The document provides an overview of the internship experience of the author at Fauji Fertilizer Company Limited (FFC). It describes visits to different departments including planning, machine shop, fabrication shop, and equipment maintenance. Key lessons included learning about turbines, pumps, compressors, heat exchangers, reactors, and various types of valves. Suggestions were provided such as using chip breakers, 3D drawings, safety improvements, and increasing field visits and project work for interns. The conclusion was that the internship provided practical application of knowledge and exposure to various plant operations and maintenance aspects.

1. 1
Summary:
During this first o all i went to the TTC (technical training centre) there I saw different Model
of valves, different model of turbines, different model of heat exchanger and different types
of machines e.g. lathe, milling, shaper and welding machines .After visit of TTC I went to the
plant site in the plant site area first I went to the planning & scheduling department in this
department I learned about planning how planning is work about maintenance. In planning
department I learned about SAP. What is it? How it is work? After planning department I
went to the machine shop .In this department I have seen different operation on lathe, milling,
lapping, grinding and boring and observe different type of tools and visit vehicle shop. After
machine shop I went to the fabrication shop in this department I learned about welding
technology, exchanger types and different facilities available in fabrication shop. Further I
went to the equipment maintenance department 1 in this section I seen the maintenance of
different types of valves ,construction of valves ,study of steam trap history and seen different
types of steam traps, construction of E-110 and visit plant area and observe the working of E-
110. This department is responsible the all stationary part using in the plant 1.After this I
went to the machinery 1. This department is responsible the all rotary part using in the plant
1.in this department I learned about TK-101 and visit to the plant area and observe the
working of TK-101.In equipment maintenance department 2 I learned about construction of
reactors e.g. R-4101 and different study of valves . This department is responsible the all
stationary part using in the plant 2.In machinery 2 I learned about different about P-4301 and
K-4421. This department is responsible the all rotary part using in the plant 2.
Introduction:
Fauji Fertilizer Company Limited (FFC) is the largest chemical fertilizer producer
of Pakistan with biggest market share in the country. With a vision to acquire self -
sufficiency in fertilizer production in the country, FFC was incorporated in 1978 as a private
limited company. This was a joint venture between Fauji Foundation (a leading charitable
trust in Pakistan) and Haldor Topsoe A/S of Denmark. The initial authorized capital of the
company was 813.9 Million Rupees. The present share capital of the company stands at Rs.
3.0 Billion. Additionally, FFC has Rs. 1.0 Billion stakes in the subsidiary Fauji Fertilizer Bin
Qasim Limited (formerly FFC-Jordan Fertilizer Company Limited). FFC commenced
commercial production of urea in 1982 with annual capacity of 570,000 metric tons. the
production capacity of the existing plant increased to 695,000 metric tons per year.
Production capacity was enhanced by establishing a second plant in 1993 with annual
capacity of 635,000 metric tons of urea. FFC participated as major shareholders in a new
DAP/Urea manufacturing complex with participation of major international/national
institutions The facility is designed to produce 551,000 metric tons of urea and 445,500
metric tons of DAP. -1- This excellent performance was due to hard work and dedication of
all employees and the progressive approach and support from the top management.

2. 2
Plant DescriptionAmmonia, Urea and Utilities:
Plant location : Goth Machhi Sadiq Abad
Product : Sona Urea
PLANT-I
Commencement of Commercial Production: June14, 1982
Project cost : RS 3300 million
PRODUCTION CAPACITY
Ammonia -I : 1220 tons per day
Urea -I : 2105tons per day
PLANT-II
Commencement of Commercial Production: March21, 1993
Project cost : RS7215 million
PRODUCTION CAPACITY
Ammonia –II : 1100 tons per day
Urea –II : 1925 tons per day
Urea product quality Nitrogen 46.0%
Moisture 0.3%
Biuret 0.9%
Ammonia:
Natural gas is broke down to CO,CO2 and Hydrogen gas. Here we get Carbon dioxide which
is one of the raw materials for the preparation of Urea. In order to get the 2nd raw material
(Nitrogen), the air from the compressor is passed through a catalyst to get Nitrogen, as
Nitrogen has 79% presence in air. Now the combination of these gases which has Nitrogen
also is passed through Absorber which absorbs Carbon-dioxide.
Urea:
For the production of urea two things are required ammonia and CO2. At urea plant, ammonia
from storage tank is pumped to urea reactor along with carbon dioxide. 31% urea is formed in
urea reactor. It is then concentrated to 99% when it reaches at the top of periling tower. There
it is put to a bucket which rotates at some rpms and the hot urea from its pores comes out due
to centrifugal force. Periling tower is natural draft type, urea droplets free fall and the air
coming upward takes its heat. Urea is cooled down and solidifies.
Utilities:
Steam and Power Generation:
Utilities section is common for both the plants. It provides assistance to both the plants in the
form of power generation, water purification. Raw materials are well water, canal water and
natural.
For Electric Power Generation : Capacity of Both Generators
Two Electric Generators : 37mw (Combined)
Gas Turbine Rpm : 5100
Generator Rpm : 3000
Voltage : 6.3kv
Two Waste Heat Boiler Capacities : 55 Tons Per Hours Each
Temperature : 3700c
Pressure : 37kg/Cm2

3. 3
Machinery -1:
This department is responsible for the all rotary part using in the plant 1. This
department keeping detailed maintenance records for all equipment recording the date
and the details of the completed service. In this department I learned about different
turbines gas turbines and steam turbines. A turbine is a spinning wheel that gets its
energy from a gas or liquid moving past it. The steam turbine is powered by the energy
in hot, gaseous steam. Steam turbines use high-pressure steam to turn
electricity generators. All steam turbines have the same basic parts e.g. Rotor and
blades, alloy steel outer case etc. In one type of turbine, the rotating blades are like
deep buckets. In impulse turbines High-velocity jets of incoming steam from nozzles
kick into the blades, pushing them around with a series of impulses, and bouncing off to
the other side with a similar pressure but much-reduced velocity. In a reaction turbine,
there's a second set of stationary blades attached to the inside of the turbine case. These
help to speed up and direct the steam onto the rotating blades at just the right angle,
before it leaves with reduced temperature and pressure but broadly the same velocity as
it had when it entered. And study about TK-101 this turbine is use for drive the CO2
compressor. And observation the working of this turbine in the plant area.
Machinery -2:
This department is responsible for the all rotary part using in the plant 2. This
department keeping detailed maintenance records for all equipment recording the date
and the details of the completed service like other departments. In this department I
learned about centrifugal pumps and compressors. A centrifugal pump convert’s input
power to kinetic energy .The fluid enters the pump impeller along or near to the
rotating axis and is accelerated by the impeller, flowing radials outward into a diffuser
or volute chamber (casing), from where it exits.
Main Parts: Casing, EYE, Impeller Blade. The pump part that spins the liquid is called
impeller.
Series & Parallel Combination: In series, pumps should have same capacity.Inparallel, pumps
should have same total head characteristics.
Compressor an instrument or device for compressing a machine used to supply air or
other gas at increased pressure, e.g. to power a gas turbine. In this department study and
learned about of P-4301 and K-4421.

4. 4
Equipment Maintenance 1:
This department is responsible for the all stationary part using in the plant 1.This
department is providing the maintenance necessary to obtain a high quality of
production and the most useful service life of the equipment. Keeping detailed
maintenance records for all equipment recording the date and the details of the
completed service. Refer to service procedures, processes, or manuals for the required
service specifications and details of items to be serviced. In this department I saw the
maintenance of different types of valves and observe the construction and working of
the valves, study about different types of valves e.g. gate valves, globe valve, plug
valves, ball valve and etc. This valve is use for control and regulates the flow. Steam
traps are a type of automatic valve that filters out condensate (i.e. condensed
steam).there are three basic types of steam trap thermostatic (temperature difference),
mechanical (density difference) thermodynamic (change of state). And construction of
exchanger, study about E-110. A heat exchanger is a device that allows heat from a
fluid (a liquid or a gas) to pass to a second fluid (another liquid or gas) without the two
fluids having to mix together or come into direct contact. I seen the I-type and u-type
exchanger .Cotton wool is use for exchanger insulation.
Equipment Maintenance 2:
This department is responsible for the all stationary part using in the plant 2.this
department same as equipment maintenance 1 Keeping detailed maintenance records for
all equipment recording the date and the details of the completed service. Refer to
service procedures, processes, or manuals for the required service specifications and
details of items to be serviced. In this department I saw maintenance of some other
types of valves observe the construction and working of the valves e.g. angle globe
valve, check valve, lift check valve, ball check valve, safety valve, butter fly valve and
control valve. These valves are use for control and regulate the flow of fluid. And study
about R-4101.This reactor is use for CO2 and ammonia reaction and convert into urea.
Ammonia and CO2 enter in the reactor from below sides NH3 inlet and CO2 inlet .these
gases is passing through sieve trays and converted into urea outlet from above side of
reactor.

5. 5
FabricationShop:
Fabrication is a simple and powerful object generation. Metal fabrication is the building
of metal structures by cutting, bending, and assembling processes. In fabrication shop I
saw cutting is done by sawing, shearing or chiselling all with manual and powered
variants torching with hand-held torches such as oxy-fuel torches or plasma torches and
cutters (using a laser, mill bits, torch, or water jet). Assembling (joining of the pieces) is
done by welding, binding with riveting fasteners. Rolling is done by rolling machine and
made different diameter of vessel, shell and cylinder. In this fabrication shop mostly
SMAW (shield metal arc welding) and GTAW (gas tungsten arc welding) is use for
welding. See different types of exchanger e.g. shell and tube type I-type and u-type
exchanger. And study about these exchanger. And valve reclamation, stripper shop,
carpentry shop other facilities available in this fabrication shop.
Machine Shop:
This Machine shop consist of different type of machines e.g. lathe machines ,drilling
machines, milling machines, grinder machines ,surface grinder, crank grinding machine.
In machine shop i saw different operations in these machines e.g. lathe operation
(turning, boring, threading, knurling).during this operation cutting fluid is also use. Raw
materials is cast iron, high speed steel, stain less steel, Teflon is use for different jobs.
Machine shop is further consisting of tool room, lapping room and vehicle shop. Lapping
is use when high finishing is required during lapping silicon carbide is use coarse,
medium fine, fine and very fine .on the psv lapping is done by hand. Flatness is check by
mono chromatic light. Tool room consist of different types of tool using all over the
plant. In vehicle shop cranes, Hino dump truck, de-watering pump, mobile compressors
welding plants send to different area’s in plant when is things are required.
Planning & Scheduling:
Planning & scheduling department make pre- plan about turn around and shut down of
plant. In the shut down any emergency breakdown of equipment / machinery of the plant
without which, plant cannot be run and in turn around planned shutdown at
predetermined interval of time and with optimize resources to carry out required
inspection / repairs/ modifications and preventive maintenance. Turn around consists of
three phases .In phase 1 planning /pre-turn around activities. Phase 2 consist of
execution, controlling managing .phase 3 consist of post turn around activities. Planning
department provides an opportunity to make significant design changes in piping
modification, equipment and to address safety and reliability issues. Supports in
developing a long term strategy and accuracy of turnaround schedules. During turn
around focus every department activities .SAP is software it is use for send notification
to different department of plant maintenance.

6. 6
Health Safety and Environment System:
Safety means the protection of human, machine, and environment. Without Personal
Protective Equipment’s no entry in the plant area.
Personal Protective Equipment’s are:
 Safety helmet
 Safety shoes
 Goggles
 Masks
 Air locks
 Smoking is not allowed in the operating areas except in the offices, control room,
work shop & smoking cabins.
 It is forbidden to carry out any repair /maintenance without a valid work permit.
 Wearing of safety shoes is mandatory in the plant.
 Use of safety helmet & glasses is mandatory in operating areas except where
exempted.
 Use special personal protective equipment where required.
 Observe safety procedures/regulations as prescribed or advised for accomplishing all
job at the plant.
 All accidents, near misses and injuries on the job should be reported to immediate
supervisor and safety section without loss of time.
 It is forbidden to remove or modify safety locks and protection devices without
authorization.
 Visitor are not allowed to enter the operating areas unless approved by competent
authority and guided.
 Vehicle entry in operating areas is forbidden except under a valid permit.
 Observe traffic rules.
 All hazardous and unsafe conditions should be rectified by the areas themselves;
safety section is an audit and advisory function.

7. 7
Conclusion:
My Internship at FFC was quite a wonderful and fulfilling experience. It has provided me with a
chance to cover my theoretical knowledge studied at university to their practical applications here
at FFC.
During my internship to the FFC, I learned about many things use in my practical life.
And visited different departments and learned about different department responsibilities. It was a
very comprehensive training program, covering almost all the important aspects of plant
maintenance.
Suggestions& Feedback:
 In the machine shop I observe the there is no chip breaker is use. Remove the material with
hook when machine is running position it is very dangerous .Use chip breaker on the tool.
 Use 3D drawing for jobs .Because technician easily understand 3D drawing. Benefit is time
saving.
 There is no specific foot path on plant main road. Sign boards and anything should not on the
foot path.
 Only issued the blue safety helmet for internee maintenance engineer .During this internship
issued different colors of helmets. OR specific color for internee.
 Increased field visit for internees.
 Project work should be assigned to internees.
 Internee should be taken to Plant by the Area engineer along with himself during his
routine visit to plant as it will enhance chances to learn.
 A general descriptive meeting of the internee should be arranging in a week to discuss
the work done in their respective section in that particular week.
FFC is a well-organized and disciplined industry. It has so much to learn, to
experience the new things, to put the theoretical knowledge into practice. I felt during
the visit that there must be some non-regular crew which can give max response to the
people coming here for internships because higher management and Engineers are
much busy in their works. So I felt there should be some crew for internee as well.