Australian Winders Proves its Worth 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.
The Client
Operating some of the world’s most demanding sites, this client needs every asset running flawlessly—especially at their Delta location. When a critical ball mill motor faced catastrophic issues, they called in Australian Winders, knowing that only a global leader in motor winding could deliver under pressure.
On July 24, 2024, Australian Winders USA LLC (AWUSA) was contracted to conduct a 21-day onsite outage to complete a full rewind of the ball mill. The scope of work included using customer-supplied tools, consumables, and OEM-supplied coils. However, prior to the mill’s disassembly, we recommended testing and verifying the viability of the coils, as no testing documentation could be produced for the coils, which had been stored for a year. It was recommended to the customer that surge and Hipot testing be conducted on the coils to confirm their dielectric strength.
The Crux
In 2023, a severe event involving Foreign Material Exclusion (FME) compromised the gold producer’s ball mill motor. This required the replacement and splicing of coils in various locations due to a Foreign Material Exclusion (FME) issue. The motor had already been through a temporary repair by another contractor, but it was clear a complete rewind was necessary to maintain operations. The client’s operation couldn’t afford downtime, so they called on us to handle a full rewind in just 21 days.
But there was a catch: key components had been sitting in storage for over a year with no testing documentation. We had to navigate unexpected scope changes, core damage, and a ticking clock to deliver the reliability that the client depends on.
Precision in the Face of Complexity
Our team began with an intensive inspection and immediate coil testing, including surge and Hipot tests to verify the component’s suitability for installation. Issues quickly surfaced: heavy wear and heat damage were observed in the slots between 163-195 at the 3 o’clock position and contamination from remnants of old insulation material. We combined meticulous cleaning with advanced techniques and recommended targeted epoxy treatments to reinforce the motor’s integrity.
What We Did
In just three weeks, we delivered:
- A comprehensive coil testing and inspection regime
- Customised repairs, including targeted epoxy treatments for damaged slots
- ELCID testing to establish a solid baseline for ongoing monitoring
- Installation of recommended maintenance tools like an inspection hatch for better access
All while keeping stakeholders fully informed and confident in our approach.
Restoring Operations
The project was a resounding success. The motor now runs smoother than ever, with all tests confirming long-term reliability. The global-scale gold producer can continue operations without fear of unexpected breakdowns, and we’ve set them up with a robust maintenance plan that will keep this asset performing for years to come. Ongoing ELCLID testing will confirm the core is operating within the expected range, ensuring long term stability.
Maximising Asset Longevity
We didn’t stop at the rewind. By advising regular ELCID testing, integrating thermal imaging, and recommending strategic maintenance upgrades, we’ve set the client’s operation up for long-term reliability.
Australian Winders advises an annual shutdown for inspections at the 3 o’clock position, including ELCID testing, to track any changes against the baseline data from this project. If results stay within acceptable limits, future testing can transition to visual inspections, though this carries a slight risk from reduced data points.
Our approach ensures their investment continues to deliver, minimising risk and maximising asset life.
Unparalleled Power Performance
By adhering to stringent protocols and pioneering solutions, Australian Winders delivered a successful mill motor rewind that extended the asset’s life and ensured operational excellence. This project highlights the critical role of regular maintenance in maximising industrial equipment longevity. As the global leader in industrial motor winding, Australian Winders is dedicated to delivering unmatched performance, every time.
Looking to maximise the lifespan of your critical assets? Speak to the experts at Australian Winders today.
