Presentasi sedang didownload. Silahkan tunggu

Presentasi sedang didownload. Silahkan tunggu

1 EPC Business Process. 2 Proyek EPC Kontraktor mengerjakan proyek dengan ruang lingkup tanggung jawab penyelesaian pekerjaan meliputi studi desain, pengadaan.

Presentasi serupa


Presentasi berjudul: "1 EPC Business Process. 2 Proyek EPC Kontraktor mengerjakan proyek dengan ruang lingkup tanggung jawab penyelesaian pekerjaan meliputi studi desain, pengadaan."— Transcript presentasi:

1 1 EPC Business Process

2 2 Proyek EPC Kontraktor mengerjakan proyek dengan ruang lingkup tanggung jawab penyelesaian pekerjaan meliputi studi desain, pengadaan material dan konstruksi serta perencanaan dari ketiga aktifitas tersebut

3 3 Proyek EPC  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

4 4 Pelaksanaan Proyek EPC dari sisi kontraktor memiliki risiko yang cukup besar karena melakukan pekerjaan simultan dari engineering sampai suatu fasilitas berproduksi Risiko Proyek EPC

5 5 Keuntungan Proyek EPC 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

6 6 Business Process EPC  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

7 7 Manfaat Memahami Business Process  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

8 8 Cara Mendapatkan Manfaat dari pembelajaran business process 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

9 9 Kendala untuk mendapatkan manfaat dari pemahaman business process  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

10 10 Kategori Business REK ClientProyekJenis fasilitasScope GasPertaminaPPGSpengumpul gasEPC PGNSSWJpipeline, stationEPC R&PPertaminaBBSPrefineryEPC KujangK1BpetrochemicalEPC GeothermalPertaminaKamojang4pengumpul steamEPC PLNLahendong2pembangkit listrikEPC MEIAntamFeni3pelebur logamC

11 11 Kesamaan & Ketidaksamaan Business Process Pertamina Gas Pertamina Geothermal Pertamina refinery PLN Geothermal PGN Gas Kujang Petrochemical Kesamaan business process (generic)

12 12 Project Life Cycle Eng Procurement Construction Com Warranty M/CP/AF/A EPC period

13 13 Ideal EPC Steps Engineering Procurement Construction Material MTO, specifications, drawings X bulan MTO, specifications, drawings

14 14 Concurrent EPC Engineering Procurement Construction Material MTO, specifications, drawings Extended time Y bulan dimana Y

15 15 Time vs Cost untuk EPC Work 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

16 16 Engineering Basic engineering Prepare requisition Vendor Print Check Tender, PO, vendor print Finalization for construction procurement Detailed engineering Requistion plan IFC

17 17 Hubungan E-P: Vendor Data Engineering PO Procurement Specification, data sheet, drawings, MTO Vendor data finalization Engineering tak akan bisa tuntas jika vendor data belum tuntas

18 18 Hubungan E-C: As built data Construction Engineering Drawings, specifications, MTO As built for earlier built facilities procurement updatingAs built Engineering dan Procurement selalu perlu mendampingi konstruksi untuk antisipasi ketidaksesuaian hasil design dengan actual hasil erection di site

19 To become a new and innovative energy company 19 Procurement Requistion plan Inquiry plan engineering requisition RFQ Inquiry to PO Vendor print Manufacturing & test Pack & transport Support from engineering & QC

20 20 Kategori Periode Construction Perencanaan Area wise (progress oriented) System wise (M/C readiness oriented) 0%70%100% Set up 95% Corporate perlu melakukan internal check pada tahap 0%, 30%, 70%, 95%

21 21 PT REKAYASA INDUSTRI ENGINEERING & CONSTRUCTION PT Rekayasa Industri today is one of the foremost Engineering Procurement Construction Commissioning (EPCC) companies in Indonesia. The company’s scope of EPCC business includes: Gas, Geothermal, Refinery, Petrochemical, Mineral, Environmental, and Infrastructure. In addition, the company also provides services for Project/Plant Feasibility Studies and Plant Maintenance. Vision: To become a new and innovative energy company

22 22 EPC Scope of Work 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

23 23 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

24 24 Capacity : 200 MMSCFD Value: US$ 10,833,000 Rp.124,558,000,000. Schedule: 16 Months Plant acceptance: 31 Oct’ 2003 Scope: EPC Owner: PERTAMINA Location: SUBANG, WEST JAVA Partner : None Licensor: BASF CO2 Removal (Gas Purification Plant)

25 25 Cap Urea (Granule): 1725 MTPD Cap Ammonia: 1000 MTPD Value: US $ 322,000,000 Schedule: 40 Months Plant acceptance: May 2003 Scope: EPC Owner: PT. Pupuk Kaltim Location: Bontang, East Kalimantan Partner: MHI Japan Licensor: Haldor Topsoe (NH3) Snamp SpA (Urea) Kaltim 4 (Urea & Ammonia Fertilizer Plant)

26 26 Capacity: 420 MMSCFD Value: US $ 21,000,000 Schedule: 11 Months Plant acceptance: 26 Dec’ 2002 Scope: EPC Owner: PERTAMINA Location: Jambi & Riau, Sumatera Partner: None Licensor: None PGN Project (Gas Booster Station Plant)

27 27 Capacity: 330,000 TPY Value: RM 135,515,000 or US $ 41,000,000 Schedule: 21 Months Plant acceptance: Nov’ 3 rd 2004 Scope: EPC Owner:Malaysian NPK Fertlizer Sdn Location: Gurun Kedah Malaysia Partner: None Licensor: Incro SA (NPK Process Tech) Snamp. SpA (Urea Concentration Tech) NPK Malaysia (NPK Fertilizer Plant)

28 28 Cap Urea (Granule): 1725 MTPD Cap Ammonia: 1200 MTPD VALUE: US $ 264,000,000. Plant acceptance: May 2005 Scope: EPC OWNER: PT. Pupuk Iskandar Muda, Aceh Location: Lokseumawe, Aceh Indonesia Partner: TEC, Japan Licensor: KBR (Nh3) TEC (Urea) PIM 2 (Urea & Ammonia Fertilizer Plant)

29 29 Capacity: Naptha : 52,000 BPSD Penex : 23,000 BPSD CCR : 29,000 BPSD Value: US$152,975,000 Schedule: 27 Months Plant Acceptance: May 2005 Scope: EPC Owner: Pertamina Location: Balongan, West Java Partner: TEC, Japan Licensor: UOP BALONGAN BLUE SKY PROJECT (Oil Refinery Plant)

30 30 Cap Urea: 1725 MTPD Cap Ammonia: 1000 MTPD Valule: ¥ 7,294,000,000 Schedule: 36 Months Plant acceptance: 26 Dec’ 2005 Scope: EPC Owner: PT. Pupuk Kujang Location:Purwakarta, West Java Partner: TEC, Japan, IKPT Licensor: KBR (NH3) TEC (Urea) Kujang 1B (Urea & Ammonia Fertilizer Plant):

31 31 Capacity: 300 MMSCFD Value: US $ 33,016,000 Schedule: 24 Months Plant acceptance: 30 June, 2006 Scope: EPC Owner: PERTAMINA Location: South Sumatra Partner: MHI Licensor: None SUMBAGSEL PAKET 1 (Gas Gathering Station)

32 32

33 33

34 34

35 35  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

36 36 Project Contract Structure Construction Management Owner Contractor (Fabrication) Supplier Contractor (Installation) Supplier Contractor (Major Equipment Supplier) Supplier Construction Manager Supplier Architect Engineer

37 37 Project Contract Structure Traditional EPC : Single Point of Responsibility Subcontracts Owner EPC Contract Preliminary Design/ FEED Contractor

38 38 Project Contract Structure 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

39 39 Procurement Under ground structural Mechanical & electrical Piping electrical instrument system U/G composite structural Piping, instrument, electrical Electrical system Mechanical Process system engineering construction EPC Sequence

40 40 Engineered Item Equipment 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

41 41 Piping Engineering Process Engineering Mechanical Engineering Civil Engineering Electrical & Instrument Basic Engineering

42 42 Vessel (Basic Engineering & Proc Stage) 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

43 43 Steam Turbine

44 44 Gas Turbine

45 45 Hydroelectric Turbine

46 46 Centrifugal Compressor

47 47 Boiler (Gas Fueled)

48 48 PIPING ISOMETRIC P & ID AND PLOT PLAN PIPING LAYOUT MATERIAL TAKE-OFF SPOOL DRAWING Piping Engineering

49 49 FRAMING PLAN & DETAIL PLOT PLAN STRUCTURAL DESIGN MATERIAL TAKE-OFF SHOP DRAWING Civil Engineering

50 50 Delivery Equipment

51 51 Existing pile at Main Process Area Piling work at Bulk Material Store Preparation of permanent fencing installation Site office Civil Construction

52 52 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

53 53 Mechanical Construction

54 54 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

55 55  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

56 56  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 Development

57 57 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

58 58 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 planning, and other resource Project Scope Content

59 59  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

60 60  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 Project Scope Content

61 61 Project Execution Strategy 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

62 62 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) Project Execution Strategy

63 63 Work Flow Process

64 64 Work Flow Process

65 65 Work Flow Process

66 66 Risk Assessment Risk Assessment covering: Risk identification Impact & consequences Counter measure Risk control

67 67

68 68 Hubungan P-C: MRR & OSDR Procurement Construction MRR / OSDR MRR Procurement tuntas jika sudah tak ada lagi OSDR


Download ppt "1 EPC Business Process. 2 Proyek EPC Kontraktor mengerjakan proyek dengan ruang lingkup tanggung jawab penyelesaian pekerjaan meliputi studi desain, pengadaan."

Presentasi serupa


Iklan oleh Google