EPC SPAM - Detailed Design

LEMBAGA PELATIHAN KOMPETENSI – TEKNIK DAN MANAJEMEN INDUSTRI
(LPK –TMI)
ADVANCED ENGINEERING, PROCUREMENT & CONSTRUCTION (EPC)

SISTEM PENYEDIAAN AIR MINUM (SPAM)
Online Workshop
25, 27 – 28 May 2021
DETAILED ENGINEERING DESIGN (DED)
BKTI-PII - BKSTI - ISTMI

Advanced EPC Sistem Penyediaan Air Minum (SPAM)
Instructor / Facilitator:
Ir. Daru Wiyono, IPU
Received bachelor degree in Chemical Engineering from Engineering Faculty, Gadjah Mada University (UGM). He has
a professional and practice experiences as Senior Process Engineer / Senior Resident Engineer / Engineering
Manager / Commissioning Coordinator more than 35 years in both National and Multinational Company specially Oil
& Gas Onshore , Offshore Industries and Water Treatment Plant (WTP). He works at various engineering company
and operating oil company in Indonesia and overseas: PETRONAS Carigali, PT. ELNUSA, PT. PETROSEA Tbk, CNOOC
(China National Offshore Oil Corporation) SES Ltd, Ranhill Worley Parson Sdn. Bhd., Malaysia, PT. Enerkon, PT
Synergy Engineering and PT. Kelsri. Implementing both International and National best practice of safety.
Email : daru.wiyono@gmail.com
HP : 08121399761
Online Workshop Agenda

1. Feasibilty Study / Identify & Appraise / Identify & Assess Opportunity
2. Conceptual Design / Pre - Front End Engineering Design (Pre-FEED) / Select & Otimize
/ Generate & Select Alternative.
3. Basic Design / Engineering Design / Front End Engineering Design (FEED) / Develop
Preferred Alternative / Define
4. Detailed Engineering Design (DED)
5. Procurement
6. Construction / Installation
7. Engineering, Procurement & Construction (EPC) / Engineering, Procurement,
Construction & Installation (EPCI) / Engineering, Procurement, Construction &
Commissioning (EPCC).
8. Start Up & Commissioning and Performance Test
9. Operation / Operate & Evaluate.
AGENDA
Day 1
1. Introduction to ” Sistem Penyediaan Air Minum (SPAM)”
2. Feasibilty Study
3. Feasibilty Study – SPAM Case Study
4. Conceptual Design
Day 2
5. Front End Engineering Design (FEED)
6. Front End Engineering Design (FEED) – SPAM Case Study
7. Detailed Engineering Design (DED)
8. Procurement
Day 3
9. Construction
10. Engineering, Procurement & Construction (EPC)
11. Start Up & Commissioning and Performance Test
12. Operation
Day 1 : 25 May 2021 Day 3 : 28 May 2021

1. Pembukaan 1. Sesi 1 : Construction
2. Sesi 1 : Introduction to “Sistem Penyediaan Air Minum” 2. Break Pagi
3. Break Pagi 3. Sesi 2 : Engineering, Procurement & Construction (EPC)
4. Sesi 2 : Feasibilty Study 4. Ishoma
5. Ishoma 5. Sesi 3 : Start Up & Commissioning and Performance Test
6. Sesi 3 : Feasibilty Study – SPAM Case Study 6. Break Sore
7. Sesi 4 : Operation
7. Break Sore
8. End Day 3
8. Sesi 4 : Conceptual Design
9. End Day 1
Day 2 : 27 May 2021

1. Sesi 1 : Front End Engineering Design (FEED)
2. Break Pagi
3. Sesi 2 : Front End Engineering Design (FEED) – SPAM Case Study
4. Ishoma
5. Sesi 3 : Detailed Engineering Design
6. Break Sore
7. Sesi 4 : Procurement
8. End Day 2
Project Phase – From Feasibility Study to Start Up & Commissioning

CASE 3 - MINIMUM FACILITIES ON NEW
Feasibility Study
MIGAS
REMOTE PLATFORM
(CASE 10 FOR WIRELINE ONLY OPTION)
DRILL TYPE WELL LOCATION FACILITIES LOC'N OIL EXPORT GAS EXPORT
Jack-up cantilever MLA - 'shark alley' MLA MLA MLA
Jack-up skidded MLA - existing TRA - bridge linked WTN WTN
Platform rig TRA - bridge linked TRA - remote SNA SNA
TRA - remote WTN
REINJECTION INJECTION
GAS WELLS
GAS
SEPARATOR
NEW
SLUGCATCHER
PROD
WELLS
WEST TUNA
INSTALLATION BARGE REQUIRED
Conceptual Design
TURRUM
PLATFORM
DSV FOR TRUSS INSTALLATION
Power Cable
Fuel Gas?
Glycol
Flowline (insulated)
POTENTIAL WAX PROBLEM

BOTTOM TOW PIPELINE BUNDLE
INSTALLATION
Front End Engineering Design (FEED)
Engineering, Procurement & Constuction (EPC)
Start Up & Commissioning

Project Phase – From Feasibility Study to Start Up & Commissioning

CASE 3 - MINIMUM FACILITIES ON NEW
Feasibility Study
PUPR
REMOTE PLATFORM
(CASE 10 FOR WIRELINE ONLY OPTION)
DRILL TYPE WELL LOCATION FACILITIES LOC'N OIL EXPORT GAS EXPORT
Jack-up cantilever MLA - 'shark alley' MLA MLA MLA
Jack-up skidded MLA - existing TRA - bridge linked WTN WTN
Platform rig TRA - bridge linked TRA - remote SNA SNA
TRA - remote WTN
REINJECTION INJECTION
GAS WELLS
GAS
SEPARATOR
NEW
SLUGCATCHER
PROD
WELLS
WEST TUNA
INSTALLATION BARGE REQUIRED
Conceptual Design
TURRUM
PLATFORM
DSV FOR TRUSS INSTALLATION
Power Cable
Fuel Gas?
Glycol
Flowline (insulated)
POTENTIAL WAX PROBLEM

BOTTOM TOW PIPELINE BUNDLE
INSTALLATION
Basic Design
Design & Build
Start Up & Commissioning

Source : The Oil & Gas Enginering Guide, Herve Baron

DETAILED ENGINEERING DESIGN (FEED) -TABLE OF CONTENT
1. Contoh Detailed Engineering Design

2. Process Flow Diagram (PFD)
3. Piping & Instrument Diagram (P&ID)
RENCANA KEGIATAN
RENCANA TEKNIS TERINCI (DED)
SISTEM TRANSMISI DAN UNIT DISTRIBUSI
Sumber : https://bpsdm.pu.go.id
RENCANA TEKNIS TERINCI (DED)

SISTEM PENYEDIAAN AIR MINUM
SISTEM TRANSMISI DISTRIBUSI

PERSIAPAN DAN PENGUMPULAN ANALISA DAN

PENGUMPULAN RENCANA
DATA PRIMER EVALUASI DATA TEKNIS TERINCI
DATA SEKUNDER
Pengumpulan Data Survey Wilayah Studi  Kompilasi Data  Laporan Rencana

Sekunder : Dan SPAM Eksisting Sekunder Dan Primer Teknis Terinci Unit
Transmisi Dan Unit
Peta Dasar, Topografi, Survey Topografi  Kebutuhan Sistem
Distribusi
morfologi, tata guna
Penyelidikan Tanah  Perpipaan Transmisi
lahan, foto udara atau  Memo Design
citra satelit Survey Sumber Daya  Reservoir Distribusi
 Gambar Teknis
Energi
Data Kependudukan  Perpipaan Distribusi
 RAB Dan BOQ
Dan Sosial Ekonomi Survey Ketersediaan
 Kebutuhan Pompa
Bahan Konstruksi Dan  Spesifikasi Teknis
Kondisi SPAM
Mekanikal Elektrikal  Zona Dan Blok
Eksisting Termasuk
Pelayanan
Data Pemakaian Air Survey Harga Satuan
Pelanggan
Studi – Studi Terkait
Dan Peraturan Yang
Belaku KRITERIA Sumber : https://bpsdm.pu.go.id
PERENCANAAN
Persiapan Peralatan
SISTEM PENYEDIAAN AIR MINUM

PERPIPAAN
TRANSMISI
TRANSMISI
AIR MINUM
AIR BAKU
AIR BAKU
PELAYANAN
IPA R
DISTRIBUSI
UNIT UNIT UNIT DISTRIBUSI UNIT PELAYANAN

AIR BAKU PRODUKSI
SPAM REGIONAL
CATATAN :
 PADA SPAM REGIONAL ADA TAMBAHAN RESERVOIR OFF TAKE.
 PADA SPAM REGIONAL UNIT DISTRIBUSI DAN UNIT PELAYANAN SPAM PERKOTAAN, MERUPAKAN SATU UNIT
PELAYANAN
UNIT DISTRIBUSI UNIT PELAYANAN
SEBAGAI CONTOH : GAMBAR SKEMATIK SPAM REGIONAL DUROLIS DI BAWAH INI.
SISTEM TRANSMISI DAN UNIT DISTRIBUSI
 Sistem transmisi meliputi sistem perpipaan transmisi air baku dan dan
sistem perpipaan transmisi air minum
 Sistem transmisi air baku berfungsi mengalirkan air dari sumber air ke Unit
Produksi/IPA atau mengalirkan air minum ke reservoir distribusi bila kualitas
air sudah memenuhi persyaratan kualitas air minum.
 Sistem transmisi air minum berfungsi mengalirkan air dari reservoir
produksi ke reservoir distribusi
 Unit distribusi air berfungsi mengalirkan air minum terkirim secara merata
(Kualitas, Kuantitas, Kontinuitas dan Tekanan) dari reservoir distribusi ke
seluruh wilayah pelayanan
GAMBAR TYPICAL
JEMBATAN PIPA
PERLETAKAN PERLENGKAPAN PERPIPAAN (i)

Perletakan perlengkapan Sistem Pengaliran Secara Gravitasi

penunjang yang penting
dalam jalur perpipaan
transmisi dan distribusi :
 Katup / Valve
 Katup Udara (Air Valve)
 Katup Penguras (Wash
Out / Blow Off)
PERLETAKAN PERLENGKAPAN PERPIPAAN (ii)

Katup / Valve :
Katup berfungsi untuk membuka dan menutup aliran air dalam pipa, dipasang pada :
 Lokasi ujung pipa tempat aliran air masuk atau aliran air keluar;
 Setiap percabangan;
 Pipa outlet pompa;
 Pipa penguras atau wash out
Tipe katup yang dapat dipakai pada jaringan pipa distribusi adalah Katup Gerbang (Gate Valve)
dan Katup kupu-kupu (Butterly Valve).
Katup Udara (Air Valve) :

Dipasang pada titik tertinggi di sepanjang pipa distribusi, di jembatan
pipa dan pada jalur lurus setiap jarak tertentu.
Katup Penguras (Wash Out / Blow Off)

Dipasang pada tempat-tempat yang relatif rendah sepanjang jalur
pipa, ujung jalur pipa yang mendatar dan menurun dan titik awal jembatan.
CONTOH TYPICAL PEMASANGAN GATE/BUTTERFLY VALVE
CONTOH TYPICAL PEMASANGAN AIR VALVE

PIPA TRANSMISI KRITERIA DESIGN PERPIPAAN TRANSMISI

 Hal yang perlu diperhatikan dalam perhitungan perpipaan adalah kaitan antara
kekuatan pipa dengan tekanan pada pada pipa.
 v (kecepatan dalam pipa)
 PVC antara 0.3 – 4.5 meter/detik; HDPE antara 0,3 – 3 meter/detik
 Steel dan DCIP antara 0,3 – 6 meter/detik
(disarankan kecepatan antara 0,3 – 1 meter/detik)
 Tekanan pada pipa antara 10 – 60 meter, pada sistem perpompaan. Sehingga
beban energi tidak terlalu tinggi, tidak memerlukan pipa dengan bahan yang lebih
tebal yang akan mengurangi kapasitas aliran dengan nominal diameter yang sama
 Untuk sistem gravitasi diperlukan BPT (Bak Pelepas Tekan) bila tekanan > 70
meter untuk pipa PVC dan HDPE atau disesuaikan dengan spesifikasi teknis pipa.
Sedangkan untuk pipa Steel dan DCIP diperlukan BPT bila tekanan > 100 meter.
 Perhitungan dimensi pipa transmisi menggunakan QMD :
Qmd= Fmd X Qrata2 Qmd = Qmax day = Qmaksimum harian
 Fmd = ( 1.1 – 1.3 ) ; Fmd = Faktor Max Day = Faktor Maksimum Harian
DEBIT YANG DIGUNAKAN DALAM PERHITUNGAN PIPA
PIPA DISTRIBUSI
PELAYANAN
R
Qjpuncak
Qmd
AIR BAKU
PIPA TRANSMISI
PIPA DISTRIBUSI
AIR BAKU
PELAYANAN
IPA R
Qmd
Qjpuncak
Reservoir Beton Reservoir Menara
Reservoir Tangki
Faktor penentu dalam membuat perencanaan secara keseluruhan

termasuk Unit Transmisi Dan Distribusi adalah Mengetahui
KEBUTUHAN AIR
Apa yang dimaksud dengan Kebutuhan air ?
Kunci untuk penyediaan air adalah mengerti tentang :
 Kebutuhan Pelanggan dan Calon Pelanggan

 Kebutuhan Sistem (Air Baku - Produksi - Transmisi -
Distribusi)
KEBUTUHAN AIR
KEBUTUHAN PELANGGAN / KONSUMEN
Jumlah Penduduk Yang akan dilayani
Pola Pemakaian Air Yang Terkait Taraf Hidup (Kesejahteraan)
Domestik (non-niaga) : Kebutuhan Perkapita x Jumlah Penduduk
Non-Domestik : tergantung jenis pelanggan (niaga, industri, institusi pendidikan,
perkantoran, dll.
Fasilitas Umum : terutama untuk menyiram taman kota dan Hidran Pemadam Kebakaran
PROYEKSI KEBUTUHAN AIR
 Pertumbuhan Penduduk
 Perubahan Pola Pemakaian Air
 Jumlah Air Terjual
 Jumlah Air Didistribusikan
 Jumlah Air Diproduksi
 Jumlah Air Baku
Detail Engineering Design – Project Scope of Work
• Review Company supply Specification

• Update and generate specification (if required)
• Project Design Basis (review and updated)
• Calculations
• Study, Report, Procedure, Schedule and index
• Data Sheet
• Deliverable List
• Design Detailed Drawings
• MTO (Material Take Off)
• RFQ (Request For Quotation)
• TBE
• Vendor Document Review (VDR)
• Update document’s based on the Vendor drawing up to AFC
• As Built
• 3D PDMS Modelling
DISCIPLINE ENGINEERING
PROCESS ENGINEERING
PROCESS SAFETY ENGINEERING
MECHANICAL ENGINEERING
PIPING ENGINEERING
INSTRUMENTATION & CONTROL ENGINEERING
ELECTRICAL ENGINEERING
CIVIL/STRUCTURAL ENGINEERING
PIPELINE
1. CONTOH DETAILED ENGINEERING DESIGN

ONSHORE RECEIVING FACILITY (ORF)
BUKIT TUA DEVELOPMENT PROJECT - ORF
ONSHORE RECEIVING FACILITIES (ORF)
OIL & GAS COMPANY : PC

Outline
1.0 Facility Overview
2.0 Facility Layout
3.0 Ground Improvement
4.0 Process Description
4.1 Main Process
4.2 Utilities

N
Ketapang PSC
Java Sea
Bukit Tua
Facilities
Field JS 2-1 JS 3-1
Garit-1
Payang-1
Bukit Tua-3A
Jenggolo-1 Bukit Tua-4

Bukit Tua-1
Bukit Tua-2
JS 8-1
Bukit Panjang-1
Perawan-1
JS 19-1
JS44A-1
~ 30 km to land
ik ~30km to Madura
es
Gr
to Madura
East
East ~9
0k
m Madura
Gresik
Java
Java
Surabaya
20
20km
km




3.0 Ground Improvement

Currently the land at ORF site is not in ideal condition for construction, hence
a land improvement work is required prior installation of all equipments and
building.
- The ground improvement methods is using pre-fabricated vertical drain.
- Considering the land condition, all civil foundation for equipments and
building will be piled.
- Major structural work is at building works, other structural are for access
platform and pipe sleeper.
- Excavation work will be performed for open drain pond, pit of closed drain
vessel, and fire water pond.

A. Main Process Equipment: B. Utilities:
• Pig Receiver • Fuel Gas Package (include
• Inlet Separator Instrument Gas Receiver)
• Gas Custody Metering • Oily Water Treatment System
System • Flare System
• Liquid Burner System
• Diesel System
• Power System (PLN as main
source & EDG)
• Fresh Water System
• Fire Water System

PIG RECEIVER
• Pig Receiver is provided for pigging activity from WHP to ORF in

order to maintain pipeline integrity.
• Pig receiver and related piping system is designed for intelligent
pigging
• Size & Rating
- Major Barrel : 16”
- Minor Barrel : 12”
• Complete with pig signaller, quick opening closure, and interlock
system.
PIG RECEIVER
44
INLET SEPARATOR
Description Requirement
Type Horizontal, 2 Phase
Size (mm) 2850 (ID) x 7200 (T/T)
Design Pressure (barg)/(psig) 46.5 (674.3)
Design Temperature (°C) max./min. 65 / -45
Operating Pressure (barg)/(psig) 38.5 (558) / 24.5 (355)
Operating Temperature (°C) max./min. 23 - 14
Material LTCS + 3mm CA + internal lining (epoxy) at bottom of

vessel
INLET SEPARATOR
46
GAS METERING SYSTEM
Type Ultrasonic
Size (mm) 10”, redundant meter run
Design Pressure (barg)/(psig) 46.5 (674.3)
Operating Pressure (barg)/(psig) 38.5 (558) / 24.5 (355)
Operating Temperature (°C) max./min. 22.8 – 13.2
Capacity (MMscfd) 77
Material LTCS + 3mm CA

FUEL GAS PACKAGE

Fuel Gas Scrubber Fuel Gas Filter Separator Fuel Gas Superheater Instrument Gas Receiver
Equipment
(V-6060) (S-6060A/B) (E-6060) (V-6070)
Size (mm) 1800 (ID) x 4500 (T/T) 273 (OD) x 2845 (S/S) - 1950 (ID) x 4900 (T/T)
Design 14 (203) 14 (203) 14 (203) 14 (203)

Pressure
(barg)/(psig)
Design 65 / -15 65 / -15 100 / -15 65 / 0
Temperature
(°C) max./min.
Operating 10.38 (151) 9.7 (141) 9 (131) 9 (131)
Pressure
(barg)/(psig)
Operating 2.8 – 3.8 2.3 – 3.3 2.3 – 3.3 / 52 (IN/OUT) 52
Temperature
(°C) max./min.
Material LTCS + 3mm CA LTCS + 3mm CA LTCS + 3mm CA CS + 3mm CA
Internal: SS316L Sheath: Incoloy 800
CLOSED DRAIN/FLARE KO DRUM
Type Horizontal Vessel, below ground level installation
Size (mm) 3000 (ID) x 7500 (T/T)
Design Pressure (barg)/(psig) 12 (174) / FV
Operating Pressure (barg)/(psig) 0.1 – 6.45
Operating Temperature (°C) max./min. AMB
Material LTCS + 3 mm CA + internal lining (epoxy) at bottom of

vessel
CLOSED DRAIN/
FLARE KO DRUM
OPEN DRAIN SYSTEM

OILY WATER TREATMENT

Type Corrugated Plate Interceptor (CPI) Tank
Design Pressure (barg)/(psig) ATM + Full of water
Design Temperature (°C) max./min. 65 / 18
Operating Pressure (barg)/(psig) ATM
Operating Temperature (°C) max./min. AMB
Capacity (m3/hr) 11
Oil in water spec at inlet (mg/l) 1000 (normal operation)
Max oil in water spec at inlet (mg/l) 3000 (process upset)
Oil in water spec at outlet (mg/l) 15
Pumps 2x100% recovered oil pumps

2x100% treated water pumps
OILY WATER TREATMENT

FLARE SYSTEM
Type of Flare Sonic
Capacity (MMscfd) 133
Seal Velocity
Size of Tip 12”

Material of Tip Inconel 625
Flare Stack Height 32 m, free standing
Number of Pilot 2 ea
Flame Detection Thermocouple
Ignition System High Energy

FLARE SYSTEM
LIQUID BURNER SYSTEM
Size of Tip 3”
Capacity (MMscfd) Gas: 602 kg/hr; Liquid: 5998 kg/hr
Inlet Pressure (barg) 7.8
Atomizing Gas Flowrate (scfm) 625
Atomizing Gas Supply Pressure (barg) 9.31
Burner Orientation Horizontal
Burner Nozzle Height (mm) 1219 (above grade)
Shield Height (mm) 4ooo
Shield Material Zincalume G550 (Hi-Ten)
Flame Detection Thermocouple
Ignition System High Energy

LIQUID BURNER SYSTEM

FRESH WATER SYSTEM

DIESEL SYSTEM
EMERGENCY DIESEL GENERATOR

FIREWATER SYSTEM

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LEMBAGA PELATIHAN KOMPETENSI – TEKNIK DAN MANAJEMEN INDUSTRI

ADVANCED ENGINEERING, PROCUREMENT & CONSTRUCTION (EPC)

DETAILED ENGINEERING DESIGN (DED)

BKTI-PII - BKSTI - ISTMI

Online Workshop Agenda

Day 1 : 25 May 2021 Day 3 : 28 May 2021

Day 2 : 27 May 2021

Project Phase – From Feasibility Study to Start Up & Commissioning

POTENTIAL WAX PROBLEM

Front End Engineering Design (FEED)

Engineering, Procurement & Constuction (EPC)

Start Up & Commissioning

Project Phase – From Feasibility Study to Start Up & Commissioning

POTENTIAL WAX PROBLEM

Design & Build

Start Up & Commissioning

Source : The Oil & Gas Enginering Guide, Herve Baron

DETAILED ENGINEERING DESIGN (FEED) -TABLE OF CONTENT

1. Contoh Detailed Engineering Design

RENCANA TEKNIS TERINCI (DED)

SISTEM TRANSMISI DISTRIBUSI

PERSIAPAN DAN PENGUMPULAN ANALISA DAN

Pengumpulan Data Survey Wilayah Studi  Kompilasi Data  Laporan Rencana

SISTEM PENYEDIAAN AIR MINUM

UNIT UNIT UNIT DISTRIBUSI UNIT PELAYANAN

SISTEM TRANSMISI DAN UNIT DISTRIBUSI

PERLETAKAN PERLENGKAPAN PERPIPAAN (i)

Perletakan perlengkapan Sistem Pengaliran Secara Gravitasi

PERLETAKAN PERLENGKAPAN PERPIPAAN (ii)

Katup Udara (Air Valve) :

Katup Penguras (Wash Out / Blow Off)

CONTOH TYPICAL PEMASANGAN AIR VALVE

PIPA TRANSMISI KRITERIA DESIGN PERPIPAAN TRANSMISI

Reservoir Beton Reservoir Menara

Faktor penentu dalam membuat perencanaan secara keseluruhan

Apa yang dimaksud dengan Kebutuhan air ?

Kunci untuk penyediaan air adalah mengerti tentang :

 Kebutuhan Pelanggan dan Calon Pelanggan

Detail Engineering Design – Project Scope of Work

• Review Company supply Specification

1. CONTOH DETAILED ENGINEERING DESIGN

BUKIT TUA DEVELOPMENT PROJECT - ORF

ONSHORE RECEIVING FACILITIES (ORF)

OIL & GAS COMPANY : PC

2.0 Facility Layout

3.0 Ground Improvement

4.0 Process Description

4.1 Main Process

1.0 Facility Overview

Jenggolo-1 Bukit Tua-4

1.0 Facility Overview

1.0 Facility Overview

1.0 Facility Overview

1.0 Facility Overview

3.0 Ground Improvement

4.0 Process Description

4.0 Process Description