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EPC Project Contract Cost Estimation Contractors Know-How For EPC Project Executing Project Work Break Down Structure (WBS) Identifying and Managing Risks in EPC Projects Managing & Control of Project Changes in EPC Projects Engineering & Design Phase Documents Flow Diagram EPC Project Management
Seminar Approach
1. 2. 3. 4. 5. 6. 7.
EPC Project Definition Functional WBS Code for EPC Project Methodology and Flow of Cost Estimating Main Questions to be Asked to Cost Estimate Why People Get Estimating Wrong Risk Related Cost Estimating Summary
Agreement and Engineering Design (Basic, FEED & Detail Activities) / Erection and Pre-Commissioning and Start-up
Procurement Construction
Commissioning Training
Feasibility Study
PMC/Engineer Selection
Project Execution
Define Scope
ITB Preparation
Engineering Design
Procurement /Supply
Funding / Budgeting
Construction
Description
Feasibility Study License & Engineering Procurement Construction Pre-Com Commissioning and Start-up Training Logistic and Others
% Range
1 7-10 50-60 20-25 2 1 1
EPC Project
Prefossinal Services
Materials
Labor Work
Transportation
Others
Professional Services
Professional services
Project MGT Detail Engineering Quality MGT Comm. & Operation Training Basic Engineering Procurement Const. MGT & Supervision Project Administration Others
Basic Engineering
Process Design, Plant Safety, Instrumentation, General Civil, Plant Layout and Piping Specification
Detail Engineering
Civil and U/G, Structure, Building, Equipment, Piping, Instrumentation, Electrical, Paint AND Insulation,
Procurement
Procurement General, Purchasing, Subcontracting, Expediting, Traffic and Custom Clearances
Project Administration
Administration General, Personnel Control, Project Accounting, Communication and Correspondence, Document Handling, Camp Organization, General Affairs
Materials
Materials
Direct Materials
Spare Parts
Others
Materials
Direct Materials
Civil Materials, Structure Materials, Building Materials, Equipment, Piping and Bulk, Instrumentation, Electrical, Insulation and Painting,Fire Proofing and Surface Protection, Catalysts, Chemicals, and Utilities
Indirect Materials
Temporary Building, Utilities and Telecommunications, Housing Equipment and Furniture, Shop Equipment and Tools,Common Scaffolding, Canteen
Spare Parts
spare Parts for Commissioning and Start-up, Spare Parts for Operation (2 Years)
Labor Work
Labor Work
Ind. Lab. Work for Temp. Work
Supervisory
Construction Equipment
Others
Supervisory
Civil General, Concrete Structure, Steel Structure, Building, Equipment Installation, Piping, Instrumentation, Electrical, Insulation and Painting, Fire Proofing and Surface Protection, Catalysts, Chemicals and Utilities
Transportation
Transportation
Onshore
Offshore
Ocean Frieght
Others
Transportation
Offshore
Packing, Handling, Transportation, Shipping and Custom Clearances
Ocean Freight
Ocean Freight, Air Freight
Onshore
Packing, Handling, Transportation,
Home and Branch Office Expences Financial Charge Tax and Duties Third Party Inspection Charge Agent Fee
Financial Charge
L/C Charge, Bond Charge, Interest Charge
Insurance
Governmental Insurance, Transport Insurance, Travels, Accident Insurance, Social Insurance, Construction Insurance, Provisional Liability Insurance
Licensors Charge
Royalty, Know-How Fee, Basic Design Fee, Design Checking Fee, Operation Charge
Consultant Fee
Engineering Consultant Fee, Training Consultant Fee, Accountant Fee, Lawyer Fee
Others
Others
Rate Difference
General Overhead
Contingency
Definition of Cost 3.2 Type of Costs 3.3 Cost Estimation Methodology (Tools and Techniques) 3.4 Cost Estimation Templates for EPC Project
Variable Costs: Any Cost that Changes With the Amount of Production or the Amount of Work. Examples Include the Cost of Material, Supplies, Labor, etc. Fixed Costs: Costs That Do Not Change as Production Changes. Examples Include Set-Up, Rental, etc. Direct Costs: Costs That Are Directly Attributable to the Work on the Project. Examples are Team Travel, Recognition and Rewards, Cost of Materials, Training Indirect Costs: Overhead Items or Costs Incurred for the Benefit of More Than on Project. Examples Include Taxes, Benefits, Insurances, etc. Opportunity Costs: Net Present Value of a Project. Is Really a Choice to Do / Not to Do a Project
Accuracy Rate
-25% to 75% -10% to 25% + or 15% + or 5%
Rough Order of Magnitude (ROM) Budgetary Approximate Estimate (Informational) Definitive (Based on Detailed Information)
Uses the Actual Cost of a Previous, Similar Project as the Basis for the New Estimate Advantages:
Quick Activities Need not be Identified Less Costly to Create
Disadvantages:
Less Accurate Estimates are Prepared with a Limited Amount of Detailed Information and Understanding of the Project Requires Considerable Experience to Do Well Extremely Difficult for Project With Uncertainty
Estimate Individual Work Items and Sum Them to Get a Total Estimate Advantages:
More Accurate Gains Buy-In From Team Because the Team Creates Estimates the Can Live With Has Been Prepared Based On a Detailed Analysis of the Project Provides a Basis for Monitoring and Controlling, Performance Measurement and Management
Disadvantages:
Takes Time and Expenses Tendency for the Team to Pad Estimates Unless Taught About Reserves Requires that the Project be Well Understood Requires Time to Break the Project Down into Smaller Pieces
General Methodology
Establish rules for C/S & define assumptions Set up tools and format for data input Establish C/S Coordinator for each Work Package Create Technical Requirements Document Develop Technical Conceptual Design
Create the WBS Estimate Cost & Schedule and create the BOE Develop the RLS and Mgmt Docs
C/S = Cost & Schedule WBS = Work Breakdown Structure BOE = Basis of Estimate RLS = Resource Loaded Schedule
Review
Yes Report from GG5, Dec. 20, 2005 Fund Starts
No
Power (Basic Engineering, Endorsement, Detail Engineering) Consumable Office and Furniture Management Overhead Contingency
Procurement
Procurement
Engineering and Man Power (Technical Doc. Preparation and Material requisition, Bidder Clarifications, Proposal Evaluation (Technical, Commercial, Expediting and Inspection) Equipment (LC Opening, Purchase Order, Manufacturing, Test and Inspection) Bulk Materials (LC Opening, Purchase Order, Manufacturing, Test and Inspection) Logistic (Shipment, Custom Clearances and Delivery to Site)
Construction
Site
Preparation Site Establishment Plant Construction Safety and Security Camping Pre-Commissioning Commissioning Management Man Power Contingency Construction Insurance
Actual
Finishin g Period
Early Pla 0
PROGRESS
100
10
20
30
40
50
60
70
80
90
0 May-2005
Jun-2005
July-2005
Aug-2005
Sep-2005
11
Oct-2005 18 Nov-2005 26 Dec-2005 37 Jan-2006 48.2 Feb-2006 59.8 Mar-2006 72 Apr-2006 83 May-2006 90.9 Jun-2006 96 July-2006 98 Aug-2006 99 Sep-2006 100
Oct-2005
Nov-2005
Dec-2005
Jan-2006
Overall S Curve
MONTH Feb-2006 Mar-2006 Apr-2006 May-2006 Jun-2006 July-2006 Aug-2006 Sep-2006 Oct-2006
Oct-2006
Actual
Finishing Period
Early Plan
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
0.00 May-2005 Jun-2005 July-2005 Aug-2005 Sep-2005 Oct-2005 Nov-2005 Dec-2005 MONTH Jan-2006 Feb-2006 Mar-2006 Apr-2006 May-2006 Jun-2006 July-2006 Aug-2006 Sep-2006 Oct-2006
Aug-2005
Sep-2005
Oct-2005
Engineering S Curve
51.50 60.00 70.30 78.70 80.01 84.27 88.31 90.40 91.09 91.60 92.05 95.80 100.00
Oct-2006
Actual
Finishing Period
Early Plan
PROGRESS 100.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 0.00 May-2005
0.00 May-2005
Jun-2005
0.00
Jun-2005
July-2005
0.00
July-2005
Aug-2005
0.00
Aug-2005
Sep-2005
1.35
Sep-2005
Oct-2005
7.95
Oct-2005
Nov-2005
15.14
Nov-2005
Procurement S Curve
MONTH Dec-2005 Jan-2006 Feb-2006 Mar-2006 Apr-2006 May-2006 Jun-2006 July-2006 Aug-2006
Dec-2005
Jan-2006
Feb-2006
Mar-2006
Apr-2006
May-2006
Early
Actual
Finishing Period
PROGRESS
0.00 May-2005
100.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
0.00
0.00
Jun-2005
May-2005
0.00
Jun-2005
July-2005
0.35
July-2005 Actual
Aug-2005
6.20
Early Plan
Aug-2005
Sep-2005
12.35
Sep-2005
Oct-2005
20.11
Oct-2005
Nov-2005
28.54
Nov-2005
Dec-2005
37.54
Dec-2005
Jan-2006
Jan-2006
47.04
Feb-2006
Construction S Curve
MONTH Feb-2006 Mar-2006 Apr-2006 May-2006 Jun-2006 July-2006 Aug-2006 Sep-2006 Oct-2006
Mar-2006
Apr-2006
May-2006
Jun-2006
July-2006
Aug-2006
Sep-2006
Oct-2006
Were Historical Data Used? Were Inflation Rates Used? Were Project Scope Definition Have Been Completely Understood and Interred in the Cost Estimating Formats? Were Geometrical and Site Condition Completely Understood? Were Codes and Standards Have Been Clarified? Were Any Regulation to be Followed During Contract Have Been Asked From Client? Were Training Requirements for Client Personnel Have Communicated? Is There Any Client Facilities during Contract Execution?
Over Optimistic Nothing Will Go Wrong Underestimating Things Like Control the Activity, Coaching, Supervision, Project Meeting Lack of Understanding of Project Scope Ignoring Reality Assuming Nothing Will Change Just Guessing Estimating Isnt a Managed Activity! Junior People Involvement Cross Section Communication During Estimation Time Double Estimating Unclear Scope of Supply Between Procurement and Construction Department Underestimating Cost of Temporary Facilities, Consumables, Tools, etc., for Construction, Pre-commissioning, etc. Lack of Good Relations With Subcontractors (Vendors) Giving Gold Plating Instead of Following Scope
/ Complexity of Project Procurement Restriction and Law Client / Contractor Resources (personnel, etc.,) Project Schedule Clients / Contractors Ability to Finance Project Scope Changes Design Criteria
7.Summary (1/2)
Project Cost Management / Estimating is Primarily Concerned with the Cost of the Resource Needed to Complete a Defined Activity. Project Cost Management Should Also Consider the Effect of Project Decisions on the Cost of Using, Maintaining, and Supporting the Product, Service, or Result of the Project. Project Cost Estimating Consider the Information Requirements of the Project Stakeholders. Different Stakeholders will Measure Project Costs in Different Ways and Different Items. On Some Projects, Especially Ones of Smaller Scope, Cost Estimating and Cost Budgeting are so Tightly Linked that are Reviewed as a Process that can be Performed by a Single Person.
7. Summary (2/2)
Some Organizations have Predefined Approached to Cost Estimating. Where these Exist, the Project Operates Within the Boundaries Defined by the Policy Cost of Quality Should be Also be Used to Prepare the Schedule Activity Cost Estimate.
Thank You