ptw loto training

PTW & LOTOTraining

PTW & LOTO Compliance

30915

Perception Check

Q.1 There are several types of energy sources. List five of them.

Q.2 What is Energy Isolation?

Q.3 What is an “Energy Isolation” or “Control” Device?

Q.4 Why do we need to isolate energy

Q.5 What is a Lock out device?

Q.6 What is a Tag out device?

Q.7 Why do we need to apply LOTO?

Q.8 What could be the potential consequences if a EI & LOTO procedure was not followed?

Debriefing

Debriefing

Can you narrate any

incident highlighting the

importance of LOTO or

the consequences of not

complying with LOTO

How bad can it be?

Consider how you would feel if you inadvertently re-energized equipment & caused the death of a co-worker.

Introspection

Risk Assessment

PTW System

Energy Isolation Procedure

LOTO program

Elements of the Control Process

Communication

Communication

Factors in Risk Assessment

What factors you would consider when carrying out a risk assessment w.r.t. isolating energy for a planned maintenance activity?

ProceduresScope, Purpose, Roles &

Responsibilities, Forms & Records, Specific & Relevant,

TrainingAuthorized employees, Affected employees, Others, Refresher

trainings,

LOTO Hardware

Energy control devices, Locks & tags, Standardized & dedicated,

Durable & identifiable

Inspection & Monitoring

Procedure compliance, Employee competence, Physical arrangements,

Record keeping.

LOTO Complete Energy Control Program Elements

Authorized employees include electricians, maintenance personnel, & some machine operators. These workers are the only ones allowed to perform LOTO. They must be trained to understand how machinery is powered & to recognize hazardous energy sources. They also need to learn how to isolate & control that energy by implementing the LOTO procedures.

Affected employees are those who work with machines but aren't authorized to perform LOTO. This group is predominantly made up of machine operators & helpers. These workers need to understand the purpose & use of LOTO. They must also understand that they can't perform any repairs or maintenance on their equipment until it has been properly locked & tagged out. And they need to know that they are not to interfere with LOTO procedures-for example, by removing a lock or tag.

Other employees include anyone who works in an area where LOTO procedures are used. These workers must understand the purpose of energy control procedures & the importance of not operating locked or tagged out machinery or interfering with locks or tags.

Permit to Work

A formal documented system & recorded process used to control work in a safe manner

What is a PTW System

The issue of a permit does not, by itself, make a job safe. That can only be achieved by dedication & competency of those preparing for the work, those supervising the work & those carrying out the work.

PTW Essentials

• Clarity of Job Scope • Assessment of hazards & risks• Incorporating controls• Formal authorization & acceptance• Communication• Supervision, monitoring & control• Formal closure & hand back

Supervision Authority (SA) Employee supervising the effectiveness of PTW

Permit Authorizer (PA) Highest Authority ordering issuance of permit

Permit Issuer (PI) Employee issuing the permit

Permit Originator (PO) Requestor of job

Isolation Authority (IA) Employee responsible for installing Isolations

Permit Acceptor (PC) Highest Authority (team leader) accepting the permit

Permit User (PU)Personnel complying with and working under the terms of Permits

Area Authority (AA) Employee in Control of location of work

Site Checker (SC) Employee carrying out site checks/tests

PTW Roles

PTW Roles

PTWDocuments

CONTRACT

Permit Issuer(Issuing the Permit)

Permit Originator(Requester of job)

Isolating Authorities(Responsible for installing Isolations)

Area Authority(Employee in control of location of work) Site Checker

(Carrying our site checks & tests)

Permit AuthorizerHighest Authority ordering issuance of permit

Permit Acceptor(s)(Highest authority (TL) accepting the permit)

Supervision AuthoritySupervising effectiveness of PTW System

Permit User(s)(Personnel complying with & working under the terms of Permits)

Supervision Authority (SA)

• Ensure understanding & competence of all employees using or complying with PTW system.

• Ensure that the conditions & precautions specified in permits are fully understood, implemented & effectively monitored.

• Ensure the arrangements that PA & PI will be timely informed when a job has been completed, suspended, conditions altered, task need to alter and/or any emergency exists.

Permit Authorizer (PA)

• Ensures that PTW contains clear, simple, precise & complete descriptions & limitations of works, details of location & start/end timing.

• Reviews & certifies the list of activities interacting with the PTW. • Define control measures for the activities of PTW which are

interacting or affecting with other site activities being done with or without using PTW System.

• Certify that all other works that would create hazards if undertaken at the same time are either suspended or made safe.

• Define pre-determined actions in the event of emergencies at site or plant.

• Identify competent persons engaged in preparation of permits. • Identify the competent persons responsible for supervision.

Permit Issuer (PI)

• Ensure that all hazards associated with job have been identified & suitably addressed.

• Ensure that all steps necessary to ensure safety have been taken.

• Ensure that all the required PTW system certificates & permits are identified, prepared & attached to the PTW.

• Ensure that work activities that may interact or affect one another are clearly identified & either conflict avoided or precaution included in PTW.

• Ensure that all precautions & isolations are withdrawn at the end of the job unless they are cross referenced to other permit based activity.

Permit Originator (PO)

• Identify the work requiring PTW System’s activation.

• Clearly & completely describe the works & tasks, the location, the scheduled start & end times

• Conduct preliminary RA.

• List of other ongoing activities under live permits or otherwise which may affect job or may be affected by undertaking job.

• Define limitation on timings from PO perspective.

• Define precisely the boundaries of proposed work w.r.t Plant Functions & Plant Technical Objects.

Isolation Authority (IA)

• Ensure that baseline isolation standard is determined & applied.

• All precautions & safety measures stated on permit are strictly followed.

• Ensure Isolation is fully implemented & documented.

• Issue Isolation Certificate.

• Conduct RA for Isolation & De-isolation scheme.

• Identify & maintain register for extended isolations.

• Identify & manage cross referenced isolations with other PTWs or activities.

• Prepare isolation & de-isolation sequence scheme.

Permit Acceptor (PC)

• Lead, supervise & monitor the team undertaking the works.

• Accept the permit on behalf of Permit User (PU) who carries out the work.

• Ensure the work being done comply with all PTW & safety requirements.

• Fully understands the PTW system & is fully competent to supervise / undertake the proposed work.

Permit User (PU)

• Undertake the works in full compliance with the PTWS & all HSE requirements.

• Be aware of & manage the works’ risks, scope, limits, nature & location related issues.

• Be competent & trained to undertake the works & work within the PTW system.

• Stop work when in doubt & seek advice & support.

• Stop work if conditions change or become hazardous, make the area safe & immediately seek advice or follow predetermined action list for such kind of happenings.

Area Authority (AA)

• Custodian of the location of work.

• Ensure all hazards associated with the work are identified & risk controls are applied.

• Monitor the works, location & permit user(s) to ensure that all precautions & safe systems of work have been effectively implemented & are understood by the PU (undertaking the works).

• Ensure Interaction is controlled and known.

• Copies of PTW, Permits & Certificates applicable to job are available & displayed.

• Accept & acknowledge the return of plant or equipment into his full control on completion of the works, reinstatement of good housekeeping practices & cancellation of the PTW.

Site Checker (SC)

• Have certified competency to check all site conditions associated with Plant functions & processes.

• Competent to understand, implement & monitor compliance with the PTW system

• Only permit to start / continue works when / if necessary permits authorized, available & understood

• Stop work when in doubt & seek advice & support. • Responsible for checking conditions at site before start of any activity• Remain conscious of possible degradation of site condition during the job

& document it. • Let & verify AA & PU know about the limitations of site conditions. • Stop work if conditions change or become hazardous, make the area safe

& immediately seek advice or follow predetermined action list for such kind of happenings.

PTW Case Study

SAP Maintenance Order will be raised in 3 cases by PO:

• Malfunction (Operation) Notification

• Predictive Notification

• Preventive Notification.

Maintenance Orders

Category of job activity assessed (on basis of RA) by PO among:

• A ( Access Required) - PO will fill first part of PTW Form NC/PTW/SP-001/FM-001, mentioning it is now used as Access Permit & inform Operation about activity, obtain signatures of PI/PA & conduct work. When Job is completed, it is responsibility of PO to inform PI/PA by closing the Access Permit.

• B (Permit required) - 4 documents required to be raised, PTW form, RA Form, Isolation Certificate & Tool Box talk.

• C (permit with work pack required) - Work pack which consists of all necessary documents including work instructions, drawings etc will also be required.

• D (New activity, no RA) - RA team already nominated by Plant will conduct RA & ascertain the category of activity

Category of Job Activity

Permit types Responsibility

Permit to Work PI

Working at height Permit PI

Hot work Permit PA

Confined Space Entry Permit PA

Confined Space Working Permit PA

Ground Disturbance Permit PA

Diving Permit PA

Containment Break Permit PA

Forms & Records

Record Title Responsibility

Isolation Certificate IA, PI

Logic Isolation Certificate IA, PI

Access Barrier Isolation Certificate AA,PI

HV Environment Isolation Certificate PA, PI

PD containment Isolation Certificate IA, PI

Allowed to Test Certificate IA, PI

Test Certificate SC, PI, PO

Interaction Certificate PI

Machinery Certificate PI

Radiation Certificate PI

Forms & Records

Record Title Responsibility

Standard Work Statement Sheet PM

Standard Work Centers Sheet PM

Standard Work B/D Structure Sheet PO

Standard Tool Box Talk Sheet PO

Standard Hazard and Controls Sheet PM

Standard Risk Analysis Form PO

PTWS Implementation Certificate PM

PTWS Resourcing PM

Formation of CAC PM

PTWS Monitoring PM

SAP Maintenance Order-Printed PO

PTW Supplementary activity Sheet PO

Forms & Records

Energy Isolation

29 CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout)

Energy:Energy & Energy Isolation

Power required for performing work / action.

Energy Isolation:Mechanism (mechanical, electrical, chemical, hydraulic or other) for separating stored energy primarily to enable execution of safe work by competent person(s).

Identifying the sources of Energy. Method of Isolating the Energy.Release of Residual / Stored Energy.Applying Locks & Tags.Testing of the effectiveness of installed isolation.Periodic monitoring of isolation effectivenessSafe removal of the isolations & reinstatement of plant integrity. Communicate to all involved.

100% Safety …………………

0% Energy

EI – Key Principles

• Prepare for shutdown by notifying affected employees.

• Shutdown machine by using normal stopping or rundown procedures.

• Isolate machine or equipment from all energy sources.

• Apply appropriate lockout / tagout devices.

• Safely release all potentially hazardous energy.

• Verify that the equipment cannot be turned on.

LOCKEDOUT

This Lock/Tag mayonly be removed by

NAME: _______________DEPT : _______________EXPECTED COMPLETIONDATE: ________________TIME: _________________

DO NOT OPERATE

DANGER

Steps for EI

LOTO of the supply circuit breaker/switch in the OPEN or OFF position

Physically removing (rack-out) of the supply circuit breaker & LOTO of the drawer

Removal of fuses from the fuse holder & ensure they are locked in the lockbox

Electrical Isolation

To isolate electrical energy, supply circuits must be de-energized by one of the following actions

Equipment that has been locked out for work must be TRIED & TAGGEDTry to restart the equipment using the local

switch,OR

TRY by testing the electrical leads with a voltmeter if switch is not available

It is a serious Safety Violation to ignore, bypass or otherwise defeat the purpose of Tag.

NEVER try to restart the equipment once it is tried, verified & tagged.

Electrical Isolation

• Ensure it’s safe to re-energize equipment.

• Clear equipment of tools & materials.

• Remove employees from equipment area.

• Remove lockout / tagout devices as necessary.

• Energize & proceed with testing & adjustment.

Steps for Re-energization

• Very High Risk, Multidisciplinary workgroup • Locking system with secure key control, using specialized LOTO

solution • Medium risk activities

• Access to keys/actuating mechanism controlled separately to work party using lockout box.

• Locking system using chains or cables to secure valve, with tagging reference to permit.

• Low Risk • Tagging only. Where there is tight control of the isolation point/work

area & lower process hazards• No security

• procedural control only. Requires constant attendance of AA & PC

Level of Security & Isolation Method

Control Key - A key capable of operating the control lock of a Key Safe.

Safety Key - A key unique at the Location capable of operating a lock which will cause an Isolating Device, Earthing Device, vent or drain to be Locked

Key Safe Key - A key unique at the Location capable of operating a lock, other than the control lock, on a Key Safe.

Keys

EI Case Study

• Before carrying out any isolation to enable intrusive work, PA will ensure to minimize risk associated with task. Preferably shut down relevant plant to enable work to be carried out safely, or postpone the job until the next planned shutdown.

• PA & PO will make all efforts to minimize number of people exposed to risk.

• PA will nominate IA. Before proceeding with any isolation activity, IA will determine all hazards associated with particular Isolation task that need to be controlled.

• IA will also conduct assessment of potential isolation failures.

• IA will ensure isolations should remain effective till scheduled completion of job.

• IA will evaluate the base line standard of Isolation by:

• considering standardized substance property list,

• calculating the Release factor using pressure & line size,

• evaluating the Location Factor & then

• evaluating Outcome Factor using Release Factor & Location Factor.

Energy Isolation- Key Process Steps


• IA will implement the Isolation & Issue the Isolation Permit.

• Implementation of Isolations will be maintained till the job is completed.

• AA will monitor the permit-controlled task and integrity of Isolation scheme.

• While designing the isolation scheme IA will make sure that up to date Extended Isolation register is available and taken into due consideration.

• For high risk jobs PA will verify the Isolation scheme. And visit the site after implementation of Isolation scheme before issuance of Isolation Certificate.

• IA will implement isolation scheme in 2 stages - 1. Initial Isolation & 2. Final Isolation.

• LOTO procedure will come in force at this point if multiple tasks or multiple parties are simultaneously working. PI , PC, PA & IA is responsible to manage this situation using LOTO procedure.

• IA has to prove each part of isolation separately & proved to the highest pressure which can be expected.



• On job completion PU, PI, AA inform IA to prepare for re-commissioning activities

• IA to beware that re-commissioning will require equal controls as used during implementationof isolation.

• IA to define sequence of reinstatement in Isolation certificate.

• Before any reinstatement activity IA will list out all existing cross-referenced permits.

• IA to check & list of all plant functions overridden for job & PO will be responsible for their normalization with the information to PI & PA.

• IA normalize the system & cancels the Isolation Permit.



Issue Timing Description of activities Responsible (doing it)

Accountable (ensure it is done)

Competency Assessment

Pre-planning

Check availability of personal with required competency for the scope of work

PO MM, PM

Initial Risk Assessment

Pre-planning

Complete initial risk assessment & assemble competent team to undertake full RA

PO MM, PM

Initiate the Maintenance Order

Planning Complete planning part of Maint Order by precisely dividing the maint activities into autonomous tasks mentioning duration, resources & material for each tas

PO MM

Work Request

Planning Raise the work request by presenting maint order & filling part 1 of PTW Form

PO MM

Scope of works

Planning Determine exactly what the task will involve, the need for any special safety studies or assessments. whether it is obvious that task cannot be carried out safely & should be immediately discarded or delayed until other operations due to take place at the same time have been completed. If the likely hazards cannot be reconciled at this stage through task or other RA, then the task should be rejected or redefined.

PO, PA OM,SC, ME, MM, SS

Full Risk Assessment

Planning Full RA is undertaken for tasks that do not have a completed & available risk assessment. PA with supporting HSE team & PO will identify hazards associated with job & conduct RA & suggest controls in a predetermined formal way

PA, PO, PI HO, SC, ME

Interaction with other works

Planning Define controls required to manage new planned works that could interact or impact with ongoing & on existing works & operations & vice versa.

PO, PA,PI, AA,IA

SC, ME,SS, LO,CO



Permits & Certificates

Planning Define Residual risks associated with proposed job & determine the required PTW System supplementary permits & certificates.

PO, PA, SK, PI

SS,HO,SC, ME

Draft PTW Planning With all information at hand, decision to proceed with the job (or not) is taken. At this point in time PTW procedure will come in force. & draft PTW Form, with all required RA controls, required Permits, required Certificates is prepared

PO, PA, PI, SK

ME, HO, SC

Define isolations

Make safe

Determine isolation & LOTO base line standards for the proposed job. Prepare Isolation scheme. Prepare Isolation De-isolation sequence sheet. Determine common Isolation scenarios. Determine extended Isolation possibility.

PI, IA, AA SC,SS, LO

Effect isolations

Making safe

Implement isolations & issue IC as relevantVerify Isolation Implementation

IA, PI SS,SC,LO

Effect safe technical environment

Making safe

Access Barrier Isolation Certificate High Voltage Environment Isolation CertificatePD containment Isolation Certificate Allowed to Test Certificate Test Certificate Interaction Certificate Machinery CertificateRadiation Certificate

AAPIAA, PIPA, PISKPO, PIPA, POPO, SK

LO, SSSBLO, SSPIHOSC, SSPIHO

Supplementary Permits

MakeSafe

Issue supplementary permits after making assessment of job & determining the requirement of Permits & Certificates. Working at Height Permit

PA, PI, PO

SK, PI

ME,SC,SS

HO, SC, SS



PTW Issued

Made safe

PTW Form issued with additional permits and/or certificates prepared & issued

PI, PA, IA SS, SC, LO

Permit acceptance

Accepted as safe

Check & accept PTW form & supporting documents PC, PU,PI, IA behalf of PU

MT,MS,ME,SS,SC

Under take works

Safe works in progress

Undertake job in compliance with all precautions & instructions as per PTW documentation

PU, PC, AA, PI,

MT, MS, ME, LO, SC, SS,

Confined Space

Safe works in progress

Ensure that additional personnel for confined space entry are available

PO, SC, PC PC

Supervision

Ensure safe works in progress

The Job will be carried out under mandatory supervision SA HO, PO, PA

Change of scope

Works change managment

During the job if any change in scope is required PU will inform PC, PO, AA and PI

PU, PC, AA PU, MS, MT, ME

Unplanned situation

Work in progress

During job if any unplanned situation occurs the job will be stopped & a revised RA may be undertaken & implemented under Job suspension procedure.

PU, PC,AA,IA,PI

PU, PC, PI, MT, MS,SL,LO,SS, SC



Shift change

Works in progress

If Operation Shift changed over during job, job handover procedure will come in force. If Maint team change over during the job this procedure will become effective

Extended isolations

Work in progress

When extended isolations are required a formal procedure will be followed leaving no room for any mistaken activity.

IA, AA, PI, PO

ME, LO

Monitoring Works in progress

Continuous checking of controls in place during the pendency of permit controlled job

AA, PI, IA, PA LO, SS, SC, MO, ME

PTW Compliance

Works in progress

Periodic verification of compliance with PTW system and procedures

PI. PA, PO OM, MM, PM, GMQ

Suspension of works

Works in progress

If task is suspended due to any reason then compliance with suspension procedure is required

PU, AA, PI MS, MT, SL, LO, SS, SC

Completion of works

Works completed

When task is completed as per plan then job hand back procedure come into effect

PU,AA,IA,PI, LO,SC,SS,

Compliance Audit

After completion

Periodic audits of compliance with the PTW system should be undertaken

PA OM, MM, PM, GMQ

LOTO Procedure

• Isolations must remain secure through the duration of the intrusive task. Degree of security required will be proportionate to risks resulting from isolation failure.

• Wherever required, IA will ensure locking arrangements or barriers to physically prevent accidental or unauthorized removal of the isolation..

• IA to keep in mind that the need for security is greatest where a single action (for example opening a valve) could lead to the release.

• IA will take particular care of valve types more susceptible to inadvertent opening. E.g., small dia. ball valves, especially where they are easily accessed.

• IA will physically disable & secure (by padlocking or removal of handle ) valves which require only a 90º movement between shut & open.

• IA & PI will use Trapped key interlocked system to allow a number of people if the job involve multi-disciplinary work groups to apply individual locks.

• Where a remotely actuated valve is part of an isolation scheme, IA will prevent inadvertent valve operation on command.

LOTO - Key Process Steps

• Where motive power required for closure, valve be mechanically constrained by IA by lockout, & isolation tested after de-energizing motive power supply by SC & IA.

• Where absence of motive power is required for valve closure, isolation must be tested after de-energizing motive power supply by SC & IA. Motive power supply should be isolated by physical disconnection by IA in coordination with PI & PC.

• Motive power disconnection points should be labeled by IA & described with their status recorded & maintained on an isolation certificate by IA.

• Where isolation of motive power is effected by venting, the vent valves should be secured in open position by locking arrangement selected proportion to risk by IA

• Where electrical power is switched off & fuse removed, means of isolation must be secured by locking off by IA.

• Keys & locks used to secure isolation must be issued in accordance with work permit control by PI & PA.

• IA will give special consideration to the reinstatement of remotely actuated valves located an appreciable distance away from the worksite.

LOTO - Key Process Steps

• Lockout locks shall be individually identified by a number, color, or similar marking to identify individual / Department that installed the lock. Lockout locks shall be used only for lockout purposes.

• LOTO devices should be durable & capable of with-standing the environment to which they are exposed for the max. period of time that exposure is expected.

• Tags shall be constructed & printed so that exposure to weather conditions or wet & damp locations or corrosive environments will not cause the tag to deteriorate or the message on the tag to become illegible

• Tags shall be affixed to the lockout or isolation device by a means of a fastening device (e.g., wire or nylon cable ties) that exhibits a min. breaking strength of 50 pounds

LOTO - Essentials

• In process facilities, there will usually be a min. of two locks on all isolation locations - the Operations Control lock & the worker's Individual lock

• If more than one teams are performing different tasks on same equip, then each team shall install their own Individual locks in addition to Operations Control lock

• If an energy-isolating device is incapable of being locked out, some other means equivalent to placing a lock shall be adopted

• In addition, a tag must be attached at all isolation points.

LOTO - Essentials

LOTO Procedures

What possible hazards exist?

Lockout / Tagout procedures Lockout / Tagout procedures

• Nine steps for safety

• Rules and regulations

• Nine steps for safety

• Rules and regulations

The basics The basics

• Lockout

• Tagout

• Individual responsibilities

• Lockout

• Tagout

• Individual responsibilities

Hazards Hazards

• Mechanical

• Kinetic

• Pneumatic

• Thermal

• Mechanical

• Kinetic

• Pneumatic

• Thermal

Hazards, continuedHazards, continued

• Hydraulic

• Pressurized liquids or gasses

• Combined energy types

• Hydraulic

• Pressurized liquids or gasses

• Combined energy types

Shutting off and securingShutting off and securing

• Required for service or maintenance

• Never bypass safety features

• Authorised employees

• Affected employees

• Required for service or maintenance

• Never bypass safety features

• Authorised employees

• Affected employees

• Step 1: Preparation

- Understand the equipment

- Identify the energy sources

• Step 2: Shutting off

- Follow all operating instructions

• Step 1: Preparation

- Understand the equipment

- Identify the energy sources

• Step 2: Shutting off

- Follow all operating instructions

6 steps to take before working in the danger area6 steps to take before working in the danger area

6 steps to take before working in the danger area, continued6 steps to take before working in the danger area, continued

• Step 3: Blocking

- Isolate each form of energy

- Set fuses to zero

- Install disconnection devices

• Step 3: Blocking

- Isolate each form of energy

- Set fuses to zero

- Install disconnection devices


• Step 4: Securing

- Locks

- Tags

- Lock box

- Cords and plugs

• Step 4: Securing

- Locks

- Tags

- Lock box

- Cords and plugs


• Step 5: Inspection

- Residual energy

- Check continuously

• Step 5: Inspection

- Residual energy

- Check continuously


• Step 6: Checking and testing

- Check and re-check all energy sources are shut off and marked

- Test that all energy sources are switched off

- Inform everyone in the vicinity

• Step 6: Checking and testing

- Check and re-check all energy sources are shut off and marked

- Test that all energy sources are switched off

- Inform everyone in the vicinity

3 steps to take after working in the danger area3 steps to take after working in the danger area

• Step 1: Restore

- Clear the area

- Check all safety features

• Step 1: Restore

- Clear the area

- Check all safety features

3 steps to take after working in the danger area, continued3 steps to take after working in the danger area, continued

• Step 2: Inform your colleagues

• Step 3: Removal of lockout/tagout devices

- Must only be removed by the person who put them on

- Must follow your employer’s energy control procedures

• Step 2: Inform your colleagues

• Step 3: Removal of lockout/tagout devices

- Must only be removed by the person who put them on

- Must follow your employer’s energy control procedures

Case closed Case closed

• Your safety is important

• Know the six steps of lockout / tagout

• Know the three steps of lock and tag removal

• Never skip steps or cut corners!

• Your safety is important

• Know the six steps of lockout / tagout

• Know the three steps of lock and tag removal

• Never skip steps or cut corners!

NOMAC WCM CREATION

SAP PTW SYSTEM

DOCUMENTATION

WCM CREATIONAt first click the icon to start login in SAP. Below shows login pad.

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WCM CREATION

Enter login credentials :

1. Client 300 use for Production Server.2. User: Username (Authorized to you).3. Password: Your password.4. Language: En (Blank is En by default).

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WCM CREATIONAfter logging first screen like belowFor creating Notification T-code IW21.

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WCM CREATIONSelect from M1 to M9 as configured for our usage and SM & WN for Shutdown and Warranty Notifications.

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WCM CREATIONEnter short desc or brief about the job activity here.

Enter “SQWP” and click this adjacent button you can reach to equipment in hierarchy level.

Enter detail information of the problem in this area.

This item must be entered.

Damage and Cause code should be entered to technically close the order completely .

After entering all information’s and saving, release the notification. Click here to get Maint. order screen. See in next slide.

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WCM CREATION

Under Operation tab enter in line item about the activities and in column ‘N’ no. of persons and in ‘Durat’ no. of hours and press enter.

Finally release the Maint. Order to get permit print by Opr. dept.

Enter emp no. who is attending this job and press enter key.

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WCM CREATION

Finally Operation dept give approval if this order is for access permit.

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WCM CREATION

• WCM PERMITS…….

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WCM CREATIONIf the order required WCM permit. The Ctrl key should be select as “WCM” by default it is ”PM01” used for access permit.

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WCM CREATIONIf this activity required any material select “PP03” as ctrl key and click below internal button to enter components details.

If required external servicesSelect “PM03”. Select the lineItem and click “External” to Enter details. Refer slide No.13

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WCM CREATIONBy selecting required component no. required qty and plant. System will generation reservation if selected ‘L’ from stock item. If selected ‘N’ system will generate Purchase Requisition. Save to take changes.

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WCM CREATION

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WCM CREATIONTo get reservation no. highlight the line item which selected ‘L’ as stock item and click Gen. Data button.

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WCM CREATIONThis is the reservation no. by entering in new session “Zreservation” T-code and entering this no. you will get print report as shows next slide.

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WCM CREATIONUse Zreservation in command line and after getting this screen past reservation no. and click execute button system will show you print dialog screen.

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WCM CREATIONSimilarly to get PR generated. highlight the line item which selected ‘N’ as Non stock item and click Purch. button.

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WCM CREATIONCopy this PR no. and use “ME53n” T-code to view the system generated PR for procurement. As shows in next slide.

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WCM CREATIONPR requested for order.

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WCM CREATION

Start creating “Work Approval” to this order.

Click here to create “Work Approval”.Another two screen executes and accepts by Entering two times.

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WCM CREATION

Work Approval screen appears save it.

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WCM CREATIONAfter saving work approval one dialog screen appears accept it and save the order. The below window display just refresh to see work approval attached to the order.

Click green color highlighted to create Work Applications like “Main Permit”, “Work at Height”, “Hot work permit”,“Confine space permit”, “TRA” etc.

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WCM CREATION

To create “Work Applications”.

Click here to create “Work Application”.

Check the Main Work Permit above.To create “Work Application”.Another two screen executes and accepts by Entering two times.

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WCM CREATIONClick check list button to select type of permit and tests required.

Click here to Multi selection as shows beside.

Select only three items and click copy to effect in main Permit.Accept the next screen and save the WCA.

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WCM CREATION

Similarly click here to create another WCA with template (means already created for TRA’s in the system can be attached).

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Click to get search criteria and keep the same data as shows and click execute.

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WCM CREATIONSelect desired TRA to attached with the order.Next cut and paste the application no. In below item Reference application.Finally accepts two times.

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WCM CREATIONSave the application and WCA to attached with this order.

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Upto this part Maintenance Dept. is responsible.Refresh the screen to see the graphical level of created objects.

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WCM CREATIONTo create isolation sheet go to main permit and click this icon, it will give You to create tags on isolation equipments.

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WCM CREATIONAfter creating isolation equipments select the check box and click this button to set prepare.

Operation Group

Tag Sequence Untag Sequence

Lock No.

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After releasing all applications Initial, beginning, and printing of tag stage becomes ready.

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Click this icon to make set as prepare, than accept Yes.

WCM CREATION

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Click this icon to give approval and this should be for all WCA and WCD’s by Operation Engineer and Safety Engineer.

WCM CREATIONFinally release for execution of Maintenance order and take all print out with AP sign.

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Work completed should be execute before closing technically.

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WCM CREATIONFor closing technically use T-Code IW42.

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