Lead Project Controller
Emirates Aluminium
Total years of experience :24 years, 4 Months
•Reports directly to the Sr. Project Control Manager and is responsible for all of the Project Controls requirements on the Project.
•Develop and implement processes and systems to continually improve efficiency and quality of Project Control deliverables within the project.
•Prepare/ Manage the Project Controls requirements like Cost Estimating, Control, Forecasting, Scheduling and Executive Reporting, Cash flow reporting, Area KPI dashboards and analysis of overall project performance on monthly basis.
•Management of Project & Operations Owners Cost and EPCM/ Capital Cost including PCN (Project Change Notice)/ BTN (Budget Transfer Notice), CCCA (Capital Cost Commitment Approval) and AFE (Approved for Expenditure).
•Alarm the management about potential budget overruns and help support them to find out possible corrective actions/mitigations.
•Manage the accounting and invoicing requirements of the project and monitor the Project cash flow especially for Project costs payments to major suppliers/ for Treasury Dept.’s hedging plan.
•Manage and oversee day to day operations of the Project Control Department to effectively support company’s operation in accordance to the company’s policies and procedures.
•Collect the monthly reports from EPCM Contractor, review and ensure/ comment on the integrity of the data within a timely and effective manner.
•Support the Internal Audit team in conducting periodic control assurance audits, review current business processes and assess capability to detect, prevent, mitigate financial and compliance risks.
•Challenge the Functional/ Area Managers from a financial perspective, particularly in relation to the achievement of margins in Projects and provide support interpretation of timely and accurate results.
•Review the cost trends & risks on monthly basis analyze the effect of risks by Monte Carlo Simulation
Period: Aug '09 to till date for their Ras Al Khair Aluminium Complex Project, KSA
Owner/Client: MA'ADEN /ALCOA JV
Scope of Work: Feasibility Study, FEED, Detailed Engineering, Procurement, Construction,
Commissioning & Operation of Aluminium Complex project consists of Bauxite Mining, Refinery, Smelter, Rolling Mill and Integrated Infrastructure Project with Smelter capacity of 740 KTA, Refinery 1, 800 KTA & Rolling Mill 380 KTA
Job Title: Lead Project Control Engineer for the Integrated Aluminium Project
2) Company: M/s. Black Cat Engineering & Construction W.L.L, DOHA, QATAR
Period: May '07 to Jul '09 for their various EPIC & Construction Projects
Owner/Client: Qatar Petroleum, Rasgas, Snamprogetti
Scope of Work: Engineering, Procurement, Installation, Construction & Commissioning of various Oil & Gas EPC Projects with QP named GTC/129, GTC/147, etc
Snamprogetti's 23 Km 18" Pipeline construction project for QP& EPIC for Naphthenic Caustic Injection Project with Rasgas.
(GTC/129 - EPIC for Raw NGL facility, Dukhan
GTC/147 - EPIC for desalinated Water network (24" GRP line), Raslaffan)
Job Title: Sr. Project Planning & Costing Engineer (HO)
3) Company: M/s. Nasser S Al-Hajri Corporation, Yanbu Al Bahr, K.S.A
Period: Oct '04 to Dec '06 for various Petrochemical/Steel Plant Construction Projects
Owners: National Petrochemical Industrial Company (Natpet), Yanbu, K.S.A,
Saudi Iron & Steel Company (HADEED), Al-Jubail, K.S.A
Saudi Petrochemical Company Limited (SIPCHEM), Al-Jubail, K.S.A
Clients: Lurgi AG, Frankfurt, Germany (for Al Fasel PDH Project with Natpet)
Danieli & C.SpA, Italia (for Wire Road and Rebar Mill Project)
Aker Kvaerner, Netherlands (for GACIC BDO Facility Project)
Scope of Work: Construction/ Installation of Civil, Structural, Equipment, Piping, Insulation, HVAC, Fire Proofing, Electrical & Instrumentation Work.
Job Title: Sr. Planning & Costing Engineer
• Reports directly to the Project Director, and is responsible for all of the Project Controls requirements on the EPCM of Integrated Infrastructure Project and PMC for the entire Aluminium Complex Project.
•Prepared various Project Control related procedures including Change Management Procedure, Cost Control Procedure, Progress Monitoring Procedures, and Planning & Reporting Procedures etc.
•Effectively manage the Project Controls Group personnel, and foster continued training & development.
•Prepared various Project Control related procedures including Change Management Procedure, Cost Control Procedure, Progress Monitoring Procedures, and Planning & Reporting Procedures etc.
•Part of the team who developed the initial cost estimate for the overall Aluminium Project for the lenders and prepared original cost estimate, basis of cost estimate and 90% definitive estimate for the Integrated Infrastructure Project (IIP) and carried out risk assessment by Monte Carlo simulation analysis.
•Developed the Chart of Account for the Program level and implemented it in to the cost control program.
•Preparation of owners cost reports which includes actual cost todate, current forecast, Cash flow curve, contingency draw down curve, escalation draw down curve, cost trend register etc and monthly & quarterly reconciliation of project actual cost with finance Oracle Reports and class-5, Class-4 & Class-3 cost estimates as per stage gate review requirements.
•Review and approval of Purchase Requisition, PTNs (Project Trend Note), PCAs (Potential Change Alert) & CVs (Contract Variations) related with EPCM/Construction works in line with Project Procedures.
•Development of PTNs for the Owner’s Cost if there is a change in the scope/ estimate from the budget, and get it approved in order to draw from contingency/escalation and for proper monitoring/ reporting.
•Verification and approval of PMC’s/ EPCM’s/ Contractor’s Payment Certificates and Progress invoices in line with the contracts terms & conditions.
•Review and raise comments on EPCM’s Monthly Reports regarding Progress, Cost, Schedule and Risk.
•Preparation and monitoring of Weekly & Monthly KPI dashboards and adhoc level Progress Reports including the high-level overall integrated schedule/ cost reports for the BoM or Excom/ JV Partners with the help of individual project reports from the EPCM companies.
•Preparation of Quarterly executive progress report for Aramco as part of Gas Allocation Letter.
•Preparation of preliminary estimates for the various contracts as per the request from management and participate in the technical / commercial evaluation of received bids.
•Interpretation of Contract terms to protect the company from the various claims from the Contractors
•Preparation of Change Order Request to the management as and when required for the Contracts.
•Keeping record of the Fixed Assets on facility wise in order to fulfill the requirements of finance department for their yearend balance sheet/ financial statement preparation and support them with the project budget as per company’s COA/WBS for the finalization of annual budget.
Scope of Work: Engineering, Procurement, Installation, Construction & Commissioning of various Oil & Gas EPC Projects with QP named GTC/129, GTC/147, etc
Snamprogetti's 23 Km 18" Pipeline construction project for QP& EPIC for Naphthenic Caustic Injection Project with Rasgas.
(GTC/129 - EPIC for Raw NGL facility, Dukhan
GTC/147 - EPIC for desalinated Water network (24" GRP line), Raslaffan)
Activities & Responsibilities:
• Preparation of Planning Packages for the EPIC Projects including Preliminaries, Engineering, Procurement, Construction & Commissioning in Primavera with statistics in excel for monitoring
• Preparation of Weekly & Monthly Progress Reports including Engineering, Procurement, Construction & Commissioning activities, Manpower Histograms, S-curves and Matrices with areas of concerns and remedial actions to be taken.
• Interpretation of Contracts for the extension or to raise the claims in various execution stages.
• Prepare cash flow calculations, profit analysis calculations and appropriate reviews and coordinate cost interfaces with other corporate groups and project teams
• Monitoring of project budget Vs actual costs against each discipline / project and preparation of project financial status reports.
• Materials follow up with Procurement Department for the timely delivery and to reduce the lead time and to ensure that the same is in-line with the approved materials.
• Preparation/Monitoring of Work Productivity Reports against Company's Std. Norms and coordinate with Proposal Dept. (Estimation & Tendering) for implementing in new projects.
• Preparation of Progress Invoices including additional claims, Variation Order, Change Order Request etc during the execution of Projects.
• Planning & logistics of resources (Manpower, Equipments, machineries & Vehicles) for the ongoing and upcoming projects and coordinate with Personnel Dept. for timely deployment.
Scope of Work: Construction/ Installation of Civil, Structural, Equipment, Piping, Insulation, HVAC, Fire Proofing, Electrical & Instrumentation Work.
Activities & Responsibilities:
• Preparing Lev-I, II, III & IV Schedule (resource loaded) using Primavera Project Planner.
• Preparing Man Power & Equipment Deployment Schedule (Histogram) for the Project.
• Preparing revised Level-III & IV Time Schedules and Man Power & Equipment Deployment Schedules based on the latest ETA dates of deliverables for the Target Achievements.
• Correspondence with HO, Client and Sub Contractors regarding site requirement, Quantity Variation and Contractual Discrepancies & Disputes.
• Conducting Weekly Meeting with different Disciplines for the review and achievement of scheduled targets and preparation of new targets by monthly & weekly.
• Preparation of Weekly & Monthly Engineering Reports, Progress Reports & S-curves.
• Preparation of Progress Invoices based on the actual quantity executed by verifying the drawings/ documents including additional claims.
• Preparation of Cost Estimation for Sub Contract Work as well as Subcontract Work Order
• Attending daily & weekly progress review meeting with clients and sub contractors.
• Preparation of Project Profitability Forecasting/ Month wise Costing report for HO based on the Progress Invoice, Man hours consumed, Equipment utilized & indirect expenses.
• Development of Construction Progress Measurement Systems & Progress Monitoring.
• Preparation of Two Week look ahead schedules using MS Project.
• Preparation of Progress & Final Invoices including additional claims.
• Allocation of Manpower, Equipments & consumables by discipline and arranging materials to meet the schedule of the Project.
• Attending daily & weekly progress review meeting with clients and sub contractors.
• Vibration Monitoring & Predictive Maintenance of Rotating Machineries such as Pumps, Turbines, Compressors etc. by using the Instruments like ENTEK IRD Mechanalysis Model 811 & RION Vibration Analyser-10.
• Corrosion Monitoring and Preventive Maintenance of Static Equipments such as Tanks, Pressure Vessels, Pipelines etc. by using Ultrasonic Thickness Gauge ETM-1.
• Evaluation of Quotations from vendors/Sub Contractors
• Preparation of Technical Documents for Budget Preparation / Tender Submission
• Piping Design and Preparation of Materials Take Off (MTO) sheet.
• Preparation of Technical Procurement Specification (TPS) sheet.
• Preparation of P&IDs, Isometric drawings by using AutoCAD-2000.
• Stress Analysis of Pipelines by using software CAESAR-II.
5) Company: M/s. V.J.CHARLES Contractors, Kochi, India
Period: Jan '01 to Jun '02 for various construction sites at FACT Petrochemical division, Udyogamandal & Kochi Refineries Ltd.
Client: Fact Engineering & Design Organization (FEDO), Kochi, India
Scope of Work: Erection & Testing of 1.7 Km Utility Piping
Job Title: Site Engineer (Mechanical)
Activities & Responsibilities:
• Site Supervision for various Piping & Pressure Vessel Construction works.
• Selection of Pipes, Valves, Pipe Fittings etc as per Standards for Construction Works.
• Coordination for Fabrication, Erection, Testing, Insulation & Comm. of Various Piping Systems.
• As-Built preparation for documentation and records.
6) Company: M/s. ABAD Group, Kochi, Kerala, India
Period: Jan '00 to Dec '00 in CAP Sea foods Division, Kochi
Job Title: Asst. Maintenance Engineer
Activities & Responsibilities:
• Preparation of Purchase Orders as per quotations and Store Keeping of materials.
• Preparing day to day preventive and corrective maintenance activity schedules and work allocation especially for the maintenance of Pumps, Valves, Compressors etc.
• Preparation & Maintaining of Annual Maintenance Contract.
• Co-ordinate/Supervise the maintenance activities with in the Plant.
• Spare parts analysis by each Equipment.
Qualities:
• Proactive, Tolerant, Leadership, Hard work and Team work.
• Aptitude to learn and Keep the inter-personal relations rich.
• MBA (Master of Business Administration) in Project Management on distance education mode from Sikkim Manipal University, India (Year 2012)
• B.Tech (Bachelor of Technology) in Mechanical Engineering from Calicut University, Kerala, India and passed out with First Class (1996-2000)