
Project Management in the Oil and Gas Industry
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Mohamed El-Reedy has over 20 years of experience working on oil and gas projects and electric power projects, working with BP, Apachi, Amoco, Saipem, Agip. He has worked as a chief engineer with Worley Parsons in Egypt, and has published many papers in international conferences sponsored by API, ASME, ASCE, ACI. He has taught numerous courses in construction management and project management throughout the Middle East, Malaysia and Singapore, and he has published 3 books with CRC Press and 4 books in Arabic.
Inhalt
Preface xv
About the Author xvii
1 How to Manage Oil and Gas Projects 1
1.1 The Principal of Project Management 1
1.2 Project Characteristics 2
1.3 Project Life Cycle 5
1.3.1 Initiation of the Project 7
1.3.1.1 Getting to the Scope Baseline 9
1.3.2 Feasibility Study 10
1.3.3 FEED (Preliminary) Engineering 11
1.3.4 Detail Engineering 15
1.3.5 Decision Support Package 17
1.3.6 Design Management 19
1.3.7 Execution Phase 20
1.3.8 Commissioning and Startup 21
1.4 Is this Project Successful? 22
1.4.1 Project Management Goals 22
1.4.1.1 Project Integration Management 23
1.4.1.2 Project Scope Management 23
1.4.1.3 Project Time Management 24
1.4.1.4 Project Cost Management 24
1.4.1.5 Project Quality Management 24
1.4.1.6 Project Human Resource Management 25
1.4.1.7 Project Communications Management 25
1.4.1.8 Project Risk Management 25
1.4.1.9 Project Procurement Management 25
1.5 Project Management Tasks 26
1.5.1 Define the Project Target 26
1.5.2 Define the Scope of Work 27
1.5.3 Define the Time Frame 27
1.5.4 Define the Available Resources 27
1.5.5 Define the Cost 28
1.5.6 Evaluate the Master Plan 28
1.5.7 Accept the Master Plan 28
1.5.8 Schedule Follow Up 29
1.5.9 Cost Follow Up 29
1.5.10 Comparing Between Actual Work and Master Plan Cost 29
1.5.11 Performance Evaluation 29
1.6 Project Manager Skill 30
Quiz 31
2 Project Economic Analysis 39
2.1 Introduction 39
2.2 Project Cash Flow 40
2.2.1 Depreciation Methods 43
2.2.1.1 Straight-Line Method 44
2.2.1.2 Declining-Balance Method 45
2.2.1.3 Sum-of-the-Year-Digits 45
2.2.1.4 Sinking-Fund Method 46
2.2.1.5 Service-Out Method 46
2.2.2 Method of Net Present Value (NPV) 47
2.2.2.1 Inflation Rate 47
2.2.3 Minimum Internal Rate of Return (MIRR) 48
2.2.4 Payout Method 49
2.3 Economic Risk Assessment 50
2.3.1 Probability Theory 50
2.3.2 Probability Distribution of Variables 55
2.3.2.1 Normal Distribution 55
2.3.2.2 Log Normal Distribution 57
2.3.2.3 Binominal Distribution 60
2.3.2.4 Poisson Distribution 63
2.3.2.5 Exponential Distribution 63
2.3.2.6 Weibull Distribution (Rayleigh Distribution) 63
2.3.2.7 Gamma Distribution 64
2.3.2.8 Logistic Distribution 65
2.3.2.9 Extreme Value (Gumbel Distribution) 66
2.3.2.10 Pareto Distribution 66
2.3.3 Distribution for Uncertainty Parameters 67
2.3.3.1 Triangular Distribution 67
2.3.3.2 Uniform Distribution 68
2.3.4 Choose the Appropriate Probability Distribution 69
2.3.4.1 Chai Square Method 70
2.3.4.2 Kolmograv-Smirnov (K-S) 70
2.4 Decision Tree 71
2.5 Monte-Carlo Simulation Technique 75
2.6 Risk Adjusted Value (RAV) 78
3 Pitfalls in Time Schedule Planning 81
3.1 Introduction 81
3.1.1 Plan Single Point of Accountability (SPA) 84
3.1.2 Starting the Plan 85
3.1.3 Work Breakdown Structure (WBS) 87
3.2 Responsibilities of the Team 90
3.3 Expected Activity Time Period 91
3.4 Calculate the Activity Time Period 93
3.5 Time Schedule Preparation 94
3.5.1 Gantt Chart 95
3.5.2 Arrow Diagram Method (ADM) 95
3.5.3 Precedence Diagram Method (PDM) 96
3.5.4 Critical Path Method (CPM) 96
3.5.5 Program Evaluation and Review Technique (PERT) 97
3.5.6 Example 98
3.5.7 Application of the PERT Method 102
3.5.7.1 Statistics Calculation for Activity Time 102
3.5.7.2 Example 103
3.5.7.3 Time schedule control 104
3.6 Planning Overview 107
Quiz 109
4 Project Cost Control 113
4.1 Introduction 113
4.2 Cost Types 115
4.2.1 Cost Estimate 116
4.2.1.1 Top-Down Estimates 117
4.2.1.2 Bottom-Up Estimates 117
4.2.1.3 Analogous Estimates 117
4.2.1.4 Parametric Estimates 118
4.2.2 Steel Structure Cost Estimate 122
4.2.3 Detailed Cost 124
4.2.4 Cost Estimate to Project Control 124
4.3 Economic Analysis to Project Cost 125
4.3.1 Work Breakdown Structure (WBS) 125
4.3.2 Organization Breakdown Structure (OBS) 126
4.3.3 OBS/WBS Matrix 126
4.3.4 Work Packages 127
4.3.5 Cost Control 128
4.3.6 (S) Curve 131
4.3.7 Engineering Cost Control 134
4.4 Cash Flow Calculation 135
4.4.1 Project Cash Flow 135
4.4.2 Impact on Increasing Cost 137
4.4.3 Project Late Impact 137
4.4.4 Impact of Operation Efficiency 138
Quiz 139
5 Resource Hiring 143
5.1 Introduction 143
5.2 Project Organization 144
5.2.1 Types of Organizations 144
5.2.1.1 Project Organization as a Part of the Company 145
5.2.1.2 Separate Project Organization 146
5.2.1.3 Matrix Organization 147
5.2.2 Selecting the Best Organization 149
5.3 Roles and Responsibilities of the Project Manager 151
5.3.1 Project Manager as a Leader 152
5.4 Administrative Organization for Total Quality Management 154
5.5 Team Member Selection 155
5.6 Managing the Team 157
5.7 Allocate Resources to Project Plan 158
5.7.1 Example 158
5.8 Relation Between Project Parties 162
5.9 Document and Information Transfer 162
5.10 Information Transfer 163
5.11 Quality Control in the Design Phase 164
5.11.1 Inputs and Outputs of the Design Phase 169
5.11.2 Design Verification 169
5.11.3 Change in the Design 169
5.11.4 Approval of the Design 174
Quiz 177
6 Tendering, Bidding, and Contract Traps 183
6.1 Introduction 183
6.2 Contracts 184
6.2.1 Measured Contract 186
6.2.2 Lump Sum 186
6.2.3 Cost Plus 187
6.3 Contract Between the Owner and Engineering Office 187
6.4 The Importance of Contracts in Assuring the Quality of the Project 189
6.5 Contracts in ISO 190
6.6 FIDIC Contracts 190
6.7 General Conditions in the Contracts 197
6.8 Arbitration and the Arbitrator 198
6.9 Bids and Tenders 200
6.9.1 Public (Open) Tender 200
6.9.2 Limited Tender 202
6.9.3 Negotiated Tender 203
6.9.4 Direct Order 203
6.9.5 Tender Technical Evaluation 204
6.9.6 Commercial Evaluation 207
6.9.6.1 Commercial Evaluation Methods 207
6.10 Closeout Report 208
Quiz 210
7 New Approach in Managing Oil and Gas Projects 215
7.1 Introduction 215
7.2 Quality System 216
7.3 ISO 9000 217
7.4 Quality Management Requirements 218
7.4.1 Quality Manual 218
7.4.2 Quality Plan 219
7.4.3 Quality Control 219
7.4.3.1 Why is Quality Control Important? 220
7.4.3.2 Submittal Data 221
7.4.3.3 How to Check Incoming Materials 222
7.4.3.4 Methods of Laying Out and Checking Work 222
7.4.3.5 Material/Equipment Compliance Tests 224
7.4.3.6 When to Inspect Work 225
7.4.3.7 Paperwork/Documentation 226
7.4.3.8 Quality Control Plans 228
7.4.4 Quality Assurance 229
7.4.4.1 Quality Assurance in the ISO 231
7.4.4.2 The Responsibility of the Contractor (Manufacturer) 232
7.4.4.3 Responsibility of the Owner 233
7.5 Project Quality Control in Various Stages 234
7.5.1 Feasibility Study Stage 234
7.5.2 Feed (Preliminary) Engineering 235
7.5.3 Detailed Engineering Study 238
7.5.3.1 Design Quality Control 239
7.5.4 Execution Phase 240
7.5.4.1 ISO and Control Work 242
7.5.4.2 Inspection Procedures 242
7.5.4.3 Importance of Contracts in Assuring the Project Quality 243
7.5.4.4 Checklists 243
7.6 Operational Phase of the Project 249
7.7 Total Building Commissioning System 250
7.7.1 Planning Stage 252
7.7.1.1 Identify Commissioning Team 252
7.7.1.2 Define Owner's Project Requirements with the Customer Agency 258
7.7.1.3 Develop Preliminary Commissioning Plan 258
7.7.1.4 Commissioning for Certifications (LEED, Energy Star, etc.) 258
7.7.1.5 Commissioning Agent Costs 261
7.7.1.6 Cost-Benefit Analysis for Commissioning 262
7.7.2 Design Stage 262
7.7.2.1 Incorporate Commissioning into A/E and CM Scope of Services 262
7.7.3 Construction Stage 272
7.7.3.1 Review Submittals for Performance Parameters 272
7.7.3.2 Develop and Utilize Construction Checklists 273
7.7.3.3 Oversee and Document Functional Performance Testing 274
7.7.3.4 Test Data Records 274
7.7.3.5 Hold Commissioning Team Meetings and Report Progress 275
7.7.3.6 Conduct Owner Training 276
7.7.3.7 Turnover Commissioning Record 277
7.7.4 Building Commissioning Process Post-Construction Stage 279
7.7.4.1 Post-Construction Stage 279
7.7.4.2 Perform Deferred and Seasonal Testing 279
7.7.4.3 Re-inspect/Review Performance Before End of Warranty Period 280
7.7.4.4 Complete Final Commissioning Report 280
7.7.4.5 Recommission Facility Every 3-5 Years 282
7.7.4.6 Recommissioning 282
7.7.5 Advantages for Total Building Commissioning System 283
Quiz 284
8 Practical Risk Management for Oil and Gas Projects 287
8.1 Introduction 287
8.1.1 The Risk Management Process 288
8.2 Project Risks 289
8.3 Risk Assessment 293
8.4 Risk Identification 294
8.4.1 Methods of Defining Risk 296
8.4.1.1 Brainstorming 296
8.4.1.2 Delphi Technique 297
8.4.1.3 Nominal Group Technique 298
8.4.1.4 Crawford Slip 299
8.4.1.5 Expert Interviews 299
8.4.1.6 Root Cause Identification 300
8.4.1.7 Checklists 300
8.4.1.8 Documentation Reviews 300
8.4.2 Grouping the Risks 301
8.5 Define Priorities 302
8.5.1 Matrix Method 302
8.5.2 Tabulated Method 303
8.6 Risk Response Planning and Strategies 305
8.7 Risk Monitoring and Control 306
8.8 Example 307
8.9 Operations risk 310
8.10 Methods of Risk Avoidance 312
Quiz 313
References 315
Chapter 1
How to Manage Oil and Gas Projects
1.1 The Principal of Project Management
The subject of project management has become one of the most common themes in the recent past, and that is due to the increase in the number of mega projects worldwide and the development of modern technology in all areas of knowledge, which requires new methods of project management to cope with fast-pace developing.
Oil and gas companies are clear examples of the difference between the concept of a project and daily routine operations. These companies, in most cases, have an operations department and project department and they should work together.
Therefore, project management is different from the daily activity in operation management. Thus, most books and references that discuss project management define a project as a number of tasks and duties to be implemented during a specific period of time in order to achieve a specific objective or set of specific targets.
In operation management, production managers focus on the daily oil or gas production compared to the previous day. Oil and gas production is measured by the number of oil barrels produced per day (BOPD) in millions of standard cubic feet of gas (MMSCF). So, the monitoring of production daily is very important to the present income of the company.
On the other hand, the definition of project management can be summed up as planning, organization, recruitment, direction, and controlling of all kinds of resources in a certain period of time in order to achieve a specific objective for financial and non-financial targets.
To clarify the difference between project management and operations management, we should consider what goes on in the mind of these two managers. The project manager's goal is to finish the project on time. Then they evaluate where they will relocate after finishing the project. This is very different from the thinking of the operations manager, who never wants daily production to stop. So, they could not dream of work stopping, which is contrary to the project manager's target. Therefore, you can imagine the difference between the thinking of the two managers.
The first difference in the definition of project management is the goal to finish the project in a certain amount of time and its set of objectives all at once. While some measures are applicable for both operation and project management, the use of budget and manpower puts an end to specific actions.
1.2 Project Characteristics
One of the most important features of a project is the selection of individuals at different locations of the same company. In some international projects, the individuals are from different countries, cultures, educations, and employment and all of these individuals have different skills. With all those differences, they must work together to complete the work in a specific time and definite target.
The project manager has to coordinate between the members of the project to reach the goal of the project. As a result of rapid development in modern technology, this specialty has become important because, now days, any project contains many different disciplines. An explicit example is in construction projects, where there is a team for constructing the reinforced concrete and other teams for finishing the work, such as plumbing work. So, every branch of the construction activity has its own technology and skills. Therefore, the project manager has to cooperate between the different disciplines to achieve the project objective.
The primary goal of a project manager is to complete a project with high quality and achieve the objective at the same time.
Every project has a main driver. In general, the driver is one of the two driving forces or, in other words, is one of the two philosophies in managing a project. One of them is cost-driven and the other is time-driven.
The driver is considered to be the underlying philosophy in the management of a project, which must be determined by the director of the project with other parties, as well as the official sponsor of the project and the stakeholder. The project driving philosophy should be known to both the technical and administrative department managers.
To illustrate the above two factors' effects, we should think about all types of projects that are running around us. We will find that, in some projects, reducing the cost is the major factor and the time will be the second factor and, when the project duration time increases, it will not affect the project in the operation phase or, in precise meaning, it will not affect the owner and his investment. The building of houses, mosques, churches, museums, and other projects that have a social aspect is an example.
On the other hand, the aim of some projects is to reduce the time, which is the main challenge, so it will be a time-driven project. Examples of these projects include hotel projects because any projects that save in time will gain in profit, for an owner's profit from a hotel is calculated per day of using the rooms in the hotels. Other examples are oil and gas or petrochemical projects in the petroleum industry, where any day that can be saved will save millions of dollars per day since production is measured by barrels of oil per day (BOPD) or millions of standard cubic feet per day (MMSCFD), which will multiply the oil or gas price respectively and bring in more revenue. For example, if the gain of production from the project is 50,000 BOPD with an oil price of forty dollars per barrel, every day can save and the owner can gain 2,000,000 dollars.
From the above discussion, the main driver in petroleum projects is time. Therefore, the main target in these projects is to reduce the time. It is very important to define the basic driving force for a project, which is either cost or time. It is essential that all staff working on the project should know this information and this is the responsibility of the project manager.
Any group of teams at work, both in design or execution, should provide proposals, recommendations, and action steps that are in the same direction of the project driver in reducing the time or cost.
It is necessary that the target is clear to everyone to avoid wasting time in discussing ideas and suggestions that are not feasible. Imagine that you are working on a housing project and one of the proposals from the engineers is to use a type of cement to provide a rapid setting to reduce the time of construction, but it will increase the cost. Is this proposal acceptable? Certainly, it will not be accepted. On the other side, in the case of the construction of an oil or gas plant or new offshore platform, imagine if one of the proposals is the use of materials that are the cheapest, but it requires extra time to import from abroad, which will delay the project some days. Is this proposal acceptable? Of course this proposal is unacceptable, but if we use these proposals for the other project, we will find that the two proposals are excellent and acceptable.
It is clear that when we lose communication between the project manager and the personnel, there is a lot of confusion. If everyone works hard, but in different directions, this becomes wasted effort and everyone is not going in the same direction in order to achieve the success of the project.
Moreover, it is important to communicate with suppliers and contractors, so that their proposals in supply materials and construction should be within the project driven criteria.
Project characteristics can be summarized as follows:
- A project has a specific target.
- A project is unique and cannot be replicated with the same task and resources expecting to give the same results.
- The focus is on the owner requirements and his or her expectations from the project.
- It is not routine work, but there are some tasks that are routine.
- A project consists of a number of activities that contribute to the project as a whole.
- There is a specific time in which to finish a project.
- A project is complex in that it works by a number of individuals from different departments.
- Project managers must be flexible to cover any change that occurs during the project.
- There are uncertainty factors, such as the performance of individuals and their skills, for some of the unfamiliar work or unknown external influences that may not have happened before.
- The total cost is defined and has a limited budget.
- A project gives unique opportunities to acquire new skills.
- It gives impetus to the project manager to learn to work under changing circumstances, as the nature of the project is to change.
- There are risks with each step of the project and the project manager should manage the risks to reach the project goal at the end.
1.3 Project Life Cycle
The project definition is a set of activities that has a start time, time period, and end time. These activities vary from project to project depending on the nature of the project. For example, a cultural or social project or civil project such as the construction of a residential building, hospital, road and bridges or industrial projects are different in their characteristics. In our scope we will focus on industrial projects.
Civil projects, in general, vary from project to project depending on the size and value of the project. It can be anything from constructing a guard-room to constructing a nuclear plant.
Therefore, the quality varies depending on the size of the project, especially in developing countries.
In a small project, it might be sufficient to apply a quality control only where small contracting...
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