The pursuit of operational efficiency and emissions reduction has become one of the main drivers of transformation in the oil and gas sector. Faced with the need to balance productivity, safety, and environmental responsibility, companies in the sector have been accelerating the adoption of technologies that allow for a broader and more precise view of their industrial processes. Among these solutions, intelligent monitoring has stood out as an essential resource for improving energy management and reducing waste in a measurable way.

Throughout this article, we will explore how advanced intelligent monitoring technologies have enhanced resource management and sustainability in industrial operations. We will also highlight common challenges and the concrete benefits that digital solutions offer to increase operational efficiency and achieve important environmental goals.

Next, we will present a real-world case study that demonstrates how the application of these technologies can bring consistent and measurable improvements to the oil and gas sector.

The role of energy efficiency in industrial operations

In refineries, steam is an indispensable resource, fundamental for heating, powering equipment, and other critical production stages. However, good management of this resource has a direct impact on the efficiency and environmental performance of operations. Leaks or losses along the pipeline network not only require more energy for compensation but also increase maintenance costs and expand the use of water and fuel.

With the increasing digitalization of industrial plants, the traditional approach, based on sporadic manual inspections, is being replaced by continuous monitoring systems, which make the process more predictable, autonomous, and efficient. This change represents a significant step towards more sustainable operations aligned with ESG practices.

Technology and innovation applied to steam management

To improve energy control in complex environments such as refineries, new technologies based on the Internet of Things (IoT), thermal cameras, and artificial intelligence have become integrated into companies' operational routines. These resources allow for the identification of thermal patterns and the monitoring of minute variations in real time, offering an additional layer of precision and reliability to industrial management.

In this regard, ALTAVE has developed an automatic steam leak detection solution that combines thermal sensors and advanced algorithms to transform data into operational insights. The system, integrated with the ALTAVE Harpia software, continuously processes images and field indicators, identifying steam dispersion points and prioritizing the most relevant occurrences for maintenance.

In this way, technical teams can operate in a more targeted manner, with agility and data-driven support, reducing the effort of manual inspections and increasing the predictability of maintenance actions.

Case Acelen: intelligent monitoring for integrated efficiency

One of the most notable examples of this application is the Mataripe Refinery project, operated by Acelen, which sought to improve its sustainability and energy efficiency indicators. In partnership with ALTAVE, the company implemented a Proof of Concept (PoC) for steam monitoring, using thermal cameras positioned in critical areas of the plant.

In just two days of operation, the system recorded five significant incidents. Estimates, considering the full implementation of the system with eight cameras, showed that it would be possible to identify leaks equivalent to a year's worth of operation in approximately 35 days, with a significant reduction in response time and energy losses.

With this, Acelen projected an optimization of approximately 60% in losses due to leaks and savings close to R$ 20 million in six months. The project also presented a return on investment (ROI) exceeding 1800%, reinforcing the potential of automation and intelligent data analysis as tools for industrial competitiveness.

Conclusion

Acelen's experience with ALTAVE signals a new management model for the oil and gas sector: more digital, connected, and data-driven companies. Technological solutions like ALTAVE's allow for faster and more precise decision-making, strengthening not only productivity but also the commitment to social and environmental responsibility.

As the sector moves towards the energy transition, intelligent monitoring technologies play a central role in building safer, more sustainable and efficient operations.

About ALTAVE

ALTAVE offers intelligent monitoring solutions that increase safety in critical operations, protecting people, assets, and processes. By combining cutting-edge technology with automated analysis, it is possible to identify risk situations in real time and prevent accidents before they happen.

With real-time monitoring, intuitive dashboards and 24/7 support, ALTAVE contributes to operational safety and the protection of lives and essential resources. The company has patented technologies in Brazil and abroad, and is present around the world, serving sectors such as Defense and Security, Energy, Mining, Ports, Agribusiness and Oil and Gas. 

Recognized for its strategic relevance, ALTAVE is accredited as a Strategic Defense Company by the Brazilian Ministry of Defense and a supplier to Petrobras.

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