Project ManagementNot only a Life Skill
But a Life Changing Skill
Thomas Chacko
PM- Profession & Life Skill
• PM techniques can be applied by non-project
managers to help implement change
• Set of knowledge, profession and career choice
• Can be learned and applied by a variety of groups,
including school students
• Helps to step into leadership roles
• Can apply the techniques in real life situations
PM- in EPC Projects
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Engineering, Procurement, Construction (EPC)
All disciplines of Engineering
Longer duration with several players
Vast Interface, logistics and obstacles
Varied and huge resources- men and material
Location specific
Subject to clearances, legalities, external factors
PM-Common World Language
“Project Management can be
used as a common language
around the world to help bring
people together and enable
organizations to prosper.”
Philip Diab (Past Chairman PMI)
Life Changing Project
• A major EPC Project linked to Infrastructure,
changes the area, economy and life of people
• Public sector Projects are examplesGoshree bridges, Delhi Metro
• BPCL Kochi Refinery recently implemented 2
major Projects
– Crude Oil Receipt Facilities (SPM) in Puthu
Vypeen and
– Capacity Expansion and Modernization
Project Phase II (CEMP II) in the Refinery
Life Changing Project
• SPM Project was dogged with problems right
from conceptualization.
• Project was all about overcoming obstacles.
• A challenge during implementation
• A life long memory on completion.
• Affected the lives of many people who
directly or indirectly benefited or did not.
• For the benefited, it changed their lives and
are examples of a Life changing Project.
CRUDE OIL RECEIPT FACILITIES
(SPM) PROJECT
BPCL KOCHI REFINERY
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CONCEPT
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KOCHI REFINERY WAS BRINGING CRUDE OIL THROUGH COCHIN
PORT TRUST’S CRUDE OIL TERMINAL (COT)
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THE DRAUGHT AVAILABLE AT COT (11.6m) LIMITED SHIP CAPACITY
TO 60000 MT.
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WITH CHEAPER CRUDE BECOMING AVAILABLE FROM SOUTH
AMERICA AND AFRICA, USE OF VLCC (Very Large Crude Carriers)
CONSIDERABLY REDUCED TRANSPORTATION COSTS.
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VLCC REQUIRES A DRAUGHT OF 29 M, SETTING UP A SPM (Single
Point (Buoy) Mooring –TERMINAL BECAME A NECESSITY.
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VARIOUS LOCATIONS CONSIDERED FROM 2000
PUTHU VYPEEN FINALIZED BASED ON MOU WITH CPT IN 2005
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LAND ON LEASE FROM CPT, SPM LOCATION, WHARFAGE CHARGES
AND LAND PIPE ROUTES AGREED UPON.
Crude Oil Receipt Facilities Project
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SPM SYSTEM FLOW DIAGRAM
Existing line
from COT
SPM
Hose
Crude
transfer
pumps
PLEM
Refinery
corridor
VLCC
(3,00,000 DWT max)
To Refinery
Existing line
Offshore
piping
(48” dia 20 km)
OFFSHORE AREA
Onshore /Backwater
cross country piping
(30’’ dia 10 km)
Crude Oil Tanks
79 m dia X 18 m Ht
STF AREA
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CCPL PIPE LINE
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Aerial view of Puthu Vypeen
To Refinery
Cross country pipeline
STF
Sub sea pipeline
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SPM
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SALIENT DETAILS
• Project Approved cost- Rs 820 crores
Actual Executed Cost
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- Rs 760 crores
Pre Project activities commenced
70 ha land handed over by CPT
Project Approval Date
Approved Completion date
- Mar 2005
- Jul 2005
- Sep 2005
- May 2007
– Actual Completion (27 months)
- Nov 2007
• Conventional EPMC
– PMC- INTEC, Kula Lumpur with FEDO as Associate for
Onshore jobs
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SCOPE OF MAJOR JOBS-OFFSHORE
GEOTECHNICAL &
BATHYMETRICAL SURVEYS
DESIGN, SUPPLY SPM (250 MT) &
PLEM (175 MT)-
Assembled at Batam, Indonesia,
transported in a dedicated ship to
Cochin
SUBMARINE & FLOATING HOSES
ITALY
48” PIPES API 5L X 65 20.6 mm
MUNDRA
thick with CTE coating – 1650 nos Slabs from Mexico, rolled into
each 12M long
plates in Romania and shipped to
Kandla.
CONCRETE COATING OF PIPES
(90-120 MM THICK)
MUNDRA
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SCOPE OF MAJOR JOBS-STF
EARTH FILLING BY ADDL 3 M (AVG) TANK FOUNDATIONS- 3 NOS
with 1360 PILES EACH 900 MM DIA & 50-60M LONG
BUILDINGS , ROADS, COMPOUND WALL (5 KM)
CEMENT SUPPLY- 38000 MT
REINFORCEMENT STEEL SUPPLY- 4500 MT
TANK PLATES- 8 T0 37 MM THICK- 5000 MT
PUMPS
TANK CONSTRUCTION- 3NOS EACH 79 M DIA & 18 M HIGH WITH
FLOATING ROOF
TERMINAL PIPING
EFFLUENT TREATMENT PLANT
FIRE FIGHTING FACILITIES
ELECTRICAL SUPPLY & SUBSTATION
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SCOPE OF MAJOR JOBS- CROSS COUNTRYPIPE LINE
30” API 5L PIPE SUPPLY- 10 KM
BACK WATER CROSSINGS- 4 NOS – 4 KM LONG
HORIZONTAL DIRECTIONAL DRILLING METHOD (HDD)
ONSHORE PIPE LAYING
- THROUGH VYPEEN AREA- 4 KM
- THROUGH CITY AREA - 2KM
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First Tanker Berthing at SPM Buoy
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Uniqueness of the Project
 First Investment after opening of Goshree bridges
in the underdeveloped Puthu Vypeen area
 First Project over Rs. 500 cr in Kerala after 1990
 First Offshore job off the Arabian Sea coast
 STF construction on accreted land
 Water jetting for seabed dredging
 HDD for buried pipe lines
 Started as KRL and ended as BPCL Project
 Annual savings of about Rs. 120 Cr
 Completed in 27 months and commissioned next day.
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Obstacles faced
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Resistance from Fishing Community, blockades
Militant Labor in area – 152 days lost
Communally and politically sensitive issues
Physical threats, loading/unloading disputes
Tsunami hit the Vypeen coast in Dec 2004
6 lakh cum of Earth for filling to come from 45 km
Narrow road approach; Logistics for Material
Limited crane facility at Cochin Port
6 months unfavorable weather (May-Oct)
Poor soil conditions
Pipeline across backwater &through heart of city
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How we overcame-1
• Priority in befriending local inhabitants and earning
their acceptance and trust.
• Unskilled locals were also employed in construction.
• Continued interaction with unions, Panchayat
• Helped in improving schools, solving flooding
• Close cooperation with CPT and District
Administration, Police
• Spent Rs 16 cr on CSR activities thro transparent
means involving local and district authorities
• Changed STF entry to South side to avoid blockade
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How we overcame- 2
• Changed pipe routing thro new CPT road making the
road open for transportation
• Excavated earth from narrow north end to fill south
side where construction was focused
• Detailed study made and action for optimized
logistics and handling heavy loads
• Pile foundations used and sea wall built to resist
tsunami waves
• HDD used for water crossing and through city road
• New interconnection made to existing crude line
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Still …the Unexpected
• 4 hours after inauguration in Sep 2005, a child
drowned in a lagoon inside STF.
• One fatal accident during Pile driving for tank
• 70 km/hr winds lash STF site in 2006
• Offshore accident on 1st May 07 during Pile
driving resulting in work abandonment
• Damaging Unknown Sewer lines in city
• Delay by Railways in clearing crossing at Ekm Jn
• Cyclone “Gonu” in Arabian sea in Oct 2007.
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Factors for Success in PM-Investor view
Resources
Communication
Control
Planning
Creativity
Team effort
Functional vs Project
Functional Manager
Project Manager
Approach
Analyst
Generalist
Style
Expert
Facilitator
Technology &
Resources
Results
Area
Whole
Responsibility
Vision
Skills/Factors that can change lives
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Influence others
Create values that will be respected
Carry the support of your organization
Be Positive-Keep moving forward- never give up
Use technology to overcome obstacles
Have back up plans ready
Be realistic -street smart
Have the bird’s eye view always in your mind
Life Changing Projects- Core Skills to Succeed
• Credibility Technical and Administrative
• Leadership
Along with Management Style
• Sensitivity
Conflict Resolution, Negotiation
• Ability to handle stress
Ups and downs
Project Success
“Ultimately the SPM Project Success was achieved
by the Team winning the hearts of the local
people, converting their hostility into creative
contribution, synchronizing with the larger
national objective of development.”
Yes their lives changed; so did ours;
all for the better.