FFBL Internship 2009

INTEERNSHIP REPO
ORT 2009

FAU
UJI FER
RTILIZER
R BIN Q
QASIM L
LIMITED
D

Sum
mmer In
nternship
p Reportt
8th ju
une17th Jully
2009
Submitted to Tech
hnical Train
ning Centree
Fertilizer Bin Qasim
Fauji F m Limited
d
Subm
mitted by
y:
Muuhammad W
Wahab Udddin Nazaar
Qu wam University of E
uaideAw Engineeriing Science and Te
echnology
y

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INTERNSHIP REPORT 2009
Cover page

FAUJI FERTILIZER BIN QASIM LTD.
Summer Internship Report

Submitted By:
Wahab uddin Nazar
4th Year Electronics Engineering
Quaid‐E‐Awam University of sciences and Technology
Nawabshah
Submitted To:
The Technical Training Centre
FAUJI FERTILIZER BIN QASIM LIMITED
Date of Submission: July 15, 09
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ACKNOWLEDGEMENT

I am very thankful to Allah for the successful completion of my four week internship the FFBL which is
one of the largest and growing Fertilizer Complex in Pakistan .During my internship I have learnt about
the Fertilizer industry, and its environment. As my field is related to instrument I have learnt about PLC`s.
Distributed Control System, Emergency Shutdown System , various types of instrument and many more
which is helpful in my future practical life as a professional Engineer. I learnt about the FFBL as an
organization, job handling procedures, maintenance and repairing procedures, job environment in FFBL
especially including E & I Department.
I am thankful to ENGR Rao Jameel (Trainer Engineer) who guide us to understand the environment and
rules of the in FFBL , ENGR Ammanullah Khan , ENGR Iqbal , ENGR Amjad khan ,Amir Tunio in
Instrument section CCR who instruct and guide me in orientation of Urea Plant and provide me many
important material and information which helps me apply my knowledge and built own my Technical
skills ,ENGR Muhammad Aniq , ENGR Ali provide a healthy environment When I study about DAP plant.
The technician and other staff of Instrument Department greatly cooperated, guided and helped me to
lead to a successful training of four weeks.
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PREFACE

This report is based on the training at in different plants of FAUJI FERTILIZER BIN QASIM LTD providing
necessary knowledge for carrying out various kind of instruments maintenance and repair work .
The aim to write this report is to share a meaningful material and concepts about the field of
instrumentation and its application in industry.
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INDEX
SERIAL # CONTENT PAGE#
1 Title Page ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1
2 Cover Page‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2
3 Acknowledgement‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐3
4 Preface‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐4
5 Index‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐5
6 An introduction of Fauji fertilizer bin Qasim Limited‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐6
7 Safety‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐7
8 Complex Description‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐9
9 Instrumentational Safety‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐9
I0 Utilities & Power Generation‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐11
11 Ammonia Plant‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐14
12 Urea Plant‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐19
13 DAP Plant‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐25
14 Scope of Instrumentation in FFBL‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐27
15 Control Systems of FFBL‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 37
16 Mentorship of FFBL‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐45
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AN INTRODUCTION OF FAUJI FERTILIZER BIN QASIM LIMITED
FFBL is one of the largest granular Urea and Dap fertilizer complex in Pakistan, built at the cost of
US$469 Million in November 1993, located in Eastern Zone of Bin Qasim. The plant is approximately 45
km 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‐AMONIUM PHOSPHATE) .It is
the soul producer of Urea and Dap in the country and forms part of Fauji group, one of the largest
conglomerates of Pakistan. FFBL and FFC jointly holds 63% of Urea and 51% of DAP share of Pakistani
fertilizer market.
FFBL increases its product capacity which is higher than the designed parameters.
PRODUCTION DESIGN ONWARDS

Granular Urea 1670 MT/Day 1900 MT/Day
DAP 1350 MT/Day 2230 MT/Day
Ammonia 1270 MT/Day 1570 MT/Day

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.
FFBL is now close seeking Certification for following Quality Standards, which will continuously
improving the company`s operation.
ISO 90012000 (QAULITY MANAGEMENT SYSTEM)
ISO 14001 (ENVIRONMENT MANAGEMENT SYSTEM)
OHSAS (OCCUPATONAL HEALTH AND SAFETY ASSESSMENT SERIES)

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SAFTEY

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
9 Employs
9 Company assets
9 environmental
PERSONEL PROTECTIVE EQUIPMENTS:
Following Equipments are available for personal protection.
⊗ Safety helmets and shoes should be worn at plant site during working and any other activity.
⊗ Googols for protection against liquids and gases
⊗ Gloves for protection against acid and alkaline solution and heat
⊗ Respiration Mask with filters for duct and poisonous gases(H 2S,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
persons and Department. Any work which is related to concern Department is carried by his permission
of maintenance and technical service Department. The permission is sought on a presubscribed 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 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
This permit is issued to cover all excavation work inside the plant
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COMPLEX DISCRIPTION
FFBL complex includes the following process units, offsite and on site.
PROCESS UNITS:
The process Units are
1. Ammonia Plant
2. DAP Plant
3. Urea Plant
4. Utilities & Power Generation.
FINAL PRODUCT RAW MATERIAL & CHEMICAL STORAGE:
¾ Final product storage & bagging Facilities
¾ Ammonia Storage (5000 MT/Day)
¾ Phosphoric Acid , Sulfuric Acid storages
¾ Nitrogen Storage Unit
OFF SITES AND OTHER BUILDINGS
¾ Fire water
¾ Natural gas Station
¾ Effluent Treatment Facility

BUILDING INCLUDING
¾ Control Room and electrical Room
¾ Laboratory
¾ Technical service Building
¾ Ware house and Workshop
¾ Technical Training Center
¾ Administration Building
¾ OCEA
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FFBL PLANT PROCESS

BLOCK DIAGRAM
7/12/2009
UREA PLANT
CARBONDIOXIDE
UTILITIES AMMONIA PLANT
MATERIAL PACKING
AMMONIA BULK STORAGE
DAP PLANT
PRODUCT & SHIPPING

Instrumental Safety

Safety is the back bone of any Process industry. The instrumentation plays an important role in the
startup, shutdown and working procedure of a process industry. Before installing, handling and
application of instruments we should keep in mind some safety precautions. For the safe instrumentation
I met the Engineers and staff of Instrumentation Section and discuss about the safety issues in
Instrumentation. They share many important safety precautions and issues to me which helped me
through my internship in handling and analyzing different instruments in plant site of FFBL.I like to
share some important points for the study of safety issues in Instrumentation.
SAFTETY PRECAUTIONS:
" Make sure that the tools you are using is in good condition because it not only important
for your safety but also the screw and bolts can`t damaged and faulty when you apply that
tools
" Check the voltages with the help of multimeter when instrument is removed or installed
from the connection even if it is sure that the Loop is dead.
" When you remove any sort of electric wire when it is 24v or 110v it should by insulate with
insulating tape
" Before working in a process line first find the temperature and pressure of the line
" After issuing the Job permit when you starting your relevant Job your first work to find
where is the nearest SAFE ASSEMBLY POINT and the location of water showers
" During the uninstallation of pressure gauge the process line should not be depressurized
.Drain the whole process and make proper isolation with the help of isolating valves.
" Keep in mind that the thermo wall is not disturbed while the uninstallation of Temperature
Indicator is carried out. Keep the thermo well in the process line because when we
disconnect the Temperature Indicator the high pressure comes outside which is very
harmful and dangerous
" Protect your self while handling and testing the IGNITOR because there is a chance of an
accident due to high voltages
" For the installation or maintenance of scanner/ignitor it is necessary to issue a hot permit
for this job
" Make sure that there is no Auto Cut while working on a machine or motor. It is better to
Rack out from sub station
" While working in acidic/caustic area of Utilities relevant type of safety suit must be worn.
" Lead suit must be worn while working in Radio Active source of Area
" Safety from the hazardous gases like Ammonia & Chlorine, gas mask should be worn to
avoid accidents
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Utilities and Power Generation
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 the Storage systems of Utilities.
Gas Turbines (Electrical power at 60 Hz frequency)
Emergency Diesel Generator
Demineralization Plant
Steam Generation System
Instrument & Service Air System
Cooling Water System
Waste Water Treatment
Nitrogen Storage
Utilities production unit
9 Power generation consisting of two 26.3 MW (ISO rating) gas turbine generators.
9 Emergency power generation consisting of one 2MW emergency diesel generator a no no.2 oil uploading &
storage.
9 Water processing consisting of storage basin, raw water clarification & filtration and demineralization
units.
9 Sulphuric acid and caustic unloading and storage.
9 Cooling water system
9 Boiler feed water consisting of one gas fired heat recovery steam generator (HRSG) and one gas fired
auxiliary boiler
9 Compressed air unit consisting of three air compressors ,two air dryers and one instrument air receiver
9 Chilled and hot water plant consisting of two steam absorption chillers and one hot water system
9 Natural gas system consisting of knockout drums and pressure reducing &distribution system
9 Natural gas consisting of knockout drums and pressure reducing and distribution systems
9 Storm sewer system consisting of one storm water impoundment and underground gravity collection and
discharge system
9 Storm sewer system consisting of one collection basin, underground gravity collection and discharge
system.
9 Chemical severs system consisting of one collection basin, underground collection, and discharge system
and evaporation pond.
9 Fire protection system consisting of fire water storage ,hydrants and carbon di‐oxide system

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Utility Control ROOM
Control room has following control units:
1. Power and steam generation control
2. Water board
3. Boiler
I. Auxiliary
II. HRSG

4. Gas Turbine
I. Gas turbine control (Mark V)
II. Electrical GT
Fuel Gas Control System
• Fuel gas Stop/ratio and control valve assembly is used to control fuel gas supply
• Both are servo controlled by signal from the SPEEDTRONIC control panel and actuated by single acting
hydraulic cylinders moving against spring loaded plugs
• It is the gas control valve that controls the desired flow fuel in response to the command voltage .To enable
it to do this in a predictable y , the stop/ratio valve is designed to maintain a predetermined pressure
Components of Fuel Gas Control System:
The fuel gas control system contains the following components:
1. Gas supply pressure switch
2. Stop/ratio valve assembly
3. Three redundant fuel gas pressure transducers
4. Control valve assembly :four linear variable differential transformer
5. Two servo type valves
6. Dump valves: three pressure gauges
Cooling tower
Cooling tower has ten cells.cell#1,2&3 are dedicated for Urea, Dap and utilitiea,Cell # 5,6,7,8,9 & 10 are
dedicated for NH3 plant.Cell#4 is a spare cell common for both the networks.
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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 or in other words a
shutdown of ammonia plant means a shutdown of whole fertilizer company. Following are the names of some
of the major equipment under ammonia plant.
¾ Furnace (Primary Reformer).
¾ Secondary Reformer.
¾ Heat Exchangers (Shell & Tube, Flat Plate, Finned Type).
¾ Boiler.
¾ Start up Furnace.
¾ Start up Heater and many more.
AMMONIA PLANT DESCRIPTION:
Design: Bechtel 1965 vintage. Single Front‐End and Two parallel Back‐End Loops.
Process:
o Braun, U.S.A.
Plant History:
o Shutdown at USA : Jul 1992
o Relocated : Apr 1996
o Re‐commissioned: Nov 1998
o Revamped: May 2007
Capacity:
Design: 1,270 MTPD
Post BMR: 1,570 MTPD
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Ammonia Manufacturing Process:

Natural Gas Desulphurization Primary Secondary
Compression Reforming Reforming

Low Temperature Shift High Temperature Shift
Converters Converters
Absorption Meth nation Syn. Gas Ammonia

Compressor Converter

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MODICON PLC
Controller

I/P MODULE COMMUNICATION
O/P MODULE

PROCESSOR

PROCESS UNDER
CONTROL

PROGRAMMING SOFTWARE (MODSOFT):
• DOS based programming software
• Offline program development
• Online program maintenance
• Combine mode programming
• I/O module health and status monitoring
• Modsoft Supports Modbus, Mod bus plus and Ethernet for Communication with other devices
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MODICON QUANTUM SERIES
o Remote I/O Processor
o Hot Standby Processor
o Power supply for I/O and RIO
o Remote I/O Module
o I/P Module
o O/P module
o Power Supply
o Programmable controller

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SERIALLY LINKED:
Modicon is serially linked with 2 systems
I. Distributed Control System
II. Vibrating Monitoring System
• Max. no. of Drops 31
• Max. no. of segments 32
• Max. no. of I/P 16384
• Max. no. of O/P 16384
• Use memory 48k
• Scan Time 1ms
SAFTEY INTERLOCKS
• Input relay is used for on/off signal duplication.
• Output relay is 24 VDC fail safe relay used to control 120 V AC actuator (solenoid valve or motor).
O/P relay is used to communicate with DCS is included in card
• "4~20 mA duplicate" is an analog signal duplication module
•
"Red" is I/O column means redundant card fail safe type.

INPUT HAS THE FOLLWING FEATURES:
• Redundant used for safety signal.
I. F3236 testable (16 Folds)
II. 73237 testable with line monitoring (8 Folds)

• Non‐Redundant used for MOS,POS and non Safety signals
I. F3236 testable (16 folds)

OUTPUT HAS FOLLOWING FEATURE:
• Redundant used for safety signal
• Non‐redundant for safety panel signalization.
• Non‐redundant used for signal exchange with DCS
I. F3322 with rely module (8 folds)
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Urea Plant
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 ant
actual is 1900 MT/Day.
Urea Plant Description:
Process:
o Urea Wet Stamicarbon, Holland
o Urea Dr Hydro Agri, Belgium
Capacity:
o Design 1,670 MTPD
o Current 1,920 MTPD
Raw Material:
o Ammonia 1,110 MTPD
o Carbon Dioxide 1,480 MTPD
o Urea Formaldehyde 18.0 MTPD

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UREA DRY PART
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(GRANULATION UNIT)
Process Flow chart
96% UREA
SOLUTION 95C
GRANULATOR SAFETY SCREEN FINAL FLUID BED

VIBRATION SCREEN
COOLER
FROM
WET
PLANT
ON
SIZE
PRODUCT
UF-85
UNDER
AIR
SIZE
PRODUCT
AIR
FLUIDIZATION
AIR
ATOMIZATION AIR
CRUSHER


S TORAGE T ANK L EVEL I NSTRUMENTATION

Enraf 854 liquid level guage includes a calibration chamber, A local indicator and a transmitter .The
4~20mA signal is transmitted to the DCS.
Level switch (displacer type level switch) used for the measurement of the level of the liquid.
Level indicator has float level gauge
DP Level Indicator:DP TX with nitrogen bubbler sptum
Temperature Instrumentation:9 RTD temperature elements mounted on storage tank.3 elements mounted
in inner tank shell.6 element mounted in annular space as outer tank bottom will generate alarm at DCS if
the temperature below 31 c.
Radiation Type LT: Its working principle is based on physical law attenuation of nuclear radiation as it
passes through matter. The absorption of gamma radiation follows an exponential law. A beam of ray with
original intensity Lo is weakened as it passes through matter having the thickness and density.
Solid Flow Meter: Supply excitation for flow meter transducing element (LVDT or Load cell).Material
flowing through the flow meter is directed towards sensing plate. The sensing plate deflects horizontally
proportional to material flow. The horizontal deflection is applied to the transducing element which
produces a signal proportional to material flow.

F LOW M ETERS :
Following are some types of flow meters which are used as an instrument at plant:
• Variable Area: For liquid & gases
• Magnetic: For Liquids/without solid contacts
• Electromagnetic: For liquids/with out contacts
• Mass: Measure of fluids without independent measure of density & volume
• Ultrasonic: For non‐contact materials. Especially used for hazardous area
• Vortex: For Volumetric flow rate of gases and vapors
• Miniature: For low gas and fluid quantities

Motors:
Two Voltage level Type Motors are used
1. Medium Voltage Motor
2. Low Level Voltage Motor
Medium Voltage Motor drive on 24 KVA while Low Voltage Motors drive on 480 V.
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HIMA PLC: EMERGENCY SHUTDOWN SYSTEM
It Consist of on 19 inch central rack, 5 units high and up to 16 I/O racks in the 19 inch size.
Central rack has following parts:
• One or two Microprocessor controlled central modulus
• At a time three co‐processor modulus, can be assigned to each central module.
• 2 includes RS485 (2 on central module and 2 on each of up to 3 co‐processor) allows the
connection of other suptum respective to built up bus system with PLC master with a transmitter
rate of up to 57600bps.
• 1 to 3 power supply modulus 24 VDC / 5 VDC to generate the voltage operating for the central
module and the control voltage for the I/O modulus.
• Power supply monitoring module with battens to buffer the RAM area and the real‐time clock on
the central modulus
ONE I/O RACK CONTAINS:
• Up to 4 power distribution modulus to protect the I/O circuit.
• One coupling module to connect the I/O bus, with fail‐safe switch off of the watch dog
signal with care of fault
• Maximum of 16 slots for input and output modulus for binary, digital and analog signals
ELOP System Software & Operating System for Programming & operation:

• HIMA and DCS communicating with MODUS protocol, the two suptum are interconnected by RS
232/485 interface converter.
• 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 PLESY
bus respectively.
• Consider a situation with field switch actuation. This signal is received through hard wired links
PLC 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

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CETRAL MODULE F8630:
• HD64180H Microprocessor with 10 MHZ clock frequency.
• Static memory in EPROM and CMOS RAM
• 2 interfaces RS485 up to 57600bps.
• Fail safe watch dog

CO‐PROCESSOR MODULE F8621:
• HD64180 Microprocessor with 10 MHz clock frequency
• RAM for PLC master Project
• 2 Interfaces RS485
• Dual port RAM (DPR)

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DAP PLANT
The DAP plant design is based on double pipe reactor(DPR)AZF process from Grande Paroisse, France.Comissioned
in November 1988.DAP Plant design capacity is 1350MT/DAY and actual is 1500 MT/DAY
DAP PLANT DESCRIPTION:

Process:
o Base Plant:
AZF Grande Paroisse, France
o Revamp:
Jacobs Engineering, U.S.A.
Capacity:
o Design: 1,350 MTPD
o Post Revamp: 2,230 MTPD
Raw Material:
o Ammonia: 450 MTPD
o Phosphoric Acid: 1,750 MTPD
o Sulphuric Acid: 92 MTPD
o Sand: 117 MTPD
o Coating Oil: 10 MTPD
Manufacturing Process Of DAP Plant:
1. Dual pipe Reactors
2. Granulation
3. Drying
4. Screening
5. Cooling
6. Product Coating
7. De‐dusting & Off gases scrubbing
8. Storage/Bagging
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SCOPE OF INSTRUMENTATION IN FFBL
As we know that the FFBL is a chemical process industry so it is very essential to measure, calculate and
control variables so instrumentation is a building block of any process industry. In FFBL process variables are
measured by different kind of instruments located at the Plant site.
Instrumentation:

Below is a list of some of Instruments, I studied during my stay at different Plants of FFBL.
Flow Measurement:
The Instrument below is used to measure flow. It has a flow sensor that measure flow and communicate it.
Flow control system
The Instrument below is used for flow measurement without touching any liquid. It can be used to
measure hazardous liquids like sulfuric acids or Phosphoric acid.

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P&ID study.
The diagram below is called P&ID.It helps us understand the process from Instrument to the control
system.

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Speed Sensor
The diagram below show a speed sensor. As wheel of any vehicle revolve, it produces proportional EMF
is solenoid. The strength of EMF is directly proportional to speed. That is how it communicates an
effective signal for speed measurement.
Pressure Gauge
A Pressure measurement Instrument based on Bourden tube. Bourden tube turn in direct proportion to
pressure applied. The pointer of meter attached to Bourden tube move on scale directly proportion to
pressure applied. This is how, we measure pressure.
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Relay:
Relay is a switch that switches on/off in proportion to signal applied. On execution of applied signal, it
turns on or off and helps us control some another device.
As coil in picture is energized, the position of switch changes and switch changes it orientation from one
position to another position.

Liquid Level measurement
The Instrument below is used for level measurement. As level of liquid changes, position of rope changes
and rope moves pointer along its scale. To sum up, Pointer moves in direct proportion to float pointer.
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The same above rule is applied on below system. The rise in flow produces a change is position of angular
sensor and this change is appeared on meter.
Ultrasonic Level measurement:
The ultrasonic system is composed of transmitter and a receiver. The transmitters send a signal that is
received by receiver. The time the signal takes is directly proportional to height of liquid.
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Diaphragm type valve
The instrument below is used to switch position of devices with flow measurement. As flow increases, it
changes position of compressor and in turn on or off devices.
Valves and regulators
The picture below shows a regulator that reduces flow of some fluid but regulates it and prevents jerks.
32 | P a g e

Pressure Relief Valve:
The Instrument below indicates a pressure safety valve. The valve open as pressure increases a pre‐set
set point and in that way it helps us in safety precautions.
Resistive Transmitter:
The transmitter below is used to transmit change in pressure via a change is resistance. It changes it
resistance with change is pressure and hence the voltage across it changes. This change in voltage is
transmitted to control system.
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Installation of Orifice plate
Orifice plate is installed in pipe. Orifice plate is installed is such a way that it changes pressure across
some point and helps us calculate differential pressure. The differential pressure helps
Annubar:
The instrument below is called Annubar.It helps us judge differential pressure. Orifice plate does not help
us judge differential pressure across a point but it helps us be rising level in tubes.
One can say that
Annular = Orifice plate + Monometer.
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Level Measurement
The instrument below is used to indicate whether level has crossed two particular points or not.
Thermocouple and its Installation;
The instrument below is a thermocouple adjoined to a transmitter.
Thermocouple produces a temperature in direct proportion to temperature and transmit is to
transmitter. Transmitter takes this signal, amplify it a bit and transmit it to control system.
35 | P a g e


Bourden tube
The device below is called Bourden tube and it bends itself in proportion to pressure applied. The pointer
is attached to a scale and hence it produces a change is scale in proportion to pressure applied.
Linear variable differential Transmitter:
A electromachanical mechanism that provides a voltage reference that is proportional to the movement
or displacement of a core inside a coil (I to 5 volts AC).

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CONTROL SYSTEM OF FFBL

The control Philosophy of FFBL

CONTROL SYSTEM

PLC`S

DISTRIBUTED
COTROL SYSTEM

SIEMEN ALLEN BRADLEY HIMA HS‐52 MODICON

QUANTUM
SERIES
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 with in specified target parameters through the manipulation of
the control variable

37 | P a g e

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.
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INTEERNSHIP REPO
ORT 2009

Disttributed Co
ontrol systtem (DCS):
A Distributed Control Systeem is a partt of manufaccturing indu ustry.DCS is used in ind dustrial and civil
engiineering app plications to
o monitor and control ddistributed equipment with remotte human in ntervention..
It is generally, ssince the 1970s digital aand normallly consists of field insttrument, con
nnected via wiring to
commputer busess to MUX/DEMUX and A A/D`s or an
nalog to digital and finally the Hum man Interface (HMI) or
conttrol consoles. A DCS is aa process coontrol system that usess a network to intercon nnect sensorrs,
DCS typically contains o
conttrollers, opeerator termiinals and acctuators. A D one or moree computerss for control
and mostly use both propriety interco onnections aand protoco ols for comm munication.
Distributted Control System (DC
CS) in generral providess:
9 Fastest execcution of prrocess contrrol algorith

hms with ad
djustable sccan rates as fast as 20
0
tiimes per seccond.
9 Highest level
H l of availabiility,
9 Redundancy
R y,
9 O
Operational ease, mainttenance easse and otheer provision
ns like scalaability and flexibility
f in
n
user defined tasks.
Fauji Ferrtilizer Bin Qasim Limiited is usingg ABB‐Bailey
y’s Infi‐90 D
DCS For Pro
ocess
Monitorring / Control of Ammonia, Urea, D DAP and Utillities plant.
39 | P a g e


PROGRAMMABLE LOGIC CONTROLLER (PLC)
A solid state control device that can be programmed to control process or machine
operation.
In an automated system, the PLC is commonly regarded as the heart of the control system.
With a control application program (stored within the PLC memory) in execution, the PLC
constantly monitors the state of the system through the field input devices feedback
signal. It will then base on the program logic to determine the course of action to b carried
out at the field input devices.
It consists of five basic components
1. Process
2. Memory(RAM ,ROMEPROM,EEPROM)
3. INPUT/OUTPUT Modules
4. Power supply
5. Programming devices
INPUT:
9 Intelligence of PLC lies in the signals from sensors, actuators & field devices.
9 Push buttons
9 Keypads
9 Toggle switches
9 Proximity switches
9 Piezoelectric sensors
9 Level sensors
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Interfaced to PLC through PLC INPUT MODULES

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OUTPUTS:
9 Motors,
9 Solenoids
9 Relays indicators
9 Buzzers
9 LEDs

Can control a simple pick & place function to a complex servo positioning system.
Output devices are interfaced through OUTPUT MODULES
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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

43 | P a g e

INTEERNSHIP REPO
ORT 2009

MACHINE MO
ONITORING
G SYSTEM
Com
mplete Mach hine Monitorring Systemm based on P Proximity Trransducer SSystem capaable of meassuring
machine vibratiion and the position of a shaft or o
other part off a machine in relation to the locattion of the
prob
be tip. The ssystem shou
uld consist o
of a probe, aan extension
n cable and a proximatee.
The above comp
ponents of ttransducer system should work ass a single un nitoring Modules.
nit with Mon

Fig: Bentley N
Nevada maachine con
ntrol systeem

44 | P a g e


Mentorship of FFBL

Engineers, technicians and Operators put all efforts to help me learn faster, quicker and deeper.
FFBL provided me with all resources, necessary in this learning process.
45 | P a g e

FFBL Internship 2009

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INTEERNSHIP REPO

PRODUCTION DESIGN ONWARDS

FFBL PLANT PROCESS

PRODUCT & SHIPPING

Absorption Meth nation Syn. Gas Ammonia

GRANULATOR SAFETY SCREEN FINAL FLUID BED

S TORAGE T ANK L EVEL I NSTRUMENTATION

SIEMEN ALLEN BRADLEY HIMA HS‐52 MODICON

9 Fastest execcution of prrocess contrrol algorith

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