EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme

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EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
Eskom Power Plant
Engineering Institute

EPPEI
2018-2019 Programme

     Eskom Academy of Learning
 Driving towards Engineering Excellence
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
How to join EPPEI

Acknowledgements                                                Are you interested in advancing your engineering career in
                                                                Eskom through EPPEI? Below are the minimum requirements
Prof Alison Lewis – University of Cape Town                     and how to apply.
Prof Ian Jandrell – University of the Witwatersrand
                                                                The minimum requirements to apply for admission into the EPPEI programme for 2018 are:
Prof LJ Grobler – North-West University
Prof Sunil Maharaj – University of Pretoria                     •   an Engineering or BTech degree (BSc or BEng)
                                                                •   must be interested in obtaining an MSc degree or MTech or MEng in one of the specialisation areas
Prof Cristina Trois – University of KwaZulu-Natal                   listed in this document either at a University or a University of Technology (UoT)
Prof Hansie Knoetze – Stellenbosch University                   •   an overall average final year mark of 60% and above

                                                                Candidates need to attend a short preparatory program at the Eskom Academy of Learning during
                                                                August/September in 2017 prior to registration at a University or UoT. Candidates will be allowed to
                                                                register at the University or UoT after successful completion of the screening exams.

                                                                The process for the intake of students for 2018 will start during June 2017. Keep an eye out for the
                                                                advertisements primarily on Eskom’s intranet! Candidates are also invited to apply for the Postgraduate
                                                                Qualification (PG-Q) stream to commence in 2018. Different courses are on offer at universities across
                                                                the country which result in Postgraduate qualification relevant to the power industry.

                                                                In preparation for the application prospective students are required to submit the following documentation:

                                                                •   certified copies of ID, degree and academic record
                                                                •   short description of your responsibilities and main outputs over the last six months
                                                                •   short resume and motivation for admission into the programme
                                                                •   a single colour passport size photo
                                                                •   a research topic title and description and possible industrial mentor

                                                                For further information and to apply online, please visit our website at http://www.eppei.co.za/how-
                                                                to-apply.html

Eskom Holdings SOC Ltd Reg No 2002/015527/30
Issued by Eskom Power Plant Engineering Institute – July 2018
                                                                                                                                                EPPEI 2018-2019 Programme
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
Contents                                                  Foreword by Dr Titus Mathe                                                                                     1

1   Foreword by Dr Titus Mathe                        1   Nelson Mandela said that education is a powerful weapon that can be used to change the world. We
2   EPPEI Eskom management team                       2   currently find ourselves in challenging times and it is imperative that we equip our staff to adapt and deal
                                                          with the challenges that we are faced with now, and those that may present themselves in the future.
3   Universities consortium management team           5
                                                          The Eskom Power Plant Engineering institute (EPPEI) is a partnership between Eskom and academia
4   Specialisation Centre academic representatives    6   to improve the skills and knowledge of the electric power industry and more specifically, Eskom’s
5   Completed project summaries                      18   workforce. EPPEI has grown from strength to strength since it was first launched in 2012. Despite the
6   Current students – research topics               29   many challenges, the unwavering support from Eskom management and our academic partners have
                                                          ensured that EPPEI continues to grow to serve Eskom’s needs. Last year, we had 42 graduates, bringing
7   Student workshop                                 54
                                                          the total number of master’s and doctoral graduates to 154 since EPPEI’s inception, and the numbers
                                                          are expected to increase significantly. We currently have more than 200 masters and doctoral students
                                                          registered on the programme, all of whom are working closely with industrial mentors and academic
                                                          supervisors on Eskom-specific challenges.

                                                          EPPEI leverages the classic benefits of close collaboration between industry and academia to provide
                                                          Eskom’s employees with opportunities to study towards a masters or doctoral degree whilst
                                                          simultaneously addressing Eskom-specific technical challenges. Skills and knowledge can be improved
                                                          by participating in the master’s programme, post-graduate qualification programme or the engineering
                                                          practitioner programme. This year, EPPEI seeks to build on the co-operation we have in place with
                                                          our Universities of Technology and Previously Disadvantaged Universities who will be involved in
                                                          research and the development of specialised training courses for Eskom’s engineering practitioners.
                                                          Communication platforms between Eskom specialists, academics and students will be strengthened
                                                          through established EPPEI governance structures and relevant Eskom technical forums. This will serve
                                                          both to share and grow the body of knowledge that can ultimately be utilized to improve Eskom’s
                                                          technical performance.

                                                          Dr Titus Mathe
                                                          EPPEI Programme Director

                                                          “This year will no doubt bring new, significant
                                                          challenges for the industry but I am confident
                                                          that the EPPEI team will continue to support
                                                          Eskom, as we adapt to tackle these challenges.”

                                                                                                                                       EPPEI 2018-2019 Programme             1
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
2   EPPEI Eskom Management Team

           Name Dr Titus Mathe                 Name       Andrew Johnson
           Position EPPEI Programme Director   Position   Chief Learning Officer
           Email MatheZT@eskom.co.za           Email      JohnsoAJ@eskom.co.za

           Name       Ouma Bosaletsi           Name       Sumaya Nassiep
           Position   EPPEI Research Lead      Position   General Manager: Research Testing & Development
           Email      MotaleOE@eskom.co.za     Email      NassieS@eskom.co.za

           Name       Riekie Swanepoel         Name       Ravi Moodley
           Position   EPPEI Research Lead      Position   Senior Manager: Eskom Academy of Learning
           Email      SwanepHF@eskom.co.za     Email      Moodleru@eskom.co.za

           Name Morakanele Thipe               Name Roman Pietrasik
           Position Project Manager            Position Contracts Manager
           Email ThipeM@eskom.co.za            Email PietraWR@eskom.co.za

2 EPPEI 2018-2019 Programme                                                                             EPPEI 2018-2019 Programme   3
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
EPPEI Eskom Management Team continued...      Universities consortium management team                                              3

                                                      Name       Louis Jestin
           Name       Abré le Roux
           Position   Technical Advisor – Tx/Dx       Position   Interim Consortium Director Mechanical Engineering
                                                                 (UCT)
           Tel        +27 43 703 5484
                                                      Tel        +27 21 650 3239
           Email       abre.leroux@eskom.co.za
                                                      Email      louis.jestin@uct.ac.za

           Name        Carolynn Koekemoer             Name       Bradley Oaker
           Position    Senior Advisor                 Position   EPPEI Consortium General Manager
           Tel         +27 13 693 2032                Tel        +27 21 650 1932
           Email       koekemCI@eskom.co.za           Email      bradley.oaker@uct.ac.za

                                                      Name       Sara Booley
                                                      Position   Consortium Administrative Officer
                                                      Tel        +27 21 650 2043
                                                      Email      sara.booley@uct.ac.za

                                                      Name       Bernadene Minnaar
                                                      Position   Consortium Administrative Officer
                                                      Tel        +27 21 650 2037
                                                      Email      bernadene.minnaar@uct.ac.za

4 EPPEI 2018-2019 Programme                                                                                     EPPEI 2018-2019 Programme   5
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
4   EPPEI Specialisation Centre
    academic representatives

             EPPEI specialisation centre in Energy Efficiency   Partner Universities:
             at University of Cape Town
                                                                                          Nelson Mandela University
             Name        A/Prof Wilhelm Fuls
             Position    Coordinator, Senior Lecturer
             Dept        Mech. Eng. (UCT)
             Education   PhD Nuclear Eng. (NWU)                               Name        Igor Gorlach
             Tel         021 650 2600 / 083 417 7494                          Position    Professor & Chair
             Email       wim.fuls@uct.ac.za                                   Dept        Mechatronics (NMU)
             Interests   Engineering design and Thermo-fluid                  Tel         041 504 3289
                         process modeling                                     Email       Igor.Gorlach@nmmu.ac.za

             Name        Priyesh Gosai
             Position    Programme Manager                                    Vaal University of Technology
             Dept        Mech. Eng. (UCT)
             Education   MSc (UCT)
                                                                              Name        Prof Alfayo Alugongo
             Tel         021 650 5720
                                                                              Position    Head of Department
             Email       Priyesh.gosai@uct.ac.za
                                                                              Dept        Mechanical Engineering
             Interests   Power Plant Condition Monitoring
                                                                              Education   PhD
                                                                              Tel         016 950 9302
                                                                              Email       AlfayoA@vut.ac.za
                                                                              Interests   Condition monitoring and vibrations
             Name        Pieter Rousseau
             Position    Professor
             Dept        Mech. Eng. (UCT)
             Education   PhD Mech. Eng. (UP)
             Tel         021 650 5822
             Email       pieter.rousseau@uct.ac.za

6 EPPEI 2018-2019 Programme                                                                                                     EPPEI 2018-2019 Programme   7
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
EPPEI Specialisation Centre
    academic representatives continued...

             EPPEI specialisation centre in Combustion        Partner Universities:
             Engineering at University of the Witwatersrand
                                                                            University of Johannesburg
             Name      Walter Schmitz
             Position  Coordinator, Professor
             Dept      School of Mechanical Industrial and
                       Aeronautical Engineering (Wits)                      Name        Dr Daniel Madyira
             Education PhD Mech. Eng.                                       Tel         076 029 8563
             Tel       011 717 7047                                         Email       dmadyira@uj.ac.za
             Email     Walter.Schmitz@wits.ac.za                            Interests   Fluid Mechanics, Heat transfer and
             Interests Computational Fluid Dynamics                                     Strength of Materials

             Name      Reshendren Naidoo
             Position  Lecturer/Researcher                                  Cape Peninsula University of Technology
             Dept      School of Mechanical Industrial and
                       Aeronautical Engineering (Wits)
             Education MEng Eng. Man. (UP)
             Tel       072 246 4233                                         Name        Prof Stephen Bosman
             Email     Reshendren.naidoo@wits.ac.za                         Position    Co-ordinator of Postgraduate Studies
             Interests Numerical Combustion                                 Tel         061 406 5065
                                                                            Email       bosmans@cput.ac.za
                                                                            Interests   Industry 4.0, Risk, Systems Engineering

8 EPPEI 2018-2019 Programme                                                                                                       EPPEI 2018-2019 Programme   9
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
EPPEI Specialisation Centre
    academic representatives continued...

             EPPEI specialisation centre in Emission Control at
             North-West University                                               Partner Universities:
             Name      Stuart Piketh
             Position  Coordinator, Professor                                                  Vaal University of Technology
             Dept      Unit for Environmental Science & Mngmnt
                       & Chemical Resource Beneficiation
             Education PhD (Wits)
             Tel       018 299 1582                                                            Name       Dr Hilary Limo Rutto
             Email     Stuart.Piketh@nwu.ac.za                                                 Position   Senior Lecturer
             Interests Atmospheric and environmental impacts                                   Dept       Chemical Engineering (VUT)
                                                                                               Tel        016 950 9598
                                                                                               Email      hilaryr@vut.ac.za
             Name        Hein Neomagus
             Position    Professor
             Dept        School of Chemical & Minerals Engineering
             Education   PhD (University of Twente, NL)
             Tel         018 299 1535                                                          University of Venda
             Email       Hein.neomagus@nwu.ac.za
             Interests   Coal conversion and characterisation, reactor
                         modelling, membrane processes
                                                                                               Name       Prof John Ogony Odiyo
                                                                                               Position   Professor and Dean
                                                                                               Dept       School of Environmental Sciences
             Name        Louis le Grange
             Position    NWU EPPEI Adminstrator                                                Tel        015 962 8511
             Dept        School of Chemical & Minerals Engineering                             Email      John.Odiyo@univen.ac.za
             Education   M. Eng. Mech. (NWU)
             Tel         018 2991664
             Email       10066578@nwu.ac.za
             Interests   Multiphase flows
                                                                                               Tshwane University of Technology
             Name        Dr Dawie Branken
             Position    NWU EPPEI Researcher                                                  Name       Dr Aloys O. Akumu
             Dept        School of Chemical & Minerals Engineering                             Position   Senior Lecturer
             Education   PhD Chem. NWU                                                         Dept       Electrical Engineering
             Tel         018 299 1953                                                          Tel        013 655 3232
             Email       dawie.branken@nwu.ac.za
                                                                                               Email      akumuao@tut.ac.za
             Interests   Emissions control, electrostatics, reaction kinetics,
                         computational modelling

10 EPPEI 2018-2019 Programme                                                                                                                 EPPEI 2018-2019 Programme   11
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
EPPEI Specialisation Centre
    academic representatives continued...

             EPPEI specialisation centre in Materials and      EPPEI specialisation centre in Asset Management
             Mechanics at University of Cape Town              at University of Pretoria

             Name         Robert Knutsen                       Name      Stephan Heyns
             Position     Professor, Head of Department        Position  Coordinator, Professor
             Dept         Mechanical Engineering (UCT)         Dept      Mechanical and Aeronautical
             Education    PhD (UCT)                                      Engineering (UP)
             Tel          021 650 4959                         Education PhD (UP)
             Email        Robert.knutsen@uct.ac.za             Tel       012 420 2432
             Interests    Materials microstructure, electron   Email     Stephan.heyns@up.ac.za
                          microscopy                           Interests Machine and structural health monitoring

             Name         Dr Richard Curry                     Name        Prof Johann Wannenberg
             Position     Senior Research Officer              Position    EPPEI Curriculum Committee
             Dept         Mechanical Engineering (UCT)         Dept        Mechanical & Aeronautical Engineering
             Education    MSc. Eng. (UCT)                      Tel         012 420 3695
             Tel          021 650 2744                         Email       johann.wannenburg@up.ac.za
             Email        rj.curry@uct.ac.za                   Interests   Life cycle management, condition
             Interests    Mat characterisation, structural                 monitoring, maintenance engineering
                          response, DIC, numerical modelling

                         Partner University:                   Partner University:
                         Nelson Mandela University             Tshwane University of Technology

             Name         Dr Johan Westraadt
             Position     Senior Researcher                    Name        Dr Dawood A Desai
             Dept         Centre for HRTEM                     Position    Acting Section Head Mechanical
             Education    PhD (NMMU)                           Dept        Mechanical Engineering (TUT)
             Tel          041 504 2301                         Tel         012 382 5886
             Email        Johan.westraadt@nmmu.ac.za           Email       desaida@tut.ac.za

12 EPPEI 2018-2019 Programme                                                                                  EPPEI 2018-2019 Programme   13
EPPEI Eskom Power Plant Engineering Institute - 2018-2019 Programme
EPPEI Specialisation Centre
    academic representatives continued...

             EPPEI specialisation centre in High Voltage Alternating   EPPEI specialisation centre in High Voltage Direct
             Current (AC) at University of the Witwatersrand           Current at University of KwaZulu-Natal
             Name      John van Coller                                 Name        Dave Dorrell
             Position  Coordinator, Senior Lecturer                    Position    Coordinator, Professor
             Dept      School of Electrical and Information            Dept        Eskom CoE HVDC and FACTS (UKZN)
                       Engineering (Wits)                              Education   PhD (Cambridge), MSc (Bradford),
             Education PhD                                                         BEng (Leeds)
             Tel       011 717 7211                                    Tel         031 260 2730 / 7024
             Email     John.vancoller@wits.ac.za                       Email       dorreld@ukzn.ac.za
             Interests Power system modelling, high voltage            Interests   Electrical machinery, renewable energy,
                                                                                   power systems
                       engineering

             Name      Hugh Hunt                                       Name      Andrew Swanson
             Position  Lecturer                                        Position  Senior Lecturer
             Dept      School of Electrical and Information            Dept      Electrical, Electronic and Computer
                       Engineering (Wits)                                        Engineering
             Education MSc(Eng)                                        Education PhD (Wits)
             Tel       011 717 7254                                    Tel       031 260 2713
             Email     hugh.hunt@wits.ac.za                            Email     swanson@ukzn.ac.za
             Interests High voltage, lightning                         Interests High voltage engineering

             Partner University:                                       Partner University:
             University of Johannesburg                                Durban University of Technology

             Name        Dr Wesley Doorsamy
             Education   PhD (Electrical Engineering)                  Name        Mr Eamon Bussy
             Tel         011 559 6094 / 072 570 9629                   Position    Senior Lecturer
             Email       wdoorsamy@uj.ac.za                            Dept        Steve Biko Campus
             Interests   Condition monitoring on electrical            Tel         031 373 2062
                         machines, intelligent diagnostics             Email       eamonb@dut.ac.za

14 EPPEI 2018-2019 Programme                                                                                           EPPEI 2018-2019 Programme   15
EPPEI Specialisation Centre
    academic representatives continued...

             EPPEI specialisation centre in Renewable Energy
             at Stellenbosch University                                 Partner Universities:

             Name         Bernard Bekker                                              Cape Peninsula University of Technology
             Position     Coordinator, EPPEI Research Committee Chair
             Education    PhD (Electrical Engineering)
             Tel          021 808 4041 / 082 581 5004
             Email        bbekker@sun.ac.za                                           Name       Dr Naim Rassool
             Interests    Power system studies                                        Position   Director SARETEC (CPUT)
                                                                                      Tel        021 959 4231
                                                                                      Email      rassooln@cput.ac.za

             Name         Karin Kritzinger
             Position     Programme Manager, Senior Researcher
             Tel          021 808 3605 / 082 412 4466
             Email        karink@sun.ac.za                                            Central University of Technology
             Interests    Electricity tariffs, energy modelling

                                                                                      Name       Herman Vermaak
                                                                                      Position   Professor
                                                                                      Dept       Electrical, Electronic & Computer Eng.
             Name        Ndamulelo Mararakanye                                        Tel        051 507 3898
             Position    Research Engineer                                            Email      hvermaak@cut.ac.za
             Education   BSc (Eng), MSc (Eng) (UCT)
             Tel         021 808 3605 / 072 338 2142
             Email       ndamulelo@sun.ac.za
             Interests   Power system studies

16 EPPEI 2018-2019 Programme                                                                                                              EPPEI 2018-2019 Programme   17
C O M P L E T E D P RO J E C T
                                                                                                                                                       Student
                                                                                                                                                       Nikki Basson (Energy Efficiency)
                                                                                                                                                       Email: nicol.rous@gmail.com

5   Completed projects                                                                                                                                 Industrial mentor
                                                                                                                                                       Russell Tarr
                                                                                                                                                       Academic supervisor
                                                                                                                                                       Wim Fuls

    The following students have                                                                                                                        Studying water-wedging as a cause for short term overheating in the
    completed their studies                                                                                                                            boiler of a coal-fired power plant
    through EPPEI over the
    last year.                                                                                                                                         The purpose of this study was to investigate the root cause of the failure known as short term overheating,
                                                                                                                                                       which is usually attributed to a water blockage formed within the tube due to over-attemperation, and to
                                                                                                                                                       verify the validity thereof. A transient flow model was constructed and verified by comparing its results with
                                                                                                                                                       a numerical model developed from fundamental principles. Once the simulation modelling methodology
                                                                                                                                                       was confirmed, the model was modified to resemble the geometry of a final superheater outlet leg setup
                                                                                                                                                       to facilitate direct comparison with a pendant boiler component as found on a power plant. A number of
                                                                                                                                                       scenarios were executed in transient state on the model at different boiler loads. The results showed that
                                                                                                                                                       short term overheating is unlikely to occur. The stresses exerted over the tube wall and throughout the tube
                                                                                                                                                       length is not enough to overcome the yield stress of the superheater tube material. Thus, the claim of over-
                                                                                                                                                       attemperation as the root cause of a short term overheating failure is improbable.

                                                                                                                      C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                             C O M P L E T E D P RO J E C T
    Student                                                                                                                                            Student
    Dr Arif Arif (Emissions Control)                                                                                                                   Leslie Borrill
    Email: arifnwu@gmail.com
                                                                                                                                                       Industrial mentor
    Industrial mentor                                                                                                                                  Richard Candy
    Mr Naushaad Haripersad
                                                                                                                                                       Academic supervisor
    Academic supervisor                                                                                                                                Prof CT Gaunt
    Prof Raymond Cecil Everson

    The simulation of an industrial wet flue gas desulfurization absorber                                                                              Duality derived topological model of single phase four limb
                                                                                                                                                       transformers for GIC and DC bias studies
    The modelling of the slurry droplets injectors was successfully accomplished with a numerical model based
    on an optimised number of parcel streams per injector to ensure uniform distribution of the slurry droplets                                        Geomagnetic disturbances brought about by solar activity cause geo-electric fields in the earth that drive
    in the absorber.The droplet and gas velocities were found to be within the ranges appropriate for controlling                                      geomagnetically induced currents through the earthed neutrals of transformers and through power
    conditions to avoid carryover of the smaller droplets in the outlet gas stream, and thus to ensure effective                                       transmission networks. The flow of these currents cause the magnetic cores of transformers to half-wave
    operation of the mist eliminator. The distortion of slurry droplets was found to be insignificant with the                                         saturate. Saturated transformers pose problems for power system operators since they can cause harmonics,
    largest effect occurring near the flue gas inlet to the tower. The addition of the effect of evaporation in the                                    transformer heating, mal-operation of protection relays, generator heating and vibration, and consume a
    model proved to be important to precisely describe the temperature and moisture concentration profiles                                             large reactive power that can cause voltage collapse. Network studies of slow transient phenomena such as
    within the absorber. The chemical model was successfully developed and implemented in the CFD software                                             transformer half-wave saturation require appropriate models to be developed. In this study a novel duality
    by user defined coding, which couple the hydrodynamic model with SO2 mass transfer and related aqueous                                             derived reversible model was developed of a single phase four limb transformer that included the non-step
    phase equilibrium reactions. The model is able to predict the desulfurization efficiency, pH, enhancement                                          lap butt type core joints. The pi model parameters and saturation characteristics were determined through
    factor and species concentration at every droplet position in the absorber.                                                                        laboratory testing and a complete pi model was presented.

18 EPPEI 2018-2019 Programme                                                                                                                                                                                                        EPPEI 2018-2019 Programme           19
C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                                     C O M P L E T E D P RO J E C T
    Student                                                                                                                                              Student
    Jacques Brits (Asset Management)                                                                                                                     Colin Francois du Sart (Energy Efficiency)
    Email: u11004623@tuks.co.za                                                                                                                          Email: dsrcol001@myuct.ac.za
    Industrial mentor                                                                                                                                    Industrial mentor
    Michael Hindley                                                                                                                                      Pieter Rousseau
    Academic supervisor                                                                                                                                  Academic supervisor
    Stephan Heyns                                                                                                                                        Pieter Rousseau

    Probabilistic fatigue crack life estimation of a turbomachinery blade                                                                                Design and prototyping of a dilute phase pneumatic conveying test
    during resonance conditions                                                                                                                          facility
    In this study, an approach has been developed to probabilistically estimate the fatigue crack life of a                                              This project involved the design, development, prototyping, construction and commissioning of a dilute phase
    turbomachinery blade during resonance operating conditions. The developed approach makes it possible                                                 pneumatic conveying test facility. The facility allows for accurate online monitoring and control of the particle
    to assess the sensitivity of the life prediction to input parameters and calculate the probability of failure at                                     and gas mass flow rates through a SCADA system developed using LabVIEW. A conceptual system layout for
    a predefined crack length. A finite element model was used to create a reference database of cracks with                                             a final test facility was also developed.This facility may be implemented and used to obtain accurate empirical
    associated stress intensity factors of representative cracks within the blade under cyclic loading. To stimulate                                     data associated with the pneumatic conveying of pulverised fuel and/or fly ash.
    crack growth in the test specimens, a base excitation, at resonance, was applied and digital image correlation
    was used to measure the crack growth. Raju-Newman formulations were employed on a simplified blade
    geometry with a semi-elliptical crack to characterize the Paris Law material constants. A Monte Carlo
    simulation was performed to estimate numerous fatigue crack lives taking material variations and modelling
    uncertainties into account, which correlated well with experiments.

                                                                                                                        C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                                     C O M P L E T E D P RO J E C T
    Student                                                                                                                                              Student
    Nicolas Cardenas (Materials and Mechanics)                                                                                                           Ronald Graham du Toit (Asset Management)
    Email: nicolas.cardenas@eskom.co.za                                                                                                                  Email: dutor06@gmail.com
    Industrial mentor                                                                                                                                    Industrial mentor
    Mark Newby                                                                                                                                           Dr DH Diamond
    Academic supervisor                                                                                                                                  Academic supervisor
    Robert Knutsen                                                                                                                                       Prof Stephan Heyns

    Feasibility study into the use of digital image correlation (DIC) for                                                                                A stochastic hybrid blade tip timing approach for the identification and
    creep strain monitoring of fossil power plant welds                                                                                                  classification of turbomachine blade damage
    Within Eskom, creep damage is primarily quantified by way of metallographic replication (replicas). Although                                         Blade Tip Timing (BTT) has been in existence for many decades as an attractive vibration based condition
    well-known and used extensively, replicas, as with any technology, have their shortcomings including subjectivity                                    monitoring technique for turbomachine blades. The technique is non-intrusive and online monitoring
    during extraction and analysis, and cumbersome management of large quantities of physical replicas. These                                            is possible. For these reasons, BTT may be regarded as a feasible technique to track the condition of
    challenges can potentially be addressed by a technology known as digital image correlation - a non-contact,                                          turbomachine blades, thus preventing unexpected and catastrophic failures. The processing of BTT data to
    full field, deformation measurement technique. This study looks into the feasibility of setting up a DIC system,                                     find the associated vibration characteristics is however non-trivial. In addition, these vibration characteristics
    optimised for measuring strain, in an area of the pipework welds known as the Heat Affected Zone (HAZ) –                                             are difficult to validate, therefore resulting in great uncertainty of the reliability of BTT techniques. This study
    the weakest part of the weldment. The achievable accuracy of this technique was established and the major                                            proposed the use of a hybrid approach comprising of a stochastic Finite Element Model (FEM) based modal
    parameters that affect DIC accuracy were investigated. Additionally, DIC’s potential to be used online, where                                        analysis and a Bayesian Linear Regression (BLR) based BTT technique. The use of this stochastic hybrid
    elevated temperatures are foreseen to introduce measurement errors, was investigated and conclusions on                                              approach was demonstrated for the identification and classification of turbomachine blade damage and it has
    its applicability in such a scenario established.                                                                                                    shown many short- and long-term benefits for the practical implementation of this technique.

20 EPPEI 2018-2019 Programme                                                                                                                                                                                                              EPPEI 2018-2019 Programme             21
C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                               C O M P L E T E D P RO J E C T
    Student                                                                                                                                             Student
    Arnold J.J. Hayes (Asset Management)                                                                                                                Ian Kuiler (Renewable Energy)
    Email: ajjhayes@gmail.com                                                                                                                           Email: kuilerian@gmail.com
    Industrial mentor                                                                                                                                   Industrial mentor
    Lukas J. Haarhoff                                                                                                                                   Dr Nad Moodley
    Academic supervisor                                                                                                                                 Academic supervisor
    Stephan Heyns                                                                                                                                       Dr Marco Adonis

    Characterisation of the core and winding vibrations of power                                                                                        Condition monitoring of squirrel cage induction generators in wind
    transformers with regulator windings                                                                                                                turbines
    This study involved the characterisation of the core and winding vibrations of power transformers with regulator                                    Eskom constructed Sere Wind Farm with a rated capacity of 100 MW in 2015, which is its largest renewable
    windings by measuring the tank vibrations. The experimental tests were performed in the manufacturing                                               energy power plant. Sere Wind Farm has 46 Siemens wind turbines with an individual capacity of 2.3 MW.
    plant whilst the transformers under investigation were subjected to the standard factory acceptance tests.                                          Due to a lack of skills and knowledge within Eskom, Siemens was offered an operating and maintenance
    The test results show that the characteristics of the core and winding vibrations of transformers with and                                          contract until 2020 to ensure the power facility provides reliable and cost effective power. Siemens uses its
    without regulator windings are very similar, but in the case of transformers with regulator windings, the                                           Turbine Condition Monitoring System to perform optimum maintenance using vibration monitoring, which
    winding vibrations have a few more dependencies. Thus this research and experimental work provide                                                   is the most common condition monitoring technique for modern wind turbines. Vibration monitoring has
    key insights into how the core and winding vibrations of power transformers with regulator windings are                                             certain limitations such as the detection of electrical failures in components like the generator. To ensure
    influenced by the regulator windings, how the tank vibrations of transformers with regulator windings should                                        all forms of failures related to the generator are detected in advance, this study investigated a condition
    be measured and the difference between the vibrations of transformers with and without regulator windings.                                          monitoring technique for generator stator windings. This method can be used in conjunction with existing
                                                                                                                                                        Siemens maintenance strategies to provide optimum life cycle management of the wind turbines.

                                                                                                                       C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                               C O M P L E T E D P RO J E C T
    Student                                                                                                                                             Student
    Richard Huchzermeyer (Materials and Mechanics)                                                                                                      Hendrik Frederik Laubscher (Renewable Energy)
    Email: rlhuchzermeyer@gmail.com                                                                                                                     Email: hflaubscher@gmail.com
    Industrial mentor                                                                                                                                   Industrial mentor
    Marthinus Bezuidenhout                                                                                                                              Prof Frank Dinter
    Academic supervisor                                                                                                                                 Academic supervisor
    Dr T Becker                                                                                                                                         Prof Theodor Willem von Backström

    Measuring mechanical properties using digital image correlation (DIC):                                                                              Developing and testing a cost effective thermal rock bed storage system
    Extracting tensile and fracture properties from a single sample
                                                                                                                                                        In the concentrating solar power industry, thermal energy storage (TES) is an attractive solution for storing
    A combined approach to extracting multiple material properties from in-plane (two-dimensional) surface                                              excess energy for the periods with insufficient solar resource. The goal of a more cost effective TES for
    displacements, measured on a single sample through DIC, has been developed assuming an isotropic linear                                             concentrating solar power is to decrease the levelized cost of electricity. With thermal energy storage, a
    elastic material. This approach utilizes the virtual fields method to obtain Young’s modulus and Poisson’s ratio                                    renewable energy electricity production plant can deliver electricity on demand. The development of a
    for a material. These tensile stiffness properties are in turn used as input to a non-linear least squares field                                    novel cost effective TES for air at 600 °C with a unique system layout was covered in this project. The test
    fitting approach, which is then used to obtain the critical stress intensity factor associated with a crack or                                      facility has a scalable design of a specific concept of a packed rockbed TES system. A cost effective layout is
    notch in a material.                                                                                                                                presented, with each component and subsystem optimized to reduce the installation cost of the TES test
                                                                                                                                                        facility. The experimental results show that the TES concept can be used for short term energy storage with
                                                                                                                                                        a usable energy recovery efficiency of 60 %. The overall performance of the TES system indicates that the
                                                                                                                                                        concept under consideration in this project still needs to be adapted to find an improved solution that is a
                                                                                                                                                        viable option to utilize in industry. Current challenges to improve the volume efficiency of the packed bed of
                                                                                                                                                        rocks and the energy recovery efficiency are identified in this project for future research.

22 EPPEI 2018-2019 Programme                                                                                                                                                                                                          EPPEI 2018-2019 Programme           23
C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                                C O M P L E T E D P RO J E C T
    Student                                                                                                                                              Student
    Matthew Molteno (Materials and Mechanics)                                                                                                            Geoff Raikes (Energy Efficiency)
    Email: mattmolteno@sun.ac.za                                                                                                                         Email: geoffraikes@gmail.com
    Industrial mentor                                                                                                                                    Industrial mentor
    Marthinus Bezhuidenhout                                                                                                                              Prof Louis Jestin
    Academic supervisor                                                                                                                                  Academic supervisor
    Thorsten Becker                                                                                                                                      A/Prof Hennie Mouton

    Measuring fracture properties using digital image and volume                                                                                         Temperature reconstruction and acoustic time of flight determination
    correlation: decomposing the J-integral for mixed-mode parameters                                                                                    for boiler furnace exit temperature measurement
    The degradation of material properties over time is one of the core constituents of structural integrity                                             Acoustic pyrometry, a technique that measures temperature based on the travel time of an acoustic wave
    monitoring. For this purpose, the materials’ resistance to brittle fracture is the most widely used property                                         in a gas, has been identified as a viable solution for direct measurement of the furnace exit gas temperature.
    in the determination of safe operation and predicting component life. Measuring such properties by                                                   This project focused on the use of acoustic pyrometry to reconstruct the temperature profile at the furnace
    conventional methods presents challenges: large numbers of samples are needed, accounting for mixed-                                                 exit and methods for determining the time of flight of acoustic waves. An improved reconstruction technique
    mode loading. Non- contact measurements by digital image correlation shows promise in extracting such                                                using radial basis functions for interpolation and a least squares algorithm was simulated. Its performance was
    parameters from in situ loaded structures, accounting for their complex geometry and loading. This thesis                                            compared to cubic spline interpolation, regression and Lagrange interpolation by evaluating its reconstruction
    developed a framework that allows for the extraction of mixed-mode brittle fracture properties, using three-                                         accuracy in terms of mean and RMS error when reconstructing set temperature profiles. Various parameters
    dimensional (3D) image correlation techniques: multi-camera Digital Image Correlation (stereo-DIC), and                                              were investigated in terms of how they inform the acoustic pyrometry implementation. In addition to this, a
    Digital Volume Correlation (DVC).                                                                                                                    low-cost experimental set-up was constructed to measure the TOF. The various signal processing methods
                                                                                                                                                         were applied to determine TOF and their accuracy was evaluated in the presence of noise.

                                                                                                                        C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                                C O M P L E T E D P RO J E C T
    Student                                                                                                                                              Student
    Seeralin Nayager (HVDC)                                                                                                                              Trisha Rasiawan (Materials and Mechanics)
    Email: nayages@eskom.co.za                                                                                                                           Email: RasiawT@eskom.co.za
    Industrial mentor                                                                                                                                    Industrial mentor
    Adesh Singh                                                                                                                                          Marthinus Bezhuidenhout
    Academic supervisor                                                                                                                                  Academic supervisor
    Andrew Swanson                                                                                                                                       Prof Robert Knutsen

    Transformer design considerations utilising natural ester oils                                                                                       The influence of prior creep damage on the fracture localisation in
                                                                                                                                                         X20CrMoV12-1 cross-weld creep tests
    A multiphysics model that couples thermal performance and fluid performance was developed in COMSOL
    for part of a typical transformer winding. The results of the model displayed the expected results, with the                                         This study investigated the microstructural changes of X20CrMoV12-1 (X20) at various stages of creep
    highest temperature occurring at the top of the winding. The boundary conditions were shown to be of high                                            exposure.The severity of creep exposure renders the pipe exhausted and requires replacement, this involves
    importance as changing the inlet velocity altered the performance of the winding. The difference between                                             welding of new X20 pipe onto the creep exposed X20 pipe. In this study weldments comprising of new X20
    mineral and ester oils is minimal in this particular study. However, it must be noted that the full transformer                                      welded to creep-exposed X20 were creep tested until rupture. The weakest part of microstructure created
    needs to be considered to have more accurate movement of fluid. The results from the FEM simulations                                                 by the welding was identified using light microscopy (LM), scanning electron microscopy (SEM) and electron
    show that the electric field stresses are higher in the paper for ester oil than mineral oil. Due to the long gap                                    backscattered diffraction (EBSD). The microstructural results show that the failure always occurred in a fine-
    and streamer propagation in natural ester oil, high electric fields must be minimised as far as possible. Results                                    grained section within the heat affected zone (HAZ) of the creep exposed X20, showing concentrated creep
    of the model was used to make design suggestions for the transformer.                                                                                cavitation in this area. This result is consistent with several observations made in previous studies.

24 EPPEI 2018-2019 Programme                                                                                                                                                                                                          EPPEI 2018-2019 Programme            25
C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                          C O M P L E T E D P RO J E C T
    Student                                                                                                                                             Student
    Christine Schutte (Emissions Control)                                                                                                               Nicole Seumangal (Materials and Mechanics)
    Email: schuttcr@eskom.co.za                                                                                                                         Email: SeumanN@eskom.co.za
    Industrial mentor                                                                                                                                   Industrial mentor
    Naushaad Haripersad                                                                                                                                 Thobeka Pete
    Academic supervisor                                                                                                                                 Academic supervisor
    Prof Hein Neomagus                                                                                                                                  Robert Knutsen

    Value added utilisation possibilities of coal combustion products in                                                                                Influence of the heat treatment procedure on the stress corrosion
    South Africa                                                                                                                                        cracking (SCC) behaviour of low pressure turbine blade material FV566
    To reduce the environmental and economic impacts of the disposal of the coal ash and future Flue Gas                                                In this study the SCC behaviour of LP turbine blade material (FV566) treated to different temperature
    Desulphurisation (FGD) gypsum, alternative utilisation of these products was investigated. The proposed                                             conditions was evaluated. For the 480°C tempered specimen, the failure mechanism was IGSCC by hydrogen
    quality of FGD gypsum that can be expected from different South African limestone sources were evaluated.                                           embrittlement. Intergranular SCC or sensitisation was observed for samples treated to temperatures 550 –
    A Polish limestone and corresponding FGD gypsum sample was used as a base case in creating synthetic                                                620 °C.The 480°C and 550°C temper specimens were the most sensitive to SCC.There was limited success
    gypsum samples from three South African limestone samples. It was found that the gypsum quality correlates                                          in determining the threshold stress intensity for the different temper specimens. A change in tempering
    well with the limestone purity. Samples of ash from both Poland and South Africa were studied and compared                                          temperature resulted in a change in the quantity and type of precipitates formed. No chromium-rich
    to the South African legislation parameters. A comparison was drawn between the legislation regulating Coal                                         precipitates were observed in the matrix of the 480°C temper specimen. Isolated areas of chromium-rich
    Combustion Products (CCP) in both South Africa and the European Union. The classification of European                                               precipitates were observed for the 550°C temper specimen. Chromium-rich precipitates were observed for
    Union CCP as by products enables the utilisation of it in a bigger spectrum of applications, whilst the South                                       the samples tempered above 560°C. The material’s resistance to SCC improved with increasing tempering
    African classification hinders this development.                                                                                                    temperature.

                                                                                                                       C O M P L E T E D P RO J E C T

                                                                                                                                                                                                                                                                          C O M P L E T E D P RO J E C T
    Student                                                                                                                                             Student
    Peet Schutte (HVAC)                                                                                                                                 Lavhelesani Oliet Tshamano (Materials and Mechanics)
    Email: schuttpj@eskom.co.za                                                                                                                         Email: tshamalo@eskom.co.za
    Industrial mentor                                                                                                                                   Industrial mentor
    Chris van der Merwe                                                                                                                                 Phillip Doubell
    Academic supervisor                                                                                                                                 Academic supervisor
    Dr John van Coller                                                                                                                                  Prof Robert Knutsen

    Voltage uprating of existing high voltage substations when transient                                                                                Development of the small punch test platform to evaluate the
    voltage stress and available withstand strength are coordinated                                                                                     embrittlement of power plant materials
    When uprating is considered to increase the power transfer capability, the withstand levels of existing external                                    This research work assessed the practicality of employing the Small Punch Test (SPT) technique as
    insulation demands an optimization to find a new stress versus strength balance that allows reliable operation                                      an alternative option to assess the remaining life of ageing and prolonging safe operation of the critical
    of substations at higher voltages. The research involves primarily an investigative simulation study to evaluate                                    components within power plants as compared to traditional mechanical tests which are impractical due to
    the current Eskom available design clearances in terms of their withstand capability when subjected to over-                                        large amount of specimen required to carry out the tests. An ex-service low-pressure steam turbine rotor
    voltage transients. Two voltage range classes were evaluated and the results were discussed. For voltage                                            (NiCrMoV steel) was tested in three varied states, namely; as received (AR), heat treated at 600°C (de-
    range 1, it was found that the over-voltage stress was low enough to allow for a higher nominal operating                                           embrittled, DE) and 700°C (hardened, HD) to assess the difference in damage using the SPT technique.
    voltage while maintaining the existing clearances. For voltage range 2, existing clearances were also found to                                      Standard mechanical tests (tensile, Charpy-V-Notch and fracture toughness) of AR samples were performed
    be conservative and smaller safety margins will most likely be acceptable. From a transient analysis evaluation,                                    at various testing temperature to validate the adopted modified Ramberg-Osgood model from EPRI using
    voltage uprating is considered as a very attractive option to increase the power transfer capability of existing                                    a Finite Element Model (FEM). The SPT produced repeatable test. The SPT test data successfully estimated
    substations. Current Eskom clearances for 88 kV and 275 kV are expected to perform well during transients                                           tensile test properties (within ±5% error band), CVN test properties (within ±5% error band) and KIC
    generated in uprated systems.                                                                                                                       properties (within ±25% error band).

26 EPPEI 2018-2019 Programme                                                                                                                                                                                                      EPPEI 2018-2019 Programme          27
C O M P L E T E D P RO J E C T
    Student
    Rikus van Niekerk (Asset Management)
    Email: vniekjo@eskom.co.za
    Industrial mentor
    Christiaan Erasmus                                                                                                                             New Projects                                                                                                  6
    Academic supervisor
    Stephan Heyns

    Degradation estimation of high energy steam piping using hybrid                                                                                The following students are currently studying
    recurrent neural networks                                                                                                                      through EPPEI. These are summaries of
                                                                                                                                                   their research topics.
    A hybrid recurrent neural network was created that consists of a combined recurrent neural network and
    a feed forward neural network. The hybrid model is trained on historical data that has been captured over
    a six-year time period. The adaptive movement estimation optimization algorithm, called Adam, is used to
    optimize the machine learning model. The model was successful in recognizing patterns within the data and
    offers an automated way to parse large data sets that consist of a temporal and static data mixture. This
    suggests a generic approach to make objective decisions on similar complex data driven problems and its
    application is not limited to this particular problem. The methods applied in this research are expected to
    perform even better on problems where the frequency of data collection is higher than what is used in this
    research.

                                                                                                                                                   Student

                                                                                                                                                                                                                                                                      N E W P RO J E C T
                                                                                                                                                   Devan Atkinson (MSc, Materials and Mechanics)
                                                                                                                                                   Email: 17732913@sun.ac.za
                                                                                                                                                   Industrial mentor
                                                                                                                                                   Mark Newby
                                                                                                                                                   Academic supervisor
                                                                                                                                                   Thorsten Becker

                                                                                                                                                   Unifying Framework for Gradient- Descent, Subset Based Digital Image
                                                                                                                                                   Correlation
                                                                                                                                                   This project focuses on the development of DIC, in specific, an open source DIC framework that can be
                                                                                                                                                   utilised for future research projects.

                                                                                                                                                   Applicability to Eskom
                                                                                                                                                   Successful completion of the project aims to establish an open source DIC framework that can be utilised
                                                                                                                                                   for future research projects, as well as for other Eskom-related investigations the require disablement and
                                                                                                                                                   strain measurements.

28 EPPEI 2018-2019 Programme                                                                                                                                                                                                  EPPEI 2018-2019 Programme          29
Student                                                                                                                                   Student

                                                                                                                         N E W P RO J E C T

                                                                                                                                                                                                                                                                                   N E W P RO J E C T
    Alida Auret (MSc, Asset Management)                                                                                                       Andrew Bryce (MSc, Renewable Energy)
    Email: u17380546@tuks.co.za                                                                                                               Email: Andrew.Bryce@eskom.co.za
    Industrial mentor                                                                                                                         Industrial mentor
    Phuti Ngoetjana                                                                                                                           Zoe Lincoln
    Academic supervisors                                                                                                                      Academic supervisors
    Prof Stephan Heyns & Prof Johann Wannenburg                                                                                               Bernard Bekker

    RAM analysis of water treatment plant at Grootvlei Power Station                                                                          Evaluation of utility scale battery storage for ancillary service
    under life extension and varying load conditions                                                                                          applications (network support)
    To develop a reliability, availability and maintainability model for a water treatment plant at a coal fired power                        Eskom has already invested significantly in renewable energy, mainly through the IPP Procurement Programme.
    station. The model will be used to analyse the effects on the performance of the water treatment plant of                                 The benefits of renewable energy can be further enhanced using various storage technologies, so this project
    running the units under varying load conditions.                                                                                          will provide an in-depth investigation into using large utility scale battery storage technologies effectively in
                                                                                                                                              the electrical network.
    Applicability to Eskom
    Optimised reliability, availability and maintainability for the Water Treatment Plant at Grootvlei Power Station                          Applicability to Eskom
    specifically under life extension and varying load conditions.                                                                            Renewable energy is relatively new in South Africa and when renewable energy is added, it often requires
                                                                                                                                              substantial network upgrades and reconfiguration. Energy storage facilities could provide a variety of support
                                                                                                                                              functions, potentially saving on upgrade costs, reducing losses and even providing voltage or frequency regulation,
                                                                                                                                              but further research is required to investigate the viability, applicability and effectiveness of these supporting functions.

    Student                                                                                                                                   Student

                                                                                                                         N E W P RO J E C T

                                                                                                                                                                                                                                                                                   N E W P RO J E C T
    Warren Brandt (MSc, Combustion Engineering )                                                                                              David Delekoa (MSc, Combustion Engineering)
    Email: 1968035@students.wits.ac.za                                                                                                        Email: delekomd@eskom.co.za
    Industrial mentors                                                                                                                        Industrial mentor
    Mike Lander & Willy Garnett-Bennett                                                                                                       Sharlene M’builu Ives
    Academic supervisors                                                                                                                      Academic supervisor
    Walter Schmitz & John Sheer                                                                                                               Walter Schmitz

    Prevention of dew point related air heater fouling                                                                                        Improvement of tube mill coal level measurement accuracy, reliability
                                                                                                                                              and control
    Through focusing on the dew point conditions of flue gas along with the regenerative air heater steel matrix
    metal temperatures, the research objective aims to prevent dew point related fouling. a Modeling tool will be                             The project entails improving the current coal level measurement systems used in Eskom site that uses tube
    used to generate the steel matrix metal temperatures, and to calculate the dew point conditions for flue gas                              mills and also to explore new technologies that can be utilized. The project will ultimately provide assurance
    to identify where fouling will occur. The results will be verified by means of measuring the steel matrix metal                           that mills are optimized and operate at their best optimal level.
    temperatures and the flue gas dew point temperatures at Matimba Power Station.
                                                                                                                                              Applicability to Eskom
    Applicability to Eskom                                                                                                                    The research will be applicable within Eskom’s Generation Business and it will mostly benefit the milling plant.
    The research aims to increase boiler Efficiency, reduce maintenance cost expenditure and production losses.                               This research will benefit tube milling plants by ensuring that the new coal level control systems are explored
    Prevention of dew point related fouling will increase the life expectancy of the air heater elements and                                  that can be used in future, optimizing and better the reliability of the current installed coal level control
    draught group components. The knowledge base of draught group system engineers can also be improved                                       systems to achieve the best optimum mill performance. Achieving that will reduce the likelihood of the units
    to change maintenance and operating strategies to prevent the occurrence of dew point related fouling.                                    booking loadlossess and improves the UCLFs.

30 EPPEI 2018-2019 Programme                                                                                                                                                                                                         EPPEI 2018-2019 Programme                31
Student                                                                                                                                Student

                                                                                                                      N E W P RO J E C T

                                                                                                                                                                                                                                                                  N E W P RO J E C T
    Jeanssy Brunel Diankouika (MTech, Combustion Engineering)                                                                              Louise-Marié Dreyer (MSc, Emissions Control)
    Email: jeanssydiankouika@gmail.com                                                                                                     Email: dreyerlm@gmail.com
    Industrial mentor                                                                                                                      Industrial mentor
    Louis Jestin                                                                                                                           Gabi Mkhatshwa
    Academic supervisors                                                                                                                   Academic supervisor
    Michael Petersen & Walter Schmitz                                                                                                      Gabi Mkhatshwa

    Enhanced process performance measurement in coal fired boilers                                                                         Coal combustion modelling in a semi-continuous coal stove
    (Kusile)
                                                                                                                                           The study aims to evaluate the performace of a semi-continuous coal stove in terms of heat distribution,
    The objective of this project is to improve means of measurement of key parameters of flue gas and air flow                            mass transfer and emissions.
    embedded in mass energy balance equations in order to calculate accurately the amount of coal burnt on a
    daily basis. This will help to forecast the price at which the electricity will be sold the day ahead.                                 Applicability to Eskom
                                                                                                                                           Eskom implemented air quality offset programmes as a result of some power stations’ non-compliance to the
    Applicability to Eskom                                                                                                                 minimum emission standards. The proposed study addresses the contribution of air pollution from informal
    This project will benefit Eskom by helping to control and master the amount of coal consumed everyday.                                 settlements in the vicinity of Eskom power stations.
    Knowing that coal represents 60% of cost of generation, the current project will help Eskom to predict the
    price at which the electricity will be sold the day ahead. This in turn will help to get the power cost under
    control. It will also help engineers working on the plant to have a keen spatial awareness of where the
    subsystems are and how they interface.

    Student                                                                                                                                Student

                                                                                                                      N E W P RO J E C T

                                                                                                                                                                                                                                                                  N E W P RO J E C T
    Ayanda Goodness Dlamini (MTech, HVAC)                                                                                                  Philip du Toit (MSc, Emissions Control)
    Email: 201331677@student.uj.ac.za                                                                                                      Email: dtoitpt@eskom.co.za
    Industrial mentor                                                                                                                      Industrial mentor
    Kevin Kleinhans                                                                                                                        Ken Galt
    Academic supervisor                                                                                                                    Academic supervisor
    Wesley Doorsamy                                                                                                                        Prof Percy van der Gryp

    Condition monitoring of surge arresters                                                                                                Investigation into the poor rejection rates of reverse osmosis (RO)
                                                                                                                                           membranes for low total dissolved solid (TDS) water
    The proposed study will contribute by providing insight to leakage current mechanism of monitoring and a
    means of better harnessing this method for ensuring reliable operation of the arrester.                                                The rejection rates for RO membranes are relatively low (97.5%) for feed water with a low TDS. This
                                                                                                                                           necessitates the use of a second filtering stage, where the rejection rates drop even further (
Student                                                                                                                              Student

                                                                                                                    N E W P RO J E C T

                                                                                                                                                                                                                                                                  N E W P RO J E C T
    Ockert Fourie (MSc, Emissions Control)                                                                                               Dirk Human (MSc, Asset Management)
    Email: fourieockert@gmail.com                                                                                                        Email: humandc@eskom.co.za
    Industrial mentor                                                                                                                    Industrial mentor
    Jacques Calitz                                                                                                                       Steve Barnard
    Academic supervisor                                                                                                                  Academic supervisor
    Jan-Hendrik Kruger                                                                                                                   Gazi Mahmood

    Fatigue strength of a long rod composite insulator under simulated                                                                   Parametric modeling of site based compressors using package
    loading                                                                                                                              instrumentation
    Create a model using fundamental material characteristics to accurately predict the life expectancy of a                             A parametric model of a centrifugal compressor that allows system engineers to benchmark their
    composite insulator before it mechanically fails under loading.                                                                      compressors’ performance will be created.

    Applicability to Eskom                                                                                                               Applicability to Eskom
    The results of this study will be important to line design engineers to use as it will assist to increase the                        The compressor model will allow system engineers to make informed decisions with regards to maintenance
    safety of transmission lines when composite insulators are used, improve selection of insulators from various                        and operation of the compressors on their plant. This will result in less plant down time and reduced
    manufacturers, help workers to identify mode of failure more clearly, help to create a clear maintenance plan                        maintenance costs.
    for the local grids to follow and improve the predicted maintenance cost in the life cycle cost of the line
    during the design stage.

    Student                                                                                                                              Student

                                                                                                                    N E W P RO J E C T

                                                                                                                                                                                                                                                                  N E W P RO J E C T
    Liezl Hugo (MSc, Asset Management)                                                                                                   Enitan Ibironke Titilayo (PhD, Emissions Control)
    Email: hugoli@eskom.co.za                                                                                                            Email: ronkmodel2003@gmail.com
    Industrial mentor                                                                                                                    Industrial mentor
    Houston Carstens                                                                                                                     Gabi Mkhatshwa
    Academic supervisor                                                                                                                  Academic supervisor
    Johann Wannenburg                                                                                                                    John Odiyo

    Assessment of KNPS supply chain for lessons for new build                                                                            Air pollution modelling and human health risks in urban, semi-urban
                                                                                                                                         and rural areas of the Capricorn and Vhembe district, Limpopo province
    Assess the KNPS Nuclear Supply Chain Processes using the core SNPM process, detailed in AP-908 Rev 3
    “Materials and Services Process Description”, for lessons for Nuclear New Build.                                                     This research will contribute to improvement of air quality monitoring, develop comprehensive baseline data
                                                                                                                                         and provide more knowledge on projecting impact of future changes in human activities on air quality and
    Applicability to Eskom                                                                                                               to be able to forecast air pollution.
    The benefit to Eskom is twofold, firstly for potentially improving Nuclear Supply Chain processes at Koeberg
    Nuclear Power Station through the identification of gaps within the materials and services process as well as                        Applicability to Eskom
    gaps within the interfaces to the Work Management (AP-928) and Equipment Reliability processes (AP-913).                             This study will provide more knowledge and comprehensive data for Eskom on possible solution to air
    Secondly, lessons learned from KNPS can be used to set up a more effective and efficient organization for                            pollution. It will provide more knowledge on projecting impact of future changes in human activities on air
    Nuclear New Build.                                                                                                                   quality, most especially semi urban and rural of the study area.The study will further establish a possibility of
                                                                                                                                         health risks awareness from the air pollution data.

34 EPPEI 2018-2019 Programme                                                                                                                                                                                            EPPEI 2018-2019 Programme            35
Student                                                                                                                                   Student

                                                                                                                         N E W P RO J E C T

                                                                                                                                                                                                                                                                   N E W P RO J E C T
    Bertie Jacobs (DTech, Asset Management)                                                                                                   Chantelle Janse van Vuuren (MSc, Renewable Energy)
    Email: bertie.jacobs@eskom.co.za                                                                                                          Email: 18306500@sun.ac.za
    Industrial mentor                                                                                                                         Industrial mentor
    Dr Qingbo Cai                                                                                                                             Keith Bowen
    Academic supervisor                                                                                                                       Academic supervisor
    Dawood Desai                                                                                                                              HJ (Johan) Vermeulen

    The development of a numerical methodology for optimised erection                                                                         Development of an optimisation strategy for designing regional time of
    of guyed V-towers without cranes                                                                                                          use feed-in pricing signals for optimising grid support from renewable
                                                                                                                                              energy (RE) sources
    The purpose of this study is the development of a numerical methodology for optimised erection of guyed
    V-towers without cranes by analysing the critical parameters required and presenting an optimised numerical                               The national utility is responsible for maintaining energy balance in the power network. Flat feed-in tariffs
    model.                                                                                                                                    encourage IPPs to concentrate the renewable energy plants, with high output variability, in highly localized
                                                                                                                                              geographical regions in order to optimise cumulative annual yield, which increases the variability of the
    Applicability to Eskom                                                                                                                    cumulative RE generation profile. This has negative implications for the conventional power fleet.
    Occasionally terrain conditions make it difficult to deploy mobile cranes for the erection of towers. This
    proposed alternative method will eliminate the use of mobile cranes for guyed V-towers resulting in among                                 Applicability to Eskom
    others cost and time savings.                                                                                                             An optimal geographical distribution of the RE fleet will deliver improved grid support and will also provide
                                                                                                                                              to a more equitable geographical distribution of economic benefits of RE.

    Student                                                                                                                                   Student

                                                                                                                         N E W P RO J E C T

                                                                                                                                                                                                                                                                   N E W P RO J E C T
    Preshaan Jaglal (MSc, Renewable Energy)                                                                                                   Landry Mbangu Katende (MTech, Combustion Engineering)
    Email: jaglalp@eskom.co.za                                                                                                                Email: landrymkeng@gmail.com
    Industrial mentor                                                                                                                         Industrial mentor
    Kurt Dedekind                                                                                                                             Louis Jestin
    Academic supervisor                                                                                                                       Academic supervisors
    C.T Gaunt                                                                                                                                 Michael Petersen & Walter Schmitz

    Data engineering for MV load modelling in an uncertain environment                                                                        Enhanced process performance measurement in coal fired boilers
                                                                                                                                              (Lethabo)
    The project aims to achieve a data engineering process, to enable the effective and efficient statistical
    modelling of medium voltage loads. This will provide the platform for the statistical analysis of these loads on                          The main focus of this project is to improve means of measurement of key parameters of flue gas and air flow
    our networks, by incorporating the behavioural influence introduced by disruptive technologies and external                               embedded in mass energy balance equations in order to calculate accurately the amount of coal burnt on a
    factors.                                                                                                                                  daily basis. This will help to forecast the price at which the electricity will be sold the day ahead.

    Applicability to Eskom                                                                                                                    Applicability to Eskom
    This project will benefit Eskom by creating the platform that will enable the statistical analysis of loads on the                        The project aims to develop a coal flow determination system to predict electricity cost and production
    network, incorporating the behavioural influence of disruptive technologies and external factors into load                                capacity that will benefit ESKOM plant engineering personnel substantially in ensuring the accuracy of
    models. This will effectively lead to more informed investment making decisions for the business.                                         measured parameters. Additionally, the goal of the project is to determine coal consumption at different
                                                                                                                                              loads and improve way of measuring of parameters influencing coal flow calculation by analysing every
                                                                                                                                              parameters individually like flue gas and air flow that will be useful to Eskom coal power plant to operate
                                                                                                                                              more efficiently.

36 EPPEI 2018-2019 Programme                                                                                                                                                                                              EPPEI 2018-2019 Programme           37
Student                                                                                                                             Student

                                                                                                                   N E W P RO J E C T

                                                                                                                                                                                                                                                                  N E W P RO J E C T
    Lawrence Koech (PhD, Emissions Control)                                                                                             Letsabisa Lerotholi (PhD, Emissions Control)
    Email: lawrencek@vut.ac.za                                                                                                          Email: letsabisal@vut.ac.za
    Industrial mentor                                                                                                                   Industrial mentor
    N/A                                                                                                                                 Preeya Sukdeo
    Academic supervisor                                                                                                                 Academic supervisor
    Prof H. L. Rutto                                                                                                                    Ray Everson

    Flue gas desulphurization by lime spray drying                                                                                      CFD modelling of a semi-dry FGD in a spray dry scrubber
    The project entails experimental evaluation of the performance of a typical flue gas desulphurization (FGD)                         In this work computational fluid dynamics (CFD) is used to provide a comprehensive model of semi-dry
    by lime spray drying using a laboratory scale spray dyer. The experimental data obtained shall be used to                           FGD occuring in a spray dry scrubber (SDS). The main advantage of using CFD is that it can model complex
    determine optimum operating conditions as well as absorber performance modelling which is crucial in the                            flow patterns whilst incorporating chemical kinetics and thermodynamics, thereby making it easier to study
    design of a spray dryer.                                                                                                            detailed phenomena without installing actual expensive prototypes.

    Applicability to Eskom                                                                                                              Applicability to Eskom
    The adoption lime spray drying FGD process plays a significant role in emission control in coal-fired power                         Eskom has to comply with the Minimum Emission Standards in all its operating power plants by the 1st of
    plants through:                                                                                                                     April 2020. South Africa is a water-stressed country, with some provinces more water-scarce than others,
    • Reduced environmental pollution through scrubbing of SO2                                                                          Eskom is therefore challenged to come up with FGD techniques that require minimum or no use of
    • Propagated knowledge on SO2 sorption processes                                                                                    water while achieving high desulphurisation efficiencies, hence the need to explore and optimise semi-dry
         Selection of appropriate FGD technology for respective coal-fired utility plants                                               desulphurisation techniques.

    Student                                                                                                                             Student

                                                                                                                   N E W P RO J E C T

                                                                                                                                                                                                                                                                  N E W P RO J E C T
    Carl Kohrs (MSc, Energy Efficiency)                                                                                                 Mpai Letebele (MSc, HVAC)
    Email: kohrsc@eskom.co.za                                                                                                           Email: Mpai.Letebele@eskom.co.za
    Industrial mentor                                                                                                                   Industrial mentor
    Francois du Preez                                                                                                                   Sipho Zulu
    Academic supervisor                                                                                                                 Academic supervisor
    Francois du Preez                                                                                                                   John van Coller

    Experimental and numerical investigation of multiple cooling tower fills                                                            Examining alternative energy efficient and cost effective options for
                                                                                                                                        obtaining auxiliary supplies at transmission substations
    Testing and characterizing cooling tower fills to enable commercial comparison of their thermal performance.
                                                                                                                                        This research is a technical feasibility study and cost benefit analysis of a range of energy efficiency solutions
    Applicability to Eskom                                                                                                              that can be implemented in the substation for auxiliary supplies. This is in comparison with the existing
    Reduced risk associated with cooling towers not meeting performance guarantees after repacking. Cost                                techniques.
    benefit for cooling tower repack contracts since no performance guarantee may be required.
                                                                                                                                        Applicability to Eskom
                                                                                                                                        The main benefit to Eskom is the reduction of costs of supplying auxiliary supplies in transmission substations.
                                                                                                                                        This will also help Substation Design Engineers to choose which components they should use when designing
                                                                                                                                        a substation in order to have an energy efficient substation. This includes both primary and secondary plant
                                                                                                                                        design engineers.

38 EPPEI 2018-2019 Programme                                                                                                                                                                                            EPPEI 2018-2019 Programme            39
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