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