Introduction
The programme “Maintenance Management in Major Oil Plants” develops professional practice in Mechanical Engineering. It connects the subject with workplace challenges by examining existing evidence and practices and choosing methods appropriate to the organization and its available resources.
The learning progresses from production improvement, workflow, and waste reduction to reliability, predictive maintenance, and failure analysis, with practical work on maintenance planning, work orders, and execution measurement, the oil and gas value chain and operations, mechanical equipment analysis and fault diagnosis. Participants prepare outputs to support workplace application and review the quality and results of implementation.
Learning objectives
- Analyze a production flow and identify an intervention that improves quality, time, and resource utilization in an application related to “Maintenance Management in Major Oil Plants”.
- Build a maintenance plan and work order connecting asset criticality, resources, and documentation.
- Analyze an oil and gas value chain process and connect performance to reliability and safety.
- Interpret mechanical equipment performance and identify fault hypotheses and safe verification steps.
- Analyze asset failure and condition data to define a justified warning and maintenance intervention.
Learning areas
1. Production Improvement, Workflow, and Waste Reduction
- Map a product or service flow from order to delivery, collecting data on cycle time, waiting, work in progress, and defects.
- Identify the constraint, bottlenecks, sources of waste, and rework, distinguishing improvement at one workstation from improvement in overall flow performance.
- Compare work balancing, planning, pull, and workplace organization alternatives, considering changes in demand, skills, and safety constraints.
- Design a small improvement pilot with an acceptance criterion and baseline, and define measures to maintain quality and prevent defects from passing between stages.
- Monitor productivity, quality, delivery compliance, and resources, documenting the improved work method and responsibilities for sustaining results. The application examines a case related to “Maintenance Management in Major Oil Plants”.
2. Maintenance Planning, Work Orders, and Execution Measurement
- Inventory assets and build a hierarchy, coding system, technical data, and maintenance history, classifying criticality by safety, service, and cost.
- Select a mix of preventive, condition-based, and corrective maintenance, connecting the decision to failure modes, data, and manufacturer instructions.
- Plan the work order's scope, resources, materials, time, isolation, and permits, and define readiness conditions before scheduling.
- Organize schedules, shutdowns, and equipment handovers between operations and maintenance, recording actual work, causes, parts, and time.
- Analyze backlog, recurrence, plan compliance, and reliability, and propose documented adjustments to maintenance tasks and their frequency.
3. The Oil and Gas Value Chain and Operations
- Understand the links between exploration, development, production, processing, and transportation, and define process boundaries, participants, and intended outputs.
- Read a training process diagram, identifying material and energy flows, measurement points, critical equipment, and their relationship to product quality.
- Analyze production, downtime, losses, and resource consumption data, distinguishing measurement problems from process or equipment problems.
- Define coordination requirements among operations, maintenance, safety, and contractors, and document handovers and changes under facility procedures.
- Prepare a process improvement proposal covering hypotheses, controls, resources, and review criteria, using a training case without unauthorized field operations.
4. Mechanical Equipment Analysis and Fault Diagnosis
- Read training equipment data and diagrams, identifying function, operating conditions, design limits, and key measurement points.
- Analyze relationships between load, flow, pressure, temperature, and vibration, and review measurement quality before interpreting performance deviations.
- Identify failure modes involving components, seals, bearings, alignment, and lubrication, and connect fault symptoms to multiple testable hypotheses.
- Select inspections and diagnostic methods suited to the condition and criticality, and refer to manufacturer instructions and isolation and permit procedures before any intervention.
- Prepare a diagnostic report showing readings, evidence, possibilities, the next verification step, and the limits of conclusions from the available data.
5. Reliability, Predictive Maintenance, and Failure Analysis
- Define the asset's function, functional failure, and usage context, and assess the effects of failure modes before selecting a maintenance task type.
- Organize fault, downtime, repair, and condition reading histories, checking the quality of timestamps, classifications, and record completeness.
- Analyze trends, vibration, temperature, or other appropriate condition indicators, linking alerts to documented thresholds and specialist technical review.
- Distinguish correlation and prediction from proof of a failure's cause, and assess false and missed alarms and warning lead time before intervention.
- Design a condition monitoring pilot for a training asset, with escalation criteria and documentation of the maintenance decision, and verify the intervention's effect on reliability.
Practical outputs
- A value stream map, bottleneck analysis, and production improvement plan.
- A maintenance plan, work schedule, work order card, and monitoring indicators.
- An oil operations process map, requirements matrix, and operating indicators.
- An equipment profile, fault diagnosis tree, and preliminary inspection plan.
- A failure mode analysis, condition monitoring plan, and alert and review rules.
Who should attend
- Engineers, technicians, supervisors and operations staff whose work relates to the programme subject.
- Managers and teams working in mechanical engineering, according to their practical responsibilities.
- Professionals responsible for applying the outputs of “Maintenance Management in Major Oil Plants” within their organizations.
Prerequisites
- Working familiarity with the programme field and the ability to discuss a professional case or challenge.
- Confirm the suitability of your experience and any specialist prerequisites with the Union before participation.
Conclusion
The programme “Maintenance Management in Major Oil Plants” brings together concepts, case review and a practical application. Participants prepare steps that can be adapted to their responsibilities and organizational resources, with an indicator to follow application and review results after returning to work.
Participation arrangements and any special requests are specified in the confirmation issued by the Union.