Internship Report

Hafiz Abdul Rehman
2015
Zealcon Internship Report

Zealcon Engineering (Pvt.) Ltd
Ghulam Ishaq Khan Institute Of Engineering Sciences And Technology Topi ,Swabi KPK
Contents
Company Description: ..................................................................................................................................3
Projects: ....................................................................................................................................................3
Specialities:...............................................................................................................................................3
Acknowledgement: .......................................................................................................................................4
Preface: .........................................................................................................................................................5
UCH-II Gas Development Project..................................................................................................................6
Location:....................................................................................................................................................6
Capacity:....................................................................................................................................................6
Plant Layout: .............................................................................................................................................6
Production Capacity:.................................................................................................................................6
Process:.........................................................................................................................................................7
Gas Gathering Area:..................................................................................................................................7
Slug Catcher: .............................................................................................................................................7
Amine Contactor:......................................................................................................................................7
Amine Stripper:.........................................................................................................................................8
Dehydration unit:......................................................................................................................................8
Gas Metering Area:...................................................................................................................................8
Departments on Project Site:.........................................................................................................................9
Work department: .........................................................................................................................................9
Supervisors:.................................................................................................................................................10
Dehydration Unit(With Glycol):.................................................................................................................11
Process:...................................................................................................................................................11
Rich Glycol:........................................................................................................................................11
Lean Glycol:........................................................................................................................................11
Dry gas:...............................................................................................................................................11
Observations and Activities:...................................................................................................................12
Responsiblities:.......................................................................................................................................13
New knowledge acquired:.......................................................................................................................13
Quality Assurance and Quality Control Department:.................................................................................14
Inspection And Testing on Dehydration unit:.........................................................................................14

Inspections: .........................................................................................................................................14
Testing: ...............................................................................................................................................14
New Knowledge Acquired:.....................................................................................................................15
Dye penetration test: ...................................................................................................................................15
Radio Graphic Test:....................................................................................................................................15
Hydro-Testing:............................................................................................................................................16
Key Observations:...................................................................................................................................16
Mechanical Piping Near CCR:....................................................................................................................17
Activities:................................................................................................................................................17
Responsibilities:......................................................................................................................................17
New Knowledge Gain:............................................................................................................................17
General Arrangement Diagram:..................................................................................................................17
Characteristics:........................................................................................................................................17
Isometric Diagram: .....................................................................................................................................17
Piping And Instrumentation Diagram:........................................................................................................18
Welding:......................................................................................................................................................18
Key Points:..............................................................................................................................................18
Types of Weldings:.....................................................................................................................................18
Gas Tungsten Arc Welding:....................................................................................................................18
Key Points:..........................................................................................................................................19
Electric Arc Welding: .............................................................................................................................20
Basic Steps: .............................................................................................................................................20
Key Points:...............................................................................................................................................20
New Knowledge acquired from other Departments: .................................................................................21
Planning Department:.............................................................................................................................21
Invoice:................................................................................................................................................21
Bill of quantity:....................................................................................................................................21
Mechanical ( Structure ):.........................................................................................................................21
Civil Department:....................................................................................................................................21

Company Description:
Zealcon Engineering (Pvt.) is a known entity to the Civil Engineering sector of Pakistan. A
vibrant group of highly qualified professionals with diversified backgrounds have joined hands
under the banner of ZEALCON to offer Mechanical, Civil & Electrical Engineering to the
valuable customers at large.
Being a fast emerging engineering firm; ZEALCON has exuberant market standing with high
repute among the customers.
The company has a well-defined system in place to operate, already certified to ISO-9001:2008.
ZEALCON has a state of the art manufacturing, assembling and maintenance facility, fully
equipped with qualified engineering and technical staff. The latest tools and techniques are
applied at the manufacturing factory to ensure quality assurance.
ZEALCON is a valuable partner towards development of EPC concept of services to specified
areas and quality of after sales service is ideal. The company maintains an ideal work
environment.
Projects:
 Mehar Gas Development Project at District Dadu – Sindh
 Civil works at Bus Rapid Transit System (RBTS) at Lahore
 Supply Fabrication and Erection of Flue Stacks – for Byco Oils Limited – Karachi
 UCH-II Gas Development Project
 Rohri Cement Plant
Specialities:
 Design and Engineering
 Turnkey Solutions
 Project Management and Consultancy
 Plant Construction and Plant Turnaround
 Manufacturing Facility
 Infrastructure
 After Sales Support

Acknowledgement:
All the praises for the Almighty, Allah who bestowed us 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.
The internship opportunity I had with ZEALCON Engineering (Pvt.) Ltd 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.
Bearing in mind previous I am using this opportunity to express my deepest gratitude and special
thanks to the Mr. TARIQ ( Project Manager ) , Mr. MIR HAZAR ( Site Manager Uch-II )
and MR. GHULAM SHABBIR ( Manager Planning UCH-II ) of ZEALCON Engineering
(Pvt.) Ltd who in spite of being extraordinarily busy with their duties, took time out to hear,
guide and keep me on the correct path and allowing me to carry out my internship at their
esteemed organization and mega UCH-II GAS Development project.
I express my deepest thanks to Mr. RAZA ( HR Department ) for providing me requisite
information and arranged all facilities to make life easier. I choose this moment to acknowledge
his contribution gratefully.
It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to Mr.
ALTAF SHAH ( Area Incharge Piping ) , Mr. TARIQ ( Supervisor Piping ) , Mr. MUNIR
( Supervisor Hot Oil Heaters) , Mr. ASGHAR ( QC/QA ) , Mr. TANVEER ( QC/QA ) ,
Mr. ADIL( Civil Department ) , Mr. BURHAN ( Mechanical Engineer In Planning
Department ) for their careful and precious guidance which were extremely valuable for my
study both theoretically and practically.
I perceive as this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with all
of you in the future.

Preface:
Internship is one of the keys for understanding more deeply the concepts learned from formal
education by going through practical practices adapted by different companies. And this logic
brought me and my fellows to Zealcon Engineering (Pvt.) Ltd.
During my internship I learned a lot about piping system and AMINE unit along with different
welding techniques. Every topic was explained to me very professionally and this report is an
overview of what I learned.
Information in this report is gathered from different sources like isometric and P&I diagrams
provided by our supervisors and also from carefully examining the processes every day from
dust till dawn under the kind supervision of our superiors.
This report gives reader an insight to different techniques of assembling, inspection and punch
listing of piping system in Dehydration unit along with Hot Oil Heater. Also a brief overview of
structural assembling of Hot Oil Heater and module installation. A bit of welding techniques and
also on different technical as well as site problems which I have faced during my time here.
I tried my best to work efficiently but since its natural for humans to make mistakes, I ask for
your pardon in advance for mistakes I’m held fully responsible

UCH-II Gas Development Project
Location:
 Dera Murad Jamali near Sohbatpur.
 600 KM North of Karachi
Capacity:
 300 MMSCFD
Plant Layout:
 Gas Turbines
 CCR Building
 Dehydration unit
 Amine train-I
 Amine train-II
 CPI unit
 Hot oil heaters
 Slug Catcher
Production Capacity:
 Around 404 MW

Process:
Gas Gathering Area:
 Gas is collected from 15 wells
 Wells are divided into 3 regions
 Western ( low BTU of around 400 )
 Central ( high BTU of Around 750 )
 Eastern ( low BTU of around 380 to 400 )
Slug Catcher:
 Removes contaminants
Amine Contactor:
 Gas contain high H2S value which is hazardous
 In amine contactor lean MDEA ( Methyl Di Ethanol Amine ) is sprayed to absorb H2S
 12 plates are installed in contactor to increase contact area
Gas
Gathering
Area
Slug Cather
Amine
Contactor
Amine
Stripper
Dehydration
Unit
Gas
Metering
Area

Amine Stripper:
 Rich Amine enters amine stripper
 By reducing pressure and increasing temperature gas solubility is decreased.
 H2S is separated from gas in this way and supplied back to amine chamber
Dehydration unit:
 Glycol (TEG) is fed to the top of a glycol contactor where it is contacted with the wet
natural gas stream.
 The glycol removes water from the natural gas by physical absorption.
 Upon exiting the absorber the glycol stream is often referred to as "rich glycol".
 After leaving the absorber, the rich glycol is fed to a flash vessel where hydrocarbon
vapors are removed.
 After leaving the flash vessel, the rich glycol is heated in a cross-exchanger and fed to the
stripper (also known as a regenerator).
Gas Metering Area:
 Measurement of gas flow

Departments on Project Site:
 Planning
 Mechanical
 Electrical And Instrumentation
 QC/QA
 Civil
 Store
 Administration
Work department:
 Dehydration with Glycol unit
 Mechanical Piping near CCR
Site Manager Mr. HAZAR assigned me the Piping and Dehydration unit which comes under the
Mechanical department to carefully learn and understand the proceedures. To learn every basic
knowledge of piping system which includes many aspects like
 Fit ups
 Coating
 Installation
 Pipe Welding
 Schedules
 Inspection And Punch listing
 Pipe Thickness And Diameter Effects
 Workers Handling
Furthermore I also worked on AMINE-I for couple of days to see the difference in piping and
welding proceedures.

Supervisors:
 Mr. Altaf Shah ( Area Incharge Piping )
 Mr. Tariq ( Supervisor Piping )
I was very fortunate to work with people like these because they helped me a lot in
understanding the different aspects of piping and also treated me like their own son to adapt in
difficult field conditions

Dehydration Unit(With Glycol):
Most of the water vapor has to be removed from natural gas before it can be commercially
marketed; all natural gas is subjected to a dehydration process. One of the most common
methods for removing the water from produced gas is glycol.
Process:
Glycol (TEG) is fed to the top of a glycol contactor where it is contacted with the wet natural
gas stream. The glycol removes water from the natural gas by physical absorption. Upon exiting
the absorber the glycol stream is often referred to as "rich glycol". The dry natural gas leaves the
top of the absorption column and is fed either to a pipeline system or to a gas plant.
After leaving the absorber, the rich glycol is fed to a flash vessel where hydrocarbon vapors are
removed.
After leaving the flash vessel, the rich glycol is heated in a cross-exchanger and fed to the
stripper (also known as a regenerator). The glycol stripper consists of a column, an overhead
condenser, and a re-boiler. The glycol is thermally regenerated to remove excess water and
regain the high glycol purity.
Some Key Terms:
Rich Glycol:
Glycol that contains water released by wet gas while moving upward in contactor.
Lean Glycol:
Glycol which is free of water (99% purity).
Wet gas:
When hydrocarbons are present, gas is considered as “Wet”
Dry gas:
Gas is considered “Dry” when it is almost pure methane, having most of the hydrocarbons
removed.

Observations and Activities:
Following are the activities performed at above mentioned unit
 Understanding the process of De-hydration with Glycol
 Tracing of whole unit which includes pipes of different diameter and also valves of
different significance.
 Examine Separator characteristics like
 Horizontal type
 Large Liquid Handling Capacity
 Sufficient time to settle out of liquid droplets from gas
 Inlet Device to reduce turbulation
 Carefully examine Valves and pumps of different applications like
 Globe Valve
 Gate Valve
 Ball Valve
 Centrifugal pump
 Pressure Safety Valve ( PSV )
 Check Valve ( Non-Return )

 Check Foaming level from Amine-II
Responsiblities:
 Examine the structure to indicate possible flaws like
 Not proper Bolting
 Usage of stud bolts in place of nut bolt
 Absence of washers
 Absence of shim plates
 Provide necessary back up in case supervisors are not there
 Assist the workers if they need
New knowledge acquired:
 Type of Glycol used which is TEG (TRI-Ethylene Glycol) because of
 TEG is more easily regenerated to a higher degree of purity
 Operating costs are lower
 Different sections of Dehydration unit like
 Stripper
 Contactor
 Flash vessel
 Importance of these units
 Significance of Different valves installed in unit
 How to read P&I Diagram
 It is essential that the inlet separator provide good separation between condensed liquids
and gas going to the contactor.
 Usage of Anti-foam is a temporary solution but effective in controlling foaming
 Different key terms like
 Wet gas
 Dehydrated Gas
 Rich glycol
 Lean Glycol
 Dry Gas

Quality Assurance and Quality Control Department:
Quality assurance and Quality Control Department commitment starts at the very top and
cascades through the entire line management. Quality processes are designed to add value to
internal and external customers. Processes are completely aligned with the customer
requirements and are continuously improved as the process evolves.
Quality Department delivers a comprehensive range of services including
 Inspection
 Testing
 Certification
 Handing over
Inspection And Testing on Dehydration unit:
Every part of dehydration unit has to go through a series of test before it can be declared
operational.
Inspections:
 All the Weld Joints must be cleaned and painted
 Lines must be installed as per direction
 Line should be level and align properly
 All the valves must be installed as per drawing
 Bolts must be tight properly
 All support must be installed as per drawing
Testing:
Following are the tests used by Q/C on Dehydration unit



Naked eye
inspection
DPT
Radiographi
-c test

New Knowledge Acquired:
 Process of Different inspection tests and their significance
Dye penetration test:
DPT is widely applied and low cost inspection method used to locate surface breaking defects.
Basic steps are:
 Clean the part with power brush and cleaner
 Apply the penetrant on cleaned weld surface
 Wait for 15 min
 Remove penetrant from weld surface
 Apply a developer
 And allow developing
 Different defects will appear if any like
 Cracks
 Pin-Holes
 Under Cuts
Radio Graphic Test:
Radiographic testing can be used to detect internal defects in castings and welding by exposure
the construction to x-ray radiation. Defects are detected by differences in radiation absorption in
the material.
Basic Steps are:
HYDRO
testing

 Weld surface is properly cleaned
 Otherwise there will be more absorption detect on films due to dust or some other
particles
 Source of radiation is applied at one end of weld joint
 RT is applied only on Butt joints
 Detecting device is attached opposite to source
 Cracks will absorb more radiation than normal area
 Two-dimensional projection is formed on the detecting screen of varying densities
according to the amount of radiation reaching each area.
Hydro-Testing:
Hydrostatic testing has long been used to determine and verify pipeline integrity.
Basic steps involved in hydro testing:
 Test section must be isolated from other pipeline section
 Block valve is used to shut the flow in a section
 Water is filled in test section with pressure
 Pressure is usually 1.5 times of maximum operating pressure ( MOP )
 Wait for 1 hour
 Any drop in pressure will indicate leakages
 Visual inspection is also done to see any leakages
Key Observations:
 Dye penetration test is used only for socket joints
 RT is only used for Butt joints
 Hydro Test pressure is 1.5 times of MOP

Mechanical Piping Near CCR:
Activities:
 Learn about different scheduling of pipes
 Welding of pipes under different conditions like in hot as well as cloudy days
 Installment of Pipes as per design requirement
 Inspection of weld joints
 Drawing analysis
 10 inch dia. pipes installed connecting Gas turbine and Hot oil Heater for Oily
water transport.
Responsibilities:
 Surveying the site
 Preparing reports as required
 Daily plan reading with the help of drawings
 Assist labour if they need help
New Knowledge Gain:
 Learn how to read Piping & Instrumentation diagrams
 Isometric diagram
 And General arrangement diagrams
General Arrangement Diagram:
These drawings indicate the locations of main equipment’s in the plant.
Characteristics:
Following are indicated on GA
 piping items
 valves
 fittings
Isometric Diagram:
It is popular within the process piping industry because it can be drawn and read
with ease and shows the piping in a realistic view.
Characteristics:
 Bill of Material
 Layouts

 Exact Dimensions
 Fitting symbols
 Reference to assembly
 Mostly used in construction industry
 Simplicity
 Sectional views
Piping And Instrumentation Diagram:
A Piping and Instrumentation Diagram is a schematic illustration of functional relationship of
piping, instrumentation and system equipment components.
Characteristics:
 No exact dimensions
 No directional restriction
 Used mostly for inspection
 Welding techniques
Welding:
Welding is a material joining process which produces coalesces of materials by heating them to
suitable temperature with or without application of pressure and with or without filler material.
Key Points:
 Welding form a permanent joint
 Filler metal is melted in the gap, combines with the molten metal of the work piece and
upon solidifications form a integral part of the weld.
 For high pressure pipes we use Argon welding because it produce weld of good quality
 For oily water or hot water we use electric arc welding.
 Joint must be grind properly before any welding
Types of Weldings:
Here on UCH-II mostly used welding techniques are
Gas Tungsten Arc Welding:
TIG or GTAW is a welding process that uses a non-consumable electrode to produce a
weld. Weld area is also protected from atmospheric contamination by an inert gas. Filler
metal is also used.

Key Points:
 Tungsten is used as a non-consumable electrode
 Argon is used as shielding gas
 Direct Current Electrode Negative is mostly used here on plant
 Above method concentrates about 2/3 of the heat onto the metal welded. This produces a
deep penetration weld.
 TIG is two handed weld operation
 Purging is required which replace the air in a pipe with argon that will not react with the
root of the weld. Purging prevents weld oxidation.
 Better weld quality
 Mostly used for SS

Electric Arc Welding:
Arc welding is the process by which two metal parts are joined by melting the parts at the point
of contact
Basic Steps:
 Prepare the base material
 Remove paint and dust
 Choose the right filler material
 Protect the molten metal from contamination
 Inspect the weld
Key Points:
 Only use for similar metals
 Mostly used for CS
 Weld quality is not as good as argon welding
 Cost effective

New Knowledge acquired from other Departments:
Planning Department:
Invoice:
Invoice is a document that states a commitment from the seller to provide specified goods
to the buyer at specific prices.
Bill of quantity:
An itemized list of materials, parts, and labor (with their costs) required to construct,
maintain, or repair a specific structure
Objective:
 To provide sufficient information on the quantities of Works to be performed to
enable bids to be prepared efficiently
 To provide a priced Bill of Quantities for use in the periodic valuation of works
executed
 Day work Schedule
 Summary
Mechanical ( Structure ):
 Scaffolding
 Installation of refractory material
 Discussion with professional Chinese engineer on structure drawings
 Module installation
 Module significance
Civil Department:
 Learn how to use leveling machine.

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