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
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 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

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 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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