1khz103019 erp-sap-pm rev7 en

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Maintenance Management with SAP/PM

Optimax Maintenance Solutions

Introduction ABB's solution for plant maintenance consists of apowerful package of tools that have been designed toenhance the quality and reliability of maintenanceactivities and to lower the operating costs and IT costs.

This specialized maintenance system covers all stageswith high performance processes for cost, schedule andcapacity planning and supports all activities connectedwith handling and invoicing. Thanks to its ability to be

easily integrated into existing control and informationsystems, it offers major time and cost benefits by way o f automated recording and scanning of maintenancemessages and the provision of vital data for a transitionfrom cyclic maintenance to utilization-based and condition-based maintenance.





Features

With an SAP/R3 solution specifically adapted tothe maintenance needs in power generationfacilities, ABB can offer a powerful concept whichis fully integrated with the chain of businessfunctions and covers all processes for planning,implementing, documenting and analyzing themaintenance activities. This solution guaranteesan integration of the existing process automationand information sys-tems.

Master dataThe master data can be integrated into the SAPPM quickly by using pre-installed importroutines. For this purpose, the user can usespecial templates in the form of Excel files for handling the maintenance objects, their classification and the pertinent technical details.

SAP/R3 PM solution for maintenance

Today, SAP/R3 is one of the most commonlyused ERP systems (Enterprise Resource

Planning). A maintenance solution is providedwith the PM (Plant Maintenance) module. In acompany, where a SAP solution has alreadybeen installed and is being used as an ERPsystem, the optimal maintenance solution wouldbe a SAP/R3 solution.

ABB offers a tailored, preconfigured SAP PMsystem solution for power generation anddistribution operations. The main objectivesand advantages of such a standardized solutionprimarily affect the maintenance staff and the ITpersonnel.

Basic functions

ABB's standard solution for SAP PM alreadyincludes the following important functions:

Screen masks

SAP PM offers a largely industry-independentmaintenance system with a wide variety of masks and database fields.

Workflow

Many of these data fields are irrelevant to power generation processes and may even hinder the

daily workflow. Modified, power plant specificmasks for maintenance objects, maintenancemessages and maintenance job orders areimported into the customer's system as soon asthe project is started.

User roles and tasks within the workflow arepredefined to match typical power plant require-

ments. The workflow includes the entire chain of maintenance activities, from the message to thetechnical completion of the maintenance activity.The user roles are linked to a role-specificnavigation menu. Depending on the tasksdefined for a role, each user will have his/her own menu for calling the functions he/she needs.This makes working and handling the SAP tool alot easier.

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In addition, power plant specific data (needed bySAP) are structured and imported in the form of files.

Power plant structure

Predefined structural codes are used for imagingthe maintenance objects in a proven power plantstructure (using the KKS code system or equipment tags). The structural codes enableefficient navigation and search for maintenanceobjects, messages or jobs.

This way, a fully functional and operable SAPPM system solution is available as soon as theproject is started and can be used to explain andteach the SAP PM functionality as it will beadapted later. This provides a basis for preparingspecific technical specifications.

Classification

The ABB standard solution includes aclassification system for technical objects (Eclass, i.e. equipment classes). For each class,the program creates a database structure for the

technical data needed for maintenance andpurchasing. The technical data are collected inExcel lists and are imported with the help of anSAP integrated importing program.

Advantages

Combining the ABB standard solution with ABB'swell-founded power plant expertise allows quickand easy adaptation of the system to customer-

specific processes and effectively promotes highacceptance among employees.

Integrated with budgeting and bookkeeping

A tight linkage of technical maintenance activitieswith the commercial systems highly simplifies themanagement of the activities. Consistentprocesses are used in the planning, budgetingand monitoring of the activities. In any stage of the project, the system can display data on theconsumption of resources upon request. Theaccounting procedures for intra-company

services or for material withdrawn from theinventory by other departments can be handledvery conveniently.

Damage profiles and causes

The ABB standard solution includes predefinedcause codes for faults and damages that mayoccur as well as predefined damage profilesbased on VGB classifications.

Project sequence

For the start of a project, the preconfigured SAPPM system solution is imported into a customer supplied development machine.

Integration of maintenance, plant management, and process control

In order to make the transition to condition-basedmaintenance – which is a prerequisite for cost-efficient plant operation – a wide variety of dataand parameters must be included in the planningand the analysis. These data are either alreadyavailable or can be collected from the control

system and the associated information systems.Integration of control system, plant managementand maintenance system is a vital factor for economic success.






Typical maintenance data are:

Operating hours and lifetime consump-tionof equipment.Operating cycles.Protective trips, disturbance and failuremessages.Number and type of starts.Trends, critical setpoint variations.Results of recurrent inspections.

The Optimax ERP processor allows condition-based maintenance by closing the gap betweenthe information coming from the controlsystems, plant management and ERP systems.

ABB servicesWith a wide variety of supplies and services, ABB assists its customers in the introduction of the tools and in integrating them into existingSAP installations and IT landscapes:

The ERP Processor With the help of the ERP Processor, it ispossible to configure not only the transmissionof counter values (e.g. operating hours or switching cycles), but also any type of binaryvalues that may serve as indicators for maintenance demand. The ERP Processor:

Reduces the amount of time required for recording maintenance messagesmanually

Enables navigation from the ERP

Processor to SAP, facilitates andaccelerates the work for employees whorarely work with SAP.

The ERP Processor is the link between theprocess data (available through the ProcessInformation Management System) and SAP.

SAP Server SAP Clients

Process Information

Management

Process Information

Management

ERP Processor ERP Processor

Efficiency

Variations

Efficiency

Variations

Gas Turbine &LifeTime

Monitoring

Gas Turbine &

LifeTimeMonitoring

ShiftManager ShiftManager ePAT

Mobil datacollection

ePATMobil datacollection

Teleperm XP /ME

ABB PLSHoneywellTDC3000

anderePLS, SPSWin CC /OPC

Its functions are:

Creating counters for operating hours,

switching cycles and volumetric meters.Transfering counter readings to maintenanceapplications.

Forming and logically combining maintenancetrigger signals independent of the processcontrol system.

Generating automatic or manual maintenancemessages and transfering them after their release to SAP PM.

Providing tools for easy configuration of thedata in the ERP Processor and SAP PM.

Providing a navigation platform for SAP PM.

© ABB Switzerland Ltd.Power Technology SystemsPTSP-PRUBruggerstr. 72CH-5400 Baden, Switzerland

Tel. +41 (0)58-585-3464Fax +41 (0)58-585-3080

E-Mail: [email protected]/powergeneration

© Copyright 2005 ABB. All rights reserved.Specifications subject to change without notice. Pictures, schematics,and other graphics contained herein are published for illustrationpurposes only and do not represent product configurations or functionality. User documentation accompanying the product is theexclusive source for functionality descriptions.

The IndustrialIT wordmark, Aspect Objects, and all above-mentionednames in the form XXXXXX

ITare registered or pending trademarks of

ABB. All rights to other trademarks reside with their respective owners


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