Bab 4Aplikasi

pada Pemilik dan Kontraktor• Pengenalan Proyek• Diagram Proses• Perancangan Alat• Keutuhan fungsi sistim,• Keselamatan kerja dan lingkungan • Lingkup Tambahan• Contoh Kasus

FEASIBILITY STUDY

FEED

DETAIL DESIGN

CONSTRUCTION

OPERATION &

MAINTENANCE

PEMILIKPERANCANG

PEMBUAT BARANG

KONSTRUKTOR

TAHAPAN PEKERJAAN

PERAN

PENGGUNAAN STANDARD

INSPEKTOR

PROJECT POSITIONS & FUNCTIONS

• Project Manager• Engineering/ Field Manager• Project Engineer• Lead Engineer• Discipline/ Field Engineer• Field Engineer• Designer

• Design• QA/QC• Construction• Inspection• Start Up &

Commisioning• Operation &

Maintanance

PROJECT ORGANIZATION CHART- OVERALL

CLIENT'S PROJECT MANAGER

PROJECT MANAGER

DEPUTY PROJECT MANAGER

PROJECT SPONSOR/ DIRECTOR

PROJECT CONTROL & MONITORING

QUALITY AND SAFETY MANAGEMENT SYSTEM

COMMITTEE

PROJECT ADMINISTRATOR

CONTRACT & SCOPE MANAGER

PROJECT MANAGEMENT OFFICE

PLANNING AND SCHEDULING MANAGERSHE MANAGER COST ADMINISTRATORQA MANAGER

ENGINEERING MANAGER PROCUREMENT MANAGER FIELD MANAGER

CORPORATE MANAGEMENTCORPORATE MANAGEMENT

GENERAL METHODOLOGY FLOW CHART

Design Packages

Regulation, Code& Standard

Scope & COMPANY'srequirement Data

Discipline Kick OffMeeting

Objective & Criteria

Design Basis &Preliminary Design

Philosophy

Specification

Design Philosophy

Design Activities(See Design Methodology Chart)

"Fit for Purpose" Design Check(Operability, Constructability, Maintainability, Interdiscipline, etc)

Cost Estimation

Option Study(See General Study Methodology Chart)

DESIGN METHODOLOGY FLOW CHART

DESIGN AND COORDINATION

DATA & INFORMATION

- Design Basis- Survey Data- Study Report- Inter-discipline Data & Requirement

MODELING & DESIGN

ANALYZE

- Strength Capability- Constructability- Operability/Serviceability- Maintainability- Life Cycle Cost

INTER-DISCIPLINE/

INTEROFFICE

CHECK

COMPANY APPROVAL

RE-DESIGN &

RE-ANALYZE

OUTPUT- Report- Drawing- Procedure- Boom

       

   Clarify to Experts all the associated project scope, schedule, and project goal.8 

   Establish format to prepare Addendum on Company's supplied specification7 

   Establish specification development priority for long lead equipment6 

   stated in bid addendum, minutes etc.  

   Guide Lead Engineer to incorporate any additional clarification or requirements5 

   Reconfirm applicable Company's supplied specification c/w revision number4 

   Establish Specification Interdiscipline Distribution Matrix3 

   Establish clear assignment what discipline to prepare which specification2 

   Construction Specification (Discipline)c  

   Technical Specification (Discipline)b  

   General Specification (Multi discipline)a  

   Establish Specification Grouping1 

   Engineering Manager1

Distributed **File in DCCompleted

Initial/DateDescriptionNo

.

WORK INSTRUCTION FOR SPECIFICATION DEVELOPMENT

ENG-04-03

LANGKAH PELAKSANAAN• Baca Lingkup Kerja pada Kontrak• Basic Philosophy dan Design criteria• Kenalilah PFD dan PID lingkup kerja• Kenali sifat materi yang diproses• Kumpulkan Design Specification, Common Practice Pemilik• Kumpulkan data lingkup kerja lainnya• Kumpulkan Standard & Code yang terkait• Baca Peraturan Lembaga Pemerintah yang berlaku• Perhatikan pola cuaca, gempa dan sifat alam lainnya yang terkait• Kenali peta dan tataletak peralatan dalam lokasi kerja• Kumpulkan Data Vendor, teknis, dokumen dan pengadaanya• Lakukan perancangan alat dan sistim beserta perhitungannya • Pemilihan jenis, kapasitas dan materialnya• Perhatikan keterkaitannya pada Disiplin lainnya• Kumpulkan Gambar Vendor dan Gambar instalasinya • Perhatikan penanganan material (beracun, pekat dlsb) dan keadaan tidak

normal pada saat instalasi maupun oprasi• Perhatikan faktor biaya, operability dan constructability dari rancangan• Siapkan bill of Material dan jalankan proses pembeliannya• Buat prosedure kalibrasi, start up & pengoprasiannya

DIAGRAM PROSES• PROCESS FLOW DIAGRAM

• PROCESS & INSTRUMENTATION DIAGRAM

• Peralatan utama dan fungsinya dalam proses• Pipa penghubung utama beserta komposisi aliran dan besaran fisisnya• Tabel material balance• Merupakan diagram yang disederhanakan (Tanpa Utility dan detail Instrumentasi)

• Diagram peralatan lebih rinci, termasuk unit pelengkapnya dengan penjelasan spesifikasinya• Setiap peralatan lengkap dengan setiap pipa pemasok dan pipa produknya, disertai nomor pipanya• Dilengkapi dengan berbagai keterangan lainnya seperti tag number, set point, pressure rating dlsb• Loop utama kontrol proces lengkap dengan jenis instrumen maupun aktuatornya

DIAGRAM PROSES

Scrubber Pump 1 Separator Pump 2 Heat Exchanger

Mixer

Kebutuhan Perancangan• Bejana tempat terjadinya reaksi• Pipa proces ataupun utilitasnya• Pengaduk, motor beserta kontrolnya• Indikator dan kontrol process• Pompa dan Pertukaran Panas• Struktur penyangga Peralatan• Pengecatan• Isolasi

PARAMETER PERANCANGAN• Design Philosophy• Design Basis• Design Criteria

• Regulations• Codes• Standard• Recommended Practice• Guidelines

• Company Specification• Company Standard Practice• Company Guide

• Project Specification• Contractor Specification

Standard Alat

• Standard Instrumentasi Industri• Standar Keamanan : Intrinsically

Safe, Explosion Proof• Standard Kelistrikan : UL• Standard Mekanikal/Piping

• ROTATING AND RECIPROCATING MACHINERY• MECHANICAL EQUIPMENT AND PACKAGE SYSTEMS• VESSEL DESIGN• HEAT EXCHANGERS• MACHINE DESIGN• PIPING DESIGN/STRESS ANALYSIS• MECHANICAL ENGINEERING STUDIES• MATERIAL ENGINEERING

MECHANICAL SCOPEMECHANICAL SCOPE

Work scope:1. Furnish complete design and drafting of code pressure vessels. API tanks, stacks, and like

equipment.2. Check vendor supplied drawings and calculations.3. Maintain design trend and fabrication method awareness.4. Recommend alternate constructions or design conditions.5. Select or evaluate construction materials.6. Erectability and fabricability studies / evaluations.7. Analyses of vendor supplied extras.

Equipment Fields:1. Pressure Vessel2. Fractionation Columns, Absorbers, etc.3. Storage Tanks - Atmospheric and Pressurized4. Reactors5. Steam Drums6. Stacks

Usual Design Standards:1. American Society of Mechanical Engineers (ASME)2. American Petroleum Institute (API)

VESSEL DESIGNVESSEL DESIGN

Work Scope:1. Provide planning, mechanical design, cost estimating, heat exchanger rating and checking as

required for heat transfer equipment.2. Determine materials, requirements, and fabrication methods for heat transfer equipment.

Type Equipment:1. Shell and tube heat exchangers2. Air - cooled heat exchangers3. Double pipe heat exchangers

Usual Design Standards:1. American Society of Mechanical Engineers (ASME)2. Tubular Exchanger manufacturers Association (TEMA)3. Heat Exchanger Institute (HEI)4. American Petroleum Institute (API)

HEAT EXCHANGERSHEAT EXCHANGERS

HASIL PERANCANGANALAT

• Line list dari pipa• Equipment List• Tagging• Instrument Index• Data Sheet• Hook up Drawings• Cause & Effect Diagram• Control Diagram• Annunciator• Cable schedule• Termination Diagram

CONTOH DATA SHEET

Keutuhan fungsi sistim

• Pemilihan alat• Optimalisasi Proses : Monitoring,

Kontrol• Keamanan Proses : Pressure Relief,

Shut Down • Pengoprasian : Operatibility,

Maintainability

Cara yang DisarankanRecommended Practice

Keselamatan Kerja dan Lingkungan

• Masa Konstruksi

• Masa Pemeliharaan

• Standard OHSA 18001, BS 8800

Bekerja di tempat tinggiBekerja dengan alat alat beratBekerja di Hazardous AreaBekerja dengan zat berbahaya

Bekerja pada tempat yang tertutupPlant shut downBekerja ditempat yang mudah terbakar//meledakMelaksanakan Kalibrasi

PENGUNAAN STANDARD

• Membutuhkan banyak baca dan menggunakannya untuk :

• Menentukan Standard yang dipakai sampai nomornya, karena

• Satu barang dapat diikat oleh berbagai Standard• Satu barang terangkai dengan alat lain yang bisa

menggunakan standard yang lain

• Dapat mengenal berbagai Badan Standard yang diperlukan

• Dapat mengenal struktur Standard dari berbagai Badan Standard

LINGKUP TAMBAHAN

• PUBLIC ADDRESS• TELECOMMUNICATION• SEA AND AIR BEACON• FIRE WATER• INSTRUMENT AIR• HYDRAULIC POWER• ELECTRICAL POWER• CONTROL CENTER• SAFETY DEVICES

Brosur Chromatograph

Biaya konstruksi dan oprasi

• Rencana kerja : Urutan Kerja, schedule kerja

• Perlengkapan Kerja untuk instalasi dan pemeliharaan

• Reparasi dan kalibrasi

KASUS 1

• API 550 : 1 Scfm requirement / instrument

• Vendor Catalog requirements are : Function of type and size

• Client Standard• Project Requirement

Kasus 2

PERSYARATANCONTROL VALVE

• API 550 : One size down• Vendor Calculation : 2 or 3

sizes down• ( Vendor : Less

Conservative )

PERSYARATANLINE SIZE

• Velocity limit• Pressure drop limit• Noise limit• Cost considerations