Learning & Sharing Project Management

in Oil & Gas,Batch # 3

Manajemen Proyek EPCI

Offshore untuk Kontraktor
EPCI
by: Wisnu Wahjusaputra

Komunitas Migas Indonesia (KMI) &

Magister Manajemen Universitas Gajah Mada (MMUGM)
MMUGM Kampus Jakarta, Gedung B
Sabtu, 23 Agustus 2014

Introduction
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 Offshore
2) Melaksanakan
phase
EPCI:
engineering,
procurement,
construction, commissioning and hand-over
3) Memahami Organisasi Proyek EPCI
4) Menerapkan HSE Management System (Sistem Manajemen K3LH)
5) Menerapkan Quality Management System
6) Mengetahui problem solving dalam mengelola proyek EPCI
Offshore
Referensi : PMBOK 5th Edition

Agenda
1. Pengenalan Obyek Kontrak EPCI Offshore
2. Tahapan Pelaksanaan Proyek EPCI
3. Project Management
4. Detailed Engineering
5. Procurement
6. Construction / Onshore Fabrication
7. Offshore Transportation & Installation
8. Pre-commissioning & Commissioning Support
9. Operations Readiness & Assurance
10.Project Control
11.QA/QC (Quality Assurance/Quality Control)
12.HSE (Health, Safety & Environmental)

Chapter-01

PENGENALAN OBYEK KONTRAK

EPCI OFFSHORE

Oil & Gas Exploration & Production

F a s i l i t a s Top s i d e s

Struktur Bangunan Pendukung

Fasilitas Topsides
Fixed Platform

Up to
520 m (1,710 ft)

Compliant Tension Leg

Platform Spar Platform
Tower

370 to 910 m
180 to 1,300 m
(1,210 to 2,990 ft) (590 to 4,270 ft)

Semi-Submersible
Platform

590 to 1,710 m
(1,940 to 5,610 ft)

60 to 3,000 m
(200 to 10,000 ft)

Floating
Fixed
Production Platform
Systems

Fasilitas 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

Chapter-02

TAHAPAN PELAKSANAAN PROYEK EPCI

Tahapan Pelaksanaan Proyek EPCI

Chapter-03

PROJECT MANAGEMENT

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

CLIENT
Project Manager

EPCI
CONTRACTOR
Project
Manager

Engineering
Manager

Construction/
Commissioning Project Control
Fabrication
Manager
Manager
Manager

Procurement
Manager

Offshore
Ops. Assurance
Installation
Manager
Manager

Interface
Manager

Contract &
Subcontract
Manager

HSE
Manager

QA/QC
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

Participants KOM
Project Sponsor
Project Director
Engineering Manager
Procurement Manager
Construction Managers
Installation Manager
QA/QC Manager
HSE Manager
Project Control/Services Manager
Others (Key Personnel)

Chapter-04

DETAILED ENGINEERING

Setup Engineering Team

Topsides
Lead
Engineer

Process
Mechanical
Piping
Electrical

Instrument
Structure
Safety
Drafter

Subsea Lead
Engineer
Pipeline
Umbilical
SPCS

Topsides Engineering
Subcontractor

Subsea Engineering
Subcontractor

Company A
Name
01 Jul 12

Company B
Name
01 Jul 12

T&I Engineer
Naval
Engineer
Offshore
Engineer

T&I Engineering
Subcontractor
Company C
Name
20 Dec 12

SUBCONTRACTOR

Engineering
Admin.

EPCI MAIN CONTRACTOR

Engineering
Manager

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, T ransportation & Installation
Control Engineering Quality
Intern Discipline Check
Engineering Review Process: IFC-IFA-AFC

Memonitor dan melaporkan Engineering Plan vs Actual status

Chapter-05

PROCUREMENT

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

Procurement
Manager
Procureme
nt Admin.

Buyer

Expeditor

Logistics

Contract & Subcontract Team

Contract/Subcont
ract 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

Chapter-06

CONSTRUCTION / ONSHORE
FABRICATION

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

Construction
Manager
Site
Planner

Material
Control

Site
Engineer

Fabrication
Supervisor

Welding
Supervisor

Chapter-07

OFFSHORE TRANSPORTATION &

INSTALLATION

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 Team

Offshore
Installation
Manager
Site Planner &
Scheduler

Topsides
Installation
Superintendent

Subsea
Installation
Superintendent

Field Engineer

Field Engineer

Work Vessel
Superintendent

Diving Vessel
Superintendent

T&I Crew

Diving Crew

Vessel Crew

Vessel Crew

QA/QC
Supervisor

HSE
Supervisor

Chapter-08

PRE-COMMISSIONING &
COMMISSIONING SUPPORT

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 Team
Pre-comm. &
Commissioning
Manager
PIMS
Administrator

Comm.
Mechanical
Engineer

Comm. Piping
Engineer

N2/He Leak
Testing
Subcontractor

Comm.
Electrical
Engineer

Vendors
Representative

Comm.
Instrument
Engineer

Chapter-09

OPERATIONS READINESS & ASSURANCE

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 Team

Operations Assurance
Manager

Operations
Lead Engineer
-

Process
Mechanical
Piping
Subsea Pipeline
E&I
Lifting
Technical Writer

Maintenance
Lead Engineer
-

RBI (Risk Based

Inspection)
RAM (Reliability,
Availability &
Maintainability)
RCM (Reliability
Centered Maintenance)
Asset Registering
CMMS
Technical Writer

Training
Engineer
-

POPM (Plant
Operating
Procedures &
manuals) for
Operator
Technical Writer

Chapter-10

PROJECT CONTROL

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

Overall EPC Project Progress
As of 11 October 2013:
Percentage Progress Against Total
Phase

Weight
Factor

This Period
Forecast
Plan

Actual

To Date
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%

6.20

0.00%

0.38%

0.37%

35.61%

34.79%

-0.82%

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%

2.44

0.00%

0.00%

0.00%

43.04%

0.00%

-43.04%

100.00

2.05%

0.69%

-1.35%

65.06%

55.32%

-9.74%

Fabrication
Construction /
Installation

Precom /
Commissioning
Total

Project Control/Services Team

Project Control/
Services
Manager

Cost
Control

Planner/
Scheduler

Document
Control

IT
Engineers

Project
Administration

Chapter-11

QUALITY ASSURANCE & QUALITY

CONTROL

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 Team
QA/QC Manager
Quality
Engineer

QA/QC Onshore
Fabrication Spv.
QC Inspector
-

Structural Welding
Mechanical
Electrical & Instrument
Coating / Painting

NDT
Technicians
- Ultrasonic
- X-Ray

QA/QC
Offshore Spv.
QC Inspector
-

Structural
Pipeline
Mechanical / Piping
Electrical & Instrument
Coating / Painting

NDT
Technicians
- Ultrasonic
- X-Ray

Chapter-12

HEALTH SAFETY ENVIRONMENTAL (HSE)

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 Team
HSE Manager

HSE Onshore
Fabrication
Coordinator

HSE Officer

HSE Offshore
Coordinator

HSE Officer