Oil and Gas Facility Maintenance Management Training Course

Course overview

Oil and gas facilities depend on disciplined maintenance decisions to protect containment, sustain production, and meet regulatory obligations. Yet maintenance teams commonly face growing backlogs, repeat pump and compressor failures, incomplete work orders, unreliable spare-parts availability, and conflict between planned shutdown work and immediate production demands. This course equips participants to turn maintenance data, asset condition, and operational risk into practical priorities for upstream, midstream, LNG, refinery, petrochemical, and terminal environments.

Participants learn how to build an asset maintenance strategy that connects criticality, failure modes, preventive maintenance, condition monitoring, inspection findings, and corrective work. They practise planning and scheduling work through a CMMS, developing job plans, estimating labour and materials, controlling maintenance backlog, and selecting KPIs that reveal schedule compliance, wrench time, mean time between failures, and repeat failures. The course also covers risk-based inspection principles, reliability-centred maintenance, shutdown planning, spare-parts control, permit-to-work interfaces, and contractor performance management.

Instruction uses realistic facility scenarios involving rotating equipment, pressure systems, pipelines, electrical assets, and safety-critical equipment. Teams analyse equipment histories, prioritise an overdue work backlog, develop a weekly schedule, investigate a recurring failure, and construct a maintenance improvement plan. Each participant leaves with a completed Facility Maintenance Management Action Plan, including an asset-criticality matrix, KPI dashboard specification, 90-day backlog-reduction plan, and improvement priorities that can be adapted to their own site.

The programme is suited to maintenance and operations professionals moving from reactive work control toward planned, risk-informed maintenance management, as well as supervisors and engineers who need a common operating language across operations, integrity, reliability, and maintenance functions.

Course objectives

By the end of this course, participants will be able to:

• Apply an asset-criticality ranking method to prioritise maintenance work by safety, environmental, production, and cost consequence
• Develop preventive maintenance job plans with task steps, labour estimates, materials, acceptance criteria, and safety controls
• Use CMMS work-order data to calculate backlog age, schedule compliance, PM compliance, MTBF, MTTR, and repeat-failure indicators
• Conduct a basic failure mode and effects analysis for rotating and static oil and gas equipment
• Build a weekly maintenance schedule that balances labour capacity, permits, production constraints, materials, and equipment availability
• Prioritise inspection and maintenance actions using risk-based inspection concepts aligned to API RP 580
• Prepare a shutdown worklist with scope validation, critical-path interfaces, resource requirements, and readiness gates
• Produce a 90-day facility maintenance improvement plan with KPIs, ownership, milestones, and review cadence

Benefits of attending

Target competencies

Who should attend

• Maintenance Supervisors — who allocate crews, control work quality, and must reduce reactive maintenance
• Maintenance Planners and Schedulers — who convert work requests into executable, resource-loaded maintenance plans
• Reliability Engineers — who need to connect failure analysis and asset strategies to field maintenance execution
• Operations Supervisors — who coordinate equipment availability, isolations, permits, and production priorities with maintenance
• Asset Integrity and Inspection Engineers — who prioritise inspection findings and manage pressure-equipment risk
• Facilities and Operations Managers — who require defensible maintenance performance measures and improvement plans

Requirements and prerequisites

Participants should have basic familiarity with industrial equipment and maintenance work processes, gained through operations, engineering, maintenance, inspection, or supervision in an oil and gas or comparable process-industry setting. They should understand common terms such as work order, preventive maintenance, corrective maintenance, permit to work, equipment isolation, and shutdown. Experience using a CMMS such as IBM Maximo or SAP PM is useful but not essential; exercises explain the relevant fields and reports. No advanced reliability-engineering qualification, coding ability, statistical software, or prior knowledge of API risk-based inspection calculations is required.

Training methodology

The instructor combines focused technical briefings with facilitated analysis of oil and gas facility maintenance cases. Participants work with sample CMMS work orders, equipment histories, inspection findings, labour-capacity data, and shutdown scopes rather than abstract examples. Small groups build criticality rankings, review failure modes, prepare weekly schedules, and defend their decisions against changing operating constraints. Instructor feedback links each exercise to recognised practice in ISO 55001 and API RP 580. The final session converts learning into an individual 90-day improvement plan for the participant's own facility or maintenance area.

Course outline

Day 1: Asset Management, Maintenance Risk and Work Control

• Oil and gas asset lifecycle and maintenance value drivers
• Safety-critical equipment and barrier assurance responsibilities
• ISO 55001 asset management principles for maintenance teams
• Asset-criticality ranking using consequence and likelihood criteria
• Reactive, preventive, predictive, and corrective maintenance distinctions
• Maintenance workflow from notification to work-order closure
• Maintenance-operations interfaces for permits, isolations, and handback

Workshop: Participants create an asset-criticality matrix for a process train containing pumps, vessels, compressors, valves, and electrical equipment.

Day 2: Maintenance Strategies and Reliability Improvement

• Reliability-centred maintenance decision logic
• Failure mode and effects analysis for facility equipment
• Preventive maintenance task development and task frequencies
• Condition monitoring routes for vibration, thermography, lubrication, and ultrasound
• Bad-actor identification from repeat work-order histories
• Root cause analysis using five whys and cause-and-effect logic
• Maintenance strategy selection for rotating, static, and electrical assets

Workshop: Teams perform a failure mode analysis on a recurring centrifugal-pump failure and recommend revised tasks, controls, and ownership.

Day 3: Planning, Scheduling and CMMS Data Discipline

• Work-order quality standards and notification screening
• Job plan structure, task sequencing, and acceptance criteria
• Labour estimation, craft loading, and productivity assumptions
• Materials identification, bill of materials, and kitting requirements
• Weekly scheduling with permit, isolation, and production constraints
• Backlog segmentation by priority, age, readiness, and work type
• IBM Maximo and SAP PM maintenance reporting fields

Workshop: Participants clean and prioritise a simulated maintenance backlog, then produce a resource-loaded one-week schedule.

Day 4: Inspection, Turnarounds and Maintenance Performance

• API RP 580 risk-based inspection concepts
• Inspection finding disposition and repair prioritisation
• Pressure-equipment degradation mechanisms and maintenance implications
• Turnaround scope challenge and worklist governance
• Shutdown readiness gates for engineering, materials, permits, and contractors
• Maintenance KPIs for compliance, backlog, reliability, and cost
• KPI visualisation and performance-review meeting routines

Workshop: Groups evaluate an inspection and turnaround worklist, identify readiness gaps, and build a risk-ranked shutdown action register.

Day 5: Contractor Control and Facility Improvement Planning

• Contractor work-pack requirements and technical scope definition
• Maintenance quality assurance, test records, and work verification
• Spare-parts criticality, min-max levels, and obsolescence exposure
• Maintenance cost analysis and repair-versus-replace decisions
• Management of change triggers for maintenance modifications
• Cross-functional maintenance review meetings and escalation paths
• Ninety-day maintenance improvement roadmap development

Workshop: Each participant completes and presents a 90-day Facility Maintenance Management Action Plan with KPIs, owners, milestones, and priority initiatives.

Tools & standards covered

IBM Maximo, SAP PM, API RP 580, ISO 55001

A typical training day

Live online deliveries follow the same structure in the East Africa Time zone, with shorter screen blocks and longer breaks.

What the fee includes

How you can take this course

Certification

Participants who complete the full five days receive the Skillset Development Certificate of Completion, stating the course title, course code, dates and delivery format — suitable for professional-development records and employer reimbursement.

Frequently asked questions