EPC Project by Salman (Sipilpedia Webinar)

 

EP

PROJE T Presented by : M. A. Salman Alfarisi

 

PROFILE Much.. Agus Much Agus Salman Salman Alfaris Alfarisii Education :

 – Bachelor Bachelor : Seb Sebelas elas Mare Marett Unive University rsity ((UNS) UNS) 20 2002022008, Civil Engineering.

Professional Experience : PT.. Wijaya PT Wijaya Karya Karya (P (Perse ersero), ro), Tb Tbk k  – Senior Civil Engineer for Power Plant Project with experience 9 years.  – Head of Civil-Structure-Archite Civil-Structure-Architecture cture Engineering Section for Coal Fired Steam Power Plant Project at Palu Palu Loca Location. tion.

Professional Membership & Certification :  – Cer Certif tified ied SKA Ahl Ahlii Mad Madya ya HAK HAKI. I.

LinkedIn : https://www.linkedin.com/in/magus-salman-al-farisi-69b41743/

 

DEFINISI & JENIS PEKERJAAN adalah h su suat atu u ra rang ngkai kaian an proy proyek ek ya yang ng EPC/C - Engineering Procurement Procurement Construction and Commissioning, adala dimula dim ulaii dar darii kegiat kegiatan an design design (rekaya (rekayasa sa engine engineeri ering, ng, rancang rancang ban bangun gun)) kem kemudi udian an dilan dilanjut jutkan kan den dengan gan pe peng ngad adaa aan n ba bara rang ng da dan/ n/at atau au ja jasa sa,, be berl rlan anju jutt samp sampai ai ta taha hap p ko kons nstr truk uksi si atau atau pela pelaks ksana anaan an dan dan dise disert rtai ai de deng ngan an commissioning commissionin g (seran serangka gkaian ian keg kegiat iatan an pem pemeri eriksa ksaan an dan pen penguj gujian ian).

Jeni Jeniss peke pekerj rjaa aan n EP EPC C  – FEED (Front End Engineering Design)  – EPCC (Engineering Procurement Construction & Commisioning)  – BOT (Built Operation Transfer)

 

WILAYAH KERJA •

Wilayah Wilay ah ker kerja ja EPC be berda rdasar sar pro produ duksi ksinya nya :  – Power generation plant : Coal fired steam power plant (CFSPP), Gas Fired Power plant (GFPP), Gas Engine Power Power Plant (GEPP), Diesel Engien Engiene e Pow Power er Plant (DEPP), etc.  – Oil Plant: Refinery, Gathering station, Terminal, etc  – Gas Plant: LNG/LPG L NG/LPG production, LNG/LPG storage  – Fertilizer: Ammonia, Urea, Gassification  – Petrochemical: Olefin, Polypropheline, etc  – Pipeline: Onshore, Offshore  – Indu Industria striall plant plant lain : Pabrik Pabrik Ke Kertas rtas,, pabrik pabrik prod produksi uksi has hasil il perke perkebuna bunan, n, et etc. c.

•

Wilayah Wilay ah ke kerja rja EPC b berd erdasa asarka rkan n area area kerja kerja :  – Onshore plant (daratan).  – Off Offsh shore ore pla plant nt (le (lepas pas pan pantai tai ata atau u jau jauh h dar darii dar darata atan). n).

 

LINGKUP PEKERJAAN EPC  – Engineering (Portion (Portion 2 % ~ 8 %) • Basic Engineering, Detail Engineering, Commissioning, Operation  – Procurement (Portion ± 70 %) • Buying, Expediting, Traffic  – Construction (Portion ±25 %) • Survey Survey,, Site preparation, permit, Subcon Administ Administration, ration, Installation, T Test, est, Training and

Handover

 

PROYEK EPC Gas Engine Power Plant

Sumbagut-2 Peaker Peaker Power P Plant lant 250 MW (Lhokseumawe, North Sumatera)

 

PROYEK EPC Coal Fired Steam Power Plant

 

PROYEK EPC Coal Fired Steam Power Plant

 

PROYEK EPC Coal Fired Steam Power Plant

 

PROYEK EPC Coal Fired Steam Power Plant

 

PROSES Coal Fired Steam Power Plant

Coal Fired Steam Power Plant

 

PROSES Coal Fired Steam Power Plant

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Jetty & Associates Area : Marine

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Ship Unloader Area : Marine

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Conveyor, Crusher House, Transfer tower. Area : Balance of Plant

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal yard, Coal Fired Steam Power Power Plant

•

Coal Shed & Stacker Reclaimer. Area : Balance of Plant

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Boiler Area : Power Block

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Boiler Structure Area : Power Block

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Steam Turbine Area : Power Block

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Steam Turbine Turbine Building / Main House

Area : Power block

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Electro Static Precipitator & Stack

Area : Power block

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Circulating Water Intake Area : Balance of Plant

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Circulating Water Pump House Area : Balance of Plant

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant •

Tank Farm Area : Balance of Plant

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant Switchyard Area : Balance of Plant •

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant Pipe Rack Structure Area : Balance of Plant •

 

EQUIPMENTS & F FACILIT ACILITIES IES Coal Fired Steam Power Plant Outfall Channel Area : Balance of Plant •

 

EPC PROJECT STRUCTURE ORGANIZATION PROJECT MANAGER SHE DEP. PROJECT MANAGER

ENGINEERING

CONSTRUCTION

PROCUREMENT

COMMERCIAL

PRJ. CONTROL

BUSINESS

CONTRACT

HUMAN

ADMINISTRATION

CAPITAL QA & QC

 

EPC PROJECT STRUCTURE ORGANIZATION

ENGINEERING

PROCESS

UNDERGROUND

MECHANICAL

STRUCTURAL

PIPING & LAYOUT

CIVIL

GEOTECHNICAL

ELECTRICAL

MARINE & OFFSHORE

INSTRUMENT & CONTROL

ARCHITECTURAL

 

PROPOSA PROP OSAL L ST STAGE AGE Kick-Off 

ITB Document 1. Scope Of Work 2. Proposal & EPC Schedule 3. ITB Review Check list 4. WBS

Review ITB Document

Conceptual Design Verification 1. Specificatio on n 2. Data Sheet 3. Calculation & Drawing 4. Bulk Material BoQ 5. Project Execution Plan 6. Construction Method

Engineering Document (Issued For Proposal)

A

1. Technical Technical Questio Questionnaries nnaries 2. Conceptual Verification Report 3. Inter discipline check List 4. Innovation Idea check list 5.Asumption Asumption Base Base 6. Deviation List

 

PROPOSA PROP OSAL L ST STAGE AGE (cont’d)

A 1. Risk Register 2. EPC Schedule 3. EPC Draft Contract 4. Organization Chart 5. Resource Loading 6. Other documents

Non Engineerin Engineering g Document (Issued For Proposal) SUBMIT TECHNICAL DOCUMENT TO CLIENT

COMMERCIAL DOCUMENTS

SUBMIT COMMERCIAL DOCUMENT TO CLIENT

YES

CHECK 1 (CLIENT)

CHECK 2 (CLIENT) YES WINNER ANNOUNCEMENT

NO

FAILED (1 stage technical) st

NO

FAILED (2 stage commercial) nd

 

EXECUTION STAGE WINNER ANNOUNCEMENT

1. Di Disc scus usss tech techni nica call list. 2. deviation Di Disc scus usss com comme merc rcia iall issues.

Contract Document issued to EPC contractor

Kick-off 

1. Soil investigation 2. Topography Topography surv survey ey

Contract Discussion Agreement

Contract Signed

Site Investigation

Engineering Execution Plan

3. Bathymetri and hydro oceanography oceanography 4. Bathymetriand Climate Survey/Data

1. Template Doc. & Numbering 2. Basic Communication (Approval Document Docu mentFlow Flow)) 3. Engineering Deliverable List 4. EPC EngSchedule Eng Schedule / Milestone 5. Engineering Structure Organization chart

1. Cont Contrract act Sign Signed ed.. 2. La Land nd Hand Hand-o -ove verr. 3. Fina Financ ncia iall Cl Clos osed ed..

Effective Date

B

 

EXECUTION STAGE (cont’d)

B

Detail Engineering Design

1. Design Basis 2. Data Sheet & Specification 3. Calculatio on n 4. Simulation / Study 5. Drawing 7. BQMTO 8. General Document 9. Construction And Commissioning Commission ing Method

Produce Engineering Documents

1. As built document. 2. QA/QC document. 3. Checklist.

IFA/IFI To Client

Final Document (AFC)

Backfeeding

First firing

1. Power House. 2. Transformer (Generator Transfomer, Unit Auxiliary Transformerr d Transforme dan an Neutral GroundingResistor). 3. Pump (Boiler Feed Pump, Circulating Water Pump, Condense Pump, etc). 4. Fire fighting system. High speed diesel in aux. boiler 

Synchronize  Aux  Au x. Ele ect ctricity Pow Power 

Execution

Finish Construction Stage

COD (Commercial on Date) TOC (Taking Over Contract)

Hand over

 

BASIC ENGINEERING DESIGN  – Project Description • Process description. • Mechanical equipment description. • Piping description. • Electrical description. • Instrument and control description. • Civil, Structure and Architecture description.

 

BASIC ENGINEERING DESIGN  – Basic Design Design Calcalut Calcalution ion shee sheett

• HMB, Water Bala lan nce, Flow Rate Calc lcu ulation of Duct, Flue, Coal Bunker Size, Thick ickness of Main Pipi iping, Capacity of Boiler Feed Pump, Capac aciity of Condensate Pump, Main Stea eam m Pipe Stress Anal An alys ysis is,, Ca Calc lcul ulat atio ion n of Ci Circ rcul ulat atin ing g Wat ater er Sys yste tem, m, Shor Shortt Circ Circui uitt Ca Calcu lcula lati tion on,, Ca Calc lcul ulat atio ion n of Fly Fly Ash Ash Silo Silo,, Ca Calc lcul ulat atio ion n of Bo Bottto tom m As Ash h Si Silo lo,, Ca Calc lcul ulat atio ion n of Lime Limesstone tone Silo Silo,, Ca Calc lcul ulat atio ion n of Coa oall Co Con nveyo veyorr, Calcul Calc ulat atio ion n of Cl Clea earr wat ater er Pond, ond, Ca Calc lcul ulat atio ion n of Fres Fresh h Water ater Tan ank, k, Ca Calc lcul ulat atio ion n of Fire Fire Pr Prev even enti tion on System.  – Basic Design Drawing

• Equipment data sheet. Equipment Layout.

• • Basic design drawing civil structure and architectur architecture e facilities. • Plant layout.

 

Plant Layout A. Power Block Area. B. Balance of Plant (BOP) Area. C. Miscellanous

D

B

Building Area. D. Marine Area.

C

B A B

B B

 

DETAIL DET AIL ENGINEERI ENGINEERING NG DESIGN INTERDICIPLINE

SOURCE : HERVE BARON, The oil and gas Engineering Guide

 

DETAIL DET AIL ENGINEERI ENGINEERING NG DESIGN INTERDICIPLINE

SOURCE : HERVE BARON, The oil and gas Engineering Guide

 

CIVIL ORGANIZATION STEEL STRUCTURE SECTION

CIVIL SECTION

MARINE & OFFSHORE SECTION

UNDERGROUND SECTION

ARCHITECTURE SECTION

1

Equipment Structure (Boiler Structure, etc)

1

Soil Investigation

1

Bathymetri and Oceanography Survey

1

Topography Survey

1

Architectural Building

2

Steel Structure Building (Shelter, Storage, Warehouse)

2

Soil A An nalysis

2

Marine St Structure (J (Jetty, W Wh harf, G Grroin,

2

Site D De evelopment/Grading P Pllan

2

Control B Bu uilding

3

Steel Pipe Rack, Pipe Bridge

a So Soil Improvement

Break Water, etc)

3

Sewer System

3

Substation

3

Offshore Structure (Single Mooring,

aS Sttorm Dirty Water

4

Plumbing

Bouy Structure, etc)

b Chemical Water

5

Elevator

c Oily Water

6

E Esskalator

7

H VA VA C

4

Stack and Stack Support

b S So oil Bearing Capacity

5

Conveyor Structure

c P Piile Bearing Capacity

6

Elevator Structure El

d Slope Stability

7 O perating Platform

3

8

Steel Tower

4

9

Steel Bridge

5

Vibrating Equipment Foundation (Turbine, Gas Engine, Pump, etc) Static Equipment Foundation (Tank, etc) Vertical & Hor izontal Vessel Foundation

4

Ro ad ad (R ig igi d/ d/ F Fll e exxi bl ble P a av ve me men t) t)

5

Paving

6

Culvert

10 Steel Pipe Stanchion

6

Concrete Pipe Rack, Pipe Bridge

7

Cable Trench

Miscellaneous Steel Structure

7

Concrete Building Co

8

Duct Bank Du

8

Chimney Structure Cooling Tower Intake Structure

9

Sleeper and Trust Block

10 Rip Rap & Gabi Gabion on

11

9

10 Co C oncrete Bridge

11 Un U nderground Composite

11 Earth Structure

12 Pit & Pond

a Retaining Wall b Earth Earth Di Dike ke c Sheet Sheet Pile Pile

13 Co Cooling Tower Basin