Fauji Jordan Fertilizer Complex
FJFC Bin Qasim Karachi Pakistan
1350 t/d DAP Plant, 1670 t/d Urea Plant and 1350 t/d Ammonia Plant
Civil Consultancy Work including planning, designing, construction documentation of the multi-million Fertilizers Complex being set up by Fauji Fertilizers Ltd. in joint venture with State of Jordan in Port Qasim Karachi; for the consortium of Krebs (France), Klockner (Germany), HRL and Descon. Project includes 1350 tons/day DAP Plant, 1670 tons/day Urea Plant and 1350 tons/day Ammonia plant relocated from USA consisting of plant buildings, foundations, power plant, utilities plant, office building, technical services building, workshop and stores, water tanks, cooling towers, Phosphoric acid area, Ammonia and other chemicals storage areas, products storage building, bagging & Shipping building, roads, water supply, sewerage, drainage, electrical illumination, HVAC and other utilities.
Urea Granulation Plant
Scope of work includes the analysis and design of foundations against the provided base plate forces, design of grade slab, equipment foundations at grade and production of structural drawings after wetting/approval by consortium partners. The system was modeled for three different options, first as a three dimensional grid with pedestals, second as a mat foundation and finally as a three-dimensional grid system with mats at selected locations after comparing the results from first two models. Soil springs were taken in to account during analysis in all cases. The production of the drawings involved the coordination with services and plant layout drawings. The precision of levels was maintained for sump pits, oil pits, cable trenches, ducts and plant buildings in the vicinity area. |
Urea Wet (Solution) Plant
A concrete frame structure with various pumps, compressors, motors, tanks, vessels and other mechanical equipment installed at different levels. The system was designed against dead, live, wind and earth quake loads. A three dimensional modal of the main frame was constructed for the design of columns. Secondary framing at each level was decided as per the point loads and slab openings. Detailed analysis was performed for per storey basis. Embedded plates and anchor bolts were provided at precise locations and levels for the support and positioning of equipments, cable ducts and erection of secondary steel platforms. Grid foundation was devised in substructure. At grade industrial slab was provided with expansion and contraction joints at required equipment and column locations. Same standards of detailing and drawing coordination were maintained. |
Urea Wet (Reactor) Plant
A 48.5 m high and 9x12 m2 base area steel structure supporting a 50 tons urea reactor at its mid height. The foundation mat of the structure was modeled with pedestals against the base plate forces and calculated soil springs for all degrees of freedom. A precise analysis was performed to limit the differential settlement of column points to 12 mm to avoid the induction of P-delta forces. Standard detailing and coordination for the plant was maintained. |
Miscellaneous structures in the Urea area
Manual design calculations were performed for miscellaneous structures such as foundations for tanks, tall vessels, retaining walls, Pipe racks, oil tanks and pits with bund walls. Proper sealants, fillers and water stoppers were devised at expansion, contraction and construction joints especially between slab on grade, retaining walls and equipment pedestals. Extreme considerations were given to the coordination of the structures while defining levels, locations and orientation. Standards of detailing and coordination were followed throughout the Urea area. |
DAP (Diammonium Phosphate) Plant
A multi storey plant with secondary steel platforms and levels. The system was analyzed against the precisely calculated loads as two-dimensional frames on both axes specifically to get column biaxial moments. Slabs were designed as per ACI coefficients method. A sagged slab panel was reanalyzed and checked as curved geometry caused accidentally by 150mm deflection of scaffolding at the mid span during the pouring of concrete. The first DAP plant constructed in the country having a number of embedded plates and anchor bolts which were coordinated with consortium partners prior to the issuance of formwork drawings. These embedded parts were precisely located and coordinated to facilitate the erection of steel structures, steel platforms, hanging platforms and the support for cable trays and other mechanical equipment. The foundation was designed as three- dimensional grid beam system however, at few locations mat was also introduced to accommodate heavier loads. Industrial slab was provided on grade with fully coordinated trench layout and pits. |
Final Products and Material Storage Building
A 215m long and 65m wide storage building for Urea and DAP products. The structure consists of various structural elements such as prestressed beams, precast purlin and beams, precast and cast in place columns, industrial slabs and precast retaining walls. Crack width criteria was strictly followed to avoid any possible corrosion to steel reinforcement. The scope of work for this job involved complete design coordination, management and assistance to supervisor in designing the various structural elements. The main frame of the structure was analyzed using the frame element end moment releases option to cater for actual end conditions. Maximum deflection of 25mm was limited at crane level due to mechanical constraints. The most responsible task involved in this job was project management, design coordination and the coordination with site and consortium partners. |
Reinforced Concrete Stack/Chimney
A 73m high and 6.4m dia concrete chimney with varying shaft thickness and vent pipe openings. The system was analyzed three-dimensionally using plate elements as per finite element theory against earthquake loads. Wind loads were taken as permanent loads and the deflections were restricted to 300mm at the top as per ACI code for chimneys and towers. A combined model for superstructure and substructure was constructed using soil springs to get more realistic and precise stresses. More than 1000 plate elements contributed in constructing the model. The design was also cross checked by manual calculations under the supervision of chief engineer. |
Bagging and Shipping Building
A steel structure with mat foundation and industrial slab. The base plate forces were applied in the foundation analysis. Two different models were constructed to analyze the mat, first as a three-dimensional mat with plate elements and soil springs and secondly as 8-noded solid elements with soil springs to cross check the results and for future modeling with solid elements. Drawings were fully coordinated with other plants and services drawings. |
updated: June 2002