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INTERNSHIP REPORT
Submitted to:
MR.KHAN KASHIF
Internee-Instrument
ACKNOWLEDGEMENT
Syed Ahsan Ghaffar student of NED University of Engineering and
Technology, Karachi worked as internee in FFBL.I thank Almighty ALLAH
who empowered me to complete this internship.
I would like to thanks My Father ABDUL
SUPERVISOR AT FFBL.
GHAFFAR SENIOR
Table of Contents
ACKNOWLEDGEMENT .................................................................................... 2
Introduction ........................................................................................................... 5
COMPANY HISTORY: ....................................................................................... 6
Performance & Production.................................................................................... 6
GRANULAR UREA:............................................................................................ 7
DI-AMMONIA PHOSPHATE (DAP): ................................................................ 7
SAFETY ................................................................................................................ 8
PERSONEL PROTECTIVE EQUIPMENTS: ..................................................... 8
WORK PERMIT PROCEDURE: ......................................................................... 8
Ammonia Plant: ..................................................................................................10
Ammonia Plant: ..............................................................................................10
CAPACITY: ........................................................................................................11
UREA PLANT ....................................................................................................12
.............................................................................................................................14
UTLILIES AND POWER GENERATION: ......................................................15
Utility Control Room: .........................................................................................16
Fuel Gas Control System: ...................................................................................16
Components of Fuel Gas Control System:..........................................................16
Cooling Tower: ...................................................................................................17
DAP PLANT: ......................................................................................................18
DAP PLANT DESCRIPTION: ...........................................................................18
Process .......................................................................................................18
Revamp: ........................................................................................................18
Capacity: ....................................................................................................18
4
FOUR BASIC PROCESS VARIABLES OF INDUSTRY ................................21
Pressure: ..............................................................................................................21
Pressure Sensors: .................................................................................................21
1. Bourdon Tube Pressure Sensors: ..................................................................22
2. Bellows Pressure Sensors: ............................................................................22
3. Diaphragm pressure sensors: ........................................................................22
4. Piezo-Electric pressure Sensors: ...................................................................23
Flow:....................................................................................................................23
Introduction to Flow Meters and Flow sensors: .................................................24
Level:...................................................................................................................24
Level measuring Instruments: .............................................................................24
Temperature: .......................................................................................................24
Temperature Measuring Instruments: .................................................................25
HIMA PLC: EMERGENCY SHUTDOWN SYSTEM ......................................26
ONE I/O RACK CONTAINS: ............................................................................26
ELOP System Software& Operating System f o r Programming &
operation:.............................................................................................................26
CETRAL MODULE F8630: ...............................................................................27
COPROCESSOR MODULE F8621: ................................................................27
CONTROL SYSTEM OF FFBL: .......................................................................27
Control System ....................................................................................................28
Process control: ...................................................................................................28
DISTRIBUTED CONTROL SYSTEM (DCS): .................................................30
Programmable logic controller (PLC): ...............................................................31
Input: ...................................................................................................................31
Output:.................................................................................................................32
.............................................................................................................................33
Introduction
Fauji Fertilizer Bin Qasim Limited is US$460 Million Project, one of the
largest in the private sector in Pakistan. Producing both dap and granular
urea for the first time in the century. The largest and well known industrial
group of Fauji and Jordan phosphate mines company sponsors the project.
But now its the whole property of FFBL.
COMPANY HISTORY:
By the early nineties, Pakistan was
almost one million tons of urea and 800,000 tons of DAP per annum. At that
time management of Fauji Fertilizer embarked on the FFC Jordan fertilizer in
order to make Pakistan self-efficient in Urea Fertilizer and to drastically
reduce the import of DAP fertilizer.
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.
1670
1920
DAP
1350
Ammonia
1270
GRANULAR UREA:
(GURRATED 46% NITROGEN)
With its state of the art of Fertiliser plant, Fauji Fertilizer Bin Qasim Limited
is the only granular urea manufacture in Pakistan. Its product granular urea
has the cutting edge over the conventional pill urea fertilizer with the
following superior qualities.
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 equipments condition will
not contribute to an accident. In FFBLsafety is considered equal to
production.
Safety priorities of FFBL
1. Employs
2. Company assets
3. Environmental
9
and technical service Department. The permission is sought on a
presubscribed format known as work permit.
FFBL complex includes the following process units, offsite and on site.
Process Units:
1. Ammonia Plant
2. DAP Plant
3. Urea Plant
4. Utilities & Power Generation
BUILDING INCLUDES:
10
Ammonia Plant:
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.
Following are the names of some of the major equipment under ammonia
plant.
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Then in secondary reformer air is introduce to have Nitrogen required for
Ammonia syntheses compressed by air compressors.
In carbon monoxide conversion section carbon monoxide to converted o
carbon dioxide in the presence of steam and catalyst. This carbon dioxide
removed in carbon dioxide removal section using Benfield solution which
absorb carbon dioxide which is further stripped of and send to urea section.
CAPACITY:
Design:
1,270 MTPD
Post BMR: 1,570 MTPD
12
UREA PLANT
There are two sections in urea plant.
Urea Wet
Urea Dry
Urea Wet section designed based on CO2 stripping process of stamicarbon.
Netherlands and Urea Dry section designed is based on the Fluidized based
Granulation technology from Hydro Fertilizer Technology (HFT), Belgium.
Commissioned in April, 1999. Urea Plants design capacity is 1670 MT/day
and actual is 1900 MT/day.
Urea Plant Description:
Process
Urea wet stamicarbon, Holland
Urea dry Hydro Agri, Belgium
Capacity:
Design 1,670 MTPD
Current 1,920 MTPD
Raw Material:
Ammonia 1,110 MTPD
Carbon Dioxide 1,480 MTPD
Urea Formaldehyde 18.0 MTPD
13
14
15
Utilities plays an important role in the running of whole plant .it gives all
basic inputs according to the required input of different plants located at
FFBL. Following are storage systems of Utilities.
Gas turbines (Electrical power at 60Hz Frequency)
16
Storm sewer system consisting of one collection basin, underground
gravity collection and discharge system.
Fire protection system consisting of fire water storage, hydrants and
carbon di-oxide system.
17
3. Three redundant fuel gas pressure transducers
4. Control valve assembly: Four Linear variable differential
transducers
5. Dumper Valve: three pressure gauges.
6. Two servo type valves
Cooling Tower:
Cooling tower has ten cells. Cell #1, 2 & 3 are dedicated for urea, Dap and
utilities. Cell # 5, 6,7,8,9 & 10 are dedicated to NH3 plant. Cell # 4 is a spare
cell common for both networks.
18
DAP PLANT:
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 1350MT/DAY and actual is 1500 MT/DAY
Revamp:
Jacobs Engineering, U.S.A.
Capacity:
Design: 1,350 MTPD
Post Revamp: 2,230 MTPD
Raw Material:
Ammonia: 450 MTPD
Phosphoric Acid: 1,750 MTPD
Sulphuric Acid: 92 MTPD
Sand: 117 MTPD
Coating Oil: 10 MTPD
19
20
21
1.
2.
3.
4.
Temperature
Pressure
Flow
Level
Pressure:
Pressure is defined as the amount of force applied to an area.
This can be defined mathematically as pressure is equal to force per unit
area.
P=F/A
The unit of pressure can be described in pounds per square inch (psi), which
is the common standard for English.
Pressure Sensors:
Pressure sensors are among the most useful
sensors for industrial applications because pressure can be converted to
determine the liquid level of a tank or the temperature in addition to
measuring the amount of force that is placed on an object. Pressure can be
used to determine the level of fluid in a tank by converting the amount of
head pressure into the height of a column of the liquid. Pressure can also be
used to determine temperature from conversion tables because this is a direct
correlation between the temperature and the pressure of confined gases.
Pressure can also be used to measure flow by calculating the pressure drop
across on orifice plate.
The pressure sensors are:
22
23
Common uses for diaphragm seals are to protect pressure sensors from
the fluid whose pressure is being measured.
Flow:
Flow measurement is the quantification of bulk fluid movement.
Flow can be measured in a variety of ways. Positive-displacement flow
meters accumulate a fixed volume of fluid and then count the number of
times the volume is filled to measure flow. Other flow measurement methods
rely on forces produced by the flowing stream as it overcomes a known
constriction, to indirectly calculate flow. Flow may be measured by
measuring the velocity of fluid over a known area.
Both gas and liquid flow can be measured in volumetric or mass flow rates,
such as litres per second or kilograms per second. These measurements are
related by the material's density. The density of a liquid is almost
independent of conditions. This is not the case for gasses, the densities of
which depend greatly upon pressure, temperature and to a lesser extent,
composition.
When gases or liquids are transferred for their energy content, as in the sale
of natural gas, the flow rate may also be expressed in terms of energy flow,
such as GJ/hour or BTU/day. The energy flow rate is the volumetric flow
rate multiplied by the energy content per unit volume or mass flow rate
multiplied by the energy content per unit mass. Energy flow rate is usually
derived from mass or volumetric flow rate by the use of a flow computer.
In engineering contexts, the volumetric flow rate is usually given the symbol
, and the mass flow rate, the symbol .
24
For a fluid having density , mass and volumetric flow rates may be related
by
.
Level:
Level Measurement is the determination of the linear vertical
distances between a reference point or datum plane and the surface of a
liquid or the top of a pile of divided solids
Gauge glass
Electronics Gauge
Float type level gauge
Ultra Sonic Level Transmitter
Differential Pressure level Sensor
Temperature:
A temperature is a numerical measure of hot and cold. Its
measurement is by detection of heat radiation, particle velocity, kinetic
energy, or most commonly, by the bulk behaviour of
25
a thermometric material. It may be calibrated in any of various temperature
scales, Celsius, Fahrenheit, Kelvin, etc.
Measurements with a small thermometer, or by detection of heat radiation,
can show that the temperature of a body of material can vary from time to
time and from place to place within it. If changes happen too fast, or with too
small a spacing, within a body, it may be impossible to define its
temperature. Thus the concept of temperature in general has an empirical
content.
RDT
Thermocouple
Thermistor
Bimetallic thermometer
26
27
Global alarms and permissive are transmitted via this link.
Field devices are connected by hard wired links to shutdown system.
This satisfies related data is read by one PLC and is shared with other
PLC`s over HIBUS FS protocol over HIMA System bus.
The ELOP and PLESY station are connected via H7505 interface
converter over ELOP and PLESYbus respectively.
Consider a situation with field switch actuation. This signal is received
through hard wired linksPLC generates an O/P and shutdown the
process via field SOV`s and relays to return the system to the safe
state with in milliseconds.
Then it transmits data over PLESY bus for logging and arching and to
ELOP station over ELOP bus. This data is also conveyed to DCS for
alarm updating. In this way HIMA guarantee reliable plant operation
and ensure safe operation
28
Control System:
Control system is a collection of electronic devices &
equipment which are in place to ensure the stability, accuracy & smooth
transition of a process or a manufacturing activity.AS we know FFBL is a
Process industry so the process control is very mean to it for the production
and as well as the safety of Employs, company assets and environment.
Process control:
The regulation of process parameters to within
specified target parameters through the manipulation of the control variable
29
A TYPICAL PROCESS CONTROL
Plant controls scheme or philosophy varies from plant to plant but normally
it depends on type of process, size of hardware and software configuration to
handle process I/O signals
30
31
Input:
Intelligence of PLC
lies in the
signals from
sensors,
actuators & field
devices.
Push
buttons
Keypads
Toggle
switches
32
Proximity switches
Piezoelectric sensors
Level sensors
Output:
Motors
Solenoids
Relays indicators
Buzzers
LEDs
33
34
Programmable Logic Controllers (PLCs) is dedicated Control system and
used in:
1. Emergency Shutdown System (ESDS)
2. Logical and loop controls, ON / OFF valves, motor: start / stop
commands.
3. Equipment local emergency stop (belt conveyor, elevator)
4. Main pumps start / stop
5. Fail safe operation