How PT Pertamina TII Improved Pilot Plant Reliability and Extended Maintenance Intervals
Addressing Reliability Challenges in Critical Pilot Plant Systems
PT Pertamina Technology Innovation and Implementation (TII) improved pilot plant reliability by working with Swagelok Indonesia to address recurring fluid system failures, strengthen maintenance practices, and build internal expertise. The collaboration extended maintenance intervals from multiple interventions per year to approximately one maintenance cycle every two years while reducing maintenance demands and operating costs.
PT Pertamina TII, based in Jakarta, Indonesia, operates pilot plants that help validate new technologies and catalyst performance before deployment in refinery and energy applications. Because these facilities operate under high-pressure, high-temperature, and severe process conditions, reliability and process consistency are essential to successful testing programs.
Any interruption to pilot plant performance can delay technology validation efforts and increase operating costs, making equipment reliability a critical requirement.
PT Pertamina TII faced recurring reliability issues across several pilot plant systems. Leakage, shortened component life, and frequent maintenance interruptions were affecting operations. Some components had been sourced through channels where authenticity could not be readily verified, creating additional uncertainty around system performance. In some applications, component failures required replacement as frequently as three times per year, increasing maintenance workloads and slowing technology development efforts.
Solving Pilot Plant Reliability Challenges Through Technical Collaboration
In 2020, PT Pertamina TII began working directly with Swagelok Indonesia to address recurring operating and maintenance challenges within its fluid systems. The relationship initially focused on understanding the root causes of recurring failures and identifying opportunities to improve system performance and reliability. Through workshops and technical discussions, PT Pertamina TII gained a stronger understanding of how component selection could affect safety, efficiency, and long-term operation.
Swagelok Indonesia worked alongside PT Pertamina TII engineers to evaluate existing applications, identify reliability improvement opportunities, and recommend upgrades for reactor systems operating in demanding pilot plant environments.
Improving Fluid System Reliability Through Training and Maintenance Best Practices
Rather than simply replacing failed components, Swagelok Indonesia worked with the customer to improve how equipment was maintained and supported over time.
Traditionally, PT Pertamina TII replaced complete fittings and valve assemblies when individual components reached the end of their service life. Swagelok Indonesia demonstrated how seals, gaskets, and valve actuators could be replaced independently, helping to reduce inventory requirements, lower replacement costs, and minimize downtime.
Swagelok Indonesia also helped strengthen PT Pertamina TII's technical capabilities through workshops, seminars, and knowledge-sharing sessions. In 2025, 25 personnel completed Tube Fitting Essentials and FK Series fitting training, helping build internal expertise around fluid system reliability and maintenance. The ongoing collaboration also led to Swagelok Indonesia specialists contributing to the customer's annual Upscaling Skills Seminar for two consecutive years.
Extending Maintenance Intervals and Reducing Operating Costs
The improvements delivered measurable operational benefits.
Results
- Extended maintenance intervals from three service events per year to nearly once every two years
- Reduced maintenance workload
- Lowered operating costs
- Reduced spare-parts inventory requirements
- Improved confidence in pilot plant system reliability
The project demonstrated how technical expertise, application support, training, and proactive maintenance practices can improve reliability in demanding pilot plant environments. By working together, PT Pertamina TII and Swagelok Indonesia extended maintenance intervals from months to years while creating a more sustainable and reliable operating approach.
Improve Fluid System Reliability with Swagelok Support
Swagelok can help evaluate your fluid systems, identify reliability improvement opportunities, and develop maintenance strategies that support long-term performance in demanding operating environments.
