AVEVA (Schneider Electric) Case Studies Operator Training Simulation Solution Strengthens Operator Skills, Improves Safety and More

	Operator Training Simulation Solution Strengthens Operator Skills, Improves Safety and More AVEVA (Schneider Electric)

Operator Training Simulation Solution Strengthens Operator Skills, Improves Safety and More

AVEVA (Schneider Electric)

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
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. Read More
About 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. Read More
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. Read More Log in to view content
Contents

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

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.

About 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.

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.

Impact #1	The number of unscheduled shutdowns has been significantly reduced.
Impact #2	Emergencies and unplanned startups have been reduced.
Impact #3	Operators are responding confidently and consistently, because they’ve had virtual experience with almost every possible disruption through their OTS experience.

Impact #1

The number of unscheduled shutdowns has been significantly reduced.

Impact #2

Emergencies and unplanned startups have been reduced.

Impact #3

Operators are responding confidently and consistently, because they’ve had virtual experience with almost every possible disruption through their OTS experience.

Benefit #1	Within the first year, 22 FFC engineers have become Operator Training Simulator (OTS) instructors and conducted 130 training sessions.
Benefit #2	A total of 93 managers and staff members have been trained via the OTS so far.
Benefit #3	Training time has decreased from years to months.

Benefit #1

Within the first year, 22 FFC engineers have become Operator Training Simulator (OTS) instructors and conducted 130 training sessions.

Benefit #2

A total of 93 managers and staff members have been trained via the OTS so far.

Benefit #3

Training time has decreased from years to months.

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Overview

Operator Training Simulation Solution Strengthens Operator Skills, Improves Safety and More

Operational Impact

Quantitative Benefit