Internship Report FFBL

7/21/2019 Internship Report FFBL

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INTERNSHIP REPORT

(Maintenance Unit)

Prepared For:

Learning and Development Center (L & D)

Fauji Fertilizer Bin Qasim Ltd. Krachi

Prepared BY:

Asif Nadeem Khan

Undergraduate Student at

Department of Mechanical Engineering University of Engineering and

Technology, Lahore

Email: [email protected]

Contact: 0345-4522858

June 27, 2014


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Declaration

July 28, 2010

TO WHOM IT MAYCONCERN

Dear Sir:

Submitted for your review is the report of my four week internship at Maintenance Unit of Fauji

Fertilizer Bin Qasim Ltd. plant, during June 2014.

It is hereby declared that the report is compiled in long report format, as per the guidelines and

is based upon the literature review; plant manuals and standard operating procedures; process

flow diagrams and sharing and learning from management and staff of the company. Maximum

possible references from literature are cited and sources are mentioned.

It is anticipated that response will be reflected.

Regards

Asif Nadeem Khan

Undergraduate Student at

Department of Mechanical Engineering University of Engineering and Technology, Lahore

Under Registration No. 2011-ME-341

Email: [email protected]

Contact: 0345-4522858


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Acknowledgements

Author is thankful to

Almighty Allah,

For His unlimited blessings and bounties,

And for keeping him sane, sound and successful;

His parents and friends,

For all their support and trust in him and his aims;

His teachers and guides,

For teaching him things he knew not;

UET Internship and Placement Office,

For bringing the opportunity of this excellent learning and exposure;

And last but never the least

Management and Staff of Fauji Fertilizer Bin Qasim Ltd. Krachi

Especially Unit Managers, Shift Engineers, Supervisors and Operators,

For their utmost help, guidance and time

Which made author make most of his internship at plant site;


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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) are

applied on plant site.


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Abstract

Maintenance unit manages the urea, DAP and Ammonia Plant. The unit is divided into:

Utilities unit; provides plant utilities like electricity, cooling water, instrument air etc

Ammonia unit; produces ammonia and carbon dioxide from natural gas and

atmospheric air

Urea unit; produces urea by dehydration of carbamate, made by reaction of liquid

ammonia and carbon dioxide gas

DAP(Diammonium Phosphate) unit; produces DAP from ammonia and phosphoric acid

Bagging and shipment unit; bags the urea product and sends it to the consumer market

Utilities unit has the most diverse ground of operation ranging from water treatment to steam

generation, boiler operation to power generation, cooling tower to waste water treatment.

Ammonia unit has the maximum learning exposure with catalytic steam reforming, carbon

dioxide removal and recovery, compression and gas synthesis section. Urea unit develops an

exposure to handling of chemicals from urea synthesis to its purification through stripper, MPD,

LPD, pre-concentrator, vacuum separators to the prilling bucket. DAP unit has also same type of

learning opportunities. Bagging shipment unit gives an understanding of meeting the consumer

requirements in easy way.

These units are such designed and operated to ensure safety of personnel and plant. Process

optimization in economizing the process in terms of heat load recovery, production and

capacity is the governing factor.


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Utilities Unit

The objective of utilities unit is:

To provide desired quantity and quality of certain utilities to the ammonia and urea units for

smooth functioning. These utilities include electricity, cooling water, instrument air, fuel gasand steam network.

Water, air and natural gas are the basic utility raw materials, which are processed and improved

in order to meet the plants criterion of quality and ensure a longer life and safety of

equipment.

Water Air Natural gas

Cooling water

Steam

Utility / service water

Drinking water

Instrument air

Utility / service air

Process air

Process stream

Fuel stream

Utilities unit is a pre-requisite for other units because their smooth running depends upon the

utilities supplied by it. In case of utility failure plant has to face an emergency shutdown. Major

sub-divisions of utility section are:

Natural Gas Station

Power Generation and Distribution

Raw water storage and distribution

Raw Water Treatment

Cooling Tower and cooling water pumps

Waste Water Disposal

Instrument Air Compression

Auxiliary Boilers and Steam Network

Chilled and hot water system (HVAC)

Fire water distribution

Natural Gas:The purpose of natural gas station is to supply natural gas after filtration to meet the demands:

Process gas

Fuel gas

Township supply

Natural gas is drawing from Sui Southern Gas Limited. Normal pressure at the batter limit is 31

Kg/cm2. This natural gas is divided into feed (for Nh3) and fuel gas headers. The fuel gas

pressure is controlled by the letdown station. Then it passes through GV-111, knock out drum,

where moisture is removed. The gas pressure is further reduced for use in auxiliary boiler, HSRG

and gas turbines. Pressure safety valves are provided to protect against over pressurizing. The

natural gas has 92% CH4, 3% CO2and 4% N2.


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Power Generation System:

Electric Power is generated through turbo generators (TG), which are the turbine driven for the

production of electricity. These are the major source of electricity for all the plant having a

capacity of 52 Mega Watts (2 generators each has capacity 26 Mega Watts). A diesel driven

emergency generators (DDEG) having a capacity of 2 Mega watts, is also installed. All the three

generators are synchronized and are connected with the main bus bar. Generation voltage is

13800 volts and frequency at 60 Hz.

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

Here 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 heaterandwater pre-heater. 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 boilerAuxiliary 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

Instrument and Service air System:

The section provides compressed air for instrument and utilities to all units of ammonia andurea plant. Instrument air make possible the functioning of pneumatic valves installed over

multiple locations on plant. The area is of extreme importance because in case of its failure,

plant might lead to shut down.

Chillers and HVAC: The chillers and HVAC system are installed to supply comfort and air

conditioning system for fertilizer complex. The chillers can operate in parallel at part load. The

chillers are steam absorption type.
http://en.wikipedia.org/wiki/Economizerhttp://en.wikipedia.org/wiki/Economizerhttp://en.wikipedia.org/wiki/Economizerhttp://en.wikipedia.org/wiki/Evaporatorhttp://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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Raw water Storage:

Raw water is supplied from kinjherGajju canal by 6 pumps booster pumps with each with a

capacity of 180m3/hr .the capacity of the raw water storage is 90000m

3/hr sufficient for 3 days

requirement of the complex at full load. Raw water system consist of

One storage basin

Three industrial water pumps one stand by and 2 operatingPortable water storage:

Raw water from industrial water pumps is taken for portable purpose after treatment and

stored in portable water storage tank. This water is used for drinking purpose and emergency

purpose.

RAW water processing:

The raw water treatment plant is designed to remove suspended solids, turbidity, organic

matter and colour from raw water consist of

One re-activator type clarifier

One alum dosing

One polymer dosing One caustic soda dosing

One hypochlorite dosing

Raw Water Clarifier:

Clarifier is fed by flow regulated raw water from pump. Clarifier has rapid mixing and

recirculation at centre and slow mixing at outer side from centre and chemicals mentioned

above are introduced. So there is sedimentation and sludge recirculation. Sludge is collected at

bottom of clarifier and removed by positive sludge scraper covering the entire bottom.

Alum dosing System:

Alum is used as coagulating agent and injected into clarifier inlet. It is solid lumps form so it is

dissolved and mixed in mixing basin and then transferred to dosing tank. The dosing system isskid mounted.

Caustic soda dosing:

It is used to increase the alkaline nature of water influent to the clarifier.

Hypochlorite dosing

It is used as a disinfectant to protect the clarifier and filter from bugs and algae growth and to

eliminate organic growth. The system consist of polyethylene tank metering pumps etc.

Fire Water System:

The fire water storage is common with Raw water storage but has reserve capacity of 5000m3

available even when Raw water basin is empty. The fire water system is designed of 600 m3/hr.

Cooling water:

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.


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There are transfer pumps in cooling tower that supply water. 2 pumps for urea and utilities, 4

for ammonia.

The cooling water system has capacity of 36800 m3/hr (23100 m

3/hr for ammonia and rest for

Urea, Utility and DAP).

Chemical dosing in CoolingTower

Zinc poly phosphate is used as corrosion or scale inhibitor and is injected into the cooling towerbasin. The zinc phosphate is delivered in liquid form and fed as such.

Polymeric dispersant Dosing System:

Polymeric dispersant is used to maintain the phosphate solubility in the zinc phosphate at 90%

or better. The dispersant is injected into the cooling tower basin.

Chlorination Dosing System:

Chlorine is used to control biological and algeagrowth..Chlorine is in liquid form cylinders.

Demin Water System:

Filtered water is fed from the clear well via two filtered water pumps to the demin plant for

further processing. The process water is stored in the demin water tank.

Ion exchange regeneration system:

Sulphuric acid and caustic soda will be used to regenerate cation and anion exchange units

respectively. Sulphuric acid is 98% is diluted 2 to 4 % before injection into the cation. Caustic

soda 48% feed system used for regeneration of anion units. Caustic soda is diluted 2 to 4 %

before injection into the anion. Water from regeneration is transferred to neutralizing tank. The

demineralized water is transferred to the demine water storage tank. Then transferred to

demine water tank and fed to dearetor.


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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 ofwhole 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. 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

oC.

2N2+3H2=2NH3

Liquid ammonia is produced.

Goes to Urea if storage is full.

Di-ammonium Phosphate(DAP) Plant:

Inputs:

1.

Ammonia

2.

Sulphuric acid

3.

Phosphoric acid4. Sand

Output:

1. DAP granules


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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 90oC 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 1/3rd

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.

Urea Plant:

The unit manages the urea production from raw materials:

Ammonia (liquid)

Carbon dioxide (gas)

These raw materials are provided by the ammonia unit, are reacted to form ammonium

carbamate, which dehydrates to give urea. Urea synthesis is divided into following sections:

High pressure section

o Urea synthesis

o Stripping

o Carbamate recovery

Medium pressure/Low pressure section

o Ammonia recovery

o Carbon dioxide recovery

DAP

De dusting Granulation Scrubbing


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Vacuum section

o Urea concentration

o Prilling

Waste water treatment section

Optimum temperature conditions and retention time in process are extre3mely important becausehigh temperature and more residence time causes:

High biuret content

More energy input

More water circulation

Overloading of vacuum condensers and ejectors

Pressure increase in system

Reduced efficiency

These highly disturb the economics of the process and are always prevented.

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 Plant

and Their Function:

Heat Exchangers:

Heat exchangers are used to transfer heat from one media to other media. They are classifiedon 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:


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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.

Scrubber:

It is a high pressure vessel where liquid ammonia is stored under pressure. It is an efficient non-

corrosive alloy which can handle liquid Urea for a long time. It separates reactive and nonreactive 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


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Thera are two types of drafting:-

1)

Natural

2)

Mechanical or Forced

At urea plant we do natural drafting.

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 pipe. 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


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c)

Plug valve

d)

Check valve or value

e) Butter fly valve

Valves:

Valves are used for controlling and regulating the flow. Valves are also used forthrottling 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 valves:

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 itsname 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 moreheight.

Machinery of Urea, DAP and Ammonia Plant:

This includes the moving parts of the plant. Their summary is as follows:


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Compressors (screw type mainly and centrifugal)

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.

Our main focus is on the centrifugal pump (axial flow) because of its availability and ease of

operation.

Construction:

A centrifugal pump is of very simple design the only moving part is an impeller attached to a

shaft that is driven by a motor.

The two main parts of the pump are the impeller and diffuser. The impeller can be made of

bronze, stainless steel, cast iron, polycarbonate and a variety of other materials. A diffuser or

volute houses the impeller and captures the water off the impeller.

Parts

Stuffing box

Packing

Shaft


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Shaft sleeve

Vane

Casing

Eye of impeller

Impeller

Casing wear ring

Discharge nozzle

Diffuser

Figure 1: Parts of Pump

The Impeller:

The most important part of the centrifugal pump

Mounted on shaft and rotates with it

Comprises of eye vane and/or rings

Contains balancing holes and ribs in some cases

Increase velocity of liquid through vane

Impeller adds energy by increasing velocity of the liquid at the liquid tip

Increase in tip size increases energy

Increase in flow reduces energy


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Figure 2: The Impeller

Impeller has further sub-sections briefly described below

Impeller hub: Central part of impeller, bored out according to shaft diameterSuction eye: The impeller inlet just ahead of vans.

Impeller shroud: Impeller enclosing sideways totally enclose the impeller water ways fromthe suction eye to the periphery.

Impeller vans: Vans are parts that pick up the liquid and accelerate it high velocityWear ring: Wear ring provide protection and an economically renewable leakage joint between

impeller and casing.

Casing:

Casing gathers and directs the liquid to the discharge pump

Enclosed space where impeller rotates with the shaft

Converts velocity of liquid into pressure

Has close clearance with impeller

Has two ends suction and discharges

Stuffing box is also provided with it

Diffuser:

It is stationery component of pump casing.

It converts velocity head into pressure

It also guide liquid towards discharge nozzle

in multistage pump, diffuser guides liquid to the eye of next stage impeller

Operating Principle:

A centrifugal pump converts energy of a pump first into velocity or kinetic energy and then into

pressure energy of a fluid that is being pumped. The energy changes occur due to two main

parts of the pump, the impeller and the diffuser.


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Liquid enters the suction nozzles and then into the eye of the impeller. When impeller rotates,

it spins the liquid that is between vanes outwards and provide centrifugal acceleration. As liquid

leave the eye of the impeller, it creates low pressure area causing more liquid to flow towards

the inlet. Because impeller blades are curved, the fluids is pushed in the tangential and radial

direction by centrifugal force.

Figure 3: Flow through Impeller

The energy created by centrifugal force is kinetic energy. The amount of energy given to the

liquid is proportional to the velocity at the edge or vane tip of the impeller. The faster the

impeller revolves or bigger the impeller is, then higher will be the velocity of the liquid at the

vane tip and greater the energy imparted to the liquid. This kinetic energy of a liquid coming

out of an impeller is harnessed by creating a resistance of flow. The first resistance is created by

the pump diffuser that catches the liquid and slows it down. In the pump discharge, the liquid

further decelerates and its velocity is converted to pressure.

Steam Turbines:

The turbines installed at FFBL are multi stage impulse turbines. The gas turbines at utility plant

are 16 stage turbines in which turbine and compressor are mounted on the same shaft. The

compressor is first of all made to start with the help of diesel engine. When more than 50% of

the required RPM are achieved the diesel engine goes to shut down and compressed air starts

to go in combustion chambers. There are 10 combustion chambers which are lined inside with

refractory. The natural gas is also mixed with this compressed air here. There are two igniters in

two chambers where flame is produced and this flame is transferred to other chambers by the

help of canes. Combustion takes place and exhaust gases run the turbine which is connected to

generator which gives electricity. As turbine and compressor are on same shaft so running

turbine also runs the compressor. In this way the cycle continues.

A brief introduction of turbines is given here:


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There are two types of turbines.

Impulse turbines, which are single stage or multi stage compressed turbines to which impulse

blades are attached. They use nozzles for impingement. In impulse turbines velocity decreases

and pressure remains constant while passing through blades.

Reaction Turbines, where there are no nozzles. Velocity remains almost constant in blades and

pressure decreases. Its blades are also called moving nozzles.


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Mechanical Seals


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Sections of Product Handling and Shipping

Following four sections describe the functioning of product handling and shipping facility

Products to Stockyard

Storage and Product Reclaiming

Screening and Conveyor Network to Bagging

Products to Bagging and Shipping

DAP/UREA Handling & Storage:

Final DAP/Urea product from the production is stored in the storage building consisting of two

parallel stockpiles, besides each other & separated by a concrete wall, in one common building,

of length 227m, width 55m.Th storage capacity of each one is 35000 tons of granulated

products. Each pile of Urea / DAP is fed in by a conveyor with tripper car arranged in the top of

building. There tripper cars are fitted with a by pass chute allowing either to discharge on the

stockpile or to the belt again in order to reach the rear end of the building where the product is

transferred to the screening machine (DAP) or directly to the Shipping Section(Urea). The

tripper cars are protected by limit switches at the both ends of the rail. Additionally a sectionalposition indicator is available in PH &S control room. The tripper car is connected with the

machine & integrated into the quay cross conveyor.

There is ne reclaiming unit for each stockyard, Urea & DAP and the reclaimer travels along the

pile enabling the operation to reclaim wherever possible. Stockpile Urea/DAP is reclaimed with

a rail mounted semi-portal chain-scraper & conveyed with belt conveyor to the feeder point of

next belt conveyor. Also a belt weighing scale is installed at each scraper and magnetic

separator is located over the belt conveyor I order to protect the delumper. Integrated in these

feeder points is the delumper, which can be by-passed by moving the complete delumper unit

out of feeding chute. The belt conveyor to bagging hopper is equipped with belt scale which

conveys the Urea/DAP product directly to Bagging Section. In by-pass operation mode, the urea

product is conveyed from the belt conveyor via bypass belt conveyor to belt conveyor ofshipping section. In case of DAP, screen can be by-passed and product can be directly sent to

shipping belt conveyor.

Shipping Section:

In Shipping Section the final product from the storage building is packed separately in 50 kg

bags by modern techniques. Shipping Section contains 11 bagging hoppers of which 6 hoppers

are designed for Urea bagging and 5 hoppers are designed for DAP bagging. The product is

dispatched to these hoppers by means of movable 7 reversible belt conveyors respectively.

Starting from these hoppers six specific line have been defined for Urea, 7 five ones are

dedicated to DAP.

Bagging line components:

Each bagging line includes,

The storage hopper to store the bagging product over corresponding bagging machine.

The electronic weighing unit for separation of 50 kg product.

Bagging machine includes bag-clamp & additional equipment for filling of bags.


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The automatic sewing machine for the simultaneous sewing of the inner PE liner &

outer cotton bag.

The wooden slat type conveyors below the bagging machine for continuous conveying

of filled bags.One sewing machine is provided in standby, that could be brought I

working position by turning the supporting arm by 180 degrees.

After that the bag tipper allows the regular placing of the bags on the belt conveyorfrom the end of which the synchronizing drum allows the regular ordering of the bags

on the telescopicable&liftable truck loader.

Provision is made so that the telescopic conveyors maintain their lateral position

relative to the platform. Each loading bay has only accommodation for one truck.

Each bagging line is able to deliver 800 bags/hr as a maximum, eleven lines together

deliver 4800 bags/hr of Urea & 4000 bags/hr of DAP.


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Nearby the outlet of shipping facility, an underground weighing bridge (60 ton capacity)

allows to weigh each truck.

Features of PH & S:

Two independent systems for product handling and shipping of Urea and DAP.

Bagging is composed of 11 lines, six for Urea and 5 for DAP. Each line is designed to

produce 800 bags/hr.

70,000 metric-tons product storage facility i.e., 35000 metric-tons each for Urea and

DAP.

Simultaneous storage and reclaiming arrangement for each product i.e., Urea and DAP.

1.

Reclaiming capacity for Urea : 240 MT/hr

2. Reclaiming capacity for DAP : 200 MT/hr

Centralized PLC based control system with MMI plus Mimic Panel in control room.

Centralized dedusting system for the whole plant.

Climatized air circulation inside storage building to reduce temperature variation.

Screening system for the separation of fines from DAP.

Magnetic separators are provided for preventing product contamination.

Automatic bag conveying, tripping, leveling system with telescopic truck loader.

60 metric-tons weigh bridge for truck weighing.

An area of 7 m2

is provided in the storage building for maintenance purposes.


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Machine Shop:

Several machines are there at FFBL, they are as follows:

1.

Universal Boring and Milling Machine:

Horizontal boring milling machine is a universal machine tool, which can be adapted to machine

casting, steel, and nonferrous work-pieces. Operations include drilling, hole enlarging, boring,

reaming, plane milling, spot facing, threading, and other machining processes. The faceplate

slide can be fed radially, which enables this boring milling machine to bore large size holes,

turning outside diameters, and grooving. Today, SMTCL horizontal boring milling machine is

widely used in the industries of energy, metallurgy, mining, machinery, military, etc., becoming

a reliable choice for machining box-type parts.

The spindle of our horizontal boring milling machine has 3 supporting points and good rigidity.

Nitrogen treatment is employed on the main surface, which enables the spindle to have high

hardness and long service life. The spindle and feed speed change adopt manual rotary valve in

the headstock and hydraulic pre-selection, which is convenient for operation

Small Duty Lathe Machine:The Lathe Machines made available by us are very powerful and are extensively used for

turning, boring, facing or threading of different components.These Industrial Lathe Machines

are available in different ranges and specifications as required by the valued clients.


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FEATURES:

Head Stock Gear Helical

Main Spindle & Tailstock Spindle hardened & ground

Head Stock / Counter pulley dynamically balanced

Hardened and Ground Bed for minimum wear

Apron is fully oil bath

Steel parts made from EN-8 steel

Needs minimum care and low maintenance

All components machined using jigs and fixtures to close to tolerances,

thus providing easy interchange abilityFlame Hardened & Ground Bed,

chuck plate, faceplate, motor pulley, motor pulley, toolpostkey ,dead

centre ,Spindle ,Sleeve Steady ,Rest Nylon ,Flat Belt ,Oil Can are its

components

2.

Heavy Duty Lathe Machine:These are unsurpassable in output and sturdy in features. Same is the case with our

Mechanical Lathe Machine which is made of heavy and pure iron which is obtained from

the best of vendors these are highly useful in heavy metal industries


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Features:

Flame hardened bed ways.

Hardened and profile ground headstock gears.

Headstock spindle is made from high tensile steel duly hardened & ground & runs in

precision taper roller bearings. Maintained contact starting shaft

Meticulous care is taken in selecting the right raw material for every component. Each &

every component is passed through strict quality control & the machine is put to

rigorous tests confirming to IS : 1878 (Part I) 1971 before dispatch from our ultra-

modern plant having sophisticated mother machinery.

Standard Accessories:

Electricals, 2 MT Centres with Centre Bush, Inch & MM Gears, Oil Can, Spanner & Allen Key Set.

Optional Accessories:Face Plate, Steady rest, Follow Rest, Machine lamp, Elec. Coolant pump with tank

fittings, Taper turning attachment, and Quick change tool post with 5 tool holders.

chuck plate, self-centering 3 jaw chuck revolving center.

4.

Shaper Machine:

This is widely used in various industries for different applications and admired for its corrosion

resistance, optimum performance and longer service life. Further, this range in varied shapes,

sizes and capacities in order to cater the variegated needs


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5.

MD BALANCING MACHINE

Balancing machines are simple and easy to use, ensuring the best balancing quality

available. Using a personal computer as its console, the machine will balance closely andquickly. Dynamics Research Corp. dynamic balancing machines provide a computer printed

report that clearly shows the state of balance before and after. In addition, the use of the

computer allows storage of a virtually unlimited number of setups on the hard drive, drastically

reducing the length of time used to spend on each balance process.

6. HD BALANCING MACHINE

Roll Balance Machine used for rolls, pumps, and fans 5 ton & 50 ton weight capacity Belt drive

Top plate accommodates roll bearing assemblies Bearing assemblies for balancing on the roll

are available

Roll whip indicator is available.


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7.

Milling Machine:

Milling machine may be defined as the type of machine in which the metal is removed by

causing the job to be fed against a revolving cutting tool called the milling cutter, which has one

or more cutting edges. There are several ways of holding milling cutter, which rotates with the

machine spindle, or held in a col let or other adopter which fits the spindle.Rigid millingmachine, easy to operate, for semiautomatic machining of complex work pieces.High intrinsic

weight (3500 kg) ensures maximum torsional rigidity. Automatic pendulum-type cycles and

semi-automatic straight-line cycles operated through camshaft gear. Work table swivels

45Universal milling head adjusts on 2 levels to virtually any spherical angle (HURON system).

Table with rigid square guides.Feeds and rapid feeds on all 3 axes


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8.

RADIAL DRILL MACHINE

The Main Parts of Radial Drilling Machine are

1. Base: The base of the machine is a large cast iron material on which is mounted a cylindricalvertical column. The base is provided with T-slots, which help the work piece to be clamped

rigidly to the base of the machine.

2. Vertical column: The column is a long, cylindrical shaped part fastened rigidly to the base.The column carries a radial arm that can be raised or lowered by means of an electric motor

and can be clamped to any desired position. The radial arm can also be rotated (swiveled) in a

complete circle around the column.

3. Drill head: The drill head is mounted on the radial arm and carries a driving motor and amechanism for revolving a feeding (power feed) the drill bit into the work piece. The drill head

can be moved horizontally on the guide ways provided in the radial arm, and can be clamped to

any desired position.


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9.

Hacksaw Machine:

The sewing machine is a machine tool designed to cut material to a desired length or contour. It

functions by drawing a blade containing cutting teeth through the work piece. The sewing

machine is faster and easier than hand sawing and is used principally to produce an accurate

square or mitered cut on the work piece.

The power hacksaw and the band saw are two common types of sawing machines used to cut

metal in the machine shop. The power hacksaw uses a reciprocating (back and forth) cutting

action similar to the one used in a hand hacksaw. The power hacksaw is used for square orangle cutting of stock.

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


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Jack

Fabrication Shop:

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 color of flame is very important. Yellow color indicate reducing flame and

blue color 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: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 coating 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 tankersand loaders.

In cranes one crane has load capacity of 55ton, other two have 20ton. They are hydro crane,

with 6 cylinder 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.


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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:

There are three types of hardness Vicker, brinell and Rockwell Hardness. Hardness testing

machine gives us the hardness of given material.

Ferrite scope:Checks 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 inside the exchanger tube.

Thermographic camera:

For temperature measuring and spot temperature measuring. Gives thermographic photo ofthe machinery using infrared radiations.

Tacho Meter:

Measures the RPM of rotating element like shafts etc. A tape is glued on shaft and

then during running laser is thrown on tape to find RPM.

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 inFFBL.

Crane weight testing:

We use this test to determine how much weight crane can carry

Documents

Internship Report FFBL