MAXIMO ENTERPRISE ASSET MANAGEMENT IMPLEMENTATION … · HSE incidents roll-up to the sub-system,...
Transcript of MAXIMO ENTERPRISE ASSET MANAGEMENT IMPLEMENTATION … · HSE incidents roll-up to the sub-system,...
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PT PANCA AMARA UTAMA
MAXIMO ENTERPRISE ASSET
MANAGEMENT IMPLEMENTATION
Syamsul Arifin Twin Plaza Hotel, Jakarta
15 Nov 2018
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THE COMPANY
01
THE PROJECT
02
SYSTEM INTEGRATION
03
FUTURE ENHANCEMENTS
04
DOCUMENTATION
05
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OVERVIEW
01 The first ammonia plant in Sulawesi with
total project cost USD 830 million
01 Applying KBR’s patented KRES + Purifier technology, making Indonesia the first
country in the world to leading edge
Ammonia technology.
700,000 Produce 700,000 metric
tons ammonia per annum.
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PRE-CONSTRUCTION CONSTRUCTION POST-CONSTRUCTION
2004
June 21st - PAU established
2011
June 9th - PT Surya Esa
Perkasa Tbk. (“SEP”) takes a 60% stake in PAU
2015
June 22nd - EPC Agreement
signed with PT Rekayasa
Industri
2015
August 2nd - Groundbreaking
attended by President of
Republic of Indonesia Mr. Joko
Widodo
2018
August 6th – 1st Ammonia
Shipment
2018
April 28th
Mechanical
Completion
2014
March 13th - Gas Sales
Aggreement (GSA) With
JOB Pertamina, Medco
and Tomori
2018
Aug 18th – Performance
Test Completed
HISTORY
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2018
Sept 24th - 1st
Commercial
Shipment
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PROJECT
SPONSOR PAU is sponsored by SEP, a publicly listed Indonesian firm (ticker: ESSA). SEP acquired 59,98% of PAU in August 2011
SEP owns and operates the second largest privately-owned domestic LPG refinery in Indonesia, and commenced commercial operations in 2007. Its main business is the refining and processing of natural gas to produce LPG (Propane and Butane) and Condensate. The Company’s facilities are located in Palembang, Indonesia.
SEP also supports the government’s directive to increase domestic value addition within the country.
In November 2014, SEP successfully completed plant expansion project. Currently, the plant is operating on 230 MTPD as compared to the design capacity of 190 MTPD (21% above design)
Completed successful listing on the Indonesia Stock Exchange (IDX) in February 2012, with stock price appreciation of 415% till date. Current Market Capitalization of USD 300 million
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THE COMPANY
01
THE PROJECT
02
SYSTEM INTEGRATION
03
FUTURE ENHANCEMENTS
04
DOCUMENTATION
05
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GOALS
• Implementation of Maximo
for Oil and Gas 7.6.1 as
Enterprise Asset
Management in Jakarta Head
Office and Luwuk plant
• Integration with Microsoft
Dynamics AX as Enterprise
Resource Planning
• Integration with Microsoft
Active Directory
• Integration with OPC server
• Standardized processes for
asset management
• Ensuring that asset
condition does not impact
throughput
• Decisions support system
using real time data &
reports
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A
KICK OFF Business Requirement
Specification
BRS
Business Solution Design
BSD
System Configuration &
Development
Development
User Acceptance Test
UAT
User Training
Training
After Go Live Support
Support
GO LIVE
B
Data Gathering & Upload
METHODS
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Steering Committee BOD
PAU
Project Manager Pramudyo Ananto
TALIAN
Functional Fitri Wahyuni
Jason Rahardja TALIAN
Technical Adi Wibawa
Cesario Dody TALIAN
Data & Report Dev. Rani Purbasari Nobel Gustama
TALIAN
Project Manager Syamsul Arifin
PAU
Project Team
PAU
Project Director Seno HP
TALIAN
PMO & RBM
Biju Varughese KBR
PROJECT
TEAM
Steering Committee
Implementation Team
Counterpart Team
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TIMELINE
REQUIREMENT & DESIGN DEVELOPMENT & TESTING DEPLOYMENT & SUPPORT
November 27th 2017
Kickoff
Dec 2017 – Jan 2018
Business Requirement
Specification
Mar – July 2018
System Configuration &
Development
July 23rd – 28th 2018
User Acceptance Test
August 6th – 15th
2018
User Training
Sept – Dec 2018
After Go Live
Support
Jan – Feb 2018
Business Solution
Design
September 3rd 2018
Go Live
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MS Dynamics AXMS Dynamics AX IBM MaximoIBM Maximo
WorkstationWorkstationWorkstationWorkstation
Jakarta HOJakarta HOLuwuk PlantLuwuk Plant
MS Active DirectoryMS Active Directory
WorkstationWorkstation
OPC ServerOPC Server
WAN
WorkstationWorkstation
ARCHITECTURE
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MAXIMO
STANDARD
BUSINESS
PROCESS
Maximo was configured with the focus on mapping it to the out of the box
functionalities. All the PAU key maintenance management, inventory and procurement
management processes were implemented.
All the necessary integration with the Microsoft Dynamics AX was in place for managing
a seamless financials, procurement and inventory management processes
Supplier
Purchasing
Inventory & Warehouse
Assets
Operations
Maintenance, Reliability & Engineering
Health,
Safety &
Environment
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PLANT
RELIABILITY
ENGINEERING FRAMEWORK
During the PAU Maximo Implementation project the key focus had been on setting up the
Maximo system to support the Reliability Based Maintenance (RBM) framework to leverage
the RBM and HSE from the day 1 of go-live
The following were the key steps and considerations:
Location & Asset
Hierarchy
• Location Hierarchy – (Functional hierarchy) created to manage:
• Failure rollup to the sub-system, system and section level
• Cost Roll-up to the sub-system, system and section level
• HSE incident roll-up to sub-system, system and section level
Asset Prioritization
• Asset Prioritization – The following were the process steps:
• Asset prioritization matrix finalization
• Asset prioritization activity
• Identification of top 150 critical assets
Maintenance Strategy
Development
• Maintenance Strategy Development – For 150 assets, the following were the process steps:
• Failure Mode and Effect Analysis
• Identification of key indicators – Check sheet activities and location / asset meters (manual and automated)
• Identification of Condition Monitoring points
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LOCATION
&
ASSET HIERARCHY
The Location Hierarchy was created for the following areas:
• Main Ammonia Plant (MAP) Area assets
• Utilities & Offsite Area (UOA) assets
• Non-Plant Function (NPA)
The key highlights are as follows:
• Enables the failures, costs (direct and indirect), risks and
HSE incidents roll-up to the sub-system, system and
section level
• Enables the open work order grouping for a system
shutdown planning and execution
• Provides a strong framework for the reliability
engineering with it’s roll-up and roll-down features in
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ASSET
PRIORITIZATION The Asset prioritization is done to identify the following:
• Asset Consequence Priority (Asset Criticality) identification
• Identifying the top critical assets to practice RBM in a cost effective manner
The following are the key consideration for the Asset Prioritization and Relative Risk:
• Asset Prioritization Criteria
• Failure Probabilities
• Consequence Priority Rules
• Failure Consequence Score
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ASSET
STRATEGY
DEVELOPMENT
The Asset Strategy Development activity is conducted for identifying the following:
• Asset inspection tasks and frequencies for failure prevention
• Key location & asset meters for the automated or manual entries
• Condition monitoring points, the warning and action limits
The following are the key consideration for the Asset Strategy Development:
• Setting up the Risk Prioritization Matrix and the scoring rules
• Failure Mode and Effect Analysis (FMEA)
• Identification of Potential Failure intervals
• Inspection tasks and frequencies for early detection
• Key Indicators (meters – Manual and Automated)
• Condition Monitoring points for automated monitoring
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ASSET
STRATEGY
DEVELOPMENT
RISK
- PRIORITIZATION
MATRIX
The Asset Strategy Development activity is initiated with the setting up of the Risk Prioritization
Matrix and the scoring rules:
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ASSET
STRATEGY
DEVELOPMENT
FMEA
&
INDICATORS
Once the Risk Prioritization Matrix and the scoring rules are finalized, the FMEA of the critical assets
are conducted. Based in the Failure Mode various inspection tasks are identified for the early
identification and the inspection frequencies are deduced with respect to the Potential Failure Interval
Based on the FMEA, Inspection Tasks, Frequency and the available opportunity for measurement, the
indicators and the inspection tasks and frequencies are identified:
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ASSET
STRATEGY
DEVELOPMENT
METERS
&
CONDITON
MONITORING
The Key Indicators will be the meters and the mode of data capture will be managed. The Condition
monitoring points will be defined based on the Location / Asset Meter, upper/lower warning limits
and upper / lower action limits.
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ASSET
STRATEGY
DEVELOPMENT
METERS
&
CONDITON
MONITORING
Further to this the dash board views and location / asset meter views will be configured for the visual
alerts in case of any deviations
For the meter where in the
current reading has breached
the limits, the text color will be
displayed in AMBER
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PERMIT
TO WORK
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WO Created
WO Approved
PTW Created
PTW Created
WO Executed
WO Completed
PTW Closed
BENEFITS
Registration/Creation of PTW in Maximo System, Easy to Maintained and Accessed
PTW Record Related to WO Record, Easy to Evaluated in the Future
PTW Report Generated by Maximo System. Can be Printed and Re-printed Anytime, Anywhere
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THE COMPANY
01
THE PROJECT
02
SYSTEM INTEGRATION
03
FUTURE ENHANCEMENTS
04
DOCUMENTATION
05
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MAXIMO-AX
INTEGRATION
MODULES
Asset Management
Work Management
Inventory Management
Purchasing Management
Financial Management
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MAXIMO-AX
INTEGRATION
POINTS
Unit Of Measurement Unit Of Measure
Conversion Conversion
Companies Vendors
Item Master Invent Table
Purchase Requisitions Purchase Requisitions
Purchase Orders Purchase Orders
Receipts Receipts
Inventory Cost Inventory Cost
Issue/Return Transactions Inventory Movement
Transfer Transactions Inventory Movement
Inventory Adjustments Inventory Adjustments
Reconcile Balances Stock Count
Asset Registration Fix Asset Registration
Asset Decommissioning Fix Asset Decommissioning
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MAXIMO -
PLANT
INSTRUMENT
DATA
INTEGRATION
Yokogawa ExaQuantum (Plant Historian)
Maximo EAM Solution Document Management
System
Field Data Management Enterprise Historian
Plant Data
Yokogawa ExaOPC (DCS)
GE System 1 Wartsila
Siemens STG
ABB PMCS
Emerson AMS
wall
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MAXIMO-OPC INTEGRATION
Connect directly to OPC Servers using Maximo OPC Adapter. Read All Tags values
Can be scheduled via Maximo crontask
Integrate to Maximo Asset Meter Reading / Condition Monitoring Measurement
Avoid asset meter reading manual data entry
Reduce technician work order for asset meter reading data inspection
OPC ServerOPC ServerIBM MaximoIBM Maximo
ASSET/LOCATION
METER READING
CONDITION
MONITORING(Autogenerate Work
Order when beyond
lower and upper limit
values)
OPC SERVER
TAGSREAD OPC
SERVER TAGS
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OPC SERVERS CONNECTED
Yokogawa Exaquantum: 3,248 Tags
Yokogawa ExaOPC: 483 Tags
ABB PMCS: 737 Tags
Siemens STG : 97 Tags
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THE COMPANY
01
THE PROJECT
02
SYSTEM INTEGRATION
03
FUTURE ENHANCEMENTS
04
DOCUMENTATION
05
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BIM EXTENSIONS
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BIM EXTENSIONS
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MAXIMO
ANYWHERE
Maximo Anywhere mobile apps can be used in online and offline
scenarios
Run on the Android, iOS, and Microsoft Windows operating
systems
Maximo Anywhere app provides map capabilities for mobile
workers with the geographical location
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MAXIMO
ANYWHERE
FUTURE
ENHANCEMENT
MAXIMO OIL & GAS
FUNCTIONALITIES
Preventive Maintenance
Condition Monitoring Points (Additional CM Points to be brought into Maximo)
Enhancements in the permit to work
Isolation Management
Operators Logs
Failure Investigation
Benefits and Losses
Management of Change
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THE COMPANY
01
THE PROJECT
02
SYSTEM INTEGRATION
03
FUTURE ENHANCEMENTS
04
DOCUMENTATION
05
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BAPP
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BAPP
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1st SHIPMENT
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MAXIMO
IMPLEMENTATION
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MAXIMO
IMPLEMENTATION
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Head Office
PT. Panca Amara Utama
DBS Bank Tower 18th Floor
Ciputra World Jakarta 1
Jl. Prof. Dr. Satrio Kav.3-5
Jakarta 12940, Indonesia
Phone: +62 21 2988 5700
Fax: +62 21 2988 5701
Plant
Jl. Poros Sulawesi, Desa Uso
Kecamatan Batui, Kabupaten
Banggai, Sulawesi Tengah
94762, Indoensia