In 2022 a large NSW power facility faced severe inefficiencies in its fuel preparation plant. Working with the operator’s Reliability Engineering team, Secora lead a project focused on eliminating key constraints and shifting from a ‘run to failure’ maintenance approach to a reliability-centred one. Using Lean Six Sigma tools, the team identified the root causes and implemented solutions. Within three months, production losses were reduced by 84%, and generation capacity increased by 50 GWh per month.

THE PROJECT

Secora was engaged to address production constraints, optimise revenue, and maintain operations amid the recurrence of unscheduled downtime.

In 2022, severe power shortages plagued Australia's east coast. And at a large power plant in NSW, inefficiencies in the fuel preparation plant resulted in production losses equivalent to the power needs of 123,000 households, causing unsustainable revenue losses.

THE CHALLENGE

The power station's fuel processing plant included 28 coal mills and 56 volumetric feeders across four generating units, each capable of 660 MW. These mills and feeders were identified as major causes of production loss, which totalled 690 GWh each year. Key issues included trunnion bearings, lift and lube systems, gear lubrication, drive train failures, and sub-optimal feed unit availability.

The project required shifting from a ‘run to failure’ maintenance approach to Secora's reliability-centred maintenance culture.

WHAT WE DID

Secora integrated into the Operator’s Reliability Engineering team, forming and leading the mill reliability project and facilitating collaboration across maintenance, operations, and subcontractor teams.

Regular workshops provided senior management with progress updates and opportunities for proactive engagement. After a brief definition and scoping phase, the team conducted data gathering and analysis to quantify system constraints.

Using Lean Six Sigma tools, Secora identified the root causes and developed plans to eliminate primary constraints. They also analysed service schedules, trained maintenance teams in change management, and implemented Lean productivity principles. Daily progress meetings and visual management ensured sustainability.

THE RESULTS

In three months, fuel processing plant de-ratings decreased by 84%, key constraints were resolved, and generation capacity increased by 50 GWh per month, equivalent to supplying power to 110,000 homes.

The client's reliability teams now independently apply Secora principles, sustaining the improvement processes. By the end of 2022, Secora extended its efforts to other operational areas for further environmental, safety, and productivity enhancements.