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PCAMS Pre-Commissioning & Commissioning Activities Management System

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Presentation on theme: "PCAMS Pre-Commissioning & Commissioning Activities Management System"— Presentation transcript:

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

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