8.4-capacity-increase-1-84cc18333641ca6e.pdf

This report, produced by Siemens and subcontractors Babcock and Steinmuller, evaluates the feasibility and costs of a 10% capacity increase and life extension to 2035 for the Hendrina Power Station. The study identifies critical equipment limitations across boiler, turbine, and electrical plants, recommending extensive replacements of generators, motors, and piping to achieve the uprate.

• A 10% capacity increase for the turbine plant is possible, though the HP outer casing is identified as the limiting factor.
• The existing gas/water-cooled generators cannot be uprated due to design limitations in the excitation system and geometrical constraints of the slip rings; therefore, a full replacement with air-cooled Footprint generators is recommended to enable a power increase of up to 35 MW per unit.
• For Units 1-5, the report recommends converting to a Tower boiler tube bank configuration to mitigate erosion, as uprating would otherwise increase erosion rates by at least 80% for the existing El-Paso design.
• The existing fleet of Low Voltage (LV) and Medium Voltage (MV) motors cannot support a capacity increase as they are beyond their economic or design life and would require a large-scale replacement program with higher-rated machines.
• The Steam Feed Pump (SFP) system is currently operating at 110% capacity and cannot be further increased without replacing the pump, retrofitting internals, or redesigning the SFP Booster pump.
• To achieve a 10% capacity increase, the main condenser requires a full re-tube or a new modular unit, as existing admiralty brass tubes are prone to erosion and pitting and may suffer from vibration.
• The air ejector system is insufficient for a 10% capacity increase due to the expected rise in incondensable gasses; it is recommended that components be increased by 15%.
• Existing H2 and lube oil coolers cannot dissipate the heat generated by a 110% load, necessitating the installation of new coolers.
• The cost for a capacity increase for a single unit (Units 1-5) is estimated at R 737 804 000 (priced in 2013, excluding VAT), with the Tower Boiler Conversion (R 487 247 000) being the largest expense.
• The non-binding price indication for Scenario C, which involves replacing all ten generators with air-cooled Footprint generators over 20 years, is 1.264.400.000 ZAR (87.200,000 EUR).

APA

Centre for Environmental Rights (n.d.). 8.4-capacity-increase-1-84cc18333641ca6e.pdf. https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-1.pdf?x21779

Chicago

Centre for Environmental Rights. 8.4-capacity-increase-1-84cc18333641ca6e.pdf. n.d. https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-1.pdf?x21779.

Wikipedia

{{cite report |author=Centre for Environmental Rights |title=8.4-capacity-increase-1-84cc18333641ca6e.pdf |url=https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-1.pdf?x21779 |access-date=17 August 2026 |via=Climate Insights Directory}}

BibTeX

@techreport{centreforenvironmentalrightsnd84capacityincrease184cc18333641ca6epdf, author = {{Centre for Environmental Rights}}, title = {{8.4-capacity-increase-1-84cc18333641ca6e.pdf}}, institution = {Centre for Environmental Rights}, url = {https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-1.pdf?x21779}, urldate = {2026-08-17}, note = {Indexed by Climate Insights Directory} }