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USE OF ESTIMATES
12 Months Ended
Dec. 31, 2015
Accounting Policies [Abstract]  
USE OF ESTIMATES

NOTE 3—USE OF ESTIMATES

The following is a discussion of our most significant changes in estimates, which impacted 2015, 2014 and 2013 operating income.

Year ended December 31, 2015

Operating income for 2015 was impacted by net favorable changes in cost estimates totaling approximately $53 million.

AEA―The segment had net favorable changes in estimates aggregating approximately $10 million. During 2015, the extension of the PB Litoral project completion date resulted in a $12 million reversal of liquidated damages. The Agile charter project provided $11 million of favorable changes due to (1) productivity improvements and (2) our cost reduction initiatives. Those were partly offset by a $17 million charge associated with a legal settlement, see Note 17, Commitments and Contingencies.  Other projects experienced net favorable changes in estimate of $4 million, which were individually not material.  

MEA―The segment had net favorable changes in estimates aggregating approximately $20 million.  Two Saudi Aramco projects were positively impacted in aggregate $24 million related to: (1) productivity improvements and associated cost savings on the Intermac 406 vessel, which is working on the Abu Ali cable-lay project; and (2) offshore installation-related cost savings as well as reimbursement for standby cost incurred on the Manifa project.  The KJO Hout project in the Neutral Zone was positively impacted by $9 million due to a favorable discussion with the customer on reimbursement for vessel downtime and cost savings resulting from customer-approved design optimization.  Those net favorable changes were partly offset by a $20 million change in estimate to complete on the ADMA 4 GI project in the U.A.E. because of changes in our execution plan, increased costs associated with the DB 32 vessel demobilization and productivity related cost increases during hookup and pre-commissioning work. Other projects experienced net positive changes in estimate of $7 million, which were individually not material.

ASA―The segment had net favorable changes in estimates aggregating approximately $23 million. It was positively impacted by $5 million benefit on our Ichthys project due to project execution cost savings. Our Gorgon MRU project in the ASA had net positive changes in estimates of $4 million due to close out improvements. Other multiple projects experienced net positive changes in estimate of $14 million, which were individually not material.

Year ended December 31, 2014

Operating income for 2014 was impacted by changes in estimates relating to projects in each of our segments.

AEA―The segment was negatively impacted by net unfavorable changes in estimates aggregating $37 million associated with five projects. On the PB Litoral, an EPCI project in Mexico, we increased our estimated cost to complete by approximately $69 million, due to liquidated damages and extended project management costs arising from unexpected project delays and projected fabrication cost increases reflecting reduced productivity, and execution plan changes to mitigate further project delays, as well as procurement and marine installation cost increases. This project is in a loss position and is estimated to be completed in the first quarter of 2016. On the Jack & St. Malo subsea project, in the Gulf of Mexico, we increased our estimated cost to complete by approximately $6 million, primarily due to equipment downtime issues on the North Ocean 102 (the “NO 102”), our primary vessel working on the project, partially offset by project close-out savings on marine spread costs and increased cost recovery estimates based on positive developments from the ongoing negotiations with the customer. This project, which was in a loss position, was completed in 2014. On a fabrication project in Morgan City, the BG Comp Module, completed during 2013, we reduced our cost recovery estimates by approximately $8 million, mainly based on an agreement in principle with the customer in 2014, which resulted in lower-than-anticipated recoveries. These negative impacts were partially offset by $40 million of project close-out improvements on the Papa Terra EPCI project in Brazil, which resulted from marine cost reductions upon completion of activities and increased recoveries due to successful developments from the ongoing approval process for additional weather-related compensation. We also recognized $5 million of cost reductions on the Gulf of Mexico, a marine installation project in, the Gulfstar project, primarily due to project close-out improvements.

MEA―The segment was negatively impacted by net unfavorable changes aggregating about $4 million, primarily attributable to changes on four projects. On Safaniya Phase-2, a Saudi Aramco EPCI project, we increased our estimated cost at completion by approximately $23 million, net.  Increases of $43 million were primarily as a result of vessel downtime due to weather and standby delays, and were partially offset by increased cost recovery estimates of approximately $20 million based on positive discussions with the customer during the fourth quarter of 2014. On Safaniya Phase-1, another Saudi Aramco project, we increased our estimated cost to complete by $19 million, primarily as a result of increased cost estimates to complete the onshore scope. Although the project recognized a loss in 2013, it remains in an overall profitable position and is substantially complete. On the KJO Ratawi project, we increased our estimated costs to complete by approximately $12 million, to reflect cost overruns related to (1) the onshore work, which was substantially completed in July 2014, and (2) delays in completing the offshore work, due to delayed access to the project site, resulting in a revised execution plan. The revised execution plan included the costs of an incremental mobilization and reflected inefficiencies of executing out-of-sequence work. This project was completed in the third quarter of 2015. These negative changes were partially offset by approximately $54 million of increased cost recovery estimates on a completed pipelay project in the Caspian based on positive negotiations with the customer in 2014, in connection with the ongoing project close-out process.

ASA―The segment experienced net favorable changes aggregating approximately $52 million, primarily attributable to changes in estimates on seven projects. Changes in estimates on the Siakap subsea development (“Siakap”) project in Malaysia resulted in an improvement of approximately $34 million in 2014, primarily related to productivity improvements on our marine vessels and offshore support activities, as well as the favorable resolution of cost contingencies relating to offshore performance risks. On the BSP Champion marine installation project in Brunei, a reduction in estimated cost to complete due to productivity improvements on marine vessels and offshore support activities resulted in project savings of approximately $12 million. On the Dai Hung SURF and Macedon projects, insurance claim collection and final project close-out adjustments resulted in an additional recovery of approximately $10 million during in 2014. In addition, completion of the Sepat FEED and Esso KTT projects resulted in project close-out savings of approximately $6 million. These positive changes were partially offset by a negative change in estimate of $11 million on the Ichthys project in Australia, primarily due to lower than expected fabrication productivity, increase in procurement costs as well as an increase in marine costs primarily due to changes in marine asset utilization.

Year ended December 31, 2013

In 2013, we recognized net project losses of approximately $315 million due to changes in estimates across all three operating segments.

AEA―The segment was negatively impacted by changes in estimates on six projects resulting in approximately $79 million of project losses. On the Hereema project in Morgan City, we incurred additional fabrication costs of approximately $9 million, primarily due to labor productivity. That project was completed during the fourth quarter of 2013. On the Kambesah marine project in Mexico, which was completed during 2012, we reversed previously recognized claim revenue by approximately $10 million due to unsuccessful claim resolution efforts. On the five-year charter of the Agile in Brazil, we increased the estimated cost to complete the project by approximately $9 million. The completion of this charter is expected during the first quarter of 2017. On two EPCI projects at Altamira, Ayatsil-B and PB Litoral, we increased our estimated costs at completion by approximately $41 million, primarily due to higher procurement costs, reduced labor productivity, and reduced utilization of the fabrication facility. Both of those projects were in loss positions. Ayatsil-B project was completed in 2014 and PB Litoral is expected to complete in the first quarter of 2016. On the Jack & St. Malo subsea project, we recognized a loss of approximately $10 million, primarily driven by liquidated damages due to the anticipated late arrival of vessels currently engaged on projects in Brazil and Malaysia. This project was completed in December 2014.

MEA―The segment was negatively impacted by losses of $174 million due to changes in estimates on four projects. On the pipelay project in the Caspian Sea, we reduced the estimate of cost recovery as a result of ongoing negotiations with the customer.  This project was completed in June 2014 with subsequent improvements of approximately $54 million in 2014, as discussed above. On Safaniya Phase-1, a Saudi Aramco EPCI project, we increased our estimated cost at completion by approximately $63 million, primarily as a result of revisions to the project’s execution plans, increases in our estimated cost to complete due to an extended offshore hookup campaign requiring multiple vessel mobilizations and delays in completion of onshore activities. On the KJO Ratawi EPCI project in the Neutral Zone, we increased our estimated cost to complete by approximately $17 million, primarily due to weather downtime and revisions to our estimated cost to complete the hookup campaign. On the KJO Hout EPCI project in the Neutral Zone, we increased our estimated cost to complete by approximately $16 million due to procurement and design issues which were settled on less favorable terms than previously expected.

ASA―The segment was negatively impacted by net losses of approximately $62 million due to changes in estimates on four projects. On the Siakap subsea development project in Malaysia, we increased our estimated cost at completion by approximately $127 million primarily due to downtime on the NO 105 resulting from mechanical and offshore productivity issues. This project was completed in June 2014 with subsequent improvements of approximately $34 million in 2014, as discussed above. On an EPCI project in Australia we completed a settlement with the customer which resulted in lower-than-expected recoveries. This project was completed in the first quarter of 2013 and the settlement documents were executed in February 2014. These deteriorations were partially offset by improvements on two projects. On an EPCI project in Australia, we reduced estimated costs to complete the project by approximately $64 million as a result of efficiencies and productivity improvements related to offshore hookup activities. This project was completed in early 2013. On a fabrication project in Australia, we increased our change order recovery and bonuses recognized by approximately $15 million resulting from settlements and achieved milestones. This project was completed in March 2014.