How a Modern CMMS Supports to Optimize Maintenance Harald Spliessgardt 2 September 2015
Contents
(1) Overview STEAG Energy Services (2) Maintenance with CMMS (3) The CMMS Solution SI®/PAM (4) Example of Implementation (5) Conclusion
2 September 2015
"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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Overview STEAG Energy Services
Revenue € 151 million (consolidated)
Employees 2,054 (consolidated) data 2014
STEAG Energy Services Energy Technologies
Design, site supervision and commissioning of power plants
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Plant Services
Nuclear Technologies
Operation & Maintenance, catalyst management and –regeneration, personnel services
Decommissioning and dismantling of nuclear plants, safety, radiation protection and realization of final disposal sites
System Technologies
Energy Management Systems, IT solutions for monitoring, optimization and advanced process control
"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
Information Technologies
Operation Management Systems, Site IT
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Overview STEAG’s international references Crucea North Wind Farm Romania (108 MW el)
Termopaipa IV Coal Power Plant Colombia (165 MW el)
Own power plants / investment projects
Vishakhapatnam Coal Power Plant India (1,040 MW el)
Engineering / projects STEAG headquarters
5% shareholding and operation & maintenance
Representative offices / subsidiaries Operation and maintenance contracts Disposal and marketing of power plant by-products
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Mindanao Coal Power Plant Philippines (232 MW el)
Arenales Concentrated Solar Power Plant Spain (50 MW el) "How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
Iskenderun Coal Power Plant Turkey (1,320 MW el) 4
Maintenance with CMMS STEAG Energy Services’ solutions
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CMMS solutions by STEAG Energy Services since 1989
SI® has been field-tested and proven worldwide at public utilities, waste management companies and at the power plants of our parent company STEAG
SI® for MS-DOS
SI®
SI®/PAM current version of our maintenance software offers maximum flexibility and can be applied across industries SI®/PAM
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"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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Maintenance with CMMS General Approach
Challenge High availability and undisturbed operation of plants
Maintenance Strategies
Reactive maintenance Failure-oriented maintenance = repair
Preventive maintenance Time-oriented maintenance like periodic servicing
Condition-based maintenance Demand-based, e.g. on the basis of measurements
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Maintenance with CMMS Realization in SI®/PAM
Reactive maintenance Documentation of fault indications in the shift log Control and documentation of the fault clearance by way of tasks
Preventive maintenance Automatic generation of tasks with defined responsibilities Preconfiguration of deadline strategies for consistent deadline control
Condition-based maintenance Connection of external systems for condition monitoring Automatic generation of fault indications in the shift log Automatic generation of tasks for checking / fault clearance (optional)
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"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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The CMMS Solution SI®/PAM Module Overview
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"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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The CMMS Solution SI®/PAM → Plant Index
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Flexible structure • Any hierarchical structure can be implemented • Encoding schemes, e.g. according to KKS or RDS-PP can be applied, but are not required • „Tabbed“ structure for improved navigation
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Freely definable attributes
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Direct access to all important data (documents, event log, tasks, …)
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"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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The CMMS Solution SI®/PAM → Tasks
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Definition of tasks Any desired number of task types can be defined with freely definable work flows
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Examples of application • Repair tasks • Scheduled tasks • Warranty tracking • …
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Generation of tasks automatic or manual from event log entries
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Responsibilities determined according to configurable rules
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The CMMS Solution SI®/PAM → Recurring Items
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Automatic generation of periodic tasks
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Responsibilities determined (configurable rules)
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Possible cases of application • complying with official requirements • preventive maintenance measures • inspection rounds
Information box
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Task 1
Scheduling strategy
+ Plant + Task type + Work schedule +
Start data/parameters 2 September 2015
“Manual“ tasks
Task 2 Task 3
Scheduler Recurring task Terminserver “Automatic“ tasks
"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
Task 4 Task 5
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The CMMS Solution SI®/PAM → Event Log
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Flexible Structure •
Unlimited number of logs
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Unlimited number of message types
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Freely definable data fields
Secure documentation •
Time limit for changes
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Limitation of changes to the original author
Integration of external data sources, e.g. •
Alarms from the DCS
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Automated weighing
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The CMMS Solution SI®/PAM → Documents
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Additional information Documents can be added
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Linking One document can be linked with different object types (e.g. plant components, tasks,…)
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Metadata Document types with corresponding metadata can be freely configured
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Storing (inside) Documents are stored in the database
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Storing (outside) Documents are linked easily outside of the database
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"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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The CMMS Solution SI®/PAM → Information Box
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Proactive information on upcoming tasks and relevant event log entries
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Direct access from the entry to the processing step
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Automated determination of the correct recipients according to diverse criteria (e.g. plant, plant category, type of work, value limits)
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Escalation of exceeded deadlines according to the organizational structure configured in SI®/PAM
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"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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The CMMS Solution SI®/PAM Mobile solution
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Apps available Use of CMMS on smartphones and tablet computers
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Comfortable handling Data is available where ever you are!
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Offline capability Operation without connection to the server (e.g. in the case of poor reception) Transfer of the required data from the CMMS to the mobile device via wireless LAN or USB interface.
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"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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Example of implementation Biomass CHP plant
Customer EVO Oberhausen, Germany
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Implemented modules in order of implementation - plant index - event log - tasks - recurring items - documents
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"How a Modern CMMS Supports to Optimize Maintenance" | STEAG Energy Services GmbH
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Example of implementation Biomass CHP plant
Customer EVO Oberhausen, Germany
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Challenge CMMS with individual plant index
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Flexibility During commissioning staff required special shift logs for logging of unplanned outages. Individual message types and special reporting for claim management were implemented.
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Openness Further requirements were implemented by customer itself.
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Conclusion
What is a modern CMMS? •
Controlling of the maintenance procedures
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Support in complying with legal requirements
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Improvement and simplification of operation and maintenance processes
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Easy to implement
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Flexible in configuration
When do you start?
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