Induced draft (ID) fan lubrication system design review and proposed modification upgrade at Callide C Power Station

Abstract

[Abstract]: Australia’s coal fired power stations are the most efficient form of providing bulk base load power generation (i.e. electricity) to consumers. This is due to Australia having an abundance of thermal coal reserves, which is the fuel used in coal fired power stations. Therefore it is extremely important that these power stations operate at maximum availability and reliability to ensure the consumer receives cost effective and uninterrupted electricity. Callide C Power Station in Biloela Queensland is a 900 Megawatt (MW) coal fired power station that was commissioned in 2001. Unfortunately Callide C Power Station has been plagued with continuous operational and reliability problems caused from the induced draft (ID) fans since initial commissioning. The ID fan problems have arisen from the bearing lubrication system which provides oil recirculation to the induction motor bearings and fan main shaft bearings. Consequently these issues have caused half-load unit (225 MW) run-backs and full unit (450 MW) trips over the past decade. This project’s aim is to analyse the ID fan lubrication system and then identify and define all root causes and their associated failure modes. Once all root causes are identified through Root Cause Analysis (RCA) process, effective design solutions can be researched and evaluated so a proposed modification design project can be finalised. This final design proposal will be used to justify capital expenditure so implementation can occur in the near future.