AIPPC – Advanced Industry Project Planning & Controls
Oil & Gas EPC Project Oriented Internship Program (12 Weeks)
MODULE 1 — Introduction to Oil & Gas EPC Projects
Objective: Understand how end-to-end EPC megaprojects are executed and controlled.
Topics Covered
- Overview of upstream, midstream, downstream industries
- EPC vs EPCM contracting structures
- FEL (Front-End Loading) Stages: FEL-1 → FEL-2 → FEL-3
- Engineering → Procurement → Construction → Commissioning workflow
- Project baselines: Scope, Cost, Schedule, Quality
Outcomes
- Clear understanding of how Oil & Gas projects function
- Role of Project Controls in each project stage
MODULE 2 — Work Breakdown Structure (WBS) Development
WBS is the backbone of schedule, cost, progress, and reporting systems in Oil & Gas EPC projects.
Topics Covered
- Area-based, System-based, Discipline-based WBS models
- WBS dictionary creation
- Engineering WBS → Procurement WBS → Construction WBS integration
- Level 1–5 WBS structures for refinery, pipeline, tank farm, offshore platforms
Practical Exercise
- Create WBS for a Hydrotreater Unit
- Develop WBS dictionary in Excel
MODULE 3 — Engineering Planning & Progress Control
Topics Covered
- Engineering Deliverables Register (EDR)
- Weightages & progress curves
- P&IDs, 3D Model milestones, Isometrics release planning
- Vendor document management
- Engineering progress reporting (PEC, trend analysis)
Hands-On Tasks
- Create Engineering Register in Excel
- Build Engineering S-curves
- Update IFC deliverables in Primavera
MODULE 4 — Procurement Planning & Controls
Topics Covered
- LLI identification & strategy
- Procurement lifecycle: MTO → RFQ → TBE → PO → FAT → Delivery
- Incoterms and logistics
- Vendor expediting & manufacturing progress
- Procurement Register development
Hands-On Tasks
- Create Procurement Register
- Vendor progress tracking & reporting
- Integrate procurement milestones into Primavera
MODULE 5 — Construction Planning
Topics Covered
- Construction Work Packaging (CWP, EWP, FIWP)
- Sequence: Civil → Steel → Mechanical → Piping → E&I
- Construction productivity and constraints
- 4D Planning concept
- Quantity-based progress measurement (QTY curves)
Practical Exercises
- Create construction lookahead plan
- Prepare installation sequence for a process unit
MODULE 6 — Piping Planning & Hydrotest Management
Topics Covered
- Spool fabrication vs field fit
- Weld inch-dia forecasting
- NDT, PWHT, painting & reinstatement
- Hydrotest pack creation & closure
- Punch listing & mechanical completion
Hands-On Tasks
- Create spool tracking sheet
- Hydrotest schedule preparation
- NDT progress curve
MODULE 7 — Commissioning & System Completion
Topics Covered
- System & subsystem breakdown
- Tagged equipment readiness
- Mechanical Completion (MC), Pre-commissioning, Commissioning
- Loop checks, ITRs, RFI, final handover
Exercises
- Develop commissioning execution plan
- System readiness tracking
MODULE 8 — Cost Control & Budgeting
Topics Covered
- Cost Breakdown Structure (CBS)
- Budgeting of Direct, Indirect & Overheads
- Commitments, accruals, actuals
- EVM: SPI, CPI, ETC, EAC
- Trend & change management
Hands-On Tasks
- Build cost-loaded Primavera schedule
- Run EVM analysis
- Prepare monthly cost report
MODULE 9 — Risk Management
Topics Covered
- Qualitative risk analysis
- Quantitative risk analysis (Monte Carlo)
- Schedule Risk Analysis (SRA)
- Cost Risk Analysis (CRA)
Exercise
- Create risk register
- SRA scenario simulation
MODULE 10 — Reporting & Dashboards
Topics Covered
- Weekly / Monthly EPC reports
- Progress narratives & highlights
- S-curves & progress curves
- Delay analysis narratives
- Power BI dashboard fundamentals
Hands-On Tasks
- Create integrated EPC dashboard
- Generate S-curves
MODULE 11 — Primavera P6 Integrated Planning
Topics Covered
- Level 1–5 schedules
- Calendar creation (offshore/onshore)
- Baselining & progress updates
- Critical path & near-critical path
- Delay analysis (TIA, Windows, As-built vs As-planned)
Exercises
- Create Level 3 EPC schedule
- Run schedule update cycle
- Perform critical path analysis
MODULE 12 — Final Internship Deliverables
- A1. CBS Development – Excel + P6 screenshots
- A2. Cost Loading in P6 – .xer file + tables
- A3. EVM Report – Monthly PDF + Analysis
- A4. Cash Flow Curve – S-Curves
- A5. Forecasting Exercise – EAC, ETC, VAC
- A6. Final Dashboard + Presentation – PowerPoint
AIPPC – Advanced Industry Project Planning & Controls
Specialized Training for Oil & Gas EPC Projects • EDGE Project Controls Academy
MODULE 1 — Introduction to Oil & Gas EPC Projects
Objective: Provide a complete understanding of how Oil & Gas megaprojects are structured, executed, controlled, and governed from concept to commissioning.
1️⃣ Upstream, Midstream, Downstream — Detailed Industry Overview
Upstream — Exploration & Production
- Exploration drilling, well testing, reservoir modelling
- Platforms (fixed, floating), FPSOs, subsea trees, manifolds
- Drilling rigs, BOPs, risers, SURF packages
Characteristics:
- Highest uncertainty due to subsurface conditions
- Extreme logistical and weather dependencies
- Critical marine operations (towing, heavy lifts)
Typical Planning & Controls Challenges:
- Offshore calendars (weather downtime, wave height limitations)
- SIMOPS (simultaneous operations with existing platforms)
- Marine spread availability and vessel scheduling
Midstream — Transport & Storage
- Pipeline networks, compressor stations
- LNG import/export terminals
- Tank farms and distribution hubs
Planning Challenges:
- ROW (Right-of-Way) acquisition and clearances
- Spread-based execution planning
- Seasonal weather shutdowns (monsoons, floods)
Downstream — Refining & Petrochemicals
- Refineries (CDU, VDU, FCC, Hydrocracker, CCR)
- Gas processing plants
- Chemical units (ethylene, polymer plants)
Key Challenges:
- Piping and mechanical erection dominate critical path
- Complex commissioning and systemization
- High density of equipment and interconnections
2️⃣ EPC vs EPCM Contracting Models — Full Explanation
EPC — Engineering, Procurement & Construction
Contractor Responsibilities:
- All engineering deliverables
- Procurement of all materials, equipment, and services
- Construction and site execution
- Commissioning and performance guarantees
Characteristics:
- Single point responsibility
- Used mainly for downstream O&G projects
- Price certainty (Lump Sum)
EPCM — Engineering, Procurement & Construction Management
Contractor Responsibilities:
- Engineering + Procurement support
- Manage multiple construction subcontractors
- Provide oversight and reporting to the client
Planning & Controls Challenges:
- Multiple contractor schedules to integrate
- Interfaces between civil, mechanical, piping, electrical contractors
- Baseline more dynamic compared to EPC
EPC vs EPCM (Planning Perspective)
- EPC: Stronger baseline control, strict reporting, contractor holds risk
- EPCM: More flexible, owner holds risk, but high integration workload
3️⃣ Stage-Gate / FEL Model — Full Breakdown
FEL-1 — Concept Development
- Business case study
- High-level scope and cost (+50% accuracy)
- Technology screening
FEL-2 — Feasibility
- Plot plan, PFDs, preliminary P&IDs
- Budgetary equipment lists
- Schedule accuracy improves to ±30%
FEL-3 — FEED (Front End Engineering Design)
- 30–50% engineering completed
- Major vendor lists and early MTOs
- Cost accuracy improves to ±15%
- Basis for EPC tendering
Why FEL is critical:
- Poor FEL = unstable baselines + massive EPC overruns
- Defines clear scope and minimizes change orders
- Reduces execution risk
4️⃣ Scope Definition & Contract Baselines — In-Depth Notes
Scope Baseline
- WBS + WBS dictionary
- Process design basis
- IFC drawings & engineering deliverables
- Equipment lists, datasheets
Schedule Baseline
- Approved Level 3 P6 schedule
- Critical path + near-critical paths
- Logical relationships + calendars
Cost Baseline
- CBS linked to WBS
- Budget allocation (Engineering, Procurement, Construction)
- Contingency and escalation
Why Baselines Matter:
- Progress measurement
- Change management & claims
- Forecasting (EAC/ETC)
- Client reporting
5️⃣ EPC Workflow — Engineering → Procurement → Construction → Commissioning
Engineering Phase
- P&IDs, 3D models, isometrics
- Critical deliverables to unlock procurement & construction
- Model review cycles (30%, 60%, 90%)
Procurement Phase
- MTO
- RFQ
- TBE/PBE
- PO
- Manufacturing
- FAT
- Delivery
Construction Phase
- Civil → Structural → Mechanical → Piping → E&I
- Piping is usually on the critical path
- Test packs, welding inch-dia, NDT cycles
Commissioning
- System/subsystem breakdown
- Pre-commissioning checks
- Loop checks, MC → Commissioning → Start-up
Module 2 — WBS Development
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Module 3 — Engineering Planning
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Module 4 — Procurement Planning
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Module 5 — Construction Planning
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Module 6 — Piping & Hydrotest Planning
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Module 7 — Commissioning
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Module 8 — Cost Control
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Module 9 — Risk Management
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Module 10 — Reporting
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Module 11 — Primavera
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Module 12 — Final Internship Deliverables
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