EPC Business Process

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

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

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

Keuntungan Proyek EPC Tanggung jawab berada disatu tangan yaitu kontraktor utama. Perancangan, pembelian dan konstruksi bisa berjalan paralel sehingga menghemat banyak waktu. Lebih murah karena terjadi suatu integrasi gabungan aktifitas pekerjaan dengan sistem manajemen proyek Kontrak dalam satu kontrak EPC Pelaksanaan konstruksi dapat dipertimbangkan lebih matang Pekerjaan selesai lebih cepat pemilik dapat segera mengoperasikan dan mengasilkan produk

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

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

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

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

Kategori Business REK Client Proyek Jenis fasilitas Scope Gas Pertamina PPGS pengumpul gas EPC   PGN SSWJ pipeline, station R&P BBSP refinery Kujang K1B petrochemical Geothermal Kamojang4 pengumpul steam PLN Lahendong2 pembangkit listrik MEI Antam Feni3 pelebur logam C

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

Project Life Cycle Eng M/C P/A F/A Procurement Construction Com Warranty EPC period

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

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

Time vs Cost untuk EPC Work 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 106 100 cost 99 22 24 36 (Y) (X) time

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

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

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

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

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

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

EPC Scope of Work 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

EPC Scope of Work 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

(Gas Purification Plant) CO2 Removal (Gas Purification Plant) 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

(Urea & Ammonia Fertilizer Plant) Kaltim 4 (Urea & Ammonia Fertilizer Plant) 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)

(Gas Booster Station Plant) PGN Project (Gas Booster Station Plant) 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

(NPK Fertilizer Plant) NPK Malaysia (NPK Fertilizer Plant) Capacity : 330,000 TPY Value : RM 135,515,000 or US $ 41,000,000 Schedule : 21 Months Plant acceptance : Nov’ 3rd 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)

(Urea & Ammonia Fertilizer Plant) PIM 2 (Urea & Ammonia Fertilizer Plant) 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)

BALONGAN BLUE SKY PROJECT (Oil Refinery Plant) 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

(Urea & Ammonia Fertilizer Plant): Kujang 1B (Urea & Ammonia Fertilizer Plant): 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)

(Gas Gathering Station) SUMBAGSEL PAKET 1 (Gas Gathering Station) 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

Types of Project Grass-Root Projects Revamping 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

Project Contract Structure Construction Management

Project Contract Structure Traditional EPC : Single Point of Responsibility

Project Contract Structure National Government Production Sharing Contract or Concession Agreement Joint Venture Joint Venture Agreement Operating Agreement Project Company/ Oil & Gas Field Operator Lender Security & Financing Agreements EPC Contractor O&M Contractor Offtaker Drilling Contractor

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

Engineered Item Equipment Review Licensor Basic Engineering Basic Design Detail Engineering Supervising for Detail Engineering Construction & Other Field Activity Pre-commissioning Activity Supervising for Commissioning Activity Overall Project Management Inspection of Equipment & Material Transportation

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

Vessel (Basic Engineering & Proc Stage) Strength Calculation and Weight Estimation Preparation of Engineering Drawing Preparation of Loading Data Preparation of Requisition Preparation of Bid Evaluation Report Purchase Order Kick Off Meeting Coordination with Other Discipline

Steam Turbine

Gas Turbine

Hydroelectric Turbine

Centrifugal Compressor

Boiler (Gas Fueled)

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

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

Delivery Equipment

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

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)

Mechanical 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 Scope of Supply 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 Deliverables Battery Limit 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

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

Project Execution Strategy 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)

Work Flow Process

Work Flow Process

Work Flow Process

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

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