The Challenge
HWC was called to a remote site to troubleshoot a critical, recurring issue on an apron feeder system. With minimal documentation available on-site and conflicting reports regarding the root cause, the system was experiencing uncontrolled speed spikes, overfeeding downstream equipment and causing repeated production trips.
Our Approach
1. On-Site Diagnostics & Trend Analysis
Our technician met directly with Mill Control operators to analyse historical trend data and isolate operational anomalies.
2. Back-Office Engineering Support
Recognising the legacy design of the system, the technician leveraged HWC’s Perth engineering office. Our team tracked down obsolete pump control schematics and uploaded them to a shared repository for immediate field reference.
3. Cross-Disciplinary Collaboration
We facilitated a collaborative troubleshooting session linking site operators, mechanical and instrumentation teams, and HWC technical specialists.
The Root Cause & Resolution
By systematically reviewing combined hydraulic, mechanical and electrical data alongside historical schematics, the team identified the exact fault: a worn, sticking pump controller.
Fix: The faulty controller was replaced on-site, and full system operational performance was tested and verified.
Knowledge Sharing: All newly sourced schematics and diagnostic logs were archived to streamline future maintenance and site training.
The Outcome
Zero Recurring Downtime: Complete resolution of the speed control fault and full restoration of throughput stability.
Long-Term Value: Obsolete documentation was recovered and digitised, safeguarding the client against future legacy system knowledge gaps.
