8.2-run-until-2025-2-d31614e3729643ab.pdf

The Hendrina Power Station Consolidated Life-ex Report outlines the necessary technical interventions and capital investments required to extend the station's operational life to 2025. Key recommendations include the modernization of the main turbines to improve efficiency and reduce emissions, a partial replacement of generators (Scenario B), and the large-scale replacement of aging LV and MV motors and PILCSWA cables. Critical infrastructure needs include the construction of Ash Dam 6 by 2018 and the lining of water reservoirs for legal compliance. The report emphasizes that continuing with existing old equipment will lead to higher maintenance costs and lower reliability compared to the proposed modernization.

• The turbine plant requires significant capital investment in modernized equipment to operate until 2025. Siemens recommends a complete replacement of the main turbine with a modern design for all 10 units, as the current HP-turbine internals and HP ESV/CV casings are at the end of their life due to "creep exhaustion". This modernization could create "10MW green power for each unit or 100MW to the station output" or reduce CO2 emissions by approximately "700.000 tons per year".
• For the generators, Siemens recommends 'Scenario B' for operation until 2025. This involves keeping some existing hydrogen-cooled generators in operation while installing three new air-cooled footprint generators and one spare. This scenario is described as the "cost optimized solution for operation until 2025" and is preferred over Scenario A (maintenance only) and Scenario C (full replacement of all 10 units), as it mitigates the risk of stator core failure in units 8, 9, and 10.
• The electrical plant requires extensive replacements of aging motors and cables. A large percentage of low voltage (LV) motors are beyond their "end of economic life" and should be considered for immediate replacement. Similarly, a large-scale replacement program is recommended for most medium voltage (MV) motors because the average remnant economic life is "less than 10 years". Additionally, approximately 90% of the MV cable network consists of original PILCSWA cable in poor mechanical condition, requiring a partial replacement program for 2025.
• The Control and Instrumentation (C&I) systems require phased upgrades. The existing SIMATIC S5 DCS system will no longer be supported for spares beyond 2020, necessitating a migration to the "latest DCS SPPA-T3000". Other critical replacements include the GPS system and Ethernet system by 2019, and a comprehensive upgrade of the on-line vibration monitoring system to be completed by 2023.
• The auxiliary transformers are entering a state of "rapid ageing" due to high moisture content. The report states that the original transformers "will not operate reliably until 2025 in their present condition" and requires a comprehensive intervention to dry out solid insulation and improve oil quality.
• The boiler plant requires various component replacements and monitoring. For Units 6-10, recommendations include replacing all economiser elements and the Superheater 4 Outlet Header. The report notes that the Superheater 3 Outlet Header will require replacement in "8 to 12 years". For Units 1-5, the report suggests replacing all piping for the attemperator supply to ensure reliability.
• The boiler draft plant requires the replacement of air heater packs for all units (1-10). Regarding the Flue Gas Desulfurization (FGD) system, the report recommends applying for a concession due to the high capital costs of retrofitting, as the plant would only operate for a few years from the application of the Air Quality Act until the end of plant life.
• Critical civil and common plant issues must be addressed to ensure operation until 2025. Most urgent is the construction of Ash Dam 6, which must be commissioned by mid-2018; otherwise, the "life of Hendrina Power Station is effectively limited". Other critical needs include lining the maturation pond, raw water reservoirs, and the 7 Year Dam to comply with the National Water Act and Water Use License.
• The main condenser tubes are in poor condition due to scale build up, pitting, and erosion/corrosion caused by "poor water chemistry of the cooling water system". Tubes in the air extraction zone for units 3, 6, 8, and 10 require replacement as a minimum for continued operation until 2025.

APA

Centre for Environmental Rights (n.d.). 8.2-run-until-2025-2-d31614e3729643ab.pdf. https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-2.pdf?x21779

Chicago

Centre for Environmental Rights. 8.2-run-until-2025-2-d31614e3729643ab.pdf. n.d. https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-2.pdf?x21779.

Wikipedia

{{cite report |author=Centre for Environmental Rights |title=8.2-run-until-2025-2-d31614e3729643ab.pdf |url=https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-2.pdf?x21779 |access-date=17 August 2026 |via=Climate Insights Directory}}

BibTeX

@techreport{centreforenvironmentalrightsnd82rununtil20252d31614e3729643abpdf, author = {{Centre for Environmental Rights}}, title = {{8.2-run-until-2025-2-d31614e3729643ab.pdf}}, institution = {Centre for Environmental Rights}, url = {https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-2.pdf?x21779}, urldate = {2026-08-17}, note = {Indexed by Climate Insights Directory} }