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?

Strategic Asset & Service Mgmt:Six key functional areas…

IBM Maximo Asset Management Suite

Utilities Life Sciences Nuclear Power

Oil & Gas

Industry Solutions

Transportation Government

Maximo Asset Management

Maximo 7.1 IT Asset & Service Mgmnt

OptionsMobile Work

Manager

Mobile Inventory Manager

SAP ERP Adapter

Adapter for MS Project

Oracle ERP Adapter

Adapter for Primavera

Compliance Assistance Documentation

* Enterprise Adapter

* Available with Maximo Asset Management 7.1

Linear Assets

Calibration

Add-On Solutions

Asset NavigatorAsset Configuration

Manager

SpatialChange & Corrective

Action Mgr

SLA Manager

Service Provider

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

Work Mgmt Incident

Investigation

Materials Mgmt

Procurement

Improvement

Change

Action

Safety

Cost Resource Management Planning & Scheduling Operations Management

Contract Mgmt

PR’s, PO’s

RFQ’s

Invoices

Receipts

Inventory

Inspections

Tools

Storerooms

Conditions

Leases

Warranties

Purchase

Labour

Qualifications

Work Orders

Activities

Job Plans

Priority Matrix

Defects

Incidents

Global Issue

Failure Reporting

Escalations

Investigations

AAR

Benefits

Losses

Actions

Job Plans

Documents

Regulations

SLAs

Preventive

Maintenance

Projects

Improvements

MOC

Assets

Locations

Relationships

Item Master

Systems

Production Assets IT AssetsFacility Assets Transportation Assets

Service Request

Work Log

Solutions

Templates

Communications

Business Drivers

Risks HSE MarketPerformanceRegulations

Hazards

Precautions

Plans

RCFA

Authorization

Rep

ort

ing

an

d G

overn

an

ce

The Business: (Missions, Goals, Customers, Users)

Mobile Work

Chemical & Petroleum Asset Management

Inte

gra

tion

Standards – ISO14224/API 689

Drilling Assets Refinery Assets Pipeline Assets

Primavera

ERP

Real Time

MS Project

GIS

Engineering

Petroleum Industry Solution, Integrated Operations

IBM Maximo for Oil and Gas module overview

Maximo for Oil and Gas – Capability Summary

Release 7.1.0 Release 7.1.1

All future release dates are estimates and specific content is subject to change.

Maximo 7.1 Maximo 7.1

Release 7.1.2

Maximo 7.1

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 for Oil and Gas – Capability

Release 7.5 Release 7.X

All future release dates are estimates and specific content is subject to change.

Maximo 7.X Maximo 7.X

Release 7.X

Maximo 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 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)

Inline with HSEMS

Procedures

Data of

Lagging Indicators

Mechanism of

Reporting

Data of

Leading IndicatorsAnalysis of DataNotification Process Tracking

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

Audits – Dashboard View

Audits – Drilldown Lists

Audits - NCRs

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

Sample Prioritization Matrix

Reason for Work

RFW6 RFW5 RFW4 RFW3

Imminent Danger

Safety Environment Routine

Asset/Loc Priority

Matrix Index

Matrix Priority

Matrix Index

Matrix Priority

Matrix Index

Matrix Priority

Matrix Index

Matrix Priority

5 78 5 65 4 58 4 50 3

4 77 5 59 4 51 3 45 2

3 76 5 52 3 41 3 38 2

2 75 5 45 3 39 2 36 1

1 74 5 40 3 37 2 35 1

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.

Regulatory Compliance main tab screenshot

Incidents (Oil) main tab screenshot

Defects main tab screenshot

Investigations main tab screenshot

Investigations After Action Review tab screenshot

Investigations Lessons Learned tab screenshot

Investigations Root Cause Failure Analysis tab screenshot

Prioritization Matrix – Reason For Work tab

Prioritization Matrix – additions to Work Orders

Action Tracking Main Screen Layout

Solutions main tab screenshot

Solutions Benefits tab screenshot

Improvements main tab screenshot

Impact tab screenshot

Losses sub-tab screenshot

Management of Change screenshot