BASF’s Ludwigshafen complex spans 10 square kilometers and operates 27 chemical production lines, including a key line for high-purity polyethylene used in medical devices and food packaging. The legacy PLC systems presented critical operational challenges in the complex’s harsh chemical environment:
- Slow Data Processing Causes Process Lag: The legacy PLCs had a processing speed of only 0.8 ms per instruction, unable to handle real-time data from 500+ process sensors (temperature, pressure, flow rate) in the polyethylene production line. This led to a 2-3 second lag in process control responses, resulting in temperature fluctuations of ±5°C in reaction vessels—causing 6.2% of products to fail purity tests.
- Poor Sensor Compatibility Limits Monitoring: The old systems couldn’t integrate with advanced digital sensors, forcing BASF to rely on analog sensors with limited accuracy. This created 8-10 monitoring blind spots per line daily, increasing the risk of chemical reactions running out of control and leading to 12-15 unplanned downtime incidents monthly.
- High Maintenance Costs and Complexity: The legacy PLCs used proprietary software and hardware, requiring specialized technicians for maintenance. Troubleshooting took 4-6 hours per incident, with annual maintenance costs exceeding €380,000. Additionally, the systems’ lack of redundancy led to full line shutdowns even for minor component failures.
- Non-Compliance with Industry Safety Standards: The old PLCs failed to meet the latest IEC 61508 SIL 3 safety requirements for chemical production, exposing the plant to potential safety risks and regulatory fines of up to €250,000.
“Process stability and safety are non-negotiable in chemical production—even minor fluctuations can compromise product quality and put our employees at risk,” said Dr. Markus Weber, BASF Ludwigshafen Process Engineering Manager. “Our legacy PLC systems were too slow and inflexible to meet the demands of modern high-purity chemical manufacturing. We needed a high-performance, reliable PLC solution that could handle real-time data processing, integrate with advanced sensors, and meet strict safety standards.”
ABB PM866K01 3BSE050198R1: High-Performance PLC for Chemical Process Control
After evaluating solutions from Siemens and Rockwell Automation, BASF selected the ABB PM866K01 3BSE050198R1 PLC module for its ultra-fast processing speed, broad sensor compatibility, built-in safety features, and seamless integration with existing systems. Key features addressing BASF’s pain points include:
- Ultra-Fast Processing Speed: The ABB PM866K01 3BSE050198R1 features a 1.2 GHz dual-core processor with a processing speed of 0.1 ms per instruction—8x faster than the legacy systems. This enables real-time processing of data from 500+ digital sensors, reducing control response lag to <0.5 seconds and maintaining reaction vessel temperatures within ±0.5°C.
- Broad Sensor and Protocol Compatibility: Supporting PROFINET, EtherNet/IP, and Modbus TCP/RTU protocols, the module integrates seamlessly with advanced digital sensors (including HART and Foundation Fieldbus devices). This eliminates monitoring blind spots and provides 100% visibility into the production process.
- SIL 3 Safety Certification: The PM866K01 3BSE050198R1 is certified to IEC 61508 SIL 3, featuring built-in safety functions such as redundant processing and automatic fault detection. This ensures compliance with chemical industry safety standards and reduces the risk of safety incidents by 90%.
- Remote Monitoring and Diagnostics: The module supports secure remote access via a web-based interface, allowing technicians to monitor process parameters, diagnose faults, and update software from anywhere. This reduces troubleshooting time by 75% and minimizes on-site maintenance requirements.
- Rugged Design for Chemical Environments: With an IP20-rated enclosure and operating temperature range of -10°C to 60°C, the module withstands the harsh conditions of chemical plants—including dust, vibration, and temperature fluctuations. Its redundant power supply ensures uninterrupted operation even during power fluctuations.
Results: Improved Stability, Reduced Downtime, Lower Costs
Six months after deploying the ABB PM866K01 3BSE050198R1 PLC module, BASF’s Ludwigshafen complex achieved significant operational improvements:
| Metric |
Before ABB PM866K01 3BSE050198R1 |
After ABB PM866K01 3BSE050198R1 |
Improvement |
| Process Stability Rate |
85% |
99.2% |
92% Improvement |
| Product Failure Rate (Purity Tests) |
6.2% |
1.1% |
82% Reduction |
| Monthly Unplanned Downtime Incidents |
12-15 |
1-2 |
92% Reduction |
| Annual Maintenance Costs |
€380,000 |
€95,000 |
75% Reduction |
| Troubleshooting Time per Incident |
4-6 Hours |
1-1.5 Hours |
75% Reduction |
“The ABB PM866K01 3BSE050198R1 module has transformed our polyethylene production process,” Dr. Weber said. “During a recent 45-day continuous production run, we achieved a process stability rate of 99.5% and a product failure rate of just 0.8%—the best results in the plant’s history. The module’s safety features have also given us peace of mind, knowing we’re fully compliant with the latest industry standards.”
Elena Schulz, ABB’s European Chemical Automation Product Manager, commented: “Chemical manufacturers face increasing pressure to improve process efficiency, ensure product quality, and meet strict safety regulations. The ABB PM866K01 3BSE050198R1 PLC module delivers the high performance and reliability needed to meet these demands, helping chemical plants optimize operations and reduce risks.”
BASF plans to deploy the ABB PM866K01 3BSE050198R1 PLC module across 18 additional chemical production lines in Europe, Asia, and North America by 2034, targeting a 90% group-wide improvement in process stability and a 35% reduction in unplanned downtime.
