Kurzbeschreibung Base-SI Eng Steag

Brief Description Base-SI - Maintenance and Plant Operation -

2011 STEAG Energy Services GmbH Page 1 of 13

Base-SI Description

1 Base-SI - Maintenance and Plant Operation - Statistically, about 40 % of the cost of a plants operation account for maintenance and repair. For many plant managers, this is the motive for tracking and controlling their assets and all processes related to maintenance with the help of computers. Software designed for this purpose is commonly labeled as CMMS (Computerized Maintenance Management System). However, these systems may differ significantly in functionality.

The Plant Management System SI not only comprises a comprehensive set of CMMS-modules. Instead, SIs full scope goes far beyond a standard CMMS. The SI-system includes a large number of tightly integrated applications that taken together provide a major contribution to the improvement of:

the workflow that has to reflect the plants organization properly, the controlling of the maintenance processes, the conformance to standard procedures, official regulations and laws, to name only a few.

The introduction of such a highly integrated system cant be achieved from one day to the other. On one hand the daily work of the maintenance personnel runs in parallel. On the other hand, some fundamental information must be put together such that other modules can base on them. Therefore, a stepwise introduction to the computerized maintenance management is often preferable to an introduction of a CMMS in one giant leap. For stepwise introduction, certain SI-modules have been bundled to form the package Base-SI. These modules are:

Recurrent Measures, Electronic Log Book (Shift Log), Maintenance Measures incl. the related Workflow and Document Management. The following figure presents these applications together with the required fundamental modules.


Base-SI Description

-ME01 001

Responsible for Budget

Executing person

Responsible for Maintenance

Responsible for Operations

Responsible for Technology

Responsible for Work Planning

Responsible for Technical Planning

Coordination with

Information for


Executing person

Responsible for Maintenance

Responsible for Operations

Responsible for Technology

Responsible for Work Planning

Responsible for Technical Planning

Coordination with

Information for

Responsible for TOW

Executing Person for TOW

TOW-Controlling Person

TOW-Feedback

CT PI TOWAssignments

Department Structure

Distribution list

General Manager

Author

Book keeper

Foreman

WA

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Roles

9 LAC10 AP001 -M01

M

TOW: Type of Work Free selection per work area (WA)

Boiler MaintenanceMr. Boiler

KWx/K

Electrical Dept.Mrs.. Etech

KWx/E

Boiler & TurbineMr. Masch

KWx/M

Boiler&Turb. Maint.Mr. Baumann

KWx/MI

Electrical Maint.Mrs. Current

KWx/EI

Shift leaderDay ShiftKWx/SD

Shift leaderShift 1

KWx/S1

Shift leaderShift 2

KWx/S2

Shift leaderShift 3

KWx/S3

Shift leaderShift 4

KWx/S4

Control SystemsMr. LeitKWx/L

Controls Maint.Mr. Leithammel

KWx/LI

FGDDr. ReaKWx/C

Maintenance

XYZ

ABC

Shift OperationMr. Masch

KWx/S

General ManagerDr. KernKWx/L

Grtner, Theo

Fleischer, Benno

Herzog, Trine

Haller, Hanno

Maier, Sepp

Herberger, Sepp

Fleischberger, Anne

Schlauberger

Personal data

Documents

Scheduled Maintenance(Recurrent Measures)

MMrz 06

D M D F S S1 2 3 4 5

6 7 8 9 10 11 1213 14 15 16 17 18 1920 21 22 23 24 25 2627 28 29 30 31

MApril 06

D M D F S S1 2

3 4 5 6 7 8 910 11 12 13 14 15 1617 18 19 20 21 22 2324 25 26 27 28 29 30

M1

Mai 06D M D F S S2 3 4 5 6 7

8 9 10 11 12 13 1415 16 17 18 19 20 2122 23 24 25 26 27 2829 30 31

MJuni 06

D M D F S S1 2 3 4

5 6 7 8 9 10 1112 13 14 15 16 17 1819 20 21 22 23 24 2526 27 28 29 30

Deadlines

Planned Maintenance(Measures)

measure was created

Measure

acknowledgemeasure

measure acknowledged

Execute measure

Measure was executed

create measure

measure is necessary

Autor

Verantwortlicher

Ausfhrender

Measure

Executing Person

Author


Shiftlog

Information

Operating hrs.

Permit to Work

Need more?

ControllingWork Planning

Budget Planning Warranties

Need more?

Material Payment

SI-Infobox

Maintenance Schedules

Datum Einsatz

Technical Data

Curriculum Vitaeof Components

Datum Einsatz

3473567

1239

Plant Index

9 LAC10 AP001 KP01

M

Register of Component Use

KPA02 001 00000001

Component Type Index

KPA02 001


Base-SI Description

SIs fundamental and indispensable modules are those that handle the master data. These include:

the Plant Index (which, for example, could utilize the KKS-key), the Registry of all Components, i.e. the complete equipment inventory, the Component Curriculum Vitae and the Plant History, the Component Type Register, referring to Technical Data and Standard Maintenance

Plans and

the Address Book along with the Staff Appointment Scheme, showing supervisors, employees and deputies.

Two essential concepts of the SI-system are shown in the figure as well:

The concept of Roles and Role Assignments which is used to support a standardized information flow and assignment of tasks in a flexible manner. In the SI dialogs, a user merely specifies a plant index, a component type or type of work. By applying the role assignments that have been configured in the master data, SI automatically deduces responsible and work performing personnel from the given information. Role assignments do not only reflect responsibility assignments in a plant, but also internal standard procedures and individual information paths.

The central information dispatch mechanisms provided by the SI-Info box Each individual SI-user exactly receives those pieces of information and those tasks that are destined to him or her, respectively.

Utilization of the role and communication concepts significantly contributes to the fact that the daily work can be executed fast and in a clearly structured way. By granting individual access privileges to SI users the SI administrator makes sure that unintended or unauthorized data access is prevented and individual SI-modules (e.g. Shift Log) are only available to a desired group of users.

2 The Introduction of an SI-System In most cases, plant managers who plan to introduce a CMMS have considered the following questions in the forefront:

What do I want to achieve by using a CMMS system? What are my specific demands of the future data processing system? In detail: which functionalities should the new system provide? During the introduction phase of a CMMS it is important to pursuit ones most prominent objectives and to always keep an eye on the cost-benefit-ratio. Whatever the priorities of an upcoming SI-user may be: positive effects do always arise during the introduction of an SI-system as they directly result from assembling the data base needed for the execution of the SI-applications.

Examples of objectives:

If the primary objective of a future CMMS user is merely the creation of a well structured technical plant documentation he already completes this task with the comprehensive collection of the plant and component structure and all related technical data and documents.

If, however, the objective is not to miss repetitive inspections and maintenance tasks and to record the uninterrupted evidence of all performed inspections and tasks, the creation of


Base-SI Brief Description

It is important for the customer that a new SI-system will not be delivered as an empty shell. Instead, it will already contain a large amount of master data providing easy first steps within short time.

New customers will become independent from SI-consultants after only a few introductory training sessions and will be able to handle the further buildup of the system with own personnel in a cost effective fashion and adapted to his own needs.

SI contains its own privilege administration for the individual applications.

Aside from the normal users there is also a special SI-administrator who administers user-specific privileges and should also have a deeper understanding of the SI-system concepts and applications. If desired, this function as well as the supervision of the systems hardware, operating and database system can also be provided by STEAG through remote access.

2.1 Step by Step

We strongly recommend the stepwise introduction of an SI-system, whereas first SI-applications can already be launched immediately after the buildup of the master data.



SI-Introduction, Phase 1: Collection of Base Data

At the beginning of the SI-introduction, it is necessary

to collect the personal data of the future SI-users and their organization in the Staff Appointment Scheme (organigram)

to record the Technical Components in a hierarchical structure (can be achieved by simple data import mechanisms).

Phase 1b:

If the objective of the SI-introduction is a well structured technical documentation of the plant, the Component Type Index along with related Technical Data as well as the Register of Component Use should be set up or imported (CSV file format) in addition to the plant index and the organigram.

Phase 1 is finished now. If desired, the technical plant documentation can be completed by assigning documents to component types or plant indexes (see phase 4).


Base-SI Brief Description 2.1.1 SI-Introduction, Phase 2: First Applications Basing on Responsibilities

Basing on the master supplied in phase 1, the plant internal standard procedures concerning responsibility assignments for budget and work execution can be mapped to the SI-system.

The SI-concept of assignments takes into account that in most plants it is known well in advance who has to perform which tasks of the daily work. There is no point in rethinking who to inform of a generic incident over and over again.

Examples: Assignments of Responsibilities

Instead of having to retrieve responsibility assignments from a persons memory over and over again, It is much more efficient to store these plant internal rules in the database and to apply them automatically, e.g. in relation to a specific components damage or maintenance task.

Once it is stored in the database, this wheelwork of assignments can now drive first applications like the Electronic Shift Log or the Maintenance Measures.

In general, the execution of all

lubrication tasks is assigned to the mechanical workshop.

Unless the task has to be performed on a machine in the warehouse in which case Mr. Maiwald is responsible for lubrication, as he is responsible for the whole warehouse.

However, Mr. Maiwald doesnt touch the large Ansaldo-machines. This in turn is done by the mechanical workshop.

The responsibility for this complete plant

section bears the job holder machine technology, Mr. Meier.

Only if the subsection water treatment is affected, Ms. Schulz is responsible.

The general rule is: if there is an electro-technical failure, the (job holder) E-Workshop is responsible.

Exceptions are the special actuators of type XY for which Mr. Knorr is responsible.

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By investigating these assignments, the SI-system finds the responsible and work performing persons e.g. in case of a damage report and informs them automatically!!

If larger individual maintenance measures need to be supervised (module Measures) where different persons have to contribute their activities (like ap4proving or authorizing) individual workflows can be defined that also access the stored rules, thus controlling the information mechanism of the SI-Info box.

Each SI-user has his own SI-Info box in which he receives all information addressed to him. The information is structured and sorted by topics and comprises a list of all tasks he has to perform.

The SI-Info box is superior to a normal e-mail application with respect to work assistance because on one hand the SI-system deduces the receiver of information and tasks automatically from to the prepared rules. On the other hand, the SI-Info box hand provides access to the task dialogs just by double-clicking.

You cant be faster!

measure was created

Measure

acknowledgemeasure

measure acknowledged

Execute measure

Measure was executed

create measure

measure is necessary

Author

Responsible Person

Executing person

Measure

2.1.2 SI-Introduction, Phase 3: Maintenance Plan

For the periodic reminder on planned maintenance measures, there is enough master data is present in the SI-system: the plant index, the address book and the rules of work responsibilities all contribute to the Recurrent Measures. Once set up in the SI system, a recurrent measure will ring up the staff responsible for execution of the specified type of work in due time.



TOW: Type of Work

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9 LAC10 AP001 KP01KPA02 001 00000001

KPA02 001

ReferencingStandard-

MaintenanceSchedules for

CTI

PI-Maintenance Schedule

Register ofComponent Use

PI Plant Index

CTI Component Type Index

1. Request 2. Execute

3. Feedback

If there are many components of the same type and the user desires to plan the maintenance tasks in more detail, the Component Type Register should be built up prior to setting up recurrent measures. For a given type of component you can not only add technical data but also create standard maintenance plans. When you set up a recurrent measure, the SI-system allows you to automatically refer to those standard plans for component types. By assigning components to mounting locations new entries are recorded in the Register of Component Use, the technical inventory of the plant.


Base-SI Brief Description 2.1.3 SI-Introduction, Phase 4: Document Management

It is about time to focus on the documentation of the plant and the components which may still be spread out. The SI-system supports the storage and management of documents and their relations to components, mounting locations, shift log entries, maintenance measures etc. by utilizing a document key.

In the SI-system, each document is uniquely identified by a DOKU-Key to which a data sheet with characteristic data can be assigned. The document can be linked to maintenance objects and is stored on a document server, to which the SI-workstations have access rights to.

In the ideal case the DOKU-key already tells the most prominent information, whether it is

an operating manual or a schematic pipe drawing for an object in the plant index,

a CAD-cross view of a specific

component type or

the text of regulations stemming from an authority or a scanned

document of the plants permission for erection.

With the associated viewer applications or the full-blown applications (e.g. CAD or office applications), documents can be visualized or modified. The SI-system controls the access to documents depending on a users permissions and keeps track of document versions after modifications.

3 Utilization of Key Systems

Many plants already use key systems to identify their plant sections and/or components. Beyond this, in the SI-system several other naming domains are coded with the help of key systems. These include the following:



Key Meaning Length Example Use

AVZ Plant Index 22 9 LAC10AP001

(KKS-Key1 for a pump in the feed water supply)

Naming of technical assets, aggregates, components/equipment (technological view)

BMA Component Types

8 KPA02001

(Rotary pump of a specific type from a specific manufacturer)

Coding of components or equipment (component oriented view)

ADA Type of Work 3 WWS (Recurrent measure: lubrication)

Recurrent Maintenance Measures

DOHI Documentation Key for Plant Index History / Component Curriculum Vitae

3 331

(Change of component)

Coding of events that are related to a component or plant section.

DOKU Document Key 24 XK30/ 9 LAC10AP001 /001

Unique name of a document, e.g. a CAD-drawing. The key tells the related part a KKS here.

SMS Damage Characteristics Key

3 AEL

(A=Noise,

E=Galling/lubricated

L=Damage or Malfunction due to lubrication)

Gets assigned to a damage report:

Expression of the damage

Damage symptoms Cause of the damage

With regard to the key systems, new SI users do not have to start with an empty data base. Instead, SI gets delivered along with a large number of preconfigured keys (orgware).

1 Instead of a KKS-key the plant index can also use any other (hierarchical) key system or arbitrary textual identifications.


Base-SI Brief Description 4 Technical Structure of the SI-System

In principle, the SI-system consists of two components: the SI-server, utilizing the Oracle data base, and the SI-client, which is a Windows application. The network communication between client and server is based on the TCP/IP network protocol.

Thus, the SI-system neatly fits into existing networks in a flexible manner. Several details of the technology can be adapted to the special needs and desires of the customer. SI server computers recommended by STEAG are carefully chosen to provide for high but still affordable data security and performance.

Beyond technology recommendations STEAG provides consultancy, delivers and operates complete systems ranging from server hardware to data base systems including backup and network components.

If the simple client-server architecture isnt sufficient in a LAN because e.g.

the administration has to cover a large number of application servers or

the internet must be bridged between SI-clients and the SI-server,

STEAGs System Services department offers an application server concept, providing a scalable solution which is not only suitable for the operation of an SI-system.

Office & Co:Word, ExcelE-Mail, Windows...

Updates?

Technical and Control Applications:

Procontrol-PFuturaSEZEBIS

SIMBSSiemens-TXP...

Installation

Crash




To Conclude

With a decision in favour of the SI-system you choose a plant management system that has accumulated 15 years of experience.

The concepts in the SI-system are designed to achieve optimal work time efficiency by supporting the rapid execution of daily tasks of maintenance and plant management personnel.

The entrance into computerized maintenance management with Base-SI is extremely efficient because of the included orgware. For the future extension of your Base-SI system a large number of integrated SI applications is available.

In the past and also in future SI-system enhancements are continuously led by the demands of customers inside and outside the STEAG group.

By choosing the SI-system you choose a plant management system with future!

Contact:

STEAG Energy Services GmbH Rttenscheider Strae 1 3 45128 Essen, Germany

Dr. Martin Stephan E-Mail: [email protected] Tel.: +49-201-801-4109

www.steag-systemtechnologies.com

1 Base-SI - Maintenance and Plant Operation -2 The Introduction of an SI-System2.1 Step by Step

3 Utilization of Key Systems4 Technical Structure of the SI-System

Kurzbeschreibung Base-SI Eng Steag

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