IL PROJECT MANAGEMENT NEI PROGETTI
COMPLESSI DI COGENERAZIONE
Milano, 11 Luglio 2013
Marcello Laviani
Responsabile Costruzioni
Enel Ingegneria e Ricerca
Engineering, Procurement and Construction
Structure
~750 Resources
EPC Strong presence in foreign countries
(~50% of the resources is involved
in foreign projects)
Technical Staff
Safety
Project Control Project
Quality Assurance EPC Management
Dpt.
Engineering Procurement Construction
Feasibility studies
Bids management
Process design
Machinery and Boiler Negotiations
Safety
Effluent treatment Contracts awarding
Main Scheduling & Cost Control
Instruments and control Vendor rating
duties Construction supervision
Layout & Piping Vendor scouting
Civil Commissioning & Start-up
Expediting
Electrical systems
Supply follow-up
Safety Engineering
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Engineering, Procurement and Construction
Main Projects Reftinskaya (3800 MW CFPP):
-DARS
- Unit 5 (300 MW)
- Unit 4 (300 MW)
- Unit 7 (500 MW)
Great Island CCGT
Sredneuralskaya CCGT
(430 MW)
(450 MW)
Marcinelle CCGT Conventional Island- NPP
(410 MW) EMO 3&4 (942 MW)
Litoral Porto Tolle (1.980 MW USC CFPP)
(557 MW) TVN (1980 MW-Ultra Super Critical CFPP)
Punta Alcalde CFPP Algeciras (800 MW)
(2x370 MW)
Bocamina CFPP Brindisi CFPP: - Dome for coal storage
(350 MW) - Fabric Filter UNIT 4
EW – LNG Terminal
Porto Empedocle - Jetty refurbishment
Legenda:
NPP: Nuclear Power Plant
CFPP : Coal Fired Power Plant
CCGT: Combined Cycle Gas Turbine
LNG: Liquef. Natural Gas
DARS: Dry Ash Removal System Guarantee Porjects under Support serrvices
management development
3
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 …
Bid Request Contract Award Mechanical Completion PAC FAC
WBS by units and systems
Specs
BASIC DESIGN
PFDs Specs
P&IDs P&IDs
Specs Info Drawings
Data Sheets Data Sheets
WBS by disciplines WBS by area & disciplines
CONSTRUCTION
DETAILED DESIGN
Drawings & ERECTION
Material / Work Material / Work Systems
Requisitions Requisitions Materials & Units
Info Components
Info
Works
Main Aux. & Bulk COMMISSIONING
Equip. MATERIAL SUPPLY TRIAL RUN
& START UP
WBS by commerce commodities WBS by systems & units
Offer Preparation Project Implementation Start Up Warranty Period
Hand Over
Combination of Breakdown in the same phase of the project;
Combination of Breakdown in different phases of the project. 4
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
6
EPC Projects
Some Numbers
A Combined Cycle Power Plant- CCGT 410mw (typical)
> 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
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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
ESCATRON (Spagna) - CCGT 800 MW
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
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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:
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.
Check list of constructability
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Planning methodology and assembly and erection control
Contractors - 1/2
Contractors may be:
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 ….)
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;
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
Progress control
Contractual target New target
Synthesis of physical progress
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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
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Supply Chain Management
SCM for a General Contractor
Supply Chain Management, cradle to grave.
For a general Contractor:
Engineering Procurement Expediting Transportation Site Material Mgmt.
Mat.Tak Purch Qualit
Inspec Shippi Site
e-Off/ Procur Req/ Purch Inspec Delive Packin Good y and
tions ng Wareh
Requisiti ement Req. ase tion ry g List Receip Non
and Tracki ouse
on Plan For Order Plan Plan t confor
Tests ng mgmt.
Quote mity
Fabrication/Erection Analysis (Forecast and Actual)
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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.
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Supply Chain Management
Monitoring of Bulk quantities during project development
Materials
Cost
Book
Work
DESIGN
CONSTRUCTION
Safety;
Tender, Contracts (works &
Quality;
materials requisitions), Design, Management of
Construction…. Costs;
Time
Supply Chain Management
Material Tracking and quantity monitoring
BoQ = Bill of Quantity
During Project Development … BoM = Bill of Material
Kg steel,
Mc concrete, BoQ BoM
Km cables,
Km pipes….
Driver Bulk
Items items
Same - Material Requisitions
- Work Requisitions objects from
different - Material Tracking
- Quantity Monitoring
prospectives
- Cost Control - Bulk Material Control
- Subcontract Management - Feasibility Analysis
- Construction Planning - Warehouse Management
- Quality issues
Supply Chain Management
Drivers quantity monitoring ENG = Engineering
CON = Construction
PrC = Project Control
Project Manager,
Cost Controller, • Control Times and Costs
Planner • Control Progress
PrC • Update Project Control Schedule
• Manage and Give the sequences
between ENG & COS WBS
ENG CON
• Give BoQ, BOM
• Supports CPC in Planning
• Give Driver Qty by Engineering construction activities
WBS
• Manages the
• Estimate driver quantities Subcontractors, controls
forecast to complete adequate resources are
• Estimate release dates of provided
documents • Update subcontractor
productivity 17
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 Monitoring with several tools:
3d Model, SmartPlant Material
o Construction: Analysis of delay
(SPM) …
o Project Team: Need of common recovery plan
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Supply Chain Management
Time and costs control
Feasibilities curves – 3/3
Recovery plan:
o Engineering: Decrease of delay thanks to ENG actions New feasibility with several
tools: 3d Model, SPM …
o Construction: Decrease of delay thanks ENG and COS actions
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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
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