The challenge
Synergy needed to extend the life of Generator 3 at West Kalgoorlie Power Station, an ALSTHOM 24 MVA unit installed in 1982, while bringing its performance in line with modern reliability standards. The project required a full stator rewind, but key components were undocumented, ageing, or no longer available.
One of the most demanding parts of the job was producing a new set of Roebel bars. These conductors are exceptionally difficult to manufacture, which is why most rewinders avoid making them themselves and instead rely on imported stock or third-party suppliers. However, as the only Roebel bar manufacturer in the country, Australian Winders took on this challenge and manufactured each bar in-house. This ensured full control over quality, dimensional integrity, and electrical performance from start to finish.
Australian Winders’ solution
The stator rewind began with the in-house manufacture of new single-turn Roebel bars, each built to Class F (IEC 60085) insulation standards using a resin-rich system. To ensure optimal thermal fit, the bars were modelled in 3D and cured in a dummy stator before installation. Custom end-winding supports and slotted insulation were applied during the rewind process, optimising mechanical integrity and stress distribution.
With no original documentation available for the generator’s air baffles, the team reconstructed them from legacy photographs, modifying the design to suit the new winding geometry and material profile. All lead connections were completed using integrated mechanical, electrical and insulation techniques, including custom wrapping, epoxy encapsulation, and ductor-verified jointing.
Unparalleled power performance
The rebuilt winding system underwent comprehensive electrical, thermal, and mechanical testing. Slot insulation withstood over 46 kV, far exceeding IEC and IEEE requirements. Final joints recorded ductor values between 3.3 and 3.5 µΩ, confirming strong electrical continuity and low-resistance performance.
Additional protection was built in through semi-conductive corona shielding and silicon carbide stress grading, further reducing discharge risk and extending the life of the system’s insulation.
With next-generation insulation and integrated discharge protection, the completed system has been designed to reliably deliver this strong performance over the long haul.
Engineered for longevity
This project highlights the unique technical skillset and full-cycle capability that sets Australian Winders apart in the industry. By managing the full process from design to installation to validation, Australian Winders delivered a solution that not only meets modern performance standards while extending the operational life of a critical generation asset.
If you’re looking to extend the life of your critical infrastructure, partner with Australian Winders today.