Introduction
The programme “Emergency Failure Analysis and Prevention” develops professional practice in Oil and Gas Maintenance. 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 reliability, predictive maintenance, and failure analysis to process safety, barriers, and management of change, with practical work on occupational safety, risk assessment, and prevention, maintenance planning, work orders, and execution measurement, mechanical equipment analysis and fault diagnosis. Participants prepare outputs to support workplace application and review the quality and results of implementation.
Learning objectives
- Analyze asset failure and condition data to define a justified warning and maintenance intervention in an application related to “Emergency Failure Analysis and Prevention”.
- Prepare a work risk assessment and prevention and response plan based on the hierarchy of controls.
- Build a maintenance plan and work order connecting asset criticality, resources, and documentation.
- Interpret mechanical equipment performance and identify fault hypotheses and safe verification steps.
- Analyze an operational hazard scenario and review barriers and change control responsibilities.
Learning areas
1. 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. The application examines a case related to “Emergency Failure Analysis and Prevention”.
2. Occupational Safety, Risk Assessment, and Prevention
- Identify task hazards, exposed people, and site conditions, gathering information from observations, records, and equipment instructions.
- Estimate the risk level and select appropriate controls from elimination, substitution, engineering controls, administrative controls, and personal protective equipment.
- Review work procedures, permits, isolation, communication, and supervision according to the task, and define responsibility for stopping unsafe work.
- Analyze an incident or near miss using facts and evidence, examining systemic causes and failed controls beyond blaming individuals.
- Prepare a tabletop emergency exercise and an inspection, awareness, and follow-up plan, assigning field execution to qualified personnel under approved procedures.
3. 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.
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. Process Safety, Barriers, and Management of Change
- Identify sources of hazardous materials and energy and process boundaries, distinguishing process safety from individual occupational safety in the case presented.
- Analyze the sequence, causes, and consequences of a hazardous event, and identify preventive and mitigating barriers and evidence for verifying their readiness.
- Review work permits, isolation, and coordination among parties under facility procedures, and identify hold points requiring specialist approval.
- Prepare a change request identifying its rationale, risks, and effects on documents, training, and emergencies, with technical review before implementation.
- Conduct a tabletop exercise involving a hypothetical barrier failure or leak, and document escalation and response actions, lessons, and the subsequent verification plan.
Practical outputs
- A failure mode analysis, condition monitoring plan, and alert and review rules.
- A task risk assessment and an inspection, training, and response plan.
- A maintenance plan, work schedule, work order card, and monitoring indicators.
- An equipment profile, fault diagnosis tree, and preliminary inspection plan.
- A register of risk scenarios and barriers, and an operational change review plan.
Who should attend
- Engineers, technicians, supervisors and operations staff whose work relates to the programme subject.
- Managers and teams working in oil and gas maintenance, according to their practical responsibilities.
- Professionals responsible for applying the outputs of “Emergency Failure Analysis and Prevention” 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 “Emergency Failure Analysis and Prevention” 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.