8.2-run-until-2025-5-464c7f87ca73e9f7.pdf

This report provides a consolidated life-extension (Life-ex) assessment of the Hendrina Power Station, focusing on the boiler, draft plant, and turbine plant. It details component failures, modifications, and inspection results to determine the feasibility of running the plant until 2025 or 2035, highlighting critical life exhaustion in high-pressure turbine components and erosion in air heaters and PA fans.

• The high-pressure (HP) turbine components, including rotors, inner casing, steam inlets, combined ESV&CV-casings, and loop pipes, have already exhausted their lifetime according to calculations and investigations, with some remaining operation time under 30,000 equivalent operating hours (EOH).
• The low-pressure (LP) turbine exhibits several critical issues, including the risk of uncontrolled Low Cycle Fatigue (LCF) failure in rotor stage 4 TS/GS, severely eroded LP stage 1 TS & GS diaphragms, and stage 2 blades that have reached the end of their life after exceeding 200,000 EOH.
• The turbine's control and protection systems are outdated, with obsolete parts for steam pressure and vacuum operated load reducers and Herion solenoid valves, making operation until 2025 or 2035 impossible without a complete exchange for a modern system.
• The Primary Air (PA) fans are in very poor condition due to minute fly ash erosion, which is exacerbated by blocked air heaters causing ash overflow into the fans, necessitating the replacement of casings for ongoing operation.
• Inspection of the boiler's superheater (SH) components showed that the SH 3 inlet and outlet header have an estimated remaining useful life of 60,000 to 90,000 hours, while the final SH header's remaining life was also estimated between 60,000 and 90,000 hours in 2011.
• The boiler's pulverized fuel system has experienced various failures, including 42 incidents of feeder pick-ups not working and 28 spiral feeder trips on unit 8, with site personnel reporting continuous repairs to feeder motors and the replacement of spirals.

APA

Centre for Environmental Rights (n.d.). 8.2-run-until-2025-5-464c7f87ca73e9f7.pdf. https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-5.pdf?x21779

Chicago

Centre for Environmental Rights. 8.2-run-until-2025-5-464c7f87ca73e9f7.pdf. n.d. https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-5.pdf?x21779.

Wikipedia

{{cite report |author=Centre for Environmental Rights |title=8.2-run-until-2025-5-464c7f87ca73e9f7.pdf |url=https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-5.pdf?x21779 |access-date=17 August 2026 |via=Climate Insights Directory}}

BibTeX

@techreport{centreforenvironmentalrightsnd82rununtil20255464c7f87ca73e9f7pdf, author = {{Centre for Environmental Rights}}, title = {{8.2-run-until-2025-5-464c7f87ca73e9f7.pdf}}, institution = {Centre for Environmental Rights}, url = {https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-5.pdf?x21779}, urldate = {2026-08-17}, note = {Indexed by Climate Insights Directory} }