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Maximo Oil & Gas. O&G Fit for HSE Tony Turner – Projects Director, Vetasi. Summary. Maximo is a Best of Breed EAM Application Addresses All Strategic Asset Classes from an Operational View IBM has made significant investment in producing targeted Industry Solutions
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Maximo Oil & Gas O&G Fit for HSE Tony Turner – Projects Director, Vetasi
Summary • Maximo is a Best of Breed EAM Application • Addresses All Strategic Asset Classes from an Operational View • IBM has made significant investment in producing targeted Industry Solutions • The Oil & Gas Industry Solutions bring industry specific Best Practices to Maximo • So why haven’t all of the O&G customers gone with Oil & Gas?
Maximo Asset Management Maximo 7.1 IT Asset & Service Mgmnt Industry Solutions Utilities Life Sciences Nuclear Power Government Oil & Gas Transportation Add-On Solutions Service Provider Change & Corrective Action Mgr Spatial Linear Assets Asset Configuration Manager SLA Manager Asset Navigator Calibration Options * Available with Maximo Asset Management 7.1 Adapter for MS Project Mobile Work Manager SAP ERP Adapter * Enterprise Adapter Compliance Assistance Documentation Oracle ERP Adapter Adapter for Primavera Mobile Inventory Manager IBM Maximo Asset Management Suite Maximo Essentials
Adoption of O&G in large ME Oil Companies • Maximo has been deployed at KOC – 5,500 Users • Maximo has been deployed at KNPC – 3,200 Users • Maximo deployed at Gasco – 2,000 Users • Maximo deployed at ADMA – 1,500 Users • Maximo has been deployed at PIC – 200 Users • These are major Oil Companies covering Upstream and Downstream • None of these Companies initially bought into the Maximo Oil & Gas Solution. • Why?
Example – KOC • All Asset Classes are addressed – Wells, Operations, Pipelines, Transport, Plant, Marine Vessels, IT Assets, Ahmadi Township, Roads, etc. • Replacement of Indus Passport System • Purchased many Maximo options: • Spatial – for GIS • Linear – for Pipelines, Roads and Telecomms • Transport – for Plant, Vehicles and Marine Fleet • Utilities – for Crew Management • Mobile Work Management, Inventory Management • ITAM and ITSM • Calibration • KOC Did NOT Purchase Oil & Gas!! • Maintenance team felt it was too advanced for their needs.
Example – KOC • During Application Discovery, the team identified 135 “stand alone” applications • 20 systems to be integrated (Oracle Finance, HRMS, GIS, Scada, TPIMS, Landmark, etc.) • 70 standalone apps to be replaced by Maximo • HSE has 5 Applications: • HSE Live Incident Reporting • HSE Audit Tracking • ePermits • HSE Management System • FileNet Document Management • In process of developing more applications! • KOC adopted Oil & Gas to handle HSE Requirements during the project
The Business: (Missions, Goals, Customers, Users) Integration Business Drivers Reporting and Governance Primavera Risks Regulations Performance HSE Market Petroleum Industry Solution, Integrated Operations Service Request Mobile Work ERP Work Mgmt Incident Real Time Investigation Contract Mgmt Materials Mgmt Improvement Safety Procurement Change Action Cost Resource Management Planning & Scheduling Operations Management PR’s, PO’s RFQ’s Invoices Receipts Inventory Inspections Tools Storerooms Conditions Leases Warranties Purchase Labour Qualifications Hazards Precautions Plans RCFA Authorization Work Orders Activities Job Plans Priority Matrix Investigations AAR Benefits Losses Actions Job Plans Documents Regulations SLAs Preventive Maintenance Projects Improvements MOC Assets Locations Relationships Item Master Systems Work Log Solutions Templates Communications Defects Incidents Global Issue Failure Reporting Escalations Engineering Production Assets Facility Assets Transportation Assets IT Assets MS Project Drilling Assets Refinery Assets Pipeline Assets GIS Chemical & Petroleum Asset Management Standards – ISO14224/API 689
Maximo for Oil and Gas – Capability Summary Release 7.1.0 Release 7.1.1 Release 7.1.2 GA: Sep 28, 2008 GA: Dec 2009 GA: Nov. 2010 • ISO14224 Asset Classifications • ISO14224 Failure Codes • Location and Work Details • Prioritization Matrix • Condition for Work • Regulations • Incidents • Defects • Investigations • Solutions • Improvements • Benefits and Losses • Management of Change • Action Tracking • Standard Actions • Control of Work • Permit and Certificate Types • Risk Analysis • Risk Matrices • Operator’s Log • Standard Action Groups • Maximo Spatial Integration • Support for MIMOSA • Miscellaneous enhancements • Hazards • MOC Risks and Projects • Target Availability • Legacy Tag • Bad Actor Dialog • Service Request (Oil) • Operating Policies • Operating Procedures • Operator Tasks • Cause Analysis/FMECA • Drilling and Completion • Run Log • Material Inspection • Operator Log Enhancements • Scheduler integration • MOC enhancements • Miscellaneous enhancements • Extra failure fields • Incident impact • Regulations extra where used Maximo 7.1 Maximo 7.1 Maximo 7.1 All future release dates are estimates and specific content is subject to change.
Maximo for Oil and Gas – Capability Release 7.5 Release 7.X Release 7.X GA: GA: GA: • Non-conformances • ISO I4224 Failure Mechanism • ISO14224 Sub unit/maint item • Multiple persons on Incident • Classification of risk assessments • Item Master on MOC • Add Regulation to Incidents • Qualifications link to certificates • Qualification verification on Labor • Editable fields on People (Oil) Maximo 7.X Maximo 7.X Maximo 7.X All future release dates are estimates and specific content is subject to change.
Maximo Oil & Gas for HSE • Brings HSE Reporting into the same Platform as Work Management • Can view all Activities against an Asset – SR, WO, PM, Incident, Defect, Change, Moves, etc. • Uses a common database – Assets, Locations, Regulations, Permits, Work Orders, Incidents, Personnel, Qualifications, etc. • Eliminates duplicate data entry (e.g. leaking valve requires a WO and an Incident)
Data of Lagging Indicators Data of Leading Indicators Mechanism of Reporting Notification Process Analysis of Data Tracking Fatalities Inline with HSEMS Procedures Near Miss Company wise/Directorate wise/Group wise/Team wise/Individual wise Statistics Status of incident/ Near Miss/ SOC –Open/Close IDI’s/IDIFR SOC MVA’s /MVAFR HSE Trainings Formats Access to KOC Employees & Contractor employees Audits Pending action items Environmental Incidents Crude Oil Leaks /Gas Leaks etc. Output as per the approved formats of Senior Management, frequency rates etc Senior Management HSE visits Reminders to close the action items Defining the Admin Power & Security Level HSE Campaigns Property Damages Provision to link the statistics with targets to get the status of HSE KPIs Provision to update the formats as & when required Integrating with other data to capture the inputs such as training details traffic violations etc. Fire Incidents Integrity Related Incidents Provision to add the Old data What is Required From Any Software on HSE? Inline with HSEMS Procedures Action items as per the roles & responsibilities
HSE Audits, Inspections and Visits • Set up Dashboard to show HSE Audits • Create WO type Audit to plan, schedule and track audit • Create Follow On Activities for NCR • On NCR attach recommendations
Regulatory Compliance • What is it? • Provides ability to hold details of regulations relevant to work carried out in Maximo, and relate these regulations to both work planned in Maximo and actual work carried out • Use cases • Provide documented proof that work carried out in Maximo was completed based on the required regulation • Provides the ability to demonstrate compliance with many statutory requirements covering safety, health and environment • Business Value • Identifies compliance with relevant regulations • Simplifies work required to demonstrate compliance
Incident Management • Product Capability • An application to record and management incidents occurring during plant operation and maintenance • Incorporates high context incident reporting • Benefits for the Industry • Improved process safety management, encourages collaboration between maintenance and operations • Incident management becomes part of the work management process, rather than a stand alone process • Significant reduction in costs of incident management program since an incident can be ‘raised’ from a work order (automatically copies over related information) • Enables additional automation of process, e.g., an incident on a safety valve can automatically create an investigation • Reduced requirement for other software or spreadsheets
Defect Elimination (Integrity Management) • Product Capability • A defect reporting and management application • Classification of defects supports deeper analysis of equipment integrity issues • Benefits for the Industry • Drives reliability improvement programs, e.g., Six Sigma, Continuous Improvement, Mechanical Integrity • Forms the basis for engineering analysis for the removal of equipment problems and defects • Collaborative application between maintenance, operations and engineering • Enables automation of defect analysis, e.g., escalation of a defect on critical equipment would be different than non-critical equipment • Reduced requirement for other software or spreadsheets
Investigations (Oil) • What is it? • Supports investigations of incidents or defects • A problem may be the result of one or many incidents • Use cases • Raised when a Root Cause Failure Analysis or After Action Review is required • Could be initiated from an incident that requires further investigation into the cause of the incident • Business value • Improved process safety management • A mechanism for initiating the recording of lessons learned by an organization
Prioritization of Work • Product Capability • A matrix based system of work or risk prioritization, reason for work definitions • Configure multi variable (safety, economics, health, regulatory, etc..) operational standards for the prioritization of work based on subject matter expertise • Benefits for the Industry • Standardizes work prioritization based on corporate compliance and operational standards, not personal or ‘tribal knowledge’ decisions • Balances work priorities based on many parameters, not just asset criticality • Ensures compliance, some regulatory, to corporate priorities • Reduced cost / time associated with work planning and scheduling, first step in enabling work planning and scheduling automation
Action Tracking • Product Capability • A means of tracking actions agreed with regulatory authorities or internal review and audit teams • A way of following up actions arising from investigations or improvements • Benefits for the Industry • Drives implementation of business critical actions and improvements • Reduced costs, e.g., regulatory reporting and implementation of improvement programs • Improved safety and reliability • Reduced requirement for other software or spreadsheets
Some thoughts on integrity management? • It is often latent conditions created by maintenance lapses that set an accident sequence in motion or threaten its recovery * • An organization must possess the technical competence necessary to achieve safety goals * • Competence is very closely related to the quality of an organization’s safety information system * * J. Reason, 1997. Managing the Risks of Organizational Accidents
Solutions (Oil) • What is it? • A repository for proven solutions and lessons learned by an organization • Identification of benefits associated with Solutions • Extends People application to provide authorization capability • Use cases • Record details of a successful project to replace a compressor oil cooling system that resulted in a significant increase in compressor reliability • Log a Lesson Learned arising from an After Action Review on an isolation valve repair that led to a potential loss of containment that led to a change to standard operating procedures when performing work that could potentially cause a containment issue • Business value • Supports organizational learning
Improvements • What is it? • An application to record suggestions for improvements to plant operation and maintenance • Supports Six Sigma or similar methodologies • Use cases • Could arise from a defect identified by a maintenance technician or operator • Could be initiated from a Problem that requires improvement action to address the cause • Business value • A mechanism to drive continuous improvement
Benefits and Losses • What is it? • A new Maximo application that defines benefits that can be associated with Improvements and Solutions • Provides a loss reporting capability • Use Cases • Use to document a cost/benefit analysis • Use Losses sub-tab to record production losses associated with planned and unplanned shutdowns and near miss losses • Business value • Drive improvements in plant availability • Focus on business benefit
Management of Change • Product Capability • An application to support a company’s full management of change process from request to closure • Manages review and approval process, pre and post management of change actions; audit trail on entire process • Standard action application to reduce manual data entry • Benefits for the Industry • Improved safety, reliability and compliance • Reduced cost through greater process conformity / standardization through integration with work management process • Encourages collaboration with operations, maintenance and engineering • Improved organizational learning • Reduced requirement for other software or spreadsheets
Full Cycle MOC • Request Change • Review • Approve • Pre-MOC actions • Authorize • Post-MOC actions • Closure • Decision support – identification of bad actors
Conclusion • Maximo Oil & Gas provides platform to integrate HSE Activities with Work & Asset Management • Avoids Siloed Systems and “pop up” applications • One Stop Shop for Incident Reporting, Work Management, Investigations, Management of Change, Safety Compliance • The advantage of a “single version of the truth” outweighs possible shortfalls in depth of base functionality. • An Oil Company implementing Maximo should look at O&G from an HSE and Integrity Management perspective – not from the traditional Maintenance viewpoint.
