IPA Newsletter 2010 Q2 (Volume 2, Issue 2)
IPA Newsletter 2010 Q2 (Volume 2, Issue 2)
IPA Newsletter 2010 Q2 (Volume 2, Issue 2)
Independent Project Analysis, Inc. is the preeminent organization for quantitative analysis of
capital project effectiveness worldwide. At IPA, we provide practices you can use to ensure
your success.
Research Spotlight:
Sustainable Capital Project Delivery
Christopher Carabetta
Editor: Kelli L. Ratliff To view registration details and to learn about special discounts, please visit our website at
[email protected] www.IPAInstitute.com, or call +1 (703) 729-8300.
jects are being deployed in less-developed and familiar locations with little infrastructure and high impact on the
local population. Maintaining a social license to operate in the presence of increased NGO and government
activism and rapid global communications is a challenge that affects the bottom line. Proactively managing a
complex network of stakeholders is essential to remaining on the A-list of companies invited to develop and
expand assets. Missteps can tarnish corporate reputations and take years to recover from. In extreme cases,
production can be interrupted or assets expropriated.
Corporate responsibility, as translated into capital projects, can take many forms. Some projects include budg-
ets for building infrastructure such as schools and health clinics. Others focus on achieving zero water dis-
charge and restoring local flora and fauna. The form of sustainability investment has evolved over the years
from unilateral local content and livelihood replacement to more participative community investment and capac-
ity building. Investments are designed to help ensure short- and long-term enterprise and community sustain-
ability. Success is now measured over the asset life cycle and seeks to answer the question: After the asset is
closed, is the community better off than if the resource had never been developed in the first place?
Applying sustainability
concepts to capital
projects requires a
new performance
model to identify and
measure Best Prac-
tices (Figure 2). One
could envision that
Best Practices exist
for integrating sustain-
ability into capital pro-
jects, engaging stake-
holders, and making
effective investments.
Further, the magni-
tude, timing, and type
of investment might
also be correlated with
outcomes and bench-
marked. Linking sus-
tainability practices in
capital project delivery
to outcomes is key to
isolating Best Prac-
tices. Sustainability
outcomes include
Figure 2. Sustainability Applied to Capital Projects
both direct value
creation, such as the benefits of training local labor, and indirect value protection. Value protection can take the
form of fewer project delays, added costs, avoidance of project cancellation or expropriation, and fewer disrup-
tions to production. Ultimately, through more effective sustainable project delivery, companies will benefit over
the long term through higher company valuation, a better reputation, and more development opportunities.
IPA has been engaged by a major financier of capital projects to use its extensive databases to quantify capital
project sustainability risk. The first stage effort is to examine differences in general risk for petroleum E&P and
mining projects. We are investigating whether the annualized rate of occurrence (ARO) and severity of risks
such as project delays and cost growth are different for developed and developing regions and for onshore and
(Continued on page 3)
offshore petroleum E&P projects. Future research opportunities include isolating specific practices that reduce
sustainability driven risks.
Sustainable project delivery is emerging as an increasingly relevant area in the body of capital project knowl-
edge. Research in this field is particularly well suited to IPA’s benchmarking capabilities and proven research
methodologies.
If you have an interest in participating in a multi-company research study or would like to pro-
vide comments on this topic, please contact Christopher Carabetta of IPA at ccara-
[email protected] or +1 (703) 726-5388.
Before joining IPA, Chris worked as a product development management intern for the online brokerage
unit of the Donaldson, Lufkin, and Jenrette investment bank. He has also been a consultant with ITT In-
dustries in international programs management where he worked with the Office of the Secretary of De-
fense to develop international technical cooperation programs. Prior to joining ITT Industries, he served
as a project engineer in naval architecture for General Dynamics Electric Boat Division. Chris completed
engineering degrees from Penn State and Rensselaer Polytechnic Institute and an MBA from George-
town University.
In evaluating over 6,000 small site-based projects around the globe, IPA has observed
that many manufacturing sites, being understaffed with owner personnel, delegate man-
agement of their small projects to an alliance or preferred contractor. IPA research has
consistently found that assigning key roles on small projects to a contractor without ade-
quate owner oversight is a leading root cause of poor project performance. This article will
examine disadvantages in delegating small project management to a contractor, and ex-
plain how owners can mitigate these risks to achieve competitive performance.
ing result, given that sites which delegate project management to contractors often fail to retain (or never
had) ownership of the project control function.
Contractor-led projects tend to use more resources than owner-led projects to accomplish the same
amount of work.
Site-based projects with a contractor project manager or contractor cost estimator use significantly more en-
gineering hours to complete the same scope of work than projects in which these roles are filled by owner
personnel (Figure
1). This difference
can be somewhat
mitigated if an owner
specialist conducts a
detailed cost valida-
tion of the contrac-
tor’s cost estimate,
but unfortunately
many small projects
lack owner capability
in this area. In addi-
tion, there are clear
advantages in engi-
neering productivity
when basic design is
conducted by the
owner rather than by
a contractor and the
improvement in en-
gineering productivity Figure 1. Contractor Project Manager/Estimator Has Negative Effect on Engineering
is magnified when Productivity
both basic and de-
tailed design are conducted by the owner. Delegating either of these responsibilities to the contractor results
in more engineering hours. Owner engineering tends to have a greater stake in producing competitive pro-
jects, whereas contractor engineering―even when well integrated into the site―is ultimately beholden to its
own management, and motivated to maximize profitability.
Contractor-led projects tend to be more expensive than owner-led projects.
Cost competitiveness is affected because (1) contractor-led projects do not use the same level of Best Prac-
tices as owner-led projects and (2) contractor-led projects tend to use more engineering hours to accomplish
the same scope of work. These discrepancies translated to a 14 percent difference in cost performance
for the sites IPA benchmarked in 2009. The sites with a greater proportion of owner project managers
achieved an average cost index on their small projects of 0.93 (in other words, they spent 7 percent less
than industry average) versus an average of 1.07 for the sites with a greater proportion of contractor project
managers.
We recognize that it may not be practical for some sites to routinely staff key functions with owner personnel.
Furthermore, some of the best sites in Industry―sites that consistently pay 10 to 15 percent less for their small
projects than industry norms―have an alliance contractor that is heavily leveraged to support their small project
portfolio. How do these sites achieve excellent performance despite filling many roles with contractor person-
nel? The role of the owner and the owner process is crucial; these are some key practices that help drive excel-
lence when sites rely on contractor personnel:
An owner cost specialist performs a quantitative validation of each cost estimate.
The validation process helps push back against any over-estimating by the contractor, and ensures that the
project targets set at authorization are competitive.
(Continued on page 5)
The owner provides clear business objectives for all small projects.
Contractor-led projects sometimes struggle to obtain clarity of objectives from the owner and, as a conse-
quence, suffer more churn and recycle in the definition phase than owner-led projects. This can drive up the
amount of engineering hours used. Consistently providing and documenting clear objectives helps mitigate the
delays that often occur when objectives are not understood. Owner leadership can also be instrumental in as-
sisting contractor-led projects in obtaining input from other key functions at the site.
In summary, all sites, regardless of their contracting approach, have the opportunity to achieve excellent per-
formance. The best sites make consistent use of Best Practices, often have more owner project managers than
contractor project managers, and retain key functions such as cost estimating and validation. Even when they
delegate project management to a contractor, best sites maintain strong gatekeeping processes, and site lead-
ership helps projects succeed by giving them clear objectives and promoting team development. In contrast,
poorly performing sites have turned over key functions (particularly cost estimating and validation) to the con-
tractor with little or no owner oversight. The owner’s “hands off” approach can undermine small project perform-
ance even when Best Practices are employed.
For more information, contact Phyllis Kulkarni, Manager Plant-Based System, by e-mail at
[email protected] or by phone at +1 (703) 726-5472.
Previous to her promotion to a managerial position, she served on IPA’s Review Board for two years, re-
viewing projects for multiple IPA business areas. Before her position as a Reviewer, she was a Senior
Project Analyst with IPA's Latin American Project Center (Centro de Proyectos Latinoamericanos) and
was involved in the analysis of petroleum, chemical, and mining projects in Latin America, the U.S., and
Spain. In addition, Phyllis has led megaproject assessments, site benchmarkings, turnaround evalua-
tions, and analyses of exploration and production projects. In 2003, Phyllis presented the results of a
research study that she led on Joint Venture projects at IPA’s annual Industry Benchmarking Consortium
(IBC). Phyllis was the Coordinator for IBC 2010.
Prior to joining IPA in 2002, Phyllis interned as a translator for Repsol YPF in Buenos Aires, Argentina.
Phyllis holds a B.S. in Languages and Linguistics from Georgetown University, Washington, D.C.
To be kept informed regarding upcoming IPA Institute programs and courses being devel-
oped for capital project improvement, join our mailing list at www.IPAInstitute.com
Over the last several years, IPA has invested in developing a better understanding of the
cost and operational performance of mining, minerals, and metal (MMM) projects. This
article discusses our recent research results in the areas of mine definition, mineral proc-
essing project operational performance, heavy haul railroad cost analysis, hydrometallur-
gical plant cost per tonne analysis, and coal handling and preparation plant cost curves.
The Database
IPA’s MMM project database has grown from 300 projects in 2005 to 700 projects and now contains more than
35 owner organizations. Since 2005, approximately 65 mine development projects have been evaluated by IPA,
including data from 25 completed mine development projects. The database has worldwide coverage across
remote and diverse locations, containing both open pit and underground mine developments. The primary com-
modities represented include bauxite, coal, copper, diamonds, gold, iron ore, nickel, and oil sands.
ity and currency market, placing the project definition phases at risk of extreme business pressure.
IPA’s MFEL data are showing strong links Figure 3. Better Mine Definition Drives Reduced Startup/Operability
to key project outcomes and IPA’s MFEL Problems
Index is a tool that can be used in Industry
to enable more successful mine development projects and enhance shareholder returns through competitive
and predictable project outcomes.
To capture and discuss differences between the planned early operability targets and actual early operability
performance, IPA will now report early operability performance deviation, which, by definition, is the difference
between planned and actual design nameplate capacity expressed as a percentage of the target, for all MMM
projects containing a processing plant and for mine production shortfalls.
The research found a strong cost relationship between cost and throughput, which can now be applied in cases
in which a project contains a hydrometallurgical processing plant. Capacity ranges up to 150,000 tonnes per
day of throughput are contained within the regression.
The study found that the plant design ROM capacity (expressed in millions of tonnes per annum [MMtpa]) is a
significant driver of CHPP total installation cost, with the statistical model explaining a majority percentage of
the cost variation in the dataset. This preliminary cost analysis tool can be applied, with limitations, to both cok-
ing and thermal CHPPs with capacity ranges of between 5 and 18 ROM MMtpa.
Future Research
The next generation of cost relationships is now being tested on the following scopes: residue and tailings
ponds, port/marine facilities, materials handling, and copper/gold and iron ore plant cost regressions.
For additional information regarding IPA’s mining and minerals project cost and operational perform-
ance research, please contact:
As a project analyst, Sally has evaluated more than 100 petrochemicals, refining, mining and minerals,
and oil and gas projects, ranging from small projects to megaprojects. Sally has been a facilitator at sev-
eral of IPA’s Front-End Loading and Lessons Learned workshops, and in 2004, spent two months in Bra-
zil and the United States co-facilitating a capital project system redesign for a major minerals client.
Sally rolled out the Mine Front-End Loading Index at the Industry Benchmarking Consortium (IBC) 2005,
and researched and presented IPA’s Hot Spot Research for Western Australia at IBC 2006. Sally has
been client coordinator for three of IPA’s clients from the MMM and Oil and Gas industry sectors, and has
taught a range of capital effectiveness-related topics for the IPA Institute. Sally has also been a guest
lecturer at the University of Western Australia since 2007 for fourth-year mechanical engineering stu-
dents. Sally holds a B.E. (Hons) in Civil Engineering from the University of Melbourne.
Practices for Shorter, More Cost Effective Turnarounds (14 Professional Development Units)
June 16 - 17: São Paulo, Brazil October 12 - 13: The Hague, The Netherlands
Best Practices for Small and Plant Projects (22 Professional Development Units)
July 13 - 15: Shanghai, China August 3 -5: Houston, Texas
September 14 - 16: Dusseldorf, Germany September 21 - 23: Singapore, Singapore
November 16 - 18: Beijing, China November 23 - 25: Sydney, Australia
Establishing Effective Capital Cost and Schedule Processes (16 Professional Development Units)
August 24 - 25: São Paulo, Brazil
Exploration and Production Project Best Practices (22 Professional Development Units)
September 6 - 8: Reading, England September 14 - 16: Anchorage, Alaska
November 23 - 25: Rio de Janeiro, Brazil
On June 1st, I left for my very first sabbatical. I left UCLA the year before I was eli-
gible for sabbatical and there have always seemed to be reasons for not taking one
at IPA. We started our sabbatical program 12 years ago to provide a break of four
months or so for analysts to recharge and gain perspective. I believe it has been an
unqualified success. One becomes eligible after six years of unbroken ser-
vice. The only requirement is that the time be planned; sitting in front of the TV is
not an option.
My plan is to do something I have wanted to do for some time now: write a compre-
hensive book on what goes wrong with megaprojects and what to do about it. I am
writing in the morning and then fishing in the evening--not the ideal order but the
one that is most likely to get the book done. While I am away, the corporate manag-
ers and regional directors will mind the store and I expect my absence will be hardly
noticed.
IPA improves the competitiveness of our customers through enabling more effective
use of capital in their businesses. It is our mission and unique competence to con-
duct research into the functioning of capital projects and project systems and to ap-
ply the results of that research to help our customers create and use capital assets
www.ipaglobal.com more efficiently.
The IPA Institute’s mission is aligned with the overall IPA mission to improve the
capital productivity of its clients. The programs offered provide a forum for in-depth
understanding of key elements of the capital project process and how to apply these
www.IPAInstitute.com learnings to effect positive changes and improvements, resulting in the more effec-
tive use of capital.
Independent Project Analysis Newsletter is published and Copyrighted © 2010 by Independent Project Analysis, Inc.
Editor: Kelli L. Ratliff, IPA Institute Analyst. [email protected]
Reproduction of material which appears in Independent Project Analysis Newsletter is prohibited without prior written permission from IPA.