Drilling down on Petrobras' maintenance: How the oil giant keeps operations flowing smoothly

Brazil’s Petrobras has one of the world’s largest upstream and downstream asset portfolios, comprising approximately 30 owned offshore production units and 10 oil refineries.

These assets are set to grow, as the federal oil giant’s 2025-29 business plan calls for starting operations of six owned FPSOs (P-78, P-79, P-80, P-82, P-83 and P-84), the construction of a second refining train at the RNEST refinery in Pernambuco state, and new lubricant and diesel plants at its Boaventura (formerly Gaslub) complex in Rio de Janeiro.

In order to conduct necessary maintenance and operations for its refining, exploration and production (E&P), among other assets, the company has more than 4,000 contracts in force, involving a total value of approximately 270bn reais (US$44.4bn). 

At the request of BNamericas, Petrobras explained how it manages to keep such an enormous and complex structure in the correct conditions and highlighted the main challenges ahead. 

E&P

BNamericas: What are the main strategies, techniques and tools adopted by Petrobras to guarantee the maintenance of its assets over the years, with a view to maximizing their longevity and minimizing interruptions? 

Petrobras: Petrobras' maintenance planning is based on strict internal procedures and full compliance, such as compliance with NR-13 [a standard that regulates workplace safety for boilers, pressure vessels and pipelines]. Regular inspections of equipment and structures guide planning throughout the months of operation. 

Today, we use new technologies to support us, such as 3D mapping of operating plants, inspections with drones for areas that are difficult to access, among others. 

In addition, in the exploration and production [E&P] area, there are different programs and strategic initiatives focused on maintaining the integrity and increasing the reliability and efficiency of the assets.  

BNamericas: Could you cite examples of technological innovations that have been applied and are being carried out? 

Petrobras: We have intensified the use of drones and robots as alternatives for inspecting equipment and structures that are difficult to access. In addition, Petrobras’ research center Cenpes has conducted several studies on practices and materials to improve the preservation of current and future E&P assets. We can also highlight the development of new paints that are more resistant to offshore conditions, as well as the use of painting robots. 

In addition, we can cite other examples of research and projects developed, such as: 

– Design of alternative materials and coatings to mitigate corrosion failures, implementing autonomous analysis to verify inspection reports and data using AI [artificial intelligence]; 

– Use of drones and surface and underwater robots for various activities;  

– Development of alternative coatings to mitigate corrosion failures; 

– Development of self-monitoring repair techniques; 

– Use of large-scale additive manufacturing and artificial intelligence to support inspection and maintenance recommendations. 

BNamericas: What are the main challenges? What solutions is Petrobras looking for? How can suppliers help the company overcome them? 

Petrobras: The biggest challenge for Petrobras is the prospect of increased demand for technical labor to meet the needs of the maintenance areas for existing units and the construction and assembly of new facilities, resulting from the investment projects planned for the coming years. 

BNamericas: In the last two years, which E&P and refining units have undergone maintenance stoppages? 

Petrobras: Between 2023 and 2024, Petrobras carried out scheduled downtime on 35 platforms, both owned and chartered units.

Editor’s note: Petrobras has 20 chartered offshore production units in operation. Its current business plan foresees the installation of three additional chartered FPSOs by 2029 (Almirante Tamandaré, Alexandre de Gusmão and Barracuda/Caratinga). 

BNamericas: Has Petrobras managed to reduce the average downtime of its assets? Is it pursuing any targets in this regard? 

Petrobras: Our E&P area uses internal and external benchmarks for its shutdowns, seeking best practices for safe execution and maintaining the expected levels of efficiency, guaranteeing the longevity of its assets. 

BNamericas: What is the universe of goods and services suppliers that work with Petrobras in the maintenance area? 

Petrobras: In order to carry out the maintenance and operation activities for refining, exploration and production, thermoelectric plants and other Petrobras units, we have more than 4,000 contracts in force with a total value of approximately 270bn reais [US$44.4bn]. These contracts include more than 1,000 suppliers of all sizes, 95% of which are national.

Refining

BNamericas: What are the main strategies, techniques and tools adopted by Petrobras to guarantee the preservation of its assets over the years, with a view to maximizing their longevity and minimizing interruptions?

Petrobras: Petrobras has inspection and preventive, predictive and proactive maintenance plans for all its assets, which are implemented during the campaign and scheduled shutdowns of its production units. Throughout the useful life of the equipment, engineering studies are also carried out which propose design improvements and modernizations, making the asset park more reliable and available.

BNamericas: Could you cite examples of technological innovations that have been applied and are being developed?

Petrobras: We have intensified the use of drones and robots as alternatives for inspecting equipment and structures that are difficult to access. The adoption of PDAs [Personal Digital Assistants] to support operation, inspection and maintenance activities has improved safety, reliability and productivity in the performance of these teams' routines.

Examples of use include scheduled unit maintenance stoppages:

– Low-intensity gammagraphy test for detecting defects in equipment and metal structures, which uses relatively smaller isolation radii to protect people;

– Self-propelled equipment for removing tube bundles from heat exchangers;

– Air mattress device for moving large loads; and

– Ultrasonic cleaning of heat exchanger bundles (currently being tested).

BNamericas: What are the main challenges? What solutions is Petrobras looking for? How can suppliers help the company overcome them?

Petrobras: The biggest challenge for Petrobras is the prospect of increased demand for technical labor to meet the needs of the maintenance areas of existing units and the construction and assembly of new facilities, resulting from the investment projects planned for the coming years. 

Service providers can help to overcome this challenge by investing, together with Petrobras, in implementing more staff training and certification programs.

BNamericas: In the last two years, which refining units have undergone maintenance shutdowns?

Petrobras: Scheduled maintenance shutdowns occurred at the following refineries throughout 2023: REDUC, REFAP, REGAP, REPLAN and RPBC.

In 2024, these events took place at the following refineries: RECAP, REDUC, REGAP, REPAR, REPLAN, REVAP and RPBC.

BNamericas: What is the planned schedule for maintenance stoppages at offshore production and refining units over the next two years?

Petrobras: Scheduled refining shutdowns follow an annual timetable that takes into account the national supply plan.  

Editor’s note: Petrobras plans to invest US$3.8bn in scheduled shutdowns by 2029. In 2025 alone, the following refineries will undergo scheduled shutdowns: Replan and RNEST in the first quarter, RPBC and REFAP in the second quarter, and REVAP in the third quarter, requiring an investment of 900,000 reais and mobilizing 22,500 workers. Details in the company’s business plan, slide 58. 

BNamericas: Has Petrobras managed to reduce the average downtime of its assets? Is it pursuing any targets in this regard?

Petrobras: We use international benchmarks highlighted by Solomon Associates in its biannual studies, which compare the performance of refineries installed on different continents around the world. Solomon provides strategic insights based on data from the entire energy sector, leading to greater efficiency, reliability and profitability for its clients.