SUMMER INTERNSHIP REPORT

SUBMITTED TO:
Mr. Asghar Bhutta
Section Head
(Instrument 1)
Summer Internship Report 2010 Fauji Fertilizer Company Ltd

Preface &Acknowledgements
PREface
This internship report contains a general overview of plant 1 the
basics of instrumentation. The process control variables, their
measuring devices and Field Instrumentation has been discussed.
The Triconex PLC based ESD system and the Yokogawa Centrum
3000 have also been discussed. At the end general overview and
of the utilities plant have been done.

Acknowledgements
I am thankful to all the people who have guided me during the
course of my internship in making these 6 weeks a truly
memorable experience. I am grateful to our Unit Manager Mr. Asif
Raja,Section Head Mr. Asghar Bhutta and Senior Engineer
Mr.Usama for their cooperation and guidance during the course
of internship. I express my vehement sense of gratitude to Mr.
Aftab Ahmed Mazari and our Internship Co-ordinator Mr.Harris
whose guidance helped me learn a lot & who have always proved
to be a fountain of knowledge for me and my colleagues. Finally I
would like to thank the rest of the engineering staff especially
trainee engineers Mr. Zeeshan and Mr.Ali with whom I was really
frank in asking all sorts of questions.

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Table of contents:
Preface & Acknowledgments
General Plant Overview
Process variables:
Pressure measuring devices
Flow measuring devices
Level measuring devices
Temperature measuring devices
Intrinsic safety
Work Permit familiarization
Process & Instrumentation Diagrams
Field Instrumentation
Transmitters
Switches
Curent to Pressure Converters
Solenoid Operated Valves
Vibration Monitoring Systems
Programable Logic controllers
Triconex Trident Emergency Shutdown System
Distributed Control System
Utilities

General Plant Overview:

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Area-1
This is the urea processing area. It mainly comprises of CO2
compressor and the prilling tower. In the prilling tower molten urea is
poured down the tower.Natural air drift is blowing upwards which solidifies
these urea droplets into small prills.
• Area-2
In this section cracking of methane is carried out in the reformers.This area
consists of the furnace, primary reformer and secondary reformer.
• Area-3
Area-3 comprises of the de-methanator.
• Area-4
Area-4 comprises of three main compressors.
1. Synthesis Gas Compressor
2. Ammonia Compressor, which liquefies ammonia
3. Instruments Air Compressor, which compresses air for operation of
different instruments at the plant.
• Area-5
Area-5 consists of ammonia reactor and ammonia production.

Process Variables:
Pressure measuring devices:
Pressure is the force exerted per unit area. Two types of pressure are
exerted by fluids:

i. Hydraulic pressure (dynamic Pressure): due to the flow of the

liquid.
ii. Hydrostatic pressure(static pressue): pressure exerted by the fluid
on its surroundings.

 Barometers: these are used to measure atmospheric pressure.

 Manometers: these are used to measure pressure difference between
two processes or between atmosphere and the process. Manometers
have three different types :
o U-shaped manometers
o Well shaped manometers
o Inclined manometers
 Diaphragm gauges: these also measure pressure difference.
Preferably used for low pressure difference applications.

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 Bellows: same principle as Diaphragm guages, however they are

more sensitive to small pressure differences due to larger contact
area.
 Bourdon Tubes: these Measures difference between atmospheric
pressure and process pressure . Bourdon tubes have three different
types:
o C-Shaped Bourdon Tube
o Spiral shaped Bourdon Tube
o Helix shaped Bourdon Tube
Spiral and Helix shaped bourdon tubes are used for low pressure and
more sensitive applications.

FLOW RATE MEASURING DEVICES:

Direct displacement method:

 Impeller Meter: Fixed amount of liquid passes per unit time. The
impeller shafts are turned by the moving liquid. Increased rpm means
increased flow rate.
 Turbine Meter: The liquid flows smoothly as the turbine rotates. The
no. of rotations is counted.
 Vortex Meter: In this method a rotor is used instead of a turbine.
There is no friction between the liquid and the moving parts.

Differential pressure measurement methods: pressure difference is

created by restricting the flow of the fluid.
 Orifice plate: is the least expensive and most widely used. three
types include:
o Concentric
o Eccentric
o Segmental
 Flow Nozzle: provide better flow to fluid and has lower pressure
energy loss.

 Venturi Tube: used in applications where high permanent pressure

loss is not tolerable. It can be used to minimize plugging by allowing
the flow to sweep suspended solids through without obstruction.

LEVEL MEASURING DEVICES:

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Level measurement may be affected by excessive turbulence, temperature

and Pressure:

Pressure type level indicators:

 Gage Glass: Attached on side of the tank and indicates level. Needs
to be very long for larger tanks.
 Diaphragm Level Detector: Diaphragm used to indicate level.
Diaphragm place inside tank.
 Bubbler: Level is dependent on the amount of pressure required to
force the fluid out of the bottom of the dip tube.

Float-Type Level Indicators:

 Dipsticks: Simple sticks with indicator that measures the level of
open tanks.
 Float and Lever Gage: Consists of float, shaft, lever and pointer.
 Torque Tube: Consists of displacer attached via lever to torque
tube. As the weight decreases due to buoyancy, the pointer moves as
the torque is changed.
 Floating Magnet: A magnet floats in the centre of a tank that has
level indicators that change color with the magnetic field at the outside
indicating the level.

Light-Detector Level Indicator:

 Gamma Rays: For muddy, black fluids, we use gamma rays to
measure level.

Temperature Measuring devices:

 Fluid thermometers: Fluid thermometer works on the principle of

the expansion and contraction of fluid. When liquid is heated its
pressure will increase.
 Bimetallic thermometers: Use the principle of uneven expansion of
different metals to measure and indicate temperature.
 Electrical thermometers or RTDs: Resistance Temperature
Detectors are made up of metals like Platinum wire in which resistance
increases as temperature is increased. Within its range it is more
accurate and has higher sensitivity than a thermocouple.
Thermocouples are avoided in motors as they generate voltages and
thus RTDs are preferred.

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 Thermocouples and Thermopiles: measure the voltage difference

between the junction(sensing end) and the reference end using a
voltmeter/Galvanometer. Several thermocouples connected in series
make a thermopile.

Intrinsic Safety:

Intrinsic safety is a protection technique based upon the restriction of

electrical energy to a level below a threshold that can cause ignition by
either sparking or heating effects. Therefore an intrinsically safe circuit is
one in which any spark or thermal effect produced is not capable of causing
ignition.

Another aspect of intrinsic safety is controlling abnormal small component

temperatures. Under certain fault conditions (such as an internal short inside
a semiconductor device), the temperature of a component case can rise to a
much higher level than in normal use. Safeguards, such as current limiting
by resistors and fuses, must be employed to ensure that in no case can a
component reach a temperature that could cause auto ignition of a
combustible atmosphere.

The use of intrinsic safety for instrumentation brings with it a number of

benefits, for example :

The lack of threshold electrical energy means that circuits can be tested
adjusted and repaired in the presence of a gas without disconnecting power.

Usually the low costs of installation including inexpensive cables and the
ability to use perfectly ordinary items of simple apparatus.

Work Permit Familiarization

A work permit is an official document to start a job and is issued by the
Operations department. In industry no work can be done without the work
permit. Work permits are for the safety of both the technician and the area
where work is to be done. It is a standard procedure followed world-wide.
FFC also issues work permits like:

 Instrument Work Permit

For check of valves, regulators, PSVs, measuring instruments and
controllers this permit is issued to the instruments department.

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 Vehicle Entry Permit

For the movement or utilization of industrial vehicles needed inside
plant area this permit need to be signed.
 Electrical Work Permit
It is required to carry out electrical work like repairing of transformer
or a motor or some power outlet.
 Cold Work Permit
It is required to carry out machining work.
 Hot Work Permit
This permit is issued for Work that involves spark and flame like
welding,etc.
 Excavation and Civil Work Permit
Work permits for digging purposes.Issued for excavation work with
depth of 6 inches or more.
 Confined Space Entry Permit
When doing work in some closed vessel or area, this permit is issued.
It clearly specifies the no of persons entering the confined area and
demands one person to remain at the door always.
 Radiography Work Permit
Permit for checking the radiation emissions. A large area need to be
restricted.

Process and Instrumentation Diagrams

A diagram which shows the interconnection of process equipment and the
instrumentation used to control the process. In the process industry, a
standard set of symbols is used to prepare drawings of processes. The P&ID
includes a graphic representation of the equipment, piping, and
instrumentation. Process operators can look at their process and see how
the engineering department has automated the unit. Pressure, temperature,
flow and level control loops are all included on the unit P&ID. All the symbols
and abbreviation used in P&IDs are based on ISA Codes for Process
Instrumentation.

Field Instrumentation
Transmitters:

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Transmitters are those devices which take a measurement and besides

displaying it on some dial at the measuring spot, the information is
converted into proportional electronic or pneumatic signal. This proportional
signal is then received at some distant point and can be displayed over
there.

In FFC electronic transmitters are used which transmit an analog signal of a

4 – 20 mA . This signal is used to control other instruments directly, or sent
to a ESD/DCS system where it is interpreted into readable values and used
to control other devices and processes in the system.

Switches:

Switches are the devices which open or close a circuit depending upon the
measured value of the control parameters, i.e pressure, temperatureflow
and level. They are usually connected to control valves. CCS pressure
switches were studied.

Current to Pressure Converters:

Current to pressure or Electrical to Pneumatic converters are those devices

which convert electronic signals (4-20mA or 10-50mA) into equivalent
pneumatic signals(3-15 Psi). After conversion the information that was
previously travelling in the form of electronic signals, travels in the form of
pneumatic signals and can operate any pneumatic device.

The Foxboro E69 series Current to Pneumatic Converters were studied.

These converters work on the position balanced system. Galvanometric
motor changes position of flapper,which is than balanced by pneumatically
actuated system The E69 can be calibrated to work in both forward action
and reverse action modes.

Solenoid Operated Valves (SOVs):

Solenoid valves are electrically operate valves, which connects or

disconnects the ports connected to it. They are usually operated using 110V
DC. When the signal comes to the solenoid, the coil energizes and interacts
with the permanent magnet. The magnet attracts the coil and it is pulled up,
opening or closing the valve depending on the configuration.

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Vibration monitoring systems

Vibration is cyclic or pulsating motion of a machine or machine component
from its point of rest. It is caused by either force changing in direction or a
force changing in magnitude or friction (rub).

Units of Vibration

The two units used to measure vibrations are

 Macrons =1000th of mm
 Mills = 1000th of inch

Types of Vibration

 Radial Vibration: Vibrations perpendicular to axis of rotation

 Axial Vibration: Vibration along the axis of rotation, also known as
thrust.

Measurement techniques

There are two types of method to measure vibration

 Contact Method: Measuring instrument is in contact with the device
 Non-contact Method: Measuring instrument is not in contact with the
device. This method is most widely used in industry due to thick casing
of instruments.

Programmable Logic Controllers (PLCs):

A programmable logic controller, also called a PLC or programmable
controller, is a computer-type device used to control equipment in an
industrial facility. The kinds of equipment that PLCs can control are as varied
as industrial facilities themselves Conveyor systems, food processing
machinery and auto assembly lines in modern industry are all controlled
using PLCs. In FFC ltd Plcs are used to control the emergency shutdown
procedure

A PLC basically consists of two elements:

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• the central processing unit

• the input/output system

The central processing unit (CPU) is the part of a programmable controller

that retrieves, decodes, stores, and processes information. It also executes
the control program stored in the PLC’s memory.
The three main parts of the CPUI are shown in the figure.

The processor is the section of the CPU that codes, decodes, and computes
data. The memory system is the section of the CPU that stores both the
control program and data from the equipment connected to the PLC. The
power supply is the section that provides the PLC
with the voltage and current it needs to operate.

The input/output (I/O) system is the section of a

PLC to which all the field devices are connected. It
consists of two main parts the rack and the I/O
modules

The rack is an enclosure with slots in it that is connected to the CPU.I/O

modules are devices with connection terminals to which the field devices
are wired. Together they form the interface between the field devices and
the PLC.

All of the field devices connected to a PLC can be classified in one of two
categories:
• Inputs
• Outputs
Inputs are devices that supply a signal/data to a PLC. Typical examples of
inputs are push buttons, switches, and measurement devices. Outputs are
devices that await a signal/data from the PLC to perform their control
functions

There are two basic types of input and output devices:

• Discrete
• Analog
Discrete devices are inputs and outputs that have only two states: on and
off. As a result, they send/receive simple signals to/from a PLC.

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Analog devices are inputs and outputs that can have an infinite number of
states. These devices send/receive complex signals to/from a PLC.

PLCs have been gaining popularity on the factory floor and will probably
remain so for some time to come. Most of this is because of the advantages
they offer.
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.

Emergency Shutdown System (ESD):

The Triconex Tricon PLC based ESD system has replaced the now obsolete
carlogawazi relay based ESD system. The Tricon controller is a state-of-the-
art programmable logic and process controller that provides a high level of
system fault tolerance. To ensure the highest possible system integrity
at all times, the Tricon controller includes these features:

• Provides Triple Modular Redundant (TMR) architecture whereby each of

three identical system channels independently executes the control program,
and specialized hardware/software mechanisms “vote” all inputs and
outputs.
• Withstands harsh industrial environments.
• Enables field installation and repair to be done while the controller remains
online. Replacing an I/O module does not disturb field wiring. It also allows
normal maintenance while the controller is in operation.
• Supports up to 118 I/O modules and various optional communication
modules.
• Provides support for remote I/O modules located as far away as 12 km
from the Main Chassis, using SRXM modules.
• Executes control programs developed and debugged with TriStation 1131
software.
• Provides intelligence in the input and output modules to reduce the
workload of the Main Processors.
• Provides integral online diagnostics with adaptive-repair capabilities.

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TriStation 1131 is a Windows NT-based programmer’s workbench for

developing, testing and documenting process-control applications that
execute in the TRICON controller. Three languages which are available for
programming in TriStation 1131:
 Function Block Diagram (FBD)
 Ladder Diagram (LD)
 Structured Text (ST)

The triconex tricon system is compatible with the following chassis types
 Main Chassis:
 Expansion Chassis: generally an Expansion Chassis must be located no
more than 100 feet (30 meters) from the Main Chassis or an RXM
Chassis.
 Remote Extender Chassis: An RXM Chassis enables a system to extend
to remote locations up to 12 km from the Main Chassis.
The Triconex tricon system at ffc uses only the main and expansion chassis
types.

Modules:
Main Processor (MP) Modules
A TRICON system contains three Main Processor modules. Eachcontrols a
separate leg of the system and operates in parallel with the other two Main
Processors

Power Modules
Each TRICON chassis houses two Power Modules arranged in a dual-
redundant configuration. All modules receive power from the dual Power
Modules and power rails in the Main Chassis. A failure on one Power Module
or power rail does not affect system performance.

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Compatible Communication Modules:

The TCM (tricon communication module) is one such module. It establishes
communication between the ESD system and the tristation programming
system in a remote pc. Each TCM has four serial ports, two Ethernet network
ports, and one debug port (for Triconex use).

Network Communication Module (NCM)

The Network Communication Module (NCM) enables the Tricon controller to
communicate with other Triconex controllers and with external devices on
Ethernet networks.

I/O Modules:
Each I/O module has three microprocessors. Input module microprocessors
filter and debounce the inputs and diagnose hardware faults on the module.
Output module microprocessors supply information for the voting of output
data, check loopback data from the output terminal for final validation of the
output state, and diagnose field-wiring problems.

i. Digital Input/Output Modules: digital communication to and from field.

In the digital input module each channel contains an 8-bit microprocessor
called the I/O communication processor which handles communication with
its corresponding Main Processor.

ii. Analogue Input/Output Modules

Analog input modules are available to support a wide variety of analog
inputs: 0-5 VDC, 0-10 VDC, 4-20 mA, thermocouples (types K, J, T and E),
and resistive thermal devices (RTDs).
Analogue Output modules have A to D Converters attached to them.

DISTRIBUTED CONTROL SYSTEM (DCS):

DCS performs the functions of Control, supervision and provide stable and
accurate plant control to ensure safety and facilitate plant maintenance. The
main features of the system are:
 Single part failure does not bring the whole system down.
 Redundancy at each level to improve system availability and reliability.
 Much modular fashion than centralized system.
 All modules are interconnected and communicate with each other to
create an integral control system.
 The system modular structure is characterized by micro processor
based unit to provide ease of expansion and high degree of flexibility.

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ADVANTAGES OF THE YOKOGAWA CENTUM 3000

1. Reliable System
2. Low Cost
3. Easy Engineering
4. Fast Data Transform Rate (10 Mbps)
5. No Separate History Module is required
6. One Second Trend Update
7. HIS Runs on Windows NT

UTILITIES:

The last few days of internship were on the utilities department.

Following areas of the plant comes under utilities
1. Water treatment plant (Area 9)
2. Gas Turbines and Generators (Area 7)
3. Boilers (Area 6)
4. Cooling Tower (Area 8)
5. Nitrogen (Area 10)
6. Instrument Air (Area 10)
Water treatment plant (Area 9)
There are two sources of water:
o Canal Water
o Well Water
 Filtering of water
Both the well and the canal water contains some minerals and mud,
Hence its treatment is done before use. Firstly the water is filtered to
remove the mud from it and clear it apparently.This water still contains
mineral and needs further treatment before use at plant.
 Softening of Water
The filtered is hard water. It is softened by treatment with lime.
 Demineralization of Water
The softened water is then demineralized by passing it through the cation
and anion exchanger. Here the transfer of ions takes place and the water
is demineralized. Now this water is completely fit for the process.
 Water Storage
The water from well and canal comes to a reservoir at the plant which has
a capacity to store water for 24 hours requirement. It has a capacity
of30000 m3.
 Water Treatment Control Room (WTCR)
WTCR controls the water treatment process.

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Gas Turbines and Generators (Area 7)

Area 7 contains two gas turbines with two generators coupled to the
turbines, each of 18MW.The Gas Turbines require natural gas (can work on
diesel also) and compressed air as fuel.

Boilers (Area 6)
Boilers heat the water to HS (high pressure and high temperature steam)
and KS (very high temperature and pressure steam).

Cooling Tower (Area 8)

Cooling tower is the place where the hot water from the process comes and
is cooled to be used again.There are big fans on the top of the tower, which
blow the air out of the tower.The air rises up and the water is falling down,
as a result the water gets cooled.

Nitrogen (Area 16)

Nitrogen is used as a purge gas. It is stored in area 16. First air is sucked
from the atmosphere and filtered. Then it is sent to the combustion
chambers to remove oxygen. Then it is sent to carbon dioxide absorbers.
Now the only gas left is nitrogen which is stored in a large vessel.

Instrument Air (Area 10)

This area provides air for all the pneumatic control of the plant. Here first
the air is sucked and filtered.Then is dried and then sent and compressed to
the storage vessel, from where is it is supplied to the plant.

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