31 may 2014 1 pcams pre-commissioning & commissioning activities management system (ver 3.0)
TRANSCRIPT
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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