Dear Members,

We have been in the Process of PM optimization (by Reviewing of Existing Maintenance)in 25 years old gas Plant. Noticed minor variance of assets in Maximo Vs Field Due to consequent upgrades. As part of this PMO Process we started to validate Asset Register and Functional Hierarchy in the MAXIMO by Comparing in field and P&ID, Inst and Electrical Documents. While doing that we are facing following Challenges as we dont have specfic Policy related to that.

#1-Asset Registration - what are the equipments/Instruments to be added as Asset(in particular block valves or hand valves ,Inter connecting Power cables, DCS Cards shall be added as Asset ?) any guidelines/best practice related to this type of industries, asset registration.

#2-Item Subject to Maintenance (Maintainable Equipment), What are the selection Criteria any guidelines/best practice to the oil and gas related Industry.

Understood many industries have been following Different kind of Selection and registration is there any Value added Selection criteria/Approach or best practice is available. Appreciate your Valuable inputs in this regard.

Regards,
KJAP

Hi KJAP,

Good luck on your as-built walkdown. You are not alone; most companies I deal with have configuration management problems like yours.

If I understand correctly, you are conducting the as-built plant configuration project in parallel with your PMO project. If so, then here is what I recommend:

Item 1:
To reflect the true list of assets included in the PM program, each PM/JP must be directly associated with the asset(s) on which the work or test is performed, or for which the condition is monitored.

Create dummy Equipment IDs. Start each dummy ID with the character “+” and use the convention in place for the respective unit. Placing a “+” on the front end of each dummy equipment ID allows the database administrator to query the database for dummy IDs.

The created Equipment ID will be of a similar construct as existing IDs in Maximo. For example, if a pump and motor are both referred to using one ID with the pump component type, 3ABC-P1A, and then the created motor ID should be of the construct 3ABC-M1A.

Once the PMO project is completed, add the newly identified assets to Maximo’s equipment list only if they require preventive maintenance.

Item 2:
Typically gas and oil use risk-ranking to prioritize failure consequences in each unit. Each asset is assigned a risk priority number based upon its failure detectability, likelihood of failure, and failure consequences. This results in a nice Pareto chart of failure risk ranking. The higher risk assets receive more maintenance attention lower ranked receive less or none.

Here is a partial list of failure effects:
Personnel Hazard
Unit Throughput Loss
Minor Throughput Loss
Startup Delay
Major Impact On Quality Or Purity
Minor Impact On Quality Or Purity
Impact On Upstream/Downstream Process
Unit Shutdown
Reduced Process Efficiency
Personnel Hazard - Low probability of injury
Environ./Other Reg. Event - Major Incident
Environ./Other Reg. Event - Incident
Environ./Other Reg. Event - Near Miss
High Corrective Maintenance Cost
Moderate Corrective Maintenance Cost

Regards,

Thanks Mr. Larry for your swift response in this regard.
Well, appreciate your reply in both but need some clarifications in
Item#1, my query is related to setting up asset in maximo or registering the asset in maximo.
We do have many categories of equipment such as pumps, compressors. Heat exchangers, definitely we do incorporate them as asset as we do Maintenance routinely.
Apart from those categories as instance
Hand valves such as 5" Manual Gate valve in a critical heat exchanger inlet line (those are not tagged in P&ID ,so it is not registered in MAXIMO) If it got struck it may impact the production output. Since, it is not in Maximo and no Planned Maintenance. May result with down time at any point of its life cycle, so we must have determined Policy based on Business risk to set up an Item as ASSET in CMMS.
I have been looking for any best Practice/Guidelines related to this type of industry.
Item#2, Agree with your suggestion. Thank you once again.

KJAP

Here are my responses to your questions:

1) Register all equipment in CMMS as much as possible as the asset register should as complete as possible. We have tagged all hand/manual/blcok valves, cables and DCS cards which are not normally tagged in P&IDs and subsequently, we advised the project people to tag all equipment which are not normally tagged in P&IDs such as fans, small motors, etc. for asset register and maintenance purposes.

Do you have an asset register change request form in place and this is tied to the plant change request procedure?

Do you have equipment hierarchy in your CMMS e.g. you have to tie the manual valve for a heat exchanger under the heat exchanger tag as the parent tag, the DCS card under the DCS parent tag, etc.?

Do you register your pipings and DCS in CMMS?

2) As for Maintainable Equipment or group, decide on which group of equipment can be maintained at the same time if one equipment is shut down.

Mr Josh,
Thanks for your response ,yes I agree with you tagging all the items as asset would be helpful but how do you define as asset since the word it self has broad mean, 1/2 " valve or 4"valve or both we must have some policy or guideline to make some sort of boundary Do u have any best practice or copy of policy to determine the asset selection.

we do have P&ID amendment as part of PCR process.not asset register change form ,it is good idea to add that.

ourCMMS hierachy is based on functional and some discipline have equipment hierarchy(like electrical they do have motor movement,to track the motor electrical have functional hierarchy)not all discipline.

KJAP,

Sorry in the delay getting back to you. I've attached a section of our PMO procedure we use at refineries.

Is this what you were looking for?

Regards,

Fractal_Solutions_PMO_Guide.pdf (103 Kb, 26 downloads) Developing the MEL

Thanks Mr Larry for your efforts.

1/2" or 4" valve: You can register both if both are important. Else, register all valve above 50mm as a cut off point.