Plant Lay out

Introduction

Before getting started, I would like to discuss the differences between the Code, the standard, and the recommended practices.

A code is a collection of general principles or systematic norms for design, materials, manufacture, installation, and inspection that has been constructed with the intention of being adopted by a legal jurisdiction and then enacted into law. The ASME B31.1 Power Piping and the ASME B31.3 Process Piping documents are examples of documents that fall within this category.

Documents that are considered to be standard are drafted by a professional group with requirements that are considered to be excellent and proper engineering practice. These documents are also created with the required requirements (that is, the verbs shall be used).

The term "recommend practice" refers to documents compiled by a professional group that indicate acceptable engineering practices. However, these materials are available for use, and the verbs should be utilized. 

Various engineering procedures that are deemed to be good practice are enumerated in guides and guidelines, which are publications that are produced by agencies, organizations, and committees. These documents do not include any specific recommendations or requirements. The engineer has the authority to decide whether or not to use these guides.

Engineers must have the information described above before beginning to work on plant layouts. The terms "shall," "may," "should," and "could" are essential to comprehend in the context of terminology.

Plot plan

Generally speaking, plot plans may be broken down into two primary categories: general plot plans and unit plot plans, which are also referred to as equipment layouts. Plot plans are fundamental designs that are utilized in engineering projects. Various design inputs are utilized in the preparation of these blueprints, which serve a variety of unique objectives. An overview of each category has been provided below, along with the potential design inputs:

Plot plan categories

1. General Plot Plan:

   • Purpose: Provides a comprehensive overview of the entire project site, including the arrangement of buildings, roads, major equipment, and utility systems.
   • Scope: Encompasses the overall layout and spatial relationships of all major elements on the site.

2. Unit Plot Plan (Equipment Layout):

   • Purpose: Focuses on the detailed arrangement of individual units or systems within the larger site.
   • Scope: Includes the precise location and orientation of equipment, piping, instrumentation, and other components within a specific area.

Design Inputs for Plot Plan Preparation

1. ITB/Contract Documents:

   • Client’s standards and related documents that provide specific requirements and guidelines for the project.
   • Ensure compliance with contractual obligations and client preferences.

2. Basic Engineering Design Data:

   • Initial design parameters and criteria that form the foundation of the project.
   • Includes information on process design, capacity, and overall plant configuration.

3. Process Flow Diagram (PFD) and/or Piping & Instrumentation Diagram (P&ID):

   • PFD: Represents the process flow of the plant, showing major equipment and the flow of materials.
   • P&ID: Provides detailed schematics of the piping, instrumentation, and control devices in the plant.
   • Crucial for understanding the process and instrumentation layout.

4. Design Basis for Plant Layout:

   • The document outlines the fundamental design principles, objectives, and constraints for the plant layout.
   • Includes considerations for safety, operability, maintainability, and accessibility.

5. Detailed Engineering Design Data:

   • Comprehensive engineering information is required for the detailed design phase.
   • Covers aspects such as mechanical, electrical, civil, and structural engineering.

6. Utility Flow Diagram:

   • Diagram showing the flow and distribution of utilities (e.g., steam, water, air, electricity) throughout the plant.
   • Essential for planning the utility systems and their integration with process equipment.

Preparation of Plot Plans

The preparation of plot plans involves several steps, often requiring close collaboration between different engineering disciplines:

1. Data Collection:

   • Gather all relevant design inputs, including client standards, engineering data, and diagrams.

2. Initial Layout:

   • Develop a preliminary layout based on the design basis and spatial constraints.
   • Ensure that the layout accommodates process requirements, safety considerations, and future expansions.

3. Review and Iteration:

   • Conduct reviews with stakeholders, including engineers, clients, and regulatory authorities.
   • Iterate the design based on feedback and new information.

4. Finalization:

   • Finalize the plot plan with detailed dimensions, equipment locations, and utility connections.
   • Ensure that all design criteria are met and that the plan is ready for implementation.

And what happens if there is some consistency between the documents? When inconsistencies are found between related documents, prioritizing them helps ensure clarity and consistency in the engineering and construction process. Here is the priority order typically followed:

1. Basic Engineering Design Data (BEDD):

   • This foundational data sets the overall design criteria and parameters, providing the primary guidance for the project. It includes essential information such as process design, operating conditions, and equipment specifications.

2. Detailed Engineering Design Data (DEDD):

   • This data builds on the BEDD and provides more specific and detailed information necessary for the final design and construction phases. It includes detailed schematics, equipment details, and comprehensive engineering calculations.

3. Client’s Standards and Related Documents:

   • These documents outline the specific requirements and guidelines set by the client, including industry standards and any client-specific preferences or regulations.

4. Process Flow Diagram (PFD) and/or Piping and Instrument Diagram (P&ID):

   • These diagrams provide crucial information on the process flow, piping arrangements, and instrumentation details. They are essential for understanding how the process operates and how various components are interconnected.

5. Contractor Individual Project Documents:

   • These documents include the contractor's project-specific plans, drawings, and specifications. They are tailored to the particular project but should align with the higher-priority documents listed above.

Data requirements for Plot plan

Designing a plant layout requires a comprehensive set of data to ensure that all aspects of the project are considered and integrated effectively. Here is a detailed list of the requirement data typically needed for the design of a plant layout:

1. Terrain, Climate, and Related Laws and Regulations:

   • Terrain Information: Topography, soil characteristics, drainage, and site accessibility.
   • Climate Data: Temperature ranges, precipitation, humidity, wind patterns, and seismic activity.
   • Laws and Regulations: Local, regional, and national regulations, zoning laws, environmental regulations, and building codes.

2. Client’s Standards, Regulations, and Requirements:

   • Client’s Standards: Specific standards and guidelines provided by the client.
   • Regulations and Requirements: Compliance with the client’s operational and safety requirements.

3. Safety Requirements:

   • Safety Standards: OSHA regulations, safety codes, and best practices for safe plant operation.
   • Hazard Analysis: Identification of potential hazards and implementation of mitigation measures.

4. Fire Fighting Requirements:

   • Fire Safety Standards: Codes and regulations for fire prevention and control.
   • Fire Fighting Systems: Requirements for fire detection, suppression systems, and emergency response plans.

5. General Plot Plan:

   • Overall Layout: The spatial arrangement of all major components, including buildings, roads, utilities, and green spaces.

6. Equipment Layout of Adjacent Process Units:

   • Adjacent Units: Layouts and data for existing or planned adjacent units to ensure integration and compatibility.

7. Process Requirements:

   • Process Flow: Detailed process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs).
   • Process Conditions: Operating conditions, material balances, and energy balances.

8. Erection and Maintenance Requirements:

   • Construction Requirements: Guidelines for the construction and installation of equipment and structures.
   • Maintenance Access: Provisions for maintenance, including space for equipment access and removal and safety considerations.

9. Operational Requirements:

   • Operational Efficiency: Layout considerations to optimize workflow and efficiency.
   • Accessibility: Ensuring easy access to all areas for operation, monitoring, and control.

10. Economic Requirements:

    • Cost Considerations: Budget constraints and cost-effective design choices.
    • Economic Analysis: Cost-benefit analysis and lifecycle costing.

11. Equipment List:

    • Equipment Inventory: A comprehensive list of all equipment, including specifications, quantities, and locations.
    • Data Sheets: Detailed equipment data sheets with technical specifications and requirements.

By systematically gathering and analyzing this data, engineers can develop a plant layout that meets all technical, safety, regulatory, and economic requirements, ensuring efficient and safe operation. 

What is the plant design engineering?

Introduction

For some companies, the plant design function may be integrated within the piping and layout department, reflecting the interconnected nature of these areas. In certain contexts, plant design is synonymous with 3D Layout, emphasizing the critical role of three-dimensional modeling in modern engineering practices. Consequently, plant design engineering emerges as a specialized discipline focused on multidisciplinary design within a 3D environment, requiring expertise in various engineering domains to ensure cohesive and efficient plant operations.

Plant designers and engineers are responsible for the comprehensive development of 3D models, which serve as the blueprint for the entire plant layout. Their role encompasses integrating various components, such as piping, equipment, structural elements, and electrical systems, into a unified model. This model not only facilitates visualizing the final design but also allows for simulations and analyses to optimize the plant's functionality and safety.

Moreover, plant designers and engineers collaborate closely with other departments, including process engineering, construction, and maintenance, to ensure that the design meets all operational requirements and standards. They use advanced software tools to create detailed and accurate representations of the plant, enabling stakeholders to make informed decisions throughout the project lifecycle. Their expertise ensures that the plant layout is both practical and efficient, ultimately contributing to the successful execution and operation of the facility.

The following are the main activities/tasks of the Plant Design Team:

• Ensure consistent development of 3D models
• Assuring Ergonomic, Safe, Operable, and Maintainable Design
• Ensure the constructability of all components of the project
• Disciplines design input in 3D is in accordance with project requirements
• A customer-oriented approach is applied during the design development
• Maximize the use of clash detection to help minimize site clashes
• Reduce design modifications and avoid rework
• Eliminates field reworks
• Optimize the design to reduce overall project cost
• Maximize the use of drawings, MTO, and reports extracted from 3D models to save time and avoid incoherent design deliverables.
• Meeting Project schedule and milestones
• Meeting required model content for stage reviews
• Ensuring progress of the 3D model
• Review, supervise, and monitor multidiscipline activities during design development. 
• Progress monitoring, reporting the status of model reviews and comment closeouts
• Facilitating 3D model review meetings 

 Function

The plant Design function covers any item, such as

• Plot Plans – layout for the on-plot facilities “Inside Battery  Limits” (ISBL).
• Site Plans – layout for the off-plot facilities “Outside Battery  Limits” (OSBL).
• Plant layout and layout criteria.
• Equipment segregation, separation, and arrangement
• Plant safety, maintenance, and operation.
• Construction issues affecting plant layout.
• Aspects of piping routing and arrangement affecting plant layout.
• Aspects of Electrical and Instruments functions
• Equipment and piping arrangements are interlinked and cannot be considered in isolation.
• Plant layout, however, also includes other issues, such as;
• Plant access – roads, paths, platforms, stairways.
• Drainage.
• Structures, buildings, shelters.
• Constructability and construction facilities.
• Impact on local communities and environment.
• The piping layout must be integrated with the equipment layout to produce the final plant layout.

Summary

Thus, what kinds of skills are required to become a plant design engineer?

Plant Design must be carried out by an Engineer/Designer  with the right skills:

• Must be aware of safety and ergonomic issues.
• Common sense and reasoning.
• Understand the plant design intent.
• Overall understanding of how the plant will operate and be maintained.
• Cost-conscious.
• Good understanding of construction issues.
• Creative, open-minded, multidiscipline background.
• Probing nature, able to question the reliability of information or data and resolve issues.
• Must be able to defend the chosen design but able to compromise while still achieving acceptable results

So, ready to expand your skills and knowledge?

Never ending Studies.

     Setelah sekian lama menunggu untuk melanjutkan sekolah kembali, tiba saatnya untuk bersaing dengan darah muda. Ada perasaan yang campur aduk antara malu dan keinginan untuk belajar lebih. Tapi semangat untuk maju dan pantang menyerah begitu mendarah daging.

    Setelah mencari-cari jenis pendidikan, ragam bidang study, macam-macam universitas dan institute, maka pilihan jatuh ke SIMT-ITS (Sekolah Interdisiplin Manajemen dan Teknologi Institut Teknologi Sepuluh Nopember Surabaya) dengan pilihan bidang studi Energi Terbarukan (renewable energy). Dimana menurut penulis, jenis pendidikan tersebut sangat sesuai dengan latar belakang dan pekerjaan yang dijalani karena bisa PJJ (Pendidikan Jarak Jauh).. Yeeyy..!!. Mau tahu lebih lanjut, silahkan click link disini https://www.its.ac.id/simt/

    Dimulai dengan kegugupan dengan teknologi, yang harus dibiasakan dengan segala sesuatu serba online, dilanjutkan dengan TPA (Tes Potensi Akademik), bahasa Inggris TOEFL yang syarat minimum 477 dan Test kesehatan, dan yang paling penting adalah rencana penelitian? 

    Hmm..apa lagi ini ya? Alhamdulillah saya mempunyai keponakan yang jenius dan bisa saling bertukar pikiran mengenai rencana study master ini. Setelah diskusi maka didapatkan sebuah rencana penelitian yang menurut saya sedang gencar-gencarnya mengenai potensi energi terbarukan di Indonesia ini. 

    Dengan semangat membaja, prepare all and submitted.. All DONE..? Nope

Masih ada interview untuk bisa lolos menjadi mahasiswa baru, kurang lebih ditanya objective nya apa dan mau meneliti mengenai apa dan tentu saja komitmen dengan masalah finansial.

And Whatt... I pass the test. Alhamdulillah keterima menjadi mahasiswa baru ITS setelah 20 tahun meninggalkan dunia perkuliahan. It's been a long time my friend.

But Never Ending studies is my motto 😁

Piping Allowance Philosophy

Why we need allowance 

During EPC Project, many constrain to be considered to complete the project. One of the major item is Materials.

In case piping material which is many piping bulk material are need allowance.

Before go to that part, let me explain that piping have two type materials, piping bulk materials and pipe specialty materials. For both type of material depend on the project philosophy how to manage the allowance.

In general pipe specialty no need allowance except some item such as steam trap, piping bulk material need allowance except some part such as large bore and exotic materials which is already fix the quantity.

Objective of the allowance

Piping allowance objective are to take care such as condition below:

1. Design changes due to unclear design or possibility changes.
2. Waste and scrap
3. Field Design Change 
4. Pre-Commissioning
5. Damages

And many other consideration depend on the situation. Please discuss with Project Manager.

Rules of allowance

During Material Take Off activity, some consideration shall be taken such as :

• Percentage of shall be discussed and agreed with project team. It shall be describe on BMBQ Policy.
• During final MTO, reducing percentage shall be reviewed as necessary.
• If necessary brown field area should be considered higher than green field.
• Hydro test and commissioning MTO shall be added separately.
• Timing to take MTO shall be considered the ROS (Required on site)

BMBQ Policy

Bill of Material and Bill of Quantity Policy is describe in early stage of project as guidance for lead engineer to take action.

In BMBQ policy mention about

• How many time the MTO.
• The timing of MTO.
• The reference for MTO.
• Method of MTO.
• MTO allowance.
• etc.

This BMBQ policy shall be reviewed by Project Manager and Piping Management .

Coaching in Engineering Company

Coaching

Before start explain the coaching in engineering company, we should know the coaching meaning is.

Coaching is all about helping people make positive changes. So the more people coaching touch, the more positive the world can be.
Coaching is partnering with clients to provoke in creative process to inspire them to unreleased their personal potential.

Training, Mentoring, Counseling and Coaching

What is the different those four type above?

In my language :

1. Training is provide knowledge from the trainer to the trainee.

2. Mentoring is to provide insight or inspire normally in life value or wisdom from mentor to mentee.

3. Counseling is to heal or cure the counselor from counselor, 

4. Coaching is to provoke the coachee to find the way by them self.

You can see from number 1 to no 3, all the knowledge or value or cure are give from people who more senior, or more having knowledge to the person.

It's different from coaching, the coachee try to find the way out or solution based on his own with provoke by coach.

Like a soccer games, sometime the coach doesn't  have soccer skill as his player. But the coach have skill to manage to unseals unique potential for each player to win the games.

Coaching in Engineering Company

Same as the image soccer player, in engineering company have many various skill and personnel. The coach task to collaborate and to maximize the everyone potential to get in same directions.

Coaching for Senior Engineer is different when you do coaching session with Designer.

In this level coach shall have special skilled to do coaching session.

In general, coach should have skill such as:

1. Coach shall have good leadership, therefore coach sometime is more higher postion or level than coachee 

2. Make good relationship with client, (in this case is coachee), It is impossible that coachee can explore in front of you his thinking or his idea.

3. Good skill in Listening and Questioning, mean open question or provoke question skill is very important. Don't forget about listening skill, that we can not assume before the coaching session is finished.

4. Facilitate skill for coachee for his thinking, idea and assumption.

5. Make Summary and Action Item to lock the idea or path forward.

6. Don't forget to wish them in good way.

To make different between coaching session and chit-chat talking is the path forward.

Lock the idea and follow up action item.

Off course become coach need time and experience, so never late to start.

Try it..!!

Execution for Piping Engineering

Execution for Piping Engineering

1. Introduction

Piping Engineering is one of discipline in the Engineering and Construction Company, like us we are one of the local private company in Indonesia which already exist since 1973.

Piping discipline is about 30% of the Engineering. People said that the Project will good in execution if the piping have good execution. Therefore I will share my knowledge about this piping execution.

2. Execution of Piping Engineering

Before we start, it is very important that for engineer to understand the job description. Knowing "What" to be define before take next step.

Overall Piping engineering can defied for some category :

1. Internal execution.

2. External execution.

3. Organization execution.

2.1 Internal Execution 

Internal execution normally already defined by Company Rules. Internal Work Break down structure already mention what is the battery limit among discipline.

In case Piping normally prepare such as :

1. Basic Piping Design, such Specification, Plot Plan Drawing, and Standard Drawing.

2. Piping Information, such as Piping Information to others discipline such as piping information to Civil discipline for piping loading data, Piping Information to Mech static for Nozzle Load and orientation. and etc.

3. Detail Piping Design such as prepare for Piping drawing such as Key Plan, Piping Plan drawing and Isometric Drawing.

4. Piping Calculation such as Wall Thickness calculation, stress calculations, AIV/FIV Calculation and etc.

5. Prepare Bill of Material and Bill of Quantity. BOM will deliver to SCM (Procurement) team buy the piping material and BOQ will deliver to Construction team as their basis for Subcontracting.

6. Prepare RFQ (Request for Quotation) and TBE (Technical Bid Evaluation) for piping materials.

7. Review the Vendor Documents.

2.2 External Execution

External execution mean to others discipline or to client. This kinds execution is very unique based on project. Therefore before prepare the external execution please discuss with Principle Engineer or to Piping HOD (Head of Department).

Therefore please prepare "Split of Work with others discipline" to make clear demarcation.

These kinds of sample demarcation to be cleared during project executions:

1. P&ID Mechanism, which area and what the limitation of piping scope, such as line number identifications, break class, insulation break, and P&ID Distribution diagram.

2. Un-pressurized buried pipes, some project sewer pipes is civil scope, and some project is piping scope.

3. Piping inside buildings, such as FW System inside building normally by Civil discipline

4. Piping inside package, it must be cleared for tie in point and battery limits area.

5. Piping Spool generation, current execution this pipe spool generation under construction but always open become engineering scope due to reduce the mistake.

The external execution with Client mean we  shall be working closed together with Client to have reduce miss understanding, faster closing comments, and get approval. 

2.3 Organization Execution

This execution shall be determine by Senior Engineer or Head of Department to select manpower with kinds of considerations:

1. Project scale.

2. Project schedule.

3. Project type.

4. Joint Venture or Joint Body type

5. Client type.

Those kinds consideration Department head select Lead engineer, Senior Engineer as key person to execute the project

Then Lead Engineer prepare Piping Engineering Execution plan to be presented in front of Department Head.

The preparation of Piping Engineering Execution very important to get big picture of the project.

We can know the critical path or action to be considered immediately.

One of the Organization execution is technical Audit during project executions.

Depend on the project type, how many times and what kinds of document to be audit by Piping Managements.

The usage the Company standard to be checked and compare with client standard is one of action in this execution type.

Those three type execution is very basic and general execution in Piping Engineering. Later I will continue for more detail execution.

Persatuan Insinyur Indonesia

Saya mengenal PII (Persatuan Insinyur Indonesia) sejak dari 2015. Dimana saya di minta untuk mendaftar menjadi anggota PII oleh kantor.
Iseng-iseng mencari, apa itu PII. PII atau The Institution of Engineers Indonesia adalah organisasi profesioanl para Insinyur Indonesia dimana berdiri pada tanggal 23 Mei 1952 di Bandung. PII didirikan oleh Ir. Djuanda Kartawidjaja dan Drs. Rooseno Soeryohadikoesoemo
Visi dari Persatuan Insinyur Indonesia (PII)

Visi PII adalah : 

Menjadi pendorong kemandirian bangsa
Sebagai agen perubahan dan pembangunan melalui pengembangan kompetensi profesi keinsinyuran berbasis ilmu pengetahuan dan teknologi.
Misi PII adalah menjadikan insinyur yang berdaya saing dan memberi nilai tambah yang tinggi bagi kesejahteraan dan kemakmuran bangsa

Organisasi PII

PII mempunyai perangkat organisasi sebagai berikut :

Dewan Penasehat
Dewan Insinyur
Pengurus Pusat
Majelis Kehormatan Insinyur
Dewan Pakar
Badan Pengkajian
BK dan atau BKT
Pengurus Wilayah
Pengurus Cabang
Badan Usaha dan Yayasan
Forum Anggota Muda (FAM-PII)
Saat ini Ketua umum dipegang oleh Bpk. Dr.Ir. Hermanto Dardak, M.Sc, IPU dengan mas jabatan dari tahun 2015-2018


Beberapa agenda rutin PII antara lain mempunya kegiatan tetap yaitu Kongres Nasional, Rapimnas, Rapat Anggota Cabang/Wilayah, Konvensi Nasional BK/BKT dan Temu Nasional.
Sedangkan kegiatan rutinnya adalah Kursus Pembinaan Profesi, Diskusi berkala & Pengkajian, Seminar & Workshop, Training kompetensi dan Sertifikasi Profesi.

Badan Kejuruan Teknologi

PII mempunyai 13 (Tiga belas) Badan Kejuruan/Badan Kejuruan Teknologi (BK/BKT), yaitu

Badan Kejuruan Sipil
Badan Kejuruan Elektro
Badan Kejuruan Kimia
Badan Kejuruan Mesin
Badan Kejuruan Fisika
Badan Kejuruan Industri
Badan Kejuruan Geodesi
Badan Kejuruan Lingkungan
Badan Kejuruan Teknologi Pertambangan 
Badan Kejuruan Teknologi Pertanian
Badan Kejuruan Teknologi Kedirgantaraan
Badan Kejuruan Teknologi Kelautan
Badan Kejuruan Teknologi Perminyakan.

Persyaratan Anggota PII

Persyaratannya adalah : 

A. Warga negara indonesia bergelar Insinyur yang telah lulus uji profesi Insinyur (di perguruan tinggi), atau
B. Warga negara indonesia Sarjana Teknik (ST) atau Sarjana Teknik Terapan (STT) yang telah tersertifikasi sebagai Insinyur Profesional (sesuai dengan ketentuan peralihan pasal 52 ayat b UU No. 11 tahun 2014 tentang Keinsinyuran). (untuk mendapatkan sertifikasi Insinyur Profesional (SIP), terlebih dahulu mengikuti Lokakarya Sertifikasi Insinyur Profesional (LSIP)
– Pengalaman dibidang keteknikan lebih dari 5 tahun setelah S1 sarjana teknik
– Pengalaman dibidang keteknikan lebih dari 5 tahun setelah S1 sarjana teknik terapan
C. Mengisi formulir keanggotaan
– Melampirkan FC Ijazah (legalisir) 1lembar
– Melampirkan FC KTP
– Melampirkan photo berwarna ukuran 3×4 2 lembar
– Membayar iuran Pendaftaran Rp. 100.000 dan iuran tahunan Rp. 300.000,- (biasanya disatukan dengan biaya LSIP)
D. Melampirkan CV Dalam Format Bahasa Indonesia file : docx/doc.( Paling lambat 7 hari setelah pelaksanaan LSIP )

Source

Untuk  menjadi anggota PII harus membuat FAIP (Forum Aplikasi Insinyur Profesional), dimana FAIP ini menjelaskan siapa kita dan bagaimana kita sebagai seorang insinyur.
FAIP ini akan di review oleh Majelis Penilai (MP) yang nantinya kita akan di kategorikan sebagai IPP (Insinyur Profesional Pratama), IPM (Insinyur Profesional Madya) and IPU (Insinyur Profesional Utama).

Let's become professional engineer..!!!