Sustainability 10 02469
Sustainability 10 02469
Article
Detail Engineering Completion Rating Index System
(DECRIS) for Optimal Initiation of Construction
Works to Improve Contractors’ Schedule-Cost
Performance for Offshore Oil and Gas EPC Projects
Myung-Hun Kim 1,2 , Eul-Bum Lee 2, * and Han-Suk Choi 2
1 POSTECH University & Hyundai Heavy Industries, Engineering Management Team,
400 Bangeojinsunhwan-doro, Dong-gu, Ulsan 44114, Korea; myunghunkim@postech.ac.kr
2 Graduate Institute of Ferrous Technology & Graduate School of Engineering Mastership, Pohang University
of Science and Technology (POSTECH), 77 Cheongam-Ro, Nam-Ku, Pohang 37673, Korea;
hchoi@postech.ac.kr
* Correspondence: dreblee@postech.ac.kr; Tel.: +82-54-279-0136
Received: 9 April 2018; Accepted: 12 July 2018; Published: 14 July 2018
Abstract: Engineering, Procurement, and Construction (EPC) contractors with lump-sum turnkey
contracts have recently been suffering massive profit losses due to re-works and schedule delays
in offshore oil and gas EPC megaprojects. The main objective of this research is to develop and
implement a detail engineering completion rating index system (DECRIS) to assist EPC contractors to
optimize fabrication and construction works schedules while minimizing potential re-work/re-order.
This is achieved through adequate detail design development and results in minimizing schedule
delays and potential liquidated damages (i.e., delay penalties). The developed DECRIS was based
on findings from an extensive review of existing literature, industry-led studies, expert surveys,
and expert workshops. The DECRIS model is an evolution, and improvement of existing tools such
as the project definition raking index (PDRI) and front-end loading (FEL) developed specifically
for the early stage of engineering maturity assessment (i.e., planning, basic design, and front-end
engineering design (FEED)), prior to EPC projects. The DECRIS was evaluated and validated
with thirteen sample as-built offshore megaprojects completed recently. When the DECRIS was
applied to the completed projects post-hoc, a correlation (R-squared 0.71) was found between
DECRIS scores and schedule/cost performances. This is much superior to the PDRI-Industrial
model’s correlation (R-squared 0.04), which was primarily devised for owners’ basic engineering or
FEED completion assessment. Finally, as a means of further validation, project schedule and cost
performance of an ongoing project was predicted based on the correlations found on the thirteen
completed projects. The resultant predicted schedule and cost performance was well matched with
the current project performance status. Based on the accuracy of the DECRIS model found in the
validation, said model is an effective prospective tool for EPC contractors to manage their engineering
and procurement/construction risks during the initial detail design stages.
Keywords: oil and gas megaproject; engineering; procurement and construction (EPC) project;
DECRIS; schedule and cost integration; risks control; profitability; sustainability
1. Introduction
Crude oil was historically supplied solely by onshore reservoirs until the 1970s, when these
reservoirs were found to be insufficient to meet the growing global oil and gas demand. To supplement
demand, deep-water offshore projects were initiated in the 1990s and they now account for about 10%
of the total global oil supply [1]. In 2011, shale oil and gas were introduced to the oil and gas market
with the development of cost-effective hydrofracturing technologies. This has led to an over-supply of
oil and gas and, consequently, an era of low oil prices decreasing major oil companies’ profits [2].
An offshore project requires a significant amount of early investment for drilling and production
facility design and construction. To combat lower revenues and increase profits, major oil companies
have placed a great deal of attention on cost-saving strategies in these early stages for offshore oil
and gas projects [3]. However, these strategies are often poorly planned and implemented, leading to
inadequate resource allocation, and improperly accelerated design and construction. This all results in
poor quality of work, schedule overrun, and even safety-related accidents on site [2].
Therefore, how can planning be improved? Merrow collected and analyzed project performance
data on 100 megaprojects, finding that the success of upstream activities (i.e., planning and early
design) is one of the important factors for project success. Without this planning, Merrow found over
65% of the projects studied (>65%) reported project failure in cost, schedule, and/or production [4].
Decisions made during the detail design stage have significant impact on the overall construction
cost and schedule. Errors and omissions at this stage cause construction delays and often result in
reconstruction, especially in lump-sum turnkey contracts, which are overwhelmingly adopted for
Engineering, Procurement, and Construction (EPC) megaprojects. The resultant construction delay
and reconstruction results in owners’ claims, namely liquidated damages and performance liquidated
damages, which are major reasons for the EPC Contractor’s profit losses. In particular, incomplete
and/or inaccurate designs for fabrication (i.e., steel cutting), one of the most critical contract milestones
when initiating construction work stipulated on the contract, results in significant reconstruction and
associated labor hours. Oil and gas EPC contractors need a customized engineering completion model
to measure the completion rating in their engineering management decision-making process at the
design stage to mitigate reconstruction and avoid costly consequences. As such, this paper focuses on
aiding contractors in the initial design stages.
To compound the negative impacts of poor upfront project planning, many megaprojects are
performed to a very tight schedule. A tight schedule usually forces the EPC contractor to concurrently
design and construct the project, hoping to meet the owner’s deadline and avoid costly liquidated
damages. However, this concurrent design and construction, unless well planned, may lead to a
costlier option due to a catastrophic ripple effect when the final design is significantly different from
the partially complete design when construction started.
Concerning the contractor-owner relationship on conventional oil and gas projects, the owner hires
a contractor for construction only with fully approved for construction (AFC) engineering drawings
after AFC completion. Alternatively, in EPC projects, the owner hires a contractor for engineering (final
design), procurement of equipment, and construction. This type of contract means that the selected
contractor is responsible for completing the remaining design and procurement activities based on the
front-end engineering design (FEED) package developed by the project owner. Therefore, the contractor
must consider all risks of detail design and procurement, including undetected discrepancies during
the FEED verification period that may cause serious cost overrun and/or schedule delay.
Since the early 2000s, South Korean companies have been working as major EPC contractors
for offshore oil and gas EPC projects, specifically upstream production facility projects. Three major
shipbuilders in South Korea have executed over 50% of worldwide offshore oil and gas EPC mega projects:
H company, S company and D company. Since 2008, they have completed about 30 mega projects including
fixed platforms and floaters, typically so-called FPSO (Floating projection, storage and offloading) or FLNG
(floating Liquefied Natural Gas). The offshore oil and gas EPC contractors have recently reported massive
profit losses over US$ 10 bn as shown in Figure 1, between 2013 and 2015, after being awarded many EPC
projects since 2010.
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2000
-2000
-3000
-4000
Figure 1.
Figure 1. Profit
Profit losses
losses of
of EPC
EPC Contractor
Contractor (Modified
(Modified from
from Press
Press Release
Release[5]).
[5]).
The reasons for recent profit losses and damages for Korean offshore EPC contractors in dealing
The reasons for recent profit losses and damages for Korean offshore EPC contractors in dealing
with EPC megaprojects with lump-sum turnkey contracts are likely as follows (identified through
with EPC megaprojects with lump-sum turnkey contracts are likely as follows (identified through
subject matter expert interviews and literature review):
subject matter expert interviews and literature review):
1. Lack of EPC Contractor’s capability of FEED verification to justify complex owner requirements;
1. Lack of EPC Contractor’s capability of FEED verification to justify complex owner requirements;
2. Lack of experience in the use of exotic materials, and installation of special equipment;
2. Lack of experience in the use of exotic materials, and installation of special equipment;
3. Lack of experience in performing a fast-track process with a limited schedule;
3. Lack of experience in performing a fast-track process with a limited schedule;
4. Sub-order items including local content requirements in the host country that may impact on
4. Sub-order items including local content requirements in the host country that may impact on
project schedule;
project schedule;
5. Mandatory requirements to procure equipment from approved vendor list (AVL);
5. Mandatory requirements to procure equipment from approved vendor list (AVL);
6. Owner requirements of single-point responsibility for various contractual liabilities;
6. Owner requirements of single-point responsibility for various contractual liabilities;
7. Delay liquidated damages (so-called penalties) following schedule delay on EPC contractor are
7. Delay liquidated damages (so-called penalties) following schedule delay on EPC contractor are
unrealistically high (as much as US$ 1–2 million/day); and
unrealistically high (as much as US$ 1–2 million/day); and
8. Re-order for major equipment and critical bulk materials and reconstruction (re-work) due to early
8. Re-order for major equipment and critical bulk materials and reconstruction (re-work) due to
fabrication start with incomplete detail design to comply with the completion date and milestones.
early fabrication start with incomplete detail design to comply with the completion date and
[6]
milestones [6].
Many, if not most, of these issues result from improper front-end project planning. To aid
Many, in
contractors if not most, ofthese
minimizing theseissues,
issuesthe
result
focusfrom improper
of this study isfront-end
to developproject planning. aTo
and implement aid
detail
contractors in minimizing these issues, the focus of this study is to develop and implement
engineering completion rating index system to assist EPC contractors during the initial planning stages. a detail
engineering completion
The model aids rating
contractors in index system the
determining to assist EPCstarting
optimal contractors
timeduring the initialand
for fabrication planning stages.
construction
The model aids contractors in determining the optimal starting time for fabrication
works to minimize potential re-work/re-order through adequate detail design development. and construction
works to minimize potential re-work/re-order through adequate detail design development.
2. Literature Review
2. Literature Review
There has been minimal literature dedicated to incorporating an engineering completion rating
There has been minimal literature dedicated to incorporating an engineering completion rating
index to the project schedule and cost performance for oil and gas EPC projects. The most significant
index to the project schedule and cost performance for oil and gas EPC projects. The most significant
existing index models found were the project definition rating index (PDRI) by the Construction
existing index models found were the project definition rating index (PDRI) by the Construction
International Institute (CII) [7–10] and the front-end loading (FEL) index by Independent Project
International Institute (CII) [7–10] and the front-end loading (FEL) index by Independent Project
Analysis (IPA) [4]. These tools are mainly developed and utilized to define the level of completion of
Analysis (IPA) [4]. These tools are mainly developed and utilized to define the level of completion of
FEED, which is an engineering task prior to EPC detail engineering. These two indexes are typically
FEED, which is an engineering task prior to EPC detail engineering. These two indexes are typically
used by the project owner to quantify the level of project definition and basic engineering maturity and
used by the project owner to quantify the level of project definition and basic engineering maturity
to determine whether the project can move to the next project development stage, typically an EPC
and to determine whether the project can move to the next project development stage, typically an
contract. The model developed and presented within this paper evolved from these two indexes. As
EPC contract. The model developed and presented within this paper evolved from these two indexes.
such, a detailed discussion on each model, and associated literature, is discussed below.
As such, a detailed discussion on each model, and associated literature, is discussed below.
FEL measures the level of project definition at the front-end stage of a project, which is broken
FEL measures the level of project definition at the front-end stage of a project, which is broken down
down into three stages. At the FEL-1 stage, the project definition is reviewed based on the conceptual
into three stages. At the FEL-1 stage, the project definition is reviewed based on the conceptual design and
design and business case evaluation results. In FEL-2, the result of basic design is reviewed. At the end
business case evaluation results. In FEL-2, the result of basic design is reviewed. At the end of FEED (FEL-3),
of FEED (FEL-3), the entire FEED package is reviewed for the owner to make the final “Go” or “No-
Go” decision, which will result in a significant financial investment and commitment by hiring an EPC
Sustainability 2018, 10, 2469 4 of 31
the entire FEED package is reviewed for the owner to make the final “Go” or “No-Go” decision, which
will result in a significant financial investment and commitment by hiring an EPC contractor. The project
definition is classified according to three sections: site factors, design status, and project execution plan.
FEL is used to assess the project by numerically quantifying the project definition of each element under
each section and then aggregating them into a numeric index. When the FEL index is lower than a
pre-determined threshold value at each stage of FEL-1/2/3, over 50% of projects were successful in terms
of cost and schedule performance. On the other hand, projects in the high range of the FEL index showed
poor project performance [4].
CII’s PDRI is an alternate assessment tool to IPA’s FEL as it serves the same purpose of measuring
project definition from the conceptual design stage to the FEED stage of a project. The PDRI’s
hierarchical structure is comprised of three sections, categories, and elements [7,8,10]. Three sections
include: (a) the basis of project decisions; (b) basis of design; and (c) execution approach to holistically
evaluate the project value, scope, definition, and readiness for next stages. The PDRI has 8 to 15 types
of categories for each section [7–10]. At the bottom of the PDRI hierarchy, each element specifies details
that can be individually reviewed. Each element is assessed on a scale of 1 to 5 (1 being highly well
defined and 5 being not defined at all) and an overall PDRI index is calculated using a scoresheet
weighted and normalized for each element. Three to six PDRI reviews are recommended for the owner
during the project planning, and FEED stages [11]. The most important PDRI review should be carried
out prior to the EPC contract, which is the final investment decision (FID). The CII recommends that
the cutoff score of the PDRI at the end of the FEED stage should be 200 as the performance of a project
with a score higher than 200 was historically not satisfactory in terms of cost and schedule [10,12].
PDRI can help the owner manage project scope prior to a project authorization and/or the contractor
identify incomplete elements related to project scope definition [13].
Multiple publications were dedicated to testing PDRI’s effectiveness. Chu et al. [14] studied PDRI
for intelligent green building projects and adjusted weight factors for each element using an analytical
network process, and they also expanded PDRI elements up to the project execution phase. In another
study, with 51 surveys and statistical analysis, George et al. [15] found that seven major activities have
more impact on achieving project success among all activities conducted during front-end planning.
This finding is aligned with the fact that PDRI elements are assigned different weights depending
upon the level of influence on project outcome. Pheng and Chuan [16] also identified using an analysis
of variance (ANOVA) test the five most significant variables that affect work performance in the
construction industry and recommended focusing on those significant variables to develop a better
working environment. Since previous studies are limited to the front-end planning stage before an
EPC contract is established, EPC contractors cannot directly apply the study results to the detail
design process.
In the offshore oil and gas sector, FEL and PDRI are being used as an owner’s risk analysis tool [11].
However, these tools focus on the earliest planning phases, stopping once the EPC contractor is selected.
This means the tools are lacking and cannot cover the range of detail design and construction phase
activities. Additionally, the characteristics of offshore oil and gas projects significantly differ from
those of the other construction sectors, making the current FEL and PDRI tools difficult to use as an
EPC contractor’s risk management tools.
• Research Goal 1—modeling of DECRIS by adjusting previous assessment tools such as PDRI can
be developed to measure the optimal progress of detail engineering to initiate the fabrication of
initial modules in the scheduling critical path.
• Research Goal 2—the correlation between the developed DECRIS score and the construction cost
and schedule performance.
The research scope of building the DECRIS framework is limited to fixed platforms and floaters
such as FPSO and FLNG in offshore oil and gas EPC projects. Other types of offshore structures and
subsea structures are excluded in this study.
From discussion with industry experts, and as defined within this paper, the existing tools (PDRI
and FEL) are more than adequate in aiding owners through pre-planning of specific types. However,
they generally stop at the stage of executing a contract with the contractor and are not tailored for
contractor procurement/fabrication scheduling nor the oil and gas industries. As such, one of the main
contributions of this research is to present a superior tool than before, focusing on FEED engineering
completion prior to EPC projects. What is most lacking for oil and gas projects in using the PDRI
and/or FEL methods is when to begin fabrication (discussed above). As such, the DECRIS’s added
benefit to the industry is most significantly aiding the contractor in finding the optimal point of the
fabrication start of the oil and gas EPC projects.
To provide support that the presented tool is better than existing tools, thirteen offshore EPC
megaprojects recently completed are presented (in Section 6.1) for the verification of the DECRIS
model. Analysis is performed on the tool’s ability to predict the real projects’ actual cost and schedule
performance data. The DECRIS model can contribute to industry as a decision support tool during the
EPC contract execution stage to assist EPC contractors in making informed and timely decisions on
initiating their construction work activities.
(1) DECRIS model scope determination: collect the preliminary elements from the existing literature
and develop the element description
(2) Data collection: a workshop was performed with industry experts to determine elements that
affect the calculation of the detail engineering completion rating and to organize the identified
elements in proper sections and categories. The expert survey was also used for data collection to
calculate the relative importance of each element to engineering completion.
(3) Data normalization: to determine the weight factor for each of the DECRIS elements using
the data from the expert survey, data normalization, preliminary estimate, validation process,
element average weight calculation, and interpolation were carried out.
(4) Data analysis: one sample t-test is used to finalize the weight factor of each element. The weight
factor of each element indicates the level of importance of the element’s contribution to the detail
engineering completion rating index.
(5) Data application: the DECRIS model developed through the previous research stages is
verified by applying it to the 13 sample projects. Each project was assessed using the DECRIS
level assessments.
(6) Model verification: the score outputs were then compared with the project performances of
each project (using statistical analyses) to see the level at which the model could predict project
performance. A cutoff score was then developed based on the model and sample projects.
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Industrial
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Step1. DECRIS Model Preliminary DECRIS
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PEER REVIEW 7 of 31
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organized in line with the project objectives.
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information to understand and assess the technical requirements for the detail design of a project.
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of the be management
efficient
consultancy. for
to
Most offshore
increase
of the oil
the
survey and gas EPC
representativeness
participants projects
wereof
selected
local
survey
various from two
industry
reliability,
discipline from major
the aexpert
expertsTable EPC
practical contractors
survey
3.
invited point thisof
in was
Experience (H limit
view,
carried company
Information
research. out onofthe
judgmental
Onusing andavailability
only Seach
and
Participants
average, company
snowball
face-to-face
for theof knowledgeable
expert in Southmodel.
sampling
interviews.
DECRIS
participant Korea).
were
The
has
experts
To
overused inwith
increase
information
13
the
years
of
or
theexperience
over 10
populationyears in[17].
detail
of design
experience
However, engineering
in project
because or project
management
of the limit onmanagement
consultancy.
the availability for
Most offshore
ofof the oil andparticipants
survey
knowledgeable gas EPC
experts projects
inwere
the
selected
local from two major EPC contractors (H company and Seach
company in South Korea). To increase
on
of
or theindustry
survey
various
over
reliability,
discipline
experience
experience
10 years
from
in of the
of
detail
aexpert
experts
the practical
experiencesurvey
design survey
invitedin
point thisof
in was
participants
engineering
project
view,
carried
research. judgmental
out
orisproject
management shownOnusing only
average,
in Table
management
consultancy.
and3. snowball
face-to-face
forexpert
Most offshore
of the
sampling
interviews.
participant were
Theover
has
oil andparticipants
survey gas EPC
used
information
13 with
years
projects
were
selected
local
survey
various from
industry
reliability,
discipline two
from major
the aexpert
experts EPC
practical contractors
survey
invited point
in was
this of (H company
view,
carried
research. judgmental
outOn using and
only
average, Seach
and company
snowball
face-to-face
expert in South
sampling
interviews.
participant Korea).
were
The
has To
usedincrease
information
over 13 with
years
on
of
or the experience
experience
over 10from
years in of of
detail the
experiencesurvey
design in participants
engineering orisproject
project management shownmanagement
Details in Table 3. for
consultancy. Most offshore
Number
ofinthe oil andparticipants
survey gas EPC projects were
selected
survey
various reliability,
discipline twothe major
expert
experts EPC
invited contractors
survey in was
this (H company
carried
research. outOn using and
only
average, Seach
company
face-to-face
expert South
interviews.
participant Korea).
The
has To increase
information
over 13 years
on
of
or the experience
experience
over 10from years in of of
detail the
experiencesurvey
design in participants
engineering is shown in
or project management
project management
Participant Table
consultancy. 3. for
Most offshore
of
32inthe oil andparticipants
survey
people gas EPC projects were
selected
survey reliability,twothe major
expert EPC contractors
survey was (H company
carried out using and
onlyS 3. company
face-to-face South
interviews. Korea).
TheEPC To increase
information
on
of
or the experience
experience
over 10 years in of of
detail the
experiencesurvey
design in participants
engineering
project oris
management
Overall shown
project
Experience in Table
management
consultancy. for
Most offshore
of
425the oil andparticipants
survey
years gas projects
were
selected
survey from twothe
reliability, major
expert EPC contractors
survey was (H company
carried out using and
onlyS 3. company ininterviews.
face-to-face South Korea). To increase
The information
on the experience
or over 10from
yearstwo of of the
experiencesurvey participants
incontractors
project
Over is of
10management
years shown in Table
consultancy.
Experience Most of 25inthe survey
people participants were
selected
survey reliability, the major
expert EPC survey was carried (H company
out using and S
only 3. company
face-to-face South Korea).
interviews. The information To increase
on the experience of the survey participants is shown in Table
selected
survey from two
reliability, the major
expert EPC contractors
survey was (H
carried company
Director
out using and S
only 3. company
face-to-face
2in South
people Korea).
interviews. The information To increase
on the experience of the survey participants
Team is shown
Leader/Department inHead
Table 9 people
survey
on reliability, the
the experience of theexpert
survey survey was
participants carried
is out
shown
Project Management Professionals (PMPs)
using
in only
Table face-to-face
3. interviews. The information
5 people
on the experience of the survey participants is shown in Table 3.
Sustainability 2018, 10, 2469 10 of 31
Kline [19] suggested that, for a sampling data set which has an absolute value of skewness
less than 3 and an absolute value of kurtosis less than 10, its population can be assumed to be
distributed as normal distribution. To minimize the quantity of eliminated survey results while
maintaining the normal distribution assumption, skewness and kurtosis calculation using SASTM was
repeatedly conducted. Consequently, survey results with a contribution score of over 80 were removed.
The remaining survey data set has a skewness value of 2.02 and kurtosis value of 7.34 as the maximum
value among 69 elements; the statistical result thus shows that the population of all 69 elements can be
assumed as having a normal distribution. Through one sample t-test, individual elements were shown
to be in favor of alternative hypothesis (|t| < 0.0001) and were statistically verified as elements that
affect the detail engineering rating.
The basic relationship for each element was reviewed in the focus group workshop. The purpose
of one sample t-test for individual elements is to verify whether the weight factor as a survey result can
be considered as zero or not. If the previous workshop was well conducted, then expert participants
may give the weight factor higher than zero. Unless most experts judged that each element did
not affect the detail engineering completion, one sample t-test with zero basis for that element can
be passed.
In this research, the measurement range of DECRIS was defined as a minimum of 70 to a maximum
of 1000. This means that the DECRIS score is 70 when the level of all elements is Level 1 (i.e., all detail
engineering deliverables are completed thoroughly without further need for action), and 1000 when all
be considered as zero or not. If the previous workshop was well conducted, then expert participants
may give the weight factor higher than zero. Unless most experts judged that each element did not
affect the detail engineering completion, one sample t-test with zero basis for that element can be
passed.
In this2018,
Sustainability research,
10, 2469the measurement range of DECRIS was defined as a minimum of 70 to a maximum 11 of 31
of 1000. This means that the DECRIS score is 70 when the level of all elements is Level 1 (i.e., all detail
engineering deliverables are completed thoroughly without further need for action), and 1000 when all
elements are
elements are Level
Level 55 (i.e.,
(i.e., detail
detail engineering
engineering is is in
in the
the pre-matured
pre-matured status status far
far from
from full
full completion
completion yet).
yet).
Simply speaking, similar to PDRI assessment trend, a lower DECRIS score means lowerengineering
Simply speaking, similar to PDRI assessment trend, a lower DECRIS score means lower engineering
deficiency and
deficiency and therefore
therefore lessless re-work
re-work andand re-order
re-order at
atthe
thefabrication
fabricationstarting
startingsession.
session. The
The calculated
calculated
weight factor for each element was at a Level 5 weight, while the Level 1 weight was calculated using
weight factor for each element was at a Level 5 weight, while the Level 1 weight was calculated using
another normalizing
another normalizing multiplier
multiplierbasedbasedon onthe
theminimum
minimum DECRIS
DECRIS score of 70.
score TheThe
of 70. weights of Levels
weights 2, 3,
of Levels
and
2, 4 for
3, and each
4 for element
each element was
wasalso
alsocalculated
calculatedusing
usingaa linear interpolation formula.
linear interpolation formula. Through
Through the the
aforementioned calculation, the weight of each element and its levels was assigned into the unweighted
aforementioned calculation, the weight of each element and its levels was assigned into the unweighted
DECRIS scoresheet,
DECRIS scoresheet, which
which results
results in
in the
the development
development of of the
the weighted
weighted DECRIS
DECRIS scoresheet
scoresheet (refer
(refer to
to
Appendix B).
Appendix B). A
A part
part of
of the
the weighted
weighted DECRIS
DECRIS scoresheet
scoresheet is is shown
shownin inFigure
Figure4.4.
The weight factor of each element indicates the level of importance of the element’s contribution
Thedetail
to the weight factor of each
engineering element indicates
completion the level
rating index. Thenof importance
the relative of importance
the element’sofcontribution
each section, to
the detail engineering completion rating index. Then the relative importance of
category, and element is determined. Figure 5 shows the calculated relative importance of each section each section, category,
and
and element
category.isThe determined.
weight factor Figure 5 shows
of section II, the calculated
engineering relative importance
deliverables, of each section
the most important sectionandfor
category.
the DECRIS Theofweight
offshore factor of section
oil and gas EPCII,projects,
engineering deliverables,
is 67.3% of the totalthe most Figure
weight. important section
5 also for that
specifies the
DECRIS
the weight of offshore
factor ofoiltheand gas EPC projects, is 67.3%
process/mechanical/piping of the total
category weight.
is the highest Figure
as 2465 points;
also specifies that the
it is, therefore,
weight
the most factor of the category
important process/mechanical/piping
in the DECRIS framework. category Toisincrease
the highest as 246engineering
the detail points; it is,completion
therefore,
the most important category in the DECRIS framework. To increase the detail
rating, it implies that the engineering manager and project manager need to focus on this category. engineering completion
rating,A itDECRIS
implieslevel
that the engineering
assessment manager and
questionnaire was project
developed manager needassessment
to inform to focus on participants
this category. of a
A DECRIS level assessment questionnaire was developed to inform
descriptive definition of each level. The main purpose of the level assignment questionnaire is to assessment participants
of a descriptive
provide definitioncriteria
the assessment of eachfor level.
the The main purpose
definition level ofofeachthe level
DECRIS assignment
element.questionnaire
The sample
is to provide the assessment criteria for the definition level of each DECRIS
questionnaire included in Appendix C covers Section II—Category D. An individual questionnaire element. The sample
was
questionnaire
prepared based included
on each in Appendix
element’s C coversrating
completion Section II—Category
required D. An individual
to be achieved questionnaire
in each milestone. When
was prepared
a project based on
is assessed, anyeach element’s
element givencompletion
Level 0 was rating required
considered to applicable.
not be achievedThis in each
means milestone.
that the
When a project is assessed, any element given Level 0 was considered not applicable.
element will not be considered for measuring the engineering completion rating. The DECRIS level This means that
the element will not be considered for measuring the engineering completion rating. The DECRIS
level assessment questionnaires provide the information required to understand and assess technical
requirements for the detail engineering stage. For example, in the case of elements in section II,
engineering deliverables, the element level is assessed as the stage of repeated submissions of the
documents during detail engineering.
Sustainability 2018, 10, x FOR PEER REVIEW 12 of 31
assessment questionnaires provide the information required to understand and assess technical
requirements for the detail engineering stage. For example, in the case of elements in section II,
engineering2018,
Sustainability deliverables,
10, 2469 the element level is assessed as the stage of repeated submissions 12
of ofthe
31
documents during detail engineering.
Section Weight
II Engineering Deliverables 673
I Basis of Detail Design 166
III Execution Approach 161
Total 1000
Category Weight
D Process / Mechanical / Piping 246
K Engineering Project Management 116
G Instrument and Electrical 102
E Equipment Vendor 101
I 3D modeling 79
C Design Guideline 76
F Structural and Architectural 59
B Project Performance Requirement 51
H Material Take-Off 45
L Project Execution Plan 45
J General Facility Requirement 41
A Project Scope 39
Total 1000
5.5. Comparison of DECRIS vs. Previous Engineering Assessment Tools Layout and Use
5.5. Comparison of DECRIS vs. Previous Engineering Assessment Tools Layout and Use
As with any research endeavor, it is required that said research be an advancement of the general
As with any research endeavor, it is required that said research be an advancement of the general
body of knowledge. Although the PDRI and FEL are valid assessment tools, the PDRI was used by the
body of knowledge. Although the PDRI and FEL are valid assessment tools, the PDRI was used
authors of this paper more heavily in DECRIS development. As such, it is important to illustrate the
by the authors of this paper more heavily in DECRIS development. As such, it is important to
differences between these models for reader understanding and as a basis of support for the DECRIS
illustrate the differences between these models for reader understanding and as a basis of support
value-adding potential. Table 4 provides an illustration of the differences between the DECRIS, PDRI-
for the DECRIS value-adding potential. Table 4 provides an illustration of the differences between
Industrial, and PDRI-Infrastructure elements. The main distinctions between the DECRIS model and
the DECRIS, PDRI-Industrial, and PDRI-Infrastructure elements. The main distinctions between the
the previous assessment models is summarized as below.
DECRIS model and the previous assessment models is summarized as below.
1. The sections, based on project decision and front-end definition, are thus major components of
1. PDRI-Industrial
The sections, based (given
on aproject
922 score) [7] and
decision andPDRI-Infrastructure
front-end definition,(given a 730
are thus score)
major [8]. PDRI
components
focuses on front-end planning and does not represent work packages in the detail engineering
of PDRI-Industrial (given a 922 score) [7] and PDRI-Infrastructure (given a 730 score) [8].
stage.
PDRI The hierarchy
focuses overview planning
on front-end of the PDRI-Industrial
and does not model is briefly
represent work outlined in Appendix
packages D for
in the detail
reference purposes. As described in the introduction, the major target of DECRIS is the
engineering stage. The hierarchy overview of the PDRI-Industrial model is briefly detail
outlined
design conducted
in Appendix D forbyreference
the EPC contractor;
purposes. itAs
is thus reasonable
described in thethat the engineering
introduction, deliverables
the major of
target of
detail engineering is the most important section.
DECRIS is the detail design conducted by the EPC contractor; it is thus reasonable that the
2. From the project
engineering size pointofofdetail
deliverables view,engineering
PDRI-Industrial
is theismost
for midsize industrial
important section.projects whereas the
2. DECRIS
From theisproject
for oil size
and point
gas EPC megaprojects
of view, over US$is500
PDRI-Industrial for m.
midsize industrial projects whereas the
3. The Scope of detail engineering in PDRI-Infrastructure ism.
DECRIS is for oil and gas EPC megaprojects over US$ 500 basically the owner’s responsibility
3. (whereas
The Scopeinofcase ofengineering
detail EPC, it belongs to the EPC contractor,
in PDRI-Infrastructure therefore
is basically the completion
the owner’s of the(whereas
responsibility impact
of detail engineering completion to the schedule and cost performance is less severe than thedetail
in case of EPC, it belongs to the EPC contractor, therefore the completion of the impact of EPC
case).
engineering completion to the schedule and cost performance is less severe than the EPC case).
Sustainability 2018, 10, 2469 13 of 31
The next step in proving that DECRIS adds value to industry and academia alike is to show its
superiority in predicting project performance. This is discussed in Section 6 below. This includes,
in Section 6.3, an application of both the DECRIS model (developed to assess the correlation between a
contractor’s detail engineering completion and the project cost/schedule performance at the at the
fabrication start session) and the PDRI-Industrial model (primarily devised to assess the correlation
between an owner’s FEED completion and the project cost/schedule performance) on the same sample
offshore EPC projects. A discussion is presented on each model’s cost performance prediction accuracy
on the ongoing verification project as well.
described at the later section on this paper. The result means that maturity of detail engineering on
the construction starting session (steel cutting) is lower than the optimal point so that low schedule
performance and cost overrun is expected.
As shown in Table 6, the construction labor hours increase rate which is the primary cause of cost
overrun and construction duration delay of the sample projects were collected to validate the research
goals, to apply the DECRIS model for the offshore oil and gas EPC projects. The verification with the
sample projects is to assess the influence of the DECRIS score on the construction in the offshore oil
and gas EPC project.
Project CLIR 1 (%) CDD 2 (days) Project CLIR (%) CDD (days)
B 17.14% 411 L 0.82% 105
H 8.71% 246 E 1.61% 82
F 6.09% 305 K 2.44% 16
G 6.02% 210 I 2.84% 82
A 3.37% 246 C 2.22% -6
D 4.06% 102 J 3.24% 0
M 9.70% 111
1 CLIR = Construction labor hours increase rate; 2 CDD = Construction duration delay.
The following Equations (2) and (3) were used to calculate the construction labor hours increase
rate (cost overrun) and construction duration delay.
The calculated construction labor hours increase includes all design changes caused by a low
detail engineering completion rating and detail engineer’s error and omission. Construction duration
delay includes not only the design changes due to low detail engineering completion, but also other
minor factors such as the owner’s change order, procurement impact and construction problems
during fabrication. Considering industry practices and expert judgments, most of the cost overrun
and schedule delay is caused by premature detail engineering and design change during construction
phase. It should be noted here that a considerable number of factors have an impact on construction,
performance, and the DECRIS model cannot explain all these factors.
Sustainability 2018, 10, 2469 15 of 31
In the case of conventional PDRI, the PDRI cutoff score was determined as 200 [7]. The DECRIS is
not used for project definition of the FEED package but is used for demonstrating the detail engineering
completion rating; it is thus considered in this study that the existing PDRI cutoff score cannot be
used for DECRIS without further verification. To determine the DECRIS cutoff score, the independent
t-test was repeatedly conducted with a 0.05 level of significance to review the statistical difference
of average value between the two groups (high and low DECRIS score groups) of projects divided
by the DECRIS scores of 280, 300, and 320. The statistical difference was found in the t-test to have
a 95% level of confidence between the two groups of projects divided by 300. As shown in Table 7,
the sample projects were grouped as high- and low-score groups based on the DECRIS score of 300.
Project Group DECRIS Score CLIR (%) CDD (days) Project Group DECRIS Score CLIR (%) CDD (days)
B High 446 17.14 411 E low 299 1.61 82
H High 389 8.71 246 K low 273 2.44 16
F High 367 6.09 305 I low 264 2.84 82
G High 367 6.02 210 C low 250 2.22 −6
A High 346 3.37 246 J low 248 3.24 0
D High 304 4.06 102 L Low 258 0.82 105
CLIR = Construction labor hours increase rate; CDD = Construction duration delay.
If a project’s DECRIS score at the steel cutting session is higher than 300, the project was then
included in the high-score group, otherwise it was included in the low-score group. The DECRIS score
range of the six projects included in the high-score group was 304–446 and their construction labor
hours increase rate (cost overrun) was from 3.4% to 17.1% with an average of 7.7%. For the low-score
group, the DECRIS score range was from 258 to 299, with an increase rate of from 0.8% to 3.2% of
construction labor hours, with an average increase rate of 2.2%. Through an independent sample
t-test, the test statistic of project F was 33.60 and the significant probability for population variance
and average difference was 0.0015 and 0.0475. An alternative hypothesis for both population variance
and average difference were concluded with a 95% level of significance.
To verify that the DECRIS cutoff score is also applicable for project schedule performance, another
independent sample t-test was performed. As shown in Table 7, the DECRIS score range of six projects
included in the high-score group was 304–446 and their construction duration delay ranged from 102
to 411 days with an average of 255 days (significant delay). The low-score group shows a DECRIS
score range of from 258 to 299 with -6 to 105 days of construction duration delay and an average of
47 days. The test statistic F-value was 4.45 and the significant probability for population variance and
average difference was 0.127 and 0.0012, respectively. The null hypothesis for population variance and
alternative hypothesis for average difference were thus concluded with a 95% level of significance.
The results of two statistical reviews using project cost and schedule performance showed that the
DECRIS cutoff score for the steel cutting session for offshore oil and gas EPC projects was 300.
From a theoretical point of view, this DECRIS cutoff score (300) is the most optimal fabrication
starting session with some adjustment according to the project completion schedule requirement and
resource availability of both engineering and construction.
Finally, the authors tested the DECRIS score’s ability to predict a project’s performance successfully.
To test this, a regression analysis was conducted to determine the correlation between the DECRIS
score and the construction labor hours increase rate with the sample projects. A scatter plot with the
DECRIS score (X-axis) and project performance (Y-axis) was generated and simple linear regression
was performed as shown in Figure 6. R-squared value was 0.7054; the regression function thus clearly
represents the correlation of the population. Following the same method, regression analysis was
conducted to realize the correlation between the DECRIS score and the construction duration delay
applied to the sample projects. A scatter plot with the DECRIS score (X-axis) and project performance
(Y-axis) was generated and simple linear regression was performed as shown in Figure 7. The project
Sustainability
Sustainability 2018,
2018, 10,
10, x
x FOR
FOR PEER
PEER REVIEW
REVIEW 16
16 of
of 31
31
Sustainability 2018, 10, 2469 16 of 31
duration
duration delay
delay applied
applied to
to the
the sample
sample projects.
projects. A
A scatter
scatter plot
plot with
with the
the DECRIS
DECRIS score
score (X-axis)
(X-axis) and
and project
project
performance
performance (Y-axis) was generated and simple linear regression was performed as shown in Figure
(Y-axis) was generated and simple linear regression was performed as shown in Figure 7.
7.
The project R-squared value was 0.8881, so that the regression function clearly represents
The project R-squared value was 0.8881, so that the regression function clearly represents the
R-squared value was 0.8881, so that the regression function clearly represents the correlation the
of
correlation
correlation
the of
of the
population. the population.
population.
20%
20%
increasing
Manhourincreasing
15% y
y == 0.0006x
0.0006x -- 0.1409
0.1409
15%
R²
R² == 0.7054
0.7054
Overrun
CostOverrun
(ConstructionManhour
rate)
10%
rate)
10%
Cost
(Construction
5%
5%
0%
0%
200
200 250
250 300
300 350
350 400
400 450
450 500
500
DECRIS
DECRIS Score
Score
Figure
Figure 6.
6. Correlation
Correlation between
between DECRIS
DECRIS Score
Score and
and Construction
Construction Labor
Labor Hours
Hours Increase
Increase Rate
Rate (Cost
(Cost
Figure 6. Correlation between DECRIS Score and Construction Labor Hours Increase Rate (Cost overrun).
overrun).
overrun).
600
600
500 y
y == 1.942x
1.942x -- 470.79
470.79
500
Delay)
DurationDelay)
R² = 0.8881
R² = 0.8881
400
400
Delay
(ConstructionDuration
ScheduleDelay
300
300
Schedule
200
200
(Construction
100
100
00
200
200 250
250 300
300 350
350 400
400 450
450 500
500
(100)
(100)
DECRIS
DECRIS Score
Score
Figure
Figure7.7.
Figure Correlation
7. Correlation between
Correlationbetween DECRIS
betweenDECRIS Score
DECRISScore and
Scoreand Construction
andConstruction Duration
ConstructionDuration Delay.
DurationDelay.
Delay.
As
As highlighted
highlighted in
As highlighted inthe
in theliterature
the literaturereview,
literature review,
review,other
other engineering
engineering
other engineering assessment
assessment
assessmenttools (such
toolstools as
as FEL
(such(suchFELasand
FELPDRIs
and PDRIs
and
as they
PDRIs were
as theyaswere developed
theydeveloped
were developed to evaluate
to evaluate the project
the project
to evaluate definition
definition
the project level and
level and
definition basic
basic
level andengineering
engineering (FEED)
(FEED) maturity
basic engineering maturity
(FEED)
in the
in the initial
maturity initial project
project
in the stage,
initialstage,
project prior
prior to EPC
to
stage, EPC contracts,
priorcontracts, by
by the
the project
to EPC contracts, by theowner)
project project were
owner) were
owner)not adequate
notwere
adequate to
to apply
applyto
not adequate to
to
predict
predict
apply the
tothe influence
influence
predict of detail engineering
of detail engineering
the influence completion
completion
of detail engineering on the construction
on the construction
completion re-work/re-order
re-work/re-order
on the construction by the EPC
by the EPC
re-work/re-order
contractor.
contractor.
by On
On the
the other
the EPC contractor. otherOnhand,
hand, DECRIS
hand,shows
DECRIS
the other shows
DECRIS reliable
showsindicators
reliable indicators to
to predict
predicttothe
reliable indicators the correlations
correlations
predict between
between
the correlations
DECRIS
between score
DECRIS DECRIS (i.e.,
score (i.e.,
scoredetail
detail engineering
(i.e.,engineering progress
progress
detail engineering and maturity)
and maturity)
progress at the fabrication
at theatfabrication
and maturity) start session
startstart
the fabrication session and
and
session
potential
potential
and construction
construction
potential construction cost and
cost cost schedule
and and
schedule performance.
performance.
schedule performance.
Sustainability 2018, 10, 2469 17 of 31
where
The result means that the construction labor hours increase rate of 7.99% (about US$ 12 m) and
235 days construction duration delay are expected for the ongoing Project X. This cost estimation is only
for construction labor hours; therefore, actual cost overrun including management cost, warehouse
cost, engineering cost and subsequent liquidated damages will be much higher than the calculated cost.
According to the comparison between actual results and DECRIS prediction, researchers found
that a construction labor hours increase rate of 8.26% and a construction duration delay of 177 days are
similar with 7.99% and 235 days predicted in the DECRIS model.
This result indicates that the DECRIS model predicts the cost and schedule performance of the
ongoing project. EPC contractors can use the DECRIS score at the steel cutting session to predict project
performance using the aforementioned regression functions, Equations (4) and (5).
As the limitation of this research, the case study is just to forecast the cost and schedule
impact of the project. As the continuation of the research, the DECRIS model will be continuously
implemented further for the engineering progress control to incorporate the initiation of module
fabrication start-time.
Through the PDRI-Industrial assessments at the fabrication start stage of the 13 sample recently
Sustainability 2018, 10, x FOR PEER REVIEW 18 of 31
completed EPC offshore projects listed in Table 5 by the industrial experts and the project management
team,
team, the
the correlation
correlation between
between the
thePDRI
PDRIscore
scoreand
andthe
theconstruction
constructioncost
costperformances
performanceswas
wasanalyzed
analyzed
using
using linear regression function. As a result of PDRI-Industrial assessment, PDRI score wascalculated
linear regression function. As a result of PDRI-Industrial assessment, PDRI score was calculated
within
within the
the range
range ofof 70
70 to 83 and
to 83 and plotted
plotted with
withthe
theconstruction
constructioncost
costperformances
performances using
using scatter
scatter plot,
plot, as
as shown in Figure
shown in Figure 8. 8.
25%
Cost Overrun (Construction Manhour
15%
10%
5%
0%
60 65 70 75 80 85 90
PDRI Score
Figure8.
Figure 8. Correlation
Correlation between
between PDRI
PDRIScore
Scoreand
andConstruction
ConstructionLabor
LaborHours
HoursIncrease
IncreaseRate.
Rate.
In comparing the results of the DECRIS’s (Figure 7) and PDRI’s (Figure 8) abilities to accurately
In comparing the results of the DECRIS’s (Figure 7) and PDRI’s (Figure 8) abilities to accurately
predict cost overrun on offshore oil and gas EPC megaprojects, the DECRIS is found to be significantly
predict cost overrun on offshore oil and gas EPC megaprojects, the DECRIS is found to be significantly
superior. This is depicted in comparing the correlation coefficient (R-squared) value for the PDRI model
superior. This is depicted in comparing the correlation coefficient (R-squared) value for the PDRI model
(0.04) and the DECRIS model (0.70). (Due to the significant difference is cost overrun-model score
(0.04) and the DECRIS model (0.70). (Due to the significant difference is cost overrun-model score
correlation, no schedule-model score analysis was performed for the PDRI). This regression analysis
correlation, no schedule-model score analysis was performed for the PDRI). This regression analysis
result means that the DECRIS model is a more precise and reliable tool to estimate the correlation
result means that the DECRIS model is a more precise and reliable tool to estimate the correlation
between detail engineering assessment score and construction cost performance and to identify the
between detail engineering assessment score and construction cost performance and to identify the
optimal time point of fabrication start, compared to the previous assessment model (PDRI).
optimal time point in
Furthermore, of using
fabrication start,regression
the linear comparedfunction
to the previous
generated assessment modelassessment
by PDRI model (PDRI). and the
Furthermore, in using the linear regression function generated by PDRI model assessment and the
13 sample projects’ construction cost performance data, the cost performance (i.e., Construction Labor
13 sample projects’
Hours Increase construction
Rate) cost performance
for the ongoing data, the in
Project X (described cost
theperformance (i.e., Construction
previous Section Labor
6.2), was predicted
Hours
with theIncrease
result Rate)
of theforcostthe ongoing
overrun of Project X (described
about 6.96%. in the
This cost previous
overrun Sectionvalue
prediction 6.2), is
was predicted
less than the
with the result of the cost overrun of about 6.96%. This cost overrun prediction value
DECRIS model (7.99% of cost overrun) and actual measured cost performance (8.26% of cost overrun). is less than the
DECRIS modelfrom
In summary, (7.99% of cost
these overrun)
analyses, theand actualmodel
DECRIS measured cost performance
is more (8.26% of cost
accurate in predicting overrun).
cost/schedule
In summary, from
performance and isthese analyses,
therefore the in
superior DECRIS
aiding model is more accurate
EPC contractors in predicting cost/schedule
in their preconstruction processes.
performance and is therefore superior in aiding EPC contractors in their preconstruction processes.
7. Conclusions and Discussion
7. Conclusions and Discussion
7.1.Summary
7.1. Summaryand
andContributions
Contributions
Theobjective
The objectiveof
ofthis
thisresearch
researchisisto
todevelop
developaatool
toolto
tocalculate
calculatethe
theengineering
engineeringcompletion
completionrating
ratingof
of
offshore oil
offshore oil and
and gas
gasEPC
EPCprojects,
projects,and
andto
tovalidate
validateresearch
researchgoals
goalsusing
usingregression
regressionanalysis
analysis with
with the
the
sample projects and comparison between the predicted project performances and actual
sample projects and comparison between the predicted project performances and actual performanceperformance
ofan
of an ongoing
ongoing project.
project.
Preliminary DECRIS elements were collected using content analysis from the literature. Through
an expert workshop, an expert survey, and statistical analysis, the individual elements, DECRIS
hierarchy, and weight factor of each element were determined, and a DECRIS model for the steel
cutting session for offshore oil and gas EPC projects was established.
Sustainability 2018, 10, 2469 19 of 31
Preliminary DECRIS elements were collected using content analysis from the literature. Through an
expert workshop, an expert survey, and statistical analysis, the individual elements, DECRIS hierarchy,
and weight factor of each element were determined, and a DECRIS model for the steel cutting session for
offshore oil and gas EPC projects was established.
Thirteen existing sample projects were selected for DECRIS review. The performance review
of those thirteen projects using the DECRIS model resulted in six projects in the low DECRIS score
group for the steel cutting session which were completed with an average construction labor hours
increase rate of 2.2% and a construction duration delay of 47 days. In contrast, the other six projects in
the high group were completed with an average construction labor hours increase rate of 7.7% and a
construction duration delay of 255 days. When steel cutting is conducted with the DECRIS cutoff score
(<300) achieved, the project cost and schedule performance of the project are statistically superior to
other projects that failed to achieve the cutoff score. Through regression analysis with the 13 sample
projects, the correlation and regression functions between the DECRIS score and project performance
were found. Based on the regression functions developed in this research, the project performance for
an ongoing project was predicted, and the predicted performance was well matched with the current
project status.
The research results mean that early detail engineering completion prior to construction makes
the EPC project successful and sustainable without considerable schedule delay and associated cost
overrun. The DECRIS model contributes to EPC contractor as decision-making tools at the moment
of fabrication start. EPC contractor can acknowledge the project risks with the predicted cost and
schedule performance calculated by DECRIS, and they are able to find out mitigation plans such as
additional workforce involvement on engineering or construction works or postpone the fabrication
start after risk comparison.
The DECRIS model can contribute to the project success on the construction execution stage
by forecasting project performance and potentially reducing the project underperformance risks.
The on-time delivery within budget for offshore oil and gas EPC projects using the DECRIS model
will also give a positive motivation for major oil companies who place a great deal of attention on
project success.
Part A
Development of DECRIS model for project scale
Part B
Development of earned value calculation model
Using DECRIS and big data (EDMS)
If If
ininfuture
futureresearch,
research,the
theengineering
engineeringlabor
laborhours
hoursspent
spentononeach
eachpreparation
preparationandandsubmission
submission ofof
engineering deliverables are collected from the historical database, and EDMS and its quantitative
engineering deliverables are collected from the historical database, and EDMS and its quantitative
information
information are
areapplied
appliedfor
forthe
theweight
weightfactor
factorof
of each
each level, DECRIS can
level, DECRIS can be
beused
usedasasaatool
tooltotocalculate
calculate
the
the earned value of the detail engineering activities. In this case, DECRIS can contribute as an
earned value of the detail engineering activities. In this case, DECRIS can contribute as an engineering
engineering cost control tool to calculate the engineering progress during the detail engineering stage.
cost control tool to calculate the engineering progress during the detail engineering stage.
Author Contributions: M.H.K. developed the concept and drafted the manuscript. H.S.C. provided industry
Authoron
feedback the study andM.H.K.
Contributions: developed
E.-B.L. reviewed therevised
and concept
theand drafted the
manuscript andmanuscript. H.S.C.
supervised the provided
overall industry
work. All the
feedback on the study and E.-B.L. reviewed and revised the manuscript and supervised the overall work. All the
authors read and approved the final manuscript.
authors read and approved the final manuscript.
Funding:
Funding:TheThe
authors acknowledge
authors acknowledge that this
thatresearch was sponsored
this research by the Ministry
was sponsored of Tradeof
by the Ministry Industry and Energy
Trade Industry and
(MOTIE/KEIT) Korea through
Energy (MOTIE/KEIT) Koreathe Technology
through InnovationInnovation
the Technology Program funding
Program (Developing IntelligentIntelligent
funding (Developing Project
Management Information
Project Management Systems (i-PMIS)
Information Systemsfor Engineering
(i-PMIS) Projects; Grant
for Engineering number=10077606).
Projects; Grant number = 10077606).
Acknowledgments:
Acknowledgments : TheThe authors
authors of of thisstudy
this studywould
would liketo tothank
like thankHyundai
HyundaiHeavy
HeavyIndustry
Industry
CoCoforfortheir
their
informational support and technical cooperation. The authors would like to thank H. D. Jeong at Iowa State
informational support and technical cooperation. The authors would like to thank Prof. H. D. Jeong at Iowa State
University and D. S. Alleman (a candidate in Univ. of Colorado at Boulder) for their academic inputs and feedback
University and D. S. Alleman (a Ph. D. candidate in Univ. of Colorado at Boulder) for their academic inputs and
on this research.
feedback on this research.
Conflicts of Interest: The authors declare no conflicts of interest.
Conflicts of Interest: The authors declare no conflicts of interest
Abbreviations
Abbreviations
AFC Approval for Construction
AFC
CDD Approval for Construction
Construction Duration Delay
CLIR Construction Labor hours Increase Rate
CDD Construction Duration Delay
DECRIS Detail engineering Completion Rating Index System
CLIR Construction Labor hours Increase Rate
EDMS Electronic Document Management System
DECRIS
EPC Detail engineering
Engineering, Completion
Procurement Rating Index System
and Construction
EDMS
FEED Electronic
Front-EndDocument Management
Engineering and Design System
EPC
FEL Engineering, Procurement and Construction
Front-End Loading
FEED
FPSO Front-End EngineeringStorage
Floating Production, and Design
and Offloading
FEL
FLNG Front-End Loading
Floating LNG
FPSO
PDRI Floating
ProjectProduction, Storage
Definition Rating and Offloading
Index
fsQCA
FLNG Fuzzy Set
Floating LNG Qualitative Comparative Analysis
PCA Principal Component Analysis
PDRI Project Definition Rating Index
fsQCA Fuzzy Set Qualitative Comparative Analysis
Appendix A. Boxplot of Weight Factor by Elements
PCA Principal Component Analysis
* Note: The main purpose of the “boxplot” below is to secure reliability of the data set and similarity with
normal distribution,
Appendix A. Boxplotnumber
of Weightof extreme
Factor and outlier was collected from each participant, and the contribution
by Elements
score was calculated. The survey results with a high contribution score were eliminated.
* Note: The main purpose of the “boxplot” below is to secure reliability of the data set and
similarity with normal distribution, number of extreme and outlier was collected from each participant,
and the contribution score was calculated. The survey results with a high contribution score were
eliminated.
Sustainability 2018,
Sustainability 10,10,
2018, 2469
x FOR PEER REVIEW 21 31
21 of of 31
Sustainability 2018, 10, x FOR PEER REVIEW 21 of 31
FigureA2.
Figure A2.The
TheBoxplot
Boxplot for
for DECRIS
DECRISElements
ElementsE1E1totoH3.
H3.
Figure A2. The Boxplot for DECRIS Elements E1 to H3.
Level Description
1 Final Process Simulation was carried out and AFC stage Process Flow Diagram (PFD) was approved
without comment. No further design change in Process Flow Diagram is foreseen.
2 Updated Process Simulation in detail engineering was performed according to project requirements,
as well as Client comments from PFD and major design changes. Revised PFD (AFD) was issued.
No further major design change in Process flow diagram is foreseen.
3 Process simulation in detail engineering was performed in line with Project Requirements, and its
result including PFD (IFA, first revision) was updated and submitted to the Client.
4 There is no discrepancy between process simulation, PFD, and Heat and Material Balance in FEED.
In addition, they comply with Basis of Design. No process simulation in detail engineering stage
was performed.
5 There is no process simulation performed in FEED, or many discrepancies between process
simulation, PFD and Heat and Material Balance were found. No process simulation in detail
engineering was performed.
Sustainability 2018, 10, 2469 25 of 31
Level Description
1 AFC Heat and Material Balance and Process Description were approved without comment.
No further design change in Heat and Material Balance is foreseen.
2 Updated Heat and Material Balance and Process description in detail engineering were developed
according to Project requirements, as well as Client comments from previous documents and major
design changes. Revised Heat and Material Balance and Process description (AFD) were issued.
No further major design change in Heat and Material Balance and Process Description is foreseen.
3 Heat and Material Balance and Process Description in detail engineering were developed in line
with Project Requirements, and issued with IFA (first revision).
4 There is no discrepancy between PFD, Heat and Mass Balance and Process description in FEED.
In addition, they comply with Basis of Design and design capacity margin. No Heat and Material
Balance in detail engineering was developed.
5 Many discrepancies between PFD, Process Description and Heat and Material Balance were found.
No PFD and Heat and Material Balance in detail engineering were issued.
Level Description
1 AFC Piping and Instrumentation Diagram (P&ID) was issued with incorporated Final Equipment
P&ID (Vendor) and In-line instrument Vendor data, and approved without comment. All Hazard
and operability (HAZOP) recommendations were closed and incorporated in P&ID. No further
design change in P&ID is foreseen.
2 Updated P&ID in detail engineering were developed according to Project Requirements,
Client comments from previous P&ID and 30% Modeling Punch, and major design changes.
Revised P&ID (AFD) was issued. Process HAZOP and Package Unit HAZOP were performed and
Process Line List and Line diagram was issued. No further major change in P&ID is foreseen.
3 P&ID in detail engineering was developed in line with Project Requirements, and issued with IFA
(first revision). Preliminary Vendor Documents or Value Improving Practices for major equipment
was incorporated in IFA P&ID. Hazardous Identification (HAZID) recommendation was
incorporated.
4 There is no discrepancy between PFD, Process description, Utility Flow Diagram (UFD), P&ID in
FEED. In addition, it complies with Basis of Design and design capacity margin. No P&ID in detail
engineering was developed.
5 Many discrepancies between PFD, Process Description, UFD and P&ID were found. No P&ID in
detail engineering was issued.
Level Description
1 All HAZOP/HAZID recommendations were concluded and approved by the client. In addition,
the relevant engineering deliverables were properly documented and approved.
2 HAZOP for Vendor packaged unit and Contractor’s system were finished based on updated P&IDs.
Major HAZOP/HAZID recommendations were concluded and approved by the client.
3 HAZOP has been performed for the Contractor’s system based on P&ID issued by Contractor.
Major HAZID recommendations were concluded and approved by the client.
4 HAZID was performed during FEED stage. Environmental/Human/Process/Facility Operation
hazards have been defined. HAZOP was not performed.
5 No HAZID was performed during FEED stage. Environmental/Human/Process/Facility Operation
hazards have not been defined yet.
Sustainability 2018, 10, 2469 26 of 31
Level Description
1 AFC stage UFD was approved without comment. No further design change in the UFD is foreseen.
2 From incorporating Client comments in UFD, Vendor information for utility consumption and major
design changes, revised UFD (AFD) was issued. No further major design change in UFD is foreseen.
3 Heat and Material Balance and UFD in detail engineering were developed in line with Project
Requirements, and issued with IFA (first revision).
4 There is no discrepancy between UFD and Heat and Material Balance in FEED. In addition,
they comply with Basis of Design. Utility requirements for major consumer were defined through
equipment information.
5 Many discrepancies between UFD and Heat and Material Balance in FEED were found.
Utility requirements for consumer were estimated only with historical data and no equipment
information was developed.
Level Description
1 Final Process datasheets were approved without comment. No further design change in the process
datasheet is foreseen.
2 From incorporating Client comments in process datasheet, Selected Vendor’s information and major
design changes, the revised process datasheets were issued. No further major design change in process
datasheet is foreseen.
3 Process datasheets in detail engineering were developed in line with Project Requirements, and
issued with IFA (first revision). Value Improving Practices for major equipment were incorporated
in the process datasheet.
4 All process datasheets for major equipment were developed during FEED stage. There is no major
discrepancy between FEED P&ID and process datasheets. No process datasheet in detail
engineering was developed.
5 No process datasheet was included in FEED packages, or process datasheets were developed for
Long Lead Items (LLI) only during FEED stage. There are many discrepancies in FEED P&ID and
process datasheets.
Level Description
1 AFC stage equipment mechanical datasheets were completed with Vendor’s firm information and
approved without comment. No further design change in the equipment mechanical datasheet is
foreseen.
2 From incorporating Client comments in equipment mechanical datasheet, Selected Vendor’s
information and major design changes, the revised equipment mechanical datasheets were issued.
No further major design change in equipment mechanical datasheet is foreseen.
3 Equipment mechanical datasheets in detail engineering were developed in line with Project
Requirements, and issued with IFA (first revision). Value Improving Practices and applicable
Code/Standard requirements for major equipment were incorporated in the equipment mechanical
datasheet.
4 All equipment mechanical datasheets for major equipment were developed during FEED stage.
There is no major discrepancy between FEED P&ID and equipment mechanical datasheets.
No equipment mechanical datasheet in detail engineering was developed.
5 No equipment mechanical datasheet was included in FEED packages, or equipment mechanical
datasheets were developed for LLI only during FEED stage. There are many discrepancies in FEED
P&ID and equipment mechanical datasheets.
Sustainability 2018, 10, 2469 27 of 31
D8. Specifications
Level Description
1 AFC stage process, mechanical and piping specifications were approved without comment.
No further design change in the specification is foreseen.
2 From incorporating Client comments in specification and major design changes, the revised
specifications were issued. No further major design change in specification is foreseen.
3 Specifications in detail engineering were developed in line with Project Requirements, and issued
with IFA (first revision). The specification includes equipment type, packaged units,
piping specifications, protective coating and insulation.
4 All major specifications were developed during FEED stage. There is no major discrepancy between
specifications. No specification in detail engineering was developed.
5 No specification was included in FEED packages, or there are many discrepancies in FEED
specifications.
D9. Piping System Requirements
Level Description
1 AFC stage piping material classes were completed with Vendor’s firm information and approved
without comment. No further design change in the piping material class is foreseen.
2 From incorporating Client comments in piping material class, additional piping materials and major
design changes, the revised piping material class was issued. No further major design change in
equipment mechanical datasheet is foreseen.
3 Piping material classes in detail engineering were developed in line with Project Requirements, and
issued with IFA (first revision). Value Improving Practices and applicable Code/Standard
requirements were incorporated in the piping material class.
4 All piping material classes were developed in line with material selection in FEED stage.
All relevant devices including straight runs, elbows, tees, flanges, reducers, manual valves,
gaskets, bolts and nuts were defined in the piping material classes.
5 No piping material class was developed during FEED stage, or piping material class was partially
developed.
Level Description
1 AFC stage plot plan was completed with Vendor’s firm information, 60% and 90% modeling review
punch and approved without comment. No further design change in the plot plan is foreseen.
2 From incorporating Client comments in plot plan, 30% modeling review punch and major design
changes, the revised plot plan (AFD stage) was issued. No further major design change in plot plan
is foreseen.
3 Plot plan in detail engineering was developed in line with Project Requirements and preliminary
equipment Vendor documents, and issued with IFA (first revision). Value Improving Practices
including process function group and interconnection optimization were incorporated in the
plot plan.
4 Plot plan was developed with all equipment, evacuation path, access/handling volume, large
diameter pipe (including flexibility requirement), and access way and hazard area risks.
5 Plot plan was developed with limited equipment and device information during FEED stage.
Sustainability 2018, 10, 2469 28 of 31
Level Description
1 AFC stage project equipment list was completed with Vendor’s firm information and approved without
comment.
2 From incorporating Client comments in project equipment datasheet, Vendor information and major
design changes, the revised project equipment list was issued. All disciplines’ input was
incorporated and no additional equipment in project equipment list is foreseen.
3 Project equipment list in detail engineering was developed in line with Project Requirements,
and issued with IFA (first revision). Value Improving Practices and potential Vendor’s information
for equipment were incorporated in the package equipment list. Additionally, equipment list
includes Vendor name, equipment model, insulation and fire proofing requirements.
4 Project equipment list for all major equipment was developed during FEED stage. There is no major
discrepancy between FEED P&ID and equipment list. Equipment list includes tag number,
equipment description, equipment type, capacity/quantity, position/module/deck,
assumed dimension/weight.
5 Project equipment list was developed for major equipment only during FEED stage. No auxiliary
equipment was considered in the project equipment list. There are many discrepancies in project
equipment list and P&ID.
D12. Line Lists
Level Description
1 AFC stage line list was completed with all pipelines and approved without comment.
2 From incorporating Client comments in line list and major design changes in P&IDs, the revised line
list (AFD) was issued. All lines over 2” with insulation and Passive Fire Protection (PFP)
requirements shall be included in the line list.
3 Line list in detail engineering was developed in line with IFA P&IDs, and issued with IFA
(first revision). Line list should include large bore and exotic material lines for 1st MTO for
piping materials.
4 Line list for all major pipe route was developed during FEED stage. There is no major discrepancy
between FEED P&ID and line list. Line list includes tag number, operating and design condition,
pipe specification, insulation/tracing and painting requirement.
5 No line list was developed during FEED stage.
D13. Tie-in Lists
Level Description
1 AFC stage tie-in list was completed with AFC P&ID, verified with Vendor documents and/or
confirmations, and approved without comment.
2 From incorporating Client comments in tie-in list, Vendor documents (General Arrangement
Drawing for Equipment) and major design change in P&IDs, the revised tie-in list (AFD) was issued.
All lines over 2” with insulation and PFP requirements shall be included in the tie-in list.
3 Tie-in list in detail engineering were developed in line with IFA P&IDs, and issued with IFA (first
revision). Tie-in list should crosscheck with preliminary Vendor information for major equipment.
Structured process to validate tie-ins and tie-in strategy was documented.
4 Tie-in list for major pipe connections was developed during FEED stage. There is no major
discrepancy between FEED P&ID and tie-in list. The tie-in list includes line tag number,
reference drawings, pipe specification, and type and size of tie-in.
5 No tie-in list was developed during FEED stage.
Sustainability 2018, 10, 2469 29 of 31
Level Description
1 AFC stage piping stress analysis was completed with AFC P&ID, verified with Vendor documents
and/or confirmations, and approved without comment. All support and anchor locations were
settled, and no further design change is expected.
2 From incorporating Client comments in piping stress analysis, Vendor information for boundary
condition (allowable nozzle load) and major design changes in P&IDs, the revised piping stress
analysis (AFD) was performed.
3 Piping stress analysis in detail engineering was conducted in line with IFA P&IDs, and issued with
IFA (first revision). Support and anchor locations, and pipe wall thickness were updated as per the
piping stress analysis.
4 Guidelines for piping stress analysis were developed in FEED package. Applications for high
temperature, large diameter, and heavy wall thickness, upstream and downstream of rotating
equipment were well defined.
5 No guidelines for piping stress analysis were developed during FEED stage. FEED package does
not specify the extent of piping stress analysis.
D15. Piping Isometric Drawings
Level Description
1 AFC stage piping isometric drawings were completed with AFC P&ID, and approved without
comment. All support and anchor locations were settled, and no further design change is expected.
2 From incorporating Client comments in piping isometric drawings and major design changes in
P&IDs, the revised piping isometric drawing (AFD) was generated and submitted.
3 Methodology to generate piping isometric drawing was settled. Piping isometric drawings in detail
engineering were generated from 3D modeling, and issued with IFA (first revision). Support and
anchor locations, and pipe wall thickness were updated as per the piping stress analysis.
4 Guidelines for piping isometric drawing were developed in FEED package. Requirements for
piping isometric drawings were well defined.
5 No guidelines for piping isometric drawing were developed during FEED stage.
Level Description
1 AFC stage piping specialty items list was completed with AFC P&ID, and approved without
comment. Catalog for 3D modeling was settled, and no further design change is expected.
2 From incorporating Client comments in piping specialty items list and major design changes in
P&IDs, the revised piping specialty items list (AFD) was generated and submitted.
3 Piping specialty items list in detail engineering was developed in line with IFA P&IDs, and issued
with IFA (first revision). Scope of supply was defined and preliminary Vendor information
was given.
4 Guidelines for piping specialty items were developed in FEED package. Types of piping specialty
items including strainers, steam traps, flexible hoses, and expansion joints were defined.
5 No guidelines for piping specialty items were developed during FEED stage.
Sustainability 2018, 10, 2469 30 of 31
Level Description
1 AFC stage instrument index was completed with approved AFC P&ID, and approved without
comment. All information on instrument index was settled, and no further design change is
expected.
2 From incorporating Client comments in instrument index and major design changes in P&IDs,
the revised instrument index (AFD) was generated and submitted. No major change on instrument
index is foreseen.
3 Instrument index in detail engineering was developed in line with IFA P&IDs, and issued with IFA
(first revision). Information of tag numbers, service conditions, instrument type, and signal output,
material of construction, range and set point was provided.
4 Guidelines for instrument index were developed in FEED package. Requirement for instrument
index was defined.
5 No guidelines for instrument index were developed during FEED stage.
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