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.

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

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.

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.

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.

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.

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

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

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

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.

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.

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:

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:

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

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.

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