SPIE RODIAS – The Maximo Experts – Part 3:
Unlocking with IBM Maximo
What exactly is an activation process in the energy industry, especially for companies that operate their own power plants?
The isolation process creates the conditions in a technical system for carrying out maintenance work on a technical component more safely. For example, fuses are pulled, valves are actuated and physical labelling is applied. Once the planned disconnection status has been ensured, the maintenance work is carried out. Subsequently, the system is restored to an operational condition. There is a close connection between order-related work and the lockout/tagout.
Why is the topic of activation critical to security and what are the risks if it is not carried out correctly?
If the work is not carried out correctly and under safe conditions, e.g. if the pump is still energised and a worker attempts to remove the motor, this can lead to a fatal accident. To avoid such accidents, the de-energising process exists as a structured safety measure.
What regulatory or legal requirements do companies in Germany or internationally have to observe when activating?
In general, the following laws and regulations apply:
- Every employer must take the necessary measures for occupational safety – regulated in Germany in the Occupational Health and Safety Act (ArbSchG)
- The regulations of the German Social Accident Insurance (DGUV)
What are the current challenges in the industry when implementing such processes?
The process cannot be fully automated. Humans are still required to carry out certain checks or do the work. In the current state of typical systems, it is necessary to be able to handle both components that are already digitally controlled and components that can only be operated by humans.
One specific feature is deeply integrated into the handling of the maintenance or order process. The tool must be very well understood by the users, as they are the ones who define the specific work clearance process steps. Maximo supports the specialists in their work; the expertise for the respective system naturally comes from the employees themselves. Consequently, a solution must map the specific work clearance management process of the company well and facilitate error-free operation for the employees.
How could a digital activation process be implemented with Maximo? Which Maximo modules or components would be particularly relevant here?
IBM Maximo already offers support for the basic work clearance management processes as standard. Maximo also offers a lean solution for work clearance management directly by the maintenance technicians themselves.
With the Maximo add-on modules such as HSE and Nuclear, there is then support for more sophisticated work clearance management processes, e.g. mapping a dual control or conflict check.
The customising options also enable customer-specific optimisation to support work clearance planning. For example, you can control the granularity of the lockout/tagout (which system components are protected together) or recommend the selection of switching actions for certain system components based on common practice.
What are the advantages of carrying out the activation process with Maximo compared to manual or previous solutions?
If you support the work clearance management process with Maximo, you can achieve a much better flow of information. During planning, the tagging information stored in Maximo for the system components can be used in a structured manner and conflicts with other work can be recognised, even if they are still in the planning stage.
During execution, a promptly updated system status can be maintained in combination with mobile devices. For example, a shift supervisor can quickly gain an overview of the active tag-outs and ongoing work. This means, for example, that redundant disconnection work can be recognised and avoided.
How can companies customise the solution to their individual requirements? Are there any industry-specific features that need to be taken into account?
Maximo’s high degree of customisability means that it can be adapted to the special features of customer-specific systems. If, for example, the system operator’s activation process does not match the standard Maximo process, the Maximo process can be adapted or even replaced.
How would the unlocking process work in practice?
A work order is created with a list of the tasks to be completed and all possible hazards and precautions that must be taken. When the work order has been finalised, the work release is created from this work order. This work authorisation would contain the list of all components (installations) with conditions such as switched off, switched on, connected, accepted, open, closed, etc.
The conflict check is used to check the planning for inconsistencies. The disconnection instructions are then issued to those carrying out the work.
Once the planned lockout/tagout status has been ensured, the actual maintenance work is carried out.
This is followed by the restoring steps, with which the plant section is brought back to an operational state.
How important is consistent documentation and traceability for operators and supervisory authorities?
Such consistent documentation is extremely important. After all, in the event of damage, liability issues can be of existential importance for the company concerned.
Is there a general trend in the automation and digitalisation of activation processes within the energy industry?
These processes are already largely digitalised for large-scale plants, but can be further optimised (e.g. avoidance of unnecessary routes, fewer paper documents). In the case of field service processes, there is often still very little IT support. Here, the technician can be supported when using mobile devices on site by bundling the relevant information for the activation.
What further innovations or developments can be expected in this area?
A much broader use of mobile applications is to be expected. Due to the security-critical nature of the topic, the activation area is rather conservative. If used correctly, further digitisation of the activation process will make the information available to those involved more accurate and up-to-date. This will improve work and plant safety.