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Data Management
Plant Condition Management Software (PCMS)

PCMS Mechanical Integrity Inspection Database Management Software (IDMS)

PCMS Equipment Status
PCMS Analysis
PCMS Inspection Report

MISTRAS Group’s Plant Condition Management Software, PCMS, is the industry’s most experienced inspection database management system (IDMS), 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 a data management system 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 any technology platform. From phone to tablet to computer, from plant to headquarters, PCMS acts as both the highway and the warehouse for MI data management. You’ll have access to company-wide inspection data, anytime, anywhere.

Decades of Experience in Mechanical Integrity Data Management

PCMS has decades of experience in asset, corrosion, and inspection data management. The collection of modules embedded in PCMS create a web of interconnected compatibility, eliminating 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 any company's Mechanical Integrity initiatives, including:

Industries That Implement PCMS

Approximately 50% of the U.S. refining capacity, as well as many pipeline operators, utilize PCMS' advanced capabilities.

The software is utilized by a variety of different customers and facilities to manage inspection information 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.

Utilized extensively in the downstream refining sector, PCMS is also an invaluable tool for pipeline operators to develop risk-based integrity management (IM) programs. PCMS can perform complex engineering calculations that assess an asset’s criticality by analyzing the probability and consequence of failure.

PCMS serves customers that operate in the following industries:
  • Downstream Refining
  • Midstream
  • Renewable Fuels
  • Offshore
  • Chemical
  • Exploration and Production
  • Pipeline
  • Power
Industry and Governmental Regulations Served
  • Industry Regulatory Compliance (API, OSHA, ABSA, ASME, EN, EEUMA, GOST)
  • Process Safety Management Compliance (PSM)
  • Insurance Compliance
  • Environmental Compliance

Data Management for Fixed and Rotating Equipment

As PCMS has grown over time, it has extended its reach to more and more applications, assets, and facilities. But the software has built its unmatched industry reputation through proven successes in fixed equipment MI data tracking.

Amongst other assets, PCMS offers data management applications for:

  • Piping
  • Pipelines
  • Vessels
  • Safety Relief Devices
  • Valves
  • Tanks

Among its vast capabilities, the program tracks inspection information, generates schedules for future dates, and integrates with monitoring solutions for real-time trending graphics, simplifying asset integrity and corrosion management and keeping operators informed. 

Our embedded RBI calculators analyze the inherent risk in fixed asset operations in terms of probability of failure and consequence of failure. Having all of this information centralized through a single interface allows operators to more effectively plan maintenance strategies.

In addition to its expansive capabilities for fixed equipment, PCMS is also an ideal tool for a reliability-centered maintenance (RCM) program for rotating equipment.

The key to the system is Failure Modes & Effects Analysis (FMEA), in which all equipment components are measured against similar assets and processes present in PCMS' library of hundreds of equipment types and thousands of failure mechanisms.

The module provides FMEA tables to analyze thousands of potential problems, keeping facility operators informed about when maintenance is necessary, consequences of failure, and recommended actions to mitigate risks.

Corrosion Inspection Data Management

The Corrosion Management module has been the foundation to 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.

The Corrosion Management module also:

  • Calculates average rates of corrosion per circuit as well as adjusts rates per statistical scenarios.
  • Provides statistical adjusted rates based on inspection exposure and reliability of data.
  • Evaluates corrosion circuit data to determine proper circuitization.
  • Analyzes inspection frequencies to determine proper inspection intervals.
  • Calculates an estimated thickness based on any user supplied future date.
  • Takes into account safety factors and adjusts corrosion rates based on location, human hazard, flammability, and data confidence.
  • Flags data anomalies, alerts the user, and bypasses anomalies in corrosion calculations.

PCMS Software as a Service (SaaS)

PCMS 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.

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