Cape East 2 Month Work experience Report

By Tushar Chopra

IndexTitle/ Topic Slide No:

• Company Profile- CAPE 3• Objectives of Work Experience 4• Cost Estimations 5-6• RLIC Workshop/ Warehouse 7• Machinery used at Workshop 8-10• Blasting and Painting 11-12• Insulation 13-14• Strategic Planning 15• Health and Safety 16

Company Profile Established in 1893 Cape plc Ltd is a contracting firm, whose shares are

traded on the main market of the London Stock Exchange.

International leader in the provision of critical industrial services principally to the energy and natural resources sectors; offering services such as insulation, specialist coatings, passive fire protection, refractory linings, etc.

Consists of 17000 employees in several regions around the world (21 countries); Cape Qatar has around 5500.

In 2013, Cape reported an adjustment revenue of £697.1m

Internationally reputed for having excellent reliability, implementing noteworthy health and safety regulations, and supplying outstanding quality.

Objectives of Work Experience To develop the basic office skills which are essential to every industry such as

excel data logging and PowerPoint presentations while ameliorating my financial and industrial vocabulary.

Working in the cost estimations department in order to improve excel skills and ascertain the process that takes place during contract bidding.

To be able to interpret isometric drawings and client specifications in order to create a complex file on which materials are required to carry out the task and the costs involved.

Visiting and supervising the operations that take place at the workshops/site and observing the different functions Cape completes such as insulation, fireproofing, blasting, painting, etc.

Taking note of the machinery that is used at the workshops and its uses. To gain a thorough understanding in the processes of painting, blasting and

insulation. To gain insight into the strategies used by firms and the extensive long term

planning that takes place in order to maintain profits and foster market share; exclusively looking into the techno-commercial aspects of Cape.

Recognizing the extent of health and safety regulations in Cape and their effectiveness.

Cost Estimation In contracting firms such as Cape, a cost estimate is usually prepared to submit a bid or tender in order to win contracts. An approximation of the probable cost of a product, program, or project, computed on the basis of available information such as the client specification and isometric drawings provided (such as the one on the right).There are 3 main reasons Cape carries out cost estimations;(1) To gain a rough approximation of costs within a reasonable range of values, prepared for budgetary bidding. (2) To make a Firm estimate: a figure based on cost data sound enough for entering into a binding contract. (3) To be aware of the exact amount required to accomplish a given task, known as the budget to execute.

Cost Estimation

The primary method of making estimations is through resource necessity (e.g., the amount of construction material quantities that are required) and then multiplying the estimated construction material quantities by the corresponding unit cost. One advantage of making estimates in this way is that it allows for the segregation of quantities and costs. This way they can be updated separately as new information becomes available. They can also be tracked separately allowing decision makers to make better decisions about the project during its conceptual phase.

tube (m) no. of fittings

boards (m) base jacks ladders tube cost fittings

costBoards

cost base jacks ladders IRR Mat cost

IRR Mat Price

Install - mhr

norms

Dismantle - mhr

norms Install - mhrs

Dismantle - mhrs

Total - mhrs Lab Cost Lab Price Ind Price

16,695.68

20,869.60

10,434.80 417.39 960.00 129.11 133.15 322.78 16.28 109.44

995.07

1,243.84 0.30 0.80 1.80 3,339.14 7,513.06 10,852.19

138,917.47

173,646.84

666,107.10

10,483.20

13,104.00   262.08 602.78 81.07 83.60 - 10.22 68.72

341.06

426.32 0.16 0.65 0.20 1,703.52 524.16 2,227.68 28,516.24

35,645.29

136,734.91

15,323.43

19,154.29 9,577.15 383.09 881.10 118.50 122.20 296.25 14.94 100.45

913.28

1,141.60 0.30 1.00 2.00 3,830.86 7,661.72 11,492.57

147,114.92

183,893.65

705,413.74

10,483.20

13,104.00       81.07 83.60 - - -

230.54

288.18 0.11 0.70 0.35 1,834.56 917.28 2,751.84 35,225.94

44,032.42

168,907.83

7,051.30 8,814.13 3,917.39     54.53 56.23 121.18 - - 324.72

405.90 0.23 1.05 0.55 1,850.97 969.55 2,820.52

36,105.13

45,131.41

173,123.52

RLIC Workshop Huge camp consisting of 3000 workers, warehouse and functioning

workshop situated in Ras Laffan. Consists of all the raw materials used to conduct the insulation,

painting, blasting and scaffolding processes. Contains machinery such as rolling and grooving machines along with

blasting furnaces used to prevent and solve the issue of rusting/degradation of materials.

Machinery being Used

Sheet Metal DecoilerManual Metal Folding Machine

Folding machines can process work pieces according to the customer's requirements, and can fold sheet into a box/pan with four sides. They are suitable for site use due to their light design, economical use and efficiency.

A sheet metal decoiler is a mechanical reel used to dispense steel coil material normally in to a power press or roll forming line. It is a very reliable machine as it ensures complete flatness and uniformity in the metal sheet.

Machinery being Used

Manual Grooving Machine

CNC Cutting machine

Grooving machines are used for roll grooving of pipes and is unparalleled in performance due to its light weight, resistance to corrosion and simplicity of use. Their durability makes them great value for money which is an aspect Cape appreciates in machinery; output per unit of cost.

Computer Numerical Control (CNC) machines are automated milling devices that make industrial components without direct human assistance. They use coded instructions that are sent to an internal computer, which allows factories to fabricate parts accurately and quickly. They tend to be very expensive but beneficial to CAPE as they are efficient and save a lot of time & labour.

Machinery being Used

Computer numerical control, or CNC, systems are computer controlled machining tools used in manufacturing. The advantage to computer numerical control systems is the increased accuracy and processing speed for the production machines. Cape’s new CNC machines use computers for the entire process from design to production. The initial product design is created with a computer assisted design, or CAD, program. CAD not only creates detailed images and drawings of the product, but also in depth schematics and measurements.

CNC Machine cutting polyisocyanurate(PIR)From Right to left: Operating machine, CNC cutting machine, CAD program.

Blasting and Painting Blasting is the operation of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface, or remove surface contaminants. Cape generally uses a pressurized fluid to propel the blasting material. The three main types of abrasive blasting Cape uses are Sand blasting, bead blasting and shot blasting.

After blasting, the next step is usually painting. Most of Cape’s clients ask for several paint coats, not for the aesthetical reasons but for caution. Painting a material that rusts, usually an iron rich material like steel, keeps the metal from exposure to the environment such as air and humidity. Rust is actually the oxidation of metal, and protecting metal with paint does not allow this to happen. Therefore, most of the clients request for a paint job after blasting in order to prevent the need for blasting in the future.

Blasting Painting

Blasting and PaintingFrom left to right: Garnet grade 20-40, Steel shot & Grit, Garnet Grade 30-60, Steel grit, Glass beads.

Cape sits with its clients to decide which abrasive (Glass beads, steel shot/grit or garnet) will work best for the project discussing efficiency, cost effectiveness and quality. Smaller steel shots are used to obtain a smoother finish, while larger ones lead to a rougher finish. Blasting with steel grit is used for jobs where aggressive cleaning is required, such as removing contaminants from a metal. Sand blasting is an easy process which uses little machinery; it can also be used for paint removal and perfect cleaning. Glass beads are used specifically to clean smooth surfaces as it maintains the uniformity. Glass beads tend to be the most expensive, followed by steel shots/grit and then garnet. However, steel shots can be reused up to 50 times making it the most cost effective in the long run.

Quality Control needs to check abrasive quality using the Test Sieve

Insulation

Insulation is never installed as a single unit or machine. Insulation material is part of a system that includes the insulation; the securement; a vapor barrier, in the case of low-temperature applications; and an outer layer that might be referred to as the cover, jacket or lagging.

Each component plays an important part in the overall function of the system. The insulation material itself is the primary barrier to the flow of energy, while the securement holds the insulation in place. The function of the vapor barrier is to prevent the passage of moisture into the insulation.

Insulation Jacketing The most versatile component in the insulation system is the outer covering, known as the jacket. It has a variety of functions, including protecting the insulation from mechanical damage, providing support, preventing moisture penetration and establishing the system emissivity and appearance.

Aluminum and stainless steel are the most commonly used jacket materials at CAPE because, among many other desirable characteristics, they have sufficient corrosion resistance to meet a basic low-maintenance, high-durability requirement. Furthermore, both are available in a range of thickness, finishes and corrugations.

5 Year StrategyFortunately for me, I was able to work with the strategist at Cape while he was working on the 5 year strategy and the overall review for the company.While reviewing the company’s progress and assessing the development, we made various graphs and reports. We were required to analyze the

company’s financial performance over the past 15 years to set 5 year long term goals and create plans/strategies in order to achieve these goals. Furthermore, we even discussed the market share percentages of the maintenance and construction industries in Qatar enabling us to infer that Cape has a significant share of the market and set goals to achieve over 50% of the market share in maintenance by 2020.

Health and SafetyIt was great to see that in the new RLIC yard, CAPE had implemented several health and safety measures. Every machine had a distinct “safe work instructions” guide and each room had at least 3/4 supervisors who overlooked the entire process and prevented carelessness. Silica sand blasting results in large amounts of dust which could cause lung infections. Therefore, Cape has started using garnet blasting which releases much less dust which doesn’t cause health problems. Cape invests significant resource into training facilities that provide employees with the essential skills required to work safely and protect themselves and others at all times.