inter pipeline asset management & reliability program with

2015 GOMaximo Annual Conference and Training,

Houston, TX

October 9, 2015

Inter Pipeline

Asset Management &

Reliability Program with

Maximo Oil & Gas

Dan Wood – AMRP Master Data Transitional Lead

Agenda

� Inter Pipeline Ltd. (IPL)

� Maximo

� Asset Management & Reliability Program (AMRP)

– Master Data

– Maintenance Strategies (Work Management)

– Supply Chain Management (SCM, Purchasing and Inventory)

– Reliability Analysis and Life Cycle Cost (RA and LCC)

– Reliability Centered Maintenance (RCM)

– Management of Change (MOC)

– Incident Management

� Mobile Maximo

� Organizational Change Management (OCM) and Interim Processes

� Questions

2

2

World Scale Energy Infrastructure Assets

Oil Sands

Transportation

NGL Extraction Conventional

Oil Pipelines

Bulk Liquid

Storage

Over 2.2 million

b/d of contracted

capacity

3,800 km pipeline

network in

western Canada

Process 40% of

natural gas

exported from

Alberta

27 million barrels of storage capacity in

Europe

Inter Pipeline transports, processes and handles 1.9 million barrels of energy

products per day

3

Inter Pipeline Ltd. (IPL)

4

Maximo

� IPL has been a Maximo user for the past decade (early 2000s)

through the use of Work Management, Inventory and Purchasing

throughout the Canadian operations.

� Upgraded to Maximo 7.1 in 2010.

� Upgraded to Maximo 7.5 in 2015.

� IPL has 500+ employees (200+ Field Personal)

� We have 70+ authorized licenses and 200+ limited use licenses.

� Extraction vs Pipeline

5

Asset Management & Reliability Program (AMRP)

6

� 'I tried being reasonable, but I didn't like it.‘

- Clint Eastwood


� In 2013 IPL began an aggressive initiative, Asset Management and Reliability Program (AMRP),

to take advantage of the available functionality within Maximo 7.5 Oil & Gas, for more robust

business processes.

– Optimize the financial and operational performance of Inter Pipeline’s physical assets

– Improved operational reliability, safety & environmental performance

– Implement standardized scalable practices, processes, and technology for future growth

� AMRP Project Execution Plan

– Design

• Definitions

• Processes

• Process Narratives

• Functional Specifications

• Technical Specifications

• Implementation

– Training, Training, and more Training.

� Best Practices

� ISO 14224 – Petroleum, petrochemical and natural gas industries - collection and exchange of

reliability and maintenance data for equipment.

7

Master Data - Definitions

Inter Pipeline definition of a Location:

� “A static physical place where work is performed and has, had or may have an

asset, or an abstract place that is used to group related places together into a

structure”

Inter Pipeline definition of an Asset:

� “A piece of equipment that requires detailed tracking to support maintenance

activities, supply chain activities, reliability analysis or compliance reporting”

Inter Pipeline definition of the Item (catalog item):

� “A part or supply, with descriptive details, that may be required in operations.

The collection of all items is the Item Master (catalog)”

Inter Pipeline definition of a Structure/Hierarchy:

� “A series of relationships used to organize locations or assets”

8

Spare

Parts

Asset

Structure

Location

Structure

Inter Pipeline Structure

How are these 4 terms are related?:

Parent

Location

Asset

Parent

Location

Operating

Location

Asset

Item

cLocation

Hierarchy

Item

Assembly

Structure

Item

Master Data –Item Master

� Worked with a third party and their standard modifier dictionary(SMD) to optimize

our Item Master, improve the effectiveness and Standardization.

� A standard approach and naming convention was defined for the Item Master,

including required attributes for each Item type.

� Defining Items vs Inventory vs Material

� The current Item Master was reviewed and the new approach and naming convention

was applied to existing items.

� Duplicate items were identified and removed.

� Interim processes and to-be processes were implemented to keep Item Master data

current. Limited people have access to create new items; further limited access

applies to classification and attributes.

� We had roughly 10,000 items in our Item Master that were standardized.

� The third party company enriched 10% of our items.

� We have internally enriched an additional 25% of our items to date.

� The remaining 65% is being enriched on an ongoing bias.

10

Master Data – Assets

� Defined a common definition of “assets” that IPL has adopted by Pipeline Operations,

Extraction Operations and Project Development. This definition includes the list of

asset types to be included in scope. Rotating vs Non-Rotating, we have whole

presentations on this.

� All operating assets are identified, tagged and the required data is collected and

entered into Maximo.

� Interim processes and to-be processes are implemented to keep asset data current.

Interim processes are required prior to the new Maintenance Strategies and Supply

Chain Management processes being implemented.

� A business process is being worked on for Operations to work with Project

Development during the life of a project. The end result of the process will allow for

required information about new assets to be added to Maximo. PD to OPs process.

� All affected staff members are trained on the new processes.

� Challenges involved with the rotating assets and maintaining asset records within

Maximo in a diverse operating network

� One-to-one asset to location relationship.

11

Master Data – Assets

� 71 equipment types as assets, then we defined if they were rotating assets, non-

rotating assets, or tools.

12

Master Data – Locations

� Apply a standard approach and naming convention for defining the Location

Hierarchy, including required attributes for each location type.

� The current Location Hierarchy is reviewed and the new approach and naming

convention is applied to existing locations, as well as new locations being entered as

required.

� Interim processes and to-be processes are implemented to keep location data current.

To-be processes might change with the possible implementation of Linear Asset

functionality.

� A business process is implemented for Operations to work with Project Development

during the life of a project. The new process will allow for required information about

new locations to be added to Maximo.

� All affected staff members are trained on the new processes.

� High Level Hierarchies – System approach

� Low Level Hierarchies – ISO 14224

� Using Visio and Excel.

� Facilities, LACT sites, Valve sites (Mainline and Lateral), and Junctions, etc.

13

Master Data – Naming and Tagging Standard

� The purpose of the Location and Asset Naming and Tagging Standard is to provide a

method for naming and tagging for equipment, instruments, and ancillary devices

located at Inter Pipeline Ltd. (“IPL”)

� This Standard applies to:

– All Canadian assets and locations operated by IPL

– New-build construction, expansion or modifications of assets.

� Existing Equipment that meets Asset Criteria will be tagged according to this standard.

� Cross referencing existing tags with new tags (within Maximo)

� Out of Scope

– Updating Drawings and changing SCADA tags will not be considered In-Scope

work for existing equipment that meets asset criteria for tagging

– Removal of existing equipment/locations tags

14


� There are two different types of tagging that apply to equipment and assets:

– Location/Equipment Tags

• These tags will be used for identifying a piece of equipment by location, type

and function. The physical equipment tag will be used on engineered

drawings and site tags.

• The physical equipment tag (on site) will display text containing the

information presented in next slides.

– Asset Tags

• Asset Tags will be assigned and managed within Maximo for history tracking

purposes. They will be physically affixed to assets.

15

Tag String Breakdown

16

The Facility Location

Identifier (AAAA) will be a

distinctive 4 letter

acronym used to identify a

Facility

A unique site identifier xxxx is

sometimes required after the

Facility acronym to further classify

a site. These will be used for

facilities such as Mainline Block

Valve Sites, Lateral Valve Sites and

LACT Sites.

The equipment Designator will be used

to identify Instrument, Electrical and

Mechanical equipment.

The Stream Number will refer

to the specific line number

within the Pipeline System. The

line numbers range from 1-99;

00 indicates it is common to the

facility.

The Unit identifier designates the

equipment unit number which can be

from 1–9. The Unit Identifier is used for

both series and parallel configurations

where multiple units of the same type

may be installed.

Equipment tag numbers are

sequential from 0 – 9. The

general preference is to use

the “Tag Number” to

consecutively number

similar equipment under

the same “Unit Number”.

Indicates

Redundancy

{A, B, C, D,etc.}

Examples of Facility Location Identifiers

HRBF FACILITY Hardisty Booster HRMF FACILITY Hardisty Meter

HTBF FACILITY Hardisty Trim Blend

KSLT LATERAL Kerrobert South Lateral

LBLT LATERAL Little Bow Lateral

LHLT LATERAL Lathom Lateral

GSLT0415 LACT SITE Gooseberry LACT 04-15



17


� CAPL System Hierarchy

18


� CAPL Gathering Hierarchy

19


� Marked up existing drawings, P&ID, PFDs, Plot Plans, etc.

20

Master Data – Hierarchy in Maximo

21

Data Collection and Tagging

� The logistics involved is a massive field data collection initiative including:

– Pre-collection hierarchy and template development

– High level hierarchies built in Visio, low level (detailed) built in Excel

– Data collection sheets

– Physical collection of asset information through a diverse operations area

– Data validation and mass loads into Maximo

� Interim processes necessary to maintain asset quality

� Tags – Durablack (black anodized aluminum) and tesa Tape (indoors), Barcode 2D

Matrix,

� SS ball chain and 3M adhesive.

� Epilog Laser Printer

� Pilot Tagging and Data Collection (3 days – collected and tagged 330

locations/assets 650 pictures)

� Winter tagging (team of 3) ~100 assets per day, Summer tagging (team of 3) ~200

assets per day.

22

Lessons Learned

23

� Recognize mistakes / problems

� Observe what works / opportunities

� Document them

� Share them

� What went well

� What did not go well

� Remove for Improvement

� After action review / next steps

Tagging and Data Collection

24

Current and Estimated Asset Count

System Current

Locations

Future

Locations

Current

Assets

Future

Assets

Actual

Locations

Actual

Assets

BRPL 633 13,500 155 13,500 3,948 (x3) 2,547 (x3)

CAPL 183 5,500 60 5,500 2,724 1,347

CEP 7,712 15,000 9,033 15,000 TBD TBD

CLPL 200 6,500 10 6,500 TBD TBD

CRPL 183 4,500 0 4,500 TBD TBD

MSPL 110 2,500 49 2,500 TBD TBD

PSPL 61 2,500 0 2,500 TBD TBD

Totals 9,082 50,000 9,307 50,000 TBD TBD

25

• Estimated Future Locations and Assets are based on our Asset List and current Locations in Maximo. Class 5 Estimate +/-

50%, 2014.

• Current equipment lists and assets are track via spreadsheets.

• Actual Assets ~ 10% Rotating Assets

Maintenance Strategies (Work Management)

26

� “Another flaw in the human character is that

everybody wants to build and nobody wants

to do maintenance.”

- Kurt Vonnegut, Hocus Pocus

Maintenance Strategies (Work Management)

� IPL has used the Work Management module within Maximo for the past decade but until

this point there has not been a workflow developed to assist in the planning, scheduling

and execution of maintenance activities.

� There are several challenges encountered when developing a workflow process, which

could be successful in a company which has not used one until this point. It can be quite

easy to build a workflow process which is very robust, but not practical for the maturity of

the organization.

� Developing a workflow process which is suitable for the maturity of your organization is

vital to the implementation of the program.

� Configuration of the ‘out of the box’ screens to simplify the user experience .

� IPL intends to utilize the Job Plan module and some of the limitations to expect based on

interfaces with inventory control and procurement processes.

� Preventative Maintenance philosophy for asset and location relationships and when it is

appropriate to use the Routes module based on your location hierarchy

� Plan on utilizing Maximo Scheduler.

� We have 14 current WO statuses. End state will have 19 WO statuses. The minimum

amount of statuses a WO needs to go through will be similar to current state. The

additional statuses can be used by new teams (Planners / Schedulers to organize their

work).

27

Work Orders and the Process it Drives


� Organization Change Management (OCM) and Interim Processes

– Training requirements to ensure that users are brought along with the changes being

made to the way we do business and the challenges involved. There are two main

categories of training within IPL’s AMRP initiative:

• Interim processes, which are necessary to maintain the integrity of the asset

information which has been collected in the field.

• End state processes, which are extensive but necessary to bring the above initiatives

together.

� Mobile Maximo

– IPL has chosen a mobile vendor which meets the needs of the end state processes,

requiring little to no customization and only simple configuration. This year IPL will have

Maximo users on mobile devices throughout several operating districts. IPL will discuss:

• Rollout of a proof of concept for the mobility initiative

• User experiences with mobility

• Working in remote locations with the mobility product

• Plans for full implementation

29


� Supply Chain Management (SCM, Purchasing and Inventory)

� Reliability Analysis and Life Cycle Cost (RA and LCC)

� Reliability Centered Maintenance (RCM)

� Management of Change (MOC)

� Incident Management

30

Conclusion

31

� “I just hope that one day - preferably when

we’re both blind drunk - we can talk about it.”

- J.D. Salinger

Program Highlights

� Attendee Survey

– Your feedback on this event is very important

to the GOMaximo Board.

• Access gomaximo.org/training to provide feedback

on specific training sessions

• Go to gomaximo.org/conference to let us know

your thoughts on the overall conference.

– Everyone who completes a survey will be

entered into a drawing for cash prizes.

32

Questions

33

Contact Information:

Dan Wood, P.Eng., PMP

AMRP Master Data Transitional Lead

[email protected]

403.218.9560

inter pipeline asset management & reliability program with

Documents