EPC Projects: Improvement Opportunities for EPC Contractors through Automation

 

 

 

 

 

 

EPC Projects: Improvement Opportunities for EPC Contractors through Automation

 

 

 

 

 

 

 

Contrasting EPC and AEC

 

  • ‘C’ component is the principal target for both
  • EPC – explicit emphasis on ‘P’ component
  • EPC – relatively minor ‘A’ component
  • AEC – relatively minor ‘E’ component

 

EPC Engineering Disciplines for EPC Contractors:

  • Process
  • Mechanical
  • Geo-technical
  • Civil-Civil
  • Civil-Structural
  • Plant Layout
  • Piping
  • Electrical
  • Instrumentation and Controls

 

AEC Engineering Disciplines for EPC Contractors:

  • Architectural
  • Mechanical (HVAC & Plumbing)
  • Geo-technical
  • Civil-Civil
  • Civil-Structural
  • Electrical & Telecomm

 

EPC Challenges for EPC Contractors

 

  • Execute EPC “mega-projects” within budget and on schedule by EPC Contractors
  • Minimize construction delays by EPC Contractors due to lagging information, material or equipment.
  • Track progress and maintain contingency plans by EPC Contractors to stay on schedule.
  • Document project progress in terms of installed quantities by EPC Contractors.

 

The Challenge for EPC Contractors

 

  • Intelligently apply IT/CAD to the EPC environment.
  • Overcome conservative mind-set of builders.
  • Push progression of 2D to 3D, 4D and even 5D.
  • Apply IT/CAD tools to the advantage of constructors and their clients. Better productivity by EPC Contractors leads to better gross margins.

 

Coordinating EPC Functions

 

a) ENGINEERING:

  • Budgeted Deliverables
  • 3D Model w/ attribute data
  • Parsed MTO
  • Quantity Estimate & Tracking

 

b) PROCUREMENT:

  • Parsed MTO
  • ROS Dates
  • Prioritization
  • Material Receipt/Release

 

c) CONSTRUCTION:

  • Parsed MTO
  • Work Scope Packaging
  • Resource Management
  • Progress Tracking

 

d) PROJECT CONTROLS:

  • Schedule
  • Code of Accounts
  • Definitive Cost Estimate
  • MTO Parsing Criteria

 

EPC Sequences by EPC Contractors

 

a) EPC Engineering Sequence by EPC Contractors:

1)

  • Studies
  • OM Cost Estimate
  • NTP

2)

  • Basic Engineering
  • Criteria & Specs.
  • MTO Estimate

3)

  • Purchase Requisitions
  • Calculations
  • Detailed Engineering
  • Definitive Estimate

4)

  • Issue “Engineering “Deliverables” to Construction

5)

  • RFI’s and FCD’s
  • Produce “As-Built”
  • Project Close-Out

 

b) EPC Procurement Sequence by EPC Contractors:

1)

  • Develop Bidders Lists
  • Purchase Order Pro-Forma
  • Contracts Pro-Forma
  • Transportation and Logistics

2)

  • Specifications (Eng.)
  • Quantities (Eng.)
  • Solicit/Evaluate Bids
  • Award P.O. / Contract

3)

  • Shop Inspections
  • Track Status
  • Expedite per ROS Dates

4)

  • Transport & Receive
  • Warehouse
  • Maintain
  • Release to Construction

 

c) EPC Construction Sequence by EPC Contractors

1)

  • General Const. Plan
  • Site Layout Plan
  • Temporary Facilities

2)

  • Geo-Tech
  • Mass Earth-Works
  • Structural Concrete
  • Structural Steel

3)

  • Equipment (mech. & elec.)
  • Piping
  • Raceway
  • Instrumentation & Controls

4)

  • System Turn-over
  • Start-Up & Commissioning
  • Performance Run
  • Turn-Over to end-user

Note: Construction is supported by Field Engineering

 

d) Project Controls Sequence by EPC Contractors

  • Milestone Schedule
  • Code of Accounts
  • Cost Estimate
  • Budget Definition and Tracking
  • Level 3 CPM Schedule (aka P3)
  • Trend Program
  • Contingency Tracking
  • Schedule Optimization

 

Slice and Dice the Project

 

a) Physical Breakdown:

  • Project
  • Facility
  • Sub-Facility
  • Commodity Type
  • Tag Items or Bulk Materials

 

b) Temporal Breakdown:

  • Milestone Schedule
  • Level 3 CPM Schedule
  • Level 4 Detailed Schedule
  • Level 5 Work Packaging by work front

 

c) Sequential Breakdown:

1.Detailed Engineering
2.Materials Specification AND Quantification
3.Procurement
4.Construction
5.Commissioning and Start-Up

 

Levels of Modelling

 

  • 2D Drawings and Sketches (E)
  • 3D CAD Model with data attribute links (E)
  • 4D Construction Simulation Model (EC)

–4Dc –Construction Planning & Sequencing
–4Dr – Resource Management (and Lift Plans)
–4Ds – Construction Status

  • 5D Cost Tracking Model (EPC)

–5Dm: material costs
–5Dr: resource costs

 

Source: Stanford University