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Abstract(s)
A presente dissertação surgiu no âmbito do Mestrado em Engenharia Química, ramo de
Energia e Biorrefinaria, do Instituto Superior de Engenharia do Porto (ISEP). O projeto foi desenvolvido
no Departamento de Manutenção da UNICER Bebidas, S.A., no Centro de Produção de Leça do Balio e
teve como principais objetivos o desenvolvimento e implementação de um sistema de manutenção
preventiva para a rede de vapor e condensados e a avaliação da eficiência energética da Cogeração e
das caldeiras da Central Térmica.
De modo a atingir o primeiro objetivo enunciado, começou-se por efetuar uma identificação
dos equipamentos da rede de vapor e condensados nas diferentes áreas da fábrica. Através dessa
informação constituiu-se a rede de vapor e condensados no software SAP-PM (Systems Applications
and Product – Plant Maintenance) e elaboraram-se diagramas em Microsoft Visio para cada uma das
áreas identificadas. Seguidamente, definiram-se as tarefas de manutenção preventiva que devem ser
realizadas em cada um dos equipamentos desta rede, possibilitando a elaboração de planos de
manutenção preventiva no SAP-PM.
A manutenção preventiva aplicada à rede de vapor e condensados no período de estágio
consistiu na inspeção de fugas, com o auxílio de uma câmara termográfica, aos equipamentos das
áreas do Fabrico e das Adegas. Relativamente à inspeção da área do Fabrico, verificou-se que os
purgadores de boia dos conjuntos de purga dos tanques de soda, C801 e C802, que fazem o Cleaning
in Place (CIP) dessa área, permitiam a passagem direta de vapor. Assim, procedeu-se à aquisição de
dois purgadores e determinaram-se os valores de payback obtendo-se 3 anos e 2 meses, para os
purgadores associados aos tanques C801 e C802, respetivamente. Com a substituição dos purgadores,
que foi feita no início do mês de junho, retomou-se o aproveitamento dos condensados, o que
contribuiu para uma recuperação global de condensados de 74 %, cerca de 11 % mais do que a
registada no mês anterior. A substituição dos purgadores permitiu ainda reduzir o consumo de vapor
nesta área, em cerca de 28 %, face ao mês de maio, para uma diminuição de volume de mosto
produzido de apenas 9 %. Estes resultados originaram o consumo específico de vapor mais baixo dos
últimos 5 meses avaliados (fevereiro a junho de 2017).
Relativamente ao segundo objetivo, de avaliação do desempenho energético da Cogeração e
das caldeiras da Central Térmica, foi possível desenvolver e atualizar folhas de cálculo, que podem ser
utilizadas para controlo do desempenho diário destas unidades. Em termos de elementos novos,
introduziu-se no programa de cálculo mais um circuito de recuperação de energia (“baixa
temperatura” – LT). Foram registados os dados médios diários de caudais e de temperaturas de todas
as correntes envolvidas, para cada uma das unidades produtoras de vapor. Através da análise efetuada
verificou-se que a Cogeração apresentou, no mês de maio, um REE (Rendimento Elétrico Equivalente)
constante e de aproximadamente 70,4 %. No que diz respeito às perdas energéticas, verificou-se que
estas apresentaram valores praticamente invariáveis na ordem dos 13 %.
No que diz respeito às caldeiras, verificou-se que o rendimento médio das caldeiras 2 e 3 no
mês de maio foi de 91 e de 71 %, respetivamente. Constatou-se ainda que o baixo rendimento da
caldeira 3 se deveu, sobretudo, à produção de caudais horários de vapor muito abaixo da sua
capacidade nominal, que contribuíram para elevadas perdas por radiação (em média 19 %).
De um modo geral, concluiu-se que com o desenvolvimento do sistema de manutenção
preventiva se criou uma ferramenta que mostrou ser muito útil na identificação de situações de perdas de energia significativas e respetiva correção. O estudo do desempenho energético, em paralelo,
permitiu evidenciar a importância de desenvolver e manter atualizado um sistema de gestão de
energia robusto, fiável e simultaneamente de utilização expedita. Considera-se que o trabalho
desenvolvido constitui uma contribuição importante para o desenvolvimento desse sistema de gestão.
This master thesis reports the progress of a project carried out at Maintenance Department of UNICER Bebidas, S.A., at the Production Center of Leça do Balio, in the frame of Chemical Engineering Master Degree of Instituto Superior de Engenharia do Porto (ISEP) from Polytechnic of Porto. The work aimed the development and application of a preventive maintenance system for the steam and condensates loop, and the evaluation of Cogeneration efficiency as well as the energetic efficiency of Thermal Plant boilers. To attain the first objective, it was made an identification of the steam and condensates loop in the different factory areas. Through this information, it was possible to organize the steam and condensates loop in SAP-PM (Systems Applications and Product – Plant Maintenance) and to develop Microsoft Visio diagrams for each of the identified areas. After that, preventive maintenance tasks were defined for each equipment, enabling the planning of preventive maintenance procedures in SAP-PM. During the internship period, the preventive maintenance applied to the steam and condensates loop consisted in the leaks inspection to all equipment in Manufacturing and Wineries areas, using a thermographic camera. Regarding the inspection performed in the manufacturing area, it was observed that the ball float steam traps of the soda tanks, C801 and C802, that do the Cleaning in Place (CIP) of that area, allowed the direct passage of steam. Thereby the acquisition of two steam traps was the next step. The payback values were determined, resulting in 3 years and 2 months, for the steam traps associated to C801 and C802 tanks, respectively. With the replacement of these steam traps that took place at the beginning of June, it was possible to harness the condensates, contributing to an overall recovery of 74 %, about 11 % more than in the previous month. Replacing the steam traps also allowed the reduction of 28 % in steam consumption, compared with May, for a decrease on the wort produced volume of only 9 %. This specific steam consumption was the lowest observed value of the last 5 months evaluated (February to June 2017). In relation to the second objective, the evaluation of the energetic performance of the Cogeneration and Thermal Plant boilers, it was possible to develop and update the spreadsheets that can be used to control the daily performance of these units. In terms of new elements, one more circuit of energy recovery (“low temperature” – LT) was introduced in the program. The average daily flowrates and temperatures of all the streams involved were recorded for the steam generator units. Through this data analysis, it was verified that in May, Cogeneration Unit presented a constant Equivalent Electric Efficiency of 70,4 %. Considering the energy losses, they were almost invariable and around 13 %. Concerning the boilers, it was found that the average efficiency of boilers numbers 2 and 3 in May was 91 % and 71 %, respectively. It was also found that the low efficiency value observed for boiler number 3 was mainly due to the hourly flow rates of steam production deeply below its nominal capacity, that contributed to high radiation losses (averaging 19 %). In general, it was concluded that with the development of the preventive maintenance system, a tool was created and it showed to be very useful in the identification of situations of significant energy losses and their correction. In parallel, the energetic performance study allowed to demonstrate the importance of developing and keeping updated a robust, reliable and simultaneously xpeditious energy management system. It is considered that the developed work represents an important contribution for the development of this management system.
This master thesis reports the progress of a project carried out at Maintenance Department of UNICER Bebidas, S.A., at the Production Center of Leça do Balio, in the frame of Chemical Engineering Master Degree of Instituto Superior de Engenharia do Porto (ISEP) from Polytechnic of Porto. The work aimed the development and application of a preventive maintenance system for the steam and condensates loop, and the evaluation of Cogeneration efficiency as well as the energetic efficiency of Thermal Plant boilers. To attain the first objective, it was made an identification of the steam and condensates loop in the different factory areas. Through this information, it was possible to organize the steam and condensates loop in SAP-PM (Systems Applications and Product – Plant Maintenance) and to develop Microsoft Visio diagrams for each of the identified areas. After that, preventive maintenance tasks were defined for each equipment, enabling the planning of preventive maintenance procedures in SAP-PM. During the internship period, the preventive maintenance applied to the steam and condensates loop consisted in the leaks inspection to all equipment in Manufacturing and Wineries areas, using a thermographic camera. Regarding the inspection performed in the manufacturing area, it was observed that the ball float steam traps of the soda tanks, C801 and C802, that do the Cleaning in Place (CIP) of that area, allowed the direct passage of steam. Thereby the acquisition of two steam traps was the next step. The payback values were determined, resulting in 3 years and 2 months, for the steam traps associated to C801 and C802 tanks, respectively. With the replacement of these steam traps that took place at the beginning of June, it was possible to harness the condensates, contributing to an overall recovery of 74 %, about 11 % more than in the previous month. Replacing the steam traps also allowed the reduction of 28 % in steam consumption, compared with May, for a decrease on the wort produced volume of only 9 %. This specific steam consumption was the lowest observed value of the last 5 months evaluated (February to June 2017). In relation to the second objective, the evaluation of the energetic performance of the Cogeneration and Thermal Plant boilers, it was possible to develop and update the spreadsheets that can be used to control the daily performance of these units. In terms of new elements, one more circuit of energy recovery (“low temperature” – LT) was introduced in the program. The average daily flowrates and temperatures of all the streams involved were recorded for the steam generator units. Through this data analysis, it was verified that in May, Cogeneration Unit presented a constant Equivalent Electric Efficiency of 70,4 %. Considering the energy losses, they were almost invariable and around 13 %. Concerning the boilers, it was found that the average efficiency of boilers numbers 2 and 3 in May was 91 % and 71 %, respectively. It was also found that the low efficiency value observed for boiler number 3 was mainly due to the hourly flow rates of steam production deeply below its nominal capacity, that contributed to high radiation losses (averaging 19 %). In general, it was concluded that with the development of the preventive maintenance system, a tool was created and it showed to be very useful in the identification of situations of significant energy losses and their correction. In parallel, the energetic performance study allowed to demonstrate the importance of developing and keeping updated a robust, reliable and simultaneously xpeditious energy management system. It is considered that the developed work represents an important contribution for the development of this management system.
Description
Keywords
Rede de vapor e condensados Manutenção preventiva SAP-PM Eficiência energética Steam and condensates loop Preventive maintenance SAP-PM Energetic efficiency