Plant Condition Management Software (PCMS®)

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Industry-leading asset integrity management software

MISTRAS Group’s Plant Condition Management Software, PCMS, is the industry’s most experienced asset integrity management services (AIMS) software, specializing in asset integrity, corrosion, and inspection data management.

Process-industry regulations require facilities to maintain huge amounts of mechanical integrity (MI) data. With thousands of individual components – each with their own individual inspection, damage, and repair histories – facility operators require an asset integrity management (AIMS) software that doesn’t just store this data, but turns it into actionable information that they can use to maximize safety, enhance productivity, and optimize budgets.

MISTRAS’ industry-leading Plant Condition Management Software (PCMS) database is a comprehensive mechanical integrity data management software that was developed specifically for process industries and equipment.

PCMS stores, organizes, and analyzes inspection and mechanical integrity data from all of an organization’s facilities and equipment, and it links that information across your technology platforms. From phone to tablet to computer, from plant to headquarters, PCMS acts as both the highway and the warehouse for MI data management and analysis. You’ll have access to company-wide inspection data, anytime, anywhere.

PCMS helps operators comply with a variety of regulations, including:

  • Industry Regulatory Compliance (API, OSHA, ABSA, ASME, EN, EEUMA, GOST)
  • Process Safety Management Compliance (PSM)
  • Insurance Compliance
  • Environmental Compliance

Decades of experience in mechanical integrity data management

PCMS has decades of experience in asset, corrosion, and inspection data management. Its integrated modules eliminate the need to manage multiple applications to perform total asset integrity analysis.

PCMS is truly a 'single-source' inspection management solution that provides an array of solutions to execute industrial facilities' mechanical integrity initiatives, including:

  • Comprehensive inspection tracking & analysis
  • Integrated Risk-Based Inspection (RBI) calculators
  • Inspection & turnaround planning
  • Corrosion analysis & trending
  • Safety relief valve management

PCMS capabilities

PCMS tracks historical integrity data, generates inspection schedules, and performs advanced engineering calculations, simplifying asset integrity and corrosion management for industrial operators.

Asset Management

Optimize asset lifecycles & performance

PCMS Asset Management provides a centralized platform to track, analyze, and optimize asset performance throughout their lifecycle. It helps ensure regulatory compliance, improves efficiency, and minimizes downtime by integrating inspection, maintenance, and reliability data. This module helps organizations make informed decisions to enhance asset integrity and operational effectiveness.

Activity Tracking

Streamline Inspection & Maintenance Activities

The Activity Tracking module in PCMS allows users to efficiently plan, schedule, and document inspections, repairs, and maintenance activities. With automated workflows and real-time updates, it enhances collaboration, reduces missed tasks, and ensures compliance with industry standards, helping organizations maintain asset integrity and operational continuity.

Corrosion Management

Monitor & Mitigate Corrosion Risks

The Corrosion Management module has been the foundation of PCMS for decades. The module allows plant personnel to track wall thickness, corrosion rates, next inspection dates, and retirement dates on any type of asset. PCMS offers a variety of methods capture corrosion data, including the establishment of CML areas (Corrosion Monitoring Locations), TML points (Thickness Monitoring Locations), Corrosion Probe Readings, and Corrosion Coupons.

Risk-Based Inspection (RBI)

Prioritize Inspections Based on Risk

The Risk-Based Inspection (RBI) module helps prioritize inspections based on asset risk, optimizing maintenance strategies while reducing unnecessary inspections. It incorporates industry methodologies to assess probability and consequence of failure, ensuring resources focus on high-risk areas, improving safety, compliance, and cost-efficiency.

Maintenance Management Link

Seamless Integration with CMMS Systems

The Maintenance Management Link module connects PCMS with Computerized Maintenance Management Systems (CMMS), enabling seamless data exchange for work orders, inspections, and asset history. This integration ensures accurate record-keeping, enhances maintenance planning, and reduces redundant data entry, improving efficiency and decision-making.

Software Interfaces

Flexible Integration with Third-Party Systems

PCMS Software Interfaces provide integration with various third-party applications, including enterprise asset management (EAM), ERP, and data acquisition systems. This ensures seamless data flow between platforms, enhancing analytics, automation, and operational efficiency while maintaining data consistency across multiple systems.

Reporting

Advanced Data Analytics & Visualization

The Reporting module in PCMS offers comprehensive reporting and visualization tools for asset integrity and inspection data. Users can generate customizable reports, dashboards, and trend analyses to support data-driven decision-making. This module enhances regulatory compliance, performance monitoring, and strategic planning through detailed insights and real-time analytics.

PCMS® software versions & licensing options

PCMS offers flexible software versions and multiple licensing options to support asset integrity management at facilities of all sizes. Compare PCMS versions and explore licensing choices to match your operational needs.

PCMS Express

Ideal for small to medium sized process facilities with a small centralized onsite inspection department

License types supported:

  • Single-site

Typical industries served:

  • Small downstream refining
  • Chemical
  • Manufacturing
  • Clean energy

PCMS Standard

Ideal for large sized facilities that require access to PCMS from multiple personnel & departments

License types supported:

  • Single-site
  • Enterprise

Typical industries served:

  • Large downstream refining
  • Large chemical
  • Power

PCMS Multi-facility

Ideal for companies that require a method to centrally manage remote assets in a wide geographic area

License types supported:

  • Enterprise

Typical industries served:

  • Exploration & production
  • Midstream
  • Terminals
  • Pipelines
Product typeExpressStandardMulti-facility
Customizable module list✓✓✓
Global database & administrative settings✓✓✓
Global user-defined pick list valves✓✓✓
Multi-Language Capable✓✓✓
Customizable Security & User Profile DefinitionsLtd.✓✓
Unlimited User Access3✓✓
Interface to Maintenance Management Systems✓✓
Custom Regional and Facility Search & Filtering✓
Flexible Data Hierarchy (Up to 5 Levels)✓
Custom Regional and Facility Reporting Segregation✓

PCMS offers two kinds of licensing options: On-Premise or Software-as-a-Service (SaaS). Whether you need licensing for a single site, an enterprise option or prefer to utilize PCMS’ cloud-based options, we offer the tools to fit your specific needs.

On-Premise Licensing

Companies have a pair of on-premise licensing tools they can access to fit their individual needs and cover options for both single-site and enterprise programs. Key on-premise licensing benefits include:

  • Software licensed per database or corporation
  • Databases that can be added to an existing license
  • Reduced maintenance and support fee structure
  • Volume discount; future license options for usual rates
  • License transferability

Software as a Service (SaaS)

PCMS also offers a commercial hosting solution of the PCMS suite through an online cloud environment, or Software as a Service (SaaS).

For clients with limited on-site IT infrastructure or personnel, a simple software subscription offers the full benefits of PCMS, with no need to purchase hardware or software, or dedicate resources for the ongoing management of the PCMS application.

For progressively larger facilities, a PCMS SaaS model can support various areas of an MI program, including general inspection management, Risk-Based Inspection (RBI), and Key Performance Indicator (KPI) development through the PCMS Business Intelligence (BI) platform.

The platform is scalable to fit a growing operation’s needs. MISTRAS personnel implement and manage the platform, providing technical support and keeping systems up-to-date with new PCMS suite updates.

The cloud environment also offers access to file sharing, real-time collaboration, and a convenient central home page where all applications are located. The platform is compatible with any mobile device, as well, allowing operators to manage their facilities no matter where they are.

PCMS implementation services

MISTRAS Group’s PCMS Implementation Services provide expert support for deploying and optimizing the PCMS platform, ensuring seamless integration with plant operations.

PCMS offers onsite training classes that include both program instruction as well as consultative implementation strategy development & execution sessions. Members of the PCMS training team possess numerous years of experience in mechanical integrity software applications as well as in-depth industry knowledge. Our training programs are tailored to the specific site's implementation initiatives. We will share implementation tips and strategies that have been applied within the 150+ PCMS worldwide client sites. Classes are typically 4 days in length, but can be customized to meet the individual facility's needs. Onsite training classes meet the requirements of PCMS procedure 75-PCP-001.

Training topics include:

Implementation consultation

  • Data hierarchy set up and best practices
  • Systemization/circuitization
  • PCMS best practices implementation recommendations

Program Instruction

  • Basic program navigation
  • Data entry techniques (mass data manipulation/UT Dataloggers/import/export)
  • Defining PCMS fields and practical application
  • Recording inspections
  • Planning inspections

Data Analysis

  • Identifying failures before they occur
  • Addressing data anomalies
  • Reviewing PCMS statistical outputs

Reporting

  • Review of Key Performance Indicator (KPI) reports
  • Creating custom reports for both public and private use
  • Customizing dashboards
  • Developing Web Reports

Administrative Training

  • Global system settings and recommended practice
  • Linking PCMS to the CMMS system and other plant systems
  • Security administration

Risk Based Inspection (usually a workshop class format)

  • Integrating the inspection and RBI process
  • Data systemization and circuitization
  • RBI Damage Mechanism screening and analysis
  • Applying 'What-if' scenarios
  • RBI Customization- a 'How to'

MISTRAS is the only company in the marketplace that can offer certified Level I, Level II, and PCMS Project Management personnel. All Implementation levels are required to meet the requirements within PCMS Procedure 75-PCP-001. PCMS Implementers are given formal classroom instruction and must pass both a practical and written examination as well as satisfy the work and training hour requirements within the procedure.

Each certification level will have the ability to perform various tasks to support the implementation. An onsite implementer will ensure that the user is getting the most of the PCMS program and adhering to PCMS Best Practices. Others tasks may include:

  • Streamlining and improving the site's PCMS implementation practices
  • Providing efficient and accurate data entry
  • Creating, deploying, and managing all reporting functions
  • Data mining and reviewing of analytical outputs
  • Developing and delivering customized training sessions to onsite personnel

MISTRAS Implementers are also afforded direct channels of communication with both a network of worldwide onsite PCMS implementers as well as MISTRAS PCMS Development teams.

MISTRAS offers a wide variety of data services. Our expertise in the PCMS product makes us the number one service provider in this arena. Whether you are a site that needs support collapsing multiple data sources into one single data source or you have been running PCMS for a number of years and need a database 'tune-up', we cover all aspects to help guide you to a leading edge implementation.

Data Conversions

Our Data Conversion Team is led by industry experienced professionals that have comprehensive technical and working knowledge of other IDMS systems including UltraPIPE, Metgrity, MaxiTrak, Credo, Meridium, and Capstone to name a few. The conversion team will diligently work with your onsite personnel to deliver you a timely and successful data conversion.

  • MISTRAS owns and operates a proprietary conversion program that links any data source type to PCMS, allowing you to collapse multiple data sources into one database.
  • We provide a systematic procedural approach in the data conversion process. Our team will analyze data conditions, cleanse legacy data, electronically script specific rules, and safely transfer all legacy data to PCMS.
  • Our team can electronically convert and link existing CML (Corrosion Monitoring Location) bubbles on existing inspection sketches to PCMS data

Database Optimizations

The Database Optimization Service provides a full diagnostic of the site's PCMS database. We analyze data conditions, configurations, implementation parameters, system settings, and overall data structure. A full report is provided with a priority of conditions discovered as well as an overall rating benchmarked against similar sites and detailing the necessary steps to improve the implementation.

Report Writing

The Data Service Team is comprised of individuals who have years of experience developing custom reports for a multitude of clients. We are experienced in all types of report writing tools and delivery applications such as Crystal, Crystal Server, Xcelsius, Business Objects applications, and PCMS report writers.

Data Entry

Any type of hard copy data can be sent to the PCMS data center for manual input. We will replicate your PCMS database at the PCMS Data Center, allowing you to continue to work within your production environment and avoiding any downtime. Upon completion, we electronically merge the data back into the production database.

Industries that implement PCMS

PCMS is utilized by a variety of different customers and facilities to manage and analyze integrity data on piping, pressure vessels, safety relief devices, valves, tanks, and other process equipment. PCMS offers tremendous benefits to any facility to budget and plan long-term maintenance strategies, by enabling operators to identify problems before critical failures occur, limiting repair costs, and reducing unplanned shutdowns.

Approximately 50% of U.S. refineries, as well as several leading midstream operators, utilize PCMS' advanced capabilities.

Industries that utilize PCMS include:

Oil & Gas
Chemical / Manufacturing
Downstream / Petrochemical
Midstream
Upstream
Power

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