Strength in Numbers: How Australian Winders Revived Generator Windings Longevity
- Project Scope: Water-Cooled Motor Rewind & Upgrades for 660 MW-720 MW Turbo-Generators on-site at Bayswater and Mount Piper Power Stations in NSW
- Critical Challenge: Generator windings approaching design end of life, requiring urgent and expert intervention.
- Time Of the Essence: All four rewinds were successfully completed within a demanding timeframe of 6 weeks each.
- Safety Excellence: Zero loss time injuries (LTI) were recorded throughout the entire project.
- Quality Assurance: All tests rigorously met or exceeded the acceptance criteria, ensuring optimal performance and reliability.
Understanding the Challenge: Ageing Infrastructure and Its Impact on Operational Reliability
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.
The ageing windings threatened the reliability of the power stations, leading to increased downtime, higher maintenance costs, and potential disruptions to energy delivery. These challenges were compounded by the urgency of the situation, requiring a solution that could be executed swiftly and without margin for error.
Understanding the gravity of this motor’s situation, we approached the project with a deep sense of responsibility, ensuring that every step was meticulously planned and executed to prevent any further impact on their operations.
Setting the Stage: A Controlled Environment
A highly skilled team of electrical engineers and electromechanical technicians were brought in to tackle this complex project. Their first step was establishing a controlled environment to ensure peak safety and efficiency:
- Full asbestos containment setup
- Marquee erected and clean flooring installed
- Daily checks of all tools and equipment
- Strict access control with sign-in and sign-out protocols
Precision in Action: Removing the Existing Windings
Using an electric winch, the team carefully removed the existing stator bars while preserving the circuit rings, which remained in serviceable condition. This methodical process showcased Australian Winders’ ability to blend cutting-edge technology with practical motor winding experience.
Installation of New Windings: Bottom and Top Bars Installation
The installation phase was where Australian Winders’ motor winding expertise truly came to the forefront:
- Bottom and top bars were installed with precision, each undergoing dielectric testing to meet high-voltage withstand standards.
- Innovative ripple spring technology was applied for lateral wedging, providing added stability.
Advanced Techniques for Optimal Performance
Bar Seating and Epoxy Molding
The team used pressurised hoses for seating the bars and industrial heaters for uniform epoxy moulding during the bakeout. This attention to detail ensured optimal performance and durability.
Brazing and Leak Checks
Sophisticated brazing techniques were employed, followed by a four-stage leak check process, reaffirming our commitment to quality. We don’t stop at one check. We check once, then again and again and again, ensuring no impurities slip through the cracks.
Ensuring Excellence With Rigorous Electrical Testing
The final phase of the project involved a series of comprehensive electrical tests, including:
- ELCID, IR, PI, HV, offline PD, DDF, and bump tests.
- Each test confirmed that the new windings met all performance criteria.
Project Success: Delivering Superior Power Performance
On-Time Completion
On-time, within budget, and incident-free: all four rewinds were completed in just six weeks each from start to finish, with zero LTIs – a testament to the team’s dedication to safety and excellence.
Long-Term Benefits
The successful rewinds extended the life of these critical assets, ensuring sustained superior power performance and reinforcing Australian Winders’ reputation as a global specialist in industrial motor winding and manufacturing services.
