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Project Control Procedure
Project Control Procedure
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WWOYED
COKSTRUOiOfl
08-SepM 1 Approve for construction CGA IJC
Issue for approval CGA IJC
14-Mar-11 Issue for Review CGA IJC
REV. DATE DESCRIPTION PREP'D CHK'D APP'D
EMPLOYER:
Contractor:
Project:
Doc. No.:
TABLE OF CONTENTS
1.1 Overview
The Nigerian National Petroleum Corporation (NNPC) intends to expand the existing
Escravos - Lagos Gas Pipeline System with the provision of a 36inch x 342km class
600 gas transmission loop pipeline from PS1 at KP38 to PS5, Alagbado/ltoki.
The scope of work of the second phase of this project is to provide the detail
Engineering, Procurement, Construction and Commissioning of the latter mentioned
pipeline system.
1.2 Definitions/Abbreviations
All other definitions and interpretations in clause 1.1 in the Terms and Conditions
of the Contract Agreement also apply to this procedure.
2. INTRODUCTION
2.1 Purpose
This Project Control Procedure has been prepared to demonstrate the requirements for
Zakhem Construction Nigerian Limited (CONTRACTOR) in monitoring and controlling of
the contract for the Nigerian National Petroleum Company (NNPC) (EMPLOYER) for the
Escravos - Lagos Gas Pipeline System Phase-ll.
This document describes the systems put in place such that the project can be
monitored and controlled in a fully integrated manner by using a common approach.
Each CONTRACTOR department is responsible for its own procedures. However, all
departments have a responsibility to ensure that the systems and controls are
maintained and developed to provide a consistent approach such that the projects can
be confident that reports and information are processed efficiently to provide accurate
data in accordance with their needs.
Where subsequent usage indicates that a revision to these procedures is required, the
amendments shall be mutually agreed prior to their incorporation into this procedure.
The respective document shall then be reissued.
The entire project team has responsibility for ensuring adherence to the project
controls system. However, the following hold the prime responsibilities:
Project Director Project Manager
HSE Coordinator
Project : Expansion of Escravos - Lagos Pipeline Phase II
Procedure : Project Control Page
4 of 21
Number : 0807-100-47-AA-N-006 REV 2
NNPC ZAKHEM
Nigeria National Petroleum Corporation Zakhem Construction Nigeria Ltd
3. PROJECT CONTROL
The Contractor overall Project Control Management System is based upon a series of
integrated systems that are a departmental responsibility, and are designed to interface
with each other.
Project monitoring and control measures shall be implemented to successfully deliver
the project safely, on schedule and within budget. This requires the following:
• An agreed action program / plan
• The tools to monitor the progress of the plan.
• Reporting systems and formats to evaluate the work
• A system for evaluation of the work
•Trend measurement capability such that corrective actions can be taken when
required.
• An effective system to monitor and control scope changes
• Adequate resources to execute the work.
These steps shall comply with the requirements of the project. If EMPLOYER project
procedures or project circumstances dictate a change in approach to meet EMPLOYER
expectations then project procedures will be tailored to suit
The project planning system is based on the use of critical path analysis techniques
which focuses on the considered 'Key Issues' in terms of criticality to the achievement
of overall project objectives. The plan is produced and owned by the project team.
The plan is derived from both tender documents and contract scope, utilising the
appropriate level of discipline resource to develop timing and logic. Cognisance of the
major project milestones is taken. Work pack activities are defined, planned and
continuously monitored to identify exceptions for management intervention.
The above mentioned project planning system shall be developed utilising a multi level
approach structured in accordance with an overall project Work Breakdown Structure
(WBS).
Update management
report
Level 2
ANALYSIS Develop basis of milestone Overall project
LEVEL schedules at work package control level
level & major targets at the
control schedule level Progress overall schedules,
identify problem areas &
trend & develop strategy.
Level 3
CONTROL Detailed network Engineering,
LEVEL planning by system & Procurement,
discipline forms the basis Construction
control for the work. detail schedule
With reference to the diagram above, the planning levels are described in more detail
below:
Level I - Contract Master Schedule
A Summary Schedule, consisting of a direct summation of the Level II Contract
Milestone Schedule and includes all the project key activities and key contract dates.
CONTRACTOR shall implement a work breakdown structure covering all areas and
phases of the project. Each component of the WBS will be weighted according to its
financial value to the overall project. Progress measurement for each of these WBS
components will be carried out in accordance with Section 3.4.1.
Planned and actual progress for the overall project is then calculated by summarising
the weighted progress values for each WBS element.
During the course of the work, constant monitoring of progress is performed to ensure
that all activities are occurring on time and in sequence. This procedure allows for early
flagging of critical items for review and action by project management. Time and
resource network provides the basis for project control. Progress is measured by
assessing the physical state of completion of each deliverable group.
Progress of detailed engineering shall be weighted and measured based issue status of
deliverable. The key measurement criterion to be used is as follows:
• START deliverable - 25%
• Issue For Review (IFR) - 65%
• Issue For Approval (I FA) - 85%
• Issue For Information (IFI) - 100%
• Issue For Construction (IFC) - 95%
• Approve For Construction (AFC) - 100%
Procurement status shall be controlled by utilising the Procurement Status Report and
schedule of procurement and supply.
These documents shall include all the Enquiry Requisitions and Purchase Orders and
identifies Planned, Forecast and Actual dates for each stage as follows:
• Receipt of technical requisition
.Enquiry Issue
• Receive Bids
• Evaluation
• Purchase Requisition Preparation
• Issue of Purchase Order
• Receipt of Vendor Data
• Structural
AFC structural shop drawings with man-hour content are identified within the work
pack database and progressed by the Foreman in line with the following
benchmark categories as appropriate.
• Fabrication
• Erection
o Spool Fabrication
Number Completed/Number Required (Split by Area)
Prep, Fit, Tack 30%
Welding 60%
NDT 10%
o Spool Installation
Number Installed/Number Required (Split by Area)
Erect Spool 45%
Welding 50%
NOT 5%
o Piping Runs
No of Dia-Meters completed x Material Performance Factor
%=
Total No of Dia-Meters x Material Performance Factor
o Install Supports
Number Installed/Number Required (Split by Area)
Fitting 40%
Welding 60%
o Electrical Equipment
Number Installed/Number Required (Split by Area)
o Pulling Cables
Amount Installed/Amount Required (Split by Area)
Liner Feet/Meters Measurement
o Glandina Cables
Number Completed/Number Required
o Terminations
Number Completed/Number Required (Split by Area)
o Testing
Number of systems Test/Number Required
Instrumentation
o GlandinQ Cables
Number Completed/Number Required
o Terminations
Number Completed/Number Required (Split by Area)
o Testing
Number of systems Tested/Number Required
o Install Tubing
Liner Feet / Meters
Amount Installed/amount required
o Calibrate Instruments
Number of Systems Tested/Number /Required
o Loop Checking
Number of Loops Checked /Total Number of Loops
• Civil
o Foundations
Excavate & Prep Bindings 10%
Erect Formwork 25%
Erect Rebar & Install embedded items 30%
Pour Concrete & Cure 25%
Strip Forms 10%
• Equipment Installation
• Certification
• Pre-Commissioning
• Commissioning
• Painting
Topcoat 30%
Inspect accept 10%
The flow diagram for progress monitoring and reporting is as shown below.
The CONTRACTOR shall prepare a monthly report to cover all aspect of the project
progress. The period of progress performance shall span between the first and last day
of the particular month. The CONTRACTOR shall submit the report on or before the 10th
day of the following month.
• Project Overview
• Executive summary
• SHE summary report
• EPC progress with weighted summary (See exhibit A for sample)
• Engineering progress breakdown
• Procurement progress breakdown
• Construction progress breakdown
• Progress S curves (See exhibit B for sample)
• Manpower Histograms (See exhibit D for sample)
• Organizational Chart
• Project schedule
• Resource Management report
• Subcontracts report
• Quality performance
• Key performance indications
• Next month look ahead
• Challenges, areas of concern and corrective action required.
Distribution of these reports will generally be carried out by Project Control Engineer
on an "as required" basis in agreement with the Project Director. Information from
these reports will be incorporated into monthly project reports to the EMPLOYER.
The percentage completion of each Level III activity is reported on a weekly basis by the
respective supervisor/section leader of each activity. (See section 3.2.1. 'Planning
techniques overview chart' for Level III activity definition)
The progress cut-off will be on by close of business on the last day of the work week.
The progress will be issued to the Planning/Control Engineer for inclusion into the
Management Progress Reporting System.
Where possible, progress is always rolled-up from the projects' Level IV deliverable
databases against the Level III activity. It is the responsibility of all supervisors /
sectional leaders to compile and keep up to date their respective databases.
Progress shall be input and aggregated to produce the Level l/ll (Monthly) progress
summary. (See exhibit C for sample weekly progress report)
The Quality Document Management System (QDMS) shall be used for the project to
issue, register and track documents throughout their life cycle from calculation and
design through to final issue and handover. Full details of each document are recorded.
QDMS Key functions are:
There is a corporate document control area which facilitates the filing and management
of design deliverables and correspondence. The review and issue of design
deliverables within the project team is controlled by Document Distribution Matrices.
To enable the project procurement and materials management function to proceed, two
key engineering deliverables are essential: A management approved fully detailed multi-
disciplined equipment list and bulk material take offs (MTOs).
Close liaison between procurement and engineering via detailed procurement schedule,
shall determine an optimum number of requisitions required to procure the defined
commodities.
The materials management system is set-up at project start to suit scope of work
requirements and comprises:
• Procurement Scheduling
• Enquiry/Purchase
• Expediting/Inspection/Shipping
• Site Receipt/lssue/Traceability
3.7 Sub-Contract
Progress 'S' curves and histograms are a mandatory requirement and will be a product
of the schedule and agreed activity weight factors. Progressed schedules and 'S' curves
and histograms will form part of a progress report of which the text section will contain
but is not limited to the following:
Each will be weighted according to its financial value to the overall project and planned
and actual progress will be aggregated on this basis into the overall project planned and
actual curves and reports. The procedure is described in more detail in Document No.
0807-100-47-AA-N-009 (Sub Contracting Procedure)
It is the CONTRACTOR policy that continuous risk review and analysis exercises be
conducted throughout the project execution to its successful realisation.
The Risk Management process is initiated at the commencement of the work and
Project : Expansion of Escravos - Lagos Pipeline Phase II
Procedure : Project Control Page
16 of 21
Number : 0807-100-47-AA-N-006 REV 2
NNPC ZAKHEM
Nigeria National Petroleum Corporation Zakhem Construction Nigeria Ltd
• Risk Assessment:
- Risk identification
- Qualitative and quantitative risk evaluation
• Risk Control:
- Risk reduction planning
- Risk monitoring
• Risk Reporting:
- Reports
- Review meetings
• Continuous evaluation of the degree of technical and commercial risk inherent in the
decision-making processes throughout the project.
4. EXHIBITS
Item Weighted
Description of Work Planned (%) Actual (%)
No. Average (%)
1. Engineering
2. Procurement
3. Construction
Total Overall
120.00
100.00
80.00 -
V)
V)
2 60.00 -
01
2
Q.
40.00
20.00
0.00
Jan-11 Feb-11 Mar- 11 Apr-11 May- 11 Jun-11 JuH1 Aug-11 Sep-fl Oct-11 Nov-11 Oec-11 Jan-12 Feb-12 Mar- 12 Apr- 12 May- 12 Jun-12 Jul-12 Aug-12
—4— Planned % 202 496 ID 64 1878 25.28 28.57 37.07 44.66 52.95 59.45 6774 76.23 8274 8881 92.21 94.15 95.23 96.89 98.08 1DO .00
—• — Actual% 136
Months
MANPOWER HISTOGRAM
Actual
000
900
800
700
600 •:
:
500
-..
400
n
300
200 '•
tea m
Urni
TOO « 7*~~»
v\,V VV*
Months
ssssvs,
NNPC ZAKHEM
Nigeria National Petroleum Corporation Zakhem Construction Nigeria Ltd
--=;=
WEEKLY PROGRESS RETORT: 17
TIME UPDATED WE:&hTF4CTOR [i.-sl RECORD
5- NO *CTTtfITIES Target Pr*». ACHVD CUMM. COMP.pc]
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