TABLE D-2 Petroleum Refinery Industry: Projected Repair and Replacement Frequencies and Relative Costs

Activity

Unit

Estimated Frequency (years)

Replacement Cost (% per 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

Sulfur recovery unit (SRU)

 

x

 

x

 

Replace catalysts

not specific

x

x

x

 

x

x

 

Columns Reactors

Repair or replace trays and hardware

All

 

x

 

x

 

Repair or replace reactor internals

All

 

x

 

x

 

Replace weld overlays inside of columns, vessels, and reactors

All

 

x

x

x

 

Pressure Safeties

Repair, replace, test PSVs

All

 

x

 

x

 

Exchangers

Repair or replace exchanger

All

 

x

 

x



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