Aalborg, Denmark – October 2026 – Vestas Wind Systems, a global leader in wind energy solutions, has announced a 12% increase in annual energy output and 30% lower maintenance costs after deploying the ABB 3BHE039426R0101 industrial control module at its 600MW offshore wind farm in the North Sea. The upgrade, completed in Q3 2026, addressed critical inefficiencies in the farm’s power conversion system—where legacy control modules struggled with variable wind conditions and frequent voltage fluctuations, costing Vestas €2.1 million annually in lost revenue.
The Challenge: Unstable Power Conversion in Offshore Wind
Prior to adopting the ABB 3BHE039426R0101, Vestas’ North Sea wind farm faced three core operational hurdles:
- Low Conversion Efficiency: Legacy control modules achieved only 95.2% power conversion efficiency, wasting 4.8% of wind-generated energy as heat—equivalent to 28.8GWh annually.
- Voltage Fluctuation Issues: Variable wind speeds caused frequent voltage spikes, triggering grid-compliant curtailment (reduced output) 15–20 times monthly, losing 3.2GWh of potential energy.
- High Maintenance Downtime: The old modules required quarterly calibration, necessitating turbine shutdowns that totaled 96 hours annually, costing €384,000 in lost production.
“Offshore wind energy lives or dies by power conversion reliability—our legacy modules couldn’t keep up with North Sea wind variability,” said Karsten Jensen, Vestas’ Offshore Wind Technical Director. “We needed a control solution that could optimize conversion efficiency while stabilizing grid output, even in stormy conditions.”
ABB 3BHE039426R0101: The Smart Control Backbone for Wind Energy
After testing competitors from Siemens Gamesa and GE Renewable Energy, Vestas selected the ABB 3BHE039426R0101 for its offshore-grade durability, real-time optimization, and seamless integration with existing turbine controls:
- 98.7% Conversion Efficiency: Advanced SiC (silicon carbide) power electronics and adaptive control algorithms boost conversion efficiency by 3.5 percentage points, capturing more usable energy.
- Grid Stability Features: Built-in voltage regulation (±2% tolerance) and frequency synchronization adapt to wind speed changes in 50ms, eliminating curtailment triggers.
- Rugged Offshore Design: IP66-rated housing, corrosion-resistant aluminum alloy, and operating temperature range of -40°C to +70°C withstand saltwater spray and extreme North Sea conditions.
- Predictive Maintenance: Integrated IoT sensors monitor module temperature, current, and component health, sending alerts via ABB Ability™ platform 4–6 weeks before potential failures.
- Seamless Compatibility: Works with Vestas’ V164-9.5MW turbines and existing SCADA systems, requiring no software overhauls—installation took just 4 hours per turbine.
Results: Quantifiable Efficiency and Reliability Gains
Six months post-deployment, Vestas’ wind farm achieved transformative results:
| Metric |
Before ABB 3BHE039426R0101 |
After ABB 3BHE039426R0101 |
Improvement |
| Conversion Efficiency |
95.2% |
98.7% |
3.5 Pts Increase |
| Annual Energy Output |
580.8GWh |
650.5GWh |
12% Increase |
| Curtailment Events |
15–20/Month |
0–2/Month |
92% Reduction |
| Maintenance Downtime |
96 Hrs/Year |
24 Hrs/Year |
75% Savings |
| Annual Cost Savings |
— |
€1.87M |
Direct ROI |
“The 3BHE039426R0101 has redefined how we manage offshore wind power conversion,” Jensen said. “We’re capturing energy we previously wasted, and curtailment is now a rarity. The predictive maintenance alerts have also eliminated surprise failures—our technicians can plan repairs during low-wind periods.”
Lars Andersen, ABB’s Global Product Manager for Renewable Energy Controls, emphasized the module’s role in energy transition: “Wind farms need control systems that are both efficient and resilient. The 3BHE039426R0101 delivers on both, helping operators hit sustainability targets while improving profitability.”
Vestas plans to deploy the ABB 3BHE039426R0101 across 4 more offshore wind farms in the Baltic Sea by 2028, targeting a combined 15% increase in energy output.
