One of the largest costs after erection of a boiler is the maintenance cost. Typically these costs are manageable and modest except when replacement of pressure parts is required. When replacing pressure parts in a boiler the owner should take advantage of the opportunity to evaluate the boilers history, mechanical condition and thermal performance. This evaluation is critical as it can benefit the capital replacement cost and the maintenance cost after installation. Solutions can vary from replacement with an exact duplicate, upgrade to improve mechanical reliability, or modifications to improve the thermal performance. After an initial evaluation, further studies into future operating conditions such as cycling of the boiler, fuel changes and other plant modifications can greatly change the recommended replacement. Conducting an evaluation and developing a plan upfront will help support an optimized design and ensure the optimal replacement part is designed and installed. This paper discusses options and considerations to evaluate when developing a replacement plan for pressure parts utilizing current codes and standards.

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