Internship Report FFC

Submitted By:
Zeshan Aziz
Final Year (Mechanical Engineering)
University of Engineering & Technology, Lahore (MNS UET Multan Campus)
Internship Duration (27-07-2015 to 04-09-2015)
Internship
Report
Submitted To:
Technical Training Center (TTC)
FFC Goth Machi
Start with the name of Allah who is most merciful and beneficent

Summary:
Fauji Fertilizer Company is the place where a professional can get benefits best to his knowledge in the
field of engineering & management. Being an internee here in FFC for 6 Weeks, many new things come
to me. It is all due to the efforts of well cooperation from managerial level to the staff level and off course
mine too. I tried my best to get the things properly.
I visited the plant site, observed the things being done at different sections, different areas .It was a good
experience and I will try my best to be the official part of this industry after my graduation In Shaa Allah.
In addition to all this, I would like to specially thank Mr. Talha for being very cooperative to me as he
was the very first person who encouraged me, to learn something, to observe the industrial
environment after I entered FFC. After that many known personalities like, Mr. Abdul Wahab, Mr. Waqar
, Mr. Raja Shahid, Mr. Zaigham Abbas, Mr. Ikhlaq , Mr. Hammad Hafiz, Mr. Billal, Mr Taj Farooq and at
last but not the least Mr. Khurram, all these people behaved well, tried to give their best as per their
availability.
Introduction:
Fauji Fertilizer’s Company is a national group that is reputable among chemical industry. 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 Key product of company is urea, a fertilizer used widely all over Pakistan. Since Pakistan is an
agro-based economy, the contribution of the fertilizer to the economy is vital and FFC is a prime share
holder in the fertilizer industry of Pakistan.
FFC commenced commercial production of urea in 1982, from its plant located at Goth Machi. At
present the foundation has three fertilizer plants one at Goth Machi, second at Mirpur Mathelo and
third in Karachi named FFBL (formerly FFC-Jordan Fertilizer Company Limited).
In the year 2002, FFC acquired ex Pak Saudi Fertilizers Limited (PSFL) Urea Plant situated at Mirpur
Mathelo, District Ghotki from National Fertilizer Corporation (NFC) through privatization process of
the Government of Pakistan.
This acquisition at Rs. 8,151 million represents one of the largest industrial sector transactions in
Pakistan.
The company defines its motto as:
“SERVING THE NATION"

Plant Description:
Fauji Fertilizer Company Goth Machi plant site is divided into two main categories
Plant –I Plant –II
These two plants are further divided into:
Ammonia Urea Utilities
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 for utility plant are
 Well water
 Canal water
 Natural gas.
Raw Material for Ammonia plant:
 Natural Gas
 Process Steam
 Air
Raw Material for Urea plant:
 Ammonia
 Carbon dioxide
Natural gas from Mari Petroleum Gas Company (MPCL) is coming to the ammonia plant .It enters the
furnace where carbon monoxide, carbon dioxide and hydrogen are formed in the presence of catalyst.
Carbon monoxide is then converted to carbon dioxide in the presence of catalyst and air coming gives
out nitrogen. Nitrogen and hydrogen from natural gas are sent to ammonia reactor where in the
presence of iron oxide catalyst ammonia is formed under a reversible reaction. Syn gases are formed
which are sent to Syn gas compressor. Ammonia is liquefied and cooled .It is then sent to ammonia
storage tanks.
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 prilling
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. Prilling tower is natural draft type, urea droplets free fall and the air coming

upward takes its heat. Urea is cooled down and solidifies. It is then sent to bagging section with the help
of conveyor belts.
In this whole process, utilities plant provide assistance in the form of power, cooling towers which cools
the hot circulated water of both the plants.
Planning and Scheduling (P&S):
P&S is the department which provides assistance in the form of human resource, finance and other
required facilities from outside or inside industry to other departments of FFC. Most importantly it
plans and schedules the jobs to be done in turn-around or shutdown. Also it deals with the contractors
and assistance required from outside or is to be given to some other industry.
 SAP: It is the software being used for planning of different jobs on plant. It is online
communication between different concerned departments. If a department or industry itself have
to purchase something, PURCHASE REQUISITION (PR) is formed for that purpose and all this is
done in SAP. PRIMEVERA is also in use for that purpose but FFC is totally shifting to SAP soon.
 T/A Planning: Turnaround is a pre-planned maintenance of plant at some specified frequency.
It includes three phases: Phase-I is PLANNING, Phase-II is EXECUTION, CONTROLLING &
MANAGING, and Phase-III is WIND UP / POST T /A ACTIVITIES. T/A of FFC is done after 2-3 years.
Machine Shop:
Machine shop provides assistance in machining and producing different parts like shafts, impellers or
any part of machinery, equipment being used at plant. Every machine has its own functions and cutting
tools for the sake of material removing. During my visit to the machine shop, I observed:
 Safety is of primary importance while working on machines. Machining on lathe, drilling, milling
and grinding and the capability of other small to giant size machines available in the shop.
Turning, facing, taper turning, drilling can be done on lathe machine. Tool materials include:
Carbon steel, stainless steel, carbide tip, HSS, tungsten and diamond etc. Carbide tip is used for
hard materials.
 Balancing of rotary parts (impeller) by material removal or material addition. Drilling machine
uses drill bit for its operation. Grinding machine uses grinding wheel (aluminum oxide) for its
operation. If rpms of grinding wheel are greater than rpms of work piece should be smaller for
better surface finish. Also observed balancing of rotating masses in grinding machine. Grinding
wheel material includes silicon carbide, aluminum oxide and diamond.

Fabrication Shop:
Fabrication shop fabricates different parts. It provide assistance in welding, special tools for plant
equipment’s which are necessarily required. The shop comprises of: special tool room, welding
machines, sheet rolling machines, shearing machines, HP shop and carpentry shop.
Heat Exchanger:
It is an equipment which exchanges heat b/w two fluids in the form of cooling or heating one of them.
Mode of heat transfer in heat exchanger is mainly conduction and convection. Heat exchangers are of
two types: Tubular and Plate Type. Tubular heat exchangers are of three types: (i) Fixed tube (ii) U-
tube (iii) Extended surface.
Tubular Heat exchanger consists of: Shell, Tube sheet, Tube bundle, Baffle & Channel Cover. Tube sheet
Layout is of Triangular pattern, In-line Triangular, In-line square and Diamond Square. Inline square is
most efficient where low pressure drop is required.
 Baffles are used for two purposes, for supporting tube bundle and for creating turbulence in
flow.
Welding Technology:
Welding Technology being used in fab shop is electric welding (SMAW), gas welding and argon welding
(GTAW).Available welding machines can perform both SMAW & GTAW. Gas welding uses oxygen &
dissolved acetylene for its operation.
 GTAW: It uses tungsten electrode with argon shielding and filler metal
 SMAW: It uses consumable electrode for welding.
Machinery-II:
Centrifugal Pump: Pump is a machinery which increases the pressure of a liquid flowing through it.
There are various types of pumps in use. Centrifugal pump uses centrifugal force to increase pressure
of the liquid.
Main Parts: Casing, EYE, Impeller Blade. The pump part that spins the liquid is called impeller.
 Lubrication of pump is very important. Before starting the pump, it should be filled with some
liquid for lubrication purpose. Larger the impeller dia higher will be the capacity. Pump will
operate when available NPSH (available) > NPSH (required).

Series & Parallel Combination: In series, pumps should have same capacity. In parallel, pumps should
have same total head characteristics.
 Gradual loss of pump capacity may be due to: impeller vanes become worn, balancing drum
is worn, blockage in discharge, Cavitation cause vibrations in the pump.
Seals:
A mechanical seal is a device that helps join systems or mechanisms together by preventing leakage
(e.g. in a plumbing system), containing pressure, or excluding contamination. The effectiveness of a seal
is dependent on adhesion in the case of sealants and compression in the case of gaskets
A mechanical seal is a machine element made to seal the passage point of a rotating part (usually a shaft)
through a wall (usually the machine casing). Features of the mechanical seal are two surfaces sliding on
each other – usually arranged at right angles to the rotational axle – which are pressed together by axial
forces. Between the sliding surfaces is a liquid or gaseous lubricating film.
Every mechanical seal possesses five basic elements:
1. One ring (usually the seal face) circulating synchronously with the rotating part (shaft).
2. Secondary seal (usually O-ring) between shaft and ring.
3. A stationary ring (usually the stationary seat) arranged in the stationary part (casing).
4. Secondary seal (usually O-ring) between these parts.
5. Spring for the seal face.
Machinery-I:
Those machines which are dynamic in nature and do involve rotary components are categorized as
machinery. This Section deals with the maintenance of machinery at plant –I.
Reciprocating Pump:
A reciprocating pump is a class of positive-displacement pumps which includes the piston
pump, plunger pump and diaphragm. It is often used where a relatively small quantity of liquid is to be
handled and where delivery pressure is quite large. In reciprocating pumps, the chamber in which the
liquid is trapped, is a stationary cylinder that contains the piston or plunger.

CONSTRUCTION:
The Main Parts of Reciprocating Pump are:
CYLINDER: It is made of cast iron or steel alloy. The piston reciprocates inside the cylinder. The
movement of piston is obtained by a connecting rod which connects piston and rotating crank.
SUCTION PIPE: It connects the source of water and cylinder, the water is sucked.
DELIVERY PIPE: Water sucked by pump is discharged into delivery pipe.
SUCTION VALVE: It adjusts the flow from the suction pipe into delivery pipe.
DELIVERY VALVE: It admits the flow from the cylinder in to delivery pipe.
AIR VESSEL: It is a cast iron closed chamber having an opening at its pass through which the water
flows into vessel.
Reciprocating Compressor:
A reciprocating compressor or piston compressor is a positive-displacement compressor that
uses pistons driven by a crankshaft to deliver gases at high pressure.
The intake gas enters the suction manifold, then flows into the compression cylinder where it gets
compressed by a piston driven in a reciprocating motion via a crankshaft, and is then discharged.
Applications include oil refineries, gas pipelines, plants, natural plants and refrigeration plants.
In the ionic liquid piston compressor many seals and bearings were removed in the design as the ionic
liquid does not mix with the gas. Service life is about 10 times longer than a regular diaphragm
compressor with reduced maintenance during use, energy costs are reduced by as much as 20%. The
heat exchangers that are used in a normal piston compressor are removed as the heat is removed in
the cylinder itself where it is generated. Almost 100% of the energy going into the process is being
used with little energy wasted as reject heat.
Centrifugal Compressor:
In a centrifugal compressor, energy is transferred from a set of rotating impeller blades to the gas. The
designation “centrifugal” implies that the gas flow is radial, and the energy transfer is caused from a
change in the centrifugal forces acting on the gas. Centrifugal compressors deliver high flow capacity
per unit of installed space and weight, have good reliability, and require significantly less maintenance
than reciprocating compressors. However, the performance characteristic of centrifugal compressors
is more easily affected by changes in gas conditions than is the performance of reciprocating
compressors. Process control to avoid operation in a damaging surge condition is also addressed.

Equipment Maintenance-I:
Equipment are categorized as those machines which are static in nature and do not involve any rotary
components. This Section deals with the maintenance of equipment at plant –I.
Boiler: It is Water Tube Waste Heat Recovery Boiler.
The boiler is a closed high pressure vessel in which the heat changes water into steam at a pressure of
generally 2 bar or higher. More scientifically a boiler converts the chemical energy in fuel into heat
energy in steam, or the heat energy of hot gases into heat energy of steam when no firing is involved.
The earliest form of the boiler is the kettle.
This report is based generally on water tube boilers and especially on waste heat water tube boilers
B601, B602.
There are two water tube boilers installed at the utilities plant for recovering waste heat of two gas
turbines (TG 701):
1. B601
2. B602.
It is a simple convection duct boiler for producing HS steam. It has high capacity and functions in
high pressures and temperatures, but it has high initial and maintenance cost and has operational
difficulties too.
The main features of the waste heat boilers used at the utilities plant are as follow:
 Capacity 55 Ton Per Hour
 Steam Pressure 39 KG/Cm2
 Steam Temperature 385’C
 Type Forced Circulation Water Tube
 Fuel Gas Turbine Exhaust Gases plus Firing
 Manufacturer Fooster Wheelar USA
Gasket: It is a component which is used for sealing or leakage control purposes.
Types: These are of four types, Non Metal, Metal/Machine, Metal Jacketed /Heat exchangers gaskets
and semi metal gaskets. These are used at heat exchangers, valve bonnets, high pressure piping system,
pressure vessel heads. Lens gaskets have the advantage of early leakage detection to prevent plant
shutdown.

Materials: Basically metals and nonmetals. Ferrous metals are those which contain iron by mass more
than any other single element. Carbon contents in a material increase hardness.
Killed carbon steel: It is carbon steel with inclusion of silicon or aluminum. It is used for piping, valves
and vessels for low temp liquid ammonia at fertilizer plant.
Stainless Steel: It is of austenitic, ferritic, martensitic & duplex type.
Equipment Maintenance-II:
Equipment are categorized as those machines which are static in nature and do not involve any rotary
components. This Section deals with the maintenance of equipment at plant –II.
STIPPER Heat Exchanger:
It is Carbamate Condenser heat exchanger.
Construction: It consists of Kettle type shell, In-line triangular tube- sheet, I-tube bundle and bonnet
type front end. It uses steam and condensate at shell side, & Carbamate solution at channel side.
Material: Shell is of carbon steel, while tube bundle has inside lining of urea grade material because
urea is very corrosive. So special compositions of chromium, nickel etc. are used.
Working: Carbamate vapors from stripper are sent to Carbamate condenser, where water is used as
condenser present at shell side while vapors are present at tube side which are being condensed. During
this process water is converted to steam which is low pressure steam and is recovered from top side.
Two Carbamate condensers are used at plant –I.
 Kettle type shell is used for two phase service.
Valve:
It is an equipment which controls the flow of a fluid. Valves are of various types which includes:
 Ball Valve: It is a hollow sphere centered in a disc. It is used for high pressure, high temperature
apps, less pressure drop.
 Gate Valve: It is used for high pressure and high temperature applications, not used for
throttling purpose n for viscous fluid.
 Globe valve: It is used for throttling purposes, power and process piping systems and high
pressure drop.

Health Safety and Environment Systems:
Importance of Safety:
Safety means protection of
 Humans
 Machinery and equipment
 Environment
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.
Personal Protective Equipment’s:
Devices used to protect employees from injury or illness resulting from contact with chemical,
radiological, physical, electrical, mechanical, or other workplace hazards is referred as personal
protective equipment’s. These include protective clothing, helmets, goggles, or any other
equipment specially designed depending on the hazard present.
All the interns were provided with helmets, goggles, safety shoes and ammonia mask which
clearly show the company commitment towards maintaining an injury free environment at plant.
Our goal is to protect our people, the public, our property and the Environment in which they work and
live. It is a commitment that is in the best interests of our customers, our employees and all other
stakeholders.
It is possible to run all operations without injuries or damage to equipment or the environment:
 We will comply with all applicable laws and relevant industry standards of practice.
 We will continuously evaluate the Health, Safety and Environmental (HSE) aspects of our
equipment and services.
 We believe that effective HSE management is good business and we are committed to the
continuous improvement of HSE management practices.
 We are committed to the integration of HSE objectives into our management systems at all levels.
This will enhance our business success by reducing risk and adding value to our services.

Conclusion:
During my visit to the FFC, I learned about and visited:
 Planning & Scheduling
 Machining Operations
 Fabrication of certain things
 Working of Centrifugal pumps.
 Construction and working of Ammonia reactor.
 Construction and working of steam turbines.
 Working of Urea Reactor
 Construction and working of Carbamate condenser
 Heat Exchangers
 Prills formation
 Boilers
 Cooling Tower
 Construction and working of Centrifugal Pump and Centrifugal Compressor
 Construction and working of Positive displacement Pump and Positive displacement
Compressor
Suggestions & Feedback:
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 visited the plant site, observed the things being done at
different sections, different areas .It provides best working environment to its employees no doubt.
 It provides proper environment to the internee to be able to learn as much things as possible. 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 n Engineers are much busy
in their works. So I felt there should be some crew for internee as well.
 Project work should be assigned to internee.
 Plant visit wasn’t up to the mark.
 Give preference to Local Candidates for Job interview.
 Experiments Shops and New Ideas Shops should be establish.
 Give chances to poor background students, they have much talent inside and I think only FFC
can polish them.
At Last, It was a very good experience overall, I liked the working environment, & I will try my
best to be the part of FFC after graduation in Shaa Allah.

Internship Report FFC

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