PM-WCM

PM-WCM

WORK CLEARENCE MANGEMENT (PM-WCM) 1.0 INTRODUCTION Maintenance and Inspection work for the technical object may only be carried out when work safety measures have been implemented. These safety measures include lockout/tagout, fire protection, radiation protection etc. In lockout/tagout, for example, technical objects are isolated electrically or separated mechanically from other parts of the technical system while maintenance work or special tests are performed. Work on these technical objects can then be performed safely. Work Clearance Management (PM-WCM) component can be used to control and monitor the safety measures to ensure work safety of the employees. WCM component can replace the “Permit to Work” (PTW) system employed by almost all petrochemical and utilities industry.

2.0 WCM ARCHITECTURE PM-WCM architecture defines relationship between WCM Objects and can be selected from following models:

2.1.

Standard Model Standard Model is used when Lockout/Tagout is of primary importance.

2.2.

Enhanced Model Enhanced Model is used when Safety Measures (radiation protection, safety in the workplace, and fire protection) are also required in addition to Lockout/Tagout.

Additional Applications

3.0 WCM OBJECTS Objects that supports in Work Clearance Management process for assignment of administrative data, status, approvals, technical objects etc. and good for communication between departments.

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Following are the objects used for WCM with the responsible departments. WCM Object Work Approval Work Clearance Application Work Clearance Document

Area of Responsibility Plant Maintenance, Production Plant Maintenance, Production Production

4.0 WCM ACTIVATION IN ORDER The Maintenance Orders for which WCM is activated are marked as WCM-relevant orders. Activation of WCM for Maintenance Order can be performed by two ways: i. ii.

Assigning Permits to the Order. Assigning control key ‘WCM’ to operations in an order.

5.0 ORDER PROCESSING WITH WCM Process flows for the WCM Orders defined in PM-WCM are classified as follows: i. ii. iii.

5.1.

Order Processing without Valuation Order Processing with Valuation Order Processing with WCM-Relevant Operations

Order Processing without Valuation Standard Model

Following diagram shows the schematic of this process with status of Order and WCM Objects.

STATUS WOCO CLSD EXEC ETG EUG UNT TECO PREP VAL

DESCRIPTION Work Completed WCM object is Closed Order is Released for Execution The Operational WCD is Tagged The Operational WCD is Untagged The Operational WCD is Untaggable The order is Technically Completed The WCM object is Prepared The WCM-relevant order is Valuated

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5.2.

Order Processing with Valuation Enhanced Model

Following diagram shows the schematic of this process with status of Order and WCM Objects.

5.3.

Order Processing with WCM-Relevant Operations

Following diagram shows the schematic of this process with status of Order and WCM Objects.

6.0 EXAMPLE - ORDER PROCESSING WITHOUT VALUATION STANDARD MODEL 6.1. Scenario For the WCM Order creation we have created equipment for which maintenance is required to be performed and child equipment for the parent equipment is created which is required to be locked-out and tagged-out for performance of maintenance activity safely. Note that it is not necessary to have a parent child relationship for the equipment(s) to be tagged out.

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6.2.

Procedure

Here MP denotes Maintenance Planner (i.e. Maintenance Engineer) and WP denotes Work Clearance Planner (i.e. Safety Engineer) who will perform the respective steps as follows. MP Order Creation

Order creation is not necessary if you just want to use WCM for documentation of safety measures on the assets without planning or cost collection. 1.

Type transaction code IW31 in Command Field on SAP Easy Access Screen.

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2.

Create Maintenance Order: Initial Screen

Field

Description

Order Type

PM01

Equipment

Example: 10000089

3.

Create Maintenance Order: Header

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Field

Description

Order

Example: Maintenance of Compressor

Mn.wk.ctr

Example: Test0003

4.

Click Goto Assignments Funds management

Field

Description

Commitment Item

Example: 1110103001

Funds Center

Example: F51431

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MP Work Clearance Application (Requisition for lockout/tagout)

Here Maintenance Planner will create requisition for lock-out/tag-out and will mark the order as WCM-relevant order. Activation of WC Application for an order can be accomplished by two methods as discussed in article 4. Here we will use second method i.e. by providing control key as WCM in operation. 5.

Click Operations tab control

.

Field

Description

Control key

Example: WCM

Operation short text

Example: Electrical isolation of Compressor Motor

6.

Click WC Application button

.

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7.

Click button

.

8.

Click button

.

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9.

Create WC Application Screen

Field

Description

Application

Example: Electrical Isolation of Compressor Motor

Use of WCD

Example: YU1 (Electric Work Ticket)

(marked in red box)

Cond.Tech.Syst.

10.

Click button

Example: X

.

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11.

Approvals - WC Application

Field

Description

Permit

Example: YU_X11 (Electric permit)

12.

Click button

.

13.

Click button

on WC Application Screen

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14.

Click Yes button on Confirmation Prompt

15.

Click button

on Assignments - Display WC Applications

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16.

Click button screen

and then

on Create Maintenance order: Operation Overview

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WP Work Clearance Document (Specify objects to be lockout/tagout) In this step Work Clearance Planner will specify the objects required to be locked-out/tagged-out.

17.

Using transaction code IW32 initiate the Change Maintenance order for order created previously in this case 4000000929

18.

Click WC Application button

19.

Click on

on Change Maintenance order: Header

in Assignments - Change WC Applications window

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20.

Click Operational WCDs button

21.

Click button

on Change WC Application screen

on Assignments - Change Operational WCDs screen

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22.

Click button

on Data Transfer screen

23.

Create Operational WCD: Header

Field

Description

WCD Usage

Example: YU1 (Isolation permit for Electric Motor)

(marked in red box)

24. 25.

Click button . Approvals - Operational WCD

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Field

Description

Permit

Example: YU_X11 (Electric permit)

26.

Click button

.

27.

Click button

28.

Create Operational WCD: Maintenance Screen

on Create Operational WCD: Header screen

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At this level we will provide the details of equipment(s) to be tagged out. In the present case we will provide the equipment 10000090 (Electric Motor of Centrifugal Compressor) which required to be tagged “OFF” for carrying out the maintenance of equipment 10000089 safely.

Field

Description

Item Category

Example: E (Equipment)

(marked in red box)

Equipment

Example: 10000090

29. 30.

Press "Return". Press F4 key after selecting Tagging Condition field

31.

Select First item in Tagging Condition window and press

.

Specifying the Tag condition “OFF” for the equipment with tagging type RBT (Red Danger Tag)

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32.

Select PF (Print Format) “XXXX” in present case for the Tag

33.

Click button

34.

Click Task button

. on Create Operational WCD: Header

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35.

Task - Operational WCD

Field

Description

Code group

Example: YU8101 (Electric Motor Isolation)

Code

Example: YU01 (Rackout for Electric Motor Switch Gear) YU02 (Close manual switch at site)

36.

Click button

.

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37.

Click button

on Create Operational WCD: Header screen

38.

Click Yes button on Confirmation Prompt

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WP Work Clearance Document (Approval for lockout/tagout) In this step Work Clearance Approver gives the approval for Lockout/tagout of the equipment defined in Operational WCD previously.

39.

Click

40.

Click button

on Assignments - Change Operational WCDs

on Change Operational WCD: Header screen

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41.

Approvals - Operational WCD

42.

Select the Permit YU_X11 row.

43.

Click Issue button

44.

Click button

.

.

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WP Work Clearance Document (Perform lockout/tagout) Here tags for the equipment(s) to be tagged are printed and are tagged physically on the location.

45.

Click button

on Change Operational WCD: Header screen

46.

Change Operational WCD: Switching Screen

47.

Click check box

48.

Click Tag button

49.

Click Tag button

. . .

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50.

Click Print button

on the Print window

51.

Change Operational WCD: Switching Screen

52.

Click Tagged button

53.

Click button

.

54.

Click button

.

.

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55.

Click button

on Assignments - Change Operational WCDs screen

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WP Work Clearance Application (Approval for lockout/tagout requisition) Work Clearance Approver now approves the WC Application for Order Execution.

56.

Change WC Application

57. 58.

Click button . Approvals - WC Application

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59.

Select the Permit YU_X11 row.

60.

Click Issue button

61.

Click button

62.

Click button

on Change WC Application

63.

Click button

on Assignments - Change WC Applications window

.

.

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MP Order (Releasing for execution) Maintenance planner now releases the order for execution.

64.

Change Maintenance order: Header

65.

Click Released for execution button

.

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MP Order (Conformance of Work Completion)

66.

Change Maintenance order: Header

67.

Click Work completed button

.

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WP Work Clearance Application (Approval for un-tagging) Here Work Clearance Planner closes the WC Application and consequently gives approval for un-tagging.

68. 69.

Click WC Application button Assignments - Change WC Applications

70. 71.

Click on Click Yes on Confirmation Prompt

.

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WP Work Clearance Document (Perform un-tagging) Now un-tagging can be performed at site and WC Document status is set at Untagged.

72.

Display WC Application

73. 74.

Click Operational WCDs button . Click on Assignments - Change Operational WCDs screen

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75.

Change Operational WCD: Header

76. 77.

Click button . Change Operational WCD: Switching Screen

78.

Click check box

79.

Click Untag button

80.

Click Untagged button

81.

Click button

.

.

. .

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82.

Click button

on Assignments - Change Operational WCDs window

83.

Click button

on Display WC Application screen

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84.

Click button

on Assignments - Change WC Applications window

85.

Click button

on Change Maintenance order: Header screen

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MP Technical & Overall Completion of Order

86. 87.

Type transaction code IW42 in Command Field on SAP Easy Access Screen. Overall Completion Confirmation

Field

Description

Order

Example: 4000000929

88. 89.

Complete all checks (Final Conf., Clear Reservation, No Remain Work) for all operations Provide the Confirmation Text

Field

Description

Confirmation text

Example: Maintenance of Compressor completed

Confirmation text

Example: Isolation & De-isolation performed

90.

Click Tech.completion button

91.

Click button

.

92.

Click button

.

.

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