The document summarizes an internship report by Sikandar Sarfraz at Fauji Fertilizer Bin Qasim Limited from July 18, 2016 to August 12, 2016. It provides an overview of FFBL, highlighting that it is a large fertilizer company in Pakistan that also provides training to fresh engineers. The intern learned many practical skills during the training that supplemented their university education. The intern expresses gratitude to the management and staff at FFBL for their efforts and motivation during the internship.

1. Fauji Fertilizer Bin Qasim Limited
SUMMER INTERNSHIP REPORT
PAF-KIET
Sikandar Sarfraz
TIME PERIOD: 18 JULY, 2016 – 12 AUGUST 2016
Submitted to: UM L&D

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

3. ABSTRACT
FFBL is a well-known, recognized and professional industry in Pakistan. It also
provides training of fresh Engineers as an Intern. They build their identity in
training due to their dedicated staff. This prestigious institution has educated,
disciplined and reputed trainers.
This was my best experience of training in any industry. I learnt many things and got
that practical knowledge that I wasn’t able to achieve in my University. I am
thankful to all the Management, Staff and other members that were the part of this
Organization, due to their efforts and motivation to teach me and to make me eligible
and a competent Engineer for any Industry in Pakistan.

4. ACKNOWLEDGEMENT
I am very thankful to Allah for the successful completion of my four week
internship at FFBL which is one of the largest and growing Fertilizer Complex in
Pakistan. During my internship I have learnt about the Fertilizer industry, and its
environment. I learnt about the FFBL as an organization, job handling procedures,
maintenance and repairing procedures and job environment in FFBL.
I am thankful to Management of FFBL who provided me a platform to learn and
gain practical knowledge. I am also very thankful to Engr Faheem who give me his
extra time on understanding things and make my things clear he also helped me
giving idea for my final year project
I would like to express my heartfelt thanks and appreciation to the employees of
FFBL who took the time off their busy schedule to share their expertise and
knowledge.

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

7. AN INTRODUCTION TO FAUJI
FERTILIZER BIN QASIM LIMITED
FFBL is one of the largest granular Urea and Dap fertilizer complex in Pakistan,
built at the cost of US$469 Million in November 1993, located in Eastern Zone
of Bin Qasim. The plant is approximately 45km south east to Karachi City and it
is connected to National High way.
FFBL is one and only Fertilizer complex in the Pakistan producing DAP (DI‐
AMMONIUM PHOSPHATE). It is the sole producer of Urea and Dap in the
country and forms part of Fauji group, one of the largest conglomerates of
Pakistan.
FFBL and FFC jointly holds 53% of Urea and 51% of DAP share of
Pakistani fertilizer market.
FFBL increases its product capacity which is higher than the designed
parameters. There are many features of FFBL that make it distinct from any other
Fertilizer complex in Pakistan.
 Initially named as FFC-Jordan Fertilizer Company (FJFC), wef 17th Nov
1993, with FFC (30%), FF (10%) and JPMC (10%) as main sponsors. The
company was formally listed with stock exchanges in May 1996 and
commercial production commenced wef Jan 2000. However, it continued to
run in crises due to technical, financial and managerial reasons till 2001.
DAP Plant brought to suspension in 2001 due to accumulated loss of Rs.
6.5 Billion. It resumed production in Sep 2003, after a lapse of 2 years. 


 Renamed as Fauji Fertilizer Bin Qasim Ltd. (FFBL) in 2003, as such Jordan
Phosphate Mines Co. (JPMC) had sold its entire equity in the company.
Accordingly Phosphoric acid supply agreement with Jordan was
terminated. The company turned out to be profitable after 3 years i.e, by
2004 and declared 'maiden dividend' in 2004. Profitability has constantly
been on the rise since then and 2007 has been the most profitable year of
the company. One of the milestones in the success of FFBL is its
accreditation of ISO certification, which was achieved in Mar 2006 for both
the Head Office and Plantsite. 

8.  FFBL also have membership of industry association and trade bodies;
Rawalpindi Chamber of Commerce
nternational Fertilizer Association
PERFORMANCE & PRODUCTION
FFBL fertilizer complex is state of the art manufacturing facility with advanced
Distributed Control System for safe and efficient operation. The phosphoric acid
being raw material for DAP plant is imported from Morocco and initially stored
in tanks at Port Qasim. Design capacity viz-a-viz actual production of Plants is as
under:
Manufacturing Plants Production (Metric Ton / Day)
Original Actual (Approx)
Urea Granular 1670 1920
DAP 1350 2230 (After Revamp)
Ammonia 1270 1570 (After Revamp)
FFBL is the only fertilizer complex in Pakistan producing DAP fertilizer and
Granular Urea thus making significant contribution towards agricultural growth
of the country by meeting 45% of the demand of DAP and 13% of Urea in
domestic market.

9. Safety
Safety is the first priority in the FFBL. Safety is a measure of success in any work.
It means constant evaluation of thing, we do and how we go about doing them so
that we won`t get harm, they our equipment’s condition will not contribute to an
accident. In FFBL safety is considered equal to production.
Safety priorities of FFBL are:
 Employs 
 Company assets 
 Environmental 
PERSONEL PROTECTIVE EQUIPMENTS:
Following equipment are available for personal protection.
 Safety helmets and shoes should be worn at plant site during working and
any other activity. 
 Googols for protection against liquids and gases 
 Gloves for protection against acid and alkaline solution and heat 
 Respiration Mask with filters for duct and
poisonous gases(H2S,NH3,Natural Gas etc) 
 Compressed air mask for protection against CO 
 Ear plugs for protection against mask 
 Draggers equipment (Tubes and Sniffer) for measurement of
poisonous gases like CO,H2S,NH3,Natural gas) 
WORK PERMIT PROCEDURE
The FFBL is controlled by Operation Department and no work can be carried
out by an unauthorized person or Department. Any work which is related to
concern Department is carried by its permission.
The permission is sought on a prescribed format known as work permit.

10. Types of Work Permits:
 COLD WORK PERMIT
This is required when urgent or routine repairs/inspection is to be carried out
and job doesn’t involve a flame or spark
 HOT WORK PERMIT
It is require for jobs as lighting all naked flames, fires, exposed material
including electric aces and sparks, electronic and gas welding/cutting,
blow lamps and tar heating.
 VESSEL ENTRY PERMIT
This is required when one or more persons to enter in to any confined
space such as tower/vessel/storage tank, excavation more than 1.5 deep,
column, reactor, piping will 1m, sewers etc.
 EXCAVATION WORK PERMIT
This permit is issued to cover all excavation work inside the plant.
 VEHICLE ENTRY PERMIT
This permit is required before any vehicle can enter the work area.
 RADIOGRAPHY WORK PERMIT
This permit is required to do any sort of radiographic testing anywhere in
the plant.

11. Complex Description
FFBL complex includes the following process units, offsite and on site.
PROCESS UNITS:
1. The process Units are
2. Ammonia Plant
3. DAP Plant
4. Urea Plant
5. Utilities & Power Generation.
FINAL PRODUCT RAW MATERIAL & CHEMICAL STORAGE:
1. Final product storage & bagging Facilities
2. Ammonia Storage (5000 MT/Day)
3. Phosphoric Acid , Sulfuric Acid storages
4. Nitrogen Storage Unit
OFF SITES AND OTHER BUILDINGS
1. Fire water
2. Natural gas Station
3. Effluent Treatment Facility
BUILDING INCLUDE
1. Control Room and electrical Room
2. Laboratory
3. Technical service Building
4. Ware house and Workshop
5. Learning and Development Center
6. Administration Building

12. Ammonia Process
INTRODUCTION:
Ammonia Plant is the heart of FFBL or any other fertilizer company because this
plant is responsible for Ammonia production and also Carbon Dioxide which is
used in the manufacturing of Urea or in other words a shutdown of ammonia plant
means a shutdown of whole fertilizer company. Following are the names of some
of the major equipment under ammonia plant.
POWER DISTRIBUTION:
Ammonia sub station receives eight 13.8kv lines from main station from those 8
lines 4 paires are made 1 for mediam volatge(13.8kv is stepped down to 2.4kv
through transformer) line and 3 for low volatge line (13.8kv is stepped down to
480v through tranformer).
MEDIUM VOLTAGE LINE:
13.8 kv is stepped down to 2.4kv and directly send to medium voltage motors for
their controling monitring and protection purpose.
LOW VOLTAGE LINE:
Now 13,8kv is stepped down in 480 volts and ammonia plant has 3 pairs like this
480 is then devided into MCC(motor control centre), PPB(power distribution
panel),ASPB(aux service panel board)

13. Utilities Plant
Utility plant provides the facilities to other plants to operate well
and continuously.
For that purpose it is includes the following equipment and
machinery:
Cooling tower
Power generation
Filtration of water
Supply of water and steam for the whole plant
Chillers and HVAC
Compressed air for whole plant
Demin water, hot water
Natural gas distribution
Raw water storage
Fire water
Potable water
Now we will discuss the major areas of utilities in detail.
Power Generation
For power generation in FFBL there are 2 gas turbines and one
diesel generator (in emergency). The capacity of power
generation for each gas turbine is 26 MW. The power is generated
at 60 Hz and the voltage is 13800 volts.

14. Power Distribution
The Power generated by the two gas turbines is directly fed on to
the bus bars at 13.8 kV. The two bus bar are connected by tie
breakers, which are normally open. If one of the gas turbine
trips, then the tie breakers connect the two bus bars and thus load
is taken by the other turbine. Between the two bus bars is a
Diesel Driven Emergency generator of 2MW, which comes into
action in case of emergency.
The output of these feeders are distributed to the whole plant as
under and then at other side there is a step down tranformer that
make a certain desireable
voltage level
1 Residential
2 Workshop
2 Urea
8 Ammonia
2 Bagging
2 DAP
2 Colling Tower
2 ROU
2 Utilities
Diesel driven emergency generator:
It is used if the gas turbines stop working and is used to stop
the plant from shutting down. It automatically switches on in
20 seconds and has the capacity to operate the plants until the
gas turbines come back online.

15. PRODUCT HANDLING AND SHIPPING
(PH&S):
INTRODUCTION:
Its very important department at FFBL who is responsible for storage and
checking of final product that is UREA and DAP. It has a storage capacity of 3500
MT UREA and 3500 MT DAP. It has 9 conveyer belt lines 5 for UREA and 4 for
DAP. Each bagging line has 800 bag/hr capacity. The whole process is controlled
through mini plc simens s700 in each bagging line.
FINAL PRODUCT:
Final product is weighted in a chamber and 50 KG bags are produced then sensed
and finally through a printer each sack is labbeled by current price and number.
PRINTING:
A series plus 300 printer is used for printing.
SENSING:
Proximity sensor Fx-403 that is IR based.
POWER DISTRIBUTION:
2 Feeders output of 13.8 kv are entered in T1 (transformer 1 ) and T2 (transformer
2). Transformers step them down in 480 volts then they are further devided into
DPP(distributive power station) and MCC (motor control centre). DPP is further
devided into SV(signal voltage) CV(control voltage) and LT (lightning
tranformer) for further usage. Also there is a frequency converter that converts 60
hz into 50 hz for lightning and various purposes.

17. SENSORS:
PRESSURE SENSORS:
BOURDON TUBE
Bourdon tube pressure gauges are used for the measurement of relative pressures
from 0.6 ... 7,000 bar. They are classified as mechanical pressure measuring
instruments, and thus operate without any electrical power.
The C-shaped Bourdon tubes, formed into an angle of approx. 250°, can be used
for pressures up to 60 bar. For higher pressures, Bourdon tubes with several
superimposed windings of the same angular diameter (helical tubes) or with a
spiral coil in the one plane (spiral tubes) are used.
BALLOW GUAGE
A bellows gauge contains an elastic element that isa convoluted unit that expands
and contracts axially withchanges in pressure. The pressure to be measured
canbe applied to the outside or inside of the bellows.However, in practice,
most bellows measuring deviceshave the pressure applied to the outside of the
bellows(fig. 11-7). Like Bourdon-tube elements, the elasticelements in bellows
gauges are made of brass, phosphorbronze, stainless steel, beryllium-
copper, or other metalthat is suitable for the intended purpose of the gauge.

18. TEMPRATURE SENSORS:
RTD:
Resistance thermometers, also called resistance temperature
detectors (RTDs), are sensors used to measure temperature. Many RTD elements
consist of a length of fine wire wrapped around a ceramic or glass core but other
constructions are also used. The RTD wire is a pure material, typically platinum,
nickel, or copper. The material has an accurate resistance/temperature relationship
which is used to provide an indication of temperature. As RTD elements are
fragile, they are often housed in protective probes.
THERMOCOUPLE:
A thermocouple is an electrical device consisting of two different conductors
forming electrical junctions at differing temperatures. A thermocouple produces a
temperature-dependent voltage as a result of the thermoelectric effect, and this
voltage can be interpreted to measure temperature

19. LEVEL SENSORS:
SONAR SENSOR:
Active ultrasonic sensors generate high-frequency sound waves and evaluate the
echo which is received back by the sensor, measuring the time interval between
sending the signal and receiving the echo to determine the distance to an object.
FLOW SENSORS:
The differential producing flowmeter or Venturi has a long history of uses in
many applications. Due to its simplicity and dependability, the Venturi is among
the most common flowmeters. With no moving parts or abrupt flow restrictions,
the Venturi can measure fluid flowrates with a minimal total pressure loss.
ORIFACE PLATE:
An orifice plate is a device used for measuring flow rate, for reducing pressure or
for restricting flow (in the latter two cases it is often called a restriction plate ).
Either a volumetric or mass flow rate may be determined, depending on the
calculation associated with the orifice plate.

20. WEIGNING SENSORS:
LOAD CELLS
A load cell is a transducer that is used to create an electrical signal whose
magnitude is directly proportional to the force being measured. The various types
of load cells include hydraulic load cells, pneumatic load cells and strain
gauge load cells.
The weighing unit (FW 401A-L) for sepration of 50 kg products.
CONVERTERS:
Their are some converters in FFBL that are used to control different machinery
some of famous converters are
I TO P CONVERTER
I TO H CONVERTER
I TO P CONVERTER:
A current to pressure transducer (I/P) converts and analog signal (4 to 20 mA) to a
proportional pneumatic output (3 to 15 psi). Its purpose is to translate the analog
output from a control system into a precise repeatable pressure value to control
pneumatic actuators/pnematic values, damper etc
I TO H CONVERTER
This is same as i to p it just convert small amount of current in hydraulic

21. PROGRAMMABLE LOGIC
CONTROLLERS:
INTRODUCTION:
A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial
computer control system that continuously monitors the state of input devices and
makes decisions based upon a custom program to control the state of output
devices
INPUT:
It can be directly connect to industrial equipment or with 5v DC or AC or mA etc
OUTPUT:
we can use its out;put signal directly to small motors, contractor, valves solenoid
and lights
PROGRAMMING :
It can be programmed through three methods
1) Ladder logic
2)fundamental block
3)statement list
HARDWARE:
its hardware consist of power supply may be of 24 volt DC for its power. then
comes processors that fetch decode and execute the instruction then comes i/o
card that may be analog or digital depending on usage. its operation volatge is 5V
DC.
PLC COMPANIES:
Types of PLCs installed at FFBL are
1) Siemens s7300
2) HIMA
3) Allen Bradley
4) Bendly nevada 3500/3300

22. DISTRIBUTED CONTROL SYSTEM:
INTRODUCTION:
A distributed control system (DCS) is a control system for a process or plant,
wherein control elements are distributed throughout the system. This is in contrast
to non-distributed systems, which use a single controller at a central location. In a
DCS, a hierarchy of controllers is connected by communications networks for
command and monitoring.
EXPLANATION:
It is basically same as plc to control industrial equipments but its advantage is that
it can hand a larg
system and its working is very smooth and we can operate PLC through it,
ELEMENTS:
A DCS typically uses custom designed processors as controllers and uses both
proprietary interconnections or standard communications protocol for
communication. Input and output modules form component parts of the DCS. The
processor receives information from input modules, processing the information
and decides actions to be performed by the output modules. The input modules
receive information from input instruments in the process (or field) mainly via
sensors and the output modules transmit instructions to the instruments in the field
for initiating actions mainly via final control elements . The inputs and outputs can
be either analog signal which are continuously changing or discrete signals which
are 2 state either on or off, the signals can also be via fieldbus such as foundation
fieldbus, profibus, HART, Modbus and other digital communication buses with
communicates not only input and output signals but also advance messages such
as error diagnostics and status signals.
COMPANIES:
following DCS are installed at FFBL
1) Bailey Infy 90

23. EMERGENCY SHUT DOWN SYSTEM
(ESDS):
INTRODUCTION:
Emergency Shutdown System (ESD) is designed to minimize the consequences of
emergency situations, related to typically uncontrolled flooding, escape of
ammonia, or outbreak of fire in hydrocarbon carrying areas or areas which may
otherwise be hazardous.
EXPLANATION:
An emergency shutdown system for a process control system includes an
emergency shutdown (ESD) valve and an associated valve actuator. An
emergency shutdown (ESD) controller provides output signals to the ESD valve in
the event of a failure in the process control system. A solenoid valve responds to
the ESD controller to vent the actuator to a fail state. A digital valve controller
(DVC) test strokes the ESD valve. An impedance booster device enables the dc
powering of the solenoid valve and the DVC over a two wire line while still
permitting digital communication over the same two wire line.
HIMA PLCs are specially installed at plant site to moniter shut down system it
just shuts the repected emergeny areas rest plant remains working.
EMERGENCY LOAD SHEDDING SYSTEM
(ELSS):
INTRODUCTION:
It is a system that is responsible to provide power or electricity to the whole plant
in case of any emergency this system is programmed to provide power to the most
critical areas like ammonia.
EXPLANATION:
It is a plc and dcs combined control system that are interlinked and programmed
to provide power priority wise like if their is shortage of power then it will switch
of power of residential area then workshop and etc its main job is to power up the
most critical areas like at ammonia plant hydrogen tank , chlorine tank etc

24. VIBRATION MONETRING SYSTEM:
EXPLANATION:
The vibration monitoring in machines is performed through Bentley Nevada 3300
Proximitor Sensor System. It has three main in order to sense the vibrations
which includes probe, extension cables and proximitor. Probe is installed on the
machine and has a tip assembly. The extension cable connects the probe allows
to reach junction box. The other end provides connection for the proximitor. The
proximitor is an electronic device that has two functions. firstly, it generates a
radio frequency using an oscillator and secondly it monitors the RF signal in order
to extract usable data using a demodulator circuit
BURNING MANAGEMENT SYSTEM:
INTRODUCTION:
A Burner Management System (BMS) is a safety solution for power generation
facilities that enables the safe start-up, operation and shut down of the multiple
burner furnace section of burner. It reduces maintenance, improves up-time and
provides a safe environment for the plant personnel. It monitors and controls
igniters and main burners by utilizing flame scanners. It employs safety shut off
valve, pressure, temperature, flow, and valve position limit switch
EXPLANATION:
For quick response BMS is runned on specially designed simens s7400 Plc then
moniter , control and protect it and envoirnment also.

25. GAS TURBINE:
INTRODUCTION:
Power Generation at FFBL is done through two Gas turbines.
SPECIFICATIONS:
MANUFACTURER General electronics
POWER RATINGS 36.6MW
CURRENT RATINGS 1531A
GENERATED VOLTAGES 13.8kV
RPM 3600
FREQUENCY 60Hz
PF 0.9
EX 2000:
It work on the principle of Faraday’s electromagnetic induction. The essential
part of this principle is the magnetic field. The magnetic field is produced from a
DC power source from an Exciter that is part of the generator system. The
generator while producing electricity also has to produce this at a constant
voltage for the electrical system to work properly. Controlling the magnetic field
controls the voltage output of the generator.And its main working is to maintain
3.8KV so that we can have a constant voltage level.
GOVERNER:
It is also a part of gas turbine and its working is to mentain 3600 RPM so that 60
hz remain constant. Mark 5 governer Gas Turbine Control System employs
current state-of-the-art technology, including triple-redundant 16-bit
microprocessor controllers, two-out-of-three voting redundancy on critical
control and protection parameters and Software-Implemented Fault Tolerance
(SIFT). Critical control and protection sensors are triple redundant and voted by
all three control processors.
COMPANY:
It is GOOD WORLD governer 505.

26. RELAYS:
INTRODUCTION:
Basic working of relay is switching.we basically switch circuits or power supplys
for controlling and protection purposes.
TYPES:
Following type of some relays are installed at FFBL
1) Voltz per hertz relay
2) Under voltage relay
3) Directional power relay
4) Field relay
5) Earth fault relay
6) Sync under voltage relay
7)Lock rotor relay
8) Over voltage relay
9) Alarm relay
CIRCUIT BREAKER:
A circuit breaker is an automatically operated electrical switch designed to
protect an electrical circuit from damage caused byovercurrent or
overload or short circuit. Its basic function is to interrupt current flow
after protective relays detect a fault. Unlike afuse, which operates once and then
must be replaced, a circuit breaker can be reset (either manually or automatically)
to resume normal operation. Circuit breakers are made in varying sizes, from
small devices that protect an individual household appliance up to
large switchgear designed to protect high voltage circuits feeding an entire city.
The generic function of a circuit breaker, RCD or afuse, as an automatic means of
removing power from a faulty system is often abbreviated to ADS (Automatic
Disconnection of Supply).
CONTACTOR:
A contactor is an electrically controlled switch used for switching an electrical
power circuit, similar to a relay except with higher current ratings.[1]
A contactor
is controlled by a circuit which has a much lower power level than the switched
circuit.

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