BASIC MAINTENANCE PRACTICES PROGRAM

Description

The Basic Maintenance Practices Program will provide technical skills and competencies for
implementing processes to reduce breakdowns, increase uptime, and promote overall reliability.
Maintenance is a process of ensuring that equipment is kept in good working condition
therefore it will keep running at its expected capacity and production operations are likewise
sustained.

The program will be founded on a learning model that alternates between a series of lectures for
delivery of theoretical principles and hands on training in the workshop.

Maintenance plans will be drafted, these reduce maintenance costs, maximize uptime potential,
and ultimately increase profitability reducing costs of poor maintenance culture.

Objective

The objective of the program will be to ensure learners acquire the knowledge and skills
imperative to perform maintenance to electrical, mechanical, instruments and control
equipment on an industrial level following the health and safety procedures provided.

Learning Outcomes

The desired program learning outcomes will include but not be limited to ability to execute
maintenance requirements on mechanical, electrical, instrument and control equipment in a
safe and efficient manner, identify equipment key functions and their typical applications in the
oil and gas industry.

The program will ensure learners are able to:

1) Identify and report risks, potential hazards, near misses, safe and unsafe work practices in
a workshop environment;

2) Efficiently execute basic routine maintenance tasks;

3) Prepare basic two-dimensional drawings of engineering objects to scale and add dimensions
to basic two-dimensional drawings;

4) Perform basic arithmetical operations to solve problems in an engineering context;

5) Solve mechanics’ problems in an engineering context and those involving force, mass and
acceleration;

6) Perform simple calculations on simple series and parallel electrical circuits;

7) Identify and explain the operation of various types of prime movers;

8) Outline typical maintenance requirements of transmission systems and components; and

9) Outline typical maintenance requirements of distribution systems.

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Constituent Program Modules

Constituent Modules under the Industrial Maintenance Practice Program will comprise:

1. Health and Safety in Maintenance

2. Maintenance Techniques and Practices
3. Engineering Communications
4. Numeracy Skills
5. Introduction to Physical Science and Basic Properties of Materials
6. Electrical and Electronic Principles
7. Introduction to Mechanical Maintenance: Prime Movers
8. Introduction to Mechanical Maintenance: Transmission Systems and Components
9. Introduction to Mechanical Maintenance: Distribution Systems
10. Introduction to Electrical Maintenance: Rotating Equipment and Tools
11. Introduction to Electrical Maintenance: Electrical Distribution Systems
12. Introduction to Electrical Maintenance: Protection Methods
13. Introduction to Instrument and Control Maintenance: Process Measurement Systems
and Equipment
14. Introduction to Instrument and Control Maintenance: Process Control Systems and
Equipment
15. Introduction to Instrument and Control Maintenance: Protection and Detection Systems

Module 1: Health and Safety in Maintenance

Description – This module will introduce learners to the skills required to comply with safe
working practices in an industrial maintenance environment

Specific objectives – the specific objectives of this module are to:

 Introduce learners to safe working practices and procedures for a maintenance

workshop;
 Enable learners describe risks, hazards, safe and unsafe work practices in a
maintenance workshop;
 Instill understanding of safety documentation and procedures;
 Familiarize learners with safe working practices in a maintenance workshop;
 Train learners the correct manual handling techniques for maintenance tasks;
 Familiarize learners with the correct personal protection equipment for maintenance
tasks; and
 Deepen learners’ understanding of poor Health and Safety culture in a maintenance
work shop.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Apply safe working practices and procedures for a maintenance workshop;

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  Demonstrate safety documentation and procedures;
 Take part in a tool box talk;
 Use correct manual handling techniques for maintenance tasks;
 Select and use the correct personal protection equipment for maintenance tasks; and
 Identify and report risks, potential hazards, near misses, safe and unsafe work practices
in a workshop environment

Module 2: Maintenance Techniques and Practices

Description – This module will introduce learners to the skills required to prepare for and carry
out basic routine maintenance tasks.

Specific objectives – the specific objectives of this module are to:

 Instill understanding of basic routine maintenance tasks;

 Familiarize learners with the identification and preparation of tools, equipment and
materials for basic routine and assigned maintenance tasks; and
 Ensure learners’ ability to prepare the work area for given maintenance tasks.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Prepare for basic routine maintenance tasks;

 Identify and prepare tools, equipment and material that would be required for a range of
maintenance tasks;
 Prepare the work area for given maintenance tasks; and
 Efficiently execute basic routine maintenance tasks.

Module 3: Engineering Communications

Description – This module will introduce learners to the skills required to use engineering
drawings/diagrams and verbal and written engineering instructions in the context of
maintenance tasks.

Specific objectives – the specific objectives of this module are to:

 Ensure learners interpret engineering communications and symbols;

 Teach learners how to extract information from two-dimensional and three-dimensional
engineering drawings;
 Teach learners how to extract information for basic engineering drawing symbols;
 Train learners on how to interpret supplied instructions and drawings to identify key
specifications for creating for a given artifact;
 Enable learners prepare basic two-dimensional drawings; and
 Enable learners prepare basic two-dimensional drawings of engineering objects to scale
and add dimensions to basic two-dimensional drawings.

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Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Interpret engineering communications and symbols;

 Extract information from two-dimensional and three-dimensional engineering drawings;
 Extract information for basic engineering drawing symbols;
 Interpret supplied instructions and drawings to identify key specifications for creating
for a given artifact;
 Prepare basic two-dimensional drawings; and
 Prepare basic two-dimensional drawings of engineering objects to scale and add
dimensions to basic two-dimensional drawings;

Module 4: Numeracy Skills

Description – This module will introduce learners to the skills required to gain an understanding
of numeracy in an engineering context.

Specific objectives – the specific objectives of this module are to:

 Enable learners understand basic arithmetical operations to solve problems in an

engineering context;
 Perform calculations involving statistical concepts;
 Instill knowledge of using basic graphs in an engineering context;
 Foster understanding of qualitative graphs and histograms; and
 Ensure that learners are able to interpret graphs where part of the axis has been
omitted.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Perform basic arithmetical operations to solve problems in an engineering context;

 Perform calculations involving statistical concepts;
 Interpret basic graphs in engineering;
 extract information from qualitative graphs and histograms; and
 interpret graphs where part of the axis has been omitted.

Module 5: Introduction to Physical Science and Basic Properties of Materials

Description – This module will introduce learners to a basic understanding of physical science
and the properties of materials in an engineering context

Specific objectives – the specific objectives of this module are to:

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  Introduce learners to the basic principles of matter and atomic structure in an
engineering context;
 Enable learners understand the basic properties of materials;
 Instill the knowledge of key features and mechanisms of wear and corrosion;
 Introduce learners to the key features of the concepts of hardness, ductility, plasticity,
toughness and malleability and the basic principles of mechanics;
 Enable learners read and analyze the basic principles underlying statics and dynamics
including the key concepts of equilibrium, center of mass, moment of inertia and
torque; and
 Equip learners with simple mechanics’ calculations in an engineering context.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Recall the basic principles of matter and atomic structure;

 Outline the basic properties of materials in an engineering context;
 Identify the key features and mechanisms of wear and corrosion;
 Describe the key features of the concepts of hardness, ductility, plasticity, toughness
and malleability;
 Apply the basic principles of mechanics;
 Analyze the basic principles underlying statics and dynamics including the key concepts
of equilibrium, center of mass, moment of inertia and torque; and
 Solve mechanics’ problems in an engineering context and those involving force, mass
and acceleration.

Module 6: Electrical and Electronic Principles

Description – This module will introduce learners to a basic understanding of electrical and
electronic principles in an engineering context.

Specific objectives – the specific objectives of this module are to:

 Introduce learners to units associated with basic electrical quantities, electric circuits
and resistance variations;
 Expose learners to the basic principles of atomic structure and electron theory,
magnetism and electromagnetism;
 Instill an understanding of semi-conductor diodes, transistors and the chemical effects
of electricity; and
 Deepen learners’ understanding of series and parallel electrical circuits.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Outline the basic principles of electronics;

 Outline the basic principles of atomic structure and electron theory;

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  Outline the basic principles of magnetism and electromagnetism;
 Outline and use the basic principles of voltage, current and resistance, series and
parallel circuits, capacitors and capacitance;
 Identify the components of simple series and parallel electrical circuits;
 Perform simple calculations on simple series and parallel electrical circuits; and
 Use a multi-meter to measure voltage, current, capacitance, resistance and continuity
in a circuit.

Module 7: Introduction to Mechanical Maintenance: Prime Movers

Description – This module will introduce learners to an overview of the operation of prime
movers, their key functions, typical applications in the oil and gas industry and typical
maintenance issues and requirements.

Specific objectives – the specific objectives of this module are to:

 Enable learners describe the key features of prime movers;

 Introduce learners to various types of prime movers;

 Instill knowledge of typical maintenance requirements of prime movers; and

 Help learners understand the operation of prime movers.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Identify and explain the operation of various types of prime movers;

 Outline typical maintenance requirements of each prime movers;

 Overhaul and assemble a prime mover during maintenance;

 Carry out autonomous maintenance with or without supervision;

 Troubleshoot the prime mover in question; and

 Establish a maintenance schedule i.e. daily, monthly or annually.

Module 8: Introduction to Mechanical Maintenance: Transmission Systems and

Components

Description – This module will introduce learners to an overview of the operation of transmission
systems and components, their key functions, typical applications in the oil and gas industry
and typical maintenance issues and requirements.

Specific objectives – the specific objectives of this module are to:

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  Introduce learners to transmission system requirements, main units and the types of
Transmission Systems;

 Equip learners with knowledge of manual and automatic transmission, functions and
principles of operation of each component; and

 Expose learners to the typical maintenance requirements of transmission systems and

components

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Describe the key features of transmission systems and components;

 Compare manual with automatic transmission;

 Outline the functions and principles of operation of each component; and

 Outline typical maintenance requirements of transmission systems and components.

Module 9: Introduction to Mechanical Maintenance: Distribution Systems

Description – This module will introduce learners to an overview of the operation of distribution
systems, their key functions, typical applications in the oil and gas industry and typical
maintenance issues and requirements

Specific objectives – the specific objectives of this module are to:

 list all objectives which should be focused, brief and not too many!

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Describe the key features of distribution systems; and

 Outline typical maintenance requirements of distribution systems.

Module 10: Introduction to Electrical Maintenance: Rotating Equipment and Tools

Description – This module will introduce learners to an overview of the operation of rotating
equipment and tools, their key functions, typical applications in the oil and gas industry and
typical maintenance issues and requirements.

Specific objectives – the specific objectives of this module are to:

 Introduce learners to the types of rotating equipment used in the oil and gas sector, their
key features and operation; and

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  Expose learners to preventive maintenance of rotating equipment.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Identify rotating equipment used in the oil and gas sector;

 Describe the key features of rotating equipment and tools;

 Outline typical maintenance requirements of rotating equipment and tools; and

 Create a preventive maintenance program that ensures routine maintenance tasks are
performed on a regularly scheduled basis.

Module 11: Introduction to Electrical Maintenance: Electrical Distribution Systems

Description – This module will introduce learners to an overview of the operation of electrical
distribution systems, their key functions, typical applications in the oil and gas industry and
typical maintenance issues and requirements.

Specific objectives – the specific objectives of this module are to:

 Introduce learners to electric power system and the distribution system;

 Instill understanding of the operation and design of electrical distribution systems;

 Deepen learners’ understanding of the electric distribution system stages and the factors
affecting system planning;

 Introduce learners to load Characteristics, types of electricity consumers and the basic
distribution substation design criteria;

 Provide In-depth learning of the distribution lines and sub-stations;

 Explain to learners the need to maintain an electrical Distribution system, the maintenance
types and the frequency of intervention;

 Ensure learners appreciate the protection and sectionalization of the Feeder System; and

 Introduce learners to general electrical safety practices, those specific to Distribution systems
and costs of poor maintenance culture.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Differentiate the types of loads and their characteristics;

 Explain the stages of a distribution system and plot the load profile of residential
customer;

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  Identify electricity consumers and explain the basic distribution substation design
criteria;
 Calculate the voltage drop and power loss in a distribution system;

 Identify the primary purpose of protection engineering, maintenance of the distribution

system and costs of a poor maintenance culture;

 List the factors affecting system planning;

 Explain the HV and LV Side Bus work & Protection;

 Create and follow a maintenance plan and log book; and

 Design radial and loop type distribution feeders.

Module 12: Introduction to Electrical Maintenance: Protection Methods

Description – This module will introduce learners to an overview of the operation of protection
methods, their key functions, typical applications in the oil and gas industry and typical
maintenance issues and requirements

Specific objectives – the specific objectives of this module are to:

 Introduce learners to the need of protection in an electrical system;

 Enable learners understand the various protection methods, devices and their key
features;
 Deepen learners’ understanding of the generator and transformer protection methods;
 Expose learners to protection against direct and indirect contact in an electrical
installation system;
 Introduce learners to circuit-interrupting devices and sensing devices; and
 Expose learners to maintenance requirements of protection methods.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 List the various protection methods and devices;

 Describe the key features of various protection methods;

 Explain the generator and transformer protection methods;

 Describe the methods of protection against direct and indirect contact in an electrical
installation;

 Differentiate between circuit-interrupting devices and sensing devices;

 Explain the operation of the protective devices; and

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  Outline typical maintenance requirements of protection methods.

Module 13: Introduction to Instrument and Control Maintenance: Process Measurement

Systems and Equipment

Description – This module will introduce learners to an overview of the operation of process
measurement systems and equipment, their key functions, typical applications in the oil and
gas industry and typical maintenance issues and requirements

Specific objectives – the specific objectives of this module are to:

 Ensure learners’ understanding of process measurement systems and equipment

features;

 Explain to learners the maintenance requirements of process measurement systems;

 Instill an understanding of the need to maintain and the costs of poor maintenance of
the process measurement systems and equipment; and
 Help students identify various process variables measured.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Describe the key features of process measurement systems and equipment;

 Outline typical maintenance requirements of process measurement systems and

equipment;

 Identify the various process variables measured; and

 Create a maintenance schedule of measuring equipment and instruments.

Module 14: Introduction to Instrument and Control Maintenance: Process Control

Systems and Equipment

Description – This module will introduce learners to an overview of the operation of process
control systems and equipment, their key functions, typical applications in the oil and gas
industry and typical maintenance issues and requirements

Specific objectives – the specific objectives of this module are to:

 Introduce learners to the various types of process control systems and how they work to
gather and transmit data;

 Provide in-depth learning of the typical maintenance requirements, the indications and
effects of poorly maintained control systems and equipment; and

 Expose learners to the various control systems used in the oil and gas sector.

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Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Describe the key features of process control systems and equipment;

 Explain the operation of Supervisory Control And Data Acquisition (SCADA),

Programmable Logic Controllers (PLC) and Distributed Control Systems (DCS);

 Describe the control systems used in oil and gas (up-stream, mid-stream and down-
stream) sector and the process parameters controlled at down-stream;

 Identify the indications and effects of a poorly maintained control system;

 Outline typical maintenance requirements of process control systems and equipment;

and

 Produce a Process Control and Equipment maintenance manual, use a log book and
carry out regular checks;

Module 15: Introduction to Instrument and Control Maintenance: Protection and

Detection Systems

Description – This module will introduce learners to an overview of the operation of protection
and detection systems, their key functions, typical applications in the oil and gas industry and
typical maintenance issues and requirements.

Specific objectives – the specific objectives of this module are to:

 Introduce learners to the key features of protection and detection systems; and

 Enable learners understand the maintenance requirements of protection and detection

systems.

Target Learning Outcomes – upon conclusion of this module learners will be able to:

 Describe the key features of protection and detection systems; and

 Outline typical maintenance requirements of protection and detection systems.

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