eskom power plant engineering institute eppei programme 2018.pdf · eskom holdings soc ltd reg no...

Eskom Power PlantEngineering Institute

2018-2019 Programme

EPPEI

Eskom Academy of Learning Driving towards Engineering Excellence

Eskom Holdings SOC Ltd Reg No 2002/015527/30Issued by Eskom Power Plant Engineering Institute – July 2018

Acknowledgements

Prof Alison Lewis – University of Cape Town

Prof Ian Jandrell – University of the Witwatersrand

Prof LJ Grobler – North-West University

Prof Sunil Maharaj – University of Pretoria

Prof Cristina Trois – University of KwaZulu-Natal

Prof Hansie Knoetze – Stellenbosch University

Are you interested in advancing your engineering career in Eskom through EPPEI? Below are the minimum requirements and how to apply.

The minimum requirements to apply for admission into the EPPEI programme for 2018 are:

• 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

listed in this document either at a University or a University of Technology (UoT)• 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

How to join EPPEI

EPPEI 2018-2019 Programme

EPPEI 2018-2019 Programme 1

Contents

1 Foreword by Dr Titus Mathe 1

2 EPPEI Eskom management team 2

3 Universities consortium management team 5

4 Specialisation Centre academic representatives 6

5 Completed project summaries 18

6 Current students – research topics 29

7 Student workshop 54

Foreword by Dr Titus Mathe 1

Nelson Mandela said that education is a powerful weapon that can be used to change the world. We 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. The Eskom Power Plant Engineering institute (EPPEI) is a partnership between Eskom and academia to improve the skills and knowledge of the electric power industry and more specifically, Eskom’s workforce. EPPEI has grown from strength to strength since it was first launched in 2012. Despite the 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 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 MatheEPPEI 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 32 EPPEI 2018-2019 Programme

EPPEI Eskom Management Team2

Name Dr Titus Mathe

Position EPPEI Programme Director

Email [email protected]

Name Ouma Bosaletsi

Position EPPEI Research Lead


Name Riekie Swanepoel

Position EPPEI Research Lead


Name Morakanele Thipe

Position Project Manager


Name Andrew Johnson

Position Chief Learning Officer


Name Sumaya Nassiep

Position General Manager: Research Testing & Development


Name Ravi Moodley

Position Senior Manager: Eskom Academy of Learning


Name Roman Pietrasik

Position Contracts Manager



EPPEI Eskom Management Team continued...

Name Abré le Roux

Position Technical Advisor – Tx/Dx

Tel +27 43 703 5484


Name Carolynn Koekemoer

Position Senior Advisor

Tel +27 13 693 2032


Universities consortium management team 3

Name Louis Jestin

Position Interim Consortium Director Mechanical Engineering (UCT)

Tel +27 21 650 3239


Name Bradley Oaker

Position EPPEI Consortium General Manager

Tel +27 21 650 1932


Name Sara Booley

Position Consortium Administrative Officer

Tel +27 21 650 2043


Name Bernadene Minnaar

Position Consortium Administrative Officer

Tel +27 21 650 2037



EPPEI Specialisation Centre academic representatives

4

Name A/Prof Wilhelm FulsPosition Coordinator, Senior LecturerDept Mech. Eng. (UCT)Education PhD Nuclear Eng. (NWU)Tel 021 650 2600 / 083 417 7494Email [email protected] Engineering design and Thermo-fluid process modeling

EPPEI specialisation centre in Energy Efficiency at University of Cape Town

Name Priyesh GosaiPosition Programme ManagerDept Mech. Eng. (UCT)Education MSc (UCT)Tel 021 650 5720Email [email protected] Power Plant Condition Monitoring

Name Pieter RousseauPosition ProfessorDept Mech. Eng. (UCT)Education PhD Mech. Eng. (UP)Tel 021 650 5822Email [email protected]

Name Igor GorlachPosition Professor & ChairDept Mechatronics (NMU)Tel 041 504 3289Email [email protected]

Name Prof Alfayo Alugongo Position Head of DepartmentDept Mechanical Engineering Education PhDTel 016 950 9302Email [email protected] Condition monitoring and vibrations

Partner Universities:

Nelson Mandela University

Vaal University of Technology


Name Walter SchmitzPosition Coordinator, ProfessorDept School of Mechanical Industrial and Aeronautical Engineering (Wits)Education PhD Mech. Eng.Tel 011 717 7047Email [email protected] Computational Fluid Dynamics

EPPEI specialisation centre in Combustion Engineering at University of the Witwatersrand

Name Reshendren Naidoo Position Lecturer/Researcher Dept School of Mechanical Industrial and Aeronautical Engineering (Wits)Education MEng Eng. Man. (UP) Tel 072 246 4233Email [email protected] Numerical Combustion

Name Dr Daniel Madyira Tel 076 029 8563Email [email protected] Fluid Mechanics, Heat transfer and Strength of Materials

Name Prof Stephen Bosman Position Co-ordinator of Postgraduate StudiesTel 061 406 5065Email [email protected] Industry 4.0, Risk, Systems Engineering


University of Johannesburg

Cape Peninsula University of Technology

EPPEI Specialisation Centre academic representatives continued...



Name Stuart PikethPosition Coordinator, ProfessorDept Unit for Environmental Science & Mngmnt & Chemical Resource BeneficiationEducation PhD (Wits) Tel 018 299 1582Email [email protected] Atmospheric and environmental impacts

EPPEI specialisation centre in Emission Control at North-West University

Name Hein NeomagusPosition ProfessorDept School of Chemical & Minerals EngineeringEducation PhD (University of Twente, NL) Tel 018 299 1535Email [email protected] Coal conversion and characterisation, reactor modelling, membrane processes

Name Dr Hilary Limo RuttoPosition Senior LecturerDept Chemical Engineering (VUT)Tel 016 950 9598Email [email protected]

Name Prof John Ogony Odiyo Position Professor and Dean Dept School of Environmental SciencesTel 015 962 8511Email [email protected]


Vaal University of Technology

Name Louis le GrangePosition NWU EPPEI AdminstratorDept School of Chemical & Minerals EngineeringEducation M. Eng. Mech. (NWU)Tel 018 2991664Email [email protected] Multiphase flows

Name Dr Dawie BrankenPosition NWU EPPEI ResearcherDept School of Chemical & Minerals EngineeringEducation PhD Chem. NWUTel 018 299 1953Email [email protected] Emissions control, electrostatics, reaction kinetics, computational modelling

Name Dr Aloys O. Akumu Position Senior LecturerDept Electrical EngineeringTel 013 655 3232Email [email protected]

Tshwane University of Technology

University of Venda



Name Stephan HeynsPosition Coordinator, ProfessorDept Mechanical and Aeronautical Engineering (UP)Education PhD (UP)Tel 012 420 2432Email [email protected] Machine and structural health monitoring

Partner University:

Tshwane University of Technology

EPPEI specialisation centre in Asset Management at University of Pretoria

Name Dr Dawood A DesaiPosition Acting Section Head MechanicalDept Mechanical Engineering (TUT)Tel 012 382 5886Email [email protected]

Name Prof Johann WannenbergPosition EPPEI Curriculum Committee Dept Mechanical & Aeronautical EngineeringTel 012 420 3695Email [email protected] Life cycle management, condition monitoring, maintenance engineering

Name Robert KnutsenPosition Professor, Head of DepartmentDept Mechanical Engineering (UCT)Education PhD (UCT) Tel 021 650 4959Email [email protected] Materials microstructure, electron microscopy

Partner University:

Nelson Mandela University

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

Name Dr Johan WestraadtPosition Senior ResearcherDept Centre for HRTEM Education PhD (NMMU)Tel 041 504 2301Email [email protected]

Name Dr Richard CurryPosition Senior Research OfficerDept Mechanical Engineering (UCT)Education MSc. Eng. (UCT) Tel 021 650 2744Email [email protected] Mat characterisation, structural response, DIC, numerical modelling



Name John van CollerPosition Coordinator, Senior LecturerDept School of Electrical and Information Engineering (Wits)Education PhDTel 011 717 7211Email [email protected] Power system modelling, high voltage engineering

Name Hugh HuntPosition LecturerDept School of Electrical and Information Engineering (Wits)Education MSc(Eng) Tel 011 717 7254Email [email protected] High voltage, lightning

Name Dr Wesley DoorsamyEducation PhD (Electrical Engineering)Tel 011 559 6094 / 072 570 9629Email [email protected] Condition monitoring on electrical machines, intelligent diagnostics

Partner University:

University of Johannesburg

EPPEI specialisation centre in High Voltage Alternating Current (AC) at University of the Witwatersrand

EPPEI specialisation centre in High Voltage Direct Current at University of KwaZulu-Natal

Name Dave DorrellPosition Coordinator, ProfessorDept Eskom CoE HVDC and FACTS (UKZN)Education PhD (Cambridge), MSc (Bradford), BEng (Leeds)Tel 031 260 2730 / 7024Email [email protected] Electrical machinery, renewable energy, power systems

Name Andrew SwansonPosition Senior LecturerDept Electrical, Electronic and Computer EngineeringEducation PhD (Wits) Tel 031 260 2713Email [email protected] High voltage engineering

Name Mr Eamon BussyPosition Senior LecturerDept Steve Biko CampusTel 031 373 2062Email [email protected]

Partner University:

Durban University of Technology



Name Bernard BekkerPosition Coordinator, EPPEI Research Committee ChairEducation PhD (Electrical Engineering)Tel 021 808 4041 / 082 581 5004 Email [email protected] Power system studies

EPPEI specialisation centre in Renewable Energy at Stellenbosch University

Name Karin KritzingerPosition Programme Manager, Senior ResearcherTel 021 808 3605 / 082 412 4466Email [email protected] Electricity tariffs, energy modelling

Name Dr Naim RassoolPosition Director SARETEC (CPUT)Tel 021 959 4231Email [email protected]


Cape Peninsula University of Technology

Name Ndamulelo MararakanyePosition Research EngineerEducation BSc (Eng), MSc (Eng) (UCT)Tel 021 808 3605 / 072 338 2142Email [email protected] Power system studies

Name Herman VermaakPosition ProfessorDept Electrical, Electronic & Computer Eng.Tel 051 507 3898Email [email protected]

Central University of Technology


StudentNikki Basson (Energy Efficiency)Email: [email protected]

Industrial mentorRussell Tarr

Academic supervisorWim Fuls

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StudentLeslie Borrill

Industrial mentorRichard Candy

Academic supervisorProf CT Gaunt

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Duality derived topological model of single phase four limb transformers for GIC and DC bias studies

Geomagnetic disturbances brought about by solar activity cause geo-electric fields in the earth that drive geomagnetically induced currents through the earthed neutrals of transformers and through power transmission networks. The flow of these currents cause the magnetic cores of transformers to half-wave saturate. Saturated transformers pose problems for power system operators since they can cause harmonics, transformer heating, mal-operation of protection relays, generator heating and vibration, and consume a large reactive power that can cause voltage collapse. Network studies of slow transient phenomena such as transformer half-wave saturation require appropriate models to be developed. In this study a novel duality derived reversible model was developed of a single phase four limb transformer that included the non-step lap butt type core joints. The pi model parameters and saturation characteristics were determined through laboratory testing and a complete pi model was presented.

Studying water-wedging as a cause for short term overheating in the boiler of a coal-fired power plant

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.

Completed projects5

StudentDr Arif Arif (Emissions Control)Email: [email protected]

Industrial mentorMr Naushaad Haripersad

Academic supervisorProf Raymond Cecil Everson

The simulation of an industrial wet flue gas desulfurization absorber

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 in the absorber. The droplet and gas velocities were found to be within the ranges appropriate for controlling conditions to avoid carryover of the smaller droplets in the outlet gas stream, and thus to ensure effective operation of the mist eliminator. The distortion of slurry droplets was found to be insignificant with the largest effect occurring near the flue gas inlet to the tower. The addition of the effect of evaporation in the model proved to be important to precisely describe the temperature and moisture concentration profiles within the absorber. The chemical model was successfully developed and implemented in the CFD software by user defined coding, which couple the hydrodynamic model with SO2 mass transfer and related aqueous phase equilibrium reactions. The model is able to predict the desulfurization efficiency, pH, enhancement factor and species concentration at every droplet position in the absorber.

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The following students havecompleted their studiesthrough EPPEI over thelast year.


StudentJacques Brits (Asset Management)Email: [email protected]

Industrial mentorMichael Hindley

Academic supervisorStephan Heyns

StudentColin Francois du Sart (Energy Efficiency)Email: [email protected]

Industrial mentorPieter Rousseau

Academic supervisorPieter Rousseau

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Probabilistic fatigue crack life estimation of a turbomachinery blade during resonance conditions

In this study, an approach has been developed to probabilistically estimate the fatigue crack life of a turbomachinery blade during resonance operating conditions. The developed approach makes it possible to assess the sensitivity of the life prediction to input parameters and calculate the probability of failure at a predefined crack length. A finite element model was used to create a reference database of cracks with associated stress intensity factors of representative cracks within the blade under cyclic loading. To stimulate 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.

StudentNicolas Cardenas (Materials and Mechanics)Email: [email protected]

Industrial mentorMark Newby

Academic supervisorRobert Knutsen

StudentRonald Graham du Toit (Asset Management)Email: [email protected]

Industrial mentorDr DH Diamond

Academic supervisorProf Stephan Heyns

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Feasibility study into the use of digital image correlation (DIC) for creep strain monitoring of fossil power plant welds

Within Eskom, creep damage is primarily quantified by way of metallographic replication (replicas). Although well-known and used extensively, replicas, as with any technology, have their shortcomings including subjectivity during extraction and analysis, and cumbersome management of large quantities of physical replicas. These challenges can potentially be addressed by a technology known as digital image correlation - a non-contact, full field, deformation measurement technique. This study looks into the feasibility of setting up a DIC system, optimised for measuring strain, in an area of the pipework welds known as the Heat Affected Zone (HAZ) – the weakest part of the weldment. The achievable accuracy of this technique was established and the major parameters that affect DIC accuracy were investigated. Additionally, DIC’s potential to be used online, where elevated temperatures are foreseen to introduce measurement errors, was investigated and conclusions on its applicability in such a scenario established.

A stochastic hybrid blade tip timing approach for the identification and classification of turbomachine blade damage

Blade Tip Timing (BTT) has been in existence for many decades as an attractive vibration based condition monitoring technique for turbomachine blades. The technique is non-intrusive and online monitoring is possible. For these reasons, BTT may be regarded as a feasible technique to track the condition of turbomachine blades, thus preventing unexpected and catastrophic failures. The processing of BTT data to find the associated vibration characteristics is however non-trivial. In addition, these vibration characteristics are difficult to validate, therefore resulting in great uncertainty of the reliability of BTT techniques. This study proposed the use of a hybrid approach comprising of a stochastic Finite Element Model (FEM) based modal analysis and a Bayesian Linear Regression (BLR) based BTT technique. The use of this stochastic hybrid approach was demonstrated for the identification and classification of turbomachine blade damage and it has shown many short- and long-term benefits for the practical implementation of this technique.

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Design and prototyping of a dilute phase pneumatic conveying test facility

This project involved the design, development, prototyping, construction and commissioning of a dilute phase pneumatic conveying test facility. The facility allows for accurate online monitoring and control of the particle and gas mass flow rates through a SCADA system developed using LabVIEW. A conceptual system layout for a final test facility was also developed. This facility may be implemented and used to obtain accurate empirical data associated with the pneumatic conveying of pulverised fuel and/or fly ash.


StudentArnold J.J. Hayes (Asset Management)Email: [email protected]

Industrial mentorLukas J. Haarhoff


StudentIan Kuiler (Renewable Energy)Email: [email protected]

Industrial mentorDr Nad Moodley

Academic supervisorDr Marco Adonis

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Characterisation of the core and winding vibrations of power transformers with regulator windings

This study involved the characterisation of the core and winding vibrations of power transformers with regulator windings by measuring the tank vibrations. The experimental tests were performed in the manufacturing plant whilst the transformers under investigation were subjected to the standard factory acceptance tests. The test results show that the characteristics of the core and winding vibrations of transformers with and without regulator windings are very similar, but in the case of transformers with regulator windings, the winding vibrations have a few more dependencies. Thus this research and experimental work provide key insights into how the core and winding vibrations of power transformers with regulator windings are influenced by the regulator windings, how the tank vibrations of transformers with regulator windings should be measured and the difference between the vibrations of transformers with and without regulator windings.

StudentRichard Huchzermeyer (Materials and Mechanics)Email: [email protected]

Industrial mentorMarthinus Bezuidenhout

Academic supervisorDr T Becker

StudentHendrik Frederik Laubscher (Renewable Energy)Email: [email protected]

Industrial mentorProf Frank Dinter

Academic supervisorProf Theodor Willem von Backström

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Measuring mechanical properties using digital image correlation (DIC): Extracting tensile and fracture properties from a single sample

A combined approach to extracting multiple material properties from in-plane (two-dimensional) surface displacements, measured on a single sample through DIC, has been developed assuming an isotropic linear elastic material. This approach utilizes the virtual fields method to obtain Young’s modulus and Poisson’s ratio for a material. These tensile stiffness properties are in turn used as input to a non-linear least squares field fitting approach, which is then used to obtain the critical stress intensity factor associated with a crack or notch in a material.

Developing and testing a cost effective thermal rock bed storage system

In the concentrating solar power industry, thermal energy storage (TES) is an attractive solution for storing excess energy for the periods with insufficient solar resource. The goal of a more cost effective TES for concentrating solar power is to decrease the levelized cost of electricity. With thermal energy storage, a renewable energy electricity production plant can deliver electricity on demand. The development of a novel cost effective TES for air at 600 °C with a unique system layout was covered in this project. The test facility has a scalable design of a specific concept of a packed rockbed TES system. A cost effective layout is 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.

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Condition monitoring of squirrel cage induction generators in wind turbines

Eskom constructed Sere Wind Farm with a rated capacity of 100 MW in 2015, which is its largest renewable energy power plant. Sere Wind Farm has 46 Siemens wind turbines with an individual capacity of 2.3 MW. Due to a lack of skills and knowledge within Eskom, Siemens was offered an operating and maintenance contract until 2020 to ensure the power facility provides reliable and cost effective power. Siemens uses its Turbine Condition Monitoring System to perform optimum maintenance using vibration monitoring, which is the most common condition monitoring technique for modern wind turbines. Vibration monitoring has certain limitations such as the detection of electrical failures in components like the generator. To ensure all forms of failures related to the generator are detected in advance, this study investigated a condition 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.


StudentMatthew Molteno (Materials and Mechanics)Email: [email protected]

Industrial mentorMarthinus Bezhuidenhout

Academic supervisorThorsten Becker

StudentGeoff Raikes (Energy Efficiency)Email: [email protected]

Industrial mentorProf Louis Jestin

Academic supervisorA/Prof Hennie Mouton

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Measuring fracture properties using digital image and volume correlation: decomposing the J-integral for mixed-mode parameters

The degradation of material properties over time is one of the core constituents of structural integrity monitoring. For this purpose, the materials’ resistance to brittle fracture is the most widely used property in the determination of safe operation and predicting component life. Measuring such properties by conventional methods presents challenges: large numbers of samples are needed, accounting for mixed-mode loading. Non- contact measurements by digital image correlation shows promise in extracting such parameters from in situ loaded structures, accounting for their complex geometry and loading. This thesis developed a framework that allows for the extraction of mixed-mode brittle fracture properties, using three-dimensional (3D) image correlation techniques: multi-camera Digital Image Correlation (stereo-DIC), and Digital Volume Correlation (DVC).

StudentSeeralin Nayager (HVDC)Email: [email protected]

Industrial mentorAdesh Singh

Academic supervisorAndrew Swanson

StudentTrisha Rasiawan (Materials and Mechanics)Email: [email protected]

Industrial mentorMarthinus Bezhuidenhout

Academic supervisorProf Robert Knutsen

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Transformer design considerations utilising natural ester oils

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 highest temperature occurring at the top of the winding. The boundary conditions were shown to be of high importance as changing the inlet velocity altered the performance of the winding. The difference between mineral and ester oils is minimal in this particular study. However, it must be noted that the full transformer needs to be considered to have more accurate movement of fluid. The results from the FEM simulations show that the electric field stresses are higher in the paper for ester oil than mineral oil. Due to the long gap and streamer propagation in natural ester oil, high electric fields must be minimised as far as possible. Results of the model was used to make design suggestions for the transformer.

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Temperature reconstruction and acoustic time of flight determination for boiler furnace exit temperature measurement

Acoustic pyrometry, a technique that measures temperature based on the travel time of an acoustic wave in a gas, has been identified as a viable solution for direct measurement of the furnace exit gas temperature. This project focused on the use of acoustic pyrometry to reconstruct the temperature profile at the furnace exit and methods for determining the time of flight of acoustic waves. An improved reconstruction technique using radial basis functions for interpolation and a least squares algorithm was simulated. Its performance was compared to cubic spline interpolation, regression and Lagrange interpolation by evaluating its reconstruction accuracy in terms of mean and RMS error when reconstructing set temperature profiles. Various parameters were investigated in terms of how they inform the acoustic pyrometry implementation. In addition to this, a 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.

The influence of prior creep damage on the fracture localisation in X20CrMoV12-1 cross-weld creep tests

This study investigated the microstructural changes of X20CrMoV12-1 (X20) at various stages of creep exposure. The severity of creep exposure renders the pipe exhausted and requires replacement, this involves welding of new X20 pipe onto the creep exposed X20 pipe. In this study weldments comprising of new X20 welded to creep-exposed X20 were creep tested until rupture. The weakest part of microstructure created by the welding was identified using light microscopy (LM), scanning electron microscopy (SEM) and electron backscattered diffraction (EBSD). The microstructural results show that the failure always occurred in a fine-grained section within the heat affected zone (HAZ) of the creep exposed X20, showing concentrated creep cavitation in this area. This result is consistent with several observations made in previous studies.


StudentChristine Schutte (Emissions Control)Email: [email protected]

Industrial mentorNaushaad Haripersad

Academic supervisorProf Hein Neomagus

StudentNicole Seumangal (Materials and Mechanics)Email: [email protected]

Industrial mentorThobeka Pete


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Value added utilisation possibilities of coal combustion products in South Africa

To reduce the environmental and economic impacts of the disposal of the coal ash and future Flue Gas Desulphurisation (FGD) gypsum, alternative utilisation of these products was investigated. The proposed quality of FGD gypsum that can be expected from different South African limestone sources were evaluated. A Polish limestone and corresponding FGD gypsum sample was used as a base case in creating synthetic gypsum samples from three South African limestone samples. It was found that the gypsum quality correlates well with the limestone purity. Samples of ash from both Poland and South Africa were studied and compared to the South African legislation parameters. A comparison was drawn between the legislation regulating Coal Combustion Products (CCP) in both South Africa and the European Union. The classification of European Union CCP as by products enables the utilisation of it in a bigger spectrum of applications, whilst the South African classification hinders this development.

StudentPeet Schutte (HVAC)Email: [email protected]

Industrial mentorChris van der Merwe

Academic supervisorDr John van Coller

StudentLavhelesani Oliet Tshamano (Materials and Mechanics)Email: [email protected]

Industrial mentorPhillip Doubell

Academic supervisorProf Robert Knutsen

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Voltage uprating of existing high voltage substations when transient voltage stress and available withstand strength are coordinated

When uprating is considered to increase the power transfer capability, the withstand levels of existing external insulation demands an optimization to find a new stress versus strength balance that allows reliable operation of substations at higher voltages. The research involves primarily an investigative simulation study to evaluate the current Eskom available design clearances in terms of their withstand capability when subjected to over-voltage transients. Two voltage range classes were evaluated and the results were discussed. For voltage range 1, it was found that the over-voltage stress was low enough to allow for a higher nominal operating voltage while maintaining the existing clearances. For voltage range 2, existing clearances were also found to be conservative and smaller safety margins will most likely be acceptable. From a transient analysis evaluation, voltage uprating is considered as a very attractive option to increase the power transfer capability of existing substations. Current Eskom clearances for 88 kV and 275 kV are expected to perform well during transients generated in uprated systems.

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Influence of the heat treatment procedure on the stress corrosion cracking (SCC) behaviour of low pressure turbine blade material FV566

In this study the SCC behaviour of LP turbine blade material (FV566) treated to different temperature conditions was evaluated. For the 480°C tempered specimen, the failure mechanism was IGSCC by hydrogen embrittlement. Intergranular SCC or sensitisation was observed for samples treated to temperatures 550 – 620 °C. The 480°C and 550°C temper specimens were the most sensitive to SCC. There was limited success in determining the threshold stress intensity for the different temper specimens. A change in tempering temperature resulted in a change in the quantity and type of precipitates formed. No chromium-rich precipitates were observed in the matrix of the 480°C temper specimen. Isolated areas of chromium-rich precipitates were observed for the 550°C temper specimen. Chromium-rich precipitates were observed for the samples tempered above 560°C. The material’s resistance to SCC improved with increasing tempering temperature.

Development of the small punch test platform to evaluate the embrittlement of power plant materials

This research work assessed the practicality of employing the Small Punch Test (SPT) technique as an alternative option to assess the remaining life of ageing and prolonging safe operation of the critical components within power plants as compared to traditional mechanical tests which are impractical due to large amount of specimen required to carry out the tests. An ex-service low-pressure steam turbine rotor (NiCrMoV steel) was tested in three varied states, namely; as received (AR), heat treated at 600°C (de-embrittled, DE) and 700°C (hardened, HD) to assess the difference in damage using the SPT technique. Standard mechanical tests (tensile, Charpy-V-Notch and fracture toughness) of AR samples were performed at various testing temperature to validate the adopted modified Ramberg-Osgood model from EPRI using a Finite Element Model (FEM). The SPT produced repeatable test. The SPT test data successfully estimated tensile test properties (within ±5% error band), CVN test properties (within ±5% error band) and KIC properties (within ±25% error band).


StudentRikus van Niekerk (Asset Management)Email: [email protected]

Industrial mentorChristiaan Erasmus


Degradation estimation of high energy steam piping using hybrid recurrent neural networks

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.

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StudentDevan Atkinson (MSc, Materials and Mechanics)Email: [email protected]



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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 EskomSuccessful 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.

New Projects 6

The following students are currently studying through EPPEI. These are summaries of their research topics.


StudentAlida Auret (MSc, Asset Management)Email: [email protected]

Industrial mentorPhuti Ngoetjana

Academic supervisorsProf Stephan Heyns & Prof Johann Wannenburg

StudentAndrew Bryce (MSc, Renewable Energy)Email: [email protected]

Industrial mentorZoe Lincoln

Academic supervisorsBernard Bekker

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RAM analysis of water treatment plant at Grootvlei Power Station under life extension and varying load conditions

To develop a reliability, availability and maintainability model for a water treatment plant at a coal fired power station. The model will be used to analyse the effects on the performance of the water treatment plant of running the units under varying load conditions.

Applicability to EskomOptimised reliability, availability and maintainability for the Water Treatment Plant at Grootvlei Power Station specifically under life extension and varying load conditions.

StudentWarren Brandt (MSc, Combustion Engineering )Email: [email protected]

Industrial mentorsMike Lander & Willy Garnett-Bennett

Academic supervisorsWalter Schmitz & John Sheer

StudentDavid Delekoa (MSc, Combustion Engineering)Email: [email protected]

Industrial mentorSharlene M’builu Ives

Academic supervisorWalter Schmitz

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Prevention of dew point related air heater fouling

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 used to generate the steel matrix metal temperatures, and to calculate the dew point conditions for flue gas to identify where fouling will occur. The results will be verified by means of measuring the steel matrix metal temperatures and the flue gas dew point temperatures at Matimba Power Station.

Applicability to EskomThe research aims to increase boiler Efficiency, reduce maintenance cost expenditure and production losses. Prevention of dew point related fouling will increase the life expectancy of the air heater elements and draught group components. The knowledge base of draught group system engineers can also be improved to change maintenance and operating strategies to prevent the occurrence of dew point related fouling.

Improvement of tube mill coal level measurement accuracy, reliability and control

The project entails improving the current coal level measurement systems used in Eskom site that uses tube mills and also to explore new technologies that can be utilized. The project will ultimately provide assurance that mills are optimized and operate at their best optimal level.

Applicability to EskomThe research will be applicable within Eskom’s Generation Business and it will mostly benefit the milling plant. This research will benefit tube milling plants by ensuring that the new coal level control systems are explored that can be used in future, optimizing and better the reliability of the current installed coal level control systems to achieve the best optimum mill performance. Achieving that will reduce the likelihood of the units booking loadlossess and improves the UCLFs.

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Evaluation of utility scale battery storage for ancillary service applications (network support)

Eskom has already invested significantly in renewable energy, mainly through the IPP Procurement Programme. The benefits of renewable energy can be further enhanced using various storage technologies, so this project will provide an in-depth investigation into using large utility scale battery storage technologies effectively in the electrical network.

Applicability to EskomRenewable 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.


StudentJeanssy Brunel Diankouika (MTech, Combustion Engineering)Email: [email protected]

Industrial mentorLouis Jestin

Academic supervisorsMichael Petersen & Walter Schmitz

StudentLouise-Marié Dreyer (MSc, Emissions Control)Email: [email protected]

Industrial mentorGabi Mkhatshwa

Academic supervisorGabi Mkhatshwa

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Enhanced process performance measurement in coal fired boilers (Kusile)

The objective of this project is to improve means of measurement of key parameters of flue gas and air flow 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 EskomThis project will benefit Eskom by helping to control and master the amount of coal consumed everyday. 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.

StudentAyanda Goodness Dlamini (MTech, HVAC)Email: [email protected]

Industrial mentorKevin Kleinhans

Academic supervisorWesley Doorsamy

StudentPhilip du Toit (MSc, Emissions Control)Email: [email protected]

Industrial mentorKen Galt

Academic supervisorProf Percy van der Gryp

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Condition monitoring of surge arresters

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.

Applicability to EskomSurge protection devices are utilised in various distribution and transmission subsystems of the national grid. Transmission lines, substation transformers utilise surge protection devices. Currently, monitoring of these devices is carried out where protection of critical components is required.

Investigation into the poor rejection rates of reverse osmosis (RO) membranes for low total dissolved solid (TDS) water

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 (<90%). The study will investigate the cause of the low rejection rates and determine design guidelines for improved efficiency for these installations.

Applicability to EskomIf the rejection rate be increased to greater than 99% for low TDS water, then it might be possible to bypass the second filtering stage altogether, which will be a considerable cost saving. Improved rejection rates for the second filtering stage will make the system more robust from transients in water quality fed into the first filtering stage, thus ensuring the quality of the demineralised water.

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Coal combustion modelling in a semi-continuous coal stove

The study aims to evaluate the performace of a semi-continuous coal stove in terms of heat distribution, mass transfer and emissions.

Applicability to EskomEskom implemented air quality offset programmes as a result of some power stations’ non-compliance to the minimum emission standards. The proposed study addresses the contribution of air pollution from informal settlements in the vicinity of Eskom power stations.


StudentOckert Fourie (MSc, Emissions Control)Email: [email protected]

Industrial mentorJacques Calitz

Academic supervisorJan-Hendrik Kruger

StudentDirk Human (MSc, Asset Management)Email: [email protected]

Industrial mentorSteve Barnard

Academic supervisorGazi Mahmood

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Fatigue strength of a long rod composite insulator under simulated loading

Create a model using fundamental material characteristics to accurately predict the life expectancy of a composite insulator before it mechanically fails under loading.

Applicability to EskomThe results of this study will be important to line design engineers to use as it will assist to increase the safety of transmission lines when composite insulators are used, improve selection of insulators from various manufacturers, help workers to identify mode of failure more clearly, help to create a clear maintenance plan for the local grids to follow and improve the predicted maintenance cost in the life cycle cost of the line during the design stage.

StudentLiezl Hugo (MSc, Asset Management)Email: [email protected]

Industrial mentorHouston Carstens

Academic supervisorJohann Wannenburg

StudentEnitan Ibironke Titilayo (PhD, Emissions Control)Email: [email protected]


Academic supervisorJohn Odiyo

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Assessment of KNPS supply chain for lessons for new build

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.

Applicability to EskomThe 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 gaps within the interfaces to the Work Management (AP-928) and Equipment Reliability processes (AP-913). Secondly, lessons learned from KNPS can be used to set up a more effective and efficient organization for Nuclear New Build.

Air pollution modelling and human health risks in urban, semi-urban and rural areas of the Capricorn and Vhembe district, Limpopo province

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 to be able to forecast air pollution.

Applicability to EskomThis study will provide more knowledge and comprehensive data for Eskom on possible solution to air pollution. It will provide more knowledge on projecting impact of future changes in human activities on air 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.

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Parametric modeling of site based compressors using package instrumentation

A parametric model of a centrifugal compressor that allows system engineers to benchmark their compressors’ performance will be created.

Applicability to EskomThe compressor model will allow system engineers to make informed decisions with regards to maintenance and operation of the compressors on their plant. This will result in less plant down time and reduced maintenance costs.


StudentBertie Jacobs (DTech, Asset Management)Email: [email protected]

Industrial mentorDr Qingbo Cai

Academic supervisorDawood Desai

StudentChantelle Janse van Vuuren (MSc, Renewable Energy)Email: [email protected]

Industrial mentorKeith Bowen

Academic supervisorHJ (Johan) Vermeulen

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The development of a numerical methodology for optimised erection of guyed V-towers without cranes

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 model.

Applicability to EskomOccasionally 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 others cost and time savings.

StudentPreshaan Jaglal (MSc, Renewable Energy)Email: [email protected]

Industrial mentorKurt Dedekind

Academic supervisorC.T Gaunt

StudentLandry Mbangu Katende (MTech, Combustion Engineering)Email: [email protected]

Industrial mentorLouis Jestin

Academic supervisorsMichael Petersen & Walter Schmitz

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Data engineering for MV load modelling in an uncertain environment

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 our networks, by incorporating the behavioural influence introduced by disruptive technologies and external factors.

Applicability to EskomThis project will benefit Eskom by creating the platform that will enable the statistical analysis of loads on the network, incorporating the behavioural influence of disruptive technologies and external factors into load models. This will effectively lead to more informed investment making decisions for the business.

Enhanced process performance measurement in coal fired boilers (Lethabo)

The main focus of this project is to improve means of measurement of key parameters of flue gas and air flow 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 EskomThe project aims to develop a coal flow determination system to predict electricity cost and production capacity that will benefit ESKOM plant engineering personnel substantially in ensuring the accuracy of 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.

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Development of an optimisation strategy for designing regional time of use feed-in pricing signals for optimising grid support from renewable energy (RE) sources

The national utility is responsible for maintaining energy balance in the power network. Flat feed-in tariffs 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 cumulative RE generation profile. This has negative implications for the conventional power fleet.

Applicability to EskomAn 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.


StudentLawrence Koech (PhD, Emissions Control)Email: [email protected]

Industrial mentorN/A

Academic supervisorProf H. L. Rutto

StudentLetsabisa Lerotholi (PhD, Emissions Control)Email: [email protected]

Industrial mentorPreeya Sukdeo

Academic supervisorRay Everson

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Flue gas desulphurization by lime spray drying

The project entails experimental evaluation of the performance of a typical flue gas desulphurization (FGD) by lime spray drying using a laboratory scale spray dyer. The experimental data obtained shall be used to determine optimum operating conditions as well as absorber performance modelling which is crucial in the design of a spray dryer.

Applicability to EskomThe adoption lime spray drying FGD process plays a significant role in emission control in coal-fired power plants through:• Reduced environmental pollution through scrubbing of SO2

• Propagated knowledge on SO2 sorption processes Selection of appropriate FGD technology for respective coal-fired utility plants

StudentCarl Kohrs (MSc, Energy Efficiency)Email: [email protected]

Industrial mentorFrancois du Preez

Academic supervisorFrancois du Preez

StudentMpai Letebele (MSc, HVAC)Email: [email protected]

Industrial mentorSipho Zulu

Academic supervisorJohn van Coller

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Experimental and numerical investigation of multiple cooling tower fills

Testing and characterizing cooling tower fills to enable commercial comparison of their thermal performance.

Applicability to EskomReduced risk associated with cooling towers not meeting performance guarantees after repacking. Cost benefit for cooling tower repack contracts since no performance guarantee may be required.

Examining alternative energy efficient and cost effective options for obtaining auxiliary supplies at transmission substations

This research is a technical feasibility study and cost benefit analysis of a range of energy efficiency solutions that can be implemented in the substation for auxiliary supplies. This is in comparison with the existing techniques.

Applicability to EskomThe 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.

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CFD modelling of a semi-dry FGD in a spray dry scrubber

In this work computational fluid dynamics (CFD) is used to provide a comprehensive model of semi-dry FGD occuring in a spray dry scrubber (SDS). The main advantage of using CFD is that it can model complex flow patterns whilst incorporating chemical kinetics and thermodynamics, thereby making it easier to study detailed phenomena without installing actual expensive prototypes.

Applicability to EskomEskom has to comply with the Minimum Emission Standards in all its operating power plants by the 1st of April 2020. South Africa is a water-stressed country, with some provinces more water-scarce than others, Eskom is therefore challenged to come up with FGD techniques that require minimum or no use of water while achieving high desulphurisation efficiencies, hence the need to explore and optimise semi-dry desulphurisation techniques.


StudentSizwe Makubo (MSc, Combustion Engineering)Email: [email protected]

Industrial mentorBonny Nyangwa

Academic supervisorsDaniel Madyira & Reshendren Naidoo

StudentDursman Mchabe (PhD, Emissions Control)Email: [email protected]

Industrial mentorPieter Swart

Academic supervisorProf R C Everson

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Effect of coal and air flow variations on load reduction capability of a coal fired burner

The aim of the project is to develop a better understanding of the relationship between burner load reduction capability with varying coal and air flows through a burner as would be experienced in load cycling of a boiler.

Applicability to EskomThis research will develop a method that can assist with optimizing swirl setting to ensure burners can operated over a wide range with stable flames.

StudentMapula Matjee (MSc, Materials and Mechanics)Email: [email protected]

Industrial mentorKobus Smit


StudentSibusiso Siphesihle Mngoma (MSc, Materials and Mechanics)Email: [email protected]


Academic supervisorLesley Chown

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Investigation to stress corrosion cracking (SCC) resistance properties of Duplex Stainless Steel weldments in the as weld condition

The replacement an old tank made from Austenitic stainless steel (Austenitic SS 304L) with a new tank made from Duplex Stainless Steel (DSS 2205) provided an opportunity to evaluate the technical integrity and long-term reliability of the plant asset. The construction of the new tanks involves extensive welding activities to be performed on the formed plate material. The in-situ weldments are left in the as weld condition. The study aims at the evaluation of DSS 2205 and Austenitic SS 304L corrosion properties for the as weld, post heat treated, and solution treated condition.

Applicability to EskomIt is highly imperative to confirm the long-term SCC resistance of the newly fabricated tanks (DSS 2205) that will be exposed to borated water during service.

Microstructural characterization of creep-aged ½Cr-½Mo-¼V welds

The main aim of this research is the characterisation and mechanical testing of creep aged ½Cr-½Mo-¼V (14MoV6-3) welds. The assessment will be conducted on a weldment as-removed from service, a joint created between new and creep aged material and a joint created from virgin material.

Applicability to EskomThe benefits will include getting an understanding on how to complement conventional creep exhaustion estimates with other techniques involving microstructural characterisation, creep testing, mechanical testing and small sample creep testing. The effect of welding of creep aged material on the microstructure, material properties and creep life expectancy can be quantified or qualified.

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Integrated model of sulphur dioxide absorption into limestone slurry in an agitated vessel

The study aims to develop and validate the model that integrates the roles of sulphur dioxide absorption rate, limestone dissolution rate and product crystallisation rate, on the overall performance of the wet flue gas desulphurisation process. The investigation also aims to contribute towards the development of a standard procedure of limestone selection and profiling on the basis of dissolution and sulphur dioxide absorption rate and capacity.

Applicability to EskomThe study will contribute towards the assessment and improvement of the performance of Eskom’s Wet Flue Gas Desulphurisation (WFGD) Plants. The investigation will also contribute towards the development of standard procedure for limestone selection and profiling.


StudentDorian Mokhonoana (MSc, Energy Efficiency)Email: [email protected]

Industrial mentorGerhard Gericke

Academic supervisorFrans Waanders

StudentLesego Moumakoe (MSc, Combustion Engineering)Email: [email protected]

Industrial mentorHamresin Archary

Academic supervisorsWalter Schmitz & Reshendren Naidoo

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Water minimisation at the power station

The primary objective of this study is to determine the possible reduction of the raw water intake of an existing power station by applying process integration techniques to optimise the use of water available in the system. The secondary objective is to reduce the waste water produced within the process, hence reducing the cost of water, reducing the amount of chemicals and reducing the energy needed to treat water. This will be achieved by considering a system as a whole (i.e. integrated or holistic approach) in order to improve its design and/or operation which exploit the interactions between different units in order to employ resources effectively and minimise costs.

Applicability to EskomThis approach will attempt to reduce fresh water intake, reduce the amount of waste water produced and reduce the chemicals used for water treatment.

StudentTshepo Victor Molefe (MSc, HVDC)Email: [email protected], [email protected]

Industrial mentorDavid Dorrell

Academic supervisorDavid Dorrell

StudentZuko Mthwesi (MSc, Materials and Mechanics Email: [email protected]


Academic supervisorJohan Westraadt

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DC link fault propagation on HVDC long lines

HVDC lines can be very long and faults can occur anywhere along the line producing propagating waves. The traveling waves set up can have major effects on the system if not checked. The waves can also be used to identify where the fault is. This project will investigate the propagation nature of HVDC line faults with the aim to being able to identify where the fault is.

Applicability to EskomThe demand on Eskom’s network needs to be maintained and with different types of faults that may occur on HVDC lines fault detection method by waves making it easy and fast to locate faults, so that faults can be eliminated on long lines leading to less load shedding in the country. This enables the stability of the network and therefore ensuring that the system remains secure and reliable most of the time. Hence research remains ongoing for cost-effective and innovative DC Links on long lines that will provide optimal performance as these expensive solutions, thus providing financial savings to Eskom.

Microstructure-to-property relationships in a 9%Cr steel (P91)

This project will aim to implement physical-based creep models that include microstructural measurements in order to determine the microstructure-to-property (SPCT) relationships for 9%Cr alloy steels (P91). In addition, the use of machine learning to determine the microstructure-to-property relationships will be investigated.

Applicability to EskomCorrelations between short-term tests such as small-punch creep tests and more established uni-axial creep tests will allow for physical property measurements done on a small-scale and short-timeframe to be used for long-term prediction of the creep-behaviour of power plant components.

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Effect of ash content on the heat absorption capability of coal fired boilers

The project aims at analysing the impact that ash concentration has on radiation inside the furnace and consequently the effect it has on the evaporator heat pickup.

Applicability to EskomUnderstanding of the effect of ash on radiation will help to enable improved modelling of heat transfer within the furnace and an overall improvement in combustion modelling.


StudentLouw Nagel (MSc, Combustion Engineering)Email: [email protected]

Industrial mentorsFrancois Du Preez & Heena Madhav

Academic supervisorsWalter Schmitz & Hlanganani Tutu

StudentMuziwendoda Ndlovu (MSc, Combustion Engineering)Email: [email protected]

Industrial mentorPreeya Sukdeo

Academic supervisorsWalter Schmitz & Reshendren Naidoo

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Investigation of the effect of anti-scalants and bio-dispersants on condenser tube fouling and thermal performance

Eskom is currently experiencing severe main turbine condenser load losses due to poor cooling water quality. The fouling rate inside condenser tubes and the thermal resistance of the condenser will be predicted as a result of chemical dosing of anti-scalants and bio-dispersants in the cooling water system.

Applicability to Eskom• Reduction of main turbine condenser related load losses.• Understanding of the influence of anti-scalants and bio-dispersants dosing in the cooling water system

on thermal efficiency with predictive models.

StudentRushavya Naidu (MSc, Energy Efficiency)Email: [email protected]

Industrial mentorGary de Klerk


StudentRofhiwa Nemutandani (Combustion Engineering)Email: [email protected]

Industrial mentorHenk Fourie

Academic supervisorsWalter Schmitz & John Sheer

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The dynamic modelling of a combined-cycle power plant

The objective of this project is to develop a dynamic model of a combined-cycle power plant in Flownex in order to compare it to other models created in APROS so that it may be verified.

Applicability to EskomThe shift towards renewable energy has steered the focus of power plant designing towards operating flexibility and fast response, which the combined-cycle process provides. These aspects are required to account for the fluctuation of the supply as well as the demand of power that is associated with renewable energy.

Conveying air requirements for a dense phase fly ash pneumatic conveying system

The purpose of this research is to develop air flow requirements for a dense phase ash conveying system in order to establish the minimum air flow required for reliable ash transport and to establish if the compressor capability is sufficient to service all units as per design.

Applicability to Eskom Eskom’s new built power plant utilizes dense phase ash conveying systems. However, there are concerns that the system utilizes too much air and the current compressors might not be able to service all units once they are all in operation. This project addresses this concern and ties to find ways of mitigating possible shortfalls in the air supply.

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Abatement of fly ash erosion on boiler tubes

The project aims at finding improved solutions to reduce the number of tube leaks caused by fly ash erosion on tubes in the gas path of the boiler. The identification of high erosion areas are carried out in this project as well as the evaluation of the effectiveness of distribution screen design and placement in order to reduce high velocity areas.

Applicability to EskomBoiler tube leaks, as a result of fly ash erosion, are a frequent occurrence in Eskom boilers. This mostly occurs in areas of high velocities which can be mitigated by placing distribution screens in defined locations upstream and downstream of the heat exchangers. Improving the design and placement of these screens will help to reduce boiler UCLFs.


StudentNjoku Prince Obinna (PhD, Emissions Control)Email: [email protected]


Academic supervisorJohn Odiyo

StudentKierana Govender (Pather) (MSc, Combustion Engineering)Email: [email protected]

Industrial mentorJames Sproule

Academic supervisorsWalter Scmitz & Reshendren Naidoo

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Measurementof total landfill gas, methane and carbon dioxide emissions; the past and future trends of the gaseous emissions and the health and environmental impacts of the gaseous emissions: Case study of selected landfills in Limpopo province, South Africa

This study will reduce the greenhouse gases emitted from landfills in South Africa. Also it will help as an alternative to coal generated plants for power generation.

Applicability to EskomThis study helps reduce harmful gases emitted from landfills, which will serve as an offset from the emissions of coal generated plants of Eskom. This will help Eskom consider alternative technology to power generation and understand the economic feasibility of the utilisation of methane from the landfill sites.

StudentHebendran Padayachee (MSc, Materials and Mechanics)Email: [email protected]

Industrial mentorsPreeya Sukdeo & Chris Du Toit

Academic supervisorsWalter Schmitz & Richard Curry

StudentZebron Phiri (PhD, Emissions Control)Email: [email protected]

Industrial mentorLesigen Moodley

Academic supervisorProf Raymond C. Everson

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Solid particle erosion of ductile and brittle materials at coal fired power plants

The objective of this research is to establish which pre-determined materials will be the most suitable for the erosive wear protection in different environments in a coal fired power station. To add to the international knowledge base of material wear characteristics by testing new materials that has not been published in the open literature.

Applicability to EskomUsing suitable protection material/s in high erosive areas of power plants can increase the life and operation of the plant. Testing a variety of commercially available erosion resistant materials for different erosion applications will improve the erosion resistant materials knowledge and allow each power plant to procure the most suitable materials for their erosion application. This will have cost, time and safety benefit s to Eskom.

The experimental evaluation of nitrogen transformation in South African coal chars and the concomitant release of nitrogenous species

The project entails the evolution of the main nitrogen oxides precursors during pyrolysis of typical South African coals. Experimental work comprise of coal pyrolysis in a drop-tube furnace and a bench scale fluidised bed in an endeavour to determine the influence of South African coal attributes on the release of nitrogenous species.

Applicability to EskomEskom’s power generation is heavily dependent on coal combustion, hence the need to be more vigilant and heed the call to significantly reduce emissions. The compliance with the ever-increasing stringent legislation on nitrogen oxides emissions is uncompromisable, therefore this study intends to contribute towards that envisaged bigger picture.

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Determining the design criteria for a fuel oil atomizer

Fuel oil atomizers within the Eskom fleet are in some instances reverse engineered or used beyond their design life due to obsolescence. This project will aid in creating a fuel oil atomizer that can be used throughout the Eskom fleet.

Applicability to EskomEskom currently does not have intellectual property regarding fuel oil atomizers and their combustion air criteria. The development of an atomizer design specification and combustion requirements will aid in safer plant operating with reduced fuel usage, improved purchasing capability with improved technical specifications and reduced component expenses once Eskom is able to design their own atomizers.


StudentCheriska Polton (MSc, Energy Efficiency)Email: [email protected]


Academic supervisorE Boje

StudentPreetha Sewlall (MSc, Energy Efficiency)Email: [email protected]



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Control of main steam and reheat steam temperatures

The present control philosophy accuracy of main steam and hot reheat steam temperatures at Duvha coal fired power plants will be evaluated.

Applicability to EskomBy improving and optimizing steam temperature control ensures design efficiency while maintaining long term plant health.

StudentDuduzile Ramasimong (MSc, Materials and Mechanics)Email: [email protected]

Industrial mentorRonnie Scheepers


StudentAndani Siavhe (MSc, Renewable Energy)Email: [email protected]

Industrial mentorFrancois du Preez

Academic supervisorJ van der Spuy

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XRD effectiveness in fatigue life characterisation on AISI316 stainless steel material

Quantify the effectiveness of X-ray Diffraction (XRD) as a tool for the characterisation of component fatigue life in a simple stainless steel material by subjecting the material to low cycle fatigue tests.

Applicability to EskomDevelopment of a methodology to assess fatigue initiation life using XRD. Improved predictive capability for the long term reliability and life management of base material with possible extension to a turbine blades material. This technique could also be applied for fatigue life assessments (including high cycle fatigue) of other components.

Methods of improving air-cooled condensers (ACC) under windy conditions for ACC against turbine walls

ACC against turbine halls will be modelled numerically using open source software.

Applicability to EskomThe possibility of improving the Majuba ACC’s performance by means of modifications to the existing ACC will be investigated.

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Water minimisation at a power station using process integration and modelling

The proposed research topic is to develop a water management tool through process modelling.

Applicability to EskomA well documented water balance that can be used for future optimization and water reduction. This water balance can be used to feed into other projects aiming at reducing water utilization.


StudentMonde Soni (MSc, Renewable Energy)Email: [email protected]

Industrial mentorKurt Dedekind

Academic supervisorC.T Gaunt

StudentBernard van der Westhuizen (MSc, Asset Management)Email: [email protected]

Industrial mentorShanil Singh

Academic supervisorJohann Wannenburg

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Assessment of geographical based load forecast approach in distribution planning

Assessment results of the geographical based load forecast method, recommendations of improvement in areas where improvement is needed and revision of the Eskom load forecasting standard.

Applicability to EskomThis research will benefit Eskom Network Planning with guidance that will approve or not approve the current method of forecasting. It will also propose better methods/changes if the current forecasting method is found to be inadequate.

StudentIbrahim Stacey (MSc, Materials and Mechanics)Email: [email protected]



StudentMelody van Rooyen (PhD, Materials and Mechanics)Email: [email protected]



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Development of a Small Punch Test rig for embrittlement testing of metallic materials

This project will aim to design and construct a Small Punch Test machine with incorporated Digital Image Correlation (DIC) using two rigid borescopes.

Applicability to EskomMore accurate prediction of component lifetime. Availability of an SPT rig to perform tests using very small samples whilst still ascertaining the needed material and mechanical properties of a part.

Creep damage characterisation of thermal power plant steels using digital image correlation (DIC)

A combined numerical experimental technique is developed to extract creep damage parameters from a single test. The technique is developed for larger samples (~50 mm) as well as for small punch test type samples (~8mm).

Applicability to EskomThe proposed research will develop a technique in which the damage state of creep-exposed material can be identified from accelerated tests of a single sample. By using less time and material to assess the damage level of, for instance, X20 piping steel, the task of maintaining components during scheduled downtime is facilitated.

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Drum reclaimer maintenance strategy setting based on strain measurement

This project aims to identify physical conditions possibly affecting the estimated life of the Medupi and Kusile Power Station drum reclaimers. The main focus will be on fatigue due to cyclic loading.

Applicability to EskomThe main benefit to Eskom is the identification and quantification of risk. This information would help Eskom make an informed decision based on technical knowledge about the manner in which it plans to manage the lifecycle of this machine.


StudentOuma Bosaletsi (MSc, Electrical Engineering)Email: : [email protected]

Industrial mentorPeter Langley

Academic supervisorDr John Van Coller

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Implementing electric vehicle focused tariff structure to support electric vehicle adoption and rooftop solar PVs integration

To configure dynamic distribution tariff system given the expected large penetration of rooftop solar PVs and electric vehicles.

Applicability to EskomThe South African power utility is currently experiencing flat to declining load growth due to changing customer energy consumption behaviour, energy efficiency programs, distributed generation and the downturn in the country’s economy. The number of rooftop solar PV installations is expected to grow rapidly due to falling PV panel prices, increasing price of electricity from the power utilities and supporting government policies. The power utility is thus faced with two fundamental challenges; retaining existing customers and capturing new markets to increase electricity sales. The growing electric vehicle (EV) market presents a strategic opportunity for the power utility to increase electricity sales through supplying EV recharging energy requirements. By optimally managing EV load through cost reflective dynamic tariffs, the power utility may flatten the demand profile by shaving peaks, filling valleys and allowing efficient use of excess available energy generated from renewable energy sources.

StudentDan van Tonder (MSc, Energy Efficiency)Email: [email protected]

Industrial mentorWillem Van Der Westhuizen


Boiler feed pump low load – leak off or re-circulation study

Assess and compare the different BFP leak off systems used throughout Eskom’s coal fired fleet and predict possible operating conditions that reduce the life expectancy of the system.

Applicability to EskomA thorough understanding and prediction ability of the flow control around a BFP will enable Eskom to manage the valve failures either through changes to operational decisions, or alternative valve specifications which may require design recommendations.

StudentGerald Williamse (MSc, Materials and Mechanics)Email: [email protected]



Measuring mechanical properties using digital image correlation and finite element model updating

The project focuses on the development of an finite element model updating (FEMU) approach to calculate mechanical properties from existing material degradation models.

Applicability to EskomThe project proposed will provide an approach to extract material properties using Finite Element Model updating (FEMU) which is required for small sample test techniques and creep and fracture property extraction.

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The fourth annual EPPEI student workshop was held over two days on 29 and 30 May 2017 at Eskom Academy of Learning. The workshop gives EPPEI students the opportunity to present the work they are doing or completed to an audience made up of SMEs, academics and their peers. Participation in such workshops not only disseminates information but also forms an important networking opportunity for all participants in the EPPEI programme.

The 2017 workshop was well-attended by both Eskom staff and academics, as the workshop has become a highlight for all to experience the tangible research produced by students who are studying through EPPEI. Day one of the workshop was kicked off with an opening session by Prof Wikus van Niekerk who welcomed everyone, which was followed by keynote addresses delivered by Dr Titus Mathe and Dr Andrew Johnson. Dr Mathe gave an insightful look at what the future holds as EPPEI enters its second Phase of operation in 2017, while Dr Johnson gave an overview of the plans strategic plans for the EAL.

Five sessions were held on day one, comprising of a general session followed by two parallel streams where one stream focussed on boilers and renewable energy; and the second stream on electrical topics. Day two followed with three sessions held, again opening with a general session and then followed by two sessions focusing on emissions control and asset management which ran parallel to each other.

The two-day workshop concluded with a prize-giving ceremony where EPPEI Specialisation Centres and their academics were awarded prizes from Eskom for their significant contributions and leadership displayed over the 2016/17 time-period. A big thank you must be extended to the Renewable Energy team at Stellenbosch University for arranging this enjoyable and momentous occasion once again.

Student workshop7

EPPEI 2018-2019 Programme 55

Eskom Academy of LearningEskom Power Plant Engineering Institute (EPPEI)

Dale Road Halfway HouseMidrand 1685

Tel: +27 11 651 6978

Eskom Holdings SOC Ltd Reg No 2002/015527/30

eskom power plant engineering institute eppei programme 2018.pdf · eskom holdings soc ltd reg no...

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