Name of the Project
Koeberg nuclear power station steam-generator replacement (SGR) project.

Location
Western Cape, South Africa.

Project Owner/s
Eskom.

Project Description
The current steam generators in Unit 1 and Unit 2 at the Koeberg nuclear power station have been in operation since 1984 and 1985 respectively. The aim of the project is to extend the design life of the nuclear power station by 20 years to 2045.

The project involves the replacement of all six steam generators for units 1 and 2.

The SGR project involves the design, manufacture and installation of three steam generators in each of the Koeberg power plant’s two operating units, as well as safety analyses and studies to comprehensively demonstrate the plant’s design integrity, with no adverse impact on public and worker safety and health or the environment, including the enhancement of nuclear safety.

The new generators will incorporate modern design features for easy maintenance and inspections, and improve heat-transfer efficiency, leading to an overall efficiency improvement of Koeberg.

The installation of the generators will be conducted during the scheduled refuelling, inspections and maintenance outages of the two units at Koeberg power station. Eskom is on track and progressing according to plan for installation during the next unit 1 and 2 outages.

The other major components of the life-extension plan include:

• a refuelling water storage tank replacement project, completed in 2019;
• the Unit 2 reactor pressure vessel head replacement, with the installation thereof scheduled for 2022;
• the replacement of feed-train components on the conventional power plant, which is conducted during maintenance outages; and
• the ongoing Koeberg safety aspects of long-term operation assessment. The assessment is designed to provide the equipment-ageing management confirmation to enable the Koeberg plant to operate beyond the original 40 years life span to at least 60 years.

This safety case on the life extension will be presented to the National Nuclear Regulator in mid-2022 to allow for approval of the Koeberg plant’s entering into long-term operation from mid-2024.

Capital Expenditure
Not stated.

Planned Start/End Date
Work on replacing the steam generators for the first of Koeberg’s two units is scheduled to start during a planned outage in January 2022, with the overall project taking two years to complete.

Latest Developments
Global civil nuclear body the International Atomic Energy Agency’s (IAEA's) peer review mission of the Safety Aspects of the Long-Term Operation (SALTO) at the Koeberg Nuclear Power Station from March 22, 2022 to March 31, 2022, has shown that the power station has made significant improvements and has closed gaps identified since the first SALTO mission in 2015.

The IAEA team of nuclear professionals from eight countries reviewed the safety aspects of Koeberg’s long-term operation to extend the life of the power station by 20 years, including preparedness, organisation and programmes for safe operation.

The team also provided recommendations and suggestions to further enhance the preparations for long-term operation safety, including that Eskom should comprehensively review and implement all plant programmes relevant for long-term operation.

The IAEA team also recommended that Eskom complete the revalidation of qualification of cables in the containment for the long-term operation period and ensure full functionality of the containment structure monitoring system.

Meanwhile, Department of Mineral Resources and Energy (DMRE) Nuclear Safety and Technology chief director Katse Maphoto has emphasised the strategic importance of Koeberg’s long-term operation from a national energy security and grid balance point of view.

“The government remains optimistic that the . . .  project will benefit a lot from this IAEA mission recommendations for the power station to achieve the highest level of safety that is on par with the best practices globally,” he said.

Eskom’s Chief Nuclear Officer Riedewaan Bakardien has said that Eskom has incorporated some IAEA standards and guidelines into its policies and procedures, with a robust framework having been put in place for the life extension.

To execute the long-term operation safely, Eskom has performed benchmarking exercises with other utilities worldwide, and requested the assistance of international nuclear safety review bodies, including the World Association of Nuclear Operators, the Institute for Nuclear Plant Operators and the IAEA.

The IAEA team identified Koeberg good practices and learning points that will be shared with the nuclear industry globally, including an integrated corrective action programme to extensively consider operating experience for the long-term operation.

The IAEA team also identified the use of a template by Koeberg staff – to collect vital importance parameters from original-equipment manufacturers to establish the extended qualified life of electrical components – as good practice.

The team also considers the so-called capability index – applied to characterise health, attitude and other enablers of staff to qualify if they are fit to perform a task – as good practice

Key Contracts, Suppliers and Consultants
Framatome (main SGR contractor); General Electric (modifications to the balance of plant or secondary turbine system); and Jacobs Engineering (BoP hardware changes).
 
Contact Details for Project Information
Eskom media desk, email mediadesk@eskom.co.za.