The document discusses cracking furnace management at an ethylene plant. It outlines objectives to develop an effective inspection and monitoring strategy for 6 cracking furnaces. Current issues include a lack of integration between inspection, operation and maintenance data. The proposal is to establish a cracking furnace management system (CFMS) to consolidate all relevant equipment history, procedures, records and monitoring data. The recommendation is to implement the CFMS and purchase infrared thermography equipment to closely monitor furnace conditions for degradation like high temperature corrosion.

1. Cracking Furnace Management
System (CFMS)
- Inspection and Monitoring -
Inspection Section
8thFebruary2012

2. Agenda
 Background
 Objective
 Inspection and monitoring
 Current issues
 Proposal
 Recommendation

3. Background
 6 numbers of ethylene cracking furnace operated in
EMSB plant.
 Cracking furnace cracks ethane (C2H6) to ethylene
(C2H4).
 Cracking furnace encompasses; firebox, radiant
section, convection section, steam generation section,
primary/secondary transfer line exchanger and
associated piping.
 All cracking furnace have experienced repair jobs i.e.
re-tubing, cut & raise, cut & re-weld, re-insulation or
patching as per equipments history record.

4. Objective
 To develop a manageable & effective strategy with
established planning for cracking furnace
monitoring and inspection.
 To ensure all types of inspection & monitoring
methods are fully implemented at cracking
furnace with refer to approved procedure, FSOE,
code, standard and guideline (CMP, AHC).
 To integrate CFMS with relevant parties i.e.
Operation, Process, Mechanical, PSM and FTF.

5. Inspection & Monitoring
1. Online
• External inspection & monitoring.
• Tube metal temperature & tube visual inspection.
• Shell metal temperature, top roof and convection
section (hot spot/localized overheating).
• Elongation measurement & assessment.
• Visual inspection on PSVs (all cracking heaters).
• Wire rope & counter weight visual inspection &
adjustment.
• Associated piping, cross-over & manifold.
• External corrosion i.e. CUI, painting & weldments.

6. Inspection & Monitoring
2. De-coke
• External inspection & monitoring.
• Tube visual inspection (sagging, bulging or bowing).
• Shell metal temperature, top roof and convection
section (hot spot/localized overheating).
• Elongation measurement & assessment.
• Visual inspection on PSVs (all cracking heaters).
• Wire rope & counter weight visual inspection &
adjustment.
• Associated piping, cross-over & manifold.
• External corrosion i.e. CUI, painting & weldments.

7. Inspection & Monitoring
3. Shutdown
• Internal inspection (insulation/refractory, radiant & convection coils
and hot spot/localized overheating monitoring and inspection which
detected during online & de-coke).
• External inspection & monitoring.
• Tube visual inspection (sagging, bulging or bowing).
• Elongation measurement & assessment.
• Repair or replacement activities.
• Visual inspection & testing on PSVs (all cracking heaters).
• Wire rope & counter weight visual inspection & adjustment.
• Associated piping, cross-over & manifold.
• PTLE and STLE.
• External corrosion i.e. CUI, painting & weldments.

8. Current Issues
1. Integration and sharing on data and information
between Inspection, Operation, Process and
Mechanical is not effective and established.
2. Equipment history i.e. repair, defect and degradation
record are not proper compiled and distributed to
relevant parties.
3. Inadequate system in consolidating inspection and
monitoring activities, procedure, equipment history,
material and degradation study, maintenance record
and operation record.
4. Inconsistency in temperature monitoring by
inspection (once/month only) where the result is not
adequate for assessment/trending.

9. Proposal
1. To establish RACI with enhancement on
integration of information and accountability
between relevant parties.
2. To institutionalize Cracking Furnace
Management System which includes all relevant
data/record and publish in one common folder
in common server/AXIS portal.
3. To acquire temperature monitoring equipment
which can be used frequently in order to provide
continuous assessment.

10. Recommendation
1. Cracking Furnace Management System institutionalization and
implementation which provides items below:
• Design, technical data & SOL.
• Materials study & analysis.
• Equipment history & degradation.
• Procedure & checklist.
• Corrosion & degradation risk assessment, monitoring and control.
• FSOE, CMP & AHC.
• Operational record i.e. decoking cycle, shutdown & online.
• Maintenance record i.e. cleaning, repair and replacement.
• RACI.
2. Purchase IR thermography equipment including training to staff
(competency) in order to closely monitor cracking heaters condition
especially for high temperature corrosion/degradation effect.

11. RACI
Cracking Furnace Management System institutionalization
and implementation which provides items below:
• Design, technical data & SOL (Process, Operation,
Mechanical, Inspection & PSM).
• Materials study & analysis (Process & Inspection).
• Equipment history & degradation (Inspection & Mechanical).
• Procedure & checklist (Inspection, Operation & Mechanical).
• Corrosion & degradation risk assessment, monitoring and
control (Inspection).
• FSOE, CMP & AHC (Inspection, Operation, Process &
Mechanical).
• Operational record i.e. decoking cycle, shutdown & online
(Process & Operation).
• Maintenance record i.e. cleaning, repair and replacement
(Mechanical & Inspection).

12. Q & A

13. Thanks…