Maintenance Engineering Solutions

(M.E.S.)

Maintenance Level Loading-The Benefits

29th,July,2009

Prepared By: Ahmed Rabei

History
Level loading tool were developed 3 years
ago to overcome a very serious problem of
the huge increment of overdue work orders
of safety critical equipments at one of the
biggest oil and gas districts at Egypt
Objectives
 Optimizing resources
 Align Maintenance Planning with logistics
 Minimize the overdue work orders
 Make campaign maintenance available
 Use site global prioritization process
Function
 Level loading is a tool used to scheduling the
upcoming Work orders or already exist work
orders (or both) based on year or month
 Level loading methodology can take into
consideration weather constrains, available man
hours, logistics, special events, site priority etc.
 Level loading tool for Maximo uses YPP, and
S-position techniques which were developed by
M.E.S. team
Figures
Before After

Eliminate 10,000 overdue WO’s within 1 year

What is YPP?
 Definition: is a type of sort or arrangement of areas,
sites, modules, or trains.
 Description : Year Positions Philosophy is a sort like A-Z,
0-9 and can be customized depending on specific
parameters or gained experience. YPP tell us the
projection of area, zone, site, module, or train on the
year to help the geophysical arrangements of
maintenance specially if there is a need to certain
alignment of Maintenance Planning with Logistics
Planning and if there is a bad weather possible ranges
i.e. wind speed +45 restricts helicopter flying.
YPP Method

High Probability High Probability High Probability

Good Weather Bad Weather Good Weather

Offshore Onshore Offshore

Near Far
Far Near

Priority
Priority

H2S Level
H2S Level

Mixed Ranges Transportation

Transportation

Arrange for lowest swing Arrange for lowest swing Arrange for lowest swing
What is S-Position?
 Definition: is an accumulation of more than
one distribution.
 Description: S-Position or super position
method is a very good technique used for
campaign maintenance strategy and loop
based maintenance . It is also a tool for
multiple year positioning.
 S-Position Method
Instrument Mechanical

1400 1400
1200 1200
1000 1000
800 800
600 + 600
400 400
200 200
0 0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

=
Instrument & Mechanical

1400
1200
1000
800
600 Unreal
400
200
Work load
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
How Leveling tool works?
S-Position
Filter

Ratio Table
Row data Data
Maximo from PM, To be
DB JP, and WO processed

Distribution
List
Criteria (Tuning)
Update Next date

Filter
YPP List
Data
Not sorted
Data after
Or
Leveling
sorted
Results
Using YPP

Risk
Assessment
And
approval
Case Study (Basic information)
 Company: GUPCO (JV EGAS & BP)
 Industry: Oil and Gas
 Production: produces, and treats over 120,000
SBPD of oil and 212 MMSCFD of gas.
 Location: Ras Shoukier District
 Platforms: 125 platform
 Locations/Assets: 150,000
 PM’s: 45,000
Case Study (District Map)
87 SATELLITES

8 PRODUCTION
PLATFORMS

RAS SHOUKEIR
DISTRICT
8 GAS LIFT 24 GAS LIFT
PLATFORMS MODULES

150,000
2 GAS PLANTS
LOCATIONS

3 WATER FLOOD

2 PROCESS AREAS

8 UTILITIES
(POWER HOUSE, TANK FARM, …ETC.)
Case Study ( Before/after leveling)
Before leveling
 10,000 overdue WO’s for safety critical
equipments.
 Unbalanced work load.
 Man hours utilization ratio not exceed
30%.
 Each discipline has a restricted
transportation hours ( helicopter, and
Boat) which is not sufficient for all jobs
 BP road map for maintenance strategy
has a progress near to be zero.
 No opportunity to begin maintenance
optimization process.
After leveling
 10,000 overdue WO’s for safety
critical equipments has been
eliminated within one year
 Flexible and customizable work
load.
 Man hours utilization ratio reached
50%
 Each discipline transportation hours
( helicopter, and Boat) appears
sufficient for the high priority jobs
 BP road map for maintenance
strategy jumped directly to resources
optimization, planning, and
campaign maintenance
 maintenance optimization process
was realized.
Conclusion

Maintenance Level loading

significantly enhance the direct
objectives of EAM within short
time.
Thank you