Improvements to maintenance strategy

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AGL owns and operates the 2,200 megawatt Loy Yang power station and the adjacent Loy Yang coal mine. 

With significant pressure to reduce costs at the Loy Yang power station, Ausenco Rylson were engaged to investigate the maintenance costs and risks associated with the existing maintenance strategy.

Ausenco Rylson assisted in developing an improved maintenance strategy that enabled forecasting of appropriate budgets. 

The project involved the validation of a previous pilot maintenance strategy review of the mills and a full maintenance strategy review of the precipitators. Ausenco Rylson performed the following activities during the course of this project: 

  • Reviewed existing data 
  • Deconstructed maintenance tasks to determine primary failure modes 
  • Determined accurate labour and material costs for secondary tasks 
  • Uploaded the data obtained into Rylson8 (Ausenco Rylson’s enterprise-grade proprietary asset management software) 
  • Generated and analysed OPEX reports 
  • Reviewed and reported findings. 


The mills and precipitators were targeted as the major cost areas and an operating budget was developed. The level of detail in the analysis enabled major cost drivers to be identifi ed and targeted for improvement. 

The potential savings for these improvements were estimated. A cost saving in the order of millions of dollars is achievable with the implementation of the improvements.

Project details

Asset management
Victoria, Australia
Loy Yang Power
Solution phase