www.siemens.com/comos

Professional plant management for efficient operations

COMOS Operations

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COMOSFrom Integrated Engineering ...

... to Integrated

Operations

From Integrated Engineering to Integrated Operations

Consistency due to data sharing between engineering and

operations.

The operation and maintenance phase of a plant lasts considerably longer than the preceding engineering phase and there­ fore requires more resources.

Different disciplines and departments that often work with different, isolated appli­ cations are involved in service and main­ tenance. Such isolated solutions result in increased difficulties in communication between all parties involved as well as the time­consuming and elaborate integra­ tion of maintenance and safety aspects. This approach entails a lot of administra­ tive work and the need for many special ­ ists. Data maintenance is very time­con­suming and labor­intensive due to

redundant information and a lack of clar­ity and comprehensibility. COMOS Operations is the ideal solution: Operation and maintenance can be executed on one system without media breaks due to the standardized COMOS database. The unique advantage of the innovative COMOS software solution concept is also the seamless transition and the consistent data flow between the COMOS engineering solutions and plant operation with COMOS Operations. Thus engineering and operation stay fully connected and all employees involved in the plant work with consistent data.

Integration of plant engineering and operation

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Transparency down to the last detail The integrated COMOS software concept is based on object orientation. Compo­nents are described holistically and dis­played graphically in their true­to­life representation. The graphical and data­related description, which includes all data associated with the component, forms a single unit within the database – the object.

The complete plant information is stored in a central database. As a result, all disci­plines and departments involved in the engineering and operating phases always access the same data for a given object. Changes to objects or documents are thus available to every user directly within the relevant engineering document.

Related data sheets, lists, and other docu­ments are linked to the corresponding objects. Easy navigation between the dif­ferent document types and the individual objects is provided. All plant components are perfectly matched, which makes proj­ect work much faster and easier.

COMOS provides an optimum data trans­fer between all engineering and operating phases with continuously consistent and transparent data. The entire plant, right down to the individual components, can be examined and further developed from a functional and interdisciplinary perspec­tive. Time and cost expenditures are re duced. The object­oriented approach and the central database concept of COMOS ensure optimum networking of many individual pieces of information. The result is an optimally functioning over all system.

Open architecture – customizable software The open system architecture of COMOS enables optimal integration of third­party systems. COMOS can be adapted to exactly meet company­specific requirements and can be integrated seamlessly into existing EDP (Electronic Data Processing) land­scapes. As a result, COMOS contributes significantly to reducing the number of software applications a company needs to support.

Optimum application networking with object orientation

The correct information is available for the responsible party at any time and place.

Continuously consistent and trans­parent data across the entire life­cycle of a plant.

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COMOS MRO – targeted service and maintenance management

While a plant is running, all devices and machines have to operate without prob­lems to avoid expensive production down­times or even personal injuries. COMOS MRO (Maintenance, Repair & Overhaul) encompasses the complete management, engineering and organization of operation and maintenance, including plant docu­mentation, all in one system. You always have access to the latest engineering data in COMOS. This means that any changes to the plant due to service and maintenance processes are immediately available in the engineering data.

Tremendous reduction of time spent on secondary tasks with COMOS MRO due to intelligent maintenance of all

plant data in one system.

The intuitive application of COMOS MRO makes for comprehensive, clear and redun­dancy­free processing. The time spent on secondary tasks, which take up more than half of the entire working time, is drasti­c ally reduced, making it possible to focus more on the important main tasks. COMOS MRO increases your plant operating times while lowering costs at the same time.

Complete management, engineering as well as organization of operation and maintenance

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Clear structuring and systematiza­tion of different maintenance mea­sures with Risk Based Maintenance.

Planning and implementing adminis trative tasks As a CMMS system (Computerized Main­tenance Management System), COMOS MRO supports the structured filing and management of all maintenance­related data. In this way, plant data, plant struc­ture and plant history, as well as informa­tion about plant personnel and business partners, can be clearly represented and managed.

Using an intuitive graphical display, you can easily assign qualifications and roles to personnel, ensuring the assignment of jobs in a reliable manner. The coopera­tion of the individual disciplines and departments, combined with a clear management of the different areas of responsibility, helps optimize workflows and reduce costs.

All processes and workflows can be ana­lyzed and automatically summarized in reports with COMOS MRO. The results of the analyses can be used to update work processes and further improve the work­flows. They enable the analysis of weak

spots and provide important information for goal and strategy planning on the management level. The integration of ERP applications (ERP = Enterprise Resource Planning) makes use of func­tions in COMOS MRO for optimum moni­toring and control of resources, such as demand indications, availability checks, inventory management and many more.

Flexible implementation of maintenance measures For optimum maintenance, the individual components can undergo a risk analysis in COMOS and be evaluated according to different criteria. The results can then be used to draw specific conclusions on which maintenance method should be used. A clear structuring and systemization of preventive and condition­based mainte­nance measures will then take place. Risk­based maintenance will be carried out based on regular audits of safety aspects, legal guidelines, etc.

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Your benefits with COMOS MRO

- Complete system integration for better planning accuracy

- Reduction of unproductive times to a minimum

- A high degree of automation reduces administrative effort

- Optimized planning reduces the need for stock of materials

- Improved identification of weak points reduces the failure rate

- Individual modification of mea-sures lowers maintenance costs

- High efficiency leads to a shorter amortization period

Maintenance packages individually tailored to the company’s needs

improve efficiency and profitability.

Thus plant and production downtime is reduced to a minimum. Condition­based maintenance, on the other hand, takes well­timed measures based on the equipment´s condition. It responds to error messages or specific events. The occurring problem is first analyzed and then remedied immediately, if possible. With COMOS, you can locate the cause easily thanks to completely traceable chains of events and then have specialists determine the cause.

Resources can be economically managed and used, because the maintenance package is optimally matched to the re spective plant.

Conflation of all necessary information for service and maintenance in COMOS

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For some industries, large­scale mainte­nance of the plant or several components is necessary in a very short and limited period of time. The plant is usually shut down completely for a short time so that the units in the plant can be checked and serviced. Such a process requires detailed and comprehensive planning. All eventuali­ties must be taken into consideration, because each day without production is expensive; deviations from the plan are virtually impossible and the process has to run very smoothly. This requires a lot of coordination between all disciplines and departments involved in the process.

Planning, executing and analyzing the entire shutdown in one system.

If operation and maintenance of the plant takes place in different systems, communi­cation is extremely difficult and time­con­suming. With COMOS Shutdown, the plant operation and maintenance functions all reside on one system. This means all phases of the plant shutdown are processed in one system. It ensures everyone involved in these activities always has access to the latest data.

Processing all tasks of a plant shutdown in one system

COMOS Shutdown – efficient planning and safe execution of plant shutdowns

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Based on COMOS MRO, COMOS Shutdown supports the critical shutdown planning phase with numerous functions. The scope of COMOS Shutdown includes estimating, scheduling, coordination, progress assessment, and reporting; all executing on one system. This approach enables optimal communication and allows shutdown planning to take place precisely and safely.

COMOS Shutdown also makes analysis and post­processing of the shutdown very simple. Empirical values such as duration, problems during execution etc. can be integrated into planning of the next shutdown phase to make it safer and more efficient.

Detailed evaluation of previous shut­downs can be used to optimize the shut­down procedure.

Your benefits with COMOS Shutdown

- Complete shutdown cycle in one system

- A uniform database enables improved communication

- Optimized planning for effec-tively used resources

- Integration with other COMOS solutions increases efficiency

- Detailed evaluation of prior events helps optimize future shutdowns

Safe, precise and efficient shutdown planning and execution due to uni­

form data platform.

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COMOS Portable & Direct – direct feedback on-site

The shutdown and all of the maintenance work associated with it are supported by COMOS Portable & Direct. This optimized application for feedback of maintenance data makes messages regarding the immediate status of main­tenance tasks available to planners. This means that the planners always have a good overview of the entire situa­tion and can respond to any difficulties quickly and in an appropriate manner. COMOS Portable enables easy input using a mobile device. COMOS Direct is available on a terminal station in the plant. Feedback is entered directly into the system. This approach drastically reduces the risk of errors as well as the expenditure of time and workload compared to a paper­based method.

COMOS Portable – the mobile feedback COMOS Portable is the ideal solution for maintenance work on the plant premises. Maintenance orders can be conveniently downloaded to the handheld device, such as a PDA or smartphone, and are available to the respective

employee anywhere and at any time. This makes it un ­necessary for users to copy down the tasks and it allows them to work untethered. Using an RFID chip, the equip­ment is scanned and identified on­site with the portable device. Once maintenance is complete, the steps are en­tered into the handheld device. There are no additional steps, which makes the feedback process from the field easier and more secure.

COMOS Direct – central feedback on the touch screen COMOS Direct is designed for central feedback in the workshop or in the field. Each technician is equipped with a card reader and a barcode scanner for uncomplicated login and identification. Due to the exact assignment of the maintenance object to the respective technician, the terminal interface displays only the current task to be pro­cessed. Entries regarding time, material and maintenance can be made directly using the touch screen.

Your benefits with COMOS Portable & Direct

- Improved efficiency during maintenance due to optimal information management

- Direct entry reduces error potential

- User-friendly interface simplifies work

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COMOS Inspection – simple, non-destructive material testing

Regular inspection of devices and machines in a plant is the prerequisite for efficient production as well as high safety and quality standards.

COMOS Inspection enables simple, non­destructive mate­rial testing in perfect interaction with other COMOS appli­cations. You can use COMOS Inspection to precisely deter­mine and specify the inspection points for the scheduled measurements with the help of COMOS Isometrics. These inspection points can be scheduled to be inspected at the same intervals as used by COMOS MRO, which makes for an optimized inspection process. This prevents covering unnecessary distances and means that measurements are implemented in a timely manner.

The measurements may be made on­site with mobile ul trasound or x­ray devices and the components are inspected at the specified inspection points for erosion, corrosion and condition of the welding seams.

The measured values are fed directly into the COMOS sys­tem by the mobile measuring devices via an interface.

The complete data is automatically analyzed in COMOS, but measurements of individual inspection points can also be combined and compared. Based on the analysis done on prior inspections, COMOS projects component condi­tions. This provides a detailed overview of the service life of the individual components and gives you an idea of when a certain component may have to be replaced.

This data can be integrated into all applications and repre­sented in the different document types in COMOS.

Your benefits with COMOS Inspection

- Complete integration into the COMOS system

- More efficiency due to interac-tion with other applications

- Data collected in the field can be integrated into COMOS

- Automatic status calculation of components reduces workload

Processing of all relevant COMOS information directly from the plant

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COMOS PQM – structured project and plant documentation

The operation of a plant requires numer­ous documents which are very important for information brokering, tracking and quality control. Apart from the documents created by COMOS, you also need certain external documents, such as device speci­fications from the manufacturer, commu­nication with customers, old inventory documents of other software suppliers, etc. There is no need, however, to fully integrate these documents, as they do not have to be edited in the COMOS appli­cations.

COMOS PQM enables the complete mapping of technical plant docu­mentation due to simple manage­ment of external documents.

Nevertheless, structured and simple man­age ment of the documents is required in order to be able to access external docu­ments quickly.

COMOS PQM (Project Quality Manage­ment) enables complete technical mapping of the plant in one database. External documents including metadata are at ­tached to the objects on the basis of object orientation.

Structured document management

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AutoVue and other viewers can display more than 450 CAD and

Office formats.

Data will not be lost due to versioning and individual

archiving options.

The eSign and eStamp technology enables safe and simple marking

and release of revisions.

Integration and view of external documents COMOS can be linked with all popular Office programs. In this process, add­ins are integrated into the Office interface and can be used to check in documents in COMOS. COMOS automatically saves the information on who checked in which document at what time. You can also bulk import Microsoft Excel or Access documents. The respective metadata is entered during the import by means of a form. Here, you can individually define mandatory and optional information.

COMOS offers an interface to the Oracle AutoVue viewer to view external docu­ments; the viewer can display 450 CAD and Office formats. You can also use any external viewer in COMOS via configu­ration.

Revising, versioning and archiving Internal and external documents can be easily revised. Different users can review a document which is then released in a final step. The released document is then available as Adobe PDF and can no longer be edited. The history such as author, review steps, person responsible for release etc. is attached to the respective object in the form of metadata.

Documents can be released with digital signature using the innovative eSign tech­nology. Modifications to PDF documents with digital signature are captured and stored in history. Responsibilities can be clearly assigned and documented, which ensures a legally compliant release and archiving.

Stamps can be integrated into the PDF with eStamp technology to indicate the validity or invalidity of the contents of documents.

All documents are automatically archived in COMOS. Archiving takes place with ver­sioning: If a document is edited, a com­pletely new version of the document is created. All previous versions of the docu­ment are kept and can be accessed at any time. No data is lost and you can always trace who made which changes to the document at a specific time. If necessary, old versions can also be recalled and declared to be the current version once again. You can individually set the num­ber of versions of a document that are saved in the system.

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Projects can be edited with working layer technology without changing the plant documentation.

External documents can be found quickly and easily with content and/or attributive search.

Your benefits with COMOS PQM

- Higher quality of data and docu-ments

- Working layer technology pro-vides secure project engineering

- Archiving of previous project states simplifies troubleshooting

- Information exchange with external applications through customized interfaces

- Comprehensive technical plant documentation reduces project lead times

Separation of project and plant documentation COMOS PQM differentiates plant docu­mentation from project documentation. Plant documentation includes the latest documents and describes the as­built sta­tus of the plant. Project­specific changes can be made without changing the plant documentation. This is accomplished using working layers with different views of the plant documentation. In this way, you can test and optimize projects in a safe environment. Once engineering is complete and the changes accepted, the project­specific changes can be inte­grated into the plant documentation. This process ensures the documentation of the latest as­built status of the plant remains intact and still permits projects to be executed in a flexible manner.

Flexible structuring for individual views COMOS provides tools that enable you to create flexibly structured document dis­play, e. g. specific to function, location or documentation. For example, documents are organized and displayed in a docu­ment structure based on DCC (Document Classification Code). This is best for ar­chiving, because you can search for docu­ment types. You can work with several document structures at the same time.

Comprehensive full-text search COMOS provides the latest full­text search tools for optimal searching docu­ments. The standard document search is enhanced by an attributive search. This means the full­text search in COMOS can be used to search inside documents as well as file properties. For the best result, you can combine attributive and content full­text search capabilities. The speed of the search function enables direct access to the requested results.

Separation of project and plant documentation

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Glossary

CMMS CMMS stands for „Computerized Maintenance Manage­ment System“. Maintenance processes are supported or controlled by the CMMS software.

Data consistency Data is entered only once and is then available to all stake­holders anytime and anywhere. Stringent inheritance and linkage mechanisms provide all stakeholders involved in a project with access to up­to­date and consistent data from any location and at all times.

DCC Documents can be classified and sorted according to their properties with DCC (Document Kind Classification Code). In this way, they are not only available for the associated component, but can be called according to their proper­ties – for example, all TÜV (German technical inspectorate) documents of the plant.

ERP ERP stands for „Enterprise Resource Planning“. An ERP sys­tem is an application software that is responsible for planning the resources of a company.

Media break In relation to software solutions, a media break is a change of applications for information­processing. In the case of a media break, data needs to be transfered from one applica­tion to another and does not only exist once. Possible conse­quences are more work, wasted time and reduced quality.

Object orientation in COMOS Object orientation is the holistic description of an existing component and its true­to­life graphical representation. The graphical and alphanumerical manifestations within the database constitute a single entity – the object.

RBM (Risk Based Maintenance) Risk Based Maintenance is a maintenance method for plants and technical devices which evaluates risks and consequences in the event of a failure. This evaluation helps to optimally determine maintenance measures or maintenance cycles and considerably minimize the risk potential.

Working layers Working layers are overlapping views of an engineering project in which work can be performed in parallel with­out manipulating the common database. They can be used to version control projects (unlimited number of ver­sions) and allow access to deeper­lying working layers as well as creation of objects in the working layer‘s own layer. Thus, changes can first be tested and then – if necessary – rejected and deleted.

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More detailed information is available on our website at: www.siemens.com/comos

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© 08.2011, Siemens AG

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