Best-in-Class Outcomes at Fauji Fertilizer

The results of the SimSci OTS at Fauji are very evident.

1. Within the first year, 22 FFC engineers have become OTS instructors; they have conducted 130 training sessions for nearly100 management and staff operators
2. Plant operators have benefited from best-in class training and are empowered to respond confidently and consistently in real-time
3. With the OTS, training time has decreased from years to months
4. Unscheduled shutdowns are significantly reduced, plant startup and shutdown is more efficient and emergencies have been handled smoothly

Thanks to the new SimSci OTS solution, the FFC operator program is both effective and popular. Even more important, the company is seeing improved and safer plant operations, and living up to the corporate vision.

More information

Please click on the following links for more information on the SimSci OTS.

1. SimSci Operator Training Simulators (OTS) website
2. SimSci SPC 270
3. SimSci Trisim Plus
4. SimSci Dynamic Simulation Suite

Operator Preparedness at Fauji Fertilizer with SimSci OTS

Very specific goals were created by Fauji Fertilizer directed to strengthen its operator skills and enhance productivity. They are as follows:

• To train personnel on the newly-commissioned DCS to reduce operational incidents, increase up-time and equip operators to respond to emergencies 
• To maintain a high level of performance for experienced operators and new hires alike 
• To quickly and effectively prepare new plant operators to work in actual control room and field environments 

Of course they did face a few challenges, such as:

• The Fauji plant offers only infrequent opportunities for on-the-job training for critical and emergency scenarios, so engineers must be trained and tested through simulations 
• The expected retirements and attrition of existing workers will require many new operators to be trained quickly 

As you can see, one of the main challenge of big chemical plants is the capability to maintain the skill of its workforce amidst the other major challenge of an aging workforce.

“Our preparedness level has improved by many folds. Now both newly-trained and experienced operators have gained a lot of confidence. They are well-prepared to handle the plant in normal operation, startups/shut downs and in emergency situations.”

Mubashar M. Butt, Deputy Manager Production, Fauji Fertilizer Company 

It was really time to consider using an OTS.

 

More information

Please click on the following links for more information on the SimSci OTS, .

1. SimSci Operator Training Simulators (OTS) website
2. SimSci SPC 270
3. SimSci Trisim Plus
4. SimSci Dynamic Simulation Suite

Realistic Operator Training Simulator at Fauji Fertilizer

Since 1982, Fauji Fertilizer Company (FFC) has provided 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. Production facilities encompass three plants.

An Opportunity for OTS 

In 2011, when it came time to commission a new Foxboro DCS, Fauji decided to add an Operator Training Simulator (OTS), as part of a training program that it hoped would:

• Decrease the risk of major operational incidents 
• Reduce startup and downtime 
• Increase the plant’s on stream factor 
• Improve efficient handling of emergencies 

Fauji chose SimSci OTS as the main software for its simulation and training solution.

More information

 

In my next series of posts, I will be talking about how Fauji was able to utilize the SimSci OTS to create a realistic training solution that benefits its newly hired and experienced plant operators. In the meantime, you can click on the following links for more information.

1. SimSci Operator Training Simulators (OTS) website
2. SimSci SPC 270
3. SimSci Trisim Plus
4. SimSci Dynamic Simulation Suite