INTERNSHIP REPORT

Internship Report-FFC

INTERNSHIP REPORT
Summary:
In my Report, I shall explain:

Brief Introduction of FFC and its Environment

Description of Ammonia, Urea and Utilities process
Centrifugal Pumps, P.D. Compressors, Bearings and Seals learnt at
Machinery-I
Valves, Heat Exchangers, Materials and Piping learnt at Equipment-II
Details of Fabrication and Machine Shop
Details of Health Safety Environment at FFC
Conclusion and Suggestions

Introduction:
A brief Introduction of FFC is as follow:

FFC is Pakistans largest urea manufacturing Company

Incorporated in 1978
Commissioning of first urea plant in 1982
FFC today operates three Urea plants
Capacity of over 2 million tons per annum
FFC, combined with FFBL, has a market share of 48% in urea and 50% in
DAP
FFC owns FFC Energy Limited (FFCEL) and Fauji Fresh n Freeze (FFF)
FFC has been placed in the top 25 companies in Karachi Stock Exchange
for consecutive 20 years
FFC is known globally. It is a member of the:
1. International Fertilizer Industry Association (IFA),
2. Arab Fertilizer Association (AFA)
3. United Nations Global Compact (UNGC)

FFC has been providing Quality products to its consumers since its
commission.
Fauji Fertilizer Company Goth Machhi plant site is divided into two main categories:
Plant-I
Plant-II
These two plants are further divided into:
Urea section
Ammonia section
Utilities section
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Ammonia Plant description:

Manufacturing of Ammonia Involves 6 main processes:

Purificatio
n

Reforming

CO
conversion

Ammonia
Synthesis

Methanati
on

CO2
Removal

Urea Synthesis:
Natural
Gas+Steam+
Fuel

Ammon
ia

CO2 Recovery

Urea

Utilities Plant Description:

Utilities section is common for both the plants. It provides assistance to
both the plants in the form of power generation, water purification.
Raw materials for utility plant are:
Well water,
Canal water and
Natural gas.

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In the whole process of Urea Making, utilities plant provide assistance

in the form of power, cooling towers which cools the hot circulated
water of both the plants.

Machinery-I
Centrifugal Pumps:

A Pump is a device that adds energy to the Liquid fluid.

A Centrifugal pump adds energy by Centrifugal Force created by the rotation
of Impeller.
Main Parts of the Centrifugal are:
1. Shaft: To Transmit the power from prime mover to impeller
2. Impeller: Source of Pumping Action. Increase the pressure of the fluid.
3. Wear rings: Prevents the Wearing of Impeller and Casing. Also
maintain pump Efficiency
4. Sealing: Sealing prevents the leakage. Mechanical Seals and Packing
are used to seal the leakages
Centrifugal pumps work on the principal of Bernoullis Principle due to the
Volute type Casing.
A pump cannot suck the liquid on its own, it should be Primed first. Priming
involves the removal of air and filling the pump with liquid.

Positive Displacement Compressors:

Compressor is used to increase the pressure of the gas.

Compressor increases the pressure of a gas by first entrapping it into a cylinder and
then compressing it into smaller volume.
Construction of the Compressor involves:
1. Piston: Gas is compressed by the back and forth motion of the Piston.
2. Heads: The ends of the cylinder are equipped with removable heads. The
heads may contain fluid for cooling.
3. Packing rings: The crank end contains set of Metallic rings. Packing rings
prevents the leakage around the piston rod.
4. Piston Rod is connected with the piston. Crosshead connects the
connecting rod with the Piston rod. Connecting rod is moved by the
Crankshaft.
Startup: Before startup, the compressor is unloaded first and then it is confirmed
that there is no fluid in the suction line and the lubrication is good.
Shutdown: The compressor is unloaded and prime mover is stopped. Suction valve
is closed and the compressor discharge valve is closed after opening the vent valve.

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Mechanical Seals:
Mechanical Seals prevent leakage by making use of two surfaces sliding on each other. It
provides very effective sealing and consists of following main parts:

Stationary Ring
Rotatory Ring
Compressive Ring

Equipment-II
Valves:
Valve is a mechanical device which can be used for different functions such as to
control the flow rate of the fluid, to control the direction of the fluid, to ON/OFF the
flow, to control the pressure of the fluid, to control the temperature of the fluid and
to relieve the pressure of the fluid.

Types of Valves:

Gate Valves: In these valves flow rate is controlled by gate. The

construction includes Gate, Body, Bonnet and Stem. It has two types,
Outside Stem and Yoke and Non-Rising Stem gate valves. In OS and Y,
stem rises up when the valve is opened. In NRS, stem does not rise.
Globe valves: In these valves flow is controlled by disc. They offer greater
resistance to flow than gate valves. It produces greater pressure drop due to
change in flow direction but there is very little wear due to friction. But the
erosion due to high speed fluid is higher than gate valves.
Check Valves: These are self-operated valves. The main function of these
valves is to control the direction of fluid flow. They prevent reverse flowing of
the fluid.

Heat Exchangers:
The equipment made to transfer heat between cold and hot streams through a
combined conduction-convection mechanism is called heat exchanger.

Types: According to flow: Parallel, counter and cross flow heat exchangers.
According to geometry: Shell and tube type, plate type and extended
surface type exchangers.
Construction of shell and tube type heat exchanger: Main components
are shell, tubes, tube sheets, baffles (longitudinal and segmental),
impingement plates, partition plate, sliding rod, spacers, tie rods, front
(channel) head, rear head and cover.

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Maintenance: Fouling can decrease the heat transfer rate so Anti-Foulants must be
used. Cleaning can be done Offline and Online. Cleaning methods are HP water Jets,
Bullets etc.

Materials:
Stainless steels:
They have higher resistance to corrosion than plain carbon steels. Major elements;
Cr: 12-30% Ni: 0-22% .Types are Austenitic Ferritic Martensitic.
Austenitic: They are classified in 200 and 300 series with max: 16%-30% Cr
and 2%-20% Ni for enhanced surface quality, increased corrosion and wear
resistance. They are cold harden able.
Ferritic: They are non-harden able and are classifies in 400 series, usually
with 10%-20% Cr and very little Nickel. They have more strength than
austenitic but reduced corrosion resistance.

Visit to Workshops
Machine Shop:
Machine shop provides assistance in machining and producing different parts like
shafts, impellers or any part of machinery, equipment being used at plant. Every
machine has its own functions and cutting tools for the sake of material removing.
There are two main functions of machine shop:

It works as a maintenance agency that is, it provides assistance in

maintenance of different machinery of the plant.
To manufacture spare parts locally. Thus saving the large expense of the
company which would be wasted in buying the parts from other countries.

List of some machines available in Machine Shop are:

Lathe Machine
CNC Drill Machine
Portable lathe machine
Lapping Machine
Surface grinder
Universal milling machine
Radial Drilling Machine
Boring Machine

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Fabrication Shop:
Fabrication shop fabricates different parts. It provide assistance in welding, special
tools for plant equipments which are necessarily required.
It has following services:

Valve reclamation area

Tool room
Cylinders area
Sheet cutting area
Plate rolling machine
Pedestal Grinders
High pressure jetting machine
Fume extractor
Electrode oven
Gasket cutting machine

Health Safety Environment

Importance of Safety:
Safety means protection of:
Humans
Machinery and equipment
Environment
Devices used to protect employees from injury or illness resulting from contact
with chemical, radiological, physical, electrical, mechanical, or other
workplace hazards is referred as personal protective equipments. These
include protective clothing, helmets, goggles, or any other equipment
specially designed depending on the hazard present.
Goal of FFC is to protect its people, the public, its property and the Environment in
which they work and live. It is a commitment that is in the best interests of its
customers, its employees and all other stakeholders.

HSE Objectives are:

Nurture a Safe and Healthy Work Environment.

Prevent Risk to Plant and Personnel.
Ensure Business Profitability & Sustainability.
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Compliance to Rules & Regulations

In regard of Safety, FFC has achieved:

27 Award of Honor
5 First Place Award
4 Second Place Award
6 Award of Merit
3 Industry Leader Award
4 Perfect Award
HSE

management system includes:

Leadership and Commitment
Policy and objectives
Employees Engagement and Awareness
Risk and Change Management
Incident reporting and Investigation
Emergency Preparedness
Performance Evaluation
Occupational Health

Conclusion and Suggestions

Conclusion:
During scorching days of summer internships are just like cooling ice. My stay here
in FFC was awarding. I was able to achieve the following skills:

Technical Skills: Technical Skills of the employees working at FFC are really
attracting. During my stay, I was able to gain some of these technical skills.
Time Management: As overall Engineer and Technician are always racing
against tight timeline and packed schedule, a proper time management will
minimize facing overdue deadlines. An effective time management allows us
to do our assignment efficiently and meet our schedules. Scheduling avoids
time wastage and allows us to plan ahead, and gaining more as a result.
Colleagues Interaction: In working environment, teamwork is vital in
contributing to a strong organization. Teamwork is also essential in reaching
the goals of the organization as an entity. Thus, communicating and sharing
is much needed in the working environment. Therefore, we should be
respecting each other in work, and working together as a team, instead of
working alone. This is because working together as a team is easier in
reaching our targets, rather than operating individually.
In the end, my Internship at FFC was really rewarding.

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Feedback:
FFC is a well-organized and disciplined industry. It gives maximum opportunities to
the individual to learn and excel in technical and practical knowledge. It has so
much to learn, to experience the new things. All engineers are very professional
and assist in every problem. They provide the platform to develop professional
skills along-with technical knowledge. Here at FFC, sports activities are excellent
and management club staff is also very friendly and up to the mark.
I would like to give some suggestions so that future internees can be benefited:
Proper tests and interviews should be conducted of the internees.
Plant visits should be scheduled in the program manual.
Cash system in addition chits should be available at Cafes.