MOL Group Chooses TÜV Rheinland and Metegrity to Support Goal to Increase Operational Availability and Mechanical Integrity
MOL Group is a large integrated, international oil and gas company, generating more than $19 billion (USD) in revenue in 2022. The company is active in more than 40 countries, employing 25,000 workers. MOL’s exploration and production activities are supported by more than 75 years of experience. MOL Group operates three refineries and two petrochemical plants under integrated supply chain management in Hungary, Slovakia, and Croatia, and owns a network of 1,933 service stations across 10 countries in Central and Southeastern Europe.
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.
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.
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.
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.
Metegrity is the leading provider of asset integrity management (AIM) systems and offers a complete product line to suit the various challenges facing oil and gas operations and chemical manufacturing. Visions Enterprise® manages pipelines, offshore structures, fixed, and rotating equipment from a single platform and provides built-in regulatory compliance to all major global auditing organizations. Pipeline Enterprise takes pipeline inspection data directly from inspectors and transfers it to a central reporting system. VisionsGo is an innovative mobile tool ideal for the connected worker. Visions AIPSM is a coupling of Asset Integrity Management plus Process Safety Management that optimizes mechanical availability and regulatory conformance by classifying and categorizing failure events to uncover systemic problems.
Metegrity has been the trusted name in asset integrity management since 1992, with 850 facilities over 5 continents managing $550 billion in assets.
About TÜV Rheinland
TÜV Rheinland is one of the world’s leading testing service providers with more than 20,870 employees and annual revenues of around 2.3 billion euros. TÜV Rheinland’s highly qualified experts test technical systems and products around the world, support innovations in technology and business, train people in numerous professions and certify management systems according to international standards.
In doing so, the independent experts generate trust in products as well as processes across global value-adding chains and the flow of commodities. Since 2006, TÜV Rheinland has been a member of the United Nations Global Compact to promote sustainability and combat corruption
For more information, visit www.tuv.com.