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PREFACE
Pakistan has an agricultural based economy and 25% of GDP is provided by agricultural
products. Fauji fertilizers Bin Qasim limited is itself an icon in the fertilizer industry.
FFBL owns 350 acres plot in eastern industrial zone Bin Qasim, Karachi. An additional 8 acres
is owned for phosphoric acid storage known as tank form area. It produces granular urea and
DAP and it is worth mentioning that FFBL is the sole producer of granular DAP and Granular
urea in Pakistan. FFBL has the privilege to produce 1570 MT/day ammonia, 1670 MT/day Urea
and 2250 MT/day DAP.
This report is an effort to communicate to what I have learnt during my stay at FFBL. The scope
of this internship report was to include the knowledge that is cost by means either practical or
theoretical to the internees.
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ACKNOWLEDGEMENT
First of all I would like to thank to ALLAH Almighty who enabled us to achieve what I aimed
for at FFBL. I am also indebted to my parents and all the management staff, engineers,
supervisors, technicians and others who constantly encouraged me and provided me help and
advice. I would also like to thank some of most important people who were available for us and
without whom I would not have achieved what I thought before coming to FFBL.
Mr. Ziaullah Engineer TTC
Mr. Naveed Hisam Equipment Ammonia
Mr. Ayaz Ali Khan Equipment Ammonia
Mr. Saeed Khan Afridi Equipment Urea
Mr. Rao Jameel Equipment DAP
Mr. Adil Shafique Equipment UTY
Mr. Muhammad Hanif Equipment UTY
Mr. Rizwan Qamar Machinery Ammonia
Mr. Zeeshan Machinery Ammonia
Mr. Safdar Hussain Machine Shop
Mr. S.M. Ali Fabrication Shop
Mr. Major. Shahid (Retd) Motor Vehicle Shop
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MECHANICAL MAINTENANCE
Equipment Unit
This unit of mechanical maintenance deals with the repair & maintenance of stationary parts at
plantsite.
Machinery Unit
This unit of mechanical maintenance deals with the repair & maintenance of rotary parts at plantsite.
Workshop Unit
In this unit the parts that are worn out are repaired and manufactured through different machines.
Reverse Engineering is also done in this unit.
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Ammonia
Process description:
The ammonia process is based on catalytic high pressure offered by Betchel Corporation.
Production is accomplished in following sections:
Raw synthesis gas preparation
Synthesis gas purification
Ammonia synthesis
Ammonia refrigeration
Equipment Ammonia
P & Id’s
P & Id’s are defined as Piping and Instrumentation Diagrams. All the layout of piping and
instruments is defined.
Bechtel Specifications
All the specifications and standards regarding Ammonia plant. For e.g . Length and Diameter of
the pipes, wall thickness, types of welding possible, material used and its grade etc.
For e.g. Sch 80 A106
Sch 80 defines the required wall thickness, whereas A106 is carbon steel.
Valves and its types
A valve is a device that regulates the flow of a fluid (gases, liquids, fluidized solids, or slurries)
by opening, closing, or partially obstructing various passageways. Valves are technically pipe
fittings, but are usually discussed as a separate category.
Types of valves used in FFBL.
Gate Vavle
Gate valve is a valve that opens by lifting a round or
rectangular gate/wedge out of the path of the fluid. The
distinct feature of a gate valve is the sealing surfaces
between the gate and seats are planar, so gate valves are
often used when a straight-line flow of fluid and
minimum restriction is desired.
Globe Valve
is a type of valve used for regulating flow in a pipeline,
consisting of a movable disk-type element and a
stationary ring seat in a generally spherical body.Globe
valves are named for their spherical body shape with the
two halves of the body being separated by an internal
baffle. This has an opening that forms a seat onto which a
movable plug[2]
can be screwed in to close (or shut) the
valve.
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Welding
Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding
a filler material to form a pool of molten material (the weld pool) that cools to become a strong
joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld.
This is in contrast with soldering and brazing, which involve melting a lower-melting-point
material between the workpieces to form a bond between them, without melting the workpieces.
There are two types of welding carried out at Ammonia Plant.
Electric Arc Welding
Argon Welding
Different electrodes are used for different materials respective of their properties.
There are 4 passes for Butt Joint
First Pass
Hard Pass
Filling
Gapping
Boiler (V-405)
A boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid
exits the boiler for use in various processes or heating applications.
Material Used:
Whole of the outer covering of the boiler is made of carbon-steel as it is less costly and easily
available. However, cast iron can also be used.
There are two types of boilers used in various locations of FFBL Plantsite.
Fire-tube boiler
Water-tube boiler
Water-tube boiler
HRSG( Heat Recovery Steam Generation)
Auxiliary boiler
Butterfly Valve
Butterfly valve is which can be used for isolating or
regulating flow. The closing mechanism takes the form of
a disk. Operation is similar to that of a ball valve, which
allows for quick shut off.
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Parts of Boiler
Steam Drum
Economizer
Primary super heater
Secondary super heater
Burners
Risers
Heat Exchangers
A heat exchanger is a device built for efficient heat transfer from one medium to another. The
media may be separated by a solid wall, so that they never mix, or they may be in direct
contact.[1]
They are widely used in space heating, refrigeration, air conditioning, power plants,
chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage
treatment. One common example of a heat exchanger is the radiator in a car, in which the heat
source, being a hot engine-cooling fluid, water, transfers heat to air flowing through the radiator
(i.e. the heat transfer medium).
Types of Heat Exchangers used at FFBL Plantsite.
I-type
U-type
Kettle Type
Maintenance:
Mechanical Cleaning
1. High Pressure Jetting Machine
Chemical Cleaning
Testing Techniques
Hydro Testing
Air Testing
NH3 Testing
Insulation
Building insulation, added to buildings for comfort and energy efficiency
Soundproofing, also known as acoustic insulation, any means of reducing the intensity of
sound
Thermal insulation, materials used to reduce the rate of heat transfer
Electrical insulation, the use of material to resist the flow of electric current and magnetism.
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Types of Insulation used at Ammonia Plant.
Cold Insulation
Hot Insulation
Cladding Sheets
Refectory
Refractory types
Fire proof bricks
Powder form(cold layer)
Castable
Refractory Materials
Alumina
Sand
Silica
Magnesia
Protective Coatings & Paintings
Protective coating is a paint or coating defined by its protective, rather than its aesthetic
properties, although it can provide both.
The most common use of industrial coatings is for corrosion control of steel or concrete. Other
functions include intumescent coatings for fire resistance. The most common polymers used in
industrial coatings are polyurethane,
In ammonia plant, painting is applied to Carbon steel and Low alloy steel.
Before applying paint,
The surface should be dry.
The humidity level should be 80%.
The temperature of the surface should exceed 5oC.
Temperature indicating paints (TIPs) are used at different locations on the ammonia plant
which change color when the temperature exceeds a certain level.
Color Coding
The color coding in the piping system is as follows. This helps in line tracing and identifying the
pipes that carries different fluids.
Yellow------------->danger area (natural gas)
Green-------------->safe (water)
Silver--------------->high temperature water (steam)
Orange------------->lubrication oil
Blue------------------->structure
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Symbols
C = vessels
D = tanks
E = exchangers
K = compressors
F = furnace
T = turbines
P = pumps
GLGs (gas level glass):
Glass is used at high temperatures, high pressure and steam lining. They are used to indicate the
level of the fluids in different vessels or equipments.
The magnetic GLGs are used at the plant site.
Two types used mostly:
Transparent:
Used at high temperatures and pressures. (700 Psi, 500oC)
Reflex types:
Used at low temperature and pressures. (250 Psi, 150oC)
Vessels
Vessels are pressurized containers. They are used for storage and gradual transfer of the
constituent in it to different parts of the plant.
They are of the following types:
Ball type
Cylindrical
Horizontal
Vertical
Steam Traps
A steam trap prime missions is to remove condensate and air preventing escape of live steam
from the distribution system.
The three important functions of steam traps are:
Discharge condensate as soon as it is formed.
Have a negligible steam consumption.
Have the capability of discharging air and other non-condensable gases.
There are three primary categories of steam traps:
Mechanical
Thermostatic
Thermodynamic
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Popular traps in these categories includes the inverted bucket steam trap, the float steam trap, the
thermostatic steam trap and the thermodynamic disc steam trap. Which one is preferred depends
on the application.
The inverted bucket is the most reliable steam trap operating principle known. The heart of its
simple design is a unique leverage system that multiplies the force provided by the bucket to
open the valve against pressure. Since the bucket is open at the bottom, it resists damage from
water hammers, and wearing points are heavily reinforced for long life.
Intermittent operation - condensate drainage is continuous, discharge is intermittent
Small dribble at no load, intermittent at light and normal load, continuous at full load
Excellent energy conservation
Excellent resistance to wear
Excellent corrosion resistance
Thermostatic Steam Traps
There are two basic designs for the thermostatic steam trap, a bimetallic and a balanced pressure
design. Both designs use the difference in temperature between live steam and condensate or air
to control the release of condensate and air from the steam line.
In an thermostatic bimetallic trap it is common that an oil filled element expands when heated to
close a valve against a seat. It may be possible to adjust the discharge temperature of the trap -
often between 60oC and 100
oC.
This makes the thermostatic trap suited to get rid of large quantities of air and cold condensate at
the start-up condition. On the other hand the thermostatic trap will have problems to adapt to the
variations common in modulating heat exchangers.
intermittent operation
fair energy conservation
fair resistance to wear
good corrosion resistance
poor resistance to hydraulic shocks (good for bimetal traps)
do not vent air and CO2 at steam temperature
Float Steam Traps
In the float steam trap a valve is connected to a float in such a way that a valve opens when the
float rises.
The float steam trap adapts very well to varying conditions as is the best choice for modulating
heat exchangers, but the float steam trap is relatively expensive and not very robust against water
hammers.
continuous operation but may cycle at high pressures
no action at no load, continuous at full load
good energy conservation
good resistance to wear
good corrosion resistance
poor resistance to hydraulic shocks
do not vent air and CO2 at steam temperature
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Thermodynamic Disc Steam Traps
The thermodynamic trap is an robust steam trap with simple operation. The trap operates by
means of the dynamic effect of flash steam as it passes through the trap.
intermittent operation
poor energy conservation
poor resistance to wear
excellent corrosion resistance
excellent resistance to hydraulic shocks
do not vent air and CO2 at steam temperature
Machinery Ammonia
Machinery ammonia deals with the moving and rotating parts of that are being used in the plant
for different purposes. It includes the maintenance of machinery and their overhauling after the
specific period given by vendors. The main machinery under the title of ammonia machinery is;
Turbines
Compressors
Pumps
Fans
Blowers
Gear Boxes Couplings
Turbines
Following are the turbines functional at ammonia machinery;
Gas Turbines
Steam Turbine
Hydraulic Turbine
All turbines used here at the plantsite are working as prime movers. Gas turbines employed here
serving as prime mover to sysnthesis. Gas compressor. There are numerous steam turbines
working as prime movers for compressors. Majority are condensation turbines. Hydraulic
turbines are used to run pumps.
Compressors
Compressors used at the plantsite are used to increase the pressure of the gas and air.
The compressors that are in operation
Centrifugal Compressor
Positive Displacement Compressor
There may be single stage or multistage compressors. For e.g. K-101 is a six stage centrifugal
compressor.
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Pumps
Pumps are used to increase the pressure of liquid by changing the velocity head into pressure
head. Types of pumps used in this plant:
Centrifugal Pump
Positive Displacement Pump
For provision of lube-oil and hydrogen recovery unit at ammonia plant. There may be single or
multistage pumps.
Mechanical Seals:
A mechanical seal is a device which helps join systems or mechanisms together by preventing
leakage (e.g., in a plumbing system), containing pressure, or excluding contamination. A seal
may also be referred to as "packing."
Some of the types used in FFBL are as follows:
Stationary seal ring
Rotating Seal Ring
Seal Ring Gasket
Seal Ring Packing
Retaining with driving notch and set screws.
Gear Box
A transmission or gearbox provides speed and torque conversions from a rotating power source
to another device using gear ratios. Gear box is used for variable transmission. It consists of the
following parts:
Bull
Idler or Intermediate
Pinions
Bearings
Couplings
A coupling is a device used to connect two shafts together at their ends for the purpose of
transmitting power. Couplings do not normally allow disconnection of shafts during operation,
though there do exist torque limiting couplings which can slip or disconnect when some torque
limit is exceeded.
The primary purpose of couplings is to join two pieces of rotating equipment while permitting
some degree of misalignment or end movement or both. By careful selection, installation and
maintenance of couplings, substantial savings can be made in reduced maintenance costs and
downtime.
Types of couplings:
Gear type coupling
Diaphragm coupling
Hydraulic coupling
Fluid coupling
Maintenance
Almost types of maintenance are required in machinery ammonia, for e.g lubrication,
overhauling etc.
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UREA/ DAP
UREA
Urea was the first organic compound to be prepared chemically from inorganic starting material.
Its main commercial use is as a fertilizer. Urea is synthesized from ammonia and carbon dioxide.
Ammonia and carbon dioxide react to form ammonium carbamate
2NH3 + CO2 <------------> NH4 CO2 NH2 ( dH = -119 kJ/mol)
The strongly exothermic very rapidly reaches equilibrium. The reaction system shown above is
referred as carbamate equilibrium.
The liquid phase ammonium carbamate is next dehydrated to urea and water.
NH4 CO2 NH2 <-------------> NH2 CO NH2 (UREA) + H2O (dH = +25kJ/mol)
This strongly endothermic reaction is rather slow compared with first one. The system is called
as urea equilibrium
Stamicarbon total recycle process is used here for urea production. In this process almost the
whole quantity of unconverted reactant is returned to reactor. A large portion of reactant is
removed from reactor solution at synthesis pressure by contacting counter currently with CO2.
As CO2 is used as stripping agent so process is stamicarbon
This urea is 99.6% w/w molten urea and sent to granulated portion where the slurry is converted
into the granules by the application of steam, air and urea.
The urea plant at FFBL is divided into the following 4 sections:
Ammonia storage
Carbon dioxide compression area
Urea granulation
Urea wet.
Ammonia storage:
Ammonia is stored in the storage tank of 5000 metric tonnes capacity.
Carbon dioxide compression area:
The carbon dioxide from the ammonia plant is compressed and then cooled by passing through
the heat exchangers and then finally fed to the urea wet part.
Wet Part:
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Dry part:
This section includes the granulator. In granulator hot air and steam is passed through the 99.6%
molten urea. This results in the formation of granules. The granules may be oversized,
undersized or on-size. The on-size granules are carried by bucket elevators while the oversize
granules are crushed in crusher. Undersize granules are recycled to the granulator. Finally we
obtain the desired granular area.
Equipment Urea:
Urea reactor
High temperature carbamate condenser
High pressure stripper
Scrubber
Granulator
Steam traps
Plate heat exchangers
Nozzles
Separators
DAP
Raw materials used to obtain diammonium phosphate are.
Phosphoric acid
Ammonia
Sulphuric acid
Sand
Coating oil(furnace oil)
Basic raw materials are phosphoric acid and ammonia for product formation, while sulphuric
acid is used as a chemical filler and sand is used a physical filler for grade control (grade is
controlled with nitrogen –phosphate composition of 18-46) & Coating oil is used to minimize
dust generation in product handling system and its typical application rate is 0.2% of product
rate.
DAP manufacturing process:
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Process:
Phosphoric acid, sulphuric acid, ammonia and sand are reacted in the pre-neutralizer to form a
slurry and then this slurry is pumped to the granulator where DAP is coated over and granule
form is maintained. Then they are passed to the dryer, then to the vibrating screens and then to
then through the crushers. As a result the on-size particles are formed which are polished and
then coated over by furnace oil.
Equipment in DAP plant
Storage tanks for phosphoric acid
Storage tank for sulphuric acid
Piping system
Valves
Scrubbers
Cyclones
Machinery UREA/DAP
Major machines in machinery Urea/DAP are
Rotating Drums
Blowers
Bucket Elevators
Conveyors Systems
Vibrating Screens
Fans
Pumps
Crushers
Agitators
Coders
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UTILITIES
Equipment Utilities
Utility department provides the basic necessities to run the plant. Utility section includes
Power generation and distribution
Steam generation
Cooling tower
Raw water treatment
Instrument air compressors
Heat ventilation and cooling
Power generation and distribution
For power generation two gas turbines are used having capacity of 26 MW each, but the total
plant consumption is nearly equal to 20 MW. So both operate on low load of each sharing 10
MW each. Power of 13.8 KV and 60 Hz frequency is transferred from main station to
substations. At substations transformer steps down this voltage to 480V for operations of
motors etc.
Steam generation
Two boilers are used for steam generation at Utilities section.
Auxiliary Boiler with capacity of 105 ton/hr
Heat Recovery Steam Generation Boiler
(Recovered heat is from exhaust of Gas turbine)
Capacity of HRSG is 85ton/hr.
Both are producing high pressure superheated steam at a temperature of 3750C and pressure of
39kg/cm2.
Cooling Tower
It provides the cooling water for heat transfer process in the plant. It is induced draft cooling
tower with 10 sections. Chemical dosing for cooling water treatment is referred by Buckman
Laboratories.
Raw Water Treatment
Raw water from pipe is stored in reservoir of 90,000 m3 capacity. This water is sent to clarifier to
remove turbidity and suspended solids present in water. Clarified water is then passed through
sand filters to remove any suspended solids left in water. Then this water is pumped to
demineralization section and also to portable water sections. In demineralization section water is
passed through carbon filters and then to cation filters and then sent to anion filters. Hence water
is demineralised. This demin water is sent to Deaerator section where BFW is prepared for steam
generations.
Instrument Air Compressors
These compressors provide air for instrument operations. Double stage screw type rotary
compressors are used for this purpose.
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Machinery Utility
This plant is the backbone of FFBL plantsite. Malfunctioning in this Plant can result in total
blackout. But proficient Engineers along with the staff are working 24/7 to ensure 100%
power required must be fulfilled.
Two gas turbines of capacity 26.3 MW each.
Three multistage boiler feed pumps
Workshop
Workshop consists of three units
Machine Shop
Fabrication Shop
Motor Vehicle Shop
Machine Shop
Machine shop located at FFBL plantsite consists of the following machines. Our guide Mr.
Safdar briefed about the functions of all the Machines.
Medium Definition Balancing Machine
Universal Milling Machine
Small Duty Lathe Machine
Shaper Machine
High Definition Balancing Machine
Radial Drill Machine
Micro Lathe Machine
Tool Grinder Machine
Bench Drill Machine
Medium Duty Lathe Machine
Heavy Duty Lathe Machine
Universal Boring Machine
Lapping Machine
Grinding Machine
Fabrication Shop
In Fabrication Shop we were briefed about the machines and work done by Mr. S.M.Ali.
Refurbishment of Valves
Hot Tapping Machine
Shearing Machine
Plasma Arc Cutting Machine