Acelen digitalises refinery asset integrity with AI-based asset management

Acelen operates the Mataripe Refinery in Bahia, one of Brazil’s most strategic refining assets. Established in 2021 following the acquisition of the former Landulpho Alves Refinery, the site has a processing capacity of approximately 300,000 barrels per day, representing about 14% of Brazil’s total refining capacity and supplying more than 40% of fuel demand in the Northeast region.

With thousands of static and dynamic assets—including boilers, pipelines, pumps, compressors and turbines—Acelen identified the need to modernise its integrity management and maintenance strategies as part of a broader business transformation.

Operational challenges in a large-scale refinery environment
Managing a large and diverse asset base presented several challenges. Traditional inspection and maintenance approaches relied heavily on reactive or schedule-based practices, limiting predictive capabilities and increasing the risk of unplanned shutdowns.

For static equipment, Acelen sought to optimise inspection planning and improve report quality. For rotating and dynamic equipment, the priority was to enhance asset health monitoring to minimise production disruptions and reduce maintenance costs.

At the organisational level, the company also aimed to modernise its strategy management processes and align asset integrity with long-term operational and sustainability objectives.

Deploying digital asset strategy and health solutions
To address these needs, Acelen partnered with Baker Hughes to implement Cordant™ Asset Strategy across its site. The platform structures inspection and maintenance strategies for static equipment, combining established engineering methodologies with digital workflows.

Building on this foundation, Acelen expanded the programme to include Cordant™ Asset Health for dynamic equipment. The solution integrates AI-driven analytics with traditional diagnostic models to monitor asset condition, identify emerging risks and prioritise interventions.

By consolidating asset data into a unified digital environment, the refinery can improve visibility across both static and rotating equipment, enabling more proactive maintenance planning.

Measurable improvements in inspection and planning
The digital transformation has delivered tangible results:

These outcomes have strengthened asset integrity management while supporting production continuity and sustainability goals at the Mataripe site.

Expanding digital integration and predictive capabilities
Looking ahead, Acelen plans to extend its digital asset management framework further. Upcoming steps include the implementation of Cordant™ Asset Health + Machine Health in 2026 and integration of Cordant™ solutions with SAP systems to streamline workflows and ensure seamless data exchange across maintenance and operations functions.

The case demonstrates how large-scale refineries can use AI-enabled asset integrity platforms to improve reliability, reduce unplanned downtime and align maintenance strategy with long-term business transformation objectives.