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How FFC optimizes their chemical plant operations with an ETAP Real-Time 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 Hassan Rauf, Senior Executive (Electrical), Fauji Fertilizer Company

This case study highlights how Fauji Fertilizer Company (FFC) modernized its legacy Load Management System (LMS) by replacing outdated PLC-based hardware and obsolete software with ETAP ILS鈩� intelligent load shedding system, fully integrated with numerical IEDs (Intelligent Electronic Devices) and with an ETAP Digital Twin. ETAP enabled FFC to automate load shedding decisions, accelerate response times, improve operational reliability, and remove long-standing constraints in motor starting and seasonal plant operations.

Fauji Fertilizer Company is a leading fertilizer manufacturer in Pakistan, committed to innovation and growth. 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, and banking.

Location: Rawalpindi, Pakistan

Year: 2023

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

Challenges

FFC faced critical reliability and maintainability challenges due to obsolete hardware and software:

  • Replacement of outdated PLC-5/40E controllers and obsolete Windows XP-based systems, which no longer supported modern communication protocols or updates.
  • Lack of integration with numerical IEDs, preventing access to accurate real-time field data for LMS operation.
  • Manual selection of loads, increasing the risk of human error during power disturbances.
  • Inefficient fixed load values for shedding priorities, leading to excessive or insufficient load curtailment.
  • Absence of automated transfer logic and no mechanism to consider bus-tie contingency events.
  • Difficulty starting essential service motors during system disturbances due to inadequate LMS logic.
  • Limited system visibility, making maintenance and operational decisions more reactive than predictive.
FFC required a modern, model-driven solution that could automate decision-making, reduce manual intervention, and provide full situational awareness of electrical system behavior.

Which solutions did they choose?

Selected applications

FFC implemented the following ETAP Real-Time modules:

  • ETAP ILS™ intelligent load shedding system, replacing legacy PLC-based logic with a model-driven, high-speed, event-based shedding engine.
  • ETAP Digital Twin, enabling accurate simulations, validation, and verification of LMS logic before deployment.
  • ETAP Real-Time monitoring and playback, providing operators with real-time situational awareness and post-event analysis.
These tools enabled FFC to automate load management, improve reliability, and future-proof the LMS for long-term operation.

Why do they use ETAP?

Main customer benefits

ETAP delivered a comprehensive, modernized LMS with significant technical and operational advantages:

  • Complete digital twin of the electrical system, validated using plant field data before implementation.
  • Improved visibility and monitoring, enabling operators to assess real-time system health and load flow behavior.
  • Significant reduction in manual interventions during power events due to automated decision-making.
  • Accurate, event-based load shedding using real-time IED data rather than fixed or estimated values.
  • Fast and reliable response during disturbances, especially critical to starting essential service motors.
  • Flexibility to incorporate seasonal and process-based variations, thanks to ETAP’s configurable shedding logic.
  • Seamless integration with existing communication protocols, ensuring adaptability to FFC’s operational environment.
  • Event playback capability for operator training, incident investigation, and continuous performance improvement.
Together, these benefits enabled FFC to operate with greater efficiency, enhanced reliability, and improved safety across its electrical distribution system.

What do they think about ETAP?

Customer perspectives

Considering the software-centric nature of ETAP, the ETAP Real-Time based Load Management System became the natural choice for us.
— Hassan Rauf, Senior Executive (Electrical), FFC

Real-time load flow analysis was one of the key features that enabled the plant to perform voltage profiling at different system configurations and seasonal variations. This was one of the key advantages of the ETAP-based solution.
— Hassan Rauf, Senior Executive (Electrical), FFC


Videos

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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