How To Develop A Progress S Curve That Will Make You An Expert – Part 3

In Part 2, I have shared the first three tips of STEP 1, S Curvelogy technique - determining the appropriate time scale interval, evaluating percent complete and the basis of S curve data whether to use hours, cost or weighting to get planned and earned value.

Once you went through this POST, you would learn how to get the Planned/Earned Value and determine Percent Complete which are foundation steps in developing Progress S Curve.

To achieve that, try to answer the last two questions of S Curvelogy technique,

How To Make A Progress S Curve That Will Make You An Expert – Part 2

In Part 1, I have shared the three simple steps for using “S Curvelogy”. Today, I’m going to share the first one.

Step 1: Figure out how you would get progress data that you can plot S Curve

S Curvelogy technique is so easy and simple. It is asking and answering the following five questions;

1. What is the appropriate time scale interval?

2. How can I come out with a percent compete (planned and actual) to set a progress curve?

3. Which data should I load? Budgeted value based on man hours, cost, or weighting?

4. Do we have milestone evaluation method for progress measurement? Or, have we agreed progress measurement method?

How To Build A Progress S Curve That Will Make You An Expert

The benefits of having a progress S curve is you are enabled to track project performance to create a visual way to plot information. Instead of going through numerous reports containing information about your project status, you can track your project performance as a whole in an instant just by figuring it out on the Progress S Curve.

- If DONE right, by using S Curve, you can get an instant picture of exactly what your team have already done and what needs to be done in order to complete your project on time.

- You KNOW exactly what is going on about your project and you can assist project manager/project management team to see exactly what went wrong and where by judging progress on S Curve.

Sample Pipeline Construction Project WBS for Refinery/Chemical Plant

Sample WBS for piping construction project for a refinery or chemical plant may be organized as the following. It is worth to be organized by location wise (i.e. platform and pipe rack, platform and equipment around piping) prior to “Phase” WBS. Timely completion of piping construction is not only depending on timely receiving of engineering drawings and materials from Owner/EPC Contractor but timely availability of the infrastructure should also be addressed. Sometime it refers to work front availability. Developing WBS is mainly depending on the project scope. It should be defined according to the project specific as every project is different, for instance, “Demolishing” WBS may also be added under “Phase” level priority to “Installation” WBS if your project scope involved a considerable amount of piping demolishing scope. “Above Ground” and “Under Ground” WBS can be left in case no underground piping work is included in the project.

Oil and Fuel Storage Tank Construction Project – Sample WBS

Oil and Fuel Storage tanks (API 650 design) are typically used in petrochemical plants. They are large field fabricated storage tanks operating at low pressures or atmospheric pressures. There are various types of tanks such as fixed roof tanks and floating roof tanks, etc. Tank bottom is usually constructed of overlapping steel plates welded by manual or automatic welding technique. Tank shells are constructed from courses of steel plates. E.g. First shell course, 2nd shell course and so on.

In this article, we will focus on a specific type of tank, external floating roof type with single deck and internal pontoon. Sample Work Breakdown Structure (WBS) for an external floating roof type designed tank construction project can be decomposed as the following. As tank erection work is only focused, detailed WBS for foundation work is intentionally left at level 1.  It is just to show that foundation is required for the above ground storage tank.

Steps to Estimate Activity Resource Unit (Budgeted Labor Unit) for P6

The sequence of steps producing budgeted labor unit of each activity as follows;

Study design and construction methodology

It is assumed that you are a mechanical construction contractor. You got a project requires installing a pipe rack for a chemical plant. Construction drawings are provided by engineering contractor. According to layout drawings and isometric drawings, a layer of pipe rack is to be erected on an elevated new steel structure. Pre-fabricated steel structure is to be erected on the foundations done by other. The new pipe rack header is to be connected with existing facility. Field welding, flanges and threads fitting, bolting, field pipe supports, NDT (X-Ray etc.) test and hydrostatic test are to be performed. Pre-fabricated piping and structure members are already on site delivered by engineering contractor. Scaffolds and crane are required to erect piping and steel work.

Sample WBS for Design and Build Project

Design and build contracts are usually performed by the contractor, who is responsible for the detailed design and construction. Below is a simple WBS for a building construction which may differ from your project scope, nature and organization’s preferences. However, this is a starting point for you to explore your idea to suit your project needs.

1. Design and Engineering

1.1   Architectural Design

1.2   Civil and Structural Design

1.2.1      Design Preparation and Submission

1.2.2      Design Review

1.2.3      Design Revision

1.2.4      Design Approval for Construction

1.2.5      Issue Construction Drawing

Develop Progress Tracking Sheet for Piping Touch up Painting & Insulation

Piping Touch-up Painting Progress Tracking Sheet                                          

The progress tracking sheet for piping touch-up painting work is quite simple. It includes the isometric drawing list of required painting, paint completion date, clear punch list date, diameter inches of field joints and man-hour for weightage calculation. The percent of each work step is updated upon entering the date.

Download a sample template for painting work.

Piping Insulation Work Progress Tracking Sheet

The piping insulation progress tracking sheet is developed based on the following work steps and weight factors percentages.

1. Fabricate Cladding-20%
2. Install Insulation material & Banding-35%
3. Install Insulation metal covering (aluminium cladding)-35%
4. Clear Punch list-10%

Sample Progress Measurement System for Petrochemical Plant Project Construction

Progress Measurement System plays an important part of project control. It includes the detail progress tracking sheet of its WBS elements, work categories and work steps for each deliverable. It is developed either when the additional requirements are occurred for a particular project or when progress measurement system is not in placed.

Suppose the work scope includes fabricate and installation of pipeline including tie-in work, insulation work, painting work, fabricate and installation of new pipe racks, fabricate and installation of equipment access platforms, installation of process equipments. Progress measurement system would be different depending on organizational and/or project preference. Typical progress measurement systems include, but are not limited to the following;

• Overall progress summary sheet
• The detail progress tracking sheet for each discipline or back-up system to support overall progress summary sheet
• Progress S curve/Histogram chart

How to Make Equipment Erection Progress Tracking System

Mechanical equipment erection/installation work is one of WBS elements of Sample Project measurement System for Petrochemical Plant Project Construction. Simple progress tracking sheet for mechanical equipment erection work is built based on the particular work steps and weight factors for the different equipment group. Progress summary for all type of equipments is calculated from man hour weightage and weight progress of each equipment group. You can find the additional resources at Weight factors for Mechanical Equipment Installation.

It includes equipment tracker sheet and progress tracking sheet. Equipment tag number, project area, installation status, work packages and quantity (weigh) are listed in equipment erection tracker sheet.

Weightage calculation, individual progress, overall progress calculation, progress summary by project area and work packages are included in progress tracking sheet.

Format of erection tracker sheet and progress tracking sheet are slightly different from others, for example, The Detail Tracking Sheet for Steel Fabrication which is only made from one type of work steps and percentages. There are two or more type of work steps and weight percentage depending of equipment type for this kind of progress tracking system.

Making Tie-in Installation,Pipeline Erection and Hydro Testing Progress Tracking System

The Progress Tracking System for Tie-in Installation Work

The procedure of developing progress tracking system for Tie-in work is quite similar to steel fabrication work which is one of wbs elements of Sample Progress Measurement System for Petrochemical Plant Project Construction.

Normally, piping tie-in installation scope is involved in revamp project only. The progress tracking system for tie-in work includes Tie-in Tracker Sheet and Progress tracking sheet.

Tie-in numbers against the Isometric drawings and work packages are listed in the tracker sheet. The tie-in type (Bolt-up, cut and weld, hot tap, cold tap and threaded are typical tie-in types in the process industry), project area or system name and installed dates are also included in the tracker sheet.

To develop Progress Tracking Sheet for overall Isometric drawings, the following work steps and weight factor percentages are utilized.

1. Preparation ( Scaffold erection if required/remove insulation if required)-20%
2. Tie-in work (Bolt up/cut & weld/hot tap/cold tap/threaded) -70%
3. Inspection (Sign QC document, example: flange make-up checklist)-10%

Creating Progress Tracking System for Steel Fabrication and Erection Work

The Detailed Progress Tracking System for Steel Fabrication

WBS element “Steel Fabrication” is the higher level of pipe rack fabrication and equipment access platform fabrication.
The general arrangement drawing list, project area name, work pack number, fabrication start and finish date shall be included in the progress tracking sheet. You should have an additional spread sheet/system known as steel tracker sheet/system which includes the fabrication status of each assembly member for each GA drawing.

The progress tracking sheet is linked with the steel tracker sheet to update the fabrication status of each GA drawing. 

The following hierarchical structure represents how steel fabrication progress is tracked and monitored. It shows the level of progress reporting.

Develop Progress Tracking Sheet for Piping Fabrication Work

Developing Progress Tracking Sheet/System for piping fabrication is one of the tracking system of Progress Measurement System for Petrochemical Plant Project Consruction.

The tracking sheet includes the list of drawings, the project area name, quantities (diameter-inches and man hour) and the production work steps to calculate fabrication progress. You may assign fabrication started date, finished date, and work packages for each Isometric drawing which will be useful to track and report the progress status grouped by work pack number, started date and finished date. The following are piping fabrication work steps and weight factor percentage;

1. Weld map drawing preparation-4%
2. Withdrew material-3%
3. Welding preparation (marking/cutting/end preparation)-20%
4. Spool Assemble and tack weld-25%
5. Full welding execution-20%
6. Non Destructive Examination-6%
7. Surface preparation and coating (sand blasting and painting/hot dipped galvanizing)-15%
8. Final Inspection-4%
9. Deliver at site-3%

Weight factors for Electrical Construction Work

Followings are the sample weight factors for each work step for each field work category. The activity lists are based on Sample WBS for Electrical Construction Work.

Switch gear/ Motor Control Centers Installation

Work Steps          Weightage

Installation              85%

Testing                  10%

Punch Item             5%

New Panel /IRT (Inter Posing Relay System) Installation

Panel Installation -------- 85%

Testing -------10%

Punch Item ------- 5%

Panel Modification

Preparation ------10%

Modification ------ 80%

Recovery ------10%

Cable Tray Installation

Support Installation ----- 30%

Tray Installation ---- 70%

Indoor Cable Termination

Termination ------ 95%

Testing ------ 5%

Conduit Installation

Support Installation ------ 30%

Conduit Installation ------ 70%

Power Wiring (Equipment Installation) 

Support Prefabrication ------- 30%

Installation ------- 60%

Testing -------10%

Power Wiring (Cable Termination) At Substation (High Voltage/Medium Voltage/Low Voltage)

Cable Gland Plate Installation ----- 10%

Termination ----- 85%

Testing ----- 5%


Power Wiring (Cable Termination) At Field (High Voltage/Medium Voltage/Low Voltage)

Stub up Installation ------- 10%

Termination ------- 85%

Testing ------- 5%

Power Wiring (Cable Tray Installation)

Support Installation ------ 30%

Tray Installation ------- 70%

Lighting Panel Installation & Termination

Support Prefabrication ------ 25%

Installation ----- 65%

Termination ----- 5%

Punch Item ----- 5%

Lighting Fixture Installation & Termination

Support Prefabrication ------30%

Installation ----- 55%

Termination ----- 5%

Testing ------ 5%

Punch Item ----- 5%

Street Lighting Installation and Termination

Concrete Foundation ------ 20%

Installation ----- 65%

Termination ----- 5%

Testing ------5%

Punch Item ----- 5%

Lighting Cable Laying 


Cable Laying -------- 95%

Punch Item ---------5%

Junction Box Installation & Termination

Support Installation ----- 10%

JB Installation ------ 35%

Cable Termination ------ 50%

Punch Item ------- 5%

Lighting Cable Tray Installation

Support Installation ------ 20%

Conduit Installation ------ 75%

Punch Item ------ 5%

Lighting Conduit Installation

Support Installation ------ 20%

Conduit Installation ------ 75%

Punch Item ----- 5%

Grounding Electrode Installation with Well

Electrode Installation ------ 55%

Well Installation ------ 30%

Resistance Test ------10%

Punch Item ------5%

Grounding Wire Installation and Connection

Wire Installation ------ 80%

Stub-up & Connection ------10%

Continuity Check ------- 5%

Punch Item ------- 5%

Use these sample weight factors for electrical construction work as a staring point for developing your own progress calculation sheet. The weighting percentage for each work step may be different from your project team’s preferences.

See also Weight factors for Mechanical Equipment installation Work

Weight factors for Mechanical Equipment installation Work

This post describes typical weight factors that can be utilized to establish the progress calculation sheet for equipment erection work. Followings are the sample weight factors for each work step for each equipment category.

Static Equipment-Column & Vessel, Shell & Tue Heat Exchangers Installation

Chipping & Padding --10%
Lifting & Rigging --60%
Alignment --10%
Inspection ---10%
Grouting ---10%

Package Equipment-Boiler Installation

Main Parts Installation (Main body, Economizer, Air Pre-heater, Stack)—55%
Stairway and ladder installation ----20%
Duct Installation (Including Damper) ----10%
Accessories (Fan, Silencer, Soot blower, Burner) Installation ----10%
Punch Items --- 5%

Package Equipment-Demineralization Plant

Chipping & Padding -----10%
Lifting & Rigging -----70%
Leveling & grouting ----10%
Alignment for rotating equipment-10%

Equipment access platforms/ladders
Assembly at site -----40%

Installation -----55%
Punch Item -----5%

Internal Tray Installation work for Reactor/Column/Drum/Vessel

Preparation----20%
Installation -----75%
Punch Item ----5%

Rotating Equipment-Air Fin Cooler/Air Cool Exchanger

Access platform installation -----20%
Tube Bundle Installation -----40%
Mechanical Part Installation -----30%
Final Alignment -----10%

Rotating Equipment-Pump/Compressor/Blower

Chipping & Padding -------5%
Lifting & Rigging ------40%
Leveling & Grouting ------15%
First Alignment -------30%
Final Alignment ------10%

See also Weight factors for Electrical Construction Work

Progress Calculation Sample for Pump Installation Work

If you are preparing a progress calculation sheet for a work, a weighting factor for each work step and each WBS component is used to calculate to give the weighted progress. For example, to calculate percent completion for a pump installation, the following typical work steps and weight factors are required.

Work step	Weight factor
Chipping & Padding	10%
Installation	40%
Levelling & Grouting	20%
First Alignment	20%
Final Alignment	10%

The percent complete for a pump installation can be obtained by the sum of the product of each weight factor and each work step progress.

Pump Installation Progress = Chipping & Padding (10%)* work progress + Installation (40%)*work progress+ Levelling & Grouting (20%)*work progress + First Alignment (20%)*work progress +Final Alignment (10%)* work progress

Pump installation progress would be 10% when chipping & padding activity is done 100%. Percent completion would be 50%, 70%, 90% and 100% respectively when each work step is done 100%. Generally, progress calculation method for other work is the same although weight factors are different. Read more about weight factor for mechanical equipment installation work.

Sample WBS for Mechanical Equipment Installation Work

The below sample WBS is used for mechanical equipment construction work for a petrochemical project. The scope for the following WBS are installation of static equipments such as shell & tube heat exchangers, columns & vessels, boiler and demineralization plant, and installation of rotating equipments such as Air Fin Cooler, pumps, blowers and compressors. You may modify it to suit your project scope and requirements.

WBS Code                     Description

ME                      Equipment Installation Work

 ME.1                    Area Major

  ME.1.1                   Static Equipments

    ME.1.1.1                 Column/Vessels

      ME.1.1.1.1                 Equipment No

        ME.1.1.1.1.1              Chipping & Padding

        ME.1.1.1.1.2              Lifting & Rigging

        ME.1.1.1.1.3              Alignment

        ME.1.1.1.1.4              Inspection
        ME.1.1.1.1.5              Grouting

Sample WBS for Electrical Construction Work

The WBS (work breakdown structure) for electrical construction work for a petrochemical project is broken down as below. It can be adopted and modified to suit your project scope and requirements.

WBS Code         Descriptions               

E                      Electrical Construction

 E.1                   Plant Area

  E.1.1                Building No

   E.1.1.1                Substation Work and Feeder Cabling

    E.1.1.1.1             Generator/substation work

     E.1.1.1.1.1          Switchgear & Motor Control Centers Installation

     E.1.1.1.1.2          Equipment & Panel Installation (Inter Posing Relay System)

     E.1.1.1.1.3          New Panel installation

     E.1.1.1.1.4          Panel Modification

     E.1.1.1.1.5          Cable Tray Installation

     E.1.1.1.1.6          Indoor Cable Laying

Schedule for Hot Tapping construction

Hot tapping work is a critical work especially in process industry such as pharmaceutical plants, petrochemical plants, offshore platform and FPSO. Hot tapping work is the connection of branch line piping to existing piping that contains live products such as gas or oil under pressure. More information on hot tap operation and detail, refer to this site. In this post, I would suggest the WBS and activities for a hot tap detail construction schedule.

Sample WBS are as follows;

1 Area

1.1 Work pack

1.1.1 Tie-in No

1.1.1.1 Off site Fabrication

1.1.1.2 Preliminary Activities

1.1.1.3 Execution

1.1.1.4 Post Activities

Activities such as fabrication of hot tap (split tee type or stub type), blasting and painting, delivering to site are of off site fabrication WBS.The preliminary on site construction activities before hot tap operation are as follows;