FFBL Intern ship report

7/22/2019 FFBL Intern ship report

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Internship Report

FFBLFAUJI FERTILIZER BIN QASIM LIMITED KARACHI


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Submitted By:

HAMZA AHMAD RAZA

3RD

Year Mechanical Engineering

UNIVERSITY OF ENGINEERING AND TECHNOLOGY

LAHORE

Submitted To:

Learning & Development Centre

FAUJI FERTILIZER BIN QASIM LIMITED

Date of Submission: July 26 2013


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AN INTRODUCTION OF FAUJI FERTILIZER BIN

QASIM LIMITEDFFBL 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 (DIAMONIUM 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) areapplied on plant site.


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Plant utilities

Utility plant provides the facilities to other plant to operate well and continuously.For that purpose it is included of following equipments and machinery and

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.


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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 co2 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


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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:

theeconomizer,evaporator,super heaterand 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
http://en.wikipedia.org/wiki/Economizerhttp://en.wikipedia.org/wiki/Economizerhttp://en.wikipedia.org/wiki/Evaporatorhttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Evaporatorhttp://en.wikipedia.org/wiki/Economizer


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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 gas2) Air3) Steam

Outputs:

1) Ammonia2) 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 400-600oC. 2N2+3H2=2NH3


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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:


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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 areformed by simple mixing.

The grains are then moved to the dryer where it is dried at 90oC for 2minutes. 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 1/3rdare 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


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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

Equipments Of Urea, Dap And Ammonia,Their FunctionScrubber

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


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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) Natural2) Mechanical or Forced

At urea plant we do natural drafting.

Inter coolersThey are basically heat exchangers. At plant we have 3 types of heat exchangers

1) Shell type2) Fin type3) Tube type

A)PipesThey 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 pipe2) Wall thickness on some standard e.g. 5,10,25,STD,XS,XXSTubes

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.


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B) FittingsFittings 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) FlangesFlanges are used to join the pipe. So basically they are pipe joints. They are of

following types

D)GasketUsed in flanges, exchangers, nozzles for sealing purpose.

They are circular, oval, and hexagonal in shape

E) ValvesThey are used for regulating and controlling the flow. Also used for

throttling purpose.

They are of following typesa) Gate valveb) Globe valvec) Plug valved) Check valve or valuee) Butter fly valve

.

Heat Exchangers


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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

ChillerTo 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.


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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


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Back seat test Shell test

ScaffoldingScaffoldingis 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 oxidizing flame.

Plasma cutting

In plasma cutting plasma gas is used. Its flame 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 machinerysin 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 proper, for example for heat exchangers jet of water use for cleaning of

exchangers tubes.

Arc welding


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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 isknown 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 thencrane can carry maximum load.

Crane mounted belt truck have crane that can carry about 20 ton weight.

Machinery of Urea, Dap and Ammonia

PlantThis 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)


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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.

CouplingsThe 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.

SealsGland 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


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InspectionSome 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


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Use to see inside any equipment where normal eye cant see e.g inside 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.


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Documents

FFBL Intern ship report