Operator Training Simulation Solution Strengthens Operator Skills, Improves Safety and More
Customer Company Size
Large Corporate
Region
- Asia
Country
- Pakistan
Product
- SimSci DYNSIM
- SimSci SIM4ME Common Modeling Environment
- SimSci FSIM Plus
- SimSci TRISIM Plus
Tech Stack
- Distributed Control System (DCS)
- Operator Training Simulator (OTS)
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Productivity Improvements
- Employee Satisfaction
Technology Category
- Functional Applications - Remote Monitoring & Control Systems
Applicable Industries
- Chemicals
Applicable Functions
- Discrete Manufacturing
- Maintenance
Use Cases
- Predictive Maintenance
- Virtual Training
Services
- Training
- System Integration
About The Customer
Fauji Fertilizer Company (FFC) is a leading fertilizer manufacturing company based in Goth Machhi, Pakistan. Since 1982, FFC has been providing premium quality fertilizer products to their commercial customers. As one of the largest manufacturers in the country, the operation produces 551,000 metric tons of urea and 445,500 metric tons of diammonium phosphate (DAP) annually. The company operates three production facilities. The FFC vision is to achieve excellence in every aspect of plant operation, which is tied to benchmarks of safety, reliability, efficiency and environmental sensitivity.
The Challenge
Fauji Fertilizer Company (FFC) was facing a challenge of training their personnel on the newly-commissioned Distributed Control System (DCS) to reduce operational incidents, increase uptime and equip operators to respond to emergencies. The company also wanted to maintain a high level of performance for experienced operators and new hires alike. Another challenge was to quickly and effectively prepare new plant operators to work in actual control room and field environments. The company was also facing manpower challenges due to upcoming retirements and anticipated higher attrition rate. The company needed a solution that could expose new hires to critical and emergency scenarios that happen only infrequently.
The Solution
FFC decided to implement an Operator Training Simulator (OTS) system to train their personnel on the newly-commissioned DCS. The OTS was expected to decrease the risk of major operational incidents, reduce startup and downtime, increase the plant’s on stream factor and improve efficient handling of emergencies. The company selected Schneider Electric's OTS implementation because it offered a direct-connect system with no requirement for translation, emulation or recompilation of the system configuration, a technically superior process and system model, high fidelity with an accuracy level of +2% PFD value, and strong technical and engineering expertise with long-term maintenance support. The OTS was designed and deployed in conjunction with the installation of the new DCS. The company also adopted a 'train the trainer' approach where two lead engineers were trained first who then conducted 130 training sessions in the first year.
Operational Impact
Quantitative Benefit
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