Coalmont modernized an underground power center with a complete power structure and controls upgrade, installing four Siemens G120 variable frequency drives and a Siemens PLC. This comprehensive upgrade extends equipment life while incorporating current technology benefits—providing a cost-effective solution compared to complete power center replacement. The project included power structure modifications, complete control system replacement, operator interface upgrades with enhanced diagnostics, MSHA-compliant underground power center design, and integration of modern VFDs with legacy power center infrastructure. 

With critical production schedules at stake, every effort was made to ensure the equipment, programming, and configuration met the highest reliability standards. Coalmont built a motor test stand specifically for this project, featuring two 300 HP AC motors coupled to a 500 HP DC motor with regenerative drive. This test stand enabled full load testing of the complete drive system and PLC logic—validating master-slave load sharing during ramp and steady-state velocity under real operating conditions, not just simulation. The drives were fully configured, tuned, and proven in shop before being sent underground, where tuning and repairs are exponentially more difficult and costly. This rigorous pre‑commissioning approach reflects Coalmont's commitment to high standards, ensuring new and improved systems are thoroughly tested and refined well before field commissioning. 

This modernization illustrates how legacy equipment can be effectively integrated with modern control technology—a critical capability for mining operations managing aging infrastructure. Warrior Met Coal gained improved diagnostics reducing troubleshooting time, modern operator interfaces simplifying operation, energy efficiency through VFD control, enhanced safety with updated controls meeting current MSHA standards, and extended equipment life deferring major capital expenditure.