BASF: Meeting EPA Mandates with SIS Electrical and Controls Design

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In order to meet EPA safety requirements, BASF needed to install a regenerative thermal oxidizer (RTO) and an associated safety instrumented system (SIS) in their North Carolina plant. They called on CSA to design the control system and make mandated reporting easy.

We configured the DeltaV system to support the new RTO unit, and we also configured the SIS PLC programs and system. We designed the SIS PLC data to transfer to the DeltaV system via a DeltaV Serial Card utilizing Modbus protocol. We also configured serial communications from the AB SLC500 RTO PLC to DeltaV using a ProSoft Modbus card.

The EPA requires hourly reports of the RTO operation, so we installed our Easy Process Reporter software, which emails reports to the desktop of the responsible process engineer. Time schedule triggers as well as OPC DA data triggers fire off reports containing real time and historical data.

We made EPA-compliance easy for BASF, and they were very happy with the results.

Services Provided:

  • Configuration of DeltaV Control & Equipment Modules
  • Configuration of Conventional, Foundation Fieldbus, and ASi I/O types
  • Configuration of AB GuardPLC 2000 SIS PLC
  • SIS SIL Validation
  • Operator display development
  • SFAT On-site Startup Services
  • Onsite Startup support of the DeltaV and SIS systems
  • Configuration of CSA’s Easy Process Reporter software and utilized its OPC DA and OPC HDA for system report generation.
  • Control System: DeltaV and Allen Bradley GuardPLC 2000