Details of all plants (Ammonia, DAP, UREA, Utilities) and Brief Introduction of FPCL ( Coal Power Plant)

1. Internship
Report
(July 2nd to 27th,2018)
Qasim Zia
BS-Mechanical Engineering (3rd
Year)
International Islamic University Islamabad

2. Internship Report
1
Qasim Zia
Qasim Zia
BS-Mechanical Engineering (3rd
Year)
International Islamic University Islamabad
Email: qasimziahafiz@gmail.com
Cell: +92 303 4565234

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Preface
As an engineering student it is extremely important to get a feel of what goes on
in the industry before you actually step foot in it. Fuji fertilizer proved to be that
training ground for me, a place where I learn a lot, developed my interest about
engineering and more or less brushed up my concepts regarding engineering and
gained an insight of what goes on in an industrial working environment. This
report carries the detail of all that I learned and gained during this 4 week
internship. Carries a brief detail of what goes on in different plants. It focuses
majorly on the knowledge about maintenance, process of production and utilities,
that I was acquire during this internship program. I visited the plant site,
observed the things being done at different sections, different areas .It was a good
experience and I will try my best to be the official part of this industry after
my graduation.
Coming to FFBL I didn’t know what lie
ahead but this place without a doubt gave me a boost, a direction and a goal. This
is one of the best Internship program throughout the country. Along with the
engagement in the work environment, involvement in the playing sports and the
time at OCEA with matches of FIFA’18 Worldcup matches at night time in a very
beautiful environment, good fellows from top universities of Pakistan and
facilities made this experience one of the cherish time of my life in Karachi.
Internship Report
Department of Mechanical Engineering

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Acknowledgement
Without the help of Allah Almighty it is impossible to achieve anything. So I
am very thankful to Allah for the successful completion of my four week
internship at FFBL which is one of the largest and growing Fertilizer Complex
in Pakistan. During my internship I have acquire about the Fertilizer industry,
and its environment. I learn about the FFBL as an organization, job handling
procedures, maintenance and repairing procedures and job environment in
FFBL.
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 Engineers of all plants 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.
My thanks and appreciations also go to my
parents who have always helped me and prayed for my success and sincere
friends who have willingly helped me out with their abilities.

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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 53% 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.
Introduction
Fauji Fertilizer Bin Qasim Limited

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 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
Plantsite.
 FFBL also have membership of industry association and trade bodies;
1. Rawalpindi Chamber of Commerce
2. International Fertilizer Association
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.
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:

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Manufacturing
Plants
Production (Metric Ton / Day)
Original Current (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.
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:
Safety
First Priority of FFBL

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PERSONAL 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.
 Googol 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 like CO,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.
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.

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 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
radio-graphic testing anywhere in the plant

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INTRODUCTION 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:
Regular maintenance involves checking oil levels, refilling oil,
cleaning filters, refueling of fuel driven machines etc.
 Emergency maintenance:
Emergency maintenance can involve anything from stopping
leakages to overhauling complete machinery.
Department

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Sub-department of Maintenance:
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.

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FFBL complex includes the following process units, off site and on site.
 PROCESS UNITS:
1. Ammonia Plant.
2. DAP Plant.
3. Urea Plant.
4. 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 storage tanks.
4. Carbon Dioxide Storage Unit.
 OFF SITES AND OTHER BUILDINGS:
1. Fire water.
2. Natural gas Station.
3. Effluent Treatment Facility.
 COMPLEX 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.
FFBL Complex

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Utility plant provides the facilities to other plants to operate well and
continuously.
For that purpose it is includes the following equipment and machinery:
Utilities Plants
Facilitate other Plants

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Now we will discuss major areas of utilities in description:
 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 43C to
33C. 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.
 Power Generation:
FFBL has manly two source of Power 2 Gas Turbines and recently
FFBL completed its new project of coal power plant.
 FFBL Power Company Limited:
Project AIM:
 Alternate fuel for steam and power generation owing to
shortage of Natural Gas.
 Fulfilling FFBL Steam and Power requirements.
 Provision for Power Export to National grid.
Main Components of CPP Project:
 2 x 250 MeT/hr Circulating Fluidized Bed (CFB) Boilers.
 3 x STG’s at 60 Hz.
 1 x BPSTG’s or BPSTG cum Condensing at 60 Hz.
 1 x 55 MWe STG’s at 50 Hz for Power Export.

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Relation between FFBL and FPCL
Flow chart of sharing Steam:
New Coal Power Plant
(CPP) Project
FFBL Existing
Plants
CPP Project
2 x 250 t/h CFB Boilers
3 x STGs + 01 BPSTG(60Hz)
1 x 50 ~ 60 MW (50 Hz)
Balance of Plants (BOP)
Power supply to
existing complex
(60 Hz)
Steam supply to
existing complex
Utilities supplies
to Coal Power
Plant

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Steam Turbine Inputs & Outputs:
 Gas Turbines:
For power generation in FFBL there are 2 gas turbines. The
capacity of power generation one gas turbine is 26 MW. First time
in Pakistan power is generating at 60 HZ. The voltage is
13800volts.
Major Components 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.

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 Fire detection and CO2 protection system.
 Seismic type vibration system.
 Thermocouples for measuring critical turbine temperature.
 Diesel driven emergency generator:
It is used in a case that the gas turbine is not
running and to stop the plant from closing it is automatically on in
20 seconds and have capacity of to operate the plants.
 Air Compressor:
There are three air compressors in the FFBL under the utility
section which provide, supply and generate the 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:
 1st
stage – 9000 RPM.
 2nd
stage – 14000 RPM.
 Instrument air:
Instrument air is used in control values. It is moisture free air and
used where corrosion is not affordable.
 Service air:
It has moisture in it and can cause corrosion. It is used for cleaning
equipments and to supply oxygen

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 Steam Production:
Production and supply of steam to whole plant is under
utility section.
Steam is generated by two methods:
 Heat Recovery Steam Generation(HRSG):
Hear 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.
 Water preheater.
The different components are put together to meet the operating
requirements of the unit.
 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.

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 Water Filtration:
FFBL has two major plants of water filtration for whole plant of
every use of water.
 Reverse osmosis (RO):
It is a water purification technology that uses
a semipermeable membrane to remove ions, molecules and larger
particles from drinking water. In reverse osmosis, an applied
pressure is used to overcome osmotic pressure, acolligative
property, that is driven by chemical potential differences of the
solvent, a thermodynamic parameter. Reverse osmosis can remove
many types of dissolved and suspended species from water,
including bacteria, and is used in both industrial processes and the
production of potable water. The result is that the solute is retained
on the pressurized side of the membrane and the pure solvent is
allowed to pass to the other side. To be "selective", this membrane
should not allow large molecules or ions through the pores (holes),
but should allow smaller components of the solution (such as
solvent molecules) to pass freely.
Advantages:
 RO performs a separation without a phase change. Thus,
the energy requirements are low.
 RO systems are compact, and space requirements are less
than with other desalting systems, e.g. distillation.
 RO equipment is standardized - pumps, motors, valves,
flowmeters, pressure gages, etc. Thus, the learning curve
for unskilled labour is short.

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 Many RO systems are fully automated and designed to
start-up and shutdown automatically through interlocks.
Thus, RO plants usually require little labour.
 Due to their modular design, maintenance is easy.
Scheduled maintenance can be performed without shutting
down the entire plant.
 The modular design also makes expansion an easy option.
Disadvantages:
 The applied pressure must exceed the osmotic pressure to
obtain product flow and to separate the solute from the
solvent. The maximum feed pressure for seawater devices
varies from 800 - 1000 psig, while the limit for brackish
water varies from 400 - 600 psig.
 Due to the high pressure requirement (about 200 psig or
more above the osmotic pressure) RO is usually not
applicable for concentrated solutions.
 Because all RO membranes and devices are susceptible to
fouling, the RO process usually cannot be applied without
pretreatment.
 RO feed streams must be compatible with the membrane
and other materials of construction used in the devices. If
the feed stream contains incompatible compounds, these
must be removed in pretreatment, or another compatible
device and/or membrane must be considered

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 Demineralization (DM) Water Treatment Plants:
Demineralization is the process of removing mineral
salts from Water by using the ion exchange process.
Demineralised Water is Water completely free ( or almost ) of
dissolved minerals as a result of one of the following
processes:
 Distillation.
 Deionization.
 Membrane filtration (reverse osmosis or nano filtration).
 Electrodyalisis.
In the context of Water purification,
ion-exchange is a rapid and reversible process in which impurity
ions present in the Water are replaced by ions released by an
ion-exchange resin. The impurity ions are taken up by the resin,
which must be periodically regenerated to restore it to the
original ionic form. (An ion is an atom or group of atoms with an
electric charge. Positively-charged ions are called cations and are
usually metals; negatively-charged ions are called anions and are
usually non-metals).
Advantages:
 Capable of removing 97% of suspended solids.
 Biological nitrification without adding chemicals.
 Oxidation and nitration achieved.
 Biological phosphorous removal.
 Solids and liquids separation.

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 Removes organics.
 Cost effective.
 Easily maintained mechanical work.
 Self sustaining system.
Disadvantages:
 Cleaning is a hassle.
 Most plants need at least three tanks.
 Temperature changes affect the tank greatly.

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Introduction:
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.
Major equipments 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.
Input Materials:
1) Natural gas
2) Air
3) Steam
Product Materials:
1) Ammonia Gas
2) Carbon dioxide
Ammonia Plant

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Process flow Diagram for Ammonia:

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Procedure:
 De-Sulphurization 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 C.
2N2 + 3H2 2NH3
 Liquid ammonia is produced.
 Goes to Urea if storage is full.

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Formation of Urea:
Urea is formed by reacting liquid ammonia and gaseous carbon
dioxide at about 170-185 C and 134-125 bar pressure.
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.
Urea Plant
Production Process

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Process flow Diagram for Urea:

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Formation of DAP:
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.
Input Materials:
1) Ammonia.
2) Sulphuric acid.
3) Phosphoric acid.
4) Sand.
Product Materials:
1) DAP granules.
Diammonium Phosphate Plant
Production Process

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Process flow Diagram for DAP:

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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 and their functions:
 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.
 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.
 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.
Equipment & Machinery
Used in All Plants

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 Heat Exchangers:
Heat exchangers are used to transfer heat from one
media to other media.
They are classified on different basis.
 Plate type Exchangers:
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.
 Shell and Tube Type Exchangers:
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.
 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 tub

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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 Valves:
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 Valves:
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 Valves:
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 Ball Valves:
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 Valves:
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

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 The Check Valves:
The check valve is designed to prevent backflow.
Fluid flow in the desired direction opens the valve, while
backflow forces the valve closed.
Machinery and their functions:
This includes the moving parts of the plant.
Their summary is as follows:
 Compressors:
Compressors are used to flow fluid (gases) from one place
at plant to other and also to raise their pressure. They are of two types
on basis of classification.
1. Vertical compressor.
2. Horizontal Compressor.
Also they are sub-divided into three types:
 Radial flow(Centrifugal) Compressors:
These compressors are
used for medium flow and pressure. In FFBL plantsite mainly
these compressors are installed. These are dynamic compressors.
 Axial Flow Compressors:
These compressors are used where low
pressure but comparatively high flow is required such as in gas
turbines. In plantsite, all gas turbines have multistage axial flow
compressors. These are also dynamic compressors.
 Positive Displacement Compressors:
These are uesd where low
flow but high pressure is required.

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 Pumps:
Pumps have the same functions as of compressors, instead their
working fluid is liquid. In plantsite positive displacement pumps are
installed in lubrication oil circuits to make sure the constant supply of
lube oil to compressors, turbines, bearings and other various
machines.The types of pump impellers are open impeller, partially closed
impeller and closed impeller.
 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.
 Dynamic Sealing:
These kind of sealings are used to seal different
stages in compressors or pumps to maintain pressure.
These are of various types:
1. Labyrith Seals.
2. Oil floating seals.
3.Dry gas seals.
 Bearings:
As by name it is clear, bearings are used to bear loads and also helps in
smooth running.
They are two types:
1. Axial bearing also called thrust bearing.
2. Radial bearing.

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 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
• Swivel joint
• Spigot joint
• Fix joint
 Welding in fabrication shop:
There are different types and works of 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
Fabrication Shop
Different Mechanism

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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.
 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.
Machine shop has a number of machines used for different purposes.
 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 machines:
A machine for making holes with removal of chips.
Drilling machines are used for drilling, boring, countersinking, reaming,
and tapping.
 Radial drilling machines:
A radial drilling machine or radial arm press is a
Machine Shop
Different Mechanism

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geared drill head that is mounted on an arm assembly that can be moved
around to the extent of its arm reach.
 Milling machines:
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.
 Balancing machines:
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.
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.
Motor Vehicle Shop
Introduction

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Facilities
Some memorable Clicks

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Conclusion:
It was a great experience of life at FFBL. There were a lot of things to
learn, very inspire able environment, rules and regulations, cooperative Staff
and management, Separated and well equip-ed departments of every thing.
Plant-Site was quite secure for site work, Safety was first priority,
accommodation plus all other facilities was very good. Personally I’ll very
thankful to instructor diver at Swimming pool, by his instruction I also
learned swimming in very short duration. At the end I learned a lot in this
duration of 1 month, i am now much familiar with industry environment as
well as fertilizer industry. This internship also helped me improving my
technical skills as well as official skills, I again thank to all the staff of FFBL
for giving me their precious time.