Improving Preventive Maintenance
Using Performance Based Data
Peghi Webb, Process Analyst
Bart Lewis, Logistics Specialist
Aera Energy LLC
Supported by:
Produced by:
Overview
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
About Aera Energy LLC
• Oil and gas exploration and production company with
onshore operations in California
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
o
• 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
Where Aera Operates
Coalinga
San Ardo
Bakersfield
Headquarters
Belridge
Lost Hills
Cymric/McKittrick
Coles Levee
Ecosystem Preserve
Midway Sunset
Ventura
Huntington Beach
When To Use Performance Based PMs
• Equipment is run on an irregular schedule
• Multiple equipment is alternated when needed as a
•
Slide 5
back-up
Performance data is available or can be collected for
the equipment
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
Can be strategy, single cycle or multiple counter plan
o If using a strategy plan, create a task list using the same
strategy
o
• Schedule maintenance plan
Slide 6
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
Slide 7
Used to project maintenance
plan call date
Measurement Document
• Measurement readings can
be entered as counter
reading or the difference from
the last reading
Slide 8
Connecting SAP® to Field Data
• Map SAP® measuring point
to identifier for the field data
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
o
Slide 9
Flow of Equipment Performance Data
PLC
Pump
Field Data
System
Corporate
Data
Warehouse
SAP
Measurement Documents
• Measurement documents are
automatically created daily
o
Slide 11
A reversal indicator can be set if
a measurement document with a
“bad” reading is created
Maintenance Plan
• Set the counter to the desired
•
measuring point
Offset is used to define initial
counter reading for the cycle
o
Slide 12
Also used to reset when
maintenance is performed off
schedule
Maintenance Plan
• Lead float is used to set the
call date and the basic start
date on the called order
o
Slide 13
The basic finish date on the
order is set to the plan date for
performance based
maintenance plans
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
Slide 14
Utilizing SAP® Performance Based PMs
• Two of the highest
performing pumps west of
the Mississippi
High pressure water
injection pumps in service
since 1973
o Pump performance
o

o
45000 bbl/day @ 4000 psi
Motor performance

4500 HP
 4160 VAC
Slide 15
Utilizing SAP® Performance Based PMs
• Manufacturers generally
recommend that preventive
maintenance be performed
on run hours or usage rather
than on calendar days (hard
time)
Slide 16
UNITS OF
HOURS
Utilizing SAP® Performance Based PMs
• 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
Slide 17
This is people dependant
Utilizing SAP® Performance Based PMs
• Equipment preventive
maintenance previously
based on “hard time” led
to waste
3 orders called while
equipment was down for
overhaul
o Orders frequently called for
idle equipment
o Material requisitions fulfilled
and not utilized
o
Slide 18
Utilizing SAP® Performance Based PMs
• Equipment preventive
maintenance is currently
based on runtime
Orders generate when
equipment is due
o Material requisitions fulfilled
and utilized (no waste)
o
• 8 runtime based versus
16 calendar based orders
in 2 years
Slide 19
Utilizing SAP® Performance Based PMs
• 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
Key Points To Take Home
• Performance based maintenance plans use standard
•
SAP® EAM functionality
Maintenance is scheduled at the right time based upon
equipment usage
Works best for equipment run on irregular schedules
o Eliminates waste
o
Questions
Peghi Webb
Aera Energy LLC
mawebb@aeraenergy.com
Bart Lewis
Aera Energy LLC
gblewis@aeraenergy.com
Supported by:
Produced by: