From Mexico to Texas Engineering excellence without borders
- emre öztemel
- 1 day ago
- 2 min read
When a 41,250kVA, 13.8kV turbo generator stator suddenly failed at a site in Mexico, the clock started ticking. Coil Partners quickly mobilized its expert team of design engineers to perform a full onsite survey — a high-stakes mission that required precision, speed and creative problem-solving.
Rebuilding a puzzle with missing pieces
“By the time we arrived, all top stator bars had already been removed,” recalls Emre Kaya, Technical Director. “We had to reverse-engineer complex, non-standard coil connections with limited references and under intense time pressure.” Using high-resolution mobile scanning tools and 3D-modeling software, the team reconstructed the original geometry with sub-millimeter accuracy. “It’s like rebuilding a custom puzzle when half the pieces are gone. Every tiny detail matters.”
The collected data are now being used to manufacture replacement stator bars at the Coil Partners’ facility. Before shipping, the bars will be trial-fitted in a custom-built stator model fixture, ensuring a perfect match once installed.
Shifting gears in Texas
Within the same week, the team travelled to Texas to measure a turbo rotor for a future rewind project. Unlike stator bars, rotor coils operate at 3600 RPM and endure extreme centrifugal forces. “Each turn of the rotor coil is unique in shape and radius,” explains Ensar Polat, Director of Quality and Strategic Development. “That means no coil-bending machine can help us. We need custom moulds for every turn.” Even though this project hasn’t been officially commissioned yet, the Coil Partners team has already started prototyping potential tooling concepts.
What sets Coil Partners apart While many manufacturers rely on standard designs, Coil Partners stands out by delivering bespoke solutions for non-standard challenges anywhere in the world.
What sets Coil Partners apart
While many manufacturers rely on standard designs, Coil Partners stands out by delivering bespoke solutions for non-standard challenges anywhere in the world. “What still gives me adrenaline,” says Ensar, “is seeing whether our design really works once it hits the workshop. That moment of truth keeps the work exciting.”
According to Emre, local collaboration was key in Mexico. “We couldn’t have met the deadline without the support of the local team on site.”
This project shows what Coil Partners is built for: smart people, working fast and with care, across borders and time zones. It's a reminder that great engineering isn’t just about machines. It’s about mindset.