to commence min. 1000-1500 ID / day to complete entire job. Present rate is 160 ID / day.
EIL/BPCL
30-Oct-14
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 E 50 Construction Progress: Sch: 12.3 % Front: 20.2% Act.: 2.8%
Open Constructi on
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
Management review meeting held on 19.09.14. EIL/BPCL -Subcontracting agency finalised and 30 nos addln. manpower targeted to be available at site by end Oct'14. Agency for heavy equipment erection has been finalised and mobilisation schedule under submission. -Semi automatic welding machine - 3 nos recd at site. Commissioning yet to be done. AG piping fabrication: Only 12108 ID / 304970 ID fabrication completed. AG piping erection: Only 1078 IM / 412580 IM piping erection completed.
30-Oct-14
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:76.4%; Front: 82.6%; Act: 18.8% CCD: 25.01.15 E 51 ECD: Oct'15
Open Constructi Very High on
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
Management level meeting held at Kochi site on 15.10.14. EIL/BPCL -MBEL asked to explore the methodology to reduce attrition of present labour. MBEL to augment additional resources (from 210 nos to 400 nos) MBEL committed to increase manpower upto 300 nos by end Oct’14. - Availability of front to mechanical contractor to be expedited by completing all piperack foundations by 30.10.14 and structural erection by mid Nov’14. Works offloaded to M/s Ray &M/s Deens to supplement Civil & Strlworks. Further 2 additional Civil &Structural works contracts being lined upand expected to award by end Nov’14.
Oct'14
Slow progress by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. Awarded on E 52 25.03.14. CCD: 24.09.15
Open Constructi Very High on
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
Mobilisation started. Against requirement of 12 nos welders only six number welders are available at site. Resources to be expedited to commence work. Piping fabrication work commenced.
Constr.
Oct'14
I III
Slow construction progress by M/s B&R for Composite works: Open Constructi Very High Offsite Refinery area due to delay in mobilisation. on Awarded on 25.03.14. E 53 CCD: 24.09.15
N
N
Y
N
Long term
I
0.2
0.19
0.19
0.00
- Management level meeting held 19.09.14 at site. -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works commenced.
EIL/BPCL
Oct'14
III
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for CDU/VDU. Sch: 04.09.14 E 54 CCD: 06.09.14 ECD: 06.03.15 Sch:100% Front: 99.3% Act: 82.5%
Open Constructi on
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
-TS-1 by Dec'14; TS-2, TS-3, TS-4 , TS-6: handed over. TS V : Beam & slab completion : 31.10.14. -TS VII : Civil completed. Erection to start after piperack erection completion, from this area.
Constr.
Oct'14
III
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15 Overall Progress: E 55 Sch: 95.2 % Act: 86.3 % Constr. Progress: Sch: 85.4 % Front: 88.0% Act: 61.8 %
Open Project
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Major backlog is due to manufacturing & Delivery (3%) and construction (30%). Erection of APH, Hot air ducts for VDU Heater is in progress. - Additional resources to be mobilised to recover construction backlogs Convection module 4/5 erected for Crude Heater A & 3/5 erected for Crude Heater B. CDU APH foundations to be handed over by mid Nov-14
Constr.
As Required
III
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for DCU. Sch: 04.09.14 E 56 CCD: 06.09.14 ECD: 15.03.15 Sch: 100% Front: 98.3 % Act: 78.3 %
Open Constructi Very High on
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Handing over of balance equipment foundation targeted progressively by Oct’14. - Handing over of complete branch piperack targeted by 30.10.14. TS-III : Start of structural erection in TS-III targeted by end Oct'14.
EIL/BPCL
Oct'14
Open Constructi on
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level Meeting held on18.09.14. - Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT383/391/150. - Annular plate erection for tanks YT-26&YT-28 started. - YT-150: Dismantling activities in progress. - YT-383: Dismantling activities in progress. Plate material ordered. - YT-391: tank cleaning under progress. - Ordering of plate material to be expedited. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement.
EIL/BPCL
Oct'14
5
Urgency (Long Term / Short term)
8
N
2
Schedule ( Y / N)
7
Open Constructi Very High on
1
EIL Cost (Y / N)
6
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: E 49 Sch: 8.6 %; Front: 9.8%; Act.: 2.3% AG Piping fabrication: 1980 ID / 500000 ID completed
Risk Id
Action Plan
Key Risk Description
Previous Risk Score
Job No.: A307 Aug'14 Page 667+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
Risk Owner 4
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Status (Open / Close) 3
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
Action By
Target Date
Risk Severity
18
19
17
II High
II
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) E 57
Medium
II III
Kochi Refinery, BPCL
(Current risk Score Previous Risk score)
6
7
8
9
10
11
12
13
14
15
16
Medium
N
N
Y
N
Short term
I
0.4
0.20
0.20
0.00
- Management level meeting held on 19.09.14 with M/s B&R at site. M/s B&R agreed to increase manpower from 96 nos to 180 nos. B&R agreed to complete the civil works as per below targets: 1. YT-341 : Tank pad completed, annular plate laying & welding is in progress. 2. YT-342: 20.08.14 Revised date: 02.11.14. Sand filling is in progress. 3. YT-343: 10.08.14 Revised date: 20.10.14. PCC & fire brick work is in progress. 4. YT-344: 30.07.14 Revised date: 04.11.14 5. YT-111: 15.07.14 Annular & Bottom plate welding completed & 3 nos Shell plate erection completed & welding is in progress. 6. YT-112: 20.07.14 Annular plate laying & welding is in progress. 7. YT-113: 14.08.14 RCC wall done :revised date : 20.10.14. Sand filling is in progress. 8. YT-114: 08.08.14 Revised date: 17.10.14.Sand filling is in progress. - Procurement of Balance Quantity of Plates (890 MT out of 1650 MT) to be expedited.
EIL/BPCL
Oct'14
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. -Agency has been pressurised to mobilise resources and start work. - Tank pads to be handed over from Sep'14 onwards. - SWS-1 Sour water tank & sour water storage tank pads handed over.
Constr.
Oct'14
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected. Piping fabrication work in progress.
Constr.
Oct'14
II III
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 18.09.14 at site. M/s OIL has been asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Mobilisation for 20 nos auto welding machine to be expedited.
Constr.
Oct'14
III
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 18.09.14 at site. M/s OIL has been asked to mobilise resources, fabrication yard in progress - 600 MT crane to be mobilised - At present only 4 nos welders are available at site with per day rate of 120 ID, however to achieve the completion schedule minimum 1000 ID/day to be achieved.
Constr.
Oct'14
III
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
-Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. Piping III contract awarded BPCL to M/s Keller Ground Engineering.
Oct'14
Urgency (Long Term / Short term)
5
Open Constructi on
Schedule ( Y / N)
Action Plan
EIL Cost (Y / N)
Previous Risk Score
4
Job No.: A307 Aug'14 Page 668+15 of 32
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
3
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
2 Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 85.6 % Front: 100 % Act: 39.9 %
Status (Open / Close)
Risk Id 1
Key Risk Description
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
E 58
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 CCD:18.06.15 E 59 Work yet to start
E 60
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. 5711 ID / 210605 ID piping fabrication completed.
Start of Composite works by M/s Offshore for Offsite DHDS area E 61 Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15.
E 62
Start of Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 2614 ID / 298914 ID piping fabrication completed. Piping erection work yet to commence
Completion of balance piling work (Covered under Piling-IIII Contract) E 63 (Total 2077 Nos piles approx).
Open
Constn.
Action By
Target Date
Risk Severity
18
19
17
III
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 7114 ID / 203790 ID piping fabrication completed
Open Constructi on
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
- Fabrication shed erected, side cladding in progress. Piping fabrication work in progress. Piping erection work commenced on the main pipe rack.
Constr.
Oct'14
II III
Availability of Hydrogen and Nitrogen for Pre-commissioning 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’2015 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 2 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) 3
Open
as scheduled
III
E 64
F
F
F
1
All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
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.
Kochi Refinery, BPCL
2
G
3
G
4
G
5
10
11
12
13
14
15
16
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.
As Required
IV
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.
Constn. / Projects / BPCL Process / POSD / Engg. / Projects
All by 60% constn progress
sep'13
I
I
Action By
Target Date
Risk Severity
17
18
19
Non-performing vendors
Open Inspn
Low
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
- 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. - List of buildings finalised between EIL and BPCL. Methodology for execution under finalisation.
15-Apr-13
Apr'13
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
0.00
- Documents approved from PESO
BPCL
Close
Purch / Contrc.
BPCL
Low
Implementation of environmental clearance conditions by EIL Open (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 inside TF- Close 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
7
IV
Apr'13
1
Statutory approvals - Factory inspectorate approval - CEA (Central electrical authority) approval 2 -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
Oct'14
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
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
0.00
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
BPCL
As Required
Nov'13
Mobilisation of Skilled workers
Open
Const.
High
N
N
Y
Y
Short term
I
0.5
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
Constraint in movement & transportation of ODC eqpt.
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
As Required
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open Project/En gg
High
N
N
Y
N
Long term
I
0.2
0.00
Closed as no concern as on date.
BPCL
1
K
1
K
2
K
Process / Engg.
6
J
K
Open
Previous Risk Score
9
Y
Finalisation of Non plant buildings.
G
Controllability Condition (D/I ) Impact Score => {6+7+8+9} * 10 * 11 Current Risk Score -> {5}* {12}
8
N
Urgency (Long Term / Short term)
7
N
Schedule ( Y / N)
6
Medium
EIL Cost (Y / N)
5
Const.
Scope changes & information flow to executing group
G
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)
G
Status (Open / Close)
Risk Id
3
Timely payment to sub contractor by main contractor
2
1
Job No.: A307 Aug'14 Page 669+15 of 32
Action Plan
Key Risk Description
1
G
Output Quality ( Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
3
4
0.40
0.40
At present only approx 9000 labours are working against requirement of 15000 labours.
As stated
II Jun'14
Jun'14
Kochi Refinery, BPCL
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)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)Cost Project ( Y / N)
Risk Owner
16
6
7
8
9
10
11
12
Y
N
N
N
Short term
D
0.08
0.00
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
Open
Environ.
Very High
Y
N
N
N
Short term
D
0.08
0.00
Scope of facilities finalised.
Environ.
15-Oct-13
sep'13
Variation in foreign exchange rates from Rs 50 per USD as Open on Mar 12 to Rs. 60 per USD as on date and fluctuations in the intermediate period and Scope changes w.r.t. DFR 3 (additional in scope) has significantly impacted on the overall project cost.
Project
Low
Y
N
Y
N
Short term
I
0.6
EIL/BPCL
Oct'14
M
Increase in facilities on account of deletion zero liquid 2 discharge
Total Risk Score
0.18
0.48
-0.30 - BPCL to put up Revised cost in BPCL Board and seek approval on the same.
24.42
24.55
-0.13
17
18
Risk Severity
5
1
M
15
Target Date
High
M
14
Action By
4
Close
13
Action Plan
Costing
Cost monitoring & control on regular basis
3
Job No.: A307 Aug'14 Page 670+15 of 32 (Current risk Score Previous Risk score)
2
Status (Open / Close)
Risk Id 1
Key Risk Description
EIL Cost (Y / N)
IV - RISK REGISTER
Integrated Refinery Expansion Project
19
III
Job No.: A307 AUG'14 Page 671 of 749
Integrated Refinery Expansion Project, Kochi
A
A
A
A
1
2
3
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
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
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
- 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
- All P&IDs incorporating DCNs issued.
Process
25/10/13
Oct'13
Holds, missing information, corrections, changes in PDS / P&IDs - DCU
Open
Process
- 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
15-Mar-14 Projects / Engg Process
Mar'14 & Apr'14
31-Mar-14 30-Apr-14
Delay in Process Package for TGTU (M/s CB & INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13 A
5
A
6
A
A
Close
BPCL / Process
-Process package received on 14.04.13
Close
Process
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 Close LAD : 29-Dec-12; Ant : 19-Mar-13
Process
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
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Process
Based on latest information from BOO HGU and SWII (FCC), Revised Design Basis issued.
Projects / Process
-
Mar'13
Process
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
- 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
Process
All process P&IDs issued. Pumps PDS issued for engg,. All Vessels PDS issued for engg.
Process
Delay in "issue for engineering - IFE" PDS / P&IDs for DHDT P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
-
Apr'13
7
8
Close
Close
9
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A
10
A
Delay in "issue for engineering - IFE" PDS / P&IDs for VGO-HDT 11 LAD : 29-Jan-13; Ant : 10-May-13
A
Apr'13
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
Projects / Process
Close
Close
-Preparation of Offsites 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 12 details received now. -Upgradation of Crude oil pipeline system (Inside refinery) to be taken up.
POSD
- All 32 P&ID issued for engineering
Apr'13
31-Dec-12
Jan'13
Apr'13
Apr'13
Job No.: A307 AUG'14 Page 672 of 749
Integrated Refinery Expansion Project, Kochi
In view of increase in sulphur load PDS & P&IDs for Close sulphur block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement.
A
13
A
Revision in PDS after issue of “Issued for 14 Engineering” after release of MR -Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
Close
Close
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Process
Action Plan
Target Date
- All PDS and P&ID revised and issued.
Process/EN Revision in PDS to be avoided once same is issued for engineering GG Process
Action By
Risk Severity Apr'13
Process
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New facilities) has been issued for BPCL / engineering. Balance 1 no. targeted by 15.03.13 Projects / POSD
-
15-Mar-13
Apr'13
Feb'13
A
15
Revision in PDS after issue of “Issued for 16 Engineering” after Order
Close
Process/EN Revision in PDS to be avoided once same is issued for engineering. GG/Procure
Process
-
Apr'13
A
Revision in PDS after issue of “Issued for 17 Engineering” after Equipment manufacturing
Close
Process/EN Revision in PDS to be avoided once same is issued for engineering GG/Procure
Process
-
Apr'13
A
As Required
Apr'13
Updation of estimated utilities on account of revision Close 18 in process parameters (revision of PDS based on engg comments)
Process
A
ISBL Distribution P&IDs for VGO-HDT 19 SCH: 30-Nov-12 ANT: Jun-13
Close
Process
A
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 20 ANT: 31-May-13
Close
Process
A
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
Close
Process
Distribution P&IDs issued for engineering.
A
21 Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 22 Updation of P&ID as per finalised condensate philosophy to be taken up.
Open
Process
- Revised P&ID for Condensate System issued on 15.05.13.
Open
Engg
- Inconsistency related to type of Isolation valve (Ball Vs. gate / globe/check) between Engg. instrumentation and process design basis identified during coordination meetings resolved by TSD.
A
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed 23 engineering activities.
Open
Power Tech.
- System configuration including 8 pumps, filters & centrifuge finalised and PDS for Projects (CPP 30-May-14 pumps issued. Filters & Centrifuge PDS issued for engineering on 22.05.14. group) - Readiness of the fuel forwarding system to be ensured w.r.t. GTG commg schedule (i.e. in Mar 15).
May'14
A
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new 24 GTG).
Close
Engg.
- PDS for desalting pumps issued on 25.10.13. MR issued on 13.11.13.
Engg
Nov'13
A
BPCL confirmation/clarification over datasheets/GAD’s for existing/new raw water intake pump obtained from M/s KBL 25 (LAD for MR for pumps - 07.03.13)
A
26 Identifications of hook-ups on flare lines and finalisation of methodology BPCL availability Signing of ISBL P&IDs and with battery limiti.e. P&IDs for of ShutUtility downpackages / Hot tapping. Units, & other packages.
Close Open
Projects Process / POSD
Projects / Constn. Process / POSD /
A
27
- Identification of hook ups for Flare line, FCC flare, PRU flare and NHT / ISOM completed during completed site visit byfor: EIL Process. Signing of P&IDs - Hook sketches prepared and signed by Piping / POSD / BPCL. Marking at site -CDU/VDU Blocktoonbe24.06.14. to be taken up on 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 signing to be expedited.
28
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Close
A
Process / Updated P&IDs released. POSD
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
Open
Engg.
- Equipment layout issued for engineering on 23.08.13
Piping
21-Aug-13
JUL'13
Issue of Equipment layout for engineering for VGOHDT LAD - 07-Nov-12 Ant- 26-Dec-12
Close
Engg.
Equipment layout issued for engineering
Piping
26-Dec-12
Jan'13
Close
Engg.
Equipment layout issued for engineering
Projects / 21-Dec-12 Piping / BPCL
Jan'13
Open
ENGG
NIT issued on 24.06.13, bids due on 23.07.13
Projects / Process / HMTD
May'13
Utility distribution P&IDs for DCU
A
B
B
1
2
B
3
B
4
Delay in this activity shall hamper the following: Issue Equipment layout for engineering for FCCU i) 3 D of Modelling (targeted by 27.12.2012) ii) Civil/Structural & 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
In case of revision in process parameters of an equipment the utility estimates RED / PED/ furnished by engineering against older Revision of PDS should not be used until same PROCESS is got verified/ updated for current revision. RED to update all such changes within stipulated time frame as per departmental Utility P&IDs: (14to/ incorporate 17 ) issued for engg (except for small bore piping: Pump Process guidelines andP&IDs Process in the revised PDS. Seal & Vent Drain). The same are targeted by Jun'13. Process
31-May-13
Apr'13
31-May-13
Apr'13
Jan'13
BPCL
25-May-13
May'13
30-Apr-14
May'14
30-Dec-13 15-Sep-14
Process / POSD /
Dec'13 IV
Mar'14 & Apr'14
18-Jun-13
Job No.: A307 AUG'14 Page 673 of 749
Integrated Refinery Expansion Project, Kochi
B
5
B
6
B
7
B
8
a) Cost/time overrun due to rework Close b) Non completion of critical project activities within time & delay in Project completion c) Poor performance of Sub-contractors and Vendors
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Procure/EN 1) Involvement of technical/engineering team and client with vendor where nonGG/CONS. 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
Action By
Target Date
Risk Severity
Projects
As Required
Apr'13
Engg (Elec)
15-Jan-13
Jan'13
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
-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
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; Ant: Mid Jun'13
Open
Engg.
- Layout finalised with licensor. Final layout under study. Piping - Model review for SRU completed on 30th May'13 (except TGTU, incinerator section & downstream of sulphur pit).
15-Jun-13
May'13
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant - 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.
Close
Piping
Intermediate MTO released on 31.05.13.
Piping
31-May-13
May'13
HMTD
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
Delay in thermal design for Heat exchangers & Air coolers for licensed and non licensed units LAD (DHDT): 02-Feb-13 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
Close
Apr'13
B
9
Issue Overall UG piping layout drawing for the 10 complex
Close
Engg.
- Layout for OWS, CRWS, CW & FW lines issued for Offsite.
Gen Civil
31-May-13
May'13
B
Completion of 30 % Model review 11 VGO- LAD: 09-Mar-13 FCCU-LAD : 23-Apr-13
Open
Engg.
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 12 ANT: 18-Jun-13
Open
B
C
B
a) Inaccurate assessment of quantum of work
Close
MR issue for MCC (Main combustion Chamber) packages.
Close
13
May'13
Engg/procur Wide variation of BOQ and site executed quantities for item rate tenders to be ement controlled. Past data to be analysed and used for reference purposes.
Engg
Apr'13
As Required
MR issued on 02.05.13.
Open
Engg.
- Management level meetings with package contractors being organised to expedite Projects / the works. Engg. / - Battery limit conditions for CDSP Pkg (awarded to M/s Essar on 22.08.13) submitted Process 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.
Unit and offsite interfaces (Elevation termination levels)
Close
Engg.
- Clubbed with Risk ID A27
TSD
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule 17 requirements. LAD - 28.02.13; Ant - upto Feb 14.
Open
Projects
- 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
10-Mar-13
Feb'13
15-Sep-14
III
Continuous
IV
14
B
Timely finalisation of Package Interface 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 15 by all the concerned).
B
Project / C&P 18-Jun-13
Project
B
B
Project/C&P - NIT issued for publishing on 12.06.13 with sale period from 17.06.2013 to 05.07.2013
Engg
Apr'13
LAD: 16-Feb-13 Ant: 15-Apr-13 May'14
-
Mar'14 & Apr'14
16
NIT for Heater for DCU LAD -15-Feb-13;
Close
PROCESS/ - NIT issued on 11.03.13, bids due on 16.04.13. Pre bid meeting targeted on ENGG 02.04.13. (Delivery : 18 M for Mechanical Completion including Pre-Commissioning Activities)
Open
Engg/Cont. - Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. - HAZOP review completed for GTG, HRSG & UB package. - 60% model review for HRSG targeted by mid Sep'14. -90% model review for GTG & UB package targeted by mid Sep'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
B
CPP: Integration of various packages & BOP Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas 19 Booster compressor.
Open
Engg/procur - Preparation of Inst. dwgs./ docs. by the DCS vendor, using Smart Plant ement Instrumentation (SPI) is already covered in DCS vendor’s scope in DCS
Projects
B
Distributed Control System (DCS) Detailed engg., supply and erection 20 (ordered on M/s Emerson Process on 04.11.13)
B
21
B
18
60 % Model review for DCU (LAD:03.07.13 Act:13.09.13)
Close
ENGG
- Model review completed on 13.09.13
Projects / Process Process / HMTD C&P
ENGG
Aug'13
Job No.: A307 AUG'14 Page 674 of 749
Integrated Refinery Expansion Project, Kochi
Action Plan
Action By
Target Date
Risk Severity
Open
Engg/procur - Being taken up with respective package vendors for implementation. ement
Instn / Projects
Continuous
IV
Open
Engg/procur Package vendor inputs being made available by expediting for updation of interface ement engineering documents.
Projects / Engg.
Continuous
IV
B
Delay in Interface Engineering (including control system) due to non availability of Package Vendor 23 Data
Open
ENGG
Model review completed on 04.10.13
ENGG
4-Oct-13
sep'13
B
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. 20 - Vendor drawings for sheds awaited.
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) 24 LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
GC
- All P&IDs released
G. Civil
25-Jul-13
JUL'13
Order for DG set Dely: (12 M FOB + 3 M Site work) 25 Sch: 05.11.13 Ant: 30.09.14
Open
Project
- Award recommendation issued on 07.08.14. BPCL to award.
BPCL
30-Sep-14
III
Close
ENGG
- 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
B
22
B
B
Package Vendor refuses to submit Instrumentation Drawings/ Documentation in Smart Plant Instrumentation Database as per Client Requirement
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Receipt of Inputs from Process / Vendors for 60 % 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
Open
ENGG
- Model review completed on 25.10.13.
ENGG
25-Oct-13
sep'13
B
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) 27 envisaged.
Open
ENGG
- Model review started on 28.10.13 and under progress. Targeted to complete by 31.10.13.
ENGG
31-Oct-13
sep'13
Open
ENGG
- Intermediate 2nd MTO released on 31.10.13, based on above MR under preparation.
Projects / ENGG
31-Oct-13
Oct'13
B
60 % Model review for 28 SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), 164 Delay in release 2nd MTO (SRU),15 (SWS)of & Intermediate 60(TGTU) + 155(Utilities LAD:30.09.13; -CVs Size HoldAct:31.10.13) as follows: 13 (ARU), 6 (SWS), 125 Holds: (SRU). -CDU/VDU: PumpFace nozzle 6 nos. pumps under -All Control Valve to for Face Dimensions are hold), for 256 lines under hold, Control valve HOLD.sizes All CVs for TGTU are HOLD. 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 29 (103 nos.) not considered in MTO.
Open
ENGG
Progressively
30
- Surplus material to be salvaged with effective substitution and being carried out during MTO preparation.
ENGG
B B
31 HAZOP for FCCU LAD - 23-Sep-13 Completion of 90 % engineering by Mar-14. Average progress achieved in last 3 months 3.0 %
Close Open
ENGG ENGG
- HAZOP study completed on 29.11.13. - As of 15 Aug'14 Engineering progress is 91.4 %.
ENGG ENGG
B
32 LD Milestone date - Dec'13
Open
ENGG
- MTO expected by 10.09.14.
ENGG
B
33
Finalisation of GTG fuel forwarding scheme for naptha to day tank when Naptha tank being under 34 maintenance.
Open
POSD
B
- Revised P&IDs issued for connecting tank-101 & 102. Process / As per BPCL mail dated 25.08.14, requirement of connecting tank YT-332 is under Engg. review where in procurement of additional pumps is required. Process datasheet and P&IDs expected to release by 15.09.14.
B
Generation of Surplus Piping material
Release of final Piping MTO Sch: Jul'14 Ant: Sep'14
IV
Nov'13 Aug'14
Sep'14
III
Sep'14
III
Job No.: A307 AUG'14 Page 675 of 749
Integrated Refinery Expansion Project, Kochi
Status (Open / Close)
Risk Owner
Risk Id
RISKS REQUIRING BPCL ATTENTION
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
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
30-Dec-13
Dec'13
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 Duration: 18 M
Open
Project
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
30-Aug-13
JUL'13
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
- BPCL confirmation sought for minimum nos (10.97 MW or 80% of 10.97) for qualifying criteria. Accordingly BQC changed and approved by BPCL. Draft NIT by 25.05.13. Publishing targeted by end May 13.
C&P
30-May-13
May'13
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
Close
Project
- As per latest cost status report the impact of cost variation has been neutralised by savings.
Projects
Continuous
Nov'13
Award of Heater for DHDT LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Awarded to M/s Technip on 04.09.13 (Duration 18 M)
Projects / HMTD
15-Sep-13
Aug'13
NIT for Composite Works for DCU LAD -06.06.13 ; Ant - 25.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
25-Oct-13
sep'13
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
31-Oct-13
sep'13
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
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
-Ordered on M/s Shin Nippon & M/s Flowserve on 30.01.14 (except Tag IV-P-301 A/B EIL 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.
15-Mar-14
Mar'14 & Apr'14
NIT for Composite Works for Offsite DHDS area LAD -22.07.13 ; Ant - 15.10.13
Open
ENGG
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
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 -Ordered to M/s Fabtech on 15.07.13 g
Engg/Proj
20-Jul-13
JUL'13
Project/C&P NIT issued on 29.05.13, bids due on 18.06.13.
Project / C&P 31-May-13
May'13
Key Risk Description
C
1
C
2
C
3
C
4
C
5
C
6
C
7
C
8
C
9
C
10
C
11
C
12
Action Plan
Action By
Target Date
Risk Severity
C
13
Issue NIT for Tankage-II LAD: 21-Jan-13 14 ANT: 31-May-13
Close
C
Award for RO-DM LAD:30-Jan-13 15 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Open
Project
- Awarded to M/s Driplex on 12.06.13. duration is 22 M.
Engg / C&P
29-Jun-13
May'13
Close
Project
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months.
BPCL
28-Feb-13
Feb'13
Close
Project / Licensor
21-Feb-13
Feb'13
C
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13 C
C
C
16
NIT for Reactor regenerator package for FCCU LAD : 01-Jan-13 Ant: 21-Feb-13 17 Changes in scope of supply led to revision in BQC / tender.
18
Award for Raw water quarries LAD :03-May-13 ANT: 15-Apr-13
Close
Project
BQC finalised on 15.01.13. Tender under compilation. Draft NIT being issued to BPCL Projects / for approval. BPCL NIT targeted by 21-Feb-13.
Ordered to M/s Paulose George (15 M).
BPCL
Apr'13
Job No.: A307 AUG'14 Page 676 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Ordering of Reactor for VGO-HDT LAD: 29-Dec-12 ACT: 08-Apr-13
Close
Project
Ordered on M/s L&T on 08.04.13.
Proj/Engg
Award of contract for Piling-II LAD: 31-Dec-12
Close
Project
Awarded to M/s L&T on 09.04.13 with duration of 12 M.
BPCL
Close
Project
Awarded to M/s Petron on 09.04.13 with 18 M duration.
BPCL
Close
Engg.
Awarded to M/s Technip on 07.03.13 (Duration 23 M)
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
19
Key Risk Description
Action Plan
Action By
C
20
C
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 21 Ant: 30-Mar-13
C
Award of Crude and Vacuum heaters (LAD 29.12.12) 22 Ant : 07.03.13
Storage of sulphur and related issues with Granulator to be finalised between BPCL / EIL.
Close
Project
- Scheme finalised.
Projects / BPCL
C
23
NIT for ETP package with WAO (Wet air oxidation) 24 LAD: 15-Jan-13 Ant: 16-Apr-13
Close
Project
Tender released on 26.03.13; BQC finalised on 08.04.13. NIT targeted by 16-Apr-13
Engg
C
Project
Award recommendation issued on 11.02.13. Awarded to M/s Howe baker on 07.03.13 Proj/Engg
Project
Awarded to M/s L&T (duration 20 M)
BPCL
KB tech completed development of flare area & handed over the area to M/s L&T.for piling.
Projects
Risk Severity
Target Date -
Mar'13
-
Mar'13
Ant: 15-Apr-13
Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13 C
25
C
Award of contract for Building incl substations LAD: 07-Feb-13 26 Ant: 15-Apr-13
Filling of existing part fire water pond required for area preparation.
Close
Close
Open
Strl
-
Mar'13
Projects / 7-Mar-13 C&P / BPCL
Feb'13
Apr'13
Apr'13
7-Mar-13
Feb'13
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
28
Engg / C&P - Evaluation of LLIs to be ensured with-in 1 month from receipt of bids by Engg. & Engg / C&P / PBO recommendation 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 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: 29 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
Awarded to M/s Tecnicas Reunidas S.A. on 31.12.13
BPCL
30-Dec-13
Dec'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) 30 Anticipated: 23.11.15 (27 M) Bidders quoted 27 M against schedule of 26 M.
Open
Project
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. 31 Duration (Supply) - 15 M FOB /16 M FOT as per RFQ; Sch : 20 M
Open
Project
- Awarded to M/s BHEL on 25.07.13.
Projects / Engg / C&P / BPCL
JUL'13
20-Jul-13
Job No.: A307 AUG'14 Page 677 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Delay in Ordering of HRSG (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. 32 No PTR available for LSVR Fuel Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
Close
Projects / - Awarded to M/s Thermax on 20.12.13 Projects / Engg 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.
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. 33 Bidders sought extension in dates.
Close
Project / Licensor
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) 34 Duration: 21 M+2 M No bidder could meet the BQC criteria in view of which the tender has been re-floated.
Open
Project
Open
C
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 35 Duration: 20 M
Close
C
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 36 Duration: 22 M+2 M
C
C
C
- 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 Esaar on 10.07.13.
Target Date 20-Dec-13
Projects / BPCL
BPCL
Risk Severity Nov'13
Jun'13
31-Oct-13
Oct'13
Projects / 31-Jul-13 C&P / BPCL
JUL'13
C&P/Engg/Pr oj
Aug'13
Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
Process / - 3 no. bids received on extended date of 02.02.13. Engg / - Meeting with bidders held from 19.02.13 to 26.02.13. PBO recomn. issued on constn 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 Project/C&P 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
Anticipated Completion: 29-Jul-15
C
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
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
Failure of contractors
Open
Const.
Limit the number of works being awarded to one Agency so that alternatives can be C&P 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 BPCL / only. Projects
-
sep'13
-
sep'13
37
C
38
Ordering of Ejector Pkg 39 (LAD:12-Jan-13; Ant: 15-Jul-13)
Open
Project
Awarded to M/s GEA on 10.07.13 with delivery period of 13 M.
BPCL
15-Jul-13
Jun'13
C
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). 40 Due to Technical and related commercial issues enquiry re-floated. Duration 20 M
Open
Project
Awarded to M/s Heurtey, (Duration - 20 M)
BPCL
15-Nov-13
Oct'13
Award of Civil & Strl work for DHDS offsite area (LAD: 30-Mar-13; Ant: 20.07.13) 41 Duration: 18 M
Open
Project
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
Awarded to Mcnally Bharat on 26.09.13. Duration- 16 Months
Project/C&P
Open
Project
NIT issued on 01.08.13, bids due on 30.08.13
Gen Civil/Project
25-Jul-13
JUL'13
Open
Project
Awarded to M/s McNally Bharat. Duration - 16 M
Gen Civil/Project
30-Oct-13
Oct'13
C
C
C
42
C
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) 43 Duration : 16 M
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15
Award of work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M C
44
sep'13
Job No.: A307 AUG'14 Page 678 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
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 45 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
MAB awarded to M/s Elliot Ebara on 04.09.13. WGC awarded to M/s BHEL
Award of Civil & Strl contract for CDU/ VDU & DCU LAD: 15-Dec-12 46 Ant: 07-Mar-13
Close
Project
Awarded to M/s L&T on 07.03.13. Award recomm sent to BPCL on 01.02.13. Award to C&P be targeted by 07.03.13.
Ordering of wet gas compressor for DCU 47 LAD: 02-Feb-13 Ant: 30-Jun-13
Close
Project
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
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., 49 sulphur pelletiser and sulphur granule); refloated again as financial criteria was not met by all the bidders.
Open
Project
- Ordered to M/s Sandvik.
BPCL
30-Jan-14
Jan'14
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 50 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
Awarded to M/s Sriram on 25.09.13
BPCL
30-Sep-13
Aug'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 51 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
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 52 Duration: 16 M
Open
Project
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 53 Duration: 12 M despatch and 6 M for site work (ODC)
Open
Project
Awarded to M/s Thermax
BPCL
14-Aug-13
JUL'13
Open
Project
Awarded to M/s Triveni
BPCL
19-Jul-13
JUL'13
C
Award of contract for RWTP (Refloat case) LAD: 14-Jan-13 Ant: 19-Jul-13 54 (Execution Duration - 18+2 M)
Open
Project
Ordered to M/s Callidus and M/s UOP India on 20.06.14.
BPCL
C
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 15.06.14 (Incinerator burner) 55 (Execution Duration - 14 M)
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
C
C
C
C
C
C
C
Key Risk Description
Action Plan
Action By
Target Date
C&P/Engg/Pr 30-Sep-13 oj
7-Mar-13
Risk Severity Aug'13
Feb'13
Jun'13
48
Aug'13
Jun'14
Job No.: A307 AUG'14 Page 679 of 749
Integrated Refinery Expansion Project, Kochi
56
Risk Owner
C
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
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
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
Awarded to M/s Airoil on 25.09.13 with duration of 18 M.
Projects/ 28-Sep-13 Process/ Engg / C&P/
Aug'13
Open
Project
- Awarded on M/s Ray Engineering on 23.01.14.
Engg / C&P
Jan'14
Key Risk Description
Action Plan
Action By
Target Date 19-Jul-13
Risk Severity 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
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 58 Duration: 12 M
Award for:RGC compressor for VGO-HDT (LAD: 30Mar-13; Ant: end Jun 13) Dely: 18 M
Open
Project/Eng Awarded to M/s BHEL g
Proj/Engg
29-Jun-13
Jun'13
C
59
Award of MUG compressor for VGO-HDT (LAD: 08-Apr-13; Ant: 30.11.13) 60 Dely: 16 M FOB
Close
Project/Eng Ordered to M/s Neumen & Essar on 14.11.13 g
BPCL
30-Nov-13
Nov'13
C
Award of Contract for Tankage-III (Crude tank: 02 Nos & 1 surge relief tank and crude drain tank) 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 tanks-25/26 under 61 tankage-III. Sch: 01.10.13 Ant: 15-Dec-13
Close
Project/Eng Awarded to M/s IOT Anwesha on 04.12.13. (duration: 20 M) g
BPCL
15-Dec-13
Nov'13
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: 62 Jun 13)
Close
Project/Eng Awarded to M/s BHEL g
Proj/Engg
28-Jun-13
Jun'13
C
Close
Project/Eng Awarded to M/s Dresser Rand g
Proj/Engg
C
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep-13) 63 Duration : 18 M FOB
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) 64 Sch: 30.04.13 Ant: 30-Sep-13 Duration:22 M
Close
BPCL
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 65 new crude tanks (Tankage-III; YT-25/26). Alternative scheme required to be finalised for outage.
Open
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
C
C
C
C
66
Duration - 20 M
Aug'13
Awarded to M/s B&R
BPCL
30-Sep-13
Aug'13
BPCL / Projects
Awarded to M/s Offshore on 17.04.14.
EIL / BPCL
25-Apr-14
Mar'14 & Apr'14
Project
.Awarded to M/s Offshore (Duration- 20 months)
BPCL
31-Oct-13
Oct'13
Job No.: A307 AUG'14 Page 680 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award for contract for development of flare area LAD: 01-Nov-13 Ant: end Dec'13
Close
Project
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
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, 69 Technicas, Petron, B&R, JNK). Duration 20 M
Close
Project
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)) 70 (LAD:29.12.13; Ant: 30.07.14)
Open
Project
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) 71 LAD:09.05.13 Ant: 30.09.14
Open
Project
-Award recomn. issued on 08.08.14. BPCL to award.
BPCL
30-Sep-14
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards 72 Piping intermediate MTO-II released on 30.10.13.
Open
Project
- All pipes, fittings & flanges ordered.
C&P
14-Aug-14
Ordering of Critical Valves Sch: 11.07.14 73 Ant: 30.09.14 Dely: 06/07 M FOT /FOB
Open
Project
Revised MR (MR-3415) issued covering all critical valves along with all critical valves EIL/BPCL of MR-3211 floated. Price bid opened on 09.09.14. Award recommendation targeted by 12.09.14.
30-Sep-14
Award of contract for Mechanical works-CPP area LAD: 28.02.14 74 Ant: 25.05.14
Open
Project
- Awarded to M/s Zillion on 19.05.14.
25-May-14
Release of balance piping Isometrics drawings and GAD's. 75 Target Sch: Jul'14 Ant: Sep'14
Open
Project
-Total 24054/ 30154 nos (81%) isometrics issued for units . Balance ISO's targeted progressively by Sep'14. - Piping items has been ordered for Intermediate MTO-II, delivery expected by Sep'14-Oct'14.
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM-Refloated 76 Sch: 08.05.14 Ant: 15.10.14
Open
Project
- Tender on sale from 28.08.14 to 17.09.14.
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) 77 Sch:27.06.14 Ant: 05.08.14
Open
Project
- Ordered to M/s Sulzer.
Completion of Reactor regenerator package for FCCU-M/s Esaar-GRE LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 59.8 % Act: 47.3 % Construction Progress: Sch: 16.4 % Front: 71.1% Act: 11.1 %
Open
Project
Management level meeting held on 08.08.14 at site. - Completion of hard stand targeted by 15.10.14. Projects - M/s EPIL has been pressurised to complete construction of hard stand by 15.10.14. Submission of final erection scheme targeted by mid Sep'14 and approval by EIL Constn targeted by 20.09.14. (Preliminary erection scheme discussed with EIL). - Work for assembly of hoppers and TSS to be commenced from 15.09.14. - Fdn for flue gas area, stack fdns and ESP fdn targeted to complete by end Oct'14(Excavation already completed). - Refractory lining to commence from 11.09.14 at Tarapur. - M/s EPIL asked to commence area development around FGC equipments & hard stand immediately and to be ready by 15.10.14. - M/s EPIL agreed to mobilise 1600 MT crane by end Oct'14 and will ready for erection by Dec'14. Shipment movement already started. - Delivery of Cyclones expected at site from Nov’14 to Feb’15. M/s Emtrol has been asked to pre pone the deliveries upto Dec’14 during meeting dated 25.08.14. Plennum fabrication status to be obtained from M/s GRE. - Readiness for TSS erection targeted by 2nd week of Sep'14 to Feb'15. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. - Next Management review meeting with M/s Essar planned at site on 12.09.14.
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
C
C
C
C
C
C
C
C
C
D
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
67
68
1
II Aug'14
Engg
Engg.
Sep'14
II May'14
III
15-Oct-14
BPCL
5-Aug-14
II Jul'14
Progressively upto Sep'14
EIL/BPCL
I
Job No.: A307 AUG'14 Page 681 of 749
Integrated Refinery Expansion Project, Kochi
D
D
D
D
D
D
Risk Owner
D
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
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
Clubbed with Risk ID E19
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: 78.1 % Act: 57.8 % Construction Progress: Sch: 63.3 % Front: 100 % Act: 16.6 %
Open
Project
Management review held on 01.08.14 to pressurised M/s ISGEC for completing within Project / CCD. Constn. - M/s ISGEC to expedite modelling work to carry out 90% modelling by Sep'14. - Completion of balance foundations being progressively targeted by end Oct'14. -Erection of UB-1 & UB-2 to be expedited. - Project review meeting planned with M/s ISGEC on 09.09.14 at EIL HO.
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14 Ant : 30.09.14 Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT.
Open
Project
Delivery of wet gas compressor for DCU at Site (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 27.01.15) Sch: 50.7%; Act: 48.2%
Open
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 24.12.14)
Key Risk Description
2
3
4
5
6
7
8
Action Plan
Action By Project
Target Date
Risk Severity
24-Nov-14
Nov'13
Sep'14
III
-All Indigenous component received at site within CDD. - Foreign Source Components: Delivery of ejector and LRVP pkg dispatched.
Project/Inspe Sep'14 ction
IV
Project
Material against all suborders received. Casing for compressor and turbine received at shop. Machining of components of both main compressor and steam turbine under progress.
Project/Inspe 27-Jan-15 ction
IV
Open
Project
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Order placed for Motor, turbines, Casings, forgings, impellers, gear box. Hazop and modelling in progress from 26.08.14. Close monitoring to be done to ensure delivery on CDD.
Project/Inspe 24-Dec-14 ction
IV
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: 73.0 % Act: 50.8 % - 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
-All 3685 MT Plates received at Chakan Shop, plate cutting & welding in progress. Project / - Staggered delivery of columns is required from Sep'14 onwards as major piping Constn. works is held up due to hold for crane movement for these columns. - Foundation for main fractionator column (by M/s L&T) completed and superstructural work being expedited by M/s Tuaman. - Erection for main fractionator targeted by Dec'14. Crane 1250 MT and 550 MT mobilised, erection scheme approved. - Stripper & rectifier Column: Erection expected to commence from Dec'14. Preparation of Hard stand commence from 3rd week of Sep'14. - Approach road work completed. Area improvement to be expedited.
As stated
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) Overall progress: Sch: 71.0 % Act: 63.2 %
Open
Project
- M/s Thermax seeking extension for duration due to delayed availability of burner BPCL / EIL data from M/s Aecometric. Letter issued to BPCL for recommending extension for supply portion to M/s Thermax upto 30.11.14. - Foundation readiness to be delayed till Dec'14. Bidders has requested for providing space for stoarge of MCC equipment & Refractory Materials.
15-May-15
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 49.0 %; Act: 37.0 % Construction Progress: Sch: 27.0 % Front: 92.2 % Act: 18.1 %
Open
Project
-Management review meeting held on 08.08.14 and 14.08.14 at site. Weekely review Constr. meeting held at site on 22.08.14. Following commitments have been made by M/s Essar. -Fabrication for Derrick structure agreed by Dec'14. - Meeting held with M/s Essar for financial issues on 01.09.14. - Derrick and coke drum structure offload from M/s MK Engg scope to M/s Infraprojects and M/s Universal respectively. Status to be obtained for structure BPCL/EIL readiness. - Balance fabrication (for Switch Deck 250 MT) targeted by 30.09.14. - M/s Esaar agreed for readiness of Fractionator column and coke drum for erection by 28.02.15. -Supply of balance Plates (33/38 plates received) targeted by 14.09.14. - Ordering of 2000 MT crane targeted by mid Sep'14 and Crane availability agreed from Feb'15 to May'15. - Resource augmentation for Civil & Strl works being expedited. At present 227 nos have been deployed, while requirement is 328.
Continuously
D
9
Open
Project/Eng - Drive turbine for LOP (Lube oil Pump) sub ordered to M/s KEPL on 22.03.14 & g targeted to receive at shop by Dec'14. Impeller manufacturing is in process. Turbine casings reached at BHEL workshop. - Compressor: MRT expected to complete by mid Sep'14.
Project/Inspe 27-Dec-14 ction
D
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M 10 Ordered to M/s BHEL on 28.06.13
Delivery of RGC compressor for DHDT(LAD : 05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
Open
Project/Eng - Drive turbine for LOP (Lube oil Pump) subordered to M/s KEPL on 22.03.14 & g targeted to receive at shop by Dec'14. Turbine rotors and casings reached at BHEL workshop. Steam turbine: All components except inner casing ready for assembly. Casing inner (steam chamber) got rejected in hydrotesting. Inner casing to be expedited at BHEL Haridwar shop.
Project/Inspe 27-Dec-14 ction
D
11
II III
I IV
IV
Job No.: A307 AUG'14 Page 682 of 749
Integrated Refinery Expansion Project, Kochi
D
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Oct 14 Normally 12-14 Months are required for Unit 12 Mechanical Compln after erection of Crude & Vacuum column. VTV progress Sch ( 100 %); Act (88.5%)
Open
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Oct'14 Projects / - Erection of Crude Column : Top section erection planned on 12.09.14 and / Projects Const. hydrotesting planned on 15.10.14. Middle section erected on 19.08.14 and Bottom section erected on 07.08.14. - Erection of Vacuum Column : Erection of sections expected from end Sep'14 to end Oct'14 and hydrotesting by mid nov'14.
II Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site
Open
T&CC
Open
Projects
(VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Mar'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB)
D
DHDT Reactor (M/s Doosan) expected to receive at Kochi port by Nov'14. ISGEC Josen (3 nos) Column: expected to receive 13 at Kochi port from Nov'14 to Jan'15.
Close Monitoring of ODC equipment (including site fabricated/assembled) up to receipt at site D
D
D
D
Out of total 57 nos. of ODCs; 16 nos received at site. & 3 nos under dispatch. Balance under close monitoring and are expected at site from Sep'14.
Continous
Shipping
Close
Procure/Co - Transporter philosophy frozen and hindrance enroute has been covered under Risk Shipping nstr ID K3.
II IV
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
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.
BPCL
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Mar-15 Ant: 24-Mar-15 17 Overall Progress Sch: 48.2 % Act: 36.5 % Construction work likely to start from Oct'14.
Open
Project
- Hazop review covered in offsite Hazop. - Foundation drawing released. - Flare foundation work completed. - Construction work to be started from Oct'14. Fabrication of flare structure is in progress and delivery expected from Sep'14 onwards.
Projects/Cons As Required tr.
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. 18 Completion of Flare work: Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Open
Project / Process
- 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
Nov'13
15
Jun'14
16
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15 D
Sep'14
14
Delay in delivery at site due to non-availability of transporter / hindrances enroute. D
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. EIL/BPCL - Agency confirmed availability of Barge/Trailer at the time of delivery of Reactors. Barge will be ready with reqd modification by Sep'14. - KOM held on 02.06.14 & follow up meeting held on 16.07.14. Barge readiness targeted as follows: 2 nos Ammonia Barges modifications by 30.09.14. Drawings for new barge submitted to IRS for approval. 1 nos new barge fabrication by 24.12.14. - M/s Urmila informed construction of jetty targeted by 30.09.14 (approval by 30.08.14), Construction of jetty not yet started as land for jetty is yet to be finalised. Meeting with M/s Urmila planned in 2nd week of Sep'14 to finalise modalities. - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at Kochi-Port.
19
Open
Projects
As Required
III
Oct'13
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. However close monitoring being done. Meeting held on 06.08.14. Casing delivery expected within CDD.
II
Job No.: A307 AUG'14 Page 683 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 20 CDD: 03.04.15 Ant: 03.04.15
Open
Projects
- All major items has been subordered. Air Blower: Main casing received at workshop. Main coupling expected to receive at shop by Sep'14. Steam Turbine: Casing received at shop. Bearing expected to receive by Oct'14.
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 21 EDD: 02.03.15 Overall Progress: Sch: 85.0 % Act: 80.0 %
Open
Projects
-Ordered to M/s L&T on 08.04.13; Dly 21M FOT. Close monitoring to be done to Project/Inspe Continuous ensure delivery on CDD. ction - Strike has been called off with effect from 12.05.14 at L&T Hazira workshop. Vendor being followed up continuously to deliver reactor within CDD.
III
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 22 CDD: 07.10.14 Overall Progress: Sch: 83.9 % Act: 82.9 %
Open
Projects
- Follow up visit held, though no delay anticipated as per CDD, however close monitoring to be maintained.
Project/Inspe Continuous ction
III
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13 23 Overall Progress: Sch: 46 % Act: 38.8%
Open
Projects
- Management review meeting held with M/s Thermax on 31.07.14. - Balance engineering to be expedited by m/s Thermax. - HRSG #4 & 5: Foundation works completed and handed over to M/s Thermax. Foundations works for HRSG#3 along with Stack, Pumps(10 nos) and cable trench works are planned for completion during the mid Sep'14. - 30 % model review completed & 60 % model review targeted by mid sep'14.
Project/Inspe Continuous ction
III
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) 24 LAD ;30.03.15 CDD: 30.04.15
Open
Projects
- Generator subordered - Pedestal fabrication is at final-machining. - Fabrication of exhaust diffuser and inner exhaust case targeted by Sep'14
Project/Inspe Continuous ction
III
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 25 CDD: 30.03.15 Overall progress: Sch: 30 %; Act: 26.5 %
Open
Projects
-Silos with structure & Conveyors sub ordered by M/s Sandvik. - Delivery of Semi rolled sections of Silos shall commence from Nov'14 onwards. Structure to be made ready for installation works to commence. - Space for SILO's to be expedited as material expected to receive at site by Sep'14. - Foundations for pelletiser shed to be made ready by end Nov'14.
Project/Inspe Continuous ction
III
Delivery of steel plates by M/s Essar to other vendors. CDD: Progressively by 15.01.14.
Open
Projects
Strl. Steel for R&RMajor portion of steel plates have been delivered by M/s Essar.
Project/Inspe Continuous ction
Jun'14
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 27 CDD: 10.03.15
Open
Projects
- Synchronous Motor ordered to M/s Toshiba Mitsubishi. Expected to receive at M/s Dresser shop by 03.02.15. - HAZOP review completed on 20.06.14.
Continuous
IV
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) 28 LAD : 26.02.15 CDD: 13.04.15
Open
Projects
- Main motor ordered. KOM for Motor held on 06-07.05.14 & expected to receive by 13.04.15 (FOB: Germany). - HAZOP completed on 19.06.14.
Progressively
IV
Open
Projects
- Following bidders showing slow manufacturing progress: - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.: 133, 144 & 184. Expediting meeting held at shop on 04.07.14. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 116, 189: As a parallel action separate MR-6122 released. 30 nos bids received on 25.08.14. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311, 360 & 444. Continuous expediting being made by visiting vendor workshop for all critical orders in respective regions.
Sep'14
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 30 FOB)
Open
Projects
- 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
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 (MR-5403) 31 (FOA No 550 & 551) CDD: 01.03.15
Open
Projects
- 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) and Debutaniser Column (IF-V-302) by M/s Uttam Value Steel (Ordered on 19.08.13) 32 CDD: 18.10.14 EDD: 31.03.15
Open
Projects
- Order got delayed due to delay in manufacturing works. At present only 7 shell course rolled out of 17 nos due to which there be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
sep'14
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 EDD: Sep'14 33 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
Open
Projects
- As of now around 40-45% piping material has been received at site. Around 90-95 EIL/ BPCL % material has been ordered. Ordering of balance 5-10% material is in progress and expected progressively upto end Sep'14. Delivery of ordered material against intermediate -II expected by Sep-Oct'14. -Vendors being expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL. Unit specific items: - MR for VGO (4 nos) targeted to issue by 10.09.14.
Sep'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
D
D
D
D
D
D
D
D
D
26
Key Risk Description
Delay by vendor with respect to CDD due to financial constraint.
D
D
D
D
29
Action Plan
Action By
Target Date
Risk Severity
II
D
II
Job No.: A307 AUG'14 Page 684 of 749
Integrated Refinery Expansion Project, Kochi
E
Delivery Gas Booster Compressor for CPP (Dly: 13 34 M FOB
1
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsites) - 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
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage E
E
E
E
E
Risk Owner
D
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
EIL
sep'14
Open
Constn.
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
Constn.
- During the project review meeting dated 28.08.14 following points discussed and BPCL agreed: - Balance 6 nos units in the township to be handed over for grading by M/s Ray (SGIII). - FACT area to be arranged for storage of materials of owner and package contractors. FACT area being arranged by BPCL by mid Sep'14. -A separate meeting shall be planned with BPCL for identification of storage area for package contractors by mid Sep'14.
BPCL
Sep'14
Open
2
3
4
5
6
Action Plan
Action By
Target Date
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
Open
Constn.
-Major rock blasting work completed.
Constn.
sep'14
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 65.9% Catch Up Sch: 27.2 % Act: 24.1 %
Open
Constn. / Projects
- Composite Works (Civil Strl. & Mechanical) on 03.07.14: NIT on sale 28.08.14 to 17.09.14. Award targeted by Oct'14.
EIL/BPCL
Sep'14
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.
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
BPCL / Projects
15-Jul-13
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 87.2 % Front: 100 % Act:49.3% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Management level meeting held on 18.07.14, Constn - MCR area, CPP control room area : It has been decided to complete balance strl work by Dec'14 & finishing by Mar'15. - Other building works : Finishing work to be completed by Dec'14. - L&T also agreed to augment required manpower to meet the target completion date. - Management review meeting planned at site on 17.09.14.
As Required
Backlog 27.8 (% wrt target sch) as of 15-Aug-14 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 - 29M; Remaining Duration - 17 M Desc. Catch Up sch: Const Sch Front Act Overall 26.9 53.2 51.4 25.3 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
- In order to supplement progress by failing civil contractors, 2 separate agencies has Constn been lined up (M/s Tuaman-Civil & Strl works & M/s Zillion-Strl. works). Further additional two agencies for Civil & Structural works being lined up. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the sub vendors against Performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and boost progress. - Contractors are facing problem in retaining the labour at site.Approx 7000 labours are available at site, though induction programme has been carried out for more than 15000 labours . requirement of manpower at site is approx 15000 nos.
As Required
Risk Severity IV
sep'13
I Aug'14
I JUL'13
II
E
7
BPCL/EIL
E
8
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.
EIL/BPCL
Mar'15
I IV
Job No.: A307 AUG'14 Page 685 of 749
Integrated Refinery Expansion Project, Kochi
Status (Open / Close)
Risk Owner
Risk Id
RISKS REQUIRING BPCL ATTENTION
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.
L&T has completed all piles in Demountable flare area, Air compressor & DG shed area.
Constr.
Immediate
Jul'14
Payment to contractors
Close
Constn.
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
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
Key Risk Description
E
9
E
10
E
11
E
Dismantling of LO CAT SRU and area handing over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. 12 Will affect release of front for tankages.
Unrealistic project time leading to under quality
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
E
Close
Project / Engg. / planning
Action Plan
Action By
Target Date
Risk Severity
As Required
sep'13
May'14
Open
BPCL
All 5 nos tank area cleared and released. Area handed over to M/s B&R for Tankage- BPCL II works on 30.04.2014
end Apr'14
Open
Project
- Project review meeting held on 23.08.14 with M/s Triveni. Constr. -M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barbendors (Manpower required is 300 nos while available manpower is 152 Nos). - Substation building: Foundation works commenced, completion to be targeted by Dec'14. - Chemical house works commenced. - Meeting planned in mid Sep'14 with M/s Triveni.
Sep'14
Sep'14
Overall Progress: Contr. Sch: 78.4 % Act: 48.1% Construction Progress: Sch: 72.0 % Front: 100 % Act: 42.8 % 13 Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
II
E
E
Area availability for SRU Block - At present only 95 % area given to M/s MBEL, balance Site for SRU block shall be available by end Sep'14. (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 14 M (As per Past experience minimum requirement for SRU is 30 M).
Open
Proj. / Constn.
- Management level meeting held with M/s B&R on 06.08.14 & 19.08.14 and Constn. augmentation of manpower by min. 100 nos to be expedited for concreting work progress. M/s B&R has been asked to expedite complete SRU filling. - Retaining wall in progress. B&R agreed to complete wall by 31.08.14 for which front is available and balance shall be completed by 30.09.14. B&R shall mobilize shuttering materials & manpower accordingly to meet above targets. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 964 nos piles completed against front of 1150 nos at site by M/s MBEL.Total nos of piles is 1800 EIL/BPCL nos piles
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
Open
Proj. / Constn.
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.
Clubbed with Risk ID E33
BPCL
Land acquisition for Crude tank (2 nos.) . (LAD - Jul 13; Ant - 30-Aug-13)
Close
Proj.
M/s BPCL Vide mail dated 21.08.2013 has handed over the area for SG-III.
BPCL
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
15
E
16
E
17
BPCL
18
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
E
Open
Const. / Projects
E
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 19 delivery as 24.11.14.
Close
E
HEAVY LIFT Cranes for INTALLATION OF REACTORS Finalisation of Erection scheme and capacity the crane, inclusion in scope and timely mobilisation at 20 site
E
21
Close Open
E
22
E
23
Theft of Delay in material delivery from of UGWarehouse piping material Material required at site for Civil & strl contractor.
Lighting during construction
Open
I Jul'14
Dec'13
Nov'13
Aug'13
As Required
sep'13
- All 3 GTGs received at site. Projects - Contractor for Mechanical works for CPP awarded to M/s Zillion. - N2 compressor (Delivery period is approx 6-8 M) : Ordered on 01.08.14, delivery going upto Dec 2014, However BHEL confirm that they expect supply to be completed within CDD of GTG package.
Sep'14
Const.
-Included in mechanical contractor scope. - Based on prel. Erection scheme, 1600 T heavy lift crane with 600 T trailing crane envisaged for erection of both VGO and DHDT reactors. - Timely mobilization of cranes and preparation of Load Test. - Finalization of erection scheme.
-
Nov'13
EIL Const.
Security arrangements in Warehouse in place byordered BPCL. under FOA 769, 826, 0013, Constn. - Total 3 KM pipe under shortage (IS pipes of 24") 655,652, 593 to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team.
Sep'14 -
Mar'13
Area lighting being done.
As Required
II May'13
Constn.
Project / Constn.
Constn.
III
Job No.: A307 AUG'14 Page 686 of 749
Integrated Refinery Expansion Project, Kochi
E
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 24 are reduced while floating tenders. This needs to be avoided.
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
EIL
Action Plan
Action By
Target Date
Risk Severity
-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
LPG flare - As per EIL study LPG flare is adequate. Report issued to BPCL and clarification received. 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.
BPCL / EIL
15-Nov-13
Oct'13
Constrn.
Sep'14
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
Open
Project
E
25
Open
Project
E
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 (Ant. Compln26 Nov'14, Compl date Committed by B&R – 13.11.14)
Slow construction progress by M/s KSSIIPL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIIPL on 12.09.13 Civil & Strl work-offsite IREP Area: Constr. Sch:97.3%; Front:78.0%; Act: 32.9% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 83.2%; Front: 90.7%; Act:35.0% CCD:18.12.14; ECD: Apr'15
Open
Project
Management review meeting held with M/s Essar on 08.08.14 at site. - Foundation completion for HRSG-3 targeted by 15.09.14. - Completion of Structural works for GTG shed targeted by 10.10.14. - Stack foundation targeted to complete for HRSG-3 by 07.09.14, HRSG-4 by 20.09.14 & HRSG-5 by 05.10.14. - All balance drawings for which data is available shall be targeted for issue by 15.09.14. - Next Management review meeting planned at site on 12.09.14.
EIL/BPCL
Sep'14
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 29 SCH. FRONT. ACT. 64.0% 57.8 % 20.1%
Open
Project
- Management level meeting held at site on 07.08.14. - As on date the manpower is 123 Nos against the requirement of 200 Nos. - Strl work at fabrication yard: Strl steel for TS-2 & TS-3 targeted by 15.09.14 & 30.09.14 respectively. - Breaking of Pile cap to be expedited. - Next Management review meeting planned at site on 17.09.14.
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 Cum. Sch: 25.3% 30 Front: 34.8% Act: 14.2 %
Open
Project
- Management level Meeting held with M/s OIL on 06.08.14 and following action plan EIL/BPCL has been agreed - M/s OIL advised to to augment welders to 50 nos. against 39 nos available. - Piping fabrication rate of 1500 ID / day from current 660 ID/Day targeted to achieve from 01.09.14. Concrete bunker to be constructed at fabrication yard to facilitate radiography work. - OIL to deploy their own auto blasting & priming machine. - Next Management review meeting planned at site on 17.09.14.
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 31 Construction: Sch:7.2 %; Act:7.9% Overall Progress: Sch: 32.8 % Act: 26.0%
Open
Project
-Major backlog is due to engineering (23 %), ordering (40%) & mfg.delivery (5.8 %) due to delayed finalisation of layout. - Piling work commenced (542 out of 1642 nos piles completed as on date) M/s TKII to augment piling rigs immediately. -TKII to augment manpower for Civil works as well.
Continuous
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Management level meeting held with B&R on 08.07.14. B&R agreed to execute work on extended hours to complete balance works in all respect by 13.11.14.
II
E
27
Constructio Management level meeting held with M/s KSSIIPL on 07.08.14. EIL/BPCL n - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - Additional gangs to be deployed to complete cable trenches work. - 100 MT crane assembled and testing under progress. - Additional manpower being expedited by M/s KSSIIPL. - M/s KSS informed that agency for rock blasting has been deployed since 04.08.14. - TMT bars: Out of ordered 500 MT qty only 94 MT qty received, balance expected by 12.09.14. - Next Management review meeting planned at site on 17.09.14.
Sep'14
II
E
28
II
E
II
E
E
Constr.
II III
Job No.: A307 AUG'14 Page 687 of 749
Integrated Refinery Expansion Project, Kochi
E
E
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Project
Action Plan
Action By
Target Date
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: 57.6 % Act: 53.5 % Construction work: Sch-33.6% Front:63.1% 32 Act:13.8% As of end Jul'14 Heater A: Total 66 nos panels; Received: 66 nos; Erected: 56 nos. Heater B: Total 66 nos panels; Received: 25 nos; Fabrication: 5 nos completed
Open
Review meeting held at site on 22.08.14. Constrcution As Required -Heater A: All panels received at site. Out of balance 10 nos panels for erection, 3 nos erection planned by 23.08.14 & balance 7 nos planned by 29.08.14. -Heater B: Out of 66 nos panels, 25 nos received at site. Balance panels being expedited. - 2032 MT / 2300 MT structural steel received, balance 200 MT for stack is being expedited. -Crane (150 MT) assembled and ready for testing.
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 33 M+2 M incl pre commng)
Open
Project
- Total area handed over on 05.05.14.
Progress of ETP Works LAD: 30.09.15 CCD:10.08.15 ECD: 30.06.16 Overall progress: Sch: 48.1 % Act: 15.7 % Construction Progress: Sch: 24.8 % Front: 81.1 % Act: 8.4 % Awarded to M/s Paramount on 11.09.13. (Duration: 34 21 M+2 M incl pre commng)
Open
Project
-60 % model review completed on 12.08.14. EIL/BPCL - Physical handing over of balance area for treated water tank, API/TPI, ex TPI sump completed. Signing protocall to be expedited. - In order to recover the construction backlog, paramount has agreed to mobilse resource immediately & submit catchup plan. Letter issued on 05.09.14 to submit catch up plan for mitigating backlogs in construction & manufacturing. - Revised piling drawing for API being submitted by 10.09.14. Piling drawing for ACT & SBR area approved vide across the table review meeting dated 05.09.14. - Work in progress in substation area, equalisation tank, treated water tank, sludge thickner, spent caustic tank, chemical handling areas. - Next Management review meeting planned at site on 12.09.14.
As stated
Project
As stated
Risk Severity III
Jun'14
II Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 48.1 %; Front:84.4% Act: 14.9 %
Open
Project
- Management level meeting held on 06.08.14 at site and on 19.08.14 at EIL Delhi. EIL/BPCL Total tanks: (New tanks 13 nos, work in progress for 12 nos. Balance for 1 nos is YT33 which shall be start after completion of YT-32; Modification tanks: Out of total 16 nos, work in progress for 4 nos, 3 nos handed over to BPCL.) - B&R to augment resources to complete all balance work within agreed target. - All modification work for YT-80 (MS Tank) completed by M/s B&R on 19.08.14. - PO acceptance copy from M/s B&R awaited for 375 MT Plates ( SA 516 Grade 70) & delivery for 200 MT: IS 2062 GR B to be expedited. - Next Management review meeting planned at site on 16.09.14.
As stated
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 23.9 % Front: 91.4 % Act: 19.2 %
Open
Project
- Front for YT-29 is likely to be released by 25.08.2014 - Tank Pad foundations for YT-26 & YT-28 planned for completion during the Sep’14 month. - Area graded and handed over for 2nd Crude tank.
Constr.
As stated
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 37 Overall Progress: Sch: 66.6 % Act: 13.3 % Constrcution yet to start
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. - Structural steel: Out of 190 MT, 68 MT received at Coimbatore fabrication yard. Balance being expedited by M/s Petron. - Blasting and painting at Coimbatore is in completion stage. - Fabrication started for radiant section, erection planned by last week of Sep'14. - All radiant coils have been ordered to M/s MSL - Further as directed during director level meeting with BPCL dated 13.08.14, new tenders for M/s Petron's work not to be floated.
Project
As Required
II III
Close
Project
Clubbed with Risk ID D7
BPCL
As Required
Dec'13
Open
Project
-Nozzle size for 42" finalised, M/s Callidus to expedite balance data based on 42" nozzle size. - Burner details not yet finalised affecting progress of engineering and completion of package.
Projects
As Required
Awarded to M/s B&R on 25-Sep-13 E
35
II
E
E
E
E
38
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
Supply and commissioning of Waste Heat Boiler Package for SRU Block (ordered to M/s Technicas on 31.012.13) LAD: 09.06.15 39 CCD: 30.06.15 Overall Progress: Sch: 31 % Act: 14 %
II
Job No.: A307 AUG'14 Page 688 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 Overall Progress: Sch: 87.1 % Act: 52.6% Construction Progress: Sch: 71.5 %; Front: 100%; Act:18.7 % Area handed over, part of area is water logged due to plant drain which is under completion.
Open
Project
-Management level meeting held on 21.07.14 at EIL Delhi. M/s Driplex has been asked to prepare a catchup plan to expedite constr. activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. 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 catchup plan. - Piling work nearly in completion for Substation area (112 nos out of 131 nos piles casted). - DM tanks (2 nos) piling drawing under approval. Piling yet to commenced at site. -90 % model review completed. - M/s Driplex has been asked to mobilse 200 labours against present 128 nos. - DM tanks: Piling drawing received from M/s driplex and is under review. - Next Management review meeting planned at site on 12.09.14.
EIL/BPCL
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC for FCCU Contr. Sch: 67.2%; Front: 94.0% Act: 25.1 % CCD: 24.12.14 ECD: Oct'15
Open
Project
-Due to continuous poor progress of work and repeated slippages in commitments made by M/s SEPC, Management review meeting held on 04.09.14 at EIL Delhi. -M/s SEPC asked to take immediate action to mobilise 100 manpower and take up work on multi fronts and ensure extended hours / night shift working. M/s SEPC EIL/BPCL agreed to mobilize additional 50 nos manpower by 15.09.14. At present only 140 nos manpowers available. - In addition to 2151 m3 RCC work which has been already withdrawn from SEPC scope, additional 1500 m3 RCC work being offloaded from SEPC scope to be executed through misc. civil agencies. - Tech Structure A targeted to complete by mid Sep'14. - Next Management review meeting planned at site on 16.09.14.
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15
Open
Project
-Prefabrication of radiant coils for IG-H-101, fabrication of stack and fabrication of Constr. convection module to be expedited. - Platform erection are in progress for IG-H-102. Refractory works of Radiant Section in progress for IG-H-102. - Refractory works to be taken up in both the heaters simultaneously.
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: 78.7 % Act: 14.9 % Construction work yet to start
Open
Project
Projects
As Required
III
E
43
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. - Blasting and painting at Coimbatore is in completion stage. - Fabrication for 6 panels out of 30 panels for radiant section completed, balance 20 panels under dispatch and targeted progressively by 20.08.14. VGO Heater : Erection of radiant section started on 20.08.14 by M/s Petron. - All radiant coils have been ordered to M/s Tubocex Spain. - Structural erection work agreed to start by 16.08.14. - Further as directed during director level meeting with BPCL dated 13.08.14, new tenders for M/s Petron's work not to be floated.
Open
Project
-Management level meeting held with M/s MBEL on 07.08.14 at site. M/s MBEL Constrn. agreed: - Current manpower is 410 nos. MBEL agreed to mobilise 2 separate gangs for UG piping. - 2 cranes mobilised and Additional 2 nos cranes to be mobilized in order to carry out structural erection in both VGO & DHDT simultaneously. - Management review meeting planned at site on 17.09.14.
As Required
E
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 ECD: Apr'15 44 Sch: 84.0 %; Front :86.1 % Act: 46.1 %
Open
Project
Management level Meeting held with B&R on 06.08.14 and 19.08.14 PEB1: M/s B&R agreed to complete balance work by end Sep'14. Material storage commenced. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. 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 47 Overall Progress: Sch: 96.1 % Act: 65.2 % Construction progress: Cum Sch: 98.5% Front: 100% Cum Act: 51.7%
Open
Project
-Major backlog is due to construction (46%). Last management level meeting held on 23.07.14 at Site. Commitment made by M/s PCT has again slipped. Manpower at site is 439 nos instead of committed 670 nos. Supply of balance U/G and A/G Piping Material by PCTL to be expedited. Shortage of TMT steel to be expedited. PCTL to target to complete all Civil work by Dec'14.
As Required
II III
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 Site to confirm 48 Overall Progress: Sch: 70.1 % Act: 31.0 % Construction progress: Cum Sch: 55.0% Front: 100% Cum Act: 27.7%
Open
Project
-Major backlog is due to engineering & construction. Last management level meeting held on 28.05.14 at Kolkata. Commitment made by M/s PCT has again slipped. - Balance Area for CWTP handed over after completion of grading by M/s PEL. - Manpower to be augmented urgently - Delivery of Boughtout item to be expedited. -Uninterrupted RMC supply to be ensured.
As Required
III
E
40
II
E
E
41
Constr. Progress: 42 Sch: 52.5 % front: 100 %
Act: 34.1 %
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E
E
E
46
Constrn.
Job No.: A307 AUG'14 Page 689 of 749
Integrated Refinery Expansion Project, Kochi
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area Sch:76.0%; Front: 71.9%; Act: 12.9%
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Open
Constructio Management level Meeting held with M/s KSSIIPL on 07.08.14 at site. n - M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 82 nos deployed only. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: Misc Strl Work (for 1800 MT): Awarded to M/s Zillion on 26.08.14. • Misc. Civil works-2 (approx 3000 m3 RCC) : (DHDS Pipe rack or other areas of IREP)-Award recommendation issued on 29.08.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - Award recommendation issued on 06.08.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor. - Next Management review meeting planned at site on 17.09.14.
EIL/BPCL
sep'14
Open
Constructio -Management level meeting held on 08.08.14 at site. n - Welders: 3 welders qualified and welding to be start by mid Sep'14. - Further as directed during director level meeting with BPCL dated 13.08.14, new tenders for M/s Petron's work not to be floated.
EIL/BPCL
Sep'14
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 AG piping fabrication: Only 5724 ID / 304970 ID 51 fabrication completed. AG piping erection: Only 552 IM / 412580 IM piping erection completed.
Open
Constructio Management level meeting held on 06.08.14 at site. n - B&R to mobilize 750 MT crane for erection of heavy lift. - B&R to expedite work for completion of fabrication shed. - Next Management review meeting planned at site on 16.09.14.
EIL/BPCL
Sep'14
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.) 52 Sch:59.3%; Front: 84.4%; Act: 13.4% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 07.08.14 at site. EIL/BPCL n -Manpower: As on date only 130 Nos against the requirement of 300 Nos reported to site. MBEL committed to increase manpower upto 220 nos. - In view of slow progress and delay in release of construction front to mechanical contractor, new tender under preparation and likely to be awarded by mid Sep'14. - Next Management review meeting planned at site on 17.09.14.
Sep'14
Start of work by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. 53 Awarded on 25.03.14. CCD: 24.09.15
Open
Constructio KOM held on 17.05.14. Mobilisation work initiated by M/s techsharp. Constr. n Against requirement of 10 nos welders only four number welders are available at site. Resources to be expedited to commence work. Piping fabrication work commenced.
Sep'14
I 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. 54 CCD: 24.09.15 Work yet to start at site.
Open
Constructio - Management level meeting held 06.08.14 at site and on 19.08.14. n -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works commenced. - Management review meeting planned at site on 16.09.14.
Sep'14
III
Completion of Civil & Strl works (incl. UG Piping works) by M/s L&T for CDU/VDU. Sch: 04.09.14 55 CCD: 06.09.14 ECD: 15.02.15 Sch:99.8% Front: 97.8% Act: 80.3%
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete Constr. n balance civil & strl works by end Oct'14 & TS-5 strl by Nov'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. - Management review meeting planned at site on 17.09.14.
Sep'14
III
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15 56 Overall Progress: Sch: 89.8 % Act: 79.9 % Constr. Progress: Sch: 70.2 % Front: 88.0% Act: 50.5 %
Open
Project
As Required
III
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: 99.7% Front: 98.7 % Act: 69.9 %
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete EIL/BPCL n balance civil & strl works progressively by Dec'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. -MPR : 1st tier for total length handed over, grids 25-30 expected to handed over by Sep'14. TS-IV : total handing over by 15.09.14 TS-III : total handing over by 10.09.14 - Next Management review meeting planned at site on 17.09.14.
Sep'14
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391)
Open
Constructio - Management level Meeting held on 07.07.14 n - OIL started to dismantle YT-150 Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT-383/391/150. -B&R has been informed that 2 tanks YT-383 & 391 have been handed over for taking up construction work and since these are to be made operational before taking outage of next tanks, the completion of these tanks is most critical. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement. - Management review meeting planned at site on 17.09.14.
Sep'14
E
49
E
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 50 CCD: 25.10.15
I
Construction work yet to start at site II
E
II
E
E
E
E
E
E
E
57
58
- Major backlog is due to manufacturing & Delivery (8%) and construction (20%). Erection of APH for VDU Heater is in progress. - Additional resources to be mobilised to recover construction backlogs Convection module erection for CDU Heaters commenced. CDU APH foundations to be handed over by end Sept-14
Constr.
II III
Job No.: A307 AUG'14 Page 690 of 749
Integrated Refinery Expansion Project, Kochi
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 81.0 % Front: 100 % Act: 34.1 %
E
E
E
E
E
E
E
F
F
F
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Open
Constructio - Management level meeting held on 06.08.14 with M/s B&R at site. n M/s B&R agreed to increase manpower from 90 nos to 150 nos. B&R agreed to complete the civil works as per below targets: 1. YT-341 : tank pad completed, annular plate laying commenced 2. YT-342: 20.08.14 Revised date: 15.09.14 3. YT-343: 10.08.14 Revised date: 15.09.14 4. YT-344: 30.07.14 Revised date: 10.09.14 5. YT-111: 15.07.14 tank pad completed 6. YT-112: 20.07.14 Revised date: 08.09.14 7. YT-113: 14.08.14 Revised date: 10.09.14 8. YT-114: 08.08.14 Revised date: 10.09.14 - Procurement of Balance Quantity of Plates (890 MT out of 1650 MT) to be expedited. - Management review meeting planned at site on 16.09.14.
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 60 CCD:18.06.15 Work yet to start
Open
Constructio -These tankages (Amine water and sour water services) are required for n commissioning of CDU/VDU. -Agency has been pressurised to mobilise resources and start work. - Tank pads to be handed over from Sep'14 onwards.
Constr.
Sep'14
Composite works by M/s Albana for DHDT Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15. 61 10 ID / 210605 ID piping fabrication completed.
Open
Constructio - Fabrication shed in progress and expected to be completed by 10.09.14 n Piping erection work to be expedited.
Constr.
Sep'14
II III
Start of Composite works by M/s Offshore for Offsite DHDS area Awarded to M/s OIL on 19.05.14 with CCD: 62 18.11.15.
Open
Constructio - Management level meeting held with M/s OIL on 06.08.14 at site. M/s OIL has been Constr. n asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Fabrication yard hand over targeted by 16.08.14. - Mobilisation for 20 nos auto welding machine to be expedited. - Management review meeting planned at site on 17.09.14.
Sep'14
III
Start of Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15. 63 1450 ID / 298914 ID piping fabrication completed. Piping erection work yet to commence
Open
Constructio - Management level meeting held with M/s OIL on 06.08.14 at site. M/s OIL has been Constr. n asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - 600 MT crane mobilisation targeted by 15.09.14. - Management review meeting planned at site on 17.09.14.
Sep'14
III
Completion of balance piling work (Covered under Piling-IIII Contract) 64 (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: 65 18.11.15 88 ID / 203790 ID piping fabrication completed
Open
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
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
Timely Commissioning of UB package to meet refinery commissioning schedule. Contr. Sch: 69.1%; Act: 52.4% LAD : 31.03.15 (UB 1) 30.06.15 (UB 2) Constr. Progress: Sch: 63.3%; Act: 16.6%
Open
Constn.
-Strict monitoring required at all stages upto commisioning. -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.
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.
Constn. / Projects / BPCL
As Required
IV
Process / Engg.
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
sep'13
Inspn
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
59
1
2
3
G
1
G
2
G
3
G
4
Scope changes & information flow to executing group
Non-performing vendors
Open
Open
Constn.
-Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. Award recommendation issued on 02.09.14.
Constructio - Fabrication shed in progress and expected to be completed by 10.09.14. Piping n fabrication work started. Piping erection work to be expedited.
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015 for CDU/VDU commissioning.
PROCESS/ a. Change management should be in place immediately ENGG/CON b. Strict discipline to be maintained else end objective would be difficult to meet. S. All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Sep'14
Risk Severity III
BPCL
Sep'14
Constr.
Sep'14
II III
BPCL
1-Jun-15
III
Projects
Continuous
IV
as scheduled
III
Job No.: A307 AUG'14 Page 691 of 749
Integrated Refinery Expansion Project, Kochi
G
G
I
5
7
J
1
K
1
BPCL
- Covered under risk ID C73
Action By
Risk Severity Nov'13
- BPCL-KR vide e-mail dated 06-Dec-12 sent a list of Non plant buildings to be Projects 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.
15-Apr-13
Apr'13
As required
Close
Implementation of environmental clearance conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Open
Projects
- 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.
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.
- Documents approved from PESO
BPCL
Target Date within 2 days of request
Finalisation of Non plant buildings.
BPCL
IV
Apr'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 / - IBR package for DCU targeted after 90 % model review. BPCL - List of all the buildings in IREP along with the plinth area details for taking approvals from F&B as well as Panchayath issued to BPCL on 12.04.14. Approval for tall strl/stacks: Signed documents with 6 sets handed over on 13.05.14. -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
Implementation of Health, Safety and environmental (HSE) system
Open
Const.
- 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.
Delay due to Labour strikes (due to labour issue like wage revision, other benefits) during project execution phase
Close
Const.
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
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
Constraint in movement & transportation of ODC eqpt.
Open
Project
-A separate contract to be given to agency which will take care by approaching KSEB Shipping and telephonic authority. -Fabn / transportation philosophy being finalised.
As Required
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open
2
3
K
4
M
1
M
2
M
Purch / Contrc.
Action Plan
1
2
K
Close
6
I
K
Delay in Approval of Vendor List for various items of the project (specially for Long lead items)
Risk Owner
G
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
3
Cost monitoring & control on regular basis
Close
Project/Eng Closed as no concern as on date. g
Sep'14
IV
Constn.
Continuous
III
BPCL
As Required
Nov'13
BPCL
As stated
II Jun'14
Jun'14
Costing
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
Environ.
15-Oct-13
sep'13
Increase in facilities on account of deletion zero liquid discharge
Open
Environ.
Scope of facilities finalised.
Variation in foreign exchange rates from Rs 50 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.
Open
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
Sep'14
II
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: 28.02.16 Overall Progress: Sch: 87.1 % Act: 52.6% Construction Progress: Sch: 71.5 %; Front: 100%; Act:18.7 % Area handed over, part of area is water logged due to plant E 40 drain which is under completion.
Open Project
(Current risk Score - Previous Risk score)
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
N
N
Y
N
Short term
I
0.4
0.00
Clubbed with Risk ID E33
BPCL
Very High
N
N
Y
N
Long term
I
0.2
0.00
- Total area handed over on 05.05.14.
Project
Very High
Y
N
Y
N
Long term
I
0.3
0.00
-Management level meeting held on 21.07.14 at EIL Delhi. M/s Driplex has been asked to prepare a catchup EIL/BPCL plan to expedite constr. activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. 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 catchup plan. - Piling work nearly in completion for Substation area (112 nos out of 131 nos piles casted). - DM tanks (2 nos) piling drawing under approval. Piling yet to commenced at site. -90 % model review completed. - M/s Driplex has been asked to mobilse 200 labours against present 128 nos. - DM tanks: Piling drawing received from M/s driplex and is under review. - Management review meeting planned at site on 12.09.14.
Very High
0.29
Previous Risk Score
N
Very High
Current Risk Score -> {5}* {12}
Impact Score => {6+7+8+9} * 10 * 11
Project
Controllability Condition (D/I )
Open
Urgency (Long Term / Short term)
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 E 33 incl pre commng)
Output Quality ( Y / N)
Close Proj.
Schedule ( Y / N)
Project
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Open
EIL Cost (Y / N)
E 16
Area for RO-DM Plant : Dismantling of PIB and development of area reqd. by May, 2013 Ant - Dec 2013
Risk Owner
Award for RO-DM LAD:30-Jan-13 C 15 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Aug'14 Page 692+15 of 32
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
0.29
Action Plan
Action By
Target Date
29-Jun-13
Dec'13
As stated
Risk Severity
May'13
Nov'13
Jun'14
As Required
II
Job No.: A307 JUL'14 Page 693 of 749
Integrated Refinery Expansion Project, Kochi
A
A
A
A
1
2
3
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
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
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
- 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
- All P&IDs incorporating DCNs issued.
Process
25/10/13
Oct'13
Holds, missing information, corrections, changes in PDS / P&IDs - DCU
Open
Process
- 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
15-Mar-14 Projects / Engg Process
Mar'14 & Apr'14
31-Mar-14 30-Apr-14
Delay in Process Package for TGTU (M/s CB & INC) LAD : 31-Dec-12 ; Ant : 12-Apr-13 A
5
A
6
A
A
Close
BPCL / Process
-Process package received on 14.04.13
Close
Process
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 Close LAD : 29-Dec-12; Ant : 19-Mar-13
Process
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
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Process
Based on latest information from BOO HGU and SWII (FCC), Revised Design Basis issued.
Projects / Process
-
Mar'13
Process
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
- 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
Process
All process P&IDs issued. Pumps PDS issued for engg,. All Vessels PDS issued for engg.
Process
Delay in "issue for engineering - IFE" PDS / P&IDs for DHDT P&ID's : LAD : 30-Nov-12; Ant : 08-May-13
-
Apr'13
7
8
Close
Close
9
-Preparation of Offsite interconnection P&ID’s for DHDT LAD: 30-Nov-12 A
10
A
Delay in "issue for engineering - IFE" PDS / P&IDs for VGO-HDT 11 LAD : 29-Jan-13; Ant : 10-May-13
A
Apr'13
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
Projects / Process
Close
Close
-Preparation of Offsites 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 12 details received now. -Upgradation of Crude oil pipeline system (Inside refinery) to be taken up.
POSD
- All 32 P&ID issued for engineering
Apr'13
31-Dec-12
Jan'13
Apr'13
Apr'13
Job No.: A307 JUL'14 Page 694 of 749
Integrated Refinery Expansion Project, Kochi
In view of increase in sulphur load PDS & P&IDs for Close sulphur block (ARU, SWS & SRU) is being reviewed and released as per priority of procurement.
A
13
A
Revision in PDS after issue of “Issued for 14 Engineering” after release of MR -Preparation of Offsite interconnection P&ID’s LAD :30-Nov-12
Close
Close
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Process
Action Plan
Target Date
- All PDS and P&ID revised and issued.
Process/EN Revision in PDS to be avoided once same is issued for engineering GG Process
Action By
Risk Severity Apr'13
Process
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New facilities) has been issued for BPCL / engineering. Balance 1 no. targeted by 15.03.13 Projects / POSD
-
15-Mar-13
Apr'13
Feb'13
A
15
Revision in PDS after issue of “Issued for 16 Engineering” after Order
Close
Process/EN Revision in PDS to be avoided once same is issued for engineering. GG/Procure
Process
-
Apr'13
A
Revision in PDS after issue of “Issued for 17 Engineering” after Equipment manufacturing
Close
Process/EN Revision in PDS to be avoided once same is issued for engineering GG/Procure
Process
-
Apr'13
A
As Required
Apr'13
Updation of estimated utilities on account of revision Close 18 in process parameters (revision of PDS based on engg comments)
Process
A
ISBL Distribution P&IDs for VGO-HDT 19 SCH: 30-Nov-12 ANT: Jun-13
Close
Process
A
ISBL Distribution P&IDs for FCCU SCH: 30-Nov-12 20 ANT: 31-May-13
Close
Process
A
Utility P&IDs: 30/36 issued for engineering. P&IDs for small bore Piping shall be issued by 31.05.13.
Close
Process
Distribution P&IDs issued for engineering.
A
21 Final issue for OSBL utility distribution P&IDs LAD: 30-Nov-12 ANT: 25-May-13 22 Updation of P&ID as per finalised condensate philosophy to be taken up.
Open
Process
- Revised P&ID for Condensate System issued on 15.05.13.
Open
Engg
- Inconsistency related to type of Isolation valve (Ball Vs. gate / globe/check) between Engg. instrumentation and process design basis identified during coordination meetings resolved by TSD.
A
Incompatibility between Process design basis and Engineering Design Basis (Piping / SED / RED / PED / instrumentation / HMTD design basis) - affects subsequent detailed 23 engineering activities.
Open
Power Tech.
- System configuration including 8 pumps, filters & centrifuge finalised and PDS for Projects (CPP 30-May-14 pumps issued. Filters & Centrifuge PDS issued for engineering on 22.05.14. group) - Readiness of the fuel forwarding system to be ensured w.r.t. GTG commg schedule (i.e. in Mar 15).
May'14
A
Fuel oil system for GTG: Implementation of the system based on modalities finalised (associated system for existing Fuel oil tank tapping with new 24 GTG).
Close
Engg.
- PDS for desalting pumps issued on 25.10.13. MR issued on 13.11.13.
Engg
Nov'13
A
BPCL confirmation/clarification over datasheets/GAD’s for existing/new raw water intake pump obtained from M/s KBL 25 (LAD for MR for pumps - 07.03.13)
A
26 Identifications of hook-ups on flare lines and finalisation of methodology BPCL availability Signing of ISBL P&IDs and with battery limiti.e. P&IDs for of ShutUtility downpackages / Hot tapping. Units, & other packages.
Close Open
Projects Process / POSD
Projects / Constn. Process / POSD /
A
27
- Identification of hook ups for Flare line, FCC flare, PRU flare and NHT / ISOM completed during completed site visit byfor: EIL Process. Signing of P&IDs - Hook sketches prepared and signed by Piping / POSD / BPCL. Marking at site -CDU/VDU Blocktoonbe24.06.14. to be taken up on 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 signing to be expedited.
28
Offsite Interconnection P&ID - Updation of P&IDs based on HAZOP review for offsite.
Close
A
Process / Updated P&IDs released. POSD
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
Open
Engg.
- Equipment layout issued for engineering on 23.08.13
Piping
21-Aug-13
JUL'13
Issue of Equipment layout for engineering for VGOHDT LAD - 07-Nov-12 Ant- 26-Dec-12
Close
Engg.
Equipment layout issued for engineering
Piping
26-Dec-12
Jan'13
Close
Engg.
Equipment layout issued for engineering
Projects / 21-Dec-12 Piping / BPCL
Jan'13
Open
ENGG
NIT issued on 24.06.13, bids due on 23.07.13
Projects / Process / HMTD
May'13
Utility distribution P&IDs for DCU
A
B
B
1
2
B
3
B
4
Delay in this activity shall hamper the following: Issue Equipment layout for engineering for FCCU i) 3 D of Modelling (targeted by 27.12.2012) ii) Civil/Structural & 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
In case of revision in process parameters of an equipment the utility estimates RED / PED/ furnished by engineering against older Revision of PDS should not be used until same PROCESS is got verified/ updated for current revision. RED to update all such changes within stipulated time frame as per departmental Utility P&IDs: (14to/ incorporate 17 ) issued for engg (except for small bore piping: Pump Process guidelines andP&IDs Process in the revised PDS. Seal & Vent Drain). The same are targeted by Jun'13. Process
31-May-13
Apr'13
31-May-13
Apr'13
Jan'13
BPCL
25-May-13
May'13
30-Apr-14
May'14
30-Dec-13 08-Aug-14
Process / POSD /
Dec'13 IV
Mar'14 & Apr'14
18-Jun-13
Job No.: A307 JUL'14 Page 695 of 749
Integrated Refinery Expansion Project, Kochi
B
5
B
6
B
7
B
8
a) Cost/time overrun due to rework Close b) Non completion of critical project activities within time & delay in Project completion c) Poor performance of Sub-contractors and Vendors
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Procure/EN 1) Involvement of technical/engineering team and client with vendor where nonGG/CONS. 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
Action By
Target Date
Risk Severity
Projects
As Required
Apr'13
Engg (Elec)
15-Jan-13
Jan'13
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
-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
Updation of Equipment layout for engineering for TGTU LAD - 21-Jan-13; Ant: Mid Jun'13
Open
Engg.
- Layout finalised with licensor. Final layout under study. Piping - Model review for SRU completed on 30th May'13 (except TGTU, incinerator section & downstream of sulphur pit).
15-Jun-13
May'13
Issue 2nd MTO Piping (Sch - 30-Apr-13; Ant - 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.
Close
Piping
Intermediate MTO released on 31.05.13.
Piping
31-May-13
May'13
HMTD
Thermal design completed for DHDT, VGO-HDT and FCCU.
HMTD
Delay in thermal design for Heat exchangers & Air coolers for licensed and non licensed units LAD (DHDT): 02-Feb-13 LAD (VGO-HDT): 09-Feb-13 LAD (FCCU): 08-Mar-13
Close
Apr'13
B
9
Issue Overall UG piping layout drawing for the 10 complex
Close
Engg.
- Layout for OWS, CRWS, CW & FW lines issued for Offsite.
Gen Civil
31-May-13
May'13
B
Completion of 30 % Model review 11 VGO- LAD: 09-Mar-13 FCCU-LAD : 23-Apr-13
Open
Engg.
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 12 ANT: 18-Jun-13
Open
B
C
B
a) Inaccurate assessment of quantum of work
Close
MR issue for MCC (Main combustion Chamber) packages.
Close
13
May'13
Engg/procur Wide variation of BOQ and site executed quantities for item rate tenders to be ement controlled. Past data to be analysed and used for reference purposes.
Engg
Apr'13
As Required
MR issued on 02.05.13.
Open
Engg.
- Management level meetings with package contractors being organised to expedite Projects / the works. Engg. / - Battery limit conditions for CDSP Pkg (awarded to M/s Essar on 22.08.13) submitted Process 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.
Unit and offsite interfaces (Elevation termination levels)
Close
Engg.
- Clubbed with Risk ID A27
TSD
Timely availability of piling and foundation load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule 17 requirements. LAD - 28.02.13; Ant - upto Feb 14.
Open
Projects
- 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
10-Mar-13
Feb'13
13-Aug-14
III
14
B
Timely finalisation of Package Interface 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 15 by all the concerned).
B
Project / C&P 18-Jun-13
Project
B
B
Project/C&P - NIT issued for publishing on 12.06.13 with sale period from 17.06.2013 to 05.07.2013
Engg
Apr'13
LAD: 16-Feb-13 Ant: 15-Apr-13 May'14
-
Mar'14 & Apr'14
16
NIT for Heater for DCU LAD -15-Feb-13;
Close
PROCESS/ - NIT issued on 11.03.13, bids due on 16.04.13. Pre bid meeting targeted on ENGG 02.04.13. (Delivery : 18 M for Mechanical Completion including Pre-Commissioning Activities)
Open
Engg/Cont. - Integration of packages incl. GTG, HRSG & UB to be ensured based on vendor inputs. - HAZOP review completed for GTG, HRSG & UB package. - 60% model review for HRSG targeted by 12-13th Aug'14. -90% model review for GTG & UB package targeted by mid Aug'14. - GBC ordered to M/s BHEL on 25.07.14. KOM planned with M/s BHEL for Gas booster compressor on 12-13 Aug'14.
Engg
B
CPP: Integration of various packages & BOP Items of CPP. 90 % model review for CPP Package wise HAZOP for GTG, HRSG, UB,Gas 19 Booster compressor.
Distributed Control System (DCS) Detailed engg., supply and erection 20 (ordered on M/s Emerson Process on 04.11.13)
Open
Engg/procur - Preparation of Inst. dwgs./ docs. by the DCS vendor, using Smart Plant ement Instrumentation (SPI) is already covered in DCS vendor’s scope in DCS - Resolution of NDA issues for NHT to be resolved by Aug'14.
Projects
B B
21
B
18
60 % Model review for DCU (LAD:03.07.13 Act:13.09.13)
Close
ENGG
- Model review completed on 13.09.13
Projects / Process Process / HMTD C&P
ENGG
Aug'14
IV
Aug'13
Job No.: A307 JUL'14 Page 696 of 749
Integrated Refinery Expansion Project, Kochi
Action Plan
Action By
Target Date
Risk Severity
Open
Engg/procur - Being taken up with respective package vendors for implementation. ement
Instn / Projects
Continuous
IV
Open
Engg/procur Package vendor inputs being made available by expediting for updation of interface ement engineering documents.
Projects / Engg.
Continuous
IV
B
Delay in Interface Engineering (including control system) due to non availability of Package Vendor 23 Data
Open
ENGG
Model review completed on 04.10.13
ENGG
4-Oct-13
sep'13
B
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. 20 - Vendor drawings for sheds awaited.
Delay in completion of P&IDs by gen Civil LAD: 09-Jan-13 (DHDT) 24 LAD: 30-Jan-13 (VGO-HDT) LAD: 30-Mar-13 (FCCU)
Open
GC
- All P&IDs released
G. Civil
25-Jul-13
JUL'13
Order of MR for DG set Dely: (12 M FOB + 3 M Site work) 25 Sch: 05.11.13 Ant: 20.08.14
Open
Project
- Award recommendation issued on 07.08.14. BPCL to award.
BPCL
20-Aug-14
III
Close
ENGG
- 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
B
22
B
B
Package Vendor refuses to submit Instrumentation Drawings/ Documentation in Smart Plant Instrumentation Database as per Client Requirement
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Receipt of Inputs from Process / Vendors for 60 % 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
Open
ENGG
- Model review completed on 25.10.13.
ENGG
25-Oct-13
sep'13
B
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) 27 envisaged.
60 % Model review for 28 SRU (LAD:31.08.13; Ant:31.10.13) -As per P&IDs, No. of lines hold are 51 (ARU), 164 Delay in release 2nd MTO (SRU),15 (SWS)of & Intermediate 60(TGTU) + 155(Utilities LAD:30.09.13; -CVs Size HoldAct:31.10.13) as follows: 13 (ARU), 6 (SWS), 125 Holds: (SRU). -CDU/VDU: PumpFace nozzle 6 nos. pumps under -All Control Valve to for Face Dimensions are hold), for 256 lines under hold, Control valve HOLD.sizes All CVs for TGTU are HOLD. 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 29 (103 nos.) not considered in MTO.
Open
ENGG
- Model review started on 28.10.13 and under progress. Targeted to complete by 31.10.13.
ENGG
31-Oct-13
sep'13
Open
ENGG
- Intermediate 2nd MTO released on 31.10.13, based on above MR under preparation.
Projects / ENGG
31-Oct-13
Oct'13
Open
ENGG
- Surplus material to be salvaged with effective substitution. ENGG - Letter to be written to BPCL with backup details on reasons of Surplus generation on account of changes by them :- Process & POSD to consolidate changes in P&IDs on account of BPCL and forward to piping for attribution of surplus material to owner. Based on the report, projects to take up the issue with BPCL.
Close Open
ENGG ENGG
- HAZOP study completed on 29.11.13. - Catch up plan has been prepared as per discussion held on 18th Apr’14. 90 % completion of engineering targeted by Aug'14.
ENGG ENGG
Aug'14
Nov'13 IV
Open
ENGG
- HAZOP for all packages targeted to complete by end Aug'14. Revised process package targeted by 26.08.14. Accordingly MTO expected by mid Sep'14.
ENGG
Aug'14 to Sep'14
III
B
B
Generation of Surplus Piping material
B
30
B
31 HAZOP for FCCU LAD - 23-Sep-13 Completion of 90 % engineering by Mar-14. As of 15.07.14 engineering progress is 89.2 %. Average progress achieved in last 3 months 3.0 % 32 LD Milestone date - Dec'13
B
Release of final Piping MTO Sch: Jul'14 Ant: Sep'14 B
33
Progressively
IV
Job No.: A307 JUL'14 Page 697 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
B
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Finalisation of GTG fuel forwarding scheme for naptha to day tank when Naptha tank being under maintenance.
Open
POSD
- Scheme forwarded to BPCL on 17.07.14, BPCL to review.
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
Awarded to M/s Dresser Rand on 30.12.13
Engg / C&P
30-Dec-13
Dec'13
Award of Heater for VGO-HDT LAD -24.06.13 ; Ant -End Aug'13 Duration: 18 M
Open
Project
Awarded to M/s Petron with delivery period of 18 M on 21.08.13.
Projects
30-Aug-13
JUL'13
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 30-May-13 Duration: 16 M FOB
Close
Project
- BPCL confirmation sought for minimum nos (10.97 MW or 80% of 10.97) for qualifying criteria. Accordingly BQC changed and approved by BPCL. Draft NIT by 25.05.13. Publishing targeted by end May 13.
C&P
30-May-13
May'13
Variation in foreign exchange rates has an impact on the foreign component of overall project cost
Close
Project
- As per latest cost status report the impact of cost variation has been neutralised by savings.
Projects
Continuous
Nov'13
Award of Heater for DHDT LAD -24.06.13 ; Ant - Mid Sep13 Duration: 18 M
Close
ENGG
Awarded to M/s Technip on 04.09.13 (Duration 18 M)
Projects / HMTD
15-Sep-13
Aug'13
NIT for Composite Works for DCU LAD -06.06.13 ; Ant - 25.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
25-Oct-13
sep'13
NIT for Composite Works for DHDT/VGO LAD -06.07.13 ; Ant - 31.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
31-Oct-13
sep'13
NIT for Composite Works for FCCU LAD -12.07.13 ; Ant - 15.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
NIT for Composite Works for Offsite IREP area LAD -23.05.13 ; Ant - 15.10.13
Open
ENGG
Single tender envisaged for composite works, risk clubbed and created under new Risk ID C68
Piping
15-Oct-13
sep'13
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
-Ordered on M/s Shin Nippon & M/s Flowserve on 30.01.14 (except Tag IV-P-301 A/B EIL 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.
15-Mar-14
Mar'14 & Apr'14
NIT for Composite Works for Offsite DHDS area LAD -22.07.13 ; Ant - 15.10.13
Open
ENGG
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
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 -Ordered to M/s Fabtech on 15.07.13 g
Engg/Proj
20-Jul-13
JUL'13
Project/C&P NIT issued on 29.05.13, bids due on 18.06.13.
Project / C&P 31-May-13
May'13
Key Risk Description
Action Plan
Action By
Target Date Aug'14
Risk Severity III
34
C
1
C
2
C
3
C
4
C
5
C
6
C
7
C
8
C
9
C
10
C
11
C
12
C
13
Issue NIT for Tankage-II LAD: 21-Jan-13 14 ANT: 31-May-13
Close
C
Award for RO-DM LAD:30-Jan-13 15 Ant: end Jun'13 (Execution Duration - 20 M + 2 M)
Open
Project
- Awarded to M/s Driplex on 12.06.13. duration is 22 M.
Engg / C&P
29-Jun-13
May'13
Close
Project
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months.
BPCL
28-Feb-13
Feb'13
Close
Project / Licensor
21-Feb-13
Feb'13
C
Delay in award for Cooling tower LAD : 31-Dec-12; Ant - end Feb 13 C
C
16
NIT for Reactor regenerator package for FCCU LAD : 01-Jan-13 Ant: 21-Feb-13 17 Changes in scope of supply led to revision in BQC / tender.
BQC finalised on 15.01.13. Tender under compilation. Draft NIT being issued to BPCL Projects / for approval. BPCL NIT targeted by 21-Feb-13.
Job No.: A307 JUL'14 Page 698 of 749
Integrated Refinery Expansion Project, Kochi
C
18
C
19
Award for Raw water quarries LAD :03-May-13 ANT: 15-Apr-13
Close
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Project
Ordered to M/s Paulose George (15 M).
BPCL
Ordering of Reactor for VGO-HDT LAD: 29-Dec-12 ACT: 08-Apr-13
Close
Project
Ordered on M/s L&T on 08.04.13.
Proj/Engg
Award of contract for Piling-II LAD: 31-Dec-12
Close
Project
Awarded to M/s L&T on 09.04.13 with duration of 12 M.
BPCL
Close
Project
Awarded to M/s Petron on 09.04.13 with 18 M duration.
BPCL
Close
Engg.
Awarded to M/s Technip on 07.03.13 (Duration 23 M)
Storage of sulphur and related issues with Granulator to be finalised between BPCL / EIL.
Close
Project
- Scheme finalised.
Projects / BPCL
C
23
NIT for ETP package with WAO (Wet air oxidation) 24 LAD: 15-Jan-13 Ant: 16-Apr-13
Close
Project
Tender released on 26.03.13; BQC finalised on 08.04.13. NIT targeted by 16-Apr-13
Engg
C
Project
Award recommendation issued on 11.02.13. Awarded to M/s Howe baker on 07.03.13 Proj/Engg
Project
Awarded to M/s L&T (duration 20 M)
BPCL
KB tech completed development of flare area & handed over the area to M/s L&T.for piling.
Projects
C
20
C
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 21 Ant: 30-Mar-13
C
Award of Crude and Vacuum heaters (LAD 29.12.12) 22 Ant : 07.03.13
Risk Severity
Target Date
Apr'13
-
Mar'13
-
Mar'13
Ant: 15-Apr-13
Ordering of Desalter Internals (LAD:03-Dec-12) Ant: 07-Mar-13 C
25
C
Award of contract for Building incl substations LAD: 07-Feb-13 26 Ant: 15-Apr-13
Filling of existing part fire water pond required for area preparation.
Close
Close
Open
Strl
-
Mar'13
Projects / 7-Mar-13 C&P / BPCL
Feb'13
Apr'13
Apr'13
7-Mar-13
Feb'13
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
Close
28
Engg / C&P - Evaluation of LLIs to be ensured with-in 1 month from receipt of bids by Engg. & Engg / C&P / PBO recommendation 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 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: 29 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
Awarded to M/s Tecnicas Reunidas S.A. on 31.12.13
BPCL
30-Dec-13
Dec'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) 30 Anticipated: 23.11.15 (27 M) Bidders quoted 27 M against schedule of 26 M.
Open
Project
Awarded to M/s Essar Project on 22.08.13 (Duration: 27 M)
C&P / Engg / 30-Aug-13 Projects
JUL'13
Job No.: A307 JUL'14 Page 699 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
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. 31 Duration (Supply) - 15 M FOB /16 M FOT as per RFQ; Sch : 20 M
Open
Project
Delay in Ordering of HRSG (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. 32 No PTR available for LSVR Fuel Completion of Works Sch. : 30.06.15 Ant. : 30.08.15 (20 M)
Close
Projects / - Awarded to M/s Thermax on 20.12.13 Projects / Engg 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.
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. 33 Bidders sought extension in dates.
Close
Project / Licensor
Award of Coke handling system (DCU) LAD :22-Apr-13 Ant :30-Oct-13 (Refloated) 34 Duration: 21 M+2 M No bidder could meet the BQC criteria in view of which the tender has been re-floated.
Open
Project
Open
C
Award of UB package LAD : 19-Jan-13 Ant : 31-Jul-13 35 Duration: 20 M
Close
C
Award of ETP tender. LAD: 24-Apr-13 Ant: 30-Sep-13 36 Duration: 22 M+2 M
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
C
C
Key Risk Description
Action Plan - Awarded to M/s BHEL on 25.07.13.
- 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 Esaar on 10.07.13.
Action By
Target Date
Risk Severity
Projects / Engg / C&P / BPCL
20-Jul-13
JUL'13
20-Dec-13
Projects / BPCL
BPCL
Nov'13
Jun'13
31-Oct-13
Oct'13
Projects / 31-Jul-13 C&P / BPCL
JUL'13
C&P/Engg/Pr oj
Aug'13
Awarded to M/s ThyssenKrupp ; (Duration 21 M+2 M (Mech + Pre Commg)
Process / - 3 no. bids received on extended date of 02.02.13. Engg / - Meeting with bidders held from 19.02.13 to 26.02.13. PBO recomn. issued on constn 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 Project/C&P 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
Anticipated Completion: 29-Jul-15
C
Multiple Contracts awarded to same agency beyond their capabilities / capacities.
Close
Purch / Contrc.
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
Failure of contractors
Open
Const.
Limit the number of works being awarded to one Agency so that alternatives can be C&P 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 BPCL / only. Projects
-
sep'13
-
sep'13
37
C
38
Ordering of Ejector Pkg 39 (LAD:12-Jan-13; Ant: 15-Jul-13)
Open
Project
Awarded to M/s GEA on 10.07.13 with delivery period of 13 M.
BPCL
15-Jul-13
Jun'13
C
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). 40 Due to Technical and related commercial issues enquiry re-floated. Duration 20 M
Open
Project
Awarded to M/s Heurtey, (Duration - 20 M)
BPCL
15-Nov-13
Oct'13
Award of Civil & Strl work for DHDS offsite area (LAD: 30-Mar-13; Ant: 20.07.13) 41 Duration: 18 M
Open
Project
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
Awarded to Mcnally Bharat on 26.09.13. Duration- 16 Months
Project/C&P
Open
Project
NIT issued on 01.08.13, bids due on 30.08.13
Gen Civil/Project
C
C
C
42
C
Issue NIT for Civil & Strl work-SRU Block (LAD:24-Jun-13; Ant: 25.07.13) 43 Duration : 16 M
sep'13
Completion of works Sch: 09-Sep-14 Ant: 24-Jan-15 25-Jul-13
JUL'13
Job No.: A307 JUL'14 Page 700 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
Project
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 45 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
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 46 Ant: 07-Mar-13
Close
Project
Awarded to M/s L&T on 07.03.13. Award recomm sent to BPCL on 01.02.13. Award to C&P be targeted by 07.03.13.
Ordering of wet gas compressor for DCU 47 LAD: 02-Feb-13 Ant: 30-Jun-13
Close
Project
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
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., 49 sulphur pelletiser and sulphur granule); refloated again as financial criteria was not met by all the bidders.
Open
Project
- Ordered to M/s Sandvik.
BPCL
30-Jan-14
Jan'14
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 50 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
Awarded to M/s Sriram on 25.09.13
BPCL
30-Sep-13
Aug'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 51 19.06.13, based on past Performance of recommended bidder tender refloated.
Close
Project
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 52 Duration: 16 M
Open
Project
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 53 Duration: 12 M despatch and 6 M for site work (ODC)
Open
Project
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 54 (Execution Duration - 18+2 M)
Open
Project
Awarded to M/s Triveni
BPCL
19-Jul-13
JUL'13
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION Key Risk Description Award of work for Civil & Strl work-SRU Block (LAD:17-Sep-13; Ant: 30-Oct-13) Duration: 16 M C
C
C
C
C
C
C
C
C
C
C
Action Plan
Action By
Target Date
Risk Severity
44
7-Mar-13
Feb'13
Jun'13
48
Aug'13
Job No.: A307 JUL'14 Page 701 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 15.06.14 (Incinerator burner) 55 (Execution Duration - 14 M)
Open
Project
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
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
Awarded to M/s Airoil on 25.09.13 with duration of 18 M.
Projects/ 28-Sep-13 Process/ Engg / C&P/
Aug'13
Open
Project
- Awarded on M/s Ray Engineering on 23.01.14.
Engg / C&P
Jan'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
C
56
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity Jun'14
19-Jul-13
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
Award for SG-III (Refloated) LAD: 01.11.13 Ant: 30.01.14 58 Duration: 12 M
Award for:RGC compressor for VGO-HDT (LAD: 30Mar-13; Ant: end Jun 13) Dely: 18 M
Open
Project/Eng Awarded to M/s BHEL g
Proj/Engg
29-Jun-13
Jun'13
C
59
Award of MUG compressor for VGO-HDT (LAD: 08-Apr-13; Ant: 30.11.13) 60 Dely: 16 M FOB
Close
Project/Eng Ordered to M/s Neumen & Essar on 14.11.13 g
BPCL
30-Nov-13
Nov'13
C
Award of Contract for Tankage-III (Crude tank: 02 Nos & 1 surge relief tank and crude drain tank) 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 tanks-25/26 under 61 tankage-III. Sch: 01.10.13 Ant: 15-Dec-13
Close
Project/Eng Awarded to M/s IOT Anwesha on 04.12.13. (duration: 20 M) g
BPCL
15-Dec-13
Nov'13
Award for: RGC compressor for DHDT(LAD: 26-Mar-13; Ant: 62 Jun 13)
Close
Project/Eng Awarded to M/s BHEL g
Proj/Engg
28-Jun-13
Jun'13
C
Close
Project/Eng Awarded to M/s Dresser Rand g
Proj/Engg
C
Award for: MUG Compressor for DHDT (LAD: 30-Mar-13; Ant: 20-Sep-13) 63 Duration : 18 M FOB
Award of Tankage-II (TF-4: 5 Nos, Exist ETP-II:2 Nos, Exist Asphalt: 2 Nos) 64 Sch: 30.04.13 Ant: 30-Sep-13 Duration:22 M
Close
BPCL
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 65 new crude tanks (Tankage-III; YT-25/26). Alternative scheme required to be finalised for outage.
Open
BPCL / Projects
C
C
C
Aug'13
Awarded to M/s B&R
BPCL
30-Sep-13
Aug'13
Awarded to M/s Offshore on 17.04.14.
EIL / BPCL
25-Apr-14
Mar'14 & Apr'14
Job No.: A307 JUL'14 Page 702 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
Project
.Awarded to M/s Offshore (Duration- 20 months)
BPCL
31-Oct-13
Oct'13
Award for contract for development of flare area LAD: 01-Nov-13 Ant: end Dec'13
Close
Project
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
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, 69 Technicas, Petron, B&R, JNK). Duration 20 M
Close
Project
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)) 70 (LAD:29.12.13; Ant: 30.07.14)
Open
Project
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 71 Ant: 18.08.14
Open
Project
-Award recommendation issued on 08.08.14.
BPCL
18-Aug-14
Open
Project
- All pipes, fittings & flanges ordered, balance for valves. Ordering progressively targeted by end Aug'14.
C&P
14-Aug-14
C
Ordering for Intermediate Piping 2nd MTO. LAD: Jan'14 onwards 72 Piping intermediate MTO-II released on 30.10.13.
Open
Project
Revised MR (MR-3415) issued covering all critical valves along with all critical valves Engg. of MR-3211 floated. 10 nos bids received on 24.07.14. TBA targeted by 16.08.14.
30-Aug-14
C
Ordering of Critical Valves Sch: 11.07.14 Ant: 30.08.14 73 Dely: 06/07 M FOT /FOB
Open
Project
- Awarded to M/s Zillion on 19.05.14.
25-May-14
C
Award of contract for Mechanical works-CPP area LAD: 28.02.14 74 Ant: 25.05.14
Open
Project
-Total 22190/ 30154 nos (72%) isometrics issued for units . Balance ISO's targeted progressively by progressively upto Sep'14. - Piping items has been ordered for Intermediate MTO-II, delivery expected by Aug'14-Sep'14.
Engg.
Aug'14-Sep'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION Key Risk Description 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 C
C
C
C
C
C
66
Action Plan
Action By
Target Date
Risk Severity
Duration - 20 M
67
68
Release of balance piping Isometrics drawings and GAD's. Target Sch: Jul'14 Ant: Sep'14
30-Jul-14
II IV
Engg
C
75
Open
Project
- Award recommendation issued to BPCL on 03.07.14. Sole bidder has not ready to give any discounts during negotiation, Being refloated. Draft NIT targeted by 18.08.14.
EIL/BPCL
18-Aug-14
C
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM Sch: 08.05.14 76 Ant: 10.10.14
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) 77 Sch:27.06.14 Ant: 05.08.14
Open
Project
- Ordered to M/s Sulzer.
BPCL
5-Aug-14
II May'14
III
II
C
Job No.: A307 JUL'14 Page 703 of 749
Integrated Refinery Expansion Project, Kochi
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 57.62 % Act: 41.41 % Construction Progress: Sch: 12.4 % Front: 65.5% Act: 10.6 % D
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
1
Action Plan
Action By
Management level meeting held on 08.08.14 at site. -M/s EPIL has been asked to start site work by 26.08.14. Projects - M/s EPIL has been pressurised to complete construction of hard stand by 15.10.14. Submission of erection scheme targeted by 18.08.14. Constn - Deliveries of balance materials being expedited. (Nozzle for regenerator by end Aug'14, Reactor torricone by end Aug'14 and TSS torricone by mid Sep'14). - Work for assembly of hoppers and TSS to be commenced form 21.08.14 & 15.09.14 respectively. - M/s EPIL asked to commence area development around FGC equipments & hard stand immediately and to be ready by 15.10.14. - M/s EPIL agreed to mobilise 1600 MT crane by 1st week of Oct'14 and will ready for erection by 05.11.14. - Readiness for TSS erection targeted by 2nd week of Sep'14 to Feb'15. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up.
Target Date
Risk Severity
Progressively upto Aug'14
BPCL
D
D
D
D
D
D
D
2
3
4
5
6
7
8
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
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: 69.1 % Act: 52.4 % Construction Progress: Sch: 53.5 % Front: 63.66 % Act: 14.12 %
Open
Project
Management review held on 01.08.14 to pressurised M/s ISGEC for completing within Project CCD. - M/s ISGEC to expedite modelling work to carry out 90% modelling by end Aug'14. -Erection of UB-1 targeted by mid Aug'14. - M/s ISGEC to expedite shed drawings for equipments.
Delivery/Erection of Ejector Pkg Delivery LAD : 11.06.14 Ant : 09.08.14 Awarded to M/s GEA on 10.07.13 with delivery period of 12 M FOB / 13 M FOT.
Open
Project
Delivery of wet gas compressor for DCU at Site (M/s Eliot Ebara) LAD: 05.12.14 (CDD: 27.01.15; EDD: 27.01.15) Sch: 45.0%; Act: 42.2%
Open
Delivery of Air Blower / Compressor for SRU LAD: 18.09.14 (CDD: 24.12.14; EDD: 24.12.14)
24-Nov-14
I Nov'13
Aug'14
III
-All Indigenous component received at site within CDD. - Foreign Source Components: Delivery of ejector and LRVP pkg targeted to be dispatch from Aug'14 onwards. - HAZOP & 3D model review held on 10th-11th Jul'14
Project/Inspe Aug'14 ction
IV
Project
Sub-orders of Casing, Nozzle, end plate, end wall, shaft of rotor completed. Bearing expected to receive from Aug'14 to Sep'14 progressively. Casing for compressor and turbine received at shop.
Project/Inspe 27-Jan-15 ction
IV
Open
Project
Ordered to M/s Howden Process on 25.07.13 (17 M delivery Sch). Order placed for Motor, turbines, Casings, forgings, impellers, gear box. Close monitoring to be done to ensure delivery on CDD.
Project/Inspe 24-Dec-14 ction
IV
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: 68.8 % Act: 46.6 %
Open
Project
-All 3685 MT Plates received at Chakan Shop, plate cutting & welding in progress. Project - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority assigned to complete main fractionator (IF-V-104) by Oct'14. - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach roach upto fabrication yard, which affected shifting of sections. - Approach road work completed. - Crane under mobilisation.
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) Overall progress: Sch: 71.0 % Act: 63.2 %
Open
Project
- M/s Thermax seeking extension for duration due to delayed availability of burner data from M/s Accometric. Letter issued to BPCL for recommending extension for supply portion to M/s Thermax upto 30.11.14. -MCC: Shell Rolling is completed. - Foundation readiness targeted by Sep'14
BPCL
As stated
15-May-15
II III
Job No.: A307 JUL'14 Page 704 of 749
Integrated Refinery Expansion Project, Kochi
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 49.0 %; Act: 37.0 % Construction Progress: Sch: 27.0 % Front: 92.2 % Act: 18.1 %
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Action Plan
Action By
-Management review meeting held on 08.08.14 at site. Following commitments have been made by M/s Essar. -Fabrication for Derrick structure agreed to complete by Dec'14. - 500 MT qty out of total 1800 MT qty planned to offload from M/s MK Engg by 12.08.14. - Balance fabrication for Switch Deck 250 MT) targeted by 30.09.14. - Structural drawing for balance 1600 MT out of 3500 MT targeted to complete by EIL/BPCL 31.08.14. - M/s Esaar has been asked the readiness of Fractionator Column and Coke Drum for erection by 28.02.15. -Supply of balance Plates (33/38 plates received) targeted by 10.09.14. - Ordering of 2000 MT crane targeted by mid Aug'14 and Crane availability agreed from Feb'15 to May'15. - Completion of Coke drum structure upto 113 level by 10.09.14. - Resource augmentation for Civil & Strl works being expedited. At present 236 nos have been deployed, balance 14 nos by 14.08.14.
Target Date
Risk Severity
Aug'14
D
9
Open
Project/Eng - Drive turbine for LOP (Lube oil Pump) sub ordered to M/s KEPL on 22.03.14 & g targeted to receive at shop by Dec'14. Impeller manufacturing is in process. Turbine casings reached at BHEL workshop. - MRT targeted by 20.08.14.
Project/Inspe ction
27-Dec-14
I IV
D
Delivery of RGC compressor for VGO-HDT (LAD: 05.03.15 Ant : 27.12.14) Dely: 18 M 10 Ordered to M/s BHEL on 28.06.13
Delivery of RGC compressor for DHDT(LAD : 05.02.15; Ant : 27.12.14) Ordered to M/s BHEL on 28.06.13
Open
Project/Eng - Drive turbine for LOP (Lube oil Pump) subordered to M/s KEPL on 22.03.14 & g targeted to receive at shop by Dec'14. Turbine rotors and casings reached at BHEL workshop. Compressor MRT-1 conducted successfully. MRT-2 targeted by 30.08.14.
Project/Inspe ction
27-Dec-14
IV
D
D
11
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Oct 14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV progress Sch ( 98.5 %); Act (85.6%)
Logistics of VGO & DHDT reactors from Kochi port to BPCL-KR site
Open
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Oct'14 Projects / - Due to weld crack in all 4 nos bottom shell likely to be delayed by 2 month w.r.t CDD. / Projects Const. Revised target for erection and hydrotesting of column finalised. Root cause and rectification completed. Detailed report issued to BPCL on 28.07.14. - Crude Column: Bottom section erected on 07.08.14. Erection other sections planned from 16.08.14 to 31.08.14. - Erection of Vacuum Column targeted from 30.08.14 to 30.09.14.
Open
T&CC
Open
Projects
(VGO Reator-2 Nos - CDD (07-Jan-15 FOB) EDD: Feb'15 (DHDT Reactor-2 Nos - CDD (07-Oct-14 FOB) D
D
13
Close Monitoring of ODC equipment (including site fabricated/assembled) up to receipt at site - Preflash drum, Crude Column reflux drum, Flare 14 KOD for CDU / VDU - HP Air Receiver received for U/O
Shipping
Procure/Co - Transporter philosophy frozen and hindrance enroute has been covered under Risk Shipping nstr ID K3.
Open
Contract / Inspection
Sep'14
II IV
Aug'14-Sep'14
IV
As Required
Nov'13
15
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions.
D
Out of total 57 nos. of ODCs; 14 nos received at site. & 5 nos under dispatch. Balance under close monitoring and are expected at site from Jul'14 to Aug'15.
Close Delay in delivery at site due to non-availability of transporter / hindrances enroute. D
- Contract for ODC transportation awarded to M/s Urmila on 26.05.14. - Agency confirmed availability of Barge/Trailer at the time of delivery of Reactors. Barge will be ready with reqrd modification by Sep'14. - KOM held on 02.06.14 & follow up meeting held on 16.07.14. Barge readiness targeted as follows: 2 nos Ammonia Barges modifications by 30.09.14 drawings for new barge submitted to IRS for approval. 1 nos new barge fabrication by 24.12.14 - M/s Urmila informed construction of jetty targeted by 30.09.14 (approval by 30.08.14). - M/s Urmila to take all statutory clearance / clearance from local bodies prior to delivery of Reactor at Kochi-Port.
16
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.
BPCL
Jun'14
Job No.: A307 JUL'14 Page 705 of 749
Integrated Refinery Expansion Project, Kochi
D
D
D
D
D
D
D
D
D
D
D
Action Plan
Action By
Target Date
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 CCD: 24-Mar-15 Ant: 24-Mar-15 17 Overall Progress Sch: 42.8 % Act: 34.9 % Construction work likely to start from Oct'14.
Open
Project
- Hazop review covered in offsite Hazop. - Foundation drawing released. - Filling of area & piling work completed, excavation commenced. Delivery of foundation bolts from Airoil being expedited. - Foundation to be handed over by Aug'14. - Construction work to be started from Oct'14. Fabrication of flare structure is in progress and being delivered from Aug'14 onwards.
Projects/Cons As Required tr.
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. 18 Completion of Flare work: Sch: 31-Mar-15 Ant: 24-Mar-15 (Duration: 18 M)
Open
Project / Process
- 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
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15 D
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
As Required
Risk Severity III
Oct'13
Open
Projects
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. However close monitoring being done. Meeting held on 06.08.14. Casing delivery expected within CDD i.e
Delivery of MAB-FCCU (Ordered to M/s Eliot Ebara on 04.09.13) LAD: 09.01.15 20 CDD: 03.04.15 Ant: 03.04.15
Open
Projects
- All major items has been subordered. Air Blower: Main casing received at workshop. Steam Turbine: Casing received at shop
Delivery of VGO-HDT Reactor Ordered to M/s L&T on 08.04.13 LAD ; 29.12.14 CDD: 07.01.15 21 EDD: 16.02.15 Overall Progress: Sch: 79.0 % Act: 75.0 %
Open
Projects
-Ordered to M/s L&T on 08.04.13; Dly 21M FOT. Close monitoring to be done to Project/Inspe Continuous ensure delivery on CDD. ction - Strike has been called off with effect from 12.05.14 at L&T Hazira workshop. Vendor being followed up continuously to deliver reactor within CDD.
III
Delivery of DHDT Reactor Ordered to M/s Doosan Engg & Const Co. on 08.02.13 LAD ;15.12.14 22 CDD: 07.10.14 Overall Progress: Sch: 77.1 % Act: 73.8 %
Open
Projects
- Follow up visit held, though no delay anticipated as per CDD, however close monitoring to be maintained.
Project/Inspe Continuous ction
III
Completion of HRSG Package LAD : 30.03.15 CDD: 19.08.15 23 Awarded to M/s Thermax on 20.12.13 Overall Progress: Sch: 34.7 % Act: 24.0%
Open
Projects
- Management review meeting held with M/s Thermax on 31.07.14. - Balance engineering to be expedited by m/s Thermax by end Aug'14. - Tharmax has been asked to submit the foundations details of auxiliaries by 20.08.14. - 30 % model review completed & 60 % model review targeted by 11-14Aug'14
Project/Inspe Continuous ction
III
Delivery of Hot Gas Expander (Ordered to M/s Dresser Rand on 31.012.13) 24 LAD ;30.03.15 CDD: 30.04.15
Open
Projects
- Generator subordered - Pedestal fabrication is at final-machining. - Fabrication of exhaust diffuser and inner exhaust case targeted by mid Aug'14.
Project/Inspe Continuous ction
III
Delivery of Sulphur Forming Pkg (Ordered to M/s Sandvik on 31.01.14) LAD :01.08.14 25 CDD: 30.03.15
Open
Projects
-Silos with structure & Conveyors sub ordered by M/s Sandvik. - Delivery of Semi rolled sections of Silos shall commence from Nov'14 onwards. Structure to be made ready for installation work to proceed. - Space for SILO's to be expedited as material expected to receive at site by end Aug'14. - Foundations for pelletiser shed to be made ready by end Nov'14.
Project/Inspe Continuous ction
III
Delivery of steel plates by M/s Essar to other vendors. CDD: Progressively by 15.01.14.
Open
Projects
Strl. Steel for R&RMajor portion of steel plates have been delivered by M/s Essar.
Project/Inspe Continuous ction
Jun'14
Delivery of Make up Gas Compressor -DHDT( Ordered to M/s Dresser Rand on 11.09.13) LAD: 29.01.15 27 CDD: 10.03.15
Open
Projects
- Synchronous Motor ordered to M/s Toshiba Mitsubishi. Expected to receive at M/s Dresser shop by 03.02.15. - HAZOP review completed on 20.06.14.
Continuous
IV
Delivery of Make up Gas Compressor -VGO( Ordered to M/s Nueman & Essar on 14.11.13 ) 28 LAD : 26.02.15 CDD: 13.04.15
Open
Projects
- Main motor ordered. KOM for Motor held on 06-07.05.14 & expected to receive by 13.04.15 (FOB: Germany). - HAZOP completed on 19.06.14.
Progressively
IV
19
26
Project/Inspe Continuous ction
II IV
Job No.: A307 JUL'14 Page 706 of 749
Integrated Refinery Expansion Project, Kochi
Delay by vendor with respect to CDD due to financial constraint.
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Projects
- Following bidders showing slow manufacturing progress: - M/s Arjun Technologies (Pressure Vessel supplier): FOA No.: 133, 144 & 184. Expediting meeting held at shop on 04.07.14, vendor agreed to dispatch balance orders of FOA 133 progressively upto 30.08.14 for FOA 144 upto 02.08.14. - M/s Reynold Chem. (Heat Exchangers): FOA No.: 116, 189: As a parallel action separate MR-6122 released. - M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311 & 444. Continuous expediting being made by visiting vendor workshop for all critical orders in respective regions.
Aug'14
III
Aug'14
III
Action Plan
Action By
D
29
Open
Projects
- M/s Filtrex asking for deviations on commercial terms. Meeting held on 08.07.14 to resolve the issues with M/s Filtrex. Proposed letter has been not accepted. Vendor has been asked to submit revised request.
D
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 30 FOB)
Non acceptance of work order by M/s Flowserve for DHDT Centrifugal pumps Ordered on 30.01.14 to M/s Flowserve (MR-5403) 31 (FOA No 550 & 551) CDD: 01.03.15
Open
Projects
- Order has been accepted by M/s Flowserve and amendment issued by BPCL on 11.07.14.
Delay in delivery of Stripper column (IF-V-206) and Debutaniser Column (IF-V-302) by M/s Uttam Value Steel (Ordered on 19.08.13) 32 CDD: 18.10.14 EDD: 31.03.15
Open
Projects
- Order got delayed due to delay in manufacturing works. At present only 4 shell course rolled out of 17 nos due to which there be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 33 EDD: Sep'14 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
Open
Projects
- As of now around 35-40% piping material has been received at site. Around 85-90 EIL/ BPCL % material has been ordered. Ordering of balance 5-10% material is in progress and expected by Aug'14. Delivery of ordered material against intermediate -II expected by Aug-Sep'14. -Vendors to be expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
Delivery Gas Booster Compressor for CPP (Dly: 13 34 M FOB
Open
Project
Ordered to M/s BHEL on 25.07.14. Dely: 13 M.
Open
Constn.
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.
D
D
EIL/ BPCL
Target Date
Risk Severity
Jul'14
Aug'14
II
D
D
E
1
Slow Progress of works by Piling I contractor M/s DBM. (CDU/VDU, DCU & Offsites) - 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
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage E
E
E
E
E
Open
3
4
5
6
Aug'14
Constn.
Constn.
- Balance 16 nos units in the township handed over for grading by M/s Ray (SG-III) on BPCL 21.07.14 - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material.
2
Sep'14
Mid Oct'13
Open
Constn.
-Rock breaking in VGO area 200 cum. balance targeted by 08.08.14
Engg./Constn. 8-Aug-14
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 59.8% Catch Up Sch: 21.7 % Act: 20.9 %
Open
Constn. / Projects
- All long delivery equipments (incl. Compressors) to be awarded progressively by end EIL/BPCL Aug'14. Columns ordered to M/s Fabtech on 03.07.14 (CDD: 02.07.15) Award recommendation issued for - Refrigeration package on 29.05.14: - Composite Works (Civil Strl. & Mechanical) on 03.07.14: Being refloated.
Aug'14
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.
- Agency finalized on 07.06.2013 and investigation to commence. - Report targeted to issue by mid Jul 13.
15-Jul-13
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch:79.4 % Front: 100 % Act:46.2% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Management level meeting held on 18.07.14, Constn - MCR area, CPP control room area : It has been decided to complete balance strl work by Dec'14 & finishing by Mar'15. - Other building works : Finishing work to be completed by Dec'14. - L&T also agreed to augment required manpower to meet the target completion date.
sep'13
Aug'14
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
BPCL / Projects
II III
I III
I JUL'13
As Required
II
Job No.: A307 JUL'14 Page 707 of 749
Integrated Refinery Expansion Project, Kochi
E
E
7
8
Backlog 26.1 (% wrt target sch) as of 15-Jul-14 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 - 28M; Remaining Duration - 18 M Desc. Catch Up sch: Const Sch Front Act Overall 23.9 49.4 48.6 23.3 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Action Plan Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, contract for 2 additional Structural works & 1 civil work under evaluation and likely to awarded by mid Aug'14. Additional 1 tender for offsite refinery area is under preparation. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the sub vendors against Performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and boost progress. - Contractors are facing problem in retaining the labour at site.Approx 7000 labours are available at site, though induction programme has been carried out for 15000 labours . requirement of manpower at site is approx 15000 nos.
Action By
Target Date
EIL/BPCL
Open
Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
BPCL
Mar'15
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.
L&T has completed all piles in Demountable flare area, Air compressor & DG shed area.
Constr.
Immediate
Payment to contractors
Close
Constn.
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
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
9
E
10
E
11
E
Dismantling of LO CAT SRU and area handing over to Tankage II contractor (Required for New tankagesTF-4) by BPCL. 12 Will affect release of front for tankages.
Unrealistic project time leading to under quality
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
Close
Project / Engg. / planning
Open
BPCL
All 5 nos tank area cleared and released. Area handed over to M/s B&R for Tankage- BPCL II works on 30.04.2014
Open
Project
- Project review meeting held on 26.06.14 with M/s Triveni. -Balance engineering and complete ordering progressively by Aug'14. -M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barvendors and take up chemical house construction work. (Manpower required is 300 nos & Available manpower is 136 Nos). - Substation building: Foundation works commenced , completion to be targeted by Dec'14. - Chemical house work yet to start.
Overall Progress: Contr. Sch: 68.2 % Act: 41.2% Construction Progress: Sch: 63.8 % Front: 100 % Act: 39.5 % 13 Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Risk Severity
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 Mar'15)
E
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Constr.
I IV
sep'13
As Required
sep'13
end Apr'14
May'14
Aug'14
II Area availability for SRU Block - At present only 91 % area given to M/s MBEL, balance Site for SRU block shall be available by end Aug'14. (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). E
Open
Proj. / Constn.
- Meeting held with M/s B&R management on 06.08.14 at site and resources have been augmented. M/s B&R has been asked to expedite completion of balance area by end Aug'14 by augmenting additional dumpers. - Retaining wall in progress. B&R agreed to complete wall by 31.08.14 for which front is available and balance shall be completed by 30.09.14. B&R shall mobilize shuttering materials & manpower accordingly to meet above targets. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 952 nos piles EIL/BPCL completed against front of 1150 nos at site by M/s MBEL. Release of balance piling front at site progressively by mid Aug'14.Total nos of piles is 1800 nos piles
Area for FCC Feed Tanks (Diversion of ETP II to ETP III and development of area reqd. by Apr.13)
Open
Proj. / Constn.
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.
Clubbed with Risk ID E33
BPCL
Land acquisition for Crude tank (2 nos.) . (LAD - Jul 13; Ant - 30-Aug-13)
Close
Proj.
M/s BPCL Vide mail dated 21.08.2013 has handed over the area for SG-III.
BPCL
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
Details of area has been cleared and allocated by BPCL during Review meeting at site.
BPCL
Aug'14
14 Front for balance piling 918 nos will released progressively upto end Jul'14 on completion of site grading by M/s B&R.
I E
15
E
16
E
17
E
18
BPCL
Dec'13
Nov'13
Aug'13
As Required
sep'13
Job No.: A307 JUL'14 Page 708 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
Const. / Projects
E
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 19 delivery as 24.11.14.
Close
Const.
E
HEAVY LIFT Cranes for INTALLATION OF REACTORS Finalisation of Erection scheme and capacity the crane, inclusion in scope and timely mobilisation at 20 site
-Included in mechanical contractor scope. - Based on prel. Erection scheme, 1600 T heavy lift crane with 600 T trailing crane envisaged for erection of both VGO and DHDT reactors. - Timely mobilization of cranes and preparation of Load Test. - Finalization of erection scheme.
E
21
Close Open
EIL Const.
E
22
- Security arrangements in Warehouse in place Total 2 KM pipe under shortage (IS 3589 pipesby of BPCL. 32", 36", 44" & 48") ordered under Constn. FOA 592, 593, 652, 655 to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team.
E
23
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
E
Key Risk Description
Theft Delayof in material delivery from of UGWarehouse piping material Material required at site for Civil & strl contractor.
Lighting during construction
Open
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 24 are reduced while floating tenders. This needs to be avoided.
Constn. EIL
Action Plan
Action By
- All 3 GTGs received at site. Projects - Contractor for Mechanical works for CPP awarded to M/s Zillion. - Subordering: MCC ordered. - N2 compressor (Delivery period is approx 6-8 M) : Ordered on 01.08.14, delivery going upto Dec 2014, However BHEL confirm that they expect supply to be completed within CDD of GTG package.
Project / Constn.
Target Date
Risk Severity
Aug'14
III
-
Nov'13
Aug'14
Mar'13
Area lighting being done.
Constn.
As Required
II May'13
-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
LPG flare - As per EIL study LPG flare is adequate. Report issued to BPCL and clarification received. 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.
BPCL / EIL
15-Nov-13
Oct'13
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and CEMP-II flare
Open
Project
E
25
Open
Project
E
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 (Ant. Compln26 May'14, Compl date Committed by B&R – 13.11.13)
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 Civil & Strl work-offsite IREP Area: Constr. Sch:94.3%; Front:75.8%; Act: 31.1% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 76.6%; Front: 87.1%; Act:31.1% CCD:18.12.14; ECD: Apr'15
Open
Project
Management review meeting held with M/s Essar on 08.08.14 at site. - Foundation completion for HRSG-3 targeted by 22.08.14. - Completion of Structural works for GTG shed targeted by 10.10.14. - Stack foundation targeted to complete for HRSG-3 by 07.09.14, HRSG-4 by 20.09.14 & HRSG-5 by 05.10.14.
EIL/BPCL
Aug'14
31-Aug-14 Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Management level meeting held with B&R on 08.07.14. B&R agreed to execute work on extended hours to complete balance works in all respect by 31.08.14.
II
E
27
Constructio Management level meeting held with M/s KSSPPL on 07.08.14. EIL/BPCL n - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - Additional gangs to be deployed to complete cable trenches work. - KSS agreed to assemble the 100 MT crane from from 16.08.14. - Additional manpower being expedited by M/s KSS. - M/s KSS informed that agency for rock blasting has been deployed since 04.08.14. - TMT bars: Out of ordered 500 MT qty only 94 MT qty received, balance expected by 31.08.14.
Aug'14
II
E
28
Open
Project
- Management level meeting held at site on 07.08.14. - As on date the manpower is 123 nos against the requirement of 200 nos. 100 nos civil labour expected to join site by 12.08.14. - Strl work at fabrication yard: Strl steel for TS-2 & TS-3 targeted by 15.09.14 & 30.09.14 respectively. - Breaking of Pile cap to be expedited.
EIL/BPCL
Continuous
E
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. 17.7% 29 56.2% 52.9 %
Composite works for CDU/VDU Block (Awarded to M/s Offshore on 04.11.13) SCH: 30.06.15 CCD: 03.07.15 ECD: 03.07.15 30 Cum. Sch: 20.7% Front: 26.1% Act: 11.4 %
Open
Project
- Management level Meeting held with M/s OIL on 06.08.14 and following action plan EIL/BPCL has been agreed - M/s OIL advised to to augment welders to 50 nos. against 39 nos available. - Piping fabrication rate of 1500 ID / day from current 660 ID/Day targeted to achieve from 01.09.14. - Additional radiography source to be deployed immediately to clear the backlog approx 700 joints by carrying out 50-60 joints per day by mid Aug'14. Concrete bunker to be constructed at fabrication yard to facilitate radiography work.
Continuous
II
E
II III
Job No.: A307 JUL'14 Page 709 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
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 31 Construction: Sch:12.1 %; Act:8.5% Overall Progress: Sch: 25.9 % Act: 18.0%
Open
Project
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: 54.2 % Act: 51.1 % Construction work: Sch-26.6% Front:56.7% 32 Act:10.5% As of end Jul'14 Heater A: Total 66 nos pannels; Received: 62 nos; Erected: 45 nos. Heater B: Total 66 nos pannels; Received: 18 nos; Fabrication: 20 nos in progress.
Open
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 33 M+2 M incl pre commng)
Open
Progress of ETP Works (Handing over of graded area for ETP & dismantling of existing Oil Catcher) LAD: 30.09.15 CCD:10.08.15 ECD: Dec'15 Overall progress: Sch: 47.6 % Act: 14.5 % Construction Progress: 34 Sch: 19.1 % Front: 61.5 % Act: 7.2 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
E
E
E
E
Key Risk Description
Completion of works for Tankage-II Sch: 30.06.15; CCD: 24.07.15; ECD: Sep'15 Duration: 22 M Sch: 40.3 %; Front:84.3% Act: 12.4 % E
E
Action Plan
Action By
Target Date
-Major backlog is due to engineering (29 %), ordering (49.2%) & mfg.delivery (13.3 %) due to delayed finalisation of layout. - Piling work commenced (510 out of 1642 nos piles completed as on date) M/s TKII to augment piling rigs immediately. -TKII to augment manpower for Civil works as well.
Continuous
III
- 1312 MT steel received & Radiant Section fabrication in progress at Coimbatore Project fabrication yard. Welding completed for Panel frame of radiant end Panel for Heater 101B. Mobilization of work force & crane for erection work commenced. Procurement of steel to be augmented - Handing over of Heater-B foundation handed over. -Crane (150 MT) expected to reach at site from 1st week of Aug'14.
As Required
III
Project
- Total area handed over on 05.05.14.
As stated
Project
Management level meeting held on 21.07.14. EIL/BPCL - M/s Paramount to complete major engineering by mid Aug'14. -60 % model review being in progress from 11th Aug'14. Work commenced in substation (5 out of 42 fdns cast) and equalisation tank. - Handing over of balance area for treated water tank, API/TPI, ex TPI sump targeted by end Aug'14. Area handing over geeting delayed due to rain & U/G structure present in areas. - In order to recover the construction backlog, paramount has agreed to mobilse resource immediately & submit catsup plan. - To be followed up with M/s Paramount.
As stated
As stated
Project
Project
Open
Project
- Management level meeting held on 06.08.14. Total tanks: 27 nos (New tanks 19 nos, work in progress for 11 nos;. Modification tanks: 18 nos work in progress for 8 nos.) - B&R to augment resources to complete all balance work within agreed target. Additional manpower to be increased by 30.08.14. - B&R to complete the modification work for YT-80 (MS Tank) by 10.08.14. - Anchor bolts: 112 nos out of 206 nos expected to be available by 25.08.14.
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 14.7 % Front: 67.8 % Act: 15 %
Open
Project
- Tank pad area handed over for 3 nos out of 4 nos tank. Excavation for tank pad YT-25/26/28 completed. - Area grading in progress for 2nd Crude tank and area to be handed over by mid Aug14.
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 47.1 % Act: 12.1 %
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. - Structural steel: Out of 190 MT, 68 MT received at Coimbatore fabrication yard. Balance being expedited by M/s Petron. - Blasting and painting at Coimbatore is in completion stage. - Fabrication started for radiant section, erection planned by last week of Sep'14. EIL - All radiant coils have been ordered to M/s MSL - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited. BPCL
As Required
Handing over of fabrication space to M/s Fabtech for Main Fractionators Column of FCCU
Close
Project
Clubbed with Risk ID D7
BPCL
As Required
Open
Project
-PO amendment: Letter issued to BPCL on 31.07.14. BPCL confirmation awaited.
BPCL
As Required
35
Risk Severity
Awarded to M/s B&R on 25-Sep-13
Constr.
Jun'14
II III
As stated
II
E
E
E
37
38
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 39 Overall Progress: Sch: 20 % Act: 12 %
II Dec'13
II
Job No.: A307 JUL'14 Page 710 of 749
Integrated Refinery Expansion Project, Kochi
E
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: Dec'15 Overall Progress: Sch: 77.0 % Act: 49.5% Construction Progress: Sch: 63.2 %; Front: 100%; Act:17.7 % 40 Area handed over, part of area is water logged due to plant drain which is under completion.
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Open
Project
-Management level meeting held on 21.07.14 at EIL Delhi. M/s Driplex has been EIL/BPCL asked to prepare a catchup plan to expedite constr. activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up plan has been discussed & reviewed and issued on 26.07.14. M/s Driplex to mobilise additional resources for completion as per catchup plan. -90 % model review expected in Sep'14. - M/s Driplex has been asked to mobilse 200 labours against present 107 nos. - DM tanks: Soil strengthen to be carried out by additional work of Stone Column. Further tanks work held up.
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC Contr. Sch: 59.9%; Front: 92.7% Act: 21.7 % CCD: 24.12.14 ECD: Oct'15
Open
Project
-Management review meeting held on 06.08.14 at site. M/s SEPC has been informed that their performance to be evaluated for next one month, additional agency to be lined to supplement progress (if required). -Resource Deployment of skilled workmen to be increased (Carpenters, bar benders EIL/BPCL to be increased). -Manpower shall be increased to 400 nos. from present 135 nos. 50 nos being planned to mobilise from 30.08.14. - Tech Structure A targeted to complete by 13.08.14. -Part Civil Work in FCCU offloaded to M/s Tauman. M/s Tuaman started mobilising. Additional 2 nos Strl. work contract being lined up to offload above contracts (if required). Award recommendation issued on 25.07.14. For other structural contract 5 nos bids received on 08.07.14.
As Required
Completion of Heater Works-DHDT (M/s Technip) LAD: 24.04.15 CCD: 03.03.15; ECD: Sep'15
Open
Project
Ordering of damper completed Reactor Charge Heater - Radiant Panels erection completed Fractionator Reboiler Heater - Radiant Panel erection completed Fabrication of convections section, ducts and stack in progress
As Required
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 74.7 % Act: 13.9 %
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all Projects bought out items. - Structural steel: Out of 935 MT, 677 MT ordered, 437 MT received. 67 MT expected to receive by 17.08.14. - Blasting and painting at Coimbatore is in completion stage. EIL/BPCL - Fabrication for 6 panels out of 30 panels for radiant section completed, balance 20 panels under dispatch and targeted progressively by 20.08.14. - All radiant coils have been ordered to M/s Tubocex Spain. - Structural erection work agreed to start by 16.08.14. - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited. BPCL
As Required
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 44 ECD: 31.03.15 Sch: 78.3 %; Front :86.1 % Act: 42.6 %
Open
Project
-Management level meeting held with M/s MBEL on 07.08.14 at site. M/s MBEL agreed: - Current manpower is 410 nos. MBEL agreed to mobilise 2 separate gangs for UG piping by 25.08.14. - 2 cranes mobilised and balance 2 cranes targeted to mobilised by 25.08.14.
Projects
As Required
Open
Project
Management level Meeting held with B&R on 06.08.14 at site. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. Buildings to be expedited for storage of material / equipment being received at site.
Projects
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 45 Overall Progress: Sch: 92.0 % Act: 62.0 % Construction progress: Cum Sch: 93.9% Front: 100% Cum Act: 47.3%
Open
Project
-Major backlog is due to construction (45.2%). Last management level meeting held on 23.07.14 at Site. Commitment made by M/s PCT has again slipped. Manpower at site is 439 nos instead of committed 670 nos. Against a requirement of 2045 MT reinforcement steel only 1372 MT is received. PCTL to target to complete all Civil work by Dec'14.
As Required
II III
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 Site to confirm 46 Overall Progress: Sch: 59 % Act: 27.0 % Construction progress: Cum Sch: 50.0% Front: 100% Cum Act: 24.6%
Open
Project
-Major backlog is due to engineering (33.4%) & construction (30%). Last management level meeting held on 28.05.14 at Kolkata. Commitment made by M/s PCT has again slipped. - Balance Area for CWTP handed over after completion of grading by M/s PEL. - Manpower to be augmented urgently -Dedicated transit mixers to be arranged to ensure prompt supply of RMC. -Uninterrupted RMC supply to be ensured.
As Required
III
II
E
E
E
41
Constr. Progress: 42 Sch: 44.6 % front: 100 %
Projects
I III
Act: 24.7 %
43
I
E
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E
E
E
44
Job No.: A307 JUL'14 Page 711 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area 47 Sch:68.5%; Front: 71.9%; Act: 11.2%
Open
Constructio Management level Meeting held with M/s KSSIIPL on 07.08.14 at site. EIL/BPCL n - M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 82 nos deployed only. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-05 nos bids received on 08.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - Award recommendation issued on 06.08.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15
Open
Constructio -Management level meeting held on 08.08.14 at site. EIL/BPCL n - Piping fabrication shed: Foundations work completed, fabrication shed targeted to complete by 31.08.14. - In view of delay in start of works (5 Month elapsed) by M/s Petron, separate tender for refloating is under progress.
Open
Constructio Management level meeting held on 06.08.14 at site. n - B&R to mobilize 750 MT crane for erection of heavy lift from Aug’14 onwards. - B&R agreed to complete fabrication shed by 25.08.14. - Semi welding m/c ordered on 31.07.14.
EIL/BPCL
Aug'14
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:52.7%; Front: 67.9%; Act: 11.7% 50 CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 07.08.14 at site. n -Manpower: As on date only 110 Nos against the requirement of 300 Nos reported to site. MBEL committed to increase manpower upto 220 nos by 21.08.14. - TMT bars: 40 MT targeted to receive at site by 18.08.14. - In view of slow progress and delay in release of construction front to mechanical contractor, new tender under preparation and likely to be awarded by Sep'14.
EIL/BPCL
Aug'14
Start of work by M/s Tech Sharp for Composite works: Offsite IREP area due to delay in mobilisation. 51 Awarded on 25.03.14. CCD: 24.09.15 Work yet to start at site.
Open
Constructio KOM held on 17.05.14. Mobilisation work initiated by M/s techsharp. n Pooja held on 22.07.14, WQT commenced.
Constr.
Aug'14
I III
Open
Constructio - Management level meeting held 06.08.14 at site. n -Agency for radiography to be expedited. - Development of fabrication yard to be expedited as area has already shown. - Welder qualification works to commence by 16.08.14.
Aug'14
III
E
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 52 Work yet to start at site.
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete Constr. n balance civil & strl works by end Oct'14 & TS-4 strl by Nov'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. TS-2 total handover by 08.08.14 - TS-3 total handover by 31.08.14 - TS-6 total handover by 15.08.14 - MPR Grids 1 to 4 handing over by 22.08.14 49 welders deployed (further 3 welders by Mid Aug'14)
Aug'14
III
E
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: 15.02.15 53 Sch:98.8% Front: 97.7% Act: 77.1%
Completion of Heater Works-CDU/VDU (M/s Technip) LAD:14.03.15 CCD: 06.02.15 Ant: Jun'15 54 Overall Progress: Sch: 85.3 % Act: 77.2 % Constr. Progress: Sch: 60.5 % Front: 87.4% Act: 45.8 %
Open
Project
As Required
III
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 55 Sch: 98.9% Front: 98.7 % Act: 66.2 %
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete EIL/BPCL n balance civil & strl works progressively by Dec'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. -MPR : 1st tier for total length handed over, grids 25-30 shall be handed over by Aug'14. TS-IV : total handing over by 31.08.14
Aug'14
Open
Constructio - Management level Meeting held on 07.07.14 n - OIL started to dismantle YT-150 Scope of works : Modification of 10 No tanks and 02 No new tanks. Front has been released for YT-383/391/150. -B&R has been informed that 2 tanks YT-383 & 391 have been handed over for taking up construction work and since these are to be made operational before taking outage of next tanks, the completion of these tanks is most critical. -Agency has been asked to mobilise and start work immediately. M/s Offshore to submit action plan for completion and status of procurement. - Next Management review meeting with M/s OIL planned on 06.08.14.
Aug'14
E
Aug'14
I
E
48
Aug'14
Construction work yet to start at site II 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 E
49
II
E
E
E
E
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 Scope of modification: total 10 nos; Front released has been released for 2 nos (YT-383/391) E
56
- Major backlog is due to manufacturing & Delivery (9.8%) and construction (13.3%). Erection of APH for VDU Heater is in progress. - Additional resources to be mobilised to recover construction backlogs by Aug'14. Convection module erection for CDU Heaters to commence from Aug'14. CDU APH foundations to be handed over by end Sept-14
Constr.
II III
Job No.: A307 JUL'14 Page 712 of 749
Integrated Refinery Expansion Project, Kochi
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 ECD:Aug'15 Sch: 77.1 % Front: 100 % Act: 31.5 %
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Risk Severity
Aug'14
III
Open
Constructio - Management level meeting held on 06.08.14 with M/s B&R at site. n M/s B&R agreed to increase manpower from 90 nos to 150 nos. B&R agreed to complete the civil works as per below targets: 1. YT-341 : 25.07.14 Revised date: 12.08.14 2. YT-342: 20.08.14 Revised date: 20.08.14 3. YT-343: 10.08.14 Revised date: 10.08.14 4. YT-344: 30.07.14 Revised date: 10.08.14 5. YT-111: 15.07.14 Revised date: 29.08.14 6. YT-112: 20.07.14 Revised date: 18.08.14 7. YT-113: 14.08.14 Revised date: 22.08.14 8. YT-114: 08.08.14 Revised date: 14.08.14 - Procurement of Balance Quantity of Plates (890 MT out of 1650 MT) to be expedited.
Start of work for SRU Tankage works (Ordered to M/s Tuaman on 19.02.14 58 CCD:18.06.15 Work yet to start
Open
Constructio -These tankages (Amine water and sour water services) are required for n commissioning of CDU/VDU. -Agency has been pressurised to mobilise resources and start work. - Tank pads to be handed over from Aug'14 onwards.
Constr.
Aug'14
III
Start of Composite works by M/s Albana for DHDT & VGO Unit DHDT: Awarded to M/s Albana on 19.05.14 with 59 CCD: 18.11.15. VGO: Awarded to M/s Albana on 19.05.14 with CCD: 18.11.15
Open
Constructio - KOM held on 27.05.14. n - Fabrication shed in progress and expected to be completed by 14.08.14 - WPS/PQR in progress
Constr.
Aug'14
III
Start of Composite works by M/offshore for Offsite DHDS area Awarded to M/s OIL on 19.05.14 with CCD: 18.11.15.
Open
Constructio - Management level meeting held with M/s OIL on 06.08.14 at site. M/s OIL has been Constr. n asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - Fabrication yard hand over targeted by 16.08.14. - Mobilisation for 20 nos auto welding machine to be expedited.
Aug'14
III
Start of Composite works by M/s offshore for SRU area Awarded to M/s OIL on 25.03.14 with CCD: 24.09.15.
Open
E
61
Constructio - Management level meeting held with M/s OIL on 06.08.14 at site. M/s OIL has been Constr. n asked to mobilise resources, establish fabrication yard and site facility and start work immediately. - M/s OIL agreed to establish complete fabrication yard by end Aug'14. - 600 MT crane mobilisation targeted by 25.08.14.
Completion of balance piling work (Covered under Piling-IIII Contract) 62 (Total 2077 Nos piles approx).
Open
Constn.
-Piling balance in Chitrapuzha area, Offsite Refinery area, new tender prepared. 08 nos bids received on 22.07.14. PBO recommendation targeted by 18.08.14
Engg./C&P
E
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project
Open
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015 for CDU/VDU commissioning.
BPCL
1-Jun-15
III
F
1
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
Projects
Continuous
III
Timely Commissioning of UB package to meet refinery commissioning schedule. Contr. Sch: 69.1%; Act: 52.4% LAD : 31.03.15 (UB 1) 30.06.15 (UB 2)
Open
Constn.
-Strict monitoring required at all stages till award of UB Tender and further during execution. -Completeness of supply of all subparts, their assembly and other BOP Items to be ensured. - Special attention to be given to multi flue chimney.
as scheduled
IV
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. - 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 for more than 5CR value. - Expeditious processing of RA bills.
As Required
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.
EIL/BPCL
As Required
IV
Process / Engg.
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
sep'13
Inspn
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
- Covered under risk ID C73
BPCL
within 2 days of request
Nov'13
E
E
E
E
F
F
57
60
2
3
G
1
G
2 Scope changes & information flow to executing group
G
3
G
4
G
5
Open
Non-performing vendors
Open
Delay in Approval of Vendor List for various items of the project (specially for Long lead items)
Close
PROCESS/ a. Change management should be in place immediately ENGG/CON b. Strict discipline to be maintained else end objective would be difficult to meet. S. All Disciplines are restricted to book manhours and all HOD's should review & make strict control of manhours booking.
Purch / Contrc.
Aug'14
18-Aug-14
III
IV
Job No.: A307 JUL'14 Page 713 of 749
Integrated Refinery Expansion Project, Kochi
G
G
I
I
Finalisation of Non plant buildings.
Close
Implementation of environmental clearance conditions by EIL (received from MoEF vide Letter dated 22.11.12)
Open
Delay in commencement of site work for dyke wall Close inside TF-3 affected due to non availability of PESO approval for tankage area
BPCL
Action Plan
Action By
Target Date
- BPCL-KR vide e-mail dated 06-Dec-12 sent a list of Non plant buildings to be Projects 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.
15-Apr-13
Projects
- 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.
As required
Engg. / Proj.
- Documents approved from PESO
6
7
BPCL
Risk Severity Apr'13
IV
Apr'13
1
2
J
1
K
1
K
2
K
3
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
Implementation of Health, Safety and environmental (HSE) system
Open
Const.
- Deployment of skilled manpower for enforcement of safety precautions. - Monitoring of the HSE conditions and maintenance of records ./ reports. - Safety Drills being organised monthly basis.
Constn.
Continuous
III
Delay due to Labour strikes (due to labour issue like wage revision, other benefits) during project execution phase
Close
Const.
Client to be persuaded to settle labour issues (wage revision, other benefits) for Project duration.
BPCL
As Required
Nov'13
Non availability of Skilled workers
Open
Const.
-Utilisation of migrant labour and skilled labour from outside the state needs to be EIL/BPCL 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 of trade union leaders that workers shall be instructed to improve productivity.
As Required
III
Constraint in movement & transportation of ODC eqpt.
Open
Project
-A separate contract to be given to agency which will take care by approaching KSEB Shipping and telephonic authority. -Fabn / transportation philosophy being finalised.
As Required
Jun'14
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open
K
4
M
1
M
2
Increase in facilities on account of deletion zero liquid discharge
3
Variation in foreign exchange rates from Rs 50 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.
M
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Cost monitoring & control on regular basis
Close
Projects / - IBR package for DCU targeted after 90 % model review. BPCL - List of all the buildings in IREP along with the plinth area details for taking approvals from F&B as well as Panchayath issued to BPCL on 12.04.14. Approval for tall strl/stacks: Signed documents with 6 sets handed over on 13.05.14. -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
Project/Eng Closed as no concern as on date. g
Aug'14
BPCL
As stated
IV
Jun'14
Costing
Cost engg. to issue cost status report on regular basis
Costing
Monthly
Apr'13
Open
Environ.
Scope of facilities finalised.
Environ.
15-Oct-13
sep'13
Open
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
Aug'14
II
Job No.: A307 JUL'14 Page 714 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 71 Ant: 18.08.14
Open
Project
-Award recommendation issued on 08.08.14.
BPCL
18-Aug-14
Open
Project
Revised MR (MR-3415) issued covering all critical valves along with all critical valves Engg. of MR-3211 floated. 10 nos bids received on 24.07.14. TBA targeted by 16.08.14.
30-Aug-14
C
Ordering of Critical Valves Sch: 11.07.14 Ant: 30.08.14 73 Dely: 06/07 M FOT /FOB
Open
Project
- Award recommendation issued to BPCL on 03.07.14. Sole bidder has not ready to give any discounts during negotiation, Being refloated. Draft NIT targeted by 18.08.14.
18-Aug-14
C
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM Sch: 08.05.14 76 Ant: 10.10.14
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 57.62 % Act: 41.41 % Construction Progress: Sch: 12.4 % Front: 65.5% Act: 10.6 %
Open
Project
Management level meeting held on 08.08.14 at site. -M/s EPIL has been asked to start site work by 26.08.14. Projects - M/s EPIL has been pressurised to complete construction of hard stand by 15.10.14. Submission of erection scheme targeted by 18.08.14. Constn - Deliveries of balance materials being expedited. (Nozzle for regenerator by end Aug'14, Reactor torricone by end Aug'14 and TSS torricone by mid Sep'14). - Work for assembly of hoppers and TSS to be commenced form 21.08.14 & 15.09.14 respectively. - M/s EPIL asked to commence area development around FGC equipments & hard stand immediately and to be ready by 15.10.14. - M/s EPIL agreed to mobilise 1600 MT crane by 1st week of Oct'14 and will ready for erection by 05.11.14. - Readiness for TSS erection targeted by 2nd week of Sep'14 to Feb'15. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. BPCL
Progressively upto Aug'14
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: 68.8 % Act: 46.6 %
Open
Project
-All 3685 MT Plates received at Chakan Shop, plate cutting & welding in progress. Project - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority assigned to complete main fractionator (IF-V-104) by Oct'14. - Progress of works was affected due to delayed handing over of fabrication yards and completion of approach roach upto fabrication yard, which affected shifting of sections. - Approach road work completed. - Crane under mobilisation.
As stated
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 49.0 %; Act: 37.0 % Construction Progress: Sch: 27.0 % Front: 92.2 % Act: 18.1 %
Open
Project
-Management review meeting held on 08.08.14 at site. Following commitments have Constr. been made by M/s Essar. -Fabrication for Derrick structure agreed to complete by Dec'14. - 500 MT qty out of total 1800 MT qty planned to offload from M/s MK Engg by 12.08.14. - Balance fabrication for Switch Deck 250 MT) targeted by 30.09.14. - Structural drawing for balance 1600 MT out of 3500 MT targeted to complete by BPCL/EIL 31.08.14. - M/s Esaar has been asked the readiness of Fractionator Column and Coke Drum for erection by 28.02.15. -Supply of balance Plates (33/38 plates received) targeted by 10.09.14. - Ordering of 2000 MT crane targeted by mid Aug'14 and Crane availability agreed from Feb'15 to May'15. - Completion of Coke drum structure upto 113 level by 10.09.14. - Resource augmentation for Civil & Strl works being expedited. At present 236 nos have been deployed, balance 14 nos by 14.08.14.
Aug'14
Risk Id
Status (Open / Close)
RISKS REQUIRING ATTENTION
C
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
II
II BPCL/EIL
II
D
1
I
D
7
II
D
9
I
D
Delay in erection of Crude & vacuum column Sch: Jun 14 CCD: 21.08.14 Ant: Oct 14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV progress Sch ( 98.5 %); Act (85.6%)
Open
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Oct'14 Projects / - Due to weld crack in all 4 nos bottom shell likely to be delayed by 2 month w.r.t CDD. / Projects Const. Revised target for erection and hydrotesting of column finalised. Root cause and rectification completed. Detailed report issued to BPCL on 28.07.14. - Crude Column: Bottom section erected on 07.08.14. Erection other sections planned from 16.08.14 to 31.08.14. - Erection of Vacuum Column targeted from 30.08.14 to 30.09.14.
II
Job No.: A307 JUL'14 Page 715 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Open
Projects
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. However close monitoring being done. Meeting held on 06.08.14. Casing delivery expected within CDD i.e
Delay in delivery of Stripper column (IF-V-206) and Debutaniser Column (IF-V-302) by M/s Uttam Value Steel (Ordered on 19.08.13) 32 CDD: 18.10.14 EDD: 31.03.15
Open
Projects
- Order got delayed due to delay in manufacturing works. At present only 4 shell EIL/ BPCL course rolled out of 17 nos due to which there be likely delay of 3-5 months including site works. Vendor to be expedited to supply within CDD.
Availability of 90 % Piping materials to generate adequate piping material front to composite contractors. Sch: (Intermediate MTO-2) : JUN'14 33 EDD: Sep'14 Sch: (Intermediate MTO-3): Oct'14 EDD: Dec'14.
Open
Projects
- As of now around 35-40% piping material has been received at site. Around 85-90 EIL/ BPCL % material has been ordered. Ordering of balance 5-10% material is in progress and expected by Aug'14. Delivery of ordered material against intermediate -II expected by Aug-Sep'14. -Vendors to be expedited to prepone the deliveries. - Storage area for piping materials to be expedited by BPCL.
Risk Id
Status (Open / Close)
RISKS REQUIRING ATTENTION Key Risk Description Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15 D
19
Action Plan
Action By
Target Date
Risk Severity
II
D
Aug'14
II
D
Sep'14
II Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage E
Open
Constn.
- Balance 16 nos units in the township handed over for grading by M/s Ray (SG-III) on BPCL 21.07.14 - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material.
- All long delivery equipments (incl. Compressors) to be awarded progressively by end BPCL/EIL Aug'14. Columns ordered to M/s Fabtech on 03.07.14 (CDD: 02.07.15) Award recommendation issued for - Refrigeration package on 29.05.14: - Composite Works (Civil Strl. & Mechanical) on 03.07.14: Being refloated.
Aug'14
2
Aug'14
I
E
4
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 59.8% Catch Up Sch: 21.7 % Act: 20.9 %
Open
Constn. / Projects
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch:79.4 % Front: 100 % Act:46.2% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Management level meeting held on 18.07.14, Constn - MCR area, CPP control room area : It has been decided to complete balance strl work by Dec'14 & finishing by Mar'15. - Other building works : Finishing work to be completed by Dec'14. - L&T also agreed to augment required manpower to meet the target completion date.
As Required
Backlog 26.1 (% wrt target sch) as of 15-Jul-14 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 - 28M; Remaining Duration - 18 M Desc. Catch Up sch: Const Sch Front Act Overall 23.9 49.4 48.6 23.3 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, contract for 2 additional Structural works & 1 civil work under evaluation and likely to awarded by mid Aug'14. Additional 1 tender for offsite refinery area is under preparation. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the sub vendors against Performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and boost progress. - Contractors are facing problem in retaining the labour at site.Approx 5000 labours are available at site, though induction programme has been carried out for 15000 labours . requirement of manpower at site is approx 15000 nos.
Constn
As Required
- Project review meeting held on 26.06.14 with M/s Triveni. -Balance engineering and complete ordering progressively by Aug'14. -M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barvendors and take up chemical house construction work. (Manpower required is 300 nos & Available manpower is 136 Nos). - Substation building: Foundation works commenced , completion to be targeted by Dec'14. - Chemical house work yet to start.
Constr.
I
E
6
II
E
7
BPCL/EIL
I Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
E
Overall Progress: Contr. Sch: 68.2 % Act: 41.2% Construction Progress: Sch: 63.8 % Front: 100 % Act: 39.5 % 13 Sch: 15.11.14 CCD: 24.03.15 ECD: Aug'15 Compl: 18 M+2M
Open
Project
Aug'14
II
Job No.: A307 JUL'14 Page 716 of 749
Integrated Refinery Expansion Project, Kochi
Area availability for SRU Block - At present only 91 % area given to M/s MBEL, balance Site for SRU block shall be available by end Aug'14. (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). E
Open
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION
Proj. / Constn.
14 Front for balance piling 918 nos will released progressively upto end Jul'14 on completion of site grading by M/s B&R.
Action Plan
Action By
- Meeting held with M/s B&R management on 06.08.14 at site and resources have Constn. been augmented. M/s B&R has been asked to expedite completion of balance area by end Aug'14 by augmenting additional dumpers. - Retaining wall in progress. B&R agreed to complete wall by 31.08.14 for which front is available and balance shall be completed by 30.09.14. B&R shall mobilize shuttering materials & manpower accordingly to meet above targets. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 952 nos piles completed against front of 1150 nos at site by M/s MBEL. Release of balance piling BPCL/EIL front at site progressively by mid Aug'14.Total nos of piles is 1800 nos piles - Next Management review meeting with M/s B&R planned on 06.08.14.
Target Date
Risk Severity
Aug'14
I Delay in delivery of UG piping material Material required at site for Civil & strl contractor.
Open
Const.
- Total 2 KM pipe under shortage (IS 3589 pipes of 32", 36", 44" & 48") ordered under BPCL FOA 592, 593, 652, 655 to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team.
Aug'14
E
22
Open
Project
E
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 (Ant. Compln26 May'14, Compl date Committed by B&R – 13.11.13)
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 Civil & Strl work-offsite IREP Area: Constr. Sch:94.3%; Front:75.8%; Act: 31.1% CCD: 08.10.14; ECD: Jun'15
Open
Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 76.6%; Front: 87.1%; Act:31.1% CCD:18.12.14; ECD: Apr'15
Open
Project
Management review meeting held with M/s Essar on 08.08.14 at site. - Foundation completion for HRSG-3 targeted by 22.08.14. - Completion of Structural works for GTG shed targeted by 10.10.14. - Stack foundation targeted to complete for HRSG-3 by 07.09.14, HRSG-4 by 20.09.14 & HRSG-5 by 05.10.14.
BPCL / EIL
Aug'14
BPCL / EIL
Continuous
II BPCL / EIL
31-Aug-14
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Management level meeting held with B&R on 08.07.14. B&R agreed to execute work on extended hours to complete balance works in all respect by 31.08.14.
II
E
27
Constructio Management level meeting held with M/s KSSPPL on 07.08.14. BPCL / EIL n - M/s KSS agreed to complete all balance piperack foundations by 31.10.14. - Additional gangs to be deployed to complete cable trenches work. - KSS agreed to assemble the 100 MT crane from from 16.08.14. - Additional manpower being expedited by M/s KSS. - M/s KSS informed that agency for rock blasting has been deployed since 04.08.14. - TMT bars: Out of ordered 500 MT qty only 94 MT qty received, balance expected by 31.08.14.
Aug'14
II
E
28
Open
Project
E
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. 17.7% 29 56.2% 52.9 %
- Management level meeting held at site on 07.08.14. - As on date the manpower is 123 nos against the requirement of 200 nos. 100 nos civil labour expected to join site by 12.08.14. - Strl work at fabrication yard: Strl steel for TS-2 & TS-3 targeted by 15.09.14 & 30.09.14 respectively. - Breaking of Pile cap to be expedited. - Next Management review meeting with M/s Mcnally planned on 07.08.14.
Progress of ETP Works (Handing over of graded area for ETP & dismantling of existing Oil Catcher) LAD: 30.09.15 CCD:10.08.15 ECD: Dec'15 Overall progress: Sch: 47.6 % Act: 14.5 % Construction Progress: 34 Sch: 19.1 % Front: 61.5 % Act: 7.2 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Management level meeting held on 21.07.14. Eil - M/s Paramount to complete major engineering by mid Aug'14. -60 % model review being in progress from 11th Aug'14. Work commenced in substation (5 out of 42 fdns cast) and equalisation tank. BPCL - Handing over of balance area for treated water tank, API/TPI, ex TPI sump targeted by end Aug'14. Area handing over geeting delayed due to rain & U/G structure present in areas. - In order to recover the construction backlog, paramount has agreed to mobilse resource immediately & submit catsup plan. - To be followed up with M/s Paramount.
As stated
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 14.7 % Front: 67.8 % Act: 15 %
Open
- Tank pad area handed over for 3 nos out of 4 nos tank. Excavation for tank pad YT-25/26/28 completed. - Area grading in progress for 2nd Crude tank and area to be handed over by mid Aug14.
As stated
II
II
E
II
E
Project
Constr.
II
Job No.: A307 JUL'14 Page 717 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION Action Plan
Action By
Target Date
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 Overall Progress: Sch: 47.1 % Act: 12.1 %
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. - Structural steel: Out of 190 MT, 68 MT received at Coimbatore fabrication yard. BPCL Balance being expedited by M/s Petron. - Blasting and painting at Coimbatore is in completion stage. - Fabrication started for radiant section, erection planned by last week of Sep'14. EIL - All radiant coils have been ordered to M/s MSL - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited.
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 39 Overall Progress: Sch: 20 % Act: 12 %
Open
Project
-PO amendment: Letter issued to BPCL on 31.07.14. BPCL confirmation awaited.
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: Dec'15 Overall Progress: Sch: 77.0 % Act: 49.5% Construction Progress: Sch: 63.2 %; Front: 100%; Act:17.7 % 40 Area handed over, part of area is water logged due to plant drain which is under completion.
Open
Project
-Management level meeting held on 21.07.14 at EIL Delhi. M/s Driplex has been EIL asked to prepare a catchup plan to expedite constr. activities for compln. of RO-DM plant by Apr/May'15 in order to commission UB's & HRSG by Jun'15. The catch-up BPCL plan has been discussed & reviewed and issued on 26.07.14. M/s Driplex to mobilise additional resources for completion as per catchup plan. -90 % model review expected in Sep'14. - M/s Driplex has been asked to mobilse 200 labours against present 107 nos. - DM tanks: Soil strengthen to be carried out by additional work of Stone Column. Further tanks work held up.
As Required
Slow Construction progress for Civil Works by M/s Shriram EPC Contr. Sch: 59.9%; Front: 92.7% Act: 21.7 % CCD: 24.12.14 ECD: Oct'15
Open
Project
-Management review meeting held on 06.08.14 at site. M/s SEPC has been informed Constr. that their performance to be evaluated for next one month, additional agency to be lined to supplement progress (if required). -Resource Deployment of skilled workmen to be increased (Carpenters, bar benders EIL/BPCL to be increased). -Manpower shall be increased to 400 nos. from present 135 nos. 50 nos being planned to mobilise from 30.08.14. - Tech Structure A targeted to complete by 13.08.14. -Part Civil Work in FCCU offloaded to M/s Tauman. M/s Tuaman started mobilising. Additional 2 nos Strl. work contract being lined up to offload above contracts (if required). Award recommendation issued on 25.07.14. For other structural contract 5 nos bids received on 08.07.14.
As Required
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 74.7 % Act: 13.9 %
Open
Project
-Management level meeting held on 08.08.14 at site. Order has been placed for all Projects bought out items. - Structural steel: Out of 935 MT, 677 MT ordered, 437 MT received. 67 MT expected to receive by 17.08.14. - Blasting and painting at Coimbatore is in completion stage. BPCL/EIL - Fabrication for 6 panels out of 30 panels for radiant section completed, balance 20 panels under dispatch and targeted progressively by 20.08.14. - All radiant coils have been ordered to M/s Tubocex Spain. - Structural erection work agreed to start by 16.08.14. - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited.
As Required
Slow Construction progress for Civil Works by M/s McNally Bharat for DHDT & VGO CCD: 10.01.15 44 ECD: 31.03.15 Sch: 78.3 %; Front :86.1 % Act: 42.6 %
Open
Project
-Management level meeting held with M/s MBEL on 07.08.14 at site. M/s MBEL agreed: - Current manpower is 410 nos. MBEL agreed to mobilise 2 separate gangs for UG piping by 25.08.14. - 2 cranes mobilised and balance 2 cranes targeted to mobilised by 25.08.14.
Projects
As Required
Open
Project
Management level Meeting held with B&R on 06.08.14 at site. PEB 2 All works targeted to complete by 31.12.14. PEB 3: All works targeted to complete by 31.12.14. Buildings to be expedited for storage of material / equipment being received at site.
Projects
As Required
37
Risk Severity
As Required
II
E
Projects/BPC As Required L
II
E
II
E
41
I
E
43
I
E
II Completion of Pre-engineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses. E
44
II
Job No.: A307 JUL'14 Page 718 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING ATTENTION Action Plan
Action By
Target Date
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 Civil & Strl work-offsite DHDS Area 47 Sch:68.5%; Front: 71.9%; Act: 11.2%
Open
Constructio Management level Meeting held with M/s KSSIIPL on 07.08.14 at site. BPCL / EIL n - M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 82 nos deployed only. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-05 nos bids received on 08.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - Award recommendation issued on 06.08.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15
Open
Constructio -Management level meeting held on 08.08.14 at site. BPCL / EIL n - Piping fabrication shed: Foundations work completed, fabrication shed targeted to complete by 31.08.14. - In view of delay in start of works (5 Month elapsed) by M/s Petron, separate tender for refloating is under progress.
Open
Constructio Management level meeting held on 06.08.14 at site. n - B&R to mobilize 750 MT crane for erection of heavy lift from Aug’14 onwards. - B&R agreed to complete fabrication shed by 25.08.14. - Semi welding m/c ordered on 31.07.14.
BPCL / EIL
Aug'14
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:52.7%; Front: 67.9%; Act: 11.7% 50 CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 07.08.14 at site. n -Manpower: As on date only 110 Nos against the requirement of 300 Nos reported to site. MBEL committed to increase manpower upto 220 nos by 21.08.14. - TMT bars: 40 MT targeted to receive at site by 18.08.14. - In view of slow progress and delay in release of construction front to mechanical contractor, new tender under preparation and likely to be awarded by Sep'14.
BPCL / EIL
Aug'14
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 55 Sch: 98.9% Front: 98.7 % Act: 66.2 %
Open
Constructio - Management level meeting held on 18.07.14, It has been decided to complete BPCL / EIL n balance civil & strl works progressively by Dec'14. -M/s L&T to augment manpower and additional machineries for completion of balance works to generate front to mechanical contractor. -MPR : 1st tier for total length handed over, grids 25-30 shall be handed over by Aug'14. TS-IV : total handing over by 31.08.14
Aug'14
Risk Severity
Aug'14
I
E
48
Aug'14
Construction work yet to start at site II 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 E
49
II
E
I
E
II
M
3
Variation in foreign exchange rates from Rs 50 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.
Open
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
EIL/BPCL
Aug'14
II
Y
N
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 49.0 %; Act: 37.0 % Construction Progress: Sch: 27.0 % Front: 92.2 % Act: 18.1 %
Open
Project
Very High
Y
Y
Y
N
Short term
(Current risk Score - Previous Risk score)
Y
Previous Risk Score
Y
Current Risk Score -> {5}* {12}
Output Quality ( Y / N)
Very High
Impact Score => {6+7+8+9} * 10 * 11
Schedule ( Y / N)
Project
Controllability Condition (D/I )
EIL Cost (Y / N)
Open
Urgency (Long Term / Short term)
Risk Owner
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Status (Open / Close)
Risk Id D
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 57.62 % Act: 41.41 % Construction Progress: Sch: 12.4 % Front: 65.5% Act: 10.6 %
Key Risk Description
Job No.: A307 Jul'14 Page 719+15 of 34
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
I
0.9
0.86
0.86
0.00
Management level meeting held on 08.08.14 at site. -M/s EPIL has been asked to start site work by 26.08.14. Projects - M/s EPIL has been pressurised to complete construction of hard stand by 15.10.14. Submission of erection scheme targeted by 18.08.14. Constn - Deliveries of balance materials being expedited. (Nozzle for regenerator by end Aug'14, Reactor tricone by end Aug'14 and TSS torricone by mid Sep'14). - Work for assembly of hoppers and TSS to be commenced form 21.08.14 & 15.09.14 respectively. - M/s EPIL asked to commence area development around FGC equipments & hard stand immediately and to be ready by 15.10.14. - M/s EPIL agreed to mobilise 1600 MT crane by 1st week of Oct'14 and will ready for erection by 05.11.14. - Readiness for TSS erection targeted by 2nd week of Sep'14 to Feb'15. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. BPCL
Progressively upto Aug'14
I
0.9
0.86
0.86
0.00
-Management review meeting held on 08.08.14 at site. Following commitments have been made by M/s Essar. -Fabrication for Derrick structure agreed by Dec'14. - 500 MT qty out of total 1800 MT qty planned to offload from M/s MK Engg by 12.08.14. - Balance fabrication for Switch Deck 250 MT) targeted by 30.09.14. - Structural drawing for balance 1600 MT out of 3500 MT targeted to complete by 31.08.14. - M/s Esaar asked to ready Fractionator column and coke drum for erection by 28.02.15. -Supply of balance Plates (33/38 plates received) targeted by 10.09.14. - Ordering of 2000 MT crane targeted by mid Aug'14 and Crane availability agreed from Feb'15 to May'15. - Completion of Coke drum structure upto 113 level by 10.09.14. - Resource augmentation for Civil & Strl works being expedited. At present 236 nos have been deployed, balance 14 nos by 14.08.14.
Constr.
Aug'14
1
Action Plan
Action By
Target Date
Risk Severity
I
D
Short term
9
BPCL/EIL
I Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage E
Open
Constn.
Very High
Y
N
Y
Y
Short term
I
0.7
0.67
0.67
0.00
- During the project review meeting dated 26.06.14 following points discussed and BPCL agreed: - Balance 16 nos units in the township handed over for grading by M/s Ray (SG-III) on 21.07.14 - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material.
BPCL
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
- All long delivery equipments (incl. Compressors) to be awarded progressively by end Aug'14. Columns ordered to M/s Fabtech on 03.07.14 (CDD: 02.07.15) Award recommendation issued for - Refrigeration package on 29.05.14: Being refloated. - Composite Works (Civil Strl. & Mechanical) on 03.07.14: Being refloated.
BPCL/EIL
Aug'14
2
I
E
Completion duration for NHT/ISOM (Revamp) Open Constn. / Mechanical completion of NHT/ISOM - Target Schedule : Projects 30.09.15; Only 15 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. 4 Physical Progress: Target Sch: 59.8% Catch Up Sch: 21.7 % Act: 20.9 %
Aug'14
I
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)
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU Constn completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, contract for 2 additional Structural works & 1 civil work under evaluation and likely to awarded by mid Aug'14. Additional 1 tender for offsite refinery area is under preparation. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the sub vendors against Performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and boost progress. - Contractors are facing problem in retaining the labour at site.Approx 5000 labours are available at site, though induction programme has been carried out for 15000 labours . requirement of manpower at site is approx 15000 nos. BPCL/EIL
As Required
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Meeting held with M/s B&R management on 06.08.14 at site and resources have been augmented. Constn. M/s B&R has been asked to expedite completion of balance area by end Aug'14 by augmenting additional dumpers. - Retaining wall in progress. B&R agreed to complete wall by 31.08.14 for which front is available and balance shall be completed by 30.09.14. B&R shall mobilize shuttering materials & manpower accordingly to meet above targets. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 952 nos piles completed against front of 1150 nos at site by M/s MBEL. Release of balance piling front at site progressively by mid Aug'14.Total nos of BPCL/EIL piles is 1800 nos piles - Next Management review meeting with M/s B&R planned on 06.08.14.
Aug'14
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
-Management review meeting held on 06.08.14 at site. M/s SEPC has been informed that their Constr. performance to be evaluated for next one month, additional agency to be lined to supplement progress (if required). -Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be EIL/BPCL increased). -Manpower shall be increased to 400 nos. from present 135 nos. 50 nos being planned to mobilise from 30.08.14. - Tech Structure A targeted to complete by 13.08.14. -Part Civil Work in FCCU offloaded to M/s Tauman. M/s Tuaman started mobilising. Additional 2 nos Strl. work contract being lined up to offload above contracts (if required). Award recommendation issued on 25.07.14. For other structural contract 5 nos bids received on 08.07.14.
As Required
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Schedule ( Y / N)
Const
EIL Cost (Y / N)
Backlog 26.1 (% wrt target sch) as of 15-Jul-14 in Open 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 - 28M; Remaining Duration - 18 M Desc. Catch Up sch: Const Sch Front Act Overall 23.9 49.4 48.6 23.3 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, 7 VGO/DHDT & Offsite).
Risk Owner
Status (Open / Close)
Risk Id E
Key Risk Description
Job No.: A307 Jul'14 Page 720+15 of 34
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Very High
Action Plan
Action By
Target Date
Risk Severity
I Area availability for SRU Block - At present only 91 % area given to M/s MBEL, balance Site for SRU block shall be available by end Aug'14. (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 Proj. / Constn.
Very High
Front for balance piling 918 nos will released progressively E 14 upto end Jul'14 on completion of site grading by M/s B&R.
I Slow Construction progress for Civil Works by M/s Shriram EPC Contr. Sch: 59.9%; Front: 92.7% Act: 21.7 % CCD: 24.12.14 ECD: Oct'15
E 41
Open Project
Very High
I
Output Quality ( Y / N)
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)
Urgency (Long Term / Short term)
Schedule ( Y / N)
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
-Management level meeting held on 08.08.14 at site. Order has been placed for all bought out items. Projects - Structural steel: Out of 935 MT, 677 MT ordered, 437 MT received. 67 MT expected to receive by 17.08.14. - Blasting and painting at Coimbatore is in completion stage. - Fabrication for 6 panels out of 30 panels for radiant section completed, balance 20 panels under BPCL/EIL dispatch and targeted progressively by 20.08.14. - All radiant coils have been ordered to M/s Tubocex Spain. - Structural erection work agreed to start by 16.08.14. - In view of slow progress by M/s Petron, separate tender is ready & Project team visited at M/s Petron’s workshop in Coimbatore from 07.08.14 to 08.08.14, visit report submitted to BPCL on 09.08.14. BPCL decision awaited.
Open Constructi Very High on
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
Management level Meeting held with M/s KSSIIPL on 07.08.14 at site. BPCL / EIL - M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 82 nos deployed only. - KSS to expedite cable trench work. -Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-05 nos bids received on 08.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - Award recommendation issued on 06.08.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
Aug'14
Open Constructi Very High on
Y
N
Y
N
Short term
I
0.6
0.57
0.38
0.19
Management level meeting held on 07.08.14 at site. -Manpower: As on date only 110 Nos against the requirement of 300 Nos reported to site. MBEL committed to increase manpower upto 220 nos by 21.08.14. - TMT bars: 40 MT targeted to receive at site by 18.08.14. - In view of slow progress and delay in release of construction front to mechanical contractor, new tender under preparation and likely to be awarded by Sep'14.
Aug'14
Open Project
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) Very High
Risk Owner
EIL Cost (Y / N)
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: Sch: 74.7 % Act: 13.9 %
Status (Open / Close)
Risk Id
Key Risk Description
Job No.: A307 Jul'14 Page 721+15 of 34
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
E 43
Action Plan
Action By
Target Date
Risk Severity
As Required
I Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 E 48 Civil & Strl work-offsite DHDS Area Sch:68.5%; Front: 71.9%; Act: 11.2%
I
E 51
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:52.7%; Front: 67.9%; Act: 11.7% CCD: 25.01.15 ECD: Oct'15
BPCL / EIL
I
Job No.: A307 JUN'14 Page 722 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award of Gas Booster Compressor for CPP (Dly: 13 M FOB / 14 M FOT)) 70 (LAD:29.12.13; Ant: 11.07.14)
Open
Project
Award recommendation issued on 27.05.14. Award expected by 11.07.14. BPCL has recommended to negotiate with BHEL on the reduction in delivery time by 2 months.
BPCL
11-Jul-14
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 71 Ant: 25.07.14
Open
Project
-TBA issued on 10.06.14, PBO recommendation issued on 23.06.14. Award recommendation targeted by 10.07.14
Projects / C&P/BPCL
10-Jul-14
Open
Project
New MR (MR-3415) issued covering all critical valves along with all critical valves of MR-3211 floated. Bids due on 21.07.14.
Engg.
21-Jul-14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
II
C
II Ordering of Critical Valves Sch: 11.07.14 Ant: 20.08.14 C
73
Open
Project
- 04 bids received on 02.04.14. PBO recommendation issued on 16.05.14. Price bids BPCL/EIL opened on 17.06.14. Award recommendation targeted by 04.07.14.
4-Jul-14
C
Award of Composite Works ( Civil /Strl. Works & Mechanical) for NHT/ISOM Sch: 08.05.14 76 Ant: 15.07.14
Open
Project
- Award recommendation issued on 01.07.14. BPCL to order.
15-Jul-14
C
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) Sch:27.06.14 77 Ant: 15.07.14
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 50.78 % Act: 37.58 % Construction Progress: Sch: 23.0 % Front: 85.0% Act: 9.3 %
Open
Project
- 90 % model review & HAZOP review completed. - All R&R foundation along with TSS foundation completed. Handing over of TSS fdn Projects targeted by 08.07.14. Strl. Steel fabrication for R&R along with TSS: 3600 MT out of 3803 MT completed. Constn Strl. Steel erection for R&R- 645 MT out of 2300 (2300 MT for R&R & for TSS 1300 MT) MT erection completed. Flue gas, ESP & Stack fdn etc: Strl. material is ready for dispatch for flue gas cooler. Foundation work to be expedited. Strl. Steel erection for TSS - Work yet to be commence. Additional resource for assembly of modules, simultaneous erections of structures and delivery of cyclones to be expedited. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up.
II
II BPCL
II
D
1
Progressively upto Aug'14
BPCL
I
D
Open
Project
- Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). 3685 MT out of 3747 MT Project Plates received at Chakan Shop, plate cutting & welding in progress. - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority to be assigned to main fractionator (IF-V-104). Taken up with M/s Fabtech. - Progress of works is affected due to delay in handing over of fabrication yards and completion of approach roach upto fabrication yard, which affected shifting of sections.
As stated
7
Completion of all three site Fabricated Columns for FCCU (M/s Fabtech) LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 65.5 % Act: 43.1 %
Open
Project
-M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. -Coke Drum (4 nos) & Main Fractionator : Subordered on M/s VTV (for site fabricated works). SS Clad (2231 MT) plates received at VTV shop. All fabrication yard area released. Approach road cleared on 09.06.14. Site fabrication to start. Mobilisation of 2000 MT crane targeted in Jan'15 and erection to be targeted from Mar'15 to May'15. - Strl. Fabr.: 169 MT out of 3560 MT completed. Sch for strl. erection is from 04.08.14 BPCL/EIL to 16.07.15. Strl. Fabrication Site to be visited in 1st week of Jul'14 and accordingly to review the performance and take decision for offloading (if required). - Manpower to be increased from present 227 to 505 for Civil work.
Jul'14
9
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 44.5 %; Act: 34.21 % Construction Progress: Sch: 24.2 % Front: 92.2 % Act: 16.6 %
II
D
I
D
Delay in erection of Crude & vacuum column due to Open delayed ordering. Sch: Jun 14 CCD: 21.08.14 Ant: Oct 14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV progress Sch ( 96.9 %); Act (84.9%)
BPCL / Director level meeting held with M/s VTV. Constn. / VTV Oct'14 Projects / - Due to weld crack in all 4 nos bottom shell likely to be delayed by 2 month w.r.t CDD. / Projects Const. Revised target for erection and hydrotesting of column to be finalised after resolution of welding crack issue. - Erection of Vacuum Column targeted from 06.08.14 to 28.08.14 & hydrotest planned in Sept'14. -1000 MT Crane : Load test completed and is ready for use. -500 MT Crane : Load test completed and is ready for use.
II
Job No.: A307 JUN'14 Page 723 of 749
Integrated Refinery Expansion Project, Kochi
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15 D
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Projects
19
Action Plan
Action By
Target Date
Risk Severity
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held on 26.05.14 with BHEL & GENP along with EIL & BPCL at site. BHEL has committed to deliver within CDD and agreed to prepare micro schedule for completion within CDD after receipt of casing at BHEL shop. 90% model review completed.. Hazop review completed on 19.06.14.
II Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
E
Open
Constn.
- During the project review meeting following points discussed and BPCL agreed: BPCL - Balance 16 nos units in the township to be handed over for grading by M/s Ray (SGIII). - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material. -Part of PEB1 new ware house handed over for material storage total warehouse handover after completion of work by Jul'14.
2
Jul'14
I
E
3
Delay in completion of rock blasting affecting release of construction front for VGO & offsite area as hard rock encountered.
Open
Constn.
- M/s Mcnally to mobilise adequate resources & expedite rock breaking in VGO area. Engg./Constn.13-Jul-14 - Commitment made by Mcnally to complete balance blasting work by 31.07.14
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 51.6% Catch Up Sch: 18.1 % Act: 17.8 %
Open
Constn. / Projects
- All long delivery equipments (incl.compressors) to be awarded progressively by mid BPCL/EIL Jul'14. Reactor ordered on M/s Phills Heavy (CDD: 21.12.14) - Award recommendation issued for Columns on 05.06.14. Health check compressor (BHEL make) on 05.06.14 New Compressor on 23.06.14 Refrigeration package on 29.05.14 - Composite Works (Civil Strl. & Mechanical) : Award recommendation targeted by 04.07.14.
Jul'14
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch:73.8 % Front: 100 % Act:43% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Front available for all 11 buildings . Constn - MCR area, CPP control room area : MCR foundation completed and grade slab part 1 out of 3 completed. SS-10 grade slab part 1 out of 3 nos completed. - Manpower being augmented to 700 nos from present 550 nos. - Engineering for Packages like HVAC and Pressurization & Ventilation system in progress - Clean agent system: Drawings awaited from L&T. - Casting of foundations up to first expansion joint in MCR to be expedited. Strl. dwg. for Roof structures for MCR, SRR & substation to be cleared. - Lifts: Orders placed, drawings received and under review.
As Required
Backlog 24.6 (% wrt target sch) as of 15-Jun-14 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 - 26M; Remaining Duration - 20 M Desc. Catch Up sch: Const Sch Front Act Overall 21.1 45.3 45.3 20.7 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Director level meeting held with contractors from May'14 to Jun'14. order to complete Constn the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, additional 1 tender for civil works already awarded (M/s Tuaman) and 2 additional civil & Strl works under tendering and likely to awarded by end Jul'14.. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the subvendors against performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and expedite progress. BPCL/EIL
As Required
Completion of piling work by M/s L&T (Piling-II): CDD- 08.05.14. (Total 12003 Nos piles). (Contr.Sch- 100%, Front-89.8%, Act-84.9%) Only 10 nos. hydraulic & 4 nos. conventional rigs are currently operational at site. Total 10124 nos completed out of 12003
Open
Constn.
II
E
4
I
E
6
II
E
7
I
E
9
L&T has completed nearly 10124 pile. Piling completed in Demountable flare area, Air Constr. compressor & DG shed area. Piling balance in Chitrapuzha area, Offsite Refinery area, new tender being prepared. Tender on sale from 30.06.14 to 21.07.14, bids due on 22.07.14.
Immediate
II
Job No.: A307 JUN'14 Page 724 of 749
Integrated Refinery Expansion Project, Kochi
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating)
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Overall Progress: Contr. Sch: 58.6 % Act: 36.7% Construction Progress: Sch: 55.6 % Front: 100 % Act: 31.7 % 13 Sch: 15.11.14 CCD: 24.03.15 ECD: Oct'15 Compl: 18 M+2M
Action Plan
Action By
Target Date
- Project review meeting held on 26.06.14 with M/s Triveni. Constr. -Balance engineering targeted to complete by 15.07.14 and complete ordering progressively by mid Jul'14. -M/s Triveni shall augment manpower by mobilizing 25 Nos carpenters along with adequate no of barvendors by 1st week of July 14 and take up chemical house construction work by 1st week of July 14. (Manpower required is 300 nos & Available manpower is 136 Nos). - Substation building: Foundation works commenced , completion to be targeted by Dec'14.
Jul'14
- Retaining wall in progress. Reservoir wall dismantling & grade slab dismantling completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 28.05.14. and resources have been augmented. M/s B&R agreed to complete SRU earth filling work by 15.07.14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 905 nos piles completed against front of 910 nos at site by M/s MBEL. Release of balance piling front at site progressively by end Jul'14.Total nos of piles is 1828 nos piles
Jul'14
Risk Severity
II
E
14
Area availability for SRU Block - At present only 85 % area given to M/s MBEL, balance Site for SRU block shall be available by end Jul'14. (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
Proj. / Constn.
Constn.
BPCL/EIL
Front for balance piling 918 nos will released progressively upto end Jul'14 on completion of site grading by M/s B&R.
I Delay in delivery of UG piping material Material required at site for Civil & strl contractor.
Open
Const.
E
22
Open
Project
E
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 (Ant. Compln26 May'14, Compl date Committed by B&R – 13.11.13)
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 27 Civil & Strl work-offsite IREP Area: Constr. Sch:90.5%; Front:73.0%; Act: 28% CCD: 08.10.14; ECD: Jun'15
Open
- Total 2 KM pipe under shortage (IS 3589 pipes of 32", 36", 44" & 48") ordered under BPCL FOA 592, 593, 652, 655 to be expedited. - Shortage quantity being addressed at higher level. Being continuously monitored by inspection team.
Jul'14
II BPCL / EIL
Jul'14
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Balance work to be expedited.
II
E
Constructio Meetings held with M/s KSSPPL on 12.06.14 M/s KSSIPL to deploy cumulative 200 BPCL / EIL n Manpower for Civil fdn work alone (Inside DHDS area) & 250 Manpower for Civil Fdn (IREP area) . As on date 83 and 112 nos deployed resp. Rock Blasting in IREP area being expedited & targeted to completed by 1st week of Jul'14. M/s Tuaman being deployed to supplement KSSPPL for trenches.
30-Jul-14
II Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 66.9%; Front: 69.5%; Act:24.6% CCD:18.12.14; ECD: Apr'15
E
Open
Project
-Meeting held M/s Essar on 12.06.14 at EIL HO. M/s Essar has been asked to deploy BPCL / EIL additional manpower and machinery to recover the backlog and submit catchup plan. Structural steel fabrication works: 490 MT received for GTG shed. 295MT fabrication completed. Release of balance AFC drawings for UG piping works, Earthing layout , precast works etc. to be expedited. - RCC drawings released 8522 Cum out of 9990 Cum & steel quantity released 1173 MT out of total 1262 MT.
15-Jul-14
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. 29 48.4% 42.3 % 14.6%
Open
Project
- During management review at Kolkata in 28.05.14, M/s B&R has committed site BPCL / EIL grading works for SRU block by 06.07.14. Balance front of 58 % will be released progressively by Aug'14 on completion of site grading by M/s B&R - Manpower for all works to be increased to 150 from present 60 nos. As on date the manpower is 123Nos against the requirement of 200Nos. 25Nos reported to site and shall join. - 1018/1450MT TMT steel received at site .Non availability of sections (16/28MM) of TMT still an area of concern . MBECL informed to place orders by mid Jul'14.
Continuous
Progress of ETP Works (Handing over of graded area for ETP & dismantling of existing Oil Catcher) LAD: 30.09.15 CCD:10.08.15 ECD: Dec'15 Overall progress: Sch: 39.1 % Act: 12.9 % Construction Progress: 34 Sch: 13.6 % Front: 20 % Act: 5.6 % Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Meeting held with with M/s Paramount on 15.05.14 Project Work commenced in substation (5 out of 42 fdns cast) and equalisation tank. - Area handing over for RL-7 to M/s Paramount targeted by 10.07.14. Engineering issues to be resolved for SBR/ACT area (relating to soil bore logs based on recent testing) targeted by 15.07.14. Based on above revised drawings to be targeted by end Jul'14. - 30 % model review targeted by mid Jul'14. -API, TPI Ex TPI area handing over targeted by 10.07.14. Chemical house & DAF (Dissolved air floatation) area already handed over. Works started in Chemical house area and sludge thickner area. Dismantling of under ground structures observed while carried out foundation works to be expedited.
As stated
Completion of works for Tankage-III (Crude Tanks) (M/s IOT Anwesha ) Sch: 27.02.15; CCD: 03.07.15 36 Duration: 20 M Sch: 5.0 % Front: 25 % Act: 4.8 %
Open
- Tank pad area handed over for 1 tank. Excavation for tank pad YT-26 completed - Area grading in progress for 2nd Crude tank and area to be handed over by Jul'14.
As stated
28
II
E
II
E
II
E
Project
Constr.
II
Job No.: A307 JUN'14 Page 725 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 CCD: 03.04.15 Ant: Oct'15 37 Overall Progress: Sch: 45.3 % Act: 8.33 %
Open
Project
-Parallel action being initiated to supplement the works of M/s Petron. Final decision shall be taken after reviewing the performance of M/s Petron for next 1 month, i.e upto mid Jul'14 based on milestones upto end Jun'14. - Radiant section fabrication drawings to be finalised across the table on fast track. - Vendor being pressurised to mobilised at site immediately. - Strl. Steel: Total 193 MT. Ordering targeted by mid Jul'14 progressively. To be followed up with M/s Petron.
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 39 Overall Progress: Sch: 11 % Act: 10 %
Open
Project
- Burner / reduction furnace data from Incinerator burner vendor required (M/s Projects/BPC As Required Callidus). Input expected to receive by end Aug'14. KOM planned with M/s Callidus on L 22.07.14. - Chamber (M/s Techno Process) & stack (M/s Loyd Steel) ordered on Indian Vendors, whereas order delivery is on FOB basis. -Vendor has submitted revised proposal on 17.06.14 for splitting of supply into offshore and onshore portion. Note for the same is under internal approval and targeted by 15.07.14.
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 ECD: Dec'15 Overall Progress: Sch: 68.26 % Act: 43.88% Construction Progress: Sch: 55.5 %; Front: 100%; Act:15.2 %
Open
Project
- Director level meeting held on 20.06.14 at EIL Delhi. Following points agreed: Projects - M/s Driplex has sub ordered piling works to local agency. Agency to mobilise resources and start work from Mid Jul'14 and complete by Sep'14 for substation area. - Completion of balance civil works including chemical house expected by Mar'15. - Driplex started foundation pedestals for RO shed and targeted to complete the same by mid Aug'14. The fabrication of structural steel for shed is also to be expedited and material receipt at site by Sep’14 for starting of erection work and completing the shed at the earliest. - 90 % model review targeted by mid Jul'14. Ordering of piping material after 90 % model review. - Ordering of steam turbine to be finalised.
As Required
Slow Construction progress for Civil Works by M/s Shiram EPC Contr. Sch: 52.7%; Front: 69.4% Act: 17.6 % CCD: 24.12.14 ECD: Oct'15
Open
Project
As Required
E
41
-Director review meeting held on 13.05.14 Constr. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including approx EIL/BPCL 50 nos in fabrication yard). Manpower as on 10.06.14 is 151 nos -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. 387MT progressively by 30.06.14. Required qty. of reinforcement still not available at site. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). 06 nos bids received on 24.06.14.
Open
Project
- Mobilisation work stated. -Parallel action being initiated to supplement the works of M/s Petron. Final decision shall be taken after reviewing the performance of M/s Petron for next 1 month, i.e upto mid Jul'14 based on milestones upto end Jun'14. - Shop fabrication work started. - Strl. Steel: 400 MT out of 800 MT ordered, balance ordering targeted by end Jul'14 progressively. To be followed up with M/s Petron.
Projects
As Required
E
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: 43 Sch: 51.6 % Act: 10.1 %
Slow Construction progress for Civil Works by M/s Mcnally Bharat for DHDT & VGO CCD: 10.01.15 ECD: 31.03.15 Sch: 70 %; Front :75 % Act: 34.6 %
Open
Project
-Director level meeting held with M/s MBEL on 28.05.14. M/s MBEL agreed: -Out of indent for procurement of 4200MT of structural steel, delivery of 30MT is balance. -Balance 1480 bolts are expected at site by 15.06.14 -Strl. detailing: 5035MT out of 5630MT completed, balance by end Jul'14. - During meeting dated 28.05.14 M/s MBEL agreed to increase manpower from 320 nos to 400 nos, however at present only 320 nos have been augmented.
Constr
As Required
Completion of PreEngineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open
Project
Work under progress by M/s B&R. 85 % work completed balance targeted by mid Jul'14 for PEB1. PEB 2 structural work in progress. Buildings to be expedited for storage of material / equipment being received at site.
Constr
As Required
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 47 Civil & Strl work-offsite DHDS Area Sch:60.7%; Front: 71.9%; Act: 8.4%
Open
Constructio Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 n Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)Tender on sale from 13 06.14, BDD- 07.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - NIT issued on 12.06.14, bids due on 04.07.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
BPCL / EIL
7-Jul-14
E
Project
Target Date
Risk Severity
As Required
II
E
II
E
40
II
I
BPCL/EIL
I
E
44
II
E
44
II
E
I
Job No.: A307 JUN'14 Page 726 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By BPCL / EIL
Target Date
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15
Open
Constructio -KOM held on 21.04.14. Meeting held with M/s Petron on 06.06.14. Due to delay in n mobilisation and financial crunch. It has been decided to float parallel tender for composite works to supplement progress of composite works and decision to be taken based on performance upto mid Jul'14. - Fabrication shed work under construction and targeted to complete by mid Jul'14. - 70 MT and 273 MT crane under mobilisation.
Delay in mobilisation and start of work by M/s B&R for Composite Works-DCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15
Open
Constructio KOM held on 08.04.14. Mobilisation work initiated by M/s B&R. BPCL / EIL n - Fabrication yard work under progress. B&R is arranging crane to commence erection of Eqpts. from July'14 onwards. Already 3 month has past, work not started at site.
Jul'14
Slow construction progress for Civil & Strl work for Refinery area (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:45.9%; Front: 58.3%; Act: 9.7% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 28.05.14. n -MBECL informed that manpower available at site is 49 nos and assured to augment manpower by 100 nos. by 10.06.2014, however as on date only 64 Nos against the requirement of 200 Nos reported to site. - Anchor bolts being expedited (as on date 1189/3438Nos available at site). - Strl. Detailing: Detailing for 3129MT completed against the AFC drawing release of 5785MT.(Scope :6010MT). Balance detailing to be completed by 05.07.2014.
BPCL / EIL
Jul'14
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: 15.02.15 Sch: 95.68% Front: 95.59 % Act: 63.12 %
Open
Constructio - Management level meeting held on 13.05.14, M/s L&T to augment manpower and n additional machineries for completion of balance works to generate front to mechanical contractor.
BPCL / EIL
Jul'14
Variation in foreign exchange rates from Rs 50 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 (additionals in scope) has significantly impacted on the overall project cost.
Open
EIL/BPCL
Jul'14
Risk Severity
15-Jul-14
48
II
E
49
II
E
50
II
E
55
II
M
3
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
II
Job No.: A307 JUN'14 Page 727 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Award of Gas Booster Compressor for CPP (Dly: 13 M FOB / 14 M FOT)) 70 (LAD:29.12.13; Ant: 11.07.14)
Open
Project
Award recommendation issued on 27.05.14. Award expected by 11.07.14. BPCL has recommended to negotiate with BHEL on the reduction in delivery time by 2 months.
BPCL
11-Jul-14
Award of Slurry Filter (MR- 4880) for FCCU unit and existing refinery. (Dely: 10 M FOB) LAD:09.05.13 71 Ant: 25.07.14
Open
Project
-TBA issued on 10.06.14, PBO recommendation issued on 23.06.14. BPCL to provide PBO approval. Award recommendation targeted by 10.07.14
Projects / C&P/BPCL
10-Jul-14
Award of Fuel forwarding Pumps (08 nos) for GTG (Dely: 6 M FOB / 7 M FOT) Sch:27.06.14 77 Ant: 15.07.14
Open
Project
- Award recommendation issued on 01.07.14. BPCL to order.
BPCL
15-Jul-14
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 50.78 % Act: 37.58 % Construction Progress: Sch: 23.0 % Front: 85.0% Act: 9.3 %
Open
Project
- Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. - Handing over of TSS fdn targeted by 08.07.14.
Projects
Progressively upto Aug'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
C
Key Risk Description
Action Plan
Action By
Target Date
Risk Severity
II
C
II
C
II
D
Constn Flue gas, ESP & Stack fdn etc: Strl. material is ready for dispatch for flue gas cooler. Foundation work to be expedited. Strl. Steel erection for TSS - Work yet to be commence. Additional resource for assembly of modules, simultaneous erections of structures and delivery of cyclones to be expedited.
1
BPCL
I
D
7
Completion of all three site Fabricated Columns for FCCU (M/s Fabtech) LAD: 22.01.15 CCD:14.01.15 ECD: 15.05.15 Overall progress: Sch: 65.5 % Act: 43.1 %
Open
Project
- Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). 3685 MT out of 3747 MT Project Plates received at Chakan Shop, plate cutting & welding in progress. - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority to be assigned to main fractionator (IF-V-104). Taken up with M/s Fabtech. - Progress of works is affected due to delay in handing over of fabrication yards and completion of approach roach upto fabrication yard, which affected shifting of sections.
As stated
BPCL II
D
D
D
D
9
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 44.5 %; Act: 34.21 % Construction Progress: Sch: 24.2 % Front: 92.2 % Act: 16.6 %
Open
Project
-M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. -Coke Drum (4 nos) & Main Fractionator : Subordered on M/s VTV (for site fabricated works). SS Clad (2231 MT) plates received at VTV shop. All fabrication yard area released. Approach road cleared on 09.06.14. Site fabrication to start. Mobilisation of 2000 MT crane targeted in Jan'15 and erection to be targeted from Mar'15 to May'15. - Strl. Fabr.: 169 MT out of 3560 MT completed. Sch for strl. erection is from 04.08.14 BPCL/EIL to 16.07.15. Strl. Fabrication Site to be visited in 1st week of Jul'14 and accordingly to review the performance and take decision for offloading (if required). - Manpower to be increased from present 227 to 505 for Civil work.
Jul'14
Delay by vendor with respect to CDD due to slow progress of manufacturing works and financial constraint.
Open
Projects
- Following bidders showing slow manufacturing progress: M/s Arjun Technologies EIL/ BPCL (Pressure Vessel supplier): FOA No.: 133, 144 & 184. M/s Reynold Chem. (Heat Exchangers): FOA No.: 116, 189 M/s Bharat Pumps & Compressors (Pumps): FOA No.: 230, 311 & 444. Continuous expediting being made by visiting vendor workshop for all critical orders in respective regions.
Jul'14
I 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
- M/s Filtrex asking for deviations on commercial terms. Meeting being called on 08.07.14 to resolve the issues with M/s Filtrex.
EIL/ BPCL
Jul'14
III
Non acceptance of work order by M/s Flowserve for DHDT Centrifugal pumps Ordered on 30.01.14 to M/s Flowserve (MR-5403)
Open
Projects
- Order not accepted by vendor. Meeting with vendor held on 17.06.14.
EIL/ BPCL
Jul'14
III
29
30
31
Job No.: A307 JUN'14 Page 728 of 749
Integrated Refinery Expansion Project, Kochi
Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
E
Open
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Constn.
- During the project review meeting following points discussed and BPCL agreed: BPCL - Balance 16 nos units in the township to be handed over for grading by M/s Ray (SGIII). - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material. -Part of PEB1 new ware house handed over for material storage total warehouse handover after completion of work by Jul'14.
Jul'14
2
Risk Severity
I
E
4
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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: 51.6% Catch Up Sch: 18.1 % Act: 17.8 %
Open
Constn. / Projects
- All long delivery equipments (incl.compressors) to be awarded progressively by mid BPCL/EIL Jul'14. Reactor ordered on M/s Phills Heavy (CDD: 21.12.14) - Award recommendation issued for Health check compressor (BHEL make) on 05.06.14 New Compressor on 23.06.14 Refrigeration package on 29.05.14 Composite Works (Civil Strl. & Mechanical) on 03.07.14.
Jul'14
Backlog 24.6 (% wrt target sch) as of 15-Jun-14 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 - 26M; Remaining Duration - 20 M Desc. Catch Up sch: Const Sch Front Act Overall 21.1 45.3 45.3 20.7 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Director level meeting held with contractors from May'14 to Jun'14. order to complete Constn the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, additional 1 tender for civil works already awarded (M/s Tuaman) and 2 additional civil & Strl works under tendering and likely to awarded by end Jul'14. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the subvendors against performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and expedite progress. BPCL/EIL
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 Mar'15)
Open
Constn.
Area availability for SRU Block - At present only 85 % area given to M/s MBEL, balance Site for SRU block shall be available by end Jul'14. (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
I
E
E
E
7
8
Proj. / Constn.
Demountable flare awarded to M/s Airoil on 25.09.13. Commissioning targeted by Mar'15.
BPCL
- Retaining wall in progress. Reservoir wall dismantling & grade slab dismantling completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 28.05.14. and resources have been augmented. M/s B&R agreed to complete SRU earth filling work and targeted by 15.07.14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 905 nos piles completed against front of 910 nos at site by M/s MBEL. Release of balance piling front at site progressively by end Jul'14.Total nos of piles is 1828 nos piles
Constn.
Mar'15
I IV
Jul'14
BPCL/EIL
14 Front for balance piling 918 nos will released progressively upto end Jul'14 on completion of site grading by M/s B&R.
I
E
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 (Ant. Compln26 May'14, Compl date Committed by B&R – 13.11.13)
Open
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 27 Civil & Strl work-offsite IREP Area: Constr. Sch:90.5%; Front:73.0%; Act: 28% CCD: 08.10.14; ECD: Jun'15
Open
Project
BPCL / EIL
Jul'14
Culvert part I covering 8 m out of 13 m completed, rerouting of existing KWA drinking water supply line completed. Balance work to be expedited.
II
E
Constructio Meetings held with M/s KSSPPL on 12.06.14 M/s KSSIPL to deploy cumulative 200 BPCL / EIL n Manpower for Civil fdn work alone (Inside DHDS area) & 250 Manpower for Civil Fdn (IREP area) . As on date 83 and 112 nos deployed resp. Rock Blasting in IREP area being expedited & targeted to completed by 1st week of Jul'14. M/s Tuaman being deployed to supplement KSSPPL for trenches.
30-Jul-14
II Slow progress of M/s Essar civil & Strl. work for CPP Contr. Sch: 66.9%; Front: 69.5%; Act:24.6% CCD:18.12.14; ECD: Apr'15
E
28
Open
Project
-Meeting held M/s Essar on 12.06.14 at EIL HO. M/s Essar has been asked to deploy BPCL / EIL additional manpower and machinery to recover the backlog and submit catchup plan. Structural steel fabrication works: 490 MT received for GTG shed. 295MT fabrication completed. Release of balance AFC drawings for UG piping works, Earthing layout , precast works etc. to be expedited. - RCC drawings released 8522 Cum out of 9990 Cum & steel quantity released 1173 MT out of total 1262 MT.
15-Jul-14
II
Job No.: A307 JUN'14 Page 729 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
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 29 SCH. FRONT. ACT. 48.4% 42.3 % 14.6%
Open
Project
Slow Construction progress for Civil Works by M/s Shiram EPC Contr. Sch: 52.7%; Front: 69.4% Act: 17.6 % CCD: 24.12.14 ECD: Oct'15
Open
E
41
Open
E
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: 43 Sch: 51.6 % Act: 10.1 %
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 47 Civil & Strl work-offsite DHDS Area Sch:60.7%; Front: 71.9%; Act: 8.4%
Open
Constructio Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 n Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)Tender on sale from 13 06.14, BDD- 07.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - NIT issued on 12.06.14, bids due on 04.07.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
BPCL / EIL
7-Jul-14
Slow mobilisation by M/s Petron for Composite Works-FCCU Awarded to M/s Petron on 26.02.14 CCD: 25.10.15
Open
Constructio -KOM held on 21.04.14. Meeting held with M/s Petron on 06.06.14. Due to delay in n mobilisation and financial crunch. It has been decided to float parallel tender for composite works to supplement progress of composite works and decision to be taken based on performance upto mid Jul'14. - Fabrication shed work under construction and targeted to complete by mid Jul'14. - 70 MT and 273 MT crane under mobilisation.
BPCL / EIL
15-Jul-14
Delay in mobilisation and start of work by M/s B&R for Composite Works-DCU Awarded to M/s B&R on 12.03.14 CCD: 11.11.15
Open
Constructio KOM held on 08.04.14. Mobilisation work initiated by M/s B&R. BPCL / EIL n - Fabrication yard work under progress. B&R is arranging crane to commence erection of Eqpts. from July'14 onwards. Already 3 month has past, work not started at site.
Jul'14
Slow construction progress for Civil & Strl work for Refinery area (awarded to M/s Mcnally Bharat on 26.09.13.) Sch:45.9%; Front: 58.3%; Act: 9.7% CCD: 25.01.15 ECD: Oct'15
Open
Constructio Management level meeting held on 28.05.14. n -MBECL informed that manpower available at site is 49 nos and assured to augment manpower by 100 nos. by 10.06.2014, however as on date only 64 Nos against the requirement of 200 Nos reported to site. - Anchor bolts being expedited (as on date 1189/3438Nos available at site). - Strl. Detailing: Detailing for 3129MT completed against the AFC drawing release of 5785MT.(Scope :6010MT). Balance detailing to be completed by 05.07.2014.
BPCL / EIL
Jul'14
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: 15.02.15 Sch: 95.68% Front: 95.59 % Act: 63.12 %
Open
Constructio - Management level meeting held on 13.05.14, M/s L&T to augment manpower and n additional machineries for completion of balance works to generate front to mechanical contractor.
BPCL / EIL
Jul'14
Risk Id
Status (Open / Close)
RISKS REQUIRING BPCL ATTENTION
E
Key Risk Description
Action Plan
Action By
Target Date
- During management review at Kolkata in 28.05.14, M/s B&R has committed site BPCL / EIL grading works for SRU block by 06.07.14. Balance front of 58 % will be released progressively by Aug'14 on completion of site grading by M/s B&R - Manpower for all works to be increased to 150 from present 60 nos. As on date the manpower is 123Nos against the requirement of 200Nos. 25Nos reported to site and shall join. - 1018/1450MT TMT steel received at site .Non availability of sections (16/28MM) of TMT still an area of concern . MBECL informed to place orders by mid Jul'14.
Continuous
Project
-Director review meeting held on 13.05.14 Constr. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including approx EIL/BPCL 50 nos in fabrication yard). Manpower as on 10.06.14 is 151 nos -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. 387MT progressively by 30.06.14. Required qty. of reinforcement still not available at site. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). 06 nos bids received on 24.06.14.
As Required
Project
- Mobilisation commenced. -Parallel action being initiated to supplement the works of M/s Petron. Final decision shall be taken after reviewing the performance of M/s Petron for next 1 month, i.e upto mid Jul'14 based on milestones upto end Jun'14. - Shop fabrication work started. - Strl. Steel: 400 MT out of 800 MT ordered, balance ordering targeted by end Jul'14 progressively. To be followed up with M/s Petron.
As Required
Risk Severity
II
I Projects
BPCL/EIL
I
E
I
E
48
II
E
49
II
E
50
II
E
55
II
Job No.: A307 JUN'14 Page 730 of 749
Integrated Refinery Expansion Project, Kochi
Start of work for Tankage-IV by M/s Offshore Awarded on 17.04.14 CCD: 16.01.16 E
E
E
F
F
58
1
3
G
2
Target Date
Risk Severity
Constructio - Management level meeting held on 28.05.14 with M/s B&R at KolKata. n Agency being asked to start work immediately.
BPCL / EIL
Jul'14
III
Open
Constructio - Management level meeting held on 28.05.14 with M/s B&R at KolKata. n M/s B&R agreed to increase manpower from 90 nos to 150 nos. Agency being asked to start work immediately.
BPCL / EIL
Jul'14
III
Start of work for SRU Tankage works (Ordered to M/s Tuaman on19.02.14 CCD:18.06.15
Open
Constructio - Agency has been pressurised to mobilise resources and start work. n - Tank pads to be handed over from Aug'14 onwards.
BPCL / EIL
Jul'14
III
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project : Works to be awarded by BPCL
Open
Projects
BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015.
BPCL
1-Jun-15
III
Timely Commissioning of UB package to meet refinery commissioning schedule. Contr. Sch: 42.9%; Act: 34.1% LAD : 31.03.15 (UB 1) 30.06.15 (UB 2)
Open
Constn.
-Strict monitoring required at all stages till award of UB Tender and further during execution. -Completeness of supply of all subparts, their assembly and other BOP Items to be ensured. - Special attention to be given to multi flue chimney.
Constn. / Projects / BPCL
as scheduled
IV
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 for 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.
As Required
IV
Implementation of environmental clearance conditions by EIL (received from MoEF vide Letter dated 22.11.12)
M
Action By
Open
Slow progress for Tankage-I by M/s B&R Awarded on 07.06.13 CCD: 06.04.15 57 ECD:Aug'15 Sch: 70.6 % Front: 100 % Act: 27.9 %
1
K
Action Plan
56
G
G
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Projects
- 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. Projects (e.g. configuration for CPP) - Incorporation of EC and RRA recommendations in balance systems under progress.
As required
IV
III
7
Non availability of Skilled workers
Open
Const.
-Utilisation of migrant labour and skilled labour from outside the state needs to be Constn / encouraged. However, the same will be effective only if proper labour colony facilities BPCL are arranged by the contractors. - Slow down in progress of work by Union workmen, inspite of assurance of trade union leaders that workers shall be instructed to improve productivity.
As Required
Variation in foreign exchange rates from Rs 50 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 (additionals in scope) has significantly impacted on the overall project cost.
Open
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
Jul'14
2
3
Constn. / Projects / BPCL
EIL/BPCL
II
Job No.: A307 Jun'14 Page 731+15 of 38
Y
Y
N
Open
Project
Very High
Y
Y
Y
N
Very High
Y
N
Y
Y
(Current risk Score Previous Risk score)
Y
Previous Risk Score
Very High
Current Risk Score -> {5}* {12}
Project
Impact Score => {6+7+8+9} * 10 * 11
Open
I
0.9
0.86
0.43
0.43
- 90 % model review & HAZOP review completed. - All R&R foundation along with TSS foundation completed. Handing over of TSS Projects fdn targeted by 08.07.14. Strl. Steel fabrication for R&R along with TSS: 3600 MT out of 3803 MT Constn completed. Strl. Steel erection for R&R- 645 MT out of 2300 (2300 MT for R&R & for TSS 1300 MT) MT erection completed. Flue gas, ESP & Stack fdn etc: Strl. material is ready for dispatch for flue gas cooler. Foundation work to be expedited. Strl. Steel erection for TSS - Work yet to be commence. Additional resource for assembly of modules, simultaneous erections of structures and delivery of cyclones to be expedited. Area for storage of fabricated materials to be identified and allocated. Already discussed during director level meeting dated 26.06.14. Issues being followed up. BPCL
Progressively upto Aug'14
Short term
I
0.9
0.86
0.86
0.00
-M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. -Coke Drum (4 nos) & Main Fractionator : Subordered on M/s VTV (for site fabricated works). SS Clad (2231 MT) plates received at VTV shop. All fabrication yard area released. Approach road cleared on 09.06.14. Site fabrication to start. Mobilisation of 2000 MT crane targeted in Jan'15 and erection to be targeted from Mar'15 to May'15. BPCL/EIL - Strl. Fabr.: 169 MT out of 3560 MT completed. Sch for strl. erection is from 04.08.14 to 16.07.15. Strl. Fabrication Site to be visited in 1st week of Jul'14 and accordingly to review the performance and take decision for offloading (if required). - Manpower to be increased from present 227 to 505 for Civil work.
Jul'14
Short term
I
0.7
0.67
0.16
0.51
- During the project review meeting following points discussed and BPCL agreed: BPCL - Balance 16 nos units in the township to be handed over for grading by M/s Ray (SG-III). - FACT area to be arranged for storage of materials of owner and package contractors. - Alternatively, BPCL to take land on lease (300m X 200m) for storage of Material. -Part of PEB1 new ware house handed over for material storage total warehouse handover after completion of work by Jul'14.
Jul'14
Urgency (Long Term / Short term)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Output Quality ( Y / N)
D
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: Mar'16 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Overall Progress: Cum. Sch. 44.5 %; Act: 34.21 % Construction Progress: 9 Sch: 24.2 % Front: 92.2 % Act: 16.6 %
Schedule ( Y / N)
1
EIL Cost (Y / N)
D
Risk Owner
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 CCD: 09.10.15 Ant: Mar'16 (Upto pre commissioning) Overall Progress: Sch: 50.78 % Act: 37.58 % Construction Progress: Sch: 23.0 % Front: 85.0% Act: 9.3 %
Status (Open / Close)
Risk Id
Key Risk Description
Controllability Condition (D/I )
IV - RISK REGISTER
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Short term
Action Plan
Action By
Target Date
Risk Severity
I
I Space constraints: i) Area for Storage of materials for project and package contractors ii) Area for Spool storage
E
2
Open
Constn.
I
Job No.: A307 Jun'14 Page 732+15 of 38
IV - RISK REGISTER
Output Quality ( Y / N)
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
N
Short term
I
0.9
0.86
0.86
0.00
- All long delivery equipments (incl.compressors) to be awarded progressively by BPCL/EIL mid Jul'14. Reactor ordered on M/s Phills Heavy (CDD: 21.12.14) - Award recommendation issued for Columns on 05.06.14. Health check compressor (BHEL make) on 05.06.14 New Compressor on 23.06.14 Refrigeration package on 29.05.14 - Composite Works (Civil Strl. & Mechanical) : Award recommendation targeted by 04.07.14.
Jul'14
E
Backlog 24.6 (% wrt target sch) as of 15-Jun-14 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 - 26M; Remaining Duration - 20 M Desc. Catch Up sch: Const Sch Front Act Overall 21.1 45.3 45.3 20.7 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, 7 VGO/DHDT & Offsite).
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Director level meeting held with contractors from May'14 to Jun'14. order to Constn complete the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - In order to supplement progress by failing civil contractor, additional 1 tender for civil works already awarded (M/s Tuaman) and 2 additional civil & Strl works under tendering and likely to awarded by end Jul'14.. - To provide financial assistance to Contractors for procurement of Reinforcement steel & Cement: During review meeting dated 26.06.14, it has been decided that payment to be released to the subvendors against performa invoice submitted by contractor. BPCL to review and approve the same for maintaining the cash flow and expedite progress. BPCL/EIL
As Required
Y
N
Y
N
Short term
I
0.6
0.57
0.57
0.00
- Retaining wall in progress. Reservoir wall dismantling & grade slab dismantling Constn. completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 28.05.14. and resources have been augmented. M/s B&R agreed to complete SRU earth filling work by 15.07.14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 905 nos piles completed against front of 910 nos at site by M/s MBEL. Release of balance piling front at site progressively by end Jul'14.Total nos of piles is 1828 nos piles BPCL/EIL
Jul'14
Urgency (Long Term / Short term)
Schedule ( Y / N)
Y
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) Y
Risk Owner
Very High
Key Risk Description
Status (Open / Close)
Completion duration for NHT/ISOM (Revamp) Open Constn. / Mechanical completion of NHT/ISOM - Target Schedule : Projects 30.09.15; Only 15 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. 4 Physical Progress: Target Sch: 51.6% Catch Up Sch: 18.1 % Act: 17.8 %
Risk Id
EIL Cost (Y / N)
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
I
E
Open
Const
I Area availability for SRU Block - At present only 85 % area given to M/s MBEL, balance Site for SRU block shall be available by end Jul'14. (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 Proj. / Constn.
Very High
Front for balance piling 918 nos will released progressively E 14 upto end Jul'14 on completion of site grading by M/s B&R.
I
Job No.: A307 Jun'14 Page 733+15 of 38
IV - RISK REGISTER
Output Quality ( Y / N)
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
N
Short term
I
0.7
0.67
0.67
0.00
-Director review meeting held on 13.05.14 Constr. Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including EIL/BPCL approx 50 nos in fabrication yard). Manpower as on 10.06.14 is 151 nos -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. 387MT progressively by 30.06.14. Required qty. of reinforcement still not available at site. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). 06 nos bids received on 24.06.14.
As Required
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15 Ant: Dec'15 Overall Progress: E 43 Sch: 51.6 % Act: 10.1 %
Open Project
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.48
0.09
- Mobilisation work stated. -Parallel action being initiated to supplement the works of M/s Petron. Final decision shall be taken after reviewing the performance of M/s Petron for next 1 month, i.e upto mid Jul'14 based on milestones upto end Jun'14. - Shop fabrication work started. - Strl. Steel: 400 MT out of 800 MT ordered, balance ordering targeted by end Jul'14 progressively. To be followed up with M/s Petron.
Projects
As Required
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13 CDD: 24.01.15 ECD:. Dec'15 E 48 Civil & Strl work-offsite DHDS Area Sch:60.7%; Front: 71.9%; Act: 8.4%
Open Constructi Very High on
Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-Tender on sale from 13 06.14, BDD- 07.07.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - NIT issued on 12.06.14, bids due on 04.07.14. - Scope of Civil Work in areas 204 - 207 handed over to SG-III Contractor.
BPCL / EIL
Urgency (Long Term / Short term)
Schedule ( Y / N)
Y
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N) N
Slow Construction progress for Civil Works by M/s Shiram EPC Contr. Sch: 52.7%; Front: 69.4% Act: 17.6 % CCD: 24.12.14 ECD: Oct'15
Risk Owner
Very High
Key Risk Description
Status (Open / Close)
Open Project
Risk Id
EIL Cost (Y / N)
Kochi Refinery, BPCL Integrated Refinery Expansion Project
E 41
Action Plan
Action By
Target Date
Risk Severity
I
BPCL/EIL
I Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
7-Jul-14
I
Job No.: A307 MAY'14 Page 734 of 749
Integrated Refinery Expansion Project, Kochi
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 30.05.14 (Incinerator burner) 55 (Execution Duration - 14 M)
Risk Owner
C
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Incinerator burner:MR 7582: Price bids opened on 09.05.14. Award recommendation BPCL issued on 16.05.14. Delivery of waste heat boiler is affected due to burner data.
30-May-14
Open
Project
Award recommendation issued on 27.05.14. Award targeted by 05.06.14.
BPCL
5-Jun-14
Action Plan
Action By
Target Date
Risk Severity
I Award of Gas Booster Compressor for CPP (LAD:29.12.13; Ant: 05.06.14)
C
70
Open
Project
- 04 bids received on 02.04.14 (Petron, KSS, Techsharp & Bilfinger). PBO recommendation issued on 16.05.14, BPCL approval targeted by 30.05.14.
BPCL
20-Jun-14
C
Award of Composite Works (Mechanical & Civil /Strl. Works) for NHT/ISOM Sch: 08.05.14 76 Ant: 20.06.14
Completion of Reactor regenerator package for FCCU LAD : 09.07.15 Ant: Sep'15 (Upto pre commissioning)
Open
Project
- 90 % model review completed on 20.03.14. - All R&R foundation work completed, TSS foundation targeted by 30.05.14. Strl. Steel fabrication drawingsTotal Qty: 2444 MT; Drawings released.: 2436 MT, balance targeted by end May’14. Strl. Fabr. workFabricated Qty.: 1644 MT; Dispatched Qty: 966 MT; Under Fabrication: 721 MT - Strl. Fabr. & erection for TSSTotal Qty.:1388 MT; under Fabrication.: 211 MT
Inspection
end May'14
II
II
D
1
Projects Constn
II
D
Completion of all three site Fabricated Columns for FCCU (M/s Fabtech) LAD: 22.01.15 CDD:14.01.15 ECD: 15.05.15
Open
Project
- Ordered to M/s Fabtech on 15.07.13 (18 M incl erection). Order placed for Plates Project (BQ + LAS) on M/s Essar. 3685 MT out of 3747 MT Plates received at Chakan Shop, plate cutting & welding in progress. - Staggered delivery of columns is required from Sep'14 onwards as major piping works is held up due to hold for crane movement for these columns. - Priority to be assigned to main fractionator (IF-V-104). Taken up with M/s Fabtech.
Completion of MCC pkg for SRU LAD: 23.06.15 CDD:18.02.15 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 vendor from M/s Accometric. Meeting held with M/s Accometric on 28.05.14. Burner Flange details from burner vendor targeted by end May'14. -MCC: Shell Rolling is completed, C-seam welding is in process
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 21.11.15 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Bidder facing Financial crunch. Cum. Sch. 42.6; Act: 29.3 %
Open
Project
• M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. • Main Fractionator: 265 MT out of 290 MT clad plates received at VTV site & is under rolling, balance targeted by end May’14. Coke Drum: SS Clad (177 MT) plates received at VTV shop, balance 2054 MT expected to receive at VTV shop progressively by mid Jun’14. • The fabrication area to be cleared of rock and handed over by end May’14. Temporarily fabrication works panned near canteen area. Area marked for Coke drum A has been handed over to EPIL on 27.05.14.
7
As stated
II
D
8
EIL/BPCL
30-May-14
II
D
9
Area handing over by endMay'14
I
D
Delay in erection of Crude & vacuum column due to Open delayed ordering. Sch: Jun 14 Ant: Sep 14 Normally 12-14 Months are required for Unit Mechanical Compln after erection of Crude & 12 Vacuum column. VTV progress Sch ( 94.2 %); Act (83.5%)
BPCL / Director level meeting held with M/s VTV. M/s VTV agreed: Constn. / VTV 5-Sep-14 Projects / - Erection for crude column targeted from Jun'14 & hydro testing targeted by / Projects Const. 25.08.14. - Erection of Vacuum Column targeted from 07.07.14 to 02.08.14 & hydrotest planned in 05.09.14. -1000 MT Crane : Assembly work started. -500 MT Crane : Assembly work & Load test completed. II
Delay in delivery of equipments: - M/s Gansons due to substantial rise in raw material cost due to current market conditions. - M/s Tema due to financial constraint.
D
Open
Contract / Inspection
Equipment by Ganson Inspection - M/s Ganson agreed to supply balance item of CDU/VDU. Items for SRU and DCU refloated under MR-6560 (DCU) & MR-6120 (SRU): All items ordered. Projects -Slow progress by M/s Tema due to financial constraint. Meeting held on 06.05.14 with M/s TEMA.
30-May-14
16
II
Job No.: A307 MAY'14 Page 735 of 749
Integrated Refinery Expansion Project, Kochi
D
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Project
Action Plan - Hazop review completed. - Foundation drawing released. - 30 % model review targeted by mid Jun'14. - Filling of area & piling work completed, excavation commenced. Delivery of foundation bolts from Airoil being expedited. - Foundation to be handed over by Aug'14.
Action By
Target Date
Completion of Demountable Flare works (Awarded to M/s Airoil on 25.09.13) Sch: 31.03.15 Duration: 18 M 17 Ant: 24-Mar-15
Open
Delivery of WGC-FCCU (Ordered to M/s BHEL on 26.09.13) LAD: 09.01.15 CCD: 25.04.15 EDD: 25.09.15
Open
Projects
- Compressor casing has been ordered on NP Italy on 14.12.13 (Dely - end Aug 2014 Project/Inspe Continuous & 03.12.14 FOB). ction - Receipt of compressor casing expected at BHEL shop from Oct'14. - Further delivery of compressor takes normally 10-11 month after receipt of casing. Meeting held with M/s BHEL & M/s GE NP on 19.02.14, M/s BHEL to submit detailed catch-up plan. Meeting held on 26.05.14 with BHEL. BHEL has committed to deliver within CDD. 60% model review completed.
Open
Projects
- All load data and layout received from M/s Thermax. - Fan subordered to M/s Andrew Yule. -HRSG casing engineering targeted to complete by 25-June-14
Project/Inspe Continuous ction
- Target sch for completion by Sep'15 finalized and issued. All long delivery equipments (incl.compressors) to be awarded progressively by May'14. Reactor ordered on M/s Phills Heavy. - Unit shut down held from 04th May'14 to 14th May'14 all shutdown hook ups, blinding and dismantling of 7 equipments identified for shut down & is completed. - 70 % ISO's targeted to release by Jun'14, At present only 200/1296 nos ISOs released.
Project
Risk Severity
Projects/Cons As Required tr.
II
D
19
II
D
Delivery of HRSG Package LAD : 30.03.15 23 CDD: 19.08.15 Awarded to M/s Thermax on 20.12.13
II
E
4
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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.
Open
Constn. / Projects
May'14
Slow Progress of Building Works by M/s L&T for MCR and CPP control Room. Contr. Sch: 67.9% Front: 100 % Act: 39.7% CCD: 20.12.14 Ant: 15.05.15
Open
Const
Front available for all 11 buildings . Constn - MCR area, CPP control room area : all substructure RCC work targeted for completion by end May'14. - Manpower being augmented to 700 nos from present 550 nos. - Engineering for Packages like HVAC and Pressurization & Ventilation system in progress - Clean agent system: Drawings awaited from L&T. - Casting of foundations up to first expansion joint in MCR to be expedited. Strl. dwg. for Roof structures for MCR, SRR & substation to be cleared. - Lifts: Orders placed, drawings awaited.
As Required
Backlog 22.6 (% wrt sch) as of 15-May-14 in Construction activities viz., Piling work & Civil works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 26M; Remaining Duration - 20 M Desc. Const Sch Front Act Overall 40.8 37.1 18.6 Backlog in Civil / strl works will affect availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Const
Director level meeting held with contractors from Apr'14 to May'14. rder to complete Constn the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - Civil Works-CDU/VDU & DCU : Structural work being expedited. -Civil Works -FCCU/VGO/DHDT/IREP/DHDS/Refinery area : Requirement for adequate mobilisation of resources being taken up with higher management of respective contractors. All agencies being expedited to submit catch-up plan for accumulating backlogs. - Misc. Civil & Strl works floated and awarded to M/s Tuaman.
As Required
Open
Project
- Project review meeting held on 15.04.14 with M/s Triveni at EIL HO. Huge backlog seen in detailed engg.Slow construction progress due to inadequate mobilization (asking rate has now gone up to 9-10% Per month). (Manpower Req 284 nos. Avl 118 Nos)
As stated
I
E
6
II
E
7
E
Completion of Raw water treatment plant Pkg (M/s Triveni Engg).(Delayed due to refloating) Contr. Sch: 47.7 % Front: 100 % Act: 25.4% Sch: 15.11.14 CCD: 24.03.15 ECD: 24.03.15 13 Compl: 18 M+2M
I Constr.
II Area availability for SRU Block - At present only 75 % area given to M/s MBEL, balance Site for SRU block shall be available by mid Jun'14. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) - As per present trend 17 months (starting from end Apr’14) are available with respect to schedule of 25 M (As per Past experience minimum requirement for SRU is 30 M). E
Open
Proj. / Constn.
- Retaining wall in progress. Reservoir wall dismantling & 70& grade slab dismantling Constn. completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 26.04.14. and resources have been augmented. - At present only 313 nos manpower deployed at site. M/s B&R agreed to increase manpower upto 375 nos. Along with 3 excavators & dumper to be increased upto 40 nos from present of 20 nos by end May'14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 608 / 1828 nos piles completed at site by M/s MBEL.
End May'14
14
I
Job No.: A307 MAY'14 Page 736 of 749
Integrated Refinery Expansion Project, Kochi
E
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Constructio Meeting held with M/s KSSPPL on 05.05.14. M/s KSSIPL to deploy cumulative 200 Constr. n Manpower for Civil fdn work alone (Inside DHDS area) & 250 Manpower for Civil Fdn (IREP area) . As on date 83 & 216 nos deployed resp. Rock Blasting in IREP area being expedited for completion by end May'14. M/s Tuaman shall be deployed to supplement KSSPPL for trenches.
Target Date
Slow construction progress by M/s KSSIL for Offsite IREP area. Civil & Strl work for IREP area awarded to M/s KSSIL on 12.09.13 27 Civil & Strl work-offsite IREP Area: Constr. Sch:84.8%; Front:70.2%; Act: 24.0% CCD: 08.10.14; ECD: 15.05.15
Open
Release of balance front to M/s Essar to start civil & Strl. work for CPP Contr. Sch: 56.3%; Front: 57.2%; Act:18.2% CCD:18.12.14; ECD: 18.02.15
Open
Project
- M/s Essar agreed to deploy additional manpower and machinery. Constr. Structural steel fabrication works: 490 MT received for GTG shed. 295MT fabrication completed. Release of balance Arc drawings for UG piping works, Earthing layout , precast works etc. to be expedited.
30-May-14
Open
Project
Director level meeting held with M/s Mcnally on 23.04.14 . - Manpower for all works to be increased to 150 from present 60 nos. - Strl Steel works: 370 MT shall be delivered progressively by 05-May-14. 170 MT of structural steel fabrication for TS-2 shall be done by 30-May-14
Continous
Progress of ETP Works (Handing over of graded area for ETP & dismantling of existing Oil Catcher. ) LAD: 30.09.15 (CDD:10.08.15) Awarded to M/s Paramount on 11.09.13. (Duration: 21 M+2 M incl pre commng)
Open
Project
Meeting held with with M/s Paramount on 15.05.14 Project Work commenced in substation (5 out of 42 fdns cast) and equalisation tank. - Area handing over for RL-7 to M/s Paramount targeted progressively from 15.05.14. - Area for chemical house by 25.05.14 - area for TPI/API by 31.05.14
As stated
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 Ant: 03.04.15
Open
Project
KOM held at site on 29.01.14 BPCL - Radiant section fabrication drawings to be finalised across the table on fast track. - Vendor being pressurised to mobilised at site immediately. - Strl. Steel: Total 193 MT. Ordering targeted by mid Jun'14 progressively. To be followed up with M/s Petron. - Management meeting held with M/s Petron on 07.05.14. Action for slow progress to be taken against PETRON based on EIL’s CCEC decision, tender under preparation.
As Required
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
Open
Project
-KOM held on 28-29Jan'14 at EIL Delhi. Projects/BPC As Required - Burner data from Incinerator burner vendor required and same under ordering. L Input expected to receive by Jun'14. - Chamber (M/s Techno Process) & stack (M/s Loyd Steel) ordered on Indian Vendors, whereas order delivery is on FOB basis. Vendor has requested to amend free trade warehouse zone requirement to enable dispatch of materials. Matter taken up with BPCL.
Progress of RO-DM Plant (Awarded to M/s Driplex on 12.06.13) LAD: 31.01.15; CCD: 11.04.15 Sch: 47.6 %; Front: 93.3%; Act:11.6 %
Open
Project
- Director level meeting held on 06.05.14 at EIL Delhi. Following points agreed: - Balance engineering including piping targeted to complete by mid Jun'14. - 90 % model review targeted by 15.06.14. - M/s Driplex advised to complete soil investigation substation building & RO-DM Shed areas.
Projects
As Required
Slow Construction progress for Civil Works by M/s ShriRam EPC Contr. Sch: 45.4%; Front: 56.7% Act: 12.8 % CCD: 24.12.14 ECD:31.05.15
Open
Project
-Director review meeting held on 13.05.14 Projects Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including approx 50 nos in fabrication yard) -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). NIT issued on 26.05.14, bids due on 17.06.14.
As Required
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15
Open
Project
- M/s Petron yet to mobilise at site to start work. BPCL - Shop fabrication work started. - Fans ordered. Load data expected by end May'14. - Strl. Steel: 160 MT out of 800 MT ordered, balance ordering targeted by mid Jun'14 progressively. To be followed up with M/s Petron. - Management meeting held with M/s Petron on 07.05.14. Action for slow progress to be taken against PETRON based on EIL’s CCEC decision, tender under preparation.
As Required
Risk Severity
30-May-14
II
E
28
E
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: 03.07.15 SCH. FRONT. ACT. 10.8% 29 40.7% 39.9 %
II Constr.
II
E
34
II
E
37
II
E
39
II
E
40
II
E
41
I
E
43
II
Job No.: A307 MAY'14 Page 737 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
Key Risk Description
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION Action Plan
Action By
Target Date
Slow Construction progress for Civil Works by M/s Mcnally Bharat for DHDT & VGO Sch: 61 %; Front :71.7 % Act: 28.9 %
Open
Project
-Director level meeting held with M/s MBEL on 23.04.14. M/s MBEL agreed: 323 MT of matching steel urgently required – shall be delivered progressively by 05May-14. All rock blasting targeted for completion by end May'14
Projects
As Required
Completion of PreEngineered Building Works (3 Nos) by M/s B&R (SG-II) - Warehouses.
Open
Project
As Required
E
44
Work under progress by M/s B&R. 50 % work completed balance targeted by end Projects May'14 for PEB1. Buildings to be expedited for storage of material / equipment being received at site.
Open
E
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13. Civil & Strl work-offsite DHDS Area 47 Sch:54.2%; Front: 33.9%; Act: 5.4%
Constructio Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 n Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)SOR issued on 20.05.14. NIT targeted by 05.06.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - SOR issued on 20.05.14. NIT targeted by 05.06.14.
E
Risk Severity
44
II
II BPCL / EIL
5-Jun-14
I
Job No.: A307 MAY'14 Page 738 of 749
Integrated Refinery Expansion Project, Kochi
Risk Owner
C
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
Open
Project
Incinerator burner:MR 7582: Price bids opened on 09.05.14. Award recommendation BPCL issued on 16.05.14. Delivery of waste heat boiler is affected due to burner data.
30-May-14
Award of Gas Booster Compressor for CPP (LAD:29.12.13; Ant: 05.06.14)
Open
Project
Award recommendation issued on 27.05.14. Award targeted by 05.06.14.
BPCL
5-Jun-14
Ordering of additional Critical Valves
Open
Project
MR-3211 (417 nos): Award recommendation issued on 08.05.14. Award targeted by 30.05.14 Balance MR under preparation.
BPCL
30-May-14
20-Jun-14
Key Risk Description
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 30.05.14 (Incinerator burner) 55 (Execution Duration - 14 M)
Action Plan
Action By
Target Date
Risk Severity
I C
70
II III
C
73 Open
Project
- 04 bids received on 02.04.14 (Petron, KSS, Techsharp & Bilfinger). PBO recommendation issued on 16.05.14, BPCL approval targeted by 30.05.14.
BPCL
C
Award of Composite Works (Mechanical & Civil /Strl. Works) for NHT/ISOM Sch: 08.05.14 76 Ant: 20.06.14
Completion of MCC pkg for SRU LAD: 23.06.15 CDD:18.02.15 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 vendor from M/s Accometric. Meeting held with M/s Accometric on 28.05.14. Burner Flange details from burner vendor targeted by end May'14. -MCC: Shell Rolling is completed, C-seam welding is in process
EIL/BPCL
- Part Township area handed over by BPCL, 6 out of 19 buildings in colony handed over for dismantling, balance to be expedited by May'14 so as to ready for allocating to mechanical agencies by Jul/Aug'14.
BPCL
30-May-14
II III
BPCL / EIL
May'14
III
II
D
8
Space constraints: i) Area for Storage of Client materials ii) Area for Spool storage
E
Open
Constn.
30-May-14
'-Part of PEB1 new ware house handed over for material storage total warehouse handover after completion of work by end May'14. (Fabrication area handing over: R&R -90 % fabrication area handed over, CDSP (8500 out of 1000 sq.m handed over) balance by end May'14.
2
Meeting held with FACT authorities to lease out some land from FACT.
E
E
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 (Ant. Compln26 May- June'14, Compl date Committed by B&R – 13.11.13)
Open
Project
Culvert part I covering 8 m out of 13 m shal be completed by first week of June 14. further the balance stretch shall be taken up.
Slow progress of FCCU Heater works (Awarded to M/s Petron on 04.12.13 (16 M) LAD: 09.07.15 Ant: 03.04.15
Open
Project
KOM held at site on 29.01.14 BPCL - Radiant section fabrication drawings to be finalised across the table on fast track. - Vendor being pressurised to mobilised at site immediately. - Strl. Steel: Total 193 MT. Ordering targeted by mid Jun'14 progressively. To be followed up with M/s Petron. - Management meeting held with M/s Petron on 07.05.14. Action for slow progress to be taken against PETRON based on EIL’s CCEC decision, tender under preparation.
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
Open
Project
-KOM held on 28-29Jan'14 at EIL Delhi. Projects/BPC As Required - Burner data from Incinerator burner vendor required and same under ordering. L Input expected to receive by Jun'14. - Chamber (M/s Techno Process) & stack (M/s Loyd Steel) ordered on Indian Vendors, whereas order delivery is on FOB basis. Vendor has requested to amend free trade warehouse zone requirement to enable dispatch of materials. Matter taken up with BPCL.
Slow progress of Heater Works-VGO (M/s Petron) LAD:24.04.15 CCD:20.02.15
Open
Project
- M/s Petron yet to mobilise at site to start work. BPCL - Shop fabrication work started. - Fans ordered. Load data expected by end May'14. - Strl. Steel: 160 MT out of 800 MT ordered, balance ordering targeted by mid Jun'14 progressively. To be followed up with M/s Petron. - Management meeting held with M/s Petron on 07.05.14. Action for slow progress to be taken against PETRON based on EIL’s CCEC decision, tender under preparation.
Open
Constructio Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative 200 n Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)SOR issued on 20.05.14. NIT targeted by 05.06.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - SOR issued on 20.05.14. NIT targeted by 05.06.14.
37
As Required
II
E
39
II
E
43
E
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13. Civil & Strl work-offsite DHDS Area 47 Sch:54.2%; Front: 33.9%; Act: 5.4%
As Required
II BPCL / EIL
5-Jun-14
I
Job No.: A307 MAY'14 Page 739 of 749
Integrated Refinery Expansion Project, Kochi
1
1
G
2
I
2
K
2
M
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project : Works to be awarded by BPCL
Open
Projects
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 for 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.
As Required
IV
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
30-May-14
III
Non availability of Skilled workers
Open
As Required
IV
ODC transportation in view of Kochi Metro ODC movement schedule is from Nov'13 to Feb 15.
Open
Variation in foreign exchange rates from Rs 50 per USD as on Mar 12 to Rs. 59 per USD as on date and fluctuations in the intermediate period and Scope changes w.r.t. DFR (additionals in scope) has significantly impacted on the overall project cost.
Open
Key Risk Description
G
K
Risk Owner
F
Status (Open / Close)
Risk Id
RISKS REQUIRING BPCL ATTENTION
4
3
Action Plan BPCL-KR to ensure that Hydrogen & Nitrogen are available by Jun’2015.
Action By BPCL
Constn. / Projects / BPCL
Projects / - IBR package for DCU targeted after 90 % model review. EIL/BPCL BPCL - List of all the buildings in IREP along with the plinth area details for taking approvals from F&B as well as Panchayath issued to BPCL on 12.04.14, BPCL to take approval Approval for tall strl/stacks: Signed documents with 6 sets handed over on 13.05.14, BPCL to take approval -Compilation of documents for Factory Inspectorate, CEA approval to started on priority.
Const.
Utilisation of migrant labour and skilled labour from outside the state needs to be Constn / encouraged. However, the same will be effective only if proper labour colony facilities BPCL are arranged by the contractors.
Project/Eng - BPCL to inform the probable date of commencement of metro work. g - Alternate route for ODC movement to be checked. - RCM issued letter to BPCL . Issue has been put to the notice of Kochi metro & District Collector.
Project
- BPCL to put up Revised cost in BPCL Board and seek approval on the same.
BPCL
EIL/BPCL
Target Date 1-Jun-15
As stated
30-May-14
Risk Severity III
III
III
Job No.: A307 May'14 Page 740+13 of 36
IV - RISK REGISTER
Schedule ( Y / N)
Output Quality ( Y / N)
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)
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Incinerator burner:MR 7582: Price bids opened on 09.05.14. Award BPCL recommendation issued on 16.05.14. Delivery of waste heat boiler is affected due to burner data.
30-May-14
Completion of CDSP Package: Target Sch: 01.05.15 Ant Compl.: 21.11.15 (Duration: 24 M + 3 M grace). Awarded to M/s Essar on 22.08.13. Bidder facing Financial crunch. 9 Cum. Sch. 42.6; Act: 29.3 %
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
• M/s Essar to mobilise addl. resources and expedite balance procurement. Constr. • Main Fractionator: 265 MT out of 290 MT clad plates received at VTV site & is under rolling, balance targeted by end May’14. Coke Drum: SS Clad (177 MT) plates received at VTV shop, balance 2054 MT expected to receive at VTV shop progressively by mid Jun’14. • The fabrication area to be cleared of rock and handed over by end May’14. Temporarily fabrication works panned near canteen area. Area marked for Coke drum A has been handed over to EPIL on 27.05.14.
Area handing over by endMay'14
Completion duration for NHT/ISOM (Revamp) Mechanical completion of NHT/ISOM - Target Schedule : 30.09.15; Only 15 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. 4 - Change in the scope based on health check report has an impact on Project cost and schedule.
Open Constn. / Projects
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
0.00
- Target sch for completion by Sep'15 finalized and issued. Project All long delivery equipments (incl.compressors) to be awarded progressively by May'14. Reactor ordered on M/s Phills Heavy. - Unit shut down held from 04th May'14 to 14th May'14 all shutdown hook ups, blinding and dismantling of 7 equipments identified for shut down & is completed. - 70 % ISO's targeted to release by Jun'14, At present only 200/1296 nos ISOs released.
May'14
Backlog 22.6 (% wrt sch) as of 15-May-14 in Construction activities viz., Piling work & Civil works for offsite area as well as unit areas. Target Duration - 43 M; Contractual Duration - 46 M; Time lapsed - 26M; Remaining Duration - 20 M Desc. Const Sch Front Act Overall 40.8 37.1 18.6 Backlog in Civil / strl works will affect 7 availability of front for mechanical contractor (CDU / VDU / DCU, FCCU, VGO/DHDT & Offsite).
Open
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
Director level meeting held with contractors from Apr'14 to May'14. rder to Constn complete the Construction and liquidate Revised catch-up schedule prepared as per discussion held on 18th Apr’14 with CDU/VDU completion by Sep’15 and balance units by Dec’15. - Civil Works-CDU/VDU & DCU : Structural work being expedited. -Civil Works -FCCU/VGO/DHDT/IREP/DHDS/Refinery area : Requirement for adequate mobilisation of resources being taken up with higher management of respective contractors. All agencies being expedited to submit catch-up plan for accumulating backlogs. - Misc. Civil & Strl works floated and awarded to M/s Tuaman.
As Required
Award of Thermal oxidiser burner & reduction pkg LAD: 28.05.13 Ant: 30.05.14 (Incinerator burner) C 55 (Execution Duration - 14 M)
Urgency (Long Term / Short term)
EIL Cost (Y / N)
Project
Key Risk Description
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
Risk Owner
Open
Risk Id
Status (Open / Close)
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Action Plan
Action By
Target Date
Risk Severity
I
D
I
E
I
E
Const
I
IV - RISK REGISTER
Schedule ( Y / N)
Output Quality ( Y / N)
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)
N
Short term
I
0.6
0.57
0.57
0.00
- Retaining wall in progress. Reservoir wall dismantling & 70& grade slab Constn. dismantling completed and filling in progress. FWPH dismantling under progress. - M/s B&R demobilised manpower due to organisational restructuring. Meeting held with M/s B&R management on 26.04.14. and resources have been augmented. - At present only 313 nos manpower deployed at site. M/s B&R agreed to increase manpower upto 375 nos. Along with 3 excavators & dumper to be increased upto 40 nos from present of 20 nos by end May'14. - Piling for SRU block included in Civil/ structural tender to save time and work awarded to M/s Mcnally on 04.11.13 (duration: 16 M) At present 608 / 1828 nos piles completed at site by M/s MBEL.
End May'14
Very High
N
Y
Y
N
Short term
I
0.7
0.67
0.67
0.00
-Director review meeting held on 13.05.14 Projects Resource Deployment of skilled workmen to be increased (Carpenters, bar benders to be increased). -Requirement of approx 450 nos while available is approx 163 nos (including approx 50 nos in fabrication yard) -Detailing of Structural Steel Drawings to be expedited to facilitate Structural Steel fabrication. Precast manhole/trench works to be taken up. Fabrication of Structural Steel to be expedited. -Part Civil Work in FCCU offloaded to M/s Tauman. Additional Strl. work contract being lined up to offload above contracts (if required). NIT issued on 26.05.14, bids due on 17.06.14.
As Required
Open Constructi Very High on
Y
Y
Y
N
Short term
I
0.9
0.86
0.86
Meeting held with M/s KSSIIPL on 02.05.14. M/s KSSIPL to deploy cumulative BPCL / EIL 200 Manpower for Civil fdn work alone (Inside DHDS area). As on date 83 nos deployed only. Additional contracts lined up to supplement site work: • Misc. Civil works-2 (approx 3000 m3) : (DHDS Pipe rack or other areas of IREP)-SOR issued on 20.05.14. NIT targeted by 05.06.14. • Misc. Structural works-2 (approx 3100 MT): For Units & offsite - SOR issued on 20.05.14. NIT targeted by 05.06.14.
5-Jun-14
Open Proj. / Constn.
Slow Construction progress for Civil Works by M/s ShriRam EPC Contr. Sch: 45.4%; Front: 56.7% Act: 12.8 % CCD: 24.12.14 ECD:31.05.15
Open Project
Slow construction progress by M/s KSSIL for DHDS Offsite area. Civil & Strl work for DHDS area awarded to M/s KSSIL on 05.03.13. Civil & Strl work-offsite DHDS Area Sch:54.2%; Front: 33.9%; Act: 5.4%
Very High
Urgency (Long Term / Short term)
EIL Cost (Y / N)
Y
Area availability for SRU Block - At present only 75 % area given to M/s MBEL, balance Site for SRU block shall be available by mid Jun'14. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) - As per present trend 17 months (starting from end Apr’14) are available with respect to schedule of 25 M (As per Past experience minimum requirement for SRU is 30 M).
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%) Project Cost ( Y / N)
N
Risk Owner
Y
Status (Open / Close)
Risk Id
Kochi Refinery, BPCL Integrated Refinery Expansion Project
Key Risk Description
Job No.: A307 May'14 Page 741+13 of 36
E 14
Action Plan
Action By
Target Date
Risk Severity
I
E 41
I
E 48
I
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 742+12 of 749+12 As of 08-Mar-13
13
14
15
0.4
0.38
0.38
0.00
- Awarded to M/s UOP on 22-Nov-12. - Agreement singed with M/s UOP on 15.02.13 - PFD review held from 25th to 27th Feb’13. - P&ID submission from Licensor expected by 04-Apr-13 and review targeted from 22-Apr-13 at USA.
Projects / Process
24-May-13
Delay in Process Package for TGTU (M/s CB & Open INC) LAD : 31-Dec-12 ; Ant : 15-Apr-13
BPCL / Process
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
-P&ID review meeting held from 25 Feb 13 to 06 Mar 13 at Texas. Final Process package targeted by 15.04.13.
Projects / Process
15-Apr-13
Projects / POSD
22-Mar-13
(Current risk Score Previous Risk score)
12
I
Previous Risk Score
11
Short term
Current Risk Score -> {5}* {12}
10
N
Impact Score => {6+7+8+9} * 10 * 11
Controllability Condition ( D / I ) ((40% / 100%)
9
Y
Output Quality ( Y / N) (10% / 0%)
8
N
Schedule ( Y / N) (40% / 0%)
7
N
EIL Cost (Y / N) (30% / 0%)
6
Very High
3
Project Cost ( Y / N) (20% / 0%)
5
BPCL / Process
2 Delay in Process Package for NHT / ISOM LAD : 30-Apr-13 ; Ant : 24-May-13
A
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Urgency (Long Term / Short term) (50% / 100%)
1
Risk Owner 4
Open
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
1
Action Plan
16
Action By
17
Target Date
Risk Severity
18
19
II
A
2
II
A
-Preparation of Offsites P&ID’s for tankages (LAD - 21.01.13) - Delay has been due to delay in receipt of Asbuilt drawings from BPCL-KR (except CEMP#REF! II). All details recieved now. -Upgradation of Crude oil pipeline system (Inside refinery)
Open
POSD
High
N
N
Y
N
Short term
I
0.4
0.32
0.32
0.00
- Out of 32 P&IDs, 29 nos. issued for engineering and 3 nos. issued for comments. Balance P&ID-1142 & 1143 (Fuel Oil), and 1140 (ATF) issue for engineering targeted by 22-Mar-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.
Open
Process
Very High
Y
Y
Y
Y
Short term
D
0.4
0.38
0.38
0.00
- All PDS for ARU & SWS revised. P&IDs for ARU (part) Process / R&D 31-Mar-13 issued. All Revised P&IDs (ARU & SWS) targeted to issue by 16.03.13. -Major PDS for SRU revised and balance PDS / P&IDs targeted for issue by 19.03.13. Utility distribution P&IDs Issued for engineering - ARU/SWS/SRU from 20.03.13 onwards. ' - Rev.A issued for CW, N2 , Air , Steam and BFW/Service water/DM water (7 / 15 issued).
Finalisation of Utility import / export requirements from BOO by BPCL. Flare load changed substantially and repeatedly from estimated values.
Open
Process
Low
N
N
Y
N
Short term
I
0.4
0.12
0.12
0.00
Based on latest information from BOO HGU and SWII (FCC), Projects / Revised Design Basis targeted by 04.03.13. Process Approval from BPCL targeted by 18.03.13.
II
A
A
18-Mar-13
II III
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 743+12 of 749+12 As of 08-Mar-13
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
12
13
14
15
I
0.4
0.20
0.152
0.05
- Out of 2 nos offsite interconnection P&IDs, 1 no. (New BPCL facilities) has been issued for engineering. Balance 1 no. targeted by 15.03.13 -During PRM dated 28.02.13 and 01.03.13, EIL informed that pending information (for CPP, FCCU, NSU-I, SRU and HGU) is required from BPCL on priority to clear the OSBL distribution drawings.
31-Mar-13
Finalisation of tender for Civil works including piling in demountable Flare area (Delay in award of Flare adversely affecting the sch.) Sch - 20-May-13; Ant - 31-Jul-13
Open
Strl
Very High
Y
Y
Y
N
Long term
I
0.45
0.43
0.4275
0.00
Load details required from Flare vendor for finalisation of piling Projects tender and drawings. Load data from demountable flare vendor to be obtained at offer stage and tender to be finalised based on recomnended vendors data (load data is likely by end Jun'13).
31-Jul-13
Timely availability of piling and load data from Package (GTG, UB, HRSG) Vendors to meet piling tender & Civil / Strl tender schedule requirements. LAD - 28-Feb-13; Ant - from Mid Apr 13 to Sep 13.
Open
Projects
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
- Firm layout and other relevant data for piling to be asked ENGG/PLNG from Package Vendors at offer stage. -Award of GTG package targeted by 15.06.13. -Award of UB package targeted by 15.04.13. -Award of HRSG package targeted by Aug'13 - Issue piling layout targeted progressively from Apr to Sep'13. - Any balance piling left to be taken up through additional piling tender III.
Sep'13
HRSG package on critical path since the HRSG PDS can be finalised after receipt of GTG exhaust data. Sch Order - 22-May-13; Ant - Aug 13 Tender prepared & uploaded in eDMS, BQC approved by BPCL on 05.03.13, further BQC being revised.
Open
Engg
Very High
Y
N
Y
N
Long term
I
0.3
0.29
0.285
0.00
- To finalise PDS for HRSG based on GTG exhaust data of selected vendor (data received with offers) and issue amendment. The same is expected by end May 13. - Based on the above Award of HRSG targeted by Aug 13. - Strict monitoring of HRSG Tender at various stages preaward and during execution.
ENGG
Aug'13
Issue of RFQ for PRT (Hot gas expander) LAD: 25-Jan-13 Ant: 31-Mar-13 Duration: 16 M FOB
Open
Project
High
Y
Y
N
N
Short term
I
0.5
0.40
0.40
-Licensor’s reply (for flow, temp & pressure related issues) recd on 06.03.13. Revised MR targeted to be issued by 18.03.13.
Engg (Elec)
31-Mar-13
(Current risk Score Previous Risk score)
11
Short term
Previous Risk Score
10
N
Current Risk Score -> {5}* {12}
9
Y
Impact Score => {6+7+8+9} * 10 * 11
8
N
Output Quality ( Y / N) (10% / 0%)
7
N
Schedule ( Y / N) (40% / 0%)
6
Medium
EIL Cost (Y / N) (30% / 0%)
5
Process
Project Cost ( Y / N) (20% / 0%)
4
Open
2
Risk Owner
Controllability Condition ( D / I ) ((40% / 100%)
B
Urgency (Long Term / Short term) (50% / 100%)
1
A
3
Final issue for OSBL distribution P&IDs LAD: 30-Nov-12 ANT: 31-Mar-13
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
###
#REF!
Action Plan
Action By
16
17
Target Date
Risk Severity
18
19 III
II
B
II
B
II
C
1
II
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 744+12 of 749+12 As of 08-Mar-13
13
14
15
0.9
0.86
0.3325
0.52
- NIT issued on 11.02.13 and NDA signed upto 19.02.13.BDD C&P / Engg / extended upto 04.04.13, original BDD- 19.03.13. Projects -Post bid receipt, Techno/commercial evaluation to be done across the table within 1 month
15-Jun-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
0.32
-0.32
Awarded to M/s Paharpur on 21.02.13. Duration is 20 Months. BPCL
28-Feb-13
Ordering of GTG Pkg (LAD:10-Mar-13; Ant 15-Jun-13) Bid due date further extended to 22.03.13. (Earlier BDD - 11.02.13, 08.03.13) 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
0.86
0.855
0.00
- Technical evaluation targeted by 30.04.13. Projects / BPCL - Task force from concerned disciplines will be centrally located for evaluation of bids and action plan will be issued for adherence to the above target.
Ordering of Reactor regenerator package for FCCU LAD : 10-Apr-13 Ant: 15-Jun-13 Changes in scope of supply led to revision in BQC / tender due to which NIT was delayed.
Open
Project / Licensor
Very High
Y
Y
Y
N
0.9
0.86
0.86
-Tender on sale from 19.02.13 to 25.03.13. Pre bid meeting Projects / BPCL 15-Jun-13 held on 11.03.13. Amendment targeted by 15,03.13. Bid due date being extended to 16.04.2013. -Techno/commercial evaluation by task force will done across the table within 1 month i.e. by . An action plan for evaluation will be issued for adherence by the team. - Bidders seeking extension in execution duration (30-36 months against RFQ duration of 24 months). Proposed to extend to 27 Months.
Award of UB package LAD : 19-Jan-13 Ant : 21-Apr-13
Open
Process / Engg / constn
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
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. targeted by 25.03.13.. Award targeted by 21.04.13.
Engg. / Projects 21-Apr-13 / Process / C&P / BPCL
Ordering of Ejector Pkg (LAD:12-Jan-13) Ant: 30-Apr-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
02 Bids received on 11.01.13. Meeting held with bidders. TBA under preparation.
Proj/Engg
30-Apr-13
Award of Sulphur Pelletiser LAD: 03-Apr-13 Ant; 15-Jul-13 Enquiry being re-floated due to changes in MR requirements by BPCL.
Open
Project
Very High
N
Y
Y
N
Short term
D
0.28
0.27
0.06
0.21
-Evaluation Process of original MR stalled based on BPCL mail dated 12.03.13. - Revised MR targeted by 15.04.13. - Award targeted by mid Jul 13.
C&P
15-Jul-13
(Current risk Score Previous Risk score)
12
I
Previous Risk Score
11
Current Risk Score -> {5}* {12}
10 Short term
Impact Score => {6+7+8+9} * 10 * 11
Controllability Condition ( D / I ) ((40% / 100%)
9 N
Output Quality ( Y / N) (10% / 0%)
8 Y
Schedule ( Y / N) (40% / 0%)
7 Y
EIL Cost (Y / N) (30% / 0%)
6 Y
2
Delay in award of CDSP package Sch: 02-Mar-13 Ant:15-Jun-13 Earlier PQ was envisaged as NDA agreement was to be signed with prospective bidders. Now #REF! Bidders has to sign NDA before downloading the tender.
Project Cost ( Y / N) (20% / 0%)
5 Very High
1
Risk Owner 4 Project
Key Risk Description
Status (Open / Close) 3 Open
Risk Id
Urgency (Long Term / Short term) (50% / 100%)
C
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Integrated Refinery Expansion Project
Action Plan
Action By
16
17
Target Date
Risk Severity
18
19
I
C
C
###
15-Jun-13
I
C
Short term
I
#REF!
I
C
II
C II
C
II
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 745+12 of 749+12 As of 08-Mar-13
12
13
14
15
I
0.4
0.38
0.38
0.00
Award recommendation sent on 08.03.13. Award targeted by BPCL 31.03.13. BPCL response on L1 bidders under holiday, under review by C&P
31-Mar-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Bids due date extended upto 26.03.13 Orginal: BDD:26.02.2013
31-May-13
###
Award for RO-DM LAD:30-Jan-13 Ant: 31-May-13
Open
Project
Very High
Y
Y
Y
N
Short term
I
0.9
0.86
0.855
0.00
Projects/ '- The revised design basis issued to BPCL-KR for their Process/ approval on 06.03.13 Engg / C&P/ - Process data sheet (IFE) targeted by 16-03-13 and layout by 16-03-13. - Due to significant Technical and commercial changes (consortium bids is acceptable) tender to be refloated. Same is targeted by end Mar'13. Award targeted by end Jul'13.
31-Jul-13
###
Delay in Award of contract for Demountable flare (LAD: 08-Apr-13; Ant: 31-Jul-13) - Change in type of Flare. Initially as per DFR normal flare was envisaged. - Post enquiry significant changes in Flare Load/Process Data Sheet due to enormous increase in BOO flare load and non acceptance of mitigation measures by FCCU Licenser.
NIT for ETP package with WAO (Wet air oxidation)
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Tender under preparation, readiness by 18.03.13. BQC to BPCL by 18.03.13. NIT publishing targeted by 22.03.13
Engg
22-Mar-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Price bids opened on 11.03.13. Award recommendation targeted by 18.03.13.
C&P
31-Mar-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
Award recommendation sent on 07.03.13. Award targeted by 31.03.13.
C&P
31-Mar-13
Award of Civil & Strl work for offsite new area LAD: 22-Jan-13 Ant: 30-Mar-13
Open
Project
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.475
-0.10
Price bids opened on 19.02.13. Award Recommendation issued on 05.03.13. Award of works by end Mar'13.
C&P
30-Mar-13
Handing over of Land for project usage
Open
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
Client to be followed up to acquire the allocated land and hand BPCL over to the project usage at the earliest.
Risk Owner
(Current risk Score Previous Risk score)
11
Previous Risk Score
10 Short term
Current Risk Score -> {5}* {12}
9 N
Impact Score => {6+7+8+9} * 10 * 11
Controllability Condition ( D / I ) ((40% / 100%)
8 Y
Output Quality ( Y / N) (10% / 0%)
7 N
Schedule ( Y / N) (40% / 0%)
6 N
2 Award of contract for RWTP
EIL Cost (Y / N) (30% / 0%)
5 Very High
1
Project Cost ( Y / N) (20% / 0%)
4 Project
Key Risk Description
Status (Open / Close) 3 Open
Risk Id
Urgency (Long Term / Short term) (50% / 100%)
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Integrated Refinery Expansion Project
LAD: 14-Jan-13
C
Action Plan
Action By
16
17
Target Date
Risk Severity
18
19
Ant: 31-Mar-13 (Execution Duration - 22 M)
C
II Engg
II
C
I
C
###
LAD: 15-Jan-13 Ant: 22-Mar-13 II Award of contract for Building incl substations LAD: 07-Feb-13
C
###
Ant: 31-Mar-13
II Award of contract for Piling-II LAD: 31-Dec-12 C
###
Ant: 31-Mar-13 II
C
E
###
#REF!
Proj.
Continuous
II III
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 746+12 of 749+12 As of 08-Mar-13
E
E
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
10
11
12
13
14
15
Y
Long term
D
0.1
0.03
0.03
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.
Dismantling of LO CAT SRU (Required for New tankagesTF-4) by BPCL : will affect release of front for tankages.
Open
BPCL
Medium
N
N
Y
Y
Long term
D
0.1
0.05
0.05
0.00
Relocation of existing FWPH (Constn. / Commng.) and site grading of area for handing over for SRU. (Ant - Aug'13) Site for SRU block shall be available only after dismantling of existing FWPH & reservoir. (The works are covered under SG-II Tender : Awarded to B&R on 22.11.12) As per present trend 25 months are available with respect to requirement of minimum 30 M.
Open
Proj. / Constn.
Very High
Y
N
Y
N
Short term
I
0.6
0.57
0.57
Area for MCR and FCC Feed Tanks: Diversion of ETP II to ETP III and development of area reqd. by Apr.13 Ant: Jun'13
Open
Proj. / Constn.
Very High
N
N
Y
N
Short term
I
0.4
0.38
Land acquisition for Crude tank (2 nos.) . (LAD - Jul 13; Ant - Apr 13)
Open
Proj.
Very High
N
N
N
N
Short term
I
0
Allocation of identified fabrication areas for ODC Equipments & Other Agencies
OPEN
Medium
Y
N
Y
Y
Long term
I
0.35
Risk Owner
(Current risk Score Previous Risk score)
9
Y
Previous Risk Score
8
N
Current Risk Score -> {5}* {12}
7
N
Impact Score => {6+7+8+9} * 10 * 11
6
Low
Output Quality ( Y / N) (10% / 0%)
5
Constn.
Schedule ( Y / N) (40% / 0%)
4
Open
2
EIL Cost (Y / N) (30% / 0%)
3
Payment to contractors
Project Cost ( Y / N) (20% / 0%)
Controllability Condition ( D / I ) ((40% / 100%)
E
Urgency (Long Term / Short term) (50% / 100%)
1
Key Risk Description
Status (Open / Close)
Risk Id
Integrated Refinery Expansion Project
Action Plan
Action By
16
Target Date
Risk Severity
17
18
19
within 7 days of certified RA bills
IV
Tender being floated by BPCL-KR and site will be available by BPCL Apr 13
30-Apr-13
IV
0.00
- Relocation of FWPH and reservoir (including civil works and Constn. grading of area) targeted by end Aug 13. (Contractual milestone of SG II contractor M/s B&R for civil works is July 13) - Award of Composite works (by ROC) for relocated pump house targeted by end May 13. Award to local agency for rerouting of piping works to be taken up by RCM, if works can be taken up parallely. - Engineering / Procurement activities for Sulphur block to be expedited parallely. - Award for Piling II (which includes piling of reatining wall) by -Mar-13. - Construction Execution Philosophy for award of Piling / Civil under review/ finalisation. Award of works being targeted by end Aug 13.
30-Aug-13
0.38
0.00
- Scheme for re-routing of ETP-II to ETP-III finalised. - Routing to be completed by end Apr 13 so that dismantling of ETP-II can be commenced. Constn. - All MR's (for pumps & piping materials) have been floated. Availability of OWS & CRWS pumps to be ensured within 4 Projects months of order i.e. by Jun 13. - Electrical procurement initiated, Cables (part) ordered. BPCL to confirm the availability of cables (For connection with ETPIV) by May 13. - Readiness of CRWS / OWS sump by Apr 13 to be monitored. Micro schedule for completion of works under preparation by EIL site for rigorous monitoring. Constn
0.00
0.38
-0.38
During meeting held on 28/29.01.13, BPCL-KR informed that BPCL land shall be made available by Mar/Apr’13. EIL requested BPCL to provide survey/ coordinate details and bore hole data details of land area for preparation of site grading work tender
Apr-13
II IV
0.18
0.175
0.00
BPCL to expedite
As Required
III
BPCL
#REF!
#REF!
#REF!
I
E
E
#REF!
E
#REF!
BPCL
BPCL
1-Jun-13
Job No.: A307
IV - RISK REGISTER
Kochi Refinery, BPCL
Page 747+12 of 749+12 As of 08-Mar-13
I
13
14
15
0.2
0.19
0.19
0.00
- Adequacy report for CDU II issued on 11.03.13. - Adeauqcy report for CEMP II targeted after finalisation of IREP flare design.
Availability of Hydrogen and Nitrogen for Precommissioning and commissioning of Project : Works to be awarded by BPCL
Open
Projects
High
N
N
Y
N
Long term
I
0.2
0.16
0.16
0.00
1
Statutory approvals - PESO Approval for IREP complex - DGCA approval
Open
Projects / BPCL
Very High
N
N
Y
N
Short term
I
0.4
0.38
0.38
0.00
12.09
10.86
1.24
(Current risk Score Previous Risk score)
12
I
Previous Risk Score
11
Current Risk Score -> {5}* {12}
10 Short term
Impact Score => {6+7+8+9} * 10 * 11
9 N
Output Quality ( Y / N) (10% / 0%)
8 N
Schedule ( Y / N) (40% / 0%)
7 N
EIL Cost (Y / N) (30% / 0%)
6 Y
2
Adequacy Check for Hook-up of LPG Flare and ACID Flare between existing CDU-II flare and #REF! CEMP-II flare
Project Cost ( Y / N) (20% / 0%)
5 Very High
1
Risk Owner 4 Project
Key Risk Description
Status (Open / Close) 3 Open
Risk Id
Controllability Condition ( D / I ) ((40% / 100%)
F
Urgency (Long Term / Short term) (50% / 100%)
E
Probability (Very High / High / Medium / Low / Very Low) (95% / 80% / 50% / 30% / 10%)
Integrated Refinery Expansion Project
1
Action Plan
Action By
16
17 BPCL / EIL
Target Date
Risk Severity
18
19
31-Mar-13
III
BPCL-KR to ensure that Hydrogen & Nitrogen are available by BPCL Jun’2015.
1-Jun-15
III
- Documents for submission to PESO authorities for approval BPCL sent to BPCL-KR on 25.01.13. Meeting with PESO authorities scheduled on 13.03.13 at Nagpur. - BPCL to obtain DGCA approval on priority (in any case before award of flare).
18-Mar-13
II Total Risk Score
7718
Related Documents
Risk Register Project
February 2021 2
Project Risk Register
February 2021 0
Risk-register-of-common-project-risks
January 2021 0
Project Risk Analysis.pdf
January 2021 0
Project Risk Management Procedure
February 2021 1
Risk Register - Wilmont's Drone Project.pdf
January 2021 11More Documents from "Arvin Dalisay"