PURPOSE:
The idea behind this blog is to highlight some of the custom developments in SAP PP module named as Production Information System implementation for Process Manufacturing Industry Scenario.
REQUIREMENTS:
They wish to keep track and update the Water and Power Production/Consumption data against each Plant and Phase Level (sublevel of Plant).
They will monitor against the Unit level for the boiler, turbine, and desal. Approval will be based on the Actual
SOLUTION:
This is going to be totally customized (custom screen and a table will be developed to meet the business requirement) solution as standard SAP functionalities will not match the requirement. Standard PP functionalities will match to some extent, but to maintain the uniformity of the solution, it is recommended to go with a Tailer Made solution.
The main objective of this project is to facilitate the below functionalities.
- Screens for Updating the production/consumption details i.e., replica of PIS.
Key parameters which are needed for calculation and reports.
PIS MASTER DATA:
Outage Types:
This master data table will be used in all the Production Recording screens. Below outage types will be maintained in a custom table and will be used in production screens.
Maintenance, Planned, Un Scheduled Shut Down, Reserved, Overhaul Outage
FORECAST:
A custom table will be used to maintain the forecast values of Water in SAP PIS. Below fields are needed.
Plant, date, Power, Water.
MAIN PLANT SCREEN: (Plant entry daily for plant Information)
This screen is needed to update the following information against a plant. Main Plant Date will be in the header level.
Max Power Generation
Max Generation Time
Min Power Generation
Min Generation Time
PHASE LEVEL ENTRY: (Phase entry daily for phase information)
Water / Electricity consumptions will be recorded at Phase Level. Below are the data will be updated in the screen. Plant and Phase will be there in the header section.
Fields details:
Water Consumed for Housing (M3)
Water Consumed Phase Utilities(M3)
Demin Water (M3)
DESAL ENTRY DAILY & OUTAGE HOURS
This is one of the major screens where business will record Production for MSF and MED units. The entry is at Unit level.
Plant and Phase will be there in the header section with date.
Fields details:
Online production – Production of the Multistage Flash (MSF) / Multiple Effect Distillation (MED).
Dump Production – Dump Production of the MSF/MED unit.
Reserve Production – Reserve Production of the MSF/MED unit.
Total Production - Auto Calculated (Online + Dump + Reserve)
Reason per min – The code for the less production. Predefined fields will be given, and business will select accordingly.
OUTAGE REASON SCREEN
This sub screen is needed to record the outage time and reason for the attached unit. Outage Reason screen will be added to all the production units.
Available hours = Service Hours + Reserve Shutdown Hours
Service Hours = Running hours of Unit with production
Forced Outage Hours = Trip Hours + Forced S/D Hours
Scheduled Outage = Planned Outage Hours + Maintenance Outage Hours + Overhaul Maintenance
RO ENTRY DAILY & OUTAGE HOURS
Plant and Phase will be there in the header section with date.
Fields details:
On-line production – Production of the RO unit.
Dump Production – Dump Production of the RO unit.
Reserve Production – Reserve Production of the RO unit.
Total Production - Auto Calculated (Online + Dump + Reserve).
TURBINE ENTRY DAILY & OUTAGE HOURS
Plant and Phase will be there in the header section with date.
Fields details:
Gross Power - Power Generated for the TG
Auxiliary consumption - Power Consumption for BTG
Fuel Gas - Fuel Consumption of TG unit (Eastern Region)
Liquid Fuel - Fuel Consumed of TG in (Ton)
Diesel - Diesel Consumed entered in (M3) of TG.
BOILER DATA ENTRY & OUTAGE HOURS
Plant and Phase will be there in the header section with date.
Fields details:
Steam Production – Produced steam of Boiler/HRSG.
Flue Gas Temperature – Temperature of the Fuel Gas of Boiler / HRSG
Combustion Air Flow - Combustion air flow for Boiler/HRSG
DATA APPROVE (FOR PRODUCTION & PIPELINES)
Computed - Value which is entered in unit level and summed up at plant level.
Entered - Values entered in the plant screen.
City, quantity - Data entered in export water to cities daily against plant against each city.
Total Water Export - Data entered in export water to cities daily against plant.
Total Power Export - Data entered in Phase Screen for export Power against plant Summed up.
Phase Power Export - Data entered in Phase Screen for export Power against Phase
Phase Power Import - Data entered in Phase Screen for Import Power against Phase
Desal / Power / Boiler / RO - Data entered in unit level against the Phase selected.
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Abishek K G
