New Source Review for Stationary Sources of Air Pollution (2006) / Chapter Skim
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Appendix E Repair and Replacement Activities in Selected Industries
Appendix E Repair and Replacement Activities in Selected Industries
Pages 294-310
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From page 294... ...
The cost of this activity is estimated to be up to 10% of the replacement cost of the FCCU. Because not all refineries are of the same size and configuration, there are likely to be variations in the replacement-cost percentages.
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From page 295... ...
The repair and replacement activities presented here are expected to have different frequencies and costs among industrial sectors, production facilities, and types of process units because many factors, such as equipment design and operating conditions, affect their frequency and cost (R. Bessette, Council of Industrial Boiler Owners, November 10, 2004, letter to committee)
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From page 296... ...
26 APPENDIX E TABLE E-1 Summary of Common Repair and Replacement Activities, Frequencies, and Cost for Coal-Fired Electricity-Generating Facilities Category Description Repair or Replacement Needs Boiler-tube Rows or bundles of heat-exchanger Wear and periodic failure attributable assemblies tubes to erosion, corrosion, and temperature/pressure-related stresses, leading to such outcomes as leaks, forced outages, loss of reliability, and potential for substantial boiler failure Air heaters Heat exchangers that transfer Exposure to ash, condensate, and heat from flue gas to incoming acid gases in flue-gas path can lead combustion air to plugging, corrosion, and erosion, leading to loss of heat-transfer efficiency. Leakages or pluggage in the air preheater can reduce effective capacity at the plant Fans Forced-draft fans push combustion Erosion and cyclic fatigue; fans air into the furnace; induced-draft exposed to flue gases often subject to fans pull flue gas from the furnace.
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From page 297... ...
APPENDIX E 2 Frequency Cost Considered to be common; entire tube Up to $40/kW to replace tube assemblies on a assemblies replaced at nearly every boiler, large boiler and potentially more on a smaller as early as 5 years after the beginning of boiler commercial operation Replacement in over 80% of units of Up to $6/kW on large boilers, higher costs per basket layers and tubes. Seal replacement is kW on smaller boilers also common Fans have been substantially replaced in Replacement of a large fan can cost up to over 70% of units $20/kW.
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From page 298... ...
28 APPENDIX E TABLE E-1 Continued Category Description Repair or Replacement Needs Control Control and monitoring of boiler, Control systems affect combustion systems turbine, and balance of plant efficiency and other operations of the management plant. When systems fail and require replacement, replacement parts for the original design may no longer be available Coal Unloading, storage, and conveying Wear of conveyor belts, motors, and and ash coal.
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From page 299... ...
APPENDIX E 2 Frequency Cost Replacement of pneumatic controls with Replacement projects can cost up to $10/kW solid-state, computerized, or automated on larger units and $40/kW on smaller units controls has occurred in "most" units Replacement of such components as Replacement of key components of coal conveyor belts, motors, and barge and rail handling can cost up to $4/kW. Replacement unloaders is "common" of key components of ash-handling systems can cost up to $14/kW More than 80% of units have replaced Replacement of a feedwater heater can cost feedwater heaters or major tube bundles up to $5/kW therein Sootblowers have been replaced at "most" Replacement projects can cost up to $9/kW units Replacements have occurred "one or more Replacements can cost up to $30/kW times at most units" Rewind or replacement of motors is Replacements can cost up to $5/kW per "common" motor Replacement of switchgear and other Replacement projects cost up to $9/kW equipment is "very common" Nearly 100% of units have overhauled or Replacement projects can cost $10/kW replaced boiler feedpumps continues
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From page 300... ...
300 APPENDIX E TABLE E-1 Continued Category Description Repair or Replacement Needs Piping/ Pipes carry fluids or slurries. Ducts Leaks can occur because of ducts/ carry gases.
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From page 301... ...
APPENDIX E 301 Frequency Cost Replacements of pipes, ducts, and Repair and replacement can cost up to expansion joints is "common" $23/kW Replacement is a typical choice, but Replacement projects can cost up to $2/kW frequency is not reported
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From page 302... ...
Activity Unit 1 3-5 5 >5 <5 5-10 10-20 >20 Pumps Replace pump seals All X X X X X Repair pumps All X X Replace pumps All X X X X Valves Replace valve packing All X X X X X Replace valves All X X Catalysts Regenerate catalysts Reformer X X Replace catalysts Hydrotreaters X X Replace catalysts SRU X X Replace catalysts not specific X X X X X Column reactors Repair or replace trays All X X and hardware Repair or replace All X X reactor internals Replace weld overlays All X X X inside columns, vessels, and reactors Pressure safeties Repair, replace, test All X X PSVs Exchangers Repair or replace All X X exchanger Repair or replace All X X X bundle Clean tubes All X X Crude unit Crude unit turnaround Crude X X X Fluidized catalytic cracking unit (FCCU) FCCU turnaround FCCU X X X X X FCCU turnaround with FCCU X X cyclone replacement Replace or repair spent FCCU X X X catalyst deflectors in an FCCU
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From page 303... ...
Replace or repair spent FCCU X X X X X catalyst slide-valve actuators Replace or repair FCCU X X X X FCCU regenerator cyclones Replace or repair FCCU X X X X FCCU reactor cyclones Replace or repair FCCU X X X X fractionation-tower internals Repair fractionation- FCCU X X X X X tower internals Replace or repair wet- FCCU X X X gas compressor Turnaround Reformer X X Alkylation unit Turnaround Alkylation X X Hydrocracker Turnaround Hydrocracker X X MTBE (methyl tert-butyl ether) unit Turnaround MTBE X X Diesel desulfurization Turnaround with Hydrotreatment X X catalyst change unit Coker Coke drum Coker X X X replacement Crude/coker Coker X X turnaround Sulfur plant SRU thermal-reactor SRU X X repair SRU thermal-reactor SRU X X replacement Turnaround SRU X X continues
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From page 304... ...
Activity Unit 1 3-5 5 >5 <5 5-10 10-20 >20 Flare Flare-tip replacement Flare X X Flare knockout drum Flare X X replacement Replace flare Flare X X Piping Repair piping All X X X X recorrosion Replace piping All X X X X X recorrosion Heaters/boilers Replace or repair All X X X X heater tubes Replace or repair boiler Boilers X X X X X tubes Replace burners All X X X Steam turbine Steam turbine repairs Turbine X X Steam turbine Turbine X X replacement Storage tanks Repair storage tanks Tank farm X X X X Replace storage tanks Tank farm X X X Replace floating roofs Tank farm X X X in tanks Replace floor in tanks Tank farm X X Wastewater systems General maintenance Wastewater X X Metallurgical changes Metallurgic changes X X to accommodate feedstock quality changes Instrumentation Replace CEMS X X Repair CEMS X X General X X instrumentation Replace X X instrumentation
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From page 305... ...
Activity Unit 1 3-5 5 >5 <5 5-10 10-20 >20 Electric substations Replace substations X X Repair substations X X Replace transmission X X lines ABBREVIATIONS: CEMS = continuous emission monitoring system; SRU = sulfur recovery unit. SOURCE: National Petrochemical and Refiners Association, unpublished material, 2004.
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From page 306... ...
306 APPENDIX E TABLE E-3 Pulp and Paper Industry: Repair and Replacement Activities Percent Estimated Frequency Replacement Cost 1 5 10 20 Activity Categorya year years years years <5 5-10 10-20 Boiler used to generate power Repair superheater tie lugs 4 X X X Repair superheater steam- 4 X X X cooled spacers Replace superheater loops 4 X X X Replace superheater 4,7 X X X assemblies Replace desuperheater 4 X X liner assembly Replace economizer 4,7 X X assemblies Replace generating bank 4,6,7 X X X tubes Replace lower-wall tube 4,6,7 X X X sections Replace lower-wall tube 4,6,7 X X panels Replace lower furnace 4,6,7 X X Repair tubular air heaters 4,5 X X X X X Replace tubular air heaters 4 X X X Repair refractory 4 X X Repair/replace cyclone 4,6 X X X burners Clean and scaffold fire 1,2,4 X X side Auxiliary equipment for power boiler Repair/rebuild coal 4 X X pulverizers Repair/rebuild traveling 4 X X X grates Repair/rebuild ash- 4 X X X X handling system Repair/rebuild coal-feeder 4 X X systems Repair/rebuild boiler 1, 2 X X safety relief valves Remove, calibrate, 1, 2 X X and simulate boiler protective interlock devices
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From page 307... ...
APPENDIX E 30 TABLE E-3 Continued Percent Estimated Frequency Replacement Cost 1 5 10 20 Activity Categorya year years years years <5 5-10 10-20 Auxiliary equipment for power boiler continued Replace, calibrate, 1, 3, 4 X X and simulate boiler protective interlock devices Repair/rebuild burner 4 X X assemblies Repair/rebuild 4 X X sootblowers Repair/rebuild dust 4 X X collectors Repair/rebuild 4 X X precipitators Repair/rebuild turbine 1, 2, 4 X X drives Repair/rebuild FDand ID 4 X X fans Upgrade safety systems to 1, 2, 3 X X revised standards Replace unsupported 3, 4 X X X control hardware Inspect/repair stack 2, 4 X X Repair/rebuild ducts and 4 X X X flues Building structural repair 4 X X X Chemical recovery furnace Replace smelt spout tube 1, 2, 3, X X X openings 4, 5 Replace lower-wall tube 1, 2, 3, 4 X X X sections Replace lower-wall tube 1, 2, 3, 4 X X X panels Replace lower furnace 1, 2, 3, 4 X X X Repair superheater tie lugs 1, 2, 4 X X X Repair superheater steam- 1, 2, 4 X X X cooled spacers Replace superheater loops 1, 2, 4 X X X Replace superheater 1, 2, 4 X X X assemblies Replace desuperheater 2, 4 X X X liner assembly Replace economizer 1, 2, 4 X X X assemblies continues
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From page 308... ...
308 APPENDIX E TABLE E-3 Continued Percent Estimated Frequency Replacement Cost 1 5 10 20 Activity Categorya year years years years <5 5-10 10-20 Chemical recovery furnace continued Replace generating bank 1, 2, 4 X X X X tubes Complete NDE 1, 2, 3, 4 X X Repair refractory 2, 4 X X Clean and scaffold fire 1, 2, 4 X X side Chemical recovery furnace auxiliaries Repair/rebuild ash- 4 X X X handling system Repair/rebuild green- 4 X X X liquor system Repair/rebuild dissolving- 4 X X X tank scrubber system Repair/rebuild dissolving 3, 4 X X X tank Repair/rebuild black- 4 X X X liquor system Repair/rebuild boiler 1, 2, 3 X X safety relief valves Remove, calibrate, 1, 2, 3 X X and simulate boiler protective interlock devices Repair/rebuild burner 4 X X assemblies Repair/rebuild 4 X X sootblowers Repair/rebuild direct- 4 X X X contact evaporators Rebuild direct-contact 4 X X X evaporators Repair steam-coil air 4 X X X heaters Replace steam-coil air X X X heaters Repair/rebuild precipitator 4 X X X Repair/rebuild turbine 4 X X drives Repair/rebuild forced-draft 4 X X and induced-draft fans Upgrade safety systems to 1, 2, 3 X X X revised standards
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From page 309... ...
APPENDIX E 30 TABLE E-3 Continued Percent Estimated Frequency Replacement Cost 1 5 10 20 Activity Categorya year years years years <5 5-10 10-20 Chemical recovery furnace auxiliaries continued Replace unsupported 4 X X X control hardware Inspect/repair stack 4 X X Repair/rebuild ducts and 4 X X flues Building structural repair 4 X X Power-plant auxiliary devices Repair/rebuild deaerator 1,3 X X X X Repair/rebuild 4 X X X demineralizers Repair/rebuild boiler- 4 X X X feedwater pumps Repair/rebuild air 4 X X X compressors Repair/rebuild air dryers 4 X X X Repair/rebuild 4 X X X demineralized-water transfer pumps Repair/rebuild condensate- 4 X X X transfer pumps Repair/rebuild condensate 4 X X X polishers Repair/rebuild condensate 4 X X X magnetic filters Repair/rebuild water 4 X X X softeners Repair/rebuild sand filters 4 X X X Repair/rebuild water 4 X X X clarifiers Repair/rebuild drive 4 X X X turbines Repair/rebuild 4 X X X uninterrupted power supply Repair/rebuild station 4 X X X batteries Repair/rebuild steam 4 X X X pressure relief valves and desuperheaters Repair/rebuild oil storage 1, 4 X X X tanks continues
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From page 310... ...
7. Required because of unforeseen mechanical damage.
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