Acknowledgements

I would like to express my sincere gratitude to all those individuals who played a pivotal role in
making my internship journey at Pak Arab Fertilizers Multan not only a reality but also an
incredibly enriching experience. I extend my heartfelt appreciation to:

1. Engr. Nibras Salman

I am deeply thankful to Sir Nibras Salman GTE at Pak Arab Fertilizers, for providing me with
this invaluable opportunity to gain hands-on experience in various aspects of the industrial
landscape. His guidance and mentorship were instrumental in shaping my understanding of real-
world engineering practices.

2. Field Maintenance Urea Department

The people in this department played a big part in showing me various job positions, like
fixing things, upkeep, and building. They were really opened to giving me advice,
responding to my questions, and talking with me. All of this really made my learning
experience much better.
3. NFC IET Multan
I want to thank my university for making this internship possible and for giving me the education that
helped me do well in the tasks I was given.
Abstract

This internship report summarizes a comprehensive four-week experience at Pak Arab Fertilizers
Multan, where I engaged in a variety of tasks and responsibilities, including repairing, upkeep,
and creating equipment. The report goes into detail about my learning in areas like pumps,
mechanical seals, pipes and fittings, engineering drawings, and gas turbines. Additionally, I
gained a strong grasp of how the urea plant and demineralized water plant function. Through
hands-on work and theoretical lessons, this internship allowed me to explore different parts of
the industry, giving me insights into engineering methods, maintenance approaches, and how
operations work. The report emphasizes how important maintaining equipment is, the role of
fluid dynamics in pipes, understanding engineering drawings, and how gas turbines operate.
Moreover, I also gained a complete understanding of how fertilizer is produced and how water is
purified in the process.
 Executive Summary

Throughout my 4-week internship at Pak Arab Fertilizers Multan, I had a chance to get valuable
insights into different parts of how the organization works. The internship showed me many
different tasks and things to be responsible for, which gave me practical experience in lots of
areas. One main thing I did was help with keeping equipment in good shape and making new
parts. I got to see and be a part of fixing things up, which taught me how important it is to take
care of equipment, so it works well. During my time there, I also learned about pumps,
mechanical seals, valves, and different pipes and fittings. This helped me understand how fluids
move around and why that's important in industry. I also got to practice reading and
understanding drawings that engineers make, which is a big skill in the engineering field. I spent
a good amount of time learning about gas turbines too. Figuring out how they work and what
they do taught me a lot about making power and using it in different industries. Another
important part of my internship was learning about how they make urea and clean water in the
plant. I got to know a lot about making urea, which is a big part of making fertilizer. I also
learned about making water clean, which is super important for industry. Overall, my time at Pak
Arab Fertilizers Multan was a big learning experience. I learned a lot about fixing things, making
stuff, and dealing with equipment, and I learned a lot about how things work in different
industries. This internship didn't just teach me things from books, but it also helped me
understand how to work well and be flexible in a real job. I'm sure that what I learned here will
really help me in my future career in engineering and beyond.

Table of Contents

Acknowledgements.............................................................................................
Abstract...............................................................................................................
Executive Summary……………………………………………………………
Introduction…………………………………………………………………….
Company Overview……………………………………………………………
Location………………………………………………………………………..
Plants & Processes………………………………………………………….....
Internship Task & Activities…………………………………………………...

Introduction:
Pak Arab Fertilizers Limited came into existence on November 12, 1973, through a partnership
between the Government of Pakistan and Abu Dhabi National Oil Company Limited (ADNOC).
Later on, the Pakistan Industrial Development Corporation (PIDC) transferred 52% of its shares
to the National Fertilizer Corporation (NFC) of Pakistan, while ADNOC allocated 48% of its
shares to the International Petroleum Investment Company. The initial paid-up capital amounted
to PKR 743.061 Million.

Company Overview:
Over the past 38 years, Pak Arab Fertilizers Limited has held the distinction of being Pakistan's
sole producer of compound fertilizers, specifically Calcium Ammonium Nitrate (CAN) and Nitro
Phosphate (NP). Additionally, the facility also manufactures Urea.
Fatima Group has taken substantial measures to modernize Pak Arab Fertilizers Limited,
introducing enhanced processes aimed at optimizing production while minimizing any adverse
effects on the environment. Notably, the Clean Development Mechanism (CDM) plant marked a
pioneering initiative in Pakistan by Fatima Group. This project was designed to reduce NOX
emissions from the stack gases of the Nitric Acid plant. Through such endeavors and investments
geared towards lowering greenhouse gas emissions, Fatima Group demonstrates a strong
commitment to fostering a cleaner and healthier environment for the forthcoming generations of
Pakistan.

Location:

Pak Arab Fertilizers Limited is located at Khanewal Road, Multan adjacent to Mukhtar A.
Sheikh Hospital. The site area comprises 302 acres, which includes area for the factory and the
Housing Colony with all amenities including Medical Centre, School, Management and Staff
Clubs for recreation of employees and their families.
Plants and Processes:

 Demin Water Plant

 Nitric Acid Plant
 Carbon dioxide Plant
 Ammonia Plant
 Urea Plant
 CAN Plant
 NP Plant

Internship Tasks & Activities:

During my internship at Pak Arab Fertilizers Multan, I had the opportunity to:

 Urea Plant:
Learn about the intricate processes involved in the urea plant, gaining insights into the
production of this essential component in the fertilizer industry.
Urea is a concentrated straight nitrogenous fertilizer that contains 46% nitrogen. It provides
nitrogen to promote green leafy growth and make the plants look lush.
• Urea is colorless, crystalline solid.
• It is highly soluble in water.

Molecular Weight 60.06 g/mol

Density 1.32g/cm³
Melting Point 133° C
Appearance White solid
Sections of Urea Plant:

 Workshop:
Visit the workshop area, where I had the chance to observe and familiarize myself with various
maintenance and fabrication activities.

 Machines: Lathe, milling, shaper, drilling, balancing, plasma cutting

 Local fabrication: It is also carried out in the workshop. Here maintenance work is being
done like maintenance of pumps, valves, nitric acid pre heaters
 Garage: Include heavy vehicles
 Crafts

 Studied Pumps:
Studied pumps in detail, which included understanding their mechanisms, functionalities, and
roles within industrial operations.
 Parts of Pumps
 Types of Pumps
 Uses of Pumps
Also studied the behavior of energy, pressure and velocity throughout the pump.
Suction head, Delivery head, NPSH, Cavitation.

 Concept of Flow Diagrams:

Understood the concept of process flow diagrams of demineralized water plant and urea plant.

 Overhauling of P6 Pump:

Take part in the overhauling of a pump, gaining hands-on experience in maintenance and repair
activities. Seen different parts of pump like shaft, mechanical seal, wear rings, sleeves, prime
mover, rigid coupling etc.

 . Cleaning of Lube Oil Cooler:

Witnessed the cleaning process of a lube oil cooler E-30B of pump P-1B which highlighted the
significance of proper maintenance for equipment longevity.

 Dye Penetrant Testing of Valve:

Observed the DPT of valve to check the irregularities in the surface of material and locating
cracks and estimating the depth.
 Working of Gas Turbines:
Comprehend the entire process of a gas turbine, from its operation to its maintenance
requirements.

 Cleaning of Carbamate Condenser:

Observed the cleaning procedure of a carbamate condenser, underscoring the importance of
cleanliness and efficiency in cooling system

 Combustion Chamber Inspection (CCI) of Gas Turbine:

Participated in the inspection of a combustion chamber within a gas turbine, providing insights
into the critical inspection procedures of such machinery.
The combustion chamber inspection of a gas turbine is a critical maintenance procedure aimed at
assessing the condition, performance, and overall health of the combustion chamber within the
gas turbine engine. The combustion chamber is a crucial component where the fuel-air mixture is
ignited and burned, generating the high-temperature and high-pressure gases that drive the
turbine and ultimately produce power.
Regular combustion chamber inspections help prevent unexpected failures, optimize combustion
efficiency, ensure compliance with emissions standards, and extend the operational life of gas
turbines. These inspections are a vital part of routine maintenance and play a significant role in
maintaining the reliability and performance of gas turbine power plants.

Centrifugal Pump
A centrifugal pump is defined as a hydraulic machine that changes mechanical energy into
hydraulic energy by the use of centrifugal force acting on the fluid. This is a machine that uses
rotation to enforce velocity on a liquid, the velocity will then be converted into a flow. Every
centrifugal pump is made up of mechanical components that make the operation of the pump
possible.

Working Principle

Fluid enters the impeller through its central axis, known as the 'eye,' and exits along the
periphery between the vanes. The impeller, opposite to the eye, is linked to a motor via a drive
shaft and rotated at significant speeds (typically ranging from 500 to 5000 revolutions per
minute). As the impeller rotates, it imparts a rotational motion to the fluid, propelling it outward
through the vanes and into the pump casing.
Two fundamental designs of pump casings exist: volute and diffuser. Both designs serve the
common purpose of converting the fluid's flow into a controlled discharge at a specified
pressure.
In a volute casing arrangement, the impeller is positioned off-center, effectively giving rise to a
curved funnel shape that progressively widens towards the pump's outlet. This specific design
induces a gradual rise in fluid pressure as it approaches the outlet
Construction:

Components of Centrifugal Pump

Impeller: The impeller is a rotating component at the heart of the centrifugal pump. It consists of
blades or vanes that impart kinetic energy to the fluid as it rotates. The high-speed rotation of the
impeller causes the fluid to move radially outward from the center, increasing its velocity.
Casing or Housing: The casing, also known as the housing or volute, surrounds the impeller and
provides a pathway for the fluid to flow from the impeller's discharge to the pump's outlet. The
casing is designed to convert the high velocity of the fluid into pressure energy.
Inlet and Outlet Ports: The pump has inlet and outlet ports where the fluid enters and exits,
respectively. The inlet port is connected to the suction side of the pump, while the outlet port is
connected to the discharge side.
Shaft: The shaft connects the impeller to the motor. It transmits the rotational energy from the
motor to the impeller, causing it to spin and generate fluid flow.
Seals and Bearings: Sealing mechanisms, such as mechanical seals or gland packing, prevent
leakage of fluid along the shaft and out of the pump. Bearings support the shaft and ensure its
smooth rotation. Bearings can be located in different parts of the pump, including at the impeller
end (thrust bearing) and the motor end (radial bearing).
Wear Rings: Wear rings are stationary components located between the impeller and the casing.
They help reduce the clearance between the impeller and casing, minimizing internal
recirculation and improving pump efficiency.
Coupling: The coupling connects the pump's shaft to the motor's shaft, enabling the transfer of
power from the motor to the impeller.
Prime Mover (Motor): The prime mover, typically an electric motor, provides the power to
rotate the impeller. The motor's speed and power rating are selected based on the pump's design
and the required flow and pressure conditions.
Baseplate or Foundation: The pump is often mounted on a baseplate or foundation, which
provides stability and support for the entire pump assembly.
Suction and Discharge Pipework: The pump is connected to the fluid source (suction) and the
destination (discharge) using pipes or hoses. Proper design of these pipelines is crucial for
efficient fluid transportation.
Ammonia Booster Centrifugal Pumps
Ammonia booster centrifugal pumps are specialized industrial pumps designed to handle and
move ammonia fluid within various processes, particularly in ammonia-based production plants
like those used in the fertilizer industry. These pumps are crucial for maintaining the flow of
ammonia under different pressures and stages of production. Here's a breakdown of their key
characteristics:
Centrifugal Pump Design: Ammonia booster pumps are based on the centrifugal pump design,
which uses an impeller to impart kinetic energy to the fluid, increasing its velocity. This kinetic
energy is then converted into pressure energy, propelling the fluid through the system.
Boosting Pressure: These pumps are specifically engineered to boost the pressure of the
ammonia fluid. They take in ammonia at a lower pressure and discharge it at a higher pressure,
enabling it to meet the requirements of subsequent stages in the production process.
Critical Function: In ammonia-based processes, the booster pumps play a critical role in
ensuring a consistent flow of ammonia at the desired pressure levels. For instance, in a urea
plant, they might take ammonia from a lower pressure storage tank and elevate its pressure for
feeding into reactors or other high-pressure systems.
Motor Driven: Ammonia booster pumps are generally driven by electric motors or other
suitable prime movers. The motor-driven mechanism provides the necessary power to the
impeller, creating the centrifugal force needed to move the ammonia fluid.
Suction and Discharge: These pumps typically have two main connections: the suction side,
where they draw in the ammonia fluid from a storage tank or receiver, and the discharge side,
where they send the pressurized ammonia to the next stages of the process.
Precision Engineering: Due to the critical nature of their function, ammonia booster pumps are
engineered with precision to ensure reliable and efficient performance. They need to withstand
the challenges of handling ammonia and the associated pressures.
Sealing Mechanisms: Given that ammonia can be corrosive and potentially hazardous, these
pumps are equipped with specialized seals and materials to ensure the safe containment of the
ammonia fluid and to prevent leaks.
Process Integration: Ammonia booster pumps are integrated into larger industrial processes,
often as part of ammonia production, storage, and utilization systems. Their smooth operation
directly impacts the overall efficiency of these processes.
Maintenance and Monitoring: Regular maintenance and monitoring are essential for these
pumps to prevent breakdowns and maintain their performance over time. Any failure can have
serious operational, financial, and environmental implications.

Types of Centrifugal Pumps

Based on number of impellers in the pump

1. Single stage pump

2. Two-stage pump
3. Multi-stage pump
Based on orientation of case-split,

1. Axial split Pump

2. Radial split Pump
Based on type of impeller design,

1. Single suction Pump

2. Double suction Pump
Based on the basis compliance with industry standards,

1. ANSI pump – (American National Standards Institute)

2. API pump – (American Petroleum Institute)
3. DIN pump – DIN 24256 specifications
 4. ISO pump – ISO 2858, 5199 specifications
5. Nuclear pump – ASME (American Society of Mechanical Engineers) specifications
Based on type of volute

1. Single volute Pump

2. Double volute Pump
Based on where the bearing support is,

1. Overhung
2. Between-bearing
Based on shaft orientation

1. Horizontal Pump
2. Vertical Pump

Application of Centrifugal Pumps

1. Oil & Energy - pumping crude oil, slurry, mud; used by refineries, power generation plants
2. Industrial & Fire Protection Industry - Heating and ventilation, boiler feed applications, air
conditioning, pressure boosting, fire protection sprinkler systems.
3. Waste Management, Agriculture & Manufacturing - Wastewater processing plants,
municipal industry, drainage, gas processing, irrigation, and flood protection
4. Pharmaceutical, Chemical & Food Industries - paints, hydrocarbons, petro-chemical,
cellulose, sugar refining, food and beverage production
5. Various industries (Manufacturing, Industrial, Chemicals, Pharmaceutical, Food Production,
Aerospace etc.) - for the purposes of cryogenics and refrigerants.

Pressure behavior throughout the pump

Inlet: Certain inlet pressure
Impeller: Creates low pressure at impeller’s eye
Centrifugal force: Increases fluid’s K.E
Diffuser or Casing: K.E converts into Pressure Energy
Outlet: Higher pressure, allows fluid to be transported to required destination
Velocity behavior throughout the pump
Inlet: low velocity
Impeller inlet: Gains velocity due to rotation of impeller blades
Impeller outlet: Fluid attains maximum velocity due to centrifugal force
Diffuser or Casing: K.E converts into Pressure Energy and velocity decreases due to increasing
cross sectional area
Outlet: Reduced velocity
Energy behavior throughout the pump
Input Energy: Pump receives mechanical energy from external source like electric motor or
diesel engine
Impeller K.E: Impeller rotates and provides K.E to fluid
Centrifugal Force: Pushes away fluid impeller’s center eye towards outer edge. K.E of fluid is
increased.
Velocity Head: K.E of fluid can be expressed in velocity head. v²/2g
Pressure Energy: In diffuser K.E converts into Pressure Energy
Output Energy: Fluid exits pump with increased pressure and reduced K.E compared to inlet
Mechanical Energy Kinetic Energy Pressure Energy
All input energy is not converted into pressure energy and useful work. Some energy is lost to
friction and other inefficiencies within pump

NPSH
NPSH, short for Net Positive Suction Head, refers to a critical parameter in the context of
centrifugal pumps, specifically addressing the pressure conditions encountered by a fluid at the
pump's suction side. This measurement is quantified in terms of "head," expressed in units such
as feet or meters, as opposed to being stated as a direct pressure value, be it pounds per square
inch (lb/in²), psi, or pascals (Pa). This preference for utilizing the concept of "head" arises from
the fact that it represents a characteristic that remains constant regardless of the fluid's particular
attributes. Essentially, it signifies that a pump possesses the capability to raise diverse fluids to
the same vertical height, irrespective of their varying densities.
NPSHA = h1 + hss – hf – hvp
Purpose of NPSH

The purpose underlying NPSH lies in its capability to detect and steer clear of operational
scenarios that trigger the transformation of a fluid into vapor upon entering a pump, a
phenomenon known as flashing. Within a centrifugal pump, the pressure of the fluid is at its
lowest at the impeller's eye. Should this pressure fall below the fluid's vapor pressure, it prompts
the formation of bubbles. These bubbles then progress through the impeller's vanes toward the
discharge outlet. As these vapor bubbles traverse into a zone of elevated pressure, they can
spontaneously implode, a detrimental process referred to as cavitation (depicted in Figure 1).
This sequence of vapor bubble collapse creates recurring shock waves, which can notably
contribute to the degradation and wear of impellers and pump casings.

NPSH R
NPSH-R is a pump property. Net Positive Suction Head Required is quoted by pump
manufacturers as a result of extensive testing under controlled conditions. NPSH-R is a
minimum suction pressure that must be exceeded for the pump to operate correctly and minimise
flashing and cavitation.

Method of Calculating NPSHR

Manufacturers evaluate pumps through tests where they keep the flow steady and lower the
suction pressure (NPSH) step by step while observing the change in discharge pressure
(measured as differential head). These tests are generally conducted using water at 20°C. The
value of NPSH-R is established as the point at which the discharge pressure drops by about 3%
due to the start of cavitation.
 Sometimes, NPSH-R is indicated as NPSH3 or NPSH3% to emphasize this characteristic. In the
case of pumps with multiple stages, only the pressure drop in the first stage is considered to
determine the 3% reduction in pressure.

NPSH A
NPSH-A, known as Net Positive Suction Head Available, is a property tied to the overall system.
It's determined by evaluating the setup on the suction side of the system. In essence, it's the
pressure at the suction side minus the vapor pressure of the fluid being pumped at that specific
location. To avert cavitation, NPSH-A needs to surpass the pump's NPSH-R value established
for the chosen operating conditions. A prudent practice is to have a safety buffer of about 0.5 to 1
meter. This accounts for a variety of factors including:
 The pump’s operating environment – is the temperature constant?
 Changes in the weather (temperature and atmospheric pressure).
 Any increases in friction losses that may occur occasionally or gradually during the lifetime of
the system.

NPSH margin

The NPSH margin describes the safety factor by which NPSH-A must exceeds NPSH-R to avoid
cavitation.

It can be quoted in two ways:

 As a ratio of NPSH-A to NPSH-R. For example, an NPSH margin ratio of 1.1 indicates that
NPSH-A is 10% greater than NPSH-R
  As the difference between NPSH-A and NPSH-R. As a rule of thumb, it is necessary to ensure
that the NPSH margin is 0.5m or higher (that is: NPSH-A ³ NPSH-R + 0.5m)


 Selected NPSH Margins from ANSI/HI 9.6.1-2012 Guideline for NPSH Margin

Pump Cavitation

Cavitation is the formation of bubbles or cavities in liquid, developed in areas of relatively low
pressure around an impeller. The imploding or collapsing of these bubbles trigger intense
shockwaves inside the pump, causing significant damage to the impeller and/or the pump housing.

Causes of Pump Cavitation

 Failure of pump housing

 Destruction of impeller
 Excessive vibration - leading to premature seal and bearing failure
 Higher than necessary power consumption
 Decreased flow and/or pressure
 Types of Pump Cavitation

Suction Cavitation

When a pump is under low pressure or high vacuum conditions, suction cavitation occurs. If the
pump is "starved" or is not receiving enough flow, bubbles or cavities will form at the eye of the
impeller. As the bubbles carry over to the discharge side of the pump, the fluid conditions
change, compressing the bubble into liquid and causing it to implode against the face of the
impeller.

An impeller that has fallen victim to suction cavitation will have large chunks or very small bits
of material missing, causing it to look like a sponge. Damage to the impeller appears around the
eye of the impeller when suction cavitation is present.

Possible Causes of Suction Cavitation

 Clogged filters or strainers

 Blockage in the pipe
 Pump is running too far right on the pump curve
 Poor piping design
 Poor suction conditions (NPSH requirements)

Discharge Cavitation

When a pump's discharge pressure is extremely high or runs at less than 10% of its best
efficiency point (BEP), discharge cavitation occurs. The high discharge pressure makes it
difficult for the fluid to flow out of the pump, so it circulates inside the pump. Liquid flows
between the impeller and the housing at very high velocity, causing a vacuum at the housing wall
and the formation of bubbles.
As with suction cavitation, the implosion of those bubbles triggers intense shockwaves, causing
premature wear of the impeller tips and pump housing. In extreme cases, discharge cavitation
can cause the impeller shaft to break.

Cavitation Prevention
Start by identifying the cause of the pressure drop. In many cases moving the pump closer to the
fluid source and removing as many bends and valves as possible corrects the problem because
each component causes additional pressure drop. When suction lift is too high to maintain
pressure, move the pump closer to the fluid source or move the fluid source closer to the pump.
Enlarging suction lines can also be effective. In some obvious cases, a blockage occurs in piping
or hoses near the pump. Clear those blockages to resolve the issue. Clean suction lines by
clearing debris. Avoid blowing the debris back toward the fluid source because it’s likely to
create a blockage again.
Don’t exceed your pump manufacturer’s performance guidelines. Pump curves tell you how
much net positive suction head the pump requires, so check your pump’s performance curve to
ensure it has the right specifications for your application.
 Right pump selection
 Addressing discharge cavitation
 Routine pump maintenance
 Proper installation

Learning Outcomes

 Gained insights into water purification techniques and the importance of maintaining high
water quality for industrial processes
 Acquired knowledge of the complex process involved in urea production, from raw materials
to the final product.
 Gained exposure to maintenance and fabrication practices, witnessing real-world applications
of engineering principles.
 Developed a comprehensive understanding of pump mechanisms, types, and applications.
 Acquired knowledge of fluid transportation systems, including the role of pipes and fittings
in industrial operations.
 Understood the significance of regular equipment maintenance for optimal performance and
longevity.
 Acquired a holistic understanding of gas turbine operations, from fuel combustion to power
generation.
 Gained hands-on experience in pump maintenance and repair, understanding the steps
involved in overhauling.

Skill Developments:

 Understanding of water treatment methods, knowledge of water quality parameters,

awareness of the significance of water purity in various industries.
 Understanding of chemical processes, insight into the intricacies of fertilizer production,
familiarity with industrial-scale manufacturing.
 Familiarity with workshop tools and equipment, understanding of repair and maintenance
procedures, insight into workplace safety protocols.
 Knowledge of fluid dynamics, ability to select appropriate pumps for specific tasks,
understanding of pump maintenance and troubleshooting.

Observations & Recommendations

The demineralization water plant employs intricate processes to purify water for industrial use,
highlighting the significance of water quality in manufacturing. Implement continuous
monitoring and analysis of water quality to ensure consistent purification levels, minimizing the
risk of contamination. The complexity of the urea production process involves multiple stages
and chemical reactions, showcasing the intricacies of fertilizer manufacturing. Consider
streamlining specific stages of the process to improve overall efficiency, potentially leading to
reduced resource consumption.
The workshop serves as a hub for maintenance and fabrication activities, showcasing the hands-
on application of engineering principles. Ensure regular safety training and proper equipment
handling procedures to mitigate workplace hazards and enhance the well-being of workers. In-
depth pump study revealed the diversity of pump types and their roles in fluid management
across industries. Encourage cross-training among engineers to enhance knowledge of different
pump types, enabling efficient selection and troubleshooting.
Comprehensive study of pipes and fittings emphasized the importance of proper installation and
maintenance for fluid transportation. Develop standardized protocols for pipe installation and
maintenance, including periodic inspections and leak detection measures. The inspection of the
combustion chamber in a gas turbine underscored the critical importance of thorough inspections
for safe and efficient operation. Establish a routine inspection schedule for all critical
components of gas turbines, ensuring early detection of potential issues and preventing
downtime.

Conclusions

Overall, my internship at Pak Arab Fertilizers Multan was a comprehensive learning experience.
I acquired practical skills in maintenance, fabrication, and equipment handling, and I expanded
my understanding of various industrial processes.
The internship not only strengthened my theoretical knowledge but also instilled in me a sense of
responsibility and adaptability in a professional working environment. I am confident that the
knowledge and experiences gained during this internship will contribute significantly to my
future career in the field of engineering and beyond.

 Safety Precautions:
Safety is of paramount importance in fertilizer plants due to the potentially hazardous materials,
processes, and equipment involved. Implementing robust safety requirements helps prevent
accidents, protect personnel, and ensure environmental compliance. Here are essential safety
requirements that should be observed in fertilizer plants:

Comprehensive Safety Training:

All employees, contractors, and visitors should undergo thorough safety training, including
hazard identification, emergency procedures, proper equipment usage, and the use of personal
protective equipment (PPE).
Hazardous Material Handling:
Proper handling, storage, and labeling of hazardous materials, including fertilizers, chemicals,
and flammable substances, are essential. Clear guidelines should be in place for safe storage and
disposal of these materials.
Process Safety Management (PSM):
Establish a comprehensive PSM program to identify, assess, and mitigate potential risks
associated with critical processes. This includes hazard analysis, risk assessments, emergency
response planning, and regular process safety audits.
Equipment Inspection and Maintenance:
Regular inspection, maintenance, and testing of equipment, machinery, and safety systems (such
as fire alarms, sprinklers, and gas detectors) should be conducted to ensure their proper
functioning.
Fire Prevention and Protection:
Implement fire prevention measures, including fire-resistant construction, fire alarms,
extinguishers, hydrants, and well-defined evacuation plans. Conduct fire drills and training to
ensure employees are familiar with evacuation procedures.
Electrical Safety:
Adhere to electrical safety standards and guidelines to prevent electrocution and fire hazards.
Regularly inspect and maintain electrical equipment to minimize risks.
Personal Protective Equipment (PPE):
Provide appropriate PPE, such as helmets, gloves, safety glasses, and protective clothing, based
on the specific tasks and potential hazards in different areas of the plant.
Confined Space Entry:
Establish strict protocols for entering confined spaces, including proper ventilation, monitoring,
communication, and rescue plans.
Emergency Response Plans:
Develop and regularly update emergency response plans that cover various scenarios, including
chemical leaks, fires, explosions, and medical emergencies. Conduct drills to ensure all
personnel are familiar with these plans.
Training and Competency:
Ensure that all personnel are adequately trained and competent to perform their tasks safely. This
includes regular refresher training and assessments.
Process Isolation and Lockout/Tagout (LOTO):
Implement proper procedures for isolating and locking out equipment before maintenance or
repair work. This prevents accidental energization and ensures the safety of personnel working
on the equipment.
Environmental Protection:
Ensure that processes and waste disposal methods comply with environmental regulations to
prevent contamination and harm to the environment.

Project: Frequent Mechanical Seal failures at Ammonia Booster

Pump (P-5)

Executive Summary:
This comprehensive report delves into the persistent mechanical seal failures encountered in the
Ammonia Booster Pump (P-5) at Urea Plant of Pakarab Fertilizers Limited Multan. The repeated
breakdowns of mechanical seals have brought about operational interruptions, maintenance
complexities, and financial setbacks. The purpose of this report is to uncover the underlying
causes of these failures, evaluate their consequences on plant operations, and propose actionable
recommendations to rectify the issue and fortify the reliability of the pump system.

Introduction:
The Ammonia Booster Pump (P-5) stands as a pivotal component within the operational
framework of Pakarab Fertilizers Limited Multan. It is entrusted with the critical task of
elevating ammonia flow to higher pressures within the production process. The recurring failures
of mechanical seals in this pump have emerged as a pressing concern, significantly impacting not
only operational efficiency but also imposing substantial burdens in terms of maintenance
expenses and operational costs. This report meticulously examines the root causes behind these
frequent mechanical seal failures and aims to furnish pragmatic strategies for addressing the
issue and fostering sustainable improvements.

Background:
At the heart of Pakarab Fertilizers Limited Multan urea production process, the Ammonia
Booster Pump (P-5) assumes a paramount role. However, the issue of recurrent mechanical seal
failures has cast a shadow over its reliability. These failures have translated into unscheduled
downtime, necessitated heightened maintenance efforts, and triggered elevated operational
expenditures. Understanding the implications of these failures requires a comprehensive analysis
of the problem's origins and a concerted effort to pinpoint effective solutions

Pump Specifications:

Pump Type Single suction, closed impeller, over-hung

centrifugal pump
Pump make M/s Weir Gabbionetta

Mechanical Seal Double mechanical seal in Tandem

arrangement
Mechanical seal make M/s John Crane

Flushing plan of secondary seal Plan 52

Flushing plan of primary seal Plan 11

Mechanical seal
Mechanical seals prevent leaks of the pumped fluid and the loss of expensive pumped products.
They keep or seal the pump so that the fluid stays inside it. Since about the 1950s, mechanical
seals have almost eliminated the inefficient and expensive stuffing box
They are installed where the pump shaft enters or leaves the pump housing. Seals of various
types, sizes, and configurations are available. However, they all use the basic principle of a
combination of fixed and rotating surfaces

Parts of Mechanical Seals:

Following are the parts of mechanical seal;
Stationary Face:
This part remains fixed and is usually made of a hard material like ceramic.
Rotating Face:
This part moves with the pump shaft and often made of a softer material like carbon.
Secondary Sealing Elements:
They are additional sealing elements that help maintain the fluid-tight seal and include O-rings,
elastomers, gaskets.
Springs & Energizing Elements:
These components apply pressure to keep the stationary and rotating faces in contact, creating
the sealing interface

Working Principle
The mechanical seal works by using two very flat overlapping surfaces, which makes leakage
difficult to occur. One surface does not rotate with the axis (stationary), while the second surface
rotates with the axis (rotates).

When the two faces rub together, the fluid film between the two faces migrates for cooling and
lubrication purposes. Ideally, the pumped fluid will flow out between the two faces, enter as a
liquid, and evaporate when it reaches the atmosphere

It must be pointed out at this point that all mechanical seals leak some very small amounts of
steam, so even the best mechanical seal design will lose a small part of the pumped fluid.
Types of Mechanical Seals:

Following are the types of mechanical seals;

 Single Mechanical Seal

 Double Mechanical Seal
 Cartridge Mechanical Seal
 Split Mechanical Seal
 Metal Bellow Seal
 Elastomer Bellow Seal
 Pusher-Type Seal
 Non-Pusher (O-Ring) Seal
 Mixer Seal
 Slurry Seal
 Gas Seal

Mechanical seals classified by design

Mechanical seals are classified by structure

Seal points in Mechanical Seal

In the mechanical process, three sealing points are essential.

 Leakage between the casing and the stationary element

 Leakage between the shaft and rotating element

 Leakage between rotating and seal elements, and the mating surface

The three basic components are:

 A set of primary sealing element

 A set of secondary sealing element

 The hardware that attaches, positions and maintains face to face contact

API plan 52

API Seal Plan 52 employs a reservoir to facilitate the circulation of an unpressurized buffer fluid
between the inboard and outboard seals. This aids in maintaining a favorable environment within
the sealing system. A pumping ring is integrated into the design to ensure the active circulation
of the buffer fluid, promoting efficient flow between the seals. It is crucial to mitigate frictional
losses within the buffer fluid inlet and outlet lines. This can be achieved by carefully selecting
appropriate tube dimensions, incorporating generous curves or 45-degree bends, and minimizing
the length of tubing runs. Seal Plan 52 is a prevalent choice when dealing with light
hydrocarbons or fluids characterized by high vapor pressures. It's important to note that the
buffer fluid must be compatible with the process fluid, as any potential leakage from the inboard
seal could eventually mix with the buffer fluid.

This plan:

 Provides additional heat removal from the inboard seal when required
 Acts as a secondary seal to prevent process fluid leakage to atmosphere

Plan 52 is available as a seal pot assembly. The associated field installation kit for use in
connecting the seal pot assembly to your system is also available.

Assembly components may include:

 Swagelok tube fittings

 63 series ball valves
 CH series check valve
 V series 2-valve manifold
 QTM series quick-connects
 Bimetal thermometer
 TTW series thermowell tee
 PGI series gauges
 Swagelok pipe fittings
 Pressure transmitter
 Level transmitter
 Level switch
 Seal pot
Applications of API Plan 52 Seal System

While plan 52 is beneficial and often necessary for applications including light hydrocarbons and
high vapor pressure fluids, it may also be used for non-flashing services. This plan is favorable
for applications where the process fluid or product should not be contaminated by a buffer fluid.
In oil and gas operations, including steam-assisted gravity drainage (SAGD), API plan 52 can be
used for dual mechanical seals for centrifugal pumps in upstream, midstream, and downstream
operations with either high vapor pressure or lower vapor pressure fluids. In chemical plants and
petrochemical refineries, dual mechanical seals may be used for high vapor pressure fluid
applications. For chemical plants where chemicals are extremely hazardous, a more robust
sealing system may be implemented. For power generation, API Plan 52 may be used for water
pumping applications, such as boiler feedwater pumps and water treatment pumps.

Mechanical Seal Failures

Mechanical seals play a pivotal role across diverse industries, guaranteeing the leak-proof
operation of pumps, compressors, and other rotational machinery. The frequent breakdowns of
these seals can give rise to considerable operational and financial predicaments. This report
deeply explores the root causes behind these malfunctions, their consequences for industrial
processes, and recommended actions to forestall or curtail their incidence.
Failures in mechanical seals pertain to the dysfunction, deterioration, or collapse of the sealing
constituents employed in pumps, compressors, and similar rotating equipment. These
malfunctions can result in the seepage of fluids, containment loss, and disturbances in operations.
The role of mechanical seals in forestalling fluid leakage and upholding system integrity is of
paramount importance.
Chronic mechanical seal leakage has afflicted NH3 pumps for numerous years. In 2018, a
comprehensive assessment of the mechanical seal failure issue was conducted, taking into
account the subsequent factors:
Accumulation of carbamate residues in mechanical seals due to the obstruction of the E-7
exchanger.
• Efficiency of buffer fluid circulation through the pumping ring.
• Compatibility of the buffer fluid.
• Conformance of the seal installation with the OEM drawing.
• Vibrations and misalignment.
• Improper installation and upkeep.
• Particles and impurities in the process fluid can erode the seal surfaces, diminishing their
efficacy and resulting in leaks.
• Frequent abrupt start-stop cycles or exposure to fluctuating temperatures can subject seals to
thermal strain, culminating in cracks or deterioration.
• Cavitation, characterized by the formation and collapse of vapor bubbles within the fluid, can
induce erosion and pitting on the seal surfaces, undermining their sealing effectiveness.
• Corrosive fluids have the potential to corrode seal components, diminishing their efficiency
and causing leaks.
• Inadequate or incorrect lubrication of the seal surfaces can lead to excessive friction and the
generation of excessive heat, hastening premature malfunction.
• Over time, seals can undergo fatigue and aging, leading to diminished flexibility and reduced
sealing performance.

Recommendations to Mitigate Mechanical Seal Failures

Select seal materials that are compatible with the characteristics of process fluids and the specific
operating conditions.
• Engage in consultations with seal manufacturers to ascertain the most fitting material choices
for optimal performance.
• Install dedicated piping from the pump casing vent to effectively expel vapors present in the
casing.
• Evaluate the current piping infrastructure meticulously to identify any potential areas of flow
constriction. Consider the addition of a make-up line (Cold shot) if necessary.
• Thoroughly investigate any potential sources of vapor generation and take necessary measures
for their removal before initiating pump operations.
• Enforce meticulous precision during the installation process to eliminate misalignment-related
failures.
• Conduct a comprehensive assessment of the liquid NH3 filtration requirements, considering
the potential presence of oil or foreign particles.
• Thoroughly assess the hydraulic characteristics of the existing piping system to identify the
potential for vapor formation. Implement any required modifications accordingly.
• Verify the proper installation of reducers at the pump suction point.
• Adhere rigorously to installation protocols recommended by the manufacturer to guarantee
optimal sealing performance.
• Exercise caution when handling seals during both transportation and installation to mitigate the
risk of damage.
• Maintain operational conditions within the prescribed limits, avoiding circumstances that
accelerate wear and deterioration
• Implement strategic approaches to manage thermal stress during cycles of starting and
stopping
• Introduce effective filtration systems to eliminate contaminants from process fluids.
• Ensure appropriate and consistent lubrication and cooling to prevent the escalation of friction
and excessive heat buildup.

Conclusion:
The repercussions of mechanical seal failures extend widely, influencing operational
effectiveness, financial outlays, and safety protocols. Through a comprehensive comprehension
of the underlying triggers for these breakdowns and the adoption of preemptive strategies,
industries can elevate the dependability of their equipment, curtail the need for frequent
maintenance outlays, and cultivate work settings that prioritize safety.
The deliberate incorporation of suitable materials, meticulous installation methodologies, and
meticulously designed operational protocols stands as imperative to thwarting the reoccurrence
of mechanical seal failures and fine-tuning industrial workflows.

References:
https://www.iqsdirectory.com/articles/centrifugal-pump.html
https://www.michael-smith-engineers.co.uk/resources/useful-info/centrifugal-pumps#:~:text=A
%20centrifugal%20pump%20operates%20through,it%20towards%20the%20pump%20outlet.
https://www.michael-smith-engineers.co.uk/resources/useful-info/npsh
https://blog.craneengineering.net/what-is-pump-cavitation#:~:text=There%20are%20two
%20types%20of%20pump%20cavitation%3A%20suction%20and%20discharge
https://www.nbseals.com/what-is-a-mechanical-seal/
https://leakpack.com/explain-mechanical-seal-basics-seal-selection-process/
https://edmontonvalve.swagelok.com/blog/api-plan-52-seal-system-canadian-operations-
edv
https://www.swagelok.com/en/engineering-services/design-assembly/mechanical-seal-support-
systems/between-seal-plan-assemblies/api-plan-52#:~:text=API%20Seal%20Plan
%2052%20utilizes,a%20pumping%20ring%20is%20employed.
References:

 https://www.nuclear-power.com/nuclear-engineering/fluid-dynamics/centrifugal-pumps/
parts-of-centrifugal-pump/
 https://www.michael-smith-engineers.co.uk
 https://www.mtp.com.au/news/3-benefits-using-centrifugal-pumps
 https://theconstructor.org/practical-guide/centrifugal-pump-working-types/2917/
 https://www.michael-smith-engineers.co.uk/resources/useful-info/
npsh#:~:text=Summary,under%20conditions%20which%20favour%20cavitation
 https://www.csidesigns.com/blog/articles/what-is-pump-cavitation-and-how-to-prevent-it
