EPPEI Eskom Power Plant Engineering Institute - 2015-2016 Programme
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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 2015-2016 Programme EPPEI 2015-2016 Programme 5
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 Academy of Learning (Midrand)
• 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
Eskom Academy of Learning (Midrand)
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 2015-2016 Programme EPPEI 2015-2016 Programme 7
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
8 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 9
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
10 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 11
EPPEI specialisation centre
academic representatives continued...
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
Partner University: Partner University:
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
12 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 13
EPPEI specialisation centre
academic representatives continued...
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
Partner University: Partner University:
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
14 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 15
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)
16 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 17Industrial 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.
18 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 1910. 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
20 EPPEI 2015-2016 Programme EPPEI 2015-2016 Programme 21Eskom 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 23EC1
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
24 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 25EC2
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
26 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 27EC3
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
28 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 29EC4
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.
Applicability/Benefit to Eskom
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
30 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 31EC5
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
Applicability/Benefit to Eskom
• 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.
32 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 33EC6
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.
34 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 35Eskom Power Plant Engineering Institute
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
2015-2016 Programme EPPEI 22015-2016 Programme 37MS1
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
38 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 39MS2
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
40 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 41Eskom Power Plant Engineering Institute
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
2015-2016 Programme EPPEI 22015-2016 Programme 43AM1
Continuum damage modelling on
HP pipework for predicting creep
fatigue interaction
Subject background Expected deliverables
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.
Applicability/Benefit to Eskom
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
44 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 45AM2
The effect of non-uniform micro-
structure on the failure mode of
hamer forged line hardware failure
prediction
Subject background Proposed research
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.
Applicability/Benefit to Eskom
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.
46 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 47AM3
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.
48 EPPEI 2015-2016 Programme EPPEI 22015-2016 Programme 49You can also read
