From Failure to Function: Quartzelec Completes Full Generator Rewind
Quartzelec
#Rugby recently completed a comprehensive in-house rewind of an 11kV
#synchronous generator for a
#steel manufacturing facility in
#SouthWales.
The project followed a critical in-service failure, where a sheared rotor pole-to-pole support led to a severe internal collision with the windings—prompting the need for urgent and expert intervention.
Quartzelec was selected for the repair due to our proven track record in
#HV machine recovery and our ability to deliver a full turnkey solution entirely in-house.
Both the
#rotor and
#stator was transported to our Rugby-based workshop, where initial inspections were carried out by our engineering teams.
All existing windings were stripped from the rotor and stator, followed by thorough cleaning and diagnostic testing of the stator core and rotor body.
The stator core was then carefully prepared, and new
#coils were manufactured in-house by Quartzcoil, part of the Quartzelec group of companies, to meet the original specification.
Once manufactured, the coils were installed, connected, and the stator was fully varnished to ensure durability and performance.
On the rotor, refurbished coils were installed along with newly insulated leads and connections. A new slip ring hub and slip rings were also fitted and precision-machined in-house using our Noble & Lund lathe.
Both rotor and stator were then painted to specification in our workshop.
Final electrical and quality assurance tests—including insulation resistance and surge testing—were successfully completed before the equipment was securely packaged for return to site.
This project highlights the importance of fast, reliable, and technically precise repair services for critical infrastructure. With end-to-end in-house capabilities—from coil manufacture to precision machining—Quartzelec offers full quality control, reduced lead times, and a responsive, dependable service.
The stator and rotor are now back with the client, ready to support generation demands as soon as they’re brought back into operation.
#synchronousgenerator #diagnostictesting #insulationresistance #surgetesting #generatorrewind #steelmanufacturing #UnparalleledInEngineeringServices