Media Briefing 2 Damage to Majuba power station coal storage silo - - PowerPoint PPT Presentation

Media Briefing 2

Damage to Majuba power station coal storage silo

7 November 2014

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Introduction Conclusion Progress: Majuba power station recovery The system outlook and plan

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Introduction Conclusion Progress: Majuba power station recovery The system outlook and plan

Overview

• Eskom has not load shed since Sunday, 2 November 2014 at 22:00
• The system is still tight but remains stable, with Majuba power station currently generating

1 600 MW

• Four of the six units at Majuba are in operation and will be available for full load during

peak periods

• Eskom employees have worked tirelessly for the sake of the country
• The following has been prioritised:
• the safety of our personnel and securing the area surrounding the silo, as well as the

remaining outside coal handling plant

• assessing the damage caused, identification of risks

and rolling out the recovery programme

• providing internal and external investigators the
• pportunity to review the incident in detail
• The investigation could take between 3 – 6 months

to finalise

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Introduction Conclusion Progress: Majuba power station recovery The system outlook and plan

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The damage to a pivotal part of Majuba power station’s outside plant occurred on 1 November

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• Majuba power station has a coal handling and feed

design that is unique within the Eskom fleet

• Coal is sent from the stockyards by conveyor to a

central silo (silo 20) that is pivotal to coal supply of all 6 generating units

• By design the silo has a 50 year life of plant
• The silo has been externally inspected every 2 years

and the most recent inspection in September 2013 showed no signs of deterioration or structural damages

• Unit 4 was scheduled for a 90 day general overhaul
• utage (“GO”) commencing on 1 November
• No inclement weather was experienced and no geo-

activity was reported on the day

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Our emergency and major incident procedures have proven to be effective

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• At approximately 12:30 on Saturday, 1 November, operators on

duty reported a vertical crack on silo 20 to the Engineering Manager and Power Station Manager

• The immediate response was to ensure the safety of our

people; the site and access/ egress points to the silo and conveyor systems were cleared

• Roll-calls were undertaken to account for all employees and

contractors on site – all people were accounted for

• Full escalation to the group executive had taken place by 13:30

with the full collapse occurring at 13:12

• A team of experts were deployed to the site on Saturday

afternoon to rescue capacity and put in place further preventive measures to safeguard the continued operation of the plant

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We have initiated an investigation to determine the root cause of the collapse

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• We have setup a dedicated site recovery team led by

Dan Marokane, Group Executive Group Capital

• A full investigation into the root cause of the collapse is under

way

• The mechanical nature of conveyor and chain driven systems

naturally result in vibrations

• Historical monitoring data, including vibrations monitoring,

have been analysed and there were no indications that the silo was about to fail

• Our investigations will be based on plant data from the time of

the incident and will call on expertise from across Eskom (as well as international independent experts)

• Full details of the investigation will be disclosed to the

shareholders and regular updates on progress will also be made available

Recovery Project : high Level scope of work

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Majuba Recovery Project Immediate Interim Permanent

Two key aspects:

• 1. Recovery of Power

Plant Output

• 2. Safety of Site

(demolishment of the unsafe and collapsed structures) Solution required to maintain power plant

• utput whilst permanent

solution is designed, procured and constructed Construction of temporary conveyor system to feed coal from coal stock yard to power station units Solution that offers long sustainability could be “like-for-like” or an

• ptimised design

Construction of full works to feed coal from coal stock yard to power station units Immediate Actions undertaken:

• Project Manager is appointed
• Project set-up in progress including project controls with resources
• Group Technology and Group Commercial support mobilized
• All other required support for the project to be mobilized as scope of work unfolds

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Our plans to restore capacity in the short- and medium-term are yielding results

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• In the immediate term, mobile feeders are installed to feed units 1, 2, 5, and 6
• By-pass systems that allow unit 2 to feed 60% of unit 3 coal bins are been utilised
• Capacity has already been restored at 4 of the 6 units (Unit 4 remains offload as

it is on planned maintenance for 90 days)

– The plant is already operating with at least 70% of expected capacity

• Coal supply from the stockyard to the generating units is secured by means of a

short-term truck-based solution

– This solution will not increase coal truck volumes on the outside roads, but will

increase traffic in the outside plant areas and at the station entrance

– A system to ensure safe trucking of coal within the outside plant areas has

already been established

• This short-term solution is envisaged to be in place for 6 months
• As the site is cleared additional solutions will be put in place to further rescue

additional capacity and ensure safe working conditions

• The full recovery of the coal feed systems will be completed within 24-months

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Our teams are committed to recovering normal

• perations and are focused on a critical set of actions

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Critical actions to take

• Complete scope of work for making the

construction site safe

• Detailed recovery plan, including design, the

build and financial implications

• Demolishing of damaged structures
• Install second Buffalo feeder on silo 30
• Clearance and removal of rubble from site
• Redesign of coal conveyer system and silo

structure Timing

• 10 November 2014
• 28 November 2014
• 21 November 2014
• 17 November 2014
• 12 December 2014
• 31 December 2014

Overview of Majuba power station

Sequence of incident

Intact silo 20 and coal feed system Major vertical and lateral cracks Collapse of silo 20 Damaged conveyor and coal feed system

Situation before failure of silo

Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Silo 1 Silo 2 Silo 3 Coal stock- yard Delivery of coal by truck and train

Online Maintenance Conveyor belts

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Current situation

Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Coal stock yard Delivery of coal by truck and train

Online (partly with reduced capacity) Offline Conveyor belts Truck delivery Mobile feeders

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Current operations – replenishment of coal stocks

Standard procedure - deliveries to stock yards Coal transshipped from yards to outside plant areas Coal delivered to silos 10 and 30

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Current operations – coal feed to generating units

Mobile feeders Front-end loaders Delivery trucks

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Current operations – safety focus

Contained traffic flow pattern within the plant to service replenishment from stocks to silos Temporary road for passenger vehicles to limit coal truck and passenger vehicles crossing paths Barricading 1-metre from buildings and for pedestrians walkways; pedestrian crossings also installed

Coal stocks Silos 10 and 30

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Introduction Conclusion Progress: Majuba power station recovery The system outlook and plan

Assumptions for the week ahead

• Weather
• Scattered showers are forecasted for tomorrow evening 08 Nov 2014
• Sunny weather is forecasted over the weekend, with some scattered

clouds

• System Outlook
• Improved system condition is expected over the weekend with a reduction

in demand

• This will assist with restoring emergency resources for next week
• As Majuba stabilises the system looks stable for the next few days, with all

peaking plant required for evening peaks and system contingencies.

• While the system remains vulnerable and tight, the probability of load

shedding is low over the weekend and in the coming week. Any changes will be communicated via the media

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NB: Only shortfall on demand is shown. Reserves are required to meet peak-in-peak.

Saturday view

(8 November 2014)

Date Time Expected Avail Cap (Incl Primary Constraints) Forecast Shortfall/Surplus

• n demand

08/11/2014 00:00 to 01:00 29502 23276 6226 08/11/2014 01:00 to 02:00 29002 22750 6252 08/11/2014 02:00 to 03:00 29002 22577 6425 08/11/2014 03:00 to 04:00 29295 22533 6762 08/11/2014 04:00 to 05:00 29587 23036 6551 08/11/2014 05:00 to 06:00 29587 23989 5598 08/11/2014 06:00 to 07:00 30337 25100 5237 08/11/2014 07:00 to 08:00 30737 26819 3918 08/11/2014 08:00 to 09:00 30737 28060 2677 08/11/2014 09:00 to 10:00 30737 28201 2536 08/11/2014 10:00 to 11:00 31887 27904 3983 08/11/2014 11:00 to 12:00 31887 27798 4089 08/11/2014 12:00 to 13:00 31887 27542 4345 08/11/2014 13:00 to 14:00 31637 27029 4608 08/11/2014 14:00 to 15:00 31137 26501 4636 08/11/2014 15:00 to 16:00 30737 26241 4496 08/11/2014 16:00 to 17:00 30737 26473 4264 08/11/2014 17:00 to 18:00 30737 26897 3840 08/11/2014 18:00 to 19:00 30737 28113 2624 08/11/2014 19:00 to 20:00 30937 28740 2197 08/11/2014 20:00 to 21:00 30737 27379 3358 08/11/2014 21:00 to 22:00 30737 25542 5195 08/11/2014 22:00 to 23:00 30087 24196 5891 08/11/2014 23:00 to 00:00 29587 23042 6545

Keeping to scheduled hours at Palmiet and Drakensberg, to maximise hours for Monday. Sufficient reserves available including OCGTs. Require water and GTs to manage peaks.

Sunday view

(9 November 2014)

Date Time Expected Avail Cap (Incl Primary Constraints) Forecast Shortfall/Surplus

• n demand

09/11/2014 00:00 to 01:00 29587 22431 7156 09/11/2014 01:00 to 02:00 29587 21882 7705 09/11/2014 02:00 to 03:00 29587 21652 7935 09/11/2014 03:00 to 04:00 29587 21706 7881 09/11/2014 04:00 to 05:00 29587 21928 7659 09/11/2014 05:00 to 06:00 29587 22656 6931 09/11/2014 06:00 to 07:00 29587 24034 5553 09/11/2014 07:00 to 08:00 30337 25856 4481 09/11/2014 08:00 to 09:00 30737 27298 3439 09/11/2014 09:00 to 10:00 30737 27620 3117 09/11/2014 10:00 to 11:00 31387 27454 3933 09/11/2014 11:00 to 12:00 31137 27130 4007 09/11/2014 12:00 to 13:00 31137 26774 4363 09/11/2014 13:00 to 14:00 30737 26251 4486 09/11/2014 14:00 to 15:00 30737 25822 4915 09/11/2014 15:00 to 16:00 30087 25708 4379 09/11/2014 16:00 to 17:00 30337 25739 4598 09/11/2014 17:00 to 18:00 30737 26467 4270 09/11/2014 18:00 to 19:00 30737 28078 2659 09/11/2014 19:00 to 20:00 30937 29352 1585 09/11/2014 20:00 to 21:00 30737 27923 2814 09/11/2014 21:00 to 22:00 30737 25649 5088 09/11/2014 22:00 to 23:00 29587 23937 5650 09/11/2014 23:00 to 00:00 29587 22537 7050

Keeping to scheduled hours at Palmiet and Drakensberg, to maximise hours for Monday. Sufficient reserves including OCGTs to manage instantaneous demand. Require water and gas turbines to manage peaks.

How can consumers help?

• Saving electricity reduces pressure on the grid and cuts your electricity

bill and South Africa’s carbon emissions

• The power system remains vulnerable all day up to 10pm

1. Switch off air-conditioning or use efficiently

• Set air-conditioning at 23 degrees

2. Switch off all geysers and pool pumps all day until 10pm 3. Switch off all non-essential lighting 4. Respond to the Power Alert messages by switching off all appliances that are not being used

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Introduction Conclusion Progress: Majuba power station recovery The system outlook and plan

Conclusion

• The team have worked tirelessly to ensure that two thirds of the load at Majuba is

restored to the grid by the weekend

• As a result load shedding was limited to Sunday, 2 November at 22:00
• An investigation is already underway into the cause of the incident, but it appears that

this is an isolated incident specific to the coal infrastructure at Majuba.

• A recovery team has been established and a high level recovery scope of work is in

place

• We call on stakeholders who have additional information on the incident to contact us ,

to ensure that the investigation is robust

• Eskom apologises to all electricity consumers but call on you yet again to switch off

unnecessary lights, the geyser, pool pump and air-conditioning

• In the event of load shedding , schedules are available on Eskom’s website, and

municipal customers should contact their municipalities for details

• We are painfully aware of the impact of this incident given the electricity supply situation

in the country

• We will continue to communicate with stakeholders, customers and the media

Thank you

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