1khz103019 Erp-Sap-Pm Rev7 en

Maintenance Management with SAP/PM
Optimax Maintenance Solutions
Introduction
ABB's solution for plant maintenance consists of a powerful package of tools that have been designed to enhance the quality and reliability of maintenance activities and to lower the operating costs and IT costs. This specialized maintenance system covers all stages with high performance processes for cost, schedule and capacity planning and supports all activities connected with handling and invoicing. Thanks to its ability to be easily integrated into existing control and information systems, it offers major time and cost benefits by way of automated recording and scanning of maintenance messages and the provision of vital data for a transition from cyclic maintenance to utilization-based and conditionbased maintenance.

Features
With an SAP/R3 solution specifically adapted to the maintenance needs in power generation facilities, ABB can offer a powerful concept which is fully integrated with the chain of business functions and covers all processes for planning, implementing, documenting and analyzing the maintenance activities. This solution guarantees an integration of the existing process automation and information sys-tems. SAP/R3 PM solution for maintenance Today, SAP/R3 is one of the most commonly used ERP systems (Enterprise Resource Planning). A maintenance solution is provided with the PM (Plant Maintenance) module. In a company, where a SAP solution has already been installed and is being used as an ERP system, the optimal maintenance solution would be a SAP/R3 solution. ABB offers a tailored, preconfigured SAP PM system solution for power generation and distribution operations. The main objectives and advantages of such a standardized solution primarily affect the maintenance staff and the IT personnel. Master data The master data can be integrated into the SAP PM quickly by using pre-installed import routines. For this purpose, the user can use special templates in the form of Excel files for handling the maintenance objects, their classification and the pertinent technical details.
Basic functions
ABB's standard solution for SAP PM already includes the following important functions: Screen masks SAP PM offers a largely industry-independent maintenance system with a wide variety of masks and database fields. Many of these data fields are irrelevant to power generation processes and may even hinder the daily workflow. Modified, power plant specific masks for maintenance objects, maintenance messages and maintenance job orders are imported into the customer's system as soon as the project is started.
Workflow User roles and tasks within the workflow are predefined to match typical power plant requirements. The workflow includes the entire chain of maintenance activities, from the message to the technical completion of the maintenance activity. The user roles are linked to a role-specific navigation menu. Depending on the tasks defined 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 a lot easier.
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Power plant structure Predefined structural codes are used for imaging the maintenance objects in a proven power plant structure (using the KKS code system or equipment tags). The structural codes enable efficient navigation and search for maintenance objects, messages or jobs. Classification The ABB standard solution includes a classification system for technical objects (E class, i.e. equipment classes). For each class, the program creates a database structure for the technical data needed for maintenance and purchasing. The technical data are collected in Excel lists and are imported with the help of an SAP integrated importing program. Damage profiles and causes The ABB standard solution includes predefined cause codes for faults and damages that may occur as well as predefined damage profiles based on VGB classifications. Project sequence For the start of a project, the preconfigured SAP PM system solution is imported into a customer supplied development machine. In addition, power plant specific data (needed by SAP) are structured and imported in the form of files. This way, a fully functional and operable SAP PM system solution is available as soon as the project is started and can be used to explain and teach the SAP PM functionality as it will be adapted later. This provides a basis for preparing specific technical specifications. Advantages Combining the ABB standard solution with ABB's well-founded power plant expertise allows quick and easy adaptation of the system to customerspecific processes and effectively promotes high acceptance among employees. Integrated with budgeting and bookkeeping A tight linkage of technical maintenance activities with the commercial systems highly simplifies the management of the activities. Consistent processes are used in the planning, budgeting and monitoring of the activities. In any stage of the project, the system can display data on the consumption of resources upon request. The accounting procedures for intra-company services or for material withdrawn from the inventory by other departments can be handled very conveniently.
Integration of maintenance, plant management, and process control In order to make the transition to condition-based maintenance which is a prerequisite for costefficient plant operation a wide variety of data and parameters must be included in the planning and the analysis. These data are either already available or can be collected from the control system and the associated information systems. Integration of control system, plant management and maintenance system is a vital factor for economic success.
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Typical maintenance data are: Operating hours and lifetime consump-tion of equipment. Operating cycles. Protective trips, disturbance and failure messages. Number and type of starts. Trends, critical setpoint variations. Results of recurrent inspections. The Optimax ERP processor allows conditionbased maintenance by closing the gap between the information coming from the control systems, plant management and ERP systems.
The ERP Processor is the link between the process data (available through the Process Information Management System) and SAP.
SAP Server
SAP Clients
ERP Processor ERP Processor

ePAT ePAT Mobil data Mobil data collection collection
Shift Manager Shift Manager
Efficiency Efficiency Variations Variations
Process Information Process Information Management Management
Gas Turbine & Gas Turbine & LifeTime LifeTime Monitoring Monitoring
ABB services
With a wide variety of supplies and services, ABB assists its customers in the introduction of the tools and in integrating them into existing SAP installations and IT landscapes:
ABB PLS
Teleperm XP / ME
Win CC /OPC
Honeywell TDC3000
andere PLS, SPS
The ERP Processor

With the help of the ERP Processor, it is possible to configure not only the transmission of counter values (e.g. operating hours or switching cycles), but also any type of binary values that may serve as indicators for maintenance demand. The ERP Processor: Reduces the amount of time required for recording maintenance messages manually Enables navigation from the ERP Processor to SAP, facilitates and accelerates the work for employees who rarely work with SAP.
Its functions are: Creating counters for operating hours, switching cycles and volumetric meters. Transfering counter readings to maintenance applications. Forming and logically combining maintenance trigger signals independent of the process control system. Generating automatic or manual maintenance messages and transfering them after their release to SAP PM. Providing tools for easy configuration of the data in the ERP Processor and SAP PM. Providing a navigation platform for SAP PM.
ABB Switzerland Ltd. Power Technology Systems PTSP-PRU Bruggerstr. 72 CH-5400 Baden, Switzerland Tel. +41 (0)58-585-3464 Fax +41 (0)58-585-3080 E-Mail: [email protected] www.abb.com/powergeneration
Copyright 2005 ABB. All rights reserved. Specifications subject to change without notice. Pictures, schematics, and other graphics contained herein are published for illustration purposes only and do not represent product configurations or functionality. User documentation accompanying the product is the exclusive source for functionality descriptions. The IndustrialIT wordmark, Aspect Objects, and all above-mentioned names in the form XXXXXXIT are registered or pending trademarks of ABB. All rights to other trademarks reside with their respective owners
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Maintenance Management with SAP/PM

Optimax Maintenance Solutions

Maintenance Management with SAP/PM

Maintenance Management with SAP/PM

Maintenance Management with SAP/PM

ERP Processor ERP Processor

Shift Manager Shift Manager

Efficiency Efficiency Variations Variations

Process Information Process Information Management Management

andere PLS, SPS

The ERP Processor

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