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EPC Business Process

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

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EPC Business Process

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  1. EPC Business Process

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

  5. 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

  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. 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. 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. 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. Kategori Business REK

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

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

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

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

  15. 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

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

  17. 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

  18. 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

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

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

  21. PT REKAYASA INDUSTRIENGINEERING & 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. 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

  23. 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, heatexchangers, gas pumps, pressure vessels and storagetanks, etc 4. Project Financing • Supply source of financing

  24. 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

  25. 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)

  26. 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

  27. 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)

  28. 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)

  29. 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

  30. 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)

  31. 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

  32. Types of Project • 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

  33. Project Contract Structure Construction Management

  34. Project Contract Structure Traditional EPC : Single Point of Responsibility

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

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

  37. 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

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

  39. 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

  40. Steam Turbine

  41. Gas Turbine

  42. Hydroelectric Turbine

  43. Centrifugal Compressor

  44. Boiler (Gas Fueled)

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

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

  47. Delivery Equipment

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