8.4-capacity-increase-3-2b1c4460b15f7719.pdf

This report section provides a detailed technical assessment of the equipment and infrastructure at Hendrina Power Station, specifically evaluating the feasibility and requirements for a 10% capacity increase. It identifies critical components that would fail under increased load—including generators, MV motors, and various pumps—and recommends extensive replacements, upgrades, and maintenance strategies to enable higher output.

• The existing gas/water-cooled generators cannot be uprated due to design limitations in the excitation system and geometrical constraints of the slip rings. A capacity increase is only possible through a replacement strategy using new air-cooled Footprint generators, which could potentially increase power output by up to 35 MW beyond the installed 200 MW.
• Current MV motors are unable to accommodate a capacity increase because many are already overloaded or operating beyond their original design, which is contributing to high failure rates. The report recommends replacing the MV motor fleet to allow for the capacity increase and to achieve energy savings through improved efficiency.
• Several critical pump systems require replacement or significant redesign to support a 10% capacity increase. Specifically, the Condensate Extraction Pumps (CEP) must be replaced as they operate on the right-hand side of the best efficiency point. The Electric Feed Pump (EFP) system requires a review or redesign because the pressure head will drop and the required NPSH will increase with higher flow.
• The turbine plant's condenser and heaters are largely incapable of handling a 10% capacity increase in their current state. The condenser requires a complete re-tube with superior materials or a new modular unit due to vibration and the state of current tubes. Similarly, heaters with a plugged rate of 10% or more will not cope unless they are replaced or restored to good condition.
• The air ejector system must be increased by 15% to handle a 10% capacity increase, as it will not cope if incondensable gases increase by 10% or more. Additionally, new H2 coolers must be installed because existing ones cannot dissipate the losses of 2186 kw associated with a 110% load.
• While auxiliary transformers and the bus duct system are expected to handle a 10% increase, the MV cables for EFP motors are currently utilized to 86%. If these motors are increased in size or operated continuously, the cable ratings may need to be increased.
• The PA Fans are in a poor state, particularly the casings, and require replacement due to wear from fly-ash. For a capacity increase, larger ID fans must be installed to provide sufficient capacity for the boiler.

APA

Centre for Environmental Rights (n.d.). 8.4-capacity-increase-3-2b1c4460b15f7719.pdf. https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-3.pdf?x21779

Chicago

Centre for Environmental Rights. 8.4-capacity-increase-3-2b1c4460b15f7719.pdf. n.d. https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-3.pdf?x21779.

Wikipedia

{{cite report |author=Centre for Environmental Rights |title=8.4-capacity-increase-3-2b1c4460b15f7719.pdf |url=https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-3.pdf?x21779 |access-date=17 August 2026 |via=Climate Insights Directory}}

BibTeX

@techreport{centreforenvironmentalrightsnd84capacityincrease32b1c4460b15f7719pdf, author = {{Centre for Environmental Rights}}, title = {{8.4-capacity-increase-3-2b1c4460b15f7719.pdf}}, institution = {Centre for Environmental Rights}, url = {https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-3.pdf?x21779}, urldate = {2026-08-17}, note = {Indexed by Climate Insights Directory} }