1. Internship
Report
Submitted To:
Technical Training Centre,
FFC GOTH MACHHI
Submitted By:
Muhammad Bilal
Final Year (Mechanical Engineering)
University of Engineering & Technology, Lahore
Internship Duration (15-06-2015 to 17-07-2015)

2. 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 5 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. Waqar and Mr. Shujja Hameed Butt for being very
cooperative to me as they were 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. Bilal Hassan Mr.
Wajahat, Mr. Rashad Mr. Afzal Kiani and at last but not the least Mr. Zaigham, all these people behaved well,
tried to give their best as per their availability.
Lastly, I would like to take this opportunity to thank my fellow interns without the help of whom; the
internship could not have been such a huge success.
I am in debt to all the people at FFC who supported me throughout the internship.
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 Machhi. At present
the foundation has three fertilizer plants two at Goth Machhi (Plant 1, Plant 2) and 3rd at Mirpur Mathelo
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"
FFC has very committed and hardworking environment that facilitates its employees, the Management,
staff and crew workers.
I found their working capabilities up to mark in their relevant field of expertise.

3. Plant Description
Plant-I two plants are further divided into:
 Ammonia, Urea and Utilities
The plant has been recognized by various areas that have been assigned with their respective Area numbers.
 Plant 1:
01 rea (Urea ) 02 Area (Reforming of Natural Gas)
03 Area (Isolation of Carbon dioxide) 04 Area (compressors)
05 Area (Ammonia reactor) 06 Area (Boilers)
07 Area (Gas turbines) 08 Area (Cooling towers)
09 Area (Demine-water) 10 Area (Instrumentation Air)
11 Area (Ammonia storage)
 Plant 2 has got the same areas with coding starting from 41, 42, 43…….46, 48,49,50,51 Area.
There is no 47 Area as there are no Gas turbines separately functional at plant 2.
 Ammonia plant:
Both plants has separate Ammonia complex that utilizes in the production of respective Urea in plant 1 and
plant 2.
Natural gas is reformed to produce Ammonia for the entire Complex and carbon dioxide for the Urea Plant.
Natural gas from Marri (48km from FFC) arrives in 02 Area where its reforming is done in the presence of
catalysts.
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.
The remaining gases including Sync gas (Hydrogen+Nitrogen) and some Natural gas. The synthesis gas reacts
in Ammonia tower in the ratio of 1:3 by volume to yield Ammonia.
 Urea plant :
The Ammonia from the ammonia plant and carbon dioxide from the compressors reacted in Urea tower
to form carbamate. The carbamate formed in gaseous state is reversible process and it proceeds further
to form Urea with the removal of water. The Urea formed in molten state is then poured into the
Periling tower where it is placed in a porous bouquet and Air is passed in upward direction .As the
Molten Urea come down from top of periling tower and Air is passed in opposite direction, its
temperature cools down and it seems like ice swirling coming from top to bottom.
As the temperature cools down ,molten urea is converted to white perils, Which is then move onward to
bagging and shipping section, from where it is packed and transported to various part of countries.
 Utilities:
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.

4. Fabrication Shop
Fabrication shop fabricates different parts. It provides 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 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.
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.
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 horizontal & vertical lathes,
drilling & boring machines, universal milling machines, crank shaft grinding & rotary surface grinder
machines, lapping machines, radial drilling machine, balancing machines 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 addition.Drillling machine uses drill bit for its
operation. Grinding machine uses grinding wheel (aluminums 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, AlO2 and diamond.
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 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 it 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, Phase-III is WIND
UP/ POST T/A ACTIVITIES. T/A of FFC are done after 2-3 years.

5. Equipment Maintenance-I
The assigned task at EM1 was the study of Boiler-601 (Waste heat boiler) and gaskets.
Boiler: The function of the waste heat boilers was to recover heat from the exhaust gases of two gas turbines. This
is a simple convection duct boiler producing HS steam.
 Main parts of boiler:
(1)-Super heater, (2)-Economizer, (3) - Evaporator, (4)-Observation port, (5)-Wind box assembly, (6)-Steam
drum, (7)-Water drum (lower drum), (8)-De-Superheater
The BFW (Boiler feed water) is pre-heated by the economizer. The heated liquid water is then poured into the
Evaporator where its temperature is raised and evaporation of liquid water take place. This evaporated steam
(liquid steam) is then passed to steam drum, having temperature of 250 degree celcius.The steam drum supply
high quality steam to the super heater.
In between the two sections of super heater, there is a De-Super heater installed. The function of the De-Super
heater is to lower down the temperature of KS steam in accordance with your desired temperature.
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: is CS with inclusion
of Si or Al.
Equipment Maintenance-II
Heat Exchanger: It is Carbamate Condenser heat exchanger.
 Construction: It consists of: Kettle type shell, In-line triangular tube- sheet, U-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 is 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.
Valves: It is equipment which controls the flow of a fluid. Valves are of various types which include:
 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.

6. Machinery-I
The assigned task in this section was,
 Study of PD-compressor (k-104)
 Study of centrifugal Pump (P-105)
A PD-compressor first traps a volume of gas in a cylinder or casing, and then the gas is displaced into smaller volume
and hence results in pressure increase. PD compressors may be rotary or reciprocating.
Single acting compressors: If the gas is discharged on only the forward stroke or only the back stroke, the compressor
is single acting compressor. The forward stroke is the compression stroke and the backstroke is the suction stroke.
Double acting compressor: In double acting compressor gas is compressed on both sides of the piston and has two
discharge strokes per revolution.
Centrifugal Pump: Pump is 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.
Machinery-II
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 –II.
The assigned task in machinery 2 section was the detail study of Dry steam turbine pump (DSTP-4601) and seals.
Dry steam turbine pump: This pump is a feed pump of boiler which is providing water to boiler. This pump is
run by a dry steam turbine. It is a centrifugal pump.
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.
Seals: It reduces the leakage. They may be of many types like mechanical seals, which have less maintenance
and min. leakage, wear rings, which minimize leakage from discharge back to suction, lantern ring, through
which lubricating oil flows, and packing box, which minimize leakage of oil from pump. A small amount of
leakage is necessary for the lubrication.
 O-ring makes a tight seal b/w the rotating elements and the shaft.

7. 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 are 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:
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. 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 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.

8. 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 steam turbines.
 Construction and working of Carbamate condenser
 Heat Exchangers
 Perils formation
 Compressors
 Cooling Tower
 Different types of valves and their testing systems
 Mechanical seals
 Vehicle shop facilities
 Tool room and lapping room
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 and 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.
 No one was asking the internees until they did not say to the responsible engineers to learn about something.
 The internet facility need attention as it will help to address the issues and broaden our concepts by
searching various sources.
 A general overview of daily jobs to be executed should be given to internee in receptive section on that
particular day.
 SAP overview in particularly should be added in internship schedule given to internee.
 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 arrange in a week to discuss the work done in their
respective section in that particular week.
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.
If given the opportunity to serve this organization I would feel honored to do so.