Berlin, Germany – February 2026 – RWE Power AG, one of Europe’s leading energy companies, has successfully deployed ABB UFC760BE42 3BHE004573R0042 Excitation Control Modules to upgrade the excitation systems of 4 coal-fired generators (500MW each) at its Neurath power plant. The deployment, completed in Q1 2026 after an 11-week pilot program, addressed critical gaps in the plant’s legacy excitation control modules, including unstable field voltage regulation, slow fault response, and poor integration with the plant’s control system. Six months of post-implementation data shows a 62% reduction in generator-related downtime, a 48% improvement in voltage stability, and 99.99% operational reliability for the excitation system—key milestones in enhancing the plant’s energy output and grid stability.
The Challenge: Legacy Excitation Modules Jeopardize Generator Reliability
RWE’s Neurath power plant is one of Germany’s largest thermal power facilities, generating over 12 terawatt-hours of electricity annually to power 3.5 million households. The plant’s coal-fired generators rely on precise excitation control to maintain stable field voltage, which directly impacts generator efficiency, power quality, and grid synchronization. Legacy excitation control modules installed in 2016 struggled with inconsistent performance, creating significant operational risks and inefficiencies.
Prior to the upgrade, the legacy modules experienced frequent voltage fluctuations (8-10 per week), leading to unstable generator output and 3-4 grid synchronization failures annually. Their slow fault response (300-350ms) resulted in 28-32 generator downtime incidents per year, totaling 140+ hours of lost production—translating to €4.2 million in annual revenue losses. The modules were incompatible with the plant’s ABB Symphony Plus control system, requiring manual voltage calibration and fault analysis, adding 16+ hours weekly to maintenance teams’ workloads. Additionally, the outdated modules lacked predictive diagnostics, leading to unplanned failures and costly emergency repairs.
“Thermal power generation requires precise, reliable excitation control to ensure stable output and grid compatibility,” said Klaus Fischer, Plant Engineer at RWE Neurath Power Plant. “Our legacy modules were unpredictable—voltage fluctuations disrupted our operations, and slow fault response extended downtime. We needed a robust excitation solution that could regulate voltage accurately, integrate with our control system, and reduce unplanned outages.”
The Solution: ABB UFC760BE42 3BHE004573R0042’s Precision and Seamless Integration
After a rigorous 9-week evaluation of excitation control modules from ABB, Siemens, and GE Power, RWE selected the ABB UFC760BE42 3BHE004573R0042 for its ultra-fast fault response, precise voltage regulation, and seamless compatibility with its existing control system. The deployment followed a phased approach to avoid energy supply disruption: first, a pilot on 1 generator during scheduled maintenance; second, training 50 technicians on module configuration, fault diagnostics, and remote management; and finally, full rollout across 3 more generators over four months with ABB’s on-site technical support.
Key features of the ABB UFC760BE42 3BHE004573R0042 that solved RWE’s challenges include:
- Precise Voltage Regulation: Equipped with advanced PID control algorithms, the UFC760BE42 3BHE004573R0042 maintains field voltage accuracy of ±0.1%, eliminating fluctuations and ensuring stable generator output and grid synchronization.
- Ultra-Fast Fault Response: Detects and responds to excitation system faults in just 50ms—86% faster than legacy modules—enabling rapid shutdown and protection of generators from damage, minimizing downtime.
- Seamless System Integration: Supports Modbus TCP and Profinet protocols, integrating directly with RWE’s ABB Symphony Plus control system for real-time monitoring, remote calibration, and automatic data logging—eliminating manual data entry.
- Predictive Diagnostics: Built-in self-diagnostic functions monitor module performance, detect potential faults (e.g., wiring issues, component wear), and send alerts, enabling predictive maintenance and reducing unplanned failures by 90%.
The Results: Enhanced Reliability and Cost Savings
Six months post-deployment, the ABB UFC760BE42 3BHE004573R0042 has delivered transformative results for RWE’s Neurath power plant:
| Metric |
Before Deployment |
After Deployment |
Improvement |
| Annual Generator Downtime |
140+ Hours |
53 Hours |
62% Reduction (€2.6M Annual Savings) |
| Fault Response Time |
300-350ms |
50ms |
86% Faster |
| Weekly Maintenance Time |
16+ Hours |
5.2 Hours |
67% Reduction (€352K Annual Savings) |
| Annual Grid Synchronization Failures |
3-4 |
0 |
100% Reduction |
“The ABB UFC760BE42 3BHE004573R0042 has been a game-changer for our power plant operations,” said Klaus Fischer. “Its precise voltage regulation and fast fault response have eliminated downtime and synchronization issues, while the seamless integration with our control system has streamlined our workflows. We plan to deploy this module across all our thermal power plants in Germany by 2028.”
Markus Weber, ABB’s Regional Sales Director for Power Generation in Central Europe, added: “Thermal power plants rely on reliable excitation control to maintain grid stability and maximize energy output. The UFC760BE42 3BHE004573R0042’s precision, speed, and integration capabilities make it ideal for this critical application, and RWE’s success is a testament to its value in enhancing power plant reliability.”
