Case study background
A Case StudyHRRL — CDU/VDU, VGO, DCU
EPCPROMAN for HPCLRajasthan Refinery Limited
EPCPROMAN
Contractor
TATA Projects Limited
Owner
HRRL
The Client

TATA Projects / HRRL

HPCL Rajasthan Refinery Ltd. (HRRL) was incorporated on 18th September 2013 as a Joint Venture between Hindustan Petroleum Corporation Limited (HPCL) and Government of Rajasthan (GOR). TATA Projects served as the primary EPC contractor for the Barmer refinery project.

Requirements

HRRL required an Integrated Piping Management System for their project in Barmer, Rajasthan — covering Isometrics Spooling generation, complete Material Management, Project Planning activity, Project Control activity, Fabrication activity, Erection activity till Project completion, and Final documentation submissions.

Implementation

Solution & Approach

The scope was to implement a full EPCPROMAN solution for HRRL. The team identified key execution pillars and executed each with precision to deliver on time with limited manpower.

01

Project Task Identification & Team Setup

All project tasks were identified and listed before execution began, categorized across four levels: PCPL HO (Spooling Activity), TATA PROJECTS HO Tasks, Fabrication Shop Tasks, and Erection Site Tasks.

Team selection was a critical responsibility — the best team was assembled from the organization and right tasks were assigned based on each member's capability. Daily internal meetings were held to ensure alignment across all workstreams.

02

Project Planning & Input Collection

EPCPROMAN input collection was structured correctly from day one. All required inputs were listed and collected at the correct time. Procedures for each task were created and approved by the client — including Spooling, Revision Control, Fabrication, Erection, TestPack Control, and Barcode Activity procedures.

03

Production Monitoring & Reporting

Major production outputs — spooling outputs and progress data entry — were updated daily to the client without fail. On-time reporting to project management was a key commitment met throughout the project.

Look Ahead Reports weekly planning for upcoming workfronts

Weekly Progress Reports spooling and erection status

Fabrication & Erection Forecast Reports

Test Pack Summary Reports

NDT Coverage and Shortage Reports

04

Revision Control

Revision control was managed proactively with client involvement. Weekly revision control logs identified upcoming revisions, helping the team hold ISOs and release SWN (Stop Work Notice) and HRN (Hold Release Note) at the right time. This procedure saved significant material wastage and minimized fabrication modifications on impacted spools.

05

3D Progress Monitoring

The key differentiator in the HRRL project was 3D progress monitoring. Real-time 3D visualization was implemented as per client requirements. Weekly 3D Model progress was shared with client management, providing clear evidence of site progress and earning strong client appreciation.

06

QA/QC, Material & Test Pack Control

QA/QC outputs were delivered in client ITP format from the outset. Material was controlled across 4 fabricators and 3 site contractors with job cards issued based on project priority. Test Pack monitoring was fully managed through the system, covering package finalization, testing execution, and test pack history sheets as the final output delivery.

Fit-up/Welding Reports, NDT Coverages, Penalty Logs, Repair Logs

Test Pack History Sheets for final documentation handover

Weekly shortage reports shared with all management teams

Material tracking with Heat No., MTC No., and Batch No.

Barcode activity for asset and progress tracking

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