Pertemuan-2 PSLI
Kontraktor mengerjakan proyek dengan ruang lingkup tanggung jawab penyelesaian pekerjaan meliputi studi desain, pengadaan
material dan konstruksi serta perencanaan dari ketiga aktifitas tersebut
▪ Tanggungjawab desain sepenuhnya kontraktor
▪ Persyaratan spesifikasi performansi tertentu
▪ Fully equipped facility
▪ Pengawasan langsung oleh Pemilik
▪ Lumpsum
▪ Test After Completion
▪ Prosedur klaim yang ketat
▪ Kontraktor ambil alih semua risiko
▪ Final contract price
▪ Waktu penyelesaian lebih pasti
Pelaksanaan Proyek EPC dari sisi
kontraktor memiliki risiko yang cukup besar karena melakukan pekerjaan
simultan dari engineering sampai suatu
fasilitas berproduksi.
1. Tanggung jawab berada disatu tangan yaitu kontraktor utama.
2. Perancangan, pembelian dan konstruksi bisa berjalan paralel sehingga menghemat banyak waktu.
3. Lebih murah karena terjadi suatu integrasi gabungan aktifitas pekerjaan dengan sistem manajemen proyek
4. Kontrak dalam satu kontrak EPC
5. Pelaksanaan konstruksi dapat dipertimbangkan lebih matang
6. Pekerjaan selesai lebih cepat pemilik dapat segera
mengoperasikan dan mengasilkan produk
▪ Business Process: tahapan-tahapan aktifitas untuk pelaksanaan business baik yang generik maupun yang special
▪ EPC: Engineering-Procurement-Construction, satu
paket kerja untuk merealisasikan suatu fasilitas fisik
pabrik/bangunan dengan menggunakan gabungan
business process yang generic dan special
▪ Dapat membedakan business process yang generik dan special
▪ Dapat lebih tune in bekerja dalam team yang beragam scope of work-nya
▪ Dapat memberikan solusi terbaik terhadap masalah spesifik dalam sebuah bisnis EPC dengan client
spesifik
▪ Dapat menyelesaikan scope kerja dengan efektif
Pahami :
▪ generic business process EPC
▪ client requirement & kontrak kerja
▪ karakter client
▪ kondisi fisik fasilitas yang akan dibangun
▪ lingkungan yang akan mempengaruhi business process
Integrasikan pemahaman di atas dalam perencanaan proyek
multi disiplin seawal mungkin
▪ Fanatik pada pakem pelaksanaan EPC project as usual seperti pengalaman sebelumnya
▪ Enggan memahami new spesific business process dari new business yang akan dihadapi
▪ Kurang akses informasi
▪ Keterbatasan waktu untuk mendapatkan informasi
Client Proyek Jenis fasilitas Scope
Gas Pertamina PPGS pengumpul gas EPC
PGN SSWJ pipeline, station EPC
R&P Pertamina BBSP refinery EPC
Kujang K1B petrochemical EPC
Geothermal Pertamina Kamojang4 pengumpul steam EPC PLN Lahendong2 pembangkit listrik EPC
MEI Antam Feni3 pelebur logam C
Pertamina Gas
Pertamina Geothermal
Pertamina refinery
PLN
Geothermal PGN
Kujang
Petrochemical
Kesamaan business
process (generic)
Eng
Procurement
Construction
Com
Warranty
M/C P/A F/A
EPC period
Engineering
Procurement
Construction Material
MTO,
specifications, drawings
X bulan
MTO,
specifications,
drawings
100 99
106
36 24
22
time cost
(X) (Y)
Akan selalu ada titik optimum cost EPC dengan durasi tertentu dimana cost akan
bertambah bila durasi
diperpanjang atau
dipersingkat tanpa
mengubah karakter
resources dan metoda
kerja
Basic
engineering
Prepare requisition
Vendor Print Check
Tender, PO, vendor print
Finalization for
construction procurement
Detailed engineering
Requistion
plan
Engineering
PO
Procurement
Specification, data sheet,
drawings, MTO Vendor
data
finalization
Engineering tak akan bisa tuntas jika
vendor data belum tuntas
Construction Engineering
Drawings, specifications, MTO
As built for earlier built
facilities procurement
updating As built
Engineering dan Procurement selalu perlu mendampingi konstruksi untuk
antisipasi ketidaksesuaian hasil design dengan actual hasil erection di site
Requistion plan
Inquiry plan
engineering
requisition
RFQ
Inquiry to PO
Vendor print
Manufacturing &
test
Pack &
Support from engineering &
QC
Perencanaan
Area wise
(progress oriented)
System wise (M/C readiness oriented)
0% 70% 100%
Set up Set up Set up
Corporate perlu melakukan internal check pada tahap 95%
0%, 30%, 70%, 95%
1. TOTAL EPC/EPCC, consist of:
Engineering Services (E)
Basic & detail engineering services– from PFD (Process Flow Diagram), P&ID, Plant layout, Single line diagram, Loop diagram, Civil GA including foundation and structure design, pipe stress analysis, Equipment & motor list, if necessary shop drawing - up to inquiry documents–PDS (Plant Design System of INTERGRAPH and AUTOCAD)
Procurement Services (P)
Purchasing, expediting, shipping & transportation of foreign and local equipment/material, including, if necessary, provide imported raw material for local fabricator
Construction and Commissioning (C & C)
Multi disciplines construction works, including our latest PDS Rigging Simulation, and commissioning. disciplines construction works (including our latest PDS rigging simulation) and commissioning
2.Project Management Consultancy services
▪
Project management services on behalf of owner (EPC
–Management)
3. Operation & Maintenance
Run to failure : performing maintenance only at time of failure Preventive maintenance : maintenance according to a fixed schedule Predictive maintenance : maintenance base on actual condition
Equipment base service : HP compressors, gas turbine generators, heat exchangers, gas pumps,
pressure vessels and storage tanks, etc
4. Project Financing
▪
Supply source of financing
EPC Scope of Work
▪Grass-Root Projects
▪ Starting from site preparation (site soil study, reclamation) up until commissioning of the plant
▪Revamping Projects
▪ Basic and detail engineering of plant improvement, including its simulation, procurement &
commissioning
▪Expansion Projects
▪ Basic and detail engineering of plant capacity increase, including its simulation, procurement, construction & commissioning
▪Relocation Projects
▪ Dismantling engineering & works, engineering of new facility, procurement and construction
Types of Project
Owner
Contractor (Fabrication)
Contractor (Installation)
Contractor (Major Equipment
Supplier)
Construction Manager Architect
Engineer
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Contractor
Subcontractor Subcontractor Subcontractor
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Subcontractor
Supplier
Supplier
Subcontracts
Owner
EPC Contract
Preliminary Design/
FEED Contractor
Subcontracts
Owner
EPC Contract
Preliminary Design/
FEED Contractor
National Government
Joint Venture
Project Company/
Oil & Gas Field Operator
EPC Contractor O&M
Contractor Offtaker Drilling
Contractor Lender
Joint Venture Agreement
Production Sharing Contract or Concession
Agreement
Operating Agreement
Security & Financing Agreements
Procurement
Under
structural
Mechanical
& electrical Piping
electrical instrument
system
U/G structural Piping,
instrument, electrical Electrical system Mechanical Process
system
EPC Sequence
1. Review Licensor Basic Engineering
2. Basic Design
3. Detail Engineering
4. Supervising for Detail Engineering
5. Construction & Other Field Activity
6. Pre-commissioning Activity
7. Supervising for Commissioning Activity
8. Overall Project Management
9. Inspection of Equipment & Material
10. Transportation
Piping Engineering Process Engineering
Mechanical Engineering
Civil Engineering
Electrical & Instrument
Basic Engineering
1. Strength Calculation and Weight Estimation
2. Preparation of Engineering Drawing
3. Preparation of Loading Data
4. Preparation of Requisition
5. Preparation of Bid Evaluation Report
6. Purchase Order
7. Kick Off Meeting
8. Coordination with Other Discipline
PIPING ISOMETRIC
P & ID AND PLOT PLAN PIPING LAYOUT
MATERIAL TAKE-OFF SPOOL DRAWING
Piping Engineering
FRAMING PLAN & DETAIL PLOT PLAN
STRUCTURAL DESIGN
MATERIAL TAKE-OFF SHOP DRAWING
Civil Engineering
Existing pile at Main Process Area Piling work at Bulk Material Store
Preparation of permanent fencing installation Site office
Civil Construction
Concreting of slab & beam (Bagged Material Store)
Concreting of pedestal (Packing Bin Building)
Installation formwork & pouring concrete
of column (Process Building) Installation of formwork & rebar (TNB Substation)
Civil Construction
SCOPE MANAGEMENT
▪
Project Scope Development
▪
Project Scope:
▪ Project Identity
▪ Project Description
▪ Overall Project Scope
▪ Contractor Scope of Work
▪ Scope of Supply
▪ Split of Responsibility
▪ Deliverables
▪ Battery Limit
▪ Exclusion
▪
Project Schedule
▪ Project Execution Schedule
▪ Project Milestone
▪
Project Cost
▪ Project Execution Budget
▪ Project Cash Flow
▪ Working Capital & Profitability
▪
Project Execution Strategy
▪ Work Flow Process
▪ Engineering Strategy
▪ Procurement Strategy
▪ Construction Strategy
▪
Project Procedure
▪ Coordination Procedure
▪ Correspondence Procedure
▪ Document Numbering Procedure
▪ Review & Approval Procedure
▪ Invoice Procedure
▪ Safety Procedure
▪
Risk Assessment
PROJECT SCOPE DEVELOPMENT
▪
Initiation
Identify the project scope from Client’s RFQ
▪
Scope definition
Decompose or subdividing major work items into smaller component to:
▪ Improve accuracy of cost, duration & resources estimate
▪ Define a base line for performance measurement & control
▪ Facilitate clear responsibility assignment
The result of scope definition is a Work Breakdown Structure
▪
Scope verification
Make sure & confirm the defined project scope will conform to Client requisition
▪ Communicate the defined project scope to client
▪ Survey, inspection and take site data
The result of scope definition is a formal client acceptance, usually in MOM form.
PROJECT SCOPE CONTENT
Project scope content in project execution & planning, consist of:
Project Identity
Short information about identity of the project, should contain information such as project name, project number, owner, location, etc.
Useful for reference, coordination, and correspondence
Project Description
Brief description about the project, should contain information such as: type of work, duration of project, project owner, summarized scope of work & supply, project costing & payment scheme, specific correlation to other party such as: licensor, consultant, finance, etc.
Overall Project Scope
All of work, material, man power, resources, legal issues, etc that correlated to project. Should be defined for:
Identify the interface of scope between contractor & client Risk analysis
Project controlling input
PROJECT SCOPE CONTENT
Scope of Work
All of work items have to be accomplished by contractor.
Scope of Supply
All of design, equipment, tool, manpower, and facility that have to be supplied by contractor
Split of Responsibility
List or description that divide the project scope responsibility between Contractor & Client.
All of above items should be:
▪ Conform with client requisition
▪ Should be communicate to client and get confirmation to minimize dispute matter
▪ Project management have to identify and be familiar with
▪ Should be specified carefully in a complete & detail break down
▪ Used for basic calculation of project execution such as: schedule, budget, facility, man power
PROJECT SCOPE CONTENT
▪
Deliverables
▪ Items, equipments, documents, that have to be delivered to Client or project site, such as: engineering drawing, report, construction material, equipment, tools, etc.
▪ Have to define for project controlling, preparation of transportation and lay down area, etc.
▪
Battery Limit
▪ The point or line that function as interface to separate contractor scope and client scope. Usually covering electrical work, piping work, and instrumentation work.
▪ The battery limit is an item to be discussed and decided together between contractor and client to minimized any dispute matter.
In EPC project, usually battery limit as follow:
▪ Piping work : 1 m out of plant building
▪ Electrical : Cable feeder socket in MCC panel
▪ Instrument : Power cable feeder socket in main panel
PROJECT SCOPE CONTENT
▪
Exclusion
▪
Work item that not include project scope
▪
Work Item that not include in contractor scope of work.
▪
Have to be defined and informed to client
▪
Will be acomplished by owner.
Exclusion in EPC activity could be such as:
▪
Process Licensee
▪
Land acquisition
▪
Soil test
▪
All soil work, such as: land clearing,
▪
Legal & permits
▪
Lightning protection
▪
Raw Material, Chemical, fuel, oil, etc for commissioning
Engineering
▪ Diutamakan Sizing, Data Sheet, & Gen spec main equipment agar fabrikasi & procurement dapat dieksekusi
▪ Detail design (nozzle size & orientation, mech seal, etc) ketika fabrikasi berlangsung
▪ Detail: skid arrangement, lay out, piping, electrical, & instrumen
Fabrication
▪ Dikerjakan dengan cara sub-contracting
▪ Untuk menjaga kerahasiaan proses maka fabrikasi dilakukan pada minimal 2 fabrikator:
▪ Proprietary equipment
▪ Skid installation
▪ Kriteria Fabrikator
▪ Berpengalaman mengerjakan pekerjaan sejenis
▪ Tidak di sub-kon kan lagi
▪ Hindari fabrikator besar (antri, mahal, kurang responsif)
▪ Didukung oleh man power (engineering), peralatan, dan modal.
▪ Kontrol kualitas & schedule dilakukan dengan
▪ Mereview detail execution plan
▪ Menempatkan QC Supervisor di work shop
▪ Tes & Inspeksi dilakukan di work shop
▪ Up-date status setiap minggu
Site Construction
▪ Dilakukan dengan cara sub-contracting
▪ Pekerjaan dibagi menjadi tiga paket:
▪ Mechanical erection & piping installation
▪ Electrical & Instrument installation
▪ Painting, tracing & insulation
▪ Tim punch list untuk mendampingi Pre-Com dan Com
▪ Kontrol schedule & kualitas
▪ Menempatkan personel yang cukup (field controller, Field Eng, QC Spv, Const. Spv, etc)
▪ Daily updating status
▪ Safety Policy
▪ Follow safety policy owner
▪ Menempatkan Safety Officer
Training
▪ Transfer basic know how oleh principal engineer
▪ Training plant operation oleh process engineer, ME, EE, IE
▪ Training prosedur Laboratorium oleh pihak ketiga (O/S)
PROCESS ENGINEER
MECHANICAL ENGINEER
PIPING ENGINEER
INSTRUMENT ENGINEER
ELECTRICAL ENGINEER
PROJECT ENGINEER PFD & EMB
P&I Diagram
EQUIPMENT DATA SHEET
GENERAL ARRANGEMENT EQUIPMENT LAY OUT MECHANICAL SPECIFICATION
PIPING LAY OUT DIAGRAM ISOMETRIC DIAGRAM
PIPING MATERIAL TAKE OFF
LOOP DIAGRAM INSTRUMENT LAY OUT INSTRUMENT WIRING DIAGRAM
INSTR. MATERIAL TAKE OFF
SINGLE LOOP DIAGRAM INSTRUMENT SPECIFICATION PIPING SPECIFICATION PIPE SUPPORT SPECIFICATION MECHANICAL TAKE OFF
ISSUED FOR REVIEW
ISSUED FOR REVIEW START UP PROCEDURE
ISSUED FOR REVIEW
ISSUED FOR REVIEW
ISSUED FOR REVIEW
PROJECT MANAGER ISSUED FOR APPROVAL
CONSTRUCTION MANAGER
FOR CONSTRUCTION ALL ENGINEERING DOCUMENT
PROJECT MANAGER OWNER
ISSUED FOR OWNER APPROVAL
VENDOR #1 VENDOR #2 VENDOR #3 VENDOR #X
PROCUREMENT MANAGER
TECHNICAL CLARIFICATION PROJECT ENGINEER COMMERCIAL CLARIFICATION
PROJECT MANAGER NEGOTIATION
PROJECT MANAGER
PURCHASE ORDER SELECTED VENDOR INQUIRY
PROPOSAL
PROJECT DIRECTOR REVIEW
SUB-CON #1 SUB-CON #2 SUB-CON #3 SUB-CON #X
CONSTRUCTION MANAGER
TECHNICAL CLARIFICATION PROJECT ENGINEER COMMERCIAL CLARIFICATION
PROJECT MANAGER NEGOTIATION
PROJECT MANAGER
SUB-CONTRACT SELECTED SUB-CON ITB
PROPOSAL
PROJECT DIRECTOR REVIEW
Risk Assessment covering:
• Risk identification
• Impact & consequences
• Counter measure
• Risk control
▪ Buatlah Review Dokumen Tender atau Petunjuk Lelang di
Bidang Kelistrikan Industri/Electrical! → Scope/Deliverables,
FEED, DED, dll.