March 2008

Special Report: Instruments and Networks

Online transfer from an analog electronic control system to a modern DCS

Proper planning, personnel training and interdepartmental communications were keys to the success of this project

Ali, R., Anwar, Z., Fauji Fertilizer Co. Ltd.

Replacing obsolete, nonrepairable, inefficient instrumentation and controls improves plant operation, reduces maintenance cost and increases production. The task becomes more challenging, interesting and risky when the control system is switched over on line from an obsolete system to a latest one without any production loss. This article describes the online transfer experience of Fauji Fertilizer Company's (FFC's) utilities unit control system from an old electronic analog system to a modern hybrid digital distributed control system (DCS). Introduction. FFC is the leading urea manufacturer in Pakistan with a market share of more than 60%. It is a private-sector company, operating three

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