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Appendix D: Repair and Replacement Activities in Selected Industries
Pages 208-226

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From page 208... ... Appendix D REPAIR AND REPLACEMENT ACTIVITIES IN SELECTED INDUSTRIES A summary of common repair and replacement activities for specific areas of a typical coal-fired power plant is given Table D-1. The table does not attempt to summarize less frequent major replacements at a plant, such as repowering with a new furnace using an existing steam cycle or replacing major components (e.g., turbine generator) Read the entire page →
From page 209... ... Bessette, Council of Industrial Boiler Owners, November 10, 2004, letter to committee) Read the entire page →
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From page 211... ... 211 r wea llim st kW /kW e can of can $5 co Wk to ng acipleR anis $2/ ent zer ent ; ent ethfo eldn ent up veri stoc re-llimd topu adlbein to rotor up ell bu st part pul can an placem co rbuT Wk0/ and replacem cost $2 replacem sheth canein stoc rbtu 60/$ot be Wk0/ up Tu replacem can $1 enebevahs stinufo ve ha n veah tha tially itsnu besut illm 50%re rsotorro reom of in substanro erizerlv acedl ovnider esdablenib 60% placedre stinu of % anhter sernednocd ace Pu rep repai Tur been 90 Mo repl lsarenim es,l ot or re , teriorni tab cen in on; orlai eht n ca ts ducesre rdahote where owfl llers, ngpipid ent ttereb er ca part failue ofn ro bearings ritiesu with replacem modna eadln osirr teraweht alloys) ; ong atio erosion strikesr belts, an, experie ally lin e;blsi tubd of esd su espa ble onita reusopxeot aninmatn eamstniseit besutfo an amint du and including (u co fou ge de bla sh availa purimi es cootdaeln sfer, con sionarbA-erlv classifiers, tors,om cesvi impote rol du coal, requiring,m ed sulniro or rat desirehteino ical on; pososalsi tran tos cycle m in solids/powde surfaces, teriorationed balls, seals, cont Turbine wear stea adlbfo gnised dueeatrorie eath care ow recently gene det to Fl erosi wat ogloib desi ggaupll ful eath lead stea r e pud dewop fo ng e side cuum on an rs;o tubd verrihc steam vaa are ing edefrof nefiaotni posedmoc nozzles, posed udiclni, lation an (at are esn es,d rotd bla comera suni whini tubeth shella on eraturep sure bient) Read the entire page →
From page 212... ... 212 stoc on of st and en gni st of ent Wk to of en cost can its no ent ndl up ent gnild Wk ent stocn stoC 10/$ot itsnu un ha ; han- waterd ca /kW $5 er Wk0/ onpm onpm llera Replacem projects up larg"t $4 sm Replacem coyek,s coal stoc Wk of can $4/ replacem coyek cansm ash 14/$ot of syste up Replacem feea heater topu os d atic um tedamo "mni nts torom an veah orsr rs, -state, heate ereinth pne aut edr oade itsnu lid les of so or cur ponemoc of oc of belts,ro unll beotdetro ent 80% with ncy ls hass ent nveyoc repsi on" feedwaterd undbe que rotn puterized, rol rs Fre Replacem co com cont itsnu ash raidnaeg anhter tubro Replacem suc bar heot "comm Mo replace maj sd Nee and nte affect acempleR efficiency ;tnaplehtfosnoi ; d parts quirere ent daels ent noyam and gn lts,ebr pmui eq ducereot ubetd fails desi replacem blea eyo rat ent, avail nv herotd eadls citya cap orr systems co ggeupl; oper be an of of paieR bustion systemn ubetgn encyci Control com heot alnigiroehtr ear whe replacem fo longer W rs,otom sslo corrosion Leaki effi to fo m ofgnriot ncea ozers ser d lld bald an ) ,elpi ,revi nk nte fro bu delot onim an nte e, eatmrt ag e,n orst coaleht and rs, psmup teraw essc theot onipt dnalor key;aloc (Continued) Read the entire page →
From page 213... ... 213 stoc to ent can ent /kW to ents up rotomr pe $9 up Replacem projects topu Wk0/ stoc Wk Replacem costs $3 Replacem can $5/ d st rreu ts of been uni" occ nte veahsrewoblot ost have "nomm "m atd ents motasemiter acemplre "co ace So repl Replacem moroeno" ordn is its"nu wieR rstoom ni rs weo latter ge;a if and and which otd -bl the ss, dam rel fall failure als h, d of lea an stresses ess ootsfon to re laitne enev efficient or slag as, callyi cau ssle to aces;rfus es boino uncontrolled ich potd loss agsl adlen of ternin can typ failuot atior ffectie gases on,isore of to ple, e-relatedr wh, leads lead amxe ofpudl ca ounts am Deterio reduces turn cleaning can for bui surfaces large ilerobegamad eraturesp tem n,oisor le angni ts High corrosive cor eratupmte failuresrto abtu lation eathr t-ou Mo attrib suin or ove sh at eamst ove such ubest a,ivli d and nu an ;d ou ry of veryi remotrai omrf rs,e lts,eb van ent tubes an ugh r ca del or aglsdna include nozzles, scann thro s,pm uipmqe alocdez ems veri troduceniera s, used pue heotdna s, rsotom; size for ressp h, of angerhcxe ses,acem vane syst so amelf, snt zer ent in emst com as, in heat d, pulhc air calpiytrehotera are driv ers,p box ers pone tot pm Sy or soot surfaces as Burner an whi staged dam ndiw rsto ghtil com Mo anlp veri pul equi eatlyrg srewoblot r wate rsto So and lances Burners Mo Read the entire page →
From page 214... ... 214 up stoc ent cost ent can /kW $9 Wk0/ Cost Replacem projects to Replacem projects $1 dnar ducts, to itchgeaws eryv"si havest boiler up of ent unifo pes,pi sistn dnar stoc replaced of ent pm 0% ord joino repai can ents nsi ent ncy que quier on"m 10y spm pa rhaule ex on";m Fre Replacem heot Wk3/ com Nearl ove eedpuf Replacem and "com replacem $2 s re r Needs andt, short fo peratu noisnap e rat ent dust, anlpeth to lead toeud heotd onsitidn ot use an co ure, ex; sepa placem in can ceiv -temh beca hig sion ork Redna coal dueru ds ser re, or,s rro to esr tnaplehtfos ent pect oarl callyi on,isore eratpmet ent co ure typ ng occn accrn ca Repair Expos eratupmte asr ronm ove re ndia re) u nm ro heot n,oisor ghhi.,g ssurep-h envi and Failu cor dem (e. Read the entire page →
From page 215... ... 215 stoc ent can /kW $2 Replacem projects topu tonsi typicala ncy is que ent fretub d ce, rteo Replacem choi rep -l ot ectjbuserasrt leadnac fai ,.g or (e.s ade soot not d eth 2. reduce of failure ctiveness orr rfacesus failedyb ed 200t pa ess effe ponentmocr wear; en clean ) Read the entire page →
From page 216... ... (% per Unit) Activity Unit 1 3-5 >5 <5 5 5-10 10-20 <20 Pumps Replace pump All x x x x x seals Repair pumps All x x Replace pumps All x x x x Valves Replace valve All x x x x x packing Replace valves All x x Catalysts Regenerate Reformer x x catalysts Replace Hydro- x x catalysts treaters Replace Sulfur x x catalysts recovery unit (SRU) Read the entire page →
From page 217... ... Replace or repair FCCU x x x x x spent catalyst slide valve actuators Replace or repair FCCU x x x x FCCU regenerator cyclones Replace or repair FCCU x x x x FCC reactor cyclones Replace or repair FCCU x x x x fractionation tower internals Repair FCCU x x x x x fractionation tower internals (Continued) Read the entire page →
From page 218... ... Diesel Desulfurization Turnaround with Hydro- x x catalyst change treatment (HDT) unit Coker Coke drum Coker x x x replacement Crude/coker Coker x x turnaround Sulfur Plant SRU thermal SRU x x reactor repair SRU thermal SRU x x reactor replacement Turnaround SRU x x TABLE D-2 (Continued) Read the entire page →
From page 219... ... (% per Unit) Activity Unit 1 3-5 >5 <5 5 5-10 10-20 <20 Flare Flare tip Flare x x replacement Flare knockout Flare x x drum replacement Replace flare Flare x x Piping Repair piping All x x x x re-corrosion Replace piping All x x x x x re-corrosion Heaters/Boilers Replace or repair All x x x x heater tubes Replace or repair Boilers x x x x x boiler tubes Replace burners All x x x Steam Turbine Steam turbine Turbine x x repairs Steam turbine Turbine x x replacement Storage Tanks Repair storage Tank farm x x x x tanks Replace storage Tank farm x x x tanks Replace floating Tank farm x x x roofs in tanks Replace floor in Tank farm x x tanks Wastewater Systems General Waste- x x maintenance water (Continued) Read the entire page →
From page 220... ... Source: National Petrochemical and Refiners Association, unpublished material, 2004. TABLE D-3 Pulp and Paper Industry: Repair and Replacement Activities Estimated Frequency Percent Replacement Cate- (years) Read the entire page →
From page 221... ... Cost Activities gory 1 5 10 20 <5 10-20 5-10 Boiler Used to Generate Power (Continued) Replace superheater 4,7 x x x assemblies Replace desuperheater 4 x x liner assembly Replace economizer 4,7 x x assemblies Replace generating 4,6,7 x x x bank tubes Replace lower wall 4,6,7 x x x tube sections Replace lower wall 4,6,7 x x tube panels Replace lower furnace 4,6,7 x x Repair tubular air 4,5 x x x x x heaters Replace tubular air 4 x x x heaters 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 4 x x x traveling grates Repair/rebuild 4 x x x x ash-handling system Repair/rebuild 4 x x coal-feeder systems Repair/rebuild boiler 1,2 x x safety relief valves (Continued) Read the entire page →
From page 222... ... 222 Appendix D TABLE D-3 (Continued) Estimated Frequency Percent Replacement Cate- (years) Read the entire page →
From page 223... ... Cost Activity gory 1 5 10 20 <5 5-10 10-20 Chemical Recovery Furnace (Continued) Replace lower wall 1,2,3,4 x x x tube panels Replace lower furnace 1,2,3,4 x x x Repair superheater tie 1,2,4 x x x lugs Repair superheater 1,2,4 x x x steam-cooled spacers Replace superheater 1,2,4 x x x loops 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 Replace generating 1,2,4 x x x x bank 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 dissolv- 4 x x x ing tank scrubber system Repair/rebuild 3,4 x x x dissolving tank Repair/rebuild black 4 x x x liquor system (Continued) Read the entire page →
From page 224... ... Cost Activity groy 1 5 10 20 <5 5-10 10-20 Chemical Recovery Furnace Auxiliaries (Continued) Repair/rebuild boiler 1,2,3 x x safety relief valves Remove, calibrate, and 1,2,3 x x 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 4 x x x precipitators Repair/rebuild turbine 4 x x drives Repair/rebuild 4 x x forced-draft (FD) Read the entire page →
From page 225... ... Cost Activity groy 1 5 10 20 <5 5-10 10-20 Power Plant Auxiliary Devices Repair/rebuild 1,3 x x x x deaerator 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 4 x x x dryers Repair/rebuild 4 x x x demineralized water transfer pumps Repair/rebuild 4 x x x condensate transfer pumps Repair/rebuild 4 x x x condensate polishers Repair/rebuild 4 x x x condensate magnetic filters Repair/rebuild water 4 x x x softeners Repair/rebuild sand 4 x x x filters Repair/rebuild water 4 x x x clarifiers Repair/rebuild drive turbines 4 x x x Repair/rebuild uniterrupted power supply 4 x x x (UPS) Repair/rebuild station batteries 4 x x x (Continued) Read the entire page →
From page 226... ... and 4 x x x desuperheaters Repair/rebuild oil storage tanks 1,4 x x x Repair/rebuild woodwaste receiving 4 x x x equipment Inspect/repair woodwaste storage 4 x x x equipment Repair/rebuild coal receiving equipment 4 x x x Repair/rebuild coal storage equipment 4 x x x Repair/rebuild natural gas piping 1,4 x x x Repair/rebuild water storage tanks 4 x x x Category: 1. Required by state regulatory agency or insurance carrier 2. Read the entire page →

From page 208...

... Appendix D REPAIR AND REPLACEMENT ACTIVITIES IN SELECTED INDUSTRIES A summary of common repair and replacement activities for specific areas of a typical coal-fired power plant is given Table D-1. The table does not attempt to summarize less frequent major replacements at a plant, such as repowering with a new furnace using an existing steam cycle or replacing major components (e.g., turbine generator)

Appendix D: Repair and Replacement Activities in Selected Industries Pages 208-226

Appendix D: Repair and Replacement Activities in Selected Industries
Pages 208-226