39
ENCI 693 – Project Engineering Management Session #1 Introduction / EPC Business – 2011 ENCI 693 ENCI 693 Project Engineering Project Engineering Management Management Session #1 Introduction / EPC Session #1 Introduction / EPC Business Business Janaka Ruwanpura and Don McKenzie Janaka Ruwanpura and Don McKenzie Winter 2011 Winter 2011

Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Embed Size (px)

Citation preview

Page 1: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

EN

CI 6

93

– P

roje

ct E

ng

ineeri

ng

M

an

ag

em

en

tS

ess

ion

#1

In

trod

uct

ion

/ E

PC

Bu

sin

ess

20

11

ENCI 693ENCI 693Project Engineering Project Engineering

ManagementManagement

Session #1 Introduction / EPC Session #1 Introduction / EPC BusinessBusiness

Janaka Ruwanpura and Don McKenzieJanaka Ruwanpura and Don McKenzie

Winter 2011 Winter 2011

Page 2: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 2EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

2

1. Introduction1. Ground Rules2. Course Outline (see handout)3. Teaching Assistants4. Course Context5. Project Development and Execution Process6. Importance of Engineering Management to

Project Success7. Discussion

2. The “EPC” Business3. Typical Industrial Project4. EPC Company Resources5. Commercial and Contractual

Considerations

AgendaAgenda

Page 3: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 3EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

3

1. Participation is key Share your experience!

1. Relate learning to your scenario Challenge the instructor! Disagree with respect!

2. Expect good quality of work

3. Open to your concerns

4. Return promptly from breaks

5. Cell phone off during class

Ground RulesGround Rules

“EPC” Business

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

Page 4: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 4EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

4

Course OutlineCourse Outline

Learning OutcomesLearning Outcomes Final Grade DeterminationFinal Grade Determination Timetable, topics and the Timetable, topics and the

instructorsinstructors WorkloadWorkload

Quizzes Individual Case Studies Final Group Project and Presentations

“EPC” Business

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

Page 5: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 5EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

5

Teaching Teaching AssistantsAssistants

Ph.D. Candidates with several years Ph.D. Candidates with several years of professional experienceof professional experience Fereshteh Khoramshahi ([email protected]) Reza Dehghan ([email protected])

They are responsible to mark your They are responsible to mark your quizzesquizzes

“EPC” Business

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

Page 6: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 6EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

6

1. Project Engineering Management from a Balanced Perspective Owner’s and Contractor’s viewpoints

2. Methods of dividing and executing projects will vary: Owner needs Nature of project Location of project Level of industrial activity

3. Owner’s view of project span: Recognition of need Project Execution Corrections of shortcomings Ongoing operations

4.4. Contractor’s view:Contractor’s view: Limited to specific responsibilities assigned to

contractor

Course ContextCourse Context

“EPC” Business

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

Page 7: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 7EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

7

Project Development & Execution Project Development & Execution Process ChevronProcess Chevron

PHASE 2SELECT fromAlternatives

Determine Project Feasibility andAlignment withBusiness Strategy

PHASE 1IDENTIFY & Assess

Opportunities

Finalize Project Scope, Cost and Schedule and Get the Project Funded

Select thePreferred Project Development Option

Evaluate Asset to Ensure Performance to Specifications and Maximum Return to the Shareholders

PHASE 3DEVELOP Preferred

Alternative

PHASE 4EXECUTE

(Detail EPC)

PHASE 5OPERATE &

Evaluate

Produce an Operating Asset Consistent with Scope, Cost and Schedule

1 2 3 4 5

… … Need discipline to follow process by all project stakeholdersNeed discipline to follow process by all project stakeholders

“EPC” Business

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

Page 8: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 8EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

8

1. Project Schedule Engineering critical to specification and award of

long delivery equipment Engineering deliverables needed for construction

2.2. Project CostProject Cost Most of our ability to influence / control project costs

is during the early part of the projecta. Scope definitionb. Engineeringc. Equipment selection

Importance of Engineering Management to Importance of Engineering Management to Project SuccessProject Success

“EPC” Business

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

Page 9: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 9EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

9

QuestionsQuestions

CommentsComments

“EPC” Business

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

Introduction DiscussionIntroduction Discussion

Page 10: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 10EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

10

The “EPC” Engineering BusinessThe “EPC” Engineering Business

Project Project Engineering Engineering Management Management

CourseCourse

University of University of CalgaryCalgary

Winter 2011Winter 2011

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

“EPC” Business

Page 11: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 11EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

11

1. Engineering Consultants2. Engineering Design & Drafting3. Engineering-Procurement Firms4. EPC/CM Firms5. EPC Firms6. Engineered-Equipment Companies7. Specialized Technology Companies8. Technology-Midstream Operators9. Engineering Joint Ventures

Types of Engineering FirmsTypes of Engineering Firms

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

“EPC” Business

Page 12: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 12EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

12

EPC Versus ConsultantEPC Versus ConsultantNormal CharacteristicsNormal Characteristics

EPC CompanyEPC Company Consulting CompanyConsulting Company

Can Engineer, Procure and Can Engineer, Procure and Construct * complete projectsConstruct * complete projects

Provide Engineering, Procurement Provide Engineering, Procurement or Construction services onlyor Construction services only

Specialized by facility type or Specialized by facility type or industry (e.g. tank farms, power industry (e.g. tank farms, power industry)industry)

Specialized by technical Specialized by technical competency (e.g. civil engineering, competency (e.g. civil engineering, international logistics)international logistics)

Many large firms, few smallMany large firms, few small Few large, many smallFew large, many small

** All EPC’s subcontract some construction workAll EPC’s subcontract some construction work

Some “EPCM’s” subcontract all construction work to multiple construction Some “EPCM’s” subcontract all construction work to multiple construction contractors.contractors.

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

“EPC” Business

Page 13: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 13EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

13

“Company which provides integrated Engineering, Procurement and

Construction Services to deliver completed facilities (“project”) to

multiple clients”

What is an “EPC” Company?What is an “EPC” Company?

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

“EPC” Business

Page 14: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 14EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

14

1. Owner’s job is to produce and sell product

2. Projects result from:1. Change in Feedstock (raw materials)2. New products3. Expansion4. Modernization (new technology)

3.3. Project justification influenced by:Project justification influenced by:1. Market trends2. New resources3. Technology changes4. Environmental legislation5. Politics

The Need for Engineering FirmsThe Need for Engineering Firms

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

“EPC” Business

Page 15: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 15EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

15

1. EPC is not core business for owners2. Specialists in project execution3. Specialists in “Technologies”4. Access to large resource levels5. Access to diverse resources

(Internationally)6. Access to fluctuating resource levels

Why are there EPC companies?Why are there EPC companies?

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

“EPC” Business

Page 16: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 16EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

16

1. Engineering design, in all project phases2. Engineering design systems and tools3. Procurement of commodity and

fabricated materials4. Construction planning5. Integrated “EPC” planning and

scheduling6. “As-built” technical definition of the

completed project (Regulatory)

““EPC” Engineering DefinedEPC” Engineering Defined

CompanyResources

Typical Project

CommercialConsideratio

ns

Introduction

“EPC” Business

Page 17: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 17EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

17

A Typical Project DescriptionA Typical Project Description

The typical project that we will refer to for the The typical project that we will refer to for the remainder of the course will be a grassroots 100k remainder of the course will be a grassroots 100k BBL/day Atmospheric and Vacuum (A&V) Unit. We BBL/day Atmospheric and Vacuum (A&V) Unit. We have chosen this project for the following reasons:have chosen this project for the following reasons: Is core competency type project for your instructional

team Grassroots, because it has minimal outside influences Relevant to the Alberta Oil Sands economy while being a

common type unit found in many other refineries around the world

Is NOT a “Mega-Project” Requires an execution strategy which employs resource

utilization (Time, Money, People, Material) on a world-wide basis for Engineering, Procurement, Fabrication and Construction

Has a schedule which runs typically 36 to 48 months, Concept Inception through Commissioning

CompanyResources

CommercialConsideratio

ns

Introduction

Typical Project

“EPC” Business

Page 18: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 18EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

18

Typical A & V UnitTypical A & V Unit

CompanyResources

CommercialConsideratio

ns

Introduction

Typical Project

“EPC” Business

Page 19: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 19EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

19

Typical A & V Units are Extensively Typical A & V Units are Extensively ModularizedModularized!!

CompanyResources

CommercialConsideratio

ns

Introduction

Typical Project

“EPC” Business

Page 20: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 20EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

20

Typical A & V UnitTypical A & V Unit

MaterialMaterial QuantityQuantity

Pieces of Major EquipmentPieces of Major Equipment 150150

EarthworkEarthwork 100,000 m100,000 m33

ConcreteConcrete 12,000 m12,000 m33

Structural SteelStructural Steel 4,000 Te4,000 Te

PipingPiping 70,000 m70,000 m

Electrical Electrical 350,000 m350,000 m

InstrumentsInstruments 1,8001,800

CompanyResources

CommercialConsideratio

ns

Introduction

Typical Project

“EPC” Business

Page 21: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 21EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

21

Typical Project Cost StructureTypical Project Cost Structure

TOTAL CAPITAL COSTTOTAL CAPITAL COST

$ Millions$ Millions ManhoursManhours

Mechanical EquipmentMechanical Equipment 7575

Bulk Materials (Structural Steel, Bulk Materials (Structural Steel, Piping, etc.)Piping, etc.)

8585

Construction (Module Assembly, Construction (Module Assembly, Site)Site)

175175 200,000 Field Non-Manual200,000 Field Non-Manual1,800,000 Craft1,800,000 Craft

““Engineering” CostEngineering” Cost 5050 500,000 Home Office500,000 Home Office

Owners CostOwners Cost 4040

ContingencyContingency 7575

TOTAL PROJECTTOTAL PROJECT 500500

CompanyResources

CommercialConsideratio

ns

Introduction

Typical Project

“EPC” Business

Page 22: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 22EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

22

Typical Project Personnel Typical Project Personnel ResourcesResources

FEL 1 FEL 2 FEL 3 Start-up & Commissioning

“EP” “C”ProjectPhase

EP(300 People)

C(2,000 People)

Owner Personnel

EPC Personnel & Sub-Contractors

Res

ourc

es

CompanyResources

CommercialConsideratio

ns

Introduction

Typical Project

“EPC” Business

Page 23: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 23EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

23

Project Team (EPCM) - ExampleProject Team (EPCM) - Example

Project Director /ManagerProject Director /Manager&&

Functional Team LeadsFunctional Team Leads

EngineeringEngineeringManagerManager Sr. Project EngineerSr. Project Engineer

Supply ChainSupply ChainManagerManager

ConstructionConstructionManagerManager

HSE & HSE & RegulatoryRegulatoryTeam LeadTeam Lead

Corporate Corporate Human Human

ResourcesResources

Corporate Corporate Business Business ServicesServices

ProcessProcessCivilCivilStructuralStructuralMechanicalMechanicalElectricalElectricalI&CI&CMaterialsMaterialsDraftingDrafting

Project AdminProject AdminCost EstimatorsCost EstimatorsCost ControlsCost ControlsSchedulingSchedulingDoc ManagementDoc Management

ContractsContractsPurchasingPurchasingExpeditingExpeditingMaterials Materials ManagementManagementQA/Vendor QA/Vendor InspectionInspectionLogisticsLogistics

SuperintendentsSuperintendentsLabour RelationsLabour RelationsField InspectionField InspectionQuantity SurveyQuantity SurveyConstructabilityConstructabilitySite SafetySite Safety

EnvironmentalEnvironmentalOH&SOH&SPermitsPermitsRegulatoryRegulatory

-- RecruitingRecruitingBenefitsBenefitsEmployee Employee RelationsRelationsTrainingTraining

AccountingAccountingPayrollPayrollFinanceFinanceTaxTaxLegalLegalITIT

CompanyResources

CommercialConsideratio

ns

Introduction

Typical Project

“EPC” Business

Page 24: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 24EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

24

Engineering Team (EPCM) - Engineering Team (EPCM) - ExampleExample

Engineering ManagerEngineering Manager&&

Team LeadsTeam Leads

Process Process EngineeringEngineering

Team LeadTeam Lead

Civil-StructuralCivil-StructuralEngineeringEngineering

Team LeadTeam Lead

Mechanical Mechanical EngineeringEngineering

Team LeadTeam Lead

Electrical Electrical EngineeringEngineering

Team LeadTeam Lead

InstrumentationInstrumentation& Controls& Controls

Team LeadTeam Lead

Materials Materials EngineeringEngineering

Team LeadTeam Lead

DraftingDrafting

Team LeadTeam Lead

Technology Technology licensinglicensingProcess DesignProcess DesignHeat Heat IntegrationIntegrationMaterial Material BalancesBalancesEmissionsEmissionsOperabilityOperabilityStart-Up & Start-Up & erf’m Testingerf’m Testing

CivilCivilFoundationsFoundationsStructuralStructuralArchitecturalArchitecturalSpecs, Datasheets, Specs, Datasheets, MTOsMTOs

Mech Equip Mech Equip DesignDesignPiping designPiping designSpecs, Specs, Datasheets, Datasheets, MTOsMTOs

Elect Equip DesignElect Equip DesignPower systems & Power systems & distributiondistributionMotor control Motor control centrecentreEl.heat tracing El.heat tracing designdesignSpecs, Datasheets, Specs, Datasheets, MTOsMTOs

Controls Controls SystemsSystemsInstrumentsInstrumentsCablingCablingESD LogicESD LogicSpecs, Specs, Datasheets, Datasheets, MTOsMTOs

Metallurgy& Metallurgy& CorrosionCorrosionCoatings & Coatings & MaterialsMaterialsSpecs & Specs & DatasheetsDatasheets

Piping draftingPiping draftingElectrical Electrical draftingdrafting3D Modeling3D ModelingOperating Operating ManualsManuals

CompanyResources

CommercialConsideratio

ns

Introduction

Typical Project

“EPC” Business

Page 25: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 25EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

25

EPC Corporate Organization EPC Corporate Organization ChartChart

CEO

Manager of Operations

ChiefPiping & Layout

ChiefProcess

ChiefProcess

Technology

Manager of Engineering

ChiefProject

Engineer

ChiefMechanical

ChiefCivil/

Structural

Manager of IS&T

Manager of Facilities &

Office Supplies

ChiefControl

Systems

ChiefElectrical

Chief Financial

Officer

Corporate Controller

Manager of Human

Resource

Manager of Admin.

ServicesManager of

Risk / Insurance

Corporate Communications

& Public Affairs

ChiefEng Doc

MgmtGroup

Manager of Projects.

Special Assignments

Manager of Business

Development

General Manager

Office “A”

General Manager

Office “B”

Project Managers

Manager of Project Controls

Manager of Construction

Manager of Quality

Manager of Systems

Integration

Manager of Procurement

Manager of HSE

CommercialConsideratio

ns

Introduction

CompanyResources

“EPC” Business

Typical Project

Page 26: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 26EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

26

Corporate DepartmentsCorporate Departments

ENGINEERING - Design, Etc.

PROCUREMENT - Managing The Supply Chain

- Buying

- Expediting

- Inspecting

- Logistics

- Contract Formation

- Contract Administration

CONSTRUCTION (H.O.) - Construction Strategy Development

- Construction Planning

- Construction Scheduling

QUALITY - Procedural Auditing

- Continuous Improvement

- Value-improving Processes (Vip’s)

HEALTH, SAFETY & ENVIRONMENTAL - Workplace, Environmental Compliance and Improvement

BUSINESS DEVELOPMENT - Strategic Marketing Management

- Prime Contract Administration

- Sales

- Sales Proposals

CommercialConsideratio

ns

Introduction

CompanyResources

“EPC” Business

Typical Project

Page 27: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 27EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

27

Engineering Disciplines & Engineering Disciplines & SpecialtiesSpecialties

PROJECT ENGINEERINGPROJECT ENGINEERINGTECHNICAL CO-ORDINATIONTECHNICAL CO-ORDINATIONWORK PLANNINGWORK PLANNINGSCOPE (OF WORK) CONTROLSCOPE (OF WORK) CONTROLCOST & PROGRESS MONITORINGCOST & PROGRESS MONITORINGMATERIAL REQUISITIONINGMATERIAL REQUISITIONINGCONSTRUCTION PACKAGE DEFINITION (“EWP”: “CWP”)CONSTRUCTION PACKAGE DEFINITION (“EWP”: “CWP”)

CIVIL/STRUCTURAL/ARCHITECTURAL ENGINEERINGCIVIL/STRUCTURAL/ARCHITECTURAL ENGINEERINGCIVIL ENGINEERING (AND DESIGN)CIVIL ENGINEERING (AND DESIGN)**STRUCTURAL ENGINEERINGSTRUCTURAL ENGINEERING**MATERIAL SPECIFICATIONMATERIAL SPECIFICATION**BUILDING, SIZING / SPECIFICATIONBUILDING, SIZING / SPECIFICATION**

PROCESS ENGINEERINGPROCESS ENGINEERINGTECHNOLOGY SPECIALISTSTECHNOLOGY SPECIALISTSUNIT OPERATIONSUNIT OPERATIONSPROCESS SIMULATIONPROCESS SIMULATIONSYSTEM FLOWSHEET DEVELOPMENTSYSTEM FLOWSHEET DEVELOPMENT**

PROCESS CONTROL SYSTEMS ENGINEERINGPROCESS CONTROL SYSTEMS ENGINEERING“FIELD” INSTRUMENTATION SELECTION“FIELD” INSTRUMENTATION SELECTIONELECTRONIC INSTRUMENTATION SYSTEM DESIGNELECTRONIC INSTRUMENTATION SYSTEM DESIGN**AUTOMATION SPECIFICATIONAUTOMATION SPECIFICATIONAUTOMATION DESIGNAUTOMATION DESIGN

MECHANICAL ENGINEERINGMECHANICAL ENGINEERINGEQUIPMENT SPECIFICATION AND DESIGNEQUIPMENT SPECIFICATION AND DESIGNEQUIPMENT TYPE SPECIALISTSEQUIPMENT TYPE SPECIALISTS**(ROTATING MACHINERY, PRESSURE VESSELS, ETC.)(ROTATING MACHINERY, PRESSURE VESSELS, ETC.)METALLURGY SELECTIONMETALLURGY SELECTION**SAFETY SYSTEM MANAGEMENT (LOSS CONTROL)SAFETY SYSTEM MANAGEMENT (LOSS CONTROL)**

ELECTRICAL ENGINEERINGELECTRICAL ENGINEERING

POWER SYSTEM DESIGNPOWER SYSTEM DESIGNEQUIPMENT SPECIFICATIONEQUIPMENT SPECIFICATION**POWER DISTRIBUTION DESIGN (“WIRING”)POWER DISTRIBUTION DESIGN (“WIRING”)INSTRUMENTATION DISTRIBUTION DESIGNINSTRUMENTATION DISTRIBUTION DESIGN

PIPING ENGINEERINGPIPING ENGINEERINGOVERALL PLANT LAYOUT (3D-MODEL)OVERALL PLANT LAYOUT (3D-MODEL)PIPING MATERIAL SELECTION (BY “CLASSIFICATION”)PIPING MATERIAL SELECTION (BY “CLASSIFICATION”)**PIPING LAYOUT DESIGNPIPING LAYOUT DESIGNPIPING STRESS ANALYSISPIPING STRESS ANALYSIS**PIPING MATERIAL TRACKING / CONTROLPIPING MATERIAL TRACKING / CONTROL

CommercialConsideratio

ns

Introduction

CompanyResources

“EPC” Business

Typical Project

Page 28: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 28EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

28

Technology ResourcesTechnology Resources

Proprietary process technologies (“licenses”)

Work procedures:- single – discipline

Work procedures:- multi – discipline

Work procedures: - multi – department (EPC)

Work procedures:- multi – company (technical co-ordination)

Company – specific computer programs

Information technology infrastructure

Resource allocation systems

CommercialConsideratio

ns

Introduction

CompanyResources

“EPC” Business

Typical Project

Page 29: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 29EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

29

EPC Company HeadcountEPC Company HeadcountOfficeOffice PermanentPermanent

StaffStaffSpecialists/Specialists/ConsultantsConsultants

(A)(A)

Agency/Agency/ContractorsContractors

(B)(B)

TotalTotalEmployeeEmployee

ss

LocatedLocatedOutsideOutsideOfficesOffices

EngineeringEngineering

014 Engineering Management014 Engineering Management

021 Process021 Process

023 Mechanical023 Mechanical

024 Piping and Layout024 Piping and Layout

025 Civil / Structural025 Civil / Structural

026 Control Systems026 Control Systems

027 Electrical027 Electrical

029 Project Engineering029 Project Engineering

ProcurementProcurement

050 Procurement050 Procurement

ConstructionConstruction

070 Construction (Field)070 Construction (Field)

080 Field Client Support080 Field Client Support

Project ManagementProject Management

016 Project Management016 Project Management

030 Project Controls030 Project Controls

OtherOther

010 Corporate010 Corporate

012 Administration Support012 Administration Support

013 Business Development013 Business Development

015 Quality Management015 Quality Management

017 Health, Safety and Environmental017 Health, Safety and Environmental

020 Document Management020 Document Management

028 Information Systems Technology028 Information Systems Technology

040 Construction (Home)040 Construction (Home)

060 Corporate Services060 Corporate Services

33

280280

130130

226226

207207

226226

179179

125125

162162

128128

1717

3737

158158

1111

8181

55

1919

66

159159

9595

2525

100100

33

2020

66

1414

77

55

11

11

22

11

22

77

22

3838

4343

288288

107107

6868

8888

66

1919

5050

11

55

2525

77

44

88

66

11

77

33

321321

193193

520520

328328

301301

272272

132132

181181

179179

1818

4242

183183

1111

9090

66

1919

1010

169169

108108

2626

109109

00

88

11

66

22

1414

99

1919

1010

161161

1818

44

1111

00

22

00

11

22

22

44

77

00

TotalsTotals 2,3792,379 7171 771771 3,2213,221 281281

CommercialConsideratio

ns

Introduction

CompanyResources

“EPC” Business

Typical Project

Page 30: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 30EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

30

Why are Personnel Resources Why are Personnel Resources Important?Important?

1. “Typical” (large) project requires 300 personnel at peak

2. No more than 50% of an office / company dedicated to a single project (“rule of thumb”)

3. “Small” project ($50 million?) requires 50 – 100 personnel at peak

4. Difficult to be “full service” company under 200 personnel

CommercialConsideratio

ns

Introduction

CompanyResources

“EPC” Business

Typical Project

Page 31: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 31EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

31

Manpower Resource (Back log) CurveManpower Resource (Back log) CurveShowing timelines for major projectsShowing timelines for major projects

-

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

Mar

-07

May

-07

Jul-0

7

Sep-0

7

Nov-0

7

Jan-

08

Mar

-08

May

-08

Jul-0

8

Sep-0

8

Nov-0

8

Jan-

09

Mar

-09

May

-09

Jul-0

9

Sep-0

9

Nov-0

9

Jan-

10

Mar

-10

May

-10

Jul-1

0

Sep-1

0

Nov-1

0

Jan-

11

Mar

-11

May

-11

Jul-1

1

Sep-1

1

Nov-1

1

Proposed New Project

Project #3-Oilsands Mine

Project #2-Bitumen SAGD

Project #1-Bitumen Upgrader

Non Project Personnel

3200 Employees

CommercialConsideratio

ns

Introduction

CompanyResources

“EPC” Business

Typical Project

Page 32: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 32EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

32

Mark-Ups and FeesMark-Ups and Fees

1. Poorly defined in the industry2. Sometimes a “fee” is total engineering

price

3.3. ““Overhead” is a matter of opinion!Overhead” is a matter of opinion!

4.4. Analysis of “all-in” rate per manhour of Analysis of “all-in” rate per manhour of production effort is requiredproduction effort is required

Introduction

CommercialConsideratio

ns

“EPC” Business

Typical Project

CompanyResources

Page 33: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 33EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

33

EPC Contractors Cost StructureEPC Contractors Cost Structure(Home office services only)(Home office services only)

PROJECT AVERAGEPROJECT AVERAGE$ / HR$ / HR

PROJECT PERSONNEL (85%)PROJECT PERSONNEL (85%)- SALARIES- SALARIES- BENEFITS (30%)- BENEFITS (30%)- TOTAL PAYROLL- TOTAL PAYROLL

505015156565

PROJECT – SPECIFIC SERVICESPROJECT – SPECIFIC SERVICES- AUTOMATION- AUTOMATION- REPRODUCTION- REPRODUCTION- COMMUNICATION- COMMUNICATION- BUSINESS TRAVEL- BUSINESS TRAVEL

66111122

PROJECT DIRECT COSTPROJECT DIRECT COST 7575

OVERHEAD ALLOCATIONOVERHEAD ALLOCATION- FLOOR SPACE- FLOOR SPACE- BUSINESS DEVELOPMENT, OPERATIONS & OTHER EMPLOYEE COMPENSATION- BUSINESS DEVELOPMENT, OPERATIONS & OTHER EMPLOYEE COMPENSATION

551515

PRE-TAX PROFITPRE-TAX PROFIT 55

TOTAL BILLING PRICE (“ALL-IN RATE”) (RANGE $85 - $125)TOTAL BILLING PRICE (“ALL-IN RATE”) (RANGE $85 - $125) 100100

Introduction

CommercialConsideratio

ns

“EPC” Business

Typical Project

CompanyResources

Page 34: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 34EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

34

Commercial ProposalCommercial Proposal

Definition of client project and services required Definition of client project and services required (scope of work)(scope of work)

Company capability Company capability

-- TechnologyTechnology

-- PersonnelPersonnel Project execution planProject execution plan

-- Organization (key personnel)Organization (key personnel)

-- Resources requirementsResources requirements

-- Schedule of activitiesSchedule of activities

-- Estimated cost of servicesEstimated cost of services Price structure for services proposedPrice structure for services proposed Proposed form of contractProposed form of contract

Introduction

CommercialConsideratio

ns

“EPC” Business

Typical Project

CompanyResources

Page 35: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 35EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

35

Joint Ventures and Sub-Joint Ventures and Sub-ContractsContracts

Contractors form a joint “Entity” for specific Contractors form a joint “Entity” for specific venturesventures

Joint Venture shares scope/ risk among multiple Joint Venture shares scope/ risk among multiple contractorscontractors

Sub-Contractors have no contract with the OwnerSub-Contractors have no contract with the Owner

Introduction

CommercialConsideratio

ns

“EPC” Business

Typical Project

CompanyResources

Page 36: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 36EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

36

Types of Commercial ContractsTypes of Commercial Contracts

Lump SumLump Sum Fixed price; fixed work scope Limited commitment to schedule High risk /opportunity to contractor

Unit RateUnit Rate Fixed price per unit of production Well defined units of measure Limited commitment to schedule Moderate risk / opportunity to contractor

Cost ReimbursableCost Reimbursable Direct costs are reimbursed at cost Profit and overhead charged separately Lower risk / opportunity to contractor

Variations and Combinations of the AboveVariations and Combinations of the Above

Introduction

CommercialConsideratio

ns

“EPC” Business

Typical Project

CompanyResources

Page 37: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 37EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

37

Typical Contracting Typical Contracting ArrangementsArrangements

“E”

EPC Contractor“P”

“C”

SelfPerform

Construction

CM

Sta

rt-U

p &

Com

mis

sion

ing

Sta

rt-U

p &

Com

mis

sion

ing

Owner

Owner

“E”CM

C

Suppliers of Materials

Suppliers of Materials

EPC Contractor“P”

ConstructionSub-

Contractor

ConstructionSub-

Contractor

Contractual Relationship

Introduction

CommercialConsideratio

ns

“EPC” Business

Typical Project

CompanyResources

Page 38: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 38EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

38

EPC BusinessEPC Business

DiscussionDiscussion

CommentsComments

QuestionsQuestions

Page 39: Introduction and EPC Business Don McKenzie_Janaka Ruwanpura

Page 39EN

CI 693

– P

roje

ct E

ng

ineeri

ng

Managem

en

tSess

ion #

1 Intr

oduct

ion /

EPC

Bu

siness

– 2

011

39

Thank YouThank You