Fauji Fertilizer Bin Qasim Limited

SUMMER INTERNSHIP REPORT

NUST-PNEC

TAYYAB BIN TAHIRBE-ME

TIME PERIOD: 18 JULY, 2016 – 12 AUGUST, 2016Submitted to: L&DCONTACT NUMBER: +92-334-0387082

EMAIL ID: tayyabbintahir91@gmail.com

ABSTRACTFFBL is a well-known, prestigious and professional industrial setup in Pakistan. It provides training to students as well as graduates in there respective disciplines. .

It was one of my best experience in any industrial setup which has enabled me to procure practical knowledge of chemical formation and turbomachinery. I am thankful to all the Management, Staff and other members that were the part of this Organization, due to their efforts and motivation to teach me and to make me eligible and a competent Engineer for any Industry in Pakistan.

ACKNOWLEDGEMENT

I am very thankful to Allah for the successful completion of my four week internship the FFBL which is one of the largest and growing Fertilizer Complex in

Pakistan. During my internship I have learnt about the Fertilizer industry, and its environment. I learnt about the FFBL as an organization, job handling procedures, maintenance and repairing procedures and job environment in FFBL.I am thankful to Management of FFBL who provided me a platform to learn and gain practical knowledge.

I would like to express my heartfelt thanks and appreciation to the employees of FFBL who took the time off their busy schedule to share their expertise and knowledge.

AN INTRODUCTION TO FAUJI FERTILIZER BIN QASIM LIMITED

FFBL is one of the largest granular Urea and Dap fertilizer complex in Pakistan, built at the cost of US$469 Million in November 1993, located in Eastern Zone of Bin Qasim. The plant is approximately 45km south east to Karachi City and it is connected to National High way.FFBL is one and only Fertilizer complex in the Pakistan producing DAP (DI‐AMMONIUM PHOSPHATE). It is the sole producer of Urea and Dap in the country and forms part of Fauji group, one of the largest conglomerates of Pakistan.FFBL and FFC jointly holds 63% of Urea and 51% of DAP share of Pakistani fertilizer market.FFBL increases its product capacity which is higher than the designed parameters. There are many features of FFBL that make it distinct from any other Fertilizer complex in Pakistan.

• Initially named as FFC-Jordan Fertilizer Company (FJFC), wef 17th Nov 1993, with FFC (30%), FF (10%) and JPMC (10%) as main sponsors. The company was formally listed with stock exchanges in May 1996 and commercial production commenced wef Jan 2000. However, it continued to run in crises due to technical, financial and managerial reasons till 2001. DAP Plant brought to suspension in 2001 due to accumulated loss of Rs. 6.5 Billion. It resumed production in Sep 2003, after a lapse of 2 years.

• Renamed as Fauji Fertilizer Bin Qasim Ltd. (FFBL) in 2003, as such Jordan Phosphate Mines Co. (JPMC) had sold its entire equity in the company. Accordingly Phosphoric acid supply agreement with Jordan was terminated. The company turned out to be profitable after 3 years i.e, by 2004 and declared 'maiden dividend' in 2004. Profitability has constantly been on the rise since then and 2007 has been the most profitable year of the company.

PERFORMANCE & PRODUCTION FFBL fertilizer complex is state of the art manufacturing facility with advanced Distributed Control System for safe and efficient operation. The phosphoric acid being raw material for DAP plant is imported from Morocco and initially stored in tanks at Port Qasim. Design capacity viz-a-viz actual production of Plants is as under:

Manufacturing Plants Production (Metric Ton / Day)Original Actual (Approx)

Urea Granular 1670 1920DAP 1350 2230 (After Revamp)Ammonia 1270 1570 (After Revamp)

FFBL is the only fertilizer complex in Pakistan producing DAP fertilizer and Granular Urea thus making significant contribution towards agricultural growth of the country by meeting 45% of the demand of DAP and 13% of Urea in domestic market.

SafetySafety is the first priority in the FFBL. Safety is a measure of success in any work. It means constant evaluation of thing, we do and how we go about doing them so that we won`t get harm, they our equipment’s condition will not contribute to an accident. In FFBL safety is considered equal to production.Safety priorities of FFBL are:

• Employs• Company assets• Environmental

PERSONEL PROTECTIVE EQUIPMENTS:Following equipment are available for personal protection.

• Safety helmets and shoes should be worn at plant site during working and any other activity.

• Googols for protection against liquids and gases• Gloves for protection against acid and alkaline solution and heat• Respiration Mask with filters for duct and poisonous

gases(H2S,NH3,Natural Gas etc)• Compressed air mask for protection against CO• Ear plugs for protection against mask• Draggers equipment (Tubes and Sniffer) for measurement of poisonous

gases like CO,H2S,NH3,Natural gas)

WORK PERMIT PROCEDUREThe FFBL is controlled by Operation Department and no work can be carried out by an unauthorized person or Department. Any work which is related to concern Department is carried by its permission.The permission is sought on a prescribed format known as work permit.

Types of Work Permits:• COLD WORK PERMIT

This is required when urgent or routine repairs/inspection is to be carried out and job doesn’t involve a flame or spark

• HOT WORK PERMITIt is require for jobs as lighting all naked flames, fires, exposed material including electric aces and sparks, electronic and gas welding/cutting, blow lamps and tar heating.

• VESSEL ENTRY PERMITThis is required when one or more persons to enter in to any confined space such as tower/vessel/storage tank, excavation more than 1.5 deep, column, reactor, piping will 1m, sewers etc.

• EXCAVATION WORK PERMITThis permit is issued to cover all excavation work inside the plant.

• VEHICLE ENTRY PERMITThis permit is required before any vehicle can enter the work area.

• RADIOGRAPHY WORK PERMITThis permit is required to do any sort of radiographic testing anywhere in the plant.

Intro to MaintenanceThe maintenance department at FFBL is responsible for checking and maintaining all machinery and equipment at the plant to ensure smooth running and continuous production. This includes regular maintenance as well as emergency maintenance. Regular maintenance involves checking oil levels, refilling oil, cleaning filters, refueling of fuel driven machines etc. Emergency maintenance can involve anything from stopping leakages to overhauling complete machinery.

The maintenance department at FFBL is further divided into 2 sub departments:

• Machinery: The machinery department deals with all rotary machines at the plant such as pumps, compressors, turbines etc.

• Equipment: The equipment department is responsible for all stationary equipment at the plant like heat exchangers, valves etc.

Types of machinery equipment • Pumps

• Compressors

• Steam turbines

• Gas turbines

• Motors

• Cooling towers

• Agitators

• Blowers

Types of stationary equipment The various types of stationary equipment used at FFBL are:

• Heat exchangers

• Vessels

• Tanks

• Furnaces

• Boilers

• Piping

• Insulation

• Glass Level Gauge (GLG)

• Scaffolding.

• Reactors

Utilities PlantUtility plant provides the facilities to other plants to operate well and continuously.

For that purpose it is includes the following equipment and machinery:

• Cooling tower

• Power generation

• Filtration of water

• Supply of water and steam for the whole plant

• Chillers and HVAC

• Compressed air for whole plant

• Demin water, hot water

• Natural gas distribution

• Raw water storage

• Fire water

• Potable water

Now we will discuss the major areas of utilities in detail.

Cooling towerCooling tower is basically used for cooling hot water coming from the plant of urea or any other also using in the heat exchanger. For this purpose hot water is injected from the top of the cooling tower and there are fans at the top of cooling tower. Air from the fan passes through the hot water and takes heat, so temperature of water will decrease from 43 c to 33 c. Total time of flow of water is about 15 minutes. There are 10 cooling towers; 3 for Ammonia, 3 for DAP and 3 for Urea and 1 is on standby.

Power GenerationFor power generation in FFBL there are 2 gas turbines and one diesel generator (in emergency). The capacity of power generation of one gas turbine is 26 MW. The power is generated at 60 Hz and the voltage is 13800 volts.

Air compressorsThere are three air compressors in FFBL under the utility section which provide, supply and generate compressed air known as instrument air and service air. The compressors are screw type PD compressors that use a dry paper type filter.

The compressors have 2 stages:

• 1st stage – 9000 RPM

• 2nd stage – 14000 RPM

Steam ProductionThe production and supply of steam to the whole plant is under utility section. Steam is generated by two methods

• Heat recovery steam generation

• Auxiliary boiler

Auxiliary Boiler:Auxiliary boilers are used for maintaining the variation in the steam production. In this forced drafts fans are used to provide combustion air in the burner. It is water tube type. The components of an auxiliary boiler are:

• Steam drum

• Water drum

• Boiler tube

• Inner casing

• Outer casing

• Refractory

• Tiles

• Economizer

• Super heaters

Ammonia Process

Ammonia Plant is the heart of FFBL or any other fertilizer company because this plant is responsible for Ammonia production and also Carbon Dioxide which is used in the manufacturing of Urea or in other words a shutdown of ammonia plant means a shutdown of whole fertilizer company. Following are the names of some of the major equipment under ammonia plant.

• Furnace (Primary Reformer).• Secondary Reformer.• Heat Exchangers (Shell & Tube, Flat Plate, Finned Type).• Boiler.• Startup Furnace.• Startup Heater and many more.

Inputs: • Natural gas

• Air

• Steam

Outputs:• Ammonia

• Carbon dioxide

PROCEDURE:• Desulphurization of natural gas.

• Crack natural gas in steam to produce hydrogen.

• Remove oxygen from air to give nitrogen in secondary reformer.

• Cool nitrogen and hydrogen in heat exchanger.

• Steam is removed and temperature elevated to 400-600 oC.

• 2N2 + 3H2= 2NH3

• Liquid ammonia is produced.

Urea Process

There are two sections in Urea plant1. Urea Wet2. Urea DryUrea wet section designed based on CO2 Stripping process of Stamicarbon, Netherlands and Urea Dry section designed is based on the Fluidized Bed Granulation technology from Hydro Fertilizer Technology (HFT), Belgium. Comissioned in April, 1999 Urea Plant`s design capacity is 1670 MT/Day and actual is 1900 MT/Day.

Raw Material: • Ammonia• Carbon Dioxide

Diammonium Phosphate (DAP) ProcessThe DAP plant design is based on double pipe reactor(DPR)AZF process from Grande Paroisse, France Commissioned in November 1988. DAP Plant design capacity is 2200MT/DAY and actual is 2450 MT/DAY.

Inputs: • Ammonia • Sulphuric acid • Phosphoric acid • Sand

Output: • DAP granules

Procedure:• Ammonia, sulphuric acid and phosphoric acid added in the pre neutralizer.

This forms the slurry.• The slurry is added along with sand to the granulator. Here grains are formed

by simple mixing.• The grains are then moved to the dryer where it is dried at 90oC for 2

minutes. The heat is provided by the hot gas generator which maintains the temperature.

• Then with the help of belts this is fed to the vibratory feeder for screening.• Only 1/3rd are on size and are moved to the de dusting section De dusting is

done to remove large lumps.• Scrubbing is also done to absorb ammonia by water.• The oversize grain, undersize grain and ammonia water are all recycled.

Equipment’s Of Urea, DAP And Ammonia & Their FunctionScrubberIt is a high pressure vessel where liquid ammonia is stored under pressure. It is an efficient non-corrosive alloy which can handle liquid Urea for a long time. It separates reactive and non-reactive gases. Scrubbers can also be used for heat recovery from hot gases by flue-gas condensation.

ReactorIt is a type of heat exchanger. In this horizontal type of reactor ammonia and carbon dioxide react with each other to produce Urea. It has tubes inside filled with steam.

ColumnsIt is a high pressure vessel for mixing and separating the things. Different type of processes takes place in it at a time.

PipesThey are the close conduits in which the fluid flows. They are designed to bear only the internal pressure. For a pipe we define two things”

• Nominal pipe size (NPS) , usually the outer diameter of the pipe

• Wall thickness on some standard e.g. 5,10,25,STD,XS,XXS

TubesThe only difference b/w a pipe and a tube is, tubes are designed to bear both internal and external pressure of the fluid. In tubes we exactly define the thickness.

Heat ExchangersHeat exchangers are used to transfer heat from one media to other media. They are classified on different basis.

Types of Exchanger• Plate type

• Shell and tube type

Plate type:A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that the fluids are exposed to a much larger surface area because the fluids spread out over the plates.

Shell and Tube Type:A shell and tube heat exchanger is a class of heat exchanger designs. It is suited for higher-pressure applications. As its name implies, this type of heat exchanger consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. The set of tubes is called a tube bundle, and may be composed of several types of tubes: plain, longitudinally finned, etc.

Baffles: These are panels responsible for obstructing and redirecting the flow of fluid in the shell side of an exchanger. They are situated normal to the walls of the shell and force the liquid to flow at right angles to the axis of the tubes.

ValvesA valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing various passageways. In an open valve, fluid flows in a direction from higher pressure to lower pressure.

The Gate Valve: The gate valve is a general service valve used primarily for on - off, non-throttling service. The valve is closed by a flat face, vertical disc, or gate that slides down through the valve to block the flow.

The Globe Valve: The globe valve effects closure by a plug with a flat or convex

bottom lowered onto a matching horizontal seat located in the center of the valve. Raising the plug opens the valve, allowing fluid flow. The globe valve is used for on - off service and handles throttling applications.

The Pinch Valve: The pinch valve is particularly suited for applications of slurries or liquids with large amounts of suspended solids. It seals by means of one or more flexible elements, such as a rubber tube, that can be pinched to shut off flow.

The Ball Valve: The ball valve is similar in concept to the plug valve but uses a rotating ball with a hole through it that allows straight-through flow in the open position and shuts off flow when the ball is rotated 90 degrees to block the flow passage. It is used for on-off and throttling services.

The Butterfly Valve: The butterfly valve controls flow by using a circular disc or vane with its pivot axis at right angles to the direction of flow in the pipe. The butterfly valve is used both for on-off and throttling services.

The Check Valve: The check valve is designed to prevent backflow. Fluid flow in the desired direction opens the valve, while backflow forces the valve closed.

Fabrication ShopValve testing methodsThere are three types of valve testing in fabrication shop.

• Seat test

• Back seat test

• Shell test

ScaffoldingScaffolding is under fabrication shop. Its purpose is to provide temporary working condition to work at some height by joining pipes. There are about three types of pipe joint we see in scaffolding area in which there are

• Swivel joint

• Spigot joint

• Fix joint

Welding in fabrication shopGas cutting area:

For gas cutting acetylene cylinder and oxygen cylinder are used. When acetylene burns with oxygen then it creates high temperature flame that can cut metals. To check the percentage of oxygen and acetylene colour of flame is very important. Yellow colour indicates reducing flame and blue colour indicate oxidizing flame.

Plasma cutting:

In plasma cutting plasma gas is used. Its flame temperature is higher than the gas cutting flame. It has advantage that its flame is not oxidizing flame and so it can be used for cutting of aluminum also. There are two machines in fabrication shop for plasma welding. One has capacity to cut of thick 0 to 6mm and other has 0 to 32mm.

Arc welding:

Arc welding in fabrication shop are SMAW and GTAW. The difference between SMAW and GTAW is that for shielding purpose tungsten gas is used in GTAW while in SMAW on electrode there is coting which melt and create a gas shielding area which protect weld bead from oxygen.

Machine ShopMachine shop has a number of machines used for different purposes. They include:

• Lathe machines: A lathe is a machine tool which rotates the workpiece on its axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with tools that are applied to the workpiece to create an object which has symmetry about an axis of rotation. There are 3 types of lathe machines in the machine shop; small duty lathe, medium duty lathe and heavy duty lathe machine.

• Drilling machine: A machine for making holes with removal of chips. Drilling machines are used for drilling, boring, countersinking, reaming, and tapping.

• Radial drilling machine: A radial drilling machine or radial arm press is a geared drill head that is mounted on an arm assembly that can be moved around to the extent of its arm reach.

• Milling machine: Milling is the machining process of using rotary cutters to remove material from a workpiece advancing (or feeding) in a direction at an angle with the axis of the tool.

• Balancing machine: A balancing machine is a measuring tool used for balancing rotating machine parts such as rotors for electric motors, fans, turbines, disc brakes, disc drives, propellers and pumps. The machine usually consists of two rigid pedestals, with suspension and bearings on top supporting a mounting platform. The unit under test is bolted to the platform and is rotated either with a belt-, air-, or end-drive. As the part is rotated, the vibration in the suspension is detected with sensors and that information is used to determine the amount of unbalance in the part. Along with phase information, the machine can determine how much and where to add weights to balance the part.

Motor Vehicle ShopIn automobile section of FFBL there are 3 cranes , one crane mounted belt load truck, oil tankers and loaders. In cranes one crane has load capacity of 55ton, other two have 20ton. They are hydrocrane, with 6 cylider v type engine. Load chart of crane depend upon the radius, angle and boom of the crane. If crane have minimum radius, minimum angle and minimum boom length then crane can carry maximum load. Crane mounted belt truck have crane that can carry about 20 ton weight.

Machinery at Urea, DAP and Ammonia Plant & Their Function This includes the moving parts of the plant. Their summary is as follows:

• Compressors:

Compressors are used to flow fluid (gases) from one place at plant to other and also to raise their pressure. They are of two types on basis of classification.

1. Verticle compressor

2.Horizontal Compressor

Also they are sub-divided into various types:

1. Radial flow(Centrifugal) compressor:

These compressors are used for medium flow and pressure. In FFBL plantsite mainly these compressors are installed. These are dynamic compressors.

2.Axial Flow Compressors:

These compressors are uesd where low pressure but comparatively high flow is required such as in gas turbines. In plantsite, all gas turbines have multistage axia flow compressors. These are also dynamic compressors.

3.Positive Displacement Compressors:

These are uesd where low flow but high pressure is required.

• Pumps: Pumps have the same functions as of compressors, instead their working fluid is liquid. In plantsite positive displacement pumps are installed in lubrication oil circuits to make sure the constant supply of lub oil to compressors, turbines, bearings and other varios machines.The types of pump impellers are open impeller, partially closed impeller and closed impeller. In pumps there are steam turbine pumps which are run by steam turbines.

• Steam turbines:

Steam turbines are installed in many places. These are running pumps and motors etc. These are powered by steam producing by boilor.

• Gas turbines There are three gas turbines at plantsite. Two at the utilities and one at synthesis gas.

The major components of a gas turbine are:

• Self-cleaning type air filter

• Multi-stage axial flow compressor

• Combustion system

• Closed forced lubricating oil system

• Diesel engine storage system

• Natural gas firing system

• Fire detection and co

• protection system

• Seismic type vibration system

• Thermo couples for measuring critical turbine temperature

• Couplings : The two types of coupling are mechanical and hydraulic. The advantage of hydraulic coupling over mechanical is that there are no jerks. Thermal plug and fuse plug are two methods for the safety of the coupling.

• Dynamic Sealings: These kind of sealings are used to seal different stages in compressors or pumps to maintain pressure. These are of variuos types:

1. Labyrith Seals

2. Oil floating seals

3.Dry gas seals

• Bearings: As by name it is clear, bearings are used to bear loads and also helps in smooth running. On basis of classification they are two types

1. Axial bearing also called thrust bearing.

2. Radial bearing

Tool ShopSome of the tools are as follows:

• Argon set

• Baby grinder

• Angle grinder

• Cutting set(gas cutting)

• Plasma cutter (for CS)

• Eye bolt

• Crow bad

• Pneumatic gun

• Rubber hammer

• Pump set

• Ladder

• Jack