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

Location
Western Cape, South Africa.

Project Owner/s
State-owned power utility Eskom.

Project Description
The current steam generators in Unit 1 and Unit 2 at the Koeberg NPP have been in operation since 1984 and 1985 respectively. The aim of the project is to extend the design life of the NPP 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.
• the replacement of feed-train components on the conventional power plant, which is conducted during maintenance outages.
• 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 its original life span of 40 years to at least 60 years.

Capital Expenditure
The cost of the project is estimated at R25-billion.

Planned Start/End Date
Not stated.

Latest Developments
Eskom reconnected Unit 1 at the Koeberg NPP to the national grid on October 29, which it says marks an important milestone in further enhancing the security of South Africa’s electricity supply and returning 930 MW to service.

Loading of the fuel started in early September, followed by commissioning activities before the unit’s successful synchronisation.

Eskom has reported that Koeberg Unit 1 and Unit 2 are online, with Unit 1 ramping up and Unit 2 generating 941 MW.

Once Unit 1 reaches full output, the two units will jointly provide more than 1 860 MW of capacity to the national grid – this is about 5% of Eskom’s total electricity output.

Koeberg’s maintenance outages are strategically staggered every 16 to 18 months, ensuring the two units are never offline at the same time. The maintenance, which included comprehensive inspections, safety checks and the statutory ten-year integrated leak rate test (ILRT), has ensured the unit is ready to operate safely and efficiently until its next major maintenance cycle. The ILRT confirms the containment building’s structural integrity and leak-tightness, in line with international nuclear safety standards.

Unit 2 has been running at full capacity for 234 days at a 99.88% year-to-date energy availability factor. Eskom is awaiting the National Nuclear Regulator’s decision on its 20-year long-term operation licence on November 9.

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

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