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
1
TABLE CONTENT
NO.
1.
CONTENT
Background of Company
-
2.
Organization Chart
-
3.
Objectives
Scope of works
Work Flowchart
Project Management
-
6.
Client Background
BOM
Description of Project
-
5.
Task Description
Project Ooverview
-
4.
Introduction
Contract
Risk Assessment
JSA
Project Plan Summary
WBS
-
Work Schedule
7.
Scheduling
8.
Resource of Project
9.
Conclusion
2
PAGE
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
3
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
4
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)
5
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.
Project Leader
Supervisor
Instrument Technician
Helper
Conduct and give a briefing in toolbox meeting, informal safety
meeting held before the start of a work shift.
Overseeing plant projects and ensuring that teams meet
production projections.
Install, repair, and maintain assorted plant control and process
monitoring instrumentation.
Supplying or holding materials or tools, and cleaning work area
and equipment.
6
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
Petronas Chemical Sdn Bhd Base
COST OF PROJECT
RM19,627.00
7
BILL OF MATERIALS
Bill
Description
Part code
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
2
70.00
922
Total Cost
Unit rate
Per unit
Quantity Price
RM 5003.00
8
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
9
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.
10
WORK FLOWCHART
START
All tools needed were prepared.
All part has been cleaned. Rusty
and failure parts were checked.
No
Inspection approved?
Have not
approved
Yes
Material and parts have been
purchased.
The consumable parts were
repaired and replaced.
Recycle pump have been tested and ran
smoothly.
FINISH
11
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)
(Owner)
(month)
(year)
(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
(Mohamad Aqid Syafaat)
Bob Helmie
(Bob Helmie)
Date 20/01/2023
Date 20/01/2023
12
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.
13
RISK ANALYSIS
LIKELIHOOD VALUE
LIKELIHOOD(L) XSEVERITY(S) = RISK(R)
VALUE
SEVERITY
RISK ASSESSMENT RESULT RANKING
SEVERITY
LIKELIHOOD 3
2
1
Risk
Ranking
What to do?
High
Immediate attention and action required.
Shall consider whether to eliminate or modify
the activity. (Stop the
Score
Unlikely
1
Minor
1
3
9
6
3
6–9
(H)
work.)
Likely
2
Moderate
2
2
6
4
2
3–4
Medium Specific monitoring procedures required;
management responsibility must be specified.
(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
(L)
JOB SAFETY ANALYSIS
14
Manage through routine procedures. Can
proceed with the activity as planned
NO
1
Risk Description
Preparing for every tools
Impact
Impact
Probability
Priority
Description
Level
Level
Level
1. Physical
To
hazard
Ndt Dye Penetration test
wear
full
Personal
Protective Equipment (PPE)
1
2
Mitigation Notes
2
2
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
4
Cleaning the impeller
1. Hand injury
2. Eye injury
3
Removal casing, motor and capacitor, 1. Hand injury
impeller, shaft. Shaft sleeve, wearing 2. Eye injury
ring, all bearings and sleeve
3. Spark
4. Chemical burn
15
3
2
3
6
9
Use full Personal Protective
Equipment
1. Ensure set screws are
loose.
2. Ensure pump has cooled
and Use full Personal
Protective Equipment.
5
Noise and vibration
Hearing impairment
Vibration injury
3
6
7
8
9
Electric shock
Pump Pressurized
Installation and replacement
Housekeeping
3
9
1. Body burn
2. Electrocution
3. Death
Regular
equipment
familiarization using a stationbased training plan Personal
Protective Equipment (PPE)
must be always worn (ear
plugs)
1.
2
2
4
3
3
9
2
3
6
1. Steam Escape with
contaminants
2. Jets of Hot Liquid
1. Physical hazard
1. Slipping on greasy,
wet, or dirty
surfaces.
2. Physical hazard
16
1
2
2
keep your hands clean
and dry when doing any
electrical work. Be sure
to wear full Personal
Protective
Equipment
(PPE) and safety clothes
in a dry condition.
2. Ensure electricity supply
is shut off and pump
driver locked out
1. Ensure pump has cooled
sufficiently and pipework
drained before attempting
disconnection.
2. Check external casing
temperatures.
3. Open bolts slowly
To wear full Personal
Protective Equipment (PPE)
To wear full Personal
Protective Equipment (PPE)
WORK BREAKDOWN STRUCTURE
WBS
OVERHAUL 1 UNIT EFFLUENT
RECYCLE PUMP
1)PLANNING
2)PREPARATION
TOOLS
3)CLEANING
ALL PARTS
4)INSPECTION
5)IDENTIFY AND
PURCHASE
MATERIAL/PARTS
BLASTING/GRINDING
/POLISHING
6)REPAIR/REPLACE
THE CONSUMABLE
PARTS
8)TESTING AND
RUN
7)INSTALLATION
ALL PARTS
CHECK THE RUSTY
AND FAILURE
PART
COATING AND
PAINTING PARTS
NDT INSPECTION
(DYE PENETRATION)
ALIGNMENT
17
WORK SCHEDULE
Task
Day
PHASE 1: PLANNING
Analytical and identify production
1
Identify product requirement
Cost effectiveness analysis
Preparation tools include special tools
PHASE 2: Site Work
Removal casing
Removal motor & capacitor
Removing the impeller
Cleaning the impeller
Inspect its eye, vanes, shrouds, wearing rings,
passages, hub and other parts
Removing the shaft
2
Remove shaft sleeve
Inspection alignment
NDT Dye Penetration test
Inspection of crack, corrosion, rusty, and failure
Removing wearing rings from casing or impeller
Inspection the crack, corrosion, rusty and failure
Removing all bearings
Removing sleeve
PHASE 3: Installation and Replacement
Cleaning all parts
BLASTING/GRINDING/POLISHING
Replace the new motor & capacitor
Installation the new shaft
Install the new line shaft
Alignment the shaft
Replace the new impeller
3
Replace the new sleeve
Install new circlip
Replace the set of all bearings
Coating and painting
Replace the new casing
Instrument Tech
Instrument Tech
Instrument Tech
Instrument Tech, Supervisor
Instrument Tech, Supervisor
Instrument Tech
Instrument Tech, Supervisor
Instrument Tech, Helper
Instrument Tech, Helper
Install
new: Gasket, Washer, Screw, Nut Bolt, Stud, Key
Oil Seal, Lubricant Oil, Grease
Instrument Tech, Helper
PHASE 4: Testing and run
Testing and run
1
18
Resources
Supervisor
Supervisor
Work Leader
Work Leader
Instrument Tech
Instrument Tech
Instrument Tech
Instrument Tech, Helper
Instrument Tech, Helper
Instrument Tech, Helper
Instrument Tech, Helper
Instrument Tech
Instrument Tech
Instrument Tech
Instrument Tech, Helper
Instrument Tech, Helper
Instrument Tech, Helper
Instrument Tech, Helper
Instrument Tech, Helper
Instrument Tech, Helper
Instrument Tech, Helper
Instrument
Supervisor
Tech,
Helper,
PROJECT SCHEDULLING
19
20
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-centrifugalpumps-step-by-step-guide/
22
CONCLUSION
Point of fact, Rusoh Accurate Maintenance Sdn. Bhd. will offer exceptional service and highquality 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.
23