HamzaHasanffbl

INTERNSHIP REPORT July24, 2014
NUST, H-12, Islamabad Page 1
InternshipReport
Submitted by:
Hamza Hasan
Representing : National University of Science & Technology, Islamabad. (NUST)
Dated: 24/7/2014
Details:

Table of Contents:
Preface……………………………………………………………………………..Page 3
Acknowledgement……………………………………………………………Page 4
Introduction & overview…………………………………………………...Page 5
Experience at L&D……………………………………………………………Page 6
 Introduction
 Safety measures
Experience at Machine Workshop……………………………………..Page 8
 AC workshop
 Substation of workshop
Experience at Ammonia Substation…………………………………. Page 6
 Plant procedures
 Substation workings
Experience at Main station…………………………………………Page 7
 Generation at FFBL
 Main station working
Experience at Bagging section…………………………………………..Page 8
 Basic layout
 PLCs

Preface
In this report I have summarized my whole experience of four
wonderful weeks of healthy learning at Fauji Fertilizers Bin
Qasim. I have divided this report in 6 Basic parts. Initial part
goes in favor of Acknowledgements and introduction, while
rest is divided into four major parts each representing my
experience of a week at a new station. My report will be
putting more emphasis on Single Line diagram, protection
methods & protection relays used in system feeders and
generation & distribution of Electricity at FFBL.

Acknowledgement:
The credit for my massively useful learning experience of this internship goes to Allah
without whom it would have been a miserable failure. All glory to Almighty Allah who
enabled me to complete this internship at Fauji Fertilizer Bin Qasim, which is one of the
largest and growing Fertilizer Complex in Pakistan. During my internship I have learnt a
lot about the Fertilizer industry, and its environment. Thanks to the support of all
colleagues and staff with gratitude. I wish to acknowledge all of them.
Sincere thanks to teachers & mentors Mr. Salman Ahmad, Mr. Kashif , Mr. Faisal,
Mr. Danish, Mr. Rehan, & specially Mr. Tahir for their kind support. They were a
very valuable resource of knowledge and used to answer all my queries. They have
always been considerate and recognized our efforts as well as encouraged us.
I am also thankful to Heads Electrical department in Machine shop and AC
workshop. I want to thank the people of L&D department for their guidance and
cooperation in every matter. Special thanks to the MT department for every facility. I
am in debt to all the people at FFBL who supported me throughout the internship.
I am grateful to FFBL to provide me with this opportunity and to make this
experience relishing by providing their best department, and also with suitable
conditions for me to learn out of this experience.
I would like to express my sincere and profound gratitude to Dr Salman Gafoor,
Instructor & my mentor at NUST, who recommended me for this internship.
Hamza Hasan

Overview of FFBL
Introduction:
Fauji Fertilizer Bin Qasim Limited is mainly engagedin manufacturing fertilizers. The Company also
invests in fertilizer raw material manufacturing operations. FFBL is a subsidiary of Fauji Fertilizer
Company Limited, which holds a 50.88% interest in the Company. The company is principally engaged
in developing, manufacturing and supplying of Di Ammonium Phosphate(DAP) and granular urea to
its customers across the country.In addition, it is engagedin the production of ammonia which it
uses itself as a direct raw material in the production of urea and DAP. The company has a capacity to
produce 551,100 tons of Urea and 660,000 tons of DAPeach year.Fauji Fertilizer has its operations
across various locations in Pakistan. The company is headquartered at Rawalpindi, Pakistan
Corporate mission
Fauji Fertilizer Bin Qasim Limited is committed to remain amongst the best companies by maintaining
the spirit of excellence throughsustained growth rate in all activities, competitive price,quality
fertilizer and providing safe and conducive working environment for the employees.
Corporate vision
To be a premier organization focused on safety, quality and growth leading to enhanced
stakeholders’ value.
•FFBL incorporated in 1993
•FFBL has now become one of the top 25 companies of the country
•First offshore direct investment by FFBL is in PMP
•Sole manufacturer of DAP in Pakistan
•FFBL aims to be the leader in Fertilizer business
•FFBL is the best quality fertilizer producer in Pakistan
History of FFBL:

Fauji Fertilizer Bin Qasim Limited Plant site is a modern Granular Urea and Di-Ammonium Phosphate (DAP)
fertilizers manufacturing complex, built at a cost of US$ 468 Million and located in Eastern Zone of Bin Qasim,
Karachi, with Head Office at Harley Street,Rawalpindi. 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 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 Plant site.
Role of FFBL:
FFBL is the only fertilizer complex in Pakistan producing DAP fertilizer Granular Urea. Thus making significant
contribution toward agriculture growth of country by meeting 45% of the demand of DAP and 13% of Urea in
domestic market.
Experience at Learning and development
department:
We were introduced to this fertilizer complex at L&D. All the interneeswere provided with enough time to get
to know each other and clear any kind of Queries . A few Precautionary and safety measures were told, details
of them are
Safety and Its Importance
Safety means protection of humans, machinery, equipment and environment from hazards that exist in every
workplace in many different forms: sharp edges, falling objects, flying sparks, chemicals and gases, noise, fire
and a myriad of other dangerous situations. The key to employee productivity is to keep them motivated which
is possible only if they feel safe and enjoy their workplace. It is only when the employees feel safe at work that
they can invest the fullest of their capacities and exploits the best of their potentials to their work. Workplace
safety is the management’s responsibility. It requires the formation and implementation of safety policy and
training programs that are meant to teach the employees to handle emergency situations.

Week 1: Experience at Machine shop:
During our first week we were given an opportunity to roam around freely in electric workshop and interact
with technicians there to understand how they fix different electrical equipment that runs the plant.
Part 1: AC SHOP
AC shop was a small part of electric workshop that dealt in the maintenance of all the AC’s, HVAC,
Refrigerators and other related electrical equipment.
We were told following points in general discussion:-
a) AC gas is heavier i.e Chlorodifloro Methane (ClF2CH4). It is commonly known as 22no.
b) Fridge gas is lighter then AC and is known as 134no.
c) Car AC gas is the lightest of them all.
d) Motor, relay and inductor are electrical parts where as compressor is mechanical part.
Compressors force the gas to go from lower pressure to high pressure
Types of Compressors:-
a) Reciprocating system:
Reciprocating air compressorsare positive displacement machines, meaning that they
increase the pressureof the air by reducing its volume. This means they are taking in
successive volumes of air which is confined within a closed space and elevatingthis air to a
higher pressure.The reciprocating air compressor accomplishes this by a piston within a
cylinder as the compressingand displacing element. Used for ½ ton to 100 tonsfridge /Ac.
b) Centrifugal system:
The centrifugalair compressoris a dynamic compressor which depends on transfer
of energy from a rotating impeller to the air. Centrifugalcompressors producehigh-
pressuredischarge by convertingangularmomentumimparted by the rotating
impeller (dynamic displacement). In order to do this efficiently, centrifugal
compressorsrotate at higher speeds thanthe other types of compressors. These

types of compressors are alsodesigned for higher capacity because flow throughthe
compressor is continuous.Used for 100 tonto 3000tons.Has a jet engine.
c) Rotary system:
Rotary air compressors are positive displacement compressors.The most common
rotary air compressor is the singlestage helical or spiral lobe oil flooded screw air
compressor. These compressorsconsist of two rotorswithin a casing where the
rotorscompress the air internally.There are no valves.These unitsare basically oil
cooled (with air cooled or water cooled oil coolers) where the oil seals the internal
clearances. Rotary screw air compressorsare easy to maintain and operate.
Working & procedure:
a) The compressortakes refrigerant vaporin from the low pressureside of the circuit,
and dischargesit at a much higher pressureinto the high side of the circuit. Hence
high temp/ high pressure.
b) When the hot refrigerant vapordischarged from the compressortravelsthroughthe
condenser, the cool air flowing throughthe condensercoil absorbsenoughheat
from the vaporto cause it to condense. Hence low temp/ highpressure.
c) The metering device, component #3 on this air conditioning circuit and cycle diagram,
is the dividing point between the high pressureand low pressuresides of the system.
d) The air conditiong system is designed so that the refrigerant will evaporate in the
evaporatorat a temperature of about40 degrees, so thatit will be cold compared to
the warm air flowing over it.
Part 2: Workshop Sub-Station
We had a brief visit to Workshop Sub Station and learnt some basics regarding the Sub Stations that certainly
helped us in our visits to Ammonia and Main Sub Stations in the weeks to follow.

We were told following points in general discussion:-
- 7 sub stations in total
- The main voltage produced by the plant turbines is 13.8 kV.
- 2 feedershaving 3 wires/3 phase eachpass through 2 main panels and then into
transformers.
- Transformers step down the voltage to 480 V.
- A redundant system is set up in the sub stations, I.e to shift load on the other equipment
incase of the failure of one.
- Our main transformers are of 2.5 MV.
- Because the plant is purchased from USA,it operates at 60 hz.
- But most of our appliances in the plant work on 50 hz , they include Admn Block, L&D,
Medical Complex and others.
- Motor Generator Set(MG SET)is used to convert 60 hzto 50 hz.
- Plant lighting is at 120V hence another step down transformer is placed in the sub station
which step downs 480 V to 208 V.
- This transformer is a dry type transformer.
Motor Generator Set:
Generator changes freq from 60 Hzto 50 Hz while keeping V/Freq ratio constant hence voltage
decreasesto 380 V from 480 V. it is a rotary freq converter that makes noise as well.
Switch Gear:
Switchgear is the combination of electrical disconnectswitches,fuses or circuitbreakers used to control,protect
and isolateelectrical equipment.Switchgear is used both to de-energize equipment to allowwork to be done and
to clear faults downstream.This type of equipment is directly linked to the reliability of the electricity supply.
Switch gear consists of 3 parts:
a) Switchingequipment i.e air circuits,breakers ,isolaters and etc.
b) Metering equipment i.e CT, PT, DMM etc.

c) Controllingequipment.
In our substation the breakers would trip if the inputcurrent is greater than 4000 amp.
Isolation Switch:
Isolator switch isused to ensure that an electrical circuitis completely de-energized for serviceor maintenance.
Such switches areoften found in electrical distribution and industrial applications,where machinery must have its
sourceof drivingpower removed for adjustment or repair.High-voltageisolation switches areused in electrical
substations to allowisolation of apparatus such as circuitbreakers,transformers,and transmission lines,for
maintenance. Disconnectors lack a mechanismfor suppression of electric arc,which occurs when conductors
carryinghigh currents areelectrically interrupted.Thus, they areoff-load devices, intended to be opened only
after current has been interrupted by some other control device. Safety regulations of the utility must prevent any
attempt to open the disconnector whileit supplies a circuit.
Redundant System:
Redundancy is a common approach to improve the reliability and availability of a system. Adding redundancy
increases the costand complexity of a system design However, if the cost of failureis high enough, redundancy
may be an attractiveoption. In our casebus B is the redundant or emergency bus. 50% load is divided on
redundant system.
A backup diesel generator is also there that gives power to essential equipment by Electric Load sheddingSystem.
ControlVoltage:
Control voltage is required to excite breakers. In workshop sub station a control voltage of 110 DC is applied.
1) Motors
Duringour stay at workshop we learned a lotabout the motors especially induction and synchronous motors.We
got a chance to see them firsthand and to see their construction and workingin great detail.
a) Induction Motors:
An induction or asynchronous motor is an AC electric motor in which the electric current in the rotor needed to
produce torque is obtained by electromagnetic induction from the magnetic field of the stator winding. An
induction motor therefore does not require mechanical commutation,separate-excitation or self-excitation for all
or partof the energy transferred from stator to rotor, as in universal,DC and largesynchronous motors.

Actuators:
These are used as shifters & diverters,simply aremotorized valves for switching.
a) Synchronous Motors:
A synchronous electric motor is an AC motor in which,at steady state, the rotation of the shaftis synchronized
with the frequency of the supply current; the rotation period is exactly equal to an integral number of AC cycles.
Synchronous motors contain electromagnets on the stator of the motor that create a magnetic field which rotates
in time with the oscillationsof the linecurrent. The rotor turns in step with this field,at the same rate.
Speed is constantbecause if load increasewhen south of rotor lagwith north stator tries to go to proceedings of
stator but repelled back.
StartingMethods of Synchronous Motors:
I have studied these methods from Chapman’s book .
- Pony Motor moves rotor, supply given to rotor then finally to stator.Disadvantageis if operating2
synchronous motors together if one trip other will takedelay to startboth motors.

- Other method could be givingsupply to stator firstestablishingcontrolled magnetic field then moving
rotor by pony motor then supply to rotor. If one trips other stator take over. Disadvantageis field of
stator to be controlled , then wirerotor stator will notsync.
- Last method is to use Amortisseur Windings. When motor is turn on, amortisseur supplies stator and
energizes it, rotates rotor when rpm of synchronous achieved, connection is made and rotor is given
supply.
Case Study:
Whilewe were at workshop an induction motor was brought from the plantfor maintenance. The motor had
tripped off and now it was the work of the technicians to determine the faultin it.
Followingcan be the reasons for the trippingof:
a) Weak Insulation
b) Penetration of moisture
c) Over heating
d) Mechanical partbroken
e) Balanceweight might have broken
Technician’s comments:
Fuse didn’t heat up, only thermal tripping hence relay switch operated. It was decided to open the motor and
see the fault internally. On opening a clear burning up of windings from one end of the motor was visible.
Hence the technicians decided to go for rewinding of the motor.
Above motor was brought to the workshop.

Varnishing :
Varnish is a transparent, hard, protective finish or film that makes windings solid. It is used to decrease losses
and to make windings moisture free. Free copper winding may vibrate and produce back emf that can cause
losses.
Electric Oven:
Before and after varnish the motor is put in it to remove moisture. Baking would also solidify the varnish.
Electro cleaner is used to clean motors.
Magger:
Magger is the equipment like DMM but its Ohm range is greater then DMM. We check whether connections
are short or not by using maggers. When short it gives zero Ohm & gives a buzzer. In our case w2 and u2 were
short.
Week 2: Ammonia Substation
Ammonia substation:

As I have already mentioned that Fauji Fertilizer Bin Qasim Ltd is currently producing two products which are
the Sona Urea and the Sona DAP. Ammonia being the major constituent for DAP as well as Urea is being given
key importance in the plant operations. The first plant installed at the FFBL plant site was the Ammonia Plant
which was bought from USA in 1998. The plant was refurbished, upgraded and installed at the FFBL plant site
at Port Qasim Karachi.
The Ammonia Plant was regarded as the highly classified area due to the presence of highly carcinogenic
ammonia gas, therefore the plant has been given high safety and security privileges. The plant was mainly run
by the Process and Operation Department while the Maintenance and Services Department checks for the
safety and maintenance of the plant. Plant operations of the Ammonia Plant are controlled using a Distributed
Control System (DCS) installed at the Central Control Room(CCR)
Plant Operations:
(Info given by Sir Oun Hassan)
The Ammonia at the Plant is retrieved using two basic constituents that are Hydrogen and Nitrogen. The
nitrogen for making ammonia is taken from air as air comprises of 78% nitrogen whereas the hydrogen required
is obtained from CH4 (Methane or Natural gas).
The natural gas supplied to the plant also comprises of impurities like sulphur which suppresses the chemical
operation of obtaining hydrogen and it is highly corrosive to the plant equipments, therefore for safe and
efficient working sulphur is first separated from the natural gas.
Electrical Substation section:
The FFBL is generating its own power using two gas turbines of 26 MW each. The generator generates 13800
volts at 60 Hz. Generation at the plant is done at 60 Hz because of the NEMA standards that the Ammonia
Plant follows. From the main utilities area where the generation is taking place eight feeders are coming to the
ammonia plant substation. Each feeder is a single core, 240 mm, 3 phase cable.
Transformers
 Total transformers at the Ammonia substation= 8
 ONAF (oil natural air forced) configuration.
 Two of them are of 8 MVA which are allocated for MV (medium voltage) motors while six of the rest
are of 1.2 MVA for LV (low voltage) motors and loads.
 The transformers at the Ammonia substation are Hermetically sealed this is because Ammonia plant
area is a highly explosive area.
Hermatically sealed transformer is a transformer design which has no conservator. Here the dielectric
insulating fluid in the transformer tank is completely sealed and is in zero contact to the atmosphere. This type
of transformer is used in applications where the transformer is to be installed in harsh climatic conditions
(smoke, pollution, dusty environment, etc) or user prefers low maintenance transformer. The design avoids air
in the transformer tank thereby avoiding sludging and oxidation of the dielectric fluid. Hence it would be safe
to say that these transformers need no maintenance of the dielectric insulating fluid (usually Oil). Normally
these type of transformers are accommodated by devices that measure heat related volume variations. Gas

cushion is used to compensate the volume variation due to heat. Normally the gas is nitrogen. This gas is
thermally uncoupled from the dielectric liquid. The additional purpose of this nitrogen blanket is to provide
insulation as nitrogen being inert is a non reactive gas.
 The two 8 MVA transformers steps down 13.8 KV to 2.4 KV for running MV motors from 250 hp to 1000
hp.
 The remaining six transformers steps down 13.8 KV to 480 V for running LV motors ranging below 250
hp.
Protections
A)Transformers:
The transformers at the ammonia substation are highly sophisticated and critical equipments therefore
necessary measures have been taken to ensure their proper functioning.
1. Thermostats with thermistors and sensors are installed in each transformer room for monitoring the
temperature of the surrounding.
2. A liquid level relay along with a liquid level gauge is also present on the transformer this ensures that
the level of oil within the transformer remains well above the minimum value, as soon as the level at
the gauge drops below the minimum value the relay trips the transformer.
3. A rapid pressure relay along with the gauge is also present which checks and balances the pressure
and amount of nitrogen inside the transformer tank.
4. The (NGR) Neutral Ground Resistance is also installed in the transformer room for protection against
the ground faults. The NGR consists of resistors in parallel with a total equivalent of 3.9 ohms for
limiting the ground fault current , it can effectively limit up to 2000 A of current for 10 seconds till the
time relay operates for tripping the transformer if this does not happen the NGR burns.
B) Cables:
The cables used for distribution at the FFBL are ranging from single core to quad core 3 phase cables. The high
voltage distribution system is done through underground cables. There is a separate cable room at each
substation where all the high tension cables are running. The system is underground, therefore Cathodic
Protection is done to prevent the cables from rusting due to underground moisture. A common mesh is layed
under the surface of earth which is provided with high DC voltage or in other words electrons are provided to
the mesh near the cables which opposes oxidation(rusting) and this prevents cables from rusting
PART 1: Switch Gear Low voltage (SGL)
The ammonia substation comprises of three switch gears and three motor control centers for LV motors. Each
SGL at the substation is supplied with two incoming feeders from two 1.2 MVA transformers which steps down
13.8 KV from main utilities to 480 V 60 Hz. Each SGL has subsequently two compartments named as Bus A and
Bus B
The switch gears comprises of three basic parts that are
 The breakers used for making and breaking connections.
 The metering equipment for measuring and monitoring the parameters such as current, voltage,
temperatures etc.

 The control equipment which involves the relays, magnetic contactors and sensors. Out of the three
SGL two of them supply 480 V to two MCC(motor control centers) each while the remaining one
supply to two MCC and also to an auxiliary load supply compartment. The basic use of switch gears is
to make and break connections and to isolate any part of the system in case of emergency.
Tie Breaking Scheme
There is a tie breaker installed at the SGLs, the purpose of the tie breaker as the name suggest is to shift load
from one Bus to another. Since the system at the FFBL is a redundant system that is two networks run in
parallel as backup to one another and also share the load, therefore if in case of emergency when isolation of
supply is needed at any one network then to avoid time and production delay load is shifted to the other
faultless network running in parallel.
Part 2: Motor Control Center (MCC)
The motor control center comes after the SGLs. There are a total of six MCC at the ammonia substation which
are tagged as 3A, 4A, 5A, 6A, 7A and 8A. The MCC comprises of
 The soft starters that are the Direct Online Circuits (DOL).
 Tthe protection relays
 The metering devices such as Current transformers etc. The MCC is basically designed for the
controlling the starting, running and protection of the LV motors at the ammonia plant. All the motors
below 250 hp are controlled from these panels.
Protection and Measuring Devices at the MCC
There are a number of protection relays at the MCC;
 A flag relay is installed at the MCC that flags white color when any of the fuses opens contacts due to
loosening or gets burned. There is a synchronize check relay which ensures that the supply voltage,
the phase angles and other critical parameters of the two parallel buses A and B remains synchronized
 There is an overload relay that signals the operator in case of overload by ringing the alarm or simply it
trips the load running through it.
 There is a lockout relay at the MCC that is installed immediately after the main breaker, the function of
this relay is to lockout the loads or cut off the supply from the SGLs in case of any fault inside or
outside the MCC.
Auxiliary Load Supply Panel
This panel is responsible for feeding the normal loads of the plant such as the welding loads, substation
lightning, the chilling system etc. SGL 3 is responsible for feeding this panel. The panel also feeds the space
heaters which are installed with the MV and LV motors to prevent the motors from moisture during halt
condition.
Other Supplies
The other supplies to the ammonia substation include the separate dc 120 and 110 supply for supplying to the
control equipments. Most of the control equipments such as protection relays are supplied by 110 DC from this
panel. As a backup for this DC supply a UPS supply coming from the Central Control Room (CCR) is given to the
ammonia substation.

Week 3: Main Station
Generationofpower
FFBL is generating total of 52.6Megawatts from two units with capacity
of 26.3Megawatt each at ambient temperature of 15OC. These units work on Gas turbine to generate electricity
therefore, Sui gas is the main fuel in FFBL. The components of each unit are same as they are installed
together. Each generating unit of FFBL contains following components.
Diesel engine (for startup):
It rotates the shaft of compressor at about 2200r.p.m. that is coupled with gas
turbine. Compressor shaft gets uncoupled with GT as it starts rotating itself.
Comressor:
Fresh atmospheric air flows through a compressor that brings it to higher pressure.
Combustion chamber:
In combustion chamber energy is added by spraying fuel into the high pressure air coming from compressor
and igniting it so the combustion generates a high-temperature flow. This high-temperature high-pressure gas
enters a turbine, where it expands down to the exhaust pressure, producing a shaft work output in the
process. The turbine shaft work is used to drive the electric generator that may be coupled to the shaft.
Gas turbine: (Speed=5094r.p.m)
It is also called combustion turbine. It uses the Brayton cycle to rotate the shaft of
generator. There are two types of Brayton cycles, open to the atmosphere and using internal combustion
chamber or closed and using a heat exchanger. It is conventionally assumed for the purpose of
thermodynamics analysis that if exhaust gases are reused in the intake while using internal combustion
chamber it is also closed cycle.

Synchronous generator:
In each unit synchronous generator has following characteristics,
2 poles, 3 phase wye connected 50hz, Power factor=0.9, field amps: 808, excitation voltage= 12.5, R.P.M= 3000,
armature volts=13800v.
Generator line accessory compartment (GLAC): Generator line leads, A non-segregated bus duct flange allows
for connection to either a generator line accessory compartment or a bus duct run from the generator to a
switchgear compartment.
Generator neutral accessory compartment (GNAC): The neutral tie is made up in the generator neutral
accessory compartment that also houses the neutral grounding equipment and neutral current transformers.
Digital generator protection: DGP
It gives following protections to generator.
- Stator differential - Current unbalance - Loss of excitation - Anti-Motoring - Stator ground.
- Ground overcurrent - Over excitation -over voltage - under voltage - Voltage transformer fuse failure
- Accidental energization - Over and under frequency - Time overcurrent with voltage restraint.
Backup generators:
Two backup generator are available in plant side of FFBL to be used in case of black out
and turnout.
Main substation:
Substations transform voltage from high to low, or the reverse and perform any of
several other important function. Like it incorporate load power and protection schemes. In FFBL main
substation contains 13.8kv feeders of NH3, Urea, DAP, Cooling tower, bagging, workshop, OCEA substaions. It
is also stepping down 13.8kv to 480v for L.V loads and 2.4kv for M.V loads at utilities and process area. For
stepping down it contains 4 Transformers.
2 Dual Step-down T/Fs of 12MVA rating: In this T/F 13.8kv is step downed to 2.4kv and 480v for supplying power
to utilities. It further give power to,
- MV motor Panel for motors at utilities(2.4kv)
- SGL: Switch gear for low voltage motors of utilities.(480v, above 80kw). It also feeds following,
- MCL: Motor control panel for low voltage. (480v, below 80kw)
- DPP: Distribution power plant: It supplies power to 480v DBs etc.
- Lightning Transformer: It gives out 208v, 60 Hz for lighting purposes.
- Static Frequency converter: It gives out 380v, 50 Hz
2 T/Fs of 12MVA rating: Inthis T/F 13.8kv is step downed to 2.4kv only for supplying power to process. Main
substation further contains,
MV motor Panel for process; motors of UREA and DAP.(2.4kv)
Week 4: Bagging Section:
PH & S (Product Handling and Shipment)

This Unit provides the handling of the products. It provides the means by which the product is stored, bagged
and shipped to the consumer.
Urea/DAP
From Plant
Valve
Process:
 Final product from Urea/DAP plant is brought in storage facility by the use of Conveyor Belts.
 The conveyor Belts are fastened by Mechanical Fasteners.
 Through a valve the product is either sent to storage or Hopper.
 Hopper is a machine which collects the product and sends it to the weight sensors. These sensors
sense the weight of the granules. If the weight is 50kg these sensors open a gate and product is sent
down.
 Then the product is bagged and shipped by cargo.
Scrapper:
 It is a machine which is used in the storage.
 It collects the product from the storage and puts it onto the conveyors which transfer the product to
the hopper.
 It does that by bucket shaped conveyors which continuously operate and push the product from the
storage and onto the grains.
 The scrapper moves in the storage area by riding on a moveable platform which also contains the
compartment for the operator.
PH & S CONTROL ROOM:
Conveyors
Storage Scrapper
50kg
Sensors
Bagging
Area
Hopper

 All the processes in the P H &S unit are controlled by the control room.
It contains monitor screens and Electronic Boards for the monitoring of operational parameters.
PLCs:
In general, a Control System is a collection of electronic devices and equipment which are in place to ensure
the stability, accuracy and smooth transition of a process or a manufacturing activity. It takes any form and
varies in scale of implementation, from a power plant to a semi-conductor machine.As a result of rapid
advancement of technology, complicated control tasks accomplished with a highly automated control system,
which may be in the form of Programmable Logic Controller (PLC) & possibly a host computer, etc.The Role of
the Programmable Controllers (PLC)In an automated system, the PLC is commonly regarded as the heart of the
control system.With a control application program (gored within the PLC memory) in execution, the PLC
constantly monitors the state of the system through the field input devices’ feedback signal.
It will then based on the program logic to determine the course of action to be carried out at the field output
devices.The PLC may be used to control a simple and repetitive task, or a few of them may be interconnected
together with other host controllers or host computers through a sort of communication network, in order to
integrate the control of a complex process.
The End

HamzaHasanffbl

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