A smarter approach to drilling is already delivering real results. In this article, Fabio Rodrigues, Product Manager at ESSS Oil and Gas, shares how Petrobras saved over $300 million using Smart Monitoring—a solution that merges high-fidelity simulation, AI-powered diagnostics, and 24/7 expert support to drive safer, more efficient well operations.
In complex drilling operations, time isn’t just money—it’s risk, performance, and competitive advantage. Over the past decade, Petrobras has redefined real-time well construction monitoring by adopting Smart Monitoring, a solution developed in partnership with ESSS that combines digital twin technology, AI, and 24/7 expert surveillance.
This approach has enabled the early detection of operational anomalies, minimized non-productive time (NPT), reduced Invisible Lost Time (ILT), and maximized drilling performance across hundreds of wells in Brazil, the USA, and Colombia.
The Challenge: from reactive monitoring to predictive intelligence
Petrobras faced familiar industry pressures: tighter timelines, deeper wells, complex geologies, and the need to operate with greater safety and efficiency. Traditional real-time operating centers (RTOCs) offered limited insight, often reacting to problems after they had already impacted operations.
The company needed a smarter, integrated approach—one capable of simulating well behavior in real time, diagnosing operational anomalies, and recommending corrective actions before performance was compromised.
The Solution: Smart Monitoring, powered by ESSS
Smart Monitoring is built on three core pillars:
- Advanced Simulation Technology – The system runs real-time physics-based simulations and AI using surface and downhole data, detecting over 15 types of operational anomalies and offering 20 different advisory modules.
- Expert 24/7 Monitoring Team – A dedicated surveillance team interprets the system’s diagnostics, uses specific advisory tools for operation optimization and works side by side with the operator’s engineers to support rapid, informed decision-making.
- Integrated Data & Visibility – An intuitive dashboard makes key insights accessible to field personnel, engineers, and managers—strengthening both real-time decisions and future well planning through retrospective analysis.
The result is a seamless collaboration between human expertise and advanced technology.
The Results: efficiency, safety, and over $300 million in savings
In over a decade of use, Smart Monitoring has supported hundreds of wells across Brazil, Colombia, and the USA, delivering:
- ~US$ 333 million in cumulative savings
- Faster identification and resolution of operational problems
- Significant reductions in NPT and invisible lost time (ILT)
- Greater safety and consistency in execution
- Lower CO₂ emissions per well drilled
With a proven ability to optimize drilling performance in real time, Smart Monitoring adds tangible business value while supporting sustainability and operational excellence.
What’s Next: automation on the horizon
With its robust advisory capabilities and continuous evolution, Smart Monitoring is paving the way toward drilling automation. The next step: integration with rig control systems to enable real-time automated adjustments. The vision is clear—safer, more efficient, and more autonomous drilling.
Turn your drilling data into a competitive advantage. With Smart Monitoring, you’re not just avoiding NPT — you’re accelerating decision-making, enhancing safety, and unlocking proven multimillion-dollar savings.
Speak with our experts today and start drilling smarter, faster, and safer.
