sap eam
DESCRIPTION
SAP condition based maintenance in plant maintenanceTRANSCRIPT
Produced by: Supported by:
Improving Preventive Maintenance
Using Performance Based Data
Peghi Webb, Process Analyst
Bart Lewis, Logistics Specialist Aera Energy LLC
About Aera Energy LLC
How to set-up SAP® for performance based PMs
How performance based PMs are used at Aera
Benefits from using performance based PMs
Key points to take home
Questions
Overview
About Aera Energy LLC
• Oil and gas exploration and production company with onshore operations in California o Began operating on June 1, 1997
o 1200 Employees
o Produce 143,000 barrels of oil per day and 40 million cubic feet of natural gas per day
• Jointly owned by affiliates of Shell and ExxonMobil
• SAP® went into production in 1999 o Upgraded to ECC 6.0 in 2006
• North American Maintenance Excellence (NAME) award winner in 2002 and 2004
Bakersfield
Headquarters
Coalinga
San Ardo
Lost Hills Belridge
Coles Levee
Midway Sunset
Ventura
Huntington Beach
Cymric/McKittrick
Ecosystem Preserve
Where Aera Operates
Slide 5
When To Use Performance Based PMs
• Equipment is run on an irregular schedule
• Multiple equipment is alternated when needed as a
back-up
• Performance data is available or can be collected for
the equipment
Slide 6
SAP® Set-up for Performance Based PMs
• Create measuring point
o Can be attached to equipment or functional location
• Create initial measurement document
o If needed, set-up process for automated creation of
measurement documents
• Create maintenance plan
o Can be strategy, single cycle or multiple counter plan
o If using a strategy plan, create a task list using the same
strategy
• Schedule maintenance plan
Slide 7
Measuring Point
• Use counter checkbox
o Indicates that measurements
are cumulative values
• Provide counter over reading
o Sets value for when counter
goes back to zero
• Provide annual estimate
o Used to project maintenance
plan call date
Slide 8
Measurement Document
• Measurement readings can
be entered as counter
reading or the difference from
the last reading
Slide 9
Connecting SAP® to Field Data
• Map SAP® measuring point
to identifier for the field data
o This is a custom table with a
custom transaction to maintain
the data
o Used by the program that
creates measurement
documents each night from field
data
Flow of Equipment Performance Data
Corporate
Data
Warehouse SAP
Field Data
System PLC
Pump
Slide 11
Measurement Documents
• Measurement documents are
automatically created daily
o A reversal indicator can be set if
a measurement document with a
“bad” reading is created
Slide 12
Maintenance Plan
• Set the counter to the desired
measuring point
• Offset is used to define initial
counter reading for the cycle
o Also used to reset when
maintenance is performed off
schedule
Slide 13
Maintenance Plan
• Lead float is used to set the
call date and the basic start
date on the called order
o The basic finish date on the
order is set to the plan date for
performance based
maintenance plans
Slide 14
Maintenance Plan Schedule
• Cycle data shows latest
counter reading and
projected plan date based
upon annual estimate from
the measuring point
o Plan date calculation
(46776 – 45953) * 365 / 8400 = 36 days
01/03/2012 + 36 days = 02/08/2012
• Two of the highest
performing pumps west of
the Mississippi
o High pressure water
injection pumps in service
since 1973
o Pump performance
45000 bbl/day @ 4000 psi
o Motor performance
4500 HP
4160 VAC
Utilizing SAP® Performance Based PMs
Slide 15
• Manufacturers generally
recommend that preventive
maintenance be performed
on run hours or usage rather
than on calendar days (hard
time)
Utilizing SAP® Performance Based PMs
Slide 16
UNITS OF
HOURS
• Runtime is seldom spread
equally between primary and
secondary equipment
• Time based (hard time)
preventive maintenance
requires monitoring and
manual adjustments to be
effective when equipment is
actually due
o This is people dependant
Utilizing SAP® Performance Based PMs
Slide 17
• Equipment preventive
maintenance previously
based on “hard time” led
to waste
o 3 orders called while
equipment was down for
overhaul
o Orders frequently called for
idle equipment
o Material requisitions fulfilled
and not utilized
Utilizing SAP® Performance Based PMs
Slide 18
• Equipment preventive
maintenance is currently
based on runtime
o Orders generate when
equipment is due
o Material requisitions fulfilled
and utilized (no waste)
• 8 runtime based versus
16 calendar based orders
in 2 years
Utilizing SAP® Performance Based PMs
Slide 19
• Removes the question “Is it really due?”
• Provides more effective scheduling
• Eliminates need to adjust maintenance plans to stay in
compliance and possibly miss needed maintenance
• Eliminates unnecessary requisitions (materials)
• Can be used as a trigger to rotate equipment
• Reduces costs
• Reduces the possibility of human error
Utilizing SAP® Performance Based PMs
• Performance based maintenance plans use standard
SAP® EAM functionality
• Maintenance is scheduled at the right time based upon
equipment usage
o Works best for equipment run on irregular schedules
o Eliminates waste
Key Points To Take Home
Questions
Produced by: Supported by:
Peghi Webb Aera Energy LLC
Bart Lewis Aera Energy LLC