CASE STUDIES
NLINK OPC TO SAP SOLUTION CASE STUDIES
The NLINK® OPC to SAP Solution can be used for a wide variety of applications that involve SAP SCADA integration, SAP PLC integration, SAP DCS integration and more. Examples include Preventive and Predictive Maintenance with the SAP PM Module, Inspection Readings in Assembly and Testing with the SAP QM Module and Inventory Reconciliation with the SAP IM Module. There are many more applications of this technology. The examples listed here are just a sample.
CONDITION BASED MAINTENANCE
This Mining Company customer needed a solution that could retrieve the raw operational data from its various mine assets (pumps, motors, etc.) and create SAP measurement documents. They also wanted to monitor the raw data and to automatically create SAP Work Notifications (Work Orders) when any value exceeded its pre-set threshold.
RAILCAR LOADOUT SYSTEM
This Utility Company customer initiated a project to replace an existing HMI (used to control a pelletized fertilizer load-out system) with Wonderware InTouch. The old HMI connected to SAP via a web services interface that required a lot of programming and was not as reliable as they would have liked and difficult to troubleshoot when things went wrong. They replaced it with the NLINK OPC to SAP Solution.
NLINK OPC TO SAP SOLUTION USE CASES
SAP PM MODULE – PREVENTIVE MAINTENANCE WITH OPC
Preventive Maintenance is a schedule of planned maintenance actions aimed at preventing breakdowns and failures, which can lead to downtime in plant or production activities. These planned maintenance actions are typically time-based (i.e. based on a routine schedule), or based on a maintenance cycle (i.e. based on actual run time data) from the equipment. Preventive maintenance plans based on a routine schedule can incur unnecessary cost if the equipment has been inactive, or if the equipment is being used as a redundant component in a system.
Typically, these shop floor devices are connected to an OPC server via a SCADA, PLC or DCS.
To reduce the cost of unnecessary scheduled maintenance, the NLINK OPC to SAP Solution can help facilitate maintenance plans based on cycles (i.e. based on actual run time data). The delivered solution will allow the equipment to automatically report to the SAP PM module its respective readings, via SAP Measurement Documents.
Sample applications of the NLINK OPC to SAP Solution may include:
- Reporting run time data on redundant pumps in a water pumping system
- Reporting hours of engine operation on electrical generators
- Reporting fuel consumptions and flue gas temperatures on industrial boilers
SAP PM MODULE – PREDICTIVE MAINTENANCE WITH OPC
Predictive Maintenance is a Condition Based Maintenance (CBM) approach to monitor and extend the useful life of a piece of equipment. Unlike the maintenance cycle approach used in Preventive Maintenance, Predictive Maintenance requires measured data or device monitoring data in order to predict when maintenance should be performed.
Typically, these shop floor devices are connected to an OPC server via a SCADA, PLC or DCS.
To support Predictive Maintenance in SAP (Condition Based Maintenance plans), the NLINK OPC to SAP Solution can allow the monitoring devices to automatically report their run time data to the SAP PM module via the creation of SAP Measurement Documents.
Sample applications of the NLINK OPC to SAP Solution may include:
- Vibration Readings on pumps or compressors to determine remaining useful life
- Electrical Resistance Readings (Ohm Readings) on motors to determine winding insulation integrity
SAP PM MODULE – MAINTENANCE PROCESSING WITH OPC
For unexpected breakdowns or out-of-range readings as registered by the equipment monitoring devices, Maintenance Notifications or Malfunction Reports in SAP can be created automatically from the devices.
Typically, these shop floor devices are connected to an OPC server via a SCADA, PLC or DCS.
Sample applications for the NLINK OPC to SAP Solution may include:
- Stronger than normal vibration readings on pumps or compressors
- Weaker than normal electrical output from generators
- Equipment breakdown (non-functioning) for any equipment
SAP PP-PI MODULE – PRODUCTION PLANNING WITH OPC
The SAP PP-PI Module (Production Planning – Process Industries) provides a comprehensive suite of process planning tools to manage resource, recipe and process management, as well as process planning and production information management.
Typically, these shop floor devices are connected to an OPC server via a PLC.
To fully support production planning in SAP the NLINK OPC to SAP Solution can allow the Process Control System (i.e. the SCADA, DCS, or PLC) to receive planned orders from SAP and then generate real-time process data during production that is automatically fed back to SAP to allow further processing, such as:
- Materials Management
- Quality Management
- Process Costing
- Generation of Electronic Batch Records
SAP QM MODULE -INSPECTION READINGS IN ASSEMBLY AND TESTING WITH OPC
In the manufacturing of actuators and control devices where torque readings need to be tested, or in process industries where quality control data needs to be tracked, the devices that capture these readings can automatically report the readings into the SAP QM module as Inspection Results.
Typically, these shop floor devices are connected to an OPC server via a PLC.
Sample applications for the NLINK OPC to SAP Solution may include:
- Operating Output Torque Ranges / Maximum Torque output reading for an Electric Actuator
- Operating Supply Pressure Ranges for Pneumatic Actuators
SAP IM MODULE – INVENTORY RECONCILIATION ON TANK FARMS WITH OPC
Through the use of various OPC compliant devices and gauges that monitor the tank farms and provide feedback on tank information, inventory levels in a tank farm can be automatically interfaced with SAP’s Inventory Management module.
Typically, these tank level measurement devices are connected directly to an OPC server.
Sample applications for the NLINK OPC to SAP Solution may include:
- Reporting differences between inventory levels in the tank versus expected levels in SAP
- Reconciling inventory differences between planned consumption and actual consumption in SAP
- Triggering purchase requisitions based on actual tank levels.
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