MOL Danube Refinery Named 2015 Plant of the Year

By FieldComm Group

Nov 15, 2016

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FieldComm Group announced that the Danube Refinery of MOL, Plc, located in Szazhalombatta, Hungary, has been selected as its 2015 Plant of the Year. This award is given annually by FieldComm Group to recognize the people, companies and plant sites around the globe that are using the advanced capabilities of FOUNDATION Fieldbus, HART and WirelessHART technology in real-time applications for improved operations, maintenance and asset productivity.

This is the first time in the 14-year history of the Plant of the Year award that the same recipient has been recognized twice. Danube Refinery was first recognized for the distinguished citation in 2010. Building upon their past successes, the management and staff aggressively continued their digital transformation by initiating no less than 10 major projects to provide additional diagnostics, maintenance and information integration to other processes and operating units.

Representatives of Danube Refinery presented their facility’s success story as part of the proceedings at the FieldComm Group’s 2016 General Assembly in Rotterdam, The Netherlands.

“This project began by integrating process instrument diagnostics and device utilization with CMMS (computerized maintenance management system), AMS (asset management system) and SAP, combining islands of systems that used to be separate, and creating triggers for launching transmitters, control valves and positioners,” said Gábor Bereznai, head of maintenance engineering at MOL Danube. “This was done by having the diagnostic system inform the CMMS about the valves. This data could then be used in morning meetings with our maintenance team and other staff to help us do risk assessments, and identify other problems.”

Ted Masters, FieldComm Group president and CEO commented, “The proven performance of FOUNDATION Fieldbus, HART and WirelessHART protocols have enabled users like MOL to experience a digital transformation by connecting to valuable process and device data within their plant – to improve performance in a cost-effective way. Connectivity to the enterprise for visualization, analytics and integration into other systems multiplies the value that leveraging FOUNDATION Fieldbus, HART and WirelessHART device data in real-time can bring to the enterprise.”

Masters added, “We congratulate the management and staff of the Danube Refinery for their outstanding achievement and for being recognized a second time for this award.”

After winning their 2010 Plant of the Year Award, Bereznai and his colleagues launched expansions and multiple diagnostic and maintenance projects to bring similar benefits to other facilities at MOL Danube. So far, they’ve expanded the use of FieldComm Group technologies up to more than 4,700 connected devices on 15 operating units including 42 WirelessHART devices and six gateways connected to SAP-PM CMMS.

“We are also planning to adopt HART-IP (Internet protocol) with their OSIsoft PI historian and software” said Tibor Komróczki, head of process information and automation.

József Bartók, head of maintenance instrumentation and electrical engineering at MOL Danube, noted, “Online diagnostics provided by HART and FOUNDATION Fieldbus instruments do more than preventive maintenance. They ensure stable operation of the system and increase control precision. This adds directly to the bottom line.”

According to Bereznai, HART, WirelessHART and FOUNDATION Fieldbus technologies helped MOL realize benefits and savings throughout plant operations:

  • Saved $2 million in reduced maintenance costs and avoided unscheduled shutdowns;
  • Reduced commissioning time 20 percent with HART;
  • Increased plant profit potential with increased loop-control accuracy and data availability;
  • Saved two days of unscheduled downtime or at least €637,000 when data let staff diagnose and repair a head pressure control’s intelligent positioner, instead of removing the entire valve;
  • Reduced valves selected for repair during a planned shutdown from 60 percent to 5 percent for an estimated savings of €54,600 per unit per shutdown.

FieldComm Group's Plant of the Year award is given annually to recognize the people, companies and plant sites around the world using the advanced capabilities of FOUNDATION Fieldbus, HART Communication and/or FDI technologies in real-time applications to improve operations, lower costs and increase availability. Previous award recipients include Nucor Steel (USA), Dow Chemical (USA), Monsanto (USA), Shell (Canada), MOL (Hungary), Mitsubishi Chemical (Japan), Petropiar (Venezuela), Statoil (Norway), Sasol Solvents (South Africa), BP (USA), Clariant (Germany) and Dupont (USA).

This is a supplier and industry independent awards program. Its goal is to promote the application and use of FieldComm Group technologies, not to endorse a specific supplier’s products. Selection is based on the use of technology – not on the size or location of the installation.

To qualify, nominees must be able to supply documented examples of real-time integration of device diagnostics and multi-variable implementations with control, safety and plant information/asset management systems that have delivered significant benefits to the operation. Complete a Nomination Form Today!

For more information and previous award winner articles, please visit the Plant of the Year section of the FieldComm Group website.