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 Design

Engineering/ Field Manager QA/QC
Project Engineer Construction
Lead Engineer Inspection
Discipline/ Field Engineer Start Up &
Field Engineer Commisioning
Designer Operation &
Maintanance
 PROJECT ORGANIZATION CHART- OVERALL

CLIENT'S
PROJECT MANAGER

CORPORATE MANAGEMENT CORPORATE MANAGEMENT

QUALITY AND SAFETY PROJECT MANAGER

MANAGEMENT SYSTEM PROJECT SPONSOR/
COMMITTEE DEPUTY DIRECTOR
PROJECT MANAGER

PROJECT MANAGEMENT PROJECT CONTROL &

OFFICE MONITORING

PROJECT CONTRACT & SCOPE

ADMINISTRATOR MANAGER

PLANNING AND
QA MANAGER SHE MANAGER COST ADMINISTRATOR
SCHEDULING MANAGER

ENGINEERING MANAGER PROCUREMENT MANAGER FIELD MANAGER

 GENERAL METHODOLOGY FLOW CHART

Regulation, Code Scope & COMPANY's

& Standard requirement Data

Discipline Kick Off

Meeting

Objective & Criteria

Design Basis &

Preliminary Design
Philosophy

Option Study
Specification (See General Study Methodology Chart)

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 Initial/Date
Description
. Completed File in DC Distributed **

1 Engineering Manager

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 Heat Exchanger

Mixer
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 PERSYARATAN
CONTROL VALVE LINE SIZE

API 550 : One size down Velocity limit

Vendor Calculation : 2 or 3 Pressure drop limit
sizes down Noise limit
( Vendor : Less Cost considerations
Conservative )