National Academies Press: OpenBook

New Source Review for Stationary Sources of Air Pollution (2006)

Chapter: Appendix E Repair and Replacement Activities in Selected Industries

« Previous: Appendix D Permit and Permitted Emission Data
Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
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APPENDIX E
Repair and Replacement Activities in Selected Industries

A summary of common repair and replacement activities for specific parts of a typical coal-fired power plant is given in Table E-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 (for example, a turbine generator) with an entirely new system.

Table E-2 presents the aggregated responses to a National Petrochemical and Refiners Association member survey, initiated in response to an information request from the committee. Sixty-four petroleum refineries responded to the survey, constituting half (8,808,122 barrels/day) of the total U.S. petroleum-refining capacity (16,894,314 barrels/day) (EIA 2004c). Table E-2 presents about 60 activities that typically are undertaken as repair and replacement at petroleum refineries. Each activity is listed with an estimate of how frequently it occurs and its cost. The cost of each activity is presented as a percentage of the total replacement cost of the major process unit with which the activity is associated. For example, replacing or repairing the fluidized catalytic cracking unit (FCCU) regenerator cyclones is estimated to occur at intervals of 3-5 years or longer. 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. The results presented in this survey, although not exhaustive, illustrate the diverse nature of repair and replacement activities typically undertaken at petroleum refineries.

Table E-3 lists repair and replacement and other activities peculiar to Kraft mills that are periodically undertaken. Both the structure of Table E-3

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

and its contents were provided by representatives of International Paper, Inc., in response to an information request from the committee. Table E-3 lists about 90 repair and replacement activities that are periodically undertaken in a Kraft mill. For each activity, the table provides an estimate of how frequently the activity occurs, an estimate of how likely the activity is to occur within the specified interval, and the relative cost of the activity. The relative cost of the activity is presented as a percentage of the replacement cost of the major process component with which the activity is associated. For example, repairing or replacing the boiler safety relief valves is estimated with near certainty to be an annual activity at a Kraft mill, with an estimated cost that is less than 5% of the replacement cost of the entire boiler. Although the list of activities in Table E-3 is not certified as exhaustive, it illustrates a variety of repair and replacement activities that may be undertaken in pulp and paper manufacturing facilities.

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).

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

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 assemblies

Rows or bundles of heat-exchanger tubes

Wear and periodic failure attributable 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 heat from flue gas to incoming combustion air

Exposure to ash, condensate, and acid gases in flue-gas path can lead 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 air into the furnace; induced-draft fans pull flue gas from the furnace. A balanced-draft system has both. Other typical fans include primary air fans for pneumatic transport of pulverized coal and flue-gas recirculation fans for NOx control

Erosion and cyclic fatigue; fans exposed to flue gases often subject to higher temperatures as well as erosive ash and corrosive acid gases. Reduced effectiveness of fan reduces plant output; failure leads to shutdown

Mills/feeders

System for feeding and pulverizing coal into a fine powder

Abrasion due to hard minerals in coal, and erosion where solids/powder strikes interior surfaces, including deterioration of rollers, tables, balls, classifiers, bearings, seals, motors, belts, flow-control devices, and piping

Turbines and generators

Steam turbines are composed of a shell, blades, nozzles, diaphragms, and rotors. Generators are composed of rotors and stators, including windings and insulation

Turbine blades experience wear due to impurities in steam, requiring replacement of blades (usually with better designed shapes and more recently available alloys). Generator insulation can deteriorate because of exposure to heat or contaminants

Condensers

Typically, a shell and tube heat exchanger in which river water flows on the tube side and low-temperature steam and low pressure (at a vacuum compared with ambient) are on the shell side

Flow on either side can lead to erosion. Impurities in steam or water can lead to corrosion. Biologic fouling on the water side is also possible. Partial or full pluggage of tubes reduces heat transfer, and tube failure leads to contamination of the steam cycle

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Frequency

Cost

Considered to be common; entire tube assemblies replaced at nearly every boiler, as early as 5 years after the beginning of commercial operation

Up to $40/kW to replace tube assemblies on a large boiler and potentially more on a smaller boiler

Replacement in over 80% of units of basket layers and tubes. Seal replacement is also common

Up to $6/kW on large boilers, higher costs per kW on smaller boilers

Fans have been substantially replaced in over 70% of units

Replacement of a large fan can cost up to $20/kW. Retrofitting a balanced-draft system in place of a forced-draft system can cost $70/kW

Pulverizer mills have been replaced or substantially repaired in over 50% of units

Replacing wear parts in a pulverizer mill can cost $2/kW and mill replacement can cost up to $5/kW

Turbine blades or rotors have been replaced in more than 90% of units

Turbine blade and rotor replacement can cost up to $20/kW. Replacement of the shell of the turbine can cost up to $60/kW

More than 60% of units have replaced condenser tubes

Tube bundle replacement can cost up to $10/kW

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Category

Description

Repair or Replacement Needs

Control systems

Control and monitoring of boiler, turbine, and balance of plant management

Control systems affect combustion efficiency and other operations of the plant. When systems fail and require replacement, replacement parts for the original design may no longer be available

Coal and ash handling

Unloading, storage, and conveying coal. Key subsystems include bulldozers (to manage the coal pile), conveyor belts, and bunkers (or silos)

Wear of conveyor belts, motors, and other equipment; corrosion

Feedwater heaters

Heat exchangers, treatment system, and pumps to deliver, heat, and process water from the condenser to the economizer

Leaking tubes lead to reduced efficiency. Plugged tubes lead to loss of capacity

Sootblowers and water lances

System for delivery of steam or compressor air to remove soot, ash, and slag from surfaces of such equipment as heat exchanger tubes

Deterioration of sootblowers reduces effectiveness, which leads to less-efficient cleaning of surfaces. The latter can lead to losses or damage. For example, uncontrolled buildup of slag on boiler surfaces can lead to failure if large amounts of slag fall and damage boiler internals

Burners

Burner systems include tubes and, in some cases, annuli through which pulverized coal and staged air are introduced. Dampers, vanes, nozzles, windbox, flame scanners, and lighters are other typical components

High temperatures, ash, and corrosive gases can lead to corrosion, erosion, and temperature-related stresses

Motors

Motors are used throughout a plant to drive pumps, belts, pulverizers, and other equipment. Motors can vary greatly in size

Motor failures typically attributable to failure of insulation, which causes overheating and potential shortouts

Electric equipment

Equipment used to convert and transmit electricity in a form useful for internal plant end uses, such as motors, fans, and lighting

Exposure to coal dust, temperatures in the plant, and other aspects of the plant environment can lead to shorts and overloads

Pumps

Pumps are used throughout the plant for feedwater, cooling water, and slurries (such as ash sluice). Pumps can be exposed to corrosive materials, erosive materials, and extremes of temperature and pressure

Failure typically due to corrosion, erosion, and other demanding service conditions (such as high temperature and pressure)

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Frequency

Cost

Replacement of pneumatic controls with solid-state, computerized, or automated controls has occurred in “most” units

Replacement projects can cost up to $10/kW on larger units and $40/kW on smaller units

Replacement of such components as conveyor belts, motors, and barge and rail unloaders is “common”

Replacement of key components of coal handling can cost up to $4/kW. Replacement of key components of ash-handling systems can cost up to $14/kW

More than 80% of units have replaced feedwater heaters or major tube bundles therein

Replacement of a feedwater heater can cost up to $5/kW

Sootblowers have been replaced at “most” units

Replacement projects can cost up to $9/kW

Replacements have occurred “one or more times at most units”

Replacements can cost up to $30/kW

Rewind or replacement of motors is “common”

Replacements can cost up to $5/kW per motor

Replacement of switchgear and other equipment is “very common”

Replacement projects cost up to $9/kW

Nearly 100% of units have overhauled or replaced boiler feedpumps

Replacement projects can cost $10/kW

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Category

Description

Repair or Replacement Needs

Piping/ ducts/ expansion joints

Pipes carry fluids or slurries. Ducts carry gases. Expansion joints are flexible connections between pipes or ducts

Leaks can occur because of high-pressure, high-temperature environments or because of erosion or corrosion. Expansion joints can crack or separate

Air compressors

Compressed air is used for pneumatic drives, system controls, some sootblowers, and some power tools

Moving parts are subject to typical wear. Reduced effectiveness of the compressor or failure can lead to reduced effectiveness or failure of other components (such as sootblowers and surfaces not adequately cleaned by failed sootblowers)

SOURCE: ERCC 2002. Reprinted with permission; copyright 2002.

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Frequency

Cost

Replacements of pipes, ducts, and expansion joints is “common”

Repair and replacement can cost up to $23/kW

Replacement is a typical choice, but frequency is not reported

Replacement projects can cost up to $2/kW

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

TABLE E-2 Projected Repair and Replacement Frequencies and Relative Costs in Petroleum-Refinery Industry

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

SRU

 

 

X

 

X

 

 

 

Replace catalysts

not specific

X

X

X

 

X

X

 

 

Column reactors

Repair or replace trays and hardware

All

 

X

 

 

 

X

 

 

Repair or replace reactor internals

All

 

X

 

 

X

 

 

 

Replace weld overlays inside 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

Repair or replace bundle

All

 

X

 

 

 

X

X

 

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 cyclone replacement

FCCU

 

 

 

X

 

 

 

X

Replace or repair spent catalyst deflectors in an FCCU

FCCU

 

X

 

X

X

 

 

 

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Activity

Unit

Estimated Frequency (years)

Replacement Cost (% per unit)

1

3-5

5

>5

<5

5-10

10-20

>20

Fluidized catalytic cracking unit (FCCU)

Replace or repair slide valves (orifice plates and tongues)

FCCU

 

X

 

 

X

 

 

 

Replace or repair spent catalyst slide-valve actuators

FCCU

 

X

X

X

X

X

 

 

Replace or repair FCCU regenerator cyclones

FCCU

 

X

 

X

X

X

 

 

Replace or repair FCCU reactor cyclones

FCCU

 

X

 

X

X

X

 

 

Replace or repair fractionation-tower internals

FCCU

 

X

 

X

X

 

X

 

Repair fractionation-tower internals

FCCU

 

X

X

X

X

 

X

 

Replace or repair wet-gas compressor

FCCU

 

X

 

X

X

 

 

 

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 catalyst change

Hydrotreatment unit

X

 

 

 

X

 

 

 

Coker

 

 

 

 

 

 

 

 

 

Coke drum replacement

Coker

 

 

 

X

 

 

X

X

Crude/coker turnaround

Coker

 

 

X

 

X

 

 

 

Sulfur plant

SRU thermal-reactor repair

SRU

 

X

 

 

X

 

 

 

SRU thermal-reactor replacement

SRU

 

 

 

X

 

 

X

 

Turnaround

SRU

 

X

 

 

 

 

X

 

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Activity

Unit

Estimated Frequency (years)

Replacement Cost (% per unit)

1

3-5

5

>5

<5

5-10

10-20

>20

Flare

Flare-tip replacement

Flare

 

 

 

X

 

X

 

 

Flare knockout drum replacement

Flare

 

 

 

X

 

 

 

X

Replace flare

Flare

 

 

 

X

 

 

X

 

Piping

Repair piping recorrosion

All

 

X

 

X

X

X

 

 

Replace piping recorrosion

All

 

X

X

X

X

 

X

 

Heaters/boilers

Replace or repair heater tubes

All

 

 

X

X

X

X

 

 

Replace or repair boiler tubes

Boilers

 

 

X

X

X

X

X

 

Replace burners

All

 

 

 

X

X

X

 

 

Steam turbine

Steam turbine repairs

Turbine

 

X

 

 

X

 

 

 

Steam turbine replacement

Turbine

 

 

 

X

 

X

 

 

Storage tanks

Repair storage tanks

Tank farm

 

 

X

X

X

 

X

 

Replace storage tanks

Tank farm

 

 

 

X

X

 

X

 

Replace floating roofs in tanks

Tank farm

 

 

 

X

X

 

 

X

Replace floor in tanks

Tank farm

 

 

 

X

 

 

X

 

Wastewater systems

General maintenance

Wastewater

X

 

 

 

X

 

 

 

Metallurgical changes

Metallurgic changes to accommodate feedstock quality changes

 

 

 

X

 

 

 

X

 

Instrumentation

Replace CEMS

 

 

 

 

X

 

 

X

 

Repair CEMS

 

 

 

X

 

 

 

X

 

General instrumentation

 

X

 

 

 

X

 

 

 

Replace instrumentation

 

 

 

 

X

 

 

X

 

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Activity

Unit

Estimated Frequency (years)

Replacement Cost (% per unit)

1

3-5

5

>5

<5

5-10

10-20

>20

Electric substations

 

 

 

 

 

 

 

 

 

Replace substations

 

 

 

 

X

 

 

X

 

Repair substations

 

 

X

 

 

X

 

 

 

Replace transmission lines

 

 

 

 

X

 

 

X

 

ABBREVIATIONS: CEMS = continuous emission monitoring system; SRU = sulfur recovery unit.

SOURCE: National Petrochemical and Refiners Association, unpublished material, 2004.

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

TABLE E-3 Pulp and Paper Industry: Repair and Replacement Activities

Activity

Categorya

Estimated Frequency

Percent Replacement Cost

1 year

5 years

10 years

20 years

<5

5-10

10-20

Boiler used to generate power

Repair superheater tie lugs

4

X

X

 

 

X

 

 

Repair superheater steam-cooled spacers

4X

 

 

 

X

 

 

X

Replace superheater loops

4

 

X

X

 

X

 

 

Replace superheater assemblies

4,7

 

 

X

X

 

X

 

Replace desuperheater liner assembly

4

 

 

 

X

X

 

 

Replace economizer assemblies

4,7

 

 

 

X

 

X

 

Replace generating bank tubes

4,6,7

 

 

X

X

 

X

 

Replace lower-wall tube sections

4,6,7

 

 

X

X

X

 

 

Replace lower-wall tube panels

4,6,7

 

 

 

X

X

 

 

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 burners

4,6

X

X

 

 

 

X

 

Clean and scaffold fire side

1,2,4

X

 

 

 

X

 

 

Auxiliary equipment for power boiler

Repair/rebuild coal pulverizers

 

 

4X

 

 

 

X

 

Repair/rebuild traveling grates

 

 

4X

 

X

 

X

 

Repair/rebuild ash-handling system

 

 

4X

X

X

 

X

 

Repair/rebuild coal-feeder systems

 

 

4X

 

 

 

X

 

Repair/rebuild boiler safety relief valves

1, 2

X

 

 

 

X

 

 

Remove, calibrate, and simulate boiler protective interlock devices

1, 2

X

 

 

 

X

 

 

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Activity

Categorya

Estimated Frequency

Percent Replacement Cost

1 year

5 years

10 years

20 years

<5

5-10

10-20

Auxiliary equipment for power boiler

Replace, calibrate, and simulate boiler protective interlock devices

1, 3, 4

 

 

X

 

X

 

 

Repair/rebuild burner assemblies

4

X

 

 

 

X

 

 

Repair/rebuild sootblowers

4

X

 

 

X

 

 

Repair/rebuild dust collectors

4

X

 

 

X

 

 

Repair/rebuild precipitators

4

X

 

 

X

 

 

Repair/rebuild turbine drives

1, 2, 4

 

X

 

 

X

 

 

Repair/rebuild FDand ID fans

4

 

X

 

 

X

 

 

Upgrade safety systems to revised standards

1, 2, 3

 

 

X

 

X

 

 

Replace unsupported control hardware

3, 4

 

 

X

X

 

X

 

Inspect/repair stack

2, 4

 

X

 

 

X

 

 

Repair/rebuild ducts and flues

4

 

X

X

 

X

 

 

Building structural repair

4

 

 

X

X

X

 

 

Chemical recovery furnace

Replace smelt spout tube openings

1, 2, 3, 4, 5

 

X

X

 

X

 

 

Replace lower-wall tube sections

1, 2, 3, 4

 

X

X

 

X

 

 

Replace lower-wall tube panels

1, 2, 3, 4

 

 

X

X

X

 

 

Replace lower furnace

1, 2, 3, 4

 

 

X

X

 

X

 

Repair superheater tie lugs

1, 2, 4

X

X

 

 

X

 

 

Repair superheater steam-cooled spacers

1, 2, 4

 

X

X

 

X

 

 

Replace superheater loops

1, 2, 4

 

X

X

 

X

 

 

Replace superheater assemblies

1, 2, 4

 

 

X

X

 

X

 

Replace desuperheater liner assembly

2, 4

 

 

X

X

X

 

 

Replace economizer assemblies

1, 2, 4

 

 

X

X

 

X

 

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Activity

Categorya

Estimated Frequency

Percent Replacement Cost

1 year

5 years

10 years

20 years

<5

5-10

10-20

Chemical recovery furnace

Replace generating bank tubes

1, 2, 4

 

X

X

X

 

X

 

Complete NDE

1, 2, 3, 4

X

 

 

 

X

 

 

Repair refractory

2, 4

X

 

 

 

X

 

 

Clean and scaffold fire side

1, 2, 4

X

 

 

 

X

 

 

Chemical recovery furnace auxiliaries

Repair/rebuild ash-handling system

4

X

X

 

X

 

 

Repair/rebuild green-liquor system

4

X

X

 

X

 

 

Repair/rebuild dissolving-tank scrubber system

4

X

X

 

X

 

 

Repair/rebuild dissolving tank

3, 4

X

X

 

 

X

 

 

Repair/rebuild black-liquor system

4

X

X

 

X

 

 

Repair/rebuild boiler safety relief valves

1, 2, 3

X

 

 

 

X

 

 

Remove, calibrate, and simulate boiler protective interlock devices

1, 2, 3

X

 

 

 

X

 

 

Repair/rebuild burner assemblies

4

X

 

 

X

 

 

Repair/rebuild sootblowers

4

X

 

 

X

 

 

Repair/rebuild direct-contact evaporators

4

X

X

 

X

 

 

Rebuild direct-contact evaporators

4

 

X

X

 

X

 

 

Repair steam-coil air heaters

4

X

X

 

X

 

 

Replace steam-coil air heaters

 

 

X

X

 

X

 

 

Repair/rebuild precipitator

4

X

 

X

 

 

X

 

Repair/rebuild turbine drives

4

 

X

 

 

X

 

 

Repair/rebuild forced-draft and induced-draft fans

4

 

X

 

 

X

 

 

Upgrade safety systems to revised standards

1, 2, 3

 

X

X

 

X

 

 

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Activity

Categorya

Estimated Frequency

Percent Replacement Cost

1 year

5 years

10 years

20 years

<5

5-10

10-20

Chemical recovery furnace auxiliaries

Replace unsupported control hardware

4

 

 

X

X

 

X

 

Inspect/repair stack

4

 

X

 

 

X

 

 

Repair/rebuild ducts and flues

4

 

X

 

 

X

 

 

Building structural repair

4

 

 

 

X

X

 

 

Power-plant auxiliary devices

Repair/rebuild deaerator

1,3

 

X

X

X

X

 

 

Repair/rebuild demineralizers

4

 

X

X

 

X

 

 

Repair/rebuild boiler-feedwater pumps

4

X

X

 

X

 

 

Repair/rebuild air compressors

4

X

X

 

X

 

 

Repair/rebuild air dryers

4

X

X

 

 

X

 

 

Repair/rebuild demineralized-water transfer pumps

4

X

X

 

X

 

 

Repair/rebuild condensate-transfer pumps

4

 

X

X

 

X

 

 

Repair/rebuild condensate polishers

4

 

X

X

 

X

 

 

Repair/rebuild condensate magnetic filters

4

 

X

X

 

X

 

 

Repair/rebuild water softeners

4

 

X

X

 

X

 

 

Repair/rebuild sand filters

4

 

X

X

 

X

 

 

Repair/rebuild water clarifiers

4

 

X

X

 

X

 

 

Repair/rebuild drive turbines

4

X

X

 

X

 

 

Repair/rebuild uninterrupted power supply

4

X

X

 

X

 

 

Repair/rebuild station batteries

4

X

X

 

X

 

 

Repair/rebuild steam pressure relief valves and desuperheaters

4

X

X

 

X

 

 

Repair/rebuild oil storage tanks

1, 4

 

X

X

 

X

 

 

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×

Activity

Categorya

Estimated Frequency

Percent Replacement Cost

1 year

5 years

10 years

20 years

<5

5-10

10-20

Power-plant auxiliary devices

Repair/rebuild woodwaste receiving equipment

4

X

X

 

X

 

 

Inspect/repair woodwaste storage equipment

4

X

X

 

X

 

 

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

 

 

aCategory:

1. Required by state regulatory agency or insurance carrier.

2. Required by company or industry standards.

3. Required to maintain safe operation.

4. Required to maintain reliable operation.

5. Required because of design deficiencies.

6. Required because of unforeseen operational problems.

7. Required because of unforeseen mechanical damage.

SOURCE: Council of Industrial Boiler Owners, 2004. Reprinted with permission; copyright 2004, American Forest & Paper Association, Inc.

Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
×
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Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
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Suggested Citation:"Appendix E Repair and Replacement Activities in Selected Industries." National Research Council. 2006. New Source Review for Stationary Sources of Air Pollution. Washington, DC: The National Academies Press. doi: 10.17226/11701.
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Page 310
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The Clean Air Act established a pair of programs—known as New Source Review (NSR)—that regulate large stationary sources of air pollution, such as factories and electricity-generating facilities. Congress then asked the National Research Council to estimate the effects of NSR rule changes made in 2002 and 2003 in terms of the effects on emissions and human health, and changes in operating efficiency (including energy efficiency), pollution prevention, and pollution-control activities. New Source Review for Stationary Sources of Air Pollution provides insights into the potential effects of the rule changes on national emissions from the electric power industry. Although this book focuses on the 2002 and 2003 rules, its analytic framework applies to other possible changes in NSR and to other regulatory contexts. Helpful, in that it outlines the data-collection efforts needed to assess the impact of the NSR rules, the book recommends EPA and other government agencies undertake and sustain the recommended methods.

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