Inventory Management and Spares Maintenance: An Asset Performance Case of Business Continuity and Pigging Spares at AON Crude Pipelines
Authors: Shaapera T. T. , Saleh A. M. , Omanovic F. , Belooshi A. , Suwaidi A. , Emmanuel J. I. , Marzooqi A. , Backer M. 
Published: November 2024

The handling and maintenance of spares in operating companies remains a requisite pillar upon which asset performance lies. With most business continuity spares being of the long lead type, shelf-life of seals limited and pigging spares wearing out; it is pertinent to devise ways of maintaining these vital spares. The paper shares the main oil line (MOL) spare management strategies and their effectiveness in asset performance of over 1000 km of pipelines.

This paper relies on quantitative and qualitative data obtained from in-house inspection records of Business Critical (BC) items (clamps, split sleeves, stop kits, sole mates, weld+end couplings, pipes), seals, shelf-life records, training of personnel by original equipment manufacturer (OEM) vendors, pigging spares management, materials forecast and replenishing assessment. With varying sizes of pipelines (12’, 14″, 16″, 20″, 24″, 26″, 32″, 36″, and 48″); each pipeline has a minimum stock of the essential business continuity spares estimated based on a criticality factor. The MOL team undertakes the inspection and management of these critical spares using industry's best practices, thus ensuring it is at all times fit for purpose.

For the past five years, the MOL team embarked on aggressive strategies to ensure the integrity of its BC materials and pigging spares right from when it is delivered to storage conditions. The team has been trained in the management of seals and pigging spares before and beyond its shelf-life. With over 120 Business Critical (BC)/pigging items of various sizes and types in stores, their preservation has been a herculean task. The seals for the split-sleeves and weld+end couplings have been adequately maintained depending on the state of fitness; over the years and replacement done as at when due using best practice.

Planning has been an integral part in ensuring the minimum sizes of pipes, pigging spares and sole mates are kept in-store for attending to emergencies and replenishment after it is consumed, or quantities reduced below the economic order quantity. The effective management of inventory ensured that the crude pipelines are maintained at optimal performance with minimum stock of BC and pigging spares available for repair and maintenance continually over the years. The paper highlights and discusses the challenges, solutions, and the new strategies adopted in the maintenance of critical spares of the 21 crude pipelines spanning over 1000 km.

The inventory management of critical spares plays the most important role in asset performance as it reduces downtime and ensures business continuity of operations. The paper serves as a conduit of knowledge for new UAE nationals working in the oil industry and bridges the awareness gap on the importance of spares management of critical facilities. The research opens the door for further studies on how asset performance can be enhanced by spares management.