The Kusile Power Station project in South Africa leveraged 3D modeling and simulation technology to improve project execution, maximize returns, and deliver an integrated information asset. By using Bentley software like MicroStation for 3D modeling and simulation tools, the project achieved benefits like improved commissioning, training, and lifecycle management. This supported delivering the large, complex plant faster while enhancing safety and operational readiness.

1. Kusile Power Station Project
South Africa
InnovationinPowerGeneration
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.

2. 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

3. 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

4. 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.

5. 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

6. 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

7. 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.

8. 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.

9. 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).

10. 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.

11. 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.

12. 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

13. 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