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

 

 

 



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