Project Risk Register

Long-lead equipment delivery delay — Converter, WHB, or TG set fabrication exceeds planned 36–44 week delivery window

Monsoon impact on civil & structural works — Heavy rainfall at Paradeep (Jun–Sep) disrupting piling, foundations, and structural erection

Skilled labour shortage at Paradeep site — Difficulty in mobilizing sufficient welders, fitters, riggers, and E&I technicians

Delayed statutory approvals — Environmental clearance, factory license, boiler registration, or electrical inspector approvals delayed beyond planned timelines

Licensor Basic Engineering Package (BEP) delivery delay — Late receipt of process design, equipment datasheets, or catalyst specifications from technology licensor

Client review and approval delays — Slow turnaround on engineering deliverables, vendor drawings, or change requests from PPL project team

ODC (Over Dimensional Cargo) transport route restrictions — Road permits, bridge load limits, or route obstructions delaying heavy equipment delivery to site

Single-source vendor dependency for proprietary items — MECS internals, Zecor-Z alloy castings, or Lewmet mist eliminators available from sole manufacturer

Steel and alloy price escalation — Significant increase in CS plate, SS 316L, or specialty alloy prices during procurement window

Import clearance delays — Catalyst shipment, TG components, or imported instruments held at customs beyond planned clearance time

Vendor quality rejection at third-party inspection — Major equipment failing TPI at hold points, requiring rework or re-fabrication

Sub-vendor financial distress or default — Critical equipment vendor faces financial difficulties, impacting fabrication progress or delivery commitment

Vendor drawing submission delays — Late GA drawings, fabrication drawings, or weld maps delaying engineering and construction activities

Adverse soil conditions at Paradeep — High water table, soft clay, or unexpected rock requiring deeper piling or ground improvement

Converter pressure drop exceeding design limits — Higher-than-expected gas-side pressure drop across catalyst beds affecting blower capacity and plant throughput

Acid mist emission exceeding environmental norms — Stack SO₃/acid mist concentration above CPCB/SPCB prescribed limits

WHB tube failure during startup or operation — Thermal shock, water chemistry issues, or fabrication defects causing tube leak in waste heat boiler

Catalyst activation issues — Improper temperature profile during initial catalyst activation leading to reduced conversion efficiency or catalyst damage

Acid brick lining failure — Cracking, debonding, or acid penetration through brick lining in absorption or drying towers

DCS integration issues — Communication failures between DCS and field instruments, or logic errors in safety interlock system

INR/USD exchange rate fluctuation — Adverse currency movement impacting cost of imported catalyst, TG components, and licensed technology fees

GST rate changes during project execution — Change in applicable GST rates affecting project cost and cash flow

Client payment delays affecting contractor cash flow — PPL payment beyond agreed 15-day terms, impacting vendor payments and site operations

Insurance claim disputes — Disagreement on CAR/EAR policy coverage for construction damage, equipment transit damage, or third-party liability

Working at height incidents — Falls during converter erection (30m+), stack construction, structural steel erection, or equipment installation at elevation

Confined space entry hazards — Oxygen deficiency, toxic gas exposure, or engulfment during entry into vessels, tanks, towers, or underground structures

Acid handling incidents during commissioning — Skin/eye contact, inhalation, or spill during initial acid charging, circulation, and concentration adjustment

Fire during hot work — Welding, cutting, or grinding near flammable materials, insulation, or temporary structures causing fire

Crane and heavy lifting accidents — Crane failure, rigging failure, or load drop during equipment erection (converter, towers, WHB, TG)