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22 papers on this date.
Aaron José Mota Lamônica
Effectiveness Analysis of Emergency-Switch Inspections: From Corrective to Predictive Maintenance
The objective of this work was to reduce failures in the emergency switches of belt conveyors through the standardization of inspections and maintenance activities and the transition from a corrective approach to a…
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Technical panel · June 10
Effectiveness Analysis of Emergency-Switch Inspections: From Corrective to Predictive Maintenance
Aaron José Mota Lamônica
The objective of this work was to reduce failures in the emergency switches of belt conveyors through the standardization of inspections and maintenance activities and the transition from a corrective approach to a predictive strategy, increasing asset MTBF and strengthening system maturity and reliability while ensuring greater operational availability and functional safety.
Adriano Xisto
Increasing Reliability and Reducing Maintenance Costs of Large Mining Buckets through Reliability vs. Time Analysis
The project was developed by the Reliability Engineering team at the Salobo mine, focusing on the PC5500 and 7495 excavator fleet. The main objective was to increase bucket useful life and significantly reduce…
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Technical panel · June 10
Increasing Reliability and Reducing Maintenance Costs of Large Mining Buckets through Reliability vs. Time Analysis
Adriano Xisto
The project was developed by the Reliability Engineering team at the Salobo mine, focusing on the PC5500 and 7495 excavator fleet. The main objective was to increase bucket useful life and significantly reduce maintenance costs through the use of more wear-resistant materials and improvements to maintenance processes. The methodology compared two types of liner plates: Hardox 450 (quenched steel) and high-chromium cast iron (FFBAC). Laboratory tests and field trials evaluated wear resistance, hardness and material microstructure, together with application of a degradation-versus-time curve. The TRL (Technology Readiness Levels) methodology was also applied for technological validation.
Arthur Melo Pereira
FMEA
Application of the FMEA Methodology to Increase the Reliability of an Electrical Substation
This paper presents the application of FMEA (Failure Modes and Effects Analysis) to the incoming-power substation of an onshore logistics terminal in the Oil & Gas value chain. It first presents the electrical…
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Technical panel · June 10
Application of the FMEA Methodology to Increase the Reliability of an Electrical Substation
Arthur Melo Pereira
This paper presents the application of FMEA (Failure Modes and Effects Analysis) to the incoming-power substation of an onshore logistics terminal in the Oil & Gas value chain. It first presents the electrical infrastructure, highlighting equipment such as transformers, circuit breakers and control panels, which are essential for safe and efficient power distribution. It then explains the FMEA method, a structured tool used to identify and evaluate potential equipment failures by considering severity, frequency and detection capability in order to prioritize risks through the Risk Priority Number (RPN). The main objective is to apply FMEA to the substation, detailing possible failures, their causes and effects on the system for each piece of equipment. As a result of the study, corrective actions are proposed to mitigate the identified risks. The results highlight the substation’s critical points, helping reduce failures and unplanned shutdowns, improve maintenance management and increase operational reliability. The study also creates an opportunity to expand the methodology to other substations, consolidating a preventive culture focused on safety and energy efficiency across TRANSPETRO terminals.
FMEA
Bruno Pedra Loureiro
Indirect Production Weighing on Belt Conveyors through Energy Consumption: A Reliable, Contactless and Low-Maintenance Solution
Reliable production measurement on belt conveyors is a recurring challenge in industrial plants, especially in harsh environments where conventional weighing systems based on load cells have high installation,…
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Technical panel · June 10
Indirect Production Weighing on Belt Conveyors through Energy Consumption: A Reliable, Contactless and Low-Maintenance Solution
Bruno Pedra Loureiro
Reliable production measurement on belt conveyors is a recurring challenge in industrial plants, especially in harsh environments where conventional weighing systems based on load cells have high installation, maintenance and calibration costs as well as low operational robustness. This paper presents the development and application of an innovative indirect-weighing solution that eliminates the need for load cells and any physical intervention on the belt conveyor.
Bruno Peres Klafke
RAMAsset Management
LCC (Life Cycle Cost) Study Applied to the Komatsu PC1250 Excavator Fleet
The LCC (Life Cycle Cost) study applied to Vale’s Komatsu PC1250 excavator fleet plays a fundamental role in understanding the total cost of ownership of this asset throughout its useful life. The fleet currently…
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Technical panel · June 10
LCC (Life Cycle Cost) Study Applied to the Komatsu PC1250 Excavator Fleet
Bruno Peres Klafke
The LCC (Life Cycle Cost) study applied to Vale’s Komatsu PC1250 excavator fleet plays a fundamental role in understanding the total cost of ownership of this asset throughout its useful life. The fleet currently operates eight units of this model, with the oldest having started operation in 2018. However, none of these assets had yet reached end of life and been withdrawn from service, and the company did not have an LCC study for this asset model to support decision-making. The analysis was built on three pillars: reliability, maintainability and maintenance costs. Reliability curves made it possible to identify failure patterns, intervention frequency and degradation trends. The maintainability assessment provided insights into repair times, team effectiveness and impacts on asset availability. Finally, consolidated cost data — including components and scheduled and unscheduled downtime — were used as the basis for RAM Analysis simulations of Physical Availability and for calculating equivalent cost across the life cycle. Integrating this information made it possible to determine the minimum life-cycle cost point and support strategic decisions on reinvestment, replacement and long-term planning for the PC1250 fleet.
RAMAsset Management
Christiano Calijorne
RAM
Computer Simulation of a Maintenance-Bay System at a Mining Operation
This study presents the integrated application of computer simulation and RAM (Reliability, Availability and Maintainability) analysis to determine the ideal number of maintenance bays for off-highway trucks in an…
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Technical panel · June 10
Computer Simulation of a Maintenance-Bay System at a Mining Operation
Christiano Calijorne
This study presents the integrated application of computer simulation and RAM (Reliability, Availability and Maintainability) analysis to determine the ideal number of maintenance bays for off-highway trucks in an open-pit mining operation. The research used real data from 1,158 maintenance events collected over 12 months, making it possible to characterize intervention times, intervals between maintenance events and the fleet’s operational behavior.
RAM
Cinara Piazzarolo Lana
LDAAsset Management
Structural Asset Integrity Management Based on Degradation Curves: Methodology and Applications in Industrial Asset Reliability
The presentation describes an integrated methodology for managing the integrity of industrial assets, applied to piping, tanks, steel structures and other critical equipment. The work brings together practical cases…
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Technical panel · June 10
Structural Asset Integrity Management Based on Degradation Curves: Methodology and Applications in Industrial Asset Reliability
Cinara Piazzarolo Lana
The presentation describes an integrated methodology for managing the integrity of industrial assets, applied to piping, tanks, steel structures and other critical equipment. The work brings together practical cases involving the development of strategic maintenance and investment roadmaps based on determining remaining useful life and building asset degradation curves. Structural diagnosis uses visual inspection, conventional nondestructive testing and automated measurements, enabling risk assessment, intervention prioritization and medium- and long-term scenario planning. The central objective is to provide a strategic view extending up to 10 years, guiding decisions related to cost, reliability, process safety and sustainability through digital tools for planning and asset management.
LDAAsset Management
Devans Rocha
RAM
Reliability Analysis of the Filtration System in a Copper Beneficiation Plant Using RAM Simulation (Reliability, Availability, Maintainability)
This study modeled, simulated and evaluated qualitative and quantitative information to assess the performance of the production system of a copper-beneficiation filtration process through reliability,…
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Technical panel · June 10
Reliability Analysis of the Filtration System in a Copper Beneficiation Plant Using RAM Simulation (Reliability, Availability, Maintainability)
Devans Rocha
This study modeled, simulated and evaluated qualitative and quantitative information to assess the performance of the production system of a copper-beneficiation filtration process through reliability, maintainability and availability analysis (RAM analysis). Reliability Block Diagram (RBD) simulations were used to evaluate the performance of the main filtration equipment. The study also provided indicators and actionable information to support management decisions focused on resource optimization, implementation of improvements and maintenance-cost reduction. One of the main results was the prioritization of a relevant preventive-maintenance activity on one of the plate filters, which produced a short-term performance increase.
RAM
Fabiano Fernandes de Melo
Intelligent Spare-Parts Inventory Optimization Using Advanced Statistical Analysis and Monte Carlo Simulation
This paper presents a reorder-point optimization methodology that integrates advanced statistical analysis with stochastic simulation for data-driven inventory decisions. A system was developed to automate analysis…
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Technical panel · June 10
Intelligent Spare-Parts Inventory Optimization Using Advanced Statistical Analysis and Monte Carlo Simulation
Fabiano Fernandes de Melo
This paper presents a reorder-point optimization methodology that integrates advanced statistical analysis with stochastic simulation for data-driven inventory decisions. A system was developed to automate analysis of consumption history — peaks, trends, seasonality, multiple-order patterns, frequency and other factors — feeding a multi-criteria algorithm that proposes adjustments to the reorder point for each material analyzed. Unlike classical methodologies based only on average and standard deviation, the system incorporates broader context. Validation is performed through Monte Carlo simulation to estimate the actual stockout probability, followed by historical backtesting to compare the proposed reorder point with real data. Practical results for a small group of materials demonstrated reductions exceeding R$6 million while keeping risks controlled. The solution was implemented in Python with a web interface and can process more than 1,000 materials in minutes, while significantly reducing the hours spent on manual analysis. The work demonstrates how automation combined with reliability can transform inventory management from an operational function into a strategic tool.
Felipe Araujo Houri
Asset Management
Determining the Economic Life of a Medium-Voltage Inverter through Integrated Reliability and LCC Analysis
This work aimed to carry out a structured Reliability and Life Cycle Cost (LCC) analysis to evaluate the reliability behavior of the current asset, estimate its technical useful life, determine its economic life,…
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Technical panel · June 10
Determining the Economic Life of a Medium-Voltage Inverter through Integrated Reliability and LCC Analysis
Felipe Araujo Houri
This work aimed to carry out a structured Reliability and Life Cycle Cost (LCC) analysis to evaluate the reliability behavior of the current asset, estimate its technical useful life, determine its economic life, compare technically and financially the scenario of maintaining the current asset versus acquiring a new model, and support data-driven decision-making.
Asset Management
Gabriela Nascimento Queiroz Carvalho
Component Risk Map: Applying Reliability Engineering by Integrating Visual Inspection and Parts Planning
This paper presents the development of a Reliability Engineering product applied to component and peripheral risk management, integrating condition inspection performed through MTA (Machine Touch Application) with…
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Technical panel · June 10
Component Risk Map: Applying Reliability Engineering by Integrating Visual Inspection and Parts Planning
Gabriela Nascimento Queiroz Carvalho
This paper presents the development of a Reliability Engineering product applied to component and peripheral risk management, integrating condition inspection performed through MTA (Machine Touch Application) with strategic parts planning. MTA makes it possible to map the actual condition of assets, identifying wear, damage and intervention needs before functional failure. By connecting this information with estimated useful-life data and inventory status, a risk map was developed in heat-map format, in which the Y axis represents MTA criticality and the X axis represents component useful life as a percentage. The quadrants indicate clear priorities for intervention, monitoring and inventory planning, transforming a visual inspection into a strategic decision-making tool. The solution was standardized and is being implemented at several mines, enabling reduction of unavailability risk, anticipation of failures and technically grounded and sustainable investment decisions. The work highlights Reliability Engineering as an integrator of data, people and decisions, contributing directly to preserving asset reliability and availability.
Gilberto Barbosa Lima Filho
Asset Management
LCC of Vibrating Screens
In 2025, high costs associated with vibrating screens were identified, driven by recurring overhauls, operation in a highly degraded condition and the absence of technical criteria for defining the optimal time for…
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Technical panel · June 10
LCC of Vibrating Screens
Gilberto Barbosa Lima Filho
In 2025, high costs associated with vibrating screens were identified, driven by recurring overhauls, operation in a highly degraded condition and the absence of technical criteria for defining the optimal time for overhaul or replacement. This scenario increased maintenance costs and affected asset reliability and availability. At the Salobo Plant, the process includes 14 vibrating screens, all considered critical, with no standby units available, making planned replacements more difficult and increasing exposure to unplanned failures. In this context, a Life Cycle Cost (LCC) study was developed to determine economically optimal overhaul and replacement intervals, considering acquisition cost, maintenance cost and operational impact. As a complement, an hour-meter monitoring system was structured for the main wear components. Together with the supplier, operating limits were defined and a visual monitoring system ('traffic light') was created and reviewed weekly to identify screens approaching overhaul or end of useful life. One of the study’s main challenges was treatment of the historical database, an essential step to ensure reliable results.
Asset Management
Helerrandro Santos Ribeiro
Asset Management
Optimization of Preventive-Maintenance Workload Balancing Using a Computational Tool – Case of Crushers 1483
This paper presents the development and application of a computational optimization tool to rebalance preventive-maintenance plans for CA quaternary crushing, focusing on Crushers 1483. The objective was to level…
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Technical panel · June 10
Optimization of Preventive-Maintenance Workload Balancing Using a Computational Tool – Case of Crushers 1483
Helerrandro Santos Ribeiro
This paper presents the development and application of a computational optimization tool to rebalance preventive-maintenance plans for CA quaternary crushing, focusing on Crushers 1483. The objective was to level workload over 52 weeks, reducing variability in the Labor-Hours curve, peaks in resource demand and idle time. The solution used the Solver add-in, treating activity start weeks as decision variables and minimizing the standard deviation of weekly labor load as the objective function while respecting periodicity and capacity constraints. The model executed more than 20,000 iterative simulations, evaluating different distributions until the most linear possible workload curve was achieved. The results indicated lower weekly peaks, elimination of zero-load weeks, a significant reduction in standard deviation and optimization of the required workforce, increasing stability and predictability in planning. The tool contributed to efficient labor allocation, reduced overtime and greater adherence to maintenance plans, reinforcing Operational Excellence and Asset Management principles through the integration of maintenance engineering, statistics and computational optimization.
Asset Management
Kamila Matias Rodrigues
LDA
Life Data Analysis as a Decision-Support Tool for Investments in Hydroelectric Power Plants
Decision-making for resource allocation and investment is a critical factor for business sustainability and competitiveness. When performed in a technical and structured manner, it improves the accuracy of investment…
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Technical panel · June 10
Life Data Analysis as a Decision-Support Tool for Investments in Hydroelectric Power Plants
Kamila Matias Rodrigues
Decision-making for resource allocation and investment is a critical factor for business sustainability and competitiveness. When performed in a technical and structured manner, it improves the accuracy of investment prioritization and efficient CAPEX allocation by directing resources toward assets and systems requiring faster intervention. Life Data Analysis was used to support this approach, enabling evaluation of failure behavior over time and identification of equipment-degradation trends. Quantitative reliability metrics provide a solid basis for decision-making, reducing subjectivity and increasing operational predictability. Applied to hydroelectric power plants, this methodology supports investment prioritization, optimization of maintenance strategies and maximization of asset availability, ensuring greater return on invested capital and mitigation of operational risks. This case study presents a practical application of LDA to investment prioritization in hydroelectric plants with the goal of improving operational performance, increasing the reliability of generating-unit systems, reducing the number of failures and shortening machine return-to-service time (MTTR).
LDA
Leonardo Borges Fernandes Da Silva
RAMRCMLDARCAAsset Management
Reliability as a Driver of Growth in Iron Ore Production
Between 2021 and 2025, the structured implementation of Reliability Engineering transformed asset management across the iron-ore production chain, directly supporting achievement of production plans. Advanced…
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Technical panel · June 10
Reliability as a Driver of Growth in Iron Ore Production
Leonardo Borges Fernandes Da Silva
Between 2021 and 2025, the structured implementation of Reliability Engineering transformed asset management across the iron-ore production chain, directly supporting achievement of production plans. Advanced methodologies including RAM (Reliability, Availability, Maintainability), LDA (Life Data Analysis), RCM (Reliability-Centered Maintenance) and RCA (Root Cause Analysis) were applied to define the best shutdown strategy and adapt reliability to the requirements of the production plan. The results demonstrate the effectiveness of the approach: an increase of nearly 5% in overall production capacity and MTBF gains exceeding 100% in critical circuits. Highlights include RCM applications on long-distance belt conveyors, RAM analyses of shipping silos and yard machines, and systematic RCA across all site assets. This work demonstrates how integration between reliability and operational planning is decisive for maximizing availability, reducing MTTR and sustaining production growth in highly complex environments.
RAMRCMLDARCAAsset Management
Luan da Silva Nobre
LDA
Influence of Welding Processes on the Reliability of Track-Type Tractors
The structural integrity of stabilizer-bar trunnions in large track-type tractors is critical to suspension-system availability and reliability. In a bauxite mining operation, an increase in failure rate was observed…
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Technical panel · June 10
Influence of Welding Processes on the Reliability of Track-Type Tractors
Luan da Silva Nobre
The structural integrity of stabilizer-bar trunnions in large track-type tractors is critical to suspension-system availability and reliability. In a bauxite mining operation, an increase in failure rate was observed after refurbishment interventions performed using an inappropriate welding process (SMAW), which differed from the OEM recommendation of GMAW/FCAW. This paper presents an applied Reliability Engineering study combining failure-mode analysis, metallurgical inspections, operational history and evaluation of maintenance processes. The investigation identified a direct correlation between the SMAW process, trapped slag, lack of fusion and early nucleation of fatigue cracks. Based on these findings, structural actions were developed: revision of the welding procedure, welder qualification, standardization of the WPS according to the OEM, nondestructive-testing inspection and monitoring using Weibull 3P to validate the new strategy. The result was a significant increase in component reliability and a reduction in unplanned downtime. The study demonstrates how an integrated approach combining failure analysis, maintenance processes and reliability engineering can mitigate systemic root causes and optimize refurbishment strategies for critical components.
LDA
Lucas Rodrigues Silva
Heat Map as a Strategic Reliability Driver: Reducing Production Impacts at the Vargem Grande 1 Plant
This paper presents the application of a reliability-management model based on a heat map at the VGR1 plant, focusing on prioritizing offending assets and reducing production losses. VGR1 has the particular…
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Technical panel · June 10
Heat Map as a Strategic Reliability Driver: Reducing Production Impacts at the Vargem Grande 1 Plant
Lucas Rodrigues Silva
This paper presents the application of a reliability-management model based on a heat map at the VGR1 plant, focusing on prioritizing offending assets and reducing production losses. VGR1 has the particular characteristic of operating with five simultaneous feed lines, which masks maintenance impacts in the physical-availability metric. As a result, failure effects are diluted in production rate and asset utilization when the plant stops due to external impacts, requiring a more refined analytical approach. The adopted methodology involves weekly analysis of the loss profile in tons, enabling accurate targeting of corrective, preventive and predictive maintenance actions. Based on consolidated operational data, heat maps are generated to guide technical decision-making, promoting interventions on critical assets and mitigating production impacts. The project produced significant gains in plant reliability, including increased MTBF, reduced backlog and improved utilization rate. Integration among engineering, operations and maintenance was essential to the strategy’s success, and the approach can be replicated in other highly complex operating units.
Luiz Felipe Leitão Martins
RAM
RAM Analysis as a Reliability Tool for Decision-Making in Port Operations
Reliability, Availability and Maintainability (RAM) analysis of industrial systems is crucial to ensure operational efficiency and reduce adverse impacts on the logistics chain for oil and its derivatives. This paper…
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Technical panel · June 10
RAM Analysis as a Reliability Tool for Decision-Making in Port Operations
Luiz Felipe Leitão Martins
Reliability, Availability and Maintainability (RAM) analysis of industrial systems is crucial to ensure operational efficiency and reduce adverse impacts on the logistics chain for oil and its derivatives. This paper addresses the relevance of this analysis to the Oil & Gas industry, highlighting how understanding the reliability and availability of the Suape Terminal Oil Loading Arm System can affect vessel stay time and the ability to meet a refinery’s logistics demands. Simulation results from two operating scenarios were analyzed, emphasizing the importance of considering equipment reliability and maintainability to ensure efficient system operation. Finally, recommendations are presented to increase system availability and meet operational logistics demand.
RAM
Marie Clayre Freitas Ferreira
LDAAsset Management
Reliability and Useful-Life Optimization Using LDA for the PV351 Drill Fleet
This paper presents a technical approach to optimizing replacement cycles for the main components of PV351 drills using Life Data Analysis (LDA) as a statistical tool. Historical failure and replacement data from…
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Technical panel · June 10
Reliability and Useful-Life Optimization Using LDA for the PV351 Drill Fleet
Marie Clayre Freitas Ferreira
This paper presents a technical approach to optimizing replacement cycles for the main components of PV351 drills using Life Data Analysis (LDA) as a statistical tool. Historical failure and replacement data from 2010 to 2025 were analyzed, with technical validation by the Reliability Engineering and Asset Management team. The study identified opportunities to increase component useful life, such as the PTO, whose cycle was extended from 5,000 to 8,000 hours (a 60% increase), raising reliability from 45.49% to 61.57% and avoiding costs of R$4.4 million. For the diesel engine, the cycle was extended from 12,000 to 15,000 hours (a 25% increase), maintaining reliability above 51% and projecting savings of R$14 million. The final drive cycle was extended from 10,000 to 12,000 hours (20%), with R$1.4 million in avoided cost. The methodology was standardized in an internal technical document and can be replicated in other operations. The study demonstrated total financial gains of R$18.8 million, greater operational reliability and better resource utilization, contributing to optimized Asset Management and maintenance in mining.
LDAAsset Management
Matheus Henrique Rosa Duarte
Optimization of Gas-Detector Inspection Intervals on an Oil Production Platform
Offshore oil-production platforms are highly complex assets in which gas detectors serve as critical barriers to operational safety. Maintaining thousands of these devices distributed throughout the plant is…
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Technical panel · June 10
Optimization of Gas-Detector Inspection Intervals on an Oil Production Platform
Matheus Henrique Rosa Duarte
Offshore oil-production platforms are highly complex assets in which gas detectors serve as critical barriers to operational safety. Maintaining thousands of these devices distributed throughout the plant is challenging because onboard maintenance labor is limited. The manufacturer of one detector model recommends semiannual inspections. This paper therefore evaluates, based on actual inspection data, the impact of different test intervals on asset reliability. The objective is to optimize maintenance-resource allocation while ensuring the integrity of platform safety systems. The analyses were conducted through computer simulations in reliability software and demonstrated that average availability of systems in a 2oo3 voting arrangement remains high — above 99.5% — even when intervals are extended to 12 months. These results provide quantitative support for reviewing inspection frequency for these detectors, reducing the labor-hour demand dedicated to these activities by 50% without compromising process safety.
Rosalvo Alves Paes Barreto Filho
RCA
Daily Production Monitoring as a Strategic Tool for Reliability Management and Actions to Reduce Production Losses
This paper presents a case study from a petrochemical unit using daily production monitoring as a strategic tool for managing production losses, monitoring failure events and increasing operational reliability. The…
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Technical panel · June 10
Daily Production Monitoring as a Strategic Tool for Reliability Management and Actions to Reduce Production Losses
Rosalvo Alves Paes Barreto Filho
This paper presents a case study from a petrochemical unit using daily production monitoring as a strategic tool for managing production losses, monitoring failure events and increasing operational reliability. The methodology enabled identification and prioritization of load-reduction events, scheduled shutdowns and unscheduled shutdowns according to the resulting volume of lost production and failure frequency, enabling direct action on the main contributors to production losses. Multidisciplinary Working Groups were structured for root-cause analysis using established tools such as 5 Whys, Ishikawa Diagram, Fault Tree, Brainstorming and 5W2H. Results included a 79.94% reduction in production losses, a 199.3% increase in MTBF at the PTA production plant, a 14.63% increase in availability and a 22% increase in consecutive production days compared with 2024, setting a new historical record. In addition to technical gains, the approach generated intangible benefits and strengthened integration among operations, maintenance, reliability and maintenance engineering, increasing the maturity of the reliability culture.
RCA
Thiago Stefane Junior Magalhães
Human Reliability
Human Reliability: A Knowledge-Management Methodology Focused on Asset Reliability
Technical training of maintenance teams has become a global challenge and a determining factor for operational sustainability in highly competitive environments. Based on the premise that human development adds value…
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Technical panel · June 10
Human Reliability: A Knowledge-Management Methodology Focused on Asset Reliability
Thiago Stefane Junior Magalhães
Technical training of maintenance teams has become a global challenge and a determining factor for operational sustainability in highly competitive environments. Based on the premise that human development adds value to asset reliability, this paper presents a structured method for prioritizing knowledge using qualitative and quantitative criteria. Application of the methodology not only increased training hours and the share of the workforce trained, but also improved the accuracy of management decision-making. As a practical result of this strategic training approach, a significant reduction in equipment-failure frequency was observed, reinforcing the direct correlation between technical competence and industrial-system availability.
