Académique Documents
Professionnel Documents
Culture Documents
Revamping Projects
Oil & Gas Downstream Projects
8. Project Control
1. Project control 04 - 06
Scope:
• Engineering, Procurement and Construction stages of the project
(including main Contractor, Subcontractors and Suppliers)
• Mainly Cost and Schedule (for HSE and Quality: see previous chapter)
Schedule Control objectives:
• Establish an optimized project schedule, accepted by all contributors
• Determine constraints and critical path
• Define method to measure progress, and apply it throughout execution
Cost Control objectives:
• According to Owner cost structure, produce an optimized Cost Estimate
• Make sure the budget is kept under control
− Using appropriate tools
PROJECT (Monthly)
SCHEDULE Baseline CONTROL Schedule
SCHEDULE
SYSTEM (e.g CPM) Schedule ACTION Status
STATUS LINE
Contractor Scheduling
• Same content as above
Progress Control
• Progress measurement
year J F M A M J J A S O N D J F MA M J J AS O N D J F M A M J J A S O
JACKET & FLARE 4
Basic Engineering 4
CFT - EPCI 5
Detail Engineering
Procurement 8
Construction 1
Installation
TOPSIDES 4
Basic Engineering 4
CFT - EPCI 8
Detail Engineering 10
Procurement 11
Construction & Transportation
Installation
Hook up & commissionning
PIPELINES & CABLES 3
Engineering 3
CFT 9
Procurement & transport
Critical Path
Critical Path
Address progress, but also all key events, problem areas and
higher level problem areas (« areas of concern »)
Prepared:
• Daily at site (construction / pre-com / com).
• Weekly for Head Office activities and for construction
• Monthly
• Issued before periodic Owner / Main Contractor review meetings
During execution:
• Measure progress achieved for each elementary step
• Then, aggregate to the different Levels and compute overall progress
100% 100%
99%
97%
95%
92%
90% 90%
87%
84%85%
82%
80% 79%
76%
73%
70% 70%
67%
60% 61%
56%
50% 51%
46%
40% 40%
35%
30% 30%
25%
20% 20%
17%
14%
10% 11%
9%
6% 7%
2% 3% 4%
0% 0% 0% 1%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Months
• Change Management
The Budget may be adjusted (Revised Budget) during the Project Life:
• Budget transfer from other projects
• Scope deletions or additions, approved by Owner
Main Equipment
Bulk Direct Costs
Fabrication/Construction(onshore/offshore)
+
Transportation
Temporary Facilities Indirect Costs
Construction camps
+
Engineering Services General
Management & Supervision Expenses
Surveys +
Associated Expenses
Insurance
Commissioning +
Contingencies
=
Fabrication / Construction cost are the highest costs and the most difficult to estimate,
in particular for works in revamped process units and brown field; they are very site dependent (productivity)
RC - PR GES - 08174_A_A - Rev.1 - 18/07/2013 35
Cost estimating
Preliminary Estimate: a Challenge
CAPEX estimate usual desired accuracy is +/- 30% for « new » or « expanded »
parts of projects in existing facilities, which may be relatively easy if the Plant
is recent and cost data base available or difficult depending on:
• Project complexity and location
• Onshore or Offshore projects
• Concerned facilities
• Modifications to facilities (Expansion, Debottleneck, Upgrade, Revamp)
Estimating methods are global as project details such as P&IDs are not prepared; the
estimating methodology will combine available cost data base and estimating tool box.
Estimators use cost data breakdowns, unit costs, etc. from similar recent project units at
the location, or at similar (in terms of cost) location, with corrections for location
(importance of construction cost), escalation, and other foreseen different project
conditions. (Often the estimators will use units information from several projects).
Cost information is gathered from all possible sources at the time, e.g:
• Major / special equipment or packages (glycol treatment, water
treatment, utilities and power packages, etc.): prices from Vendors
« budget » quotes.
• Interconnecting preliminary quantities estimated by engineering from
preliminary MTOs & unit costs used from previous project at the facilities,
for bulks cost & for construction cost; quotations from Vendors for large
pipe / pipelines
• Engineering, construction supervision manhours may be estimated by
ratios.
• Contingencies or CRP (Contingency, Risks and Profit) factor, added on top
of estimate
Construction cost: the most important cost item, the most difficult to estimate
CRP (Contingency, Risks and Profit factor) is added on top of the cost estimate
Site Cost Control Manager responsible for cost control at the site
and reporting operationnally to the Site Manager but functionally
to the Cost Control Manager
Day-to-day:
• Review work progress and consistency with contract terms
• Inform Management of any non-budgeted items
• Review all invoices received and consistency with contract terms
Typically on a monthly basis:
• Calculate the escalation formulae and price revisions, if any
• Manage the various provisions
• Review the estimate to complete and the final forecast
Less frequently (quarterly, annually, or ad hoc):
• Formal reporting to EPC Management, Owner and Partners
• Regulatory reporting if applicable (e.g. tax)
OVERALL
PROJECT
HOME OFFICE MANUFACTURING CONSTRUCTION AND HOME OFFICE MANUFACTURING CONSTRUCTION AND
SERVICES DELIVERY PRECOMMISSIONING SERVICES DELIVERY PRECOMMISSIONING
SPS 14,3%
Engineering 4,0%
Procurement 22,1%
Manufacturing 67,3%
Systems Testing 3,3%
Transport 3,3%
UFR 24,5%
Engineering 4,5%
Procurement 36,2%
Construction 14,5%
Offshore Installation 27,8%
OLT 17,0%
TOTAL 100,0%
RC - PR GES - 08174_A_A - Rev.1 - 18/07/2013 68
Recovery plan example: loss of mobilisation at year end
and drifting
RECOVERY PLAN:
INCREASE MOBILISATION
TO INCREASE PROGRESS
ACTUAL PROGRESS
ON TIME UNTIL END DEC.
BUT DRIFTING
Four S/Ds
at actual
EPC time
start
One
major S/D
initially
Project Level*
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Approve Scope Budget Current Commit Estimate Forecast Variance Expend. Approved
Description d Change Transfer Budget To (5+6) (+/-) Incurred Invoices
Budget (1+2+3) Complete (4-7)
AFE
X 100 0 0 100 90 12 102 2 70 65
Y 50 0 10 60 60 0 60 0 60 60
Z 90 0 - 10 80 80 -5 75 -5 73 65
Provisions
Contingen 24 0 0 24 0 22 22 -2 0 0
cy
Total 264 0 0 264 230 29 259 -5 203 190
5*** TOTAL 42430 0 2700 45130 43170 1960 45130 0 18823 16450