FACULTY OF CHEMICAL & PROCESS ENGINEERING TECHNOLOGY

BACHELOR OF OIL AND GAS FACILITY MAINTENANCE TECNOLOGY WITH

HONOURS

BVF 2213
OIL & GAS PROJECT MANAGEMENT

TOPIC:
OVERHAUL EFFLUENT PUMP AT PETRONAS CHEMICAL SDN BHD

STUDENT NAME & ID:

AISYA SHAHIZAH BINTI ABDUL RAZAK (VA21021)
MUHAMMAD WIDAD ASFA SHAFIE (VA21031)
MOHAMAD AQID SYAFAAT BIN AMRAN (VA21020)
NURUL KHALEEDA BINTI MOHD KAMAL BOKORI (VA21032)

LECTURER:
TS.DR. NURUL SA’AADAH BINTI SULAIMAN

DATE SUBMISSION:
31 JANUARY 2023

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 TABLE CONTENT

NO. CONTENT PAGE

1. Background of Company
- Introduction

2. Organization Chart
- Task Description

3. Project Ooverview
- Client Background
- BOM

4. Description of Project
- Objectives
- Scope of works
- Work Flowchart

5. Project Management
- Contract
- Risk Assessment
- JSA
- Project Plan Summary

6. WBS
- Work Schedule

7. Scheduling

8. Resource of Project

9. Conclusion

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INTRODUCTION OF COMPANY

Rusoh Accurate Maintenance Sdn. Bhd a wholly - owned subsidiary of Rusoh Accurate is a
company involved in the business of installation, maintenance, and restoration. Its related
services such as repairs and overhaul services. Rusoh Accurate provides installation,
maintenance, and restoration to repair and maintain the equipment that are essential to mitigate
corrosion, increase safety and reliability, and reduce expenses long term. Rusoh Accurate
Maintenance Sdn. Bhd laboratories are in Johor and Kuantan.

Today, we operate throughout Malaysia, servicing projects ranging from small to large scale in
equipment maintenance in oil and gas industry, processes of preparing, maintaining, and
restoring equipment before, during, and after oilfield production. Our field of experience cover
all types of equipment maintenance in oil and gas industry ranging from small equipment to
factories. Through the use of our services, customer can realize substantial maintenance and
repair cost savings and higher system uptime and reliability

Our vision is to expand the branches of business conducted and strength the reputation
achievement as a professional provider of quality maintenance service for our clients. To achieve
the vision, our company provided a professional who are skilled in performing tasks more
productively.

Our mission is striving to perform tasks better and more efficiently that provide benefits to the
company to ensure high risk work are carried out safely

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CORPORATE DETAIL

Company’s Name: Rusoh Accurate Maintenance Sdn Bhd

Company Reg. No.: 1320254-T

Corporate Status: Private Limited Company

Date of Incorporation: 1 April 2019

Paid Up Capital: RM 4,000.00

Registered Address: 5430, Tingkat 1, Jalan J9 Fasa 6,

Taman Melawati, Kuala Lumpur,

53100 Wilayah Persekutuan.

Company Secretary: Rodhiah Management Services

Business Address: C 01-15, Jalan Pulai Perdana 11/7,

Taman Sri Pulai Perdana,

81300 Skudai, Johor

Tel: 607 980 1987

Fax: 603 743 7779

Email: rusohaccurate@gmail.com

Bankers: MAYBANK Malaysia Berhad,

Taman Universiti,

Skudai, Johor

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DIRECTOR PROFILE

Director’s Name : MOHAMAD AQID SYAFAAT BIN AMRAN

NRIC Number : 940410-01-0085

Date of Birth : 10 April 1994

Home Address : 290, Jalan Pulai Jaya 17,

Bandar Pulai Jaya,

81300 Skudai, Johor

Certificate : 2011 - Sijil Pelajaran Malaysia

2012– 2014 - Diploma in Mechanical Engineering, Politeknik Port Dickson

2015 – 2018 – Bachelor of Oil and Gas Maintenance Facility with Honour

Position : Managing Director

Experience : 4 Years

2018 - 2019 - Technical Executive

(Hull and Deck Machinery)

2020 – 2022- Assistant Ship Repair Manager LNG

(Hull and Deck Machinery, Scaffolding, Painting Blasting)

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ORGANIZATION CHART

Work descriptions
Position Duties

Manages and coordinates the activities of designated projects

Project Manager/Director with a specific timeframe and funding amount to ensure that
goals or objectives of the project are accomplished.

Conduct and give a briefing in toolbox meeting, informal safety

Project Leader
meeting held before the start of a work shift.

Overseeing plant projects and ensuring that teams meet

Supervisor
production projections.

Install, repair, and maintain assorted plant control and process

Instrument Technician
monitoring instrumentation.

Helper Supplying or holding materials or tools, and cleaning work area

and equipment.

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PROJECT OVERVIEW

Rusoh Accurate Maintenance Sdn. Bhd a wholly - owned subsidiary of Rusoh Accurate is a
company involved in the business of installation, maintenance, and restoration. Our company
Project is Overhaul 1 unit of Effluent Pump. Our client is Petronas Chemical Sdn Bhd. This
project is a one-day project. The supervisor, Work Leader, Instrument Tech, and Helper are
assigned to do the overhaul of 1-unit effluent pump at Petronas Chemical Sdn Bhd. At the first
phase, Supervisor do a planning. In the phase is consistent with an analytical and identify the
product and product requirement. Cost analysis is also included in this phase. Phase 2 at the site
work, Instrument Tech Start to do the overhaul. It starts from Removal of the effluent pump
casing until installation all of the new parts to replace the old part. The last phase is Testing and
running. After all the Installation and replacement, the effluent pump is ready to use. This project
cost is RM 21,540.00.

CLIENT BACKGROUND

FULL NAME OF CLIENT COMPANY : Petronas Chemical Sdn Bhd.

CLIENT COMPANY PERMANENT ADDRESS : Lot 3633, Kawasan Bukit Tengah KM 105,
Jalan Kuantan- Kuala Terengganu 24300
Kertih, Kemaman Terengganu Darul Iman

NO. TELEPHONE : + 609 830 5648

FAX : + 609 830 5618

LOCATION OF THE PROJECT COST OF PROJECT

Petronas Chemical Sdn Bhd Base RM19,627.00

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BILL OF MATERIALS

Bill Description Part code Unit rate Quantity Price

1. Gasket N/A Per unit 1 200.00

2. Washer N/A Per unit 1 200.00

3. Screw N/A Per unit 1 20.00

4. Nut N/A Per unit 1 40.00

6. Bolt N/A Per unit 1 40.00

7. Stud N/A Per unit 1 30.00

8. Key N/A Per unit 1 15.00

9. Oil Seal N/A Pe unit 1 200.00

10. Lubricant Oil N/A Per unit 1 50.00

11. Grease N/A Per unit 1 250.00

12. Impeller 211 Per unit 1 800.00

13. Bearing Sleave 529.01 Per unit 1 300.00

14. Bearing Sleeve 529.01 Per unit 1 300.00

15. Line Shaft 211 Per unit 1 200.00

16. Shaft Seal Ring 420 Per unit 1 500.00

17. Insert Sleave 932 Per unit 1 400.00

18. Oil Level Tube 641 Per unit 1 1200.00

19. Impeller ring N/A Per unit 2 100.00

20. Tube 707.01 Per unit 1 88.00

21. Impeller Nut 922 Per unit 2 70.00

Total Cost RM 5003.00

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WORKERS
Position Wages Total days Total Wages

Work Leader RM 88.00/hour 1 days RM 704.00

Helper RM 70.00/hour 6 days RM 3360.00

Supervisor RM 150.00/hour 4 days RM 4800.00

Instrument Technician RM 120.00/hour 6 days RM 5760.00

Total Cost RM 14,624.00

PROJECT
Project Overhaul Effluent Pump
Project Reference P1-2710a
Client Petronas Chemical Sdn Bhd
Date 20/1/2023
Place Petronas Chemical Sdn Bhd Base

EQUIPMENT
No Name Of Equipment
1 Wrenches
2 Seat puller rods
3 Seat puller heads
4 Pony rod clamps
5 Hydraulic hoses
6 Hand pumps
7 Grease guns
8 Lifting subs
9 Foot pumps

Total Estimated Project Cost: RM 19,627.00

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DESCRIPTION OF PROJECT

OBJECTIVES
Rusoh Accurate Sdn Bhd hereinafter referred to as ‘PGB’ intends to enter into a contract to
overhaul 1 Unit of Effluent Recycle Pump P1-2710a For Utilities Kertih, Kemaman, Terengganu
Darul Iman. Our experts provide our clients with personal support in every phase of the project,
from design and configuration, through to commissioning and maintenance. Our systems and
product solutions set new standards in terms of technical performance, cost efficiency, security
standards, and durability in all applications relating to Effluent Recycle Pump.

SCOPES OF WORK
1. To mob/de-mob pump from UK to contractor workshop.
2. To produce ‘As Found Report’ after 5 working days of initial pump inspection which
include but not limited to disassembly, record all findings with picture, record as found
clearance, recommendation of repair & overhaul schedule.
3. To submit repair, work procedure, QAQC procedure & acceptance criteria prior execution
if necessary/required.
4. To perform incoming shaft run out check.
5. To perform impeller balancing.
6. To perform cleaning of all pump parts (blasting/grinding/polishing/power brush).
7. To perform NDT (Dye Penetration) if necessary/required.
8. To perform a 5-point check.
9. To reassemble pump & record all clearances.
10. To perform 3 coat system painting (if necessary/required).
11. To supply required spare parts for overhaul activity.
12. To replace damaged pump parts.
13. To prepare all required special tools necessary to perform the work.
14. To carry out performance test if necessary/required.
15. To reinstate the pump at site.
16. To stand by for pump test run.
17. To produce detailed overhaul report (close out report) stating general findings or
observations pertaining to the works.

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WORK FLOWCHART

START

All tools needed were prepared.

All part has been cleaned. Rusty

and failure parts were checked.

No Have not
Inspection approved?
approved
Yes

Material and parts have been

purchased.

The consumable parts were

repaired and replaced.

Recycle pump have been tested and ran

smoothly.

FINISH

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PROJECT MANAGEMENT

CONTRACT FOR PROJECT MANAGEMENT SERVICES

Overhaul 1 unit of Effluent Pump

This Contract is made this 20 day of JANUARY in the year 2023 between
(day) (month) (year)
(Owner) (street) (city)

the Rusoh Accurate Maintenance Sdn.Bhd, C 01-15, Jalan Pulai Perdana 11/7, Taman Sri
Pulai Perdana, 81300 Skudai, Johor
(State) (Zip Code)

hereinafter called Rusoh Accurate Maintenance Sdn.Bhd and Petronas Chemical Sdn
Bhd
(Owner’s Project Manager)

Lot 3633, Kawasan Bukit Tengah,KM 105, Jalan Kuantan-Kuala Terengganu,24300

Kertih, Kemaman ,Terengganu Darul Iman(street) (city) (Zip Code) (State)

The Petronas Chemical Sdn Bhd, hereinafter referred to as The Petronas Chemical Sdn
Bhd, will offer the Project Management services required to execute the Basic and Extra
Services outlined below at Overhaul 1 unit of Effluent Pump. Through the Project
planning, Rusoh Accurate Maintenance Sdn. Bhd is permitted to provide the services
required by this Contract. The Project Manager may be authorised to provide services
for the Overhaul 1 unit of Effluent Pump following the Overhaul, at which point a
mutually agreed upon amendment to this Contract will be executed between the client
and the Project Manager.

Rusoh Accurate Maintenance Sdn. Bhd. will be paid by Petronas Chemical Sdn. Bhd.
for rendering the services needed by this Contract for the maintenance and
troubleshooting of pumps in the oil and gas plant.

IN WITNESS WHEREOF, the respective authorised officers of Petronas Chemical Sdn

Bhd and Rusoh Accurate Maintenance Sdn.Bhd have caused the execution of this
Contract.

Rusoh Accurate Maintenance Sdn.Bhd (Manager) Petronas Chemical Sdn Bhd(Manager)

Qied Bob Helmie

(Mohamad Aqid Syafaat) (Bob Helmie)

Date 20/01/2023
Date 20/01/2023

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PROJECT PLAN SUMMARY

Rusoh Accurate Maintenance Sdn. Bhd has gone over the work schedule that needs to be
completed at the plant for a duration of 7 days in order to perform overhaul effluent pump at
Petronas Chemical Sdn Bhd. The first of the three steps are depicted in the prepared table. The
"Early Planning" phase will include a first meeting with the client when the usage of cash and
preparation for maintenance work will be discussed. The overhauling of the effluent pump,
which is the second phase in the service process, takes seven days to complete, as shown in the
table. Over the next seven days, the work will be done inside the Petronas Chemical Sdn Bhd site.
The effluent pump is given one more inspection and test run in the closing days of that process,
which is referred to as the final phase. In this report, a table has been built up to give the business
more details regarding the process of overhauling the effluent pump. The repair and
troubleshooting on the pump at the Petronas Chemical Sdn Bhd will be successfully carried out
by Rusoh Accurate Maintenance Sdn Bhd, who will make sure that the task is done.

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 RISK ANALYSIS LIKELIHOOD(L) XSEVERITY(S) = RISK(R) RISK ASSESSMENT RESULT RANKING

LIKELIHOOD VALUE VALUE SEVERITY

SEVERITY LIKELIHOOD 3 2 1 Risk Ranking What to do?

Score

Unlikely 1 Minor 1 3 9 6 3 6–9 High Immediate attention and action required.

Shall consider whether to eliminate or modify
(H)
the activity. (Stop the

work.)

Medium Specific monitoring procedures required;

management responsibility must be specified.
Likely 2 Moderate 2 2 6 4 2 3–4 (M)
Shall consider what can be done to eliminate
the risk to prevent any.

negative outcomes.

Frequent 3 Catastrophic 3 1 3 2 1 1–2 Low Manage through routine procedures. Can

proceed with the activity as planned
(L)

JOB SAFETY ANALYSIS

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NO Risk Description Impact Impact Probability Priority Mitigation Notes
Description Level Level Level
1 Preparing for every tools 1. Physical To wear full Personal
hazard Protective Equipment (PPE)
1 2 2

2 Ndt Dye Penetration test Headaches, nausea Test personnel should be

or tightness or pain aware of job-related hazards
in the chest. and safety precautions about
3 3 9 Prolonged breathing of
penetrant vapors, emulsifier
vapors or solvent remover
vapors.
3 Cleaning the impeller 1. Hand injury Use full Personal Protective
2. Eye injury Equipment
3 2 6

4 Removal casing, motor and capacitor, 1. Hand injury 1. Ensure set screws are
impeller, shaft. Shaft sleeve, wearing 2. Eye injury loose.
ring, all bearings and sleeve 3. Spark 3 3 9 2. Ensure pump has cooled
4. Chemical burn and Use full Personal
Protective Equipment.

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5 Noise and vibration
6 Electric shock
7 Pump Pressurized
8 Installation and replacement
9 Housekeeping
Hearing impairment Regular equipment
Vibration injury familiarization using a station-
based training plan Personal
3 3 9 Protective Equipment (PPE)
must be always worn (ear
plugs)
1. Body burn 1. keep your hands clean
2. Electrocution and dry when doing any
3. Death electrical work. Be sure
to wear full Personal
Protective Equipment
2 2 4
(PPE) and safety clothes
in a dry condition.
2. Ensure electricity supply
is shut off and pump
driver locked out
1. Steam Escape with 1. Ensure pump has cooled
contaminants sufficiently and pipework
2. Jets of Hot Liquid drained before attempting
3 3 9 disconnection.
2. Check external casing
temperatures.
3. Open bolts slowly
1. Physical hazard To wear full Personal
Protective Equipment (PPE)
2 3 6
1. Slipping on greasy, To wear full Personal
wet, or dirty Protective Equipment (PPE)
surfaces. 1 2 2
2. Physical hazard
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WORK BREAKDOWN STRUCTURE
WBS

OVERHAUL 1 UNIT EFFLUENT

RECYCLE PUMP

1)PLANNING 2)PREPARATION 3)CLEANING 4)INSPECTION 5)IDENTIFY AND 6)REPAIR/REPLACE 8)TESTING AND

TOOLS ALL PARTS PURCHASE THE CONSUMABLE RUN
MATERIAL/PARTS PARTS

BLASTING/GRINDING 7)INSTALLATION
/POLISHING ALL PARTS

CHECK THE RUSTY

AND FAILURE
PART COATING AND
PAINTING PARTS
NDT INSPECTION
(DYE PENETRATION)
ALIGNMENT

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WORK SCHEDULE

Task Day Resources

PHASE 1: PLANNING
Analytical and identify production Supervisor
Identify product requirement 1 Supervisor
Cost effectiveness analysis Work Leader
Preparation tools include special tools Work Leader
PHASE 2: Site Work
Removal casing Instrument Tech
Removal motor & capacitor Instrument Tech
Removing the impeller Instrument Tech
Cleaning the impeller Instrument Tech, Helper
Inspect its eye, vanes, shrouds, wearing rings,
Instrument Tech, Helper
passages, hub and other parts
Removing the shaft Instrument Tech
Remove shaft sleeve 2 Instrument Tech
Inspection alignment Instrument Tech
NDT Dye Penetration test Instrument Tech, Supervisor
Inspection of crack, corrosion, rusty, and failure Instrument Tech, Supervisor
Removing wearing rings from casing or impeller Instrument Tech
Inspection the crack, corrosion, rusty and failure Instrument Tech, Supervisor
Removing all bearings Instrument Tech, Helper
Removing sleeve Instrument Tech, Helper
PHASE 3: Installation and Replacement
Cleaning all parts Instrument Tech, Helper
BLASTING/GRINDING/POLISHING Instrument Tech, Helper
Replace the new motor & capacitor Instrument Tech
Installation the new shaft Instrument Tech
Install the new line shaft Instrument Tech
Alignment the shaft Instrument Tech, Helper
Replace the new impeller Instrument Tech, Helper
Replace the new sleeve 3 Instrument Tech, Helper
Install new circlip Instrument Tech, Helper
Replace the set of all bearings Instrument Tech, Helper
Coating and painting Instrument Tech, Helper
Replace the new casing Instrument Tech, Helper
Install
new: Gasket, Washer, Screw, Nut Bolt, Stud, Key Instrument Tech, Helper
Oil Seal, Lubricant Oil, Grease
PHASE 4: Testing and run Instrument Tech, Helper,
1
Testing and run Supervisor

18
PROJECT SCHEDULLING

19
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21
RESOURCE OF PROJECT

I. Pumps - Restoration and Efficiency Enhancement, www.belzona.com, 20 January 2023

https://www.belzona.com/en/applications/pumps.aspx
II. Pump Maintenance Tools: Oil & Gas Industry, summit, 20 January 2023
https://www.summitsalesusa.com/pump-tools
III. Maintenance & repair of Pumps: Centrifugal, vacuum, multistage, Maintenance Partners,
7 August 2020, 20 January 2023
https://maintenancepartners.com/en/pumps/
IV. Maintenance, Repair, Overhaul: End market: Oil & Gas, chempoint, 20 January 2023
https://www.chempoint.com/en-emea/industries/maintenance-repair-overhaul/oil-and-gas
V. Step-by-step guide for overhauling centrifugal pumps: Sintech, Sintech Pumps India, 29
May 2020, 20 January 2023
https://www.sintechpumps.com/pumps/centrifugal-pumps/overhauling-of-centrifugal-
pumps-step-by-step-guide/

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CONCLUSION

Point of fact, Rusoh Accurate Maintenance Sdn. Bhd. will offer exceptional service and high-
quality solutions through our professional knowledge and commitment to any maintenance and
troubleshooting task, which should be approached with an open mind and a sincere desire to
identify and resolve the problem. Excellent observational and verbal communication skills are
needed for all of these activities.

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