Client: Gypsum Customer

Overview – Restoring and Modernising a Critical Power Centre

The KF2VG Upgrade Project required a complete refurbishment and modernisation of an ageing power centre to restore safety, improve performance, and ensure long‑term reliability.

Originally supplied by Allenwest to meet the client’s operational needs, the unit was selected for a full upgrade to maximise future performance and extend service life.

The K2 is a portable 3.3kV twin‑drive/twin‑outlet power centre used to power essential mining operations such as air‑circulation fans, water pumps, and product conveyors. Its lightweight design (under 1.4 tonnes) and skid-mounted construction make it highly manoeuvrable, allowing it to be easily positioned underground wherever power is needed, providing flexibility and efficiency for our customers’ mining activities.

As part of our iDESo Group collaborative approach, the project began with the Allenwest engineering team, who carried out the detailed assessment and redesign required for the upgrade. Leveraging they’re in‑depth knowledge of the original equipment, Allenwest supplied key components essential to the refurbishment.

The load centre was then transferred to our Baldwin & Francis facility in Sheffield, where our specialist team completed the full mechanical and electrical upgrade programme, followed by a comprehensive testing process including a client attended factory acceptance testing.

By working seamlessly across multiple iDESo Group sites, we utilised the combined strengths of our engineering, manufacturing, and testing expertise to ensure the project met our client’s expectations. This integrated, multi‑site approach enabled us to provide a fully restored, modernised unit delivered back to the customer in excellent working condition.

Scope of Supply

Power Centre Assessment & Mechanical Overhaul

As part of the KF2VG Upgrade Project, the power centre was returned to our works for a detailed evaluation and mechanical overhaul.
Scope included:

• Complete engineering assessment to identify required repair works
• Full internal and external strip, clean, and repaint
• Full servicing of the isolator and return to operational condition
• Functional testing to ensure the unit meets operational and safety standards

Equipment Replacement & Modern Upgrades

To enhance performance and protection capability, Baldwin & Francis delivered a comprehensive upgrade package:

• Replacement of the existing air brake contactors with a new Allenwest Vacutac vacuum circuit breaker unit.
• Replacement of the existing drive with a dual drive system incorporating an Allenwest AWT31 protection relay for each outlet.
• Machining of the left‑hand door to fit a remote protection relay display to allow for visual indication of the drive’s operational health.
• Replacement of the units sockets due to very low insulation resistance:
  • Incomer – Installed Victor TYPE AFA33A Air‑Filled Adaptor, 500 Amp, 3.3kV
  • Outgoing – Installed Victor Flameproof Bolted Socket Type A43SB

These upgrades significantly improved operational safety, controllability, and long‑term reliability.

Engineering Re‑Design & Technical Documentation

To support the mechanical and electrical upgrades, our engineering team completed:

• Full electrical re‑design of the KF2VG configuration
• Updated ACADE/M engineering design drawings issue to reflect all changes, ensuring future maintainability

Testing, Compliance & Quality Assurance

The upgraded power centre underwent a full testing programme, including:

• FAT (Factory Acceptance Test) at Baldwin & Francis
• SAT (Site Acceptance Test) following installation at the customer’s site

Project Outcome

The KF2VG Upgrade Project resulted in a fully refurbished and modernised power centre engineered for enhanced performance and long‑term reliability. Key outcomes included:

• Modern protection and control via Allenwest AWT31 protection relay
• Improved durability through full mechanical refurbishment
• Enhanced electrical safety following socket replacements
• Updated engineering documentation for ongoing support
• Our extended 10- year warranty on the equipment supplied backed up by our after-sales service team to keep the equipment in primer operational status.

Client Feedback

Following the successful FAT, our client confirmed how impressed and pleased they were with the quality and performance of the refurbished power centre.

Due to their confidence in the outcome, they have since sent a second power centre for full refurbishment, reinforcing the value of Baldwin & Francis’ expertise and service.

Benefits to the client –

• Extended Asset Life with Confidence
  The refurbished unit is backed by a 10‑year guarantee, providing long‑term assurance on equipment that would typically be written off.
• Enhanced Safety & Compliance
  All components were upgraded to current mining safety standards, ensuring full compliance and safer operation in demanding environments.
• Increased Power Capacity
  Conversion to a dual‑drive system now enables the client to double their available power output, improving operational capability.
• Trusted OEM Quality
  The solution was designed, manufactured, and certified by the original equipment manufacturer, giving the client peace of mind through full OEM guarantees and engineering integrity

To find out how to extend the life of your electrical assets contact us to discuss.

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