Using Asset Management to Improve Maintenance and Cut Costs

Camcode recently helped petroleum company MIPC identify pipeline assets through unique products and customized asset management services.
Through Camcode’s Asset Management Services:
• MIPC developed a standardized numbering system for pipes and valves to easily and efficiently locate and identify pipeline assets
• Camcode’s Metalphoto^® barcode labels enabled MIPC to adopt a Maximo^® Mobility Solution for preventive maintenance and cost tracking programs
• Asset identification allowed for automated work order generation, thus providing better visibility to manage costs associated with each asset
• MIPC now has a clean asset database in their Maximo system through Camcode’s data remediation process

Project Background
As a petroleum storage and distribution network with more than 50 miles of pipeline and a total tankage capacity of nearly 2.8 million barrels, Monroe Energy’s MIPC pipeline staff knew they needed a serious asset identification and management system in order to track maintenance costs and implement a preventative maintenance solution using automatic data capture. However, with no common asset naming or numbering system, strict regulations to follow, and newly-implemented Maximo Asset Management software in place, MIPC staff knew identifying its equipment assets was no easy feat.
“We had no numbering or tagging system for assets,” said Caroline Kerr, Pipeline Engineer for MIPC. “Some assets, like valves, need to be tested and should be serialized in order to collect data to meet regulations. But in general, we needed some kind of standardized numbering system so everyone could locate and identify our pipeline assets the same way.”
Establishing a corporate-wide tagging solution including asset serialization and equipment descriptions with P&ID locations on the tags would not only allow for easier asset identification, but would also allow MIPC to utilize preventive maintenance and cost tracking programs within its new Maximo system.
“We want to track all costs associated with an asset,” Kerr said. “We want to properly and quickly enter a work order and track corresponding maintenance costs. That way we can see we spent $50,000 repairing that one valve eight times over the span of one year.”
Finally, MIPC wanted barcode labels to work with their planned Maximo mobility system. “In the future, we will use iPads and other mobile equipment to scan the barcode and all corresponding information will be right there and be tracked in Maximo,” said Kerr. “It’s still a work in progress, but the tags were an essential step in order for that to work properly.”
Project Implementation
Camcode engineering team assessed more than 800 valves, motors and pumps to assign asset descriptions, establish a numbering system to each piece of equipment and determined how each asset would be marked with a Maximo barcode label and/or P & ID tag. Each asset was evaluated based on its surface, usage, and environmental factors such as operational environment, equipment maintenance procedures, and interaction with other pieces of equipment.

Marking Specification Example

Camcode’s engineering team recommended Metalphoto labels for all equipment since Metalphoto labels remain readable for 25+ years outdoors. With challenging equipment surfaces and outdoor conditions, MIPC assets required a variety of attachment methods including wire, rivets and adhesives. The Camcode engineering team also created a marking specification for each asset. These specifications were used as a blueprint for Camcode’s label installation teams, and contained detailed directions and photographs on the label placement for consistent and efficient label application in the field. Going forward, these marking specifications also allow MIPC employees to identify assets and determine label placement for new assets on their own.
Project Outcomes
Each label was scanned and the asset data confirmed during the installation process to ensure MIPC had 100% data quality. This data remediation process was completed in Camcode’s secure server where it was confirmed and remediated prior to return to MIPC for submittal back to their Maximo system.
“Camcode manufactured the labels with the exact information we wanted,” Kerr said. “We knew they were durable, would not fade, and would still be readable if paint got on them.”
“The entire project went smoothly from the very start, everybody was extremely easy to work with and very responsive. The program seemed to run itself,” said Kerr. “I was confident the Camcode guys out in the field knew what they were doing and followed all safety requirements.”
“Overall, we were extremely happy with the product and services,” said Kerr. “Now every asset has a visible number and corresponds with Maximo.”
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