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)

2

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

3

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…

6

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

7

> 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)

8

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

9

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.

10

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;

11

Planning methodology and assembly and erection control

Assembly and erection planning – 2/2

Synthesis of physical progress

Contractual target

Progress control

New target

12

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:

14

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

17

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

18

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

19

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;

22

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