Internship Report- Fauji Fertilizer Company (FFC)

Internship Report ’13 (Maintenance Unit) 1

INTERNSHIP REPORT Prepared for Technical Training Centre (TTC) Fauji Fertilizer Company Ltd. (FFC) Mirpur Mathelo, District Ghotki (Sindh)

Prepared by M. Aqeel Ashraf Undergraduate Student School of Mechanical and Manufacturing Engineering (SMME) National University of Sciences and Technology (NUST) Email: [email protected] Contact: 0305-3151089

July 2013


1 Declaration July 20, 2013

TO WHOM IT MAY CONCERN

Respected Sir Submitted for your review is the report of my six week internship at Maintenance Unit of Fauji Fertilizer Company Ltd. Mirpur Mathelo plant, during June-July 2013.It is hereby declared that the report is compiled in long report format, as per the guidelines and is based upon the literature review; plant manuals and standard work procedures; isometric drawings and sharing and learning from management and staff of the company. Maximum possible references from literature are cited and sources are mentioned. It is anticipated that response will be reflected. Regards

M. Aqeel Ashraf Undergraduate Student School of Mechanical and Manufacturing Engineering (SMME) National University of Sciences and Technology (NUST) H-12 Campus Islamabad-44000 Email: [email protected] Contact: 0305-3151089


2 Acknowledgements Author is thankful to Almighty Allah, For His unlimited blessings and bounties, And for keeping him sane, sound and successful; His parents and friends, For all their support and trust in him and his aims; His teachers and guides, For teaching him things he knew not; NUST Internship and Placement Office, For bringing the opportunity of this excellent learning and exposure; And last but never the least Management and Staff of Fauji Fertilizer Company Mirpur Mathelo Especially Unit Managers, Engineers, Supervisors and Technician, For their utmost help, guidance and time Which made author make most of his internship at plant site


3 Table of Contents 1

Declaration

2

2

Acknowledgements

3

3

Table of Contents

4

4

List of Figures

6

5

List of Tables

7

6

List of Acronyms

8

Introduction

9

7

Urea Manufacturing Process- A Brief Overview

10

7.1

Production Department

10

7.1.1 Utilities Unit

10

7.2.2 Ammonia Unit

12

7.2.3 Urea Unit

13

7.2.4 Bagging and Shipment Unit

14

8

Maintenance Department

15

8.1

Introduction to Maintenance

15

8.1.1 Technical Aspect

15

8.1.2 Administrative Aspect

16

8.1.3 Productive Aspect

16

FFC Maintenance Organization

17

8.2.1 Introduction

17

8.2.2 MWR (Maintenance Work Request) Procedure

18

8.2.3 Equipment Maintenance Section

20

8.2.4 Machinery Maintenance Section

23

8.2.5 Fabrication Shop

25

8.2.6 Machine Shop

26

8.2.7 Planning & Scheduling

30

8.2

9

Technical Services Department

32


9.1

10

Inspection Unit

32

9.1.1 Function

32

9.1.2 Job Type

32

9.1.3 Technical Task

32

9.1.4 Job followed/viewed on field

33

Safety Section

35

10.1

Activities

35

10.2

Safety Training

36

10.2.1 Importance of Safety at Plant

37

10.2.2 Use of Personal Protective Equipment

37

10.2.3 Use of Fire Extinguishers

38

10.2.4 Ammonia Disaster

40

11

Conclusion

41

12

Citations and Bibliography

42

Appendix I FFC MM Site Map Appendix II FFC MM Plant Safety Policy Appendix III FFC MM Plant Safety Rules and Regulations Appendix IV Isometric Drawings

43 43 44 44 45 45 46 46


4 List of Figures Figure 1 Ammonia Storage Spheres

12

Figure 2 Urea Synthesis Loop

13

Figure 3 A Filled & Stitched Urea Bag

14

Figure 4 Technical Aspects of Maintenance

16

Figure 5 Maintenance Department Hierarchy

18

Figure 6 ME-119 A/B/C filters at 01 Area

21

Figure 7 Hot Insulation at P-109 Steam Tracing

21

Figure 8 Cold Insulation on Chiller Lines

21

Figure 9 Plunger Gland Packing of DP-1300

24

Figure 10 MP-921B Pump

24

Figure 11 Pressure Testing of a Globe Valve

25

Figure 12 GTAW

25

Figure 13 Tool Room at FFC

26

Figure 14 Lawn in front of Vehicle Shop

29

Figure 15 Procedure for Provision of Crane to the Contractors

31

Figure 16 E-208 Boiler

33

Figure 17 Chlorine Cylinder #22

34

Figure 18 Chlorine Cylinder #25

34

Figure 19 Penetrant applied on a weld

34

Figure 20 Emergency Siren Sequence

37

Figure 21 Internee Personal Protective Equipment (PEE)

38

Figure 22 Emergency Response

39

Figure 23 PASS Approach for Using Fire Extinguisher

39

Figure 24 FFC MM Site Map

43

Figure 25 Isometric Drawing: Cooling water flow increment at 2 cell cooling tower

47

Figure 26 Isometric Drawing: P-120 AB Top Shaft

48


5 List of Tables Table 1 Plant Utilities Division

10

Table 2 Tools Division in Tool Room

27

Table 3 Machines present at Machine Floor

28

Table 4 Mobile Equipment in Vehicle Shop

29

Table 5 Safety description as set by Safety Section

37

Table 6 Strategy in Fire Incident

38

Table 7 Effect of Ammonia at different Concentration in Air

40

Table 8 FFC MM Plant Area Description

43


6 List of Acronyms T/A

Turn around

CCR

Central Control Room, FFC MM

DCS

Distributed Control System

EPA

Environment Protection Agency

FFC MM

Fauji Fertilizer Company Ltd. Mirpur Mathelo

FFC

Fauji Fertilizer Company Private Limited

NEQS

National Environment Quality Standards

PSFL

Pak Saudi Fertilizers Limited

NFC

National Fertilizer Corporation

TG

Turbo Generators

EDG

Emergency Diesel Generator

SOV

Solenoid Operating Valve

MPD

Medium Pressure Decomposer

LPD

Low Pressure Decomposer

OEM

Original Equipment Manufacturer

RCM

Reliability Centered Maintenance

MWR

Maintenance Work Request

P&S

Planning and Scheduling

P/T

Prilling Tower

API

American Petroleum Institute

GTAW

Gas Tungsten Arc Welding

SMAW

Shielded Metal Arc Welding

NSC

National Safety Council, USA

MSDS

Material Safety Data Sheet

IMS

Integrated Management System


Introduction You cannot create experience, you must undergo it. Internships are supplemented to course work for enhancement of practical knowledge and expertise of students. Fertilizer being a major component of process industry has a lot to develop an understanding of a mechanical engineering student, varying from static/rotary equipment inspection to their maintenance/modification and from fabrication of equipment to planning & scheduling of daily work. FFC is a leading fertilizer production group in Pakistan, with over 60 % market share in the sector. Incorporated in 1978 as a private limited company, it is a joint venture between Fauji Foundation and Haldor Topsoe of Denmark. Since Pakistan is an agro-based economy, the contribution of the fertilizer to the economy is vital and FFC is a prime share holder in the fertilizer industry of Pakistan. At present the foundation has three fertilizer plants, two at Goth Machi and one at Mirpur Mathelo. Foundation also holds shares in FFBL (formerly FFC-Jordan Fertilizer Company Limited). The plant site at Mirpur Mathelo ex Pak Saudi Fertilizers Limited (PSFL) was acquired from National Fertilizer Corporation (NFC) in 2002. The capacity was increased through de-bottle necking of plant in 2008, to increase the production to 2300 MeT urea per day. The report starts with the brief introduction of urea manufacturing processes on the plant followed by the extensive description of Maintenance department, Technical services department and Safety section of FFC MM. It reflects the understanding of the author about the plant areas, developed during his six week internship at plant site, through study of literature, interaction with work force and site observation.


7 Urea Manufacturing Process (A brief overview) 7.1

Production Department

At FFC MM, production unit works under a Production Manager and is sub-divided into four sub-units, as per their working goals. These include: 1. Utilities Unit; provides utilities like instrument air, cooling water, electricity to other units 2. Ammonia Unit; provides raw materials i.e. ammonia and carbon dioxide for urea section 3. Urea Unit; produces the product urea (trade name: Sona Urea) 4. Bagging and Shipment Unit; bags urea and dispatch it to consumer market Each of the unit has a UM which works with a team of engineers and other technical staff to manage smooth run of unit. Shift starts with a coordination meeting of production manager, Unit Managers, staff engineers and engineers; discussing and addressing the problems to be encountered. Shift engineers coordinate with board men (operators of DCS monitoring facility at CCR) and operators (at respective areas) for following the agreed plan of action for the shift or day.

7.1.1 Utilities Unit The objective of utilities unit is: 

To provide desired quantity and quality of certain utilities to the ammonia and urea units for smooth functioning. These utilities include electricity, cooling water, instrument air, fuel gas and steam network.

Water, air and natural gas are the basic utility raw materials, which are processed and improved in order to meet the plants’ criterion of quality and ensure a longer life and safety of equipment.

Table 1 - Plant Utilities Division


Utilities unit is a pre-requisite for other units because their smooth running depends upon the utilities supplied by it. In case of utility failure plant has to face an emergency shutdown. Major sub-divisions of utility section are: 

Water Treatment (Area: 09) The core purpose of the installation is to produce two main types of water:  Make-up water for the cooling tower  De-mineralized water for boiler feed



Cooling Tower System (Area: 08) The core purpose of Cooling Tower System is to:  Cool the hot water coming from exchangers installed at different location of plant site through evaporation in induced draft cross flow cooling tower cells.



Waste Water Disposal (Area: 16) The section ensures that the effluent disposal from plant is within safety limits and regulations set by EPA or NEQS. Waste water is disposed to two places:  Masuwah Canal; when parameters are in permissible range  Evaporation ponds; when parameter are out from the set values



Instrument Air Compression (Area: 10) The function of this section is to:  Provide compressed air for instrument and utilities to all units of ammonia and urea plant. Instrument air make possible the functioning of pneumatic valves installed over multiple locations on plant. The area is of extreme importance because in case of its failure, plant might lead to shut down.



Natural Gas Station (Area: 15) The purpose of natural gas station is to supply natural gas after filtration to meet the demands:  Process gas  Fuel gas  Township supply



Power Generation (Area: 07) Electric Power is generated through turbo generators (TG), which are the turbine driven for the production of electricity. There are the major source of electricity for all the plant having a capacity of 16 Mega Watts (2 generators each has capacity 8 Mega Watts). An emergency stand by diesel generators (EDG) having a capacity of 1.5 Megawatts, is also installed.




Auxiliary Boilers (Area: 06) Boilers are designed to produce steam as dry as possible at high temperature and pressure. Steam is necessary for every plant which is used to move turbines. These turbines are used to generate electricity, to compress the air in compressors, in cracking of natural gas and in some heating processes. Boilers installed in area have a capacity of 110 ton/hr.

7.1.2 Ammonia Unit The core purpose of ammonia unit is to provide the raw materials for urea unit. They are:  

Liquid ammonia at – 4 °C Carbon dioxide gas (by-product)

Figure 1 - Ammonia Storage Spheres

For producing these urea raw materials, unit needs a mixture of hydrogen and nitrogen gas in ration 3:1. A limited degree of inert gases like argon and methane are also present. Source for hydrogen are generally hydrocarbons in the form of natural gas. The source for nitrogen is atmospheric air, both cheap and abundantly available. The following processes take place in different sections of unit: 

Desulfurization section (Area: 02) Its function is to removes sulfur content of natural gas



Reforming section (Area: 02) o Primary reformer; cracks natural gas to give hydrogen o Secondary reformer; eliminates oxygen from air leaving nitrogen



Gas purification section (Area: 03) o Shift Conversion; converts carbon monoxide to carbon dioxide o Carbon dioxide Removal; separates carbon dioxide by absorption in Benfield sol. o Methanation; convert residual carbon dioxide to methane convert o Ammonia synthesis section; hydrogen and nitrogen reacts to give ammonia o Cooling and Storage; product is compressed, cooled and stored


7.1.3 Urea Unit The unit manages the urea production from raw materials:  

Ammonia (liquid) Carbon dioxide (gas)

These raw materials are provided by the ammonia unit, are reacted to form ammonium carbamate, which dehydrates to give urea. Urea synthesis is divided into following sections: 







High pressure section o Urea synthesis o Stripping o Carbamate recovery Medium pressure/Low pressure section o Ammonia recovery o Carbon dioxide recovery Vacuum section o Urea concentration o Prilling Waste water treatment section

Optimum temperature conditions and retention time in process are extremely important because high temperature and more residence time causes:      

High biuret content More energy input More water circulation Overloading of vacuum condensers and ejectors Pressure increase in system Reduced efficiency

Figure 2 - Urea Synthesis Loop


7.1.4 Bagging and Shipment Unit Urea from urea plant is transferred to bagging unit through belt conveyers. There are three areas in unit:   

Area 12 ( storage + fresh feed belts) Area 13 ( cleaning system or screening and recycling) Area 14 ( dispatching area , packing , stitching)

Urea is fed to hoppers in area 12; there are two main kinds of hopper:  

Hopper for fresh feed Hopper for both fresh and recycle feed

Hopper feed urea to feeders for being transferred to the belts. Bags used for packing are woven poly-propylene bags. Inside covering of bag is made of nylon to prevent incoming and outgoing of moisture. In order to remove dust there is a suction air system of cleaning. In air cleaning system SOVs operate and separate air from dust by pressure Certain securities concerned in urea transferring include:    

Misalignment switches Pull card Speed monitors Thermal overload

Figure 3 - A filled & Stitched Urea Bag

Usually every belt has different capacity and speed. Fresh feed belts are having above 90 ton capacity.


8 Maintenance Department 8.1

Introduction to Maintenance

Maintenance is to preserve and improve the initial efficiency of the plant, facilities and buildings. Maintenance is not only to repair and rectify the defective or damaged parts of the plant but is also to prevent the occurrence of break down by taking measures to keep the equipment in normal operating condition. Maintenance can be consider under three aspects: 1. Technical 2. Administrative 3. Productive

8.1.1 Technical Aspect Refers only to maintenance needs as shown in the Figure no.3 8.1.1.1 Conservative maintenance results in repairing or preventing faults.  Accidental: Accidental maintenance is done after occurrence of break down in order to repair and restore the initial plant efficiency.  Programmed: This type of maintenance is done according to a defined program. o Cyclic: Cyclic maintenance is done at fixed interval, determined by the fault frequency. o Shutdown: It is the gathering of cyclic, inspective and accidental maintenance in a time dated period of plant shutdown. o Advisable: This type of maintenance is determined by an economic evaluation of the decreased efficiency. It is done during shutdown.  Inspective: This type can be further subdivided into two. o Inspection during shutdown: Different inspection techniques are used according to equipment being monitored. o Inspection during running: Systematic inspection programs such as vibrational control, noise level control, efficiency control, lubrication control etc. 8.1.1.2 Improving maintenance decreases the fault frequency and results in increase of plant efficiency.


8.1.2 Administrative Aspect Administrative aspect includes: 1. Ordinary Maintenance This type of maintenance debits its cost on the production. 2. Extraordinary Maintenance This type of maintenance cost can be considered as if new investments. It can be improving maintenance.

8.1.3 Productive Aspect Productive aspect includes maintenance intervention as follow: 1. Normal Maintenance work is carried out by the area technician or area head as previously arranged etc. 2. Emergency Maintenance intervention if:  There are safety reasons towards persons and plants.  The contribution margin is positive.  There is production loss with no recovery chance.

Figure 4 - Technical Aspects of Maintenance


8.2

FFC Maintenance Organization

8.2.1 Introduction Mission Statement “Maintenance Department is committed to improve service and capacity factor of the plant by grooming a well-trained and self-motivated team with proactive and innovative approach to provide quality and economical services to its customers” FFC has full range of maintenance services focusing on preventive maintenance and problem analysis and with aim to extend life of Plant while minimizing cost and downtime. Reliability Centered Maintenance (RCM) Approach is being followed at the company which includes:   

Preventive Maintenance: Periodic maintenance (as per OEM guidelines) Predictive Maintenance: Condition monitoring / Field data analysis Corrective Maintenance: On-line and shutdown maintenance

FFC Maintenance department consist of the following: 1. Mechanical Maintenance Mechanical maintenance consists of: 1.1 Field Maintenance This section is responsible for the field activities in urea plant, bagging and shipping, ammonia plant and utilities plant. In every unit a team of skilled technicians is assigned under control of area engineer. Mechanical works during the evenings and nights are taken care by mechanical shift staff. 1.2 Rotary Machinery and Machine Shop All the major rotary machinery works and machining works are done in the maintenance workshop. 1.3 Fabrication Shop and Motor Pool The piping and structural fabrication works together with maintenance of company transport and facilities such as cranes, dumpers, trucks, for lifters etc. 2. Electrical/Instrumentation Maintenance It is responsible for the maintenance of all the electrical and instrument present on the plant site. 3. Civil works It is a small group to take care of minor and routine civil jobs in plant. The major works are normally done through contractors. 4. Planning & Scheduling Planning & scheduling section plans the work for shutdown, coordinates the maintenance work request flow and deals with the contractors and external agencies.


Figure 5 - Maintenance Department Hierarchy

8.2.2 MWR (Maintenance Work Request) Procedure Maintenance Work Request (MWR) procedure is followed in order to acquire services of Maintenance department. 8.2.2.1 Procedure For acquiring services of maintenance department, a MWR is raised by the requesting section with relevant details on forms detailed below and sent to concerned section:


 

Preprinted / number MWR, provided by P & S System generated / number MWR through software

8.2.2.2 Work Priority Work may be prioriticed into one of the following categories: 1. Emergency: These jobs are related to those breakdowns that already have jeopardized the conditions production and/or safety of personnel/equipment. 2. Urgent: These are related to breakdowns that can lead to jeopardy of production condition or safety of personnel/equipment. 3. Safety: These are not related to production but lead to the condition that may result in a safety hazard for personnel/equipment. 4. Routine High: These are related to such routine maintenance job, that if deferred due to other priority jobs, may not incur any production loss. 5. Routine Low: These are related to such jobs that if deferred due to some reason would not cause any production loss.


8.2.3 Equipment Maintenance Section Equipment Maintenance Section is sub divided into three sub-sections. These are:

 Equipment Maintenance Urea,  Equipment Maintenance Ammonia, and  Equipment Maintenance Utilities 8.2.3.1 Description Equipment maintenance is responsible for carrying out maintenance, repair, modification and installation of all stationary equipment. Maintenance work on stationary equipment is done in accordance with Snamprogetti specifications and standards. 8.2.3.2 Objective Equipment maintenance is mainly responsible for performing: 1. 2. 3. 4.

Equipment related routine maintenance Planned/Emergency shutdown jobs Annual turnaround jobs Plant modification jobs

1. Equipment related Routine Maintenance: Equipment maintenance carries out all routine maintenance jobs against MWR received from production unit or from other section. 2. Planned/Emergency Shutdown jobs: Equipment maintenance receive job list from production unit through planning and scheduling unit. 3. Annual Turnaround jobs: Equipment maintenance receive annual turnaround job list from planning and scheduling unit. 4. Plant Modification jobs: Plant modifications are carried out against approved drawings. 8.2.3.3 Stationary Equipment There are numerous stationary equipments installed on the plant site whose repair/maintenance is done by Equipment Maintenance section. Among them, few are listed below: Steam Trap

Heat Exchanger

Valves

Boilers

Piping Network

Pressure Vessel


8.2.3.4 Jobs followed/viewed on field Following jobs were viewed / followed by the author during his stay at Equipment Maintenance. 





Area: Urea 1. Cleaning of ME-119 A/B/C filters (Cold Permit Job) 2. Cleaning, filling and painting of P/T wall (Cold Permit Job) 3. Provide hot insulation at P-109 A/B steam tracing lines (Hot Permit Job) Area: Ammonia 1. Provide cold insulation on chiller lines of admin building (Cold Permit Job) Area: Utilities 1. Cooling water flow increment at 2 cell cooling tower (Project) (for isometric drawing see: Appendix IV)

8.2.3.5 Procedure

Figure 6 - ME-119 A/B/C filters at 01 Area

Figure 7 - Hot Insulation at P-109 Steam Tracing Lines

Hot Insulation:      

Used the correct thickness of Rockwell for hot insulation depending upon the size of piping and temperature of fluid being handled. For selecting Rockwell thickness, insulation table was used. Applied the specified thickness of Rockwell around the pipe firmly. Used annealed galvanized iron wire for binding of Rockwell. Covered full length of pipe required to be insulated with Rockwell. Fabricated metal jacketing for aluminum sheet. Rolled the metal jacketing as per diameter of pipe. Installed prefabricated aluminum pieces on to the Rockwell. Used stainless steel self-tapping screws for fastening of jacketing sheet. Joints of aluminum jacketing were placed

Cold Insulation:    

Thickness for cold insulation for piping was determined on the basis of temperature and diameter of pipe. Polyurethane half sections were applied in multiple layers. Applied two layers of vapor barrier mastic with filorer glass fabric Figure 8 - Cold Insulation on Chiller Lines in between the layers. Applied 15-20mm thickness fiber glass blanket and compressed it to 10mm. Finally aluminum sheet was applied as explained above.


Note: 1. Author theoretically studied many other processes during his stay at Equipment Maintenance. These include:  Box up procedure (leakage repair technique)  Exchanger cleaning-HP Jetting  Exchanger repair  Scaffold Erection  Coating & Wrapping  Maintenance of level glasses 2. Author studied numerous books during his stay at Equipment Maintenance. These include:  Heat Exchanger (API Series)  Cooling Tower (API Series)  Valves (API Series)  Furnance (API Series)  Pipe & Pipe fittings (DuPont Series)  Steam Traps (DuPont Series)  Area General Course Mechanical Volume 1 & 2 (TTC-FFC)


8.2.4 Machinery Maintenance Section

8.2.4.1 Introduction Machinery Maintenance is responsible for carrying out maintenance, repair, modification and installation of all rotating machines (compressor, turbine, pump etc.), their accessories and other miscellaneous equipment inrelation to these machines of plant respectively. Maintenance is carried out timely and effectively to sustain efficient and continuous running of production process. The Machinery Maintenance Section is divided in to following four sub-sections. 1. 2. 3. 4.

Machinery Maintenance Urea Machinery Maintenance Ammonia Machinery Maintenance Utilities, and Machinery Maintenance Bagging & Shipping

8.2.4.2 Function Machinery Maintenance does three basic types of maintenance. These are preventive maintenance, predictive maintenance and corrective maintenance. Preventive Maintenance    

Maintenance during normal running condition Maintenance during Turnaround Maintenance during Shutdown Periodic maintenance

Predictive Maintenance Predictive maintenance is carried out for the machines, which must be operated at the lowest achievable downtime because of the criticality of function or cost of production downtime. Corrective Maintenance Corrective maintenance is done when any equipment totally shutdown which results in production loss or danger to personnel safety. 8.2.4.3 Rotary Machines There are many rotary machines whose repair/maintenance is done by machinery section. Among them few most common are listed below: Pump

Compressor

Turbine

Motor


8.2.4.4 Jobs followed/viewed on field 

Utilities 1. Repair and installation of plunger gland packing of DP-1300 Pump. 2. Repair/maintenance and installation of MP-921B Pump.



Bagging & Shipping 1. Welding of hinges of Bulk store’s door.



Urea 1. Repair/maintenance and installation of P-104B pump.



Ammonia 1. Motor installation at MP-308 pump

Figure 9 - Plunger Gland Packing of DP-1300

Figure 10 - MP-921B Pump


8.2.5 Fabrication Shop 8.2.3.1 Description The functions performed by the Fabrication Shop are:      

Equipment manufacturing, pipe fabrication for large and small projects and reclamation jobs Storage and maintenance of special tools/equipment. Insulation shop maintenance Salvage yard maintenance Scaffolding material issue, receipt and ,maintenance In-house manufacturing of warehouse coded items

8.2.3.2 Work Space Workspace in Fabrication Shop is broadly divided into following areas:      

Valve repair area Stainless steel work area Welding area Exchanger/Vessel fabrication area Store room General purpose area

Figure 11 - Pressure Testing of a Globe Valve

8.2.3.3 Machines There are many machines in Fabrication Shop. Some are as follow: 01: Hot tapping machine 03: Tube expansion machine 05: Low speed potable machine (lathe) 07: PE welding machine 08: Beveling and facing machine 09: Sand blasting machine 11: Potable petrol welding generator

02: Potable pneumatic tube cleaner 04: HP jetting machine 06: Hydraulic machine 08: Hydraulic test pump 09: Plasma cutting machine 10: Disc cutting machine 12: Magnetic base drilling machine

8.2.3.4 Jobs followed/viewed on field   

Hydraulic pressure testing of a globe valve. ME-103 Grid fabrication. Practically performed GTAW and SMAW.

Figure 12 - GTAW


8.2.6 Machine Shop

Machine Shop

Tool Room

Machine Floor

Vehicle shop

Jobs performed in Machine Shop are broadly divided into six categories: 1. Service Factor / Reliability Improvement 2. Training / Motivation Enhancement 3. Quality Improvement

4. Safety / Housekeeping Improvement 5. Cost saving projects 6. Facilities Improvement

8.2.4.1 Tool Room Objective: Tool room objective is to meet the tool demand of the Maintenance Department in an efficient way. Responsibilities:        

Tool Replenishment Adding of new tools Tools receipts and documentation Tool maintenance Permanent / Temporary issuance of tools Internal audit of tools Load test of rigging tools Scraping of tools

Tools can be divided into three types: Permanent Issued Tools: These are tools which are of daily use and they are issued to permanent employees. They return these tools once they leave the company.

Figure 13 - Tool Room at FFC

Temporary Issued Tools: These are tools which are issued to non-permanent employees and they have to return them once a certain job is finished.


Consumables: These are things which are only for one time use e.g. tape, chalk etc. TOOLS HAND TOOLS Spanners, Striking Spanners, Adjustable Spanners, Hammers, Sockets, Allen Keys, Screw Drivers, Wrenches, Pliers, Pullers, Punches, Misc.

1

2

MEASURING TOOLS Micrometer Bore, Dial, Level measuring devices, Vernier, O/D devices, Divider, Gauges, and Misc.

3

CUTTING TOOLS Drills, Drill, Taps, Die, Files, Reamers, Diamond, Round, Misc.

4

PNEUMATIC TOOLS Drill Machine, Angle Grinders, Pencil Grinder, Electric Impact Wrench, Dewatering Pump, Misc.,

5

ELECTRICAL TOOLS Drill machine, Angle grinder, Pencil grinder, Impact wrench, Dewatering pump, Misc.

6

FABRICATION TOOLS Gas Cutting, Blow Pipe, Heating, Gas Welding, Regulator, Argon Tig, Misc.

7

RIGGING TOOLS Eye, Shackles, Wire Rope Slings Dia, Sling Belt, Rope, Pulley Block, Chain Blocks, Wire Jacks, Comealongs, Rope Ladders, Misc.

8

HYDRAULIC TOOLS Hydraulic, Hydraulic, Hydraulic Puller, Misc.

9

MISCELLANEOUS TOOLS Face, Safety, Gas, Dangri, Water, Ply Wood Table 2 - Tools Division in Tool Room

Internal Audit Internal Audit of Tool room is done once in a year. In view of large movement of tools, following variations are considered acceptable at any particular instance.  

Tools inventory variance up to 0.5% Displaced Tools/Tokens of up to 20 nos.

Load Test Annually load test of Chain blocks, Wire jack, Come along, Web belts, Slings, Manila, Nylon rope, Rope ladder is done. Test load is around 1.2 times capacity load.


8.2.4.2 Machine floor Machine floor provides services in order to run Maintenance Department efficiently. Through a formal documented system of planned activities, the machine floor operates on two shift basis, to carry out following functions:    

Routine maintenance and repair activities Shop fabricated spare items Local fabricated spare items Services to other companies/agencies

Following are the machines present on the machine floor:

1. Lapping machine  Diamond liquid 14 micron  Diamond liquid 03 micron 2. Surface grinder 3. Boring machine 4. Balancing machine  3 ton capacity machine  70 kg capacity machine 5. Milling machine 6. Slotting machine 7. Pedestal grinder 8. Sharper machine 9. Tool and cutter grinder 10. Power saw (quantity= 2)

MACHINES 11. Radial drill (quantity=2)

12. Hydraulic press 13. Cylindrical grinder 14. Lathe machines  Lathe machine (1000*5000)  Lathe machine (400*1500)  Lathe machine (400*1060) (quantity=2)  Lathe machine (580*3960) (quantity=2)  Lathe machine (600*2000)  Lathe machine (500*1300)  Lathe machine (600*2000)

Table 3 - Machines present at Machine Floor

8.2.4.3 Vehicle Shop Objective: The Vehicle Shop performs different functions and provides services to various units/sections. Functions: Vehicle Shop provides following functions:     

Provides services of vehicle / equipment to various units/sections. Operation and maintenance of heavy / light mobile equipment. Services to other companies/agencies. Conduct load test of lifting equipment. Maintenance of engines used as diesel generator prime movers, overhead cranes and winches that are installed in various areas.


LIST OF MOBILE EQUIPMENT IN VEHICLE SHOP S.# EQUIPMENT S.# EQUIPMENT 1 P&H CRANE 43943 19 TOYOTA PICK UP (G-1127) 2 P&H CRANE 43944 20 TOYOTA PICK UP (G-1241) 3 LOCATELLI CRANE 21 TOYOTA PICK UP (G-1351) 4 TADANO CRANE 22 TOYOTA PICK UP(G-1396) 5 JCB FORK LIFTER 23 TOYOTA PICK UP(G-1242) 6 NISSAN 05 TON FORK LIFT 24 JEEP P&S (E-0950) 7 NISSAN 03 TON FORK LIFT 25 MASSEY TRACTOR T-0083 8 NISSAN 03 TON FORK LIFT 26 FIAT TRACTOR RNH-5213 (Warehouse) 9 HINO HIAB TRUCK AE-0484 27 MASSEY TRACTOR (Small) 10 HINO HIAB TRUCK AE-0819 28 FERMONT GENERATOR 11 FIAT TRUCK JU-4341 29 SMJ GENERATOR (V.SHOP) 12 ATLAS CAPCO COMRESSOR 286 30 SMJ GENERATOR (SONA HOSPITAL) 13 ATLAS CAPCO COMRESSOR 336 31 UNILOCK LOCOMOTIVE 14 KOMATSU BACK HOE 32 VOLVO PAYLOADER 15 JCB BACK HOE 33 CASE PAYLOADER 16 HINO FIRE TRUCK 17 DENNIS FIRE TRUCK 18 ZIEGLER FIRE TRUCK Table 4 - Mobile Equipment in Vehicle Shop

Other than mobile equipment, vehicle shop possesses Low bed trailer, Dump trolley, Long bed trailer, Tractor trolley and Scissor lift. Furthermore there are number of winches, overhead cranes and monorail/cantilever cranes installed in different areas on the plant site. Their repair / maintenance are also seen by Vehicle Shop. 8.2.4.4 Job viewed/followed on field 1. Machining of P-120 AB TOP SHAFT (for isometric drawing see: Appendix IV) on Lathe machine. (Machine floor) 2. Balancing of hydraulic pressure of Low Bed Trailer. (Vehicle Shop)

Figure 14 - Lawn in front of Vehicle Shop


8.2.7 Planning & Scheduling

Planning & Scheduling

Contract Section

Budgeting Section

T/A Planning

8.2.7.1 Function Following are the main functions of P&S:   

To provide contracted out services to all sections/units located at plant site Planning of turnaround/shutdown with reference to manpower, contracted out jobs, and monitoring of overall activities Consolidate annual expense and capital budget prepared by Mechanical Maintenance and E&I Department

8.2.7.2 Contract Section Contract section at P&S has many functions. These are:    

Dealing with outside government agencies on behalf of FFC. These include Labour Directorate, Social Security Institute, EOBI (Employee Old age Benefit Institute) etc. Issuance of gate passes to casual man power Performance evaluation of different contractors working at plant site Dealing with PR (Purchase Requisition), RFQ (Request For Quotation) and JO (Job Order) in order to avail services from outside agencies.

8.2.7.3 Budgeting Section Budgeting section at P&S has following functions:  

Making of annual budget of Mechanical Maintenance and E&I Maintenance. Monitoring the expenditure v/s allocated budget throughout the year.


 

Categorizing the expenditures in terms of CAPEX (Capital Expenditure) or OPEX (Operational Expenditure). Developing PMP (Preventive Maintenance Plan) by taking inputs from end users.

8.2.7.4 T/A Planning Section T/A Planning section at P&S has following functions:    

Give T/A Planning a project shape by planning manpower and resources in the most efficient way after communicating with area engineers. Follow up the tasks during turnaround/shutdown. Issue “Turnaround Critique” once the turnaround is completed. Provide services to outside agencies/companies.

Figure 15 - Procedure for Provision of Crane to the Contractors


9 Technical Services Department 9.1

Inspection Unit

The following section describes the working of Inspection Unit.

9.1.1 Function Inspection Unit is focused upon reliable and efficient plant operations, ensuring quality control. It covers all planned and emergency non-destructive testing (NDT), destructive testing, condition monitoring, heat treatment services for on-steam and off-steam equipment/machinery to ensure safe plant operations and equipment health. It applies to all activities being carried out in inspection unit.

9.1.2 Job Type Inspection Unit usually deals with three types of jobs. These are Daily routine jobs, Yearly planned jobs, Shutdown/Turnaround jobs.

9.1.3 Technical Task Following are the main technical tasks which Inspection Unit does:                   

Radiography/X-Ray Local heat treatment of weld joint and cold work Material analysis for chemical and mechanical properties Magnetic particle testing Boilers and W.H.R.E inspection Exchanger and condenser inspection Tank inspection Incoming material inspection Pressure vessel inspection Ultrasonic testing Inspection of pressure safety valves Dye penetrant test Thickness monitoring Coating/wrapping inspection of buried piping system by holiday detector Cathodic protection system at main plant and main gas line Paining inspection Vibration monitoring of stationary and rotating equipment Non-destructive and destructive testing Crane testing


 

Overhead crane/winch inspection Hydrostatic test

9.1.4 Job followed/viewed on field 1. 2. 3. 4. 5.

Viewed RT (Radiography Testing) results of E-208 welds PWHT (Post Weld Heat Treatment) of E-208 welds Thickness measurement of chlorine cylinder #22 &25 Vibration monitoring of MP-923B DPT (Dye Penetrant Test) on welds of newly fabricated pipeline

Viewed RT (Radiographic Testing) results of E-208 welds Once RT was done, the films were developed. First of all films were immersed in developer, and then they were washed with water and after that fixer was applied on them. It took approx. 2-2.5 min. Films were then left to dry. Material of the film was silver bromide. Films were seen closely by the author in the dark room against the white light and following defects were observed: 01: LOP (Lack of Penetration)

02: Gas pour (air drop)

03: Tungsten inclusion

04: Porosity

PWHT (Post Weld Heat Treatment) of E-208 welds      



Ensured grinding of tack welds or spatters mark from the job to be heat-treated. Tied the thermocouple on the weld joint. Wrapped heaters of appropriate size and type on the weld joint. Insulated the heaters and some additional length on the either side of the heaters. Performed heating of the weld joint, held temperature and cooled according to welding procedure. Turned off the heat treatment machine at temperature mentioned in the welding procedure and onward cooling performed under insulation. Unwrapped the heaters and removed the thermocouples.

Figure 16 - E-208 Boiler

Thickness measurement of chlorine cylinder #22 &25   

Thickness was measured by using 37DL Plus ultrasonic thickness gauge. Through visual inspection, thickness at 10 spots on each cylinder was measured. First of all, the selected spot was cleaned and then a high viscous fluid was applied. After that thickness was measured through instrument.




Observations: o Cylinder#22: Designed thickness= 11.3mm, Expiry thickness= 8.6mm, Observed thickness= 10.2mm o Cylinder#25: Designed thickness= 11.3mm, Expiry thickness= 8.6mm, Observed thickness= 10.6mm o Painting on both cylinders was damaged o Corrosion on both cylinders started

Figure 17 –Chlorine Cylinder #22

Figure 18 - Chlorine Cylinder #25

Vibration Monitoring of MP-923B    

Vibrations of the pump was measured with the instrument called CS1-2130 Probe of the instrument was placed at selected point on the pumps in vertical, horizontal and diagonal directions and readings were recorded. These readings were then stored in Master tend software. Software automatically generated various graphs using current and previously stored readings which depicted pump behavior.

DPT (Dye Penetrant Test) on welds of newly fabricated pipeline     

Cleaned the weld area before dye penetrant test. Applied penetrant by spraying. Left penetrant on the surface for 5 min. Removed penetrant from the surface using penetrant remover solvent. Applied developer and examined the weld area through naked eye.

Figure 19 - Penetrant applied on a weld


10 Safety Section FFC believes in “safety first”. FFC Management is committed to cause of safety and believes that it is everyone's responsibly. The objective is to improve the working culture through effective safety program. Zero lost work days are the target. Details are enclosed in Appendix II (FFC MM Plant Safety Policy) and Appendix III (FFC Plant Safety Rules and Regulation). Recognition for safe work is arranged in collaboration with NSC, USA. Till July 2010, 8.3 million safe hour operations have been carried out, i.e. no Lost Time Accident (LTA) has taken place since last 8.3 million hours. FFC MM has also received IMS 2009 certification for safe working other than ISO 9001, ISO 14001 and ISO 18001.

10.1 Activities FFC Safety section works in both planning and execution phases to implement safe work conditions at plant, with improved working standards and safety. This includes multi-dimensional efforts team. Key activities of unit are as follows: Managing Safety Program Main object is to plan, organize, budget, and track execution of activities to achieve safety objectives of our plant laid down in FFC MM Safety Policy (Appendix II). Through prudent planning and effective resource management safety section cater for all the needs of personal and process safety. Motivation Safety section is committed to achieve excellence in the field of safety. All projects related to safety are given top priority and good safety and housekeeping standards are appreciated through token rewards. This include slogan of the year, best housekeeping award, safe man of the year award and safe men hours’ award. Hazard Recognition It ensures the identification of conditions or actions that may cause injury, illness or property damage, is a routine activity carried out at all levels in plant areas. Plant safety committees are formed all hazards of the plant are highlighted and engineering solution are evolved. Safety section also carries out routine audits of the plant and points out hazards to concerned units. Inspection /Audits Appraise of safety and health risk is associated with equipment, materials, processes and facilities. It is monitored through routine audits.


Fire Protection It reduces fire hazards by inspections of facilities and processes. It arranges all type of fire extinguishers as per need and facilities requirement. It also oversees the design and operational fire safety of the complex and suggests and coordinates requirement-based developments. Regulatory Compliance It ensures that mandatory plant rules and regulations (Appendix II) and International Safety standards are satisfied. Health Hazard Control It conducts audit and control hazards such as noise, chemical or radiation exposure. Hazardous Material Management It creates awareness that dangerous chemicals and other products are procured, stored and disposed of in ways that prevent exposure or fire. Display of MSDS in areas to increase consciousness, are ensured. Training Safety Section provides management and employees with the information and skills necessary to recognize hazards and perform their job effectively and safely. All safety inspectors are trained as fire fighters and work permit procedure auditors. Section also maintains training record of all manpower. Accident and Incident Investigation It determines the facts related to an accident or incident based on witness interviews, site inspection and collection of other evidences. The focus of this activity is to stop reoccurrence. Record Keeping All data related to accidents/ incidents is recorded and maintained. Safety section reports it to government and NSC if required. It also maintains safe man-hours data of the company and reports it to NSC. Evaluating It evaluates the effectiveness of our program through various indices like accident/ incident rate, use of personal protective equipment, quality of job safety. It also considers reporting of near miss as an effective system to avoid occurrence of a real risk.

10.2 Safety Training FFC ensures safe work environment by providing safety training to all personnel on plant. As per the company policy all news personnel on plant receive safety training prior taking charge of their responsibilities. Safety


training was provided to the group comprised of author and two other internee engineers by Safety SubEngineer on June 11, 20103 at Safety Section, FFC MM. Training introduced with the plant safety policy and rules and regulations, while functioning of safety section was also briefed.

Table 5 - Safety description as set by Safety Section

The training comprised of:    

Importance of Safety at Plant Use of Personal Protective Equipment Use of Fire Extinguishers Ammonia Disaster

10.2.1 Importance of Safety at Plant FFC produces about 60 % of market’s urea production. Not preparing for plant safety may not only result in decrease of company production and sale but also in shortage of fertilizer in market. This may affect the country’s agriculture growth and thus shortage of food for public followed by price hiking. The plant produces ammonia as the raw material for urea production. Ammonia as a hazardous gas always has a probability of release in case of leakage or disoperation. This may result in ammonia disaster leading to a catastrophe if not avoided or duly responded. Safety is therefore an important consideration prior to working on plant. Figure 20 - Emergency Siren Sequence

10.2.2 Use of Personal Protective Equipment The Personal Protective Equipment provided to internees included safety shoes, hard hat, half face mask and safety glasses. The training gave an idea to author of when and how to use the equipment especially half face mask, which aids in breathing where air is slightly rich in ammonia or any other hazardous gas or during ammonia disaster. Escape mask provides safety in situations where concentration of ammonia in air is 50 ppm to 60 ppm.


Figure 21 - Internee Personal Protective Equipment (PEE)

10.2.3 Use of Fire Extinguishers

Table 6 - Strategy in Fire Incident

Fire is the most common form of disaster for any industry but could be dealt, if well prepared. Fire erupts due to unsafe work, and could be avoided if well planned and followed. In order to avoid any unpleasant accident, personnel are trained for firefighting. Internees were told taught to use the fire extinguishers for self-safety. Strategies in fire incidents and emergency response have been both notified and published by Safety Section.


Figure 22 - Emergency Response

Using fire extinguisher was introduced synonymously with an acronym PASS; pull, aim, squeeze and sweep side by side.

Figure 23 - PASS Approach for Using Fire Extinguisher

Controlling fire can be dangerous; therefore it was advised by the trainer: 1. Assist any person in immediate danger to safety, if it can be accomplished without risk to you. 2. Call 3222 Safety Section or 3234 Shift coordinator and activate the building fire alarm. The fire alarm will notify the fire department and other building occupants and shut off the air handling system to prevent the spread of smoke. Before using a fire extinguisher, it was suggested to know what is burning. Else, using the extinguisher would not be a wise decision as it could result in a bigger problem. Even if an ABC fire extinguisher is available, there is always a possibility that fire may explode or produce toxic fumes. Fire extinguishers are used to control fire in initial stages (OSU, 2005). If fire is continuously increasing from the source point, it is wise to immediately evacuate the building.


10.2.4 Ammonia Disaster Leakage or unwanted release of ammonia from plant has been termed as Ammonia Disaster. Ammonia being a hazardous gas chokes respiration process resulting in death. Therefore, for safe escape, plant personnel and township residents are trained for plan of action in case of ammonia disaster. All offices, buildings and homes are constructed with an ammonia shelter, in case of emergency. Shelter has no windows and only single door which can be sealed in case of ammonia release. Personnel and families can remain save in shelter until safety announcement is made.

Table 7 - Effect of Ammonia at different Concentration in Air

For personnel outside building or on pathways, it is suggested to take protection is ammonia shelter made outside the buildings. Standing below water shower would also be safe as ammonia gets readily dissolved in water, reducing its intensity of attack. Using a moist cloth for breathing in case no mask is available is highly recommended to avoid choking. On hearing the ammonia disaster siren, listener should see the wind direction through prilling tower emissions or air direction sock and move crossway from wind direction.


11 Conclusion The six week internship at FFC MM Plant site developed an understanding about the maintenance techniques and procedures that are used to run the plant efficiently at all times. Experience and exposure was not only limited to mechanical maintenance but was widened to urea fertilizer production processes, working of safety unit, day to day operations of materials unit, IMS philosophy and routine problem handling and troubleshooting. The plant division and design, management and operation enhanced the concept and perspective about safe and smooth process. Literature review from TTC library, study of isometric drawings and manuals of different plant areas and equipment, discussion with engineers and technical staff, weekly quality talks and safety talks and visit to plant site added a sound potion of knowledge. The cooperative coordination of management and staff raised the morale in the journey of lifelong learning.


12 Citations and Bibliography Pak Saudi Fertilizer Limited Mirpur Mathelo: Basic Training Manual (1979) API Series Washington, USA: Heat Exchanger, Cooling Tower, Valves, Furnance, Compressor, Pumps. DuPont Series Wilmington, USA: Pipe and Pipe fittings, Valves FFC Safety Section (2004) Mirpur Mathelo: Emergency Response Information FFC Safety Section (2013, June 11) Mirpur Mathelo. Safety Orientation Training National Safety Council (1988) Chicago: Fundamentals of Industrial Hygiene NSC (1988), Chicago, USA: Accident Prevention Manual for Industrial Operations - Administration and Programs (9th Edition) Occupational Safety and Health Administration (1999) Washington, U.S: Occupational Safety and Health Standards, Air Contaminants, 29 CFR 1910.1000, and Hazard Communication, 29 CFR 1910, 1200 Occupational Safety and Health Administration, Washington, U.S. (1999): Occupational Safety and Health Standards, Respiratory Protection OSU. (2005) Ohama State University, USA: Fire Extinguisher Training TTC-FFC MM: Area General Course Mechanical Volume 1 & 2 FFC Safety Section, Mirpur Mathelo: Safety Talk Book Volume 1&2 TTC-FFC MM: Snamprogetti Piping Manual TEMA, New York, USA: Standards of the Tubular Exchanger Manufactures Association (8th Edition)


Appendix I FFC MM Site Map

Figure 24 - FFC MM Site Map Area Number Area No. 1 Area No. 2 Area No. 3 Area No. 4 Area No. 5 Area No. 6 Area No. 7 Area No. 8 Area No. 9 Area No. 10 Area No. 11 Area No. 12 Area No. 13 Area No. 14 Area No. 15 Area No. 16 Area No. 17

Unit Urea Ammonia Ammonia Ammonia Ammonia Utilities Utilities Utilities Utilities Utilities B&S B&S B&S B & Storage Utilities Utilities Utilities

Area Urea Section Synthesis Gas Preparation Carbon dioxide removal Compression Section Ammonia Synthesis & Refrigeration Turbo Generator Boiler Cooling Tower Pre-treatment and treatment Instrument Air Urea Storage Urea storage and fresh feed belts Urea screening and recycling Urea packing and dispatch Natural Gas Waste Water Treatment Diesel Storage

Table 8 - FFC MM Plant Area Description


Appendix II FFC MM Plant Safety Policy (Policy is released from the office of GM)

FFC recognizes the significance of maintaining an injury free environment at plant and therefore must strive to avoid any injury to personnel and any damage to equipment etc. In order to achieve this, Management spells out (FFC Safety Section, 2004) the plant safety policy and expects all employees to comply. 1) The management shall always remain strongly committed to the cause of safety. 2) Safety shall be given at least the same importance as production. 3) Safety shall have a due consideration in performance appraisal of each employee. 4) Management believes that God willing most accidents can be prevented since most of them are caused by human errors and omission. 5) As and when an accident occurs, the investigation shall be carried out on high priority. 6) The company shall provide safety training and facilities to all employees, whereas working safely is the condition of employment. 7) Adequate personal protective shall be provided to employees against hazards at plant full compliance shall be demanded. 8) The Management shall formulate safety regulations / procedures while employees shall comply with these regulations and procedures. 9) The contractors shall also follow Company's safety discipline. 10) A good standard of housekeeping shall be maintained at the plant. 11) Off-The-Job safety shall be promoted among employees and their families. 12) Employees are expected to maintain pollution free environment and hygienic conditions throughout the plant.


Appendix III FFC MM Plant Safety Rules and Regulations All operating areas of the plant are hazardous, because of the fluids handled and the kind of operations involved. Therefore following rules & regulations (FFC Safety Section, 2004) are approved for compliance: 1) Smoking is not allowed in the operating areas except in the offices and smoking cabins (where provided) or designated areas. 2) It is forbidden. To carry out any repair/maintenance without a valid work permit 3) Wearing of safety shoes is mandatory in the plant. 4) Use of safety helmet, glasses & escape mask is mandatory in operating areas except where exempted. 5) Use special personal protective equipment where required. 6) Observe safety procedures/regulations as prescribed or advised for accomplishing all jobs at the plant. 7) All accidents, near misses and injuries on the job should be reported to immediate supervisor and safety section without loss of time. 8) It is forbidden to remove or modify safety locks and protection devices without authorization. 9) Visitors are not allowed to enter the operating areas unless approved by competent authority and guided. 10) Vehicle entry in operating areas is forbidden except under a valid permit. 11) Observe traffic rules. 12) All hazardous and unsafe conditions should be rectified by the areas themselves; safety section is an audit and advisory function.


Appendix IV Isometric Drawings

Figure 25 Isometric Drawing: Cooling water flow increment at 2 cell cooling tower

47

Figure 26 Isometric Drawing: P-120 AB Top Shaft

48


Figure 25 - Cooling water flow increment at 2 cell cooling tower


Figure 26 - P 120 A/B Top Shaft


Fauji Fertilizer Company (FFC), Mirpur Mathelo, 65040 District: Ghotki, Sindh, Pakistan

Internship Report- Fauji Fertilizer Company (FFC)

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