KNPC Success Story

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About Kuwait National Petroleum Company (KNPC)

•Established in 1960 ‐ Wholly owned subsidiary of Kuwait Petroleum Corporation.

2 Refineries ‐ Mina Al Ahmadi and Mina Abdullah

Our Products ‐ Refining Crude Oil, Gas Processing and Petroleum Goods

Markets ‐ Supplying to Local and International Markets

Employee Strength – 6000

We Started our Journey in 2005 ..

Control Of Work Manage

Supply Chain

Change Management

Work Management

Health Safety, Security &

Environment

Knowledge Management

ManageAssets

Compliance

Operations

Hazard Risk Matrix Risk Assessment

Work Permit Certification Work Permit

Blinding / De-blinding Plan

Inventory Purchasing

Contracts Material Certification

PrioritizationMatrix

Condition for Work Job Planning

Work Order Quick Reporting Maintenance Log

OperatorTasks

OperatorLog

OperatorProcedure Benefit & Losses

Standard Actions

RegulatoryCompliance

Qualification

Audit and Survey People

Asset List

Solutions Lessons Learned Solution Search

Certification Assets Location

Location Profile Operating Policy

KNPCMaximo

Oil & Gas Modules

Incident Reporting Investigations

Safety Performance Audits

MOC Request MOC

Plant Modification Requests

Complete Utilization

KNPCMaximo

Cross-Platform

Integration

Piping Inspection System

Digital Operator Rounds

Laboratory Information Management System (LIMS)

IP21

e Sourcing

Asset Performance Management

HSSE and Safety Training System

Cross‐System Integration

9,365,252

588,997

362,793

1,348,201

365,949

292,91

260, 903

7,768

ItemMaster

Permit to work

Invoices

Purchase OrderWork Order Tracking

AssetsTracking

DeskTop Requisitions (DTR)

Contracts

19,045

Global Vendors & Contractors record

KNPC Maximo Utilization

KNPC Strategy

Moving toward pure IBM environment with Multitenancy

KNPC will provide Maximo private cloud for its subsidiaries and Cross sister companies.

KNPC End User Experience

Jamil Hassan Alawadhi Team Leader Procurement – KNPC Commercial Department 

Mohammad Khaled Almarzouq Team Leader Mechanical Maintenance ‐ KNPC Maintenance Department 

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Mohammad Al-MarzouqTeam Leader Mech. Maint. – Mina Abdullah Refinery

Subject Matter Expert for Sealing and Bolting Technology

SUCCESS STORY AUTOMATE KNPC UNIFIED BUSINESS PROCESS USING 

MAXIMO APPLICATIONS

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

CONTENTS

Major enhancements that have been implemented in KNPC through Maximo online are as follows:

1. Electronic Work Permit System2. Maintenance E-Log Book.3. ICR – Inspection Corrosion Report4. IAT – Inspection Advice Ticket applications5. HSSE Reporting6. E-PMR.

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Electronic Work Permit System (EWPS) has been implemented in all KNPCRefineries since 2015 to meet KNPC safety requirement .

Benefits• Reduce the paper usage and save the Environment.• Top management can check the work permits status from their desktop (DCEO

and Team Leader level )• Very useful for conducting Safety Performance Audit (SPA) & Work Permit

Audits• During unit shutdown same Work Permit could be renewed up to seven days

WORK PERMIT SYSTEM

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

WORK PERMIT SYSTEM

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

WORK PERMIT SYSTEM

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

WORK PERMIT SYSTEM

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

MAINTENANCE E-LOG BOOKMaintenance E-log book system has been implemented in all KNPC Refineriesfor Maintenance division since 2016 .

Benefits• Daily report being generated in system by unit Supervisor and circulated up to

Team Leader Level through Maximo.

• Every work order status is being monitored through Maximo

• Records of all activities are available digitally in Maximo

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

MAINTENANCE E-LOG BOOK

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

• ICR – Inspection Corrosion report issued by Inspection & Corrosion division upon completion of final inspection of any equipment

• These reports were earlier issued as hard copies & distributed to Maintenance Planning & Operations.

• After Maximo implementation, ICR is being circulated to respective divisions through automated system

AUTOMATION OF ICR- INSPECTION CORROSION REPORT

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Inspection Corrosion Report (ICR) Maximo application

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

• Inspection / Corrosion engineer willissue an IAT after inspection ofequipment or piping throughMaximo.

• IAT will contain observations anddetails of repairs along with therepair procedure

• IATs were circulated throughMaximo instead of distributing thehard copies to MaintenancePlanning & Operations

AUTOMATION OF INSPECTION ADVICE TICKET (IAT)

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

AUTOMATION OF INSPECTION ADVICE TICKET (IAT)

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Reporting the Near Misses, Substandard Acts /conditions , Incidents in KNPC through Maximo online and details are as follows:

Near Misses (NM)

Substandard Act (SA)

Substandard Condition (SC)

HSSE Incidents

HSSE Improvement

HSSE Investigation

HSSE Recommendation Tracing

HSSE Lesson Learned

HSSE REPORTING

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

HSSE REPORTING

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

HSSE REPORTING

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

HSSE REPORTING

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Plant Modification is Hardware or Software change to the existing Plant.

Objectives:

• To ensure that implementation ofPlant Modification does notadversely affect the integrity of theplant, inherent safety and reliability.

• To optimize the process fromproposal initiation to implementationstage

Automation of Plant Modification Request (E-PMR)through Maximo

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Automation of Plant Modification Request (E-PMR)through Maximo

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

MAXIMO Middle East User Group Conference 2019

Supercharging Maximo with AI and Analytics

Jamil Al-AwadhiTeam Leader Procurement – Head Office

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

OUTLINE

MPID

New PPE Management System

RFID

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Material Photo IDentification

Objective• To take the image of all spares and critical materials

• Link image to item master in Maximo

• To inspire the imagination

• To provide additional tools to Users and UDs

MPID

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

MPID - BenefitsVALUE ADDED INFORMATION

SAVING TIME & EFFORT COST SAVING

Evaluation of offersHelp Engineers to see exact materials being evaluatedUseful for new UDsFamiliarize new UDs to visualize the materials used in Refinery operationsPreservation of informationPreserve both old and new informationItems’ photos still will be available in case the materials is nil balance

Physical Stock checkWill enhance the process Material InspectionEase in inspection of materialsDetails to VendorEasy to forward information to vendorMDRReduction in clarifications

GeneralizationEasy to identify the expensive spare parts that can be generalizedDuplicate itemsEasy to identify duplicate items without physically checkingAuctionEasy to exchange information with K-companies and other vendors thus increasing the realization value.

Future integration to e-auction (Reverse Auction)

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

MPID

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

MPID - Benefits

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Objective

• To standardize the process of issuance of Personal Protective Equipment (PPE)

• Tracking usage of PPE

• Budgeting of PPE requirement• Quantifying Emergency, Shutdown, Personal & Visitor PPE

issues

• Optimizing the consumption of PPE

New PPE Management

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

New PPE Management - Tracking

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

New PPE Management – Consumption & Budgeting

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

ObjectiveAutomation of Warehouse through RFID not only lead to enhancement of service but also enables the other divisions to take full benefit of the technology, connecting manufacturer to the end-user thus streamlining the data flow and visibility.

Executive alignment• Provides opportunity to process and execute company’s initiatives in alignment with

objectives• Enable business value• Optimized decisions • Streamline information

Financial benefit• Financial benefits arise from improved process and efficiency, enable transparency,

reduce of cycle time, reduction of paper work and increasing the quality and life of material

• Better usage of working capital• Reducing scrap, waste and surplus

RFID

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

RFID

PHASE -I

PILOT PROJECT

Involving various scenarios of Warehouse

operation using RFID technology

Completed

PHASE -II

IMPLEMENTATION

Preparation of scope of work and implementing on

limited items

In Progress

PHASE -III

SCALING THE APPLICATION

Maintenance, Shutdown, Assets, Space optimization,

Digital signature

Future Plan

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

Looking for below technologies

Automated re-ordering

Augmented Reality in Warehouse Operations

Identification of duplicate items

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

CONCLUSION Maximo provides Control of Work system with the right processes which not only

helps to manage risks. But, it also increases the safety of Maintenance, operationand improves productivity, cost efficiency and quality,

Paperless and Environment friendly,

Maximo system is industries best practice and gives transparency and control ofMaintenance and operations activities.

Maximo is configurable Control of Work safety software, which is designed to meetour business needs and scale up to encounter new challenges.

Maximo is industry-leading system which offers total flexibility for adopting to futurebusiness needs of KNPC.

In future, KNPC plans to provide access to Maximo system through Tablet for readyaccess anywhere & anytime.

CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY

Apr‐19

THANK YOU