PROJECT: BASF Kwinana – Admixtures Relocation Project, Western Australia
DESCRIPTION: BASF creates chemistry – and has been doing so for 150 years. Its portfolio ranges from chemicals, plastics, performance products and crop protection products to oil and gas. As the world’s leading chemical company, BASF combines economic success with environmental protection and social responsibility. Through science and innovation, BASF enable its customers in nearly every industry to meet the current and future needs of society. Its products and solutions contribute to conserving resources, ensuring nutrition and improving quality of life. BASF has summed up this contribution in its corporate purpose: We create chemistry for a sustainable future. BASF had sales of over €74 billion in 2014 and around 113,000 employees as of the end of the year. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (AN). Further information on BASF is available on the Internet at
REQUIREMENTS: KAPP Engineering was initially contracted by Symtech International to provide the engineering, design and commissioning for the Process Control System. KAPP assisted Symtech with the design of the automation platform and architecture for the plant which utilised ground-up Siemens Architecture. The PCS consisted of Sinamics Series Variable Speed Drives and a Primary Siemens S7-300 PLC Chassis communicating with a remote I/O chassis over Profinet. The HMI System utilised was 3 x Siemens Comfort panels located in various sections of the plant.

KAPP was further contracted by BASF directly to upgrade and maintain the site post commissioning.

SOLUTION: The controls system software was developed utilising the latest Siemens TIA Portal programming tool which combined both the HMI and PLC development in a single platform. The PLC consists of a primary Siemens S7-319 PN/DP CPU chassis and two ET-200 Remote I/O chassis over Profinet. Three HMI’s were located in the inloading, outloading and batching areas of the plant providing the operator full control of the process.

The HMI Layouts included P&ID views of all operational areas of the plant with clutter free viewing of equipment status. Operation of the plant via the HMI was streamlined to ensure that entire process could be controlled by a single operator. Detailed information for individual equipment (such as Pumps, Valves & Instruments) was provided utilising intuitive pop-up menus. Advanced programming methods including the usage of standardised function blocks and faceplates ensured a quick turn around with development and testing.

KAPP was also involved in both dry and wet commissioning phases of the project. This included the configuration of all instruments and Sinamics G120 series variable speed drives including testing of all I/O points and handover of the plant to production.

KAPP plays a key role with both ongoing maintenance and enhancements to the system based on feedback from operations personnel.