INTERNSHIP REPORT

(Maintenance Unit)
Prepared For:
Learning and Development Center (L & D)
Fauji Fertilizer Bin Qasim Ltd. Krachi
Prepared BY:
Asif Nadeem Khan
Undergraduate Student at
Department of Mechanical Engineering University of Engineering and
Technology, Lahore
Email: muhammadasif435@gmail.com
Contact: 0345-4522858
June 27, 2014


Declaration

July 28, 2010

TO WHOM IT MAY CONCERN


Dear Sir:
Submitted for your review is the report of my four week internship at Maintenance Unit of Fauji
Fertilizer Bin Qasim Ltd. plant, during June 2014.
It is hereby declared that the report is compiled in long report format, as per the guidelines and
is based upon the literature review; plant manuals and standard operating procedures; process
flow diagrams and sharing and learning from management and staff of the company. Maximum
possible references from literature are cited and sources are mentioned.
It is anticipated that response will be reflected.

Regards
Asif Nadeem Khan
Undergraduate Student at
Department of Mechanical Engineering University of Engineering and Technology, Lahore
Under Registration No. 2011-ME-341
Email: muhammadasif435@gmail.com
Contact: 0345-4522858



Acknowledgements
Author is thankful to
Almighty Allah,
For His unlimited blessings and bounties,
And for keeping him sane, sound and successful;
His parents and friends,
For all their support and trust in him and his aims;
His teachers and guides,
For teaching him things he knew not;
UET Internship and Placement Office,
For bringing the opportunity of this excellent learning and exposure;
And last but never the least
Management and Staff of Fauji Fertilizer Bin Qasim Ltd. Krachi
Especially Unit Managers, Shift Engineers, Supervisors and Operators,
For their utmost help, guidance and time
Which made author make most of his internship at plant site;
AN INTRODUCTION OF 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
(DIAMONIUM PHOSPHATE) .It is the soul 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 63% 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. It is the first granulated Urea plant and the first generating
60 HZ 110v power. Most modern state of the art instrumentation system like
Distributed Control system (DCS) and Programmable logic Control (PLC) are
applied on plant site.




Abstract
Maintenance unit manages the urea, DAP and Ammonia Plant. The unit is divided into:
Utilities unit; provides plant utilities like electricity, cooling water, instrument air etc
Ammonia unit; produces ammonia and carbon dioxide from natural gas and
atmospheric air
Urea unit; produces urea by dehydration of carbamate, made by reaction of liquid
ammonia and carbon dioxide gas
DAP(Diammonium Phosphate) unit; produces DAP from ammonia and phosphoric acid
Bagging and shipment unit; bags the urea product and sends it to the consumer market
Utilities unit has the most diverse ground of operation ranging from water treatment to steam
generation, boiler operation to power generation, cooling tower to waste water treatment.
Ammonia unit has the maximum learning exposure with catalytic steam reforming, carbon
dioxide removal and recovery, compression and gas synthesis section. Urea unit develops an
exposure to handling of chemicals from urea synthesis to its purification through stripper, MPD,
LPD, pre-concentrator, vacuum separators to the prilling bucket. DAP unit has also same type of
learning opportunities. Bagging shipment unit gives an understanding of meeting the consumer
requirements in easy way.
These units are such designed and operated to ensure safety of personnel and plant. Process
optimization in economizing the process in terms of heat load recovery, production and
capacity is the governing factor.


Utilities Unit
The objective of utilities unit is:
To provide desired quantity and quality of certain utilities to the ammonia and urea units for
smooth functioning. These utilities include electricity, cooling water, instrument air, fuel gas
and steam network.
Water, air and natural gas are the basic utility raw materials, which are processed and improved
in order to meet the plants criterion of quality and ensure a longer life and safety of
equipment.
Water Air Natural gas
Cooling water
Steam
Utility / service water
Drinking water
Instrument air
Utility / service air
Process air
Process stream
Fuel stream

Utilities unit is a pre-requisite for other units because their smooth running depends upon the
utilities supplied by it. In case of utility failure plant has to face an emergency shutdown. Major
sub-divisions of utility section are:
Natural Gas Station
Power Generation and Distribution
Raw water storage and distribution
Raw Water Treatment
Cooling Tower and cooling water pumps
Waste Water Disposal
Instrument Air Compression
Auxiliary Boilers and Steam Network
Chilled and hot water system (HVAC)
Fire water distribution

Natural Gas:
The purpose of natural gas station is to supply natural gas after filtration to meet the demands:
Process gas
Fuel gas
Township supply
Natural gas is drawing from Sui Southern Gas Limited. Normal pressure at the batter limit is 31
Kg/cm
2
. This natural gas is divided into feed (for Nh
3
) and fuel gas headers. The fuel gas
pressure is controlled by the letdown station. Then it passes through GV-111, knock out drum,
where moisture is removed. The gas pressure is further reduced for use in auxiliary boiler, HSRG
and gas turbines. Pressure safety valves are provided to protect against over pressurizing. The
natural gas has 92% CH
4
, 3% CO
2
and 4% N
2
.
Power Generation System:
Electric Power is generated through turbo generators (TG), which are the turbine driven for the
production of electricity. These are the major source of electricity for all the plant having a
capacity of 52 Mega Watts (2 generators each has capacity 26 Mega Watts). A diesel driven
emergency generators (DDEG) having a capacity of 2 Mega watts, is also installed. All the three
generators are synchronized and are connected with the main bus bar. Generation voltage is
13800 volts and frequency at 60 Hz.
Steam Production:
Production and supply of steam to whole plant is under utility section. Steam is generated by
two methods
Heat recovery steam generation
Auxiliary boiler
Heat Recovery Steam Generation
Here recovery steam generation is primary source of steam generation in FFBL. The function
of HRSG is that exhaust of gas turbine is to produce steam from the exhaust of gas turbine.
HRSGs consist of four major components: the economizer, evaporator, super heater and
water pre-heater. The different components are put together to meet the operating
requirements of the unit. See the attached illustration of a Modular HRSG General
Arrangement.
Auxiliary boiler
Auxiliary boilers are used for maintaining the variation in the steam production. In this forced
drafts fans are used to provide combustion air in the burner. It is water tube type. There are
following components of auxiliary boilers
Steam drum
Water drum
Boiler tube
Inner casing
Outer casing
Refractory
Tiles
Economizer
Super heaters
Instrument and Service air System:
The section provides compressed air for instrument and utilities to all units of ammonia and
urea plant. Instrument air make possible the functioning of pneumatic valves installed over
multiple locations on plant. The area is of extreme importance because in case of its failure,
plant might lead to shut down.
Chillers and HVAC: The chillers and HVAC system are installed to supply comfort and air
conditioning system for fertilizer complex. The chillers can operate in parallel at part load. The
chillers are steam absorption type.
Raw water Storage:
Raw water is supplied from kinjherGajju canal by 6 pumps booster pumps with each with a
capacity of 180m
3
/hr .the capacity of the raw water storage is 90000m
3
/hr sufficient for 3 days
requirement of the complex at full load. Raw water system consist of
One storage basin
Three industrial water pumps one stand by and 2 operating
Portable water storage:
Raw water from industrial water pumps is taken for portable purpose after treatment and
stored in portable water storage tank. This water is used for drinking purpose and emergency
purpose.
RAW water processing:
The raw water treatment plant is designed to remove suspended solids, turbidity, organic
matter and colour from raw water consist of
One re-activator type clarifier
One alum dosing
One polymer dosing
One caustic soda dosing
One hypochlorite dosing
Raw Water Clarifier:
Clarifier is fed by flow regulated raw water from pump. Clarifier has rapid mixing and
recirculation at centre and slow mixing at outer side from centre and chemicals mentioned
above are introduced. So there is sedimentation and sludge recirculation. Sludge is collected at
bottom of clarifier and removed by positive sludge scraper covering the entire bottom.
Alum dosing System:
Alum is used as coagulating agent and injected into clarifier inlet. It is solid lumps form so it is
dissolved and mixed in mixing basin and then transferred to dosing tank. The dosing system is
skid mounted.
Caustic soda dosing:
It is used to increase the alkaline nature of water influent to the clarifier.
Hypochlorite dosing
It is used as a disinfectant to protect the clarifier and filter from bugs and algae growth and to
eliminate organic growth. The system consist of polyethylene tank metering pumps etc.
Fire Water System:
The fire water storage is common with Raw water storage but has reserve capacity of 5000m
3

available even when Raw water basin is empty. The fire water system is designed of 600 m
3
/hr.
Cooling water:
Cooling tower is basically used for cooling hot water coming from the plant of urea or any other
also using in the heat exchanger. For this purpose hot water is injected from the top of the
cooling tower and there are fans at the top of cooling tower. Air from the fan passes through
the hot water and takes heat, so temperature of water will decrease from 43 c to 33 c.
Total time of flow of water is about 15 minutes. Chemical dosing is also present in cooling
tower for cleaning purpose of water.
There are transfer pumps in cooling tower that supply water. 2 pumps for urea and utilities, 4
for ammonia.
The cooling water system has capacity of 36800 m
3
/hr (23100 m
3
/hr for ammonia and rest for
Urea, Utility and DAP).
Chemical dosing in CoolingTower
Zinc poly phosphate is used as corrosion or scale inhibitor and is injected into the cooling tower
basin. The zinc phosphate is delivered in liquid form and fed as such.
Polymeric dispersant Dosing System:
Polymeric dispersant is used to maintain the phosphate solubility in the zinc phosphate at 90%
or better. The dispersant is injected into the cooling tower basin.
Chlorination Dosing System:
Chlorine is used to control biological and algeagrowth..Chlorine is in liquid form cylinders.
Demin Water System:
Filtered water is fed from the clear well via two filtered water pumps to the demin plant for
further processing. The process water is stored in the demin water tank.
Ion exchange regeneration system:
Sulphuric acid and caustic soda will be used to regenerate cation and anion exchange units
respectively. Sulphuric acid is 98% is diluted 2 to 4 % before injection into the cation. Caustic
soda 48% feed system used for regeneration of anion units. Caustic soda is diluted 2 to 4 %
before injection into the anion. Water from regeneration is transferred to neutralizing tank. The
demineralized water is transferred to the demine water storage tank. Then transferred to
demine water tank and fed to dearetor.


Ammonia Plant
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 someof the major equipment under
ammonia plant.
Furnace (Primary Reformer).
Secondary Reformer.
Heat Exchangers (Shell & Tube, Flat Plate, Finned Type).
Boiler
Start up Furnace
Start up Heater and many more.
Inputs:
1. Natural gas
2. Air
3. Steam
Outputs:
1. Ammonia
2. Carbon dioxide
PROCEDURE:
Desulphurization of natural gas.
Crack natural gas in steam to produce hydrogen.
Remove oxygen from air to give nitrogen in secondary reformer.
Cool nitrogen and hydrogen in heat exchanger.
Steam is removed and temperature elevated to 400-600
o
C.
2N
2
+3H
2
=2NH
3

Liquid ammonia is produced.
Goes to Urea if storage is full.
Di-ammonium Phosphate(DAP) Plant:
Inputs:
1. Ammonia
2. Sulphuric acid
3. Phosphoric acid
4. Sand
Output:
1. DAP granules


PROCEDURE:

All these steps are being carried out simultaneously. All the procedure can be summarized in a
few steps:-
Ammonia, sulphuric acid and phosphoric acid added in the pre neutralizer. This forms
the slurry.
The slurry is added along with sand to the granulator. Here grains are formed by simple
mixing.
The grains are then moved to the dryer where it is dried at 90
o
C for 2 minutes. The heat
is provided by the hot gas generator which maintains the temperature.
Then with the help of belts this is fed to the vibratory feeder for screening.
Only 1/3
rd
are on size and are moved to the de dusting section De dusting is done to
remove large lumps.
Scrubbing is also done to absorb ammonia by water.
The oversize grain, undersize grain and ammonia water are all recycled.
Urea Plant:
The unit manages the urea production from raw materials:
Ammonia (liquid)
Carbon dioxide (gas)

These raw materials are provided by the ammonia unit, are reacted to form ammonium
carbamate, which dehydrates to give urea. Urea synthesis is divided into following sections:
High pressure section
o Urea synthesis
o Stripping
o Carbamate recovery
Medium pressure/Low pressure section
o Ammonia recovery
o Carbon dioxide recovery
DAP
De dusting Granulation Scrubbing
Vacuum section
o Urea concentration
o Prilling
Waste water treatment section

Optimum temperature conditions and retention time in process are extre3mely important because
high temperature and more residence time causes:
High biuret content
More energy input
More water circulation
Overloading of vacuum condensers and ejectors
Pressure increase in system
Reduced efficiency

These highly disturb the economics of the process and are always prevented.
Formation of urea:
Urea is formed by reacting liquid ammonia and gaseous carbon dioxide at about
170-185 C and 134-125 bar pressure
2NH3 + CO2 NH2COONH4
NH2COONH4 NH2CONH2 + H2O

Equipments of Urea, DAP and Ammonia Plant
and Their Function:
Heat Exchangers:
Heat exchangers are used to transfer heat from one media to other media. They are classified
on different basis. Thermodynamically they are of three types
Regenerative
We have a hot plate in this type of exchanger and the cooled fluid comes and stays on that
plate for a while gets warm and finally discharges.
Re-equiperative:
Two fluids are separated by a plate. Hot fluid is one side of the plate and cooled fluid is on the
other side of the plate.
Mixed flow:
Two fluids are directly in content with each other. For example cooling tower.
On the basis of service exchangers are of following types:-
Condenser
To condense steam from downstream of steam turbine.
Cooler
To cool the fluid. Cooling media is water
Chiller
To cool the fluid. Cooling media is a refrigerant
Types of Exchanger
Plate type
Shell and tube type
Plate type:
In this type of boiler we have two type of plates placed b/w the pressure plates covered in the
shell. Plates are very narrow. Warm oil is on one side of the plate while water is on the other
side of the plates heat is transferred from oil to the water as a result oil is cooled.
Shell and Tube Type:
In this type of exchanger oil is in the tubes and water is outside the tubes contained inside the
shell.
Scrubber:
It is a high pressure vessel where liquid ammonia is stored under pressure. It is an efficient non-
corrosive alloy which can handle liquid Urea for a long time. It separates reactive and non
reactive gases.

Stripper:
Carbon dioxide at high pressure from the compressor goes to high pressure stripper. It is a high
pressure vessel.
Reactor:
It is a type of heat exchanger. In this horizontal type of reactor ammonia and carbon dioxide
react with each other to produce Urea. It has tubes inside filled with steam.
Columns:
It is a high pressure vessel for mixing and separating the things. Different type of processes
takes place in it at a time.
Priling Bucket:
It is a conical spinning bucket where liquid urea is sprinkled at about 102m high priling tower.
These droplets come down and solidify by the cooled air. This process is called drafting
Thera are two types of drafting:-
1) Natural
2) Mechanical or Forced
At urea plant we do natural drafting.
Inter coolers:
They are basically heat exchangers. At plant we have 3 types of heat exchangers
1. Shell type
2. Fin type
3. Tube type
A) Pipes
They are the close conduits in which the fluid flows. They are designed to bear only the
internal pressure. For a pipe we define two things.
1) Nominal pipe size (NPS) , usually the outer dia. of the pipe
2) Wall thickness on some standard e.g. 5,10,25,STD,XS,XXS
Tubes
The only difference b/w a pipe and a tube is, tubes are designed to bear both internal and
external pressure of the fluid. In tubes we exactly define the thickness.
B) Fittings
Fittings are tees, elbows, joints, bends, reducers, nipples, etc.
A reducer is a pipe of converging dia. At smaller size the reducer is called a sweng nipple.
In reducer 90-100% portion is converging but in a sweng nipple only 30-50% portion is
converging.

C) Flanges:
Flanges are used to join the pipe. So basically they are pipe joints. They are of following
types
D) Gasket:
Used in flanges, exchangers, nozzles for sealing purpose.
They are circular, oval, and hexagonal in shape.
E) Valves:
They are used for regulating and controlling the flow. Also used for throttling
purpose.
They are of following types
a) Gate valve
b) Globe valve
c) Plug valve
d) Check valve or value
e) Butter fly valve
Valves:
Valves are used for controlling and regulating the flow. Valves are also used for
throttling purpose. We saw many types of valves such as; gate valve, globe valve, check valve
(NRV), butterfly valve, ball valve pressure safety valves.
Normally gate values have more height than globe values. For value testing API 598 standard
are used in FFBL fabrication shop.
Gate valves:
They are used for on/off purpose. Gate valves should not be used for throttling. As the hand
wheel on the stem is rotated, the gate travels up or down the stem on the threads, while the
stem remains vertically stationary.
Globe values:
Globe valves are probably the most common valves in existence. The globe valve derives its
name from the globular shape of the valve body.
Butterfly values:
Butterfly values have a disc which rotate at 90 degree for opening and closing operation.
Value testing methods:
There are three types of value testing in fabrication shop.
Seat test
Back seat test
Shell test
Scaffolding:
Scaffolding is under fabrication shop. Its purpose is to provide temporary working condition to
work at some height by joining pipes. There are about three types of pipe joint we see in
scaffolding area in which there are
Swivel joint
Spigot joint
Fix joint
In swivel joint pipe can be joined at any degree, but in fix joint pipe can be joined at 90 degree
to each other. In spigot joint, it is basically used to increase length of pipe to work at more
height.

Machinery of Urea, DAP and Ammonia Plant:
This includes the moving parts of the plant. Their summary is as follows:
Compressors (screw type mainly and centrifugal)
Pumps
Steam turbines
Gas turbines
Two types of pumps are used:
1) positive displacement (plunger and piston types)
2) centrifugal type (mostly used)
The types of pump impellers are open impeller, partially closed impeller and closed
impeller. In pumps there are steam turbine pumps which are run by steam turbines.
Our main focus is on the centrifugal pump (axial flow) because of its availability and ease of
operation.
Construction:
A centrifugal pump is of very simple design the only moving part is an impeller attached to a
shaft that is driven by a motor.
The two main parts of the pump are the impeller and diffuser. The impeller can be made of
bronze, stainless steel, cast iron, polycarbonate and a variety of other materials. A diffuser or
volute houses the impeller and captures the water off the impeller.
Parts
Stuffing box
Packing
Shaft
Shaft sleeve
Vane
Casing
Eye of impeller
Impeller
Casing wear ring
Discharge nozzle
Diffuser

Figure 1: Parts of Pump
The Impeller:
The most important part of the centrifugal pump
Mounted on shaft and rotates with it
Comprises of eye vane and/or rings
Contains balancing holes and ribs in some cases
Increase velocity of liquid through vane
Impeller adds energy by increasing velocity of the liquid at the liquid tip
Increase in tip size increases energy
Increase in flow reduces energy

Figure 2: The Impeller
Impeller has further sub-sections briefly described below
Impeller hub: Central part of impeller, bored out according to shaft diameter
Suction eye: The impeller inlet just ahead of vans.
Impeller shroud: Impeller enclosing sideways totally enclose the impeller water ways from
the suction eye to the periphery.
Impeller vans: Vans are parts that pick up the liquid and accelerate it high velocity
Wear ring: Wear ring provide protection and an economically renewable leakage joint between
impeller and casing.
Casing:
Casing gathers and directs the liquid to the discharge pump
Enclosed space where impeller rotates with the shaft
Converts velocity of liquid into pressure
Has close clearance with impeller
Has two ends suction and discharges
Stuffing box is also provided with it
Diffuser:
It is stationery component of pump casing.
It converts velocity head into pressure
It also guide liquid towards discharge nozzle
in multistage pump, diffuser guides liquid to the eye of next stage impeller
Operating Principle:
A centrifugal pump converts energy of a pump first into velocity or kinetic energy and then into
pressure energy of a fluid that is being pumped. The energy changes occur due to two main
parts of the pump, the impeller and the diffuser.
Liquid enters the suction nozzles and then into the eye of the impeller. When impeller rotates,
it spins the liquid that is between vanes outwards and provide centrifugal acceleration. As liquid
leave the eye of the impeller, it creates low pressure area causing more liquid to flow towards
the inlet. Because impeller blades are curved, the fluids is pushed in the tangential and radial
direction by centrifugal force.

Figure 3: Flow through Impeller
The energy created by centrifugal force is kinetic energy. The amount of energy given to the
liquid is proportional to the velocity at the edge or vane tip of the impeller. The faster the
impeller revolves or bigger the impeller is, then higher will be the velocity of the liquid at the
vane tip and greater the energy imparted to the liquid. This kinetic energy of a liquid coming
out of an impeller is harnessed by creating a resistance of flow. The first resistance is created by
the pump diffuser that catches the liquid and slows it down. In the pump discharge, the liquid
further decelerates and its velocity is converted to pressure.
Steam Turbines:
The turbines installed at FFBL are multi stage impulse turbines. The gas turbines at utility plant
are 16 stage turbines in which turbine and compressor are mounted on the same shaft. The
compressor is first of all made to start with the help of diesel engine. When more than 50% of
the required RPM are achieved the diesel engine goes to shut down and compressed air starts
to go in combustion chambers. There are 10 combustion chambers which are lined inside with
refractory. The natural gas is also mixed with this compressed air here. There are two igniters in
two chambers where flame is produced and this flame is transferred to other chambers by the
help of canes. Combustion takes place and exhaust gases run the turbine which is connected to
generator which gives electricity. As turbine and compressor are on same shaft so running
turbine also runs the compressor. In this way the cycle continues.
A brief introduction of turbines is given here:
There are two types of turbines.
Impulse turbines, which are single stage or multi stage compressed turbines to which impulse
blades are attached. They use nozzles for impingement. In impulse turbines velocity decreases
and pressure remains constant while passing through blades.
Reaction Turbines, where there are no nozzles. Velocity remains almost constant in blades and
pressure decreases. Its blades are also called moving nozzles.





















Mechanical Seals
Sections of Product Handling and Shipping
Following four sections describe the functioning of product handling and shipping facility
Products to Stockyard
Storage and Product Reclaiming
Screening and Conveyor Network to Bagging
Products to Bagging and Shipping
DAP/UREA Handling & Storage:
Final DAP/Urea product from the production is stored in the storage building consisting of two
parallel stockpiles, besides each other & separated by a concrete wall, in one common building,
of length 227m, width 55m.Th storage capacity of each one is 35000 tons of granulated
products. Each pile of Urea / DAP is fed in by a conveyor with tripper car arranged in the top of
building. There tripper cars are fitted with a by pass chute allowing either to discharge on the
stockpile or to the belt again in order to reach the rear end of the building where the product is
transferred to the screening machine (DAP) or directly to the Shipping Section(Urea). The
tripper cars are protected by limit switches at the both ends of the rail. Additionally a sectional
position indicator is available in PH &S control room. The tripper car is connected with the
machine & integrated into the quay cross conveyor.
There is ne reclaiming unit for each stockyard, Urea & DAP and the reclaimer travels along the
pile enabling the operation to reclaim wherever possible. Stockpile Urea/DAP is reclaimed with
a rail mounted semi-portal chain-scraper & conveyed with belt conveyor to the feeder point of
next belt conveyor. Also a belt weighing scale is installed at each scraper and magnetic
separator is located over the belt conveyor I order to protect the delumper. Integrated in these
feeder points is the delumper, which can be by-passed by moving the complete delumper unit
out of feeding chute. The belt conveyor to bagging hopper is equipped with belt scale which
conveys the Urea/DAP product directly to Bagging Section. In by-pass operation mode, the urea
product is conveyed from the belt conveyor via bypass belt conveyor to belt conveyor of
shipping section. In case of DAP, screen can be by-passed and product can be directly sent to
shipping belt conveyor.
Shipping Section:
In Shipping Section the final product from the storage building is packed separately in 50 kg
bags by modern techniques. Shipping Section contains 11 bagging hoppers of which 6 hoppers
are designed for Urea bagging and 5 hoppers are designed for DAP bagging. The product is
dispatched to these hoppers by means of movable 7 reversible belt conveyors respectively.
Starting from these hoppers six specific line have been defined for Urea, 7 five ones are
dedicated to DAP.
Bagging line components:
Each bagging line includes,
The storage hopper to store the bagging product over corresponding bagging machine.
The electronic weighing unit for separation of 50 kg product.
Bagging machine includes bag-clamp & additional equipment for filling of bags.
The automatic sewing machine for the simultaneous sewing of the inner PE liner &
outer cotton bag.
The wooden slat type conveyors below the bagging machine for continuous conveying
of filled bags.One sewing machine is provided in standby, that could be brought I
working position by turning the supporting arm by 180 degrees.
After that the bag tipper allows the regular placing of the bags on the belt conveyor
from the end of which the synchronizing drum allows the regular ordering of the bags
on the telescopicable&liftable truck loader.
Provision is made so that the telescopic conveyors maintain their lateral position
relative to the platform. Each loading bay has only accommodation for one truck.
Each bagging line is able to deliver 800 bags/hr as a maximum, eleven lines together
deliver 4800 bags/hr of Urea & 4000 bags/hr of DAP.














Nearby the outlet of shipping facility, an underground weighing bridge (60 ton capacity)
allows to weigh each truck.









Features of PH & S:
Two independent systems for product handling and shipping of Urea and DAP.
Bagging is composed of 11 lines, six for Urea and 5 for DAP. Each line is designed to
produce 800 bags/hr.
70,000 metric-tons product storage facility i.e., 35000 metric-tons each for Urea and
DAP.
Simultaneous storage and reclaiming arrangement for each product i.e., Urea and DAP.
1. Reclaiming capacity for Urea : 240 MT/hr
2. Reclaiming capacity for DAP : 200 MT/hr
Centralized PLC based control system with MMI plus Mimic Panel in control room.
Centralized dedusting system for the whole plant.
Climatized air circulation inside storage building to reduce temperature variation.
Screening system for the separation of fines from DAP.
Magnetic separators are provided for preventing product contamination.
Automatic bag conveying, tripping, leveling system with telescopic truck loader.
60 metric-tons weigh bridge for truck weighing.
An area of 7 m
2
is provided in the storage building for maintenance purposes.


Machine Shop:
Several machines are there at FFBL, they are as follows:
1. Universal Boring and Milling Machine:

Horizontal boring milling machine is a universal machine tool, which can be adapted to machine
casting, steel, and nonferrous work-pieces. Operations include drilling, hole enlarging, boring,
reaming, plane milling, spot facing, threading, and other machining processes. The faceplate
slide can be fed radially, which enables this boring milling machine to bore large size holes,
turning outside diameters, and grooving. Today, SMTCL horizontal boring milling machine is
widely used in the industries of energy, metallurgy, mining, machinery, military, etc., becoming
a reliable choice for machining box-type parts.
The spindle of our horizontal boring milling machine has 3 supporting points and good rigidity.
Nitrogen treatment is employed on the main surface, which enables the spindle to have high
hardness and long service life. The spindle and feed speed change adopt manual rotary valve in
the headstock and hydraulic pre-selection, which is convenient for operation
Small Duty Lathe Machine:
The Lathe Machines made available by us are very powerful and are extensively used for
turning, boring, facing or threading of different components.These Industrial Lathe Machines
are available in different ranges and specifications as required by the valued clients.




FEATURES:

Head Stock Gear Helical
Main Spindle & Tailstock Spindle hardened & ground
Head Stock / Counter pulley dynamically balanced
Hardened and Ground Bed for minimum wear
Apron is fully oil bath
Steel parts made from EN-8 steel
Needs minimum care and low maintenance

All components machined using jigs and fixtures to close to tolerances,
thus providing easy interchange abilityFlame Hardened & Ground Bed,
chuck plate, faceplate, motor pulley, motor pulley, toolpostkey ,dead
centre ,Spindle ,Sleeve Steady ,Rest Nylon ,Flat Belt ,Oil Can are its
components



2. Heavy Duty Lathe Machine:


These are unsurpassable in output and sturdy in features. Same is the case with our
Mechanical Lathe Machine which is made of heavy and pure iron which is obtained from
the best of vendors these are highly useful in heavy metal industries




Features:

Flame hardened bed ways.
Hardened and profile ground headstock gears.
Headstock spindle is made from high tensile steel duly hardened & ground & runs in
precision taper roller bearings.
Maintained contact starting shaft
Meticulous care is taken in selecting the right raw material for every component. Each &
every component is passed through strict quality control & the machine is put to
rigorous tests confirming to IS : 1878 (Part I) 1971 before dispatch from our ultra-
modern plant having sophisticated mother machinery.
Standard Accessories:
Electricals, 2 MT Centres with Centre Bush, Inch & MM Gears, Oil Can, Spanner & Allen Key Set.

Optional Accessories:
Face Plate, Steady rest, Follow Rest, Machine lamp, Elec. Coolant pump with tank
fittings, Taper turning attachment, and Quick change tool post with 5 tool holders.
chuck plate, self-centering 3 jaw chuck revolving center.



4. Shaper Machine:








This is widely used in various industries for different applications and admired for its corrosion
resistance, optimum performance and longer service life. Further, this range in varied shapes,
sizes and capacities in order to cater the variegated needs
5. MD BALANCING MACHINE






Balancing machines are simple and easy to use, ensuring the best balancing quality
available. Using a personal computer as its console, the machine will balance closely and
quickly. Dynamics Research Corp. dynamic balancing machines provide a computer printed
report that clearly shows the state of balance before and after. In addition, the use of the
computer allows storage of a virtually unlimited number of setups on the hard drive, drastically
reducing the length of time used to spend on each balance process.


6. HD BALANCING MACHINE







Roll Balance Machine used for rolls, pumps, and fans 5 ton & 50 ton weight capacity Belt drive
Top plate accommodates roll bearing assemblies Bearing assemblies for balancing on the roll
are available
Roll whip indicator is available.
7. Milling Machine:










Milling machine may be defined as the type of machine in which the metal is removed by
causing the job to be fed against a revolving cutting tool called the milling cutter, which has one
or more cutting edges. There are several ways of holding milling cutter, which rotates with the
machine spindle, or held in a col let or other adopter which fits the spindle.Rigid milling
machine, easy to operate, for semiautomatic machining of complex work pieces.High intrinsic
weight (3500 kg) ensures maximum torsional rigidity. Automatic pendulum-type cycles and
semi-automatic straight-line cycles operated through camshaft gear. Work table swivels
45Universal milling head adjusts on 2 levels to virtually any spherical angle (HURON system).
Table with rigid square guides.Feeds and rapid feeds on all 3 axes
8. RADIAL DRILL MACHINE









The Main Parts of Radial Drilling Machine are
1. Base: The base of the machine is a large cast iron material on which is mounted a cylindrical
vertical column. The base is provided with T-slots, which help the work piece to be clamped
rigidly to the base of the machine.
2. Vertical column: The column is a long, cylindrical shaped part fastened rigidly to the base.
The column carries a radial arm that can be raised or lowered by means of an electric motor
and can be clamped to any desired position. The radial arm can also be rotated (swiveled) in a
complete circle around the column.
3. Drill head: The drill head is mounted on the radial arm and carries a driving motor and a
mechanism for revolving a feeding (power feed) the drill bit into the work piece. The drill head
can be moved horizontally on the guide ways provided in the radial arm, and can be clamped to
any desired position.

9. Hacksaw Machine:









The sewing machine is a machine tool designed to cut material to a desired length or contour. It
functions by drawing a blade containing cutting teeth through the work piece. The sewing
machine is faster and easier than hand sawing and is used principally to produce an accurate
square or mitered cut on the work piece.
The power hacksaw and the band saw are two common types of sawing machines used to cut
metal in the machine shop. The power hacksaw uses a reciprocating (back and forth) cutting
action similar to the one used in a hand hacksaw. The power hacksaw is used for square or
angle cutting of stock.
TOOL SHOP
Some of the tools are as follows:
Argon set
Baby grinder
Angle grinder
Cutting set(gas cutting)
Plasma cutter (for CS)
Eye bolt
Crow bad
Pneumatic gun
Rubber hammer
Pump set
Ladder
Jack
Fabrication Shop:
Welding in Fabrication Shop:
Gas Cutting Area:
For gas cutting acetylene cylinder and oxygen cylinder are used. When acetylene burn with
oxygen then it creates high temperature flame that can cut metals. To check the percentage of
oxygen and acetylene color of flame is very important. Yellow color indicate reducing flame and
blue color indicate oxidizing flame.
Plasma Cutting:
In plasma cutting plasma gas is used. Its flame temperature is more high than the gas cutting
flame. It has advantage that its flame is not oxidizing flame and so it can use for cutting of
aluminum also. There are two machinerys in fabrication shop for plasma welding. One has
capacity to cut of thick 0 to 6mm and other have 0 to 32mm.
High Pressure Jetting Machine:
It uses the high pressure jet of water. It is used fro cleaning purpose where a man cant do
proper, for example for heat exchangers jet of water use for cleaning of exchangers tubes.
Arc Welding:
Arc welding in fabrication shop are SMAW and GTAW. The difference between SMAW and
GTAW is that for shielding purpose tungsten gas is used in GTAW while in SMAW on electrode
there is coating which melt and create a gas shielding area which protect weld bead from
oxygen.
For root pass in arc welding electrode E 6010 is used. First root in welding is known as gouging.
Automobile section:
In automobile section of FFBL there are 3 cranes, one crane mounted belt load truck, oil tankers
and loaders.
In cranes one crane has load capacity of 55ton, other two have 20ton. They are hydro crane,
with 6 cylinder v type engine.
Load chart of crane depend upon the radius, angle and boom of the crane. If crane have
minimum radius, minimum angle and minimum boom length then crane can carry maximum
load.
Crane mounted belt truck have crane that can carry about 20 ton weight.



Inspection
Some the types of inspections are listed below:
Ultra sonic testing:
6-7 meters deep. High frequency waves are used.
Magnetic particle testing:
Material must be ferric. Magnetic field lines are destroyed due to the presence of defect.
Di-penetrating testing:
Spray the penetrate that goes into the cavity of material. Then spray the remover. It sucks the
penetrate and indicates the location of defect.
Hardness testing:
There are three types of hardness Vicker, brinell and Rockwell Hardness. Hardness testing
machine gives us the hardness of given material.
Ferrite scope:
Checks the iron level in material.
Stroboscope:
To measure rpm and frequency
Delta scope:
To measure the thickness of pains e.g in the storage tank to save any thickness variation.
Visual inspection:
Use to see inside any equipment where normal eye cant see e.g inside the exchanger tube.
Thermographic camera:
For temperature measuring and spot temperature measuring. Gives thermographic photo of
the machinery using infrared radiations.
Tacho Meter:
Measures the RPM of rotating element like shafts etc. A tape is glued on shaft and
then during running laser is thrown on tape to find RPM.
Radio-graphic testing:
Produce radioactive rays and used for detecting space inside weld, give a clear view of the
thing.
CP system:
Cathodic protection used for underground coating. Underground pipe lines are cp protected in
FFBL.
Crane weight testing:
We use this test to determine how much weight crane can carry