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
Management
Quality Assurance EPC
Dpt.
Engineering
Main
duties
Feasibility studies
Process design
Machinery and Boiler
Effluent treatment
Instruments and control
Layout & Piping
Civil
Electrical systems
Safety Engineering
Procurement
Construction
Bids management
Negotiations
Contracts awarding
Vendor rating
Vendor scouting
Expediting
Safety
Scheduling & Cost Control
Construction supervision
Commissioning & Start-up
Supply follow-up
2
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)
Porto Tolle (1.980 MW USC CFPP)
Litoral
(557 MW)
Punta Alcalde CFPP
TVN (1980 MW-Ultra Super Critical CFPP)
Algeciras (800 MW)
(2x370 MW)
Bocamina CFPP
(350 MW)
Brindisi CFPP:
- Dome for coal storage
- 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
management
Porjects under
development
Support serrvices
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
P&IDs
Specs
Info
Data Sheets
Specs
P&IDs
Drawings
Data Sheets
WBS by disciplines
WBS by area & disciplines
DETAILED DESIGN
Drawings
Material / Work
Requisitions
Material / Work
Requisitions
Info
Main
Equip.
CONSTRUCTION
& ERECTION
Materials
Components
Works
Info
Aux. & Bulk
COMMISSIONING
& START UP
MATERIAL SUPPLY
WBS by commerce commodities
Offer Preparation
Systems
& Units
Project Implementation
TRIAL RUN
WBS by systems & units
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…
5
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
> 15.000 m3
HRSG
concrete

> 100 km
cables

> 1.300.000 h
Contractor man-hours

> 650 units
workforce peak at site

> 85.000 h
Construction Supervisor
7
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
8
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
9
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;
10
Planning methodology and assembly and erection control
Assembly and erection planning – 2/2
Progress control
Contractual target
Synthesis of physical progress
New target
11
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
12
Supply Chain Management
SCM for a General Contractor
 Supply Chain Management, cradle to grave.
 For a general Contractor:
Engineering
Mat.Tak
e-Off/
Requisiti
on
Procur
ement
Plan
Procurement
Purch
Req/
Req.
For
Quote
Purch
ase
Order
Expediting
Inspec
tion
Plan
Transportation
Inspec
tions
and
Tests
Delive
ry
Plan
Packin
g List
Site Material Mgmt.
Shippi
ng
Tracki
ng
Good
Receip
t
Qualit
y and
Non
confor
mity
Fabrication/Erection Analysis (Forecast and Actual)
13
Site
Wareh
ouse
mgmt.
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.
14
Supply Chain Management
Monitoring of Bulk quantities during project development
Materials
Cost
Book
Work
DESIGN
CONSTRUCTION
Tender, Contracts (works &
materials requisitions), Design,
Construction….
 Safety;
Management of
 Quality;
 Costs;
 Time
Supply Chain Management
Material Tracking and quantity monitoring
BoQ = Bill of Quantity
BoM = Bill of Material
During Project Development …
Kg steel,
Mc concrete,
Km cables,
Km pipes….
BoQ
BoM
Driver
Bulk
Items
items
- Work Requisitions
- Quantity Monitoring
- Cost Control
- Subcontract Management
- Construction Planning
Same
objects from
different
prospectives
- Material Requisitions
- Material Tracking
- Bulk Material Control
- Feasibility Analysis
- Warehouse Management
- Quality issues
Supply Chain Management
Drivers quantity monitoring
Project Manager,
Cost Controller,
Planner
• Control Times and
• Give BoQ, BOM
• Give Driver Qty by Engineering
WBS
• Estimate driver quantities
forecast to complete
• Estimate release dates of
documents
Costs
• Control Progress
PrC
ENG
ENG = Engineering
CON = Construction
PrC = Project Control
• Update Project Control Schedule
• Manage and Give the sequences
between ENG & COS WBS
CON
• Supports CPC in Planning
construction activities
• Manages the
Subcontractors, controls
adequate resources are
provided
• 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
18
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) …
19
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 …
20
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;
21
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
22