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All Journal Syntax Literate: Jurnal Ilmiah Indonesia
Zulfajri
PT Pertamina Patra Niaga Refinery Unit II Dumai, Indonesia
Humanities Education Environmental Science Law, Crime, Criminology & Criminal Justice Social Sciences Other

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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 Edward Cantona Taufan Indra Harapan Situmorang Rudi Hermawan