Software Package Name -...

1 30-JUN-2010 ISSUED FOR IMPLEMENTATION DB AA SRP

0 30-MAR-2009 ISSUED FOR IMPLEMENTATION DB AA SRP

Rev. No Date Purpose Prepared by Reviewed by

Approved by

Format No. 5-2000-0600-F8 Rev. 1 Copyrights EIL – All rights reserved

Document No. 7221-0441-UM-2402

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User Manual

PCAMS

(Pre Commissioning and Commissioning Activities

Management System) Ver 2.0



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Contents

INTRODUCTION .......................................................................................................................... 3

FEATURES ................................................................................................................................... 4

BRIEF SYSTEM DETAILS ......................................................................................................... 5

OPERATING DETAILS ............................................................................................................... 6

LOGIN SCREEN .......................................................................................................................... 7

DESIGN SYSTEM DOSSIER >>PREPARE SYSTEM DOSSIER ..................................... 10

DESIGN SYSTEM DOSSIER >>PREPARE SYSTEM DOSSIER >>VIEW SYSTEM TAG NO ................ 10 DESIGN SYSTEM DOSSIER >>PREPARE SYSTEM DOSSIER>> ATTACH / DETACH PFD NO’S ...... 10 DESIGN SYSTEM DOSSIER >>PREPARE SYSTEM DOSSIER>>ATTACH / DETACH P&ID NO’S ..... 11 DESIGN SYSTEM DOSSIER >>PREPARE SYSTEM DOSSIER>>ATTACH / DETACH EQUIPMENT NO’S ................................................................................................................................................... 12 DESIGN SYSTEM DOSSIER >>PREPARE SYSTEM DOSSIER>>ATTACH / DETACH INSTRUMENTS/TAG NO’S ........................................................................................................... 14 DESIGN SYSTEM DOSSIER >>PREPARE SYSTEM DOSSIER>>ATTACH / DETACH LINE NO. ......... 15

DESIGN SYSTEM DOSSIER >>MANUAL UPDATION ...................................................... 16

DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>EQUIPMENT LIST ..................................... 16 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >> INSTRUMENT INDEX ............................... 18 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>LINE LIST ................................................ 19 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>PFD LIST ................................................ 19 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>PID LIST ................................................. 20 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>FLUSHING LOOPS .................................... 20 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>PRESSURE TEST LOOPS ........................... 21 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>EQUIPMENT TRIAL RUN TEST (AT NO LOAD) ......................................................................................................................................... 21 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION>>CATALYST ............................................... 21 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>CHEMICALS............................................. 22 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>PRECOMM CHECKLIST STATUS ............... 22 DESIGN SYSTEM DOSSIER >>MANUAL UPDATION >>PRECOMM ACTIVITY STATUS.................. 23

DESIGN SYSTEM DOSSIER>>PREPARE FLUSHING LOOP ......................................... 24

DESIGN SYSTEM DOSSIER >>PREPARE FLUSHING LOOP>>ATTACH/DETACH PID NO’S ........... 24 DESIGN SYSTEM DOSSIER >>PREPARE FLUSHING LOOP>>ATTACH/DETACH SYSTEM TAG NO’S ................................................................................................................................................... 24



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Introduction Based on the requirements defined by POSD (Plant Operation and Safety Department), PCAMS software system has been developed by ITS team to provide the online facilities for doing site co-ordination activities for smooth and safe pre commissioning and commissioning of plants. At present this software is being used by the interdisciplinary team consisting of Construction, Project, PDD, POSD, Client, PMC and other Engineering department for GGSR project (Job no 6922) with the following URL http://pcams.eil.co.in.

Earlier there was manual system to maintain data and the project teams used to enter and store pre-commissioning related data in excel sheets and word documents. There was no centralized system to maintain the consistency of information for activities carried out at HO and site office.

With the usage of PCAMS software, it caters the need of EIL and Client through a systematic array of process / engineering documents uploaded over a web server so that the same can be retrieved by a SCT /Construction /Project and Client team during process plant’s pre commissioning and commissioning activities at site and HO. It will act as an interface between SCT, Construction and Client team members.

Because of Web based environment, it facilitates 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. It acts as an interface between SCT / Construction / Project and Client. All the users have online access to view projects data which is currently available and simultaneously are able to upload files and print reports as required during the process. The Project / Construction / Client and PMC will get the current project status along with all the documents which are relevant to pre-commissioning of plant. The entire project team has the facility to view or generate multiple reports as per project requirement such as

• System dossier details • Mechanical and pre commissioning Checklist, Equipment list (overall or system wise) • Line list (overall or system wise) • Instrument Index (overall or P&ID wise or system wise) • P&ID index • Equipment / Instruments Datasheet • Characteristics / Heat curve • System mark-up P&ID • Current Format Status • Current Project Status • Equipment summary • Flushing schemes • Issued Format (I-V) reports

It also provides the Overall track record of progress of pre-commissioning and commissioning activities in the form of FORMAT-I, FORMAT-II, FORMAT-III, FORMAT-IV AND FORMAT-IV reports. During the pre-commissioning of systems at site, Client gets the auto e-mail from construction and POSD regarding the liquidation of checklist with current status.

http://pcams.eil.co.in/



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Features The main features available to user in PCAMS are:

• Admin Module

o Creation / Updation of Project no, Unit no, Area no, Site Commissioning team

o Creation of Project Team (Job wise)

o Creation of User list (Non EIL members like Client / Licensor / PMC user id)

o Role assignment as per job wise (Job Engineer, Lead Engineer , Project coordinator, Construction coordinator)

o Creation / updation of Client list / PMC list and Licensor list

o EIL employee user id and Password in Login module is linked up to time sheet software.

o Creation of Department list (Job wise)

• Create / Update System dossier (input) Library

o System Definition

o Sub System Definition (Job wise / Unit wise / Area wise)

o Mechanical checklist (Job wise)

o Checklist responsibility to different users belong to different department (Job wise and Unit wise or area wise)

o Pre commissioning Checklist (Job wise)

o Pre commissioning Activity (Job wise)

o Job Quality Plan (List of Performer / Approver ) job wise

o Commissioning group Code System Tag number (unit / area wise)

• Import Engineering data in Excel format:

o Equipment Details - from RED & SED

o Line List ,PID list & PFD list - from Process / POSD / ENV

o Instrument Index - from Instrumentation

o Vendor data - from OEM

(System allows re-importing the data anytime, if needed. In case any updation are required, can be done within the system through re-import facility.)

• Manual data entry (Insertion / deletion / updation of engineering data) related to pre commissioning activities and all the data will be Job wise / unit wise or area wise.

o Equipment List

o Instrument Index

o PFD list

o PID list

o Line Schedule

(Once the above data / component is attached or linked with system tag no., then the same cannot be deleted from the database. For deleting the record which is



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attached with the system, first user shall go to the system dossier module and select the system tag no. then detach the wanted component from the selected system tag no.)

o System Index

o Flushing / Blowing / chemical cleaning

o Pressure Test Loops

o Equipment Trial

o Catalyst

o Chemical

o Format status (System wise)

• Creation / Updation of System Index with PID color. (System Tag no area wise)

• Linkage (attachment or detachment) of Line list, Equipment list and Instrument list, PID list, PDF list with identified System.

• Uploading and Viewing functionality of engineering documents / files attached with the identified system like process data sheet (for Equipment), Instrument data sheet (for instruments) , Instrument index, line schedule with line notes, PID index, PFD index.

• Manual data entry or Editing facility of Design conditions for different type of equipments as defined in the process / vendor / HMTD / Rotating and static equipment department. (system tag no. wise) (Total seven types of equipment,)

Brief System Details The aim of developing the software is to channelize the link and data flow during pre-commissioning and commissioning in a more structured way. The software will be nested on a web browser allowing the access for any location with an internet/lease line facility. The various processes and inter-process data flow in this system has been indicated in the figure below:



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Operating Details The software can be used by accessing the server by giving the URL : http://pcams.eil.co.in. in the internet explorer. The first screen displayed is the Login Screen. The pages ahead explain the basic usage of this software.

http://pcams.eil.co.in/



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Login Screen As shown in figure below, the user can start using the software by giving his username and password in the login screen and clicking on the “Login” pushbutton. The login passwords and access to various subsequent modules are available based on the role levels that are being explained below.

The System can be accessed by only those users, who are the authorized commissioning team members of the existing jobs in the system. Once the user has logged in, it will check, whether he/she is EIL employee or NON EIL employee. If he is EIL employee then it checks among the authorized commissioning team members defined in the existing jobs. If found then it checks for the password as defined in the timesheet software. If the password matches then the system allows the user to proceed further otherwise it prompts as the unauthorized user and is disallowed to proceed further. If he/she is NON-EIL members (PMC / CLIENT / LICENSOR’S USER) but the authorized commissioning team member of the project, then he checks the user id and password as defined by the project co-coordinator. During login, all the users are assigned levels. According to this level, the rights are given to user, according to which menu items are enabled & disabled. At present five roles has been defined in the PCAMS software as defined below 1. Super user : System Coordinators (includes ITS Coordinator and POSD Coordinator

Irrespective of project) (One employee from the POSD department and one employee from the ITS Department)



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Full access has been provided in the admin module for all the projects and units and have rights to do the following activities

• Create Project / create Unit / create areas • Copy Project / Unit specific default data (library) from one unit to another unit

from the selected project. • Create / Update Clients / Licensor / PMS’s user ID. • Create / Update Commissioning Team • Create / Update Job Quality Plan (can change the performer and approver

level) • Create new commissioning code (department /division wise)

2. Project coordinator: (only one team member from project department )

Having partial access in the admin module for the selected unit and project and can do the following activities.

• Create / Update Commissioning Team (for the selected unit only) • Create / Update Job Quality Plan (can change the performer and approver

level)

3. Construction / Area coordinator: (EIL Construction Commissioning In-charge)

(Only one employee from the EIL construction site and do not have any access in the admin module)

4. Lead engineer :

(Multiple lead engineer are allowed and do not have any access in the admin module) 5. Job engineer :

(Multiple job engineer are allowed and do not have any access in the admin module)

(Separate facility has been provided to the Client is for updating their email ID and password as per their requirement.)



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Design System Dossier >>Prepare System Dossier Once all data has been imported, individual items like equipments, instruments, PIDs, PFDs, line schedule need to be attached to system tag numbers. The functionality of attaching or detaching each components like (Equipments, Instruments, PID, PFD, Line no) is explained below. Design System Dossier >>Prepare System Dossier >>View System Tag No

By clicking on “View System Tag No” in submenu “Prepare system Dossier”, user can have access to System tag number details. User can generate the report, by clicking on “Print” button at the bottom.

Design System Dossier >>Prepare System Dossier>> Attach / Detach PFD No’s

This module performs various functions, namely:

1. Display the complete PFD index (Excel file ) received from the Process department (left side grid )

2. Provide facility to attach ./ detach specific PFD details to particular system tag no 3. Facilitates to Uploads individual PFD related files on server 4. Facilitates to Views individual PFD-related files from server

The user chooses a system at the topmost combobox. Then the checkboxes in front of PFDs to be attached are checked and the “>>” pushbutton is clicked. The attached PIDs are shown at the right side of the screen whereas the complete PFD list is visible at the left. The files related to each attached PFD can be uploaded and viewed by clicking on the appropriate link at the left



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as shown below. On clicking “upload” the upload panel appears as shown in the figure above. Uploaded files can be viewed by clicking on “View” on the right panel.

Design System Dossier >>Prepare System Dossier>>Attach / Detach P&ID No’s


1. Display the complete PID index (Excel file ) received from the Process department (left side grid)

2. Provide facility to attach / detach specific PID details to particular system tag no 3. Facilitates to Uploads individual PID related files on server 4. Facilitates to Views individual PID-related files from server

The user chooses a system tag no. at the topmost combo box. Then the checkboxes in front of PIDs to be attached are checked and the “>>” pushbutton is clicked. The attached PIDs are shown at the right side of the screen whereas the complete PID list is visible at the left. The files related to each attached PID can be uploaded and viewed by clicking on the appropriate link at the right as shown below. If user wants to unload the file, attached to a PID, then the user should click on “UNLOAD” link at the rightmost column of the grid.

On clicking “upload” the upload panel appears as shown in the figure below. Uploaded files can be viewed by clicking on “View” on the right panel.



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Design System Dossier >>Prepare System Dossier>>Attach / Detach Equipment No’s


(1.) Display the complete Equipment list (Excel file) received from the Process department. (left side grid)

(2.) Facilitates to attach / detach equipment details to particular System tag no (3.) Facilitates to Uploads individual equipment-related files (like datasheets) in appropriate

directories in server (4.) Facilitates to Views individual equipment-related files (5.) Facilitates to Delete individual datasheets (6.) Facilitates to enter input design parameters for selected type of equipment. Design

parameters contains mixed data receiving from Process, Engineering (Rotating engineering, static engineering) ,HMTD and vendor .

(7.) Provide facility to Views design parameters of individual equipments (8.) Provide facility to Inputs Equipment Trial data for individual equipments

To associate equipment details to particular system tag no, the user has to first select the system tag no. The grid shows the complete details of all the equipment. Of the data from the grid which has to be associated with particular system tag no., the corresponding check box has to be checked. When user clicks “>>” button the complete data is transferred from excel table to corresponding dsn table along with the system tag no. Once the equipment has been associated with one System Tag no then it cannot be associated with other system. The equipment which are already attached with some System tag nos., have their checkboxes disabled and they cannot be associated with other system tag no. Once the data has been associated with particular system, the user can upload particular datasheet; view existing datasheet associated with the system tag no. and enter design parameters manually, if required.



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In the DSN Grid as shown above, the “Upload File”, “View File” links provide for uploading and viewing individual equipment-related files (in any format) in appropriate directories to / from server. The files would be named automatically with the datasheet number of the equipment so that the filename will always be unique. . The “Filename” column in this grid shows appropriate filename. The “Delete D/S” link deletes particular datasheets. The “Input Design Parameters” link in the same grid leads to appropriate panels or forms to provide for data input of design parameters of individual equipments. The “View Design Parameters” link is for viewing the already input design parameters. The “Trial” link opens the panel for input of Trial data for individual equipments. The user chooses a system at the topmost combo box. Then the checkboxes in front of equipments to be attached are checked and the “>>” pushbutton is clicked. The attached equipments are shown at the right side of the screen whereas the complete equipment list is visible at the left.

The file related to attach equipment can be uploaded and viewed by clicking on the appropriate link at the left as shown below. On clicking “upload” the upload panel appears as shown in the figure above. Also design parameters for each can be input by clicking on the “Design” link and inputting and saving appropriate data in the “design” panel which appears at the bottom of the screen as shown in the figure below-



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Design System Dossier >>Prepare System Dossier>>Attach / Detach Instruments/Tag No’s


(1.) Display the complete Instrument Index (Excel file ) received from the Instrumentation department (left side grid)

(2.) Provide facility to attach / detach specific instrument (loop number wise) details to particular system tag no

(3.) Facilitates to Uploads individual instrument-related files (like datasheets) on server (4.) Facilitates to Views individual instrument-related files from server

This forms allows to associate excel instrument details to particular system tag no. The user has to first select system tag no. After selecting system tag no., the user has to select PID Number, then after selecting PID Number, a list box of loop numbers appears. User can select single as well as multiple values from the loop number’s list box. On selecting loop numbers, user has to click on “Display Tag List” button, after which the grid shows instrument index details for the selected loop numbers, of particular PID Number. The user has to select the particular instrument tag no by selecting the checkbox. After that, user shall clicks “>>” button, then the excel data is transferred to right side grid. When user selects a checkbox, then all the checkboxes having the same loop number will be checked automatically. Once an instrument tag no. has been associated with particular system tag no, same instrument tag no cannot be associated with another system tag. In case, if the loop number for a particular PID Number is not available then grid appears, after selecting PID Number. The attached instruments are shown at the right side of the screen whereas the complete instruments list is visible at the left. The files (PID etc) related to each attached instrument can



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be uploaded and viewed by clicking on the appropriate link at the rightmost columns as shown below. On clicking “upload” the upload panel appears as shown in the figure above. Also design parameters for each can be input by clicking on the “Design” link and inputting and submitting appropriate data in the “Design” panel which appears at the bottom of the screen as shown in the figure below.

Design System Dossier >>Prepare System Dossier>>Attach / Detach Line No.


1. Display the complete LINE SCHEDULE (Excel file) received from the Process department (left side grid)

2. Provide facility to attach / detach specific line no details to particular system tag no (right side grid)

3. Facilitates to Uploads line notes file on server 4. Facilitates to Views line notes file from server ( which is attached with specific line

schedule) The user chooses a system at the topmost combobox. And if PID Numbers are attached with that system, then user can select it from the combobox. Then the checkboxes in front of Lines to be attached are checked and the “>>” pushbutton is clicked. The attached lines appear at the bottom in this module due to the vastness of Lines data. Also a panel at the top allows the user to upload and view Line notes word document. On clicking “upload” the upload panel appears as shown in the figure above. Uploaded files can be viewed by clicking on “View” on the right panel.



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Design System Dossier >>Manual Updation

This is the second sub menu item of the Design System Dossier menu item and meant to input data manually after the relevant files have been imported once by the user. The submenu items for Equipments, Instruments, PID, PFD, Lines function in a similar fashion.

Design System Dossier >>Manual Updation >>Equipment List

As shown in the figure below, all the equipments data that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add New Record” pushbutton at the bottom. User can also generate the report, by clicking on the “PRINT” button.



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Design System Dossier >>Manual Updation >> Instrument Index

As shown in the figure below, all the instruments data that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add New Record” pushbutton at the bottom.

User can also generate the report, by clicking on the “PRINT” button. A panel appears to slect a PID Number for printing, as shown in the figure below.



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Design System Dossier >>Manual Updation >>Line List

As shown in the figure below, all the lines data that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add New Record” pushbutton at the bottom. Reports can also be generated by clicking on the “PRINT” button.

Design System Dossier >>Manual Updation >>PFD List

As shown in the figure below, all the PFD data that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add New Record” pushbutton at the bottom.



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Design System Dossier >>Manual Updation >>PID List

As shown in the figure below, all the PID data that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add New Record” pushbutton at the bottom. Reports can also be generated by clicking on “PRINT” button.

Design System Dossier >>Manual Updation >>Flushing Loops

As shown in the figure below, all the Flushing Loops data, that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add New Record” pushbutton at the bottom. Reports can also be generated by clicking on “PRINT” button.



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Design System Dossier >>Manual Updation >>Pressure Test Loops

As shown in the figure below, all the data for Pressure Test Loops that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add Record” pushbutton at the bottom.

Design System Dossier >>Manual Updation >>Equipment Trial Run Test (At no load)

As shown in the figure below, all the Equipment trial run test data is shown on the grid. Data can be edited by clicking on the ‘edit’ link, at the left most column of the grid. Reports can also be generated by clicking on “PRINT” button.

Design System Dossier >>Manual Updation>>Catalyst

As shown in the figure below, all the data for Catalyst that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add New Record” pushbutton at the bottom. On clicking the ‘Upload’ link, a new panel appears at the bottom, wherein user can browse for a file



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and then by clicking on “UPLOAD” button, the file will be uploaded. Reports can also be generated by clicking on “PRINT” button.

Design System Dossier >>Manual Updation >>Chemicals

As shown in the figure below, all the data for Chemicals that has been imported once is shown on the screen. The data which has already been attached to a particular system tag no cannot be edited or deleted. All other data can be edited / deleted by clicking on appropriate links. New records can also be added by clicking on the “Add New Record” pushbutton at the bottom. On clicking the ‘Upload’ link, a new panel appears at the bottom, wherein user can browse for a file and then by clicking on “UPLOAD” button, the file will be uploaded. Reports can also be generated by clicking on “PRINT” button.

Design System Dossier >>Manual Updation >>Precomm Checklist Status

On click of this link, the user can select an equipment type from the dropdown list as shown in the figure below. On selecting a system tag number, user can select the related equipment tagno, related pressure test loop and related flushing loop. The grid contains the checkpoints for that equipment User can also update the status and remarks of a checklist point, by clicking on the edit link at the right most column of the grid.



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User can also generate reports by clicking on the ‘PRINT’ button below.

Design System Dossier >>Manual Updation >>Precomm Activity Status

On click of this link, the user can select a system tag number from the dropdown list as shown in the figure below. On selecting a system tag number, user can get the activity status, as displayed in a grid. User can also update the status and remarks of that system tag number, by clicking on the edit link at the right most column of the grid. User can also generate reports by clicking on the ‘PRINT’ button below.



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Design System Dossier>>Prepare Flushing Loop With Prepare Flushing Loop, user has two options available, first is ‘Attach/Detach PID No’s’ and second is ‘Attach/Detach System Tag No’s’.

Design System Dossier >>Prepare Flushing Loop>>Attach/Detach PID No’s

To attach PIDs with system tag no’s, first of all, the user will have to select a flushing loop and associated subloop from the dropdown lists Then a grid of complete list of PIDs will appear on screen, from where user can select the required PIDs, by clicking on the checkboxes at the leftmost column of the grid. After selecting the PIDs, user will have to click on ‘>>’ button, (after the first grid), the selected PIDs will be attached with that loop/subloop and can be seen in the second grid.

Design System Dossier >>Prepare Flushing Loop>>Attach/Detach System Tag No’s

To attach flushing loops with system tag no’s, first of all, the user will have to select a system tag number from the dropdown list. Then a grid of complete list of loops will appear on screen, from where user can select the required loops, by clicking on the checkboxes at the leftmost column of the grid. After selecting the loops, user will have to click on ‘>>’ button, (after the first grid), the selected loops will be attached with that system tag no and can be seen in the second grid.



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