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WINTER EDITION 2011 HIGHLIGHTS: BHP FEC Project Completed Fabrication of Spudcans PAFL Capacity Enhancement Project Wind Towers’ Manufacturing Project Cover Story - Descon Integrated Projects Ltd SUCCESS STORY BHP FEC Project 04 Fabrication of Spudcans 05 Pak American Fertilizer Plant 06 Fatima Fertilizer NP Project 07 Wind Tower Project 08 Partners in Progress 09 Descon Integrated Projects Ltd 10 ENGINEERING Overseas Business Area United Arab Emirates 12 Qatar 16 Kuwait 17 Olayan Descon Industrial Company 18 Joint Venture Presson Descon International Ltd 19 Cover Story Evolution of Engineering 21 CHEMICALS Manufacturing Hamriyah Manufacturing Works 25 Abu Dhabi Manufacturing Works 26 Lahore Manufacturing Works 27 Corporate News E&P 29 HRD&A 30 Health, Safety and Environment 33 ICT 34 QA/QC 36 PS 37 Descon Chemicals Ltd 38 Descon Oxychem Ltd 39 Descon Power Solutions 40 Interworld Travels Ltd 42 POWER EDITOR’S NOTE Dear Readers, I hope you will enjoy reading this issue of Descon News. As the year comes to a close, we too are reflecting upon our achievements in 2011 and are gearing up to greet 2012 with renewed zeal and passion. At Descon, we are moulding the engineering experts of the future. That's why we draw on the finest talent from various disciplines - engineering, manufacturing, construction and procurement. We nurture their skills and showcase their unique talents and achievements in our newsletter. This issue's cover story focuses on how we are evolving in the engineering and EPC domain, an achievement reflecting our client's confidence in Descon. It also features the people behind our success in reaching this milestone. Read about all this and much more in this edition. Wishing you and your loved ones a Happy New Year! Regards, Rabya Sheikh EDITORIAL TEAM Aamer Hadi Khan Head Business Development Rabya Sheikh Coordinator Communications - BD Ch. Muzaffar Ali Asst. I/C Communications - BD Sharaf Javed Business Development Engineer Abdul Wahab IT Officer - DCH ABBREVIATIONS BA BD BPD BSD CDR CMPS CSR DCS EPC FAT HRSG LTI LTMSA MPSCS P&PM PMP PMS PWHT TPD TSF : : : : : : : : : : : : : : : : : : : : Business Area Business Development Barrels per Day Business Support Department Carbon Dioxide Recovery Centralized Manpower System Corporate Social Responsibility Domestic Construction Services Engineering, Procurement, Construction Factory Acceptance Test Heat Recovery System Generator Loss Time Injury Long Term Maintenance Services Agreement Manpower Strength Control System Proposals & Project Monitoring Project Management Plan Project Management Systems Post Weld Heat Treatment Tons per Day Temporary Site Facilities DESCON NEWS WINTER 2011 BHP FEC Project BHP Billiton has been a valuable client for Descon with a long history of fruitful association. Descon has previously completed two earlier phases at the Zamzama Plant, the site of the current project of Front End Compression (FEC) facility. The new plant located adjacent to the existing installations presented restrictive working conditions and stringent HSE environment. It was also required to be completed within a highly compressed timeframe. Besides erection of the (GE supplied) compressor packages (along with the associated duplex steel plant piping and steel structure), the work scope also included laying of 1km of super duplex steel cross countr y pipeline. Selection of the project supervisory team was also quite stringent, requiring each member to possess strong experience related to the job. The project team also responded positively to the client's requirements and discharged their respective roles with full commitment, achieving the first critical milestone of completion of the project earthworks. This part was critical to star t off the subsequent activities of mechanical and structural foundations. The task for fabrication of CS piping and steel structure was assigned to Karachi Manufacturing Works (KMW) while the more complex and demanding part for fabrication of stainless steel piping was done by Lahore Manufacturing Works (LMW). During execution, there were unprecedented floods in the region, severing the lines of communications and impeding mobilization of the required resources like heavy cranes etc. 04 Success Story Ahmad Parvaiz Rattu At one stage the site was forced to be fully demobilized for almost a month. The project has now been completed in full compliance to the specifications and satisfaction of the client. The first ‘gas-in’, operational checks as well as commissioning of the cross-country pipeline was achieved smoothly. Moreover, the project safety record has been exemplary with active participation of all members of the working team. Considering all their projects the world over, BHP has declared the FEC project as the best performer in HSE. The BHP project team has conveyed their full satisfaction and appreciated the support they received from Descon in all stages of project execution. Success Story DESCON NEWS Fabrication & Supply of Spudcans One of our diversification objectives has been to venture into the specialized field of offshore operations. It became a reality when Descon Engineering FZE (HMW) was awarded the fabrication and supply of spudcans for Seajack's Zartan project for Jack-up rigs, by Lamprell Offshore. Spudcans form a critical part of jack-up rigs; they are attached to the lower end of the rig's legs and are also used to eject the legs settled in the ocean sands when the rig makes a move while operating in the sea. The job was to fabricate 450 tons of marine grade structural material along with 3,500 dia-inches of pressure piping installed within the spudcans. As it was Descon's first experience with marine grade material AH/EH/DH 36 (AH/EH/DH 36 material are grades having 79,000~90,000 PSI and specifically used in ship building and marine industry), the main constraint was to get welding procedures and welders approved by the American Bureau of Shipping (ABS). With a delivery constraint of six months, about 35 welders were qualified for plate and piping material with ABS for three types of material grades AH/EH/DH 36 material ranging from 3 mm to any higher WINTER 2011 Mian Omer Farooq thickness. All fabrication activities from material marking until final inspection were witnessed and recorded by the client and owner company as well. Specialized painting procedures had to be followed according to marine standards for tough operational ambient conditions as implemented by Seajacks. Metal surfaces had to be cleaned before painting with 220 bar water jet followed by salt and profile tests. Finally, the moment came when HMW made history, with the accomplishment of Descon's first ever 'off-shore fabrication job', by delivering all the four Spudcans at the end of May 2011 within the crammed schedule of 6 months and after passing stringent quality tests and inspection procedures preset by American Bureau of Shipping (ABS), our valued client Lamprell Plc and owner company Seajacks. By undertaking this challenge, HMW now stands qualified for marine grade material which is a prerequisite for marine works. This job has paved our way ahead for new opportunities in future marine projects. 05 DESCON NEWS WINTER 2011 Success Story Pak American Fertilizer Plant Pak American Fertilizer Plant is located at Iskanderabad, Punjab, Pakistan. The company operates an Ammonia/Urea fertilizer complex. The plant had the capacity of producing 600 MTPD ammonia and 1,050 MTPD prilled urea which has now augmented to 800 MTPD ammonia and 1,450 MTPD of prilled urea. The company planned to enhance the capacity of both the plants to 135% of their nameplate capacity. The award of ammonia and urea plant revamp project was a challenging task entrusted to plant services department. The work included field fabrication, assembly, installation, erection, inspection, testing and commissioning of the new equipment. The job was planned initially for 35 days with round-the-clock working. Due to proper planning, the plant services team was able to commission the plant within the stipulated time. A work force of 1,550 was deployed and the total man-hours used for the project were above 4,00,000 with zero LTI. The entire project was on a fast pace with a tough completion schedule which required a great concentration by all the on-site departments involved. The real and positive team efforts were put together by Planning, HSE, QA/QC, Execution, Commercial and Administration departments. 06 Hannan Khalid Revamp Activities 1. Reforming Area Tubes replacement in primary reformer Replacement of all auxiliaries in waste heat boiler 2. Banfield Solution Area New LP flash column was erected. 300 tons crane was used in ringer configuration. Replacement of catalyst packings of absorber and stripper Complete piping modification 3. Compressor Section Replacement of CO2 compressor Air Compressor Synthesis Gas Compressor 13 different pumps 4. Total 40 different equipment, weighing 500 tons installed. 5. Modification done for the existing equipment as per new design and technical requirements. 6. Total 49,000 ID of the piping works for ammonia and urea plant executed. Materials like carbon-steel, stainless steel, duplex and alloy used. 7. More than 100 tons of steel structure was fabricated and erected. 8. Electrical and instrumentation works for the entire revamp. 9. Heavy rigging and lifting involved the use of 450 tons, 300 tons and 210 tons cranes for installation of different equipment. DESCON NEWS Success Story Fatima Fertilizer NP Project Fatima Fertilizer Limited has been an important client for Descon. The main scope was to complete the 1,200 tons per day Nitro Phosphate (NP) plant having 480 stationary and rotary equipment including more than 100,000 dia-inches of piping, 1,000 tons of steel structure, 1,600 tons equipment within a time frame of nine months only. Descon achieved the targets on time and safely due to the commitment of its team. Besides erection of the highly complex equipment on up to 68 meter high prilling tower, refrigeration section of state-of-the-art compressors comprising of 32 tons weight was also a challenge. The team worked hard to come up to the client's expectations and managed to install more than 200 rotary equipment within the due timeline. This part was critical to start off the subsequent activities of mechanical and structural erection. The unique feature of this project was that it was designed on the latest specifications and most of the equipment including filter press and lime drying unit, centrifuges was introduced for the first time. WINTER 2011 Shahid Chaudhry The project was successfully commissioned in August 2010 and test run started in September 2010. Initially the efficiency was around 60% for a period of two to three months, but now the plant has achieved full efficiency. Descon also completed 2.2 million man-hours without LTI. The project has met the highest safety records owing to the untiring efforts of the team. The client has awarded a trophy for being the best HSE performer. 07 DESCON NEWS WINTER 2011 Success Story Wind Tower Manufacturing Project The current energy crisis and high prices of fuels have forced Pakistan to invest in renewable energy resources to meet an ever growing demand. This led to the private sector's interest in switching to wind energy. As Descon is the only company in Pakistan with the expertise and specialized hardware to carry out such a unique project; it became the first choice for clients throughout Pakistan. The first project in this sector was awarded to Descon on EPC basis by FFC Energy limited in Jhimpir, Sindh, Pakistan. Other major investors like Fauji Foundation, Lucky group and Sapphire group have also inked their interest in working with Descon for their future projects in Jhimpir and Gharo wind corridors. On Friday June 10, 2011, Mr. Faisal Dawood (Head Manufacturing - BA) inaugurated the first wind tower masts production facility in Pakistan by switching on the CNC cutting machine installed at Karachi Manufacturing Works (KMW). As a pioneer in manufacturing wind tower masts in Pakistan, Descon will deliver these to the 49.5 MW Wind Power project of FFCEL. A total of 33 wind towers are to be fabricated for the project. Today, Descon is recognized as the industry leader and slated to become a recognized wind tower manufacturer. Wind Towers’ manufacturing at Karachi Manufacturing Works 08 Kashif Qurban DESCON NEWS Success Story WINTER 2011 Partners in Progress Descon congratulates Government of Pakistan on the inauguration of Mangla Dam Raising Project 09 DESCON NEWS WINTER 2011 DIPL Descon Integrated Projects Ltd. Gohar Afzal Ranolia Hydro Power Project A 1.4 km long power channel - 1 across the hill slopes on the left side of Ranolia Khwar After contributing its share in the development of quite a few hydel projects in Pakistan, for the first time in its history, now Descon has been awarded the Ranolia Hydel project on EPC basis by Sarhad Hydel Development Organization (SHYDO). The project, located in Kohistan district, KPK, Pakistan will add 17 MW to the grid. A 830 meter siphon across Ranolia Khwar to convey water to the power channel 2 EPC award of this hydropower project marks Descon’s most significant achievement to date in its contribution towards developing Pakistan’s hydel sector. Ranolia Hydro Power Project (RHPP) is planned to generate approximately 17 MW of electricity. In summer, the plant will supply electricity 24 hours per day and in winter, when the water flow is reduced, electricity will be supplied for four hours in the evening. A 1.25 km long power headrace channel on the right side of Ranolia Khwar ending in inlet pond with a spillway. A 684 meter penstock from inlet pond to powerhouse on right bank of Dubair Khwar A double storey powerhouse with two pelton turbines and two generators RHPP connects to 132 kV grid through double circuit transmission line. Barzan Onshore Project JGC Corporation of Japan has sub-contracted a part of Barzan project's design engineering work to Descon Integrated Projects Limited. The work consists of horizontally split work packages for process, piping, civil and I&C departments that amount to about 65,000 man-hours. Additionally, JGC has also offered some positions to DIPL in their Yokohama operational center. Barzan onshore project facilities are owned by RasGas that are located in Ras Laffan area of Qatar. The project consists of two trains of 950 mmscfd each. In addition, the plant will produce ethane, LPG, condensate and sulfur. Uch II Power (Pvt) Limited Uch II Power (Pvt) Limited intends to build, own and operate a 400MW power plant within the premises of the existing The proposed power plant has the following components: A tyrolean weir and intake structure on the left bank of Ranolia Khwar. An intake channel (80 m), gravel pin, sand trap and spillway. 10 Uch power station located at Balochistan, Pakistan. This project is owned by International Power and EPC work is subcontracted to a consortium of Hyundai Engineering Company and DIPL. DIPL The scope in design, procurement and construction, commissioning, testing and defects maintenance of this project includes: Two frame-9 Gas Turbine Generating Packages supplied by General Electric Two Heat Recovery Steam Generators One Steam Turbine Generator Package DESCON NEWS WINTER 2011 Ammonia Flare Project Ruwais Fertilizer Industries (FERTIL) engaged the services of Descon as EPC contractor to carr y out Engineering, Procurement, Construction and Commissioning of Ammonia Flare System. Successful completion of this project will strengthen our presence in UAE EPC mar ket. Step-up transformers Young Engineering Leaders' Award Water storage and treatment, CW & makeup systems, fuel gas system, HSD storage & transfer system and waste water management system In an effort to locate and recognize young bright engineers in Pakistan, the Engineering Review (foremost Pakistani newspaper in Engineering circle) organized ‘Young Engineering Leaders Conference’ at NED Karachi on July 09, 2011. Main buildings including administration, centralized control room, electrical equipment, workshop and stores, security/gate house, water treatment building and laboratory Fire detection & protection system and HVAC Wind Power Project Descon and Nordex, Singapore recently inked EPC Agreements for five Wind Power projects of 50 MW each. These projects include: Fauji Foundation I (Formerly Beacon Energy Limited) Fauji Foundation II (Formerly Green Power) Younas Energy Limited Gul Ahmed Wind Power Project Metro Power Company Limited Engineering professionals from various sectors across the country were approached by Engineering Review Board and their professional accomplishments and future ambitions were critically evaluated by the jury for the 'Young Engineering Leaders' Award'. It is a matter of pride for Descon Integrated Projects Limited that four of its employees namely, Mrs. Samina Wasim, Mr. Abdus Samad, Mr. Sohail Afzal and Mr. Abdul Munnan Butt were acknowledged for their competence and value addition in various engineering sectors. The winners were honored with the following awards: The scope of work finalized includes EPC of Balance of Plant (BOP) including manufacturing of wind towers at Descon’s shop in Karachi. The towers manufacturing facility has been developed on international standards with a state-of the-art technology. Thamama 'B' Gas Lift Project Descon has been awarded the Bab Thamama 'B' gas lift pilot project for two wells on EPC basis by Adco. This is our first 10 km underground pipeline project entailing a challenging task for our engineering and EPC team. The completion of this project would provide us the strategic edge to capture more pipeline projects of similar nature. 2nd Position: Certificate of Merit: Certificate of Excellence: : : : Mr. Sohail Afzal Mr. Abdus Samad Mrs. Samina Wasim & Abdul Munnan Butt Corporate Social Responsibility To support Descon's lower tier employees and other needy people around us, DIPL’s management has initiated a campaign called EHSAS. The primary objective of this campaign is to give donations to the deserving people on monthly basis with an aim to provide everyone a chance to enjoy at least the basic necessities of life. This Ramadan, EHSAS distributed food packets containing basic items for sehri and iftari to the needy. 11 DESCON NEWS WINTER 2011 UAE United Arab Emirates Mirfa Air Separation Unit The aftermath of twentieth century ushered a quantum leap in the energy demand for the ever developing world at large. Earlier, hydrocarbons were merely utilized to meet only the energy requirement but as technology developed, the thirst for energy led to newer technologies to extract more or calorific value from each unit of hydro carbon. The wells after a passage of time get depleted, however there are still reserves available to be extracted from the reservoirs. There have been various technologies to further extract gas from these pressure depleted wells as the injecting of steam, methane gas, etc, the latest one is to inject an inert gas. Nitrogen is not only chemically inert thus safe from any reactions but also does not need any feedstock for its production as it is abundantly available in the air. The construction of the Air Separation plant at Mirfa having the latest state-of-the-art technology from Linde has been undertaken by Descon as the overall contractor of the entire plant, having constructed the entire civil, mechanical, electrical, instrumentation and HVAC scope of work. The project was completed by a workforce of over 2,000 in 4.5 million man-hours without any Loss Time Incident. These are impressive statistics as the Mirfa project right from its inception has been under sharp focus. The Mirfa Air Separation Plant consisting of two identical trains went into full production of 660,000 Nm3/hr at 40 bar and purity of <10ppm oxygen in July 2011, well within its scheduled completion time. The nitrogen produced is transported through a cross country pipeline to Habshan where it is grouted into Adnoc's gas fields. The natural gas presently used for this purpose is thus used for energy 12 generation. This is a decisive factor as the skyrocketing growth in the UAE has also drastically increased energy consumption. Linde Engineering and Gasco are joint partners in Elixier, the owner of the Mirfa plant has given the go ahead for construction of two similar additional trains for nitrogen production through the process of air separation in the near future. Having successfully completed the first two trains on schedule, Quality and above all HSE parameters, Descon is thus well-poised to take up this challenge. (Qaiser Naqvi) Borouge P3A Project Taking the cue from, ‘Nothing Succeeds like Success’, Descon’s involvement with Borouge has been long lasting! Ever since its establishment, Descon has been instrumental in accomplishing several projects for Borouge. Established in 1998, Borouge as a joint venture between the Abu Dhabi National Oil Company (Adnoc) and Austria-based Borealis, is a leading provider of chemical and innovative plastic solutions. Having tripled its annual production capacity to 2 million tons in 2010, Borouge will have an additional 2.5 million tons per year production by mid 2014. In June 2010, a major contract was awarded to a joint venture between Italian contractor Tecnimont (Maire Tecnimont Group) and Samsung Engineering to carry out construction work on Borouge 3 Expansion project. The EPC lump sum turnkey contract, scheduled to be completed at the beginning of 2014, covers the multiple polyolefin units package and the low density polyethylene package. Descon having an impressive track record with Borouge has now been awarded mechanical works for P3-A project of around 4.3 million man-hours. The scope of work consists of UAE fabrication and erection of over 600,000 dia-inches piping, 12,500 tons of steel structure and 12,000 tons of equipment erection including heavy lifts along with allied painting, insulation, cladding works and ware house services. Descon commenced direct works at P3-A project in August 2011 by steel structure erection and achieved its target on schedule. As the project completion date is May 2013, presently work is ongoing on site facilities, offices, workers’ lunch shed, mosque, lay down yard, etc. Descon project team comprises of the same experienced team who has recently completed Mirfa. This team's motivation is driven by Borouge's endeavor to become the world's largest integrated polyolefins plant. (Qaiser Naqvi) Burj Khalifa Burj Khalifa, formerly known as Burj Dubai, is a skyscraper in Dubai, United Arab Emirates and is currently the tallest structure ever built, at 828 m (2,717 ft). DESCON NEWS WINTER 2011 master plan of electricity networks, which has been developed in order to support this world's tallest building's energy sources. These counter sources of electricity have been handed over to DEWA for further distribution and utilization. Siemens as a part of the main contractor has awarded the electrical installation wor ks of these substations. The project comprises of two 132KV substations. The substations include BRES substation that supplies power to Burj Khalifa residential area and OTWN substation that supplies power to old town hotels, apartments and world's biggest Dubai shopping mall. These projects have been successfully completed within the planned duration. (Arshad Sajjad Khan) Achieved Another LTI Free Job Descon completed another LTI free, 400/132 kV GIS substation at EPC Park Dubai with the client Mitsubishi and the owner DEWA. The project was strategically very important especially due to the very stringent timeline and Descon again proved Emaar, the main contractor of the project, awarded the EPC works for the two substations to Siemens Engineering.Whereas the electrical works for the substation were subcontracted to Descon Engineering Ltd. its capability and commitment to accomplish its projects with zero LTI. Mitsubishi's corporate management participated in the HSE Award ceremony and appreciated Descon's team for completing the project in due time. They also admired the adopted safety practices and quality of the job executed. This is yet another significant milestone in E&I projects for Descon. (Arshad Sajjad Khan) Shah Gas Development Project These 132/11KV substations are a part of the extensive developments initiated by DEWA. Its cornerstone is the Descon was awarded the civil, E&I and mechanical construction scope of work for Package-2, East of Shah Gas Development project. The project's duration is 32 months starting June 2011 to Januar y 2014 with 6.95 million man-hours. Shah Gas Development project is being built on a new gas field which contains very high sulphur content (23%). This project has 10 packages, from gas gathering to sulphur handling facility at Ruwais. A new company, Al Hosn Gas, has been raised to build and operate this plant and allied operations. 13 DESCON NEWS WINTER 2011 The sulphur transport will be done through a newly-built rail system by Etihad Rail which will connect Shah-Habshan-Ruwais and transport 20,000 tons per day of granulated sulphur from Shah and Habshan plants. (Mirza Zafar Iqbal) UAE onshore packages involve the construction of a gas processing plant, offsite and utilities package, 4th NGL train and LPG storage tanks. The offshore package involves the construction of offshore platforms at Umm Shaif and gas transfer pipeline to Das Island. Gas will be initially processed at Umm Shaif, then sent to Das Island and later to Habshan and Ruwais facilities. EPC contract for the gas processing plant was awarded to JV of Japan's JGC Corporation and Italy’s Maire Tecnimont. EPC Package-2 It consists of main process plant, which is the biggest of all packages and has been divided into three, out of which Package-2 East has been awarded to Descon. The scope includes civil, mechanical and E&I wor ks up to pre-commissioning stage. The project duration is 32 months with 6.95 million man-hours. (Mirza Zafar Iqbal) Package-2 East Construction Works The project was awarded in February, 2011. Camp establishment was completed in May, 2011 and complete manpower was shifted from Liwa to our camp in June, 2011. This is worth noting that Descon was the first company to move its manpower to camp at this project. Civil works for the site started in May, 2011. Descon was first to start direct works at this project. Alongside, the structure erection also began in September 2011. (Mirza Zafar Iqbal) The new Habshan complex will have an output of 900 mm cf/d of sales gas, 12,000 t/d of NGL and 5,000 t/d of liquid sulphur, after having treated about 1bcf/d of raw gas. JGC-Tecnimont JV awarded Descon part of the processing plant project, with 8.6 million man-hours work and mechanical completion in November 2012 and pre-commissioning by May 2013. Descon’s scope includes general construction part of civil, mechanical and E&I works besides EPC part of buildings and storage tanks. It is worth mentioning that Descon is ahead of schedule on this challenging project. (M. Yousaf) Piping Work at Takreer RRE with Daewoo E&C The Abu Dhabi Oil Refining Company, Takreer signed agreements with four Korean companies to expand its oil refining capacity in Ruwais. The Ruwais Refinery Expansion Project (RRE) will increase Takreer's refining capacity of crude oil by 417,000 bpd and nearly double its production of transportation fuels, gasoline, jets and diesel. Daewoo E&C awarded Descon the major scope of piping works. Daewoo is one of the four major EPC contractors of Takreer's RRE project and has been awarded the EPC works for package 4, which encompasses tankage and associated interconnecting piping. Integrated Gas Development To keep abreast of its spiralling energy demand situation, Abu Dhabi has initiated Integrated Gas Development (IGD). The project includes onshore and offshore packages. The Our scope includes approximately 800,000 dia-inches of piping, 1,500 metric tons of structural and 650 metric tons of rotary and static equipment scheduled to be completed by April 13, 2013. (Mir Aslam Khan) 14 UAE DESCON NEWS HSE & QA/QC Activities AUH-HSE Newsletter AUH HSE has published a newsletter with an idea to highlight HSE activities of different projects. It also provides a platform to the project managers to share their ideas with each other. World Environment Day World Environment Day was celebrated at all project sites. Bilingual HSE flyer was designed and displayed at all project sites. Special toolbox talk and training sessions were arranged WINTER 2011 M.K. Mohanan on the occasion. The main event was arranged at AMW where different plants were planted to show the commitment of top management for the protection of environment. HSE Flyers prepared on World Environment Day designed by AUH HSE External Fire Fighting Training AUH HSE arranged a fire fighting training for the AUH office staff. The training was provided by renowned institute, Emirates Technical & Safety Development Centre (ETSDC). It was a day-long training comprising of theoretical and practical sessions. Achieved Milestones 6 million man-hours without LTI at IGD 5 Habshan Plant 3 million man-hours without LTI at AMW HSE In-charges Meeting Work Manager, Mr. Mumtaz Ali Khan is planting a plant on the occasion of World Environment Day To promote departmental cooperation, the project HSE has started monthly coordination meetings of In-charges at UAE BA level where participants share their views about different challenges faced. 15 DESCON NEWS WINTER 2011 Qatar QBA Umer Khan RasGas Site Operations Descon recently provided its turnaround services during trains 3 & 4 shutdown of RasGas, as a part of its 'Upgrade of trains 3, 4, 5 & AKG-1 Flare Piping System project', awarded by Chiyoda Almana Engineering Limited (CAEL) on behalf of RasGas. The project involved a total of 60,000 cubic meters of scaffolding and numerous tie-ins to be carried out during the shutdown. The result was commendable based on which RasGas handed Descon a memento of a 'Dhow Boat', which in other words clearly depicts Descon's stance of 'sailing ahead'. CAEL also presented a certificate on the completion of 2 million man-hours without LTI on various projects being done at RasGas. Platform installation on stacks Stop Cards writing by all individuals involved at PMP is one of the prominent key features of the project. Recently, QatarGas and TCJV along with all the subcontractors held a function to celebrate the completion of 20,000 stop cards. Descon's employees contributed a total of 6,994 Stop Cards which won them the 1st place during the event. Also, the 1st position for HSE poster competition was won by a Descon employee. Training & Development On May 23, 2011, QBA invited a leadership expert, Dr. Tommy Weir, for a brief session on ‘Leadership Success’. Dr. Tommy is regarded as an authority on leadership in rapidly growing and emerging markets like Qatar and a renowned speaker, advisor and author on the subject of strategic leadership. Dhow Boat Memento QatarGas Long Term Shutdown As a part of the 5 + 2 years long term shutdown contract with QatarGas, Descon executed 63,000 LTI free man-hours during the 21 days of planned shutdown of train 1. The planning and execution was coordinated so well that Descon was able to complete the shutdown 24 hours earlier than planned. Plateau Maintenance Project, QatarGas Dr. Tommy receiving a memento After the award of the QG-PMP project in September 2010, the first milestone achieved was the QG-PMP 2011 shutdown which was accomplished one day ahead of schedule. TSF and camp for QG-PMP is already 90% complete and the project team is getting ready for the mobilization and to start the construction activities. 16 In another event, to reiterate QBA management's focus on leadership development, a one-day workshop was arranged for the first tier in-charges. It was spearheaded by Ms. Hellen Tucker, who is a Principal Consultant for ‘Institute of Development and Training (IODT)’, UK. KBA Kuwait KCC 5500 TPD Line - II Expansion Project The erection phase of the project involves electro-mechanical works which comprise of almost 7,800 tons of structural steel, 15,000 tons of mechanical equipment and cover a wide scope of multidisciplinary electrical and instrumentation jobs with 2.8 million man-hours. Kuwait BA is also involved in carrying out significant work related to refractory, insulation, cladding, start-up and commissioning of different equipment of the plant. The warehouse is playing an imperative role to encompass smooth and rapid transition of material flow, systematic retrieval, storage and ensuring dedicated material resource planning. DESCON NEWS WINTER 2011 Pervaiz Iqbal The initial phase of KCC Cement Plant extension project involved fabrication of roughly 7,000 tons of steel structure and 4,500 tons of plate work. To meet the project deadline and deliver quality product it was strategically divided between Hamriyah Manufacturing Works (HMW) and Kuwait Business Area (KBA). Through excellent teamwork and acute coordination most of the milestones were met with success, whether it be detailing, prioritizing deliverables, technical assistance, material sourcing or any other issue pertaining to supply and fabrication. Approximately 2,000 tons of additional scope has been awarded which itself is a manifestation of client satisfaction. Till this day, around 10,500 tons of fabricated material has been delivered at site and we are committed to successfully accomplishing all tasks assigned by maintaining our trademark quality standards and uncompromised work ethics. Kuwait BA has subcontracted works in Kuwait region which includes fabrication and erection. The department monitors the subcontracting activities from initial ITB preparation to closing of contracts. Throughout the execution, Descon's personnel keep a close eye on proceedings thus to ensure that the same level of quality and excellence is maintained in every aspect. Successful erection of shells at raw mills, cyclones, calciners and steel structural erection at pre-heater, kiln shell and supports installation, bag filters installation at EGC and bypass etc are the major to-date project milestones. In its operational profile, Descon has also supplemented and deployed tower and mobile cranes at various plant areas to accomplish complex erection work in this brown field project. Amidst the ongoing struggle which Descon has to endure in arranging work visas for skilled manpower, our team members are performing more actively for the completion of this congested and confined cement manufacturing facility. The substantial joint efforts and commitment involving planning, procurement, admin, HR, subcontracting, QA/QC and HSE division in close coordination with other associated departments has enhanced quality, focus and client satisfaction. Internal area audits, trainings and technical supports on various critical assignments including scaffolding work, safety at height, heat stress and basic fire fighting methods are the core tasks accomplished by HSE division over the course of the project. To ensure best quality standards, both in erection and fabrication phases, QA/QC has developed strategic evaluation of standard procedures. Erection work in progress at pre-heater 17 DESCON NEWS WINTER 2011 ODICO Olayan Descon Industrial Company M. Naveed Storage Tanks - Hail 2 Power Plant Al-Fanar Construction Company has shown confidence in Olayan Descon by awarding Storage Tanks of Hail 2 Power Plant - Expansion III. This project is owned by Saudi Electricity Company (SEC). Our scope involves mechanical design, supply and fabrication, site erection, testing and painting of 02 x 20,000 m3 crude oil storage tanks and it marks our first storage tanks job with Saudi Electricity Company. Bulk Liquid Chemical Terminal Project The first ever EPC project of Olayan Descon involving the liquid chemical storage and handling facility at Jubail Commercial Port is progressing well and its first phase is near completion. The first phase involves complete civil, mechanical, E & I works of the entire facility which includes 16 storage tanks. The owner of this project 'Arabian Chemical Terminal' has reinstated its confidence in Olayan Descon by also awarding the second phase of this project. Phase II involves 16 storage tanks along with all associated work. The project will augment storage capacity by 63,600M3 of different liquid chemicals.This terminal will receive, store and redeliver petroleum-based products and liquid petrochemicals. Arabian Chemical Terminal (ACT), based in Jeddah, Saudi Arabia, operates a huge network of commercial tank farm for petrochemicals in KFIP in Yanbu, Saudi Arabia since 1987. Rabigh Power Plant - 2 Olayan Descon has been awarded with manufacturing jobs for the design, supply and fabrication of pressure vessels, heat exchangers and deareators for Rabigh Power Plant-2. ODICO is wor king with Doosan Heavy Industries, Korea. Rabigh Refining & Petrochemical The major shutdown of Petro-Rabigh Petrochemical Complex has been completed which comprised of 735,000 man-hours with a manpower of 2,450. The total duration of the project was 40 days and it was the first major shutdown of this petrochemical complex. Sahara Project Sahara and Ma'aden Petrochemical Company awarded the project of caustic soda & EDC storage and handling facility. Sahara petrochemicals, in consor tium with Ma'aden are expanding its facilities in Jubail, KSA to produce caustic soda and EDC. The unit construction is in progress by Daelim, a Korean company, who is the EPC contractor of the project. The scope of work includes design, supply and construction of two pipelines for caustic soda and EDC from Sahara to 18 Sabtank at Jubail Port, 02 x 17,000 Cu.M double walled storage tanks for each product and 16” pipelines extending from each tank to delivery berth with independent control and monitoring system at port premises. Emergency Power Back-up System Upgradation at Sabtank, KFIP Jubail Olayan Descon has won an EPC contract from Sabtank, a subsidiary company of Sabic, which handles storage and material handling facility at port. This project is for the 'Electrical Emergency Power Back-up System Up gradation' at Sabtank, Jubail, King Fahad Industrial Port, Jubail. The scope of work comprises of design, engineering, construction, testing and commissioning works at ten different areas of Sabtank which are Petrokemya, Sadaf, Sharq, Ar-razi, Kemya, Ibn-zahr, Albayroni, Gulf Farabi, S-Chem, Ibn-al-baytar. Samref Clean Fuel Oil Project, Yanbu Olayan Descon has been awarded the major part of equipment design, fabrication and supply of static equipment of Clean Fuel Oil project. The total weight of the equipment under supply contract is approximately 2,000 tons to be delivered in one year. Worley Parsons is the main EPC contractor of Clean Fuel Oil project. Cold Box Revamp Project Linde AG is an EPC contractor for revamping of cold box at Sabic, Petrokemya. The project objective is to enhance plant capacity by replacing the Old Cold Box. The construction work of the project was awarded in August. The project involves detailed design, fabrication, installation of structure for interconnecting piping (SIP) at the workshop and necessary E&I activities leading to successful completion of the job. The project is scheduled for a period of eight months starting from October, 2011 whereas system tie-ins will be accomplished in May 2012 during plant shutdown turn around. PDIL DESCON NEWS Presson Descon International Ltd. Polish Oil & Gas Company Awarded Basic Engineering Study to PDIL Polish Oil & Gas Company (POGC) intends to setup an Early Well Testing Facility at Kirthar, in district Dadu, Sindh. For the evaluation of various scenarios, proposed process scheme, equipment design basis and specifications, POGC awarded the Basic Engineering Study to PDIL. The draft report has been submitted and the final study would be concluded soon. De-bottlenecking Study of PPL Gas Processing Plant & Modification of 3 Phase Separator at PPL Mazarani Gas Processing Plant PPL (Pakistan Petroleum Ltd.) has a 10 mmscfd gas processing plant at Mazarani field, which was carried out by PDIL in 2002-2003. The inlet gas composition changed with the passage of time and quality of processed gas was not possible to be maintained with the standard that was agreed with the Sui Southern Gas Co. PPL for the purpose of finding a rational solution of the problem, awarded the job to PDIL to carry out an engineering study and modifications in the third Phase Separator and other associated facilities so that standard of the processed gas could be guaranteed afterwards. The project was completed within 6 weeks and the performance test was successfully conducted. WINTER 2011 Syed Fareed Business in Qatar PDIL successfully carried out two modification jobs with Descon Qatar for QatarGas. It provided technical support services along with necessary site supervision. The scope of work included cable sizing, layout engineering for the installation of aboveground cables between QatarGas condensate storage and condensate jetty & storm water pump pit modification. PDIL Participation in the 9th Pakistan Oil, Gas & Energy Exhibition The 9th Pakistan Oil, Gas and Energy Exhibition & Conference (POGEE) was held from May 17 to May 19, 2011, at the Expo Center, Karachi. Pegasus Consultancy (Pvt.) Ltd organized the event which was attended by the international delegates of the Oil & Gas industry. The CEO Engineering Development Board, Pakistan Mr. Aitezaz Niazi, the chief guest at this occasion inaugurated the proceedings. As a brand building effort, PDIL participated in the event through impressive posters and banners on different locations of exhibition halls and also distributed promotional material to the delegates and visitors. PDIL was among the selected few companies, who received a shield in lieu of extending continuous support to the energy events of Pakistan. The efforts were highly appreciated by the management committee. 19 DESCON NEWS WINTER 2011 PDIL Awarded with Annual Environmental Excellence Award 2011 for Second Consecutive Year PDIL Environment and Community’s well being which is depicted through its HSE policy. PDIL Team Successfully Accomplished SAP® Go-Live on July 01, 2011 PDIL SAP® implementation team along with the contribution and efforts of Descon ICT team, successfully accomplished the SAP implementation and Go-Live target on July 01, 2011. Since it is a new system, the company is slowly and steadily aligning itself with the new requirements. PDIL continues to update and improve the master data, which is the key element for the smooth functioning of the SAP system. Weekly progress review meetings are conducted for resolving the operational issues being faced. All problems are raised through a dedicated SOLMAN system, which is intended to maintain the record of problems and changes being done in the system. It is a matter of great pride for PDIL that the company for the second consecutive year has been awarded with the prestigious Annual Environmental Excellence Award 2011. A total of 148 companies participated in it. The jury was headed by renowned Scientist, Dr. Sami-uz-Zaman. A ceremony took place at Marriot Hotel, Karachi on July 29, 2011, which was organized by National Forum on Environment and Health (NFEH) Pakistan having affiliation with United Nations Environment Program (UNEP) and supported by Ministry of Environment, Government of Pakistan, as well as Ministry of Environment, Government of Sindh. Minister for Electric Power, Ms. Shazia Marri and Chairman Intellectual Property Rights and former Federal Minister Environment, Hameedullah Jan Afridi presided over the event. The AEEA award has been instituted to recognize and promote the organizations which make an outstanding contribution to sustainable development. PDIL has been selected on the basis of its contribution to environment friendly activities both within and outside its business spectrum by bringing change in its approach towards environmental and community related causes. PDIL follows a holistic approach towards Health, Safety, HR Development Activities While PDIL successfully achieved the milestone of SAP® Go-Live on July 01, 2011, PDIL HCM team started conducting in-house trainings on Organizational Change Management in order to develop a conducive environment for the acceptability and adaptability with the new systems and procedures. In this regard, HCMD conducted two training sessions to educate people about SAP® usage and requirements. HSE trainings have also star ted for this year, which will encourage the employees to maintain adherence to the HSE policies and procedures; while this will also help in promoting a positive culture of HSE compliance. The first session including introduction to Safe Behavior and PDIL HSE Management System as initial modules of HSE trainings for all has been very successful. HCM team also conducted a Focus Group on Mentoring at PDIL, which was a first of its kind and has been very successful in terms of its outcomes and affects. The Mentoring Scheme was adopted in 2010 as well. 20 DESCON NEWS Cover Story Evolution of Engineering History The origins of engineering design in Descon date back to the mid 1980’s. Descon at that time aspired to be an INTEGRATED engineering company. This concept, which translates into One-Stop Shop in layman's terms, could not work in the absence of an engineering faculty. The pioneer department was named as PEP (Process Engineering & Piping). It was located in a building opposite Descon's main office on Davis Road and operated with a staff of about 30 people. With leaders like Mr. Mohsin Ali and Mr. Ilyas A. Sajjad, this section carried out engineering design for many domestic projects. ICI Pakistan was perhaps the biggest client in those days that featured arrays of precision drawing boards, mylars, ammonia printing and most remarkably, a “clean room” for two computers when Dr. Sarmad Malik thought of CADing drawings. The experience profile and self-confidence kept growing with projects like Lucky Goldstar DOP Plant and Rafhan Expansion & Wetmill Automation. The whole ball game for Engineering changed in late 1995 when Fauji Jordan Fertilizer project was awarded to a consortium where Descon was one of the main venture partners. Sheer design work volume of FJFC project Abdus Samad Joined Descon: September 1992 Initial Position: Process Design Engineer Current Position: Head Proposals Proudest Moment: The day Descon Oxychem Plant started manufacturing H2O2 where I contributed as Engineering & Technical Manager and also being part of the team who made Descon's first EPC Proposal Toughest Challenge: - On-time successful completion of Descon Oxychem Plant - To contribute in DIPL’s vision of being a leading EPC company in the region Which one word or phrase would you use to sum-up Descon's journey from then to now? Marvelous necessitated further expansion and consolidation of the design pool. Engineering Services (ES) moved to a WINTER 2011 Faisal Zaheer two-storey purpose-built office at LMW site on Ferozepur Road in the first half of 1996. Other significant changes at that time were full introduction of CAD systems, amalgamation of Power Engineering Department into ES and merger of CAES section with Piping section. ES peaked to 350 staff members during late 1990’s. Following FJFC project, ES came across EPC projects ….new terminology and a new generation in project formation … to deal with. Engro LPG Storage, Engro VCM Storage and OMV Miano Development projects were the main EPC achievements. In same days, ES successfully accomplished two pure engineering jobs, which were awarded by Japanese E&C contractors: ARL Expansion from Mitsui E&C and PARCO MCR from JGC Corporation. Oil & gas prices touched their historical lowest in 1999. With this bleak economic outlook and recent success on PARCO project, Descon and JGC decided to join hands to establish a joint venture engineering company which would provide world-class services to both parent companies in a very competitive market place. J-Tech (Pvt.) Limited started operation in June-2000 with a strength of around 250 staff members. JGC deputed a group of five staff members in resident cadre to 21 DESCON NEWS WINTER 2011 Cover Story Milestones – 2000 JGC-Descon formed, a JV with JGC Japan – 2002 Detailed Engineering of Atyrau Refinery Retrofit – 2004 Establishment of Karachi Engineering office – 2004 Detailed Engineering of Dolphin Project – 2005 Detailed Engineering of Dung Quat Refinery, Vietnam – – – – – – 22 operate the new JV Company; rest of management positions were taken by 2007 First major EPC contract in UAE: FERTIL 2008 BP Design house, 3 years GESA contract 2010 First 50 MW Wind Power Project 2010 Descon Integrated Projects Limited formed 2011 Award of UCH II Project on EPC basis 2011 Successful commissioning of 225 MW Bhikki Power Plant Asim Aziz Joined Descon: 17th May 1980 Initial Position: Project Manager & Acting Head of Project Department Current Position: Head Management Development Center Proudest Moment: Completion of Detailed Engineering of the Banagas CS-7 Project, the first vertically split job undertaken by J-TECH/DIPL Toughest Challenge: Handling major and frequent changes in scope of work while still meeting deadlines Which one word or phrase would you use to sum-up Descon's journey from then to now? Amazing journey towards EPC capability! staff from former ES. The most salient operational feature of the early days of company was an extensive training program that helped staff to learn international-standard project execution practices. J-Tech was renamed as JGC-Descon in 2004. The same year, it established its second operational center in Karachi. In March 2010, Descon Engineering Limited acquired complete ownership of JGC-Descon by purchasing JGC's share-holding in the company. Following this acquisition, the organization and process assets of the company were merged with same of Descon's EPC business unit. The new entity was named as Descon Integrated Projects (Private) Limited [DIPL] and is chartered to operate as an independent EPC company. Services’ Portfolio DIPL has executed engineering work exceeding four million man-hours since June-2000. It operates from its modern 65,000 square feet custom-built design facility situated at Ferozepur Road, Lahore and from its office situated at Shahrah-e-Faisal, Karachi. An integrated, multi-disciplinary team of over 650 DESCON NEWS Cover Story Syed Wasim Joined Descon: 3rd October 1991 Initial Position: Assistant Engineer Current Position: DGM (Head of Department - Piping) Proudest Moment When I was selected as Department Head Piping Toughest Challenge: Working on the Pipeline Design project for OMV in 1998 Which one word or phrase would you use to sum-up Descon's journey from then to now? Here 'teamwork divides the task and multiplies the success' engineers, designers, CADD specialists and project management personnel undertake the most challenging and complex engineering tasks. DIPL offers comprehensive, integrated Engineering, Procurement and Construction services. With an approximate capacity of 800,000 engineering man-hours per year at its disposal, it is the only company operating out of Pakistan which provides such services at this scale to oil and gas, petrochemicals, refining, chemicals, power and fertilizer sectors in Pakistan as well as overseas. DIPL has experience in all phases of project development, including: Screening and technical feasibility studies Project safety reviews, Hazard studies, SIL audits, design evaluations and verifications Conceptual design, process specification, project specification; including front-end engineering packages, cost estimates etc. Basic engineering packages - where required on the basis of third party design and licensor technologies Engineering analysis including simulation, design and optimization Multi-discipline, detailed design and engineering; including design specification and documentation for WINTER 2011 complete plant facilities, cost estimates, etc. Preparation of contracts and bid documents; for execution of projects on EPCC, build-own-operate, plant rental, basis etc. Project management; including planning, scheduling, cost control and progress monitoring Procurement; including procurement management and procurement services Construction management and supervision Client engineering services; including field engineering services Commissioning; including commissioning management, commissioning supervision and operator training. Overseas, DIPL engineers have contributed to major world-class projects through JGC and Descon; a partial list of these projects include Saudi Aramco's Manifa Program in Saudi Arabia, Sonatrach's Gassi Touil Project in Algeria, Shell's Pearl GTL Project in Qatar, Petro-Vietnam's DQR Refinery Project in Vietnam, Dolphin Gas Plant Project in Qatar, Petro Rabigh's Olefins Plant 23 DESCON NEWS WINTER 2011 Project in Saudi Arabia, Exxon Mobil's BRT Expansion Project in Nigeria, KazMunaiGas' Atyrau Refinery Revamp Project in Kazakstan, Jubail Chevron Phillips' Ethylene Plant Project in Saudi Arabia, Adco Bab Field Expansion Project in UAE, Centurion's El-Wastani Plant Project in Egypt, Adco's HIPPS Project in UAE, Fertil's Ammonia & Urea Plants Revamp Project in UAE, SEC's Sharourah Power Plant Project in Saudi Arabia and Banagas' Compressor Station Project in Bahrain. In Pakistan, DIPL has been a proud partner in the country's progress and its staff has engineered entire facilities, such as OMV Pakistan's Kadanwari Gas Plant expansion projects, Petronas Carigali's Rehmat Gas Plant, MOL Cover Story DIPL’s typical clients are the ones demanding high level of technical capabilities and a very high quality of service. In Pakistan, our customers include: PARCO, Pakistan Petroleum, Pakistan Refinery, OMV Pakistan, MOL Pakistan, B.V., AES, BHP Billiton Pakistan, BP Pakistan, ICI Pakistan, Pakistan PTA, Mari Gas, Engro Fertilizer, Fauji Fertilizer, Pak-American Fertilizer and Fatima Fertilizer. Overseas, DIPL has had the honor of working for well-known clients such as JGC Corporation of Japan, ADNOC group companies of UAE, SEWA of UAE, ABB Engineering Services of UK, Chemtex of USA, DAR Engineering of Saudi Arabia, ACTC of Saudi Arabia and Mechanical Contracting and Services Company of Bahrain. Product-Orientated Engineering/ Engineering Support for Manufacturing Naveed Ahmad Malik Joined Descon: February 1985 Initial Position: Assistant Supervisor Current Position: In-charge Management & Project Support Services Proudest Moment: Ranked among top 12 employees for MYK award for Devotion to Duty Toughest Challenge: Performing diversified jobs during the early years of Descon-JGC JV in addition to Management & Project Support Services Which one word or phrase would you use to sum-up Descon's journey from then to now? Remarkable achievement by continuous effort! Pakistan's Gurguri Gas Plant, MOL Pakistan's Manzalai Gas Plant, Halmore's 225 MW Combined-Cycle Bhikki Power Plant, OGDCL's Dakhni Sulfur Recovery Unit, Pakistan Petroleum's Mazarani Gas Plant and Engro Fertilizer's Carbon Dioxide Recovery Project. 24 Descon has seven manufacturing/ fabrication facilities strategically located in Pakistan and the Gulf Cooperation countries. Each shop specializes in producing a certain type of product. In general, the product range spans industrial process equipment and fabricated items and complete packages such as boilers, process skids, tanks, heat transfer equipment, cable trays and electrical panels. Our client base has grown to include owners/operators, EPC companies OEMs, OICs from Oil & Gas, Chemical & Petrochemical, Fertilizer and Power sectors to the sugar, cement and textiles sectors. To-date, Descon has provided over 134 boilers, with cumulative steam production of more than 5,000 tons per hour, over 1,100 pressure vessels (columns, drums, separators etc), 500 heat exchangers, 450 storage tanks and over 1,00,000 tons of steel structure. We are authorized to produce ASME certified equipment (A, PP, S, U and U2 stamps). Additional certifications include Samina Wasim Joined Descon 3rd October 1991 Initial Position: Assistant Engineer Current Position: Head of Department - Process Proudest Moment: Being selected to serve as Department Head Process Toughest Challenge: Convincing JGC to transfer NHDS technology to DIPL Which one word or phrase would you use to sum-up Descon's journey from then to now? A dream come true! ‘R Stamp’ issued by National Board of Boiler and Pressure vessel inspectors and CE marking (specifically for European Region). The core of Descon Manufacturing is a strong in-house design and engineering capability that exists to support proposal generation and project execution. The design and engineering team has extensive experience of working as per international industry codes, standards, on state-of-the-art and latest engineering softwares keeping in sight best practices. We have in-house capabilities to perform Process Design, Mechanical Design including Piping and E&I design related to products. In addition to the above, Descon also has technology alliances with renowned partners like, ERK of Germany for High P r e s s u r e Wa t e r Tu b e B o i l e r manufacturing and with Alera of Germany for providing vetting of firing system design of solid fuel boilers. DESCON NEWS HMW Hamriyah Manufacturing Works WINTER 2011 Mian Omar Farooq Chemical Injection Skids Stainless Steel Tanks Descon Engineering FZE has successfully manufactured another batch of six chemical injection skids for Oxy Mukhaizna project in Oman. Frames has awarded sixty-two stainless steel tanks for chemical injection skids to Descon FZE for Adco Bab Thamama project. This project was awarded to NPCC (National Petroleum Fabrication and installation of piping, SS tanks, pumps, instrumentation and electrical items were carried out at Descon Engineering FZE within due timeline, followed by on time FAT which was appreciated by Oxy and Seko. Construction Company) by Adco and NPCC awarded the supply of chemical injection skids to Frames. Tecnimont IGD Habshan Sulphur Stacks Fabrication and supply of four flare stacks and four combustion chambers by John Zink for Gasco’s Shah Gas Development Project. The project is in the execution stage and eight equipment weighing 1,100 tons will be delivered in February 2012. Descon Engineering FZE has successfully delivered all four sulphur stacks weighing 450 tons each to Tecnimont- KTI targeting the project completion date of October 2011. These four sulphur stacks, weighing 1,800 tons are for Gasco’s IGD Habshan process plant project in Abu Dhabi. Awarded Projects Seko has renewed its confidence by awarding twenty chemical injection skids for KOC, (Kuwait Oil Company) Bulk Handling project in Kuwait. These skids will be ready for dispatch in February 2012. Saipem, Italy has awarded the job for the supply of twenty pressure vessels and columns for DPC CPF Khurbet East Field in Syria. Dijla Petroleum Co is the end user. The equipment will be delivered in June 2012. GS Engineering & Construction of Korea has awarded twenty pressure vessels for Takreer, IRP (Inter refinery Pipeline) II project. Descon Engineering FZE has already worked with two Korean EPC giants, Samsung and Hyundai in the past. Stack modules loaded on barge Naphtha Splitter Column for LITWIN Thirty-five meters long Naphtha splitter column has been successfully fabricated and dispatched to Takreer, IQI (Isometric Quality Improvement) project. Technip France has awarded the project of design, fabrication and supply of storage tanks for plateau maintenance project in Qatar. First award from Technip France and overall third award from Technip group shows the strengthened relationship of Descon Engineering FZE with leading EPCs operating in the region. 25 DESCON NEWS WINTER 2011 AMW Abu Dhabi Manufacturing Works Adnan Adeel Piping Work Waste Heat Boiler by Gasco Descon’s AMW facility is performing a huge work load of piping pre-fabrication for Takreer Refinery Expansion project Package IV. Total scope of work of all on-going projects was 12,56,365 dia-inches, out of which AMW completed 4,36,334 dia-inches till Oct 2011 with a maximum of 61,000 ID in the month of June 2011. AMW is well prepared to finish the Balance Scope of Work by March 2013. This scope included all types of piping material like, CS, SS, Alloy, P11 and P91. Currently we are 28,000 ID ahead of schedule. In addition to piping, AMW has entered into a new era of equipment manufacturing. Descon has been awarded manufacturing of a Waste Heat Boiler by GASCO. Its scope includes design, material procurement, fabrication and replacement with existing WHB at Gasco Habshan. To cope up with this huge work load, Descon has established the following facilities: AMW has done structure, ducts and stack of boiler fabrication on Borouge 2 project for Macchi, Italy. On the basis of excellent performance, Macchi awarded the same job to AMW for Borouge 3 as well. The scope includes 200 tons steel structure and 400 tons ducts and stacks. Fabrication shed of 120M X 40M with 4 overhead gantry cranes with a capacity 5 to 7 tons. A PWHT furnace to meet the project requirement and schedule. This furnace is 16 meters long, 5 meters wide and 2.5 meters high. This is an electronically operated furnace and can handle 10,000 ID per month. It is 100% designed, fabricated and constructed by Descon. 11 semi-automatic welding machines, out of these there are 3 SAW and 8 FCAW machines. FCAW machines are manufactured in AMW. Latest hydraulic beveling machines to ensure precise and accurate fabrication of piping. Ethylene Cracking Furnace for Borouge 3 Descon has been consecutively awarded the 3rd project of fabrication of Ethylene Cracking Furnace for Borouge 3 from SFPC-Linde. It includes 49 convection modules with maximum 200 tons weight. 26 Structure, Ducts and Stack of Boiler for Borouge 3 DESCON NEWS LMW Lahore Manufacturing Works WINTER 2011 Umer Khan FFC III Descon Lahore Manufacturing has made yet another addition to its list of successfully completed Cogen projects. The 30 TPH, 105 kg/cm - HRSG for FFC, Mirpur Methalo Plant has been commissioned successfully and handed over to the client. The performance of Descon’s team has been greatly appreciated by FFC. Their General Manager M&O, Mr. Zaheer Anwar expressed his satisfaction through an appreciation letter to the team. The HRSG is installed against a Turbomach T-130 Gas turbine and is equipped with additional supplementar y firing. Nestle Pakistan Ltd. Nestle Pakistan Limited has renewed its confidence in Descon by awarding contract of 1 x 20 TPH, 18 barg fire tube. Since the first boiler project awarded to Descon in 1989, this is the fourth order of boiler placed by Nestle to Descon. The boiler will be installed at Nestle, Sheikhupura plant. It is equipped with twin corrugated furnace and is designed to operate both on natural gas and HFO. Rafhan Maize Rafhan Maize Pakistan has awarded the contract of 2 x 30 TPH, 200 psig W a t e r Tu b e Boilers. This is also a repeat order by Rafhan. Three boilers of the same capacity have already been supplied, erected and commissioned by Descon at Rafhan Faisalabad plant. The new two boilers will be installed at Rafhan Kotri plant and will be supplied on turnkey basis. The project is expected to be completed by June 2012. Gul Ahmed Textile Mills Ltd. LMW has been awarded with Super Heater Addition project to the existing 30 TPH, HRSG at GATML Karachi, Unit 1. The HRSG supplied by LMW on turnkey basis in 2006 currently operates at 10 barg, 184°C. After the modification, the boiler will be able to produce steam at 42 barg, 420°C. The boiler will be coupled with Siemens Steam Turbine (ST) for power generation. The high pressure steam line to ST, ST bypass line, ST exhaust line, pressure reducing de-superheating stations, steam vent with silencer, steam header and low pressure steam line to process will also be supplied and installed by Descon. 27 DESCON NEWS WINTER 2011 LMW PARCO ABU Project Rental Steam Solutions Descon Lahore Manufacturing works has been awarded with the supply of incineration package for PARCO Asphalt Blowing Unit project through Descon Integrated Projects Limited, the main EPC contractor of the project. The scope includes off gas incinerator, waste heat boiler, super-heater, air pre-heater, KO drum and stack along with control system, associated piping, instr uments, valves and related ancillaries. Keeping in view the frequent requirement of ready steam by the industry, Descon has introduced the concept of rental steam solution. The first breakthrough in this regard is a 10 TPH, 16 barg rental boiler arranged by Descon for Nestle Pakistan Limited, Sheikhupura plant. The boiler will serve as an interim arrangement of steam supply during the period in which the existing boilers of the client will be overhauled by Descon. 225 MW Bhikki Power Plant The commissioning of 02 x 112 TPH, 94 barg for Bhikki Power project has been completed successfully and both are producing steam as per requirement. The thermal design was verified by Vogt Power International (VPI), Descon's licensor for power against gas turbines, greater than 75 MW capacity. Complete design activities including process, mechanical & electrical design and fabrication were carried out at LMW. With this project, Descon has become the first and the only company in Pakistan to provide locally manufactured power to a CCPP on EPC basis. Currently, 1 x 5 TPH, 10 barg, natural gas / LDO fired boiler is also available at Descon LMW for rental purpose. Awarded Projects Design, fabrication and supply of Shell and tube heat exchanger for Engro Chemicals Fabrication, installation and commissioning of Glycol Absorber by OGDCL Fabrication and supply of tube bundle by Pakistan Petroleum Ltd. Design, fabrication and supply of fuel oil heater and LPG vaporizer by Byco Oil Pakistan Ltd. Fabrication and supply of heat exchanger by Farooqi Pulp Mill Design, fabrication and supply of instrument air receiver, buffer tank and demin water tank by Lotte-PPTA Completed Projects Duplex, SS and CS piping for BHP Front end Compression (FEC) 28 Water Bath Heater for fuel conditioning for Bhikki Power Plant Draft tube structure for SAMBU E&P Equipment & Plant DESCON NEWS WINTER 2011 Daniyal Khan making wiser energy choices….. Wind Farm As heavy lifts and rigging comprises of almost 50% of the total Wind Farm project; transportation and logistics of such heavy equipment from port to site is a challenge in itself. Therefore with a proactive approach, E&P channelized its energies for induction of relevant equipment for the job and trained its people accordingly to get optimized results. Another training session on heavy lifts and rigging studies, followed in July 2011. All individuals were trained on Nordex transportation and lifting systems. A comprehensive dossier has also been compiled to redress the issue of transportation, rigging and erection of wind turbine and its allied components like blades, hubs and nacelles. This dossier will be shared with all the prospective clients, with whom Descon has signed EPC agreements. A special 750 tons crane, Liebherr LR 1750, is procured to carry out the job. This crane has a proven track record in the development of wind farms in several countries across the globe. E&P Orientation Training on Wind Power Projects Equipment & Plant team initiated an intensive training program with the support of DCS BA to give orientation to the entire construction team of the project for hands-on execution on wind turbine erection. This included a detailed 5 days training in April 2011 on various aspects of E&P during the development of the project. 29 DESCON NEWS WINTER 2011 HRD&A HRD & A GETP June 20 ~ August 12, 2011 The 24th batch of trainees under the Graduate Engineers Training Program (GETP) was welcomed into the company on June 20, 2011. These young engineers were hired through a highly robust recruitment and selection process conducted by the Corporate R&S team. This included initial screening of candidate profiles, followed by assessment tests, group discussions and final inter views by panel members. The eight weeks’ comprehensive program included class room tr aining on var ious BA/BSD business processes, computer-based training on PMS modules, soft skills to equip trainees with basic management skills and site visits to Bhikki Power Plant, Descon Chemicals, Descon Oxychem and Lahore Manufacturing Works. In addition, for the first time ever, the concept of 'Mentors' was introduced in this batch. Some of the potential mentors were introduced to trainees as they delivered lectures under the training program. Faculty members who conducted the actual training were 'subject matter experts' belonging to DIPL, DC&S, P&PM, Commercial, Contracts Management, QA/QC, HSE, LMW, HRD, PP&A, PDIL, BD and E&P. Their dedication contributed significantly towards the effectiveness of the program. After conclusion of the GETP, a graduation ceremony was held for the trainees on August 15, 2011. The event was graced by the honorable Chairman, Mr. Abdul Razak Dawood, besides department heads and the faculty members. The 30 Aamir Iqbal ceremony began with a recitation from the Holy Quran, followed by Head HRD&A's address and the award of plaques to the trainee engineers. Farhan Ghori (Chemical Engineer, DIPL) was declared ‘Trainee of the Batch’. Next, there were speeches of GETP alumni, Waqas Mehmood and Ehtisham Akhtar, currently working as project engineers in DIPL. Lastly, the Chairman addressed the audience with a very inspiring speech highlighting expectations from the graduating batch. Being the holy month of Ramadan, Iftari and a sumptuous dinner were also arranged for the trainees and guests. All these GETP-24 trainee engineers are now assigned to various BA/BSDs, both local and overseas, in line with the company's manpower deployment plan. Salient Features of GETP-24 A total of 12,200 training man-hours were recorded. 60 topics were delivered by various trainers. 45 trainers rendered their services for delivering various topics. A total of 8 site visits were arranged. (4 visits per 21 trainees). 24 days (12 + 12) were dedicated towards learning of PMS computer-based training modules. Every training day started with a brief motivational / inspirational clip and discussion on the same. Training effectiveness was checked through feedback and quizzes at the end of each topic. HRD&A DESCON NEWS WINTER 2011 HR Team Building Event DEL Cricket Fiesta 2011 With the purpose to promote team spirit in a subtle yet enjoyable way, an exciting team building activity named ‘The Amazing Race’ was organized for the HR team on the last day of the HR Conference. This challenging outbound activity was fully planned and administered by DEL's Administration department. All the local and overseas HR team members participated in the race. The participants were distributed in 6 teams. Each team was assigned with a different color and was equipped with team’s ID cards, colored caps and a vehicle bearing the label of the color assigned to the team. Along with a standard set of instructions and an emergency response plan, the teams were required to visit various locations in Lahore, perform some tasks and collect certain information based on the clues provided. Each task and information carried points that would determine the final score of the team. Later, all teams gathered at Uptown LA to conclude the activity. The winning team members were awarded with the prize and mementos were given to all the participants in the race. In April 2011, HR DCS-BA organized DEL Cricket Fiesta 2011, a companywide DEL cricket tournament. Eight teams from different departments took part in the tournament including Finance Rockers, DIPL Master Blaster, LMW Hammers, Commercial Tigers, HR&A Warriors, DCS Fire Balls, BD/Proposals Stingers and ICT Falcons. The tournament provided some remarkable cricketing moments in a relaxing atmosphere. Mr. Abdul Razak Dawood also honored the occasion with his presence on the field and played from the side of DCS Fire Balls. In the final, LMW Hammers grabbed the title of Champions after beating the BD-P&PM Stingers team in a crunching final game. For his stunning batting display, Mr. Mohsin Mahmood Qureshi of BD was declared Man of the Series. He was also awarded the return ticket to Dubai. Mr. Abdul Razak Dawood handed over the winning trophy to Mr. Tahir Khan, Captain LMW Hammers. Project Personnel & Administration Nofil Zaheer Nepal, Sri Lanka and Philippines as well as develop prospect markets like Iran, Indonesia, Rumania, Thailand and Burma. Implementation of CMPS For Descon, PP&A Department remains a constant source of information and advice to all administrators at Descon Headquarters, Pakistan and across the globe. Since its inception, the department has been instrumental in performing its function from identification of slot-fill requirement, to the long mile of need-based job design and nevertheless to mobilize the perfect profile. The main feature of the department is to enhance the company data bank for efficient and cost-effective manpower both at home and abroad. PP&A is also playing a vital role in mobilizing manpower to four main overseas business areas of Descon located at the UAE, Qatar, Saudi Arabia and Kuwait. In August, 2010 PP&A department implemented CMPS, a system for complete monitoring of Descon's manpower and resources. Although at that time, Descon PP&A was using software named MPSCS for this data but CMPS improved many of the features in MPSCS. With the implementation of this system the complete record has been centralized and can be viewed anytime from anywhere, which not only streamlines the information but also makes it more accurate. Although we have been able to give satisfactory results in every area, but for us the best is yet to come. No matter how much we have done, there is always more to do, more to learn and more to achieve. Besides mobilization, PP&A also explores full potential of current labor markets in Pakistan, India, Bangladesh, Egypt, 31 DESCON NEWS WINTER 2011 HRD&A Descon Institute of Technical Training Uzma Nadia Descon Institute of Technical Training, (formerly Descon Training Institute) formed in 1998, is a distinct initiative considering the presence of many public sector training institutes. Today, certified trainees are getting better jobs and earning options both in Pakistan and abroad. The institute has a highly experienced faculty which conducts short courses in specific competencies required for the construction industry. Our success is demonstrated by thousands of earning hands who have helped to build our reputation after receiving training at DITT. Heading towards industrialization and modernization, the country requires highly trained and skilled manpower and DITT is playing a pivotal role to meet this requirement. Expansion Plan of DITT Descon Institute of Technical Training (DITT) was originally established to train the workforce for the company's expected and ongoing projects. It is now meeting manpower requirement for construction within the country and overseas. Keeping in view the past growth of the institute, it is planned to expand it both in terms of enrollment of trainees as well as infrastructure. We at DITT are planning to launch new courses as per the requirements of construction industry. Also a professional architect is being engaged to prepare detailed plan of the new DITT building. Our Strength Our strength is our staff. We welcome the following staff members who joined us in 2011: Uzma Nadia Abdul Majeed Altaf Ali Jatoi M. Ahmed Raza M. Zahid Talha Mahmood : : : : : : HR Executive/Trainer Instructor E&I Technician Instructor Pipe & General Fitter Instructor Safety Assistant Instructor Welding Admin Coordinator Team Building Trip An informal team building trip to Jallo Park was arranged to unwind from the hectic routine and enhance the efficiency of DITT staff. A total of 22 staff members participated in this trip along with Mian Asim Aziz (Head Management Development Center). The staff participated in different team building exercises in a ver y pleasant environment. Training Workshops Descon Institute of Technical Training has the following well-equipped workshops, where students are imparted hands-on training: Welding Workshop 6G Welding Workshop 3G Pipe Fabrication Workshop Pipe & General Fitter Workshop Rigging & Scaffolding Workshop/Yard Millwright Workshop 32 Introduction of Human Resource Function in DITT In order to help the institute in its growth plan, a full time HR resource, Ms. Uzma Nadia has been deployed at DITT. She is mainly responsible for conducting training needs analysis (TNA) of DITT staff, developing training plan for DITT staff, implementation of training plan, handling general administrative HR issues including appointments, temporary allocations, transfers, secondments, resignations, terminations and long absence etc, administering performance appraisal process of DITT staff, looking after general management issues, imparting training on soft skills etc. DESCON NEWS HSE Health Safety Environment WINTER 2011 Madiha Shafiq Shah Gas Development Project The Shah Gas Development Project (SGD) represents a new era of production of sour gas. The sourness of the feed gases along with the magnitude of processed gas and produced sulphur will set a new benchmark for the world gas processing and treating industry. In order to manage and mitigate the risks, Abu Dhabi Gas Development Company Ltd. has implemented a plant design that places primary emphasis on all aspects of Health, Safety and Environment. The SGD field development is a critical infrastructure project for Abu Dhabi's energy needs and realisation of its Economic Vision 2030. The project is located 180 kilometres south west of Abu Dhabi. Given the challenging location and high Hydrogen Sulphide (H2S) content of the Shah Field, preference is given to protect staff and the natural environment thus ensuring a comprehensive HSE programme. The project activities will spread from Liwa via Habshan to Ruwais, covering a wide geographical area and will require a large number of workforce which would be deployed in Shah area. The major challenges to retain manpower are: extreme climate and seasonal variations vulnerable natural resources 8th Environmental Excellence Award, 2011 This is a great honor for us to consecutively win 8th Environmental Excellence Award. The award has been instituted to recognize and promote organizations which make an outstanding contribution towards sustainable development. The National For um for Environment & Health (NFEH) organized the award ceremony in Karachi on July 29, 2011. In their messages on the occasion, Chairman Intellectual Proper ty Rights, Government of Pakistan, Hameed Ullah Jan Afridi and Federal Minister of Environment, Ms. Samina Khalid Ghurkhi congratulated the winners and said that government gives importance to those industrial units who comply with environmental laws. desert terrain with tall sand dunes lack of infrastructure, long distances To maintain and execute project with all realm of HSE, a committee has been formalized. The mission of this committee is to: facilitate the continuous improvement of the HSE culture monitor the implementation of the HSE policy ensure continuous improvement of HSE performance in the project. Safety Milestones 1) 3.6M safe MH at BHP Zamzama Project: July, 2011 2) 3 million safe MH achieved without any OSHA 3) Injury free Dolphin Energy: December 05, 2010 May 14, 2011 PMP : April 22 - May 07, 2011 QatarGas: April 21-May 07, 2011 QP Refinery shutdowns: July 01- July 17, 2011 4) 6 million safe MH achieved at IGD Habshan (1335): July 21, 2011 5) Safe completion of Adgas shutdown (1501): April 29, 2011 6) Safe completion of the project at Adco Trunk Line (1338): April 2011 7) ODICO tanks construction completed, erection and installation of six tanks at Hyundai/Aramco Karan Gas facilities for achieving 140,000 safe MH: August, 2011 33 DESCON NEWS WINTER 2011 ICT Information & Communication Technology Zara Saher Power Engineering Chemicals Another feather in the cap! Network Services Descon’s Website Launched Worldwide Central Email Address Book Descon is proud to announce the launch of the new and improved website across all functions. For over a year, the old website was revisited and revamped to the contemporary fast track operations. Now, with the joint efforts of Corporate BD and ICT teams, it has been successfully put online. The efficiency and effectiveness is being monitored and updation of the latest news is ensured on a regular basis. ICT has launched web e-mail facility for all employees which can be accessed worldwide. The basic premise of this facility is to help employees access their official email account through any computer connected to internet using the link http://dm-21.descon.com. The new website has been designed with a purpose to clearly define the direction of the three businesses; Engineering, Chemicals and Power. Corporate videos and publications of all the three businesses have been uploaded in addition to the latest news of each sector thus allowing the visitor to have hands-on information on the current happenings. Every business page has its distinct features and provides a complete picture of the product and services diversity. The career’s page though is shared among all three sectors, however the main controls reside with Descon Engineering. The visitors can now apply online through their personalized accounts. 34 Instant Messaging (Lotus Sametime) Descon employees have been provided with instant messaging service called Sametime via their official e-mail account. Now Descon employees across the board can contact each other irrespective of geographical locations thus reducing cost of both local and overseas phone calls. The users are now able to share, transfer files and have web conference. Lotus Traveler Accessibility of e-mail through cell phones is a unique facility that can even replace Black Berry. It has been tested and is under trial. Initially, it has been given to 36 employees stationed at different geographical locations on trial basis. ICT DESCON NEWS WINTER 2011 VPNs with Descon Remote Offices Centralized Manpower System (CMPS) VPNs (Virtual Private Networks) provide a very cost-effective and secure channel of communication. The online applications are made accessible to all local and overseas offices which are connected to DHQ using active directory. Now information is available to all business areas simultaneously including news, announcements, new forms and policies etc. CMPS is capable of managing manpower mobilization processes and offer a consolidated database globally to all authorized personnel. It has been implemented in Pakistan, UAE and Qatar offices. Roll-out to KSA office shall be completed by the end of this year. It also facilitates users at remote offices / sites to securely exchange data. ICT has established VPNs with Musaffah, HMW, Doha, KMW, Hamriyah offices and Satpara project site. Datacenter Established in DHQ For reliable IT storage and services especially for SAP, Lotus Notes and end user data, ICT has commissioned world-class Storage Area Network (SAN). The new datacenter ensures protection against accidental data loss due to hardware failure or disaster. ICT has also developed the required skills to implement, manage and operate the Datacenter which has been successfully deployed at DHQ. ERP Section SAP IS-EC&O Implementation in PDIL This new system has state-of-the-art collaborative features, which have eliminated redundant data entry and made it possible to have efficient online information sharing globally. ACCPAC and Descon Systems at ODICO/ODECO SMART is a web-based Procurement Management System. It has been implemented throughout Descon offices both local and overseas. This system is capable of managing budget control, approval work flows and centralized material master. The procurement efficiency has increased considerably with the help of this system. ICT team along with Finance Deptt's resources has now been mobilized at ODICO. SMART will be rolled-out at ODICO which would replace three legacy in-house build applications thus automating procurement processes with visibility to indenters to track their material. For the first time ever in Pakistan, SAP IS-EC&O is implemented by Descon in PDIL. Descon went live with SAP in PDIL on July 01, 2011. This target date was set by Descon’s internal team and management after it was decided that the ICT team will go ahead with the implementation on their own without any help from external consultants. Information Systems Section Biometric Attendance System This system has helped the employees get rid of old card system and the high maintenance requirement of the card reader machines. This new system is linked with the Timesheet where data is made available online. It has been implemented at DHQ and LMW. Now employees from DHQ and LMW can mark their attendance at any location/office. Timesheet Functionality Enhanced Time sheet's functionality has been enhanced after a revision of Attendance and Leave policy in April 2011. Now the employees have self-service based online approval mechanism for late arrivals and compensatory approvals. 35 DESCON NEWS WINTER 2011 QA/QC Quality Assurance and Quality Control At Descon, the prime objective of our work is to understand the expectations of our customers and to ensure that the end product always meets the specified requirements. To accomplish this on regular basis, Descon has developed and implemented an Integrated Management System, known as DIMS, combining the guidelines of ISO 9001, ISO 14001 and OHSAS 18001 standards. The QA/QC depar tment furnishes services like Quality Planning (PQP, MS, ITPs, QIPs), Inspection & Testing, Auditing, Certification, Training, Corrective & Preventive actions and related Technical Assistance. Since quality is a continuous process of improvement, we therefore continuously review our systems and controls to comply with the requirements of our diversified business. In addition, regular trainings, internal/external audits and customer feedbacks help us in transforming ourselves into a world-class company. Manufacturing of Off-Shore Structure by HMW, UAE Descon HMW recently completed the fabrication of Spudcans. Such a job has been done for the first time in the history of Descon and HMW has achieved the highest quality and manufacturing standards in marine / off-shore field, attaining American Bureau of Shipping standards. To achieve the satisfaction of our world renowned off-shore customers, Sea Jack, Lamprell & ABS, tremendous effort was put by HMW for the preparation of quality procedures, WPS, welding/NDE details and mode of action for marine materials. Other Achievements Gap analysis of DIPL certification has been completed. Developed paperless DIMS environment at DEL Headquarters and LMW. Imran Jamil Quality Operations Committee In order to provide vision, guidance and support across the company to achieve set quality goals, Quality Operations Committee (QOC) has been formed. This committee shall be the top most forum for quality and shall evaluate projects, processes and outcomes to elevate quality across the organization and to reinforce commitment towards quality. QA/QC Human Resource Development QA/QC depar tment from July 2011, has initiated a Professional Enrichment Program (PEP) at DHQ. This program utilizes the available QA/QC resources at DHQ for conducting this session. Initially, our focus is awareness about DIMS Procedures and Method Statements pertaining to QA/QC. As to-date, 366 man-hours have been spent on this program. I/c QA/QC, LMW is utilizing his experience, expertise and certification to develop certified Level-II inspectors at LMW. Audits Business Development: April, 2011 Lahore Manufacturing Works: April, 2011 Human Resource Development: May, 2011 Administration Department: June, 2011 Four Internal Audits: PP&A, Commercial, Project Monitoring and QA/QC: August, 2011 The surveillance audits of ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 conducted by Moody International at DHQ, LMW and BHP Site. Reassessment audit of ISO 9001:2008, ISO 14001:2004, OSHAS 18001:2007 in UAE BA. JGC carried out a QMS audit of Descon at IGD-5 Habshan project site, UAE. The audit resulted in no major NCR showing Descon's compliance to the customer's requirements. Third party audit by Moody International in AMW: May 23, 2011 Zero non-compliance was observed. Re-assessment audit has been carried out by ASME for A, qp, S, U, U2 and R Stamp of AMW. ASME has renewed these stamps for AMW for the next three years. Surveillance audit of HMW for ISO9001:2008 has been conducted by Moody Intl without any non-conformance. 36 DESCON NEWS PS Plant Services Descon established the Plant Services Department with a vision to provide adequate maintenance and operation services to the growing industrial sector of Pakistan and the Middle East. The department has explicitly exhibited the forte of excellent maintenance services and has provided support to its clients. Major Shutdowns and Turnarounds Major achievements this year include following turnarounds of different plants. The scope of work was complete overhauling/maintenance of static and rotary equipment, modification jobs, electrical and instrumentation works. Pak American Fertilizer Ammonia & Urea project revamp National Refinery Limited-Lube 1 TA 2011 Complete turnaround Pakistan Refinery Limited - TA 2011 DBN at BHP Zamzama Gas field Phase-I (Trains-I & II) and EWT WINTER 2011 Hannan Khalid term services to Engro Polymer & Chemicals Limited Karachi and Lotte Pakistan PTA, Karachi. Construction of Public Buildings in New Mirpur City Mangla dam, one of the largest earth-filled dams in the world is located on the Jhelum River in the Mirpur District of Azad Kashmir, Pakistan. The construction of this dam was completed in 1967 with a gross storage capacity of 7,260 mcm (5.88 maf). At the time of its construction, the dam raising team committed to compensate the population of over 30,000 who would lose their land or other property by building them a new housing society with modern amenities including treated water supply, sewage collection, treatment and disposal, asphalt concrete paved roads, electricity, educational, health and commercial facilities, sports facility and recreational parks. This was formally signed by Government of Pakistan, Government of AJK and Wapda. The construction of remaining works of public buildings was awarded to Descon. Award of this project replicates the confidence of the client on Descon’s capabilities. This project mainly involves construction of forty-seven public buildings including secondary schools for boys & girls, primary schools, markazi and sector mosques along with allied residences and shopping centers. Descon's scope of work includes structure works, plumbing works, electrical works, finishing works and external works. Recent Turnarounds Executed PPL ADHI (ATA Maintenance 2011 Trains I & II) FFBL TA 2011 BHP Zamzama Gas Field (Annual Turnaround 2010) NRL (Lube II-TA 2010 - 2011) PRL (ATA 2011) Hub Power Station (RFO Tank - 4 Refurbishment (Mechanical Works) Indus Motor (Installation Of 2 Press M/C 1000T) LPPTA (Pac Motor Replacement Job During Overhaul2011) UCH Power Outage 2010 Long Term Maintenance Services Long Term Maintenance Services (LTMS) is also an expertise of Descon Plant Services. Currently, we are providing long 6 MW Coal & BBPP - Nishat Mills Ltd Nishat Mills Ltd awarded the electromechanical construction of 6 MW coal and biomass based power project to Descon. This is the first of its kind in Pakistan being implemented. Descon has a sound history of working with Nishat group and is looking forward to further strengthening the business ties by the successful execution of the project. 37 DESCON NEWS WINTER 2011 DCH Descon Chemicals Limited Supports Global Brands Sapphire Descon Chemicals prides itself as being the first choice chemicals provider for businesses across Pakistan and around the world. Banking on creative and innovative ideas, utilizing state-of-the-art machinery and applying the latest processes and techniques, we ensure that our customers get only the best that the industry has to offer. Our products are unmatched in terms of quality, making us the perennial choice of solutions provider for many business. It is precisely because of the reason that industry powerhouses like Akzo Noble, Interloop and Packages to name a few, choose us as their chemicals business partners. But we don't stop there; Descon Chemicals supports global brands by 38 servicing multinational companies like Akzo Nobel, Brandix textiles, Bata and Alesco (Kansai Paints). Currently we are providing Hydrogen Peroxide to the South Asian region and have a strong customer base in India, Sri Lanka and the UAE. Other chemical products like OBA (Optical Brightening Agents) and Alkyd resins are being expor ted as well to international clients. In its aim to ‘become a leading chemicals solution provider to industry worldwide’, such affiliations with global and international brands ensure that we are on the right track. For when you use a product from any of our clients, you can be sure that Descon Chemicals had a part to play in it- Their Solutions, Our Chemicals. DESCON NEWS DOL Descon Oxychem Limited WINTER 2011 Rafay Shahid First Annual Distributor Conference On 26th of July 2011, Descon Oxychem Limited held its Annual Distributor Conference, inviting its authorized distributors from across Pakistan, India and Sri Lanka to commemorate the achievements of the previous year's performance. The primary objective behind the conference was to assemble all stakeholders at a forum to review Descon Oxychem's market reach and to strategize on how to achieve market dominance. The event chaired by Descon Chemical Businesses' CEO, Taimur Saeed, also visited DOL's strategy of 'Create and Sustain' which aims at retaining local market leadership, reducing imports and focusing on emerging markets. Our distinguished distributors were pleased to hear that through their united efforts and the team at DOL, we had successfully edged out local and international competition in terms of maximum market share for Pakistan. Similarly, applauds were extended for record production and sales for the fiscal year of 2010-2011. This year's Distributor Conference also served to launch Descon Oxychem's brand name onto the local and global market. The ideology behind launching the brand name is to revitalize our hydrogen peroxide's image from being a product rather than a commodity; to distinguish ourselves from the generically named competition in the market and to create value for Descon's brand equity. All present consented that this was an excellent initiative taken to make our product stand out from the crowd. The first half of the conference concluded after the presentation by Mr. Taimur Saeed on the Oxychem business, followed subsequently by a group photograph of the participants. The distributors then joined the management team at Descon for Mr. Taimur Saeed giving a presentation on DOL's business lunch at Lahore Gymkhana where business matters were put aside for a few hours as the participants enjoyed fine dining amongst each other's company. The conclusion of lunch proceeded to the next part of the conference; the visit to the DOL plant. The guests were received by the DOL team lead by the plant manager, Mr. Yawar Mehmood. The distributors were then given tour of the 30,000 MT capacity plant. Our visitors, those who had seen the plant before were pleasantly surprised with the developments at the plant, whilst those who were seeing the plant for the first time admired the scale of operations. The conference concluded around 5 PM after the tour of the plant and the presentation of souvenirs to the participants. All in all, the 1st Annual Distributor Conference proved to be the cherry on this fiscal year's cake and a landmark moment in Descon Oxychem Limited's history for years to come. Participants of First Annual Distributor Conference held on July 26, 2011 39 DESCON NEWS WINTER 2011 DPS Descon Power Solutions Decentralized Power Generation for Pakistan! There are many reasons for the increased popularity of natural gas to both power and energy in the world. Recent regulations and public pressure have encouraged the power sector to come up with new methods of generating power and energy. New gas firing technologies are allowing natural gas to play an increasing decisive role in the generation of clean electricity. An efficient and uninterruptible power supply has become a challenge for Pakistani industries in the last decade. Higher costs for energy and shortage of power supply from the grid have brought the private, public and industrial sector to search for decentralized, efficient and clean ways to produce energy. Descon Power Solutions Descon Power Solutions focuses on decentralized, caters to the following flexible and efficient power solutions to Captive Power market segments: Plants and small Captive power for industries I n d e p e n d e n t Po w e r Small Independent Power Producers. DPS's collaboration with MWM, Producers one of the pr incipal Commercial buildings, purveyors for decentralized hospitals, banks, etc. power production in the world has facilitated DPS in achieving its targets. The company, based in Mannheim,Germany, draws over 140 years' experience in the development and optimization of combustion engines for natural gas, special gases and diesel. To date, MWM has supplied around 115 MWe in Pakistan 40 DPS DPS officially representing MWM in Pakistan caters to all requests from engine supply to equipment maintenance, having full in-house capability to foster design, install, warrant and provide long-term maintenance contracts. In short, DPS is a one-window solution provider for energy needs. MWM offers gensets with an electricity generation range from 400 KWe to 4300 KWe and can provide solutions for projects up to 100 MWe. DESCON NEWS WINTER 2011 show case the products and technology of MWM and the services provided to them through DPS. It helped in meeting existing customers, consultants, prospective customers and gaining recognition at a broader level. The main attraction at the platform was the presence of generator set model TCG 2020 V20 2 MW. DPS participated along with our German colleagues. Participants from MWM were Mr. Hassan Attasi and Mr. Melf Jasper. Optimized TCG 2016 C Genset with Improved Efficiency for Biogas Operation MWM designs various genset series for operation with natural gas or special gas types like sewage gas, biogas and landfill gas. They are the leading specialist in generation of energy from biogas and their systems are being used successfully all over the world. Their biogas portfolio has an answer to every challenge, from re-engineering all the way to fully customize complete system solutions. DPS along with its partners, MWM at POGEE 2011 Powering Quaid-e-Azam International Hospital (QIH) TCG 2016 C 12V (800KW) genset with optimized efficiency for biogas operation Now MWM has come up with the TCG 2016 C genset with power range from 400 KW to 800 KW with availability in the V8, V12 and V16 variants. Its efficiency has been increased especially for biogas. Because of the efficiency boosting measure, this genset reaches maximum electrical efficiency of 42.8% or 41.7% with biogas. DPS being the sole representative of MWM is geared to help the Pakistani market in bringing this latest technology to Pakistan. Descon Power Solutions brings MWM's decentralized power expertise to Quaid-e-Azam International Hospital (QIH). QIH is a 400 bed, state-of-the-art hospital located at Peshawar Road, Islamabad and approachable by motorway and highway to Khyber Pukhtoonkhwa, Punjab, Kashmir and Afghanistan. Considering the sensitive requirement of smooth, uninterruptable and reliable power, QIH has relied on DPS which will supply two units of 1,500 KW each TCG 2020 V16 K model gas engines 3MW as prime power from MWM and four diesel generator sets of 630 kVA each from METS Energy for standby and emergency. DPS Participation in the 9th International Exhibition for Energy Industry (POGEE) Descon Power Solutions participated in the 9th International Exhibition for Energy Industry at Karachi Expo Centre from May 17-19, 2011. The exhibition was a platform which provided DPS/MWM with an opportunity to benefit from the most influential energy event in the region by getting a chance to Quaid-e-Azam International Hospital, Islamabad 41 DESCON NEWS WINTER 2011 IWT Interworld Travels Strengthening its Relationship with the National Carrier - Popular Travels Comes to Life Interworld Travels, travel services provider for the last decade, recently qualified as a PSA (Passenger Sales Agent) for Pakistan International Airlines. Acknowledging Interworld Travels' service excellence, PIA agreed to offer a franchise, 'Popular Travels' to IWT. The operations began in July 2011 and in a very short time, IWT has become the travel agency of choice in the locality. My Holidays 'My Holidays' was launched to make holiday travel more enjoyable and stress free. Our team of dedicated and experienced travel consultants offers amazing holiday packages, with special rates for all leading hotels and resorts around the globe. My Holidays believes in making your holiday unforgettable, wherever you go, whenever you go. Reaching us is easy, just dial in at 111-111-IWT and leave the rest to us. IWT Sponsors Man of the Series Award The DEL Cricket Fiesta 2011 held by DCS-HR, was thoroughly enjoyed by all employees. The Man of the Series award was a return ticket to Dubai won by Mr. Mohsin Qureshi of BD-P&PM, sponsored by IWT. 42 Trip to Shogran During the months of January to March, Interworld's team was given the task of mobilising more than 2,500 employees in Qatar and Abu Dhabi. The IWT staff worked extremely hard and managed to successfully mobilise the required number of people within the given deadline. By way of appreciation for their tireless efforts, the team was rewarded with a trip to Shogran. Some employees from DCH and DPS also joined the IWT team for this two-day trip. DESCON NEWS IWT Supporting Local Talent - IWT Sponsors a Young Tennis Star Keeping up with the tradition of promoting sports in the country, IWT recently sponsored an upcoming young Pakistani Woman Tennis star, Ms. Iman Qureshi. At the young age of 14, Ms. Qureshi has the honour of being ranked 3rd in Asia under 15. WINTER 2011 and bagged the Runners'-Up Position and also reached the third round of 'Tournament de Nice' in the Women's Open category. Recent Achievements: Asian Tennis Federation Championship, Damascus, Syria. Winner of doubles championship and third in singles. To prepare for the grueling schedule of the under 15 World Tennis Circuit, she decided to attend a three week intensive training program at ISP Academy in the South of France, which is one of the best tennis academies in Europe. There were over 80 players attending from all over Europe mostly from England, Germany, Spain, Italy, Poland and France. Ontario Fitness Institute Under 14 Championship. Toronto, Canada Finalist Asian Junior Championship, Doha, Qatar. Finalist in Singles. ITF 14 & Under Championship in Yangon, Myanmar. Finalist in Doubles. LUMS All Pakistan Tennis Championship 2011. Winner in Ladies Singles Iman receiving Winner’s Trophy from Mr. Shadi (Director Syrian Tennis Federation) at ITF 14 & Under Tennis Championship Iman got a chance to play and compete with the top European players. After the three week training programme, she participated in the 'Sophia Antipolis Country Club Tournament' Winners and Finalists at ITF 14 & Under Tennis Championship Overall Girls Ranking Rank Last Name First Name DOB Nationality Total Played Total PTS Best Six PTS 1 BASSEL MOURAD OLLA 1998-Jul-18 QAT 5 1400 1400 2 PEREIRA RIKEETHA 1998-Jan-16 IND 6 1040 1040 3 QURESHI IMAN 1997-Jul-20 PAK 3 860 860 4 VENUGOPAL DHRUTI 1997-Jan-09 IND 3 850 850 5 YE QIUYU *WARNING CHN 1 830 830 5 LI YIHONG *WARNING CHN 1 830 830 7 YOONKEE CHOI SPACKMAN CLAIRE 1997-Mar-10 HKG 6 825 825 7 REDDY D.NAYANIKA 1997-Oct-02 IND 4 825 825 9 AL AJEELY GHADA 1998-Jan-08 IRQ 5 750 750 10 KAUR DELIZAVERNNE 1997-Apr-07 MAS 7 733 730 43 DESCON HEADQUARTERS 18 km., Ferozepur Road, Lahore-54760, Pakistan Tel: +92 42 35990034, 35805134, UAN: +92 42 111-DES-CON Fax: +92 42 35811005, 35811135, Email: [email protected] www.descon.com ENGINEERING JOINT VENTURES Descon Integrated Projects Limited 18 km., Ferozepur Road, Lahore-54760, Pakistan Ph: +92 42 3599 0053, 3581 2263-6 Fax: +92 42 3581 0867 E-mail: [email protected] KARACHI - Pakistan 9th Floor Business Avenue, 26-A Block-6, P.E.C.H.S, Main Shahrah-e-Faisal, Karachi-75400, Pakistan Ph: +92 21 3454 4481-4 Fax: +92 21 3454 4480 E-mail: [email protected] ABU DHABI, UAE Mussafah Industrial Area, ME-14 United Bank Limited Building, P.O.Box 46821, UAE Ph. +971 2 555 5807 Fax: +971 2 555 5784 E-mail: [email protected] Presson Descon International Ltd., Pakistan 18 km., Ferozepur Road, Lahore-54760, Pakistan Ph: +92 42 3588 0390 Fax: +92 42 3592 3720 E-mail: [email protected] Descon Integrated Projects Limited 9th Floor Business Avenue, 26-A Block-6, P.E.C.H.S, Main Shahrah-e-Faisal, Karachi, 75400 - Pakistan Ph: +92 21 3439 1591-5 Fax: +92 21 3439 8565 E-mail: [email protected] KUWAIT Descon Engineering FZE Building No. 14, Street No. 13, Block -3, Mangaf, Kuwait Ph: +965 237 304 71, 237 302 04 Fax: +965 237 301 48 E-mail: [email protected] QATAR Descon Engineering Qatar LLC 2nd Floor, Al-Hitmi Village, P.O.Box: 23364, Doha, Qatar Ph: +974 4405 4717, 4405 4777 Fax: +974 4405 4778 E-mail: [email protected] Olayan Descon Industrial Company P.O.Box 10108, Jubail Industrial City 31961, Kingdom of Saudi Arabia Ph: +966 3 341 0671 Fax: +966 3 341 0950 E-mail: [email protected] MANUFACTURING WORKSHOPS POWER HAMRIYAH Descon Engineering FZE Plot No. HE- 5, 6, 7 & HD-19, P.O.Box 42576, Hamriyah Free Zone, Sharjah, UAE Ph: +971 6 563 7187, 563 7203 Fax: +971 6 563 7646 E-mail: [email protected] KARACHI - Pakistan Plot No. A 35-36, Eastern Industrial Zone, Port Qasim Industrial Area, Karachi, Pakistan Ph: +92 21 3474 0031-35 Fax: +92 21 3474 0037 E-mail: [email protected] Descon Power Solutions 18 km., Ferozepur Road, Lahore-54760, Pakistan Ph: +92 42 3592 3760-64 Fax: +92 42 3592 3765 [email protected] ABU DHABI P.O.Box 46821, Ghayathi Road, Ruwais Industrial Area, Abu Dhabi, UAE Ph: +971 2 876 0390 Fax: +971 2 877 2994 E-mail: [email protected] LAHORE - Pakistan 2 km., Defence Road, off 24 km., Multan Road, Lahore-53800, Pakistan Ph: +92 42 3754 0361-66 Fax: +92 42 3754 0367 E-mail: [email protected] KARACHI - Pakistan 9th Floor Business Avenue, 26-A Block, 6, P.E.C.H.S, Main Shahrah-e-Faisal, Karachi-75400, Pakistan Ph: +92 21 3452 6564 Fax: +92 21 3454 4480 CHEMICALS Descon Chemicals Limited Descon Oxychem Limited Descon Corporation Limited Interworld Travels (Pvt) Limited 18 km., Ferozepur Road, Lahore-54760, Pakistan Ph: +92 42 35923 721-27 Fax: +92 42 35923 749 E-mail: [email protected] E-mail: [email protected] E-mail: [email protected] E-mail: [email protected]
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