Our client operates within the Utilities – Electrical Infrastructure sector, managing critical assets for water and power distribution. Pump 4 plays a vital role in maintaining operational continuity for large-scale water transfer systems. Due to the age of the existing Auto Transformer Starter and associated HV switchgear, reliability concerns and outdated control components posed a risk to performance and safety. The client required a comprehensive refurbishment and modernisation to ensure compliance with current standards, improve operational resilience, and minimise downtime.
The project demanded precision engineering, strict adherence to CDM regulations, and integration of advanced protection features to safeguard personnel and equipment. By upgrading control systems, replacing worn components, and introducing optional arc flash detection technology, the solution delivered enhanced safety, improved efficiency, and extended equipment lifecycle.
Scope of Work
Pump 4 Auto Transformer Starter – Full System Refurbishment
- Restore full operational integrity of Pump 4 Auto TX system.
- Upgrade control components for improved reliability and safety.
- Ensure compliance with manufacturer specifications and site safety standards
Key Deliverables
- TX Section
- Replaced feed and return transformer HV cabling
- Installed 3 new surge divertors
- Full interior clean of 3 starter compartments
- Replaced door seals where required
- Installed 2 new compartment heaters
- Control Section
- Removed existing LV controls and relocated into a RITTAL enclosure
- Installed cabling bridge between LV compartment and new enclosure
- New LV enclosure included:
- Motor RTD relays (x3)
- Schneider P241311B2M057BJ Motor Protection Relay
- Analogue KWH meter and new Diris digital KWH meter
- LED annunciators
- 6 Foxtam timers and 1 ABB CM timer
- Replacement contactors/relays (110Vac version)
- LV protection relays connected to 110Vac battery BTU unit
- Converted all control wiring to 110Vac
- Installed fuse-blown operators/micro-switch assemblies E-stop operation facility
- Full retest of control operation and protection settings
- Replaced door seals where required
- Incomer Section
- Replaced all contactors and vacuum interrupter bottles; tested to manufacturer specification
- Replaced incomer fuses
- PFC Section
- Replaced PFC capacitor and blown fuse striker assembly
- Testing & Return to Service
- Full insulation and resistance testing of all terminals
- Operational and run-load testing with secondary injection testing of motor protection relay and ancillary equipment
Design Standards & Safety Focus
- All works completed under CDM with B & F being the principal contractor
- Compliance with site safety protocols and manufacturer specifications
- Disposal of cleaning materials and damaged equipment managed by client
Quality & Robustness
- High-quality replacement components sourced from trusted manufacturers
- Rigorous testing ensured reliability and extended equipment lifecycle
Outcome to enhance Electrical Infrastructure
The project successfully delivered a fully refurbished and modernised Auto Transformer Starter system for Pump 4. All critical components were replaced or upgraded, including HV cabling, control systems, and protection devices.
The integration of advanced motor protection relays and optional arc flash detection technology significantly improved operational safety. Rigorous testing, covering insulation, resistance, and secondary injection, ensured compliance with manufacturer specifications and industry standards. The system was returned to service with optimised performance, reduced risk of failure, and extended lifecycle, providing the client with a robust and future-ready solution.
Client Impact
- Operational Reliability: Pump 4 is now fully functional with improved resilience, reducing the likelihood of unplanned downtime
- Enhanced Safety: Upgraded control systems and optional arc flash protection deliver a safer working environment for personnel
- Cost Efficiency: By refurbishing rather than replacing the entire system, the client achieved significant cost savings while still benefiting from modernized technology
- Compliance & Assurance: All works were completed under CDM supervision and aligned with stringent safety and quality standards, giving the client confidence in long-term performance
- Futureproofing: The integration of advanced monitoring and protection features positions the system for evolving operational demands and regulatory requirements
The refurbishment of the High-Performance Pump 4 Auto Transformer Starter is a pivotal initiative aimed at enhancing our electrical infrastructure. By employing advanced techniques and technologies, we ensure the reliability and efficiency of our systems. This commitment to excellence not only supports operational continuity but also reinforces our dedication to safeguarding vital electrical resources. Our services are designed to meet the highest standards, thereby contributing to a robust and sustainable electrical framework.
