SPE-182970-MS Keeping Oil & Gas EPC Major Projects Under Control: Strategic & Innovative Project Management Practices
SPE-182970-MS Keeping Oil & Gas EPC Major Projects Under Control: Strategic & Innovative Project Management Practices
SPE-182970-MS Keeping Oil & Gas EPC Major Projects Under Control: Strategic & Innovative Project Management Practices
Keeping Oil & Gas EPC Major Projects Under Control: Strategic & Innovative
Project Management Practices
This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 7-10 November 2016.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
The Petroleum industry requires construction and maintenance of ‘upstream’ and ‘downstream’ facilities.
Kuwait Oil Company is dealing with exploration and production of crude oil & natural gas. EPC projects
plays an important role in generation of new physical facilities to maintain or enhance production. Project
management has developed tremendously over time due to evolvement of numerous strategies to deal with
construction activities. Schedule and Budget are the two major concerns required to be optimized during
execution. Therefore, a very effective & efficient project management system is needed and has to be framed
to deal with the major capital construction projects. In effect, help organization make impact on country's
economy.
The objective of this paper is to explore few successful in-house projects to find out what went well to
identify and analyze key techniques employed to mitigate causes of delay in order to recommend strategic
and innovative methods to realize maximum benefits by completing the project on time and within budget.
This paper examines various project control methods covering project constraints for formulating strategies,
planning, budgeting, procedures, processes, performance measurement, etc. contributing to the successes
of acclaimed projects.
The paper has provided advisory-notes on the real-time innovative methods for executing projects, which
helps in making the projects more process oriented. The other critical factors, are the best practices to
simplify project management techniques and making them more explicit. By applying these innovative
approaches, most of the tacit knowledge that is used get converted into an explicit knowledge through
proactive participation.
The study has provided an insight in some novel innovative and strategic project management techniques
leading to saving in time and cost by overcoming causes of delay and highlighting suitable measures
to overcome bottlenecks during project life cycle. Some proven state-of-the-art approaches have been
developed in-house by KOC to assure project performance and uphold the Company's reputation and
corporate image. Deploying a combination of these methods as a minimum in project execution has shown
very fruitful results, which in turn has helped KOC in achieving its strategic objectives.
2 SPE-182970-MS
Introduction
As KOC's core business is to explore, develop and produce hydrocarbons, it has envisaged several growth
and development programs to achieve the oil & gas production targets in line with the company's 2020 &
2030 strategic objectives. This consists of programs and projects for construction of new surface facilities
and upgradation of the existing installations. It is usually intended and expected to complete projects earlier
and cheaper so as to attain the goal of increasing production and profitability.
Kuwait Oil Company (KOC) considers project management as one of the key elements in execution of
major EPC projects. KOC believes that a proficient project management system can help in completion of
capital projects on time, within budget, with the highest quality and in the safest manner. Profound initiatives
and mechanisms have been devised and successfully experimented to monitor and control the projects over
their entire life cycle.
It is essential for all companies to minimize risks, time and costs as any delay in completion of project will
lead to loss in production and thus revenue. However, delay in project completion is a universal phenomenon
and the construction projects in Kuwait is no exception. Therefore, the projects need adequate planning,
close monitoring and better approaches for timely completion.
Based on the vast experience, lessons learned and knowledge acquired during the execution of numerous
major capital projects, new project management processes and techniques have been developed or existing
ones are enhanced and systematically applied by KOC to minimize the effect of factors causing project
delay. Only some of the main processes are discussed and elaborated in this paper due to paper limitations.
The organizational objectives can be met through timely identification of these causes and by applying
efficient & effective project management processes and techniques to manage and control the projects.
Delay in construction projects is a situation where the project cannot be completed within the planned
time. It can be further defined as the expected completion either beyond the completion date specified in the
contract, or beyond the date agreed among the parties for project delivery. The effects of delay may include
time overrun, cost overrun, disputes, arbitration, litigation, or total abandonment of the project.
The factors of project delay in a construction project are mostly related to the following categories:
a. Project Management-Administrative
b. Design - FEED
c. Contract Action
d. Construction
e. Financial - Economical
f. Statutory Laws & Regulations
g. Act of God
Some of the most frequent causes of project delay in oil & gas construction projects (falling under one
or more categories stated above) can be seen in Figure 1.3 (as per separate study by the Authors).
In order to mitigate the risks of delay in oil & gas construction projects, it is recommended to improve
the overall project management process and carefully formulate the EPC contracts, with greater emphasis
towards the causes of delay specified in the Figure 1.3.
Bids submission date extensions requested by Bidders. (accepting due to ▪ Prospective bidders list to be updated regularly
limited participation of bidders and to maintain competition) ▪ Provide more defined & clear scope of work in the tender packages
Unavailability of Power Reservation Power Reservation shall not be redirected to other needs
Non-availability of Vendors during equipment commissioning and start-up. Advance planning and expediting with Contractor/Vendors.
Table 1.1—(continued).
Shortage of experienced project team members within the company to meet ▪ Advance planning & mobilization of manpower
capital project demand. ▪ Training & Development to increase skilled resources
Senior management & Staff commitment ▪ Performance measurement through BSC / SMAIP / MAIP targets
projects by controlling the delay causing factors at the early stage of the project without allowing them to
grow or expand so as to affect the project performances (refer Figure 1.4).
There are other added elements contributing to the successes such as right contracting strategy, better
payment terms with advance payments option in the contract, early procurement of long lead items, advance
shutdown / tie-ins plans, capturing & implementing lessons learned, incentive schemes, value engineering
and effective quality management system.
Another important aspect of gaining maximum business value from project management practices is that
the projects are led by people having strong leadership quality, business acumen and subject expertise.
The processes shown in Figure 1.4 are further elaborated below to understand their nature and benefits:
Package' to assess whether said stage is complete and the project is ready to progress to the next stage or
whether alternative courses of action are required.
Project Gate System has been beneficial by ensuring that all the requirement of a particular stage has been
completed and recommends to move ahead by closing the stage gate through effective decision making.
This has helped in improving the outcome of capital projects with less rework, thus saving time and cost.
Some of the processes are CPP approval, BP approval, AFE approval, Capex annual re-phasing,
Opex annual allocation, project documents management, etc. These processes have resulted in substantial
reduction in approval processing time thus leading to reduction in project cycle time.
Project issues can be resolved by putting up facts through verbal communications, which needs to be
recorded as Minutes of Meeting for future reference.
Proactive communication leads to information reaching to the stakeholders on time so that the corrective
measures can be taken on immediate basis.
The above is followed and encouraged, which has resulted in savings in time and cost.
Quantified Benefits
As described above in the individual process elements, there are magnitudes of benefits that can be derived
by suitable implementation of these elements in projects. It can also be seen that some benefits are tangible
while others may be intangible in nature, but eventually they all can have positive impacts on the project
performances. These benefits support the project's time, cost, and enable the project management to be more
agile to adapt to variations in project needs.
Historical data from several past projects has been collected to conduct analysis in terms of schedule for
the time taken with respect to the current and earlier approaches and utilized to compare with the standard
times for these approaches. It can be realized from the Figures 1.5 & 1.6 that considerable reduction in time
can be achieved after implementing the stated innovative and strategic practices.
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Interpretation of Outcomes
The Figure 1.5 shows the time taken before and after implementation of new/improved methods and also
indicates that there is considerable reduction in the duration of process elements compared to the earlier
approaches and has come closer to their standard times.
The analysis conducted at Figure 1.6 for percentage reduction in duration with respect to before and
standard times indicates the following:
– If the processes are properly utilized, it can lead to substantial reduction for some of the process
elements.
– It can be seen that some processes are within the range or even taking less time than the standard.
– For some processes, there is still scope for further improvement with respect to their standard
times.
Other Benefits
Few other benefits which add a long lasting strategic advantage are:
SPE-182970-MS 13
Statistical Validation
The benefits, promulgated above was further validated by converting the same data into attribute form and
conducting a test of hypothesis for comparing the achieved and not achieved targets (refer Figure 1.7).
It can be inferred from the above analysis that taking the stated 8 elements under consideration, the
exceeded time was reduced from 29.00% to 5.50% with 95% confidence after implementing the solutions.
Conclusions
Project Management is vital to project success. Effective project management can enhance the project
performance and consequently the productivity of the company. It is the key to ensure that the company's
strategic objectives are achieved as per plan. Hence, an effective project management is the need of the hour
to assure program/project performances and uphold the Company's reputation and corporate image.
Acknowledgements
The Authors would like to thank the KOC Management for allowing us to publish this paper. We would
like to thank the entire Major Project Groups and Project Support Services Group for their professional
approach, efforts and contributions in successful accomplishment of capital projects activities, which can
be produced in this paper.
Nomenclature
AFE : Approval for Expenditure
A.O : Adjustment Order
BP : Budget Proposal
BSC : Balanced Score Card
CEO : Chief Executive Officer
CPP : Capital Project Proposal
CT : Controlling Team
14 SPE-182970-MS
CR : Contract Requisition
DCEO : Deputy Chief Executive Officer
EPC : Engineering, Procurement & Construction
FEED : Front End Engineering & Design
KPC : Kuwait Petroleum Corporation
KPI : Key Performance Indicator
KPM : Key Performance Measure
KOC : Kuwait Oil Company
LSTK : Lump sum Turnkey
MAIP : Manager Annual Incentive Plan
PMC : Project Management Consultant
PMP : Project Management Plan
RT : Requesting Team
RFA : Recommendation for Award
SMAIP : Snr. Management Annual Incentive Plan
SOC : Safety Observation Conversation
TCE : Tender Check Estimate
SVV : Site Verification Visit
References
1 Project Management Book of Knowledge (PMBOK) 5th Edition, PMI, USA
2 Project Gate System Manual, KOC
3 CPP Manual, KOC
4 BSC, SMAIP, MAIP Guidelines, KOC
5 Risk Assessment Guidelines, KOC
6 Garold D. Oberlender (2000), Project Management for Engineering and Construction, McGraw
Hill Publishing, New Delhi
7 Chalabi FA, Camp D. (1984), "Causes of delay and overruns of construction projects in
developing countrie"s
8 Chan WM. Kumaraswamy MM (1998), Contributors to construction delays. Construction
Management and Economics 16, pp. 17–29
Author
Hamad Al-Hajji is a Civil Engineer. He has an experience of over 20 years with Oil & Gas Industry in
design, engineering and project management. At present, he is working with Kuwait Oil Company as Team
Leader for Project Control Team of Project Support Services Group. Email: [email protected]
Shehzad Khan is a Mechanical Engineer. He has an experience of over 25 years with Oil & Gas Industry
in maintenance, design, engineering and project management. At present, he is working with Kuwait
Oil Company as Engineer Planning in Project Control Team of Project Support Services Group. Email:
[email protected]