Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224
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The document discusses Nexen Energy's implementation of ISO 14224 standards for asset reliability data collection and analysis using SAP software. It describes how Nexen redesigned its technical hierarchy to align with ISO 14224, defining clear equipment boundaries and relationships. This improved data quality and enabled aggregated reliability metrics at the equipment level. The redesign process and lessons learned are discussed. Standard methods like the Industry Standard Plant Maintenance (ISPM) approach are presented for simplifying and automating failure analysis to identify high-risk equipment and prioritize corrective actions.
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Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224
- 1. Driving Value from Assets produced by: Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 Ramesh Vora, Senior SAP PM Business Analyst, Nexen Energy Tony Ciliberti, Principal Engineer, Reliability Dynamics
- 2. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 2 Agenda • Presentation – Process changes and benefits - Ramesh – Methods and technical concepts – Tony • Key learnings – Nexen’s experience over the past 10 years with ISO 14224 – Common issues with technical structures and how to fix them – How to construct an ISO 14224 compliant technical hierarchy • Lessons learned – Implementation and change management
- 3. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 3 ISO Standards Reference • ISO 14224:2006 Petroleum and natural gas industries — Collection and exchange of reliability and maintenance data for equipment • ISO 15926-2:2003 Industrial automation systems and integration — Integration of life-cycle data for process plants including oil and gas production facilities
- 4. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 4 Nexen Energy ULC and SAP • SAP – First go-live in January 2002 (version 4.6C) – Global implementation with shared system configuration and design • Plant Maintenance – Common order and notification types – Unique technical object structures and classifications – ISO 14224 methods implemented in 2006 – Long Lake technical hierarchy redesign completed in 2013
- 5. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 5 Nexen Energy ULC Roadmap Recognize data deficiencies and opportunities for improvement Review and choose proven methods (e.g. standard practices) Evaluate implementation cost Implement and refine methods Define expected results
- 6. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 6 Issues Identified • ISO 14224 Equipment boundaries not defined in the technical hierarchy • Malfunction reports NOT generated against technical tags • Data not aggregated to equipment level • One notification type used for both general maintenance and malfunction reporting
- 7. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 7 Challenges • Finding a solution – Difficult to find a supplier with a firm grasp of the issues and how to fix them • Implementing the solution – Entire Plant Maintenance infrastructure based on the as-is structure – How to covert to the to-be structure with a minimum of pain
- 8. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 8 Remedial Steps Taken • ISO 14224-based technical hierarchy – Consistent equipment boundary definitions • Malfunction Report data validations – Taxonomic level – Minimum data set
- 9. TECHNICAL HIERARCHY Revisions to the Nexen Energy ULC
- 10. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 10 ISO 14224 Technical Structure
- 11. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 11 Starting Point: Technical Drawings
- 12. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 12 Design Template (ISO 14224)
- 13. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 13 Functional Location / Equipment Relationship per ISO 15926-2, Section E.3.3
- 14. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 14 Results
- 15. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 15 Benefits of New Structure • Logical structure – Consistent with international oil and gas standards ISO 14224 and 15926-2 • Best in class practice and aligned with OE principles – Represents ISO 14224 equipment boundaries and interrelationship envelopes • Defines a common reporting level: primary equipment (versus components). • Exactly matches the ISO 14224 failure coding taxonomy (equipment subdivision). • Exactly matches equipment classes from ISO 14224 • Navigation and reporting easier, more accurate and quicker – Simplified tag numbers: Area ID + technical ID • Minimizes learning curve for end users • Quality assurance – Minimizes human error in specifying notifications and order reference objects – One set of standards for all current and future facilities
- 16. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 16 Challenges with the Old Structure • Structural design – Based on Process flow diagrams – Inconsistent application of WBS levels in FLOC structure • FL master records – Very long string, confusing and difficult to remember for end users – Inconsistent with engineering tags (not enough space to enter dashes) • No one-to-one cardinality between FL and equipment – Some FLs had more than 300 equipment assigned under it, making difficult to navigate • Reporting for cost analysts and maintenance managers was difficult
- 17. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 17 Steam Generation: New versus Old Structures • Structure – Entire layer eliminated – Logically organized by equipment type – Category shows taxonomic level • Tag format – Simple and short
- 18. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 18 New Structure: All Steam Generators in One Place
- 19. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 19 Old Structure: Steam Generators split between CPF and Debottlenecking
- 20. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 20 New: HP BFW Pump • The technical structure defines: – ISO 14224 equipment boundaries – Equipment interrelationships • Simple user navigation • Data relationships can be interpreted by the system
- 21. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 21 Old: HP BFW Pump • Equipment boundaries and interrelationship not defined in the structure • Primary equipment has two separate and unrelated tag numbers • Many different component tags without relationships to parents equipment • Located in different parts of the technical hierarchy • Function location IDs are long and unwieldy
- 22. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 22 Technical Hierarchy Conversion Process • One functional location created for each technical tag – Equipment objects installed with 1:1 cardinality – No new equipment objects created • Alternative labelling used to update functional location IDs • FL categories were assigned based on taxonomic level • Notifications were updated with new functional object • Maintenance plans stayed with equipment objects
- 23. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 23 Equipment Taxonomy Definitions • Starting point was ISO 14224, Annex A • Additional “extended” ISO 14224 definitions developed as required LLAK Nexen ObjTyp codes FLoc Structure Code FLoc Structure Code Description Code Source BCR CR CRANES ISO 14224:1999 BFL FL FILTERS & STRAINERS BHB HB HEATERS & BOILERS ISO 14224:1999 BHE HE HEAT EXCHANGERS ISO 14224:1999 BHV HV HVAC BLA LA LOADING ARMS BPI PI PIPING ISO 14224:1999 BSD SD STACKS & DUCTING BSE SE STEAM EJECTORS BSY SY STEAM TRAPS BTK TK STORAGE TANKS ISO 14224:2016 BVE VE VESSELS ISO 14224:1999 ELECTRICAL (E ) ECB CB CABLES & TERMINATORS ECN CN FREQUENCY CONVERTERS ISO 14224:2016 ELI LI LIGHTING EPC PC PROTECTION CTRL MNTR EPT PT POWER TRANSFORMERS ISO 14224:2006 ESG SG SWITCHING GEAR/DSTRB ISO 14224:2016 EUP UP UPS ISO 14224:2006 FAU AU AUTOMOBILES FMB MB OTHER MOBILE EQUIP FTR TR TRUCKS SAFETY & CONTROL (I) ICL CL CONTROL UNITS ISO 14224:1999 IFF FF FIRE-FIGHTING EQUIP IFG FG FIRE & GAS DETECTORS ISO 14224:1999 IIP IP INPUT DEVICES ISO 14224:1999 IVA VA VALVES ISO 14224:1999 ROTATING (R ) RBL BL BLOWERS & FANS RCO CO COMPRESSORS ISO 14224:1999 RCY CY CONVEYORS REG EG ELECTRIC GENERATORS ISO 14224:1999 RGT GT TURBINES-GAS ISO 14224:1999 RHD HD HYDRAULIC DRIVE RLX LX LIQUID EXPANDER RMX MX MIXERS RPU PU PUMPS ISO 14224:1999 RST ST TURBINES-STEAM ISO 14224:1999 RTE TE TURBOEXPANDERS ISO 14224:1999 INFRA-STRUCTURE (T) TCV CV CIVIL TSH SH SHOP & TESTING EQUIP TTL TL TELECOM EQUIPMENT MECHANICAL (STATIONARY) (B ) FLEET/MOBILE (F) EQUIPMENT
- 24. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 24 Lessons Learned • Sponsorship – Active support from the highest level of leadership is a must! • Structure should be: – Consistent for all plant areas – User friendly • Planners and craft people: easy to navigate • Asset Performance Analyst: easy to extract equipment data • Finance: allow cost roll-up per financial structure • Management: easy to generate reports • Not all equipment classes are represented in ISO 14224, Annex A – Extend Annex A for specific equipment requirements • Don’t underestimate roll-out and change management – Learning curve to get familiar with the new set up – Include support groups like Finance, HR, Supply chain, health and safety, etc. – Factor-in post go live support to end users • E.g., changes to global and user specific selection variants and report layout variants – End users may not be SAP savvy or frequent SAP users – People, especially tradespeople, don’t like system changes!
- 25. METHODS OVERVIEW
- 26. Driving Value from Assets produced by: Industry Standard Solution for Plant Maintenance (ISPM®)
- 27. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 27 ISPM • Bottom-line driven approach for optimizing asset management – Maximize production throughput – Minimize health, safety, and environmental hazards
- 28. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 28 Bottom-Line Approach • IDENTIFY – “Bad Actor” Equipment causing failure events with the greatest consequences • ANALYZE – High-consequence failure events and failure patterns of bad-actor equipment causing them – Obtain details necessary to take corrective action • RESOLVE – Implement and prioritize corrective measures
- 29. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 29 Design Principals • SIMPLIFY – Integrate equipment reliability and work execution processes – Instill data quality at inception – Structure data to facilitate accessibility • STANDARDIZE – Use methods consistent with industry and international standard processes – Represent facilities in a logical and standard manner • One system of record for all technical tags • One unique ID for each equipment object throughout all systems and records and in the field – Use standard failure data collection, merging, and assessment processes • Same look and feel for all malfunction reporting • AUTOMATE – Use system-driven data quality-assurance processes
- 30. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 30 IDENTIFY High-Consequence Failure Events The Bottom Line
- 31. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 31 ANALYZE Failure details: Equipment-Level Analysis
- 32. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 32 ANALYZE Failure details: Component-Level Analysis
- 33. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 33 ANALYZE Failure details: Component-Level Analysis
- 34. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 34 RESOLVE Bad-Actor Equipment Issues • Implement corrective measures for bad actor equipment, e.g.: – Preventive maintenance – Inspections – Procedures – Facilities changes • Prioritize corrective measures based on: – Actual consequences – Future consequence potential
- 35. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 35 Application of ISPM in SAP • Architecture – Native to enterprise software – Built-into work management processes • Equipment reliability metrics – Technical hierarchy – Malfunction reporting – PM condition reporting – Consequence accounting – Data aggregation – Data quality management • If you can’t analyze 1000+ things at once, you’re not doing it right!
- 36. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 36 Equipment Reliability Data Quality Management • Infrastructure – Standard process for technical hierarchy construction – Standard process for data collection – Capture data in a structured format – Make data quality easy with system- driven methods • Quality assurance – Technical taxonomy checks – Failure data validations • Quality control – Event record reviews – Feedback to field
- 37. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 37 ISO 14224 Technical Structure – ERP is system of record for all technical tags – One unique ID for each tag throughout all systems, records, and in the field – Equipment interrelationships defined in system Equipment Subdivison
- 38. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 38 K-102 Boundary Definition
- 39. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 39 Use/Location Data
- 40. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 40 Malfunction Reporting Impart Data Quality on Inception Step Details Responsibility Work Initiation Problem Report (equipment-level failure notations), system QA checks Facility personnel Approvals and processing Work approval, planning and scheduling, create statistical records Operations Superintendent Execution, repair notes, and close-out Repair Report (item-level failure notations), system QA checks Maintenance Lead Technician Failure data quality control QA/QC, consequence assessment, and methods feedback Reliability Engineer
- 41. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 41 Malfunction Problem Report (Work Initiation) Equipment-Level Notations
- 42. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 42 Malfunction Repair Report (Work Close-out) Component-Level Notations
- 43. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 43 Approvals and Processing System Creation of Statistical Record
- 44. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 44 Quality Control Processes • Review malfunction and condition reports to ensure completeness and a clear and concise description of what happened • Obtain and input failure consequences, area affected, etc. • Identify “non-malfunction” malfunction reports and set user status to exclude them from the failure data dataset • Review other ERP data to identify missing failure events, e.g. review materials booked against blanket orders of cost centers, review preventive maintenance and inspection results to ensure follow-on malfunction reporting was done, etc. • Identify and document follow-on requirements, e.g. preventive maintenance additions, facilities change requirements, SJP requirements • Circle-back with personnel when issues are found with completion of malfunction reports
- 45. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 45 Event Consequence Assessment
- 46. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 46 Data Aggregation K-102 aggregated failure data ISO 14224:2006 taxonomy K-102 technical structure
- 47. Enabling Corporate Failure Metrics at Nexen Energy with ISO 14224 AME Conference, Las Vegas, Nevada, USA 28-Mar-17, Page 47 Preventive Maintenance and Inspections • Program – Administered as administrative or technical tag level – Results reported at technical tag level • PM Condition Report – One condition report per technical tag inspected – Inspection verdict and condition details – Generated from object list of PM inspection order • Follow-on malfunction report – Generated for any equipment malfunction verdict – Linked to PM Condition Report as subordinate object
- 48. Driving Value from Assets produced by: Ramesh Vora Nexen Energy ULC Ramesh.Vora@nexencnoocltd.com Tony Ciliberti PE Reliability Dynamics tciliberti@rd-eam.com
- 49. Driving Value from Assets produced by: March 27-30, 2017 Green Valley Ranch Resort & Spa Las Vegas, NV
Editor's Notes
- We will now look at work processing. This slide shows the different steps in the malfunction reporting process, specifically: Work initiation Approvals and processing Execution, repair notes, and close-out And failure data quality assurance The ISPM malfunction report is designed to capture equipment failure data in a manner consistent with ISO 14224, Clauses 8 and 9, with Table 6 “Failure data” being shown on the following slide. Note that different views of the same malfunction report are used for the purpose of relevancy.
- As promised, here is Table 6 on the left, required failure data. Work is initiated via a malfunction problem report, a view for capturing equipment level failure details, as that is typically all you will have when first reporting a problem. These data include: Relevant technical tag; It’s failure mode, failure effect, and condition before malfunction; Detection method; Malfunction start date and time; Text descriptions, priority, etc. A couple things of note: Failure modes are equipment class-specific (per Annex B). The system validates data required at this reporting stage.
- Once the repair is completed, you will know component level failure details. You are able then able to complete the Malfunction Repair Report, to collect: The primary failure component and its failure mechanism, root cause, and corrective activity; The malfunction end date; and Text descriptions, etc. Once completed, the malfunction report is placed in completed system status. The system validates required data at close-out.
- We will now switch to data aggregation. ISO 14224 specifies the equipment level, taxonomy level 6, as the common reporting level. In this example, we need to aggregate all events reported within the boundary of K-102 at the parent equipment level for the purpose of failure metrics. Note the are 93 component tags with the K-102 boundary. The system is able to interpret our technical structure and generate statistical records at the equipment level. Thus we are able to get a complete reliability picture for K-102 (or all compressors) by simply running a standard system report. Some notes: Statistical records are a reliability function, transparent to work execution. Some input is required by the reliability engineer in the QA process, for example: The effect at the equipment level can be different than at the component level. Failure mode and condition before failure may be different.