Work clearance management operational switching

A collaboration of:

Work Clearance Management

Operational Switching Achieves Greater

Safety and Best Practice Compliance Wendy Underhill

State of California – Department of Water Resources

●Who Are We?

●SAP at DWR

●What is Operational Switching?

●WCM at DWR

●Key points to Take Home

●Questions

What I’ll Cover

Who Are We? – State Water Project

31 Plants

701.5 miles of canals/ pipelines

21 Lakes/Reservoirs

Generate 7.6 billion kWh year

Use 12.2 billion kWh year

Deliver up to 3.7 million acre ft

H2O

25 million people drinking water

25 million fish produced/salvaged

Slide 4

• 1999 First implementation of HR, MM and basic PM

orders on 4.5B

• 2000 Full implementation of PM, FI, FM, CO, PP and

BW

• 2003 Added PM>Impress>Microsoft Project Interface

• 2006 Migration to ECC 6.0 Public Sector (complete PM

data migration)

– added Fleet Management and Work Clearance

Management

– configured custom Operational Logging/Unit Status

section

• 2012 Went live with WCM Operational Switching and

Interface to new Fueling system.

SAP History at DWR

What is Operational Switching?

Commonly Referred to as “Lock

Out – Tag Out” (LOTO)

It is the safe shut down of

hazardous energy sources –

which makes it safe to work on

equipment.

ELECTRICAL Hazards

WATER Hazards

WCM at DWR

What were the issues?

2006 Replacement of homegrown ‘Mapper’ database

OP2 = WCM LOGGING = ?

Scared of SAP

“OTHER”

Safety Concerns

Different Terminology

WCM at DWR

What we did/didn’t do in 2006:

Old System:

Approvals = Mapper

Switching = Excel

Logging = Mapper

New System:

Approvals = WCA’s

Sign on/off = WCD’s

Switching = Excel

Logging = Z Programs

Slide 9

Icon connections

Multi or Single line

ALV Functionality

Traffic Light Status

Work Clearance Application and Document Reporting

Slide 10

WCA:

Simple Screens

Permit Process for

Approval

Full history

Workflows/e-mails

DWR added links to

other Z Programs

Slide 11

Request for Divers Workers Request for Equipment

Slide 12

WCD:

Simple Screens

Permit Process for

Worker Sign On/Off

Full history

Workflows/e-mails

Slide 13

WCM at DWR Customized Reports and Print Forms

Adobe used for

all printed forms

Custom Report to

overcome SAP

date range and

status issues

Slide 14

Logging at DWR

Unit Status

Logging –

tracks complete

unit history

Links to post

automatically in

Ops Log.

General log

entries occur all

day

Slide 15

Operational Log

Midnight Reporting from SAP

Portal/Adobe Interactive Forms

All Unit Status Entries

All Operational Log Entries

List of Active Clearances (WCD’s)

List of Current Unit Statuses

WCA’s and WCD’s

Operations staff GUI mapped to

client with no time out

This is our LEGAL document

Slide 16

2012! Ready for SAP Switching………..or

“What we didn’t do in 2006”

Stage 1

Stage 2

Stage 3

Stage 4

Stage 5

Stage 6

Define initial system settings

Set up system master data

System Design Testing

Develop Business Process & Perform Final Acceptance

Testing

Develop Training Materials

Training & Go-live

Vitally Important !!!!

Slide 17

Master Data

WCM uses Structural Lists

All equipment used for ‘switching’ must

be listed and ‘unique’

Equipment master data needs to be

linked to special classification

Equipment must be mapped in

Configuration to Operational Class and

possible conditions (e.g. Open/Closed,

On/Off). WCC8

Slide 18

WCD Maintenance Screen

Slide 19

Safety – Conflict Checks

Pump A Repair Pump B Repair

Tagged Condition = CLOSED Tagged Condition = CLOSED

Untagged Condition = OPEN Untagged Condition = OPEN

Valve X

Slide 20

WCD Switching Screen

Slide 21

Placement/Removal Forms

Used to perform

switching/sign on/off

Color coordinated

Carries over long

text based on

triggers

Kept at ACC –

Mobile Devices will

be used in future!

.

Slide 22

Tags and Printers

Thermally Printed Tags

are:

Heat Resistant

Fade Resistant (2 yrs)

Oil Resistant

Water Resistant

Will not tear

Uniquely numbered

Operators can map to different plants/printers using custom ‘Z’ transaction

Slide 23

Switching Details on List Edit

Slide 24

Key Points o Since October – less than 5 issues with system statewide (all user error)

and no Operational near miss or miss issues due to switching!

oWCM Can be implemented in stages and/or Plant by Plant

oPlants can be configured differently

oSystem can be customized – lots of user exits

oProject relies on master data – Dev/QA must be refreshed from Prod

oMust be tested extensively in development

Slide 25

Key Points

oMaster Data needs to be updated in Production before testing in Dev

oMaster data has to be mapped in SPRO separately in each client

oTerminology is learned in a few days

o2 Day Training Sessions with 6 month access to sandbox

oEnhancement Packs add ability to customize screens

oWould I do it over again – YOU BET – ONLY MUCH SOONER!

Slide 26

QUESTIONS

A collaboration of:

Wendy Underhill State of California – Department of Water Resources

wunderhi@water.ca.gov