Agnico Eagle 24-Pulse Transformer

When Agnico Eagle's Fosterville Gold operation in Victoria faced a critical infrastructure challenge, Hunter Transformers was engaged to deliver what other suppliers deemed too complex to be done at an attractive price: a precision-engineered redundant spare for their 2334kVA 11/4×1.903kV ONAN transformer powering two main sludge pumps. This highly specialized 24-pulse unit, originally manufactured overseas with an unknown design pedigree, required exact replication to serve as a drop-in replacement—yet with superior engineering that would ensure long-term reliability for this critical mining operation.

Engineering Excellence through Complex Constraints

The project presented extraordinary technical challenges that required innovative problem-solving at every stage. Working from reverse-engineered specifications, our engineering team successfully replicated the transformer's complex vector group configuration Yd(+7.5)d(-22.5)d(+22.5)d(-7.5), ensuring electrical compatibility with existing mine infrastructure. The original design utilized compact fin wall construction—a configuration Hunter Transformers deliberately avoids due to structural integrity concerns. Our challenge was to match those exact dimensions while implementing our proven detached radiator design, known for superior reliability and maintainability.

Through extensive 3D modeling and creative layout optimization, we achieved what seemed impossible: matching the compact footprint of fin wall construction using structurally superior detached radiator technology. The solution required an oversized tank—more than 50% larger than standard—to accommodate the specific radiator placement needed for dedicated cable entry points. We incorporated top-mounted bushings, conservator tank, and Buchholz relay protection, with radiators positioned on specific sides to preserve existing site cable runs. Every dimension was engineered to ensure zero modifications would be required at the Fosterville site—a critical requirement for operational continuity in a 24/7 mining environment.

Responsive Partnership and Customer-Focused Service

Throughout the project, Hunter Transformers demonstrated the kind of partnership that transforms technical challenges into confident solutions. From initial engagement through final delivery, our team maintained proactive communication at all levels—from Sales Manager Steve Kendall's personal follow-ups to Project Coordinator Aristos's transparent progress updates. When specification discrepancies arose during the iterative design process, we immediately acknowledged the issue and implemented corrections, always keeping the customer informed with clear timelines and realistic commitments.

The project progressed through multiple quote revisions as we refined specifications in close collaboration with Agnico Eagle's engineering team. When the customer requested additional gland plate location modifications to further optimize cable routing, we provided honest technical feedback about the dimensional constraints already achieved through our creative engineering. Rather than overpromising, we maintained our commitment to engineering integrity while successfully incorporating their surge arrestor requirements—demonstrating flexibility where technically feasible and transparency constraints existed.

Supporting Australia's Mining Industry Through Technical Innovation

Our successful delivery of this highly specialized transformer for Agnico Eagle's Fosterville Gold operation demonstrates Hunter Transformers' capability to tackle projects that others decline. By reverse-engineering an overseas design and improving upon it—achieving equivalent compact dimensions while delivering superior structural integrity—we provided Fosterville with a redundant spare that offers true operational security. This transformer now stands ready to ensure continuous operation of critical sludge pump infrastructure, supporting the mine's processing operations and reinforcing our commitment to Australian mining, technical excellence, and the partnerships that drive industry forward.