High‑Performance Pump 4 Auto Transformer Starter Refurbishment – Delivering Reliable Electrical Infrastructure
Our client required a comprehensive refurbishment and modernisation to ensure compliance with current standards, improve operational resilience, and minimise downtime.
Talk to a specialist about this project
0114 286 6000 or email at enquiries@baldwinandfrancis.com
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 BALDWIN & FRANCIS DIFFERENCE
Every project Baldwin & Francis undertakes is different, with its own unique set of challenges and requirements. Customer choice and specific application demands drive our design-and-build programmes, so we can deliver precisely what our customers need.
In this project, as in all projects, we worked incredibly closely and highly effectively with the consultant and the Trust’s engineering staff to ensure optimum service delivery.
All feedback from this – and every other project we undertake – is fed back into our management system as part of our continuous-improvement plan, which will ultimately help us deliver even better projects and service next time.
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Get in touch
To find out how well we can meet your needs, call our support team on +44 (0)114 286 6000.
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