Our Work | Project Portfolio | Australian Winders

Looking to extend the lifespan of your asset?

Australian Winders combines technology and the best technicians to maximise asset longevity.

Projects

Kangaroo Valley Hydro Generator Overhaul

Inspection, repairs and testing to improve power generation

Australian Winders were engaged by Origin energy to undertake a thorough inspection of their U3 Hydro Generator at the Kangaroo Valley Power Station in NSW, Australia. The inspections found the following issues which Australian Winders proposed to be rectified in the next outage: 50% hollow or loose stator wedges, loose and inconsistent stator and rotor core clamping, damage to winding insulation, damage to iron core (loose/separated core packs). Australian Winders were then contracted to carry out the works which included: Dry ice blasting of the rotor and stator core, EL-CID testing stator core, resonance testing stator core bolts, remove all stator and rotor core bolts, clean threads, grease and reinstall and torque to correct resonance settings, weld new core nut locking tabs, removal of loose stator wedges, top bar contact resistance tests and corona protection restoration, repair iron core damage, re-wedge stator, full wedge hardness tests and map, installation of new air gap sensors and flux probe, final electrical tests and paint. This project was successfully completed within the allocated timeframe.

Turbo Generator Rewind & Repair

Routine rewind and repair for large Siemens generator

Australian Winders supplies manpower to Siemens USA to assist them on their major rewind and repair projects both in the USA and across the globe. Some of these projects include:

Repairs/modifications, Kuosheng Taiwan
Strip and rewind 180MW Siemens/Westinghouse Aero Pac turbo generator at Calpine, Hermiston USA
Strip and rewind x3 240 MW Siemens Aeropac turbo generator at South Point Power station Arizona, USA
Turbogen rewind,Thomas Hill, Missouri,USA
Turbogen rewind ,Ginna Nuclear power plant , NY,USA
Turbogen Rewind, Amarillo, Texas USA
Turbogen rewind Cunningham Power station, New Mexico USA
Turbogen re-wedge, Ironwood, Pennsylvania,USA
Generator inspection / repair / blocking install (6 units) Jangmoon, South korea
Generator inspection / repair / blocking install (3 units) Dangjin, South Korea
Turbogen rewind Salem NJ, USA

Mining Mill Drive Installation, Repair and Partial Rewind

Mill Drive Installation

Complete installation of a gearless mill drive in numerous sites worldwide, repair and partial rewind done in Chile and Australia for Siemens.

Toshiba 720MW Turbo-Generator Rewinds

Rewind & Upgrades

Toshiba 660MW-720MW water cooled rewind and upgrades Bayswater and Mount Piper power stations NSW 6 week rewind durations Generator windings reaching design end of life

Removal of existing windings
Clean conditions setup and Foreign Material Exclusion (FME)
New winding install – bottom bars and top bars
Bar seating (hose moulding) and bakeout
Connection brazing (oxy propane)
Brazing checks / SCW system leak checks
Wedging and lateral wedges (side ripple)
Anti-tracking varnish, gas baffles and monitoring systems
Electrical testing

All four rewinds were completed within allocated timeframe, no LTIs recorded and all tests met the acceptance criteria.

Case Studies

Mill Motor Rewind: How Australian Winders Delivered Reliability in Alaska

When a global-scale gold producer needed to ensure the longevity of a critical mill motor at their site in Delta, Alaska, they turned to Australian Winders—the global experts in industrial motor winding and manufacturing. With challenges ranging from contaminated slots to testing uncertainties, we knew this project would require both precision and creativity.

Efficient Rewinds for 660 MW-720 MW Turbo-Generators by Australian Winders

The client was facing a critical challenge as the generator windings at Bayswater and Mount Piper Power Stations were rapidly approaching the end of their design life. The risk of generator failure threatened power supply consistency and increased maintenance costs while jeopardising operational efficiency.

Australian Winders Excels in Remote Rewind for National Power Supplier

When a National Power Supplier in Fiji faced a critical generator outage at one of its power stations, the stakes were high. Ensuring power reliability for an entire nation requires precision, expertise, and agility For this project, Australian Winders – global leaders in industrial motor rewinding and manufacturing – was the clear choice.

Kalgoorlie Power Station

Our Past Performance

Past Performance (working for OEMs):

100+ Major projects worldwide some of these include

2008 – Rewind 28 MW Allis Chalmers Hydro Generator, USA – NEC
2008 – 105MW Toshiba generator repair Paka, Malaysia – NEC
2009 – Ball mill re-wedge, Nevada USA – ABB
2009 – Sag mill rewind, Chile – ABB
2009 – 2 x Sag mill installations, Sweden – ABB
2009 – Mill re-wedge and coil change, Sossego Mine Brazil – ABB
2010 – Urgent repair work Sag mill, Olympic Dam Australia – Siemens
2010 – Re-wedge, Worsley Alumina Refinery Australia – Siemens
2010 – Hire induction welder and operator 200MW water leak, Australia – Siemens
2011 – Labour Hire, turbine generator rewind, Belgium – G.E. Dartford
2011 – Labour Hire wet tie modification, Romania – G.E. Dartford
2011 – GMD Insulation Repair – Siemens
2011 – GMD Rewind, Nevada USA – ABB Switzerland
2011 – GMD Installation, Colorado USA – ABB Switzerland
2011 – Re-wedge and wet tie modification, Israel – GE Dartford
2011 – Wet tie modification, West Burton UK – GE Dartford
2011 – Re-wedge, Israel – GE Dartford
2011 – GMD Rewind, Escondida Chile – ABB Switzerland
2011 – GMD Re-wedge, Telfer Australia – ABB Switzerland
2011 – Turbine generator partial rewedge, Malaysia – G.E. London
2011 – Wet tie modification, West Burrton UK – G.E.Dartford
2011 – 1100MW Nuclear Generator water leak repair, Spain – GE Dartford
2011 – Turbine Generator top bar repair, Vales Point Australia – Toshiba Australia
2011 – Hydro Generator Restack, Kentucky USA – Voith Hydro
2011 – Re-wedge, Yarmouth UK – G.E. UK
2011 – Generator wet tie modification, Italy – G.E.UK
2012 – 2 x winding Supervisors, Ivanhoe Mine Mongolia – Siemens Germany
2012 – Turbine re-wedge, Louisiana USA – G.E. USA/Dartford
2012 – 2nd Re-wedge, Louisiana USA – G.E. USA
2012 – Wet tie and block modification, Sermide, ITALY – G.E. Italy
2012 – Retaining Ring inspection and repair, Mexico – G.E. USA
2012 – 2 x winding Supervisors, Mongolia – Siemens Germany
2012 – Brazing end clips, Castellon Spain – G.E. UK
2012 – GMD re-wedge, Telfer Australia – ABB Switzerland
2012 – 38 MW Rotor Rewind, The Philippines – Quartz Elec
2012 – Hydro generator Rewind, Smith Mountain USA – Voith
2012 – Turbine Test and Inspection, Papua New Guinea – Interlink
2012 – Turbine Rotor Rewind, Germany – Sensoplan
2013 – Turbine generator Bump Test, Puerto Rico – Protec
2013 – 2 x turbine re-wedges unit 1 and unit 2, Florida USA – G.E. USA
2013 – GMD Re-wedge, St Ives Australia – ABB Australia
2013 – Re-wedge supervision, Spain – Protec
2013 – Nuclear Generator stator strip out, Holland – Sensoplan
2013 – Wet tie and blocking modification, New York USA – G.E. USA
2013 – Turbine End modification, Thessaloniki Greece – G.E. UK
2013 – Turbine generator Test and Inspection, Las Vegas USA – Protec
2013 – Turbine generator Testing, Missouri USA – Protec
2013 – HVB Repair, Arkansas USA – G.E. USA
2013 – Winding Supervisor, CP Mining Australia – Siemens Australia
2013 – HVB Repair, California USA – Protec
2013 – 1100MW Nuclear Generator water leak repair, Spain – G.E.UK
2013 – Clean and test turbine stator windings, Florida USA – Protec
2013 – Ball Mill rewind, Escondida Chile – ABB Chile
2013 – Turbine Rotor rewind, Germany – Sensoplan
2013 – Winding Supervisor, Zambia – Siemens South Africa
2013 – Hydro generator rewind, Ohio Falls USA – Voith
2013 – Hydro generator rewind, Smith Mountain USA – Voith
2013 – Turbine rewedge, Greece – G.E.UK
2013 – Nuclear leak repair , Spain – G.E.UK
2013 – Turbine Stator rewind, Sweden – Sensoplan
2013 – Turbine Rotor rewind, Germany – Sensoplan
2013 – Turbine Test and Inspection, California USA – Protec
2014 – Winding Supervisor, CPM – Siemens Australia
2014 – Turbine stator repair, Walter Energy USA – Protec
2014 – HV bushing repair, Mid American Energy USA – G.E.USA
2014 – Turbine Generator Ring removal, Collie Australia – Toshiba
2014 – Winding Supervisor AG Mill 2 installation, CP Mining Australia – Siemens Australia
2014 – Hydro generator rewind, Pine Falls Canada – Voith
2014 – Hydro generator rewind, Bay d’espoir Canada – Voith
2014 – Rewedge generator replace side ripple spring, Kwinana – GDF Suez
2014 – Winding Supervisor AG Mill 4 installation, CP Mining Australia – Siemens Australia
2014 – Water leak repair, Torrens Island Australia – Siemens Australia
2014 – Inspection of rotor pole failure, Olympic Dam Australia – Siemens Australia
2015 – End-winding Repair work, Olympic Dam Australia – Siemens Australia
2015 – GMD Stator Rewind, Olympic Dam Australia – Siemens Australia
2015 – GMD coil repair, Cadia Valley Australia – Siemens Australia
2015 – GMD Rotor pole refit, Olympic Dam Australia – Siemens Australia
2016 – PD Turbine Dusting repairs, West Burton UK – G.E.Dartford
2016 – Nuclear Generator repair work, Kuosheng Taiwan – Siemens
2017 – 2 x Supply winding labour to Siemens Power USA – Kuosheng Nuclear Power
2017 –Generator rewind, Sweden – GE UK
2017 – Rotor rewind, Italy – GE UK
2017 – Winding support, Russia – GE UK
2018 – Generator rewind, Sweden – GE UK
2019 – 3 x Aeropac Genertaor Rewinds – Siemens Energy US, Arizona.
2019 – Partial Rewind of GMD Mill motor, El Teniente – Siemens Chile, Chile.
2019 – Generator remedial works – Siemens Energy US, Ironwood.
2019 – Generator rewedge – Toshiba Australia, Bendeela.
2019 – Turbine works – GE, West Burton, UK.
2019 – Multiple generator/motor works – GE Rugby.
2019 – 2 x GMD installation supervision – Siemens Peru, Toromocho Minesite, Peru.
2019 – Complete rewind of 600MW Generator – Toshiba Australia, Bayswater, Australia.
2019 – Multiple GMD installation supervision – Siemens Russia, Russia.
2019 – Rotor pole change out – Siemens Australia, Cadia Minesite, Australia.
2019 – GMD Install Supervision – Siemens Germany, Panama.
2020 – GMD Install Supervision – Siemens Russia, Tominski Minesite, Russia.
2020 – Generator remidial works – Siemens Energy US, New Mexico.
2020 – Multiple generator/motor works – GE Rugby, UK.
2020 – GMD mill motor remedial works, Siemens Australia, CPM, Australia.
2020 – Supervise and installation of GMD mill motor – Siemens Russia, Tominsky Minesite, Russia.
2021 – GMD mill motor install and supervision, Cadia- Siemens Australia, Cadia Minesite, Australia.
2021 – GMD mill motor remedial works and testing, Cowal – Siemens Australia, Cowal Minesite, Australia.
2021 – GMD Bridges and Cords upgrade – ABB CH, Kazakhstan.
2021 – Multiple generator/motor works – GE Rugby, UK.
2021 – Multiple generator/motor works – Laurence Scott, UK.
2022 – GMD mill motor installation supervision, Las Bambas Minesite – Siemens Peru, Peru.
2022 – Complete generator rewind – Siemens Energy US, Israel.
2022 – Multiple generator remedial works – GE, Pakistan.
2022 – Generator remedial works – Fieldcore UAE.
2022 – Complete generator rewind – Ethos Energy, Keadby, UK.
2022 – Resin Injection repairs – VPI Immingham, UK.
2022 – Multiple generator/motor works – GE Rugby, UK.
2022 – GMD mill motor installation supervision – Siemens Germany, Peru.
2022 – Generator remedial works – Siemens Energy Germany, Pakistan.
2022 – Resin Injection repairs – Siemens Energy Germany, Keadby
2022 – Generator remedial works – Siemens Energy, Israel.
2022 – Multiple generator remedial works – Siemens Energy US.
2022 – Rotor pole segment repairs, Olympic Dam – Siemens Australia, Australia.
2023 – GMD mill motor install and supervision, Freeport – Metso Outotec, Indonesia.
2023 – Complete rewind of 600MW Generator – Toshiba Australia, Callide, Australia.

Past Performance (main contract to the end user):

30+ Major projects worldwide some of these include

2010 – Dry Ice Clean 4 x generators, Challenger Mine Australia – PowerWest
2010 – Slipring repair 700MW Alstom generator, Malaysia – TNB Malaysia
2010 – Dry Ice Clean 43MW Brush Generator, Australia – PGSR
2011 – Inspection of ball and Sag Mill – Toka Tindung
2011 – Consultant on Slipring problem, Mali West Africa – Resolute Mining
2011 – Turbine Generator water leak repair, Collie Australia – Verve Energy
2012 – Hydro Re-wedge, Montana USA – PPL Montana
2012 – PDA coupler inserts, Thompson Falls USA – PPL
2013 – Hydro Re-wedge, Holter Dam USA –PPL
2013 – Turbine generator Test and Inspection, Chile – Colbun Chile
2014 – Hydro Rewedge and neutral lead work, Holter Dam USA – PPL
2014 – Rewind wind turbine, Western Australia – Synergy
2014 – Mill motors inspections, Northern Territory – Milestone
2014 – Turbine generator dismantle, re-wedge / PD repair, Kwinana Australia – GDF SUEZ
2014 – Dry ice cleaning of stator segments, CP Mining Australia – Citic Pacific Mining
2014 – Installation AG Mill 3, CP Mining Australia – Kerman Contracting
2014 – Rotor pole testing, CP Mining Australia – Citic Pacific Mining
2014 – 2nd contract Turbine re-wedge / PD repair, + Main lead reversal – GDF SUEZ
2014 – Installation AG Mill 4, CP Mining Australia – Kerman Contracting
2014 – GMD slipring repair, Queensland – MMG Century
2014 – Turbine rewind generator Consulting, Saudi Arabia – Dhuruma E.C
2015 – Hydro generator wedge manufacture and rewedge assistance, Hydro Tasmania
2015 – Brush Generator overhaul, Alice Springs Australia – Territory Generation
2015 – Installation AG Mill 5, CP Mining Australia – Kerman Contracting
2015 – Test/Inspect/Clean Hydro Generator, Tumut 1 Australia – Snowy Hydro
2015 – Mechanical Supervisor, CP Mining Australia – Siemens Australia
2015 – Mill inspections, Queensland Australia – MMG Century
2015 – Installation AG Mill 6, CP Mining Australia – Kerman Contracting
2016 – GMD Mill repair work, Pt Freeport West Papua – PT Freeport
2016 – 3rd contract Turbine Main Lead Inversion – GDF SUEZ.
2016 – Test and Inspection 2 x Hydro Generators – Pacific Hydro
2016 – PD repair, mechanical inspection and PD coupler install Unit B – Pacific Hydro
2016 – End winding repair, Unit 2 Guthega Power Station Snowy Hydro
2016 – 160mVa Elin Generator PD repair and partial rewedge – Osborne CoGeneration
2016 – Overhaul of compressor motor – OEC Vanuatu
2016 – AEG gas turbine generator diode repair, Barrow Island – Zenith Pacific
2016 – 500MW GEC steam turbine generator water leak repair – Liddell PS – AGL Energy
2017 – 49mVa Elin Generator lead inversion, Kwinana – Engie
2017 – 21mVa Siemens Hydro Generator wedge design, manufacture and install – Hydro

Tasmania

2017 – 19mVa ACEC horizontal hydro generator – design, manufacture and install new wedge system and circuit ring connection and lead inversion – Ord River – Pacific Hydro
2017 – ABB GMD rotor pole repair, Newcrest Mine – Telfer
2017 – Supply winding labour on site turbine rotor repair, Siemens Power USA –

Philippines

2017 – Supply winding labour GE generator re wedge, Plana Del Vent – Spain
2017 – Supply winding labour hire for 180MW Aeropac Westinghouse Generator rewind, Oregon – USA
2017 – Hydro generator stator re-wedge, stator core test and core re tension – Kangaroo Valley, Origin Energy
2017 – Stator bore dry ice cleaning and varnishing of windings – Mica Creek Power station, Toshiba Australia
2017 – Hydro Generator bus bar connection support repairs – Tumut 3, Snowy Hydro
2017 – Bearing change – Zenith Pacific
2018 – Wyatinah No.2 Stator Re- Wedge – Hydro Tasmania
2018 – 61 MW Brush Turbo Generator, Major overhaul stator & rotor, Newman Power Station – Alinta Energy
2018 – Generator test and inspection, Phillippines – GN Power Mariveles Coal Plant
2018 – PD Coupler installation and generator inspection – Pacific Hydro
2018 – Replace transformer gasket, Barrow Island – Zenith Pacific
2018 – Bearing change, Daisy Milano – Zenith Pacific
2019 – Hydro Generator Splice repair Wayatinah – Hydro Tasmania.
2019 – Generator End winding Bump Test – GNPower Mariveles, Philippines.
2019 – Manufacture Circuit rings for Hydro Generator – Pacific Hydro, Australia.
2019 – Complete re-wedge of Turbo Generator – GNPower Mariveles, Philippines.
2019 – Multiple inspections of GMD Mill motor, Centinela – Antofagsata Minerals, Chile.
2019 – Hydro Generator inspection (80MW) – Hydro Tasmania, Tribute Power Station, Tasmania.
2020 – GMD mill motor coil splice repair – PT Freeport, Indonesia.
2020 – Hydro generator Fault finding and splice repair works – Hydro Tasmania, Butlers Gorge Power Station, Tasmania.
2021 – Multiple inspections of GMD Mill motor, Toromocho – Minera Chinalco, Peru.
2022 – Multiple Hydro generator inspections, testing and remedial works on 4 x hydro generator units – EFL, Fiji.
2022 – GMD mill motor install supervision, Quellaveco. Siemens Peru, Peru.
2022 – Multiple inspections of GMD Mill motor, Toromocho – Minera Chinalco, Peru.
2022 – GMD mill motor, repair of loose stator phase lead – PT Amman, Indonesia.
2022 – Hydro Genertaor remedial repairs – Snowy Hydro, Tumut 3 Power Station, Australia.
2023 – Multiple inspections of GMD Mill motor, Toromocho – Minera Chinalco, Peru.
2023 – Hydro generator inspection and remedial works – Snowy Hydro, Australia.
2023 – Hydro generator inspection – EFL, Fiji.
2023 – Generator inspection, Ord River – Pacific Hydro, Australia.
2023 – Ball motor coil splice repair – Northern Star, Pogo, US.
2023 – Multiple inspections of GMD Mill motor, Toromocho – Minera Chinalco, Peru.
2023 – Hydro Generator main leads upgrade, supply and manufacture – Contact Energy, NZ.
2023 – Hydro Generator remedial work, Tumut 3. Snowy Hydro, Australia.
2023 – GMD mill motor inspection and remedial works – Evolution Mining, Australia.
2023 – GMD rotor poles repair – Evolution Mining, Australia.
2023 – Hydro Generator inspection, remedial works and rewedge – EFL, Fiji
2023 – Hydro Generator blocking upgrade – Snowy Hydro, Australia.
2024 – Hydro Generator, complete manufacture and rewind, Ord River Power Station – Pacific Hydro, Australia
2024 – Hydro Generator, complete manufacture and rewind, Wailoa Power Station – EFL, Fiji.
2024 – Multiple inspections of GMD Mill motor, Toromocho – Minera Chinalco, Peru.

Workshop Contracts:

2013 – Manufacture and supply 24 LJB field coils – TMM
2013 – Manufacture and supply 76 LJB field coils – TMM
2013 – Manufacture and supply 1 set of rotor bars – TMM
2013 – Manufacture and supply 100 LJB field coils – TMM
2013 – Rewind 752 Armature – TMM
2014 – Manufacture and supply 1 set of stator coils – ABB Singapore
2014 – 3.5MW lead reversal – ABB Jarvis
2014 – 2333kVa Alternator rewind – ABB Jarvis
2014 – 800KW random wound alternator rewind – PowerWest
2014 – Manufacture and supply stator wedges – G.E. Perth
2014 – 11KV 2300kVa stator rewind – ABB Jarvis
2014 – Manufacture and supply 1 set of hydro generator stator wedges – Hydro Tasmania
2014 – Begin to supply HV ancillary components local workshops – UGL and TMM
2014 – Manufacture and Supply 100 LJB Field coils – TMM
2014 – HV ancillary component supply – Origin Energy
2014 – Manufacture and supply insulation kit – TMM
2014 – Manufacture and supply 1 set of stator wedges – TSSI Malaysia
2015 – Manufacture and supply stator wedge kit – Hydro Tasmania
2015 – Manufacture and supply 100 LJB field coils – TMM
2015 – Ongoing supply of HV ancillary components – TMM and UGL
2015 – Manufacture and supply LJB field coils (5th order of 100) – TMM
2015 – Manufacture and supply 1 set of P+H 489 coils and equalisers – TMM
2015 – 3.3kv generator rewind (include coil manufacture) – Zenith Pacific
2015 – Manufacture and supply sets of P+H armature wedges – TMM
2015 – Manufacture and supply two sets of AC traction motor wedges – TMM
2016 – Manufacture and supply wedge insulation kit for 750KW Stator – T
2016 – D77 and D29 traction motor rewinds – Inver Engineering
2016 – Wedge kit design, manufacture and supply for 15mVa English Electric Hydro Generator – Hydro Tasmania
2016 – Traction armature wedge manufacture and supply – TMM
2016 – 1000kVa Caterpillar Generator coil design, manufacture and rewind – Zenith Pacific
2013 – 127KW Siemens complete motor rewind – ABB Jarvis
2017 – 2000kVa ABB alternator rotor coil redesign and rewind – ABB Jarvis
2017 – 640kW Asea DC Motor shunt fields and series rewind – ABB Jarvis
2017 – DC compensating Stator rewind – ABB Jarvis
2017 – 2 GEC 317 armatures for rewind – Inver Engineering
2017 – 3.3kv Hitachi 450kw rewind and a Manufacture of coils – Global Rewind
2018 – Manufacture stator coils and a 3.3kv rewind – Global Rewind
2018 – Rewind and Manufacture coils GY19 Armature – Joy Global/ Komatsu
2018 – Rewind D77 Armatures – Inver Engineering
2018 – Wedge Manufacture (3.3kv and two 690v), rewedge and partial rewedge (magnetic) – RMEM
2019 – Wedge Manufacture, complete kit for Hydro Generator – Hydro Tasmania
2019 – Wedge Manufacture, complete kit – Toshiba Australia.
2019 – Wedge Manufacture, complete kit for Hydro Generator – Hydro Tasmania
2020 – 6.6kV 2 pole coil manufacture – ABB Sakti, Indonesia.
2021 – Manufacture of spare hydro generator coils – Pacific Hydro, Australia.
2021 – Wedge Manufacture, complete kit for Hydro Generator, Butler Gorge – Hydro Tasmania
2022 – Wedge Manufacture, complete kit for Hydro Generator, MB Century.
2023 – Manufacture 11kV spare coils for Hydro Generator – Pacific Hydro, Australia.
2024 – Manufacture complete set of 11kV coils and full rewind kit for Hydro Generator – Pacific Hydro, Australia.
2024 – Manufacture complete set of 11kV coils and full rewind kit for Hydro Generator – EFL, Fiji.
2024 – 4 x manufacture complete sets of 11kV coils and rewind kit for AVK Generators – ERM, Australia.

Projects and Case Studies