“Before the revamp, I think that downtime due to our heritage control system was every two or three months,” said Khalil Abd-Elfatah, AFC1 Compressors Instruments Head Sector. “

And just one shutdown will cost millions of pounds.” The situation was leading to operational risk. The goal was not simply to replace old technology. It was to create a safer, more reliable platform for operations and future growth. 

Delivered in 2023, the modernization project replaced the legacy control and emergency shutdown systems with ABB Ability™ System 800xA, including AC800 MHI for safety functions.

The upgrade had to be executed within a tight window while maintaining operational continuity.

In a sector where safety, uptime, and continuity matter deeply, many organizations do gradual updates to minimize risk. AFC1 chose a different path, putting in the effort up-front to avoid repeating steps later.

“Peers in Egypt with legacy systems were surprised we’d do this in one phase,” said Mohamed Ibrahim, AFC1 Instruments Head Sector and the Project Manager for the AFC1 Revamp. “We insisted to make the revamp in one phase. Because we have very old software and firmware. If we started with software only, we would have to update the old system’s firmware. While there is less risk, we’d incur more cost. But that’s why most running production plants would do this in two phases.”

Modernization in one coordinated move required confidence built on clear objectives, proactive planning, and close collaboration between AFC1 and ABB. As a deeply involved and connected team, they completed as much work as possible in advance, including preparing a new cabinet room before shutdown.

A key moment came early in the project during development of the new control logic, when differences between the legacy system and the new architecture created unexpected challenges. Rather than slowing progress, it drove close alignment between process, control, and automation teams. Together, they reviewed and validated the control philosophy and interfaces before moving forward, helping avoid downstream integration issues.

AFC1 was fully engaged throughout execution. Tie-ins, cabinet work, connections, and checks were completed within the condensed shutdown window through teams working side by side.

“My team was working with ABB day and night,” said Ibrahim. “We were working in cooperation for every cable, for every cabinet, for every connection and examination.”

Amr Hany, AFC1 Ammonia Instruments Manager, added: “The local ABB team are hard workers. The project went on without any problems, or any effect to us, even if we had different ABB people on site. This is important for a project like this.”

RETURN ON INVESTMENT IN JUST ONE YEAR

The success of the project continued in how quickly AFC1 saw the impact. Operators now manage the plant with greater visibility from a single platform, with the ability to integrate third-party systems and monitor performance across the facility.

“We can now integrate with any third party, PLCs, GCS, so the capacity for diagnostics has increased,” said Hany. “The operator has only one platform to monitor all the machines and all the equipment from only one screen.”

This has made alarm handling, maintenance, and troubleshooting faster and more effective. The fully redundant architecture has removed the singlepoint-of-failure risk that limited the legacy system’s performance.

“Since 2024, we have not had any shutdown due to the system,” said Ibrahim. “Sometimes we face a failure in analog input but the redundancy covers the problem without any issue. The system is reliable, has good availability, and it’s easy to maintain.”

By reducing maintenance and spare parts costs, and improving production continuity, AFC1 achieved return on investment within the first year of operation. The outcome validated the team’s approach. Execution was not only fast, but precise. That combination of reliability and execution translated quickly into business value.

“We are proud we achieved the successful completion of the project together with the ABB team in a really short time and exactly with zero errors,” said Hany. 

Delivered under ABB Care service agreement provided AFC1 with secure, reliable operation beyond project completion. The system is also protected by ABB’s Cyber Security Workplace that provides continuous updates to help address evolving cyber risks. “We believe AFC1 is the first fertilizer plant in Egypt to implement this advanced level of cyber security protection within its control system environment, said Mohamed Arafa, AFC1 Urea Instrumentation Manager. “Following the successful results achieved at AFC1, our management has decided to expand this approach across all production facilities.”

Together, these services help reduce operational risk across the system life cycle while supporting uptime, predictable maintenance, and long-term cost control.

“Our long-standing partnership with Abu Qir Fertilizer helped create the trust needed for this full-scale modernization,” said Charles Bennet, Global Head of Service, ABB’s Energy Industries. “From ABB Care and cyber security to modern control systems, this collaboration shows how sustained support can help customers modernize with confidence while maintaining strong operational performance.”

The project underscores what is possible when modernization is approached with preparation, alignment, and confidence. AFC1 not only reduced operational burden but also proved it is possible to modernize efficiently without compromising production continuity.

ABB was selected due to its proven modernization methodologies, extensive experience in process industries, and deep understanding of the existing automation infrastructure.

Throughout the project, ABB demonstrated strong technical expertise, effective project management, and high-quality engineering support. Their commitment to minimizing operational risks and ensuring a smooth transition resulted in a reliable, sustainable solution that continues to deliver value.

The successful execution of this project has further strengthened the long-standing partnership between Abu Qir Fertilizers and ABB, creating a solid foundation for future digitalization and operational excellence initiatives.