1. INTERNSHIP REPORT
Prepared By: Muhammad Usman Ali
Supervised By: Engr. Saif Shahzad
Department: Boiler Design
Internee No: 1282

2. 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.

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Muhammad Usman Ali, UCET, UOS.
Table of contents.
Page
NoName of Topics
Sr. No
3Introduction to Descon1
5Projects2
6Boiler3
9Software for Modeling4
10Software for Analysis5
12Workshops6
12Conclusion7

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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.

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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.

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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

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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

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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

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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)

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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:

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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.

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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.

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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.