How FFC Chemical Plant Optimizes Operations with Electrical Load Management System

ETAP Real-Time gave us unmatched system visibility. Because you have a complete electrical system model, you can use real-time monitoring and system analysis tools to gain excellent visibility into the system.
By Hassaan Rauf, Senior Executive (Electrical), Fauji Fertilizer Company

This case study highlights ETAP's collaboration with Fauji Fertilizer Company Limited (FFC) of Pakistan to replace their existing Electrical Load Management System (ELMS) with ETAP’s iLS™ (Intelligent Load Shedding System), integrating IEDs for real-time monitoring and load calculation, utilizing ETAP’s digital-twin platform and model-driven solution to address load shedding requirements and improve system reliability efficiently.

Fauji Fertilizer Company is a leading fertilizer manufacturer in Pakistan, committed to innovation and prosperity. The Company operates three world-scale urea manufacturing plants with an aggregate design capacity of over 2 million metric tons yearly. FFC holds a diverse investment portfolio comprising Fertilizer (FFBL), Renewable Energy (FFCEL), Cement (FCCL), Food (FFF), Technical Services (Olive), and Banking (Askari).

 

Location: Rawalpindi, Pakistan

Year: 2023

Real-time management of the electrical system for the chemical plant

Challenges

  • To find new, proven, scalable software and robust hardware to replace old inefficient Load Management and Load Shedding Systems.
  • To provide high-level communication between software and hardware on the site.
  • To improve motor starting by automatic management of the power reservation. To exclude a manual selection of loads to be shed. 
  • To improve the plant electrical system's reliability and make the system controllable and manageable.

Which solutions did they choose?

Selected applications

They selected ETAP Intelligent Load Shedding to analyze, model, and operate electrical power sources, focusing on energy quality and load-shedding algorithms.

Why do they use ETAP?

Main Customer Benefits

  • One window solution for a complete electrical system for hardware and software based on the ETAP modeling possibilities.
  • The electrical digital twin model of the plant was developed and validated based on data collected from the field and electrical system studies.
  • Speeding up the operation and flexibility of the electrical power system.
  • Optimizing the load management system, thanks to the automatic procedures. Manual interventions of the operator were eliminated.
  • Unmatched system visibility of the complete model of the electrical system.
  • Easy access to the system and data for operators on the field and automatic calculation of loads.
  • Real-time monitoring and the system analysis tool, with failure predictions and playback solution.
  • Seamless integration of different communication protocols and flexibility to accommodate all existing operational logic.

What do they think about ETAP?

Opinions

Considering all factors, particularly those related to the software upfront, the ETAP RT-based on management became the natural choice for us.
By Hassaan Rauf, Senior Executive (Electrical), Fauji Fertilizer Company

Real-time load flow analysis was also one of the key features that gives operators the flexibility to perform voltage profiling of the system under different loading conditions and seasonal variations. Therefore, this was one of the key advantages of the ETAP RT-based solution.
By Hassaan Rauf, Senior Executive (Electrical), Fauji Fertilizer Company



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Optimizing operations with electrical Load Management System at FFC chemical Plant

Thisproject highlights ETAP's collaboration with Fauji Fertilizer Company Limited (FFC) of Pakistan to replace their existing Electrical Load Management System (ELMS) with ETAP’s iLS™ (Intelligent Load Shedding System), integrating IEDs for real-time monitoring and load calculation, utilizing ETAP’s digital-twin platform and model-driven solution to effectively meet load shedding requirements and enhance system reliability.


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