il project management nei progetti complessi di...
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IL PROJECT MANAGEMENT NEI PROGETTI COMPLESSI DI COGENERAZIONE
Milano, 11 Luglio 2013
Marcello Laviani
Responsabile Costruzioni
Enel Ingegneria e Ricerca
Dpt.
EPC
Project Management
Engineering Procurement Construction
Feasibility studies
Process design
Machinery and Boiler
Effluent treatment
Instruments and control
Layout & Piping
Civil
Electrical systems
Safety Engineering
Bids management
Negotiations
Contracts awarding
Vendor rating
Vendor scouting
Expediting
Supply follow-up
Safety
Scheduling & Cost Control
Construction supervision
Commissioning & Start-up
Main duties
Engineering, Procurement and Construction Structure
Technical Staff
Safety
Project Control
Quality Assurance EPC
~750 Resources
Strong presence in foreign countries
(~50% of the resources is involved
in foreign projects)
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Guarantee management
Porjects under development
Support serrvices
Algeciras (800 MW)
EW – LNG Terminal Porto Empedocle
Conventional Island- NPP
EMO 3&4 (942 MW)
Marcinelle CCGT
(410 MW)
TVN (1980 MW-Ultra Super Critical CFPP)
Reftinskaya (3800 MW CFPP):
-DARS
- Unit 5 (300 MW)
- Unit 4 (300 MW)
- Unit 7 (500 MW)
Porto Tolle (1.980 MW USC CFPP)
Brindisi CFPP: - Dome for coal storage
- Fabric Filter UNIT 4
- Jetty refurbishment
Bocamina CFPP
(350 MW)
Sredneuralskaya CCGT
(450 MW)
Litoral
(557 MW)
Great Island CCGT
(430 MW)
Punta Alcalde CFPP
(2x370 MW)
Engineering, Procurement and Construction
Main Projects
Legenda: NPP: Nuclear Power Plant
CFPP : Coal Fired Power Plant
CCGT: Combined Cycle Gas Turbine
LNG: Liquef. Natural Gas
DARS: Dry Ash Removal System
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4
Planning methodology and assembly and erection control
Principles of project planning WBS – Work Breakdown Structures
Breakdown by Geography: Zone, Unit, Area …
Breakdown by System: Steam, Water, Auxiliaries, KKS …
Breakdown by Discipline: Civil, Mechanical, Engineering, Construction …
Breakdown by Commerce commodities: Cables, Valves …
Combination of Breakdown in the same phase of the project;
Combination of Breakdown in different phases of the project.
MATERIAL SUPPLY
CONSTRUCTION
& ERECTION
COMMISSIONING
& START UP
Specs
Drawings
WBS by units and systems
WBS by disciplines WBS by area & disciplines
WBS by commerce commodities WBS by systems & units
InfoMaterials
Components
Works
Bid Request
TRIAL RUN
PFDs
P&IDs
Specs
Data Sheets
Material / Work
Requisitions
Info
Material / Work
Requisitions
Info
Main
Equip.
Contract Award PAC
Offer Preparation
BASIC DESIGN
DETAILED DESIGN
Project Implementation
Mechanical Completion
Start Up
Hand OverWarranty Period
FAC
Aux. & Bulk
Systems
& Units
Specs
P&IDs
Drawings
Data Sheets
5
Current project challenges
Fast Track Projects: projects driven by expected quick returns on investment;
Locations: multiple locations with multicultural context, often in all phases of project;
Control: strict control on processes, especially those affecting schedule and, therefore, cash flow and praise/penalties
Brown fields: EPC Project on existing power plants for fuel conversion, environmental adaptation, refurbishment, revamping…
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Planning methodology and assembly and erection control
Principles of project planning Identification of LLI – Long Lead Items
A CCGT power plant GT 18-20 months
ST+Gen. 19-21 months
HSRG 18-22 months
Condenser 16 months
FW pumps 14 months
Other items
Identification of items affecting project schedule
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> 400 t BOP ( BP-HP )
> 225.000 h Engineering
> 100.000 h Project Management
> 2.300 t steel structures
> 3.600 t HRSG
> 15.000 m3 concrete
> 100 km cables
> 1.300.000 h Contractor man-hours
> 650 units workforce peak at site
> 85.000 h Construction Supervisor
EPC Projects Some Numbers
A Combined Cycle Power Plant- CCGT 410mw (typical)
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Planning methodology and assembly and erection control
Principles of project planning Critical Path - 1/2
Critical paths: CCGT
Project schedule:
o Critical paths (CP): direct and strong impact on project achievement;
o Other paths: easy to manage and not requiring specific preliminary actions
CP of HRSG - Heat Recovery Steam Generator:
o Constraint: Fast Track Project;
o Criticalities – Time Consuming Steps: long bid phase, long fabrication and delivery at site, long and complex erection;
o Planning solutions: Limited Notice to Proceed (LNTP) vs Notice to proceed (NTP), early issue of Purchase Technical Specification (PTS), early start of the bid phase
ESCATRON (Spagna) - CCGT 800 MW
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Planning methodology and assembly and erection control
Principles of project planning Check list of constructability
Check of factors influencing the construction in all project phases:
Concept and feasibility:
Check list of constructability
o Presence of existing Power Plant – Brown Fields;
o Weather conditions.
Design and engineering:
o Level of prefabrication;
o Preliminary works.
Procurement and construction:
o Heavy lift and transport;
o Material availability plan.
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Planning methodology and assembly and erection control
Contractors - 1/2
Contractors may be:
Joint ventures:
o a specific company is created for the scope of the project;
o two or more subjects directly involved and motivated to perform in the project;
o co-operation of subjects with different backgrounds leads to increase the know-how in technical and managerial fields;
Direct subcontract:
o only one subject directly involved and motivated to perform in the project;
o contractor may or may not sub-subcontract part of the works (Italian law ….)
Consortia:
o community directly involved and interested in building the power plant;
o direct involvement of the region in building PP leads to an easy welcome of the project;
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Planning methodology and assembly and erection control
Assembly and erection planning – 2/2
Synthesis of physical progress
Contractual target
Progress control
New target
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Planning methodology and assembly and erection control
Assembly and erection planning – 1/2
Contractual target (green curve):
o Acknowledgement of quantities from ENG grouped by WBS activities
o Association of standard productivities to ENG quantities and evaluation of manpower required
o First contractual planning made according to availability of Engineering and Materials as per contract schedule;
Progress control (black and pink curves):
o Review of constraints on the schedule and on manpower capacity of the site;
o Monthly check of progress and actual manpower consumption;
o Delays and low productivity is checked Viz actual workable hours, given by availability of Engineering and Materials (Fault of Erection company or mine?)
New target (orange curve):
o re-assesment of productivities (actual) and re-forecast
o Current target curve is made according to current availability and forecast of Engineering and Materials
13
Supply Chain Management
SCM for a General Contractor
Fabrication/Erection Analysis (Forecast and Actual)
Engineering
Mat.Take-Off/ Requisition
Procurement Plan
PurchReq/ Req. For Quote
Purchase Order
Procurement
Inspection Plan
Inspections and Tests
Expediting
Delivery Plan
Packing List
Shipping Tracking
Transportation
Good Receipt
Quality and Non conformity
Site Warehouse mgmt.
Site Material Mgmt.
Supply Chain Management, cradle to grave.
For a general Contractor:
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Supply Chain Management
Materials
Materials may be:
LLI = Long Lead Items:
o equipments on critical paths (see ex. of CCGT);
Other itemized equipments:
o pumps, compressors, electrical panels…
o equipments not on critical path
Bulk materials:
o concrete, piping, cables …
o not itemized materials and components.
Materials
DESIGN
CONSTRUCTION
Work
Cost Book
Tender, Contracts (works & materials requisitions), Design, Construction….
Management of
Supply Chain Management
Monitoring of Bulk quantities during project development
Safety;
Quality;
Costs;
Time
BoQ BoM
During Project Development …
- Work Requisitions
- Quantity Monitoring
- Cost Control
- Subcontract Management
- Construction Planning
- Material Requisitions
- Material Tracking
- Bulk Material Control
- Feasibility Analysis
- Warehouse Management
- Quality issues
Driver
Items
Bulk
items
- Quantity Monitoring - Material Tracking
Kg steel, Mc concrete, Km cables, Km pipes….
Same objects from different prospectives
Supply Chain Management
Material Tracking and quantity monitoring
BoQ = Bill of Quantity BoM = Bill of Material
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PrC
CON ENG
• Control Times and Costs
• Control Progress
• Update Project Control Schedule
• Manage and Give the sequences between ENG & COS WBS
• Give BoQ, BOM
• Give Driver Qty by Engineering WBS
• Estimate driver quantities forecast to complete
• Estimate release dates of documents
• Supports CPC in Planning construction activities
• Manages the Subcontractors, controls adequate resources are provided
• Update subcontractor productivity
Project Manager,
Cost Controller, Planner
Supply Chain Management
Drivers quantity monitoring
ENG = Engineering CON = Construction PrC = Project Control
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Supply Chain Management
Time and costs control Feasibilities curves – 1/3
Feasibility study:
o Schedule of Engineering: For Construction (FC) documents
o Schedule of Construction: FC documents availability + Delivered materials + manpower capacity
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Supply Chain Management
Time and costs control Feasibilities curves – 2/3
Actual data:
o Engineering: Analysis of delay
o Construction: Analysis of delay
o Project Team: Need of common recovery plan
Monitoring with several tools: 3d Model, SmartPlant Material (SPM) …
20
Supply Chain Management
Time and costs control Feasibilities curves – 3/3
Recovery plan:
o Engineering: Decrease of delay thanks to ENG actions
o Construction: Decrease of delay thanks ENG and COS actions
New feasibility with several tools: 3d Model, SPM …
21
Supply Chain Management
Criticalities – 1/2
Criticalities and consequent preventive actions for supply may be:
For LLI:
o Long bid, delivery and erection time Pre-contract agreement (see CP of CCGT);
o Need to anticipate some civil works Early works (e.g. engineering of boiler and
boiler foundations for CFPP or engineering of diaphragm for cryogenic tank for LNG – Liquefied Natural Gas)
For bulk materials:
o Long time to complete engineering DD Frame agreement or Blanket Orders;
o Quantities monitoring to find new object on time Strict material control;
o Long delivery time Massive purchase with buy back clauses;
o Availability of right material Prefabrication / erection feasibility;
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Supply Chain Management
Criticalities – 2/2 Material managements and erection feasibility
The integration of material management information inside 3D Model gives the following benefits :
o Extraction of Bill of Quantities;
o Check the status of supplies (through interface with SAP);
o Check Construction Progress;
o Visualization on 3D Model of material and components available in warehouse
Lines 100% available BOM, good for construction
Lines partly available
Lines which cannot be constructed