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

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

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)

PENGENALAN OBYEK KONTRAK EPCI OFFSHORE

Chapter-01

Oil & Gas Exploration & Production

Fas i l i tas Tops ides

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)

Fas i l i t as Subsea

• Pipeline• Flowline• Tie in Spools• Manifold• Umbilical • Subsea

Production Control System (SPCS)

• Riser

Floating Production System

FSRU _ PGN Lampung

Floating Production, Storage, Offloading System (FPSO)

Fasilitas Subsea System

TAHAPAN PELAKSANAAN PROYEK EPCI

Chapter-02

Tahapan Pelaksanaan Proyek EPCI

PROJECT MANAGEMENT

Chapter-03

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

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

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

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)

DETAILED ENGINEERING

Chapter-04

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

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

PROCUREMENT

Chapter-05

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

Setup Procurement Team

ProcurementManager

Buyer Expeditor Logistics

Procurement Admin.

Contract & Subcontract TeamContract/

Subcontract Manager

Contract Supervisor

Subcontract Supervisor

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

Proses Persetujuan Masterlist

Estimated Duration for Masterlist Approval

CONSTRUCTION / ONSHORE FABRICATION

Chapter-06

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

Setup Construction (Onshore Fabrication) Team

ConstructionManager

Material Control

Site Engineer

Fabrication Supervisor

Site Planner

Welding Supervisor

OFFSHORE TRANSPORTATION & INSTALLATION

Chapter-07

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

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

PRE-COMMISSIONING & COMMISSIONING SUPPORT

Chapter-08

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

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

OPERATIONS READINESS & ASSURANCE

Chapter-09

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

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

PROJECT CONTROL

Chapter-10

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

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:

Project Control/Services TeamProject Control/ Services Manager

Cost Control

Planner/Scheduler

Document Control

IT Engineers

Project Administratio

n

QUALITY ASSURANCE & QUALITY CONTROL

Chapter-11

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

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

HEALTH SAFETY ENVIRONMENTAL (HSE)

Chapter-12

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)

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

HSE TeamHSE Manager

HSE Onshore

Fabrication Coordinator

HSE Offshore Coordinator

HSE Officer

HSE Officer