Internship Report

August 2016

Equipment & Plant

DESCON Engineering ltd.
Ayesha Siddiqa
Email: asiddiqa44@gmail.com
Industrial & Manufacturing Engg. UET LHR

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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 muti-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.

Engineering
Power
Chemical

It has seven divisions which are:

Corporate
Plant construction
Plant maintenance & services
Infrastructure projects
Manufacturing plants
Engineering procurement & construction
Presson descon integrated ltd.

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INFRASTRUCTURE

HR
Fabricatio
n

Finance

Productio
n

IT

IP

Admin

E&P

Design

HSE

Planning

QAQC
E&I

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EQUIPMENT & PLANT

Planning
Commerci
al

Electrical

E&
P

Logistics

Rental

Rigging
Heavy
lifting

Process Flow

Maintainan
ce

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Planning
Planning is the process of thinking about an organizing the activities required to achieve a
desired goal.
The main aim of this stage is to make an equipment deployment plan based on equipment
requirement.

1.Equipment
Deployment Plan made
by Proposals and
project planning
department.

2. PDI for owned

available equipment
from existing fleet and
mobilization to site.

6.E&P BA to carry out

pre delivery inspection
for equipment,finalized
for purchase.

5.Hiring proceas shall

be initiated for
equipment not
approved for
purchase in CIR.

7. Equipment is given
an asset code by
commercial.

8.Equipment cost
center is generated.

3.Buy Vs Rent analysis

for equipment not
available in inventory.

4.Comparative
statement and
purchase order
prepared by
Commercial

9.Equipment to be
mobilized to site.

Logistics
The activity of organizing the movement, equipment, and accommodation of troops.

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1.INTER BA transfer of
equipment.

2.E&P will inspect the

equipment,stores will
arrange gate pass.

5.E&P will inspect the

machine and update status
on system.

3.For over seas tranfers

commercial wil arrange
transport to port,arrange
custom clearance and
transport to next site.

4. At the receiver site stores

will arrange gate pass in
and transfer note in.

Operation
It deals with the various tasks at the project site.

1.E&P will enter the

equipment log book
data in the system,for
own and rental
equipment.

3rd party
certification.

Data includes:
Normal/breakdown/idlin
g hrs etc.

Pol book on each

equipment

Key expiry data.

2.Actual data(utilized
hours/mileage)

Maintenance
Maintenance includes routine checks that keep the machine in working order and can be
preventative, periodic or overhauling maintenance.
1.E&P will prepare
maintenance plans.

2. Inspection carried out

according to the
maintenance checklist.

3.In case parts for repair

are available.SIR will
be raised to issue the
same from stores.

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6.Parts will be fitted to

make the equipment fit
for use and equipment
status will be updated.

5.In case external

services are
required.Indent will
be raised.

4.indent will be raised

if parts are not
available in the
inventory.

Monitoring & analysis

It involves the monitoring of all the processes to improve the overall results.
1.E&P will monitor
KPIs of equipment.

Information includes:
Equipment efficiency
report

2.Cost of repairs summary

Equipment budget cost

comparison.
Equipment deployment
plans

Equipment breakdown
summary
Pol consumption summary

Disposal:
This process involves the future of the equipment, whether it needs to be disposed of,
cannibalized or modified for further usage.
1.E&P will prepare the
inspection report.

2.E&P will analyse

B.E.R.Request based
on the inspection
report.

3.In case B.E.R request

is rejected the necessary
repair works will be
carried out on
equipment.

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5.Sale receipt from the

successful bidder would be
submitted to finance and
delivery letter is collected
by commercial.

4. B.E.R is accepted.The
document for the equipment
would be handed over to
commercial in order to float
the sale tender in market.

Equipment
Tangible property (other than land or buildings) that is used in the operations of a business.
Examples of equipment include devices, machines, tools, and vehicles.

Classification of equipment
Lifting equipment
Lifting equipment is any work equipment for lifting and lowering loads.
It includes

lifting harnesses
fork lifts
air lift bags
cranes
man lift

Construction equipment

Bull dozer
Excavator
Loader
Tractors

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Grader

Haulage equipment

Transit mixer
Prime mover
Truck
Dump truck

Concreting equipment

Super swinger
Concrete pump

Plant equipment

Batching plant
Screening plant
Ice plant
Crush plant

Power equipment
Power generator

HTVs & LTVs

Batching plant:
A concrete plant, also known as a batch plant or batching plant or a concrete batching plant, is
equipment that combines various ingredients to form concrete. Some of these inputs include
water, air, admixtures, sand, aggregate (rocks, gravel, etc.), fly ash, silica fume, slag, and cement.

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Batching plant

Crane
A crane is a type of machine, generally equipped with a hoist rope, wire ropes or chains, and
sheaves, that can be used both to lift and lower materials and to move them horizontally. It is
mainly used for lifting heavy things and transporting them to other places. It uses one or more
simple machines to create mechanical advantage and thus move loads beyond the normal
capability of a human. Cranes are commonly employed in the transport industry for the loading
and unloading of freight, in the construction industry for the movement of materials and in the
manufacturing industry for the assembling of heavy equipment.

Types of crane:
Overhead crane
Overhead crane being used in typical machine shop. The hoist is operated via a wired pushbutton
station to move system and the load in any direction.

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Mobile crane
The most basic type of mobile crane consists of a truss or telescopic boom mounted on a mobile
platform be it on road, rail or water. Common terminology is conventional and hydraulic
cranes respectively.
Truck-mounted crane
A crane mounted on a truck carrier provides the mobility for this type of crane. This crane has
two parts: the carrier, often referred to as the Lower, and the lifting component which includes
the boom, referred to as the Upper. These are mated together through a turntable, allowing the
upper to swing from side to side.

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Side lifter crane
A side lifter crane is a road-going truck or semi-trailer, able to hoist and transport ISO standard
containers. Container lift is done with parallel crane-like hoists, which can lift a container from
the ground or from a railway vehicle.

Rough terrain crane

A crane mounted on an undercarriage with four rubber tires that is designed for pick-and-carry
operations and for off-road and "rough terrain" applications. Outriggers are used to level and
stabilize the crane for hoisting.

All terrain crane

A mobile crane with the necessary equipment to travel at speed on public roads, and on rough
terrain at the job site using all-wheel and crab steering. ATs combine the roadability of Truckmounted Cranes and the manoeuvrability of Rough Terrain Cranes.

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Pick and carry crane
A Pick and Carry Crane is similar to a mobile crane in that is designed to travel on public roads,
however Pick and Carry cranes have no stabiliser legs or outriggers and are designed to lift the
load and carry it to its destination, within a small radius, then be able to drive to the next job.

Carry deck crane

A carry deck crane is a small 4 wheel crane with a 360 degree rotating boom placed right in the
centre and an operators cab located at one end under this boom. The rear section houses the
engine and the area above the wheels is a flat deck.

Crawler crane
A crawler is a crane mounted on an undercarriage with a set of tracks (also called crawlers) that
provide stability and mobility. Crawler cranes range in lifting capacity from about 40 to 3,500
short tons (35.7 to 3,125.0 long tons; 36.3 to 3,175.1 t).

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Railroad crane
A railroad crane has flanged wheels for use on railroads. The simplest form is a crane mounted
on a flatcar. More capable devices are purpose-built. Different types of crane are used for
maintenance work, recovery operations and freight loading in goods yards and scrap handling
facilities.

Floating crane
Floating cranes are used mainly in bridge building and port construction, but they are also used
for occasional loading and unloading of especially heavy or awkward loads on and off ships.
Some floating cranes are mounted on pontoons, others are specialized crane barges with a lifting
capacity exceeding 10,000 short tons (8,929 long tons; 9,072 t) and have been used to transport
entire bridge sections. Floating cranes have also been used to salvage sunken ships.

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Aerial crane
Aerial crane or 'Sky cranes' usually are helicopters designed to lift large loads. Helicopters are
able to travel to and lift in areas that are difficult to reach by conventional cranes. Helicopter
cranes are most commonly used to lift units/loads onto shopping centers and highrises.

Some aerial cranes, mostly concepts, have also used lighter-than air aircraft, such as airships.

Fixed
Exchanging mobility for the ability to carry greater loads and reach greater heights due to
increased stability, these types of cranes are characterised by the fact that their main structure
does not move during the period of use. However, many can still be assembled and
disassembled. The structure basically are fixed in one place.
Tower crane
Tower cranes are a modern form of balance crane that consist of the same basic parts. Fixed to
the ground on a concrete slab (and sometimes attached to the sides of structures), tower cranes
often give the best combination of height and lifting capacity and are used in the construction of
tall buildings. The base is then attached to the mast which gives the crane its height. Further the
mast is attached to the slewing unit (gear and motor) that allows the crane to rotate. On top of the
slewing unit there are three main parts which are: the long horizontal jib (working arm), shorter
counter-jib, and the operator's cab.

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Telescopic crane
A telescopic crane has a boom that consists of a number of tubes fitted one inside the other. A
hydraulic or other powered mechanism extends or retracts the tubes to increase or decrease the
total length of the boom.

Hammerhead crane
The "hammerhead", or giant cantilever, crane is a fixed-jib crane consisting of a steel-braced
tower on which revolves a large, horizontal, double cantilever; the forward part of this cantilever
or jib carries the lifting trolley, the jib is extended backwards in order to form a support for the
machinery and counterbalancing weight. In addition to the motions of lifting and revolving, there
is provided a so-called "racking" motion, by which the lifting trolley, with the load suspended,
can be moved in and out along the jib without altering the level of the load. Such horizontal
movement of the load is a marked feature of later crane design. These cranes are generally
constructed in large sizes and can weigh up to 350 tons.

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Jib crane
A jib crane is a type of crane where a horizontal member (jib or boom), supporting a moveable
hoist, is fixed to a wall or to a floor-mounted pillar. Jib cranes are used in industrial premises and
on military vehicles. The jib may swing through an arc, to give additional lateral movement, or
be fixed. Similar cranes, often known simply as hoists, were fitted on the top floor of warehouse
buildings to enable goods to be lifted to all floors.

Stacker crane
A crane with a forklift type mechanism used in automated (computer controlled) warehouses
(known as an automated storage and retrieval system (AS/RS)). The crane moves on a track in an
aisle of the warehouse. The fork can be raised or lowered to any of the levels of a storage rack
and can be extended into the rack to store and retrieve product. The product can in some cases be
as large as an automobile. Stacker cranes are often used in the large freezer warehouses of frozen
food manufacturers. This automation avoids requiring forklift drivers to work in below freezing
temperatures every day.

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5S methodology
5S is the name of a workplace organization method that uses a list of five Japanese words: seiri,
seiton, seiso, seiketsu, and shitsuke. Transliterated into Roman script, they all start with the letter
"S". The list describes how to organize a work space for efficiency and effectiveness by
identifying and storing the items used, maintaining the area and items, and sustaining the new
order. The decision-making process usually comes from a dialogue about standardization, which
builds understanding among employees of how they should do the work.

sort

sustain

standari
ze

set in
order

5s

shine

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CMS:
CMS is central maintaeinenance shop in Lahore.
Equipment arrived at this shop,then inspection is done,if fault is present then repairing of
equipment is done.

LTV
It contains the vehicles which are surplus at that time.

Engine Maintenance Shop

This shop deals with the maintainenance and repairing of engines.
All the equipments present there were organized.

Fabrication & welding

Many equipment like dump trucks were present there on which workers are doing work.
There was a noise in that area particularly, which is hazardous for sense of hearing. Workers
should use PPE(personal protective equipment) for their safety.

Central base warehouse(CBW)

It has storage area for spare parts of various equipment like crane,excavtors,loaders etc
All the spare parts were well organized.

5s in CMS
5s was not completely implemented in CMS. Equipment were arranged in order but there were
sustainability issues.
In CBW there was implementation of 5s.Spare parts were sorted,arranged in order and sustained.

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SAP-ERP
SAP SE is a German multinational software corporation that makes enterprise software to
manage business operations and customer relations.
SAP-ERP software is utilized in DESCON.
It has modules which are implemented in Descon.Only authorized person has access to their
respective modules.It has greater impact on efficiency of work.
It has following modules which are being implemented in Descon:

DMS(Document Management System)

All departments have access this module.

Documents centralization
Easy to attached any module

SD(Sales & Distribution)

Proposal dept. uses this module

Creation enquiry and proposal

Creation of sales order
Cost planning
Record related to rejected enquiries

PS (Project System)
Planning dept uses this module.

Project creation
Budgeting
Purchase requisition with approval
Online monitoring
Services approval
Real time reports
Work flows etc

MM (Material Management)
Commercial dept. has access to this.

Paper less system with provision of PO/SO & GR printing only.

PO Approvals by predefined approval cycle.
Vendor invoice parking
Inbuilt buying and logistics scheduling

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Centralized pricing data

MRP of level stock items
Maintanenance of IMTEs schedule on system

QM (Quality Management)

Generation of RFI
Result recording of RFI
Material acceptance/rejection through SAP
Same time reports
Stock updation and budget consumption at GR

FICO (Finance & Controlling)

Comprehensive chart of account

Project analytic studies
Fixed asset management
Employees related expenses
Vendors/customer invoice posting
In time whistle blowing
Online availability of all required information

HCM (Human Capital Management)

This module uses by HR.

Maintainence of employee personal data

Hiring of new employees
Execution of HR operations
Assignment of project roles

PM (Plant Maintainenance)
E&P uses this module.

Ordering of maintenance of plant machinery and equipment

Recording preventive/corrective actions
Maintenance schedules

ETM (Equipment Tool Management)

E&P uses this modules.

Equipment shipment control

Rental rate

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References:

Wiki.org
http://cerasis.com/