Internship Report

FFBL
FAUJI FERTILIZER BIN QASIM LIMITED KARACHI




Submitted By:

HAMZA AHMAD RAZA

3
RD
Year Mechanical Engineering

UNIVERSITY OF ENGINEERING AND TECHNOLOGY
LAHORE

Submitted To:

The Technical Training Centre
FAUJI FERTILIZER BIN QASIM LIMITED

Date of Submission: July 26 13








AN INTRODUCTION OF 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 oe ad ol Fetilize cople i the Pakista poducig DAP (DI
AMONIUM PHOSPHATE) .It is the soul 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. It is the first granulated Urea plant and the first generating
60 HZ 110v power. Most modern state of the art instrumentation system like
Distributed Control system (DCS) and Programmable logic Control (PLC) are
applied on plant site.

Plant utilities

Utility plant provides the facilities to other plant to operate well and continuously.
Fo that pupose it is icluded of followig euipets ad achie ad
departments

Cooling tower
Power generation
Filtration of water
Supply of water and steam for the whole plant
Chillers and hvac
Compressed air for whole plant
Dimin water, hot water
Natural gas distribution
Raw water storage
Fire water
Portable water

Now we will discuss major areas of utilities in description


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. Chemical dosing is also present in
cooling tower for cleaning purpose of water.
There are transfer pumps in cooling tower that supply water. 2 pumps for urea
and utilities, 4 for ammonia.

Power Generation:

For power generation in FFBL there are 2 gas turbines and one diesel generator
(in emergency). The capacity of power generation one gas turbine is 26 MW. First
time in Pakistan power is generating at 60 HZ. The voltage is 13800volts.

Gas Turbine

Major Components 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
2
protection system
Seismic type vibration system
Thermo couples for measuring critical turbine temperature

Diesel driven emergency generator:
It is used in a case that the gas turbine is not running and
to stop the plant from closing it is automatically on in 20 seconds and have
capacity of to operate the plants.

Air compressors
There are three air compressors in the FFBL under the utility section which
provide, supply and generate the compressed air known as instrument air and
service air.
Instrument Air
Instrument air is used in control values. It is moisture free air and used where
corrosion is not affordable.
Service Air
It has moisture in it and can cause corrosion. It is used for cleaning equipments
and to supply oxygen.
Steam Production

Production and supply of steam to whole plant is under utility section. Steam is
generated by two methods
Heat recovery steam generation
Auxiliary boiler
Heat Recovery Steam Generation
Hear recovery steam generation is primary source of steam generation in FFBL.
The function of HRSG is that exhaust of gas turbine is to produce steam from the
exhaust of gas turbine. HRSGs consist of four major components:
the economizer, evaporator, super heater and water preheater. The different
components are put together to meet the operating requirements of the unit. See
the attached illustration of a Modular HRSG General Arrangement.
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. There are following components of auxiliary boilers
Steam drum
Water drum
Boiler tube
Inner casing
Outer casing
Refractory
Tiles
Economizer
Super heaters


Ammonia Plant

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
someof the major equipment under ammonia plant.
Furnace (Primary Reformer).
Secondary Reformer.
Heat Exchangers (Shell & Tube, Flat Plate, Finned Type).
Boiler
Start up Furnace
Start up Heater and many more.


Inputs:
1) Natural gas
2) Air
3) Steam
Outputs:
1) Ammonia
2) 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
o
C.
2N
2
+3H
2
=2NH
3

Liquid ammonia is produced.
Goes to Urea if storage is full.

Diammonium Phosphate(DAP)
Inputs:
1) Ammonia
2) Sulphuric acid
3) Phosphoric acid
4) Sand
Output:
1) DAP granules





PROCEDURE:

All these steps are being carried out simultaneously. All the procedure can be
summarized in a few steps:-
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 90
o
C 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 1/3
rd
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.




DAP
De dusting Granulation Scrubbing












Formation of urea
Urea is formed by reacting liquid ammonia and gaseous carbon dioxide at about
170-185 C and 134-125 bar pressure
2NH3 + CO2 NH2COONH4
NH2COONH4 NH2CONH2 + H2O
Equipets Of Urea, Dap And Ammonia, Their Function
Scrubber
It is a high pressure vessel where liquid ammonia is stored under pressure. Fatima
has the only one scrubber in Pakistan which has internal linings of Safurex. It is an
efficient non-corrosive alloy which can handle liquid Urea for a long time. It
separates reactive and non reactive gases.
Stripper
Carbon dioxide at high pressure from the compressor goes to high pressure
stripper. It is a high pressure vessel.
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.
Priling Bucket
It is a conical spinning bucket where liquid urea is sprinkled at about 102m high
priling tower. These droplets come down and solidify by the cooled air. This
process is called drafting
Thera are two types of drafting:-
1) Natural
2) Mechanical or Forced
At urea plant we do natural drafting.
Equipets of Urea, Dap and Ammonia
Equipments are the stationary parts of the pant which are not rotating and
remain stationary. For example heat exchanger, boilers, furnace etc.
Scrubber
It is a high pressure vessel where liquid ammonia is stored under pressure. Fatima
has the only one scrubber in Pakistan which has internal linings of Safurex.
Stripper
Carbon dioxide at high pressure from the compressor goes to high pressure
stripper. It is a high pressure vessel.
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
Inter coolers
They are basically heat exchangers. At plant we have 3 types of heat exchangers
1) Shell type
2) Fin type
3) Tube type

A) 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.
1) Nominal pipe size (NPS) , usually the outer dia of the pipe
2) 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.
B) Fittings
Fittings are tees, elbows, joints, bends, reducers, nipples, etc.
A reducer is a pipe of converging dia. At smaller size the reducer is called a
sweng nipple.
In reducer 90-100% portion is converging but in a sweng nipple only 30-50%
portion is converging.
C) Flanges
Flanges are used to join the pip. so basically they are pipe joints. They are of
following types
D) Gasket
Used in flanges, exchangers, nozzles for sealing purpose.
They are circular, oval, and hexagonal in shape

E) Valves
They are used for regulating and controlling the flow. Also used for
throttling purpose.
They are of following types
a) Gate valve
b) Globe valve
c) Plug valve
d) Check valve or value
e) Butter fly valve

.
Heat Exchangers

Heat exchangers are used to transfer heat from one media to other media. They
are classified on different basis. Thermodynamically they are of three types
Regenerative
We have a hot plate in this type of exchanger and the cooled fluid comes and
stays on that plate for a while gets warm and finally discharges,
Re-equiperative
Two fluids are separated by a plate. Hot fluid is one side of the plate and cooled
fluid is on the other side of the plate.
Mixed flow
Two fluids are directly in content with each other. For example cooling tower.
On the basis of service exchangers are of following types:-
Condenser
To condense steam from downstream of steam turbine.
Cooler
To cool the fluid. Cooling media is water
Chiller
To cool the fluid. Cooling media is a refrigerant
Types of Exchanger
Plate type
Shell and tube type
Plate type
In this type of boiler we have two type of plates placed b/w the pressure plates
covered in the shell. Plates are very narrow. Warm oil is on one side of the plate
while water is on the other side of the plates heat is transferred from oil to the
water as a result oil is cooled.

Shell and Tube Type
In this type of exchanger oil is in the tubes and water is outside the tubes
contained inside the shell.

Values
Valves are used for controlling and regulating the flow. Valves are also
used for throttling purpose. We saw many types of valves such as; gate valve,
globe valve, check valve (NRV), butterfly valve, ball valve pressure safety valves.
Normally gate values have more height than globe values. For value testing API
598 standard are used in FFBL fabrication shop.


Gate values
They are used for on/off purpose. Gate valves should not be used for throttling.
As the hand wheel on the stem is rotated, the gate travels up or down the stem
on the threads, while the stem remains vertically stationary.
Globe values
Globe valves are probably the most common valves in existence. The globe valve
derives its name from the globular shape of the valve body.
Butterfly values
Butterfly values have a disc which rotate at 90 degree for opening and closing
operation.

Value testing methods
There are three types of value 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
In swivel joint pipe can be joined at any degree, but in fix joint pipe can be joined
at 90 degree to each other. In spigot joint, it is basically used to increase length of
pipe to work at more height.

Welding in fabrication shop

Gas cutting area
For gas cutting acetylene cylinder and oxygen cylinder are used. When acetylene
burn 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 indicate reducing flame and blue colour indicate oidizing flame.

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

High pressure jetting machine
It uses the high pressure jet of water. It is used fro cleaning purpose where a man
cant do pope, fo eaple fo heat echages jet of wate use fo cleaig of
exchangers tubes.

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.
For root pass in arc welding electrode E 6010 is used. First root in welding is
known as gouging.

Automobile section
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 of Urea, Dap and Ammonia
Plant


This includes the moving parts of the plant. Their summary is as follows:
Compressors (screw type mainly)
Pumps
Steam turbines
Gas turbines
Two types of pumps are used:
1) positive displacement (plunger and piston types)
2) centrifugal type (mostly used)
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.
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.
Seals
Gland seal and mechanical seal are used.
Bearings
Feeder
Elevator (pulley and belt)
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


Inspection
Some the types of inspections are listed below:
Ultra sonic testing
6-7 meters deep. High frequency waves are used.
Magnetic particle testing
Material must be ferric. Magnetic field lines are destroyed due to the
presence of defect.
Di-penetrating testing
Spray the penetrate that goes into the cavity of material. Then spray the
remover. It sucks the penetrate and indicates the location of defect.
Hardness testing
Vicker, brinell and Rockwell.
Ferrite scope
Check the iron level in material
Stroboscope
To measure rpm and frequency
Delta scope
To measure the thickness of pains e.g in the storage tank to save any thickness
variation.
Visual inspection
Use to see inside any equipment where normal eye cant see e.g iside the
exchanger tube.
Thermography camera
For temperature measuring and spot temperature measuring. Give
thermographic photo of the machinery.
Tako-meter
Measure the RP
Radio-graphic testing
Produce radioactive rays and used for detecting space inside weld, give a clear
view of the thing.
CP system
Cathodic protection used for underground coating. Underground pipe lines are cp
protected in FFBL.
Crane weight testing
How much weight crane can carry.