Ludwigshafen, Germany – December 2025 – BASF SE, the world’s leading chemical producer, has deployed ABB DSAI146 3BSE007949R1 input modules across 20 high-precision chemical synthesis lines at its Ludwigshafen industrial park. The deployment, completed in Q3 2025, addressed critical challenges posed by legacy input systems, including inaccurate process parameter monitoring, frequent signal interference, and incompatible data integration with the plant’s digital control platform. Six months post-deployment, BASF reported a 96% reduction in measurement errors and a 32% decrease in production rework costs.
The Challenge: Precision Gap Threatens Product Quality & Safety
BASF’s chemical synthesis processes require real-time monitoring of temperature, pressure, and chemical concentration with a measurement accuracy of ±0.1°C and ±0.2 bar. Prior to the upgrade, the plant relied on aging input modules installed in 2015, which had a measurement error margin of 2-3°C for temperature and 1.5-2 bar for pressure. These inaccuracies led to frequent deviations in reaction conditions, resulting in 18-20 batches of substandard products annually and €3.2 million in rework costs. Additionally, the legacy modules were susceptible to electromagnetic interference (EMI) from nearby welding equipment and high-voltage pipelines, causing 12-15 signal drop incidents per month. The outdated systems also lacked compatibility with BASF’s Siemens PCS 7 DCS platform, requiring manual data entry that introduced 5-7% reporting errors and delayed process optimization.
“Chemical synthesis is a precision-driven process—even minor deviations in temperature or pressure can compromise product quality and pose safety risks,” said Dr. Markus Keller, Plant Manager at BASF Ludwigshafen. “Our legacy input modules were a bottleneck for both quality control and digital transformation. We needed a high-precision, interference-resistant input solution that could seamlessly integrate with our existing DCS system and withstand the harsh industrial environment of chemical plants.”
The Solution: ABB DSAI146 3BSE007949R1’s Industrial-Grade Precision & Compatibility
After evaluating competing solutions, BASF selected the ABB DSAI146 3BSE007949R1 input module for its exceptional measurement accuracy, robust EMI shielding, and broad system compatibility. Key features addressing BASF’s challenges include:
- High-Precision Signal Acquisition: The DSAI146 3BSE007949R1 offers a measurement accuracy of ±0.05°C for temperature and ±0.08 bar for pressure, with a 16-bit resolution that captures subtle changes in process parameters. This ensures precise data transmission for critical synthesis reactions.
- Advanced Anti-Interference Technology: Equipped with dual-layer EMI shielding and differential signal processing, the module filters 99.9% of electrical interference from industrial equipment. It also supports isolated signal transmission up to 1 km, eliminating signal degradation in complex plant environments.
- Seamless DCS Integration: The module is fully compatible with ABB AC 800M, Siemens PCS 7, and Rockwell ControlLogix DCS platforms via MODBUS RTU and PROFINET protocols. This enables real-time data synchronization with BASF’s digital control system, eliminating manual data entry and reducing reporting errors to less than 1%.
- Harsh Environment Durability: Rated to IP65 protection class and designed to operate in temperatures from -40°C to +85°C, the DSAI146 3BSE007949R1 withstands corrosive vapors, dust, and extreme temperature fluctuations in chemical plants. Its mean time between failures (MTBF) of 18 years reduces maintenance frequency and costs.
The Results: Enhanced Quality, Reduced Costs & Smarter Operations
Six months after full deployment, the ABB DSAI146 3BSE007949R1 input modules have delivered transformative results for BASF:
| Metric |
Before DSAI146 Deployment |
After DSAI146 Deployment |
Improvement |
| Temperature Measurement Error |
2-3°C |
±0.05°C |
96% Reduction |
| Annual Production Rework Costs |
€3.2 Million |
€2.18 Million |
32% Cost Savings (€1.02 Million) |
| Monthly Signal Drop Incidents |
12-15 |
0-1 |
95% Reduction |
| Data Reporting Error Rate |
5-7% |
<1% |
86% Reduction |
| Annual Maintenance Hours for Input Systems |
450 Hours |
60 Hours |
87% Reduction |
“The ABB DSAI146 3BSE007949R1 has redefined precision in our chemical synthesis processes,” Dr. Keller noted. “The drastic reduction in measurement errors has improved product quality consistency, while the seamless integration with our DCS system has accelerated our digital transformation journey. We plan to deploy this input module across 30 more production lines in Europe and Asia by 2028.”
Sarah Müller, ABB’s Global Product Manager for Industrial Automation Components, commented: “Chemical plants demand input modules that can deliver uncompromising precision and reliability in harsh environments. The DSAI146 3BSE007949R1 is engineered to meet these demands, helping manufacturers like BASF enhance operational efficiency, reduce costs, and ensure process safety. BASF’s success is a testament to the module’s value in critical industrial applications.”
