Report on Industrial Visit to FEW

2013

CHAPTER-1

INTRODUCTION
ABOUT FACT The Fertilizers And Chemicals Travancore Ltd., (FACT) is Indias pioneering chemical fertilizer manufacturer, located near Cochin in Kerala State, South India. Since inception in 1944, they have witnessed a phenomenal transformation from a manufacturer of fertilizers to a multi-dimensional corporate entity engaged in the manufacture of various fertilizers, allied chemical products, petrochemicals; engineering services, fabrication, design, R&D and consultancy services. DIVISIONS Units of FACT include the two manufacturing divisions Udyogamandal complex (UC) and Cochin division (CD).

FACT Engineering and Design Organization: this division was established in the year 1965 for the sustained growth of chemical fertilizer industry.

Petrochemical Division: The petrochemical division was established in 1990 for manufacturing caprolactum.

Udyogamandal Division: This division looks after the production of ammonium sulphate and was set up in the year 1947.

The other divisions include research and development, computer service center and marketing. PRODUCTS The products manufactured by Fertilizers and Chemical Travancore Limited range from:

Ammonium Sulphate Caprolactum Sulphuric Acid Nitric Acid Ammonia Soda Ash Page 1

Report on Industrial Visit to FEW

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Fertilizers and Chemical Travancore Limited does fabrication of equipments and engineering consultancies. Besides, the company also manufactures chemicals, petrochemicals, pharmaceuticals and hydrometallurgy. The company is one of the eminent companies in Kochi, generating huge revenue. FACT Cochin Division has set up in the 1970's at Ambalamedu 30 km from Udyogamandal and adjacent to the Cochin Refineries. The factory site is well connected by rail, road and waterways which facilitate easy movement of raw materials and products. The present production facility includes manufacture of 4,85,000 TPA of Complex Fertiliser (FACTAMFOS 20:20:0:13), 3,30,000 TPA of Sulphuric Acid and 1,15,200 TPA Phosphoric Acid. The Complex has a well designed effluent treatment and waste water recycle system. There is facility to import and store raw materials required for FACT at Willingdon Island installation. The facility includes ship unloading system and storage for raw materials like Sulphur, Rock Phosphate and Ammonia. Cochin Division is an ISO 14001:2004 certified company for Environment Management System by M/s DNV and ISO 9001:2008 certified organisation for manufacture of complex fertiliser by M/s TUV.

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CHAPTER-2

FACT ENGINEERING WORKS

FACT Engineering Works (FEW), the Fabrication and Engineering Division of FACT was established in the year 1966. FEW is one of the leading contracting firms in the Country offering services through the manufacturing wing with modern fabrication and testing facilities and the project wing undertaking project construction works. To expand its shop activities, FEW acquired the assets of M/s Giovanola Binny at Palluruthy, Cochin and is operating at Palluruthy from February 1989 onwards. Present range of equipment fabricated by FEW include items like Class I Pressure Vessels, Heat Exchangers in Carbon Steel, Alloy Steel and Stainless Steel, Chemical Process Equipments, Penstock Pipes, Coloumns, Towers, etc. Since 2006 FEW has also been producing ship building components such as Hatch Covers, Bulk Storage Tanks, Spud Pipes, Crane Posts, Hull Blocks, etc. Project wing of FEW undertakes design engineering fabrication and erection of plant piping & off-site piping for process industries; design, fabrication and erection of large sixe Storage Tanks including Ammonia Storage Tanks, Vessels and other items for process industries; laying of cross country pipelines for water supply schemes/oil terminals on turnkey basis. The quality system of Manufacturing Wing as well as Project Wing has been certified to ISO 9001 since 1998. ISO 9001 certified, state-of-the-art fabrication facility for Design and Fabrication of Pressure Vessels, Heat Exchangers and Storage Tanks. Fabrication and Erection of Plant and Equipment for Process Industries, Cross Country, In-plant and Offshore Piping, Refinery shut down inspection services.

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Report on Industrial Visit to FEW

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CHAPTER-3

SERVICES AND PRODUCTS

FEW has been awarded ISO 9001 by Det Norske Veritas of Netherlands for its services like design, fabrication and supply of pressure vessels, heat exchangers, storage tanks and fabrication and erection of plant and equipment for process industries, cross country pipelines, in-plant and offshore piping. The whole range of fabrication services from FEW carries the utmost quality stamp of ISO 9001, which includes products at workshop as well as products at site.

Products at Workshop
FEW has a fully automated and finely integrated workshop equipped with state-of-the-art machinery and the latest in fabrication, testing and welding. The workshop offers fabrication of almost all equipment vital to the process industry like:

Heat Exchangers Pressure Vessels Columns & Towers Storage Tanks in ferrous & non-ferrous metals Reactors

Products at Site
FEW also has the capability and resources to undertake fabrication projects at site. A highly skilled team of engineers and craftsmen is available for projects of any description at any given site. FEW can also undertake design, engineering, fabrication and erection of:

Dry seal/wet seal industrial gas holders of vertical / spiral lifts Page 4

Report on Industrial Visit to FEW

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Plant piping and offshore piping for process industries Spillway shutters, pen stock pipes large size storage tanks, vessels and other items of process industries Cross country piping Oil terminals on turnkey basis Columns, Towers Floating roof tanks etc. Refinery shut down inspection services

Codes in Practice
At FEW all fabrication is done in accordence with the following internationally recognised codes: ASME Section VIII Div.1 TEMA R, C&B ASME Section VIII Div.2 AP1650 BS5500 IS2825-1969 AP1620 IS803

Inspection Agencies
All Major third party inspections at FEW are carried out agencies like: Lloyd's Register Industrial Services (LRIS) Bureau Veritas (BV) Indian Register of Shipping (IRS) Bax Counsel Inspection Bureau Pvt. Ltd. (BCIBPL) Directorate of Factories & Boilers FACT Engineering & Design Organisation (FEDO) Projects & Development India Ltd. (PDIL) Engineers india Ltd. (EIL)

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Technical Back up and Tie ups

When we assign a project to FEW, we are assured of technology leadership, technical expertise and management skills of a multi-product, multi-division corporation. For instance, FEW has access to the vast resource pool of FACT Engineering and Design Organisation (FEDO, a leading engineering consultant and a subsidiary of FACT, the fertiliser giant. While FEDO provides project implementation programmes and engineering designs, FACT offers back up in terms of personnel, training and commissioning expertise. Complementing comprehensive technical expertise is FEW's project to project tie-up with technology leaders

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Report on Industrial Visit to FEW

2013

CHAPTER-4

WORKSHOP FACILITIES
FEW's self-contained workshop at Kochi can provide you with state-of-the-art facilities at every stage of your venture. This workshop is well equipped to fabricate equipment up to 75mm thickness. FEW has its own stress relieving furnace of size 10.7m x 3.675m calibrated under Lloyds Register Industrial Services, India. This furnace can stress relieve almost all equipment in a large process industry. FEW has also set up a full-fledged QA/QC department staffed by engineers qualified in ASNT Level I, II & III to ensure complete compliance to engineering codes and assure quality of fabrication. Few fabrication firms take the pains for such exhaustive and stringent inspection as we do. We conduct NDT and Destructive tests such as dye penetrants tests, magnetic particle tests, X-ray and Gamma ray radiography, ultrasonic tests, tensile and bend tests.

The high-end facilities at FEW workshop include: CNC Drilling Machine

Table working area: 1200mm x 1200mm Solid drilling capacity in steel: 50mm hole diameter

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Report on Industrial Visit to FEW

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Weight carrying capacity of table: 2000kg Table travel X axis: 1500mm Spindle head travel - Y axis : 1300 Spindle vertical travel - Z axis : 400mm

Plate Bending machines of Capacities

60mm thk x 2.5m width 40mm thk x 2.5m width 36mm thk x 3.0m width 20mm thk x 2.5m width

Submerge Arc Welding Units Pinch Press - 400 T Section Bending Machine Radial Drilling Machines Guillotine Shear Lathes & Shaping Machinery Press Brake Automatic Welding Units Sand Blasting Facility Hydraulic Tube Pulling Units Hydraulic Testing Unit Self aligning self centering rotators TIG Welding MIG Welding Hydraulic Pipe Bending Hydraulic testing units Vacuum testing facility Overhead crane of various capacities Air plasma & Argon plasma cutting units

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Report on Industrial Visit to FEW

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CHAPTER-5

IMPORTANT PROJECTS EXECUTED BY FEW

Bangalore Water Supply & Sewerage Board, Bangalore

o

Fabrication, laying & commissioning of 1800mm dia pumping main (cross country) - 34 km.

Bharat Petroleum Corporation Ltd., Kochi

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Laying of petroleum product twin pipeline 600 NB (cross country) 19 km.

Madras Fertilisers Ltd., Manali, Chennai

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Design, fabrication, site erection and commissioning of MDEA Tank Package.

BPCL/Kochi Refineries Ltd., Ambalamugal

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Erection of equipment/machinery, fabrication and erection of piping for aromatic project.

BPCL/Kochi Refineries Ltd., Ambalamugal

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Fabrication and erection of piping, tankages, erection of equipment etc., for relocation Asphalt Filling Plant.

Cochin Shipyard Ltd., Kochi

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Rolling welding and supply of Conductor Guides/Conductor Protectors ONGC Project. Ship Hatch Covers.

Kerala State Electricity Board, Thiruvananthapuram

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Erection of 1650 MT of steel liners for the Lower Periyar Hydro Electric Power Project.

FACT (RAP), Udyogamandal

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Fabrication, erection, testing etc. of off-site storage tank.

FACT Cochin Division, Ambalamedu

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Design, supply, fabrication, erection and commissioning of Floating Roof Naphtha Storage Tank of 3900 m3 capacity.

FACT (RAP), Udyogamandal

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Design, engineering, manufacture/fabrication, site erection of Ammonia

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Report on Industrial Visit to FEW

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Storage System (5000 GMT capacity).

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Erection of underground piping for cooling water, fire hydrant and raw water.

o o

Fabrication, erection, testing of off-site storage tank. Fabrication, erection and testing of column and towers, drums and press vessels - 26 nos.

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Report on Industrial Visit to FEW

2013

CONCLUSION
A lot of theory is learnt in class regarding how does a heat exchanger works & how it is manufactured. The journey unfolded various aspect of the heavy duty metal joining. Starting from the nuts and bolts, to the massive structure.

It was an informative, interesting and a successful visit. As students of Mechanical Engineering, we learned more about welding, sheet bending & rolling process. We got a chance to visualize internal details of different type heat exchanges and we witnessed a heat exchanger pressure hydro test.

Also we got exposure to inspection equipments such as X-ray testing & ECO testing.

We take this opportunity to thank the entire team of FEW for providing us with the practical information and well as wonderful hospitality. We take a moment to offer our greetings to the entire FEW teams. .

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