8.3-run-until-2035-2-b25994b3fd225c13.pdf

This report provides a consolidated life-extension (Life-ex) assessment for the Hendrina Power Station, evaluating the technical requirements and physical condition of plant components to extend operational life until 2035. It details critical failures in electrical systems, the status of boiler and turbine plant areas, and the necessary capital interventions to maintain reliability.

• The 'UNITROL D' Automatic Voltage Regulators (AVRs) installed between 1994 and 2000 are becoming obsolete, with an expected end of life within 5 years. Frequent failures of electronic cards—specifically the Computing Unit (UN 0660 a), Gate Control Unit (UN 0663 b), and Power Supply Unit (UN 0664 a)—lead to unit trips and load losses due to a lack of redundancy.
• Auxiliary transformers are experiencing rapid ageing caused by high moisture levels resulting from leaks, damaged breathers, broken fittings, and missing seals. This condition contravenes Eskom Standard 240-56358993; however, 36 new transformers are on site as part of a refurbishment project to ensure reliable operation until 2035.
• Low Voltage (LV) motors exhibit widespread mechanical problems, including worn bearing housings and shaft journals, which cannot be fixed by refurbishment. Many motors show high temperatures indicative of damaged interlamination insulation or core damage from repeated rewinds, making original unit-plant LV motors uneconomical to operate until 2035.
• Medium Voltage (MV) motors are in poor condition, with 10% categorized as high risk based on partial discharge findings. Issues include cracked rotor bars, blocked cooling air circuits, and bad cores. Reliable operation until 2035 is deemed impossible with the current population, necessitating a replacement program prioritizing ID fan, EFP, and PA fan motors.
• PILCSWA MV cables are in poor mechanical condition, particularly where exposed to moisture, creating a safety risk and a high probability of failure within 0 to 2 years. While XLPE cables are stable, the report recommends complete replacement of all original PILCSWA cables to maintain reliability until 2035.
• The busduct system in Unit 6 shows excessive discharge, and a significant percentage of insulators in Units 3 and 9 failed upon removal (37.5% and 18.8% respectively). Without intervention, partial discharge may lead to the loss of structural integrity and catastrophic failure.
• Control and Instrumentation (C&I) systems, including the SIMATIC S5 family and the PCS7 control system, are reaching the end of their life spans by 2015 and 2020 respectively. The Bentley Nevada Vibration Monitoring System installed in 2012 is expected to require an upgrade by 2023.
• To accommodate ash volumes calculated for operation until 2035 (44,565,700 tons), Ash Dam 6 will require a base area of approximately 139 hectares.
• Theoretical assessments of boiler tubes for Units 1-5 indicate a life of more than 500,000 hours regarding creep rupture, meaning no boiler tubes are expected to fail due to creep, though transition pieces on the Secondary Superheater will require periodic replacement.
• The station's earthing and earth mat are estimated to have a remaining life of 25 to 50 years, provided they are upgraded to comply with Eskom standard 474-085, as current maintenance practices are not in accordance with established standards.

APA

Centre for Environmental Rights (n.d.). 8.3-run-until-2035-2-b25994b3fd225c13.pdf. https://cer.org.za/wp-content/uploads/2017/07/8.3-Run-Until-2035-2.pdf?x21779

Chicago

Centre for Environmental Rights. 8.3-run-until-2035-2-b25994b3fd225c13.pdf. n.d. https://cer.org.za/wp-content/uploads/2017/07/8.3-Run-Until-2035-2.pdf?x21779.

Wikipedia

{{cite report |author=Centre for Environmental Rights |title=8.3-run-until-2035-2-b25994b3fd225c13.pdf |url=https://cer.org.za/wp-content/uploads/2017/07/8.3-Run-Until-2035-2.pdf?x21779 |access-date=17 August 2026 |via=Climate Insights Directory}}

BibTeX

@techreport{centreforenvironmentalrightsnd83rununtil20352b25994b3fd225c13pdf, author = {{Centre for Environmental Rights}}, title = {{8.3-run-until-2035-2-b25994b3fd225c13.pdf}}, institution = {Centre for Environmental Rights}, url = {https://cer.org.za/wp-content/uploads/2017/07/8.3-Run-Until-2035-2.pdf?x21779}, urldate = {2026-08-17}, note = {Indexed by Climate Insights Directory} }