CILIANDRA PERKASA

GROUP

Engineering Department
CORPORATE VALUES
Focus on Quality
Integrity
Respect each others
Strive for Excellence
Teamwork

Engineering Department
CILIANDRA PERKASA
PALM OIL
IN RIAU

Engineering Department
Engineering Department
 PKS KAPASITAS Manager
(TPH)
Region 1:
SAM 1 90 Dody
SIR 45 Julianto
ATS 45 Hendra
Region 2:
PSA 90 Darlius
PIS 45 Hakim
CLP 45 Ridwan
Region 3:
MII 45 M Jafar
MSSP 45 Hamdan
KHL (Kaltim) 45 Benson

Engineering Department
ENGINEERING DEPARTMENT
MISSON
SENIOR MANAGEMENT
PRODUCTION CONTROLLER/ GENERAL MANAGER
OPERATION/ PROJECT EXECUTIVES

DEVELOPMENT
ENGINEERING
PROCESSING

CHANGE MANAGEMENT
ATTENTION TO DETAILS
KEY PERFORMANCE
IMPLEMENTATION &

HUMNA RESOURCE
PROJECT

DEVELOPMENT
PEOPLE
INDICATORS
EXECUTION

HUMAN RESOURCES DEPARTMENT

PROCUREMENT DEPARTMENT
FINANCE DEPARTMENT
PROCESSING & ESTATE DEPARTMENT

Engineering Department
 ENGINEERING DEPARTMENT
STRATEGIC MISSION
MISSION SCOPE STRATEGY
PROJECT To Effectively & Efficiently implement &
Mill CAPEX/ New Mill execute project to meet budget, schedule
Effective project management
Construction/ Special Project and quality.
process

PROCESSING To Continuously Improve processing

Continuous Improvement Operating Mills/ facilities standards .

ENGINEERING To provide effective technical supports

Mill CAPEX/ New Mill & technical resource centre.
Attention to Details, Key to better
Construction/ Special Project
operation controls
To continuously source for new
DEVELOPMENT Focused towards better technology and best practice to enhance
Creating Values operation & returns operation to meet changing demands &
expectations from customers.

To continuously improve skills and

Processing engineers/ Head
PEOPLE
office engineers/ Project
Human Resource Development
engineers
competency in handling and managing
technical problems to enhance operation
and engineering efficiencies.

Engineering Department
 ENGINEERING DEPARTMENT ORGANIZATION

ENGINEERING DEPARTMENT

PROCESSING ENGINEERING ADMINISTRATION

SECTION SECTION SECTION

PROJECT
SERVICES &
DESIGN &ENGINEERING EXECUTION/
MAINTENANCE
CONSTRUCTION

FUNCTIONAL

Engineering Department
 ENGINEERING DEPARTMENT ORGANIZATION
ENGINEERING DIRECTOR
(Tan How Joo)
Secretary
(Putri)

PROCESSING SECTION ENGINEERING SECTION ADMINISTRATION

SECTION

SENIOR PRODUCTION ENGINEERING ENGINEERING

CONTROLLER CONTROLLER – ENGINEERING
CONTROLLER- ADMINISTRATIVE
(Kee) DESIGN & CONTROLLER-
CONSTRUCTIO OFFICER
ENGINEERING SERVICES
N (Cahyu)
(Rudy Suseno) (Benny)
(Benhard)

Site
PC
Manager
PC (KALIMANTAN) Discipline Engineer Manager (Saut )
(SUMATRA) (vacant)
(Hoon/Amru) Civil Erica Din
Mech Vacant(1)
Elec Sapta

Engineering Department
PALM OIL MILL PROCESSING
AN OVERVIEW 2
 BUSINESS OBJECTIVES

1. To Process Oil Palm Fruits to extract

Crude Palm Oil and Palm Kernel.
Untuk Mengolah TBS menjadi Minyak Mentah
dan Inti Kelapa Sawit.
2. To Maximize Palm Products Recovery.
Memaksimalkan Pengumpulan Hasil Produksi .
3. To Minimize Palm Products Losses.
Mengurangi kehilangan Hasil Produksi.
4. To Maintain Low Operating Costs.
Mempertahankan Biaya Produksi yang Rendah.
MILL
MANAGEMENT
MANAJEMEN
PKS
What is MANAGEMENT?
Apa kah MANAJEMEN?

Who forms the management?

Siapa yang membentuk manajemen?

What do we wish to manage?

Apa yang kita inginkan dari memanage?

Why manage?
Mengapa memanage?

What role do I play?

Aturan apa yang saya lakukan?
 WHO AM I ?
• What’s my role?
• Whom do I report to?
• Who are my supporters?
• Limits of my authority?
• What do I want to achieve?
• What do I need?
• Where do I position myself?
• Do I know my strength and
weaknesses?
SIAPA SAYA ?
• Apakah tugas saya?
• Kepada siapa saya melapor?
• Siapakah pendukung saya?
• Batasan otoritas saya?
• Apa yang saya ingin capai?
• Apa yang saya perlukan?
• Dimana saya menempatkan
diri saya?
• Apakah saya tahu
kekurangan dan kekuatan
saya?
 PALM OIL MILL PROCESS MODEL
MODEL PENGOLAHAN PABRIK KELAPA SAWIT

QUALITY
RESOURCES
& QUANTITY
PEOPLE
PRODUCT
MATERIALS PROCESS/ AT LOWEST
FINANCE SYSTEM OPERATING
SUMBER DAYA COSTS
ORANG
KWALITAS
BAHAN
& JUMLAH
KEUANGAN
HASIL PADA BIAYA
OPERASI TERENDAH

LOSSES KEHILANGAN
WASTAGES SISA
INEFFICIENCIES TIDAK EFFISIEN
OUTPUT ATAU HARAPAN DARI SEBUAH PKS

• Apa yang ingin kita capai?

• Apa harapan dari kita?
• Apa rencana jangka panjang dan jangka pendek?
• Apakah kita sudah dijalur dari sasaran organisasi?
• Kebutuhan dari pelanggan? Lingkungan Pasar?
• Isu global sekarang ini?
OUTPUT OR EXPECTATIONS FROM A MILL.

• What do we wish to achieve?

• What is expected from us?
• What is the short term and long term plans?
• Are we in line with organizational goals?
• Demands of customers? Market environment?
• Current global issues?
 “WE CAN’T EXPECT TO IMPLEMENT STRATEGY
IF WE CAN’T DESCRIBE IT.
AND, IF WE CAN’T DESCRIBE IT, WE CANNOT
MEASURE IT.”
THE STRATEGY-FOCUSED ORGANIZATION by ROBERT S.KAPLAN & DAVID P.NORTON
(Founder of Balanced Scorecard)

“KITA TIDAK DAPAT MENGHARAPKAN PENERAPAN

STRATEGI
JIKA KITA TIDAK BISA MENJELASKANNYA.
DAN, JIKA KITA TIDAK DAPAT MENJELASKANNYA,
KITA TIDAK DAPAT MENGUKURNYA.”
THE STRATEGY-FOCUSED ORGANIZATION by ROBERT S.KAPLAN & DAVID P.NORTON
(Founder of Balanced Scorecard)
 MILL MANAGER’S ROLE
ATURAN MANAGER PKS

PRODUCTS
RECOVERY
• SUSTAIN OPERATION
• EFFICIENT OPERATION
• PROFITABILITY

PROCESSING
OBJECTIVES
PRODUCTS LOW
QUALITY & LOSSES COSTS

TRACK &
INTERNAL EXTERNAL MANAGE
SUPPORT SUPPORT
• Engineering Dept • Authorities • LABORATORY ANALYSIS
• Logistic/ Finance • Suppliers • BUDGET MONITORING
• Umum • Contractors/ Services • INVENTORY
• Plantation Dept • PROJECT MANAGEMENT
• Legal Dept
•HrD Dept
 DESIRED/ KPI TARGETS
SASARAN YANG
DIINGINKAN

PROCESS
PROSES

TECHNOLOGY BEHAVIOUR
TEKNOLOGI KEBIASAAN

• REENGINEERING • MANAGERIAL SKILLS

• INFORMATION TECHNOLOGY (IT) • KPI
• PARTNERSHIP •ISO QUALITY SYSTEM
• BEST PRACTICE •RSPO SYSTEM
•PERSONAL QUALITIES (A.C.I.D)
RESOURCES ASPEK
OPERATIONAL:
• MATERIALS • LINGKUNGAN HIDUP
• MONEY • PRODUKTIVITAS
• EFISIENSI
• MACHINES
• MUTU
• METHOD • KRISIS
SUMBER DAYA OPERATIONAL
ASPECTS:
• BAHAN • ENVIRONMENTAL
• UANG • PRODUCTIVITY
• MESIN • EFFICIENCY
• METODE • QUALITY
• CRISIS
 SO WHAT ARE THE APA ITU
ACCOUNTABILITIES ACCOUNTABILITIES
OF A DARI
MILL MANAGER? SEORANG MANAGER PKS?
1. ADMINISTRATION 1. ADMINISTRASI
2. PRODUCTION 2. PRODUKSI
3. MAINTENANCE 3. MAINTENANCE
4. COSTS 4. BIAYA
5. PEOPLE 5. ORANG
6. HOUSEKEEPING, 6. KEBERSIHAN,
SECURITY, SAFETY KEAMANAN,
KESELAMATAN
7. QUALITY 7. KWALITAS
 SOME OF THE THINGS A MILL MANAGER ARE
ACCOUNTABLE AND RESPONSIBLE
PRODUCTION Throughput, product stocks, despatches, FFB Throughput, stocks produksi, pengiriman, pengolahan
processed. TBS.

ADMINISTRATION Policies, procedures, legal, overheads, Policies, prosedur, hukum, overheads, budgeting, capital
budgeting, capital budget, asset, procurement. budget, asset, pembelian.

COSTS Expenditures, spare stock holding. Expenditures, nilai stok suku cadang.

PRODUCT Product losses and quality standards, water Produksi, kehilangan dan standar mutu, pengolahan air,
treatment, effluent treatment. pengolahan limbah.
QUALITY &
LOSSES
PERSONNEL Training, appraisal, personal development, SDA. Pelatihan, pengharggan, penegmbangan perorangan,
SDA.

MAINTENANCE Maintenance program, workshop, store. Program perawatan, bengkel, gudang.

SAFETY & Safety at work, SOP, SMK3, environmental Keselamatan Kerja, SOP, SMK3, Isu Lingkungan Hidup
issues, social. dan Sosial.
HEALTH

TARGETS AND EXPECTATIONS ARE REVIEWED FROM TIME TO

TIME.
TARGET DAN HARAPAN DIREVIEW DARI WAKTU KE WAKTU
 PROCESS TARGETS
ITEM %OIL/TBS
EB Stalks 0,51
Fiber 0,57
Nuts 0,06
Final Effluent 0,52
Sludge Centrifuge 12.0 (OLDM)
 PROCESS TARGETS
ITEM % PK/TBS
Fiber 0.11
LTDS 0.01
Claybath 0.05
 PALM OIL MILL
PROCESSING PLANT
Overview 3
 PALM OIL MILL
PROCESSING PLANT
DESIGN ASSUMPTIONS
ASUMSI PERENCANAAN
 PALM OIL MILL
PROCESSING PLANT
DESIGN ASSUMPTIONS
• Constant and Consistent Processing Throughput.
• Good Housekeeping : leakages, spillages, wastages.
• Good Scheduled Maintenance Program.
• Maintaining Good Standard Operating Procedures.

• Kapasitas PKS dan Pengolahan yang Konsisten dan Konstan.

• Lingkungan yang Baik : kebocoran, serpihan, buangan.
• Jadwal Program Perbaikan yang baik.
• Menjaga Prosedur Standar Operasi (SOP) yang baik.
 PALM OIL MILL – PROCESS FLOW
WEIGHBRIDGE

RAMP STORAGE

STERILISING SEPARATION PURIFICATION

THRESHING OIL RECOVERY

DIGESTING/PRESSING SCREENING

DEPERICARPING NUT RECOVERY KERNEL DRYING

STORAGE
 PALM OIL MILL
POWER AND UTILITIES PLANT
BOILER STATION
To generate steam for the steam turbine.
Equipment:
• Boilers.
• Pipings, pumps and valves.
• Boiler water treatment plant.
• Deaerator.
• Feedwater Tank.
• Air compressors.
Control Guidelines:
• Deaerator water temperature to maintain at 105 oC.
• Feedwater temperature to maintain at 100oC.
• Ensure boiler sulphite reserve level maintain at above 40ppm.
• Ensure boiler total dissolved solids maintain < 2500ppm.
• Boiler water treatment plant to backwash and regenerate on a scheduled period.
• Ensure boiler water level maintain at half gauge glass at all times.
STASIUN BOILER
Untuk membangkitkan uap untuk Turbin Uap
Peralatan:
• Boilers.
• Pemipaan, pompa dan katup.
• Pengolahan Air Umpan Boiler.
• Deaerator.
• Tangki Air Umpan.
• Kompresor Udara.
Panduan Pengoperasian:
• Temperatur air Deaerator dijaga pada 105 oC.
• Temperatur Air Umpan dijaga pada 100oC.
• Pastikan kandungan sulphite pada air Boiler dijaga diatas 40ppm.
• Pastikan Total Padatan yang Tidak larut (TDS) pada air Boier dijaga pada
< 2500ppm.
• Pencucian dan regenerasi Pengolahan Air Umpan Boiler sesuai dengan
Periode yang dijadwalkan.
• Pastikan level air pada Drum Boiler pada setengah pada Gelas Penduga.
GOOD BOILER OPERATION
GOOD STEAMING CONTROLS
THERMAL DEAERATOR
POWER STATION
To generate electrical power from the steam turbine and diesel engines.

Equipment:
• Steam turbines and diesel generator sets.
• Back pressure receiver vessel.
• Instrumentations.
• Main switchboard.

Control Guidelines:
• Ensure machinery operating procedures are complied.
• Ensure specified steam pressures are achieved for the steam turbines.
• Ensure instrumentations like pressure gauges, controllers, etc are functioning.
• Ensure steam traps are functioning.
• Ensure engines are maintained periodically.
STASION PEMBANGKIT LISTRIK
Membangkitkan tenaga listrik dari Turbin Uap dan Diesel Genset

Peralatan:
• Turbin Uap dan Diesel Genset.
• Bejana tekan penampung uap (Back pressure receiver vessel).
• Instrumentasi
• Panel Utama.

Panduan Pengoperasian:
• Pastikan prosedur pengoperasian mesin sesuai petunjuk.
• Pastikan tekanan specifik uap memenuhi kebutuhan Turbin Uap.
• Pastikan instrumentasi seperti pressure gauges, controllers, dll dapat berfungsi.
• Pastikan steam traps dapat berfungsi.
• Pastikan engines dirawat sesuai jadwal secara periodik.
RAW WATER TREATMENT STATION
To treat the raw water from the reservoir or from river source.

Equipment:
• Tanks.
• Pumps, pipings and valves.
• Chemical dosages.
• Pressure water filters.

Control Guidelines:
• Ensure treated water after the pressure filter to be < 15ppm.
• Ensure correct chemical dosages for effective flocculation and coagulation
of suspended particles.
• Periodic backwashing of pressure filters.
• Ensure clarification tank operating procedures are complied.
STASION PENGOLAHAN AIR
Untuk mengolah air baku dari waduk atau sungai.

Peralatan:
• Tangki.
• Pompa, pemipaan dan katup.
• Pompa injeksi Bahan Kimia.
• Saringa Air Bertekanan.

Panduan Pengoperasian:
• Pastikan air yang sudah diolah setelah Saringan Bertekan < 15ppm.
• Pastikan dosis bahan kimia yang tepat untuk pembentukan flocculation and
coagulation dari partikel terlarut.
• Periodik pencucian Saringan Bertekanan.
• Pastikan prosedur operasi tangki klarifikasi sesuai petunjuk operasi.
EFFLUENT TREATMENT STATION
To treat the raw effluent or waste water from the factory.

Equipment:
• Pumps, pipings and valves.
• Effluent treatment ponds.
• Fatpit.

Control Guidelines:
• Oil loss in raw effluent 0.45 % to OER.
• Ensure effluent ponds do not overload by periodic feeding.
• Ensure Volatile Free Fatty Acid (VFA) < 500ppm.
• Ensure pH at 7 and alkalinity >3000ppm.
• Desilt the ponds on a periodic basis.
STASION PENGOLAHAN LIMBAH CAIR
Mengolah limbah baku atau air buangan dari PKS.

Peralatan:
• Pompa, pemipaan dan katup.
• Kolam Pengolahan Limbah
• Fatpit.

Panduan Pengoperasian:
• Oil loss pada bahan baku limbah 0.45 % to OER.
• Pastikan Kolam Limbah tidak kelebihan beban dan diumpan secara priodik.
• Pastikan Volatile Free Fatty Acid (VFA) < 500ppm.
• Pastikan pH at 7 and alkalinity >3000ppm.
• Buang lumpur kolam secara periodik
MILL LABORATORY
To analyze processing samples taken from strategic location for
better process controls.
Equipment:
• Laboratory testing equipment and apparatus.
• Oven.
• Extraction unit.
• Chemicals.

Control Guidelines:
• Equipment and apparatus maintain according to operating procedures.
• Ensure laboratory ambient room temperature is maintained.
• Ensure good housekeeping.
• Ensure proper documentations and record keeping.
• Ensure safety and care in managing the laboratory.
LABORATORIUM PKS
Menganalisa contoh bahan proses yang diambil pada lokasi yang
strategis untuk pengawasan proses yang lebih baik
Peralatan:
• Perlengkapan Pengujian Laboratorium dan Aparatus.
• Oven.
• Unit Ekstraksi.
• Bahan Kimia.

Panduan Pengoperasian:
• Perlengkapan dand apparatus dijaga berdasarkan prosedur operasi.
• Pastikan temperatur ruangan laboratorium dijaga.
• Pastikan kebersihan lingkungan yang baik.
• Pastikan peyimpanan dokumnetasi dan catatan yang baik.
• Pastikan pengaturan operasional laboratorium peduli akan keselamatan.
MILL WORKSHOP
To support the mill maintenance program.

Equipment:
• Lathe machine, milling machine, shaping machine, grinding pedestal, power saw.
• Arc and oxy-welding facilities, oxy-cutting facilities.
• Tool boxes for mechanics.
• Special tools store.

Control Guidelines:
• Ensure good workshop practices.
• Ensure safety and good housekeeping.
BENGKEL PKS
Untuk mendukung program perawatan PKS

Peralatan:
• Mesin bubut, mesin milling, mesin scrap, bor duduk, gergaji mesin.
• Arc dan fasilitas las-oxy, fasilitas potong-oxy.
• Kotak peralatan untuk mekanik.
• Penyimpan kunci-kunci khusus.

Panduan Pengoperasian:
• Pastikan pelaksanaan kerja di bengkel dengan baik.
• Pastikan kebersihan lingkungan yang baik dan keselamatan.
MILL INVENTORY STORE
To store machinery spare-parts and consumable items.

Equipment:
• Compartmentalized racks.

Control Guidelines:
• Reconciliation stock checks on selected items on weekly basis.
• Ensure stock according to usage levels.
• Ensure good housekeeping to prevent and avoid wastages.
GUDANG PKS
Untuk menyimpan suku cadang dan bahan consumable .

Peralatan:
• Rak barang.

Panduan Pengoperasian:
• Rekonsiliasi pemeriksaan stok pada item tertentu di setiap minggu.
• Pastikan stok berdasarkan tingkatan penggunaan.
• Pastikan kebersihan lingkungan yang baik tuntuk mencegah limbah.