4160V POWER DISTRIBUTION UPGRADE
THE MANUFACTURER’S CHALLENGE
This manufacturer's aging 2400V electrical infrastructure had become increasingly difficult to maintain, troubleshoot, and support with confidence during day-to-day operations. Over time, the legacy system introduced a greater risk of unplanned outages, longer repair cycles, and limited flexibility for modern plant equipment, while also falling short of current expectations for reliability, safety, and performance. In addition, the older distribution architecture may have created concerns around equipment obsolescence, grounding integrity, power quality, and the ability to integrate newer control and motor-drive technologies. As a result, the facility needed a modernized electrical platform that could better support operational continuity, reduce maintenance burden, and provide a more stable foundation for long-term production needs.
COALMONT’S TURN-KEY SOLUTION
Coalmont executed comprehensive electrical system revitalization at Lhoist North America's New Braunfels facility, upgrading from obsolete 2400V to modern 4160V and 480V power distribution systems. The extensive installation scope included 4160V input contactor section and medium voltage PowerFlex 6000 VFD for ID fan control, medium voltage neutral grounding resistor with Sigma ground monitoring, 6kV station arrestors replacement in main switchgear, 2500kVA pad-mount distribution transformer installation, 480V 3000A power distribution center, 480V 300HP PowerFlex 755 VFD cabinet, complete cable and conduit infrastructure with underground duct banks encased in red concrete, CAT6 Ethernet cabling for VFD communications with fiber-to-Ethernet media converters, comprehensive grounding using 4/0 bare copper with exothermic bonding, and complete testing including insulation resistance (megger), VLF testing for XLPE cables, and functional checkout of all control systems.
This electrical revitalization project highlights the successful execution of complex medium-voltage installations during coordinated plant outages where safety and schedule adherence are paramount. Lhoist North America gained modernized power distribution replacing aging 2400V infrastructure, medium voltage drive technology improving motor control and energy efficiency, proper system grounding meeting current NEC requirements, comprehensive testing and documentation per ANSI/NETA standards, phased installation approach minimizing production disruption, two-week post-commissioning checkout assistance ensuring operational success, and adherence to Lhoist electrical installation and testing standards. The project highlights specialized experience in medium voltage systems, complex substation work, VFD installation and integration, underground power distribution, and coordinated multi-phase outage execution for industrial facilities.
CAPABILITIES: Medium Voltage Installation | VFD Systems | Power Distribution | Substation Work | Grounding & Testing