MAXIMO ENTERPRISE ASSET MANAGEMENT IMPLEMENTATION … · HSE incidents roll-up to the sub-system,...

PT PANCA AMARA UTAMA

MAXIMO ENTERPRISE ASSET

MANAGEMENT IMPLEMENTATION

Syamsul Arifin Twin Plaza Hotel, Jakarta

15 Nov 2018

THE COMPANY

01

THE PROJECT

02

SYSTEM INTEGRATION

03

FUTURE ENHANCEMENTS

04

DOCUMENTATION

05

15 Nov 2018 2 Maximo Implementation Project - PAU

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.


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


2018

Sept 24th - 1st

Commercial

Shipment

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


THE COMPANY

01

THE PROJECT

02

SYSTEM INTEGRATION

03

FUTURE ENHANCEMENTS

04

DOCUMENTATION

05


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


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


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


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


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


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


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


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

Maximo. 15 Nov 2018 14 Maximo Implementation Project - PAU

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


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


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:


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:


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.


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


PERMIT

TO WORK


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

THE COMPANY

01

THE PROJECT

02

SYSTEM INTEGRATION

03

FUTURE ENHANCEMENTS

04

DOCUMENTATION

05


MAXIMO-AX

INTEGRATION

MODULES

Asset Management

Work Management

Inventory Management

Purchasing Management

Financial Management


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

Budget Budget 15 Nov 2018 24 Maximo Implementation Project - PAU

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


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


OPC SERVERS CONNECTED

Yokogawa Exaquantum: 3,248 Tags

Yokogawa ExaOPC: 483 Tags

ABB PMCS: 737 Tags

Siemens STG : 97 Tags


THE COMPANY

01

THE PROJECT

02

SYSTEM INTEGRATION

03

FUTURE ENHANCEMENTS

04

DOCUMENTATION

05


BIM EXTENSIONS


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


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


THE COMPANY

01

THE PROJECT

02

SYSTEM INTEGRATION

03

FUTURE ENHANCEMENTS

04

DOCUMENTATION

05


BAPP


1st SHIPMENT


MAXIMO

IMPLEMENTATION


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

MAXIMO ENTERPRISE ASSET MANAGEMENT IMPLEMENTATION … · HSE incidents roll-up to the sub-system,...

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