20230929IPC to Staff 308 Attachment 1.pdf

HCPR200001 - HCPR U13 Generator Refurbishment
Variance Notes

CLRIS Budget ID Page (Description, Need, Consequence and notes)
HCPR200001_CLRIS

Microsoft Project Schedule Notes (PM managed schedules and routine variance notes)

2020 Budget Update 4:
Total Project Change: $5.39M
Budget Update 1: Accelerated +$651K for the stator rewind contract.
Budget Update 2: No Change.
Budget Update 3: Accelerated +$5.4M for the stator rewind contract due to failure of HCPR Unit #3.
Budget Update 4: Deferred ($617K) per the final negotiated contract payment schedule to accelerate
the refurbishment after failure of Unit 3.
Budget Update Authorized to Spend

2020 August Detailed Comments:
Details of Changes to Project That Impacted Project Cost or Schedule on Annual Basis
-Updated project costs to match revised estimates or quotes from suppliers
-Updated cash flows to match project schedule due to the failure of unit #3
Latest Current Baseline set after project plan approval.
Change Orders
-Neutral relocation
- Cost:$327,000
-Interpole connection
-Cost: $76,826
-Engineering Acceleration
-Cost: $23,400

2020 September Detailed Comments:
Details of Changes to Project That Impacted Project Cost or Schedule on Annual Basis
-Updated project costs to match revised estimates or quotes from suppliers
-Updated cash flows to match project schedule due to the failure of unit #3
Latest Current Baseline set after project plan approval.
Change Orders
-Change order 1: Neutral relocation (executed)
- Cost:$327,000
-Change Order 2: Engineering Acceleration (executed)
- Cost: $23,400
-Change Order 3: Interpole connection (executed)
-Cost: $76,826
-Change Order 4: Project Acceleration (executed)
-Cost: $1,762,071

2020 December Detailed Comments:
Details of Changes to Project That Impacted Project Cost or Schedule on Annual Basis
-Reduced operator labor to match actual use. $191K to $57K
-Updated mechanic hours to match actual use.
-Pushed services and material purchases unused to 2020 to 2021.
-$300K of discovery work will be pushed 2021.
Latest Current Baseline set after project plan approval.
Budget Update Authorized to Spend

2021 January Detailed Comments:
Details of Changes to Project That Impacted Project Cost or Schedule on Annual Basis
-Pushed unused services and material purchases to 2020 to 2021.
-$300K of discovery work pushed 2021.
Latest Current Baseline set after project plan approval.
Change Orders
-GE change Order 5: Additional NDT inspection of rotor poles and stator Frame (Complete)
-Cost: $24K
-Change order covers the additional inspection recommended by GE based on the FEA reports of
the rotor poles and the stator frame.

2021 February Detailed Comments:
Details of Changes to Project That Impacted Project Cost or Schedule on Annual Basis
-Due to the damaged rotor poles additional cost will be required for the replacement of the poles. IPC
does not have a firm offer for replacing poles but replacement of 60 poles could cost more that
$1,000,000. Costs will be updated in the project schedule once a final proposal has been received from
GE on the replacement of rotor poles.
-Schedule of unit #3 will be pushed due to the replacement of the rotor poles. The impacts to schedule
are not official but it is estimated that the unit #3 outage will be pushed to November of 2021. Project
schedule will be update once IPC has received final proposal on rotor pole replacement from GE.

2021 April Detailed Comments:
Details of Changes to Project That Impacted Project Cost or Schedule on Annual Basis
-Schedule of unit #3 will be pushed due to the replacement of the rotor poles. The impacts to schedule
are not official but it is estimated that the unit #3 outage will be pushed to February of 2022. Based on
lost generation analysis the best option for Unit #1 will be to push the Unit #1 outage to start during the
fall of 2022.
-GE is currently scheduled to finish stator work August of 2021.
Latest Current Baseline set after project plan approval.
Change Orders:
Change Order 06 - Rotor Pole Supply, Main & Neutral Design Change, Schedule Update
-Cost for rotor poles: $1,044,371.00
-Cost for Main & Neutral Redesign: $194,880

2021 June Detailed Comments:
Details of Changes to Project That Impacted Project Cost or Schedule on Annual Basis
-GE is currently scheduled to finish stator work September of 2021 and scheduled to complete rotor
work in January of 2022. Given GE's current issues onsite it is likely that they will not meet their
intermediate stator winding complete milestone in September. We do not expect this to push GE's final
complete milestone.
-IPC's project complete date for unit 3 will now be in March of 2022.
-Unit 1 schedule has been updated to start in September of 2022 and will be complete in May of 2023
Latest Current Baseline set after project plan approval.
Change Orders:
Change Order 06 - Rotor Pole Supply, Main & Neutral Design Change, Schedule Update (Executed)
-Cost for rotor poles: $1,044,371.00
-Cost for Main & Neutral Redesign: $194,880

2021 July Detailed Comments:
Details of Changes to Project That Impacted Project Cost or Schedule on Annual Basis
-GE is currently scheduled to finish stator work September of 2021 and scheduled to complete rotor
work in January of 2022. Given GE's current issues onsite it is likely that they will not meet their
intermediate stator winding complete milestone in September and will complete this milestone in
October. We do not expect this to push GE's final complete milestone.
-IPC's project complete date for unit 3 will now is now February 28th, 2022.
-Unit 1 schedule has been updated to start in September of 2022 and will be complete in May of 2023
Latest Current Baseline set after project plan approval.
Change Orders:
-GE Change Directive 01: Stator Frame Repair (Executed)
-Actual Cost: $63,757.00
-Reviewing actual costs and drafting the change order.
-GE Change Directive 03: Rotor Rim Analysis and Rotor Pole Damage Analysis (Executed)
-Waiting for actual costs to be submitted.
-GE Change Directive 05: Stator Coil Lashing and Blocking
-This change directive covers the supply, engineering, and installation of the additional blocking
of the stator coils.
-Not to Exceed Cost: $44,000 (this is for both units)

Date: 8/12/21
Current Year: Project Change -$8.57M
Total FAC Change: Project Change -$1.41M
Both current year and the FAC were changed due to as found work on the rotor poles changing the
project schedule and a insurance payment made to IPC for the failure of unit 3.
Budget Update Authorized to Spend

Date: 9/10/21
Current Year: Deferred -$133K
Total FAC Change: No Change
IPC labored shifted to 2022 due to contractor's schedule delay.

Date: 10/7/21
Current Year: Deferred -$276K
Total FAC Change: No Change
Updated GE milestone payments to reflect current project schedule and pushed assembly material cost
to 2022 for IPC assembly.

Date: 11/10/21
Current Year: No change
Total FAC Change: No Change

2021 Budget Update 4:
Total Project Change: ($8.986M)
Budget Update 1: Carryover +$188K for deferred services in 2020.
Budget Update 2: Project Change ($8.529M) for unit 3 failure insurance payment of $4.1M to IPC and
schedule push for unit 3 rotor pole replacement. Unit 1 outage start has pushed from 2021 to 2022 due
to the unit 3 schedule push.
Budget Update 3: Project Change ($225K) for larger insurance payment from the unit 3 failure.
Budget Update 4: Deffered ($420K) for labor and milestone payments due to shift in GE final completion
schedule.

Date: 1/10/22
Current Year: Project change of $235KK due to increased labor rates for 2022, carryover of $34K for
unused labor in 2022.Project change of $235K due to increased labor rates for 2022.
Total FAC Change: Project change of $235K due to increased labor rates for 2022.
Budget Update Authorized to Spend

2022 Total Project Change: $4.018M
Jan: Project Change +$235Kfor increased labor rates, Carryover of $527K or services, labor and materials
pushed to 2022 for the Unit 3 Outage.
Feb: Project Change $638 more labor used
Mar: Project Change $860 more labor used
Apr: Project Change $500 more labor used
May: Project Change $10K more labor used for the acceleration of assembly and commissioning.
June:Project Change $2.175M for spare laminations purchased from Voith.
July:Project Change $459K for increase labor and materials used in June to support unit 1 disassembly,
added $500K for Voith stator clamping system.
Aug: Project Change ($210K) reduced labor to match project plan, $657K for additional install tooling
and materials, $115K for additional Voith support services, $5K for additional vehicle use.
Sept: Deferred ($15K) for unused materials in this year.
Oct: Project Change ($154K) reduced for pressing equipment cost being less than original quote.
Nov: Project Change ($33K) in reduced labor for reduced overtime, ($122K) for unneeded onsite QA
services, ($132K) in reduced material costs.

2022 Annual Project Change: $4.306M
BU1: Project Change +$235K for increased labor rates, Carryover of $527K for services, labor and
materials pushed to 2022 for the Unit 3 Outage.
BU2: Feb: Project Change $638 more labor used, Mar: Project Change $860 more labor used, Apr:
Project Change $500 more labor used
BU3: May: Project Change $10K more labor used for the acceleration of assembly and commissioning,
June:Project Change $2.175M for spare laminations purchased from Voith, July:Project Change $459K
for increase labor and materials used in June to support unit 1 disassembly, added $500K for Voith
stator clamping system.
BU4: Aug: Project Change ($210K) reduced labor to match project plan, $657K for additional install
tooling and materials, $115K for additional Voith support services, $5K for additional vehicle use; Sept:
Deferred ($15K) for unused materials in this year; Oct: Project Change ($154K) reduced for pressing
equipment cost being less than original quote.
2022 EAC Tracker
Total EAC Variance:
Apr: $497
May: $22K Project change of labor added to 2022 and 2023
June: Project Change $2.175M for purchase of Voith Laminations.
July:Project change $724K for additional labor, materials and services added based on recent quotes and
increased labor used in June to support unit 1, added $567K for Voith stator clamping system.
Aug: Project change ($100K) for labor changes, $652K for stacking and winding materials, $1.5M for
voith labor services, $5k for additional Vehicle use.
Sept: Project Change ($3K) for recycled material credit.

2023 Annual Project Change: $783K
JAN: Carryover $112K for GE Final Payment.
FEB: No change
MAR: No Change
APR: No change
MAY: Project Change ($12k) for reduced labor used for assembly and commissioning.
JUN: Project Change $172K for updated insurance claim credit to project
JUL: Project Change $6K for increased transportation costs during demobilization.
AUG: Project Change $16K for increased labor and transportation costs during demobilization, final
equipment rental costs.
SEP: Project change $15K for increased labor costs for project closeout.