2016

INTERNSHIP REPORT
Contents Asad AZIZ( Mechanical Maintenance)
Acknowledgment…………………………………………………………………………………………..2
[Type the abstract of the document here. The abstract is typically a short
Summary ……………………………………………………………………………………………………..3
summary of the contents of the document. Type the abstract of the document
here. The abstract is typically a short summary of the contents of the document.]
Introduction…………………………………………………………………………………………………..3
Plant Description……………………………………………………………………………………………4
Machinery-1………………………………………………………………………………………………….5
EM-1……………………………………………………………………………………………………………..6
Study of Materials…………………………………………………………………………………………7
Fabrication shop visit…………………………………………………………………………………….8
Machine shop visit…………………………………………………………………………………………8
HSE………………………………………………………………………………………………………………..9
Conclusions.suggestions………………………………………………………………………………..9

Fauji Fertilizer Company,Goth Machi

7/22/2016
Acknowledgement
I would like to thank all of management and staff members for devoting their special time throughout the
internship tenure. I am also grateful to Sir SHOAIB SAEED for providing an excellent learning opportunity and
getting into technical practicalities of basic machinery parts. Special thanks to Sir Usman Naseem for
indulging me into basics of engineering and also for helping to develop basic professional attitude.

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  SUMMARY

This internship is about all of the internship activities at FFC plant regarding the mechanical maintenance and
also of different facilities given at plant and club as well. FFC is one of the major urea producing company
working under its board of directors. In “FFC Equity Participation” major contribution is of fauji foundation.
The internship report covers brief description of ammonia, urea, utilities and specifically study of
different equipments at utilities and Ammonia-1 according to defined module. Majorly two section i.e.
machinery part (covered at utilities) and equipment maintenance part (covered at Ammonia-1) is included in
the report. The report also includes the visit of Fabrication shop and machinery shop to see maintenance of
relevant equipments (heat exchangers, valves, pipe fitting and their pressure testing) and also to get general
orientation of facilities and machines provided for the maintenance.

 Introduction to FFC
FFC is one of the major corporate sector to produce urea at large scale to fulfill
needs of farmers. Its major business areas are manufacturing which include 3 urea manufacturing plants, 2
are located at Goth Machi and one at Mir Pur Mathelo. Other areas are engineering and marketing(marketing
of imported nitrogen, phosphate and potash based fertilizers). FFC also diversified its projects towards the
wind power and foods. Wind power project started in 2006 for production of first 49.5 MW grid connected
energy. Fauji fresh and freeze is also another project to provide delicious foods i.e. frozen fruits and
vegetables.
The first FFC urea plant commissioned in 1982 and along with other 3 plants has capacity of over 2
million tons per annum. FFC has consistently placed its dominant position in Karachi stock exchange. FFC
proved its capabilities not only in Pakistan but it is known internationally as it is the member of different
international organizations i.e. International Fertilizer Industry Association (IFA), Arab Fertilizer Association
(AFA) etc.
Mainly report dealt with the Goth Machi plant and its available facilities. FFC has also a training centre
named as “Technical training centre (TTC)” which is giving training to their regular employees and also gives
customized training to their companies like Hainan group and KAFCO etc.
FFC also developed residential areas for management and staff members which include all of facilities
i.e. messing facility, sports, swimming and many other recreational events held at residential sides to keep
their employees happy and keep them motivated.

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  Plant Description
All of the three plants 2 at Goth Machi and one at Mir Pur Mathelo have common
features. The main units are Ammonia, Utilities and urea.
 Ammonia Section
The ammonia plant deals with the production of ammonia and carbon dioxide. Its properties are: colorless,
has strong pungent and irritating odor. The basic raw materials for the production of ammonia are natural gas,
air and water (steam). The natural gas is taken from the MARI PETROLEUM, compressed according to
requirement, desulphrized by the reaction of zinc oxide. After that it is reacted with water to generate carbon
oxide and hydrogen. After that carbon dioxide and hydrogen are separated. Besides residual gases like carbon
dioxide and carbon monoxide are converted to methane. Now ammonia synthesis stage comes where
hydrogen and nitrogen are combined to generate ammonia gas.

 Urea section
This section of the plant is related to urea production. The resources used are all the utilities available from
the utilities department and carbon dioxide and ammonia from the ammonia section. The reaction between
ammonia and carbon dioxide occurs to produce ammonium carbamate which changes to urea on losing water.
After the reaction in the reactor the urea is removed from the mixture and sent to be prilled. From the
mixture separated the gases like ammonia and carbon dioxide are removed and then used again for the
reaction. Most of the part of the plant is related to recovery of these chemicals. The urea from the prilling
tower is sent to the urea storage from where it is taken to the bagging section.

 Utilities
The basic function of utilities is to cater the basic utilities of plant I&II and township also. It actually provides
maintenance services where required in plant .It deals with the following areas:

• Power production
Power is generated through two gas turbines that use natural gas for their functioning. The total power
generation capacity of these gas turbines is about 37MW.
• Steam production
The gases coming out of the gas turbines are at a very high temperature so instead of discharging them
directly to the atmosphere the thermal energy of those gases is used to produce steam which is then
used to drive steam turbines.
• Water cooling
Water is the cooling fluid used most often in the plant. Cooling water serves this purpose
• Water treatment
Water is treated to be used for reaction purposes, and also as the cooling water for exchangers etc

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Sections covered
 Machinery-1
This section covers machinery components and specifically holds responsibility of their maintenance.
Following are some of major equipments being studied according to the defined module.

 Centrifugal pump

Centrifugal pumps is basically a dynamic machine which by the action of centrifugal force develops Pressure.
It can be single acting or double acting or can be single stage or multi stage. Impeller is the heart of pump
which actually gives it whirling motion followed by its flow through volute casing. Wear ring provide an
economically leak proof joint. Where shaft passes through the casing, is susceptible to leakage that can be
prevented by stuffing box or mechanical seal

 Reciprocating Compressors
It is a positive displacement compressor which by the piston and cylinder mechanism compresses the gas
according to process requirement. In this mechanism it first traps the gas in a cylinder and then compresses it
by volumetric displacement. The compressor has suction and discharge valves which are of NRV type which
open and close by the differences of pressure. Some of the compressors have arrangement for capacity
control by installing clearance pockets with compressor whose volumes can be changed accordingly.

 Bearings
The bearings are integral components especially in power transmitting devices like shafts. In order for the
shaft to function properly, they must be supported properly. The locations where shafts are supported are
called bearing surfaces. There are generally two types of bearings.

1- Rolling bearings
2- Plain bearings

Rolling bearings consists of inner race, outer race, cage with various types of rolling element placed in
between. There are various types of rolling bearings like deep groove type, cylindrical roller type, self aligning
and N and NU type. On the other side plain bearings can be solid or lined bushes mounted as a single piece or
two- piece split bearing

 Mechanical Seal
Mechanical seal is one of the integral component in machinery to prevent leakage.It is one of the best sealant
against leakage.Generally it consists of stationary part and rotating part. O-rings are also provided at various
locations in the mechanical seal to form a perfect seal.

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  Equipment Maintenance (EM-1)
Equipment maintenance section deals with all of the stationary components’ maintenance. Following are
some of the equipments that I have covered and studied during training program accordingly.

 Valves
Valves are used extensively in pipeline transmission system to interrupt, divert or regulate the flow of
fluids.Based on the requirement any state can be achieved. There are various types of valves that are used in
industry to provide consistent operation.

Gate Valves: Used for complete opening and complete shutting off the line
Globe Valves: Used for throttling i-e controlling the flow by controlling the opening
Check Valves: Used to permit flow in only one direction
Ball Valve: Used like a plug valve
 Heat Exchangers
The equipment or arrangement made to transfer heat between hot and cold streams through a combined
conduction-convection mechanism is called Heat Exchanger. It can be classified depending upon the transfer
mechanism as direct or indirect transfer mechanism. In direct mechanism fluids are directly in touch with each
other to transfer the heat while in indirect mechanism two fluids are not in direct contact. Based on geometry
it can be tubular type, plate type or extended surface. In shell and tube type exchanger, one fluid flows inside
the tubes and the other flows inside the shell outside the tubes. The heat is transferred through the tube
walls. These are the most widely used type of heat exchangers in the industry.Other components of the heat
exchangers include baffles, spacers, tie rods, tube sheets etc.

 Pipe fittings
The tubular products are termed as tube or pipe. Tube is specified by its outside diameter and wall thickness
whereas pipe is identified by its ‘ nominal pipe size’ with wall thickness. Fittings permit change in direction of
piping, a change in diameter of pipe or a branch to be made from main run af pipe. Pipe fittings may be but
welded, socket welded or may be threaded depending upon the requirement. Various fittings i.e. elbows,
reducers, flanges, stub ins are provided in the transmission lines.

Elbows: make 900 or 45o changes in direction of run of pipe

Return: changes direction by 1800.

Reducer: Used to join larger pipe with smaller one.

Flanges: These are also used to join pipes with each other.They can be but welded, slip on flange or may
socket welded.Flange may be flat or raised face.

Other fittings are stub in type, sockolets or weldolets etc

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  Study of Materials
Materials selection is of major concern in industrial applications .Materials can be categorized as metals or
non metals. Metals can be ferrous or non ferrous. Ferrous metals contain a major share of iron though.
Following are some of the properties of materials which need to be considered before selection.

 Elasticity
The property of a material due to which it comes to its original shape after the removal of load is called
elasticity. There is a certain limit of every material upto which it can regain its original shape. This limit is
called Elastic Limit.

 Plasticity
The property of a material due to which it is permanently deformed (re-shaped) on the application of load,
without any rupture is called plasticity.

 Hardness
It is the property of a material due to which it resists wear, abrasion and indentation. Also hardness is the
property which enables to cut the other material.

 Toughness
Ability of material to resist fracture due to sudden shocks (impact loads) or bending/twisting is called
toughness.

 Stiffness
Ability of a material to resist deformation due to the external forces is called stiffness.

 Brittleness
The property of a material to easily break up into pieces without deformation is called brittleness.

 Ductility
Ability of a material to be drawn into wires or undergo elongation without fracture is called ductility

 Strength
It is the ability of a material to withstand the external forces of different types before undergoing the
permanent deformation or fracture

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  Fabrication shop visit
Fabrication shop deals with fabrication of different parts and also maintenance and reclamation of different
parts like valves and heat exchangers etc

 Valve reclamation
The valve reclamation includes maintenance of valves, surface finish of valve seats. This portion also includes
the pressure leakage testing of valves to check the susceptible leakage of valves at elevated pressure and
gaskets are changed or reclaimed.Major leakage areas are bonnet and body connection, stem outlet from
bonnet etc.

 Tube and tubesheet joint by roller expansion followed by welding in heat exchanger
Tube and tube-sheet joint is necessary to make a leakage proof joint to avoid mixing of shell side and tube side
fluids. In roller expansion, rollers consist of roller consisting of cylindrical cage with 3 to 7 rollers. Rollers are
inserted in the tubes to expand them.In order to make it further tight and make it leak proof it is welded at
ends with tubesheet.

Apart from above mentioned processes fabrication shop has many other facilities like pipe rolling
machine, HP jetting machine accessories, plate cutters, plasma cutters etc

 Machine shop visit

Machine shop is the workshop where are the operations related to machining of mechanical components are
carried out.

Lathe Machine: It is used for the machining of parts with cylindrical symmetry but can also be used for
some parts that do not fulfill this criteria for some specific operations. The operations
that may be done by this machine are cutting, knurling, drilling, facing, and turning.
Milling Machine: This is a universal machine for producing planar surfaces on the work-part.
Shaper Machine: Used to remove material in a plane from a work part. Used for material removal
Bench Drilling: Used to create holes in a part which may be threaded afterwards
Power Hacksaw: Used to cut long bars to desired length

Vertical Lathe: A lathe machine that handles large parts and has a vertical axis of rotation
Boring Machine: Works like a milling machine but can handle very large parts. Tools are like that of a
milling machine and working principle is also quite the same.
Balancing Machine: Used to balance a part around its axis statically
Lapping Machine: Used for the lapping of surfaces, mostly for contact sealing
Slotting Machine: Used to create keyways

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  HSE (Health Safety and Environment)
Health is condition of mind and body, safety is free from any injury or loss whereas environment is the
surroundings or conditions of activity. Every company put special efforts regarding the safety of equipments
and individuals as well. Every industry follows some protocols to ensure the safety of the workers. Here too at
FFC some rules regarding safety have been created and are followed strictly. These rules include using all the
protective equipment required at a specific workplace. Some other rules include wearing non-loose clothing
covering the whole body etc. Safety equipment is issued to every worker according to the workplace he has to
work in. Most common personal safety equipment includes goggles, gas masks, safety shoes, safety helmet,
and ear protection. The areas where a specific equipment must be used are marked with indications.

Environment protection is another goal that has to be achieved while running a fertilizer plant. No untreated
waste should exit the plant and damage the environment. FFC follows all the rules and regulations for
environment safety. Besides this, FFC initiates and works upon special projects to reduce hazardous emissions.
FFC Safety Program focuses on two major Assets

• Personal Safety

Focuses on prevention of work related injuries to individuals.

• Equipment Safety

Focuses on prevention of fires, explosions and accidental chemical release at plants which can effect (injury)
large group of individuals.

HSE management plan includes contractor safety plan, emergency management, performance evaluation and
incident reporting etc.

 Conclusion, Suggestions and feedback

FFC is one of major industries to provide a basic learning environment. It is not just a manufacturing or
Business Company, but more like a training institution. Everyone believes in transparency, hard work and hold
himself accountable. One of the major aspect of FFC is that it is running its business in corporate sector
through mutual cooperation and hard work of every member. Here I got basic professional attitude.Besides
company arranges different events and recreational activities for their employees to keep them motivated and
happy.

Here are some of the suggestions so it may help for other students coming for the internship or any other
training plan:

 Assesment should be held on regular basis to assess the performance of students

 A small project should be given so students can go into detail of any specific equipment so they can
build a basic learning and professional attitude.