Work Clearance Management Christoph Wobbe WCM GmbH Rory David Shaffer Utilities IBU
Work Clearance Management Christoph Wobbe WCM GmbH Rory David Shaffer Utilities IBU.
Jan 11, 2016
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Work Clearance Management
Christoph Wobbe
WCM GmbH
Rory David Shaffer
Utilities IBU
1. Background
2. Customers
3. Overview of WCM
4. News
Agenda
1. Background
2. Customers
3. Overview of WCM
4. News
Agenda
... the process of ensuring safe conditions
for personnel while performing maintenance
work and controlled testing
What is basic WCM?
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)
What is our background?
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
Why Work Clearance Management?
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 are the key benefits?
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 is basic Lockout/Tagout?
What are the Releases?
1. Background
2. Customers
3. Overview of WCM
4. News
Agenda
WCM Market Overview
© SAP 2008 / Page 11
WCM Projects: More than 25 countries
More than 10 different languages
More than 150 customers
More than 250 installations
WCM Market Overview
© SAP 2008 / Page 12
Canada
USA
Mexico
Venezuela
Brasil
FinlandSweden
Germany
Netherlands BelgiumFrance
Spain Italy
Singapore
Japan
China
Australia
India
Korea
Norway
Saudi Arabia
Hungary
Russia
Argentina
WCM Market Overview
© SAP 2008 / Page 13
WCM Industries: Generation Companies
Nuclear
Fossile
Transmission Companies
Oil & Gas
Mining
Public Services
Public Transport/Railways
Paper
Defense
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)
WCM Customers
Electrabel is a private power company active on the European energy market.
Our core business 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, ...
“The implementation of SAP Work Clearance Manage-ment with mySAP PLM Asset Life-Cycle Manage-ment at the Electrabel nuclear power stations fits perfectly into our policy to continuously improve safety and efficiency of maintenance processes.”
Jean Pierre Gourgue, responsible for SAP Electrabel
Generation
WORK CLEARANCE MANAGEMENT - A PERFECT TOOL FOR GENERATION FACILITY MAINTENANCE
Electrabel, Belgium
Work Clearance Management
© SAP 2008 / Page 16
Work Clearance Management
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.
„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
WORKING SAFELY IN POWER PLANTS USING WORK CLEARANCE MANAGEMENTA better solution for managing and empowering safety in power plants
Iberdrola S.A., Spain
© SAP 2008 / Page 17
Work Clearance Management
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.
“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.”
Owe Petersson, Project Leader
SAFE NUCLEAR PLANT MAINTENANCE AND OUTAGE PLANNING WITH ASSET LIFE-CYCLE MANAGEMENT
Ringhals AB, Sweden
Generation Companies (nuclear, fossile, hydro) use WCM for the safety and approval processes while they perform standard maintenance as wellas during overhalls/revisions.
Transmission Companiesuse 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 - Utilities
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 – Oil & Gas
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 - Mining
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 Services
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 – Public Transport
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 – Paper Industry
The Defense market
use WCM for the safety requirements of the nuclear submarines.
Customers:- US Navy
WCM Market - Defense
1. Background
2. Customers
3. Overview of Work Clearance Management
4. News
Agenda
Work ClearanceManagement
Work ClearanceManagement
NotificationNotification CreateOrder
CreateOrder
ReleaseOrder
ReleaseOrder
ConfirmOrder
ConfirmOrder
CompleteOrder
CompleteOrder
Analyze HistoriesAnalyze Histories
PlanOrder
PlanOrder
SCADASCADA
Maintenance planMaintenance plan
Work ClearanceManagement
Work ClearanceManagement
Maintenance
Operation
Maintenance Process with WCM
Standard Model
Applications:
Work Clearance Application (WCA)
Work Clearance Documents (WCD)
WCD Template
Operational WCD
Operational WCD
Operational WCD
Order OrderOrder
Work Clearance
Application
Operational WCD
WCM Objects – Architecture (1)
Enhanced Model
Work Approval (WAP)
Applications
Work Clearance Application (WCA)
Application for Radiation Protection
...
Work Clearance Documents (WCD)
WCD Template
Operational WCD
Order Order
Work Approval
Work Clearance
Application
Operational WCD
Application for Application for Radiation Radiation ProtectionProtection
Order
Operational WCD
WCM Objects – Architecture (2)
Maintenance Process with WCM
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 (1)
Create a Maintenance Order
Valuation of the Work Clearance Management Process
Assign additional Documents (eg drawings)
Maintenance Process with WCM (2)
Requestors Risk Analysis
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 (3)
Process Preparation
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 (4)
Work Authorisation & Acceptance
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 (5)
Execution
Close Maintenance Order
Close Work Clearance Documents
Information is moved to our Information System/BI
Analysis for future work
Maintenance Process with WCM (6)
Closure
1. Background
2. Customers
3. Overview of Work Clearance Management
4. News
Agenda
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 error-prone (duplicate confirmations).
Goals of mobile WCM
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
Mobile Work Clearance Management
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
Customer Value of Mobile 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
Operational WCD
Order
Work Clearance
Application
Operational WCD
Operation 10
Operation 20
Operation 30
Operation 40
Operational WCD
Approval Group
„Hot Work“
Approval Group
„Tagging“
Approval Group
„Untagging“
Approvals:- Hot Work- Tagging- Untagging
Operations are assigned and bundeled to Approval Groups
Linking Operations with WCM
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
Functional Location / Equipment
mechanical
electrical
01 closed
02 closed
04 open
03 open
01 on
02 on
04 off
03 onoperationalgroup
overall condition of the technical system
untagging condition
Mode Dependent Tagging - Architecture
© SAP 2008 / Page 44
Quar
terly
Rel
ease
WCM Newsletter
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