1. PCAMS Pre-Commissioning & Commissioning Activities Management System
(Ver 3.0)

2. Purpose
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).

3. 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

4. Features
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.

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 Roles
Format A,B,I,II,III,IV,V - System Dossier Files with Checklist - Format Status and User Defined reports.
System Library
PCAMS
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
Liquidation of Checklist
SCT / Construction site / Client / PMC Comments on Punch pointsI,II,III,IV,V - System Wise Exception
System 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 for
LLDPE/HDPE Swing Unit (EPCC-3 Package) in EPC mode executed by EIL
Project no : 6841 / Unit no : 31 / Area no: 100, 200, 300, 400
Jobs Running on
GGSR project for all the units in Conventional mode executed by EIL
Project no : 6922 / Unit no : All
Number of units (created) :52
Number of Systems (identified) :2251
Number of Format Issued (Process systems) :1166
MRPL (Phase-III) SRU Block in OBE mode executed by EIL
Project no : 6994 / Unit no : 322, 326, 614, 714, 814

7. GGSRP ( Project no 6922) - Current Format Status

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

9. List of Activities
Administrative Activities
POSD Activities
Construction Activities
Client Activities

10. Building of Knowledge Base
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

12. Pre Commissioning Management system
Admin Module
Pre Commissioning Management system
CREATE PROJECT/UNIT
New Project / Unit Creation Define CCC (project specific)
ADMINISTRATOR
Commissioning Team
ACCESS
Access Right based on User Type
Create Non EIL User (Client/PMC) Define User Type Role Assignment Commissioning Team’s Department
HOD/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 No
Equipment List
Instrument Index
Line Schedule
PID Index
PFD Index
Selected components (System wise)
Data into Corresponding design tables in the database
System Dossier Data (System wise)

15. Pre-Commissioning Activities Work Flow
SCT’s Rejection
Pre-Commissioning Activities Work Flow
Define List of Sub System
FORMAT-I
Attach / Upload Documents
SCT’s Acceptance
Format – I Passed
On to SCT
Format-I Approval
Enter System Exceptions
By Lead Engineer (Construction)
Acceptance / Rejection By SCT
Proceed to Format-II
FORMAT-1 Forwarded to OWNER for View
View PID & Sys Dossier
By Job engineer (Construction)
FORMAT-II
Client’s Multiple Job Engineers Enter Punch points
Accept / Reject by Client Group head
Client’s Acceptance
Client’s Punch point Copied by SCT
Client’s Group head’s Rejection
FORMAT-II viewed by OWNER
Issued by SCT and Format-II passed on to Construction
SCT Multiple Job Engineers Enter Punch points
Consolidated Punch Points of Client and SCT
FORMAT-III
Enter Completion Date
Issue FORMAT-III by Construction AND passed on POSD & CLIENT
Instrumentation
Assign Responsibilities by Construction Group Head to Job Engineers
Enter Remarks / Exception with Category
Mechanical
POSD’s comments
Client’s Comments
Civil
Upload Project related Files
Electrical
View Attached PID, System Dossier and Flushing PID
Accept/ Reject FORMAT-III by POSD
FORMAT-III viewed by OWNER
Accepted by POSD
Rejected by POSD
Client’s Rejection
Attach / Upload Documents
Client’s Acceptance
FORMAT-IV
Proceed to FORMAT-V
Accept / Reject FORMAT-IV by Client
Enter Comments by SCT
Issue Format-IV by SCT
View Sys PID, Flushing PID & System Dossier
FORMAT-IV viewed by Const.
FORMAT-V viewed by EIL
FORMAT-V
POSD’s comments
Acceptance FORMAT-V by Client and SCT
Handed over to Client’s operational deptt.
Client’s comments
Issue FORMAT-V

16. Reports 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.

17. Administrative Activities
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

18. POSD Activities
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

19. POSD Activities
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

20. POSD Activities Format-I Format-II Format-III Format-IV
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
Format-IV
View Client’s comments
Enter SCT comments
Issue (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 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
View Project Status & Reports.

22. Client Activities 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