Manajemen proyek epci offshore utk kontraktor EPCI 23 aug 2014
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Transcript of Manajemen proyek epci offshore utk kontraktor EPCI 23 aug 2014
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Manajemen Proyek EPCI Offshore untuk Kontraktor
EPCI
Komunitas Migas Indonesia (KMI) &
Magister Manajemen Universitas Gajah Mada (MMUGM)
MMUGM Kampus Jakarta, Gedung B
Sabtu, 23 Agustus 2014
Learning & Sharing Project Management in Oil & Gas, Batch # 3
by: Wisnu Wahjusaputra
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Introduct ion Tujuan :
Berbagi pengalaman praktis tentang bagaimana perusahaan jasa konstruksi EPCI (Kontraktor EPCI) mengelola proyek EPCI Offshore di Industri Migas
Sasaran :1) Menerapkan manajemen proyek pada proyek EPCI Offshore2) Melaksanakan phase EPCI: engineering, procurement,
construction, commissioning and hand-over3) Memahami Organisasi Proyek EPCI4) Menerapkan HSE Management System (Sistem Manajemen
K3LH)5) Menerapkan Quality Management System6) Mengetahui problem solving dalam mengelola proyek EPCI
Offshore
Referensi : PMBOK 5th Edition
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Agenda1. Pengenalan Obyek Kontrak EPCI Offshore2. Tahapan Pelaksanaan Proyek EPCI3. Project Management 4. Detailed Engineering5. Procurement6. Construction / Onshore Fabrication7. Offshore Transportation & Installation8. Pre-commissioning & Commissioning Support 9. Operations Readiness & Assurance10.Project Control11.QA/QC (Quality Assurance/Quality Control) 12.HSE (Health, Safety & Environmental)
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PENGENALAN OBYEK KONTRAK EPCI OFFSHORE
Chapter-01
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Oil & Gas Exploration & Production
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Fas i l i tas Tops ides
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Struktur Bangunan PendukungFasilitas Topsides
Up to520 m
(1,710 ft)
370 to 910 m(1,210 to 2,990 ft)
180 to 1,300 m
(590 to 4,270 ft)
Fixed Platform
Compliant
Tower
Semi-Submersible
Platform
FloatingProductio
nSystems
Tension Leg
PlatformSpar
Platform
FixedPlatfor
m
590 to 1,710 m(1,940 to 5,610
ft)
60 to 3,000 m(200 to 10,000 ft)
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Fas i l i t as Subsea
• Pipeline• Flowline• Tie in Spools• Manifold• Umbilical • Subsea
Production Control System (SPCS)
• Riser
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Floating Production System
FSRU _ PGN Lampung
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Floating Production, Storage, Offloading System (FPSO)
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Fasilitas Subsea System
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TAHAPAN PELAKSANAAN PROYEK EPCI
Chapter-02
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Tahapan Pelaksanaan Proyek EPCI
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PROJECT MANAGEMENT
Chapter-03
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Project Management Team Activities
• Setup PMT (Project Management Team)▫ Identifikasi Key Personil▫ Kualifikasi Personil▫ Proses perekrutan personil▫ Maintain and manaje personil proyek
• Memahami SOW (Scope of Work)• Mendefinisikan MDR (Master Deliverable Register)• Mendefinisikan Milestone & Baseline Schedule• Membuat PEP (Project Execution Plan)• Melaksanakan KOM (Kick-Off Meeting)• Memonitor Plan vs Actual status• Mengendalikan, Mengalokasikan dan Menjadwalkan Sumber Daya
yg diperlukan untuk menyelesaikan pekerjaan• Meresponse semua pertanyaan dari Client dalam waktu yg telah
disepakati
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EPCI Project Management Team
CLIENTProject Manager
EPCI CONTRACTORProject Manager
EngineeringManager
ProcurementManager
OffshoreInstallation
Manager
Construction/Fabrication
Manager
QA/QCManager
HSEManager
InterfaceManager
CommissioningManager
Ops. AssuranceManager
Project ControlManager
Contract &Subcontract
Manager
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Kick-Off Meeting• Tujuan:
▫ Memahami Project Goals & Objectives di antara Key Stakeholders
▫ Perkenalan Key Personnel, Roles & Responsibilities
▫ Membangun TRUST & COMMITMENT sesama anggota Project Team (Team
Building)
• Waktu pelaksanaan : Setelah Project Team terbentuk
• Participants adalah semua Key Stakeholders (Key Personnel) yang terlibat proyek, al;
▫ Company
▫ EPCI Contractor plus;
Subcontractors
Third Party Consultants Personal
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Pa r t i c i p a n t s KO M
• Project Sponsor
• Project Director
• Engineering Manager
• Procurement Manager
• Construction Managers
• Installation Manager
• QA/QC Manager
• HSE Manager
• Project Control/Services Manager
• Others (Key Personnel)
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DETAILED ENGINEERING
Chapter-04
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Setup Engineering TeamEngineering
Manager
Topsides Lead
Engineer
Subsea Lead Engineer
T&I Engineer
Engineering Admin.
Topsides EngineeringSubcontractor
Company A
Name01 Jul ‘12
T&I EngineeringSubcontractor
Company C
Name20 Dec ‘12
Subsea EngineeringSubcontractor
Company B
Name01 Jul ‘12
SU
BC
ON
TR
AC
TO
R
‒ Process‒ Mechanic
al‒ Piping‒ Electrical
‒ Instrument
‒ Structure‒ Safety‒ Drafter
‒ Pipeline‒ Umbilical‒ SPCS
‒ Naval Engineer
‒ Offshore Engineer
EP
CI
MA
IN C
ON
TR
AC
TO
R
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Engineering Activities
• Setup Engineering Team & Faculties
• Memahami Scope of Work (SOW)
• Membuat Engineering Execution Plan:▫ Manpower planning
▫ Schedule
▫ Menetapkan Engineering Deliverables
• Verify and Validate FEED
• Safety Review & Studies
• Detailed Engineering : Process, Mechanical, Piping, Electrical, Instrumentation, Structural, Subsea Pipeline, Transportation &
Installation
• Control Engineering Quality▫ Intern Discipline Check
▫ Engineering Review Process: IFC-IFA-AFC
• Memonitor dan melaporkan Engineering Plan vs Actual status
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PROCUREMENT
Chapter-05
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Procurement Activities• Setup Procurement Team
• Memahami Scope of Work (SOW)
• Membuat Procurement Plan & Procedures
• Melaksanakan kegiatan import/re-export termasuk membuat master list
• Menseleksi supplier/subkontraktor
• Menerbitkan RFQ, PR/PO
• Memperbaharui PMS (Procurement Master Schedule) dan FES (Field Expediting Schedule)
• Mengagendakan inspeksi dan/atau Test Witnessing
• Melakukan pengepakan dan pengiriman barang
• Melaporkan kinerja supplier dan subkontraktor
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Setup Procurement Team
ProcurementManager
Buyer Expeditor Logistics
Procurement Admin.
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Contract & Subcontract TeamContract/
Subcontract Manager
Contract Supervisor
Subcontract Supervisor
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Subcontract Procedure
• Evaluasi tender dilaksanakan menjadi 2 tahap yg terpisah ;
▫ Evaluasi Teknis oleh Project Engineer atau Discipline engineer
▫ Evaluasi Komersial oleh Subcontracts Engineer
• Evaluasi Teknis didasarkan pada dokumen tender yang mencakup al ;
▫ Pengalaman perush utk perkerjaan yg similar
▫ Key personnel & Kualifikasi
▫ Kapabilitas perusahaan utk melaksanakan service/pekerjaan
▫ HSE Management System & Records (ISO 1400 & OHSAS 1800)
▫ Quality Plan dan Sistem Manajemen Mutu (ISO 9001 Certified)
▫ Financial Statements
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Proses Persetujuan Masterlist
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Estimated Duration for Masterlist Approval
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CONSTRUCTION / ONSHORE FABRICATION
Chapter-06
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Construction (Onshore Fabrication) Activities
• Construction Management Team Organization
• Understanding SOW & Deliverables
• Prepare Construction Execution Plan
• Constructability reviews
• Prepare & review calculations, drawings and procedures for
fabrication
• Production of planning schedules
• Onshore man hour estimates (fabrication)
• Quality Assurance & Quality Control
• HSE & Emergency Response Management
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Setup Construction (Onshore Fabrication) Team
ConstructionManager
Material Control
Site Engineer
Fabrication Supervisor
Site Planner
Welding Supervisor
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OFFSHORE TRANSPORTATION & INSTALLATION
Chapter-07
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Offshore Transportation & Installation Activities
• T&I Management Team Organization
• Understanding SOW & Deliverables
• Prepare Offshore T&I Execution Plan
• Constructability reviews
• Prepare & review calculations, drawings and procedures for
offshore T&I
• Work pack & Job card preparation
• Production of planning schedules
• Offshore surveys and reporting
• Offshore man hour estimates (hook-up / installation)
• Quality Assurance & Quality Control
• HSE & Emergency Response Management
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Offshore T&I TeamOffshore
Installation Manager
Topsides Installation
Superintendent
Subsea Installation
Superintendent
Site Planner & Scheduler
Field Engineer
Field Engineer
Work Vessel Superintendent
Diving Vessel Superintenden
t
T&I Crew Diving Crew
QA/QCSupervisor
HSESupervisor
Vessel Crew Vessel Crew
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PRE-COMMISSIONING & COMMISSIONING SUPPORT
Chapter-08
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Pre-comm. & Commissioning Support Activities
• Setup PC&C Team
• Membuat Prosedur Pre-comm & Commissioning
• Mendefinisikan System & Sub-system
• Membuat Piping Testpacks (N2/He Leak test)
• Review & Witnessing of FAT
• Membuat OTP (Ops Test Procedures); piping testpacks (N2/He leak testing)
• PIMS Administration
• Vendor Mobilization
• Pre-operational checks
• Trial runs and performance tests
• Serah terima PC Dossier
More detail for MDR of Commissioning
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Commissioning TeamPre-comm. &
Commissioning Manager
Comm. Mechanical Engineer
Comm. Piping Engineer
Comm. Electrical Engineer
Comm. Instrument Engineer
PIMS Administrator
N2/He Leak Testing
Subcontractor
Vendor’s Representativ
e
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OPERATIONS READINESS & ASSURANCE
Chapter-09
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Operations Readiness & Assurance (OR&A) Activities
• Setup Project OR&A Team
• Memberikan operations input kepada desain :
▫ Mengembangkan Operations Philosophy sebagai input kepada desain
▫ Partisipasi dalam HAZOPs, HAZIDs, SIL & Risk Assessments
▫ Partisipasi dalam Constructability, Accessibility & Maintainability Reviews
▫ Mendefinisikan Isolation Philosophy
• Membuat POPM (Plant Operating Procedures & Manuals)
• Memberikan training kepada team offshore operations (client) termasuk proses
competency assessment• Mengembangkan maintenance strategy • Melakukan study maintenance (RCM, RAM, RBI, etc)• Mengembangkan Asset register • Populasi data untuk CMMS• Mendefinsikan spare part yang diperlukan untuk masa 2 tahun operasional • Memberikan dukungan kepada client saat start up and handover
More detail for MDR of Operation Assurance
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Operations Assurance TeamOperations
Assurance Manager
OperationsLead
Engineer
MaintenanceLead
Engineer
TrainingEngineer
- Process- Mechanical- Piping- Subsea Pipeline- E&I- Lifting- Technical Writer
- RBI (Risk Based Inspection)
- RAM (Reliability, Availability & Maintainability)
- RCM (Reliability Centered Maintenance)
- Asset Registering- CMMS- Technical Writer
- POPM (Plant Operating Procedures & manuals) for Operator
- Technical Writer
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PROJECT CONTROL
Chapter-10
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Project Control activities
• Setup project control team
• Perencanaan, penjadwalan (scheduling), dan
alokasi sumber daya menggunakan software
Primavera P6
• Mengukur kemajuan proyek dan pelaporannya (
S-Curve)
• Cost control
• Document control
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Project Planning & Control
PhaseWeight Factor
Percentage Progress Against Total
This Period To Date
ForecastPlan
Actual Var Forecast
Plan*Actual Var
Engineering 2.62 0.00% 0.00% 0.00% 95.00% 94.91% -0.09%
Procurement 33.29 0.25% 0.25% 0.01% 99.76% 97.65% -2.11%
Fabrication 6.20 0.00% 0.38% 0.37% 35.61% 34.79% -0.82%
Construction / Installation 55.43 3.54% 1.06% -2.48% 47.08% 32.76% -14.31%
Topsides 21.74 0.65% 2.61% 1.96% 62.82% 22.66% -40.17%
Subsea 78.26 1.01% -0.63% -1.64% 41.04% 35.57% -5.47%
Precom / Commissioning
2.44 0.00% 0.00% 0.00% 43.04% 0.00% -43.04%
Total 100.00 2.05% 0.69% -1.35% 65.06% 55.32% -9.74%
Overall EPC Project ProgressAs of 11 October 2013:
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Project Control/Services TeamProject Control/ Services Manager
Cost Control
Planner/Scheduler
Document Control
IT Engineers
Project Administratio
n
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QUALITY ASSURANCE & QUALITY CONTROL
Chapter-11
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Quality Assurance & Quality Control activities
• Setup QA/QC team
• Membuat Project Quality Plan
• Menetapkan QA/QC deliverables
• QA (Quality Assurance)
• QC (Quality Control) :
▫ Inspection and test plans
▫ Non-Conformances
▫ Design and Engineering
▫ Procurement and Logistic
▫ Construction and Installation
• Quality Audit
• MIGAS Certification :
▫ SKPP/SKKP/SKPI Certificates
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QA/QC TeamQA/QC
Manager
QA/QC Onshore
Fabrication Spv.
QA/QC Offshore Spv.
Quality Engineer
QC Inspector
QC Inspector
- Structural Welding- Mechanical- Electrical & Instrument- Coating / Painting
- Structural- Pipeline- Mechanical / Piping- Electrical & Instrument- Coating / Painting
NDT Technicians
NDT Technicians
- Ultrasonic- X-Ray
- Ultrasonic- X-Ray
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HEALTH SAFETY ENVIRONMENTAL (HSE)
Chapter-12
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HSE communication
•Daily toolbox safety meeting•Pre job safety meeting (PJSM)•Weekly site HSE meeting•Weekly project and HSE management
review•Contractor safety forum
(monthly/quarterly)
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HSE activities• Setup HSE team• Membuat HSE Plan dan Emergency Response Plan (ERP)• Menetapkan HSE Deliverables beserta jadwalnya• Bersama client melaksanakan A Joint Pre-Mobilization
Inspection• Identify hazards sebelum demobilisasi• Membekali personil dengan HSE training sebelum
memulai pekerjaannya• Memonitor dan mengukur HSE Plan vs Actual Progress • Melaporkan kinerja HSE secara regular• Melaksanakan HSE Audit & Inspection, Site Inspection,
Pre Delivery Equipment Inspection
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HSE TeamHSE Manager
HSE Onshore
Fabrication Coordinator
HSE Offshore Coordinator
HSE Officer
HSE Officer