1-Romco Sap PM BBP V.1.2

ROMCO BUSINESS BLUE PRINT
Plant Maintenance
Business Blueprint Document

PLANT MAINTENANCE
April 29, 2014, Version 1.2
SAP ECC 6.0
RABIGH OPERATIONS AND MAINTENANCE COMPANY LIMITED

IMPLEMENTATION OF MY SAP ERP ECC 6.0
By
Plant Maintenance
Certificate of Acceptance
Title: SAP - Plant Maintenance Module Business Blue Print Document

Document Version: V 1.1
Client: ROMCO (Rabigh Operations & Maintenance Company), Jeddah, Saudi Arabia
Plants Applicable: Rabigh Independent Power Plant Phase II.
Name Role Organization Signature Date
Mr.Ilyas Project Manager ROMCO
Endeavour
Mr. B.Thirupathi SAP PM Consultant
Technologies
Comments (if any):
Version Changed by & Changed ON Changes done Approved By
1.1 B.Thirupathi Preparation of BBP

Plant Maintenance
Plant Maintenance
Contents
EXECUTIVE SUMMARY 4
1. INTRODUCTION 5
1.1 INTRODUCTION TO PLANT MAINTENANCE PROCESS 7
2. ORGANIZATION STRUCTURE 8
2.1 CLIENT 8
2.2 CONTROLLING AREA 9
2.3 COMPANY CODE 9
2.4 MAINTENANCE PLANT 9
2.5 MAINTENANCE PLANNING PLANT 10
2.6 LOCATIONS 11
2.7 PLANT SECTIONS 13
2.8 PLANNER GROUPS 13
3. PM MASTER DATA ELEMENTS 14
3.1 WORK CENTERS 14
3.2 FUNCTIONAL LOCATION 15
3.2.1 FUNCTIONAL LOCATION CATEGORIES 16
3.2.2 STRUCTURE INDICATOR FOR FUNCTIONAL LOCATIONS 17
3.3 EQUIPMENT 19
3.4 PM BILL OF MATERIAL (FUNCTIONAL LOCATION/EQUIPMENT) 21
3.5 GENERAL TASK LIST 26
3.6 MAINTENANCE PLANS - SINGLE CYCLE PLAN 28
3.7 MAINTENANCE PLANS - STRATEGY PLAN 28
3.8 COUNTER/MEASURING POINT 28
4. KEY DATA ELEMENTS 30
5. PLANT MAINTENANCE BUSINESS PROCESSES 32
5.1 CORRECTIVE MAINTENANCE PROCESS FLOW CHART – PM.01 32
5.2 PREVENTIVE MAINTENANCE PROCESS FLOW CHART – PM.02 35
5.3 CONDITION BASED MAINTENANCE PROCESS - PM.03 38
5.4 SHUTDOWN MAINTENANCE PROCESS - PM.04
5.5 PREDECTIVE MAINTENANCE PROCESS - PM.05
5.6 MODIFICATION PROCESS - PM.06
5.7 OVERHAULING PROCESS - PM.07
5.8 BREAKDOWN PROCESS - PM.08
5.9 REFURBISHMENT PROCESS - PM.09
5.10 CALIBRATION PROCESS - PM.10
5.11 WARRANTY PROCESS - PM.11
6. PLANT MAINTENANCE REPORTS 39

6.1 ALL SAP STANDARD REPORTS 39
6.2 ROMCO SPECIFIC REPORTS 39
6.3 ROMCO SPECIFIC PRINTS FORMS 39
Plant Maintenance
Executive Summary
Rabigh Operation and Maintenance Company (ROMCO) Established in 2010 ROMCO is a
joint ROMCO is a joint Venture Company between ACWA Power International, NOMAC(First
National operational and Maintenance Company and KEPCO ( korean Electric Power Company,
KWPCo( Korean Western Power company) to deliver operation and maintenance services
solutions to public and private sector owners of power and desalination plants.
With the intrinsic involvement of KWEPCo as the Technical Partner in this venture and through its
significant shareholding, ROMCO is thus able to draw on the track record of KWEPCo in
Operation and Maintenance of power plants of a wide range of types including:
● Steam turbine power plants

● Gas turbines simple and combined cycle power plants
● Sea Water RO technologies
● Seawater cooling systems.
To achieve excellence, ROMCO considers new technologies and knowledge gained shall be
adapted to improve the quality and performance of the company.
ROMCO is committed to maintaining, at all times, the highest standards of quality systems to
assure top operational performance. ROMCO is committed to clients’ high plant availability, high
plant reliability, efficiency, and excellent safety records.
In order to achieve a highly integrated system across the business, ROMCO has decided to
implement ERP solution and has selected SAP ECC 6.0 and ENDEAVOUR TECHNOLOGIES is
the Implementation Partner for SAP ECC 6.0.
Plant Maintenance
1. Introduction
The purpose of this document is to present a comprehensive To-Be Business Blueprint document for Plant
maintenance module for ROMCO. The document will act as a single source material for all future Plant
Maintenance related design in SAP in remaining phases of project “Rabigh Independent Power Plant
Phase II”
The document provides an insight to all major components of a functional module design viz. Master Data
Elements and Business Processes.
The document is based on the Discussions with the Business Process owners along with the concerned.
ENDEAVOUR TECHNOLOGIES is the Implementation Partner for my SAP ECC 6.0 EHP 5 implementation.
The modules in scope of implementation are:
● FICO – Financial Accounting & Controlling
● MM – Materials Management
● PM – Plant Maintenance
● WCM – Work Clearance Management
● HCM – Human Capital Management
Business Blue Print Overview
This document summarizes the observations of the Endeavour Technologies consulting team and ROMCO
Team with respects to SAP processes that need to be implemented for ROMCO.
Following activities were carried out at various stages of Business Blue Print phase of the Project.
● AS-IS processes (suggested based on previous projects experience)
● BPML Document (Business Process Master List Finalized)
● TO-BE processes in SAP (Future State Business Process Mapping)
● Business Process Discussions with BPO’s & Core Team
Scope of PM & WCM Module Implementation:
Geographical Scope:
Plant Maintenance
Rabigh Independent Power Plant Phase II – Jeddah, Kingdom of Saudi Arabia.
Functional Scope:
Plant maintenance plays a decisive role in the success of a business due to increased level of automations
and consequent high cost factor attached to the same. Operational systems and Equipments need to be
available twenty-four hours a day in order to guarantee a cost-effective distribution of fixed costs.
More stringent safety, quality assurance requirements mean there is an ever-greater demand for regular
maintenance of operating systems and equipments. Furthermore, the status of Plant Maintenance has
been significantly raised by an increase in the number of legal and public demands for environmental
protection and system safety standards.
The SAP Plant Maintenance System provides solutions for the management and maintenance of technical
systems in all branches of industry.
The maintenance of a technical system incorporates the following types of tasks,
● Inspection: All measures that determine the actual condition of an operational system, determine
the cause of wear and tear, deducing the tasks required.
● Maintenance: All measures that delay the reduction of wear reserve of an operational system.
● Repair: All measures that restore the target condition of an operational system.
● Improvement: All measures that improve functional safety of an operational system without
changing its specified function.
SAP Plant Maintenance Module covers the following topics:
● Management of Technical Objects

⮚ Functional location
⮚ Equipment
⮚ BOM
✔ Functional location BOM
✔ Equipment BOM
✔ Material BOM
✔ Usage
Plant Maintenance
⮚ Environment
✔ Classes
✔ Work center
✔ Evaluations
✔ Production Resources/Tools
✔ Permits
✔ Measuring points/counters
● Maintenance Processing
⮚ Maintenance Notification
⮚ Maintenance Order
⮚ Completion confirmation
⮚ History
⮚ Environment
⮚ Catalog
● Preventive Maintenance
⮚ Maintenance planning
✔ Maintenance Plans
✔ Scheduling of Maintenance Plans
✔ Maintenance Strategies
✔ Cycle Sets
⮚ Work scheduling
✔ Task lists
✔ Extras
✔ Evaluations
Plant Maintenance
● Work Clearance Management

⮚ Work approval
⮚ Work Clearance Application
⮚ Additional Applications
⮚ Operational WCD
⮚ WCD Template
● Information systems
⮚ Standard Analysis Reports
⮚ List-Editing Reports
⮚ Customized Report Requirements
1.1 Introduction to Plant Maintenance Process
Plant Maintenance (PM) is a commonly adopted practice, in all Industries, to ensure that designed output
(quantitative as well as qualitative) of equipment is delivered consistently. Broadly Plant Maintenance can be
divided into two categories, Planned Maintenance & Unplanned Maintenance.
• Plant Maintenance processes can be defined as the Processes used by an organization to:
– Maintain the equipment and facilities used to produce products or services
– Efficiently manage the resources (labor and material)
• Plant Maintenance (PM) module is an integral part of SAP R/3 and comes under “Logistics”.
Following are the major components of PM Module:
⮚ Corrective Maintenance Process

⮚ Preventive Maintenance Process
⮚ Overhauling Maintenance Process (Using PM-PS Module integration)
2. Organization Structure
Plant Maintenance
ROM1 Plant
Sr. No. location Location Description
1 TBN TURBINE
2 DEATR DEAERATOR
3 BLR BOILER
4 CCB CENTRAL CONTROL BUILDING
5 FD FAN FD FANS
6 ESP ESP
7 ID FAN ID FANS
8 GAS DT GAS DUCT
9 CHMNY CHIMNEY
10 FOP HOUSE FUEL OIL PUMP HOUSE
11 HFO TNK HEAVY FUEL OIL TANKS
12 S-UP BLR H START-UP BOILER HOUSE
13 ASH HCB ASH HANDLING CONTROL BUILDING
14 F-ASH SILO FLY ASH SILO
15 CNDSR W T CONDENSER WATER TANK
16 LUB OIL T LUBE OIL TANK
17 CHL. PLT CHLORINATION PLANT
18 IWW T PLT INDUSTRIAL WASTE WATER TREATMENT PLANT
Plant Maintenance
19 BLR B PIT BOILER BLOWDOWN PIT

20 HYD. G PLT HYDROGEN GENERATOR PLANT
21 SWD DMW TP SEA WTR DESAL & DM WTR TREATMENT PLANT
22 LAB. BLDNG LABORATORY BUILDING
23 FR W TNK FIRE WATER TANKS
24 FR W PMP H FIRE WATER TANK HOUSE
25 FFF H FOAM FIRE FIGHTING HOUSE
26 CW S-PIT CW SEAL PIT
27 SW I-PMP H SEA WATER INTAKE PUMP HOUSE
28 SAN ST SANITARY SEWAGE TREATMENT
29 CL&D HOUSE CHLORINATION AND DOSING HOUSE
30 OIL-W PIT OIL WATER PIT
31 A&CAU. STG ACID AND CAUSTIC STORAGE
32 FDWTR TNK FEED WATER TANK
33 RO-2 W TNK RO-2 WATER TANK
34 DM WTR TNK DM WATER TANK
35 WWP HOUSE WASTE WATER PUMP HOUSE
36 P-WTR TNK POTABLE WATER TANK
37 D-WTR TNK DESALINATED WATER TANK
38 ADMN BLDG ADMINISTRATION BUILDING
39 FB STATION FIRE BRIGADE STATION
40 S&G BLDG STORAGE AND GARAGE BUILDING
41 WRKSP BLDG WORKSHOP BUILDING
42 CG BLDG COAST GUARD BUILDING
43 G&S HOUSE GATE AND SECURITY HOUSE
44 CG HOUSE COAST GUARD HOUSE
45 ABR ABSORBER
46 SWTR TP SEAWATER TREATMENT PLANT
47 ABR PMP ABSORBER PUMP
48 AERA FAN AERATION FAN
49 E&IC BLDG E&IC BUILDING
50 AMM. YARD AMMONIA YARD
51 380KV ESF 380KV ESF
52 GS-UP XMER GENERATOR START-UP TRANSFORMER
53 U AUX XMER UNIT AUXI. TRANSFORMER
54 UST. XMER UST. TRANSFORMER
55 6.6KV FSSH 6.6KV FGD & SWRO SWITCHGEAR HOUSE
Plant Maintenance
2.1 Plant Sections

Plant sections are processing units/ production areas within a maintenance plant. These are sub-division
of maintenance plants.
Machines or sets of machines that are represented in the system as pieces of equipment or functional
locations are installed in plant sections.
We can indicate the place for which a maintenance task was requested with the plant section. We also,
can establish a contact person for Plant Maintenance using the plant section. Plant sections are assigned
to Maintenance plants.
Defined for ROMCO:
In Rabigh Independent Power Plant Phase-II of ROMCO, the production areas/ sections will be considered
as Plant Section, as it will be used for informative assignment only.
Naming Convention for ROMCO:

The following list of Plant sections will be defined for Rabigh Independent Power Plant Phase-II. Plant
Section is a 3 character codified field and naming convention will be - NNN i.e. 3 digit code representing
various sections at plant level.
ROM1 Plant
Sr. No. Plant Section code Plant Section Description
1 BLR STEAM GENERATION
2 TGS POWER GENERATION
3 BOP BALANCE OF PLANT
4 RO REVERSE OSMOSIS
2.2 Planner Groups

A group of employees responsible for planning and processing maintenance tasks in a plant. Planner
groups or Maintenance Planner groups must be defined separately for each planning plant.
Plant Maintenance
Depending on the size and structure of your company, a maintenance planning group may be an individual
department (for central work preparation), a group of Technician or a workshop.
Defined for ROMCO:

In Rabigh Independent Power Plant Phase-II, discipline wise teams are dedicated for the maintenance of
technical objects at individual locations. This group plans and are responsible for maintaining certain
equipments.
Planner Group codification is limited to 3 characters and following are the planner groups which can be
defined for Rabigh Independent Power Plant Phase-II.
ROM1 Plant
Sr. No. Planner Group Planner Group Description
1 RP1 IPPR Planner Group
3. PM Master Data Elements
3.1 Work Centers
Operations are carried out at a work center. I.e. Group of People, In the R/3 System work centers are
business objects that can represent the following real work centers, for example:
- Machines, machine groups
- Production lines
- Assembly work centers
- Employees, groups of employees
Defined for ROMCO:
In Rabigh Independent Power Plant Phase-II of ROMCO, the Maintenance Workmen and the Supervisory
Staff can be identified as work centers with capacities. The work centers are generally arranged discipline
wise like Project, Mechanical, Electrical, Instrumentation and Individual Employee etc.
Plant Maintenance
Additional Work Centers for allocating and capturing the External Manpower (Warranty) would be created
to meet the requirements of ROMCO. Also, Work centers can be created at later stage to meet the future
requirements whenever needed.

Work Center codification is limited to 8 characters and the Work centers list that can be defined for
ROMCO, Rabigh Independent Power Plant Phase-II Plant is attached as follows,
ROM1 Plant
Sr. No. Work Center Description
1. ELEC ELECTRICAL MAINTENANCE
2. MECH MECHANICAL MAINTENANCE
3. INST INSTRUMENTATION AND CONTROL
4. OPS OPERATIONS
5 CVL CIVIL
3.2 Functional Location
Functional location & Equipment together should be able to represent ROMCO's technical (equipment)
structure in a systematic manner. Easy search facility and location hierarchy should be built in the system.
KKS Coding structure is taken as guidelines for defining the Technical Hierarchy.
Functional Locations (FL) describe physical positions in the plants, with Boiler process, turbine, generator,
etc... are performing their relevant functionalities.
A functional location is an element in a technical structure, representing an area of a system at which an
object can be installed. Objects that can be installed at functional locations are called pieces of
equipment in the PM System.
The following applies to functional location master records:

Plant Maintenance
● Define and manage each functional location in the Plant Maintenance (PM) component in a
separate master record.
● Build up a separate maintenance history for each functional location.
● The labels for functional locations are structured hierarchically. One can specify the structure
according to the company criteria.
● Using hierarchical labels, a company can easily represent systems or operational structures from a
functional perspective. The hierarchical structure of functional locations can therefore represent
the interrelations of the operational functions within a system.
● Each hierarchy level of the functional location labels represents a given level of detail in the
description of the system.
Each Functional location is managed independently in the system, so that we can

● Manage individual Maintenance data for the Functional location.
● Perform individual maintenance tasks on the Functional location.
● Collect and evaluate data over a long period of time.
The Functional Location Master Record contains the following types of data:
● General data
This is fixed data, which generally does not change in the course of time, for example, the
acquisition value of Functional Location, its size & dimensions, Manufacturer, the year of
construction etc.
● Location data
This data can be, for example, the maintenance plant, location, plant section and sort field.
● Organization data
This data includes the company code, cost center, maintenance planning plant, main work
center, maintenance planner group etc.
● Structure data
In this screen, the structure indicator used and superior functional location in the functional
locations hierarchy will be maintained.
Defined for ROMCO:

Plant Maintenance
For Rabigh Independent Power Plant Phase-II, Functional location labeling will be done based on
Functional criteria and the respective functional locations are further divided in to sub functional
locations.
3.2.1 Functional Location Categories
An indicator that let you differentiate functional locations according to how they are used. Each location
category required in the system is described using parameters. The number of functional location
categories in a system depends on the number of parameter constellations required.
Defined for ROMCO:

Considering the requirement of ROMCO, the following Functional Location categories are defined,
Functional Location Category Description
M Technical System
3.2.2 Structure Indicator for Functional Locations
Numbering of functional Locations will be based on the structure indicator. The Structure Indicator defines
the format of the code used to describe the Functional Location hierarchy.
The Structure Indicator determines the edit mask and the number of the hierarchy levels when you create
functional location structures.
The edit mask defines:
the total length of the functional location number.

the lengths of the individual blocks of the functional location number.
the characters allowed.
A Ten level hierarchical model for functional location structure will be defined for Rabigh Independent
Power Plant Phase-II. The structure indicator label can be named as "ROM1” and the edit mask default
for this structure indicator will be as shown below with hierarchical levels marked, the notation for edit
mask is X- Alpha Numeric, N- Numeric, S- Any Character.
Plant Maintenance
Structure Indicator Edit Mask

ROM1 AAAAXXAAANNAANNNXXXXXXXXX
Hierarchy levels 1 2345 6 78 9 0
Plant Maintenance
Plant Maintenance
3.3 Equipment
The business object "Equipment" is an individual, physical object that is to be maintained independently.
It can be installed in a technical system or part of a technical system. We can manage all types of objects
as pieces of equipment. Equipments can also be managed as "assets" in Asset Management.
All types of device as pieces of equipment (for example, production utilities, transportation utilities, test
equipment, production resources/tools, buildings, PCs) can be identified as Equipments.
Each piece of equipment is a separate master record and an individual maintenance history can be set for
each one. The system manages the master records for pieces of equipment at client level. This means that
their numbers are valid for the entire corporate group.
This will facilitate,
● Defining breakdown / preventive maintenance tasks.
● Measuring specific parameters.
● Classification data.
● Collection, evaluation, retrieval of data including cost of maintenance, history and usage.
● Spare parts planning.
The Equipment Master Record contains the following types of data:
● General data
This is fixed data, which generally does not change in the course of time, for example, the
acquisition value of the piece of equipment, its size & dimensions, Manufacturer and the year of
construction.
● Location data
This is time-dependent data. It can change repeatedly in the course of time. This data can be, for
example, the maintenance planner group, the responsible work centre, the maintenance plant
and the cost centre.
● Organization data
This is organization related data like Company code, Asset code, Planning plant etc.
● Serial number data
Plant Maintenance
This is data that we specify when we want to manage our pieces of equipment not only as
individual objects, but also from an inventory management perspective. This data comprises
material data as well as stock and customer information.
● Warranty data
Vendor warranty related information.
● Measuring points
● Classification
● Asset
Equipment would be either treated as an individual Asset or as a part of an Asset. Link between
Equipment and the Asset Master is established by mentioning the Asset no. in the Organisation
tab of the Equipment Master. Directly, an Asset master can be viewed by double-clicking the Asset
no. Similarly, an Equipment Master data can be accessed from an Asset master.
Considering the requirement of ROMCO, Serialization of Materials will be used for Equipments.
● The Equipment Serial number on the equipment provided by the manufacturer can be treated as
serial number of this equipment against its material number in the stores.
Equipment Categories:
An indicator used to differentiate pieces of equipment according to its characteristic & usage. In SAP,
Equipment categories control the number assignment of Equipments.
There are two possibilities when you are creating a piece of equipment:
● Internal number assignment
The numbering shall be internal (SAP generated internal number) and is limited to 18 characters.
However, Technical Identification No of Equipment (KKS Code) can be maintained in a separate
field in Equipment Master.
● External number assignment
Enter an equipment number in this field, paying attention to any company guidelines.
Defined for ROMCO:

Plant Maintenance
Considering the requirement of ROMCO, Internal Number Assignment will be made active for all
Equipment Categories of Rabigh Independent Power Plant Phase II.
Below are the Equipment Categories that will be defined for Rabigh Independent Power Plant Phase II.
● E - Machines
● C - IT Equipments
● R- Production Resources / Tools
● T- Test/ Measurement Equipments
● H- Safety Equipments

Equipment codification in SAP is limited to 18 characters and as per the requirement of ROMCO, A
eight digit code is Defined for Equipment Master and the Defined number range is as follows,
Equipment Category Description Number Range

E R-Machines
C R-IT Equipments 300000000 - 399999999
H R-Safety equipments
T R-Test/ Measurement Equipments 400000000 - 499999999
R R-Production Resources/Tools 500000000 - 599999999
Technical Object Types:

Object Type is the sub-division of the equipment category, which allows a more detailed description. This
allows, grouping of pieces of equipment that have the same use.
Defined for ROMCO:
The usage of object Types will be made active for Independent Power Plant Phase II and following is the
list of object types that will be defined in SAP system.
3.4 PM Bill of Material (Functional Location/Equipment)
A Bill of Material is a complete list of all components that makes up an object.
A functional location/equipment BOM is a list of all assemblies and spares for a functional location or
equipment.
Plant Maintenance
A BOM for a functional location/equipment is used to describe the structure of a functional location or equipment
and to allocate spares for carrying out maintenance activities.
A PM BOM is useful during:
● Material planning using task lists when the BOM is used to assign materials to the operations in the
task list.
● It also provides an overview of all spares that might be required for carrying out the maintenance
tasks.
● Bills of Materials define the lower levels of the asset hierarchy in PM.
Types of BOM:
The bill of material type is defined by the type of master record that you assign to the bill of material. The
following types of BOM are found in Plant Maintenance:
● Material BOMs
● Equipment BOMs
● Functional location BOMs
Material BOM:
A bill of material created with reference to a material master.
The BOM can contain items of different item categories such as stock items, non-stock items and text
items. It can also have Materials with BOM attached to it.
For eg: a Mechanical seal with Rotary head, Stator, Carbon, Spring etc.
Equipment BOM:
Plant Maintenance
A list used to describe the structure of a piece of equipment and to allocate spares to the piece of
equipment for maintenance. An equipment bill of material can be created for each piece of equipment or
for a group of technical objects.
For eg: a pump with BOM Items viz., Impeller, Shaft, Sleeve, Mechanical seal, Bearings etc.
Functional Location BOM:
A list used to describe the structure of a functional location and to allocate spares to the functional
location for maintenance. A functional location BOM can be created for each functional location or for a
group of technical objects.
For eg: Plant with Gas Turbine Units & Steam Generation Units can be considered as a functional location.
BOM Details:
The data which is maintained in the BOM header is valid for the entire BOM and its components (BOM
items and sub-items respectively).
Structure of BOM header:
The header data is composed of: Texts, Quantity Specifications, Administrative Data & General Data
● BOM text
This text applies to the entire BOM group.
● Quantity Specifications
The quantity specifications are the basis for all quantities entered in a bill of material (BOM). Quantity
data is only relevant for production planning.
● Administrative Data
The administrative data retained by the system tell you,
● Who created the BOM and when
● Who changed the BOM and when
● The validity of the BOM
● The change number used to make changes to the BOM.
● General Data
The remaining data in the bill of material (BOM) header can be classified as "general data". It contains
Validity data, BOM status, Authorization group, Deletion indicator, Laboratory/Office Material data
(material BOMs only) and Technical Object data (Equipment & Functional Location BOMs).
Plant Maintenance
BOM Details:
The data which is maintained in the BOM header is valid for the entire BOM and its components (BOM
items and sub-items respectively).
Structure of BOM header:
The header data is composed of: Texts, Quantity Specifications, Administrative Data & General Data
● BOM text
This text applies to the entire BOM group.
● Quantity Specifications
The quantity specifications are the basis for all quantities entered in a bill of material (BOM). Quantity
data is only relevant for production planning.
● Administrative Data
The administrative data retained by the system tell you,
● Who created the BOM and when
● Who changed the BOM and when
● The validity of the BOM
● The change number used to make changes to the BOM.
● General Data
The remaining data in the bill of material (BOM) header can be classified as "general data". It contains
Validity data, BOM status, Authorization group, Deletion indicator, Laboratory/Office Material data
(material BOMs only) and Technical Object data (Equipment & Functional Location BOMs).
Bill of Material Item :
The components of a technical object are located in the items of the BOM. Item data is only valid for a
particular item within the BOM. Items are differentiated by their category (). The item categories are
differentiated by an item category key. The different item categories are represented by a letter key in the
standard SAP System:
● L: Stock item
This item category applies to components which are kept as stock. Any components entered with
this category in the BOM must have a valid master record in the system.
Plant Maintenance
When you use this item category, stock item components are automatically reserved for the
maintenance order.
● N: Non-stock item
This item category is used for components which are not kept in stock if they are used in a bill of
material (BOM). Non-stock items can be entered in the BOM with or without a master record. To
enter a non-stock item without a master record, you must simply enter a descriptive text.
When you use this item category, the system automatically creates a purchase requisition for
these components, when they are used for maintenance purposes. This leads to order-specific
materials procurement via the purchasing department.
● R: Variable-size item
This item category enables you to specify different sized sections of a component with one
material number. Variable-size items are distinguished by the fact that format entries, such as
length and width, are taken and converted into the quantity required for warehouse management
purposes.
When you use this item category, variable data, such as the size of a steel sheet required to repair
some planking, can be entered directly by the user during order processing. You do not have
created new material master records with fixed dimensions in the system each time.
● D: Document item
This item category is for components which contain information stored as documents. A
document can be a design drawing, program, photograph and so on.
When you use this item category, the bill of material (BOM) is connected to the document
management system.
● T: Text item
When you use this item category, the system stores your text in a text file using the long text
processing function.
● I: PM structure element
This item category is for components in plant maintenance which are only used for structuring a
technical object (PM assembly). No plant data is necessary for this item.
This item category is only used in plant maintenance for equipment and material bills of material
relevant to plant maintenance.
● K: Class Items
Plant Maintenance
The class item enables you to create a class as the components in a configurable bill of material
(BOM for a standard product). Several objects can be allocated to this class, and differentiated by
different characteristics.
Item Status:
For a BOM item, you must specify whether it is relevant in a construction or plant maintenance context,
for example. In other words, you must specify in the item detail screen whether it is relevant to
construction or to plant maintenance. For a BOM of application type Plant Maintenance, the status "Plant
Maintenance" is automatically set by the system in this screen. This cannot be modified. Depending on
how the BOM usage was set, you can change - among other things - the entries in the following two item
status fields:
● Costing relevance
● Spare Part Indicator
Data relevant to Plant Maintenance:
The indicator "PM assembly" is maintained in the data section maintenance relevant data. This indicator
can only be maintained when the BOM usage allows the item status "maintenance".
If an item is indicated as a PM assembly, then it will be displayed as a component of a technical system
when maintenance tasks are processed. You can use an item which is indicated as a PM assembly to
describe an item in more detail. For example: because the maintenance work has to be carried out just on
this assembly in a technical object. The assembly can also be used to locate damage more precisely.
Naming/Numbering Convention:
Since BOM consists of materials with master records, SAP naming conventions will be used which consists
of 18 characters. Internal numbering will be used for Functional location/Equipment BOM.
3.5 General Task List
All the operations and activities required for carrying out a maintenance task should be standardized and
available in a standard format at the time of performing a maintenance task or planning a maintenance
task.
Task list describe the sequence of maintenance activities which are performed during the execution of
maintenance tasks.
Plant Maintenance
Task lists standardize the activities as well as save time and effort while creating maintenance orders and
maintenance plans.
Operations in task lists can be further subdivided into sub operations. Task list also includes information
on the tools required for carrying out an operation, the components required, and the work centers that
will be performing the operations, whether the operations are being performed by internal or external
agencies.
General maintenance task lists are task lists which are used for general maintenance tasks irrespective of
the equipment or functional location. Creation of general maintenance task lists reduces the time & effort
in creating specific equipment or functional location task lists for carrying out general maintenance tasks.
Task Lists are made up of Operations and Sub-Operations. The Operations and Sub-Operations, which
comprise Task Lists, can be created in brief or in considerable detail. Operations describe the individual
maintenance tasks to be performed in a short text field, (long text is available for a more detailed
breakdown of the task to be performed) and the resources in terms of manpower, materials or services
required carrying out the task described.
Task List Headers
To create a Task List, a code/number should be given to task list. This is called "Task List Group". You can
either have your own numbering system or use SAP generated internal numbers. The system will allocate
a 'Counter' for each "Group". Within a task list group by use of "counter". A Task List Description also
must be added.
Task List Operations
The work to be done on a PM Work Order is defined in a number of 'Operations' or 'Sub-Operations'.

Operations and Sub-Operations define the order in which activities should be carried out during the life of
the order, what has to be done, who has to do it, how long it will take and any materials or services
required.
For each Operation or Sub-Operation the following fields are defined:
The Work Centre (Work Centre) which will provide the labor or specialist equipment
The Control Key which defines the handling of the accounting activities for an operation - normal settings
are:
PM01 - own labor, contract labor treated as own labor and specialist equipment
PM03 - external service procurement
A short description of the operation

An optional 'long text' description of the operation
Naming/Numbering Convention
Task lists can be either externally or internally numbered. Both character and number formats are
allowed. It should be of 8 characters.
Plant Maintenance
Task lists can be grouped, and a task list group combines task lists from a logical perspective. A group is a
pool of maintenance tasks with the same or similar maintenance work processes. A group counter
differentiates tasks lists within a group. When one of the three types of task list is created for the first
time, the system will automatically allocate the task list to a group and the counter number 01. The group
has more significance for general maintenance task lists, as they are accessed using the group number.
Group numbers for general task lists can be internally or externally assigned. Group numbers for
equipment task lists and functional location task lists can only be assigned internally. The PM System
manages all maintenance task lists within a group as one unit. Therefore task lists could be divided into
several smaller and more manageable groups. This would reduce the volume of data processed when the
group is accessed and has a positive effect on the system response time.
Task list group is 8 character field. Following is the suggested codification structure for General Task Lists
(Type=A).
Only internal numbering is possible
3.6 Maintenance Plans - Single Cycle Plan
Single cycle plans are simple maintenance cycles consisting of one predefined interval for carrying out
maintenance tasks. In a single cycle plan exactly one time based or performance based maintenance cycle
is defined in which the interval for executing the maintenance task is specified.
Time based cycle denotes the work being done at regular time intervals -say after every 60 days
Performance based cycle is based on performance of the technical system, like after every 1000 Hours.
Internal number ranges will be used which consists of 12 characters.
3.7 Maintenance Plans - Strategy Plan
Strategy plans are maintenance plans which consist of complex maintenance cycles. Strategy plans are
made of maintenance strategies and maintenance packages.
Maintenance strategy defines the rules for the sequence of planned maintenance operations. It includes
general scheduling information, and can therefore be assigned to as many maintenance task lists and
maintenance plans as required.
Maintenance Packages contain the time or performance condition when maintenance must be performed.
For eg every 10 days or every 5000Hours
Plant Maintenance
Internal number ranges will be used which consists of 12 characters.
3.8 Counter/Measuring Point
Measuring points describe the physical and/or logical locations at which a condition is described e.g. the
pressure of gas at a certain point. Measuring points are located on technical objects i.e. on pieces of
equipment or functional locations. Measurement readings are taken at measuring points in particular
measurement units at particular intervals.
To differentiate more easily between the individual measuring points and provide them with a unit, each
measuring point is assigned to a characteristic from the classification system. For each Measuring point a
text or a descriptive number is used to describe the position of a measuring point at a technical object.
Counters are tools that are used to represent the wear and tear of an object, consumption, or the
reduction of an object’s useful life (for example, the milometer for a vehicle, or an electricity meter for an
electric-powered system). Counters are located on technical objects i.e. on pieces of equipment or
functional locations.
Counter readings are taken at counters at particular intervals and in particular measurement units.
Counter readings describe a status at a counter at a particular point in time.
Internal numbering will be used. Descriptive text or numbering can be used to identify the measuring
points and counters.
Plant Maintenance
4. Key Data Elements
Key Data Elements Significance Values

Maintenance Planner Group is a
group of employees responsible
for the planning of maintenance
Maintenance Planner Groups tasks in a particular Maintenance RP1 – IIPR Planner Group
plant. Maintenance planner
groups would be used for
evaluation purposes.
R001 – Corrective Maintenance
R003 – Preventive Maintenance
For Identifying Maintenance
Maintenance Order Types R004 - Condition Based
orders
Maintenance
.
R1- Corrective Notification
For Identifying Maintenance R3-Preventive Notification
Maintenance Notification Types
Notifications R4- Condition Based Notification
001 – Inspection
002 – Maintenance
Uniquely Identify the Maintenance
Maintenance Activity Types 003 – Repair
Activity
004 – Improvment
Plant Maintenance
Person Responsible for Work Person Responsible for Work

WCI- Work Center In-charge
Center Center
1 - Fully Operational.
System condition for the 2 - Load reduction
System Conditions
Technical object 3 - Forced Outage
4 - Scheduled Outage
0 - Not in operation
Operation Conditions of the
Operating Conditions 1 - In-Operation
Technical object
2 - Standby equipment

Definitions:
Maintenance Notification: Notifications are used to convey maintenance requirements and the
documentation for technical findings and activities performed.
Maintenance Order: These are used to plan maintenance tasks, resources planning, issue permit
to work if needful and confirm the tasks after execution at shop floor and track the costs incurred.
Maintenance orders can be through Notifications or can also be created as immediate orders without
any planning.
WCM: Work Clearance Management is SAP’s process of ensuring safe conditions for personnel
while performing maintenance work and controlled testing.
Work Approval: It’s a WCM object which helps to link Work clearance application and additional
applications with Maintenance orders.
Plant Maintenance
Work Clearance Application: The work clearance application represents the safety certificate in
particular for lockout/tagout. WCA- helps us as intermediate link between work approval and work
clearance document.
Work Clearance Document: The work clearance document consists of Item data as well as
header data. In Item data the technical objects that should be processed in conjunction with a
lockout/tagout. The work clearance document can contain pieces of equipment, functional locations
and technical objects for which we can perform Lock out / tag out functions.
5. Plant Maintenance Business Processes
5.1 Corrective Maintenance Process Flow Chart – PM.01

Corrective Maintenance can be defined as the maintenance which is required when equipment has
failed or worn out, to bring it back to working order.
The corrective maintenance scenario contains all the fundamental process steps followed whenever
maintenance is performed.
Plant Maintenance
Plant Maintenance
Plant Maintenance
Plant Maintenance
5.2 Preventive Maintenance Process Flow Chart – PM.02

The process “Preventive Maintenance” (Schedule Maintenance) is used for inspections and planned
repairs, for which time and scope of work can be planned in advance. It is used to avoid system
breakdowns or breakdown of other objects.
Plant Maintenance
Plant Maintenance
Plant Maintenance
Plant Maintenance
5.3 Condition Monitoring & Condition based Maintenance Process - PM03.
Condition-based maintenance reduces plant downtime for on-going maintenance to the minimum by
means of a heightened monitoring system. It is the process of monitoring the actual condition of an
equipment / object and carrying out maintenance to avoid the potential breakdowns in future.
This is a proactive downtime avoidance methodology, which can also be called Condition monitoring
and diagnostic maintenance. This is achieved by recording the condition of machine at a point of
time on regular basis. Inspection and exchange of data in real time communicated through open
integrated systems in real time provides increased operating time, reduced maintenance costs;
improved exploitation of resources and better maintenance of equipment.
Plant Maintenance
Plant Maintenance
5.4 Shutdown Maintenance Process Flow Chart ---- PM04

The process “Shutdown Maintenance” (Schedule Maintenance) is used for inspections and planned
repairs, for which time and scope of work can be planned in advance. It is used to avoid system
breakdowns or breakdown of other objects
Plant Maintenance
5.5 Predective Maintenance Process Flow Chart --- PM05

Predective Maintenance can be defined as the maintenance which is required when we see that
equipment is ready to get failure or worn out any problem absorption.
Plant Maintenance
The Predective maintenance scenario contains all the fundamental process steps followed whenever
maintenance is performed
Plant Maintenance
5.6 Modification Process Flow Chart ----PM06

The process “Modification” is an Planned Scenario - used for Technical Up gradation / Change
etc... of the current operating system. These are categorized under which time and scope of work
can be planned in advance. It is used to have a better advantage of the system operationally.
Plant Maintenance
5.7 Overhauling Process Flow Chart -----PM07

The process “Overhauling Maintenance” (Schedule Maintenance) is used for planned repairs
(yearly), for which time and scope of work can be planned in advance. It is used to avoid system
breakdowns or breakdown of other objects
Plant Maintenance
5.8 Breakdown Maintenance Process Flow Chart ----PM08

Breakdown Maintenance (Unscheduled Maintenance) is an umbrella term for unplanned
maintenance which deals with a situation where the equipment has failed or requires immediate
attention of the maintenance staff.
Plant Maintenance
5.9 Refurbishment Process Flow Chart ----PM09

Refurbishment is a reconditioning process that makes the spare parts/assets functional again the
intended way after carrying out Repair / Maintenance.
In production/process plants or other technical objects, high value components are often used
(pumps, motors, Gear Boxes and so on).These are replaced in case of damage by a functional
part and then refurbished using a separate order.
The company requires complete life cycle tracking of these high value spare parts. In addition,
these items are maintained at different values (based on their condition) throughout their life cycle.
Plant Maintenance
5.10 Calibration Maintenance Process Flow Chart -----PM10

This scenario describes how to process your test or measurement equipment in a calibration
inspection. The objective of a calibration inspection is to determine whether each piece of Equipment
Plant Maintenance
specified in the maintenance order meets the predefined performance specifications. In this process,
you:
● Inspect the equipment specified in a maintenance order
● Record inspection results for each piece of equipment
● Valuate each piece of equipment
● Make the usage decision for the inspection lot
Plant Maintenance
5.11 Warranty Order Process Flow Chart ------PM11

Plant Maintenance
6. Plant Maintenance Reports
6.1 All SAP Standard Reports

1. SAP-PM: List Editing Reports
2. PMIS - Plant Maintenance Information System Reports
MCI1 – Object Class Analysis
MCI2 – Manufacturer Specific Analysis
MCI3 – Location Analysis
MCI4 – Planner Group Wise Analysis
MCI5 – Damage Analysis
MCI6 – Object Statistics Analysis
MCI7 – Breakdown Analysis
MCI8 – Cost Analysis
MCJB - MTTR & MTBF of Equipment
MCJC - MTTR & MTBF of Functional Location
6.2 ROMCO specific Reports
Sl. No. List of Report Names

1 Period wise Notification Compliance Analysis Report
2 Period wise Order Compliance Analysis Report
3 Type wise Notification Compliance Analysis Report
4 Type wise Order Compliance Analysis Report
5 Equipment History Report
6 Period Wise scheduled Jobs report
7 Material Consumption Report
8 Catalogs & Codes Technical Analysis Reports
9 PM Order Print
10 Maintenance report Print
Find the Attachment for the detailed layouts of the same –
6.3 ROMCO specific Prints Forms

ROMCO will be using the same print forms which are below mentioned and being used by NOMAC.
Plant Maintenance
Sl. No List Of Forms

1 Notification Form
2 Modification Form
3 Maintenance Order
4 Material Reservation
5 TRA Form
6 PTW Form
7 Confined Space Entry Permit Form
8 Confined Space Work Permit Form
9 Diving Permit Form
10 Height Permit Form
11 Isolation List Form
12 TAG Form

1-Romco Sap PM BBP V.1.2

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ROMCO BUSINESS BLUE PRINT

Business Blueprint Document

RABIGH OPERATIONS AND MAINTENANCE COMPANY LIMITED

Title: SAP - Plant Maintenance Module Business Blue Print Document

Name Role Organization Signature Date

Mr.Ilyas Project Manager ROMCO

Comments (if any):

Version Changed by & Changed ON Changes done Approved By

1.1 B.Thirupathi Preparation of BBP

6. PLANT MAINTENANCE REPORTS 39

● Steam turbine power plants

● WCM – Work Clearance Management

● HCM – Human Capital Management

Business Blue Print Overview

● BPML Document (Business Process Master List Finalized)

● TO-BE processes in SAP (Future State Business Process Mapping)

● Business Process Discussions with BPO’s & Core Team

Scope of PM & WCM Module Implementation:

Rabigh Independent Power Plant Phase II – Jeddah, Kingdom of Saudi Arabia.

The maintenance of a technical system incorporates the following types of tasks,

SAP Plant Maintenance Module covers the following topics:

● Management of Technical Objects

✔ Functional location BOM

✔ Scheduling of Maintenance Plans

● Work Clearance Management

⮚ Work Clearance Application

⮚ Customized Report Requirements

1.1 Introduction to Plant Maintenance Process

Following are the major components of PM Module:

⮚ Corrective Maintenance Process

⮚ Overhauling Maintenance Process (Using PM-PS Module integration)

19 BLR B PIT BOILER BLOWDOWN PIT

2.1 Plant Sections

Naming Convention for ROMCO:

Sr. No. Plant Section code Plant Section Description

1 BLR STEAM GENERATION

2 TGS POWER GENERATION

3 BOP BALANCE OF PLANT

2.2 Planner Groups

Defined for ROMCO:

Sr. No. Planner Group Planner Group Description

1 RP1 IPPR Planner Group

3. PM Master Data Elements

3.1 Work Centers

Naming Convention for ROMCO:

2. MECH MECHANICAL MAINTENANCE

3. INST INSTRUMENTATION AND CONTROL

3.2 Functional Location

The following applies to functional location master records:

Each Functional location is managed independently in the system, so that we can

Defined for ROMCO:

3.2.1 Functional Location Categories

Defined for ROMCO:

Functional Location Category Description

3.2.2 Structure Indicator for Functional Locations

The edit mask defines:

the total length of the functional location number.

Structure Indicator Edit Mask

Defined for ROMCO:

Naming Convention for ROMCO:

Equipment Category Description Number Range

Technical Object Types:

3.4 PM Bill of Material (Functional Location/Equipment)