company. Moreover, from the observations, focus group discussion operational costs. These challenges have forced maintenance
with PMMS personnel and application through simulation (SAP R/3),
the paper reviews the step-by-step approach and the elements that
managers to adopt tools, methods, and concepts that could
required for the PMMS. The findings show that the PMMS integrates stimulate performance growth and minimize errors, and to
the overall business strategy in upstream operations that consist of utilize resources effectively toward making the organization a
asset management, work management and performance management. “world-class manufacturing” or a “high-performance
In addition, PMMS roles are to help operations personnel organize manufacturing” plant.
and plan their daily activities, to improve productivity and reduce Industrial maintenance has two essential objectives which
equipment downtime and to help operations management analyze the are a high availability of production equipment and low
facilities and create performance, and to provide and maintain the maintenance costs [1]. However, a strong factor militating
operational effectiveness of the facilities. against the achievement of these objectives is the nature and
intensity of equipment failures in plants. Since system failure
Keywords—Maintenance, Oil and Gas Industry, Upstream can lead to costly stoppages of an organization’s operation,
Operations
which may result in low human, material, and equipment
utilization, the occurrence of failure must therefore be reduced
I. INTRODUCTION
or eliminated. An organization can have its customers build
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hierarchy. Indeed, a CMMS is a means of achieving world- Observation, focus group discussion and simulation
class maintenance, as it offers a platform for decision analysis application were used to collect the primary data that related
and thereby acts as a guide to management [16]. to PMMS applications. The observation was focused on the
CMMS are computer-based software programs used to upstream operations and PMMS meanwhile the focus group
control work activities and resources, as well as to monitor discussion were conducted among the MCS engineers. In
and report work execution. CMMS are tools for data capture addition, the discussion was conducted not only dwell on the
and data analysis. The major features of CMMS include the past implementation, but also focus on the future plans and
processing of maintenance data to give in useful information developments via telephone and internet conference. Then, to
on which management decisions are based. This information validate the PMMS, simulation of SAP software (SAP R/3)
can be analyzed or evaluated with respect to previous results was performed with Master Data Team of PMO/PCSB.
such that performance over a period of time can be assessed. Secondary data was obtained from PCSB SAP R/3
Managers will therefore find it convenient in making use of Maintenance Control System (MCS) Guide, Carigali
the available data to plan for present and future goals. There is Maintenance Management Guide (CMMG), Carigali
also the advantage of printing out this information in hard Inspection & Maintenance Guide (CIMG), and PETRONAS
copy at any desired period. Other useful information, such as Electronic Performance Support Site (EPPS).
work done in the maintenance department and its total costs
International Science Index, Industrial and Manufacturing Engineering Vol:3, No:12, 2009 waset.org/Publication/9968
(TC), lists of jobs worked on during a period, and inventory III. CASE STUDY
taking, can be presented in a manner that will greatly ease The case study was conducted at PETRONAS Carigali Sdn
both the technical and administrative task of maintenance. Bhd (PCSB). For history, on 11th May 1978, this Malaysian
Through networking of the systems, information can be passed company, PCSB a wholly owned subsidiary of Petroliam
efficiently between the maintenance department and the Nasional Berhad (PETRONAS) was born as its exploration
organization’s management. and production arm. PCSB’s domestic operations are divided
The CMMS can be used to analyze budgets, downtime, into three regions which are Peninsular Malaysia Operations
supplies, screening of applicants, etc. The database programs (PMO), Sarawak Operations (SKO) and Sabah Operations
in CMMS systems contain structured data on workers’ names; (SBO). Effective 1st April 2002, these regional operations
job titles; daily; weekly or yearly schedules; etc. The data were put under PCSB’s Division called Domestic and South
processed on CMMS can be stored permanently or retrieved East Asia Division (DOMSEA). This paper is only focus on
much faster for future use or modifications. Also, CMMS can PMO. PMO started its operation in April 1984 (the first
be used in maintenance planning and scheduling, coordinating production of division in PCSB) with the commencement of
people, and controlling resources and costs of maintenance gas production from the Duyong field. Its main office is
functions. It can also be used in such areas as the analysis of a located at PETRONAS Office Complex in Kerteh about 110
week’s activity and budget proposals. km south of Kuala Terengganu. PMO is supported by
This paper is then to study the application of CMMS called Kemaman Supply Base (KSB) in terms of warehousing and
PMMS in Petroliam Nasional Berhad (PETRONAS) which logistics activities, Kerteh Helibase for helicopter services,
used to manage the upstream operations for over than 100 Onshore Gas Terminal (OGT) at Paka for gas receiving
plants. The PMMS is also known as ‘PETRONAS facilities and Terengganu Crude Oil Terminal (TCOT) at Paka
Maintenance Management System’ is a computerised for crude receiving facilities. Nowadays, PMO operates
maintenance management system which has supported by the sixteen producing fields namely Duyong, Dulang, Bekok,
System Application Production (SAP R/3). The SAP system is Kepong, Tiong, Tinggi, Pulai, Malong, Sotong, Anding,
an integrated suite of Order Entry, Scheduling, Manufacturing, Resak, Abu-Cluster, Puteri and Angsi. There are a total of
Inventory and Financial software. In addition, it integrates thirty three platforms, two Floating Storage and Offloading
Enterprise Resources Planning (ERP) system that consists of facilities (FSO), two Floating Production, Storage and
several modules, namely Plant Maintenance (PM), Finance Offloading facility (FPSO), and one Onshore Gas Terminal
(FI), Human Resources (HR), and Material Management (OGT). There are 20,936 equipments under PCSB’s
(MM), which supported by many functions in the day-to-day maintenance. Effective maintenance is build-out and
operations. To organize this paper, section 1 explains the implementation of the process and systems. PCSB are
overview of maintenance management system for capturing transforming their maintenance into strategic, value-adding
the key issues. Section 2 classifies the research methodology. PMMS. PMMS is a maintenance strategy based on continual
Section 3 briefs the case study at a selected oil and gas renewal so that plant and equipment are in good condition and
organisation. Section 4 explores the PMMS. Section 5 hence free of age related defects.
discusses the findings and the knowledge earned and the paper
ends with some useful conclusions and thoughts for future
IV. PMMS
research.
PCSB operates a number of complexes onshore and offshore
II. RESEARCH METHODS installations, most of which are in the remote locations. The
management and supervision of operational activities involves
An intensive case study was conducted in July 2008 and a flow of data, which can be most easily managed when
one of the authors recently undergone industrial attachment consistent, meaningful information is readily available to all
and spent almost 6 months focusing on productivity parties. This depends on the ready access to all information to
improvement activities at the case study company. design, construction, manufacturer, spare parts, skilled
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manpower resources and operating or maintenance histories. plant relationship, between organizational set-up, process and
The PETRONAS Maintenance Management System (PMMS) maintenance functions. Under Functional Location has a
which supported by System Application Production (SAP R/3) Functional Location Boundary. The boundary is termed as a
is implemented to achieve the management of such data. grouping of main and supporting equipment which provides
PMMS covers Asset Management, Work Management, and one main function for delivering intended output from a
Performance Management. maintenance perspective.
Level 6 is Equipment Master which is a uniquely
identifiable physical asset, upon which all notifications and
A. Asset Management System
work order can be carried out where costs and history can be
In PMMS, Asset Management important to ensure that a recorded. When an equipment master is dismantled and
complete maintenance master data is captured in the system, installed from one functional location to another, its
including plant asset structure, tag no, equipment master, Bill equipment master historical data remains attached. Under
of Material, maintenance plans, and data consistency in master Equipment Master have Equipment Classification and
data. Asset Management covers two areas - Plant Asset Equipment Characteristic. Equipment Classification mean is a
Structure (PAS) and Planned Preventive Maintenance Plan group’s equipment with the same functions to enable
(PPM). The first requirement for supported maintenance equipment performance analysis by class within an Operation
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system is to represent its operational systems and their detailed Unit (OPU) or benchmarking among OPUs. For example,
structure. Equipment Classification can be used to filter out all
maintenance orders created for an equipment class such as
1) Plant Asset Structure compressors. Using the classification system, pieces of
The Plant Asset Structure allows the user to control system equipment can be supplemented with technical characteristics,
management according to functional location or process which provide further information on the equipment, including
oriented criteria and to manage the individual inventory its technical and operational parameters. Equipment
maintenance resources. This will enable the planning, Characteristic means each class has a set of characteristics,
execution and analysis of the maintenance works through the which provides further information on the equipment,
system. Fig.1 shows the example of a PAS for PSCB. including its technical and operational parameters. The user
can define characteristics freely and assign any number of
Level 1 Company
them to the classes. The characteristics and their values can
(PMO) be inherited over several class levels in the case of
Level 2
hierarchically structured classes.. The failure analysis can be
Block (PM9)
done for similar equipment in the same class in each OPU and
Level 3
be projected to a higher level since the classes used are
Fields (Bekok Fields (Bekok Fields (Bekok
standardized at client level.
Level 7 is refer to the bill of materials (BOM). BOM is the
Level 4 Process (Oil) Process (Gas) Process Process
term used to describe the raw materials, sub-assemblies,
intermediate assemblies, sub-components, components, parts
Level 5 Function Function Function and the quantities of each needed to manufacture an end item
(final product). BOM structures are included in system
Level 6
Equipment Equipment Equipment Equipment structuring in the overall structuring of individual operational
(Compressor) (Turbine) (Motor) (Pump)
systems, for example functional locations or pieces of
equipment, enabling a unified and consistent structuring
Level 7
Lube
system
Compress
or unit
Control
monitorin
Switch
gear
method. The objectives of BOM are to guide the structuring of
the components to enable efficient work planning, to provide
Fig.1 An example of Plant Asset Structure based on PCSB ‘where-used’ information of each spare part, to provide fast
Level retrieval of stock material and identify parts to raise purchase
requisition, and to reduce error in selecting and purchasing
The procedure of PAS is categorized by level. Level 1 until equipment parts. Maintenance BOM describes the structure of
3 is the selection process of the asset, investing the asset, a technical object or assembly. Using maintenance BOM, the
making proper assessment of risks, and developing proper user can quickly select correct components for the
strategies to save the assets from exposure to risks. Level 4 is maintenance tasks to be performed on the technical object.
a process that execution of the Plant Maintenance System. At BOM when set up correctly would easily identify the number
PETRONAS there have two different production platforms of the equipment installed with the same spare part, thus
which are Oil or Associated Gas (AG) Platform and Gas or reduce duplicate stock material created in the system and help
Non Associated Gas (NAG) Platform. The main processes on justify adjusting stock material minimum or maximum level
the platforms are oil production, gas production, gas based on the equipment criticality and its consumption rate.
dehydration, and gas compression. Level 5 is a Functional BOM can be extended to create multi level BOM.
Location where a place in technical system. It used to capture
information related to location, process or group of functions. 2) Planned Preventive Maintenance Plan
Functional Location shall be used to structure or represent a Preventive maintenance is the generic term for planned
inspections, preventive maintenance work and planned repairs.
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In the maintenance management system, preventive and screen the notification before converting to order. It
maintenance plans are created to automatically generate requires to establish the nature of work carried out on the
preventive maintenance orders when the preventive equipment so that maintenance can identify improvement
maintenance work is due. The business objectives of areas in maintenance plan for the equipment, if necessary, to
preventive maintenance are to provide an effective planning of ensure that full equipment history is recorded in the system for
preventive maintenance schedule and to ensure good resource future maintenance work, to help planner to better response to
management which are performed on a recurring basis, to the urgency of the work request, to breakdown time period
provide effective implementation of scheduled preventive enable management to analyze reliability of the equipment and
maintenance will increase integrity and reliability of effectiveness of maintenance planning, and to attached
equipment and reduce unplanned breakdown of equipment, document is critical in providing graphical view of the work
and to reduce maintenance costs by reducing uneconomic scope or equipment condition.
maintenance or overhaul schedules, wear and tear and human
induced failures due to unnecessary equipment dismantling. (a) Notification Definition
In the preventive maintenance plans, the following important There are three major groups of maintenance work for
details are specified: notification definition. TABLE 1 shows the detail of the
• Maintenance Strategy and Functional Location - specifies notification types.
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TABLE I TABLE II
NOTIFICATION TYPE (NT) RELATIONSHIP BETWEEN NOTIFICATION TYPES (NT) AND
MAINTENANCE ORDER TYPES
Maint.
NT Description When to use?
Group NT Order Type Description
Maintenance results from equipment Type
Work request that is
(RM) breakdown, or equipment fails to
in response to an RM REM – Reactive Work performed as a response to failure to perform its intended
Reactive Reactive perform/deliver its intended service.
equipment failure Maintenance function, breakdown or situation requiring maintenance attention.
Maintenance Reactive maintenance allows tracking of
and ad-hoc situation REM order type is defaulted when you create an order against a
breakdown duration.
Maintenance to prevent damages or RM notification type.
impending failure or to improve the Notifications PPM - Planned Time or counter based maintenance to maintain equipment
(ProM) Preventive performance. PPM orders are normally generated from
equipment's reliability. Preventive, created for proactive
Proactive Maintenance maintenance plans and are automatically released.
Predictive and Proactive work are rectification
Maintenance
collectively categorized under ProM requests
Proactive
notification type.
Used to record any inspection activities Used by Inspection PDM – Activities carried out to predict impending failure using modern
(IN) particularly prior to maintenance work or Team to record Predictive technology and calculation technique which is non-intrusive in
Inspection routine static equipment inspection inspection result or Maintenance nature. Example; vibration reading, lube oil analysis,
analysis. report thermograph and bioscope activities, or ultrasound testing for wall
To record plant thickness. This order type is normally created against a PM
(PC) PM notification type.
Used to register approved plant change changes which are
Plant
request. authorized for PRM – Proactive Activities carried out to address observed deterioration of the
Change
implementation Rectification equipment’s performance. Maintenance carried out as a result of
Work which is not preventive and predictive work. PRM order type is defaulted
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Others Used to record work not related to core when you create an order against a PM notification type.
directly related to
(SM) maintenance and supporting functions
core maintenance PSI – Plant Used for plant turnaround and planned shutdown but not
Support such as housekeeping, fabrication, repair
work. Support work Statutory opportunity work. This includes DOSH inspection work, gas
Maintenance of tools, and for other departments support
for other Inspection turbine and compressor scheduled overhaul, control valve
request.
departments servicing, transformer, UPS or other major electrical servicing.
This order type is normally created against a PM notification type.
3) Planning
The purpose of planning is to ensure prudent and cost SM SSM – Support
Services
Work meant for supporting functions but not directly related to
core maintenance.
effective maintenance work practices. The estimated and Maintenance SSM order type is defaulted when you create an order against a
SM notification type.
planned cost shall assist planner to improve maintenance work PC PCM – Plant Plant change request. PCM order type is defaulted when you
planning and serve as reference in future planning. General Change create an order against a PC notification type.
Maintenance
task lists for common maintenance can be adopted to specify
operations of an order. Determine resources required to
perform job (internal and external manpower, spare parts etc).
Based on planned or estimated costs, orders will be sent for C. Performance Management
technical approval before being released for execution. Performance Management is a data from all the
maintenance work that was carried out. It will be extracted
4) Scheduling from the SAP system and stored in the SAP Business
Scheduling is used after necessary planning has been Warehouse (BW) and Carigali Maintenance Management
conducted. Scheduling process involve activities to check Performance System (CMMPS) for analysis and reporting.
availability of resources to perform the job. Subsequent to Performance Management is aims to enable the users to
ensuring the materials availability, the planner will start to generate accurate reports to analyze the efficiency and
schedule or set the working date for the job. The order will be effectiveness of their maintenance work. It is also to provide
released once it is scheduled. Operations Unit with a feedback mechanism to track their
progress towards best practice.
5) Work Execution
Print maintenance order, material issue slip and object list 1) SAP Business Warehouse (BW) reporting
(if required). Monitor user status of order e.g. if there are As an integrated system, SAP Business Warehouse (BW)
operational, material, manpower constraint or if the work is a reporting, and analysis tool and a part of a collection of
carried is only a temporary repair etc. or select and specify the solutions from SAP business suites. SAP BW gives
relevant status on the maintenance order. Monitor estimated, management the advantage of a multi perspective view of their
planned and actual cost of order. Perform partial, full or business which helps in making strategic business decisions.
collective time confirmation for the order. Under the hood, the BW engine is able to extract information
from various sources making it a flexible data processing
6) Reporting and Feedback system capable of being integrated with SAP as well as non-
Complete technical reporting in the system which includes SAP applications. The benefits of Business Warehouse are:-
maintenance report, specifications of damage and cause codes,
confirmation on measurement/counter reading, if any, and (a) SAP BW extracts data from SAP R/3 and stores it in a
specification of malfunction end date if the notification separate server making data retrieval speed much faster.
involves a breakdown. Set system status to TECO technically (b) SAP R/3 system performance is not compromised by
complete to indicate end of maintenance work. running of reports or data gathering.
(c) SAP BW is able to extract data from non SAP systems
and integrate with SAP data to give more comprehensive,
multi-dimensional information.
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(d) BW organizes reports by customized roles e.g. Plant KPI 4 : Total Non-Productive Manhours
Manager, Maintenance Planner, Operations Engineers, etc KPI 5 : Percentage of Proactive Work Created
for easy one step excess to reports of interest. KPI 6 : Equipment Availability, Reliability and Utilisation
(e) Business explorer is a very powerful and yet user friendly KPI 7 : REM Completion
data analysis tool. It gives you all the capabilities of KPI 8 : Work Order Status Details
Microsoft Excel and more. KPI 9 : Overdue Maintenance Order
KPI 10: Total Manhours % Distribution
There are five BW Reports which are Work Identification, KPI 11: Maintenance Overtime Hours
Planning and Scheduling, Maintenance Execution, Feedback KPI 12: Production Loss Shutdown
and Reporting, and Cost Management. TABLE 3 shows the KPI 13: Maintenance Mix Costs
explanation of BW Reports. BW reports can view from the KPI 14: Unit Maintenance Costs
BW Explorer. The user can select any types of reports to be KPI 15: Turbo Machinery Runhours per Start (RPS)
viewed in Microsoft Excel or on the Web. Expert Users are KPI 16: PPM Scheduled Compliance
suggested to use Excel as apart from the BEx Analyzer KPI 17: Inspection Scheduled Compliance
functions and can utilise all Excel functions. The report KPI 18: Percentage of Completed Order by Type
structure divided into three (3) items which are report title, KPI 19: Repetitive Work
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filter cells, and result area. KPI 20: Planning Effectiveness Percentage
KPI 21: Planned or Unplanned Orders Percentage
TABLE III
EXAMPLE OF BW REPORTS
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