Cost Historical

SKSM 40/80 TPH

(16STP2010)
PT Cahaya Unggul Prima

30 November 2020
QSCE Sub Division
Revision : 08
 Cost Estimation

Project Close
phase Feasibility Development Execution
out

Level of Concept design Basic engineering Detail engineering Close out

Detail - Feasibility study - Scheduling development activities
Activities - Procurement strategy Procurement
- Risk & Opportunity
Construction
+20%
Commissioning
+10%

+ accuracy +3% +1%

Cost
Estimates - accuracy -3% -1%
-10%

-15%
Feasibility Project Data Book Rancangan Anggaran Proyek Forecast At Completion
(PDB) (RAP) (FAC)

Level of
Estimates Level 5-4 Level 4-3 Level 2 Level 1

Methodology Parameter : Semi detail : Detail costs :

- System Concept - Soil test - Material take off / Bill of Quantity
- Capacity (/TPH) - Civil
- Area (/m2) - Mechanical, electrical, piping
- Length (/m) - Others
2
Historical
Sungai Kapuas Mill 40/80 TPH

IC PDB FAC
Description
2017 2019 2020
Total Installed Cost Rp. 196,261 Mio Rp. 299,472 Mio Rp 319,235 Mio
Based on Budget 2017 Level 3 Estimate Level 1 Estimate
Level 4 Estimate Accuracy -3.3% / 3.4% Accuracy -1% / 1%
Contingency Risk Analysis Rp. 10,690 Mio Include VO – Jul ’20
Currency 1 USD : IDR 13,000 Currency 1 USD : Rp 13,500 Currency 1 USD : Rp 14,500

Phase Design Basic Design Basic Design For Construction

Conventional (Capstan) Compact Indexer Compact Indexer
Standar Control Full Automation Full Automation
Building Structure PBBI 1984 Building Structure PBBI 1984 Building Structure SNI 2013

Risk Potential • Kondisi Baseline • Perubahan dan design allowance • Drawing revisi setelah Feb ’20
• Tidak ada komponen biaya • Kondisi tanah (below ground) • Site variation works setelah Jul ’20
contingency yang dianggarkan • Varian harga tender tidak termasuk
dalam Contingensi

Overrun Rp. 103,211 Mio Rp 19,762 Mio

Variant 52.6% to IC 6.6 % to PDB
47.1% without Contingency 10.5% without Contingency

Note : IC (Investment Committee ) PDB (Project Data Book) FAC (Forecast At Completion) 3
 Summary Cost
Sungai Kapuas Mill 40/80 TPH
Total Earth Works CSA MEP Automation Owner Cost1 Prop Item Contingency
Different Weight
(Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio)
FAC – RAP 14,498 1 73% (196) 3,996 15,009 (967) - (3,343) -
RAP – PDB 5,265 2 27% - 13,365 2,966 (2,038) 533 1,129 (10,690)
FAC – PDB 19,762 3 16% (196) 17,361 17,974 (3,005) 533 (2,215) (10,690)
PDB – IC 103,211 4 84% 10,542 24,465 3,624 17,268 1,647 34,973 10,690
Note : 1) incl. Housing
1 IDR 14,498 Mio ▲ FAC
3 ▲ IDR 19,762 Mio
30-Jul-20
6.6% Overrun
2 IDR 5,265 Mio ▲ 1. Bidding Price 14.9 Bio 319,235 Mio
RAP
2. Commodity 4.0 Bio - Design IFC
1. Structure Building & Platform 3.9 Bio 30-Jul-20 Material - VO
PDB
2. Structure Platform 3.8 Bio 304,737 Mio 3. Earthworks -0.2 Bio - Rate Contract
4 IDR 103,211 Mio ▲ 29-Jan-19 3. Road, Macadam & Drainage 3.6 Bio - Design IFC 4. Automation -1.0 Bio - Contingency
52.5% Variant 299,472 Mio 4. Pile Cap Foundation 3.3 Bio - VO 5. Proprietary Item -3.3 Bio exclude
- Basic Design 5. Panel, Cable, Air Conditioner 3.2 Bio - Rate Owner - Level 1 Estimate
- Rate Owner 6. Office & Ancillary 1.5 Bio incl. OH+Profit
incl. OH&Profit 7. Proprietary Item 1.1 Bio - Contingency Agreed Price
1. Proprietary Item 34.9 Bio - Contingency 8. Potential VO 0.7 Bio exclude
IC 9. Automation -2.0 Bio
(incl. Indexer) 10,690 Mio - Level 2 Estimate
01-Dec-17 2. CSA (Steel Structure 24.4 Bio - Level 3 Estimate 10. Piping -4.0 Bio
196,261 Mio & Preliminaries) 11. Contingency -10.7 Bio
Conventional 3. Automation 17.2 Bio
- Capstan 4. Piling & HDPE Liner 10.5 Bio
- Standard Control 5. Contingency 10.6 Bio Different Level Detail of Design
- Standard Boiler 6. Piping 5.6 Bio
- MPB without
OH-Crane Different System to be
- Baseline Compact Indexer, Automation,
- Level 4 Estimate Boiler Moving Grate,
MPB with OH-Crane
2017 2019 2020
Note : IC (Investment Committee ) -PDB (Project Data Book - RAP (Rancangan Anggaran Proyek - FAC (Forecast At Completion)
4
Terima Kasih
Sungai Kapuas Mill 40/80 TPH
 System Comparison
IC vs Actual [PDB – FAC]
IC Actual
- Building Area 6,580 m2 - Building Area reduce to 5,754 m2
Capstan Compact - 24 unit Cages 10 Ton
- 40 unit Cages 10 Ton
with Indexer
- 4 Transfer Carriage 2 x 10T - 4 Transfer Carriage 2 x 10T, 1 Tippler 2 x 10T
Long Railtrack with Weighing
- 1 Tippler 1x10T Hopper - Reduce significant numbers of indexer hydraulic
- Long Railtrack power pack, hydraulic cylinder, and rail track

- Make Up Steam - Labor Shortage

- Autoflushing Sludge Centrifuge - Worker Safety & Health
Standard - Productivity : streamlined and speedier completion
Control Automation - Quality : consistency and closer tolerance
Instrument - Data Collection : real-time & accurate decision

- Fix Grate Boiler with manual ash removal - Moving Grate Boiler (Reciprocating Grate)
- 3 Operator and 3 Fireman per shift with ash removal conveyor
- Inconsistent operation condition due to Boiler Boiler - Integrated with Bin System for Zero Wheel
high frequency of open/close furnace door Fix Grate Moving Grate Loader Operation
- Higher maintenance on brick furnace - 2 Operator per shift

Wheel Loader for TBS handling, ash removal and maintenance support - TBS handling by Bin System + Tipping Platform
(Diesel fuel consumption for operational) - Automatic ash removal integrated with
Moving Grate Boiler + Bin System
+ Lower CAPEX Operational Zero Wheel - Maintenance Support by overhead crane
- Very High OPEX Wheel Loader Loader - Surplus Fiber stored in Moving Floor/ Fuel
Retrieval System
+ Low OPEX
- Higher CAPEX 6
 SUMMARY COST
Sungai Kapuas Mill 40/80 TPH
IC Meeting PDB FAC
Budget 2017 Jan ‘19 July ‘20
196,261 Mio 299,472 Mio 319,235 Mio
Based on Budget 2017 Level 3 Estimate Class 1 Estimate
u/ SKSM 40-80 TPH Accuracy -3.3% +3.4% Accuracy -1% / 1%
Contingency 10.69 Mio Include VO – Jul ’20

17,975 -3,005 -2,215 533 -10,690

17,361 Pengurangan - Steam Boiler - L300 to Hilux
10,690 -196 - Structure
scope CCTV - Digester & Press - Add 2 Motor
future dan - Compact Indexer
34,973 - 363 3,125 VO upah
- Grading platform accessoies - Crane Grapple tidak
- Loading Ramp - Fiber Conv. no2
pancang Line-2 dibangun- Excess Conv .no2 dilakukan pembelian
- TD Service
sesuai aktual - EBA diperlebar - MCC Fixed to Withdrawable
- Import Duty HR for
- Pipe Rack
17,268 - 1,115 Automation
- Ancillary
- AC Split to Centralized
- Unit Price variance
3,624 Rumah G2 - Compact Indexer - VO Macadam
24,465 IC :50 Unit, - Overhead Crane - Unit rate :
PDB :35 unit - SSBC Pengecoran,
Estimasi Piping
10,542 u/ 80 TPH - Claybath Vib. screen hebel, grating,
dan baja Fixed
- Boiler Moving Grate
- MPB support OH Crane Fixed 223,697
- Pilling 204,657
- Geomembrane

Fixed Fixed Fixed Fixed

Fixed Fixed
Fixed 316,441331,411329,196328,663
288,781 299,276299,080
Fixed
172,631

Variable Variable
69,175 69,364

Variable Other Other

15,587 25,641 26,173
8,043
IC Meeting Earth CSA MEP Automation Housing Prop Items Capex Owner Contingency PDB Earth CSA MEP Automation Prop Items Capex Contingency FAC
Budget 2017 Works Cost Jan '19 Works 2020

7
 IC vs PDB
Sungai Kapuas Mill 40/80 TPH
Work Breakdown Structure
Sungai Kapuas Mill 40/80 TPH
IC PDB
Selisih Weight
Description 2017 Jan ’20 Remarks
(IDR Mio) (%)
(IDR Mio) (IDR Mio)
Earth Works 24,878 35,420 10,542 7.1% Kondisi tanah : piling, geomembrane
MPB PDB support Overhead Crane & New Design
CSA Works 44,119 68,584 24,465 21.3%
Code
MEP Works 75,187 78,811 3,624 2.4% Piping PDB untuk Mill 80 TPH
Automation 393 17,661 17,268 35.6% Standard control vs Full Automation
Housing 15,950 14,835 (1,115) 6.3% Rumah G2, IC : 50 unit, PDB : 35 unit
Compact Indexer, Boiler Moving Grate, OH-Crane,
Prop Items 27,692 62,665 34,973 0.2%
Claybath Vib. Screen.
Capex 5,849 5,486 (363) 10.1%
Owner Cost 2,194 5,319 3,125 17.0% TD Service, Import Duty, HR for Full Automation
Contingency - 10,690 10,690

Grand Total Cost 196,261 299,472 103,210 100%

10
 PDB vs FAC
Sungai Kapuas Mill 40/80 TPH
 Works Breakdown Structure (WBS)
Sungai Kapuas Mill 40/80 TPH
Pengajuan PTA berdasar setiap cost PDB RAP FAC RAP - PDB FAC - RAP FAC - PDB
WBS Item
element (WBS) : (a) (b) (c) (b - a) (c - b) (c - a)

1. CSA Works : 17,361 Earth Works 35,420 35,420 35,224 - (196) (196)
- Unit rate : CSA Works 68,584 81,950 85,945 13,366 3,995 17,361
(pengecoran, hebel,
grating, baja) MEPI Works 78,811 81,777 96,786 2,966 15,009 17,974
- Loading Ramp
Line-2 dibangun Automation 17,661 15,623 14,656 (2,038) (967) (3,005)
- EBA diperlebar
- Pipe Rack Housing 14,835 14,835 14,835 - - -
- Kontrak CSA
- VO Macadam Prop Items 62,665 63,794 60,450 1,129 (3,344) (2,215)
- Kontrak Ancillary
Operational Capital 5,486 6,019 6,019 533 - 533
2. MEPI Works : 17,974
- Stucture/platform Owner Cost 5,319 5,319 5,319 - - -
- Grading platform
- Fiber Conv. no2 Contingency 10,690 - - (10,690) - (10,690)
- Excess Conv .no2
- MCC Fixed to
Withdrawable Grand Total Cost 299,472 304,737 319,235 5,265 14,498 19,762
- AC Split to Centralized
- Unit Price variance 2 1 3
Note :
3. Ops. Capital : 533 - PDB : Project Data Book
Vehicle upgrade - FAC : Forecast At Completion
L-300 to Hilux - RAP : Rancangan Anggaran Proyek
- CSA : Civil, Structure, Architech
Total (Rp Mio) 35,868 - MEPI : Mechanical, Electrical, Piping, Instrument
- Operational Capital : Laboratory & tool, Workshop, Vehicle, Furniture, Consumables.
- Owner cost : Import duty, Permit, Project management, Recruitment
19
 Summary Cost Project
Sungai Kapuas Mill 40/80 TPH
Different Total Earth Works CSA MEP Automation Vehicle Prop Item Contingency
Weight
FAC - PDB (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio) (Rp. Mio)
FAC – RAP1 14,498 73% -196 3,996 15,009 -967 - -3,343 -
RAP – PDB2 5,265 27% - 13,366 2,966 -2,038 533 1,129 -10,690
Total 19,762 100% -196 17,362 17,974 -3,005 533 -2,215 -10,690
Class 3 Estimate Class 2 Estimate 17,974 Class 1 Estimate
Accuracy -3.3%+3.4% PTA approved incl. 8,154 Contingency excl.
Contingency 10,690 Mio 9,208 Contingency 10,690 Mio
3,005 2,215
533
10,690
196
- Kontrak CSA - L300 to Hilux VO upah pancang Unit rate : - Stucture/platform Pengurangan - Steam Boiler
- VO Macadam - Add 2 Motor sesuai aktual (pengecoran, hebel, - Grading platform scope CCTV - Digester & Press
- Kontrak Ancillary grating, baja) - Fiber Conv. no2 future dan - Compact Indexer
- Excess Conv .no2 accessoies - Crane Grapple tidak
- Loading Ramp - MCC Fixed to dilakukan pembelian
Line-2 dibangun Withdrawable
Fixed - EBA diperlebar - AC Split to Centralized Fixed
Fixed PTA Approved - Pipe Rack - Unit Price variance
223,697
204,657 209,510
Fixed Fixed Fixed Fixed
Fixed Fixed Fixed Fixed 332,140 329,925
308,680 309,017 309,017 317,171 319,235
299,472

Variable Variable Variable

69,175 73,529 69,364

Others Others Other

25,641 26,173 26,173
PDB PTA PTA Budget 2020 Earth CSA MEP Automation Proprietary Contingency FAC
2018 CSA Vehicle Works Item 2020
28-Apr-20 28-Apr-20
21