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.
The Client
As a key power provider for Fijian communities, this client depends on robust and reliable assets to deliver uninterrupted service. When one of the generators at a local power station reached a critical maintenance stage, the supplier needed a trusted partner to conduct a stator rewind with minimal downtime. The solution required precision engineering, innovative problem-solving, and the ability to navigate the complexities of working in a remote location.
Complexities at Every Turn
This was no ordinary generator rewind. The challenges Australian Winders faced went beyond technical expertise to include significant logistical and operational hurdles.
- Remote Location Logistics: Site access required careful planning, including securing working visas, arranging accommodation, and ensuring that an 11-person team had everything they needed – from groceries to reliable connectivity for both personal and work needs.
- Challenging Environment: Fiji’s tropical climate added another layer of complexity to the logistical and on-site work conditions, requiring exceptional adaptability from the team.
- Tight Deadlines: Completing the rewind within an ambitious timeline – one deemed nearly impossible by others – demanded an extraordinary level of planning, coordination, and execution.
The Australian Winders Solution
Australian Winders tackled the project with a full turnkey solution designed to address both logistical and technical demands. Its approach combined advanced engineering and streamlined project management, ensuring every detail was accounted for:
- Comprehensive Engineering Services: The design and manufacture of all necessary parts and ancillary components were completed with precision to ensure seamless integration.
- Custom Tooling and Consumables: Tailored to the specific requirements of the Wailoa Power Station, these ensured work progressed without delays.
- Expert Execution: The team managed the complete rewind process, from disassembly and stator rewinding to reassembly, testing, and commissioning – all while adhering to the highest safety standards.
Precision Execution Under Pressure
The project commenced with a rigorous inspection and planning phase, ensuring all components, tools, and consumables were ready for the remote worksite. On-site, the Australian Winders’ team executed the rewind with meticulous attention to detail, overcoming challenges such as equipment access and maintaining connectivity in an isolated location.
Ahead of Schedule, Beyond Expectations
Despite the challenges, Australian Winders completed the stator rewind ahead of the tight deadline, earning praise from the national power supplier:
“Well done, completed well within days as planned. A note of appreciation to have the station back online after stator rewinding, re-assembly, testing, and commissioning. Thank you all for your respective work, special responsibility, and assistance rendered to each other. Thank you very much.”
The result was a fully refurbished generator that is now undergoing a 30-day reliability run, providing a critical boost to the supplier’s operational efficiency.
Building Long-Term Partnerships
Australian Winders’ success in this project has strengthened its relationship with the National Power Supplier. With plans to rewind the second of four units in 2025, the collaboration is set to deliver continued improvements to Fiji’s energy infrastructure.
Maximising Asset Reliability
Beyond the immediate results, Australian Winders also advised on long-term maintenance strategies, ensuring the generator will deliver sustained, superior power performance over time. By integrating predictive maintenance tools and recommending regular inspections, Australian Winders has laid the groundwork for sustained operational excellence.
Delivering Unparalleled Power Performance
This project highlights Australian Winders’ ability to deliver under pressure, combining technical expertise with the logistical acumen required to succeed in remote and demanding environments. For organisations facing critical asset challenges, Australian Winders offers a proven approach to maximising reliability and ensuring long-term performance.
Looking to maximise the reliability of your critical infrastructure? Partner with Australian Winders – the global leaders in industrial motor rewinding and manufacturing.
