8.2-run-until-2025-4-f938aecee7974c4e.pdf

This report provides a technical assessment of the boiler plant and associated systems at Hendrina Power Station, focusing on life extension (Life-ex) studies for Units 1-10. It details boiler tube leak (BTL) patterns, component replacement histories, and the degradation of pressure parts, specifically highlighting issues with fly-ash erosion, sootblower erosion, and creep exhaustion in main steam piping.

• Boiler tube leaks (BTLs) across Units 1-5 are primarily concentrated in the economizer, with element 42 recording the highest frequency of leaks (9 total from 2008 onwards). Fly-ash erosion was responsible for 48 BTLs across these units.
• Unit 1 experienced significant sootblower erosion, accounting for 16 of its 20 recorded tube leaks. This is attributed to factors such as incorrect blowing temperatures, misaligned sootblowers, or moisture traps.
• The main steam system is subject to creep exhaustion, which leads to crack formation from prolonged operation under high temperature and stress. For Unit 3, 56% of the system remains uninspected, creating a 'surprise factor' where the number of high-risk (Class 1 and 2) components may increase.
• Severe damage was identified in the manifold drain lines of Unit 3, including a 25mm linear macro crack. This was determined to be caused by extreme external loading due to inadequate support maintenance rather than creep exhaustion.
• A 2007 Siemens capacity study identified several limiting factors preventing the boilers from operating at 110% Maximum Continuous Rating (MCR), including inadequate attemperator design, steam space rate limits in the drum, and increased fly ash erosion due to higher flue gas velocity.

APA

Centre for Environmental Rights (n.d.). 8.2-run-until-2025-4-f938aecee7974c4e.pdf. https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-4.pdf?x21779

Chicago

Centre for Environmental Rights. 8.2-run-until-2025-4-f938aecee7974c4e.pdf. n.d. https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-4.pdf?x21779.

Wikipedia

{{cite report |author=Centre for Environmental Rights |title=8.2-run-until-2025-4-f938aecee7974c4e.pdf |url=https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-4.pdf?x21779 |access-date=17 August 2026 |via=Climate Insights Directory}}

BibTeX

@techreport{centreforenvironmentalrightsnd82rununtil20254f938aecee7974c4epdf, author = {{Centre for Environmental Rights}}, title = {{8.2-run-until-2025-4-f938aecee7974c4e.pdf}}, institution = {Centre for Environmental Rights}, url = {https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-4.pdf?x21779}, urldate = {2026-08-17}, note = {Indexed by Climate Insights Directory} }