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CIVIL CONSTRUCTION INFATIMA FERTILIZER COMPANY LIMITEDPresentation Transcript
CIVIL CONSTRUCTION INFATIMA FERTILIZER COMPANY LIMITED AA GTE (Civil)
CONTENTS: Project Overview Civil Construction and Fatima Fertilizer My Working Areas Roads and its Structures Weigh Bridge Nitro Phosphate (NP) Plant
Project Overview: Salient Features: Start of Land Acquiring in Year 2005. Total Land Acquired 800 acres. Estimated Cost in Rs. = 8,000 million Start of project phase in April 2007 (NA plant). Total no of plants/supporting areas are 50+. Four Types of Fertilizer Products/Plants having design capacity. 1. Urea 1500 MTPD 2. CAN 1400 MTPD 3. NP 1200 MTPD 4. NPK 1000 MTPD
Project Overview: Salient Features: Other Supporting Plants having design capacity 1. Ammonia 1500 MTPD 2. Nitric Acid 1500 MTPD 3. Offsite & Utilities 50 MW Gas consumption of 75 MMCFD Civil Contractors 1. CNCEC China 2. IPL Pakistan Civil Designers 1. NESPAK Pakistan 2. A & A Pakistan
Civil Construction and Fatima Fertilizer: Civil Engineering role in the establishment of any kind of project is not ignorable. The project like Fatima Fertilizer, its importance is more. Fatima Fertilizer have structures From simple pumps foundations to complex pile foundation under Prilling towers and Ammonia Tank. From steel structures of Urea, CAN, Bulk Storage & Ware houses to concrete structures of Cooling Tower, Raw water Reservoir, Bagging, NA and NP plants. From Technical building, CCR I & II, Substations to Strom water drains, water pits, area development and network of roads.
Civil Construction and Fatima Fertilizer: In Fatima Fertilizer, basic form of structure is frame structure . Frame Structure is a combination of beams and columns and load is transfer through this system to design foundation. Two types of frame structures are used. 1. Steel Structures 2. Concrete Structures
Steel structures are basically composite structures having substructure of concrete and superstructure of steel e.g.
Ammonia & Urea Plants
CAN & NPK Plants
Bulk Storage (Phase-I)
Ware houses, Pipe Racks etc.
Concrete structures comprise of both substructure and superstructure of concrete e.g.
Raw Water Reservoir and Treatment Plant
Cooling Tower & Urea Prilling Tower
Bagging (Phase I & II)
Bulk storage (Phase II)
Substations CCR I & II and Equalization Basin
Workshop, Technical Building, Laboratory, etc
Pictorial View of Civil Construction in FFCL: Construction View of Urea Prilling Tower and Plant
Nitric Acid Plant Foundation of Ammonia Storage Tank
Construction View of Cooling Tower Raw Water Reservoir and Water Treatment Plant
Construction of CAN Plant Construction of Ammonia Plant
Construction of Bagging (Phase – I) Construction of Bulk Storage (Phase – I)
Bagging (Phase – II) under construction NP Plant under construction
My Working Areas: In Fatima Fertilizer during my Trainee period of 1 year, I worked on Roads and its Structures, Construction of Weigh Bridge and also play a vital role in the construction of NP plant.
Job Responsibilities: Study of Drawings Design Reviews Survey of roads Quality Control at site ( Formwork, Steel & Concrete) Inspections before concrete Checking of Bar Bending Schedule Checking of Bills
Roads and its Structures: Salient Features Total length of Roads = 17.484 km Completed Length of roads = 8.301 km Remaining Length of roads = 9.183 km Roads have Strom water drain and walkway on one side, and shoulders on both sides. Designer = Akbar & Associates Contractors = IPL, Farhan Munir & Company, AHCC Type of Pavement = Rigid Pavement Design Capacity = 90 Tons
What is Rigid Pavement? Rigid pavements are generally constructed of a reinforced concrete slab or more recently a continuously reinforced concrete road base. The pavement structure deflects very little under loading due to the high modulus of elasticity of their surface course. A rigid pavement structure is typically composed of a PCC or RCC surface course built on top of either the sub-grade or an underlying base course.
Rigid Pavement: Typical Cross-section of a Rigid pavement
Why we (FFCL) preferred Rigid Pavement instead of Flexible Pavement (Carpet Road)? Rigid Pavement lasts much, much longer i.e. 30+ years compared to 5-10 years of flexible pavements. In the long run it is about half the cost to install and maintain. But the initial costs are somewhat high. Rigid pavement has the ability to bridge small imperfections in the sub grade. Less Maintenance cost and Continuous Traffic and Flow. Low thermal variation as compared to Flexible Pavement. Rigid Pavement has one draw back in terms of its repair i.e. we have to remove 2-3 panels instead of damaged portion as in case of Flexible pavements.
Pictorial View of Roads in FFCL KLP Road under construction
Roads in the Plant Area
Weigh Bridge: Salient Features: Total No of Weigh Bridges = 4 Weigh Bridges constructed = 2 Located near Gate # 1 or KLP Gate. No of Load Cells = 8 Design Load measurement capacity = 120 Tons Designer Mechanical = Mettler Toledo Civil = Akbar & Associates Contractor = IPL
View of Weigh Bridge in FFCL
Nitro Phosphate (NP) Plant
Nitro Phosphate (NP) Plant: NP plant started from Prilling Tower in 2009. Estimated Civil Cost in Rs. = 279.1 million Civil Designer = NESPAK Civil Contractor = IPL 80% of Civil work completed. Remaining 20% include Refrigeration area and Lime Drying unit, paints, brick masonry, and finishing works.
Nitro Phosphate (NP) Plant: NP Plant is divided into four parts Prilling Tower & Lift Well Main Building Substation CN & AN Section, Refrigeration Area, and Lime Drying Unit
Salient Features: Prilling Tower supported on 72 piles of length 27m. Prilling Tower has height of 67.9m and diameter of 19m. Lift Well has height of 70.1m, supported on 900mm thick raft foundation. Main Building has dimensions of 67.5m x 27.5m x 37.3m supported on raft foundation. Main Building comprise of 10 floors max on line 1-2. Substation comprise of 2 floors supported on isolated foundation.
Special Techniques adopted at NP Plant: Prilling Tower and Lift Well concrete done by using Slip Form Method. Strengthening of Columns has to be decided.
Slip Form Method: The most common method adopted for the construction of an RCC outer shell/prilling tower is by using the ‘slip form method’. In this method the form work for the concrete literally slips up cm by cm to produce an integrated concrete column in the form of wall. Continuous pouring of concrete ensures a joint free construction. At a rate of 0.3 meters per hour, this is consider as fast construction method.
Components of Slip Form Method: Slip form method is comprise of a complicated system of jacks and radial screws. Radial steel yokes, which have an inverted “U” at both ends, support the slip form shuttering all around the shell/prilling tower. Walers strengthen and keep the shuttering in place. The working deck and scaffolding is supported from the walers and yokes. The yokes are supported on hydraulic jacks, which move on jack rods embedded in the concrete. As the concrete pouring progresses the jacks lifts up the yokes, together with the decks and slip form. Screwed on pieces extend the jack rod as the work progresses. The entire system of decks and shuttering appear as if floating on top of the tower.
NP Prilling Tower
Top View of NP Prilling Tower
Strengthening of Columns: To increase the capacity of NP Main Building columns from 3500 Tons to 5500 Tons, the procedure that is used called Strengthening of columns. Why Strengthening of columns needed? Continuous changing of mechanical design of Cfit of NP main building, load on columns increased from 3500 Tons to 5500 Tons. To counter this problem, columns has to be strengthened by using concrete and steel jacketing.
View after Completion of Lift Well and Prilling Tower Main Building and CN Section under construction Lift Well Prilling Tower Main Building Sub Station CN, AN Section and LD Unit