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 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, which was completed in 2019;
• the Unit 2 reactor pressure vessel head replacement, for which manufacturing is scheduled for completion in 2021 and the installation thereof 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
Three steam generators for Unit 1 have been completed and delivered, with the construction of the remaining three generators for Koeberg Unit 2 progressing well, despite the Covid-19 pandemic and consequences on productivity. 

The manufacturing of the remaining steam generators is progressing well for installation on the second Koeberg unit during the next outage.

Framatome is the main contractor appointed by Eskom to design, manufacture and install the replacement six steam generators for Koeberg Unit 1 and 2. As a result of the engineering analyses and system verification associated with the steam generator replacement, several hardware modifications on the balance of plant (BoP) are required to be undertaken. Eskom appointed General Electric to perform the bulk of the BoP hardware changes. A portion of these BoP hardware changes will be performed by Jacobs Engineering.

Key Contracts, Suppliers and Consultants
Framatome (main SGR contractor); General Electric (modifications to the BoP or secondary turbine system); and Jacobs Engineering (BoP hardware changes).
 

Contact Details for Project Information
Eskom media desk, email mediadesk@eskom.co.za.