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DESCON ENGINEERING LIMITED (LMW)

Internship Report
(3rd August to 28th August, 2015)

Submitted By: Umair Tahir


Student of Metallurgy and Material
Engineering
University of Punjab, Lahore

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.

2. Introduction to the Company


Descon Engineering Limited is an integrated engineering services and
manufacturing company operating in Pakistan and the Middle East. They are in the
business of delivering client-specific solutions for projects related to Energy,
Infrastructure
and
Process
industry. The
integrated
package
of
services encompasses engineering, procurement, manufacturing, construction,
commissioning and maintenance.
They are a multinational company renowned in the region for its quality, safety and
on-time delivery of projects and products. All the faculties required to deliver
turnkey projects, reside within the company. This unique strength enables us to
provide solutions as EPCC (Engineering, Procurement, Construction and
Commissioning) services provider to a host of international clients. Descon doesn't
Compromises on Quality.

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:

Witnessed different ASME codes used in company


1. ASME section 8 div 1
2. ASME section 9
3. ASME B 31.3
4. ASME B 31.3
5. ASME B 16.5
6. ASME section 5
7. ASME section 2
Witnessed hydro test and learn important parameter of hydrotesting
Have brief explanation of radiography testing ie rt1, rt2, rt3, rt4
Came ware of different parts of Heat exchanger and their manufacturing ie
baffle plates, main shell, channel head.etc

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

Have brief explanation of different welding techniques


1. SMAW
2. GTAW
3. FCAW
4. GMAW
5. SAW
Learn about importance of poles in welding.
Learn importance of Impact test

Fourth week

Learn inspection done for thickness.


Came aware of different types of electrodes use for welding ie ok 7018etc
Learn about PWHT and PRE HEATING of job.
Have knowledge of different material used in manufacturing.
Learn about documents use in store ie IR and WIN.
Learn about different color coding used in store for storage.
Learn importance of hot and cold rolling process.
Witnessing sheet dimensions.
Have knowledge of store inspection.
Learn what electrode coding show.
Have knowledge of holiday detector technique.

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).

Departments under QA/QC:

In descon there are four departments which


come under QA/QC, these are as mentioned below:

Inspectors
Welding department
NDT( Non Destructive Testing )
Material check

3.2 Whats the purpose and job of QA/QC department?

The preparation of the companies QA manual control and supervision of all


amendments and revisions

Control and the distribution of all the companies quality documentation

Monitor all quality related activities on the project

Perform all internal and external audits on behalf of the companys


management

Verify contractor quality requirements are specified to vendors and


contractor documentation submittals.

Attend all pre-bid meetings and coordinate all project requirements with the
project bidders.

Attend client quality management meetings


The preparation and control of project quality system management
documentation prior to project commencement.

Review quality inspection personnel qualifications and training requirements

Monitor the disposition of all issued nonconformance reports.

Monitor the progress and effectiveness of the project quality management


system. Recommend and implement improvements when required.
Coordinate all QA/QC activities with the site QC manager

Coordinate all QA/QC activities with the site QA/QC procurement manager
Coordinate all quality related correspondence with the customers
representatives.

Monitor statistical method reporting.

Action and close all customer complaints

Control all achieves documentation upon the completion of the project.

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

Hydrostatic/Pneumatic test reports and gauges calibration


certificates/procedures
Surface preparation/Painting report
Copy of name plate
Manufacturer data report
NCR(if any)

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.

3.4 Testing methods and the methods of welding


used in Descon:
NDT methods:

Nondestructive testing or Non-destructive testing (NDT) is a wide


group of analysis techniques used in science and industry to evaluate the
properties of a material, component or system without causing damage.
Because NDT does not permanently alter the article being inspected, it is
a highly valuable technique that can save both money and time in product
evaluation, troubleshooting, and research.
Types of NDT methods used in Descon:
Ultrasonic testing
Magnetic-particle Inspection
Radiographic testing
Die penetrating inspection
Ultrasonic Testing (UT)
Ultrasonic Examination uses high-frequency sound waves which are transmitted
into a material to detect discontinuities or locate changes in material
characteristics. Sound is introduced into the object being examined and reflections
from internal imperfections, areas of acoustic impedance, or varying geometrical
surfaces are returned to a receiver.

Magnetic Particle Testing (MT)


Magnetic Particle Examination is accomplished by inducing a magnetic field into a
ferromagnetic material and applying iron particles to the surface of the item being
examined. Surface and near-surface discontinuities affect the flow of the magnetic
field within the part causing the applied particles to gather at locations of flux

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.

Die Penetrant Testing (PT)


Penetrant Examination is performed with a dye solution. Once applied to the
surface, the dye will effectively penetrate any surface-breaking cavity. Excess
solution is removed from the object. A developer is then applied to draw out any
penetrant that remains unseen. With fluorescent dyes, ultraviolet light is used to
make the bleed-out fluoresce brightly, allowing imperfections to be readily seen.
With visible dyes, a color contrast between the penetrant and developer makes the
bleed-out easy to see.

Types of welding used in Descon:

SMAW
GTAW
GMAW
FCAW
SAW

Arc Welding or SMAW


Generally known as stick or arc welding. Arc welding is the most basic of all
welding types, is easy to master in a home welding situation.
Stick welding can be used for manufacturing, construction and repairs, very much
well suited for heavy metal size 4 millimetres upwards. Thinner sheet metals and
alloys are usually more suited to the mig welding types.

GTAW or Tungsten Inert Gas


TIG welding is comparable to oxy acetylene gas welding and needs a lot more
expertise from the operator. Employed for carrying out high-quality work when a
superior standard of finish is needed without making use of excessive clean up by
sanding or grinding.

GMAW or Gas Metal Arc Welding


More commonly called MIG welding this welding type is the most widely used
and perhaps the most easily mastered type of welding for industry and home use.
The GMAW process is suitable for fusing mild steel, stainless-steel as well as
aluminium.

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.

Materials used in Descon:


SA-516 Gr 70
SA-36
SS-304
SS-316
SS-308

Detail of Products Manufactured by Descon:


The major products which descon is manufacturing are as follows:
Heat Exchangers
Pressure vessels
Boilers
Fin Fan Cooler

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.

Fin Fan Cooler:


An air cooled heat exchanger, or ACHE or Fin tubes heat
exchanger, is simply a pressure vessel which cools a circulating fluid within finned
tubes by forcing ambient air over the exterior of the tubes. A common example of
an air cooler is a cars radiator.

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)

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