Project Engineering Management Case Study Project Title: 2 MMTPA oil refinery to process indegeneous crude Project Cost:

Rs. 45 Crores Completion Schedule: 30 months from approval of the project Project Descrition: The project will be constructed in the premises of the existing refinery. Graded land is available. The facilities consist of a crude distillation column, a crude furnace, a vacuum distilation column, a vacuum furnace, associated heat exchangers, drums & vessels, pumps, utility and safety systems, instruments & electricals, substations, control room etc. This case study illustrates how time overrun, which could have delayed project completion, was overcome and the project was completed on schedule. Gantt Chart 3 Site Clearance Process Design Detailed Engineering Statutary Approvals Equipment Ordering & Procurement Civil Work Stuctural Fabrication & Erection Equipment & Bought Out Delivery: Crude Column Vacuum Column Strippers Heat Exchangers Drums & Vessels Crude Furnace Vacuum Furnace Pumps Safety Valves Instruments Electrical Swithgear, Transformers, Cables Piping & Fittings Erection: Crude Column Vacuum Column Strippers Heat Exchangers Drums & Vessels Crude Furnace Hookup Vacuum Furnace Hookup Pumps Safety Valves Instruments Electrical Swithgear, Transformers, Cables Piping & Fittings Hydrotest Precommissioning & Commissioning 6 9 12 Months 15

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Strike at Heat Strike at Heat Exchanger's Exchanger's Workshop Workshop

Mismatch in field during piping erection. Rev. in dwgs. reqd.

Delayed delivery of electric motors for pumps, forcing import of motors

Folowing dealays took place during project execution: 1. On 15th month, there was a strike in the factory of heat exchanger fabricator, who had to supply 15 exchangers. 2. On 15 the month, pump vendor expressed inability to sullpy motors for 10 pumps in time , and said there would be a delay of 10 months, as the local motor supplier could not deliver in time. 3. Onthe 24th monthe it was found that the field piping alignment was not matching with drawings. This required making 500 fresh piping drawings suiting to field requirements, entailing a delay of 4 months. Corrective action taken by Project Management Team 1. All the 15 exchangers were brought to site in unfinished form under security protection, and the fabrication was completed at project site using fabricator's loyal workforce, supplemented by additional workforce hired from outside. In this manner, fabrication of 15 exchangers was completed within the scheduled completion time. 2. Immidiate arrangements were made to import 10 motors, which were available with very short delivery from the overseas supplier. 3. Additional agencies were immidiately deployed to prepare fresh piping drawings so that erection of balance piping was not delayed. With the help of immidiate action by the project management team, delay in scheduled completion of the project could be avoided.