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Project Completion Report. Project Summary. Client: MTU Detroit Diesel Australia Contract No.: 1161873. Project Overview. The generator package formed part of the CSBP initiated NAAN3 project which aimed to increase production in their Kwinana facility.

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slide2

Project Summary

Client: MTU Detroit Diesel Australia

Contract No.: 1161873

slide3

Project Overview

  • The generator package formed part of the CSBP initiated NAAN3 project which aimed to increase production in their Kwinana facility.
  • Aerison’s scope of supply included the following main components………
  • Painted skid base with integral double skinned fuel tank (3500L)
  • Stainless steel acoustic enclosure
  • Inlet and outlet ventilation system
  • Removable roof
  • Roof mounted muffler
  • Fitting of free issue generator set and radiator to skid base
  • Full mechanical assembly of acoustic enclosure package
slide4

Project Overview

  • Parties Involved
  • Primary Stakeholder: CSBP
  • EPCM: MTU Detroit Diesel Australia
  • Supply Contractor: Aerison
  • Aerison’s Scope
  • Design, fabricate, assemble & transport to site……
  • One off acoustic diesel generator package with integrated fuel tank
slide7

Design

  • Aerison
  • Similar to units previously supplied
  • Double skinned tank changed in regards to previous designs to
  • incorporate double skin at sides also
  • Stainless steel panels
  • Removable roof
  • Semrad fuel control system
slide8

Fabrication – In House

  • Base frame and tank
  • Structural frame work
  • Inlet ventilation system
  • Outlet ventilation system

Base Frame

slide9

Fabrication – In House

Structural Framework

Inlet / Outlet Ventilation System

slide10

Fabrication – Sub Contractor

  • Stainless steel panels Cohesive
  • Stainless steel doors Cohesive
  • Flashing Cohesive
  • Muffler Universal
  • Weather louvreBradflow
  • Surface treatment RPC
slide11

Fabrication – Sub Contractor

Insulation Fit Out

Complete Panels

Door Trial Assembly

slide12

Fabrication – Sub Contractor

Muffler

Elbow & Weather Cowl

Weather Louvre

slide13

Project Pictures-Complete Assembly

Outlet End

Inlet End

Fuel Connections

Exhaust Duct & Blankets

slide14

Project Pictures-Complete Assembly

Fuel Interface

Genset Installation

Genset

Removable Roof

slide16

Project Summary

Safety and Environment

  • Target – Nil Incident Actual – Nil Incident
  • Comments
  • Safety and environment record for project excellent
  • No reported incidents from sub contractors
slide17

Project Summary

Scope of Works

  • Target - Original Contract Scope of Works Total Number of SCN’s 4
  • Total Approved 3
  • Comments
  • Project completed on time
  • $10,260 in variations
slide19

Project Summary

Schedule

  • Original Contract Delivery 31/01/2013 Actual Practical Completion – March 2013
  • (Contractual obligations fulfilled – Extension due to external client issues)
  • Comments
  • Schedule extremely tight from the beginning
  • A lot of initiative and assisting of client required to keep the project on track
slide20

Project Summary

Budget and Margin

slide21

Project Summary

Budget and Margin

  • Original Contract Sum $189,200 Expected Final $199,460
  • Original Contract Margin $37,925 (20%) Expected Final $15,698 (8%)
  • Comments
  • Over budget items were:-
  • Drafting (-$11,408)
  • Management (-$20,017)
  • Fabrication Labour (-$7,315)
  • Assembly Labour
  • Under budget items were:-
  • Materials ($1,700)
  • Panels and Doors ($8,156)
  • Variations
slide22

Project Summary

Quality

  • Target – Nil Quality Issues or NCR’s Actual – Nil
  • Comments
  • Internal fabrication checks
  • Sub contractor quality review documentation
  • Sub contractor external expections
slide23

Issues

Budget

  • Comments
  • Drafting
  • - Significantly underestimated (~$9,000 estimated / ~$20,000 used)
  • Workshop hours
  • - Underestimated in regards to ventilation inlet/outlet system
  • - 370 hours used in total (290 allocated to work shop – Additional 80 hours
  • allocated due to shortfall with inlet/outlet ventilation system)
  • Assembly hours
  • - 140 hours estimated
  • - 80 additional hours used
  • ~ 45 hours covered by variation
  • ~ 10 hours caused by direct work shop error
  • Management and Engineering
  • - Significantly underestimated (~$18,000 estimated / ~$38,000 used)
slide24

Issues

General

  • Subcontractors
  • - Subcontractors internal quality inspections poor
  • - Subcontractors external quality inspections not adequate
  • Drafting
  • - Missing detail led to additional work and time expended
  • Engineering
  • - Lack of consideration for a few assembly items (grid mesh / silencer
  • connection to radiator)
  • - Bolt take offs not efficient or correct
  • Management
  • - Greater control needed to be taken of design process at an earlier stage
  • - Due to the lack of document control and an organised process on the clients
  • side a lot of gentle persuasion and recording required to maintain forward
  • momentum of project while maintaining contractual obligations and cover.
slide25

Project Summary

Human Resources

  • Comments
  • Expeditor – Good
  • - Expediting very good where required
  • QA – Internal Good / External Poor
  • - All internal issues identified and rectified in at work shop stage
  • - Muffler quality and panel quality documentation poor
  • Engineering – Good (Needs to flow more from the start)
  • Document Control – Restricted due to no client document control
  • Safety – Excellent
  • Management – Good
  • - Management was required to be very tight due to lack of budget in critical
  • areas
slide26

Project Summary

Communications

  • Comments
  • Internal
  • Sub contractor
  • Client
slide27

Project Summary

Client Satisfaction

  • Client and CSBP happy to date with final product – Commissioning and noise test yet to take place
slide28

Project Summary

Lesson Learnt

  • Transport
  • Quality
  • Contract management
  • At source inspections
slide29

Project Summary

Project Completion

  • Unfinished Business
  • Comments
  • Thank You Letter
  • Bank Guarantees
  • Future Business or Related Projects
  • Aerison Procedures
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