Ludwigshafen, Germany – December 2025 – BASF SE, the world’s leading chemical producer, has successfully deployed ABB DSAI146 3BSE007949R1 Analog Input Modules across 20 high-precision chemical synthesis lines at its flagship Ludwigshafen industrial park. The full-scale deployment, completed in Q3 2025 after a three-month pilot phase, addressed long-standing operational bottlenecks caused by outdated input systems, including inaccurate process parameter monitoring, frequent signal interference, and incompatible data integration with the plant’s digital control platform. Six months of post-deployment data analysis reveals a 96% reduction in measurement errors, a 32% decrease in production rework costs, and a 40% improvement in process optimization response time—milestones that strengthen BASF’s position in sustainable chemical manufacturing.
The Challenge: Precision Gaps Threaten Product Quality and Safety Compliance
BASF’s Ludwigshafen plant specializes in the production of high-purity polyurethane and ethylene derivatives, processes that demand rigorous 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 legacy 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: 18-20 batches of substandard products annually, resulting in €3.2 million in rework costs and potential non-compliance with EU REACH regulations.
Compounding these issues, the legacy modules were highly susceptible to electromagnetic interference (EMI) from nearby welding equipment and high-voltage pipelines, causing 12-15 signal drop incidents per month. Each incident required manual intervention to restart processes, leading to an average of 4 hours of production downtime per month. Additionally, the outdated systems lacked compatibility with BASF’s Siemens PCS 7 Distributed Control System (DCS) platform, forcing operators to manually enter sensor data into the digital system. This manual process introduced 5-7% reporting errors and delayed process optimization by up to 12 hours, preventing the plant from leveraging real-time data for energy efficiency improvements.
“Chemical synthesis is a precision-driven process—even minor deviations in temperature or pressure can compromise product quality, increase waste, and pose safety risks to our workforce,” said Dr. Markus Keller, Plant Manager at BASF Ludwigshafen. “Our legacy input modules were not only hindering quality control but also slowing our digital transformation journey. We needed a high-precision, interference-resistant input solution that could seamlessly integrate with our existing DCS system, withstand the corrosive and high-temperature environment of our chemical plants, and meet strict EU safety and environmental standards.”
The Solution: ABB DSAI146 3BSE007949R1’s Industrial-Grade Precision and Compatibility
After a six-month evaluation of competing solutions from Siemens and Rockwell Automation, BASF selected the ABB DSAI146 3BSE007949R1 input module for its exceptional measurement accuracy, robust EMI shielding, broad system compatibility, and compliance with ATEX Zone 2 hazardous area standards. The deployment process involved a phased approach: first, a pilot on 2 synthesis lines to validate performance; second, training for 50 plant operators and maintenance technicians on module calibration and troubleshooting; and finally, full-scale rollout across 18 additional lines with minimal production disruption.
Key features of the ABB DSAI146 3BSE007949R1 that addressed BASF’s critical 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 level of precision ensures that BASF’s synthesis reactions stay within optimal ranges, reducing the risk of substandard products.
- 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 the complex, high-noise environment of the Ludwigshafen plant.
- 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 enabled 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, while its ATEX certification ensures compliance with EU hazardous area regulations.
The Results: Enhanced Quality, Reduced Costs, and Accelerated Digital Transformation
Six months after full deployment, the ABB DSAI146 3BSE007949R1 input modules have delivered transformative results for BASF’s Ludwigshafen plant, with measurable improvements across key operational metrics:
| 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 |
| Process Optimization Response Time |
Up to 12 Hours |
Real-Time (≤10 ms) |
100% Elimination of Delay |
“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, with our polyurethane purity rates increasing from 99.2% to 99.8%. The seamless integration with our DCS system has accelerated our digital transformation journey, allowing us to leverage real-time data for predictive maintenance and energy optimization. We plan to deploy this input module across 30 more production lines in our European and Asian facilities by 2028.”
Sarah Müller, ABB’s Global Product Manager for Industrial Automation Components, commented: “Chemical plants operate in some of the harshest and most regulated environments, demanding input modules that can deliver uncompromising precision and reliability. The DSAI146 3BSE007949R1 is engineered to meet these demands, with ATEX certification, robust EMI shielding, and broad DCS compatibility. BASF’s success is a testament to the module’s value in helping manufacturers enhance operational efficiency, reduce costs, and ensure compliance with global safety and environmental standards.”
