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Internship Report
(3rd August to 28th August, 2015)
Preface:
Currently Im a student of Bachelors degree in Metallurgy and Material
Engineering at University of Punjab. Im in my 3rd year and therefore I have to
conduct a 4 month internship.
In this internship report I will describe my experiences during my internship
period. The internship report contains an overview of the internship company and
the activities, tasks and projects that I have worked on during my internship.
Writing this report, I also will describe and reflect my learning objects and
personal goals that I have set during my internship period.
For this opportunity, I thank: Zohaib Nasir , who is the HR executive of Descon
LMW. I want to thank him for giving me the opportunity to follow my internship at
company. He had the kindness to accept me in company
Almas Baig, Hamd Mazhar (QC Engineer), They helped and coached me during
my internship by giving me feedback and tips on how to handle and approach
situations. He had always time to answer all my questions concerning my
internship.They gave me demonstrations on inspection and procedures followed in
inspection.
Mr.Bilal Mehmood (QC Inspector), Mr .Mirza Umair, Mr Rafaqat were
helpful throughout my internship, without whom I wouldnt have been able to
understand the things properly
I appreciated all the interns I worked with and spent good moments with during my
internship. I want to thank Hammad, Waqas, Aamir
Besides my internship, I really enjoyed my stay in Descon LMW. It is a great
experience and I want to thank everybody for it.
Table of Contents
1. Introduction.
2. Introduction to the Company......................
3. What I learned???...............................................................
4. Main Body
3.1 QA/QC
3.2 Purpose of QA/QC department..
3.2 IDM.
3.3 Testing methods and types of welding ..
3.4 Products manufactured by descon..
5. Conclusion.
6. References.
1. Introduction
This report is about my four weeks internship program which describes the things
which I learned in the Quality Control / Quality Assurance department. It has the
basic concepts, on how an inspection is done and of which mechanical products.
This report also tells the documentation of an inspection report, how the
procedures are followed and so on.
What I learned???
First week:
Reading of isometric diagrams.
Got knowledge of different terms use in drawing i.e inlet deflector, ID, EL,
WL, lifting lugs, CS, LS joint, Man way, Materials, Groove sign, fillet sign.
Have introduction of different NDT techniques.
1. Ultrasonic testing
2. Radiography testing
3. Magnetic particle testing
4. Die penetrating testing
Have introduction of Heat exchanger, Boiler.
Have introduction of coolant, vessels.
Have introduction of welding techniques.
Second week:
Came aware of different parts of vessels i.e Skirt, saddle lifting lugs, man
way, demister, internal rugs
Got knowledge of different welding positions i.e 1g, 2g, 3g. etc.
Learn inspection of pressure vessel head.
Learn sheet development measurement for shell of vessel.
Learn inspection of shell tag/fit up.
Type of flanges
Came aware of different types of flanges and their ratings
1. WNRF
2. LWNRF
3. Blind flange
4. Socket flange
5. Threaded flange
6. Slip on flange
Third week:
Learn different welding types and joint types ie but joint, filler, groove.etc
Have brief explanation of NDT techniques ie RT, UT, MPI and DPT.
Learn about tube expansion, cutters use for CS and SS
Witnessed sand blasting technique
Learn about different documents formed in QA/QC dept ie WPS, PQR, QIP,
MTC, NCR, NDE map and IDM
Fourth week
3.Main Body
3.1 Quality:
Quality means to assure that the respective thing is according to the
prescribed standards and codes.
Quality Control:
Quality control (QC) is a procedure or set of procedures intended to ensure
that a manufactured product or performed service adheres to a defined set of
quality criteria or meets the requirements of the client or customer.
Quality Assurance:
Quality Assurance (QA) is defined as a procedure or set of procedures
intended to ensure that a product or service under development (before work is
complete, as opposed to afterwards) meets specified requirements. QA is
sometimes expressed together with QC as a single expression, quality assurance
and control (QA/QC).
Inspectors
Welding department
NDT( Non Destructive Testing )
Material check
Attend all pre-bid meetings and coordinate all project requirements with the
project bidders.
Coordinate all QA/QC activities with the site QA/QC procurement manager
Coordinate all quality related correspondence with the customers
representatives.
Flowchart:
The following Flow chart will tell us how a project is acquired and after passing it
through different phases it is finally dispatched
3.3 IDM:
IDM (Instruction Data Manual) is a comprehensive documentation in the form of a
complete file which is required in quality inspection. It consists of every single
document of the inspection done of different parts of any mechanical design or
structure.
The table of contents of an IDM and their description is as follow:
Table of contents:
As-Built Drawings
Design Calculations
Quality inspection plan
Weld matrix/Weld Map/ WPS/PQR
Welders continuity list
MTR Summary Sheet
Dimensional inspection report
NDE procedures and NDE personnel
NDE reports
Description of IDM:
Brief description is as follow:
As-built drawings are those drawings which are made after the completion
of the project, it incorporates the changes which are done during fabrication
in fabrication drawing.
Quality inspection plan consists of the steps and the procedure of
inspection and every step of inspection is recorded in it.
Weld matrix shows which process of welding is used in which portion of
the project. WPS (welding procedure specification) shows how a particular
welding is done.
leakage, thus producing a visible indication of the irregularity on the surface of the
material.
Radiography (RT)
Radiographic Examination involves using radioactive isotopes (gamma rays) or Xrays in materials to peer qualitatively for indications the same way a doctor looks
for fractures or other conditions within the body. Radiation is directed through a
part and projected onto film or a digital detection device leaving an image which
can be examined by the qualified Radiographer.
SMAW
GTAW
GMAW
FCAW
SAW
FCAW
Flux-cored welding was created and put into use in the early years of the 1950s.
Its purpose was to give another option to the popular use of stick welding. The
Flux-Cored process is mostly used for projects that require fast speed as it is an
automatic form of welding.
SAW
The Submerged Arc Welding process can only be used properly on materials
containing high iron contents, such as stainless steel. The device used in this
process can be automatic or semi-automatic making it a fairly fast welding process.
While it is a fast process, the electrical arc must constantly be covered by flux in
order to protect the metal from the atmosphere during the welding process. This
cover also prevents any welding spatter which makes it safer for welders than some
of the other forms of welding. The process is named after this need to be
submerged in a flux cover.
Heat exchanger:
A heat exchanger is a device that allows heat from a fluid (a liquid or a gas) to
pass to a second fluid (another liquid or gas) without the two fluids having to mix
together or come into direct contact. If that's not completely clear, consider this. In
theory, we could get the heat from the gas jets just by throwing cold water onto
them, but then the flames would go out! The essential principle of a heat exchanger
is that it transfers the heat without transferring the fluid that carries the heat.
Pressure Vessels:
A pressure vessel is a closed container designed to hold
gases or liquids at a pressure substantially different from the ambient pressure.The
pressure differential is dangerous, and fatal accidents have occurred in the history
of pressure vessel development and operation. Consequently, pressure vessel
design, manufacture, and operation are regulated by engineering authorities backed
by legislation.
Boiler:
A boiler is a closed vessel in which water or other fluid is heated. The fluid
does not necessarily boil. (In North America the term "furnace" is normally used if
the purpose is not actually to boil the fluid.) The heated or vaporized fluid exits the
boiler for use in various processes or heating applications, including water
heating, central heating, boiler-based power generation, cooking, and sanitation.
Air cooled heat exchangers are used for two primary reasons:
They increase plant efficiency
They are a green solution as compared to cooling towers and shell and
tube heat exchangers because they do not require an auxiliary water supply
(water lost due to drift and evaporation, plus no water treatment chemicals
are required).
5. References
1. Almas Baig
2. Mr. Sajjid Manzoor ( In-charge QC)
3. Mr.Hamd Mazhar (QC Engineer)
4. Mr.Bilal Mehmood (QC inspector)
5. Mr.Shiraaz (QC inspector)
6. Mr Umair (QC inspector)
7. Mr Rafaqat(QC inspector)