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OAR Box 1778 

Prepped by Ollie Stewart 

Document Number: 

26) ll-B-1 

Docket Number: 

A-90-06 

Printed 10/28/2008 9:50:52 AM Sheet 26 of 276 
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jJse^PORATION 

II-B-1 

MEMORANDUM 

DATE: 

TO: 

FROM: 

SUBJECT:. 

July 3, 1986 

Dianne Byrne, EPA/OAQPS/ESED/SDB 

Kathy Wertz, Radian Corporation 

Boiler Life Extension Survey 

The purpose of this memorandum is to update you on the results of our 

recent telephone survey on technical factors affecting industrial boiler 

life extension (BLE). The main purpose of the survey was 1) to establish 

contacts with major industrial boiler vendors and several A&E firms, and 

2) to obtain information on BLE for use in updating the questionnaire, if 

necessary." The survey focused on 1) identifying the range of industrial 

boiler technical problems that limit the boiler's useful life 

(distinguishing between package and field-erected units), 2) normal life 

expectancy of package and field-erected boilers, and 3) the key technical 

variables considered in deciding whether to life-extend or replace a boiler. 

A copy of the survey is given in Table 1. 

Four major industrial boiler vendors and three A&E firms were 

contacted. Table 2 lists these organizations. The individuals contacted 

were primarily involved in assessment of technical factors impacting boiler 

repair/replacement, rather than economics. Only two of the four vendors and 

one of the three A&E firms were actually surveyed in detail. Because of 

1) difficulties in reaching the appropriate persons, and 2) the lack of new 

information obtained during the initial contacts, it was decided that 

spending additional time on the survey was not warranted. The results of 

the survey contacts are summarized below. 

Progress Center/3200 E. Chapal Hill Rd./Nelson Hwy./P.O. Box 13000/Research Triangle Park. N.C 27703/(919!5<tl-9l00 
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Package Boilers 

The main technical problems that limit a package boiler's useful life 

include: tube corrosion, tube erosion, scaling, and overheating. All 

agreed that maintenance of package boilers is a problem due to limited 

training of operators. One vendor said that operators usually over-operate 

package units and that these units are usually run until they completely 

wear out. 

There was no clear answer as to when a boiler has to be replaced 

(rather than repaired). One vendor indicated that a boiler might have to be 

replaced (rather than repaired) if the tubes have to be replaced frequently 

or the amount of retubing is extensive due to an operating or maintenance 

problem. However, another vendor stated that the only time a boiler has to 

be replaced is when there is a serious problem with the steam drum. This 

same vendor (another representative) suggested that environmental 

requirements were a major consideration in deciding whether to try to repair 

rather than replace the boiler. He indicated that some boiler owners would 

rather repair the existing unit so that they would not have to deal with the 

environmental requirements that are placed on new boilers. The A&E 

representative suggested that there are no problems that force the boiler to 

be replaced rather than repaired. He indicated that all boiler parts could 

be replaced and that it was just a matter of how economical it was to 

replace the part(s). 

Common repair/replacement jobs include retubing and replacing the 

setting or casing. Less common repair/replacement jobs include auxiliary 

equipment replacement (i.e., burners, controls, thermocouples, air register 

vanes, etc.). The average life of a well-maintained package boiler, 

according to the survey, is 20 to 30 years. 

Field-Erected Boilers 

The main technical problems that limit a field-erected boiler's useful 

life include: tube erosion, tube corrosion, deteriorating boiler supports, 
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switching fuels (i.e., firing a fuel other than what the boiler is designed 

for), overheating, maintenance, and scaling. All suggested that extensive 

retubing might force a boiler to be replaced rather than repaired. 

Economics and environmental regulations play major roles in the decision to 

extend the life or replace a unit. 

Common repair/replacement jobs include: retubing, replacing 

waterwalls, air heater, ductwork, or casing, and updating the burners or 

controls. The less common repair/replacement jobs include: reinsulating 

the boiler and replacing auxiliary equipment (i.e., fans, pumps, feeders, 

burners, etc.). The A&E representative suggested a well-maintained 

field-erected boiler may have a useful life of 35 to 40 years. One boiler 

vendor estimated 25 to 30 years as the average life of a well-maintained 

boiler. 

The key technical variables considered in deciding to purchase a new 

boiler include: boiler efficiency, future intended use of the boiler, 

controls upgrade, safety, guarantees, warranties, estimated life of existing 

boiler, and the time required to rebuild vs. replace the boiler. All agreed 

the most important factor in the decision-making process is economics. 

cc: Fred Porter, ESED/SDB 

Ed Aul, Radian 

David White, Radian 

Tony Marimpietri, Radian 
TABLE 1. BOILER LIFE EXTENSION SURVEY 

I. Package Boilers - (>50 million Btu/hour a 40,000 lb/hour steam) 

a. What ore the technical problems that limit the bdllers useful life? (I.e., tube erosion, scaling) 

TF .i-~ 

b. What type of problemu force a boiler to be replaced? (rather than repaired) 

c. What is the average life of a well-maintained boiler? d. What la the average life of a poorly-maintained boiler? 

2. Field-Erected Boilers 

a. What are the technical problems that limit the boilers useful life? (i.e., tube erosion, scaling) 

b. What type of problems force a boiler to be replaced? (rather than repaired) 

c. What Is the average life of a well-maintained boiler? d. What is the average life of a poorly-maintained boiler? 

3. Package Boilers 

What are the common repair/replacement 

' Jobs that are done to extend boiler life? 

What are the less common repair/replacement 

jobs that are done to extend boiler life? 

What are the repair/replacement Jobs that 

are Infrequently done on one or two 

boilers In exceptional situations? 

a. 

b. 

c. 

d. 

How 

Frequently 

la Component 

Downtime Replaced 

If Capital Costa or 

0&M Costs are 20Z 

How Higher. Would It Now be 

Expensive* Economically Feasible Comments 

TJ 
TABLE 1. BOILER LIFE EXTENSION SURVEY (CONTINUED) 

Downtime 

How 

Frequently 

is Component 

Replaced 

How 

Expensive* 

If Capital Costa or 

OiM fonts are 20X 

Higher, Would it Now be 

Economically Feasible Comments 

«. Field-Erected Boilers 

What are the common repair/replacement 

Joba that are done to extend boiler life? 

a. 

b. 

c. 

d. 

What are the leas common repair/replacement 

Jobs that are done to extend boile r life ? 

What are the repair/replacement Joba that 

are infrequently done on one or two 

boiler s in exceptional oltuations? 

b. 

c. 

d. 

5. What, other than economics, are some of the factors considered In deciding to purchase a new boiler aa opposed to repairing an existing boiler? 

Operating flexibility or redundancy 

Compatibility with existing fuels at plant 

Security or reliability of fuel supply 

Space or land constralnta/avallablllty 

Ability to use exiatlng auxiliary equipment 

Ability to minimize need for additional operating or maintenance personnel 

Corporate policy 

Environmental regulations 

* I • Inexpensive; H » moderately expensive, commonly done; T - technically poaaiblc, very expensive, done occasionally TJ 
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f* • * 

TABLE 2. SURVEY CONTACTS 

1. Burns & McDonnell* 

Mike McComas (816)333-4375 

2. Foster Wheeler* 

Steve Winberg (201) 533-1100 

3. Riley Stoker* 

David Nourse (617) 852-7100 

Alan Dale 

4. Babcock & Wilcox 

Hayes Orender (216) 860-6228 

5. Combustion Engineering 

M. Sherrill (203) 688-1911 

6. Black & Veatch 

Eldin Shannon (913) 339-2000 

7. Stearns Catalytic Corporation 

James Damon (303) 758-1122 

Note: Information was gathered from sources 1, 2, and 3. 

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