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SAP Plant Maintenance Technical Objects

Module 2.0

Version: V1.0 Date: 24/02/2013

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Course Content

1. Functional Location

2. Equipment

3. Functional Location Structure

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Functional Location

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Functional location: DefinitionSAP says...

A Functional Location is an organisational unit used to structure the maintenance objects of the company according to functional, process-related or spatial criteria.

• A Functional Location specifies where Equipment is installed or maintenance tasks performed

• A Functional Location contains the information neededfor the assignment of the costs

• When equipment is installed in a functional location in SAP, information is inherited from the Functional Location

Functional criteria e.g. ‘'Pumping station" > “Drive unit".Process related criteria e.g. "Polymerisation" > “Condensing".Spatial criteria e.g. "Hall" > “Location"

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• Functional location: The place •answers to the question: WHERE?•doesn’t change as long as the process isn’t modified

•Equipment : The physically installed item (i.e. Pump, motor...)•answers to the question: WHAT?•can be replaced any time by another equivalent item

Functional Location versus Equipment

• An equipment (pump, motor...) is assigned to a functional location• Job history can be viewed on both the equipment and functional locations• It is possible to transfer an equipment from one functional location to another (e.g.

motor change, PCV change...)• Process technical details are held on the functional location• Equipment specific technical details are held on the equipment• The materials spares list (BOM) is held on the equipment

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Refinery

Operating Unit

Section

AA

S1

561501 571

S0 S2

AA

AA-501-S0

AA-501

1

2

3

1

2

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Functional Location: Hierarchical structure

A Functional Location structure at SATORP is hierarchical & has 5 levels.

The first 3 levels are:-- Refinery - Unit- Section (logical sub-division of the unit)

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Refinery

Operating Unit

Section

Main Function

AA

S1

561501 571

S0 S2

S1001G0002

AA

AA-501-S0

AA-501

AA-501-S0-G0002

1

2

3

4

1

2

3

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Functional Location: Hierarchical structure

Functional Location Level 4

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Function Location: Level 4

Functional Location Level 4: Main FunctionThe purpose of the Main Function is to group all the equipment of same function together.

Main Function Rules:Level 4 shall always include details of the Main Function. For example:A large machine (driven and driving machines) and all associated auxiliaries (lube oil pumps, coolers, etc) shall be included in the same Main Function

A column and all associated instruments (including the control valve and the instruments in the control loop of the valve) shall be included into the same Main Function.

The pumps and their corresponding driving machines, the control valve (and the instruments in the control loop of the valve) of the bottom circuit of a column will be included in the same main function.

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Refinery

Operating Unit

Section

Main Function

Equipment Level

AA

S1

561501 571

S0 S2

S1001G0002

S1001AG0002A

1

2

3

4

5

1

2

3

4

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Equipment is installed on the 5th level (mandatory).

Each equipment identified in SAP will be created as a Functional Location and Equipment as well. It means, there is a one-to-one relationship between 5th level functional location and the installed equipment.

Functional Location: Hierarchical structure

10001071Installed Equipment 10001070

AA

AA-501-S0

AA-501

AA-501-S0-G0002

AA-501-S0-G0002-G0002A

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Function Location: Level 5

Equipment Level Rules:The following should only be created on a Functional Location at Level 5

• Work Requests (Notification) and Work Orders for• Corrective Maintenance• Predictive Maintenance (Planned maintenance). • Preventive Maintenance (Planned maintenance).• Inspection Tasks

Functional Location Level 5: Equipment LevelIt is the lowest level of the Functional Location Structure, representing the Equipment level. It is at this level that the technical object (Equipment item) is “installed”.

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Functional Location Naming Convention

In order to make a Functional Location unique, it is made up of a five segment code, as shown in the illustration below:

Functional Location Code Identification

NAMING CONVENTION

AA – 541 – S0 – G0002 – G0002ARefinerySegment 1 (P)

Operating unitSegment 2 (U)

SectionSegment 3 (S)

Main functionSegment 4 (M)

Equipment Segment 5 (E)

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Functional Location: Example of level 5 coding

EQUIPMENT TAG ON P&ID

LEVEL 5 FUNCTIONAL LOCATION CODE ON SAP Type of Equipment

501-G-0002A AA-501-S0-G0002-G0002A Pump501-GM-0002A AA-501-S0-G0002-GM0002A Motor501-G-0002B AA-501-S0-G0002-G0002B Pump501-GM-0002B AA-501-S0-G0002-GM0002B Motor501-G-0002C AA-501-S0-G0002-G0002C Pump501-GM-0002C AA-501-S0-G0002-GM0002C Motor501-FT-0013 AA-501-S0-G0002-FT0013 Transmitter501-FT-0014 AA-501-S0-G0002-FT0014 Transmitter501-FT-0015 AA-501-S0-G0002-FT0015 Transmitter501-FV-0013 AA-501-S0-G0002-FV0013 Control Valve

Main Function Functional Location Code (Level 4) AA-501-S0-G0002

Functional Location codes that shall be created in Level 5 are as follows:

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The Tag number will be in P&ID format, but without any dashes so pump 501-G-0002-A, as shown on the P&ID will have the Tag number : 501G0002A

Tag number identifies equipment at the 5th level of the Functional Location Structure.

Tag # as it appears on

name plate of equipment

Tag Number

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AA-571-S4-D4001-G4003A(TAG – 571G4003A)

AA-571-S4-D4001-GM4003B(TAG – 571GM4003B)

AA-571-S4-D4001-GM4003A(TAG – 571GM4003A)

AA-571-S4-D4001-G4003B(TAG – 571G4003B)

AA-571-S4- D4001-PI4009(TAG – 571PI4009)

AA-571-S4- D4001-FT4008(TAG – 571FT4008)

Functional Location: Examples Examples of 5th level functional locations within 571 unit

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Functional Location: Generic (Special Case)

• If a Tag level Functional Location (5th level) cannot be found, a generic Functional Location can be chosen however these should only be used as a last resort.

Note:For example a notification should only be created on a pump Tag if the fault is on the pump (i.e. between the inlet flange and the discharge flange).

For other faults such as civil, lighting, cabling, etc. the correct Generic Functional Locations should be used.

• General faults such as, lighting, cabling, civil, etc., should not be reported using the Tag of the nearest large equipment item, as it causes problem when looking at equipment reliability statistics and also maintenance costs.

What are Generic Functional Locations and when should they be used

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Functional Location: Generic (Special Case)

Note: The format for the Tag number of these Generic Function Locations will be the same for each unit, with the first three digits denoting the unit number.

A set of Generic Functional Locations will be created for each unit:

XXXGEN_CABLINGXXXGEN_CIVILXXXGEN_LIGHTINGXXXGEN_PLATFORMXXXGEN_STRUCTUREXXXGEN_TEMPSUPPLY

Generic Functional

Location Tag numbers

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AA-571-S_-COMMON_CIVIL(571GEN_CIVIL)

AA-571-S_-COMMON_CABLING(571GEN_CABLING)

AA-571-S_-COMMON_LIGHTING(571GEN_LIGHTING)

AA-571-S_-COMMON_STRUCTURE(571GEN_STRUCTURE)

AA-571-S_-COMMON_PLATFORM(571GEN_PLATFORM)

Functional Location: Example (Generic )Below are some examples of 5th level Generic Functional Locations within 571 unit .

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Function Location: Category

The Functional Location Category is a single digit code used to identify either the functional location hierarchical level or the type of equipment.

FLOC Category Description

Level 5

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Level 2: Unit

Level 3: Section

Transaction iL03

Function Location: Category & Level

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Level 4: Main Function

(Service)

Level 5: Equipment

Function Location: Category & Level

Transaction iL03

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Functional Location: General data view in SAP

Information relating to the Functional location is held on various tabs within the master-data record.

General Tab

Inventory number is used to group all functional locations linked to a primary equipment.

Class and

Object type

Functional Locations are classified to define the type of equipment, e.g., Pumps, Motors, etc. The same classification code is placed in the object type field, because it is utilised in the Functional Location search screens.

Characteristics are the technical parameters e.g. Pump Type, Capacity, Rating, etc. and these are assigned to classes.

SATORP maintains a one-to-one relationship between Functional Location and Equipment. Technical specifications are maintained on the Equipment level and the process parameters are maintained on the 5th level Functional Location.

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Location Tab

Tag #. In Sort field

Equipment Criticality

Plant Section

Sort field:

The Sort field contains the tag # . The tag # is the main identifier to be used in the creation of notifications (work requests ) and work orders

Functional Location: Location data view in SAP

Plant Section:

The Refinery is divided into areas relating to maintenance responsibilities & these are defined in the Plant Section field.

Naming conventions: AXY A - Area X - Area No. Y – Train No.

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Tag Number

AA – 861 – S1 – BA1003 – G1003BRefinerySegment 1 (P)

Operating unitSegment 2 (U)

SectionSegment 3 (S)

Main functionSegment 4 (M)

Equipment Segment 5 (E)

The Tag number is a concatenation of the Unit number and 5th level functional location number e.g.: 861G1003B. It is held in the ‘Sort’ field of the functional location and equipment master data records.

The Tag number is used when creating notifications (work requests) and is very useful when searching for functional locations.

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Organisation Tab

Cost Centre copied

automatically into Work

Order

Functional Location: Organisation data view in SAP

At the 5th level, the maintenance planner group, main work center and catalog profile, class/characteristics and the object type will be maintained.

Unit Cost Center and Plant Section are automatically assigned to notification & work orders.

The catalogue profile defines the failure codes for a particular type of equipment, when entering history on the notification.

Main Work Center identifies the major work areas or the lead discipline for that particular type of equipment. Main Work Centers are automatically assigned to Notifications and Orders at the header level.

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Structure TabSuperior Functional

Location

Equipment installed in Functional Location

(Equipment are installed at 5th level).

Functional Location: Structure data view in SAP

Functional Location

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Equipment

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Equipment: Definition & use

An equipment master record represents and manages technical objects.

According to SATORP model, an Equipment should always be attached to the fifth level of Functional Location Hierarchy. It is a one to one relationship between the Functional Location (5th Level) and Equipment.

An equipment master record will help to:

Manage individual data for that object

Perform maintenance and service activities

Keep a record of service activities performed (e.g. for maintenance history or reporting purposes)

Record data for long-term evaluation purposes

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Equipment

Information relating to the Equipment is held on various tabs within the master-data record

Many fields are inherited from the Functional location to which the Equipment is installed e.g. Plant, Planner group, etc.

General Tab.

Transaction iE03

Equipment Category

Location Tab

In SATORP, the Equipment Categories maintained are identical to the 5th Level Functional Location Categories

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Organisation Tab

Structure Tab

Func. Loc. (5th Level) to which equipment is

installed

Transaction iE03

Equipment

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Functional Location Structure

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Functional Location: Structure

Scroll down

Expand AA-861

Transaction iH01

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Level 2 expanded

5th Level of Func. Loc. Hierarchy

Click to expand (to view equipment installed at Level 5)

We can view Functional Location by double clicking,

which will take us to transaction iL03 – Display

Functional Location

Level 1

3rd Level

4th Level

Transaction iH01

Functional Location: Structure

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Functional Location: Equipment at Level 5

Level 5 expanded to display equipment installed at level 5

We can view Equipment by double clicking, which will take as to

transaction iE03 – Display Equipment

Transaction iH01

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Bill of Materials(BOM)

Equipt. Expanded to show BOM.

Func. Loc. Level 5

Tag # Sort field.

Transaction iH01

You can also view the bill of material in the functional location structure

Functional Location: Structure - BOM

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Text Headings split the spare

parts in the BOM into logical groupings

Transaction iH01

Functional Location: Structure - BOM

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