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PCAMS Pre-Commissioning & Commissioning

Activities Management System(Ver 3.0)

http://pcams.eil.co.in

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To provide the online facilities for doing site co-ordination activities for smooth and safe pre commissioning and commissioning of plants.

To cater to the need of EIL (POSD, Construction , Project) and Client through a systematic array of pre-commissioning related data / documents available on the web server during process plant’s pre commissioning and commissioning activities at site and HO.

To provide online workflow for generating the formats (I to V).

To facilitate an integrated approach to data capture, maintenance, storage, sharing and usage of centralized database among the authorized personnel within and outside the department.

It is well structured and has provision to accommodate all different kind of jobs (Conventional or LSTK).

Purpose

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Benefits

Data sharing within project at HO/ RO / site and other disciplines

Data level security Saving of man hours during project commissioning Standardization of report formats ( I TO V ) Data import and export in a well-accepted software format Better follow up of the commissioning status Multiple users with various roles and security rights Faster communication within project team Availability of EIL standardized report to client. Building of Knowledge Base for re-usability of technical

details of pre commissioning activities of past projects

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Demarcation of Project into Units & Areas based on type of Project Creation of Project Team along with their access rights as per job quality

plan. Preparation of Mechanical and pre commissioning Checklist. Import Engineering data in Excel format ie. Equipment list, Line list,

Instrument Index, PID index, PFD index). Provide basic input for Preparing System dossier (System/sub system

identification). Linkage of Line list, Equipment list ,PID index and Instrument Index with

identified System. Collection of Checklist from the different department along with their

responsibility. Access to SCT /CONST/CLIENT/PMC for viewing and updating their

checklists (Punch points) based on their responsibility. Liquidation of CHECKLIST in consultation with Construction along with

FORMAT A Format B, Format I, format II, Format III, Format IV, Format V.

Features

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Administrator Module

System Library

Import Process / Engineering Data (Excel file)

System Dossier (Index Preparation

)

Liquidation of Checklist

Generates Reports

- PID index, PFD index, , Line list, Instrument Index , Equipments list ,

Flushing Loops index

-System Identification-Codification (system / equipment)- Mechanical Checklist (Job wise)

- Checklist Responsibilities Assignment- System Tag no Generation

- Pre Commissioning Checklist- Project Department List

- Client / PMC / Licensor’s List

-Create Project / Unit Details- Create User ID (for client / pmc /

licensor )- Create Commissioning Team

- Assign Roles

-Format A,B,I,II,III,IV,V

- System Dossier Files with Checklist - Format Status and

User Defined reports.

-SCT / Construction site / Client / PMC Commentson Punch pointsI,II,III,IV,V- System Wise Exception

PCAMS

-Collect Component Detail (System wise)-Upload Equipment and Instrument data

sheet -Create Pre Comm Design Conditions for

specific Equipment.- Upload System Markup P&ID , AFC (as

build dwg), and Flush loop Mark-up P&ID

Work Flow

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List of Projects Executed through PCAMS

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GGSRP ( Project no 6922) - Current Format Status

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System Administrator / HOD Chief commissioning Co-ordinator (CCC) Project Manager Area co-ordinator Client Commissioning In charge Lead engineer Job Engineer

Various Roles

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List of Activities

•Administrative Activities•POSD Activities•Construction Activities•Client Activities

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Archival of master database for past projects

Quick retrieval of details of past projects for start-up planning, checklist preparation and checklist liquidation follow-up for future projects

Re-usability of technical details of pre commissioning activities of past projects

Building of Knowledge Base

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Pre Commissioning Management systemAdmin Module

ADMINISTRATOR

Commissioning Team

ACCESS

CREATE PROJECT/UNIT

Create Non EIL User (Client/PMC)Define User TypeRole Assignment

Commissioning Team’s Department

Access Right based on User Type

New Project / Unit Creation Define CCC (project specific)

HOD/System Administrator Level 6Chief Commissioning coordinator Level 5Project Manager Level 4Constructor Coordinator Level 3Lead Engineer Level 2Job Engineer Level 1

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IMPORT MODULE

IMPORT Excel File

(Project & Unit wise)

Equipment List (Static & Rotating

Deptt)

PFD Index (Process Deptt)

P&ID Index (Process

Deptt)

Vendor Data

( Licensor)

Line List (Process

Department)

Instrument Index (Instrumentation

Department)

Oracle Master database

(Corresponding Excel Tables)

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System Dossier Data Preparation

Data into Corresponding design tables in

the database

Selection of System Tag No

Equipment List Instrument Index Line Schedule PID Index PFD Index

Selected components

(System wise) System Dossier Data (System

wise)

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Define List of Sub System

Attach / Upload Documents

Enter System Exceptions

Format-I Approval

By Lead Engineer (Construction)

Format – I Passed

On to SCT

Acceptance / Rejection By SCT

By Job engineer (Construction)

Client’s Multiple Job Engineers Enter Punch points

Accept / Reject by Client Group

head

SCT Multiple Job Engineers Enter Punch points

Consolidated Punch Points of Client and SCT

Issued by SCT and Format-II passed on

to Construction

Client’s Group head’s Rejection

Proceed to Format-II

SCT’s Rejection

SCT’s Acceptance

Assign Responsibilities by Construction Group Head to Job Engineers

Instrumentation

Civil

Electrical

Enter Completion Date

Enter Remarks / Exception with Category

Upload Project related Files

Issue FORMAT-III by Construction AND passed on POSD & CLIENT

POSD’s comments Client’s Comments

Accept/ Reject FORMAT-III by POSD

Issue Format-IV by SCT

Mechanical

Accepted by POSDRejected by POSD

FORMAT-I

FORMAT-II

FORMAT-III

FORMAT-IVAccept / Reject

FORMAT-IV by ClientProceed to FORMAT-V

Client’s Acceptance

Client’s Rejection

Pre-Commissioning Activities Work Flow

FORMAT-1 Forwarded to OWNER for View

Client’s Punch point Copied by SCT

Client’s Acceptance

FORMAT-II viewed by OWNER

FORMAT-V

View Attached PID, System Dossier and Flushing PID

View PID & Sys Dossier

FORMAT-III viewed by OWNER

Attach / Upload Documents

Enter Comments by SCT

View Sys PID, Flushing PID & System Dossier

POSD’s comments

Client’s commentsAcceptance FORMAT-V

by Client and SCT Issue FORMAT-V

Handed over to Client’s operational deptt.

FORMAT-IV viewed by Const.

FORMAT-V viewed by EIL

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List of System Identification List of Project Commissioning Team ( Project / Unit wise) System dossier details Mechanical and pre commissioning Checklist Pre Commissioning Activities Equipment list , Line list , Instrument Index and P&ID index

(overall / P&ID wise / System wise) Design parameters for Critical Equipments / Instruments. Equipment Datasheet, Instrument Datasheets Characteristics / Heat curve System mark-up P&ID / AFC (as build) / Flush markup P&ID Current Format Status and Current Project Status Equipment summery and Flushing schemes Overall track record of progress of pre commissioning / commissioning

activities through Format I to Format V . Issued / Accepted format reports for Format-I to Format-V.

ReportsReports

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• Project / Unit Creation - By System / HOD Administrator

• Define Chief Commissioning Coordinator (CCC) – unit wise

• Project Manager Creation - By CCC

• Commissioning Team Creation (With Access Rights) - By PM

• SCT - Lead Engineer, Job engineer• Construction team - Area coordinator, Lead engineer, Job Engineer• Project Team - Project Manager , Job engineer• Client (Core) Team - Lead Engineer , Job engineer• Client (Project) Team - Lead Engineer, Job engineer

• User ID Creation for Non EIL members (Project wise) - By PM

• Update Job Quality Plan - By PM

• Update Department ‘s list for building the Commissioning Team - By PM

Administrative Activities

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System Identification and Prioritization of the System completion

Markup the process P&ID’s with different symbol as per the System Identified. (manually)

Attach the symbol with System Tag number for reference.

Collection of Process / Engineering Data from Project (Excel files) Equipment List Instrument Index P&ID Index Line Schedule

Preparation of System Dossier . ( Attach / Detach set of data of Equipments, Instruments ,P&ID number and

piping spec along with line details )

Upload the System Markup P&ID (system wise - optional) Upload the AFC P&ID’s

POSD ActivitiesPOSD Activities

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Define the pre-commissioning related design parameters for critical Equipments / Instruments

Heater, Heat Exchanger Column Compressor, Pump ,Turbine , Fan, Blower Control Valve

Define pre information required for Equipment Trial Run (Test record for Rotating Equipments only)

Upload the required documents (optional, if required) Data sheet for Critical Equipment or Instruments Upload the Characteristics curves for rotating equipments Upload the Heat Curves for critical equipments Upload Flushing Markup P&ID (preliminary) Upload AFC (As build Dwg.) – System wise

Flushing / Blowing / Pr testing schemes

POSD ActivitiesPOSD Activities

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Format-I Accept / Reject (auto mail to project team) Forward to Client

Format-II Copy Client’s Punch points Enter SCT punch points Issue (auto mail to selective project team) Forward to Construction

Format-III View Client's and Construction comments Enter SCT Comments Accept / Reject (auto mail to project team) Forward to Client

Format-IV View Client’s comments Enter SCT comments Issue (auto mail to project team) Forward to Client

POSD ActivitiesPOSD Activities

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Create Mechanical Checklist.(Guidelines for Format-I and Format-II)

FORMAT-I (By Construction)(Intimation regarding System Completion)

View System Markup P&ID and System Dossier Attach ref Documents Enter exceptions Issue (auto mail to project team) Forward to POSD

FORMAT-III (By Construction)(Intimations of liquidation of checklist points) View Flushing Schemes (if available) Assign the Responsibilities (Area coordinator) Comments against punch points Attach ref Documents Issue (auto mail to project team) Forward to POSD

View Project Status & Reports.

Construction ActivitiesConstruction Activities

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FORMAT-II (By Core Group)(Preparation of Checklist)

View Format-I Punch points (Discipline wise) Issue (auto mail to Client Project Group) Forward to Project Group

FORMAT-II (By Project Group) (Approve the Punch points)

View Punch points) Assign the Responsibilities (Area coordinator) Accept / Reject (auto mail to selective project team) Forward to POSD

FORMAT-IV View SCT comments Enter comments Accept / Reject (auto mail to project team)

View Project Status & Reports View Process / Engineering Documents

Client ActivitiesClient Activities