EPPEI 2015-2016 Programme

Eskom Power Plant
Engineering Institute
EPPEI
2015-2016 Programme
Eskom Academy of Learning

Driving towards Engineering Excellence
Contents
Acknowledgements 1.
2.
Foreword by Sylvia Mamorare
EPPEI management report by Malcolm Fawkes
2
4
Prof Francis Petersen – University of Cape Town 3. Technical committee 5
Prof Ian Jandrell – University of the Witwatersrand 4. EPPEI management team 6
Prof LJ Grobler – North-West University 5. Specialisation centre strategies 7
Prof Sunil Maharaj – University of Pretoria 6. Specialisation centre academic representatives 8
Prof Christina Trois – University of KwaZulu-Natal 7. Academic supervisors 16
Prof Willem Perold – Stellenbosch University 8. Industrial mentors 17

9. EPPEI student population 19
10. Current projects – research topics 20

11. Completed projects 80
12. Publication list 98
13. EPPEI Junior Enterprise 109
14. Student conferences 112
15. Appendices 116
2
Produced
EPPEIby2014-2015
Eskom Power Plant Engineering Institute – February 2016
Programme EPPEI 2015-2016 Programme 1
1. Foreword by Sylvia Mamorare
The past year has been riddled with challenges as Eskom has had to tighten its belt in various areas. In Looking at our accomplishments over the past three years, I am even more convinced of the impact
times of budget cuts within a business, training and research are usually the first area to be affected. As that EPPEI will have on the Eskom business in the long term. It has been especially positive seeing the
the Chief Learning Officer (CLO) of Eskom, I find it particularly heartening that in these tough financial value added to business units when students return from their research at universities. Some of our
times, Eskom has remained committed to its training and education initiatives. students have been promoted to lead engineers in their field.
While the Eskom Academy of Learning (EAL) has been affected by budget cuts, it has recognised the We are indeed seeing the development of experts through the EPPEI initiative as well as the development
great value that the EPPEI programme has added to both Eskom and EAL, and has shouldered much of of the knowledge base necessary to take Eskom into the future.
the financial cuts to protect the EPPEI budget.
Yours in continuous learning
In late 2014 we had to reassess this position and approached universities to work with us to introduce Sylvia Mamorare
cost-saving measures. EAL and the universities identified the critical areas of spending to sustain EPPEI. CLO, Eskom
Great effort had been made to enrol academic staff, who now have experience in understanding
the power industry and specifically Eskom’s needs and they are key to EPPEI’s continued success. We
felt it was important to maintain the crucial relationships between Eskom SMEs, engineers and these
academics. Therefore we first prioritised the staff in our spending and then the short-term needs in the
coal power stations at Eskom.
We are delighted with the commitment and response from universities who have shown their support
of both EPPEI and Eskom during these trying times. I am happy to report that the partnership between
“ I that
am happy to report
the partnership
Eskom and the universities is going from strength to strength.
between Eskom and the
While 2014 has been a difficult year, there have also been some highlights. EAL was very honoured to universities is going from
be selected by the Association of Power Utilities in Africa (APUA) as a centre of excellence that will
provide training to members of APUA. We see EPPEI playing an important role in fulfilling this mandate.
strength to strength.
”
Sylvia Mamorare
EAL along with the universities have also been working on the business case to extend the EPPEI
programme for a further five years from 2017 to 2021. This business case will be brought to Exco this
year for their consideration. EPPEI is now in its fourth year of a five year mandate.
2 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 3

2. EPPEI management report for 2015 Technical committee 3.
by Malcolm Fawkes
EPPEI entered into its third year in 2014. We saw the first and second intakes of master’s students The EPPEI technical committee met twice in 2014. The members include: Eskom senior management,
completing their studies towards the end of 2014. It is encouraging to see the quality of academic EPPEI Technical Committee (TC), academic and industrial coordinators of the specialisation centres
research work that has been produced in the objective of working on real-world challenges in Eskom’s and the EPPEI Junior Enterprise. The committee provides a platform where the various specialisation
plant. Some of the solutions developed through EPPEI research will also be able to be implemented centres can give feedback to EPPEI management and implement changes for the development of EPPEI.
into current Eskom projects. In addition, the research will assist South Africa in developing its own
Intellectual Property in the power industry, one of the Visons of EPPEI. This will enhance the prospects
of our economy through local manufacture and export of goods and services. Eskom continues to EPPEI Management
experience severe technical, financial and manpower constraints. As a result of this, the EPPEI budget EPPEI Senior Manager Malcolm Fawkes
has been cut by 42%. It has thus been decided that in future the funding available will need to be EDF Senior Manager, EPPEI Louis Jestin
allocated pro rata to the eight specialisation centres in accordance with Eskom’s current challenges
EPPEI Senior Advisor Robert Jones and Carolynn Koekemoer
and in accordance with the capacity of centres to deliver. This has resulted in additional risks to some
centres in terms of ability to continue with academic appointments, for example. The Eskom restriction
on manpower numbers has resulted in Line Managers being hesitant to release young engineers for Eskom Executive Advisors
postgraduate studies. This is one of the biggest risks for the EPPEI programme. Where possible, and in Eskom Power Plant Engineering Titus Mathe
line with governance requirements, bursaries have been given to non-Eskom students to do research
Electrical Engineering Prince Moyo
towards solving Eskom’s technical challenges.
RT&D Barry MacColl and Chris Gross
The central EPPEI coordination office, currently hosted by UCT, and the Coordination and Administration
(C&A) committee of the six universities provided excellent services to EPPEI in 2014. The purpose Specialisation Centre Industrial Coordinator Academic Coordinator
of the C&A committee is to share the different administrative activities among the universities. EPPEI
Energy Efficiency Joe Roy-Aikins Wim Fuls
management is very grateful for the continued support and co-operation from the universities and their
Combustion Engineering Anton Hart Walter Schmitz
willingness to assist.The need for better monitoring of student progress has been identified by the C&A
committee as a priority. On average it is taking longer than two years for students to complete their Emissions Control Yokesh Singh Stuart Piketh
research and to complete their final dissertations. Closer monitoring of progress and more coaching Material Science Marthinus Bezuidenhoudt Bernhard Sonderegger
is required to ensure that their project plan is kept on schedule. It has also been disappointing to note Asset Management Mark Newby Stephan Heyns
how many students, relatively, have resigned from Eskom after graduation or during the completion High Voltage Engineering AC Abré le Roux John van Coller
phases of research. This has been due partly to personal reasons but in other cases it was felt that High Voltage Engineering DC Rob Stephen Inno Davidson
career paths were ‘greener on the other side’. EPPEI will continue to work with Line Management to Renewable Energy Zama Luswazi Wikus van Niekerk
see how Eskom can prevent this in future.
Very good news was received recently that Eskom had approved the continuation of the EPPEI EPPEI Junior Enterprise Leaders
programme for another five years until 2021. This continuation was intended from the first approval EPPEI Junior Enterprise Intake One (2012) Priyesh Gosai
in April 2011. Work has started in earnest to get the commercial processes finalised to conclude new EPPEI Junior Enterprise Intake Two (2013) Rudzani Mutshinya
contracts with the six partner universities. The exciting new “Hub-and-Spoke” business model is to be
EPPEI Junior Enterprise Intake Three (2014) Naeem Tootla
pursued with a Consortium of the universities.This new approach will hopefully see EPPEI prosper until
EPPEI Junior Enterprise Intake Four (2015) Christine Schutte
it can become financially independent of Eskom in 2022. Exciting times lie ahead.

4. EPPEI management team EPPEI Specialisation Centre (SC) 5.
strategies
• Eskom specialisation centre in Energy Efficiency www.uct.ac.za

Name Malcolm Fawkes
at the University of Cape Town
Position Senior Manager
Eskom Academy of Learning (Midrand)
Tel +27 11 655 2552
Email FawkesMG@eskom.co.za • Eskom specialisation centre in Combustion Engineering www.wits.ac.za
at the University of the Witwatersrand
Name Louis Jestin

Position EDF Senior Manager, EPPEI • Eskom specialisation centre in Emission Control www.nwu.ac.za
Mechanical Engineering (UCT) at North-West University
Tel +27 21 650 3239
Email louis.jestin@uct.ac.za
• Eskom specialisation centre in Material Science www.uct.ac.za
at the University of Cape Town
Name Robert Jones
Position Senior Advisor
• Eskom specialisation centre in Asset Management www.up.ac.za
Tel +27 13 693 3216 at the University of Pretoria
Email JonesRJ@eskom.co.za
• Eskom specialisation centre in High Voltage Engineering (AC) www.wits.ac.za

Name Carolynn Koekemoer at the University of the Witwatersrand
Position Senior Advisor
Tel +27 13 693 2265
• Eskom specialisation centre in High Voltage Engineering (DC) www.ukzn.ac.za
Email koekemCI@eskom.co.za
at the University of KwaZulu-Natal
Name Nicola Taylor

• Eskom specialisation centre in Renewable Energy www.sun.ac.za
Position Central Co-ordinator
Mechanical Engineering (UCT) at Stellenbosch University
Tel +27 21 650 2119
Email nicola.taylor@uct.ac.za

6. EPPEI specialisation centre
academic representatives
EPPEI specialisation centre in Energy Efficiency EPPEI specialisation centre in Combustion

at University of Cape Town Engineering at University of the Witwatersrand
Name Walter Schmitz
Name Wim Fuls Position Coordinator, Professor
Position Coordinator, Senior Lecturer Dept School of Mechanical Industrial and
Dept Mechanical Engineering (UCT) Aeronautical Engineering (Wits)
Education PhD Nuclear Engineering (NWU) Education PhD Mech. Eng.
Tel 021 650 2600 Tel 011 717 7047
Email Wim.fuls@uct.ac.za Email Walter.Schmitz@wits.ac.za
Interests Thermo-hydraulic process modelling Interests Computational Fluid Dynamics
Pieter Rousseau Name Louis Jestin

Name Reshendren Naidoo
Professor Position Professor
Position Senior Lecturer
Mech. Eng. (UCT) Dept Mech. Eng. (UCT)
Dept School of Mechanical Industrial and
PhD Mech. Eng. (UP) Education PhD Thermophysics
Aeronautical Engineering (Wits)
Habilitated Prof
Education MEng Eng. Man. (UP)
(Marseille University,
Tel 011 717 7358
France)
Email Reshendren.naidoo@wits.ac.za
021 650 5822 Tel 021 650 3239
Interests Numerical Combustion
pieter.rousseau@uct.ac.za Email louis.jestin@uct.ac.za
Partner University: Partner University:

Nelson Mandela Metropolitan University University of Johannesburg
Name Igor Gorlach

Name Dr Daniel Madyira
Position Professor & Chair
Position Lecturer
Dept Mechatronics (NMMU)
Dept Mech. and Eng. Science (UJ)
Summerstrand Campus (North)
Tel 011 559 4030
Tel 041 504 3289
Email dmadyira@uj.ac.za
Email Igor.Gorlach@nmmu.ac.za

EPPEI specialisation centre
academic representatives continued...
EPPEI specialisation centre in Emission Control at EPPEI specialisation centre in Material Science at
North-West University University of Cape Town
Name Stuart Piketh Name Bernhard Sonderegger
Position Coordinator, Professor Position Coordinator, Professor
Dept Unit for Environmental Science and Dept Mechanical Engineering (UCT)
Management and Chemical Resource Education PhD Mech. Eng. Habilitation Mater. Sci.
Beneficiation (Graz University of Technology, A)
Education PhD (Wits) Tel 021 650 3675
Tel 018 299 1582 Email Bernhard.sonderegger@uct.ac.za
Email Stuart.Piketh@nwu.ac.za Interests Materials microstructure, electron microscopy
Interests Atmospheric and environmental impacts
Name Hein Neomagus

Position Professor Name Robert Knutsen
Dept School of Chemical and Minerals Position Professor, Head of Department
Engineering (NWU) Dept Mechanical Engineering (UCT)
Education PhD (University of Twente, NL) Education PhD (UCT)
Tel 018 299 1535 Tel 021 650 4959
Email Hein.neomagus@nwu.ac.za Email Robert.knutsen@uct.ac.za
Interests Coal conversion and characterisation, Interests Materials microstructure, electron
reactor modelling, membrane processes microscopy
Partner Universities:
University of Venda and Partner University:
Vaal University of Technology Nelson Mandela Metropolitan University
Name Dr Johan Westraadt

Name Dr Hilary Limo Rutto Position Senior Researcher
Position Senior Lecturer Dept Centre for High Resolution
Dept Chemical Engineering (VUT) Transmission Electron Microscopy
Tel 016 950 9598 (NMMU)
Email hilaryr@vut.ac.za Tel 041 504 2301
Email Johan.westraadt@nmmu.ac.za

EPPEI specialisation centre in High Voltage

EPPEI specialisation centre in Asset Management
Alternating Current (AC) at University of the
at University of Pretoria
Witwatersrand
Name Stephan Heyns Name John van Coller
Position Coordinator, Professor Position Coordinator, Senior Lecturer
Dept Mechanical and Aeronautical Dept School of Electrical and Information
Engineering (UP) Engineering (Wits)
Education PhD (UP) Education PhD
Tel 012 420 2432 Tel 011 717 7211
Email Stephan.heyns@up.ac.za Email John.vancoller@wits.ac.za
Interests Machine and structural health Interests Power system modelling, high voltage
monitoring engineering
Name Bo Xing
Position Senior Lecturer Name Hugh Hunt
Dept Mechanical and Aeronautical Position Lecturer
Engineering (UP) Dept School of Electrical and Information
Education PhD (UJ) Engineering (Wits)
Tel 012 0420 2431 Education MSc(Eng)
Email Bo.xing@upt.ac.za Tel 011 717 7254
Interests Electrical and electronics engineering, Email hugh.hunt@wits.ac.za
computational intelligence Interests High voltage, lightning

Tshwane University of Technology Vaal University of Technology
Name Dr Dawood A Desai Name Mr Jerry Walker

Position Acting Section Head Mechanical Position Visiting Professor
Dept Mechanical Engineering (TUT) Dept Power Engineering – Centre for
Tel 012 382 5886 Cable Research (VUT)
Email desaida@tut.ac.za Tel 016 421 5190
Email jerrywalker@walmet.co.za

EPPEI specialisation centre in High Voltage Direct EPPEI specialisation centre in Renewable Energy
Current at University of KwaZulu-Natal at Stellenbosch University
Name Inno Davidson Name Wikus van Niekerk
Position Coordinator, Senior Lecturer Position Coordinator, Professor
Dept Eskom CoE HVDC Engineering (UKZN) Dept Centre for Renewable and Sustainable
Education PhD Elec. Eng. (UCT), (SEMAC, Energy Studies (SUN)
BC Inst. Technol., Barnaby, CA) Education PhD Mech. Eng. (University of California,
Tel 031 260 7024 Berkley, USA)
Email davidson@ukznac.za Tel 021 808 4277
Interests Modern power and energy systems, Email wikus@sun.ac.za
SMART grid utility
Interests Mechanical engineering, renewable energy
Name Andrew Swanson Name Frank Dinter

Position Lecturer Position Professor, Eskom Chair in CSP
Dept Electrical, Electronic and Computer Dept Mechanical and Mechatronic Eng. (SUN)
Engineering Education Dr.-Ing (University GH Essen, DE)
Education MSc (Wits) Tel 021 808 4024
Tel 031 260 2713 Email Frankdinter@sun.ac.za
Email swanson@ukzn.ac.za Interests Solar thermal power plants, CSP, storage
Interests High voltage engineering systems, industrial heat, demand side
management

Durban University of Technology Cape Peninsula University of Technology
Name Mr Eamon Bussy Name Dr Nawaz Mahomed

Position Head of Department Position Dean of Engineering (CPUT)
Dept Steve Biko Campus Tel 021 959 6217
Tel 031 373 2062 Email mahomedn@cput.ac.za
Email eamonb@dut.ac.za

7. Academic supervisors Industrial mentors 8.
1. Prof Gary Atkinson-Hope (Cape Peninsula University of Technology) 1. Adam Bartylak (Eskom)
2. Dr Thorsten Becker (Stellenbosch University) 2. Dr Graeme Chown (PPA Energy, UK)
3. Dr Johan Beukes (Stellenbosch University) 3. Assoc Prof Jasper Coetzee (University of Pretoria)
4. Dr BW Botha (University of Pretoria) 4. Steve Conyers (Eskom)
5. Paul Gauché (University of Stellenbosch) 5. Roger Cormack (Eskom)
6. Dr Nathie Gule (Stellenbosch University) 6. Norman Crowe (Eskom)
7. Prof Albert Helberg (North-West University) 7. Gary de Klerk (Eskom)
8. Dr Jaap Hoffmann (Stellenbosch University) 8. Manny de Sousa (Eskom)
9. Prof Zhongjie Huan (Tshwane University of Technology) 9. Philip Doubell (Eskom)
10. Prof Hanno Reuter (Stellenbosch University) 10. Dr Francois du Preez (Eskom)
11. Dr Hamed Roohani (University of the Witwatersrand) 11. Chris Du Toit (Eskom)
12. Prof Rotimi Sadiku (Tshwane University of Technology) 12. Naushaad Haripersad (Eskom)
13. Prof Christ Storm (North-West University) 13. Frans Havinga (Eskom)
14. Dr Coenie JH Thiart (University of Pretoria) 14. Herman Kleynhans (Tshwane University of Technology/UNISA)
15. Dr Johan van der Spuy (Stellenbosch University) 15. Mike Lander (Eskom)
16. Assoc Prof Johan Vermeulen (Stellenbosch University) 16. Noel Lecordier (Eskom)
17. Dr George Vicatos (University of Cape Town) 17. Arnoud Madlener (Eskom)
18. Prof Krige Visser (University of Pretoria) 18. Peter Magner (Eskom)
19. Dr Marubini Manyage (Eskom)
Note: The mentors that have already been listed as coordinators or members of the specialisation centres are 20. Nhlanhla Mbuli (Eskom)
not included in this section. 21. Dr Thabo Modisane (Eskom)
22. Sidwell Mtetwa (Eskom)
23. Phuti Ngoetjana (Eskom)
24. Ebrahim M Patel (Eskom)
25. Dr Thobeka Pete (Eskom)
26. Carel Potgieter (Eskom)

Industrial mentors continued... EPPEI student population 9.
27. Dr JP Pretorius (University of Stellenbosch/Eskom) In early 2015, 21 MSc and 3 PhD students were enrolled at the respective universities as part of intake
28. Dr Joe Roy-Aikins (Eskom) four. A breakdown of the various specialisation centres and the number of students that were placed
in these centres for each intake is shown in the following graph.
29. Ronnie Scheepers (Eskom)
30. Kobus Smit (Eskom)
31. Riaan Smit (Eskom)
RE – SUN Intake 1 (2012)
32. James Sproule (Cape Peninsula University of Technology)
33. David Tarrant (Rotek Engineering) HV(DC) – UKZN Intake 2 (2013)
34. Dr Christopher van Alphen (Eskom)
35. Willem van der Westhuizen (Eskom) HV(AC) – WITS
Intake 3 (2014)
36. Chris van Tonder (Eskom)
AM – UP
37. Kobus Vilonel (Eskom) Intake 4 (2015)
38. Nigel Russel Volk (Eskom) MS – UCT

39. Christo van Wyk (Eskom)
EC – NWU
40. Thomas Will (University of Cologne, Germany)
41. Marthinus Bezuidenhout (Eskom)
CE – WITS
42. Armien Edwards (Eskom)
43. Nico Smit (Eskom) EE – UCT
0 1 2 3 4 5 6 7 8 9
Note: The mentors that have been Number of students per intake
already listed in other sections are not
included in this list.
This book contains detailed information of the intake four student projects and showcases projects that
have been completed by students from previous intakes.

10. Current projects
Research topics
1. Emissions Control 22 4. High Voltage Engineering (AC) 64
EC1 - Influence of SO3 and moisture content on the resistivity of fly ash from typical AC1 - A method for measuring and recording changes on wood pole impedance over time 62
South African coals 24 AC2 - Power exchange optimisation of distributed energy resources utilising smart
EC2 - The effects of low quality limestone on the absorber reaction tank sizing 26 transformers and active voltage regulation 64
EC3 - Correlating South African fly-ash resistivity with electrostatic precipitator collection
efficiency 28 5. High Voltage Engineering (DC) 66
EC4 - Value-added utilisation possibilities of Coal Combustion Products (CCPs) 30
EC5 - Dissolution kinetics of representative South African lime stones in aqueous solutions 32 DC1 - Impact of DC options and VSC based facts devices on voltage stability in southern
EC6 - Characterising trade-offs between fabric filter bag dimensions, ash collection Africa 68
efficiency, associated pressure drop and pulsing behaviour 34
6. Renewable Energy 70
2. Material Science 36
RE1 - Investigation into the effect of wind on fan performance in an ACC 72
MS1 - FEM modelling of stress, deformation and damage of creep loaded components RE2 - Geographic location optimisation of wind farms in South Africa 74
in thermal power plants 38 RE3 - Integrated O&M strategy for Sere Wind Farm 76
MS2 - Experimental investigation of creep damage of a thermally exposed component in RE4 - Life cycle cost of energy technologies (fossil fuel-fired, gas, renewable and nuclear) 78
coal power plants 40
3. Asset Management 42
AM1 - Continuum damage modelling on HP pipework for predicting creep fatigue interaction 44
AM2 - The effect of non-uniform microstructure on the failure mode of hamer forged
line hardware failure prediction 46
AM3 - Vibration monitoring of transformer windings 48
AM4 - Reliability modelling for the prediction of failure probability of a critical plant at a
power station 50
AM5 - Eskom high pressure feedwater heater maintenance management optimisation 52
AM6 - Develop a troubleshooting guide for vertical spindle roller mills using process history
data and machine learning 58
AM7 - Risks and effects of turbo-generator torsional vibration in an expanding and
diversifying Southern African electricity gridT 60
AM8 - Evaluation of a viable technique to determine mass flow rate in a pneumatic ash
conveying system to validate performance requirements 62

Eskom Power Plant Engineering Institute
Emissions Control
Focus points
• Environmental legislation and compliance
for air, water and soils
• Monitoring of pollutant emissions and
environmental impact
• Technologies for reduction and control of
environmental pollutants (dust, SOx, NOx,
Mercury, CO2)
• Cost benefit assessment of emissions control
• Materials handling of by-products
22 EPPEI 2014-2015
2015-2016 Programme EPPEI 22015-2016 Programme 23
EC1
Influence of SO3 and moisture content
on the resistivity of fly ash from typical
South African coals
Subject background • The resistivity oven will be validated against Leon van Wyk’s results obtained
from the Southern Research Institute in the US using the same samples
Fly ash resistivity directly influences the efficiency of an Electrostatic Precipitator (ESP). • The study will look at resistivity values at a temperature range typical of ESP
Resistivity is the measure of the conductibility of a material given as ohm.cm. Future inlet temperatures in the Eskom fleet and different conditioning concentrations
legislation will require ESPs to have optimal performance to comply with particulate at these temperatures
limit legislation set out by the Department of Environmental Affairs (DEA). SO3 • Moisture content will be the first test where after SO3 conditioning will be
conditioning is used in Eskom to lower the resistivity of fly ash. Eskom does not have implemented in the oven and tested
data available that shows the effect of various conditioning concentrations on fly • The aim is to test 10 fly ash samples. These will be the same samples that Van
ash resistivity. This study will generate data required to inject optimal conditioning Wyk used
concentrations for the desired resistivity required. • Recommendations will be made as to what conditioning concentration is
required for optimal resistivity on the various samples
Applicability/Benefit to Eskom
Expected deliverables
• Resistivity data will enable Eskom to determine the conditioning concentration
required to get the fly ash at the desired resistivity for optimal ESP performance • Resistivity curve on 10 samples for various SO3 and moisture conditioning
• There is potential for cost reduction from an operating cost perspective as a big concentrations at various temperatures.
reduction in sulphur usage may result in only a small increase in emissions, this
has not been quantified in Eskom before. This however will rely on the fly ash
elemental characteristics that Leon van Wyk explored
• The resistivity results can be used as an input to an ESP performance prediction
model
• The modification to the resistivity oven will help in future if testing on new
conditioning technology is required Student
• Eskom (or subsidiary) can do resistivity analysis for outside companies as a form Jaco Burger
of revenue generation
Email: burgerjac@eskom.co.za
Proposed research Industrial mentor
Ebrahim Patel
• The objective of the research study is to develop a correlation between the Email: PatelEM@eskom.co.za
concentration of SO3 or moisture conditioning and fly ash resistivity
• This project will be carried out in collaboration with the North-West Academic supervisors
University Prof Hein Neomagus
• The existing resistivity oven from Eskom RT&D will be modified to Email: hein.neomagus@nwu.ac.za
accommodate ash conditioning

EC2
The effects of low quality limestone on
the absorber reaction tank sizing
Subject background quality limestone and its validity range is unknown. For sizing of the reaction tank, the
tool uses several assumptions and subsequent correction factors, based on conditions
Sulphur dioxide (SO2) in a coal-fired power plant, is generated as a result of fossil different from those encountered in South Africa. Eskom will be using this tool to size
fuel burning. When emitted into the atmosphere, it is a precursor to acid rain and and review its FGD plants but it needs to be adjusted for South African conditions.
sulphate aerosol particles which have been shown to have environmental, health and
hydrological effects. Consequently, the South African government has classified SO2 as Proposed research
criteria pollutant and has imposed limits on its levels both in the atmosphere and at
the source. • Review the absorber sizing tool to determine what correlations, assumptions
and correction factors are used and what they are based on
Internationally SO2 emissions have been controlled for years using various methods, • Obtain information about the reactivity of South African limestones and
one of which is a process called Limestone Forced Oxidation (LSFO) Flue Gas determine what correction factor(s) (if any), with specific emphasis on reaction
Desulphurization (FGD). Since SO2 is an acidic component, it can be neutralized by tank liquid retention time, need to be applied
bringing it into contact with an alkaline. In the LSFO process, limestone is ground, mixed • Choose one limestone and experimentally test if the pH correlation is valid
with water to form a slurry, and sprayed over SO2 containing flue gas in an absorber.The • If the above correlation is not valid - revise/derive a new pH correlation
absorber is mostly an open tower with several components with specific functions. At
the bottom of the absorber is a reaction tank.The reaction tank fulfils several functions Expected deliverables
namely; 1) a holding tank that provides proper conditions for limestone dissolution,
2) compressed air is injected into the contents to ensure oxidation of sulphite (which • A revised absorber reaction tank sizing tool applicable to Eskom’s specific needs
is difficult to dewater) to form sulphate, and 3) a holding tank to ensure that gypsum • A pH correlation (modified/new/ affirmed current correlation)
crystals grow to acceptable sizes for dewatering purposes. The resultant product of
the process, after undergoing the dewatering step, is synthetic gypsum.
Student
The type and quality of limestone used during the process is an important factor in Rachel Puseletso Godana
both the design and operation of the process. South Africa has a number of limestone
sources, but compared to international limestone, many of these are considered very Email: MosianRP@eskom.co.za
low quality. The process function at specific pH levels and the size of the reaction tank
is a function of the required operating pH level and the rate at which the limestone Industrial mentor
dissolves. Stefan Binkowski
Email: Stefan.Binkowski@
steinmueller.com
Applicability/Benefit to Eskom Academic supervisor Prof
Ray Everson
In 2009, Eskom obtained a tool to size the absorber and reaction tank.This tool uses a Email: Ray.Everson@nwu.ac.za
predefined correlation, as a function of several factors, to determine the operating pH Dr Dawie Branken
of the reaction during the developmental design phases. This was derived using good Email: dawie.branken@nwu.ac.za

EC3
Correlating South African fly-ash
resistivity with electrostatic precipitator
collection efficiency
Subject background Proposed research

Two thirds of the Eskom fleet currently utilizes electrostatic precipitator (ESP) The aim of this study is to correlate South African fly-ash resistivity, and the effect
technology to capture fly-ash from the flue gas stream exiting the boiler. An important of moisture thereon, with ESP collection efficiency.
design parameter of ESP is resistivity. Resistivity (measured in ohm cm) is an intrinsic
material property and denotes a materials ability to oppose the flow of electrons. The objectives of this study are to:
With the new Air Quality Act (AQA) calling for large reductions in emissions it has • Standardise and validate an experimental method for measuring fly-ash
becomes ever more important to better understand fly-ash resistivity, the effect of resistivity
ambient conditions on resistivity and how fly-ash resistivity influences ESP operation. • Characterise the effect of the water vapour fraction on fly-ash resistivity
• Establish the effect of fly-ash resistivity on ESP collection efficiency
Applicability/Benefit to Eskom • Propose and validate a simplified ESP model
• Recommissioning of the resistivity oven will facilitate the measurement of Expected deliverables
current fly-ash resistivity. These values can then be evaluated and compared to
the resistivity values with which the ESP plants were designed, giving insight into • Resistivity data of three fly-ashes, with varying water vapour fractions
current ESP operations • ESP collection efficiencies of the three ashes
• Modification is currently being conducted on the resistivity oven which will better • Simplified ESP performance prediction model
facilitate flue gas conditioning experiments
• The updated resistivity oven can be used to test martial resistivity for external
companies as a form of revenue generation
• Because of limited data, fly-ash resistivity will be measured with varying water
vapour fractions. An increase in water vapour fraction will lower fly-ash resistivity
values, leading to increased ESP performance. Flue gas conditioning with steam/ Student
water can be considered an inexpensive alternative to SO3 conditioning Jandri Ribberink
• A pilot scale ESP (currently under construction) will be used to better understand
the effect of resistivity on ESP performance Email: jandriribberink@gmail.com
• Three different fly-ashes, each with varying ash properties and resistivity values,
Industrial mentor
will be passed through the pilot scale ESP and the performance measured. These
Naushaad Haripersad
experiments will lend insight into the effect of resistivity on ESP collection efficiency Email: HariperN@eskom.co.za
(ESP pilot plant offers variable air velocity, geometry, plate to wire spacing and
discharge electrode configuration) Academic supervisor
• Once the resistivity data, ash mineralogy and ESP collection data is available, a Prof HWJP Neomagus
Email: hein.neomagus@nwu.ac.za
simplified model will be developed and validated. The simplified model can then
be used to describe current ESP collection efficiencies

EC4
Value-added utilisation possibilities of
Coal Combustion Products (CCPs)
Subject background Expected deliverables

In order to comply with more stringent air quality standards Eskom will be installing • Identify the different uses of CCP’s on a global scale
an FGD plant at its new coal fired power stations. The disposal of Coal Combustion • Conduct a market situation analysis in South Africa for fly ash and gypsum
Products (CCPs), which includes fly ash and the new FGD gypsum, causes significant • Characterise the quality of the FGD gypsum at Kusile and the fly ash from Kendal
environmental and economic difficulties for Eskom. Only a small fraction of these and Kusile
CCPs are used by other industries whilst the bulk of it is held in ash dams. To reduce • A design for wall and/or ceiling insulation products that can be used in low cost
the environmental and economic impacts of the disposal, alternative utilisation of housing applications
these CCPs must be investigated.
Alternative utilisation of these CCPs will benefit Eskom in the following areas:
• Reduction in disposal costs of the CCPs
• Reduction in land use
• Environmental impact reductions and legislation compliance
• Socio-economic contribution of Eskom towards the environment and community
Proposed research
• Investigate the possibility of designing cost effective insulation products from
the FGD gypsum to assist in making offset interventions more efficient. These Student
insulation products can be used to improve thermal efficiency in low cost Christine Schutte
housing in South Africa, which will in turn decrease the need for domestic
burning Email: schuttcr@eskom.co.za
• Investigate the possibility of replacing materials in the South African
Industrial mentor
construction environment with stronger and light weight alternative materials; Naushaad Haripersad
especially looking at the possibility of using CCPs in road construction Email: HariperN@eskom.co.za
Academic supervisor
Prof Stuart Piketh
Email: stuart.piketh@nwu.ac.za
Prof Hein Neomagus
Email: hein.neomagus@nwu.ac.za

EC5
Dissolution kinetics of representative
South African lime stones in aqueous
solutions
Subject background • Evaluation and/or modification of the current absorption reactor at NWU in
order to conduct dissolution related testing
The amount of SO2 generated during coal combustion is a function of the sulphur • Determine chemical, physical and mineralogical properties of low grade limestone
content in the fuel. None of Eskom’s current plants were designed with SO2 reduction by means of XRF, XRD QEMSCAN and other analyses if required
in mind and none of these plants will be able to comply with the 500 mg/Nm3 emissions • Develop correlations between limestone composition (chemical, mineralogical,
limit. Kusile power station is first to be retrofitted for Flue Gas Desulfurisation (FGD), physical) and parameters that influence the dissolution of limestone
followed by Medupi power station during its first General Outage (GO) cycle, while • Perform experiments with the current or new laboratory absorption reactor
Medupi power station was built as “FGD ready”. The FGD retrofit entails rotating setup and adjusted methodology for the determination of dissolution properties
the chimney by 180o, lining the chimney flues for operating in both un-saturated and
saturated environments, leaving space on the terrace for the FGD island and make Expected deliverables
provision in the plant balance for the support systems such as water, sorbent, waste
etc. Limestone is used in the FGD process and introduces CaCO3 to react with the • Characterisation of the low grade limestone selected for the FGD process for
SO2, removing it from the discharge gas. The use of lower quality limestone will result inclusion in a process model
in cost saving and is therefore important to investigate. • Comparative evaluation of the dissolution rate of available low grade limestone
sources
• The optimisation of water and sorbent resources on the FGD plant process
• Assist in mitigating the risk of resource availability and reducing associated waste
management, thereby managing the environmental footprint of the station
• If lower quality limestone sources are found to be viable in the use of FGD, it will
have an economic impact which could benefit Eskom
Student
Proposed research Pieter Swart
• Evaluate the dissolution and reactive properties of a low grade limestone, which Email: SwartPB@eskom.co.za
serves as a key input for modelling the wet FGD processes
Industrial mentor
• The project will be carried out in collaboration with students at NWU thus
Naushaad Haripersad
familiarising them with the state of research concerning determination of Email: HariperN@eskom.co.za
dissolution capacity of limestone samples from different sources with regards to:
– methods available for measuring dissolution rates Academic supervisors
– the equipment used to perform measurements Prof Hein Neomagus
– establishing the most suitable method to test dissolution after collaboration Email: hein.neomagus@nwu.ac.za
between all parties involved.

EC6
Characterising trade-offs between fabric
filter bag dimensions, ash collection
efficiency, associated pressure drop and
pulsing behaviour
Subject background • Determine the effective residual drag across the fabric material
– Test the fabric filter beg material for air permeability
Within Eskom’s fleet of coal-fired power stations almost two thirds are equipped with • Determine the specific resistance coefficient of the ash cake on the material
Fabric Filter Plants (FFP’s) to control particulate matter emissions. These stations are – Determine the K value for the specific resistance coefficient of the ash using
Majuba, Arnot, Camden, Duvha units 1 – 3, Grootvlei, Medupi, Kusile, and Hendrina. the air permeability rig along with the identified ash for application
Duvha units 4 – 6, Tutuka, Matimba, Lethabo, Matla, Kriel, Kendal and Komati are • Find the ash concentration at the inlet of the filter bags
equipped with Electrostatic Precipitator (ESP’s). • Determine the different mechanical losses with regard to the different fabric
bag sizes
Due to poor performance and high emissions, ESP’s can be retrofitted with FFP’s. – Use different sized holes in the tube plate and measure the differential
To retrofit the ESP’s the discharge electrodes and collecting plates are replaced with pressure across the tube plate
fabric filter bags. The selection of the fabric bag sizes has largely been outsourced and
currently no clear selection criteria exist. Within the Eskom fleet there are two types of Expected deliverables
fabric filter systems namely High Pressure Low Volume (HPLV) and Low Pressure High
Volume (LPHV). Within Eskom the bag sizes varies from 135 mm nominal diameter to • Establish a computational modelling method
165mm nominal diameter on the HPLV systems and the typical bag size for the LPHV • Build and use an experimental setup to study bag characteristics
system in 127mm nominal diameter. • Perform a techno-economic evaluation
• Suggest options for the retrofitting of ESP plants
Some of Eskom’s power stations equipped with FFP’s are experiencing problems
with either flow through the bags or a drop in pressure across the tube plate. The
root cause is not clear and is expected to be due to plant modification as well as
operational issues. One known contributing factor is the fabric filter size selection, both
length and diameter. In this dissertation, the focus will be to study the pressure drop
Student
across individual bags and FFP units as a whole.
Hendrik van Riel
Applicability/Benefit to Eskom Email: vrielhw@eskom.co.za
Relevant to Eskom’s existing, ESP to FFP retrofits and new built FFP’s, to reduce
Industrial mentor
Leon van Wyk
operational costs. Email: vanwykl@eskom.co.za
Proposed research Academic supervisors

Dr Dawie Branken
The aim of this study is to establish appropriate design criteria for a FFP in relation Email: Dawie.branken@nwu.ac.za
to bag size, costs, fabric bag material, and length versus diameter. The objective Prof Hein Neomagus
of this study is to apply Darcy’s law to the various FFP sections and determine Email: hein.neomagus@nwu.ac.za
the effect of each section individually and also the interaction between different
sections.

Material Science
Focus points
• Physical metallurgy of materials used in the power
generation industry
• Effects of manufacturing, construction and operation
on materials
• Welding and heat treatment of metals
• Non-destructive evaluation technologies
• Damage mechanisms and failure investigations
• Plant life management from a materials perspective
36 EPPEI 2014-2015
MS1
FEM modelling of stress, deformation
and damage of creep loaded
components in thermal power plants
Subject background with experimental results of the damage state (using investigations already made
by Eskom or in related EPPEI projects). The components to be investigated are
Creep ageing, damage and plastic deformation occurs in components exposed to high going to be selected in discussion with the student and the industrial mentors.
temperatures and pressures. The components involved include turbine rotors, disks
and blades, boiler parts and steam pipes. Even at constant load, the temperatures in Expected deliverables
these components are not uniform, and stresses vary significantly locally depending on
the geometry. Furthermore, stresses can be uniaxial as well as multiaxial. Load shedding • Identification of the components to be investigated
leads to additional temperature variations and accompanying thermal stresses in • Identification of the most suitable FEM software package
the components. It is therefore difficult to reasonably estimate the creep damage • Stress analysis of a component at constant load and temperature
and remaining lifetime of a component, using conservative safety factors and costly • Statistical analysis of the stress states
experimental investigations of the local damage states. Finite Element Modeling (FEM) • Literature study of creep and damage models considering temperature variations
calculations of the stress states can improve this situation greatly by indicating the most and multiaxial stress states
stressed areas within a component. With this knowledge, the experimental damage • Implementation of the creep and damage models into the FEM simulations
investigation can focus on these specific areas.The same FEM simulations can go a step • Comparison with experimental local damage investigations (taken from related
further when combined with creep models, and improve the lifetime predictions to a projects)
point where the local temperature and stress states can be considered.The latter part • Recommendations on damage and creep models used currently by Eskom
is the aim of this project. • Apply the resulting model for an improved prediction of the remaining lifetime of
the components
This project partially overlaps with an Asset Management topic “Continuum damage
modelling on HP pipework for predicting creep fatigue interaction”.
Applicability/Benefit to Eskom Student

Nicolas Cardenas
Improved creep life estimation and life management of creep loaded components
across the Eskom fleet. Consideration of the local stress and temperature state. Aged Email: Nicolas.cardenas@
eskom.co.za
components can be handled with greater confidence and improved safety.
Industrial mentor
Proposed research Marthinus Bezuidenhout
Email: bezuidM@eskom.co.za
Literature study of simple (phenomenological) creep and damage models
considering temperature changes and multiaxial stress states. These models Academic supervisor
should be specifically optimised for the components’ materials, i.e. martensitic Prof Robert Knutsen
and bainitic steels. FEM simulations of the (elastic) stress distribution of selected Email: Robert.knutsen@uct.ac.za
components. Coupling of the creep models with the FEM simulations. Comparison

MS2
Experimental Investigation of Creep
Damage of a Thermally Exposed
Component in Coal Power Plants
Subject background • Scanning Electron Microscopy (SEM): For more detailed investigating of the
microstructure with regards to homogeneity, inclusions, precipitates, quantification
Due to high temperature and stresses, material degradation such as creep deformation of creep pores and damage due to cree
and damage are the most prominent problems when estimating the remaining lifetime • SEM/Electron backscatter diffraction (EBSD): Quantitatively measure dislocation
of the components. In addition, the specific shape of the component leads to uneven densities. Identify recrystallized grains. Eventually will be carried out as Transmission-
distribution of the stresses, which in addition can be uniaxial as well as multiaxial. EBSD to achieve higher resolution
Furthermore, material which has been used up to date (21CrMoV57V) is continuously • Energy filtered transmission electron microscopy (EFTEM): identify and quantify of
replaced by the more modern P91. The components to be investigated are steam precipitates, investigate coarsening processes
turbine penetrations; however, the applied methodology is applicable to arbitrary
types of creep resistant steels. The task of this thesis is to investigate deterioration of Expected deliverables
the materials considering creep and damage. A detailed investigation of the mechanical
properties and the microstructure will permit accurate damage characterisation, and, • Identification of the critical positions within the steam penetrations with highest
at the same time will facilitate separating the effects of stress and temperature (as far damage
as the two effects can be treated individually). • Improvement of Eskom’s damage investigation techniques
• Detailed investigation of the local microstructural evolution
Applicability/Benefit to Eskom • Provide quantitative microstructural data for improved creep- and damage models
• Develop an understanding on the impact of temperature and stress on the local
Improved creep life estimation and life management of creep loaded components. damage
Consideration of local stress and temperature state, will improve damage investigation
techniques. Aged components can be handled with greater confidence and improved
safety. All collected data will contribute to setting up more advanced models on the
evolution of microstructural degradation and damage. They can thus be combined
with micromechanical models and finally act as part of improved creep models. Student
Kashir Singh
Proposed research
Email: kashir.singh@alumni.uct.ac.za
This research project deals with the experimental investigation of creep and damage of
steam turbine penetrations. Steam turbine penetrations will be provided from Eskom’s Industrial mentor
Marthinus Bezuidenhout
Lethabo Power Station (Unit 1). In order to accurately characterise the metallurgical
Email: bezuidM@eskom.co.za
damage, the following experimental investigations are proposed:
• Metallographic replication: to provide records and information of material Academic supervisor
degradation using microstructure damage and defect analysis Prof R Knutsen
• Hardness tests: Indicate the thermal softening of the material and can be used Email: Robert.Knutsen@uct.ac.za
to estimate the actual mean temperature to which the material was exposed to
• Light microscopy: Investigate the homogeneity of the investigated material and
indicate flaws stemming from the initial production process, such as inclusions or
delta-ferrite

Asset Management
Focus points
• Engineering approach to asset management
• Life cycle analysis
• Reliability centred maintenance
• Optimised management of strategic spares
• Preventative maintenance analysis
• Condition-based maintenance analysis
• Vibration analysis
42 EPPEI 2014-2015
AM1
Continuum damage modelling on
HP pipework for predicting creep
fatigue interaction

The High Pressure (HP) pipework in a power station experiences fluctuating high • A method of determining the accumulated creep fatigue damage in HP pipework
temperatures and pressures. Replacement of these components is planned according systems
to creep condition monitoring. Due to fatigue damage, which is not monitored, • A full FEA model of an existing HP pipework system that can be used for future
premature replacement of these components has been experienced. Consequent calculations
Non-Destructive Testing (NDT) reveals that the difference between creep damage • Known feasibility of using such a system for real time condition monitoring of
and fatigue damage is not distinguishable and only the total damaged is measured. The existing HP pipework systems
HP piping is a critical component and replacing the pipework requires long outages
ultimately leading to extended periods of power load loss. It is desirable that a method
for determining, and forecasting, the amount of fatigue damage in the HP pipework is
established.
This research will provide Eskom with a system to quantify and forecast fatigue damage
in HP pipework from operation history. This will also aid in verifying forecasted creep
damage in HP piping.
Better forecast of total damage will assist with outage planning. Furthermore, the
system will use real time indicators to alert power plant personnel to accelerated
damage due to operational conditions.
Student
Proposed research Stephen Bydawell
• Research and implement established methods for continuum damage models Email: BydaweS@eskom.co.za
for practical implementations on steady state thermal solutions on HP pipework
• Develop Finite Element Analysis (FEA) of the full HP pipe system and apply the Industrial mentor
Michael Hindley
best suited damage model to the full HP pipe system
Email: HindleMP@eskom.co.za
• Investigate sensitivity accuracy of the model using plant data creep models and
NDT testing preformed on HP piping Academic supervisor
• Using plant data on thermal and pressure cycles to quantify creep-fatigue damage Assoc Prof Schalk Kok
in the HP pipework Email: Schalk.Kok@up.ac.za
• Prescribe required measurements point of measurement that would be required
to turn this model into a real time on-line condition monitoring system

AM2
The effect of non-uniform micro-
structure on the failure mode of
hamer forged line hardware failure
prediction

The demand for electricity in South Africa had significantly increased to support To develop a probabilistic failure methodology to address scatter in strength of bow
economic growth; hence Eskom had to expand its electrical capacity. To overcome shackles subjected to cycle loads and exposed to fatigue. Particular attention will be
servitude challenges; required a change in Eskom’s overhead line design philosophy, paid to creation and propagation of fatigue cracks from edges and surface defects such
which included the use of larger conductor sizes and longer line spans, resulting in an as laps with variation in the following:
increase in mechanical loading on termination points at towers. • Microstructure changes associated with changes in geometry
• Changes in microstructure properties (tensile, hardness, layer thickness) due to
Increasing the strength classes of hardware without or limited changes to existing variation associated with manufacturing
geometry and mass, required unalloyed medium carbon steels to replace low carbon • Surface defect size that can be tolerated by the mix microstructure
steels as material of choice for hamer forged hardware and heat treatment such as • Location of such surface defects along the load distribution of a bow shackle
quench and tempering are used to further improve the strength. As the geometry
of most line hardware changes along the profile of a component, heat treatment Expected deliverables
thereof will result in a nonhomogeneous microstructure. Although, the characteristics
of the predominant microstructures are known, the characteristics and behaviour of • Both the material and mechanical characteristics of current material used for
a combination of these predominant microstructures within one component, along hamer forged hardware will be known, including the correlation between hardness
with possibly manufacturing deviations in mass production are unknown. Resulting (surface and core) and tensile properties. In addition, the relationship between
in a significant degree of uncertainty regarding the performance of hamer forged microstructure changes and the probability of failure when exposed to typical
hardware and especial where hardware such as bow shackles are used as single loading experienced under normal operating conditions will be known.
attachment point components when exposed to static and dynamic loading under • Possible new shackle design to minimise the risk of possible failures of single
normal operating conditions. attachment hardware.
Student
Probabilistic failure methodology analyses can be used to determine if existing lines are Jacques Calitz
at risk due to deviations in mass production of hardware. By knowing the effect what
manufacturing (hammer forging, pickling and galvanizing) and heat treatment would Email: calitzj@eskom.co.za
have on the mechanical and material behaviour of hardware would minimise the
risk of installing sub-standard hardware, hence minimise the risk of potential failures Industrial mentor
Dr Michael Hindley
when the introduction of alternative heat treatable material is considered to further
Email: HindleMP@eskom.co.za
increases the strength class.
Academic supervisor
In addition, by knowing the typical microstructure that will be obtained with changes Prof Schalk Kok
in geometry, as well as the mechanical behaviour of such microstructures, will help to Email: Schalk.Kok@up.ac.za
identify critical hardware that requires regular inspection and/or replacement in order
to minimise potential failures.

AM3
Vibration monitoring of
transformer windings
Subject background The secondary objectives of this project are:

• Determine the natural frequencies of the core and windings
Transformers are one of the most expensive and critical pieces of equipment in the • Conduct a literature study on thermography
electricity distribution industry. Ensuring the well-being of transformers will be a • Record the temperature profiles of the test transformer under the different load
resource saving activity for the business. During the last 20 years or so, the reasons conditions
for transformer failures have been extensively researched. No conclusions have been
made from this research regarding the failures and the challenges such as premature Expected deliverables
failure of transformers as well as compromised maintenance still remain. The use of
condition monitoring information for the identification, preparedness and mitigation of • A published MSc thesis
transformer failure is an area of interest which this project will investigate. • A better overview of plant performance, maintenance as well as design
specifications wich will facilitate optimization of asset life through preparedness
Applicability/Benefit to Eskom for plant ageing of failure
• Published condition monitoring information for the identification, preparedness
• Optimised asset life, which is of great financial benefit and mitigation of transformer failure
• Better overview of plant performance, maintenance planning and design • Expert skills acquisition on the subject of transformer failures, operations,
specifications monitoring and maintenance
• Preparedness for plant ageing or failure
• Optimised maintenance and operations
• Expert skills acquisition on the subject of transformer failures, operations,
monitoring and maintenanceThis software will equip companies operating power
plants to make financially sound operational decisions such as inspection intervals
as well as component replacements.
Student
Proposed research Arnold Hayes
Email: ajjhayes@gmail.com
The primary objectives are to:
• Conduct a literature study on:
Academic supervisors
o transformers and their operating principles, Prof Stephan Heyns
o transformer vibrations, Email: Stephan.heyns@up.ac.za
o existing transformer vibration monitoring techniques,
o stereophotogrametry
• Through physical experimentation this project will measure the core and winding
vibrations of a test transformer under different load conditions by making use of
high speed cameras. Lay a foundation for succeeding research.

AM4
Reliability modelling for the prediction
of failure probability of a critical plant
at a power station

With the constraints on the electricity supply grid in the past, Eskom’s power stations’ • Identification of critical plant failure data
maintenance has had to be delayed.This delay has led to a less reliable plant that suffers • Research time and condition based reliability models
from unexpected breakdowns in-between scheduled outages which are determined • Test results from the most suitable model using available failure data
through Reliability Based Optimisation (RBO) strategies.
An improved method for determining plant reliability as well as the time intervals
between outages can be used to develop reliable as well as safe maintenance strategies.
RBO strategies are utilised to inform the power station when to conduct maintenance
on the plant based on time alone. With the current constraints on the national power
grid, it would be advantageous for Eskom to be able to determine when to conduct
maintenance in their plants, based on factors other than time alone such as: plant
condition, past as well as operating conditions that influence the life of the plant.
This would allow Eskom to optimize their maintenance strategies, reduce the
number of unexpected plant breakdowns and help with key decision making, should
outages need to be delayed. These improved maintenance strategies will financially
benefit Eskom.
Proposed research Student

Ntombifuthi Ncongwane
This project will research reliability models that can be used to determine the
probability of failure of power plant equipment and components. The models should
Email: ncongwns@eskom.co.za
in the very least be time and condition based. The proposed research will include an
evaluation of the failure modes of a critical system. From the research work carried out,
Industrial mentor Eugene
recommendations as to which model would give the optimal solution to determine Pininski
the survival statistics of the system components can be made. The model will be Email: pinense@eskom.co.za
tested using failure data obtained from the selected critical system.
Prof. Stephan Heyns
Email: Stephan.heyns@up.ac.za

AM5
Eskom high pressure feedwater
heater maintenance management
optimisation

The cost of deterioration of the effectiveness of High Pressure Feedwater heaters due The research conducted for this topic will address:
to tube plugging must be weighed against repair/replacement options continuously
using quantitative measures of availability and risk. This enables proactive decision- • The reasons for taking HP feedwater heaters out of service
making to prevent heaters falling into disrepair. • The cost to Eskom when HP feedwater heaters are taken out of service
• The time required for HP feedwater heaters to run at reduced effectiveness
Applicability/Benefit to Eskom to justify
replacement costs and time (Cycle efficiency loss not heater efficiency loss)
High Pressure (HP) feedwater heaters form a crucial part of the power generation
process. Due to the deterioration of feedwater heating plant in Eskom the “repair or Therefore the main deliverable of this topic would be to develop an industry ready
replace” decision-making process will become a reality which must be executed swiftly. guide which will aid plant leaders in their maintenance decisions for HP heaters taking
into account plant integrity and cost effectiveness.
The effectiveness of HP feedwater heaters directly impacts the efficiency of the water-
steam cycle. A reduction in availability of feedwater heating capacity adversely affects This should evaluate the present value of assets and utilize statistical analysis to
the overall process efficiency and consequently costs Eskom money. determine optimal replacement time.
Proposed research
In the Eskom fleet, HP feedwater heaters are taken out of service for various reasons.
Some valid, and some invalid. If a monetary value could simply and easily be associated
with the time a heater is out of service, it can be used to aid plant leaders in their
maintenance decisions. To evaluate the reasons for the reduction in heater availability Student
in terms of cost and compare it to the increase in production cost due to efficiency loss. JC Pieterse
Email: Pieterjc1@eskom.co.za
Industrial mentor
Marthinus Besuidenhout
Email: BezuidM@eskom.co.za
Academic supervisor
Prof Stephan Heyns
Email: Stephan.Heyns@up.ac.za

AM6
Develop a troubleshooting guide
for vertical spindle roller mills using
process history data and machine
learning

The coal mill is the heart of the coal fired power station. It provides quality pulverised Develop a troubleshooting methodology that is designed to continuously evolve,
fuel to dynamically meet boiler demand. A poor performing milling plant can be a storing new faults and intelligently recalling past faults and solutions. Investigate machine
bottleneck in power generation and cause combustion related issues such as unburnt learning philosophies to analyse the process history coupled human fault descriptions
carbon in ash, high NOx emissions, uneven steam temperatures and high exit gas to navigate an expert knowledge database of failures and corrective actions.
temperatures. Currently mill failures or performance related issues are diagnosed based
on the judgement and experience of the operating, maintenance and engineering
staff. Eskom is currently experiencing a skills shortage with the majority of young Expected deliverables
engineers lacking mentorship and handover knowledge. Due to the huge amount of
information available, both in theoretical knowledge and system signals, engineers with A troubleshooting guide for vertical spindle roller mills based on process signals and
less experience may not be able analyse available data properly to arrive at a solution operator fault descriptions.
quickly. The field of machine learning is focussed on extracting valuable insights from
the ever increasing quantities of data being produced. It is logical to start investigating
methodologies based on machine learning algorithms to extract relevant information
to support and guide inexperienced decision makers.
Expected benefit to Eskom a more effective solution for recalling and solving recurring
issues and knowledge on how to better utilize Eskoms ever increasing amounts of Student
data. Robert Salzwedel
Email: SalzweRR@eskom.co.za
Industrial mentor
Matthew Muller
Email: MullerAM@eskom.co.za
Academic supervisor
Prof Stephan Heyns

AM7
The risks and effects of turbo-generator
torsional vibration in a changing
southern African electricity grid

Torsional vibration of large turbo-generator trains is a known phenomenon that has • Estimation of future magnitude, duration, type and frequency of grid events leading
resulted in the worldwide cracking and failure of shafts, generator coil retaining rings to torsional excitation of turbo-generators
and low pressure turbine blades. With the current expansion of the southern African • Methodology for the advanced finite element modeling of turbo-generator trains
electricity grid and diversification of generation capacity to include renewable resources which include the effects of multiple blade stages and non-linear generator rotor
such as wind and solar, the risk, frequency and magnitude of torsional excitation events behaviour for the prediction of torsional vibration response due to transient
are expected to increase. Simplified modeling techniques have been applied to predict torsional excitation
vibration response of these systems but typically require some form of calibration • Finite element simulation of turbine blade stress-strain response to rotor torsional
and do not directly allow for the quantification of the fatigue life consumption of such excitation for a large turbo-generator i.e. Koeberg Nuclear Power Station
events on associated components such as turbine blades. • Algorithm for online evaluation of steam turbine blade torsional vibration induced
fatigue damage
• Identification of the Eskom turbo-generators at risk of torsional vibration induced
fatigue cracking in a changing electricity grid.
• Development of expert skills in the fields of torsional vibration, finite element (FE)
modelling and fatigue.
• Improved predictive capability for the long term reliability and life management
of turbine blades.
Proposed research
Student
Current and likely future electrical grid stability and related sources of turbo-generator Ronnie Scheepers
torsional excitation in the expanding and diversifying southern African electricity grid.
Email: ronnie.scheepers@
Advanced methodologies for the prediction of torsional vibration response of large eskom.co.za
full scale turbo-generators with improved accuracy and the inclusion of multiple blade
stages and non-linear generator rotor response. Blade transient stress response and Industrial mentor
fatigue damage accumulation model for steam turbine blades exposed to torsional Dr Mark Newby
vibration events. Email: mark.newby@eskom.co.za
Academic supervisor
Prof Stephan Heyns
Email: stephan.heyns@up.ac.za

AM8
Evaluation of a viable technique to
determine mass flow rate in a pneumatic
ash conveying system to validate
performance requirements

With Eskom being pressurised to generate and supply electricity in bulk to the country, The objective of this research is to identify a viable measurement technique to
it is of utmost importance for the company to minimize the cost and maximize the determining the mass flow achieved in installed dense phase pneumatic fly ash conveying
efficiency associated with the production and amount of electricity. Currently Eskom systems. All the advantages and disadvantages of these techniques will be evaluated to
utilises contractors to design pneumatic conveying systems for their ash handling plants identify the optimal technique that could be utilised for determining the mass flow rate.
at new and established power station all over South Africa. Therefore Eskom requires During the investigation a number of factors such as: cost, installation, measurement
a validation method to compare the achieved capacity of the installed pneumatic requirements, required resources and safety will be taken into consideration.
conveying system with the specified design capacity. The ash handling plant requires
the transportation of fly ash from the hoppers underneath the gas cleaning equipment Expected deliverables
to the fly ash storage facilities, usually concrete bunkers or silos. Currently no proven
techniques exist to determine whether the actual capacity meets the specified capacity. • The investigation and determination of a viable mass flow measurement technique
The use of load cells to determine the mass flow would not be practical due to the • Validation as viable technique by means of experimental testing in an Industrial
size of these storage vessels. Utilizing the level increase in the storage vessel over a simulated environment
known time period is also not accurate due to the substantial bulk density variation
experienced in fly ash depending on its state of aeration. Therefore an applicable and
efficient measurement technique is required to determine the performance of the
pneumatic ash conveying system.
This will enable Eskom to conduct energy efficiency calculations and Life Cycle cost Student
Analysis. JC (Tiaan) Smit
Email: smittiaan5@gmail.com
Industrial mentor
Henk Fourie
Email: fouriejh@eskom.co.za
Academic supervisor
Prof Stephan Heyns

High Voltage Engineering (AC)
Focus points
• Design, operation and maintenance of electrical
components in power generation systems (generator,
transformer, motor, breaker, etc.)
• Performance of transmission systems
• Integrity of AC and DC main transmission systems
• Environmental impact on transmission and
distribution systems
• Safety of electrical transmission systems
• Efficiency and reliability improvement

AC1
A method for measuring and
recording changes on wood pole
impedance over time

Wood is often used to construct utility poles to support overhead distribution lines Impedance measurement will be taken on existing wooden utility poles. The
because of various favourable properties. However, for this application wood also has measurement results will be used to identify suitable, low cost, instrumentation to be
unfavourable properties. There is always a risk that the wood can catch fire (pole- designed and/or selected and thereafter implemented within existing structures to
top fires) or electrocute birds under certain conditions. The risk of catching fire is continually monitor impedance.
determined by the amplitude of the leakage current present.
While the presence of the leakage current, in turn, is determined by the impedance of
the wood. Damage to these poles results in additional costs to Eskom as replacement The proposed research aims to report on the design as well as construction of a
of these structures is then required. A need therefore exists for a low cost impedance suitable monitoring system for wooden utility pole impedance over time.
monitor to be developed in order to gather additional information regarding the
magnitude and variation of the impedance of the wood utilised.
• An improved understanding of the change of impedance of the wood with
increasing age, as well as the influence of the local environmental conditions that
the wooden utility poles are exposed to
• With this additional information regarding the impedance properties of wooden
utility poles, measures to be taken to reduce the risk of pole-top fires and bird
electrocutions can be identified
• Eskom will be able to make better specific wood selection for utility poles as Student
well as improve the design of the utility pole structures that use them Nkateko Khoza
Email: KhozaEN@eskom.co.za
Industrial mentor
Dr Andreas Beutel
Email: BeutelAA@eskom.co.za
Academic supervisor
Dr John Van Coller
Email: John.vancoller@wits.ac.za

AC2
Power exchange optimisation of
distributed energy resources utilising
smart transformers and active
voltage regulation

South Africa is facing a very difficult time balancing supply and demand as electrical • Study methods to improve hosting capacity for increased penetration levels of
energy production is under pressure as the base load generation fleet ages and to distributed energy resources
operates outside its design life. Extreme measures are implemented daily to supply • Consider international smart grid technologies to transition to a smarter
the load. distribution grid
• Evaluate the (ST) concept and determine the impact on power exchange
Introducing renewable energy sources into the main supply system could contribute optimisation between distribution and the utility grid
significantly to solve very complex and real issues in the electricity supply industry. • Evaluate voltage regulation strategies and consider the AVR to prevent voltage
Increasing pressure to reduce carbon emissions and comply with zero effluent violations on feeders with high DG penetration
discharge strategies, innovative integration of renewable energy sources is crucial.
While Government will play a big part in the growth rate of harvesting renewable
energy, industry should pave the way for increased penetration levels of Distributed • Present solutions to the challenges faced regarding the hosting capacity of DG
Generation (DG). DG primarily includes renewable energy technologies (solar, wind, • Combine Smart technologies such as the ST and AVR, and show how the voltage
geothermal and ocean tides), and non-renewable technologies (combustion engines/ violation problem is addressed in a safe and cost effective using a simulation model.
turbines and fuel cells). To enable industry and residential DG application, a vast
amount of research should be conducted to assure the successful implementation
of smart grid technologies. The Integrated Resource Plan 2010 – 2030 dedicates
additional renewable energy resources contributes 42% of the total additional new
build capacity by 2030.The projected cost efficiency increase of Solar PV and increasing
costs of conventional generating electricity, DG could become the dominant energy
supply source. Student
Peet Schutte
Integration of distributed energy resources creates new issues. The evolution of
migrating to the decentralized generation mixture includes many innovative solutions. Email: schuttpj@eskom.co.za
The research investigates smart technologies into the South African electricity supply
grid and the development of future smart grids.
Industrial mentor
Dr Andreas Beutel
Email: BeutelAA@eskom.co.za
Academic supervisor
Smart technologies including Smart Transformers (ST)s and Active Voltage Regulation Dr John Van Coller
(AVR) are aligned with the Eskom Smart Strategy. Conventional structures of Email: john.vancoller@wits.ac.za
distribution planning are changing and smart grid technologies pose promising
opportunities to migrate to a smarter, more efficient way of managing our electrical
energy distribution.

High Voltage Engineering (DC)
Focus points
• Design, operation and maintenance of electrical
components in power generation systems (generator,
transformer, motor, breaker, etc.)
• Performance of transmission systems
• Integrity of AC and DC main transmission systems
• Environmental impact on transmission and
distribution systems
• Safety of electrical transmission systems
• Efficiency and reliability improvement

DC1
Impact of DC options and VSC
based facts devices on voltage
stability in southern Africa

Incidents of voltage instability and voltage collapse have become increasingly common As part of Eskom’s overall plans for possible future system strengthening and
in power systems worldwide in recent decades. This form of instability often manifests expansion, one option that is explicitly identified for research in the EPPEI Strategic
itself in systems where load growth has not been matched by expansion of generation Plan is the addition of new HVDC lines. One valuable case study is the possibility of a
and transmission infrastructure and can lead to large areas being susceptible to separate DC line through KZN. It is therefore proposed to consider in-depth research
complete blackouts. A good example exists in South Africa where the KwaZulu-Natal into the impact and benefits of HVDC lines as well as different DC transmission line
(KZN) network has been known for many years to be at risk of voltage instability technologies, and VSC-based FACTS devices, from the particular standpoint of their
because of considerable load growth and relatively little strengthening of the capacity potential for improving voltage stability in KZN in particular and possibly in other
of the transmission grid. In cases like these, although the commissioning of new Extra regions in the SA grid.
High Voltage (EHV) transmission lines alleviates stability concerns in the short term,
the issue is one that can continue to cause problems in the medium to long term Expected deliverables
exacerbated by further load growth and the absence of generation capacity.
Specialist expertise in voltage stability analysis, DC transmission system and FACTS
Applicability/Benefit to Eskom device modelling. From the study case, a detailed study of the voltage stability
characteristics of the KZN network and the future impact of load growth. Detailed
System stability in general, and voltage stability in particular, will become increasingly evaluation of the impact of competing HVDC line technologies and FACTS technologies
important topics requiring specialist skills within Eskom, in the medium term as Eskom’s and control approaches on voltage stability.
network remains heavily stressed, and in the long term as its complexity increases as
a result of new transmission and interconnected generation coming on stream as a
result of the build programme and penetration of renewables. At present Eskom lacks
the in house skills to adequately address the issue of voltage stability. This thesis, with Student
the accompanying increase in skills transfer, will enable Eskom to better understand Aroon Sukhnandan
and deal with the issue of voltage stability in KZN and other areas as well as enable
skills transfer to take place with other planning staff. Email: sukhnaa@eskom.co.za
Industrial mentor
Dr Rob Stephen
Email: rob.stephen@eskom.co.za
Prof Bruce Rigby
Email: bruce@alectrix.co.za
Dr AK Saha
Email: Saha@ukzn.ac.za

Renewable Energy
Focus points
• Design, operation and maintenance of renewable
energy technology, specifically large wind and
concentrated solar power systems
• Viability of renewable energy sources in Southern
Africa
• Connection of renewable energies to the South
African power grid
• Economic analysis of renewable energy technologies
• Governmental policies and commitments

RE1
Investigation into the effect of wind
on fan performance in an ACC

Due to a limited water supply in South Africa, all of Eskom’s new generation coal-fired • detailed literature study of previous work done on the topic
power stations employ a so called “dry” main cooling system, in the form of an Air • a generic CFD-model of an ACC
Cooled Condenser (ACC).The ACC operates by forcing ambient air over the outside • results indicating the effect of wind on the performance of this ACC
surface of finned-tube heat exchangers, through the use of a large number of axial fans. • results indicating the performance of different variations of the generic ACC
As the air flows over the outside heat exchanger surface, heat from the heat exchanger under wind conditions
is transferred to the ambient air, while the steam condenses inside the tubes. The • conclusions regarding the most favorable ACC configuration in terms of ACC
performance of the large axial flow fans is critical to the ultimate performance of the performance
ACC and thus the power station. These fans are constantly exposed to cross-flow
conditions at the inlets of the fans, due to the inherent design of the ACC and during
low wind conditions, but especially so during windy conditions. Typical effects of these
distorted inlet flow conditions include a reduction in ACC performance, power station
unit load losses and in extreme cases, unit trips.
It is well known that windy conditions can be severely detrimental to the performance
of an ACC.The possibility of negating this effect and thereby improving plant availability
by installing different fan or condenser unit configurations at different locations within
an existing ACC will be investigated.
Proposed research Student

Ruan Engelbrecht
The project aims to investigate the technical and economic feasibility of installing Email: 16517229@sun.ac.za
different fan and condenser unit designs at different locations within the ACC and the
effect of wind conditions on the performance of these units. The project would be a Industrial mentor
progression of an existing MSc project. The objectives of this project are: Dr F du Preez
Email: DpreezAF@eskom.co.za
• modeling a generic 30-fan ACC in Computational Fluid Dynamics (CFD)
• investigating the effect of wind conditions on the performance of the ACC Academic supervisor
• investigating the effect of different fan and condenser unit configurations installed Dr J van der Spuy
at different locations within the ACC on both ACC and fan performance. Email: sjvdspuy@sun.ac.za

RE2
Geographic location optimisation
of wind farms in South Africa

Wind generation represents a considerable portion of the renewable generating • Statistical models for the power generation profiles of existing and proposed
capacity currently under consideration in Renewable Energy Independent Power wind farms, with performance evaluation in the context of grid integration
Producer Procurement Programme. The power output profiles of wind farms are considerations such as national load profile and economic dispatch
highly dependent on the climatic conditions of the wind farm’s location, resulting in a • A software solution that can facilitate studies on large scale wind integration in the
power source of a stochastic rather than deterministic nature. Large scale geographic South African electricity grid by optimizing the geographic location of future wind
planning of wind farms can enable the cumulative wind power output to better farms to match the national load profile
contribute to base load and peak demand.
In view of the existing capacity constraints in generation and transmission, it is important
to research how the power dispatch profiles of existing wind farms perform and how
future topologies can be optimized in the context of system loading.
Proposed research
• Statistical analysis of historical wind data and development of a simple model
topology for prediction of power output profiles of wind energy sources with the
view to do long term forecasting
• Analysis of predicted wind power generation profiles with the view to study
optimal location and geographic distribution of wind power generation sources Student
Chris Joubert
from the perspective of national and regional load profiles and their corresponding
Time Of Use (TOU) structures
Email: chris.joubert2501@
yahoo.com
Industrial mentor
Riaan Smit
Email: rsmit@eskom.co.za
Academic supervisor
Prof HJ Vermeulen Email:
vermeuln@sun.ac.za

RE3
Integrated O&M strategy for
Sere Wind Farm
Subject background In this study condition based maintenance will be applied through vibration analysis
on the bearings of critical components. Based on the developed power curve
The construction of Sere Wind Farm in the Western Cape region will connect model and vibration analysis an integrated Operation and Management (O&M)
100MW of renewable energy to Eskom’s power grid. Wind power is relatively strategy can be obtained to optimise performance.
“new” compared to the fossil fuel and gas power sectors which are much more
matured industries. Various analytical, statistical and mathematical models have been Expected deliverables
developed to approximate the reliability of the wind turbine for optimum life cycle
management. The lack of and/or limited operational data available is a major challenge • A site specific wind turbine power curve model
for researchers and industry to improve maintenance models. The need for accurate • Condition monitoring on gearbox and generator bearings
wind turbine modelling to control and predict failures plays an important role for • Comprehensive stock level keeping
reliable, cost-effective energy production. • Accurate performance measurement and component failure prediction
• Reduction of the operating and maintenance costs
Applicability/Benefit to Eskom • Safe, reliable, clean and cost effective power
• Developed LOPP and Technical Plan documents
To protect this large capital investment and maximise profit it is important for Eskom
to ensure high availability and reliability from Sere Wind farm. South Africa is ranked
in the top 15 international countries relating to CO2 emissions and wind energy
generation will reduce the use of fossil fuels to produce electricity, which in turn will
decrease CO2 emissions.The objective of this study is to develop a wind turbine power
curve model to ensure maximum energy production by implementing an optimum
maintenance strategy. Critical plant components will be classified to ensure that the
system addresses all statutory, safety, environmental, outage and cost parameters.
Student
Proposed research Ian Kuiler
Email: 18608493@sun.ac.za
Analysis of the wind resource data will be used to predict the yearly energy
production and operational time of the wind turbines. One way to determine the
Industrial mentor
reliability of a wind turbine is through observing its power curve depending on Dr Nad Moodley
the wind speed. The standard power curve supplied by the Original Equipment Email: MoodleyN@eskom.co.za
Manufacturer (OEM) can be compared against the site specific model to estimate
wind energy output as well as component degradation. The new developed model Academic supervisor
can be used as reference for monitoring the performance of the wind turbine. Prof Wikus Van Niekerk Email:
wikus@sun.ac.za

RE4
Life cycle cost of energy technologies
(fossil fuel-fired, gas, renewable and
nuclear)

Eskom currently requires urgent expansion of its electricity generation capacity to meet • A financial model for each of the various energy generation technologies
the energy demand in South Africa. However, Eskom is facing rising debt levels at the • Provide recommendations on the future energy policy
same time, and therefore cash is not in excess. Under these conditions it is therefore • Publication of a master’s thesis
crucial for Eskom to identify the best value for money energy generation technologies
in order to establish a cost effective energy supply for the country. Independent power
producers are using renewable energy generation and putting renewable energy on
the grid.This influx of renewable energy into the grid is subsequently driving down the
price thereof. In light of this, renewable energy generation technologies need to be
considered as feasible for best value for money energy generation.
• Develop Eskom resources and improve the knowledge base in the field of life
cycle costing
• Assist in selecting the best value for money energy generation technologies
• Introduce life cycle costing within Group Technology Engineering – Systems
Integration where it is meant to be housed
Proposed research
In order to identify the most cost effective energy generation technologies within Student
Eskom, following research will be conducted: Mark Sklar-Chik
• Investigate the life cycle costing methodology currently employed by Eskom
Email: mark.sklar.chik@gmail.com
• Compare the life cycle costs of different energy technologies (fossil fuel, gas
and renewable) within the South African electricity context
Industrial mentor
Prof Saneshan Govender
Email: GovendS@eskom.co.za
Academic supervisor
Prof Alan Brent
Email: acb@sun.ac.za

12. Completed projects
1. Energy Efficiency 7. Renewable Energy 58
EE1 - Techno-economic feasibility of a solar assisted coal-fired power plant 82 RE1 - Evaluation of the performance characteristics of a hybrid (dry/wet) induced
EE2 - Improvements to a key contributor of frequency control: co-ordination of guide draft dephlegmator 91
vane operation at a pumped storage plant 83 RE2 - Scenario modelling for short to long term rollout of concentrating solar power
EE3 - Asymmetric flow measurement in space constrained cooling water ducts using a in South Africa 92
traversing probe 84 RE3 - Simulating the effect of wind on the performance of axial flow fans in
EE4 - Development of appropriate steam turbine models in Flownex 85 air-cooled condenser systems 93
RE4 - Heliostat field layout optimisation for a central receiver 94
2. Combustion Engineering 38 RE5 - Performance enhancements of evaporative cooling towers 95
RE6 - Liquid extraction from air cooled condenser steam ducts 97
CE1 - Condition monitoring and performance optimisation of pulverised fuel vertical
spindle type mills 86
3. Emission Control 52
EC1 - Determination of the correlation between ash mineralogy and ash resistivity of
South African coals 87
4. Material Science 58
MS1 - Prediction of long term benifits of compressive residual stresses in turbine blade
roots and rotor attachments 88
5. Asset Management 58
AM1 - Enhancing the maintenance system for critical pumps in power generation 89
AM2 - Optimum refurbishment scheduling of low pressure fossil fuelled steam turbines
using risk and forensics considerations 90

Techno-economic feasibility of a Improvements to a key contributor
solar assisted coal-fired power plant of frequency control: co-ordination of
guide vane operation at a pumped
Summary of completed project storage plant
This study investigates if solar heat addition to Duvha Power Station in Mpumalanga,
South Africa, is technically and economically feasible. Duvha Power Station is one of Summary of completed project
the largest coal-fired power stations in Eskom.Two solar heat integration options were
examined in this study i.e. the use of solar heat to heat feedwater or to produce This study was done to identify the systems, which at present contribute considerably
superheated steam. A market assessment of Concentrated Solar Power (CSP) to frequency control or could affect frequency in the medium to long term. Pumped
technologies was performed to establish the maximum water/steam conditions storage was selected and it was found that their units exhibit a non-minimum phase
(temperature and pressure) produced by each CSP technology. The CSP technologies characteristic which can negatively affect the frequency response on the grid.
assessed were the Parabolic Trough Collector (PTC), the Linear Fresnel Reflector Attempts were made to improve this system’s contribution to frequency control. To
(LFR) and the Central Receiver (CR). By using the results of the market assessment, achieve this, the pumped storage unit was modelled in a thermal-hydraulic simulation
a suitable CSP technology was selected for each integration option. The technical environment to realise its transient behaviour. Thereafter, a selection of scenarios with
capabilities of each plant area of Duvha Power Station, such as the boiler, turbines, various guide vane operation techniques was proposed to improve the performance
feedwater pump etc., was also assessed by reviewing original equipment manufacturer of two connected units during load changes. The study showed that it is possible to
(OEM) data sheets. It was found that the integration options that produced high- reproduce the Non-Minimum Phase (NMP) characteristic of a pumped storage plant
temperature steam have the highest integration effectiveness, such as the steam supply using thermal-hydraulic models, and that various control schemes can be tested using
to the high-pressure turbine etc. the model.
Student
Anthony Govender Student
Email: govendat@eskom.co.za Mu’azzam Kippie
Email: kippiem@eskom.co.za
Industrial mentor
Gary De Klerk Industrial mentor
Email: DKlerkGB@eskom.co.za Dr Graeme Chown
Email: Chown@ppaenergy.co.uk
Academic supervisor
Prof Kevin Bennett Academic supervisor
Email: Kevin.Bennett@uct.ac.za Dr Wim Fuls
Dr Wim Fuls Email: wim.fuls@uct.ac.za
Email: wim.fuls@uct.ac.za

Asymmetric flow measurement in
space constrained cooling water Development of appropriate steam
ducts using a traversing probe turbine models in Flownex
Summary of completed project Summary of completed project
The majority of Eskom’s coal-fired power stations utilize surface condensers and The project aim was to develop appropriate steam turbine models in Flownex which
wet cooling towers to discard waste heat from the steam cycle. The Cooling Water use minimal data that was readily available to the end user. Acceptance test data was
(CW) flow rate to the cooling tower affects the temperature at which condensation used as the primary source because it is more reliable than plant data.Various pressure
takes place inside the condenser. There is currently no installed instrument measuring drop correlations and methods to predict off-design efficiency were investigated.
CW flow rate. The research aim was to identity and recommend a type of flow These correlations and methods were solved analytically and implemented in Flownex.
measurement suitable for flow in CW ducts. The research was constrained to a local Interpretation of the error analysis for the pressure drop correlations established that
flow measuring technique. The focus was to predict expected accuracy of local flow the general empirical law using inlet conditions and Stodola law in the volume form
measurements in asymmetric flow. It was found that flow measurement accuracy is were the most accurate and consistent in predicting mass flow rate and pressure. The
dependent on the distance of the measurement from the bend, the traversing path Ray method was shown to be most accurate to predict off-design efficiency and less
and number of measurement points along a traverse. Algorithms were developed complicated to implement. Steady state models were built for four turbine trains using
to calculate the flow based on various types of measurement traverses. One of the general empirical and Stodola laws.
these was a chord-wise approach for which only a single pipe entry is needed.
Algorithms were tested using CFD generated flow profiles, and on physical flow tests. The results produced by both correlations were similar, showing that for high vacuum
For measurements more than 2.2D downstream of the bend, the 0° traverse and conditions either correlation could be used. The general empirical law was the chosen
multiple traverses of two traverses at -45° and +45° to the plane of bending, are correlation to implement for transient analysis since it was generally more accurate
recommended. The discretization and integration scheme of the chord-wise traverse and easier to implement than Stodola. The power predicted by the model was within
does not seem to produce better results than a single vertical traverse. ±1 % of that of the actual power produced.
Student Student
Rudzani Mutshinya Rahendra L Neerputh
Email: mutshira@eskom.co.za Email: Rahendra.neerputh@eskom.co.za
Industrial mentor Industrial mentor

Dr Francois du Preez Gary de Klerk
Email: dpreezaf@@eskom.co.za Email: gary.dklerk@eskom.co.za
Academic supervisor Academic supervisor

Dr Wim Fuls Dr Wim Fuls
Email: wim.fuls@uct.ac.za Email: wim.fuls@uct.ac.za

Condition monitoring and performance Determination of the correlation
optimisation of pulverised fuel vertical between ash mineralogy and ash
spindle type mills resistivity of South African coals
In order to alleviate the current bottleneck caused by the milling plant, two problems The resistivity of ten coal ashes from various South African coal-fired power plants
were identified. Monitoring the key performance indicators of the milling plant were determined and correlated with their chemical and mineral characteristics. The
(throughput and particle fineness) required improvement, and the average throughput resistivity of only three of the coal ashes could be predicted well by the Bickelhaupt
had to be increased without sacrificing the product quality. Monitoring of the coal relation; an equation that was derived for American coal ashes, and solely based
mass flow was achieved by means of an on-line mill energy balance. The particle size on the elemental analysis of the ash. A modification to the Bickelhaupt relation was
analyser evaluation identified five key test parameters which caused inaccuracies in obtained based on the mineralogical characteristics of the ash. It was found that with
results. Relationships were established enabling the commissioning of this instrument the inclusion of the most dominant minerals, calcite, dolomite, anhydrite and calcium/
to achieve precise and accurate measurement for continued condition monitoring. magnesium oxides, an improved correlation between resistivity and ash characteristics
could be obtained. The effect of SO3 conditioning was also studied and it was found
Extensive testing was performed on a pilot scale mill where the operational control that four ash samples correlated well with the Bickelhaupt equation.
parameters were related to the key mill performance indicators. Characterisation of
the relationships between the throughput, classifier setting, air/fuel ratio and particle
fineness were successfully established. An operating regime was then developed which
increased the maximum sustainable throughput while maintaining optimal particle
fineness.
Student
Student Leon van Wyk
Hamresin Archary Email: vanwykl@eskom.co.za
Email: Hamresin.Archary@eskom.co.za
Industrial mentor
Industrial mentor Dr Chris van Alphen
Prof Louis Jestin Email: VAlpheC@eskom.co.za
Email: JestinLM@uct.ac.za
Academic supervisor
Academic supervisor Prof Stuart Piketh
Prof Walter Schmitz Email: stuart.piketh@nwu.ac.za
Email: Walter.Schmitz@wits.ac.za Prof Hein Neomagus
Email: Hein.Neomagus@nwu.ac.za
86 EPPEI 2015-2016 Programme EPPEI 2014-2015

2015-2016 Programme 87
Prediction of long term benifits of Enhancing the maintenance
compressive residual stresses in turbine system for critical pumps in power
blade roots and rotor attachments generation
Of significant importance to the design, manufacture and maintenance of turbine The aim of this study was to evaluate and enhance maintenance, an aspect of asset
components, is the fatigue life thereof when subjected to variable loading conditions. management, for critical pumps in the electricity production process.Through review of
Shot peening is known to considerably increase fatigue life of components by documented information as well as site interaction, the maintenance system for pumps
introducing residual stresses within the component’s surface layers. This created a at a selected Eskom power plant was established and evaluated against requirements
need to develop a numerical model that accurately predicts such residual stresses. from the asset management standard, ISO 55000.
A simplified numerical model depiction of the shot peening process on a target material
was developed. A FE based model was employed to simulate material behaviour and A reliability engineering model to compute optimal maintenance for pumps was
elastic-plastic deformation a metallic material undergoes during shot peening. Shot also developed – providing a quantitative tool to analyse maintenance decisions.
peening experiments were conducted on material specimens while varying certain Recommendations to enhance the current maintenance system for the pumps were
shot peening parameters, such as shot size, shot velocity and standoff distance. tabled. In addition to pumps, these recommendations are seen to be applicable to
The experimental data provided stress profiles both on and beneath the target other critical assets in power generation and other industries.
material surface layers and aided model development. Of specific interest was the
magnitude of the maximum compressive residual stress developed just below the
material surface and depth of the compressive layer formed within the surface layers
of the target material.
Student Student
Nadeem Gamiet Mangolo Masenya
Email: nadeemgamiet@gmail.com Email: MasenyMn@eskom.co.za

Mark Newby Nigel Volk
Email: newbym@eskom.co.za Email: VolkNR@eskom.co.za
Academic supervisors Academic supervisor

Dr Thorsten Becker Prof Stephan Heyns
Email: tbecker@sun.ac.za Email: Stephan.Heyns@up.ac.za
88 EPPEI 2015-2016 Programme EPPEI 2014-2015

2015-2016 Programme 89
Optimum refurbishment scheduling Evaluation of the performance
of LP fossil fuelled steam turbines characteristics of a hybrid (dry/wet)
using risk and forensics considerations induced draft dephlegmator
This aim of this research project was to address an alternative approach to time based A novel induced draft Hybrid (Dry/Wet) Dephlegmator (HDWD) was introduced
inspections for Low Pressure (LP) turbines. A decision model was created to assist in which can enhance the performance of dry Air-Cooled Condenser (ACC) systems and
making improved decisions regarding the refurbishment and/or replacement of critical a model was developed to simulate its performance. A dephlegmator is responsible
components of LP turbines. The research thesis explicates a methodology that has to concentrate and remove all the non-condensables in the ACC. The HDWD can
been developed and successfully evaluated, using risk management principles as well either be retrofitted to existing ACCs or designed into new ACCs. It consists of two
as documented root cause analysis results. The root causes were used to determine stages of cooling with the steam flow in series and the air flow in parallel through both
the parameters that should be monitored for the estimation of the likelihood of the stages. The first stage consists of downwardly inclined finned tube bundles, similar to
risk. A verification of the suggested approach has been performed in relation to past conventional air-cooled condenser bundles, and the second stage comprises horizontal
forensic results. bare tube bundles of which the outer surface can be selectively operated dry or wet
by spraying it with deluge water. A comparison of the HDWD with other existing and
new concepts revealed the significant advantages that this technology has over other
technologies.
Student Student
MJ Möller Neil Anderson
Email: mollejm@eskom.co.za Email: andersnr@eskom.co.za

Nigel Volk Dr Francois du Preez
Email: VolkNR@eskom.co.za Email: dpreezaf@eskom.co.za
Prof J Coetzee
Prof Hanno Reuter
Email: jasper.coetzee@m-tech.co.za
Email: hreuter@sun.ac.za

Scenario modelling for short to Simulating the effect of wind on
long term rollout of concentrating the performance of axial flow fans
solar power in South Africa in air-cooled condenser systems
The study investigated potential benefits of introducing Concentrating Solar Power The performance of Air-Cooled Condensers (ACCs) is highly dependent on
(CSP) into the South African electricity generating system. Power production for 2030 prevailing wind conditions. Research has shown that the presence of wind reduces
and 2050 was modelled for three scenarios from the 2013 draft IRP update. Spatio- the performance of ACCs. It has been found that cross-winds (wind perpendicular to
temporal modelling was used to model renewable energy plants and the balance of the longest side of the ACC) cause distorted inlet flow conditions, particularly at the
the generating system was modelled using a behavioural model. upstream peripheral fans. These conditions are characterised by flow separation on
the upstream edge of the fan inlets. Experimental investigations have simulated these
It was found that remuneration structure had a significant impact on CSP plant conditions by varying the fan platform height. Low platform heights resulted in higher
configuration and output. Utilizing CSP plants optimized for a rigid two tier tariff had a levels of inlet flow distortion, as also found to exist with high cross-wind speeds. This
negative impact on system adequacy measures in systems with high renewable energy investigation determined the performance of various fan configurations subjected to
uptake. The results were reasonable for a system with moderate uptake in renewable distorted inlet flow conditions through experimental and numerical investigations. The
energy and good for a system with low uptake. Results for the two higher uptake similarity between platform height and cross-wind effects were investigated and a
scenarios were improved significantly by using CSP plants optimized for base load correlation between system volumetric effectiveness, platform height and cross-wind
that were responsive to system needs. This may indicate that the higher the uptake of velocity was presented.
renewable energy is, the more flexible the electricity output of CSP plant will have to
be for optimal overall system performance.
Student Student
Christina Auret Neil Fourie
Email: auretc@eskom.co.za Email: FourieNe@eskom.co.za

Saneshan Govender Dr Johannes Pretorius
Email: GovendS@eskom.co.za Email: jp.pretorius@eskom.co.za

Paul Gauché Dr Johan van der Spuy
Email: paulgauche@sun.ac.za Email: sjvdspuy@sun.ac.za
Prof Frank Dinter
Email: frankdinter@sun.ac.za

Heliostat field layout optimisation Performance enhancements of
for a central receiver evaporative cooling towers

Eskom intends building a 100MW central receiver plant in the Upington area in South Some of the cooling towers at Eskom’s power stations employ asbestos as packing
Africa. This has been identified as an ideal location for the development of central inside the towers. This packing material must be replaced in the near future due to
receiver power plants due to the excellent solar resource that it receives. The long environmental legislation. Improvements in the packing and additional performance
term average solar resource in the area is estimated at 2816 kWh/m2. enhancement methods used in evaporative cooling towers can potentially result in
enhanced cooling tower and power station performance, which may benefit Eskom in
The inclusion of thermal energy storage increases the capacity factor of the given terms of turbine power output or cost savings. Additional performance enhancement
plant which results in a decrease in the Levelised Electricity Cost (LEC). Identifying the methods investigated included combining conventional film packing with a new
optimum storage capacity for a 100MW central receiver plant located in Upington to design type splash grid that reduces the rain zone droplet size resulting in increased
obtain the lowest LEC is the objective of this research. performance of the cooling tower.
Student Student
Shanley Lutchman Alain Michaels
Email: lutchmsh@eskom.co.za Email: Michaeaj@eskom.co.za

Dr Joe Roy-Aikins Dr Francois du Preez
Email: AikinsJ@eskom.co.za Email: dpreezaf@eskom.co.za

Paul Gauche Prof Hanno Reuter
Email: paulgauche@sun.ac.za Email: hreuter@sun.ac.za

Liquid extraction from air cooled
condenser steam ducts
Summary of completed project

Matimba Power Station experiences erosion of its Air-Cooled Condenser (ACC)
bundle tubes, as stated in an ACC degradation report by Eskom. This erosion is
caused by water droplets (wet steam) travelling at high velocities. Impurities due
to demineralization system failures and corroded metal are carried by these water
droplets to ACC bundles. Impurities lower the pH of the water droplets, promoting
corrosion. If the impurities could be reduced through water/steam separation, the
erosion of the ACC bundles would be reduced. An aerodynamic water/steam
separator reduces the pressure loss caused by the separator and the best location
for liquid extraction is in the ducting. To design a separator certain sensitivities like
separator shape and sensitivities of the shape itself. Different models were used for
different droplet sizes and these models were investigated in this study and identified
for the conditions in the power station. An airfoil shape placed on one of the vanes in
the bend of the ducting was found to be the best solution.
Student
Japie van der Westhuizen
Email: vdwastj@eskom.co.za
Industrial mentor
Dr Johannes Pretorius
Email: jppretorius@eskom.co.za
Academic supervisor
Dr Jaap Hoffman
Email: hoffmaj@eskom.co.za

12. Publication list
2014
Energy Efficiency Combustion Engineering

Conference presentations and proceedings: Conference presentations and proceedings:
By Eskom EPPEI students By Eskom EPPEI students

1. P. Gosai, A. Malan and J. Pretorius: Cooling system augmentation to enable power plants to meet 1. H. Archary, L. Jestin and W. Schmitz: Condition monitoring of pulverised fuel vertical spindle mills,
peak demand in adverse atmospheric conditions. Proceedings – POWER-GEN Africa Conference Proceedings – 12th International Conference on Boiler Technology, 21 - 24 October 2014, Szczyrk,
2014, 17-19 March 2014, Cape Town, South Africa. Poland.
2. P.L.D. Meyburgh, G. Vicatos and W. van der Westhuizen: Variable Speed Pumping. Proceedings - 2. A. Maharaj, W. Schmitz and R Naidoo: A numerical study of air preheater leakage, Proceedings –
EEC2014 ESTEQ Engineering Conference, 16 October 2014, Pretoria, South Africa. 12th International Conference on Boiler Technology, 21 - 24 October 2014, Szczyrk, Poland.
3. R. Neerputh and W.F. Fuls: Evaluation of various pressure drop correlations to develop accurate 3. C. Ramsunkar and W. Schmitz: Excess air measurement, control and optimisation, Proceedings –
steam turbine models, Proceedings - 2014 SAIMechE Conference on Mechanical, Manufacturing 12th International Conference on Boiler Technology, 21 - 24 October 2014, Szczyrk, Poland.
and Materials Engineering, 6 November 2014, Stellenbosch, South Africa. 4. S. Peta, C. du Toit, R. Naidoo, L. Jestin and W. Schmitz: Studies of firing system drawbacks at a South
4. R. Mutshinya and W.F. Fuls: Vibration effects on cylindrical yaw probe velocity measurements, African power plant, Proceedings – 12th International Conference on Boiler Technology, 21 - 24
Proceedings - 2014 SAIMechE Conference on Mechanical, Manufacturing and Materials Engineering, October 2014, Szczyrk, Poland.
6 November 2014, Stellenbosch, South Africa.
By Non-Eskom EPPEI Students Emissions Control

1. R. Banda and W.F. Fuls: Analytical Model of a Spray-Tray Type De-Aerator, Proceedings - 2014
SAIMechE Conference on Mechanical, Manufacturing and Materials Engineering, 6 November Conference presentations and proceedings:
2014, Stellenbosch, South Africa.
By Non-Eskom EPPEI Students
By teaching staff 1. I.J. Pretorius, S.J. Piketh, R.P. Burger and H.W.J.P. Neomagus: A global perspective of South African
1. W.F. Fuls and P.G. Rousseau: Progress on the Development of a High Fidelity Transient Boiler Model power plant emissions, Proceedings - 12th International Conference on Boiler Technology, 21 – 24
Using a 1D Thermal-Hydraulic Network Solver. Proceedings – ICBT2014 – 12th International October 2014, Szczyrk, Poland.
Conference on Boiler Technology, 21–24 October 2014, Szczyrk, Poland. 2. I.J. Pretorius, S.J. Piketh, R.P. Burger and H.W.J.P. Neomagus: South African coal fired power station
emissions: the past, the present and the future, Proceedings - Annual NACA Conference, 8 - 10
October 2014, Umhlanga, South Africa. ISBN: 978-0-620-63065-8.
3. K. Bosman, S.J. Piketh and R.P. Burger: Modelling emissions from domestic burning in low income
settlements using AERMOD, Annual NACA Conference, 8 - 10 October 2014, Umhlanga, South
Africa. ISBN: 978-0-620-63065-8.
4. Pretorius, S.J. Piketh, R.P. Burger and H.W.J.P. Neomagus: A global perspective of South African power
plant emissions, Proceedings - 13th Quadrennial iCACGP Symposium and the 13th Quadrennial
IGAC Science Conference on Atmospheric Chemistry, 22 – 26 September 2014, Brazil, Natal.
98 EPPEI 2015-2016 Programme 2015-2016 Programme

EPPEI 2014-2015 99
Publication list
2014 continued...
5. W.M. Walton, S.J. Piketh, P. Formenti, G. Mkhatswa and W. Maenhaut: Aerosol source apportionment 2. L. Koech, R.C. Everson, H. W.J.P. Neomagus and H. Rutto: Dissolution kinetics of sorbents and effect of
in South Africa, Poster presentation, Proceedings - 13th Quadrennial iCACGP Symposium and the additives in wet flue gas desulfurization, Rev Chem Eng 30(6), pp.553–565, (2014).
13th Quadrennial IGAC Science Conference on Atmospheric Chemistry, 22 – 26 September 2014, 3. L. Koech, R. Everson, H.W.J.P. Neomagus and H. Rutto: Dissolution kinetics of South African coal fly ash
Brazil, Natal. and the development of a semi empirical model to predict dissolution, accepted by Chemical Industry
& Chemical Engineering Quarterly DOI:10.2298/CICEQ140423032K
By teaching staff
1. S.P. Hersey, R.P. Burger and S.J. Piketh: A comparison of column aerosol properties between satellite By teaching staff
platforms and ground-based sun photometers in Gauteng and the industrial Highveld. Proceedings 1. S.P. Hersey, R.M. Garland, E. Crosbie,T. Shingler, A. Sorooshian, S.J. Piketh and R.P. Burger: An overview
- annual NACA Conference, 8 - 10 October 2014, Umhlanga, South Africa, ISBN: 978-0-620-63065-8. of regional and local characteristics of aerosols in South Africa using satellite, ground, and modeling data,
2. D. Njapha, R.C. Everson, H.W.J.P Neomagus, D.J. Branken, R.P. Burger, S.J. Piketh and J.R. Bunt: Flue Atmo. Chem. Phys. Discuss, 14, pp.24701-24752, (2014).
gas emissions on coal fired plants: A comparison study between South Africa, India, EU, China and 2. N.V. Balashov, A.M.Thompson, S.J. Piketh, and K.E. Langerman: Surface ozone variability and trends over
the US. Proceedings - annual NACA Conference, 8 - 10 October 2014, Umhlanga, South Africa, the South Africa Highveld from 1990 to 2007, J. Geophys. Res. Atmos., 119 doi 10.1002/2013JD020555,
ISBN: 978-0-620-63065-8. (2014).
3. S.J. Piketh, R.P. Burger and C. Paauw: A framework for co-operation agreements through offsetting
ambient air quality. Proceedings - annual NACA Conference, 8 - 10 October 2014, Umhlanga,
South Africa, ISBN: 978-0-620-63064-1. Material Science
4. S.J. Piketh, R.P. Burger, C. Grove and C. Paauw: The temporal profile of solid fuel, indoor temperature
and personal exposure to air pollution in a Highveld township. Proceedings - annual NACA Conference presentations and proceedings:
Conference, 8 - 10 October 2014, Umhlanga, South Africa, ISBN: 978-0-620-63064-1.
5. R.P. Burger and S.J. Piketh: In-situ characterization of air quality over South Africa. Proceedings - By Eskom EPPEI students
13th Quadrennial iCACGP Symposium and the 13th Quadrennial IGAC Science Conference on 1. G. Deysel and J.E. Westraadt: Three-dimensional visualisation if precipitates in a 12% Cr steel.
Atmospheric Chemistry, 22 - 26 September 2014, Natal, Brazil. Proceedings – Microscopy Society of Southern Africa 2014, 3-5 December 2014, Stellenbosch,
6. S.J. Piketh, R.P. Burger, and C. Paauw: Ambient air pollution and emissions measurements from South Africa, Volume 44, Page 76.
domestic solid fuel (coal) combustion in Mpumalanga, South Africa. Proceedings - 13th Quadrennial 2. R.P. Matthews, B. Sonderegger and J.E. Westraadt: Investigating stress corrosion crack initiation of
iCACGP Symposium and the 13th Quadrennial IGAC Science Conference on Atmospheric austenitic steel in the nuclear reactor environment. Proceedings – Microscopy Society of Southern
Chemistry, 22 – 26 September 2014, Natal, Brazil. Africa 2014, 3-5 December 2014, Stellenbosch, South Africa, Volume 44, Page 78.
3. N. Seumangal, B. Sonderegger and W.E. Goosen: The influence of heat treatment procedure
Journal publications: on stress corrosion cracking properties of FV566 stainless steel low pressure turbine blades,
Proceedings – Microscopy Society of Southern Africa 2014, 3-5 December 2014, Stellenbosch,
By Non-Eskom EPPEI Students South Africa, Volume 44, Page 79.
1. L. Koech, H. Rutto, R.C. Everson and H.W.J.P. Neomagus: Semi-empirical model for limestone 4. O. Tshamano and B. Sonderegger: Small punch testing for embrittlement evaluation of power
dissolution in adipic acid for wet flue gas desulfurization, Chemical Engineering Technology, 37(11), plant material, Proceedings - SAIMechE – Mechanical, Manufacturing and Materials Engineering
pp.1919–1928, (2014). Conference, 6 November 2014, Stellenbosch, South Africa.

Publication list
2014 continued...
5. T. Rasaiwan and B. Sonderegger: Creep testing of martensitic steel X20CrMoV12-1, , Proceedings - Poster presentations at conferences:
SAIMechE – Mechanical, Manufacturing and Materials Engineering Conference, 6 November 2014, 1. G. Deyzel, J.E. Westraadt, B. Sonderegger and T.J. Molokwane: Measuring M23C6 precipitate
Stellenbosch, South Africa. parameters in a 12% Cr steel. Poster Presentation - Annual Conference of the Nordic Microscopy
6. R. Matthews and B. Sonderegger: Intergranular oxidation: a precursor to primary water stress Society, SCANDEM, 11 June 2014, Linköping, Sweden.
corrosion cracking, Proceedings - SAIMechE – Mechanical, Manufacturing and Materials Engineering
Conference, 6 November 2014, Stellenbosch, South Africa. Journal publications:
7. L. Naicker and B. Sonderegger: The influence of heat treatment on the stress corrosion cracking
properties of low pressure turbine blade steel FV520B, Proceedings - SAIMechE – Mechanical, By teaching staff
Manufacturing and Materials Engineering Conference, 6 November 2014, Stellenbosch, South 1. M.R. Ahmadi, E. Povoden-Karadeniz , B. Sonderegger, K. I. Öksüzc, A. Falahaticand and E. Kozeschnik:
Africa. A model for coherency strengthening of large precipitates. Scripta Materialia 84-85 (2014) 47-50.
8. T.J. Molokwane, B. Sonderegger, R. D. Knutsen, J. E. Westraadt, M. Bezuidenhout and P. Doubell: 2. M. R. Ahmadi, B. Sonderegger, E. Povoden-Karadeniz, A. Falahati and E. Kozeschnik: Precipitate
Microstructural and property assessment of creep aged 12Cr steel after welding, Proceedings – strengthening of non-spherical precipitates extended in <100> or {100} direction in fcc crystals.
ECCC - Creep & Fracture Conference 2014, 5-7 May 2014, Rome, Italy. Materials Science and Engineering A 590 (2014) 262-266.
9. P.T. van der Meer, M. Bezuidenhout, R. Knutsen, B. Sonderegger and J.E. Westraadt: Effect of geometry
on the microstructural ageing of a 1CrMoNiV turbine rotor steel, Proceedings – ECCC - Creep & Asset Management
Fracture Conference 2014, 5-7 May 2014, Rome, Italy.
Conference presentations and proceedings:
By Non-Eskom EPPEI Students
1. M. Stracey and B. Sonderegger: Modelling of dislocation creep in 9-12% Cr steels, Proceedings - By Eskom EPPEI students
SAIMechE – Mechanical, Manufacturing and Materials Engineering Conference, 6 November 2014, 1. R. Scheepers, P.S. Heyns and M. Newby: Finite element modelling of bladed rotor torsional dynamics.
Stellenbosch, South Africa. Proceedings - Condition Monitoring 2014, 10-12 June 2014, Manchester, U.K.
2. R. Weyer and B. Sonderegger: Modelling of damage due to diffusional creep in 9-12% Chromium
steels, Proceedings - SAIMechE – Mechanical, Manufacturing and Materials Engineering Conference, By Non-Eskom EPPEI students
6 November 2014, Stellenbosch, South Africa. 1. E. Asaadi, S. Kok and P.S. Heyns: Using inverse mapping to directly solve inverse problems. Proceedings
3. J. Ghighi and B. Sonderegger: Developing a constitutive model for the creep behaviour and - Fourth International Conference on Engineering Optimization, 8-11 September 2014, Lisbon, Portugal.
microstructural evolution of 9-12% Cr steels, Proceedings - SAIMechE – Mechanical, Manufacturing 2. D.H. Diamond, P.S. Heyns and A.J. Oberholster: A comparison between three blade tip timing
and Materials Engineering Conference, 6 November 2014, Stellenbosch, South Africa. algorithms for estimating synchronous turbomachine blade vibration. Proceedings – WCEAM, 28-
31 October 2014, Pretoria, South Africa.
By teaching staff
1. S. D. Yadav, J. Rosc, B. Santory, R. Brunner, B. Sonderegger, C. Sommitsch, C. Poletti: Investigation of By teaching staff
pre-existing pores in creep loaded 9Cr steel. 2nd International Congress on 3D Materials Science 1. E. Asaadi, S. Kok and P.S. Heyns: A point-by-point inverse approach to identify stress-strain curves
2014, 29.6.-2.7.2014, Annecy, France. of materials. Proceedings - Ninth South African Conference on Computational and Applied
Mechanics, SACAM, 14-16 January 2014, Somerset-West, South Africa.

Publication list
2014 continued...
2. S.A. Aye, P.S. Heyns and C.J.H.Thiart: Health diagnostics of slow rotating bearings based on Gaussian HVAC
process regression. Proceedings - Ninth South African Conference on Computational and Applied
Mechanics, SACAM, 14-16 January 2014, Somerset-West, South Africa. Conference presentations and proceedings:
3. A.J. Oberholster, P.S. Heyns, M. Newby and H. Goldshagg: Damage detection of an air cooled
condenser fan gearbox. Proceedings - Condition Monitoring 2014, 10-12 June 2014, Manchester, By Eskom EPPEI students
United Kingdom. 1. S. Mvuyana, J. van Coller and T. Modisane: Identification of power system oscillation paths in power
4. A.J. Oberholster and P.S. Heyns: A study of radial-flow turbomachinery blade vibration measurements system networks. Proceedings - 22nd Southern African Universities Power Engineering Conference,
using Eulerian Laser Doppler Vibrometery. Proceedings – Eleventh Conference on Vibration 30-31 January 2014, Durban, South Africa.
Measurements by Laser and Non-Contact Techniques: Advances and Applications, AIVELA, 25-27 2. M. Makhetha, J. van Coller and M. Manyage: Assessment of the harmonic environment of a power
June 2014, Ancona, Italy. station’s MV auxiliary power system. Proceedings - 22nd Southern African Universities Power
Engineering Conference, 30-31 January 2014, Durban, South Africa.
Journal publications: 3. G. Lebese, G. Sikhakhane, Y. Lekalakala and J. van Coller: Tan-delta testing of MV motor stator coil
insulation. Proceedings - 22nd Southern African Universities Power Engineering Conference, 30-31
By Eskom EPPEI students January 2014, Durban, South Africa.
1. C. Booysen, P.S. Heyns, R. Scheepers and M. Hindley: Fatigue life assessment of a low pressure steam 4. Y. Lekalakala, J. van Coller: The effect of stress grading length on tan-delta and capacitance
turbine blade during transient resonant conditions using a probabilistic approach. International Journal measurements on MV motor coils. Proceedings - 22nd Southern African Universities Power
of Fatigue. Appeared online: 29 November 2014. http://dx.doi.org/10.1016/j.ijfatigue.2014.11.007 Engineering Conference, 30-31 January 2014, Durban, South Africa.
5. T. Mashau, D. Tarrant, J. van Coller: Simulating surge propagation in a rotor coil for rotor shorted
By teaching staff turn detection. Proceedings - 22nd Southern African Universities Power Engineering Conference,
1. T. Heyns, S.J. Godsill, J.P. de Villiers and P.S. Heyns: Statistical gear health analysis which is robust to 30-31 January 2014, Durban, South Africa.
fluctuating loads and operating speeds. Mechanical Systems and Signal Processing,Vol. 27, pp.651-666 6. F. Netshiongolwe, R. Cormack, J. van Coller: Development of alternative electrical stress monitoring
(2012). transducers for application to MV/LV distribution transformers. Proceedings - 22nd Southern
2. K.S. Wang, D. Guo and P.S. Heyns: The application of order tracking for vibration analysis of a varying African Universities Power Engineering Conference, 30-31 January 2014, Durban, South Africa.
speed rotor with a propagating transverse crack. Engineering Failure Analysis, Vol. 21, pp.91-101,
(2012).
3. T. Heyns, P.S. Heyns and J.P. de Villiers: Combining synchronous averaging with Gaussian mixture model HVDC
novelty detection scheme for vibration-based condition monitoring of a gearbox. Mechanical Systems
and Signal Processing, Vol.32, pp.200-215, (2012). Conference presentations and proceedings:
4. T. Heyns, P.S. Heyns and R. Zimroz: Combining discrepancy analysis with sensorless signal resampling
for condition monitoring of rotating machines under fluctuating operations. International Journal of By Eskom EPPEI students
Condition Monitoring, Vol.2. no.2, pp.1-7, (2012). 1. M. F. Khan, A. L. L. Jarvis, E. A. Young and R. G. Stephen: Comparison of Superconducting Fault
Current Limiters against Traditionally Employed Practices in the Management of Fault Levels in
the South African National Grid. Proceedings - Applied Superconductivity Conference, 11 August
2014, Charlotte, NC, USA, ASC2014-1LOr3B-061.

Publication list
2014 continued...
By Non-Eskom EPPEI students By teaching staff

1. S.T.J. Mwale and I.E. Davidson: SADC Power Grid Reliability - A Steady-state Contingency Analysis 1. I.E. Davidson, H Muashekele and N. Mukapuli: Benguela Community-UNAM Wind-Power Demonstration
and Strategic HVDC Interconnections Using the N-1 Criterion. Proceedings - 2nd International Project – Experiences in Implementation. Journal of Energy and Power Engineering 8, pp.1067-1072,
Symposium on Energy Challenges and Mechanics, 19-21 August 2014, Scotland, United Kingdom. (2014).
2. S.T.J. Mwale and I.E. Davidson: Power deficits and outage planning in South Africa. Proceedings - 2. G.P. Adam and I.E. Davidson: Robust and Generic Control of Full-Bridge Modular Multilevel Converter
2nd International Symposium on Energy Challenges and Mechanics, 19-21 August 2014, Scotland, High-Voltage DC Transmission Systems. IEEE Transactions on Power Delivery, (2014).
United Kingdom.
3. A.M Nyete, T.J.O. Afullo, and I.E. Davidson: Performance Evaluation of an OFDM-based BPSK PLC
System in an Impulsive Noise Environment. Proceedings - 35th Progress in Electromagnetics Renewable Energy
Research Symposium (PIERS), 25-28 August 2014, Guangzhou, China.
4. A.M Nyete,T.J.O. Afullo, and I.E. Davidson: On Rayleigh Approximation of the Multipath PLC Channel: Conference presentations and proceedings:
Broadband through the PLC Channel. Proceedings - 2014 Southern Africa Telecommunication
Networks and Applications Conference (SATNAC), 31 August - 3 September 2014, Port Elizabeth, By Eskom EPPEI Students
South Africa. 1. C. Auret: Replacing intermittent renewable capacity in the 2010 IRP with CSP - Effect on coal-fired
power station capacity factors in 2030, Proceedings – South African Solar Energy Conference, 27-
By teaching staff 29 January 2014, Port Elizabeth, South Africa.
1. A.C. Britten: The Scope of EPPEI-Sponsored Research into HVDC at UKZN: A Personal View. 2. S. Lutchman: On selecting a method for heliostat field layout optimization, Proceedings - South
Proceedings - 22nd South African Universities Power Engineering Conference, 30 - 31 January African Solar Energy Conference, 27-29 January 2014, Port Elizabeth, South Africa.
2014, Durban, South Africa. 3. K. Madaly, J. Hoffmann and G. de Klerk: Identifying the optimum storage capacity for a 100MW CSP
2. I.E. Davidson and N.K. Mbaimbai: Modelling and Analysis of a CSP Plant Technology for Small Power plant in South Africa, Proceedings - South African Solar Energy Conference, 27-29 January 2014,
Networks -Technical and Financial Evaluation. Proceedings - 4th Solar Integration Workshop, Port Elizabeth, South Africa.
International Workshop on Integration of Solar Power into Power Systems, 10 – 11 November 4. J. van der Westhuizen, J. Hoffman: Investigation of heat transfer and temperatures profiles at inlets
2014, Berlin, Germany, pp. 438 - 444. and undeveloped flow regions using Liquid Crystal Thermography, Proceedings - South African
3. I.E. Davidson and N.K. Amaambo: Comparative Analysis of Wind Turbine Technologies for Harsh Solar Energy Conference, 27-29 January 2014, Port Elizabeth, South Africa.
Environments. Proceedings - 13th International Workshop on Large-Scale Integration of Wind 5. J. Nye, J. Beukes, M. Bello: Reactive Power Control of Embedded Generation on Radial Distribution
Power into Power Systems as well as on Transmission Networks for Offshore Wind Power Plants, Networks, Proceedings - POWER-GEN Africa, 17-19 March 2014, Cape Town, South Africa.
11 – 13 November 2014, Berlin, Germany, pp. 810 - 816. 6. J. Nye, J. Beukes, M. Bello: Local Reactive Power Droop Control Modification for Distributed
Generators, Proceedings - IEEE PES Transmission and Distribution Conference, 14-17 April 2014,
Journal publications: Chicago, U.S.A.
7. J. Nye, J. Beukes, M. Bello: Generation increase on distribution feeders using electronic voltage
By Non-Eskom EPPEI Students regulators, Proceedings - IEEE PES Transmission and Distribution Conference, 14-17 April 2014,
1. K.N.I. Mbangula and I.E. Davidson: Power System Modelling and Fault Analysis of NAMPOWER’S 330KV Chicago, U.S.A.
HVAC Transmission Line. Journal of Energy and Power Engineering 8, pp.1432-1442, (2014). 8. A. Michaels, H. Reuter: Experimental investigating of the effect of a new splash grid on cooling
tower performance characteristics, Proceedings - International Conference on Industrial Chimneys
and Cooling Towers, 8-11 October 2014, Prague, Czech Republic.

Publication list EPPEI Junior Enterprise 13.
2014 continued...
By Non-Eskom EPPEI Students The EPPEI Junior Enterprise (JE) continues to provide leadership amongst the students and remains one
1. C. Silinga: The South African REIPPPP two-tier CSP tariff: Implications for a proposed hybrid CSP of the key contributors to the sustainability and future development of the EPPEI.
peaking system. Proceedings – SolarPACES2014, Bejing, China.
Together with the EPPEI Management, the EPPEI JE contributed to a successful Eskom Power Plant
By teaching staff Engineering Institute (EPPEI) Student Conference. This was the first of its kind. The conference was
1. F. Dinter: Operation experience of a 50MW Solar Thermal Parabolic Trough Plant in Spain. held in Midrand on 4 and 5 May 2014 and had attendance from various EPPEI faculty, students and
Proceedings - SASEC 2014, Port Elizabeth, South Africa. Eskom personnel. Furthermore, the members of the Junior Enterprise have yet another opportunity
to contribute towards hosting the second conference that will take place on 8 to 9 June 2015 at the
Journal publications: Eskom Academy of Learning in Midrand, Gauteng.
By Non-Eskom EPPEI Students The Junior Enterprise members, together with fellow students from the Energy Efficiency, Renewables
1. M. Owen and D.G. Kröger: Contributors to increased fan inlet temperature at an air-cooled steam and Material Science Specialisation Centres, raised the EPPEI flag high during the PowerGen Africa
condenser. Applied Thermal Engineering, Vol. 50, pp.1149-1156, (2013). Conference. The conference was held in Cape Town on 17-19 March 2014 and served as a great
2. W. Pierce, P. Gauché, T.W. von Backström, A. Brent and A. Tadros: A comparison of solar aided opportunity to assist the EPPEI management in marketing EPPEI and establishing new contacts for
power generation (SAPG) and stand-alone concentrating solar power (CSP): A South African case study. possible collaborations. In addition, the EPPEI Junior enterprise have thus far contributed to the
Applied Thermal Engineering, Vol. 61, pp.657-662, (2013). publication of two EPPEI Programme Annual Booklets and for the first time, the EPPEI Strategic Plan
3. L. Heller and P. Gauché: Modeling of the rock bed thermal energy storage system of a combined cycle Booklet. These booklets were distributed during the POWER-GEN Africa Conference.
solar thermal power plant in South Africa. Solar Energy, Vol. 93, pp.345-356, (2013).
4. P. Gauché, T.W. von Backström and A.C. Brent: A concentrating solar power value proposition for South
Africa. Journal of Energy in Southern Africa, Vol. 24, no. 1, (2013).
5. J.P. Kotzé,T.W. von Backström and P.J. Erens: High Temperature Thermal Energy Storage Utilizing Metallic
Phase Change materials and Metallic Heat Transfer Fluids. Journal of Solar Energy Engineering, Vol.
135, Issue 3, (2013).
By teaching staff
1. P. Gauché, A.C. Brent and T.W. von Backström: Concentrating solar power: Improving electricity cost
and security of supply, and other economy benefits. Development Southern Africa Vol. 31 No.5,
pp.692-710, (2014).

EPPEI Junior Enterprise
continued...
With any great initiative, such as EPPEI, there is always room for improvement. Hence as the voice of the • Being actively involved in training and development activities. This includes encouraging EPPEI
students, the Junior Enterprise provided feedback from the students regarding the course curriculum students who have developed certain competencies to participate in facilitating courses within the
and logistics at the Eskom Academy of Learning in Midrand. These feedbacks have seen a notable EPPEI programme as well as to other Eskom employees.
improvement in the manner in which learning is now offered at Eskom Academy of Learning with • Engaging and fostering relationships with all other Eskom bursars, including those at undergraduate
regards to the EPPEI courses. level and those who have followed the further studies route.
• Identifying potential Non-Governmental Organisation (NGO) partners to which EPPEI can add
Furthermore, proper communication between the Junior Enterprise and the EPPEI Management was value and becoming actively involved in community activities.
also key to resolving pertinent teething problems that would have otherwise affected the performance • It is our goal to encourage every student within the EPPEI programme to play a role in creating
of students. a world class learning environment by sharing research, skills and finally competencies in any way
possible.
EPPEI Junior Enterprise (JE) strategic plan

The EPPEI Junior Enterprise (JE) was initially formed by the first intake of EPPEI students on the
recommendation of EPPEI management who identified the value of student leadership within the
Junior Enterprise committee
EPPEI framework.
With each intake of students, a student-elected EPPEI JE committee is formed, whose responsibility it is
to assist in driving the growth and development of the EPPEI programme by representing the student
experience and perspective. Each JE works closely with the previous and future intakes to ensure
continuity within the programme. The JE is committed to:
• Being ambassadors for EPPEI in any capacity needed. This also includes representing EPPEI at
workshops and conferences such as POWER-GEN Africa.
• Providing our full support to the EPPEI Management team in ensuring viable growth and progress
of the EPPEI programme.
• Ensuring sustainable relationships between students within the programme, managers and specialists
within Eskom and the specialisation centres at all the respective Universities. These relationships CEO Scientific Exec
will be strengthened by means of student conferences and obtaining regular updates from each Christine Schutte Mark Sklar-Chik
specialisation centre. Deputy CEO Operational Exec
• Supporting and strengthening the role of the EPPEI Alumni. This includes supporting alumni students Nicolas Cardenas Nkateko Khoza
to ensure that the skills they have acquired during their studies are adequately utilized within the
organization, but also to keep the alumni within the EPPEI framework to promote networking so
that a reputable EPPEI community and knowledge base is developed and maintained

14. Student conference
The Eskom Power Plant Engineering Institute held its first annual conference at the Eskom Academy of During the technical session, two technical keynote addresses were delivered by Prof. Hanno Reuter of
Learning in Midrand on 5 and 6 May 2014. At the inaugural conference, EPPEI students from the first Stellenbosch University and Dr Rob Stephen of Eskom. Prof. Reuter presented a lecture on the cooling
intake - who started their studies in January 2012 -presented the results of the research they conducted of power plants which is a challenge in South Africa because of the scarcity of water. Dr Stephen’s
during their academic study. address focused on smart grid development in Eskom.
The conference was attended by approximately 300 Eskom employees and academics from various A total of 39 papers were presented by EPPEI students over 6 sessions that concluded with an awards
universities across the country. Eskom Chief Learning Officer, Mrs Sylvia Mamorare, opened the event ceremony. The following students were awarded the best presentations in their sessions:
with a few words of introduction. Mr Collin Matjila, interim Chief Executive of Eskom, spoke of the
important work EPPEI can do in using the current large power plants and the power grid extension • Priyesh Gosai, “Cooling system augmentation to enable power plants to meet peak demand in
projects that Eskom is constructing to capture knowledge and develop engineering skills. Eskom adverse atmospheric conditions.”
Chairman, Mr Zola Tsotsi, spoke about the plan for EPPEI to continue for a further five years beyond its • Sandile Peta, “Devolatilization and ignition characteristics of South African coals.”
first mandate and to foster collaboration with Original Equipment Manufacturers (OEMs), international • Candice Stephen, “Implementation of De-Sox technologies in an Eskom context.”
utilities and universities. • Jonathan Nye, “Reactive power control of embedded generation in radial distribution networks.”
• Dawie Diamond, “A novel technique for estimating synchronous turbomachinery blade vibration
The Director General of the Ministry of Public Enterprises, Mr from blade tip timing data.”
Tshediso Matona, congratulated Eskom in its foresight in initiating • Kam Madaly, “Identifying the optimum storage capacity for a 100 MWe Concentrated Solar Power
the EPPEI programme to address the significant shortage of plant in South Africa.”
engineering skills South Africa has. Mr Matshela Koko, division • Yvonne Lekalakala,“The effect of the stress grading length on tan-delta and capacitance
executive of Group Technology, presented on the technical measurements on medium voltage motor coils.”
challenges that Eskom faces – specifically on the need for Eskom
to improve the operation and maintenance of its power stations. A special award was presented to Priyesh Gosai, CEO of the Junior Enterprise from intake 1, from EPPEI
management for his hard work and dedication to EPPEI and Eskom.
Four keynote addresses were also delivered over the two day
conference. Dr Boni Mehlomakulu, an Eskom board member and Director General of the
the CEO of the South African Bureau of Standards, spoke about Ministry of Public Enterprises,
the necessity for South Africa to increase its research output and Mr Tshediso Matona.
develop its own intellectual property.
From an academic perspective, Prof. Francis Petersen, dean of the faculty of Engineering and Built
Environment at the University of Cape Town, spoke of the need for South Africa to develop more
highly skilled engineers in the engineering and the built environment sectors. This challenge needs to be
addressed at both a secondary school level where mathematics and science results are poor and at a From left to right: Prof. Louis Jestin, Mr Matshela Koko, Mr Collin Matjila, Dr Boni Mehlomakulu,
tertiary level where universities need more postgraduate research in these areas. Mr Zola Tsotsi, Prof. Francis Petersen, Mrs Sylvia Mamorare and Mr Malcolm Fawkes

Student conference continued...
Conference proceedings Conference presentations

1. R. Matthews, B. Sonderegger: Initiation of stainless steel stress corrosion cracking in pressurised 1. A.J. Michaels, Prof H.C.R. Reuter, Dr. A.F du Preez: Experimental investigation of the effect of a new
water reactors. Proceedings SAIMechE – Mechanical, Manufacturing and Materials Engineering splash grid on cooling tower performance characteristics. Proceedings EPPEI Conference 2014, 5
Conference 2013, 7.11.2013, Cape Town, South Africa, 36-37. to 6 May 2014, Johannesburg, South Africa.
2. P. van der Meer, M. Bezuidenhout, R. Knutsen, B. Sonderegger, J. E. Westraadt: Effect of geometry 2. N. Fourie, S.J. van der Spuy,T.W. von Backström, J.P. Pretorius: Investigation into the effect of distorted
on the microstructural ageing of a 1CrMoNiV turbine rotor steel. ECCC – Creep & Fracture inlet flow conditions on the performance of axial flow fans in air-cooled steam condenser systems.
Conference 2014, 5.-7.5.2014, Rome, Italy, in press. Proceedings EPPEI Conference 2014, 5 to 6 May 2014, Johannesburg, South Africa.
3. J. Nye, J. Beukes, M. Bello: Local Reactive Power Droop Control Modification for Distributed 3. N.R. Anderson, Prof. H.C.R. Reuter, Dr. A.F. du Preez: Evaluation of the performance characteristics
Generators. Proceedings IEEE PES Transmission and Distribution Conference 2014, 14.04.2014, of a hybrid (dry/wet) induced draught dephlegmator. Proceedings EPPEI Conference 2014, 5 to 6
City of Chicago, 25. May 2014, Johannesburg, South Africa.
4. J. Nye, J. Beukes, M. Bello: Generation Increase on Distribution Feeders Using Electronic Voltage 4. J. Nye, J. Beukes, M. Bello: Reactive Power Control of Embedded Generation on Radial Distribution
Regulators. Proceedings IEEE PES Transmission and Distribution Conference 2014, 14.04.2014, City Networks. Proceedings Power-Gen Africa, 18.03.2014, Cape Town, South Africa.
of Chicago, 25.
5. K. Madaly, |J. Hoffmann, G. de Klerk: Identifying the optimum storage capacity for a 100-MWe
5. K. Madaly: Identifying the optimum storage capacity for a 100MW CSP plant in South Africa. Concentrating Solar Power plant in South Africa. Proceedings EPPEI Conference 2014, 5 to 6 May
Proceedings SASEC 2014, 27.01.2014, Port Elizabeth, South Africa, 32. 2014, Johannesburg, South Africa.
6. P.S.J. van Heerden, H.J. Vermeulen: Model-based Condition Monitoring of a Doubly-Fed Induction 6. J. Van der Westhuizen, J. Hoffman, J. Pretorius: Liquid extraction on air cooled condenser steam
Generator Slip Ring Component. Proceedings Power Engineering Conference 2013 (UPEC2013), ducts. Proceedings EPPEI Conference 2014, 5 to 6 May 2014, Johannesburg, South Africa.
2-5.11.2013, Dublin Institute of Technology, Ireland.
7. S.L. Lutchman, P. Gauche, J. Roy-Aitkins: Heliostat Field Layout Optimisation for a Central Receiver.
7. S.L. Lutchman: On selecting a method for heliostat field layout optimization. Proceedings SASEC Proceedings EPPEI Conference 2014, 5 to 6 May 2014, Johannesburg, South Africa.
2014, 27.01.2014, Port Elizabeth, South Africa.
8. C. Auret, P. Gauche, S. Govender: Replacing intermittent renewable capacity in the 2010 IRP with
8. S.L. Lutchman, A.A. Groenwold, P. Gauché, S-J. Bode: On using a gradient-based method for heliostat CSP: Effect on coal fired power station capacity factors in 2030. Proceedings EPPEI Conference
field optimisation. SolarPaces 2013, 17-20 September, Las Vegas, Nevada, USA. 2014, 5 to 6 May 2014, Johannesburg, South Africa.
9. C. Auret: Replacing intermittent renewable capacity in the 2010 IRP with CSP - Effect on coal fired
power station capacity factors in 2030. Proceedings SASEC 2014, 28.01.2014, Port Elizabeth, South
Africa, 61.

15. Appendices
Appendix 1 EAL course Information
Applied courses Material Science (3 days)

The course provides an overview of the factors which govern the mechanical behaviour of engineering
Overview of the Power Generation Industry (3 days)
materials, with particular emphasis on alloys for components in power plants. These factors include
The purpose of this course is to give learners an understanding of the power generation industry. material composition, microstructure and service environmental parameters. The lectures include:
The economics and efficiencies of the different generation technologies, including both traditional
• Overview of the classification of engineering materials and ferrous alloys
(such as coal-fired and nuclear) and renewables (such as wind and solar) will be taught. They will also
• Tensile testing and the stress-strain curve, elastic and plastic behavior
be introduced to the planning and economics of the transmission and distribution segments of the
• Microstructure and mechanical behaviour
electrical utility industry including the different national plans. This training aims to equip learners with a
• Phase transformations of steel and heat treatments
more holistic view of the power generation industry and how it has evolved.
• Materials under stress: fracture, fatigue and creep
Fundamentals of Engineering Mathematics (3 days)
Microsoft Excel VB Programming (1 day)
The purpose of the course is to highlight and reinforce some of the common areas in engineering
The purpose of the course is to introduce learners to the use of functions in Microsoft Excel and the
mathematics typically covered in an undergraduate engineering curriculum. Highlighted areas include:
creation of user-defined functions and sub-routines in the VBA environment. This training aims to allow
linear algebra, functions, calculus, differentiation, integration and ordinary differential equations.
engineers to use Microsoft Excel to build numerical models of plant and equipment.
The course is structured around the electronic textbook: “Essential Engineering Mathematics” by
M Batty. Al students must have access to the textbook.The course serves as a refresher and is intended
Statistical Science in Electrical Energy (2 days)
to provide a common mathematics basis for other courses in the EPPEI programme.
The intention of this course is to provide an overview of statistical sciences as applied to the electrical
Life Cycle Management (2 days) energy industry. The attendees would learn some descriptive methodologies on how to extract
information from data.The emphasis, for this part of the course, being able to describe the behaviour of
This course introduces the basic principles of the physical asset management process in a life cycle
data by some statistical model(s). Some emphasis is also placed on the relationships between variables
context. This includes an introduction of maintenance management fundamentals, management of
(e.g. how does the water consumption relate to the energy produced by a thermalpower station).
equipment reliability, and optimising maintenance decisions. It focuses on condition based maintenance
as a part of the maintenance decision process. The course is broadly structured around the textbook:
Thermo Physics (2 days):
“Asset Management Excellence” second edition, by Cambell J.D., Jardine A.K.S. and McGlynn J.The Eskom
library is expected to have a number of copies of this book available for students to consult during The purpose of this course is to apply key thermodynamic concepts from the basic thermodynamics
their preparations. course. The main focus will be on the water-steam Rankine cycle. A step-by-step approach will
be taken throughout this course, starting from a basic open loop to a more efficient closed loop
Electric and Magnetic Systems (3 days) Rankine cycle as used by the power generation industry. Thermal performance of cycle components
such as pumps, turbines, steam generators, condensers, contact and non-contact feed water heaters,
This course gives a basic technical understanding of the operation of typical power system apparatus
etc. are evaluated and integrated into the Rankine cycle. The T-S diagram will be introduced onto
including transformers, rotating machines, and transmission lines. The course aims to provide learners
which the cycle can be potted to give better perspective into abnormal conditions as well as to
with the fundamental knowledge of the apparatus and equivalent circuit representations, an essential
predict the impact of modifications. The purpose of this course is not an in-depth investigation
tool in an engineer’s toolbox. The course also aims to provide learners with the practical aspects and
into the field of thermodynamics, but simply to use its basic principles as a starting point for more
uses of the apparatus.
detailed investigations.

Appendix 1
EAL course Information continued...
Power Plant Chemistry (2 days) Auto Controls

The course teaches a basic understanding on water treatment and basic chemistry. The learner will The training in this course will equip the learner with knowledge and understanding in order to:
understand water treatment as the production of demineralised water, control of water and steam
• explain automatic control systems in general (at a high level),
cycle chemistry, oxygenated treatment, flow accelerated corrosion, air in-leakage, condenser tube leaks,
• expand their knowledge of the organisation by including the importance of understanding
boiler deposits and chemical cleaning, steam deposits, turbine preservation. In basic chemistry, learners
automatic controls,
will learn the fundamentals of phase diagrams, states, element classification, chemical mass and electrical
• identify error likely situations, instability and flawed defences,
balances, chemical reactions and kinetics, homogeneous and heterogeneous combustion, pollutant
• manage error likely situations, instability and flawed defences,
emission reactions (CO, CO2, SOx, NOx, VOC, PAH, heavy metals), water treatment basic chemistry
• utilise error prevention tools and techniques
and corrosion mechanisms.
Common Plant
Computer Aided Analysis (2 days)
After completing this course the learner will be able to explain the basic purposes and operating
The purpose of the course is to equip engineers with some general tools and techniques to perform
principles of the followingexplain automatic control systems in general (at a high level),
computer aided analysis. The use of two general analysis software will be taught, namely Excel and
Mathcad. The focus on Excel will be mostly in programming using the built-in Visual Basic environment, • hazardous locations, • fuel oil plant,
while the Mathcad part will provide the student with the necessary basics to become proficient in its • fire and life safety, • compressor plant,
use. These skills can be used in any engineering discipline for general calculations and analysis. • bulk materials handling (ash and coal) • auxiliary cooling.
• hydrogen plant,
Electrical Systems
Condensers and Feedheat
The learner will, after completing the course, be able to:
Upon completion of this course, the learner will:
• explain power station electrical systems in general,
• understand the basic theory and operation of generators in the power generation industry, • have a basic knowledge of condensers and feedheat in the context of Eskom power stations,
• recognise the role of protection in electrical systems and the role that generator breakers and • understand role of feedwater heaters,
switchgear play within protection schemes, • be able to describe the basic principles of power plant cooling.
• describe the application of transformers in power generation,
• understand the role of excitation systems on generators as well as the different types of excitation The South African Grid Code (SAGC)
systems used in Eskom,
• list the components that the internal station reticulation/unit reticulation consists of and the After completion, the learner will have a good understanding of the:
function of each component, • definition and legal framework of the SAGC, • information exchange code,
• clarify the critical role of emergency systems in power stations, • scope of SAGC, • network code,
• understand the importance of electrical motors within the power generation process. • preamble and governance codes, • (thermal and hydro) generation connection
• system operating code, conditions,
• tariff code, • renewable power plants connection conditions,
• metering code, • generation scheduling and dispatch rules.

Appendix 1
EAL course Information continued...
Power Plant Monitoring Project Management

The learner will have both theoretical knowledge and practical exposure after completing this course On completion of this course, students will have a good understanding of:
through:
• all the relevant techniques in project management,
• measuring techniques and instrumentation, • applying these techniques through experiential learning during the workshop,
• sampling theory, signal processing and data analysis, • managing a project and project role-players effectively,
• accuracy, calibration and error propagation, • the monitor progress and enduring project success by using the correct enhancement tools,
• practical application on test loops and EtaPRO • project management definitions and phases,
• who does what in a project?,
Boiler/Combustion • the application of project management principles,
• how to keep energy dynamics at an optimal level,
After completion of this course, learners will have a thorough understanding of:
• the project managers’ role and responsibilities,
• boiler mass balances, • what is successful project leadership,
• boiler energy balances, • how to draw up a responsibility matrix,
• air heater mass and energy balances. • the process of budgeting for facilities, labour/skills and material,
• how to schedule tasks (precedence analysis/network and Gantt chart) and resources (human and
Turbines equipment),
Upon completion of this applied course, the learner will be able to identify: • how to do role player mapping,
• how to draw up a sequence of activities and plot it on a Bar chart,
• steam cycles applicable to the steam turbine, • how to draw up a risk analysis,
• basic view of turbine operations, • how to draw up a critical path,
• the main components of a steam turbine, • how to implement a project plan,
• steam turbine protection, • the close out of a project.
• types of turbine blading,
• turbine auxiliary systems,
• steam turbine protection.
MV and HV Power Transmission

The course will assist the learner in having a better understanding of how to:
• perform load flow studies,
• manage reactive power flow and voltage control in power systems,
• understand the processes of frequency control in power systems,
• manage stability issues in power systems,
• design protection schemes in HV and MV systems,

Appendix 2
How to join EPPEI
Are you interested in advancing your engineering career in

Eskom through EPPEI? Here’s how to apply.
The minimum requirements to apply for admission into the EPPEI programme for 2016 are:
• A BTech or Engineering degree (BSc. or BEng.)

• Eskom engineer in training or experienced engineer
• Interested in obtaining an MSc. degree in the specialisation areas listed in this document
• An overall average final year mark of 60% and above
The process for the intake of students for 2017 will start during June 2015. Keep an eye out for the
advertisements!
Be sure to have at least the following information available:
• Your qualifications
• Certified copies of ID, degree, academic record
• Short description of your responsibilities and main outputs over the last six months
Class of 2015 • Short resume, and motivation for admittance in the programme
• A photograph of yourself
• Current position held
• Specialisation areas you are interested in
For further information please contact:
Carolynn Koekemoer
Email: koekemC@eskom.co.za
Office: +27 13 693 2265

Appendix 3
Directions and maps
Directions to Megawatt Park (Eskom Head Office) in Sunninghill

From Pretoria:
1. Take the Ben Schoeman (M1) highway to Johannesburg
2. Stay on the Johannesburg highway, and exit at the Woodmead offramp
3. At the top of the offramp, turn right at traffic lights onto R55 to Woodmead.
4. Straight over first traffic lights (Woodlands Drive Dunwoody Centre on the left)
5. At next traffic lights, turn left into Maxwell Drive (R564)
6. At next robot turn right into Eskom Head Office entrance (security boom at the gate)
From Roodepoort:
1. Take Western Bypass (N1), and exit at the Rivonia offramp
2. At traffic lights at bottom of offramp, turn left and immediately move to the right before the next
traffic lights
3. At these traffic lights, turn right into Witkoppen Road, travelling parallel to the freeway
4. Straight over first traffic lights (Bowling Road, Sunninghill Hospital on left)
5. Continue to next traffic lights, and cross straight over into Eskom Head Office entrance (security
boom at the gate)
From Johannesburg:
1. Take M1 North to Pretoria, and exit at Woodmead offramp
2. Follow road left through yield sign onto Kyalami Road
3. Straight over first traffic lights (Woodlands Drive Dunwoody Centre on the left)
4. At next traffic lights, turn left into Maxwell Drive (R564)
5. Turn right into Eskom Head Office entrance (security boom at the gate)
Megawatt Park
Once through the Eskom gates:
* Ahead is a traffic circle, turn right at the circle
* Visitors’ parking is on your left

Directions to Eskom Research,Testing and Development (RT&D) in Rosherville
1. Travelling south on the N3 from Pretoria towards Johannesburg
2. At the Geldenhuys interchange take exit 108, M2 west towards Germiston
3. Keep right at the fork towards M2/Johannesburg onto the Francois Oberholzer highway
4. Take exit 4, Cleveland Road
5. At the traffic light turn left onto Cleveland road
6. Continue straight onto Lower Germiston Road
7. Approximately 300m after the first sharp right hand bend turn left at the ERIC sign board
8. Follow the road to the ERIC entrance on the right hand side
RT&D

Directions to Eskom Academy of Learning (EAL) in Dale Road,
Midrand (S25o 59’11,2” E28o 9’29,1”)
From Sandton/Roodepoort:
1. Take the Ben Schoeman Highway to Pretoria (N1)
2. Take the Allandale Road off-ramp
3. Turn right at the traffic lights at the top of the off-ramp (you will be crossing the highway)
4. Continue over two sets of traffic lights and turn left at the third set of traffic lights into K101 Road
5. Continue over three sets of traffic lights and turn right at the fourth set of traffic lights into Dale Road
6. Cross the traffic lights and continue straight for 0.6 km. The entrance to EAL is on your right
From Pretoria:
1. Take the Ben Schoeman Highway to Johannesburg (N1)
2. Take the Olifantsfontein Road off-ramp
3. Turn right at the traffic lights at the end of the off-ramp and continue straight
4. Cross the traffic lights and continue straight
5. At the four-way stop turn right into Allan Road and continue for approx. 3.7 km
6. At the traffic lights turn left into Dale Road
7. EAL is 0.6km down the road, on your right
From Kempton Park:

1. From the Civic Centre continue along CR Swart Road in a westerly direction, following the Chloorkop
sign and later the R561 sign
2. Turn left into Allandale Road at the R561 Halfway House sign and continue straight for 8.2 km
(crossing Setter Road)
3. Turn right into K101 Road. Continue over three sets of traffic lights and turn right at the fourth set
of traffic lights into Dale Road
4. Cross the traffic lights and continue straight for 0.6km. The entrance to EAL is on your right
From East Rand: EAL

1. From the N3 (N1) Pretoria highway take the N1 North Pretoria off-ramp and continue straight
2. Take the Allandale Road off-ramp
3. Turn right at the traffic lights at the top of the off-ramp (you will be crossing the highway)
4. Continue over two sets of traffic lights and turn left at the third set of traffic lights into K101 Road
5. Continue over three sets of traffic lights and turn right at the fourth set of traffic lights into Dale Road
6. Cross the traffic lights and continue straight for 0.6 km. The entrance to EAL is on your right.
128 EPPEI 2015-2016 Programme EPPEI

EPPEI22015-2016
2015-2016 Programme 129
Eskom Academy of Learning
Eskom Power Plant Engineering Institute (EPPEI)
Dale Road Halfway House

Midrand 1685
Tel: +27 11 651 6978
Eskom Holdings SOC Ltd Reg No 2002/015527/30
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Eskom Power Plant

Eskom Academy of Learning

Prof Francis Petersen – University of Cape Town 3. Technical committee 5

Prof Ian Jandrell – University of the Witwatersrand 4. EPPEI management team 6

Prof LJ Grobler – North-West University 5. Specialisation centre strategies 7

Prof Sunil Maharaj – University of Pretoria 6. Specialisation centre academic representatives 8

Prof Christina Trois – University of KwaZulu-Natal 7. Academic supervisors 16

Prof Willem Perold – Stellenbosch University 8. Industrial mentors 17

10. Current projects – research topics 20

2 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 3

4 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 5

• Eskom specialisation centre in Energy Efficiency www.uct.ac.za

Name Louis Jestin

• Eskom specialisation centre in High Voltage Engineering (AC) www.wits.ac.za

Name Nicola Taylor

6 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 7

EPPEI specialisation centre in Energy Efficiency EPPEI specialisation centre in Combustion

Pieter Rousseau Name Louis Jestin

Partner University: Partner University:

Name Igor Gorlach

8 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 9

Name Hein Neomagus

Name Dr Johan Westraadt

10 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 11

EPPEI specialisation centre in High Voltage

Partner University: Partner University:

Name Dr Dawood A Desai Name Mr Jerry Walker

12 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 13

Name Andrew Swanson Name Frank Dinter

Partner University: Partner University:

Name Mr Eamon Bussy Name Dr Nawaz Mahomed

14 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 15

16 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 17

38. Nigel Russel Volk (Eskom) MS – UCT

18 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 19

1. Emissions Control 22 4. High Voltage Engineering (AC) 64

20 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 21

24 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 25

26 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 27

Subject background Proposed research

28 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 29

Subject background Expected deliverables

30 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 31

32 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 33

Applicability/Benefit to Eskom Email: vrielhw@eskom.co.za

Proposed research Academic supervisors

34 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 35

Applicability/Benefit to Eskom Student

38 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 39

40 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 41

Subject background Expected deliverables

44 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 45

Subject background Proposed research

46 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 47

Subject background The secondary objectives of this project are:

48 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 49

Subject background Expected deliverables

Proposed research Student

50 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 51

Subject background Expected deliverables

52 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 53

Subject background Proposed research

54 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 55