ENHANCED WORK SAFETY IN PLANT MAINTENANCE PROCESS IN DISTRICT HEATING PLANT LJUBLJANA

Toma Lenart (TE-TOL) Miha Ular (Sapphir d.o.o.)

SAP Conference for Utilities 2012

Madrid, 18.04.2012

AGENDA

1. Termoelektrarna Toplarna Ljubljana

2. SAP PM: Key processes

3. SAP WCM implementation project overview - Enhanched worker safety 4. SAP WCM process
5. SAP PM and WCM in TE-TOL: Way foward

SAP Conference for Utilities 2012

JHL SAP IMPLEMEMNTATION PROJECT

MOL: MUNICIPALITY OF LJUBLJANA JAVNI HOLDING Ljubljana, d.o.o.
2007
JP Energetika Ljubljana d.o.o. JP Vodovod Kanalizacija d.o.o. JP Ljubljanski potniki promet, d.o.o. Snaga javno podjetje d.o.o. Termoelektrarna Toplarna ljubljana

2008

JAVNI HOLDING Ljubljana, d.o.o.

UNIFORMATION OF BUSINESS AND IT PROCESSES OF PUBLIC COMPANIES

STRATEGIC HOLDING MODEL CONFORMATION

01.01 2009

I. Phase of reorganisation was accomplished

Transfer of legal department of a business and Departement for public tenders to JHL

SAP
01.05-2010

II. Phase of reorganisation was accomplished

Transfer of FI/CO, HR and IT departments to JHL

01.01.2012

Termoelektrarna Toplarna Ljubljana

SAP ERP ISU WAS IMPLEMENTED BY SAPPHIR D.O.O.

SAP Conference for Utilities 2012

PUBLIC HOLDING LJUBLJANA - TODAY

MOL: MUNICIPALITY OF LJUBLJANA

JHL: PUBLIC HOLDING LJUBLJANA

JAVNO PODJETJE ENERGETIKA LJUBLJANA D.O.O.

JAVNO PODJETJE VODOVOD KANALIZACIJA D.O.O.

JAVNO PODJETJE LJUBLJANSKI POTNIKI PROMET, D.O.O.

SNAGA JAVNO PODJETJE D.O.O.

TERMOELEKTRARNA TOPLARNA LJUBLJANA

Distribution and supply of natural gas and heat to tariff consumers

Management and maintenance of public water supply system, connections and management, maintenance and cleaning of public sewage system

Public transportation of passengers in urban traffic

Collection, transportation and disposal of municipal waste, cleaning of public areas and management of public restrooms

Electricity and heat producing

RELATIONSHIP

SAP Conference for Utilities 2012

TERMOELEKTRARNA TOPLARNA LJUBLJANA (TE-TOL)

TE-TOL is the biggest, highly-efficient cogeneration facility in Slovenia, producing electricity and heat in cogeneration. We are providing more than 90 percent of demand for heat in the district heating system of the city of Ljubljana, the capital of Slovenia, which represents about 50 percent of total heat demand in district heating systems of Slovenia.

Total installed power:

Electrical power Heat + process steam (TE)

Possible annual generation: Electricity (EE) Heat + process steam (TE)

124 MW 350 MW

550 GWh 1.650 GWh

SAP Conference for Utilities 2012

AGENDA

1. Termoelektrarna Toplarna Ljubljana

2. SAP PM: Key processes

3. SAP WCM implementation project overview - Enhanched worker safety 4. SAP WCM process
5. SAP PM and WCM in TE-TOL: Way foward

SAP Conference for Utilities 2012

TE-TOL SAP PM/CS PROCESS - INTEGRATION

SYSTEM INFO.: SAP ERP VER. 605 IS-UTILITIES

WCM
WCD

WCA

PM
NO NOTIFICATION WOR ORDER MATERIAL ? EXTERNAL SERVICE? YES NO

YES

SAFETY MEASURES?

NO

WORK FINISHED

WORK CONFORMATION

YES

RESERVATIOM

PURCHASE REQ.

WORK COMPLETE

NO

SALES SERVICE? YES

BOOKING

PURCHASE ORDER

SD FI

STATEMENT OF ACCOUNT

WM
GOODS RECEIPT SERVICE RECEIPT

BILL

MM

CO

CONTROLING

SAP Conference for Utilities 2012

TE-TOL: SAP PM TECHNICAL OBJECTS MANAGAMENT

TECHNICAL DATA: Manufacturer, type, catalog number, serial number, weight, dimensions..

LOCATION DATA: - Functional location - strucure - BOMs

SAFETY DATA:
- Safety measures, - work permits

ORGANISATIONAL DATA: Cost center, asset number, responsible person, plannig plant, department ...

SPECIFIC DATA:
Power suction/pressure hight , capacity ...

SAP Conference for Utilities 2012

TE-TOL PM NOTIFICATION AND WORK ORDER MANAGEMENT

PREVENTIVE MAINTENANCE PLAN (Automatic generation of WO) - Equipment, - Person responsible - Task List
PERSON RESPONSIBLE

MAINTENANCE NOTIFICATION - Equipment, - Person responsible - Malfunction data WORK ORDER

WORK EXECUTE

WORK CONFORMATION

WORK COMPLETE

SAP Conference for Utilities 2012

TE-TOL PM NOTIFICATION
SHORT TEXT AND STATUS

WHERE? WHAT?

LOCATION DATA

DESCRIPTION

WHO?

PEOPLE/DEPARTMEN RESPONSIBLE

WHEN? WHY?

TERMINATION MALFUNCTION DATA

SAP Conference for Utilities 2012

TE-TOL PM WORK ORDER PROCESS

WO CREATION

WO COST OVERVIEW

WO CONFORMATION

WO HISTORY

SAP Conference for Utilities 2012

TE-TOL: SAP PM IMPLEMENTATION KEY BENEFITS

OPEARTATION AND MAINTENANCE OPTIMISATION

CONDITIONAL BASED MAINTENANCE

MAINTENANCE AND OPEARTION PLANING

AUTOMATIC GENERATION OF WO BASED ON PRED-DEFINED PLAN

WORK PLANING (FINANCIAL, WORK SCHEDULING)

PM

MAINTENANCE ANALYSES

WORK TIME ANALYSIS

BREAK DOWN ANALYSIS

WORKFLOW (Improwed inforation flow, conformation of people responsible))

NOT (YET) IMPLEMENTED

PM and WCM

SAP Conference for Utilities 2012

AGENDA

1. Termoelektrarna Toplarna Ljubljana

2. SAP PM: Key benefits

3. SAP WCM implementation project overview - Enhanched worker safety 4. SAP WCM process
5. SAP PM and WCM in TE-TOL: Way foward

SAP Conference for Utilities 2012

WHAT IS SAP WCM?

PLANING EXECUTION

PM
NOTIFICATION PM WORK OREDR PM WORK ORDER

LANS

PREPARED

EXEC.

TERM.

WCM

VALUATION

WCD EXEC. (lockout/tagout)

WCD: NORMALISATION

WAP

WCD APPROWAL

WCD COMPLETED

WCA

WCA APPROWAL

WCA COMPLETED

WCD

WAP APPROWAL

WAP COMPLETED

SAP WORK CLEARANCE MANAGEMENT HANDLES SAFETY-RELATED PROCESSES IN PLANT MAINTENANCE

SAP Conference for Utilities 2012

JPE AND TE-TOL: ENHANCHED WORKERS SAFETY SAP WCM IMPLEMENATION PROJECT

BLUEPRINT
16.12.2011

CUSTUMIZING
03.01.2011

TESTING
31.01.2012

EDUCATION
29.02.2012

GO LIVE
01.03.2012

2
WCM IT 3DAY SUPPORT

SAP Conference for Utilities 2012

SAP WCM AND PM

MAINTENANCE PLAN

WCM

PM NOTIFICATION

CREATE ORDER

PLAN ORDER

RELEASE FOR EXECUTION

CONFIRM ORDER

COMPLETE ORDER

SCADA

WCM

HISTORY/ANALYSIS

In order to ensure that safety measures are performed for maintenance work tasks, you must activate Work Clearance Management for maintenance orders. These orders are indicated as WCMrelevant orders. The linking of orders to Work Clearance Management takes place at the header level of the order.
You cannot perform the maintenance tasks for WCM-relevant orders, until you have issued the Released for execution.

SAP Conference for Utilities 2012

SAP WCM: STRUCTURE (Standard model was chosen for TE-TOL)

TE-TOL

ENHANCHED MODEL

STANDARD MODEL

WORK ORDER: WO

WORK APPROVAL: WAP

WORK ORDER: WO

WORK CLEARENECE APPLICATION: WCA

WORK CLEARENECE APPLICATION: WCA

ADDITIONAL APPLICATIONS WORK CLEARENCE DOKUMENT: WCD WORK CLEARENCE DOKUMENT: WCD

SAP Conference for Utilities 2012

OPERATIONAL CYCLE (Reduced operational cycle was chosen for TE-TOL)

OPERATIONAL CYCLE REDUCED OPERATIONAL CYCLE
TE-TOL

Initial status
TAGGING PHASE TEMPORARY UNTAGGING PHASE

Initial status

Tag

Temporary untagged

FAZA OZNAITVE

Tag printed

Test tag printed

Tag printed

Tagged

Untag temporarily

Tagged

UNTAGGING PHASE

Untag

FAZA ODZNAITVE

Untagged

Untagged

SAP Conference for Utilities 2012

WCM OBJECTS ASSIGNMENT RULES (WO/WCA/WCD = 1/1/1 was chosen for TE-TOL)
ENHANCHED MODEL
TE-TOL

STANDARD MODEL

WO 1

WO 2

WO 3

WO 4

WO 1

WO 2

WO 3

WAP 1

WAP 2

WCA 1 WCA 1 ADA 1 WCA 2

WCA 1

ADA 2

WCD 1

WCD 2

WCD 3

WCD 1

WCD 2

WCD 3

SAP Conference for Utilities 2012

WCM OBJECTS WORK CLEARANCE APPLICATION (TE-TOL CUSTUMISATION)

WCA NUMBER AND SHORT TEXT

WORK ORDER DATA

REFERENCE OBJECT DATA

DESCRIPTION OF REQUIRED SAFETY MEASURES

PERSON RESPONSIBLE

ADDITIONAL DATA

SAP Conference for Utilities 2012

WCM OBJECTS WORK CLEARANCE DOCUMENT (TE-TOL CUSTUMISATION)

WCA DATA + OPEARTIONAL SCREEN

OPERATIONAL CONDITION FOR TAGGING

OPERATIONAL CONDITION FOR UNTAGGING

FUNCTIONAL LOCATION TEXT OPEARATIONAL GROUP

COMMENT

PERSON RESPONSIBLE

OPERATIONAL TYPE AND PRINT FORMAT

ITEM NUMBER

SAP Conference for Utilities 2012

AGENDA

1. Termoelektrarna Toplarna Ljubljana

2. SAP PM: Key benefits

3. SAP WCM implementation project overview - Enhanched worker safety 4. SAP WCM process
5. SAP PM and WCM in TE-TOL: Way foward

SAP Conference for Utilities 2012

SAP PM/WCM PROCESS IN TE-TOL PROCESS (STEPS) COMMENT

PM NOTIFICATION

WORK ORDER

STANDARD PM PROCESS NO

SAFETY MEASURES?

YES

WCM ACTIVATION

Through approvals assigned to the maintenance order.

SAP Conference for Utilities 2012

SAP PM/WCM PROCESS IN TE-TOL PROCESS (STEPS)

1

COMMENT
Determination of people responsible: WCA created by Work approwed by Responsible person for safety measures at work site Responsible person for all work activities Group lider Determination of procedures: 1. Required shutdowns and manipulations, 2. Required safety measures, 3. Special remarks

CREATE WCA

WCA FORM

WCA PRINT

WCA is set to Prepared and printed

SAP Conference for Utilities 2012

SAP PM/WCM PROCESS IN TE-TOL PROCESS (STEPS)

2

COMMENT
WCA is signed by folowing person:

WCA SIGNED FORM

WCA APPROVAL

WO created by Work approwed by Responsible person for safety measures at work site Responsible person for all work activities Group lider Determination of people responsible: 1. Device operation manager 2. Responsible person for electro or mechanical safety measures 3. Work approval issued by (shift manager) 4. Work approval received by (Maintenance engineer)
Determination of LOCKOUT/TAGOUT items

CREATE WCD

TE-TOL: WORK PERMIT

WCD IS SET TO PREPARED AN PRINTED

SAP Conference for Utilities 2012

SAP PM/WCM PROCESS IN TE-TOL PROCESS (STEPS)

4

COMMENT

TAGS, TAGGING LIST

PRINTING TAGS AND TAGGING LIST

WCD (work permitt) is (hand) signeg by:

PERFORM LOCKOUT/TAGOUT

1. Device operation manager 2. Responsible for electro or mechanical safety measures 3. Work approval issued by (shift manager) 4. Work approval recieved by (Maintenance engineer) Status tagged

WORK PERMIT

CONFIRM LOCKOUT/TAGOUT

SAP Conference for Utilities 2012

SAP PM/WCM PROCESS IN TE-TOL PROCESS (STEPS)

5

COMMENT

PERFORMING MAINTENANCE WORK (WO STATUS EXEC)

Work order is released for execution. Maintenance work is performed.

Determination of person responsible: 1. 2. 3. 4. 5. Maintenance work manager Maintenance department manager Device hand over by Device recieved by Notification interposed by

WORK COMPLETED NOTIFICATION

CREATE WORK COMPLETED NOTIFICATION

When all signatures are collected set WO to Work completed

WCA is automatically completed

WCA COMPLETED

SAP Conference for Utilities 2012

SAP PM/WCM PROCESS IN TE-TOL PROCESS (STEPS)

6

COMMENT

NORMALIZATION (UNTAGGING)

Tags are removed WCD status untagged and completed

CREATE WO (LOOP)

NO

OPERATIONAL TEST YES

Determination of person responsible:

PRINT OPERATION TEST RESULT (IF OK) OPERATION TEST CONFORMATION

1. Shift manager When signed print.

WO TEHNICALY COMPLETED

SAP Conference for Utilities 2012

KEY BENEFITS OF IMPLEMEMNTING SAP WCM MODULE

1. POSSIBILITY OF CREATING WCD LIBRARY (System enables person responsible to create WCD template(s) for each functional location (equipment).

WCD template 1
WCD template 2 WCD template 3

2. EFFECTIVE USE OF CONFLICT RULES (Warning system)

WORK PROCESS 1

CLOSE

OPEN

WORK PROCESS 2

3. SAP WCM IN FULLY INTEGRATED IN EXISTING PM PROCESSES

SAP Conference for Utilities 2012

AGENDA

1. Termoelektrarna Toplarna Ljubljana

2. SAP PM: Key benefits

3. SAP WCM implementation project overview - Enhanched worker safety 4. SAP WCM process
5. SAP PM and WCM in TE-TOL: Way foward

SAP Conference for Utilities 2012

SAP PM AND WCM IN TE-TOL: WAY FOWARD

PM

WCM

CONDITION BASED MAINTENANCE (SCADA/SAP INTEGRATION)

ELECTRONIC CONFORMATIONS OF APPROWALS

WCM PROCESS UPGRADE TROUGH RELEVANT BADIS

SCADA

SAP PM

WORKFLOW
CREATE NOTIFICATION/WO/WCA ASSIGN PERSON RESPONSIBLE

INBOX

SAP ERP MOBILITY SUPPORT

SAP Conference for Utilities 2012

ADDITIONAL INFO

SAP Conference for Utilities 2012