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

1. PCAMS Pre-Commissioning & Commissioning Activities Management System (Ver3.0) http://pcams.eil.co.in

2. 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

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. 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

5. Work Flow Generates Reports Administrator Module • 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 Liquidation of Checklist • 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 • SCT / Construction site / Client / PMC Commentson 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. 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 List of Projects Executed through PCAMS

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

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

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

10. 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

12. Pre Commissioning Management system Admin Module ADMINISTRATOR CREATE PROJECT/UNIT New Project / Unit Creation Define CCC (project specific) Commissioning Team ACCESS Access Right based on User Type Create Non EIL User (Client/PMC)Define User TypeRole AssignmentCommissioning Team’s Department HOD/System Administrator Level 6Chief Commissioning coordinator Level 5Project Manager Level 4Constructor Coordinator Level 3Lead Engineer Level 2Job 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 Instrument Index Line Schedule PID Index Equipment List 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 Define List of Sub System FORMAT-I SCT’s Acceptance Attach / Upload Documents 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 Acceptance Client’s Multiple Job Engineers Enter Punch points Client’s Punch point Copied by SCT Accept / Reject by Client Group head 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 Issue FORMAT-III by Construction AND passed on POSD & CLIENT Enter Completion Date Instrumentation Enter Remarks / Exception with Category Assign Responsibilities by Construction Group Head to Job Engineers Mechanical POSD’s comments Client’s Comments Upload Project related Files Civil Electrical View Attached PID, System Dossier and Flushing PID FORMAT-III viewed by OWNER Accept/ Reject FORMAT-III by POSD Accepted by POSD Rejected by POSD Client’s Rejection Attach / Upload Documents FORMAT-IV Client’s Acceptance 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 FORMAT-V viewed by EIL POSD’s comments Handed over to Client’s operational deptt. Acceptance FORMAT-V by Client and SCT Client’s comments Issue FORMAT-V

16. 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. Reports

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. 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 Activities

19. 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 Activities

20. 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 Activities

21. 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 Activities

22. 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 Activities