Fauji Fertilizer Bin Qasim Limited

SUMMER INTERNSHIP REPORT

NUST-PNEC

TAYYAB BIN TAHIR

BE-ME

TIME PERIOD: 18 JULY, 2016 – 12 AUGUST, 2016

Submitted to: L&D

CONTACT NUMBER: +92-334-0387082

EMAIL ID: [email protected]

 ABSTRACT
FFBL 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 1920
DAP 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.

Safety
Safety 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 PROCEDURE

The 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 PERMIT

 It 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 PERMIT

This 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 PERMIT

This permit is issued to cover all excavation work inside the plant.

• VEHICLE ENTRY PERMIT

This permit is required before any vehicle can enter the work area.

• RADIOGRAPHY WORK PERMIT

This permit is required to do any sort of radiographic testing anywhere in the
plant.

Intro to Maintenance
The 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 Plant
Utility 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 tower
Cooling 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 Generation
For 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 compressors
There 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 Production
The 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 plant
1. Urea Wet
2. Urea Dry
Urea wet section designed based on CO 2 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)
Process
The 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 Function

Scrubber
It 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.

Reactor
It 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.

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

Pipes
They 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

Tubes
The 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 Exchangers
Heat 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.

Valves
A 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 Shop
Valve testing methods
There are three types of valve testing in fabrication shop.
• Seat test
• Back seat test
• Shell test

Scaffolding
Scaffolding 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 shop

Gas 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 Shop
Machine 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 Shop

In 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 Shop
Some 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