Transcript IS-U processes within Mobile Asset Management

Work Clearance
Management
Christoph Wobbe
WCM GmbH
Rory David Shaffer
Utilities IBU
Agenda
1.
Background
2.
Customers
3.
Overview of WCM
4.
News
Agenda
1.
Background
2.
Customers
3.
Overview of WCM
4.
News
What is basic WCM?
... the process of ensuring safe conditions for
personnel while performing maintenance
work and controlled testing
What is our background?
 Clearance module created in R/2, installed in Cofrentes nuclear
power plant in Spain
 Modifications and enhancements required to suit additional
European as well as North American requirements
 WCM focus group (1996-1999)
Why Work Clearance Management?
 Maintenance crews are working in a hazardous environment (high
voltage, radiation exposure, hot steam, ... )
 The guarantee of supply requires maintenance work while
systems are up and running
 The functionality of a technical system must not be affected under
any circumstances
 There are typical work-related illnesses, which require special
health and safety measures
What are the key benefits?
 Integration in SAP Enterprise Asset Management
 Easy to learn & use
 Standardized procedures
 Open model
 Authorization process
 Library of Work Clearance Document Templates
 Lockout/Tagout
 Mobile Lockout/Tagout
 Meets OSHA regulations (s. next slide)
What is basic Lockout/Tagout?
Lockout/Tagout is the common name for a process
of "Control of Hazardous Energy" as established by
the Occupational Safety and Health Administration
(OSHA) under Federal Registry 29 CFR 1910.147.
What are the Releases?
ISU-WCM
1.1 (3.1H) 12.1998
SAP ERP 6.0
ISU-WCM
4.61 (4.6B)
- 05.2000
ISU-WCM
1.2 (4.0B) 06.1999
R/3
Enterprise
R/3 4.6C 06.2000
• Enhancement
Packages 1-3
SAP ERP 5.0
Agenda
1.
Background
2.
Customers
3.
Overview of WCM
4.
News
WCM Market Overview
WCM Projects:
 More than 25 countries
 More than 10 different
languages
 More than 150 customers
 More than 250 installations
© SAP 2008 / Page 11
WCM Market Overview
Norway
Finland
Sweden
Netherlands
Belgium
Germany
France
Hungary
Canada
USA
Russia
China
Spain Italy
Saudi Arabia
Korea
Japan
India
Mexico
Venezuela
Singapore
Brasil
Australia
Argentina
© SAP 2008 / Page 12
WCM Market Overview
WCM Industries:
 Generation Companies
 Nuclear
 Fossile
 Transmission Companies
 Oil & Gas
 Mining
 Public Services
 Public Transport/Railways
 Paper
 Defense
© SAP 2008 / Page 13
WCM Customers
Electrabel (Belgium) Iberdrola (Spain) Endesa
(Spain) Ringhals (Sweden) E-ON (Germany)
RWE (Germany) CS Energy (Australia)
Macquire Generation (Australia) PSEG (USA)
OGE (USA) Edison Mission Group (USA)
New Brunswick Power (Canada) ONGC (India)
TUAS Power (Thailand) Cogen (Singapore)
Singapore MRT (Singapore) KH&NP (Korea)
Beijing Electric Power Corporation (China)
Shell (Global) Statoil/Hydro (Norway)
Work Clearance Management
WORK CLEARANCE MANAGEMENT - A PERFECT
TOOL FOR GENERATION FACILITY MAINTENANCE
Electrabel is a private power company active on the
European energy market.
Our core business
“The implementation of SAP
Work Clearance Manage-ment
with mySAP PLM Asset LifeCycle Manage-ment at the
Electrabel nuclear power
stations fits perfectly into our
policy to continuously
improve safety and efficiency
of maintenance processes.”

we sell electricity, natural gas and derived energy
products and services,

we generate electricity,

we trade electricity and natural gas,

we build, manage and service networks used for the
transmission of electricity and the distribution of
electricity and natural gas.
Other activities complete our offer in Belgium: cable
TV and radio, distribution of water, ...
Jean Pierre Gourgue,
responsible for SAP Electrabel
Generation
Electrabel, Belgium
Work Clearance Management
WORKING SAFELY IN POWER PLANTS USING WORK
CLEARANCE MANAGEMENT
A better solution for managing and empowering safety in
power plants
„The SAP Work Clearance
Management component,
developed by SAP with the
collaboration of Iberdrola, has
contributed to the increase in
safety and efficiency of work
in all of Iberdrola‘s power
plants, being specially useful
for refueling Cofrentes
Nuclear Power Plants.“
Juan Antonio Almendros
Monedero, IT
© SAP 2008 / Page 16

Iberdrola is one of Europe's leading electricity
companies, with almost 8.8 million customers in Spain
and over 7 million in Latin America. Iberdrola also has
a large Industrial Group operating in several sectors
and countries. It employs 10,800 people and had sales
of €7,000 million in 2000.

Iberdrola Generación's total installed capacity for
hydroelectric, conventional thermal and nuclear
production is16,000 MW. Gross production totals
51,200 GWh and accounts for 29 % of Spain’s total
production.
Iberdrola S.A., Spain
Work Clearance Management
SAFE NUCLEAR PLANT MAINTENANCE AND
OUTAGE PLANNING WITH ASSET LIFE-CYCLE
MANAGEMENT

“The implementation of SAP Work
Clearance Management was one
of the most important and basic
functions in the introduction of
SAP R/3 when the project began
in spring 1997. The project went
live in December 1998 and since
1999, Ringhals has successfully
planned and safely performed
maintenance activities in all four
units. Today, SAP Work
Clearance Management is
accepted as a natural modern
maintenance tool in daily work.”
Ringhals, located south of Gothenburg, is the largest
nuclear power plant in Scandinavia with four units.
Ringhals AB belongs to the Vattenfall Company. The
power plant supplies most of Sweden´s west coast
with electricity. Its total capacity is 3,500 megawatts,
approximately 15-18% of total consumption in Sweden.
Since the 1st of August 2000, the Barsebäck power
plant has become a subcompany of the Ringhals
group. A total of five reactors generate 4,100
megawatts, and with approximately 1,500 employees,
Ringhals is one of the largest power producers in the
world.
Ringhals AB, Sweden
Owe Petersson, Project Leader
© SAP 2008 / Page 17
WCM Market - Utilities
Generation Companies
(nuclear, fossile, hydro) use WCM
for the safety and approval
processes while they perform
standard maintenance as wellas
during overhalls/revisions.
Transmission Companies
use WCM for the safety processes
around maintenance work and
outages in their grid.
Work Clearance Management is
used for the isolation of high
voltage lines and gas pipelines.
Customers:
- Areva
- Compañía Mexicana de Gerencia
- Sempra Energy
- North China Grid Company
WCM Market – Oil & Gas
Oil&Gas Companies
use WCM for the safety and
approval processes while they
perform standard maintenance as
well as during overhalls/revisions.
Work Clearance Management
represents the Valve&Blind lists
and is part of the permit to work
processes.
Customers:
- Petróleo Brasileiro (Petrobras)
- Shell
- Statoil/Hydro
- Chevron
WCM Market - Mining
Mining Companies
use WCM for the safety and
approval processes while they
perform standard maintenance
processes.
Work Clearance Management
documents the safety processes
and show the users when a
certain part of a mine is safe.
Customers:
- BHP Billiton
WCM Market – Public Services
Public Services Companies
which use WCM are mainly water
companies. Here WCM is used for
hydro plants, pumpstations etc.
Customers:
- State of California
WCM Market – Public Transport
Public Transport/Railways
…use WCM to ensure the safety of their
maintenance crews while they are
working on the railway system or in the
tunnels of the undergrounds.
Customers:
TMB (Transports Metropolitans de
Barcelona)
Singapore MRT
WCM Market – Paper Industry
Paper Industry
use WCM to define the safety
processes for maintenance and
inspection work as well as the
revisions of the paper mills.
Customers:
- United Paper Mills (UPM)
- Weyerhaeuser
WCM Market - Defense
The Defense market
use WCM for the safety
requirements of the nuclear
submarines.
Customers:
- US Navy
Agenda
1.
Background
2.
Customers
3.
Overview of Work Clearance Management
4.
News
Maintenance Process with WCM
Work Clearance
Management
Maintenance plan
Notification
Create
Order
Plan
Order
Release
Order
Complete
Order
Confirm
Order
Analyze Histories
SCADA
Work Clearance
Management
Maintenance
Operation
WCM Objects – Architecture (1)
Standard Model
Applications:
Order
 Work Clearance Application (WCA)
Order
Order
Work
Clearance
Application
Work Clearance Documents (WCD)
 WCD Template
 Operational WCD
Operational
WCD
Operational
WCD
Operational
WCD
WCM Objects – Architecture (2)
Enhanced Model
Work Approval (WAP)
Order
Order
Order
Work
Approval
Applications
 Work Clearance Application (WCA)
 Application for Radiation Protection
Work
Clearance
Application
 ...
Work Clearance Documents (WCD)
 WCD Template
 Operational WCD
Operational
WCD
Application for
Radiation
Protection
Operational
WCD
Maintenance Process with WCM
Creation of
work permit
Closure
Requestors
Risk Analysis
Execution
Process
Preperation
Work
Authorisation
& Acceptance
Maintenance Process with WCM (1)
Creation of Work Permit
 Define for which Technical Objects (Functional Locations, Equipments) is a
Safety Process required
 Create WCD Template(s) for these Technical Objects
Maintenance Process with WCM (2)
Requestors Risk Analysis
 Create a Maintenance Order
 Valuation of the Work Clearance Management Process
 Assign additional Documents (eg drawings)
Maintenance Process with WCM (3)
Process Preparation
 Define WCM related Tasks
 Assign Work Clearance Application
 Create Operational Work Clearance Document based on Template
 Start Simulation for conflict checks
 Print tags/tagging list or start mobile tagging process
 Start isolation process (incl. approval process + conflict checks)
Maintenance Process with WCM (4)
Work Authorisation &
Acceptance
 Confirm Isolation
 If all Isolations are confirmed, the approval process changes the
status of the Maintenance Order
 Trafic Lights are now all in green
Maintenance Process with WCM (5)
Execution
 Order is now ready for execution
 Start maintenance process
 Confirm maintenance process
 (Start test cycle with temporary untagging/tagging)
 Final confirmation of maintenance work
 Start untagging process (incl. conflict checks, approvals)
 Confirm untagging
Maintenance Process with WCM (6)
Closure
 Close Maintenance Order
 Close Work Clearance Documents
 Information is moved to our Information System/BI
 Analysis for future work
Agenda
1.
Background
2.
Customers
3.
Overview of Work Clearance Management
4.
News
Mobile Work Clearance Management
Goals of mobile WCM
To assist the processes of orderly tagging and subsequent
untagging of technical objects, shop papers (so called operational
lists) are required. The operational list contains the necessary
information and support the performance on site. The safety
technician confirms the execution of the activities on site, on the
operational list. Afterwards the safety engineer must confirm the
execution of the activities in the system (on basis of the processed
operation list). Normally the operational list must be kept for
several years.
This processes are time-consuming (receipt and return) and errorprone (duplicate confirmations).
Mobile Work Clearance Management
 Mobile WCM is a full offline mobile solution. Mobile WCM
supports the safety processes for tagging and untagging
technical assets.
 Platform-independent application: runs on almost all mobile
devices
 Offline application: data entries can be synchronized
whenever it is convenient for technician or safety engineer
 Application is seamlessly integrated into the SAP backend
system
Customer Value of Mobile WCM
 Non paper-based standardized processes improve safety.
 Increases data entry accuracy and eliminates delays for
dependent business processes
 Minimizes or eliminates “paper work operational lists”
 Reduces outage time of transmission lines
Linking Operations with WCM
Which operations require safety activities?
Can I start operations before the tagging is confirmed?
How I can I group operations and approvals?
Linking Operations with WCM
Order
Operational
WCD
Operation
10
Operation
20
Approval Group
„Hot Work“
Approval Group
„Tagging“
Operation
30
Approval Group
Operation
40
Work
Clearance
Application
Approvals:
- Hot Work
- Tagging
- Untagging
„Untagging“
Operations are assigned and bundeled to Approval Groups
Operational
WCD
Operational
WCD
Mode Dependent Tagging
 The more generic approach of this feature is to maintain the
untagging conditions of assets/equipments in the WCM
component.
 In an Operational WCD the untagging condition of an item will
be dynamically determined, depending on the current overall
condition of the technical system.
 To achieve this the required untagging conditions of the
technical assets in the unit are stored.
 As this required untagging condition may vary with the overall
condition of the technical system the untagging conditions of
the technical assets (or components) are stored dependent on
the overall conditions of the technical system of the unit.
Mode Dependent Tagging Architecture
Functional Location / Equipment
overall condition
of the technical system
mechanical
electrical
operational
group
01
closed
02
closed
03
open
04
open
01
on
02
on
03
on
04
off
untagging
condition
WCM Newsletter
© SAP 2008 / Page 44
Thank you very much!
Questions
Rory David Shaffer
[email protected]
Contact: [email protected]
© SAP 2008 / Page 45