02-Aug-2018

INTERNSHIP REPORT
Name:
Muhammad Umair
University:
NUST Islamabad
Internship period:
3rd July 2018 to 2nd August 2018
Department:
Maintenance
Mentor:
Mohsin Ahmed (Equipment Engineer)
Table of content:
1. Acknowledgement
2. Overview of fertilizer industry
3. Overview of Fatimafert Limited
• Brief History
• Mission and Vision Statement
• Products and services
• Competitors
4. Internship training at Maintenance department
• Equipment section
• Machinery section
• Overview of industrial materials
5. Root cause analysis of compressor C501 failure
6. Conclusion

PAGE 1
 1. Acknowledgement
I want to express all my humble thanks to ALLAH who is very sensitive about each and
every activity of all his man and without whose help I am unable to accomplish this
objective of our life.

The internship opportunity I had with Fatimafert Limited (Formerly DH Fertilizer

Limited) was a great chance for learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with an opportunity to be a
part of it. I am also grateful for having a chance to meet so many wonderful people and
professionals who led me through this internship period. Bearing in mind previous I am
using this opportunity to express my deepest gratitude and special thanks to the Mr.
Farooq Ahmad (HR Coordinator) of Fatimafert Limited who in spite of being
extraordinarily busy with his duties, took time out to hear, guide and keep me on the
correct path and allowing me to carry out my internship at their esteemed organization
and extending during the training. I express my deepest thanks to Mr. Zahid Rafique
(HRBP) for taking part in useful decision & giving necessary advices and guidance and
arranged all facilities to make life easier. I choose this moment to acknowledge his
contribution gratefully. I am also thankful to all other staff of Fatimafert Limited
departments. Finally, I would like to thank my parents for a lifetime of love and support.
They have taught me the most important lessons in life, and I owe all of my achievements
to them.

Sincerely,

PAGE 2
 2. Overview of fertilizer industry:
Pakistan is an agricultural country where about 72% of the total population not only resides
in rural areas but also relies for its sustenance on Agriculture activities. This sector is
contributing a lion’s share in the national economy. Most of the national economic target
is dependent on the performance of our agricultural sector. It contributes 24% to the total
GDP. Raw Cotton, Sugarcane and Wheat are major crops having economic importance. The
fertilizer is an important input which boosts the Agriculture production. Unfortunately, it
is used three times lower in our country than that of the developed countries in the world.
We are not still self-sufficient in producing our staple food grain, soil deterioration, nutrient
mining. And there is insufficient and inadequate use of fertilizer.

Food consumption is likely to rise in emerging markets where economic growth results in
better income per capita because higher income would lead to increased food consumption
and hence greater grain demand. With growth in arable land diminishing as a consequence
of rapid soil erosion, fertilizer usage will continue to play an important role in food
production. Despite bouts of industry swings in the intermediate terms, secular industry
dynamics will remain robust for the industry because of the estimated 5-6% p.a. long terms
growth in fertilizer demand in Pakistan and the largely inelastic food demand. The
agriculture sector is important because it accounts for:  24% of the country’s GDP  50%
of the employed labor force  65% of the country’s total export earnings making it the
largest source of FX earnings  Forms the basis for over 50% of industrial production  Has
growth rate of 3-4% per annum and that population growth is roughly gauged at 2.3% p.a.
(current population: 134mn) compared to 2.2% p.a. in India and 2.4% p.a. in Egypt. With
larger population comes greater demand for food consequently higher demand for grain.

3. Overview of Fatimafert Limited:

Fatimafert Limited (formerly DH fertilizers Limited) is the wholly owned subsidiary of
Fatima Fertilizer Company Limited, and a renowned name in Pakistan’s fertilizers Industry
selling Urea under the leading brand name of “Bubber Sher” for local cultivation. Fatimafert
Limited is also the leading importer of DAP, marketed extensively across Pakistan.
Fatimafert Limited enjoys a large customer base across Pakistan owing to its trusted brand
name and upholding the trust of its loyal customers. Fatimafert Limited was incorporated
on August 2, 2010 following a decision to demerge fertilizer business from its parent
Company Dawood Hercules Chemicals Limited, named DH Fertilizers Limited. The
demerger was approved by Lahore High Court on July 25, 2010 making it effective as of July
1, 2010. Fatima Group took the control of DH Fertilizers Limited on July 1, 2015 and changed
its name to Fatimafert Limited on December 2, 2015. The brand “Bubber Sher” was also
acquired by Fatima Group by purchasing the Company Bubber Sher (Private) Ltd, as a
wholly owned subsidiary of Fatima Fertilizer Company Limited. The manufacturing facility
located at Chichoki Mallian, 28-KM Lahore Road, Sheikhupura started its commercial

PAGE 3
production on October 13, 1971. The original design capacities of Ammonia and Urea plants
were 625 MT per day and 1100 MT per day respectively. The plant revamp was carried out
from 1989 – 1991 and the design capacity was increased to 815 MT per day Ammonia and
1350 MT per day Urea. However, at present the plant is producing 1,500 MTPD of Urea, 890
MTPD of Ammonia due to Essential Equipment’s Replacement and higher capacity
utilization.

Vision:

To be a world class manufacturer of fertilizer and ancillary products, with a focus on safety,
quality and positive contribution to national economic growth and development. We will
care for the environment and the communities we work in while continuing to create
shareholders' value.

Mission:

To be the preferred fertilizer company for farmers, business associates and suppliers by
providing quality products and services. To provide employees with an exciting, enabling
and supportive environment to excel in, be innovative, entrepreneurial in an ethical and
safe working place based on meritocracy and equal opportunity. To be a responsible
corporate citizen with a concern for the environment and the communities we deal with.

Products and services:

It has three main products:

UREA:
Urea is white crystalline solid containing 46% nitrogen in the form of amide. Urea contains
the most Nitrogen when compared to other fertilizer sources. Urea is a versatile fertilizer
that is readily soluble in water and can thus be applied through different modes of delivery
to the crops. Commercially it is available in granular or prilled form. Fatimafert Limited
markets prilled urea in free-flowing form. Fatimafert Limited (formerly DH Fertilizers
Limited) markets urea under the brand BubberSher®. BubberSher® has consistently
delivered quality and value for more than 40 years and continues to enjoy a high brand
share of preference in the markets Fatimafert Limited (formerly DH Fertilizers Limited)
serves.

AMMONIA:
Ammonia is a water-soluble, colorless gas, with a pungent smell. A compound of nitrogen
and hydrogen with the formula NH3, ammonia besides being a source of nitrogen in
agriculture, has wide ranging industrial and commercial applications. Anhydrous Ammonia
has a composition of 98.8% ammonia, up to 0.20% of water and not more than 10 PPM of

PAGE 4
oil while Aqueous Ammonia contains 21-25% of ammonia dissolved in water with an overall
turbidity not exceeding 10 NTU.

DAP:
Produced from the reaction of ammonia and phosphoric acid, Di-Ammonium phosphate
(DAP) is one of the most widely used phosphate fertilizer in agriculture across the world
today. DAP is composed of 18% Nitrogen and 46% Phosphorus. DAP is alkaline with a high
pH, exceeding 7.5. It is highly soluble and thus dissolves quickly in soil to release plant-
available phosphate and ammonium.

Competitors:
FAUJI FERTILIZER COMPANY LTD (FFC)

ENGRO FERTILIZER LTD (EFL)

FATIMA FERTILIZER LTD (FFL)

AGRITECH LTD (FORMERLY PAK AMERICAN FERTILIZER LTD)

4. Internship Training (Maintenance department)

In

5. Root cause failure analysis of compressor C501:

Compressor C501 is a reciprocating compressor installed in

6. Conclusion:

PAGE 5