‘Project execution is most challenging part of project management’
Manisha Jain, Assistant Vice President, Chemtrols Industries Pvt Ltd, talks about the company, its products and projects, in this interview with Industrial Automation
Chemtrols Industries Pvt Ltd
As one of the leading players in the field, what are the main product lines of Chemtrols and the user industries?
Chemtrols is a leading solutions provider in the field of process analytics, continuous emission and ambient air monitoring systems, steam engineering, terminal automation, flow metering skids for custody transfer of liquids and natural gas, dust suppression and power distribution network system. We manufacture measurement products for level, flow, O2, dust, industrial valves (gate, globe, check and ball), plug valves, control valves, de-super heaters, HVACs, production, etc. All these products serve varied industries like oil and gas, refining, petrochemicals, chemicals, fertilizers, power, pulp and paper, cement and steel.
What are the different types of analysers offered by the company? Are these standalone units or a complete systems package?
Mostly analysers are supplied with complete system package. This includes shelters or cooled and purged cabinets, sample extraction probes, sample conditioning, sample disposal, calibration skid and data acquisition system. Analyser systems for following applications are supplied by Chemtrols:
Product quality and blending (physical properties – flash point, cloud point, freeze point, pour point, distillation analysers)
Emission monitoring systems (SO2, NOx, CO, CO2, NH3, H2S, HCL, HF, THC and Hg analysers) based on dilution, hot-wet extraction or cold dry extraction and in-situ instruments
Particulate emission monitoring systems
Ambient air monitoring systems (SO2, NOx, CO, O3, NH3, PM10, PM2.5, BTX)
Tail gas, feed gas H2S analysers in sulphur recovery plants
Moisture analysers in drier outlet and compressed air
Calorific value, air demand and Wobbe Index analysers in fuel gas
Gas chromatographs in process control and optimisation, and
Process gas analysers (O2, H2, HC, etc).
What is the Chemtrols USP? Can you give an example of a difficult project executed successfully?
Chemtrols credo has been to identify and serve the changing needs of clients. We focus on clear understanding of the project’s scope and provide the best engineering solutions and products. We have a qualified and expert workforce to support the clients. Chemtrols has completed signature project of analytics at many top corporate, like grass root refinery IOCL, RIL, Essar, Tata steel, NTPC, HPCL, etc.
Reliance Industries’ J3 Projects at Jamnagar has a huge scope of supply and commissioning of more than 350+ analysers and 30+analyser shelters. This also included construction of the world’s largest analyser shelter which was built near the river due to logistics challenges and transported by a ship to Jamnagar. This project was completed successfully and admired by the customer.
What are the challenges faced by vendors today in project execution where the stakes are high and time constraints a reality?
Project execution is the most challenging part of the project management. Involvement of multiple teams like consultants, project engineering team, contractors, sub-contractors, transporters, site execution and operation team, etc., increases the task complexity. Ineffective communication, lack of team work and slow decisions are the challenges faced. Any misunderstandings regarding scope, activity assignments, project schedules, risks, or a long list of other project essentials causes un-correctable problems during execution. In case real data is not available, assumptions have to be made that may cause schedule or cost overruns later on, if found incorrect at site.
Unrealistic expectations of customers for project schedule with agreed quality metrics put a lot of pressure on vendors and demands efficient resource management and planning. Arranging funds for projects, skilled and trained resources, logistics and transportation of materials, are also other challenges faced by vendors.
In my experience, if customers are well experienced and knowledgeable, they are able to support vendors during unexpected problems. They resolve issues as a team and are able to help finish execution within time limits.
As someone who has worked with the largest PSUs and the best private sector players, what are the differences and similarities in approach?
Competency of the people and resource availability is quite good in both – the largest PSUs and best private sector clients. Efficient use of resources is more in private sectors. Project scale, size and speed of project execution and decision making are very fast in the private sector. Plants are operated to maximum capacity overcoming all the constraints. Real time business oriented decisions are taken to maximise profit.
A greenfield project is easier to handle but a lot of work happens in brownfield projects. What are the challenges here?
In a greenfield project, there is an open field and no limits for engineering and execution. You can design the plant with best and advanced technologies and systems. No process related hazards during project execution.
When it comes to brownfield, project engineering and execution need to be done in given framework within prevailing conditions. During design and engineering, connectivity and compatibility with existing system, specifications of existing equipment need to be reviewed. Many times old engineering data and drawings are not available, hence decision making is difficult. Pre-commissioning checks to be done in running plant hence extra care to be taken with respect to process hazards and plant tripping. Overall, in a brownfield project, skilled, confident and experienced manpower and exhaustive planning is required.
Safety and security are important factors in process industries. How are these matters addressed?
The issues of Safety and Security are addressed through following ways:
Committed culture through felt leadership, operational discipline and maintaining sense of vulnerability among employees
Implementation of Process Safety Element Management System and its review periodically
Disciplined adherence to Standards for existing and new equipment through design engineering procedures and periodic audit system in place to ensure that existing equipment meets those standards
Intentional Competency Development through continuing education, seminars and symposia in their field, mentoring, job rotation, and participation in industry committees
Enhanced application and sharing of lessons learned – there is a culture in which employees are driven to learn from many sources, including benchmarking, near misses and incidents, and jobs done well
Regular risk and cyber security vulnerability assessments
Hierarchical architecture with cyber security access restrictions at each network level
Physically separated process control and process safety systems with limited access points, and
Finally best practices, policies and procedures.
(Founded in 1975, Chemtrols traces its origins to the Control of Processes in the Chemical Process Industries. The company is a leading solutions provider in process analytics, environment and emission monitoring, flow and terminal automation, process instrumentation, steam engineering, and utility management systems. With offices in all the major cities in India and a presence in the UAE, the company has an extensive reach across markets. A state-of-the-art manufacturing unit in Goa, quality certifications conforming to most global standards, and a team of some of the brightest engineers and sales & marketing personnel in the industry, makes Chemtrols a force to reckon with in the Indian industrial arena.)
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