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Gestão de Sistemas de Alarmes em Processos de Granulação de Adubos
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Orientador(es)
Resumo(s)
Os sistemas de alarmes industriais que não são monitorizados e geridos continuamente,
originam perdas avultadas para as empresas, tanto a nível financeiro como a nível de produ-
ção. Atualmente, a aplicação e implementação de boas práticas de gestão de alarmes repre-
senta um aumento de competitividade em diversos tipos de indústrias e uma alavancagem
em termos da Indústria 4.0.
O presente trabalho tem como objetivo principal a aplicação de boas práticas de gestão
de alarmes, segundo as normas internacionais ISA 18.2 e EEMUA 191, num processo de gra-
nulação de adubos.
Inicialmente foi realizada a etapa de Identificação do ciclo de vida da gestão de alarmes.
Nesta etapa, foi aplicada a metodologia Análise de Modos de Falha e seus Efeitos (FMEA) de
modo a obter uma quantificação dos riscos existentes, através do Número de Prioridade do
Risco (NPR), no processo e sugerir ações de melhoria. De forma a complementar esta análise,
foi realizado um estudo do impacto de cada melhoria na redução do risco.
No processo de granulação considerado, foram identificadas 661 potenciais causas de
falha. Destas causas, 54,8% apresentava grau de risco baixo, 23,4% grau de risco moderado,
16,5% grau de risco elevado e 5,3% apresentava grau de risco crítico.
Através da análise de criticidade e da relação entre o NPR e a criticidade, identificaram-
se 29 causas de modos de falha. Ao implementar as sugestões de melhoria, estima-se uma
redução total do NPR de 12,2%, em que 8,2% está associado a planos de inspeção periódica.
Estima-se um custo médio de 26 500€.
Adicionalmente, foi avaliado o desempenho do sistema de alarmes, em períodos distin-
tos de estabilidade do processo, através da aplicação de Key Performance Indicator's. Em perí-
odo de instabilidade, no sistema de alarmes atual, foram gerados, em média, 139 alarmes por
dia e o sistema apresentava uma instabilidade de 4%. O alarme mais frequente foi do tipo
"Falta de Carga", correspondendo a 15,7% da totalidade de alarmes gerados. No período de
estabilidade do processo, existiu uma redução de 29,5% na quantidade de alarmes por dia, o
sistema apenas apresentava instabilidade de 1,8% e o tipo de alarme mais frequente perma-
necia o mesmo. Nos dois períodos de análise, o sistema de alarmes apresentava-se como ro-
busto.
Industrial alarm systems that are not monitored and managed continuously cause heavy losses for companies, both financially and in terms of production. Currently, the appli- cation and implementation of good alarm management practices represents an increase in competitiveness in several types of industries and a leverage in terms of Industry 4.0. The main purpose of this thesis is the application of good alarm management practices, according to the international standards ISA 18.2 and EEMUA 191, in one fertilizer granula- tion processes. Initially the Identification stage of the alarm management life cycle was carried out. In this stage, the Failure Mode and Effect Analysis (FMEA) methodology was applied in order to obtain a quantification of the existing risks, through the Risk Priority Number (RPN), in the process and to suggest improvement actions. In order to complement this analysis, a study of the impact of each improvement on risk reduction was performed. In the granulation process, 661 potential causes of failure were identified. Of these causes, 54,8% presented low risk level, 23,4% medium risk level, 16,5% high risk level and 5,3% presented critical risk level. Through the criticality analysis and the relationship between NPR and criticality, 29 failure mode causes were identified. By implementing the suggestions for improvement, we estimate a total reduction in NPR of 12,2%, of which 8,2% is associated with periodic inspec- tion plans. The average cost is estimated to be 26,500€. Additionally, the performance of the alarm system was evaluated, in different periods of process stability, through the application of Key Performance Indicators. In periods of in- stability, in the current alarm system, an average of 139 alarms per day were generated and the system presented an instability of 4%. The most frequent alarm was of the "No Load" type, corresponding to 15,7% of all alarms generated. In the period of process stability, there was a reduction of 29,5% in the quantity of alarms per day, the system only presented instability of 1,8% and the most frequent type of alarm remained the same. In both periods of analysis, the alarm system presented itself as robust.
Industrial alarm systems that are not monitored and managed continuously cause heavy losses for companies, both financially and in terms of production. Currently, the appli- cation and implementation of good alarm management practices represents an increase in competitiveness in several types of industries and a leverage in terms of Industry 4.0. The main purpose of this thesis is the application of good alarm management practices, according to the international standards ISA 18.2 and EEMUA 191, in one fertilizer granula- tion processes. Initially the Identification stage of the alarm management life cycle was carried out. In this stage, the Failure Mode and Effect Analysis (FMEA) methodology was applied in order to obtain a quantification of the existing risks, through the Risk Priority Number (RPN), in the process and to suggest improvement actions. In order to complement this analysis, a study of the impact of each improvement on risk reduction was performed. In the granulation process, 661 potential causes of failure were identified. Of these causes, 54,8% presented low risk level, 23,4% medium risk level, 16,5% high risk level and 5,3% presented critical risk level. Through the criticality analysis and the relationship between NPR and criticality, 29 failure mode causes were identified. By implementing the suggestions for improvement, we estimate a total reduction in NPR of 12,2%, of which 8,2% is associated with periodic inspec- tion plans. The average cost is estimated to be 26,500€. Additionally, the performance of the alarm system was evaluated, in different periods of process stability, through the application of Key Performance Indicators. In periods of in- stability, in the current alarm system, an average of 139 alarms per day were generated and the system presented an instability of 4%. The most frequent alarm was of the "No Load" type, corresponding to 15,7% of all alarms generated. In the period of process stability, there was a reduction of 29,5% in the quantity of alarms per day, the system only presented instability of 1,8% and the most frequent type of alarm remained the same. In both periods of analysis, the alarm system presented itself as robust.
Descrição
Palavras-chave
Análise do Risco FMEA Sugestões de Melhoria Gestão de Alarmes