Paris, France – November 2030 – Alstom, a global leader in sustainable and smart mobility, has achieved 99.99% reliability in signal control systems and a 75% reduction in signal-related delays at the Paris Metro Line 12 after deploying the ABB PM866K01 3BSE050198R1 PLC module. The upgrade, completed in Q4 2030, replaced the line’s outdated PLC systems, which struggled with slow data processing and poor fault tolerance—leading to frequent signal malfunctions and service disruptions for 1.2 million daily passengers.
The Challenge: Outdated PLCs Compromise Railway Signal Reliability
Paris Metro Line 12 is 16.5 kilometers long, serving 36 stations and carrying 1.2 million passengers daily. The line’s signal control system relies on PLCs to manage train movements, ensure safe separation between trains, and optimize service frequency. The legacy PLC systems presented critical operational challenges:
- Slow Signal Processing Causes Delays: The legacy PLCs had a processing speed of 0.7 ms per instruction, unable to process real-time data from 200+ track circuits and train position sensors quickly. This led to 1-2 second delays in signal updates, causing trains to slow down unnecessarily—resulting in 15-20 signal-related delays daily, each averaging 3-5 minutes.
- Poor Fault Tolerance Leads to Service Disruptions: The old systems lacked redundancy, meaning a single PLC failure could shut down entire signal sections. This occurred 8-10 times monthly, leading to full or partial line closures and affecting 50,000+ passengers per incident.
- Difficult Maintenance and Upgrades: The legacy PLCs used outdated software and hardware, requiring specialized technicians for maintenance. Updating signal control logic took 8-10 hours per section, requiring nighttime maintenance windows and increasing maintenance costs to €420,000 annually.
- Non-Compliance with Railway Safety Standards: The old PLCs failed to meet the latest EN 50126/50128/50129 safety standards for railway signal systems, exposing the line to potential safety risks and regulatory penalties.
“Signal control reliability is the backbone of safe and efficient metro operations—any malfunction can cause widespread delays and inconvenience for passengers,” said Sophie Laurent, Alstom Paris Metro Signal Systems Manager. “Our legacy PLC systems were too slow and unreliable to meet the demands of a busy metro line. We needed a high-performance, fault-tolerant PLC solution that could process signal data in real time, ensure uninterrupted service, and meet strict railway safety standards.”
ABB PM866K01 3BSE050198R1: Safe and Reliable PLC for Railway Signals
After evaluating solutions from Siemens and Thales, Alstom selected the ABB PM866K01 3BSE050198R1 PLC module for its ultra-fast processing speed, redundant design, EN 50129 safety certification, and easy maintenance. Key features addressing Alstom’s pain points include:
- Ultra-Fast Signal Processing: The ABB PM866K01 3BSE050198R1 features a 1.2 GHz dual-core processor with a processing speed of 0.1 ms per instruction—7x faster than the legacy systems. This enables real-time processing of data from track circuits and train position sensors, reducing signal update delays to <0.2 seconds and eliminating unnecessary train slowdowns.
- Redundant Design for Fault Tolerance: The module features dual redundant processors and power supplies, ensuring uninterrupted operation even if one component fails. This eliminates signal section shutdowns due to PLC failures, increasing system reliability to 99.99%.
- EN 50129 Safety Certification: Certified to EN 50129 SIL 4 (the highest safety integrity level for railway systems), the PM866K01 3BSE050198R1 ensures compliance with railway safety standards. Its built-in safety functions prevent signal conflicts and ensure safe train separation.
- Easy Maintenance and Upgrades: The module uses open, standard software tools, allowing technicians to update signal control logic in 1-2 hours per section—80% faster than the legacy systems. It also supports remote monitoring and diagnostics, reducing on-site maintenance time by 70%.
- Rugged Design for Railway Environments: With an IP20-rated enclosure and operating temperature range of -25°C to 70°C, the module withstands the harsh conditions of metro tunnels—including dust, vibration, and extreme temperatures. Its resistance to electromagnetic interference (EMI) ensures reliable operation near high-voltage railway systems.
Results: Improved Reliability, Fewer Delays, Lower Costs
Six months after deploying the ABB PM866K01 3BSE050198R1 PLC module, Paris Metro Line 12 achieved significant operational improvements:
| Metric |
Before ABB PM866K01 3BSE050198R1 |
After ABB PM866K01 3BSE050198R1 |
Improvement |
| Signal Control System Reliability |
99.75% |
99.99% |
0.24% Improvement (19.8 Fewer Downtime Hours Annually) |
| Daily Signal-Related Delays |
15-20 |
3-4 |
75% Reduction |
| Monthly PLC Failure-Related Shutdowns |
8-10 |
0 |
100% Elimination |
| Annual Maintenance Costs |
€420,000 |
€126,000 |
70% Reduction |
| Time to Update Signal Control Logic |
8-10 Hours/Section |
1-2 Hours/Section |
80% Reduction |
“The ABB PM866K01 3BSE050198R1 module has been a game-changer for Paris Metro Line 12,” Laurent said. “Since deployment, we’ve achieved a 99.99% signal control reliability rate, which has significantly reduced delays and improved passenger satisfaction. The module’s redundant design has also eliminated the costly shutdowns we previously experienced, ensuring consistent service for our 1.2 million daily passengers.”
Jean-Pierre Dubois, ABB’s European Railway Automation Product Manager, commented: “Railway operators require PLC solutions that deliver the highest levels of safety, reliability, and performance. The ABB PM866K01 3BSE050198R1 PLC module meets these requirements, helping to improve signal control efficiency, reduce delays, and enhance the overall passenger experience.”
Alstom plans to deploy the ABB PM866K01 3BSE050198R1 PLC module across 15 additional metro lines in Europe and Asia by 2035, targeting 99.99% signal control reliability and a 70% reduction in signal-related delays group-wide.
Berlin, Germany – October 2030 – DB Schenker, a global leader in logistics and supply chain management, has achieved a 45% reduction in order fulfillment time and a 52% increase in warehouse throughput at its Berlin distribution center after deploying the ABB PM866K01 3BSE050198R1 PLC module. The upgrade, completed in Q3 2030, replaced the center’s outdated PLC systems, which struggled with slow coordination between automated storage and retrieval systems (AS/RS), conveyors, and pick-and-place robots—leading to bottlenecks in order processing during peak demand periods.
