Kusile Power Station Project South Africa

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Leveraging the plant MicroStation 3D CADD models and information content in visualisation and simulation technology .

Creating truly integrated project execution capability and to maximising the ROI3

for Eskom as the Owner-Operator. Delivering an intelligent integrated information asset of highest value across the

entire plant lifecycle.

Organisation: Eskom Holdings (Pty) Ltd

Project Name: Kusile Power Station

Category: Innovation in Power Generation

Bentley Software Used: Bentley MicroStation, Bentley InRoads, Bentley Structural, Bentley Navigator, Bentley STAAD

Other Software Used: 3D-Pact and Flownex Simulation Software

Project Phase: Under Construction

Completion Date: 2018/19

Project Location: Witbank, Mpumalanga, South Africa

Capital Cost of Kusile Project: $14,000,000,000.00

Cost of 3D Visualisation & Simulation Innovation Project: $1,454,000.00

Kusile: The Project

South Africa is currently facing electricity generation capacity constraints - in response, Eskom Holdings is in the process of building three major power station plants - Medupi and Kusile (Coal Fired) and Ingula (Pumped Storage).

To promote economic growth, meet increasing electricity demand and stimulate South Africa’s economy, it is crucial to complete these projects in the fastest time possible. With the current electricity capacity shortage, Kusile Power Station construction has been fast tracked, reducing its construction schedule from 10 to 8 years.

In 2009, Group Technology (Engineering) partnered with the Kusile Project to prototype 3D visualisation and simulation technologies to leverage the engineering and design base information and MicroStation 3D CAD model content to create truly integrated engineering, project execution optimisation and enhanced O&M capabilities.

Once complete, Kusile Power Station will exist of 6 x 800MW power generation units – making it one of the largest coal-fired power stations in the world. The first unit is planned for commercial operation in 2014, after which the other units will be commissioned at 9 month intervals with full commercial operation by 2018.

Each super-critical boiler is 115 metres high, chimneys are 220 metres high and approximately 500,000 m³ of concrete and 42,000 tonnes of reinforcement steel will be used to execute the project.

Kusile Power Station will be the first Eskom plant to implement FGD (Flue Gas Desulpherisation) technology. FGD is the current state-of-the art technology used to remove oxides of sulphur (SOx), from the exhaust flue gases in power plants that burn coal or oil. This technology is fitted as an atmospheric emission abatement technology, in line with current international practice, to ensure compliance with air quality standards, especially since Kusile power station is located in a priority air shed.

The Goal

Project Data

Project Challenges

TIMELINE TO CONSTRUCT The initial normal 10-year construction timeline for this type and size of plant was reduced to 8 years for Kusile due to electricity supply constraints. DESIGN AND CONSTRUCTION INTEGRATION COMPLEXITY With a multi-contractor EPC project design and execution strategy there are significant design and construction integration challenges, with complex lay-out/arrangement design requirements. NEW TECHNOLOGY Kusile Power Station will be the first Eskom project to implement FGD technology. It is a very complex plant process to control, requiring a very good understanding of the physical plant, process behaviour and control to ensure optimal flue gas emissions control. INTEROPERABILITY & 3D MODEL CAD FILE SIZES The multi-contractor EPC approach has resulted in 3D model submissions in various formats. Merging these very different and large file sizes for design, plant and construction integration checking into one consolidated model became a major challenge. TRAINING & SKILLS DEVELOPMENT A new generation of engineers, operators and plant maintainers need to be trained on very complex plant, new technology and processes (Medupi and Kusile will also have the first super-critical boilers installed in the Eskom fleet). SAFETY (ZERO HARM) Plant and staff safety is non-negotiable for Eskom. Decreased construction timelines and the amount of staff involved with construction activities demands increased focus on safety, the use of correct PPE and safe working practices. Training of operating staff on the actual plant, while phased construction is still happening, also posed a major safety risk. OPERATIONAL READINESS Reduced construction timelines requires earlier operational readiness - confirmation of operability and maintainability is required in the design phase. Faster, more efficient commissioning of plant is critical - the integrated nature of plant systems demands correct, sequential start-up of plant systems.

Benefits

By leveraging the MicroStation platform, 2D/3D CAD content delivered on the Kusile project; and teaming this up with 3D visualisation and simulation capability, a significant return on innovation has been delivered for Eskom - not only on these projects, but also future projects:

• Earlier and improved plant commissioning planning, preparation and execution capabilities.

• Faster, safer “virtual” pre-commissioning, operator & maintenance training and inspection route development very early on in construction, reducing plant hand-over lead times.

• Reduced risk of operability & maintainability design issues in construction/commissioning phases. O&M staff could evaluate the virtual 3D plant before construction begins. ($1:$10:$100 cost saving principle)

• Operator regulatory competency and capability testing can be done safely in a virtual plant that closely mimics the real plant asset.

• Pre-commissioning training possible on typical plant disturbances/upsets – preparing operators for abnormal/emergency situations, improving plant commissioning efficiencies and resulting in better operator response in emergencies reducing the impact of actual plant damage caused by such occurrences.

• Enhanced plant commissioning and operating – changing plant conditions and operating parameters can be simulated in a 3D virtual environment.

• Pro-active training on new plant technology to reduce the risk of “learning curve” failures during commissioning and operations.

• Correct and validated construction, maintenance and operating sequences can be developed and implemented. Technology already deployed at Medupi and Kusile Operating Departments.

• A major ROI has been the successful prototyping of this capability for use on brownfield plants as well. Existing 3D laser scans were successfully migrated into MicroStation and 3D solid models created. With MicroStation being the most efficient preparatory platform, the same 3D visualisation technology capabilities could be enabled.

Return on Innovation

Benefits

Time Savings

Money Saved

• Kusile Power Station is currently on track to deliver the units on the accelerated construction time line. This means a saving on project execution (and associated resource cost) of 24 months.

• Notable Commissioning and hand-over time savings are anticipated due to pro-active operating

staff training; and commissioning and start-up procedures being developed and validated early in construction.

• The 3D visualisation and partial simulator is already deployed at both the Medupi and Kusile

Power Station Operating Departments, where staff has been trained in the use of the technology; and they are using this platform to develop the required operating procedures, training sequences and commissioning information packs.

With Kusile Power Station on track to be commissioned 2 years faster than originally planned, there is significant benefit from Eskom in that income can be generated from this power station 2 years faster than planned (estimated profit at $1,098.80M for 4800MW capacity at 82% load factor).

The table below indicates the typical anticipated benefit that can be obtained leveraging the 3D visualisation and simulation capability in an engineering, operating and maintenance environment:

Typical Cost Impact Cost

Project Stand Time $4,750,000/day/unit

Lost production (Delayed Commissioning) $ 300,000/day/unit

Plant load loss risk (incorrect plant operations) Load Loss, 800MW Unit/day

Unit Trip, 800 MW Unit, return in 4 hours

$ 300,000/day $45,000/incident

Improved Plant & Worker Safety Prevention of 1 disabling injury Prevention of 1 fatality

$16,000/incident $225,000/incident

Reduced Commissioning Time (Pre-commissioning Operator Training)

$ 300,000/day

Alarm/abnormal condition training (Reduced load losses & trips) $4,750,000/day

Large Equipment Failure prevent (e.g. Generator failure) $10,500,000/incident

Value Add of Using Bentley Products

• All lay-out/arrangement design and changes on the coal fired projects are made using the Bentley MicroStation platform and associated Bentley Civil Products. The capabilities offered by MicroStation makes management of such a complex plant design much easier to control and manage.

• The MicroStation 3D capability also enabled fast and efficient checking of “plant problem areas” for

design or construction interferences. MicroStation’s interoperability capability made it possible to bring together multi-EPC 3D model submissions in various formats fast and effectively.

• The ability to extract additional design information and content from the .DGN files also supported

faster and more accurate creation of virtual 3D plants in 3D-Pact.

• MicroStation was found to be the most efficient and capable tool to integrate all the different and size-able 3D model submissions from the various contractors; and was the primary platform used to develop, integrate and prepare the 3D visualisation model used for simulation.

How this Project created a Competitive Edge

• The extent to which the 3D CADD models can be used for maximum ROI3 benefit for Eskom in all stages of the plant asset and lifecycle.

• The extent to which design base information and 3D CAD model content have been leveraged for use in construction, operations and maintenance activities.

• The value add that has been extracted from the 3D CADD model submissions. • The 3D virtual and interactive platform that has been created on a very large and complex plant,

without negative performance to the 3D virtual environment performance and user experience. • The creation of a platform that can readily receive and exchange information with other Eskom

business systems like the SAP ERP system.

The Project Differentiators

Meeting the Engineering Challenges

The Unique Competitive Edge • 3D CADD models are no longer just a design deliverable, but a key business information asset and

project deliverable. • A virtual, interactive 3D O&M training and plant information environment at the user

desktop/laptop. • Leveraging 3D CADD Models and PC gaming technology to create a unique and highly valuable

information asset usable to all plant staff. • The numerous applications for the 3D virtual environment capability within construction,

commissioning, training, operational readiness and skills development, which significantly enhances Eskom’s business operations and safety programs.

• Being able to effectively deal with the complexity and size of the project – and to be able to create a fully immersive 3D, virtual and interactive platform with visibility to all stakeholders and role players.

• Leveraging the 3D Model content as a critical plant information asset over the entire plant lifecycle, including O&M.

• Being able to merge and manipulate Multi-EPC 3D model submissions of large size and different file types in Bentley MicroStation.

Competitive Edge – Examples

Operational Inspection Training, including training on selecting and wearing the right PPE for the operating/maintenance task at hand.

MicroStation 3D Model and design base information integrated with plant process simulator to provide insight into plant behaviour when process parameters changes (used for operational training).

Maintenance dismantling/ assembly sequence development (used for maintenance training and as an aid to maintenance work orders in SAP ERP PM module).

Competitive Edge – Examples

Plant and component dynamics enabled to simulate actual plant behaviour (in this case a steam leak incident on high pressure pipework).

Construction planning and sequence simulation – in this case a comparison between an old and new project plan submitted to indicate changes (new activities added, activities removed, late & early construction and supply).

Plant process visual simulation used for operator training on end-to-end power generation processes.

Environmental & Community Impact

FGD is current state-of-the art, best practice technology used to remove oxides of sulphur (SOx) from the exhaust flue gases in power plants that burn coal or oil. The Kusile FGD Plant will have a minimum of 90% removal efficiency, significantly reducing the emissions impact. Bag-filter technology will be used for the control of particulate matter, while “Low NOx” burners will be used for the control of NOx emissions. The 3D visualisation and simulation enabled on top of the MicroStation 3D CAD models of Kusile has enabled Eskom to gain a thorough understanding of the plant design, process, operational and maintenance requirements of FGD technology. Efficient use of the FGD technology and having staff that can optimally operate the plant, will enable Eskom and South Africa to meet their commitments towards emissions reductions as part of the United Nations Global Compact.

The Environment

The Community All 49 million South Africans are dependent on a stable, reliable and sufficient supply of electricity – delivering our new generation capacity in the fastest and most reliable manner is in the best interest of the country as a whole. The 3D visualisation and simulation capability was exclusively developed in partnership with a local South African company, supporting Eskom’s corporate strategy to focus on local supplier and engineering capability development. FGD produces gypsum as a by-product. Gypsum is used in the manufacture of dry walls and ceilings, which opens up numerous economic opportunities for the community. Eskom is actively engaged with engineering skills development – the technology capabilities developed not only enables the world of engineering design and construction, but also show how 3D CAD models, visualisation and simulation technology is used to create smarter, optimised and highly efficient power generation infrastructure.

Collaboration Technology Used

The Black & Veatch POWRTRAK integrated system environment is used for Project Collaboration with all contractors and staff on the Project expected to submit design documentation, drawings and 3D Models into the system. The 3D-Pact platform is the primary O&M collaboration technology, leveraging 3D models and design base content from other systems and sources to bring it together in one seamless, integrated environment for O&M staff.

"3D PACT and 3D plant information platform provides unimaginable value to familiarise trainees with the plant layout, equipment internals and equipment locations. 3D PACT provides an easy, safe virtual environment for trainees to explore the full plant in real time and learn not only the plant/system layouts and view equipment internals, but it also provides an efficient platform to prepare trainees for unit commissioning tasks and operations. Even after construction of the plants are completed, I believe 3D PACT will provide a time-efficient platform for new learners... It will further allow for planning, training and testing of employees on dangerous operating tasks before they execute such tasks on the plant, thereby reducing the risk of injury to people and damage to equipment.”

Gert Geyser, Medupi Operating Training Group

Acknowledgements

Flownex Flue Gas Desulpherisation Design Module Development, Flownex-3D Pact Integration Development and Eskom Engineer Training on technology

Flownex 3D-Pact Library, Medupi and Kusile 3D operator and maintenance simulator development & deployment

Plant Process design best practice optimisation, configuration, intelligent P&ID’s, 3D simulation software and CADD system enhancements. Specialist consulting and advisory services.

Kusile Data Provision & Migration assistance, CADD 3D Model provision, best practice advisory on engineering practices, data transfer quality management & mapping

Kusile Data Migration mapping, system configuration testing, Plant Codification Reviews & Document to KKS Mapping

Group Technology - Engineering Jackie Herndler Waleed Moses Pumza Damba

Siphamandla Mnyani Johannes van Tonder Raymond Nchabeleng

Albert Mogapi

Group Capital Johann Harmse

Evelyn Monesa (Kusile)

Generation Phindile Mooketse

Deborah Maune Gert Geyser Kevin Brink

Medupi Operating & Training Departments

Project Partners Eskom Team Members