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SUMMER INTERNSHIP REPORT

NED University of Engineering and Technology

SHAKEEL AHMED QURESHI

Submitted to: UM L&D


Duration: 6 JUNE, 2016 – 1 JULY, 2016

CONTACT NUMBER: +92-315-3103621


EMAIL ID: shakeelqureshi360@gmail.com

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ABSTRACT
FFBL is a well-known, recognized and professional industry in Pakistan. It also
provides training of fresh Engineers as an Intern. They build their identity in training
due to their dedicated staff. This prestigious institution has educated, disciplined and
reputed trainers.

This was my best experience of training in any industry. I learnt many things and got
that practical knowledge that I wasn’t able to achieve in my University. I am thankful
to all the Management, Staff and other members that were the part of this
Organization, due to their efforts and motivation to teach me and to make me eligible
and a competent Engineer for any Industry in Pakistan.

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ACKNOWLEDGEMENT

I am very thankful to Allah for the successful completion of my four week


internship the FFBL which is one of the largest and growing Fertilizer Complex in
Pakistan.During my internship I have learnt about the Fertilizer industry, and its
environment. I learnt about the FFBL as an organization, job handling procedures,
maintenance and repairing procedures and job environment in FFBL.

I am thankful to Management of FFBL who provided me a platform to learn and gain


practical knowledge.

I would like to express my heartfelt thanks and appreciation to the employees of


FFBL who took the time off their busy schedule to share their expertise and
knowledge.

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CONTENTS
AN INTRODUCTION TO FAUJI FERTILIZER BIN QASIM LIMITED .................................................................... 5
Safety ............................................................................................................................................................ 7
Complex Description ..................................................................................................................................... 9
Intro to Maintenance .................................................................................................................................. 10
Types of machinery equipment .................................................................................................................. 10
Types of stationary equipment ................................................................................................................... 11
Utilities Plant ............................................................................................................................................... 11
Ammonia Process........................................................................................................................................ 16
Urea Process ............................................................................................................................................... 18
Diammonium Phosphate (DAP) Process ..................................................................................................... 20
Equipment’s Of Urea, Dap And Ammonia, Their Function ......................................................................... 22
Fabrication Shop ......................................................................................................................................... 27
Machine Shop ............................................................................................................................................. 30
Motor Vehicle Shop .................................................................................................................................... 31
Pipe Fittings................................................................................................................................................. 32
Machinery at Urea, DAP and Ammonia Plant ............................................................................................. 34
TOOL SHOP.................................................................................................................................................. 35
Inspection.................................................................................................................................................... 36

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AN INTRODUCTION TO FAUJIFERTILIZER 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 (DI‐
AMMONIUM PHOSPHATE). It is the sole 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.

 Initially named as FFC-Jordan Fertilizer Company (FJFC), wef 17th Nov


1993, with FFC (30%), FF (10%) and JPMC (10%) as main sponsors. The
company was formally listed with stock exchanges in May 1996 and
commercial production commenced wef Jan 2000. However, it continued to
run in crises due to technical, financial and managerial reasons till 2001.
DAP Plant brought to suspension in 2001 due to accumulated loss of Rs. 6.5
Billion. It resumed production in Sep 2003, after a lapse of 2 years.

 Renamed as Fauji Fertilizer Bin Qasim Ltd. (FFBL) in 2003, as such Jordan
Phosphate Mines Co. (JPMC) had sold its entire equity in the company.
Accordingly Phosphoric acid supply agreement with Jordan was terminated.
The company turned out to be profitable after 3 years i.e, by 2004 and
declared 'maiden dividend' in 2004. Profitability has constantly been on the
rise since then and 2007 has been the most profitable year of the company.
One of the milestones in the success of FFBL is its accreditation of ISO
certification, which was achieved in Mar 2006 for both the Head Office and
Plant site.
 FFBL also have membership of industry association and trade bodies;
Rawalpindi Chamber of Commerce international Fertilizer Association.

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PERFORMANCE & PRODUCTION
FFBL fertilizer complex is state of the art manufacturing facility with advanced
Distributed Control System for safe and efficient operation. The phosphoric acid
being raw material for DAP plant is imported from Morocco and initially stored in
tanks at Port Qasim. Design capacity viz-a-viz actual production of Plants is as
under:

Manufacturing Plants Production (Metric Ton / Day)


Original Actual (Approx)
Urea Granular 1670 1920

DAP 1350 2230 (After Revamp)

Ammonia 1270 1570 (After Revamp)

FFBL is the only fertilizer complex in Pakistan producing DAP fertilizer and
Granular Urea thus making significant contribution towards agricultural growth of
the country by meeting 45% of the demand of DAP and 13% of Urea in domestic
market.

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SAFETY

Safety is the first priority in the FFBL. Safety is a measure of success in any work.
It means constant evaluation of thing, we do and how we go about doing them so
that we won`t get harm, they our equipment’s condition will not contribute to an
accident. In FFBL safety is considered equal to production.
Safety priorities of FFBL are:

 Employs
 Company assets
 Environmental

PERSONEL PROTECTIVE EQUIPMENTS:


Following equipment are available for personal protection.
 Safety helmets and shoes should be worn at plant site during working and
any other activity.
 Googols for protection against liquids and gases
 Gloves for protection against acid and alkaline solution and heat
 Respiration Mask with filters for duct and poisonous
gases(H2S,NH3,Natural Gas etc)
 Compressed air mask for protection against CO
 Ear plugs for protection against mask
 Draggers equipment (Tubes and Sniffer) for measurement of poisonous
gases likeCO,H2S,NH3,Natural gas)

WORK PERMIT PROCEDURE


The FFBL is controlled by Operation Department and no work can be carried out
by an unauthorized person or Department. Any work which is related to concern
Department is carried by its permission.
The permission is sought on a prescribed format known as work permit.

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Types of Work Permits:

 COLD WORK PERMIT


This is required when urgent or routine repairs/inspection is to be carried out
and job doesn’t involve a flame or spark

 HOT WORK PERMIT


It is require for jobs as lighting all naked flames, fires, exposed material
including electric aces and sparks, electronic and gas welding/cutting, blow
lamps and tar heating.

 VESSEL ENTRY PERMIT


This is required when one or more persons to enter in to any confined space
such as tower/vessel/storage tank, excavation more than 1.5 deep, column,
reactor, piping will 1m, sewers etc.

 EXCAVATION WORK PERMIT


This permit is issued to cover all excavation work inside the plant.

 VEHICLE ENTRY PERMIT


This permit is required before any vehicle can enter the work area.

 RADIOGRAPHY WORK PERMIT


This permit is required to do any sort of radiographic testing anywhere in the
plant.

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COMPLEX DESCRIPTION

FFBL complex includes the following process units, offsite and on site.

PROCESS UNITS:
1. The process Units are
2. Ammonia Plant
3. DAP Plant
4. Urea Plant
5. Utilities & Power Generation.

FINAL PRODUCT RAW MATERIAL & CHEMICAL STORAGE:


1. Final product storage & bagging Facilities
2. Ammonia Storage (5000 MT/Day)
3. Phosphoric Acid , Sulfuric Acid storages
4. Nitrogen Storage Unit

OFF SITES AND OTHER BUILDINGS


1. Fire water
2. Natural gas Station
3. Effluent Treatment Facility

BUILDING INCLUDE
1. Control Room and electrical Room
2. Laboratory
3. Technical service Building
4. Ware house and Workshop
5. Learning and Development Center
6. Administration Building

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INTRO TO MAINTENANCE

The maintenance department at FFBL is responsible for checking and maintaining


all machinery and equipment at the plant to ensure smooth running and continuous
production. This includes regular maintenance as well as emergency maintenance.
Regular maintenance involves checking oil levels, refilling oil, cleaning filters,
refueling of fuel driven machines etc. Emergency maintenance can involve
anything from stopping leakages to overhauling complete machinery.
The maintenance department at FFBL is further divided into 2 sub departments:
 Machinery: The machinery department deals with all rotary machines at the
plant such as pumps, compressors, turbines etc.
 Equipment: The equipment department is responsible for all stationary
equipment at the plant like heat exchangers, valves etc.

TYPES OF MACHINERY EQUIPMENT

 Pumps
 Compressors
 Steam turbines
 Gas turbines
 Motors
 Cooling towers
 Agitators
 Blowers

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TYPES OF STATIONARY EQUIPMENT

The various types of stationary equipment used at FFBL are:


 Heat exchangers
 Vessels
 Tanks
 Furnaces
 Boilers
 Piping
 Insulation
 Glass Level Gauge (GLG)
 Scaffolding.
 Reactors

UTILITIES PLANT

Utility plant provides the facilities to other plants to operate well and continuously.
For that purpose it is includes the following equipment and machinery:
 Cooling tower
 Power generation
 Filtration of water
 Supply of water and steam for the whole plant
 Chillers and HVAC
 Compressed air for whole plant
 Demin water, hot water
 Natural gas distribution
 Raw water storage
 Fire water
 Potable water

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Now we will discuss the major areas of utilities in detail.

Cooling tower
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 10 cooling towers; 3 for Ammonia, 3 for DAP and 3 for Urea and
1 is on standby.

Power Generation
For power generation in FFBL there are 2 gas turbines and one diesel generator (in
emergency). The capacity of power generation of one gas turbine is 26 MW. The
poer is generated at 60 Hz and the voltage is 13800 volts.
Gas Turbine:
The major components of a gas turbine are:
 Self-cleaning type air filter
 Multi-stage axial flow compressor
 Combustion system
 Closed forced lubricating oil system
 Diesel engine storage system
 Natural gas firing system
 Fire detection and co
 protection system
 Seismic type vibration system
 Thermo couples for measuring critical turbine temperature

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Diesel driven emergency generator:
It is used if the gas turbines stop working and is used to stop the plant from
shutting down. It automatically switches on in 20 seconds and has the capacity to
operate the plants until the gas turbines come back online.

Air compressors
There are three air compressors in FFBL under the utility section which provide,
supply and generate compressed air known as instrument air and service air. The
compressors are screw type PD compressors that use a dry paper type filter.
The compressors have 2 stages:
1. 1st stage – 9000 RPM
2. 2nd stage – 14000 RPM
Instrument Air:
Instrument air is used in control valves. It is moisture free air and is used where
corrosion is not affordable.
Service Air:
It has moisture in it and can cause corrosion. It is used for cleaning equipment and
to supply oxygen.

Steam Production
The production and supply of steam to the whole plant is under utility section.
Steam is generated by two methods
 Heat recovery steam generation
 Auxiliary boiler

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Heat recovery steam generation:
Hear recovery steam generation is the 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 preheater. The different
components are put together to meet the operating requirements of the unit. See the
attached illustration of a Modular HRSG General Arrangement.

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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. The components of an auxiliary boiler are:
 Steam drum
 Water drum
 Boiler tube
 Inner casing
 Outer casing
 Refractory
 Tiles
 Economizer
 Super heaters

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AMMONIA PROCESS

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 some
of the major equipment under ammonia plant.

 Furnace (Primary Reformer).


 Secondary Reformer.
 Heat Exchangers (Shell & Tube, Flat Plate, Finned Type).
 Boiler.
 Startup Furnace.
 Startup Heater and many more.
Inputs:
1. Natural gas
2. Air
3. Steam
Outputs:
1. Ammonia
2. Carbon dioxide

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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 oC.
 2N2 + 3H2= 2NH3
 Liquid ammonia is produced.

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UREA PROCESS

There are two sections in Urea plant


1. Urea Wet
2. Urea Dry
Urea wet section designed based on CO2 Stripping process of Stamicarbon,
Netherlands and Urea Dry section designed is based on the Fluidized Bed
Granulation technology from Hydro Fertilizer Technology
(HFT),Belgium.Comissioned in April, 1999 Urea Plant`s design capacity is 1670
MT/Day and actual is 1900 MT/Day.

Raw Material:
1. Ammonia
2. Carbon Dioxide

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DIAMMONIUM PHOSPHATE (DAP) PROCESS

The DAP plant design is based on double pipe reactor(DPR)AZF process from
Grande Paroisse, France Commissioned in November 1988. DAP Plant design
capacity is 2200MT/DAY and actual is 2450 MT/DAY.

Inputs:
1. Ammonia
2. Sulphuric acid
3. Phosphoric acid
4. Sand

Output:
1. DAP granules

Procedure:

 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 90oC 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 1/3rd 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.

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EQUIPMENT’S OF UREA, DAP AND AMMONIA &THEIR FUNCTION

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. Scrubbers can also be used for heat
recovery from hot gases by flue-gas condensation.

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.There are two types of drafting:
 Natural
 Mechanical or Forced

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At urea plant we do natural drafting.

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”
 Nominal pipe size (NPS) , usually the outer diameter of the pipe
 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.

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 a cooling tower.

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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:
A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer
heat between two fluids. This has a major advantage over a conventional heat
exchanger in that the fluids are exposed to a much larger surface area because the
fluids spread out over the plates. This facilitates the transfer of heat, and greatly
increases the speed of the temperature change. They are composed of a number of
thin metal plates compressed together into a ‘plate pack’ by two pressure plates.
Within a plate heat exchanger, the fluid paths alternate between plates allowing the
two fluids to interact, but not mix, several times in a small area. Each plate is
corrugated to increase the surface area and maximize heat transfer.
There are four main types of plate heat exchangers: Gasketed, Brazed Plate,
Welded, and Semi-Welded.
Large surface areas and corrugated plates allow Plate heat exchangers to transfer
heat very efficiently. Each plate is pressed with a chevron-shaped design to create
high turblent flow, excellent fluid distribution, and to increase surface area.The
fluid passages between plates can be very wide, reducing fouling rates
significantly. Plate heat exchangers are ideal when transferring heat between two
fluids with similar temperatures and flow rates.

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Shell and Tube Type:
A shell and tube heat exchanger is a class of heat exchanger designs. It is suited for
higher-pressure applications. As its name implies, this type of heat exchanger
consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One
fluid runs through the tubes, and another fluid flows over the tubes (through the
shell) to transfer heat between the two fluids. The set of tubes is called a tube
bundle, and may be composed of several types of tubes: plain, longitudinally
finned, etc.
There can be many variations on the shell and tube design. Typically, the ends of
each tube are connected to plenums (sometimes called water boxes) through holes
in tubesheets. The tubes may be straight or bent in the shape of a U, called U-tubes.
Tubes: The tubes provide the heat transfer area in a shell and tube heat
exchanger.The tubes in a shell and tube heat exchanger are arranged in various
arrangements. They are enclosed by a shell around them. They are available in
various sizes and shapes according to B.W.G (Birmingham wire gauge)
system.The selection of wall thickness of tube depends on maximum operating
pressure and corrosion characteristics.
Shell:As shown in the figure, the shell is the outer casing of the heat exchanger.
One fluid flows between the outer wall of the heat exchanger and inner wall of the
shell while the other flows inside the tube.Shell has a circular cross section and
selection of material of the shell depend upon the corrosiveness of the fluid and the
working temperature and pressure.Carbon steel is a common material for the shell
under moderate working conditions.
Baffles:These are panels responsible for obstructing and redirecting the flow of
fluid in the shell side of an exchanger. They are situated normal to the walls of the
shell and force the liquid to flow at right angles to the axis of the tubes. This
increases turbulence resulting in greater heat transfer. Also, the baffles help in
keeping the tubes from sagging and increase the strength of the tubes by preventing
their vibration.

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Valves
A valve is a device that regulates, directs or controls the flow of a fluid (gases,
liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing
various passageways. In an open valve, fluid flows in a direction from higher
pressure to lower pressure.
The Gate Valve: The gate valve is a general service valve used primarily for on -
off, non-throttling service. The valve is closed by a flat face, vertical disc, or gate
that slides down through the valve to block the flow.
The Globe Valve: The globe valve effects closure by a plug with a flat or convex
bottom lowered onto a matching horizontal seat located in the center of the valve.
Raising the plug opens the valve, allowing fluid flow. The globe valve is used for
on - off service and handles throttling applications.
The Pinch Valve:The pinch valve is particularly suited for applications of
slurries or liquids with large amounts of suspended solids. It seals by means of one
or more flexible elements, such as a rubber tube, that can be pinched to shut off
flow.
The Diaphragm Valve:The diaphragm valve closes by means of a flexible
diaphragm attached to a compressor. When the compressor is lowered by the valve
stem onto a weir, the diaphragm seals and cuts off flow. The diaphragm valve
handles corrosive, erosive and dirty services.
The Needle Valve: The needle valve is a volume-control valve that restricts flow
in small lines. The fluid going through the valve turns 90 degrees and passes
through an orifice that is the seat for a rod with a cone-shaped tip. The size of the
orifice is changed by positioning the cone in relation to the seat.
The Plug Valve:The plug valve is used primarily for on-off service and some
throttling services. It controls flow by means of a cylindrical or tapered plug with a
hole in the center that lines up with the flow path of the valve to permit flow. A
quarter turn in either direction blocks the flow path.

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The Ball Valve: The ball valve is similar in concept to the plug valve but uses a
rotating ball with a hole through it that allows straight-through flow in the open
position and shuts off flow when the ball is rotated 90 degrees to block the flow
passage. It is used for on-off and throttling services.
The Butterfly Valve: The butterfly valve controls flow by using a circular disc
or vane with its pivot axis at right angles to the direction of flow in the pipe. The
butterfly valve is used both for on-off and throttling services.
The Check Valve: The check valve is designed to prevent backflow. Fluid flow
in the desired direction opens the valve, while backflow forces the valve closed.

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Fabrication Shop

Valve testing methods


There are three types of valve 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.
Welding in fabrication shop
Gas cutting area:
For gas cutting acetylene cylinder and oxygen cylinder are used. When acetylene
burns with oxygen then it creates high temperature flame that can cut metals. To
check the percentage of oxygen and acetylene colour of flame is very important.
Yellow colour indicates reducing flame and blue colour indicate oxidizing flame.
Plasma cutting:
In plasma cutting plasma gas is used. Its flame temperature is higher than the gas
cutting flame. It has advantage that its flame is not oxidizing flame and so it can be
used for cutting of aluminum also. There are two machines in fabrication shop for
plasma welding. One has capacity to cut of thick 0 to 6mm and other has 0 to
32mm.

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High pressure jetting machine:
It uses the high pressure jet of water. It is used fro cleaning purpose where a man
can’t 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 coting 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.

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MACHINE SHOP
Machine shop has a number of machines used for different purposes. They include:
 Lathe machines:A lathe is a machine tool which rotates the workpiece on
its axis to perform various operations such as cutting, sanding, knurling,
drilling, or deformation, facing, turning, with tools that are applied to the
workpiece to create an object which has symmetry about an axis of rotation.
There are 3 types of lathe machines in the machine shop; small duty lathe,
medium duty lathe and heavy duty lathe machine.
 Drilling machine:A machine for making holes with removal of chips.
Drilling machines are used for drilling, boring, countersinking, reaming, and
tapping. Several types are used in metalworking: vertical drilling machines,
horizontal drilling machines, center-drilling machines, gang drilling
machines, multiple-spindle drilling machines, and special-purpose drilling
machines.
 Radial drilling machine:A radial drilling machine or radial arm press is a
geared drill head that is mounted on an arm assembly that can be moved
around to the extent of its arm reach. The most important components are
the arm, column, and the drill head. The drill head of the radial drilling
machine can be moved, adjusted in height, and rotated. Aside from its
compact design, the radial drill press is capable of positioning its drill head
to the work piece through this radial arm mechanism.
 Milling machine:Milling is the machining process of using rotary cutters
to remove material from a workpiece advancing (or feeding) in a direction at
an angle with the axis of the tool. It covers a wide variety of different
operations and machines, on scales from small individual parts to large,
heavy-duty gang milling operations. It is one of the most commonly used
processes in industry and machine shops today for machining parts to
precise sizes and shapes.
 Boring machine:In machining, boring is the process of enlarging a hole
that has already been drilled (or cast), by means of a single-point cutting tool
(or of a boring head containing several such tools), for example as in boring
a gun barrel or an engine cylinder. Boring is used to achieve greater
accuracy of the diameter of a hole, and can be used to cut a tapered hole.
Boring can be viewed as the internal-diameter counterpart to turning, which
cuts external diameters.

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 Balancing machine:A balancing machine is a measuring tool used for
balancing rotating machine parts such as rotors for electric motors, fans,
turbines, disc brakes, disc drives, propellers and pumps. The machine
usually consists of two rigid pedestals, with suspension and bearings on top
supporting a mounting platform. The unit under test is bolted to the platform
and is rotated either with a belt-, air-, or end-drive. As the part is rotated, the
vibration in the suspension is detected with sensors and that information is
used to determine the amount of unbalance in the part. Along with phase
information, the machine can determine how much and where to add
weights to balance the part.

MOTOR VEHICLE SHOP

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 hydrocrane, with 6 cylider 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.

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PIPE FITTINGS
Pipe fitting is the occupation of installing or repairing piping or tubing systems that
convey liquid, gas, and occasionally solid materials. This work involves selecting
and preparing pipe or tubing, joining it together by various means, and the location
and repair of leaks.
Common fittings for piping
 Elbow: An elbow is a pipe fitting installed between two lengths of pipe or
tubing to allow a change of direction, usually a 90° or 45° angle. The ends
may be machined for butt welding, threaded (usually female), or socketed,
etc. When the two ends differ in size, the fitting is called a reducing elbow or
reducer elbow.
 Coupling:A coupling connects two pipes to each other. If the size of the pipe
is not the same, the fitting may be called a reducing coupling or reducer, or
an adapter.
 Union:A union is similar to a coupling, except it is designed to allow quick
and convenient disconnection of pipes for maintenance or fixture
replacement. While a coupling would require either solvent welding,
soldering or being able to rotate with all the pipes adjacent as with a
threaded coupling, a union provides a simple transition, allowing easy
connection or disconnection at any future time.
 Tee:A tee is the most common pipe fitting. It is available with all female
thread sockets, all solvent weld sockets, or with opposed solvent weld
sockets and a side outlet with female threads.A tee is used for connecting
pipes of different diameters or for changing the direction of pipe runs.
 Plug:A plug closes off the end of a pipe. It is similar to a cap but it fits inside
the fitting it is mated to. In a threaded iron pipe plumbing system, plugs have
male threads.

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Flange
A flange can also be a plate or ring to form a rim at the end of a pipe when
fastened to the pipe. A blind flange is a plate for covering or closing the end of a
pipe. A flange joint is a connection of pipes, where the connecting pieces have
flanges by which the parts are bolted together.
The different types of flanges include:
 Threaded flange
 Socket weld flange
 Slip on flange
 Lap joint flange
 Neck weld flange
Gasket
A gasket is a mechanical seal which fills the space between two or more mating
surfaces, generally to prevent leakage from or into the joined objects while under
compression. The 3 main type of gaskets are; metallic gaskets, semi-metallic
gaskets and non-metallic gaskets.
Metallic gasket:
 Ring joint gasket
 Lens gasket
Semi-metallic gasket:
 Spiral wound gasket
 Metal jacket gasket
 Asbestos with wire gasket
Non-metallic gasket:
 Rubber gasket
 Teflon gasket
 Asbestos gasket

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MACHINERY AT UREA, DAP AND AMMONIA PLANT

This includes the moving parts of the plant. Their summary is as follows:
 Compressors (screw type mainly)
 Pumps
 Steam turbines
 Gas turbines
Two types of pumps are used:
 Positive displacement (plunger and piston types)
 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.

 Couplings: The two types of coupling are mechanical and hydraulic. The
advantage of hydraulic coupling over mechanical is that there are no jerks.
Thermal plug and fuse plug are two methods for the safety of the coupling.
 Seals:Gland seals and mechanical seal are used.
 Bearings
 Feeder

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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

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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.
Dye-penetrant testing: Spray the penetrant that goes into the cavity of
material. Then spray the remover. It sucks the penetrant and indicates the location
of defect.
Hardness testing: Vicker, brinell and Rockwell.
Ferrite scope:Check 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 can’t see
e.g inside the exchanger tube.
Thermography camera:For temperature measuring and spot temperature
measuring. Give thermographic photo of the machinery.
Tachometer: Measure the 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.

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