8.2-run-until-2025-7-2faad66b32b626e5.pdf

This report provides a detailed technical condition assessment of the Hendrina Power Station, focusing on the life extension (Life-ex) of its generators, auxiliary systems, and common plant infrastructure. It identifies significant degradation in stator winding insulation, the presence of hot spots in stator cores, and severe corrosion and structural spalling across various civil works, including cooling towers and smoke stacks. The document evaluates the feasibility of extending plant operations to 2025, noting that while some areas are in good condition, others pose high risks to safety and operational reliability.

• The high voltage insulation system of the generator is considered to be in reasonably good condition given its age, although decades of operational stress have reduced its remaining lifespan. There are early signs of accelerated aging, including moderate delamination of the taped epoxy-mica insulation system and evidence of slot discharge activity observed between 2009 and 2013.
• Technical inspections of the stator core revealed critical hot spots. In one instance at the Turbine End (TE), a hot spot with a temperature increase of 14 K was identified; calculations suggest this could reach 20 K above normal core temperature at rated induced voltage. Because this is not monitored by sensors and was not repaired, there is a risk of core burning.
• The auxiliary systems, particularly those under hydrogen pressure, are in poor condition and are described as a very high risk and a significant threat to life or physical safety. Many components do not comply with safety rules such as ATEX, IEC, or VGB R165, specifically within the seal oil and hydrogen gas systems.
• Significant structural degradation is present in the plant's civil infrastructure. Cooling Towers 2, 5, 7, and 8 exhibit severe spalls on circular columns that could lead to sectional or overall structure failure within two years. Smoke stacks show severe cracking and mortar loss in Zone 1, and the external concrete walls of conveyors 17 and 18 show spalling where reinforcing steel is visible.
• The coal handling and ash plant systems are operating near or beyond their design limits. Up to 40% of coal staithe space is unusable due to hang-ups, and the station can only reclaim 60% of the required maximum burn rate. The ash plant cycle requires 20 hours per day, leaving little margin for maintenance or clinker handling.
• Theoretical process assessments of boilers U1-U5 indicate combustion inefficiencies. Excess air levels in the furnace are below the required 16% due to oxygen level controls at the air pre-heater inlet. Additionally, furnace ingress air and air pre-heater leakage total approximately 60 kg/s of air that does not contribute to combustion.

APA

Centre for Environmental Rights (n.d.). 8.2-run-until-2025-7-2faad66b32b626e5.pdf. https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-7.pdf?x21779

Chicago

Centre for Environmental Rights. 8.2-run-until-2025-7-2faad66b32b626e5.pdf. n.d. https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-7.pdf?x21779.

Wikipedia

{{cite report |author=Centre for Environmental Rights |title=8.2-run-until-2025-7-2faad66b32b626e5.pdf |url=https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-7.pdf?x21779 |access-date=17 August 2026 |via=Climate Insights Directory}}

BibTeX

@techreport{centreforenvironmentalrightsnd82rununtil202572faad66b32b626e5pdf, author = {{Centre for Environmental Rights}}, title = {{8.2-run-until-2025-7-2faad66b32b626e5.pdf}}, institution = {Centre for Environmental Rights}, url = {https://cer.org.za/wp-content/uploads/2017/07/8.2-Run-Until-2025-7.pdf?x21779}, urldate = {2026-08-17}, note = {Indexed by Climate Insights Directory} }