Fauji Fertilizer Bin Qasim Limited

SUMMER INTERNSHIP REPORT

PAF-KIET

Sikandar Sarfraz

TIME PERIOD: 18 JULY, 2016 – 12 AUGUST 2016

Submitted to: UM L&D

CONTACT NUMBER: +92-341-2164920 EMAIL ID: sikandarsarfraz00@gmail.com

ABSTRACT

FFBL is a well-known, recognized and professional industry in Pakistan. It also provides training of fresh Engineers as an Intern. They build their identity in training due to their dedicated staff. This prestigious institution has educated, disciplined and reputed trainers.

This was my best experience of training in any industry. I learnt many things and got that practical knowledge that I wasn’t able to achieve in my University. 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 at 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 am also very thankful to Engr Faheem who give me his extra time on understanding things and make my things clear he also helped me giving idea for my final year project

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.

Contents AN INTRODUCTION TO FAUJI FERTILIZER BIN QASIM LIMITED ............................................................. Safety ............................................................................................................................................... Complex Description ......................................................................................................................... Ammonia Process ............................................................................................................................ Utilities plant ................................................................................................................................... Product Handling and Shipping ......................................................................................................... Sensors ........................................................................................................................................... Programmable Logic Controllers ....................................................................................................... Distributed Control Systems ............................................................................................................. Emergency Shut Down System (ESDS) ............................................................................................... Emergency Load Shedding System (ELSS) .......................................................................................... Vibrational Monitering System ......................................................................................................... Burning Management System .......................................................................................................... Gas Turbine ..................................................................................................................................... Relays ............................................................................................................................................. Circuit Breakers ............................................................................................................................... Contactors ...................................................................................................................................... Conclusion ......................................................................................................................................

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 53% 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. One of the milestones in the success of FFBL is its accreditation of ISO certification, which was achieved in Mar 2006 for both the Head Office and Plantsite.

FFBL also have membership of industry association and trade bodies;

Rawalpindi Chamber of Commerce nternational Fertilizer Association

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.

Complex Description

FFBL complex includes the following process units, offsite and on site.

PROCESS UNITS: 1. The process Units are

2. Ammonia Plant

3. DAP Plant 4. Urea Plant

5. Utilities & Power Generation.

FINAL PRODUCT RAW MATERIAL & CHEMICAL STORAGE: 1. Final product storage & bagging Facilities

2. Ammonia Storage (5000 MT/Day)

3. Phosphoric Acid , Sulfuric Acid storages

4. Nitrogen Storage Unit

OFF SITES AND OTHER BUILDINGS 1. Fire water

2. Natural gas Station

3. Effluent Treatment Facility

BUILDING INCLUDE 1. Control Room and electrical Room 2. Laboratory

3. Technical service Building

4. Ware house and Workshop

5. Learning and Development Center

6. Administration Building

Ammonia Process INTRODUCTION: 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.

POWER DISTRIBUTION:

Ammonia sub station receives eight 13.8kv lines from main station from those 8

lines 4 paires are made 1 for mediam volatge(13.8kv is stepped down to 2.4kv

through transformer) line and 3 for low volatge line (13.8kv is stepped down to

480v through tranformer).

MEDIUM VOLTAGE LINE:

13.8 kv is stepped down to 2.4kv and directly send to medium voltage motors for

their controling monitring and protection purpose.

LOW VOLTAGE LINE:

Now 13,8kv is stepped down in 480 volts and ammonia plant has 3 pairs like this

480 is then devided into MCC(motor control centre), PPB(power distribution

panel),ASPB(aux service panel board)

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.

Power Generation

For power generation in FFBL there are 2 gas turbines and one

diesel generator (in emergency). The capacity of power

generation for each gas turbine is 26 MW. The power is generated

at 60 Hz and the voltage is 13800 volts.

Power Distribution

The Power generated by the two gas turbines is directly fed on to

the bus bars at 13.8 kV. The two bus bar are connected by tie

breakers, which are normally open. If one of the gas turbine

trips, then the tie breakers connect the two bus bars and thus load

is taken by the other turbine. Between the two bus bars is a

Diesel Driven Emergency generator of 2MW, which comes into

action in case of emergency.

The output of these feeders are distributed to the whole plant as

under and then at other side there is a step down tranformer that

make a certain desireable

voltage level

1 Residential

2 Workshop

2 Urea

8 Ammonia

2 Bagging

2 DAP

2 Colling Tower

2 ROU

2 Utilities

Diesel driven emergency generator:

It is used if the gas turbines stop working and is used to stop

the plant from shutting down. It automatically switches on in

20 seconds and has the capacity to operate the plants until the

gas turbines come back online.

PRODUCT HANDLING AND SHIPPING (PH&S): INTRODUCTION: Its very important department at FFBL who is responsible for storage and

checking of final product that is UREA and DAP. It has a storage capacity of 3500

MT UREA and 3500 MT DAP. It has 9 conveyer belt lines 5 for UREA and 4 for

DAP. Each bagging line has 800 bag/hr capacity. The whole process is controlled

through mini plc simens s700 in each bagging line.

FINAL PRODUCT: Final product is weighted in a chamber and 50 KG bags are produced then sensed

and finally through a printer each sack is labbeled by current price and number.

PRINTING: A series plus 300 printer is used for printing.

SENSING: Proximity sensor Fx-403 that is IR based.

POWER DISTRIBUTION:

2 Feeders output of 13.8 kv are entered in T1 (transformer 1 ) and T2 (transformer

2). Transformers step them down in 480 volts then they are further devided into

DPP(distributive power station) and MCC (motor control centre). DPP is further

devided into SV(signal voltage) CV(control voltage) and LT (lightning

tranformer) for further usage. Also there is a frequency converter that converts 60

hz into 50 hz for lightning and various purposes.

SENSORS: PRESSURE SENSORS: BOURDON TUBE

Bourdon tube pressure gauges are used for the measurement of relative pressures

from 0.6 ... 7,000 bar. They are classified as mechanical pressure measuring

instruments, and thus operate without any electrical power.

The C-shaped Bourdon tubes, formed into an angle of approx. 250°, can be used

for pressures up to 60 bar. For higher pressures, Bourdon tubes with several

superimposed windings of the same angular diameter (helical tubes) or with a

spiral coil in the one plane (spiral tubes) are used.

BALLOW GUAGE

A bellows gauge contains an elastic element that isa convoluted unit that expands

and contracts axially withchanges in pressure. The pressure to be measured

canbe applied to the outside or inside of the bellows.However, in practice,

most bellows measuring deviceshave the pressure applied to the outside of the

bellows(fig. 11-7). Like Bourdon-tube elements, the elasticelements in bellows

gauges are made of brass, phosphorbronze, stainless steel, beryllium-

copper, or other metalthat is suitable for the intended purpose of the gauge.

TEMPRATURE SENSORS: RTD:

Resistance thermometers, also called resistance temperature

detectors (RTDs), are sensors used to measure temperature. Many RTD elements

consist of a length of fine wire wrapped around a ceramic or glass core but other

constructions are also used. The RTD wire is a pure material, typically platinum,

nickel, or copper. The material has an accurate resistance/temperature relationship

which is used to provide an indication of temperature. As RTD elements are

fragile, they are often housed in protective probes.

THERMOCOUPLE:

A thermocouple is an electrical device consisting of two different conductors

forming electrical junctions at differing temperatures. A thermocouple produces a

temperature-dependent voltage as a result of the thermoelectric effect, and this

voltage can be interpreted to measure temperature

LEVEL SENSORS: SONAR SENSOR:

Active ultrasonic sensors generate high-frequency sound waves and evaluate the

echo which is received back by the sensor, measuring the time interval between

sending the signal and receiving the echo to determine the distance to an object.

FLOW SENSORS: The differential producing flowmeter or Venturi has a long history of uses in

many applications. Due to its simplicity and dependability, the Venturi is among

the most common flowmeters. With no moving parts or abrupt flow restrictions,

the Venturi can measure fluid flowrates with a minimal total pressure loss.

ORIFACE PLATE:

An orifice plate is a device used for measuring flow rate, for reducing pressure or

for restricting flow (in the latter two cases it is often called a restriction plate ).

Either a volumetric or mass flow rate may be determined, depending on the

calculation associated with the orifice plate.

WEIGNING SENSORS:

LOAD CELLS

A load cell is a transducer that is used to create an electrical signal whose

magnitude is directly proportional to the force being measured. The various types

of load cells include hydraulic load cells, pneumatic load cells and strain

gauge load cells.

The weighing unit (FW 401A-L) for sepration of 50 kg products.

CONVERTERS: Their are some converters in FFBL that are used to control different machinery

some of famous converters are

I TO P CONVERTER

I TO H CONVERTER

I TO P CONVERTER:

A current to pressure transducer (I/P) converts and analog signal (4 to 20 mA) to a

proportional pneumatic output (3 to 15 psi). Its purpose is to translate the analog

output from a control system into a precise repeatable pressure value to control

pneumatic actuators/pnematic values, damper etc

I TO H CONVERTER This is same as i to p it just convert small amount of current in hydraulic

PROGRAMMABLE LOGIC CONTROLLERS: INTRODUCTION:

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial

computer control system that continuously monitors the state of input devices and

makes decisions based upon a custom program to control the state of output

devices

INPUT: It can be directly connect to industrial equipment or with 5v DC or AC or mA etc

OUTPUT: we can use its out;put signal directly to small motors, contractor, valves solenoid

and lights

PROGRAMMING : It can be programmed through three methods

1) Ladder logic

2)fundamental block

3)statement list

HARDWARE: its hardware consist of power supply may be of 24 volt DC for its power. then

comes processors that fetch decode and execute the instruction then comes i/o

card that may be analog or digital depending on usage. its operation volatge is 5V

DC.

PLC COMPANIES: Types of PLCs installed at FFBL are

1) Siemens s7300

2) HIMA

3) Allen Bradley

4) Bendly nevada 3500/3300

DISTRIBUTED CONTROL SYSTEM: INTRODUCTION: A distributed control system (DCS) is a control system for a process or plant,

wherein control elements are distributed throughout the system. This is in contrast

to non-distributed systems, which use a single controller at a central location. In a

DCS, a hierarchy of controllers is connected by communications networks for

command and monitoring.

EXPLANATION: It is basically same as plc to control industrial equipments but its advantage is that

it can hand a larg

system and its working is very smooth and we can operate PLC through it,

ELEMENTS: A DCS typically uses custom designed processors as controllers and uses both

proprietary interconnections or standard communications protocol for

communication. Input and output modules form component parts of the DCS. The

processor receives information from input modules, processing the information

and decides actions to be performed by the output modules. The input modules

receive information from input instruments in the process (or field) mainly via

sensors and the output modules transmit instructions to the instruments in the field

for initiating actions mainly via final control elements . The inputs and outputs can

be either analog signal which are continuously changing or discrete signals which

are 2 state either on or off, the signals can also be via fieldbus such as foundation

fieldbus, profibus, HART, Modbus and other digital communication buses with

communicates not only input and output signals but also advance messages such

as error diagnostics and status signals.

COMPANIES: following DCS are installed at FFBL

1) Bailey Infy 90

EMERGENCY SHUT DOWN SYSTEM (ESDS): INTRODUCTION: Emergency Shutdown System (ESD) is designed to minimize the consequences of

emergency situations, related to typically uncontrolled flooding, escape of

ammonia, or outbreak of fire in hydrocarbon carrying areas or areas which may

otherwise be hazardous.

EXPLANATION: An emergency shutdown system for a process control system includes an

emergency shutdown (ESD) valve and an associated valve actuator. An

emergency shutdown (ESD) controller provides output signals to the ESD valve in

the event of a failure in the process control system. A solenoid valve responds to

the ESD controller to vent the actuator to a fail state. A digital valve controller

(DVC) test strokes the ESD valve. An impedance booster device enables the dc

powering of the solenoid valve and the DVC over a two wire line while still

permitting digital communication over the same two wire line.

HIMA PLCs are specially installed at plant site to moniter shut down system it

just shuts the repected emergeny areas rest plant remains working.

EMERGENCY LOAD SHEDDING SYSTEM (ELSS):

INTRODUCTION: It is a system that is responsible to provide power or electricity to the whole plant

in case of any emergency this system is programmed to provide power to the most

critical areas like ammonia.

EXPLANATION:

It is a plc and dcs combined control system that are interlinked and programmed

to provide power priority wise like if their is shortage of power then it will switch

of power of residential area then workshop and etc its main job is to power up the

most critical areas like at ammonia plant hydrogen tank , chlorine tank etc

VIBRATION MONETRING SYSTEM: EXPLANATION:

The vibration monitoring in machines is performed through Bentley Nevada 3300 Proximitor Sensor System. It has three main in order to sense the vibrations which includes probe, extension cables and proximitor. Probe is installed on the machine and has a tip assembly. The extension cable connects the probe allows to reach junction box. The other end provides connection for the proximitor. The proximitor is an electronic device that has two functions. firstly, it generates a radio frequency using an oscillator and secondly it monitors the RF signal in order to extract usable data using a demodulator circuit

BURNING MANAGEMENT SYSTEM: INTRODUCTION:

A Burner Management System (BMS) is a safety solution for power generation facilities that enables the safe start-up, operation and shut down of the multiple burner furnace section of burner. It reduces maintenance, improves up-time and provides a safe environment for the plant personnel. It monitors and controls igniters and main burners by utilizing flame scanners. It employs safety shut off valve, pressure, temperature, flow, and valve position limit switch

EXPLANATION: For quick response BMS is runned on specially designed simens s7400 Plc then moniter , control and protect it and envoirnment also.

GAS TURBINE: INTRODUCTION:

Power Generation at FFBL is done through two Gas turbines. SPECIFICATIONS:

MANUFACTURER General electronics

POWER RATINGS 36.6MW

CURRENT RATINGS 1531A

GENERATED VOLTAGES 13.8kV

RPM 3600

FREQUENCY 60Hz

PF 0.9

EX 2000:

It work on the principle of Faraday’s electromagnetic induction. The essential part of this principle is the magnetic field. The magnetic field is produced from a DC power source from an Exciter that is part of the generator system. The generator while producing electricity also has to produce this at a constant voltage for the electrical system to work properly. Controlling the magnetic field controls the voltage output of the generator.And its main working is to maintain 3.8KV so that we can have a constant voltage level.

GOVERNER:

It is also a part of gas turbine and its working is to mentain 3600 RPM so that 60

hz remain constant. Mark 5 governer Gas Turbine Control System employs current state-of-the-art technology, including triple-redundant 16-bit microprocessor controllers, two-out-of-three voting redundancy on critical control and protection parameters and Software-Implemented Fault Tolerance (SIFT). Critical control and protection sensors are triple redundant and voted by all three control processors.

COMPANY: It is GOOD WORLD governer 505.

RELAYS: INTRODUCTION: Basic working of relay is switching.we basically switch circuits or power supplys

for controlling and protection purposes.

TYPES: Following type of some relays are installed at FFBL

1) Voltz per hertz relay

2) Under voltage relay

3) Directional power relay

4) Field relay

5) Earth fault relay

6) Sync under voltage relay

7)Lock rotor relay

8) Over voltage relay

9) Alarm relay

CIRCUIT BREAKER: A circuit breaker is an automatically operated electrical switch designed to

protect an electrical circuit from damage caused byovercurrent or

overload or short circuit. Its basic function is to interrupt current flow

after protective relays detect a fault. Unlike afuse, which operates once and then

must be replaced, a circuit breaker can be reset (either manually or automatically)

to resume normal operation. Circuit breakers are made in varying sizes, from

small devices that protect an individual household appliance up to

large switchgear designed to protect high voltage circuits feeding an entire city.

The generic function of a circuit breaker, RCD or afuse, as an automatic means of

removing power from a faulty system is often abbreviated to ADS (Automatic

Disconnection of Supply).

CONTACTOR: A contactor is an electrically controlled switch used for switching an electrical

power circuit, similar to a relay except with higher current ratings.[1]

A contactor

is controlled by a circuit which has a much lower power level than the switched

circuit.

CONLUTION: As a conclution i learned alot in this duration of 1 month, i am now much familiar with industry envoirnment as well as fertilizer envoirnmen. This internship also helped me improving my technical skills as well as communication skill, I again thank to all the staff of FFBL for giving me their precious time.