PENERAPAN PROGRAM K3

PADA PROYEK MINYAK DAN GAS BUMI

EPC-1 Banyu Urip Project

Dwi Budi Sulistiyana

Corporate QSHE Manager
PT. Tripatra Engineers and Constructors
Email:budi7774@gmail.com
HP:08111555356
T h e J o u r n e y o f T R I PAT R A ’ s M a n a g e m e n t S y s t e m
Certification

04 May 2010
23 Dec 2013 01 May 2014

11 Sep 1997 08 Oct 2009 16 May 2016

09 Apr 2010 27 Apr 2016 22 Jul 2016

22 Jul 2016 22 Jul 2016

22 Jul 2016

Initial Certification
Latest Renewal
Certification

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TRIPATRA’s Management System Structure

Integrated Management System – PAS 99:2012 bsi Tripatra QMS Structure Project QMS Structure
ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007,
ISO 21500:2012, SMK3 Level I
Level
Quality Manual- Contract, Project SHE
Company Mission, Visions, Policy,
Project Management; Engineering, Procurement, Policies, Objectives Project SHE Objectives
Construction Operation & Maintenance (O&M) for
Energy Infrastructure, Oil & Gas for Onshore &
Level II Level II
Offshore, Petrochemical, Mining, and Power Plant Project Execution Plan, Project
Industry SHE Plan, Project Engineering
Procedures Plan, Project Procurement Plan,
Project Construction Plan

Level III
Level III
Project Work Instructions, Method
Work Instruction
Statements and Specifications
PTK-005/SKKMA0000/2018/S0
TENTANG PENGELOLAAN KESEHATAN,
Level IV Level IV
KESELAMATAN KERJA DAN LINDUNGAN
LINGKUNGAN DI KEGIATAN USAHA HULU Support Documents Project Support Documents

MINYAK DAN GAS BUMI

Company/ Clients Requirements

and Specification
Satutory and Regulatory Req
• Standard
Code

QSHE Department l 2018

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SHE Strategy

Assurance &
Compliance Execution Management Emergency Preparedness
Communications

 Corporate SHE Management  HSE Steering Committee  Emergency Response  HSSE Assurance Audits
System Readiness
 HSE Training incorporating  HSE Communications
 Statutory & regulatory , project and regulatory  Emergency drills and  Workshops and Working
Client & Project requirements. trainings committee’s
requirements  HSE Risk Management,  Review, continues improve  HSE Awards and
 Life Critical Activities & Method Statement and JHA of readiness Recognitions
Consequence Management  Pre-start work & Weekly  Network and Cooperation
 Performance & Reporting toolbox talks with the Authorities
 HSE daily field Inspections
 Incident Management

4 QSHE Department l 2017

 PROJECT LIFE CYCLE IN O & G

PROJECT LIFE CYCLE

FRONT END LOADING

APPRAISE SELECT DEFINE EXECUTE OPERATE

FEASIBILITY CONCEPT
FEED EPC OPERATION
DEVELOPMENT DEVELOPMENT

Cost Estimate Order of Magnitude

Class III Estimate Class II Estimate Class I Estimate
Output Estimate

Task/ PROPOSAL Preliminary Statement Final Statement of

Detail Design Operation
Deliverables REQUIREMENT of Requirement Requirement

Feed Study Decommissioning

Information

For Long Lead Demolish and Re-

Procurement
Instatement
Items
Note:
Class estimation base Fabrication
on AACE International
Recommendation
Construction and Installation
Practice no 18R – 97:
Cost Estimate
Classification System Pre-Commissioning and Commissioning

(AACE : The Association

for The Advancement Hand Over
of Cost Engineering)

Start Up

Re-Vamp
SHE Assurance on Each Phases of Oil
and Gas Project

Final
1 Engineering 2 Procurement 3 Construction 4 Commissioning 5 PSSR 6 Acceptance

 FEED Design Construction Safety  PSSR (Pre Start Up

 Project BOD/SOW Management System Safety Review)

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 Codes/Best (CSMS)  HSE Risk Assessment
Practices/Regulation  Pre Qualification Procedure

Operation
 HMB/PFD/PID  Technical Review  JSA / TRA (Job Safety
 2D Analysis / Task Risk
 Plot Plan Assessment)
 Envid/Hazid/Hazop/  SIMOPS Risk
SIL Mitigation Procedure
 RAM/FERA/QRA  ENVIID Workshop
Effective Design Reviews
 Constructability,
Maintainability and
Operability
 Process HAZOPs/LOPA
 SIL Review
 Electrical Design Reviews
(Electrical HAZOPS)
 Model Reviews
(30%, 60% and 90%)
 Supplier Document Review
 Inter-discipline design
alignment reviews

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EPC -1, Banyu Urip Project Overview &
Challenges
DESCRIPTION:
 Production Processing Facilities
Capacities:
- 185 kbpd oil/ 200 kbpd water
- 124 MCFD gas production
- 75 MCFD gas injection
- 365 kbpd water injection
- 30 Tons/day sulfur recovery
EPC-1 Project Involving :
 - Huge number of personnel (+/- 9,000 man
power)
 Tight schedule, SIMOPS Operation
 Multiple task each day (300-500)
 Huge number of equipment (+/- 146 heavy
equipments & cranes; +/- 165 heavy
vehicles;
 +/- 447 medium equipments)
 32 subcontractors
LOCATION
Kecamatan Ngasem, Bojonegoro, Jawa Timur

CONTRACT AREA:
 301.05 hectares (Process Production
Facilities)
Big challenges for SHE Management
System Implementation

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10 EPC-1 SHE Snapshot

10 EPC-1 SHE Snapshot as per 2015

1. Total Observation and Intervention cards: 767,325, peak 32,000/week
2. Transported all equipment & materials from around the world without a single incident
3. Total man-hours to date: 49 M; Site man-hours: 43 M. Man-hours to go 8.2 M of which 5.2 M direct man hours
4. Had 39 Subcontractors engaged, currently 35 active subcontractors at work
5. Current site manpower 7,211 (direct 5,467), peak 9,000
6. On-boarded (MCU, on-board training, ID batch) 35,684 people
7. Peak direct manpower 7,887 (current 5,467), on boarded since peak 2,285
8. First LTI 7.8 M site man-hours, second LTI 11.8 M man-hours. Now record stands at 23,2 M manhours LTI free
9. Prepared 2 Million meals to date without any food poisoning (14 Local Local and 3 Bojonegoro City food providers)
10. Performed 35,684 Medical Check Ups / on boarding including Pre access Alcohol and Drug test

Incident Pyramid – Overall Project

LTI free MH : 23,295,326

• Completed a year without LTI.

• Last LTI dated 08th May 2014 8
EPC-1 Employment

• Total Labor at EPC-1

Regional
Employment National Local Bojonegoro Local-local Total
(Jatim+Cepu)

Professional 125 48 17 4 194

Skilled 961 656 588 321 2526

Semi-Skilled 458 265 951 631 2305

Non-Skilled 21 41 421 839 1322

TOTAL 1565 1010 1977 1795 6347

Challenges : Local Worker - Change Mindset from Farmer to Construction worker

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Corporate SHE Policy and It’s Derivative
through Project SHE Policy

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EPC -1 Consequence Management

Critical Life Saving Rules

Any violation related to critical life saving rules will be

processed as per consequence management system.

Management of Non Compliance – Flow Diagram

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Incident Management System

Potential Hurt Based Approach Analysis (Mining the Diamond) as of 01st May 2015
• Taproot investigation
Incident happened  analyze  determine incident level (L, XY) • Effective controls monitoring
X : Actual Hurt Level (AHL) from the Tap root findings
Y : Potential Hurt Level (PHL) • Implement procedural changes if
e.g. Near Miss Incident L04 (Actual Hurt Level : 0; Potential Hurt Level : 4 (fatality) required
• Senior management attention for
Diamond event : safety incidents with Actual Hurt Level (AHL) or Potential Hurt Level safety improvements
(PHL) 3 or above

Incident Category Total Diamond Total Incident Percentage

Incident
First Aid Case 1 106 0,9%
Lost Time Incident 1 2 50%
Medical Treatment 3 13 23%
Incident
Motor Vehicle 1 67 1,5%
Incident
Near Miss Incident 8 132 6% Total diamond analyzed during the project : 14 12
Meetings-
Different level for communication

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Hazard Management Process

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Work management-
Permit To Work

• Work managed by placing permit system

• Every activity supervised by Permit holder
• No permit holder- No work
• Brownfield operation  interface with
operation team

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Hazard Management Process :
Pre Shift Safety Meeting (Tool Box Talk)

TBT topics includes

• Learnings from incident
• Safety alerts
• Safety bulletin
• Incident learnings from other projects

Total Toolbox Talk Topic : 147

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Hazard Management Process :
Last Minute Risk Assessment (LMRA)

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Hazard Management Process : EPC-1
Integrated Walkthrough

Monthly steering committee meeting  for sponsor and head office level

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Hazard Management Process : Inspection

 Pre mobilization inspection

 Periodic inspection : quarterly (color code changes)
 Daily inspection : prior to use

Required for any equipment, vehicle, tools, etc under EPC-1 operation

Heavy equipment inspection

Jan - Mar Apr - Jun

Scaffolding inspection
Red tag – unsafe
Jul - Sep Oct - Dec

Green tag –safe 19

Hazard Management Process :
Observation & Intervention (O&I)

As of 24 April 2015 :
757,622 cards collected during the project

Observation & Intervention Card Form

Award for workers

TOP 5 Hazard Category Mar 2015

10000
9267
9000

8000 Observation & Intervention Analysis

7000

6000

5000

4000 3490 3389

2759
3000 2505

2000

1000

0
Workers not using Area with no/not Scattered material on Not used / Not proper Unsafe action by
Award for subcontractor
complete PPE during adequate barricade/Fire work area (unused usage of FBH workers
work activity Blankets/Screen material, garbage)
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Subcontractor Management

Subcontractor management includes :

 Evaluation before contract award

 Kick off meeting
 Monitoring during execution Subcontractor Audit
 Control processes to address safety and
health considerations through effective HSE
management process.

Applicable to all subcontractors supporting the Weekly & Monthly SHE Committee
execution of the WORK. Meeting with Subcontractor
Management : Evaluation of
Subcontractors Weekly & Monthly
Performance

Best Subcontractor of The Month, as per Subcontractor Weekly &

Lunch & Learn, to improve safety skill for subcontractor safety
Monthly Assessment result
personnel
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Health Program

Noise Monitoring Lighting

Measurement

Mask Fit

Food Hygiene

Work Climate Measurement & Heat Stress

Site Clinic, Ambulance, & First Aid Facility
Awareness 22
Environmental Program

Spill Prevention

Chemical Handling Awareness

Dust Control
Waste Management

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SHE Publication

Total Editions as of
Category Publication Names
April 2015
YIPPEE! (banYu urIp Podo sehate, Podo slamEtE) 22
- Site SSHE Bulletin
OVAN (ObserVer teladAN) 49
Safety Bulletin - Observation & Intervention Cards Information
Si Lamat (informaSI keseLAMATan) - Safety Alert 149
DIDAN (pengemuDI telaDAN) 8
- Safety Tips for Dump Truck Drivers during DT Operation
Health Bulletin Si Ketan (informaSI kesehaTAN) 48
Environmental Bulletin Si Lian (informaSI LIngkungAN) 26
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Total : 302 Publications
Engaged Community

Community Activities – Community Activities –

EPC 1 Student Tour –1Q 13 Charity (Community Clinic & Health Support)

 To improve community
relationships especially for
children not to enter the site
area.
 Children were given
information on site
construction developments
and risks involved in these
activities and locations
 10 schools participated

Community Activities –
Construction wood distribution to local villagers
Clean usable wood were donated to local villagers to build
public facilities.

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EPC-1 Initiated Programs & Actions

EPC-1 Poster Competition (LOBSTER – Lomba Poster)

Initiative program to improve subcontractor contribution through site safety communication & also increasing the
number of safety signs at sites

 55 Participants.
 123 posters received.
 Awarded with certificates and gift on 18th Nov 2013.
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EPC-1 Milestone – Celebration

1,000,000 safe working hours

10,000,000 safe working hours

MANTRA (taMAN bermain

tripaTRA

5,000,000 safe working hours

Family Day at Site

15,000,000 safe working hours, got certificate from

Depnaker Bojonegoro
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 Emergency Drill

Emergency drill is conducted at least twice a month.

Fire drill conducted with Dinas Pemadam Kebakaran Bojonegoro

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Tripatra 45 Tahun Membangun Negeri
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