1 PCAMS Pre-Commissioning & Commissioning Activities Management System (Ver 3.0)
2 PurposeTo 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).
3 BenefitsData sharing within project at HO/ RO / site and other disciplinesData level securitySaving of man hours during project commissioningStandardization of report formats ( I TO V )Data import and export in a well-accepted software formatBetter follow up of the commissioning statusMultiple users with various roles and security rightsFaster communication within project teamAvailability of EIL standardized report to client.Building of Knowledge Base for re-usability of technical details of pre commissioning activities of past projects
4 FeaturesDemarcation of Project into Units & Areas based on type of ProjectCreation 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.
5 PCAMS Work Flow Generates Reports Administrator Module System Library Create Project / Unit Details - Create User ID (for client / pmc / licensor ) - Create Commissioning Team - Assign RolesFormat A,B,I,II,III,IV,V - System Dossier Files with Checklist - Format Status and User Defined reports.System LibraryPCAMSSystem 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 ListLiquidation of ChecklistSCT / Construction site / Client / PMC Comments on Punch pointsI,II,III,IV,V - System Wise ExceptionSystem Dossier (Index Preparation)Import Process / Engineering Data (Excel file)-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- PID index, PFD index, , Line list, Instrument Index , Equipments list , Flushing Loops index
6 List of Projects Executed through PCAMS Jobs Started forLLDPE/HDPE Swing Unit (EPCC-3 Package) in EPC mode executed by EILProject no : 6841 / Unit no : 31 / Area no: 100, 200, 300, 400Jobs Running onGGSR project for all the units in Conventional mode executed by EILProject no : 6922 / Unit no : AllNumber of units (created) :52Number of Systems (identified) :2251Number of Format Issued (Process systems) :1166MRPL (Phase-III) SRU Block in OBE mode executed by EILProject no : 6994 / Unit no : 322, 326, 614, 714, 814
7 GGSRP ( Project no 6922) - Current Format Status
8 Various RolesSystem Administrator / HODChief commissioning Co-ordinator (CCC)Project ManagerArea co-ordinatorClient Commissioning In chargeLead engineerJob Engineer
9 List of ActivitiesAdministrative ActivitiesPOSD ActivitiesConstruction ActivitiesClient Activities
10 Building of Knowledge Base Archival of master database for past projectsQuick retrieval of details of past projects for start-up planning, checklist preparation and checklist liquidation follow-up for future projectsRe-usability of technical details of pre commissioning activities of past projects
12 Pre Commissioning Management system Admin ModulePre Commissioning Management systemCREATE PROJECT/UNITNew Project / Unit Creation Define CCC (project specific)ADMINISTRATORCommissioning TeamACCESSAccess Right based on User TypeCreate Non EIL User (Client/PMC) Define User Type Role Assignment Commissioning Team’s DepartmentHOD/System Administrator Level 6 Chief Commissioning coordinator Level 5 Project Manager Level 4 Constructor Coordinator Level 3 Lead Engineer Level 2 Job Engineer Level 1
13 IMPORT MODULE IMPORT Excel File (Project & Unit wise) Equipment List (Static & Rotating Deptt)Line List (Process Department)Instrument Index (Instrumentation Department)PFD Index (Process Deptt)P&ID Index (Process Deptt)Vendor Data ( Licensor)Oracle Master database (Corresponding Excel Tables)
14 System Dossier Data Preparation Selection of System Tag NoEquipment ListInstrument IndexLine SchedulePID IndexPFD IndexSelected components (System wise)Data into Corresponding design tables in the databaseSystem Dossier Data (System wise)
15 Pre-Commissioning Activities Work Flow SCT’s RejectionPre-Commissioning Activities Work FlowDefine List of Sub SystemFORMAT-IAttach / Upload DocumentsSCT’s AcceptanceFormat – I PassedOn to SCTFormat-I ApprovalEnter System ExceptionsBy Lead Engineer (Construction)Acceptance / Rejection By SCTProceed to Format-IIFORMAT-1 Forwarded to OWNER for ViewView PID & Sys DossierBy Job engineer (Construction)FORMAT-IIClient’s Multiple Job Engineers Enter Punch pointsAccept / Reject by Client Group headClient’s AcceptanceClient’s Punch point Copied by SCTClient’s Group head’s RejectionFORMAT-II viewed by OWNERIssued by SCT and Format-II passed on to ConstructionSCT Multiple Job Engineers Enter Punch pointsConsolidated Punch Points of Client and SCTFORMAT-IIIEnter Completion DateIssue FORMAT-III by Construction AND passed on POSD & CLIENTInstrumentationAssign Responsibilities by Construction Group Head to Job EngineersEnter Remarks / Exception with CategoryMechanicalPOSD’s commentsClient’s CommentsCivilUpload Project related FilesElectricalView Attached PID, System Dossier and Flushing PIDAccept/ Reject FORMAT-III by POSDFORMAT-III viewed by OWNERAccepted by POSDRejected by POSDClient’s RejectionAttach / Upload DocumentsClient’s AcceptanceFORMAT-IVProceed to FORMAT-VAccept / Reject FORMAT-IV by ClientEnter Comments by SCTIssue Format-IV by SCTView Sys PID, Flushing PID & System DossierFORMAT-IV viewed by Const.FORMAT-V viewed by EILFORMAT-VPOSD’s commentsAcceptance FORMAT-V by Client and SCTHanded over to Client’s operational deptt.Client’s commentsIssue FORMAT-V
16 Reports List of System Identification List of Project Commissioning Team ( Project / Unit wise)System dossier detailsMechanical and pre commissioning ChecklistPre Commissioning ActivitiesEquipment list , Line list , Instrument Index and P&ID index(overall / P&ID wise / System wise)Design parameters for Critical Equipments / Instruments.Equipment Datasheet, Instrument DatasheetsCharacteristics / Heat curveSystem mark-up P&ID / AFC (as build) / Flush markup P&IDCurrent Format Status and Current Project StatusEquipment summery and Flushing schemesOverall 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.
17 Administrative Activities Project / Unit Creation - By System / HOD AdministratorDefine Chief Commissioning Coordinator (CCC) – unit wiseProject Manager Creation - By CCCCommissioning Team Creation (With Access Rights) - By PMSCT - Lead Engineer, Job engineerConstruction team - Area coordinator, Lead engineer, Job EngineerProject Team - Project Manager , Job engineerClient (Core) Team - Lead Engineer , Job engineerClient (Project) Team - Lead Engineer, Job engineerUser ID Creation for Non EIL members (Project wise) - By PMUpdate Job Quality Plan - By PMUpdate Department ‘s list for building the Commissioning Team - By PM
18 POSD ActivitiesSystem Identification and Prioritization of the System completionMarkup 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 ListInstrument IndexP&ID IndexLine SchedulePreparation 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
19 POSD ActivitiesDefine the pre-commissioning related design parameters for critical Equipments / InstrumentsHeater, Heat ExchangerColumnCompressor, Pump ,Turbine , Fan, BlowerControl ValveDefine 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 InstrumentsUpload the Characteristics curves for rotating equipmentsUpload the Heat Curves for critical equipmentsUpload Flushing Markup P&ID (preliminary)Upload AFC (As build Dwg.) – System wiseFlushing / Blowing / Pr testing schemes
20 POSD Activities Format-I Format-II Format-III Format-IV Accept / Reject (auto mail to project team)Forward to ClientFormat-IICopy Client’s Punch pointsEnter SCT punch pointsIssue (auto mail to selective project team)Forward to ConstructionFormat-IIIView Client's and Construction commentsEnter SCT CommentsFormat-IVView Client’s commentsEnter SCT commentsIssue (auto mail to project team)
21 Construction Activities 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 DossierAttach ref DocumentsEnter exceptionsIssue (auto mail to project team)Forward to POSDFORMAT-III (By Construction)(Intimations of liquidation of checklist points)View Flushing Schemes (if available)Assign the Responsibilities (Area coordinator)Comments against punch pointsView Project Status & Reports.
22 Client Activities FORMAT-II (By Core Group) (Preparation of Checklist) View Format-IPunch points (Discipline wise)Issue (auto mail to Client Project Group)Forward to Project GroupFORMAT-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 POSDFORMAT-IVView SCT commentsEnter commentsAccept / Reject (auto mail to project team)View Project Status & ReportsView Process / Engineering Documents