Definição de indicadores chave de desempenho operacional com base na análise HAZOP de uma planta de purificação de biogás por membranas

Abstract

Biomethane production through membrane-based biogas upgrading is a complex process that requires strict operational control to ensure interchangeability with natural gas. This study presents the case of an industrial-scale purification unit that, during its stabilization phase, faced efficiency losses and operational instability due to the absence of a structured routine for daily data treatment, which limited the overall visibility of plant performance. The objective was to define and structure operational key performance indicators (KPIs) based on a technical and risk-oriented methodology. To support the selection of monitoring variables, different approaches described in the literature were compared, including strategy deployment, process mapping, historical data analysis, stakeholder input, HAZID and HAZOP methods. A hybrid approach was adopted, using the Hazard and Operability Study (HAZOP) as the central axis to identify variables associated with safety and equipment integrity, complemented by historical data assessment and an as built process review focused on efficiency and product quality. Based on this framework, monitoring matrices were developed for the four main process nodes, highlighting variables that, although already instrumented, were not systematically evaluated—such as the thermal profile for condensate control. As an applied result, this work presents a set of operational key performance indicators organized into daily control sheets, designed to enhance visibility of plant behavior and support the maintenance of biomethane quality in accordance with the specifications adopted at the unit.