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All Journal Syntax Literate: Jurnal Ilmiah Indonesia Asian Journal of Social and Humanities
Edward Cantona Taufan
PT Pertamina Patra Niaga Refinery Unit II Dumai, Indonesia
Humanities Decision Sciences, Operations Research & Management Earth & Planetary Sciences Education Environmental Science Languange, Linguistic, Communication & Media Law, Crime, Criminology & Criminal Justice Social Sciences Other

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Accelerating The Readiness of The H2 Plant Unit and Maintaining the Quantity of HCU Valuable Product During Repairs to The Radiant Tube Reformer Leak Using a New Radiant Tube Reformer Plugging Method at PT Pertamina Patra Niaga Refinery Unit II Dumai Indra Harapan Situmorang; Akbar Putra Jhonem; Rudi Hermawan; Edward Cantona Taufan; Zulfajri Zulfajri
Asian Journal of Social and Humanities Vol. 4 No. 7 (2026): Asian Journal of Social and Humanities
Publisher : Pelopor Publikasi Akademika

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.59888/ajosh.v4i7.696

Abstract

This paper presents an operational reliability case study from the hydrogen plant that supports the hydrocracking complex at PT Kilang Pertamina Internasional Unit II Dumai. A crack was identified in radiant tube Row A No. 10 in reformer 702-H-1, creating an urgent risk of hydrogen release, tube rupture, fire escalation, and prolonged production loss. The conventional corrective action, namely full retubing with a new tube and ceramic-on-ceramic (COC) restoration, required approximately 138 hours and depended on spare tube availability. To reduce downtime and avoid a multiplier effect on the hydrocracker value chain, the team developed a new plugging method that isolated the failed radiant tube by installing welded plugs at both the outlet and inlet sides instead of replacing the entire tube. An engineering design package was prepared using 3D modeling, stress analysis, material selection for SS 310 and HK40 components, and load verification at the design pressure of 20.5 kg/cm². The implemented method restored operation faster than the historical retubing route, achieving a repair duration of approximately 40 hours versus 138 hours for the previous method. Operational impacts reported by the plant included normal H? plant operation above 30k Nm³/h, preserved jet fuel quality, medium-risk work exposure instead of high-risk exposure, avoided costs of approximately IDR 244.8 million, and protection of HCU profit equivalent to around IDR 10 billion. The case demonstrates that a fit-for-purpose plugging strategy can be an effective emergency repair option for radiant tube failures when supported by engineering verification, fabrication control, and formal standardization
Double C Clamp : Powerful Solution for High Pressure Air-Fin Cooler Hexagonal Tube Plugs Indra Harapan Situmorang; Akbar Putra Jhonem; Rudi Hermawan; Edward Cantona Taufan; Zulfajri
Syntax Literate Jurnal Ilmiah Indonesia
Publisher : Syntax Corporation

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.36418/syntax-literate.v11i4.64191

Abstract

Hydrocracker reliability has a direct effect on refinery margin, product availability, and process safety. This paper presents an industrial case study on the development and implementation of an online leak sealing (OLS) innovation for a leaking hexagonal plug in the fresh feed reactor effluent air cooler (REAC) 211 E-2D at the Hydrocracker Unit (HCU) of PT Pertamina Patra Niaga RU II Dumai. During hydrocracker recovery in April 2023, a leak was detected at plug tube No. 19 Bank D under hydrocarbon service containing 85-90% hydrogen, at approximately 170 kg/cm2 and 150 C. Conventional hot bolting did not stop the leak and plant procedures indicated that shutdown would normally be required. To prevent unscheduled shutdown, a high-pressure double-C clamp combined with OLS was designed, stress-checked, fabricated, and installed onstream. The new design increased clamp pressure capability from the 34 kg/cm2 reference design to 250 kg/cm2 and could accommodate multiple leak points. Post-installation monitoring showed 0% LEL around the leak area, the unit operated normally for more than five months, and a 13-day shutdown was avoided. Operational records indicated margin protection of IDR 1.9 billion and additional protected value from valuable products and HVGO lifting opportunities. The case demonstrates that a properly engineered OLS system can be a practical reliability and safety solution for hydroprocessing air coolers with hexagonal plug leakage.
Co-Authors Akbar Putra Jhonem Indra Harapan Situmorang Rudi Hermawan Zulfajri Zulfajri Zulfajri