INTERNSHIP REPORT

Prepared By: Muhammad Usman Ali

Supervised By: Engr. Saif Shahzad

Department: Boiler Design

Internee No: 1282

1 Muhammad Usman Ali, UCET, UOS.

Acknowledgement

All the praises are for Allah Almighty who bestowed me with the

ability and potential to complete this Internship. I also pay my gratitude

to the Almighty for enabling me to complete this Internship Report

within due course of time.

Words are very few to express enormous humble obligations to my

affectionate Parents for their prayers and strong determination to

enabling me to achieve this job.

I also appreciate the cordial co-operation from all my Internship

Supervisors in the different departments of Descon and also of Sir

Nofel Tayyab (HR) for providing me requisite information and

knowledge for compilation of my complete Internship. In particular to

Sir Saif, Sir Khuram and Sir Usman who gave me much help and

guidance in collecting the material for this report.

All the employers of Descon helped me a lot in performing all the

activities and in gaining the practical knowledge of industry. They gave

me best environment and knowledge to enhance my skills.

2 Muhammad Usman Ali, UCET, UOS.

Table of contents.

Page

No

Name of Topics

Sr. No

3

Introduction to Descon

1

5

Projects

2

6

Boiler

3

9

Software for Modeling

4

10

Software for Analysis

5

12

Workshops

6

12

Conclusion

7

3 Muhammad Usman Ali, UCET, UOS.

Introduction to Descon

Descon Engineering is based in Lahore, Punjab, Pakistan. Descon

Engineering was established in 1977. It started out as a plant

construction and services company. Since then it has developed itself

into a multi-discipline engineering services company serving a wide

range of industries like fertilizers, chemicals, power, cement, textile

and manufacturing within Pakistan as well as in GCC countries.

Descon provides full range of construction services encompassing civil

construction, mechanical erection and electrical and instrumentation

works in the areas of:

Oil & Gas: Since its inception, Descon has been actively involved in

high profile oil and gas projects in the Middle East. From facility

revamps to grassroots projects, we have delivered engineering

manufacturing, construction, commissioning, maintenance and EPC

services for refineries, gas fields, process plants, pipelines LNG plants

and storage facilities. Our joint venture company, Presson Descon

International (PVT) Limited (PDIL) is setting new standards for the

execution of EPC projects for oil and gas production facilities.

Chemical & Petrochemical: Over the years, Descon has accumulated

hands-on knowledge in executing engineering, construction, and

maintenance projects for the chemical and petrochemical industry in

the Middle East.

Additionally, our manufacturing bases are a highly competitive source

of stainless steel and alloy process equipment supply including pressure

vessels, reactors, heat exchangers and boilers.

Fertilizer: From the relocation of fertilizer plants to the construction

of new facilities, Descon has to a large extent helped shape the fertilizer

sector in Pakistan. Our extensive experience coupled with our network

of resources allows us to offer turnkey services including engineering,

relocation studies, manufacturing, construction, and plant maintenance.

4 Muhammad Usman Ali, UCET, UOS.

In addition to Pakistan, we have provided a host of services to leading

fertilizer operations in Saudi Arabia and UAE.

Cement: Descon has worked extensively on cement plants and is

actively involved in new projects in Pakistan and the Middle East. We

work closely with the world’s leading cement plant technology

licensors to deliver turnkey design, manufacturing, construction, and

commissioning services to our clients. Our manufacturing facilities

have delivered a wide range of cement plant equipment, including

kilns, silos, and tanks.

Power: Descon has diversified experience in providing services for

large-scale thermal and hydel power projects and has established

ourselves as the preferred contractor for leading international firms

engaged in power plants projects.

In addition to detailed engineering and construction, we have extensive

experience in power plant equipment such as heat recovery steam

generators (HRSGs), deaerators, and balance of plant (BOP)

equipment. To date, Descon has executed power projects with a total

capacity of approximately 10,000 MW.

5 Muhammad Usman Ali, UCET, UOS.

Projects

Descon has executed major projects in the sectors of oil and gas,

chemical, petrochemical, fertilizer, power, cement and infrastructure.

These projects have been delivered to clients who are investors,

operators or themselves EPC contractors. Major international

exploration and production companies, oil marketing companies and

owners/operators have had their investments secured by entrusting

Descon to implement their projects according to their budgets and time

schedules while adhering to international quality standards and with

zero tolerance towards unsafe practices and damage to the

environment.

The combination of an experienced human resource pool and well

established project management systems have enabled us to succeed

and grow in a competitive environment. From compact process plants

to large civil infrastructure projects we have delivered a wide variety

of projects of national importance. A few examples are listed below:

Halmore Bhikki 225MW Combined Cycle Power Project

Mangla Dam Raising Project Contract No. MDR–33

Construction of Water Treatment Plant for New City

7,200 TPD Fauji Cement Plant

Contract Package 3B; Construction of Part of Islamabad-

Peshawar Motorway (M-1)

6700 TPD Maple Leaf Cement Project

6700 TPD D.G. Khan Cement Project

Pakistan Motorway, Islamabad Peshawar Section (M-1)

Mirani Dam Project

6,000 TPD Pakistan Cement Plant

50 MMSCFD Gurguri Gas Plant

Attock Refinery Up-gradation (20,000 BPD)

225 MW Liberty Power Plant

Manufacturing & erection of HRSGs for 412 MW Rousch CCPP

2x362 MW Lalpir Power Plant

National Refinery Limited (NRL), Karachi Lube Oil Plant

6 Muhammad Usman Ali, UCET, UOS.

Boiler

My department in Descon is Boiler design. Descon is manufacturing

boilers of different types and sizes not only for clients in Pakistan also

in Gulf countries.

Boiler is a closed vessel in which water or other fluid is heated. The

fluid does not necessarily boil. 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 etc.

Heating surface: Heating surface is expressed in Square-feet/m

Classified into:

Radiant Heating Surfaces: (direct or primary) include all surfaces that

are directly exposed to the radiant heat of the combustion flame.

Converted Heating Surfaces: (indirect or secondary) Include all those

surfaces exposed only to hot combustion gases.

Extended Heating Surfaces: referring to the surface of economizers &

super heaters used in certain types of water tube boiler

Boilers Accessories: Boiler accessories are those components which

are installed either inside or outside the boiler to increase the efficiency

of the plant and to help in the proper working of the plant. Some of

these accessories are given below:

Air Preheaters

Feed water Pump

Economizer

Super heater

Air Preheaters

7 Muhammad Usman Ali, UCET, UOS.

Waste heat recovery device in which the air to on its way to the furnace

is heated utilizing the heat of exhaust gases

The function of air pre-heater is to increase the temperature of air

before enters the furnace.

It is generally placed after the economizer; so the flue gases

passes through the economizer and then to the air preheater.

An air-preheater consists of plates or tubes with hot gases on one

side and air on the other. It preheats to be supplied to the furnace.

Preheated air accelerates the combustion and facilitates the

burning of coal.

Economizer: A device in which the waste heat of the flue gases is

utilized for heating the feed water. To recover some of the heat being

carried over by exhaust gases. This heat is used to raise the temperature

of feed water supplied to the boiler. The temperature range between

various parts of the boiler is reduced which results in reduction of

stresses due to unequal expansion. If the boiler is fed with cold water it

may result in chilling the boiler metal. Evaporative capacity of the

boiler is increased. Overall efficiency of the plant is increased.

Super heater: The function of super heater is to increase the

temperature of the steam above its saturation point. To superheat the

steam generated by boiler. Super heaters are heat exchangers in which

heat is transferred to the saturated steam to increase its temperature.

Steam consumption of the engine or turbine is reduced. Losses due to

condensation in the cylinders and the steam pipes are reduced. Erosion

of turbine blade is eliminated. Efficiency of steam plant is increased.

Feed-water Pump: The feed pump is a pump which is used to deliver

feed water to the boiler. Double feed pump is commonly employed for

medium size boilers. The reciprocating pumps are continuously run by

steam from the same boiler to which water is to be fed. Rotary feed

pumps are of centrifugal type and are commonly run either by a small

steam turbine or by an electric motor

Boilers Mountings: Boiler mountings are the machine components

that are mounted over the body of the boiler itself for the safety of the

8 Muhammad Usman Ali, UCET, UOS.

boiler and for complete control of the process of steam generation.

Various boiler mountings are as under:

Pressure gauge

Water Level Indicator

Fusible plug

Safety Valve

Lever Safety Valve

Spring Loaded safety Valve

Steam stop valve

Feed check valve

Blow off cock

Boiler Activities at DESCON

Activity Range

Design and Engineering

Manufacturing

Erection

Commissioning & Testing

Design and Engineering

Design and engineering involves:

Basic Engineering

Process and Thermal Designs

P & IDs, PFDs, BOQs, Quotation wetting, Calculations, Specs

Generation, Sizing Selection, etc.

Orifice, Valves, Drum Internals, Pumps, Tanks, Filters, Line

Sizing, Fans, Ducts, Pre heaters, Insulations, etc.

Mechanical Design

Piping Flexibility and Stress Analysis

Piping Isometrics

Electrical and Instrumentation Design

Engineering and International Codes & Standards ( ASME, API,

ASTM, ANSI, AISC, TEMA, EN)

9 Muhammad Usman Ali, UCET, UOS.

Software for Design

Autodesk AutoCAD: AutoCAD is a commercial software application

for 2D and 3D computer-aided design (CAD) and drafting available

since 1982 as a desktop application and since 2010 as a mobile, web-

and cloud-based app marketed as AutoCAD 360.

Developed and marketed by Autodesk, AutoCAD

was first released in December 1982, running on

microcomputers with internal graphics

controllers. Prior to the introduction of AutoCAD,

most commercial CAD programs ran on

mainframe computers or minicomputers, with

each CAD operator working at a separate graphics

terminal.

AutoCAD is used across a wide range of industries, by architects,

project managers, engineers, graphic designers, and other

professionals. It is supported by 750 training centers worldwide as of

1994. As Autodesk's flagship product, by March 1986 AutoCAD had

become the most ubiquitous CAD program worldwide.

I have learnt AutoCAD and make different 2D sketches as assignments.

One of them is shown below:

10 Muhammad Usman Ali, UCET, UOS.

Auto desk Inventor: Autodesk Inventor,

developed by U.S. based software company

Autodesk, is a computer-aided design application

for creating 3D digital prototypes used in the

design, visualization and simulation of products.

It uses Shape Manager, their proprietary geometric modeling kernel.

Autodesk Inventor competes directly with SolidWorks and Solid Edge.

I have learnt Autodesk Inventor and make different 3D models as

assignments.

Software for Analysis

Descon is using different software for different types of material

analysis. A few of them are listed below:

Staad Pro: STAAD Pro is a structural analysis and design

computer program originally developed by Research

Engineers International at Yorba Linda, CA in 1997. In late

2005, Research Engineers International was bought by

Bentley Systems.

An older version called Staad-III for Windows is used by Iowa State

University for educational purposes for civil and structural engineers.

The commercial version, STAAD.Pro, is one of the most widely used

structural analysis and design software products worldwide. It supports

several steel, concrete and timber design codes.

It can make use of various forms of analysis from the traditional 1st

order static analysis, 2nd order p-delta analysis, geometric non-linear

analysis or a buckling analysis. It can also make use of various forms

of dynamic analysis from modal extraction to time history and response

spectrum analysis.

11 Muhammad Usman Ali, UCET, UOS.

In recent years it has become part of integrated structural analysis and

design solutions mainly using an exposed API called Open STAAD to

access and drive the program using a Visual Basic macro system

included in the application or by including Open STAAD functionality

in applications that themselves include suitable programmable macro

systems. Additionally, STAAD.Pro has added direct links to

applications such as RAM Connection and STAAD Foundation to

provide engineers working with those applications which handle design

post processing not handled by STAAD.Pro itself. Another form of

integration supported by the STAAD.Pro is the analysis schema of the

CIM steel Integration Standard, version 2 commonly known as CIS/2

and used by a number modelling and analysis applications.

Ansys: Ansys is a general purpose

software, used to simulate

interactions of all disciplines of

physics, structural, vibration, fluid

dynamics, heat transfer and

electromagnetic for engineers.

Ansys is a finite element analysis (FEA) code widely used in the

computer-aided engineering (CAE) field. ANSYS software allows

engineers to construct computer models of structures, machine

components or systems; apply operating loads and other design criteria;

and study physical responses, such as stress levels, temperature

distributions, pressure, etc. It permits an evaluation of a design without

having to build and destroy multiple prototypes in testing.

The Ansys program has a variety of design analysis applications,

ranging from such everyday items as dishwashers, cookware,

automobiles, running shoes and beverage cans to such highly

sophisticated systems as aircraft, nuclear reactor containment

buildings, bridges, farm machinery, X-ray equipment and orbiting

satellites.

12 Muhammad Usman Ali, UCET, UOS.

Workshops

Descon has seven manufacturing/fabrication facilities strategically

located in Pakistan and the Gulf Cooperation Countries. Each shop

specializes in producing a specific type of product. All the workshops

are well equipped with machines and tools.

In general the product range spans industrial process equipment and

fabricated items. Complete packages such as boilers, process skids,

tanks, heat transfer equipment are tailored to the client requirements

and delivered on a turnkey basis.

Conclusion

The internship opportunity I had with DESCON was a great chance for

learning and professional development. Therefore, I consider myself as

a very lucky individual as I was provided with an opportunity to be a

part of it. I am also grateful for having a chance to meet so many

wonderful people and professionals who led me though this internship

period.

I express my deepest thanks to Sir Saif Shahzad, Sir Usman Ali Akbar,

and Sir Khuram for taking part in useful decision & giving necessary

advices and guidance and arranged all facilities to make life easier. I

choose this moment to acknowledge their contribution gratefully.