Business Challenge:

In pursuit of driving production efficiency, enhancing safety, and reducing risk, MOL Group strategically partnered with industry leaders TÜV Rheinland and Metegrity to implement a three-year initiative to standardize asset integrity practices and procedures. The scope of the project spanned across MOL’s downstream plants in Hungary, Slovakia, and Croatia. Working together with TÜV Rheinland and Metegrity, MOL is leveraging specialized Asset Integrity Management (AIM) expertise, a Visions Enterprise® digital platform, and specialized Non-Intrusive Inspection (NII) knowledge to create a best-in-class business model delivering assurance in asset integrity, high equipment availability and turnaround cost reductions. The outcome of this strategic collaboration has been highly impactful. MOL is looking forward to notable advantages, including operational risk mitigation, improved safety, substantial cost savings, increased operational capacity, and regulatory compliance. A key driver for this project is the ongoing sustainability of the improvement program, ensuring there is knowledge transfer from TÜV Rheinland and Metegrity to the site-based MOL teams.

Cost Savings:

Centralizing static equipment management through AIM procedures, processes, and systems should lead to increased equipment availability and reduced turnaround duration (TAR). As a result, MOL is aiming to realize greater operational availability and production improvements as well as cost savings and margin improvement which could amount to millions of Euros each year from its downstream assets.

Leveraging TÜV Rheinland’s extensive domain knowledge and Visions Enterprise®’s integrated RBI capabilities allowed MOL to optimize inspection plans, enhance uptime, and optimize operational cash flows.

Risk Mitigation (RBI for ROI):

TÜV Rheinland and Metegrity’s implementation of a risk-based inspection capability within Visions Enterprise® allowed MOL to intelligently prioritize inspections based on estimated risk, optimizing resources and reducing unnecessary costs. Early detection of potential integrity issues enables timely corrective actions, such as repairs versus replacements, or changes in operational procedures, further mitigating risks and preventing incidents.

Utilization of the bespoke Show, Teach & Coach, and Support Consulting Methodology ensures the benefits from this program are sustainable and embedded within the MOL site’s long-term performance.

Improved Safety:

Safety remains a top priority at MOL, and the AIM program led by TÜV Rheinland and Metegrity paved the way for a shift from reactive to proactive maintenance. By utilizing Visions Enterprise®, MOL is getting able to efficiently identify critical assets, and prioritize inspection and remediation efforts based on risk, and production concerns. This transition from reactive to proactive maintenance not only increased efficiency and transparency but also minimized downtime and costly expediting fees associated with unexpected failures.

Regulatory Compliance:

Through the deployment of the AIM solution by TÜV Rheinland and Metegrity, MOL is in the process of realizing standardized and digitized asset integrity procedures. The integration of a common digitized platform Visions Enterprise® at the Danube, Slovnaft, MOL Petrochemicals, and INA refineries is enabling MOL to streamline inspections and demonstrate compliance. The centralized database of Visions Enterprise® enabled quick retrieval of asset-related information and historical data, simplifying the process of showcasing inspection results and demonstrating compliance.