Bab 4 Aplikasi pada Pemilik dan Kontraktor • • • • • • •
Pengenalan Proyek Diagram Proses Perancangan Alat Keutuhan fungsi sistim, Keselamatan kerja dan lingkungan Lingkup Tambahan Contoh Kasus
PENGGUNAAN STANDARD PERAN PEMILIK PERANCANG KONSTRUKTOR PEMBUAT BARANG INSPEKTOR
TAHAPAN PEKERJAAN FEASIBILITY STUDY FEED DETAIL DESIGN CONSTRUCTION OPERATION & MAINTENANCE
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
CORPORATE MANAGEMENT
CORPORATE MANAGEMENT
PROJECT MANAGER
QUALITY AND SAFETY MANAGEMENT SYSTEM COMMITTEE
PROJECT SPONSOR/ DIRECTOR
DEPUTY PROJECT MANAGER
PROJECT CONTROL & MONITORING
PROJECT MANAGEMENT OFFICE
PROJECT ADMINISTRATOR
QA MANAGER
CONTRACT & SCOPE MANAGER
PLANNING AND SCHEDULING MANAGER
SHE MANAGER
ENGINEERING MANAGER
PROCUREMENT MANAGER
FIELD MANAGER
COST ADMINISTRATOR
GENERAL METHODOLOGY FLOW CHART
Regulation, Code & Standard
Scope & COMPANY's requirement
Data
Discipline Kick Off Meeting
Objective & Criteria
Design Basis & Preliminary Design Philosophy Option Study (See General Study Methodology Chart)
Specification
Design Philosophy
Design Activities (See Design Methodology Chart)
"Fit for Purpose" Design Check (Operability, Constructability, Maintainability, Interdiscipline, etc)
Cost Estimation
Design Packages
DESIGN METHODOLOGY FLOW CHART
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
RE-DESIGN & RE-ANALYZE COMPANY APPROVAL
OUTPUT - Report - Drawing - Procedure - Boom
DESIGN AND COORDINATION
ENG-04-03 WORK INSTRUCTION FOR SPECIFICATION DEVELOPMENT
No . 1
Initial/Date
Description Engineering Manager
Completed
File in DC
Distributed **
1
Establish Specification Grouping
a
General Specification (Multi discipline)
b
Technical Specification (Discipline)
c
Construction Specification (Discipline)
2
Establish clear assignment what discipline to prepare which specification
3
Establish Specification Interdiscipline Distribution Matrix
4
Reconfirm applicable Company's supplied specification c/w revision number
5
Guide Lead Engineer to incorporate any additional clarification or requirements
stated in bid addendum, minutes etc.
6
Establish specification development priority for long lead equipment
7
Establish format to prepare Addendum on Company's supplied specification
8
Clarify to Experts all the associated project scope, schedule, and project goal.
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 • • • •
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)
• PROCESS & INSTRUMENTATION DIAGRAM • 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 Mixer
Heat Exchanger
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
MECHANICAL SCOPE
• • • • • • • •
ROTATING AND RECIPROCATING MACHINERY MECHANICAL EQUIPMENT AND PACKAGE SYSTEMS VESSEL DESIGN HEAT EXCHANGERS MACHINE DESIGN PIPING DESIGN/STRESS ANALYSIS MECHANICAL ENGINEERING STUDIES MATERIAL ENGINEERING
VESSEL DESIGN 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 Vessel 2. Fractionation Columns, Absorbers, etc. 3. Storage Tanks - Atmospheric and Pressurized 4. Reactors 5. Steam Drums 6. Stacks Usual Design Standards: 1. American Society of Mechanical Engineers (ASME) 2. American Petroleum Institute (API)
HEAT EXCHANGERS
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 exchangers 2. Air - cooled heat exchangers 3. 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)
HASIL PERANCANGAN ALAT • • • • • • • • • • •
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 Disarankan Recommended Practice
Keselamatan Kerja dan Lingkungan • Masa Konstruksi Bekerja di tempat tinggi Bekerja dengan alat alat berat Bekerja di Hazardous Area Bekerja dengan zat berbahaya
• Masa Pemeliharaan Bekerja pada tempat yang tertutup Plant shut down Bekerja ditempat yang mudah terbakar//meledak Melaksanakan Kalibrasi
• Standard OHSA 18001, BS 8800
PENGUNAAN STANDARD • Membutuhkan banyak baca dan menggunakannya untuk : • Satu barang dapat diikat oleh berbagai Standard • Satu barang terangkai dengan alat lain yang bisa menggunakan standard yang lain • Menentukan Standard yang dipakai sampai nomornya, karena • 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 PERSYARATAN CONTROL VALVE
PERSYARATAN LINE SIZE
• API 550 : One size down • Vendor Calculation : 2 or 3 sizes down • ( Vendor : Less Conservative )
• • • •
Velocity limit Pressure drop limit Noise limit Cost considerations
