SKILLS FOR OIL AND GAS
SUPPORT GUIDE FOR OPITO GLOBAL
LEVEL 2 TRAINING CERTIFICATES FOR
MAINTENANCE PRACTICES
VERSION 1: MARCH 2014
OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
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Version 1
AMENDMENT AND DATE
March 2014
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Version 1 – March 2014
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Contents
Section 1 - Introduction ................................................................................................................ 4
The Purpose of this Guide ......................................................................................................... 4
OPITO Framework of Global Oil and Gas Technical Standards and Qualifications ....................... 4
Section 2 – Qualifications ............................................................................................................. 6
Section 3 – Delivery Guidance ...................................................................................................... 9
Target Group ............................................................................................................................ 9
English Language Skills.............................................................................................................. 9
Notional Learning Hours ......................................................................................................... 10
Guidance on Learning, Teaching and Assessment Methods ..................................................... 12
Workshop and Equipment Requirements ................................................................................ 13
Section 4 – Further Guidance ..................................................................................................... 13
Section 5 – Overview of OPITO Global Technical Standards for Maintenance (Level 2) ................ 14
Level 2 - Mandatory Technical Standards ................................................................................ 14
Example of Maintenance Techniques Training Standard .......................................................... 16
Example of Maintenance Practice Training Standard ............................................................... 17
Level 2 - Mechanical Technical Standards ................................................................................ 18
Level 2 - Electrical Technical Standards ................................................................................... 19
Level 2 - Instrument and Control Technical Standards ............................................................. 21
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Section 1 - Introduction
The Purpose of this Guide
This document provides guidance on the delivery of the following OPITO Global Training Certificates:

OPITO Global Level 2 Training Certificate: Maintenance Practice (Mechanical)

OPITO Global Level 2Training Certificate: Maintenance Practice (Electrical)

OPITO Global Level 2 Training Certificate: Maintenance Practice (Instrument and Control)
OPITO Framework of Global Oil and Gas Technical Standards and Qualifications
The OPITO Framework of Global Oil and Gas Technical Standards and Qualifications comprises:



Training Standards which set benchmarks for the assessment of skills and knowledge and this provides a
foundation for building the skills required to work in the oil and gas industry
Occupational Standards which define the expected level of performance, knowledge, understanding and
behaviour an individual must achieve when carrying out job roles/functions in the workplace
Global Certificates and Qualifications which have been developed in conjunction with our awarding body
partner SQA and which will have global recognition.
Occupational Standards
Training Standards
Training
Skills Assessment
Competence Assessment
Training for safety,
behaviours, knowledge,
equipment and tools
Assessment of skills in a
simulated/ realistic working
environment
Assessment of competence in
the workplace.
Foundation Certificate in
Oil and Gas
Global
Skills Qualification
Global
Vocational Qualification
Global Training Certificates
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
The OPITO Framework of Global Oil and Gas Technical Standards and Qualifications was designed in
partnership with industry and covers 6 levels which reflect the range of skills and increasing levels of
complexity and risk associated with job roles in the industry.
Oil and Gas Level 5
Professional, senior/department manager.
Oil and Gas Level 4
Expert, specialist, first line manager
Oil and Gas Level 3
Maintenance technician, supervisor
Oil and Gas Level 2
Maintenance craftsman (routine maintenance)
Oil and Gas Level 1
Entry level employment/apprentice
Oil and Gas Foundation
Trainee at basic skills level
A typical progression route through the OPITO Framework of Global Oil and Gas Technical Standards and
Qualifications is illustrated below.
Training
Training Certificate:
Maintenance Practice
– M, E, I&C
Training Certificate:
Basic Maintenance
Practice
duction
Training Certificate:
Introduction to
Workshop Practice
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Skills Assessment
Skills Qualification:
Maintenance
Techniques – M, E, I&C
Competence
Assessment
Vocational Qualification:)
Oil and Gas Engineering
Maintenance – M, E, I&C
Oil and Gas
Level 3
Vocational Qualification:
Oil and Gas Engineering
Maintenance – M, E, I&C
Oil and Gas
Level 2
Oil and Gas
Level 1
Oil and Gas
Foundation
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Section 2 – Qualifications
The OPITO Global Level 2 Training Certificates for Maintenance Practice introduce Candidates to the
practice and techniques required to enable them to operate in a maintenance workshop within the oil and
gas industry.
The Training Certificates for Maintenance Practice can be achieved in 3 pathways:

OPITO Global Level 2 Training Certificate: Maintenance Practice (Mechanical)

OPITO Global Level 2 Training Certificate: Maintenance Practice (Electrical)

OPITO Global Level 2 Training Certificate: Maintenance Practice (Instrument and Control)
Each of the Training Certificates for Maintenance Practice consists of the following two mandatory Training
Standards which must be completed by all Candidates:

OGTS/L2 – M40: Health and Safety in Oil and Gas Maintenance Workshops

OGTS/L2 –M41: Maintenance Working Practices
In addition, in order to achieve a Training Certificates for Maintenance Practice for the relevant pathway,
Candidates must also undertake Techniques and Practice Training Standards for minimum of 3 equipment
groups.
Maintenance Practice (Mechanical)
3 of the following 9 equipment groups to be completed:
Mechanical Maintenance Techniques: Diesel Engines
Mechanical Maintenance Practice: Diesel Engines
Mechanical Maintenance Techniques: Power Generation Gas Turbines
Mechanical Maintenance Practice: Power Generation Gas Turbines
Mechanical Maintenance Techniques: Air Compressors
Mechanical Maintenance Practice: Air Compressors
Mechanical Maintenance Techniques: Bearings and Seals
Mechanical Maintenance Practice: Bearings and Seals
Mechanical Maintenance Techniques: Gearboxes and Gearing Mechanisms
Mechanical Maintenance Practice: Gearboxes and Gearing Mechanisms
Mechanical Maintenance Techniques: Transmission Components
Mechanical Maintenance Practice: Transmission Components
Mechanical Maintenance Techniques: Heating, Ventilating and Air Conditioning
Systems
Maintenance Practice: Heating, Ventilating and Air Conditioning Systems
Mechanical Maintenance Techniques: Centrifugal Pumps, Reciprocating Pumps and
Valves
Mechanical Maintenance Practice: Centrifugal Pumps, Reciprocating Pumps and
Valves
Mechanical Maintenance Techniques: Piping and Pipe Connections
Mechanical Maintenance Practice: Piping and Pipe Connections
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OGTS/L2 – MM50
OGTS/L2 – MM51
OGTS/L2 – MM52
OGTS/L2 – MM53
OGTS/L2 – MM54
OGTS/L2 – MM55
OGTS/L2 – MM56
OGTS/L2 – MM57
OGTS/L2 – MM58
OGTS/L2 – MM59
OGTS/L2 – MM60
OGTS/L2 – MM61
OGTS/L2 – MM62
OGTS/L2 – MM63
OGTS/L2 – MM64
OGTS/L2 – MM65
OGTS/L2 – MM66
OGTS/L2 – MM67
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Maintenance Practice (Electrical)
3 of the following 9 equipment groups to be completed:
Electrical Maintenance Techniques: Generators and Regulation
Electrical Maintenance Practice: Generators and Regulation
Electrical Maintenance Techniques: Single Phase & 3 Phase AC Motors
Electrical Maintenance Practice: Single Phase & 3 Phase AC Motors
Electrical Maintenance Techniques: Electrical Hand Tools
Electrical Maintenance Practice: Electrical Hand Tools
Electrical Maintenance Techniques: Single and 3 Phase Electrical Distribution
Systems
Electrical Maintenance Practice: Single and 3 Phase Electrical Distribution Systems
Electrical Maintenance Techniques: DC Motors
Electrical Maintenance Practice: DC Motors
Electrical Maintenance Techniques: Cells & Batteries and Uninterruptible Power
Supply
Electrical Maintenance Practice: Cells & Batteries and Uninterruptible Power
Supply
Electrical Maintenance Techniques: Heating, Ventilation and Air Conditioning
Equipment
Electrical Maintenance Practice: Heating, Ventilation and Air Conditioning
Equipment
Electrical Maintenance Techniques: Protection Devices of Electrical Equipment in
Hazardous Areas
Electrical Maintenance Practice: Protection Devices of Electrical Equipment in
Hazardous Areas
Electrical Maintenance Techniques: Circuit Protection Devices and Power
Protection Relays
Electrical Maintenance Practice: Circuit Protection Devices and Power Protection
Relays
Maintenance Practice (Instrument and Control)
3 of the following 10 equipment groups to be completed:
Instrument and Control Maintenance Techniques: Process Equipment (Measuring,
Level, Flow, Temperature)
Instrument and Control Maintenance Practice: Process Equipment (Measuring,
Level, Flow, Temperature)
Instrument and Control Maintenance Techniques: Process Control Valves
Instrument and Control Maintenance Practice: Process Control Valves
Instrument and Control Maintenance Techniques: Small Bore Tubing
Instrument and Control Maintenance Practice: Small Bore Tubing
Instrument and Control Maintenance Techniques: Metering Devices and Fiscal
Metering
Instrument and Control Maintenance Practice: Metering Devices and Fiscal
Metering
Instrument and Control Maintenance Techniques: Programmable Logic Controller
Systems
Instrument and Control Maintenance Practice: Programmable Logic Controller
Systems
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OGTS/L2 – ME50
OGTS/L2 – ME51
OGTS/L2 – ME52
OGTS/L2 – ME53
OGTS/L2 – ME54
OGTS/L2 – ME55
OGTS/L2 – ME56
OGTS/L2 – ME57
OGTS/L2 – ME58
OGTS/L2 – ME59
OGTS/L2 – ME60
OGTS/L2 – ME61
OGTS/L2 – ME62
OGTS/L2 – ME63
OGTS/L2 – ME64
OGTS/L2 – ME65
OGTS/L2 – ME66
OGTS/L2 – ME67
OGTS/L2 – MI50
OGTS/L2 – MI51
OGTS/L2 – MI52
OGTS/L2 – MI53
OGTS/L2 – MI54
OGTS/L2 – MI55
OGTS/L2 – MI56
OGTS/L2 – MI57
OGTS/L2 – MI58
OGTS/L2 – MI59
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Instrument and Control Maintenance Techniques: Distributed Control Systems
Instrument and Control Maintenance Practice: Distributed Control Systems
Instrument and Control Maintenance Techniques: Condition Monitoring Systems
Instrument and Control Maintenance Practice: Condition Monitoring Systems
Instrument and Control Maintenance Techniques: Emergency Shutdown Systems
Instrument and Control Maintenance Practice: Emergency Shutdown Systems
Instrument and Control Maintenance Techniques: Fire and Gas Detection Systems
Maintenance Practice: Fire and Gas Detection Systems
Instrument and Control Maintenance Techniques: Protection Methods and
Instrument Equipment in Hazardous Areas
Instrument and Control Maintenance Practice: Protection Methods and
Instrument Equipment in Hazardous Areas
Optional Training Standard
Instrument and Control Maintenance Techniques: Subsea Control Systems
OGTS/L2 – MI60
OGTS/L2 – MI61
OGTS/L2 – MI62
OGTS/L2 – MI63
OGTS/L2 – MI66
OGTS/L2 – MI67
OGTS/L2 – MI68
OGTS/L2 – MI69
OGTS/L2 – MI70
OGTS/L2 – MI71
OGTS/L2 – MI64
The OPITO Global Level 2 Training Certificates for Maintenance Practice are jointly awarded by OPITO and
SQA and successful Candidates who complete the relevant Training Standards will be issued with a joint
OPITO/SQA certificate.
This Training Certificate is at Oil and Gas Level 2. This is broadly comparable to training at SCQF levels 5/6,
S/NVQ level 2, QCF level 3/4 and EQF level 4/5.
On successful completion of these Training Certificates, Candidates can progress to the Level 2 and Level 3
Vocational Qualifications as illustrated below.
Vocational Qualification:
L2: Oil and Gas
Engineering Maintenance
(Electrical)
Training Certificate:
L2: Oil and Gas
Engineering Maintenance
(Instrument and Control)
Vocational Qualification:
L2: Oil and Gas
Engineering Maintenance
(Electrical)
Vocational Qualification:
L2: Oil and Gas
Engineering Maintenance
(Instrument and Control)
Vocational Qualification:
L2: Oil and Gas
Engineering Maintenance
(Mechanical)
Training Certificate:
Maintenance Practice
(Electrical)
Training Certificate:
Maintenance Practice
(Instrument and Control)
Training Certificate:
Maintenance Practice
(Mechanical)
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Training Certificate:
L2: Oil and Gas
Engineering Maintenance
(Mechanical)
Oil and Gas
Level 3
Oil and Gas
Level 2
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Section 3 – Delivery Guidance
Target Group
The Level 2 Training Certificates in Maintenance Practice are aimed at Candidates who are already familiar
with the basics of an engineering workshop environment. It is expected that Candidates will already have
completed Foundation and Level 1 Training Certificates, or equivalent training and/or experience and
knowledge.
In addition, it is recommended that Candidates should have successfully completed relevant Level 1
Introductory Equipment Technical Standards (listed below) in the equipment grouping which equates to
their choice of pathway at Level 2.
For example, in order to undertake Mechanical Maintenance Techniques/Practice: Diesel Engines (OTGS L2 –
ME50/ME51)from the Maintenance Practice (Maintenance) grouping at Level 2, it is recommended that
Candidates should first complete An Introduction to Mechanical Maintenance : Prime Movers.
Level 1 Introductory Equipment Technical Standards
OPITO Global Level 1 Training Certificate: Basic Maintenance Practices (Mechanical):
 An Introduction to Mechanical Maintenance: Prime Movers
 An Introduction to Mechanical Maintenance: Transmission Systems and Components
 An Introduction to Mechanical Maintenance: Distribution Systems
OPITO Global Level 1 Training Certificate: Basic Maintenance Practices (Electrical)
 An Introduction to Electrical Maintenance: Rotating Equipment and Tools
 An Introduction to Electrical Maintenance: Electrical Distribution
 An Introduction to Electrical Maintenance: Protection Methods
OPITO Global Level 1 Training Certificate: Basic Maintenance Practices (Instrument and Control)
 An Introduction to Instrument and Control Maintenance: Process Measurement Systems and Equipment
 An Introduction to Instrument and Control Maintenance: Process Control Systems and Equipment
 An Introduction to Instrument and Control Maintenance: Protection and Detection Systems
English Language Skills
All assessment must be carried out in English and Candidates should have the ability to express themselves
in a limited way in familiar situations and to deal in a general way with new or non-routine information.
They should be able to understand the main points of inputs on familiar matters regularly encountered in
the workplace. They should also have the ability to produce simple written and spoken responses on topics
that are familiar. This level of English is to the following International Frameworks - CEFR B1-B2/IELTs 4.0 –
5.0/ ToEFL c 30 – 45.
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Notional Learning Hours
The time taken to complete the components within The Level 2 Training Certificates in Maintenance Practice
will vary depending on the skills and experience of Candidates. It is anticipated that it is likely to take the
average Candidate around 50 hours to complete the two mandatory Training Standards and a further 90 160 hours to complete the selected Techniques and Practice Standards for the 3 equipment groups.
Notional learning hours are given for each Training Standard but these are only intended for guidance.
Level 2 Training Standards
Mandatory Training Standards
Health and Safety in Oil and Gas Maintenance Workshops
Maintenance Working Practices
Notional hours
(including
assessment)
30
20
Mechanical Maintenance
Mechanical Maintenance Techniques: Diesel Engines
Mechanical Maintenance Practice: Diesel Engines
Mechanical Maintenance Techniques: Power Generation Gas Turbines
Mechanical Maintenance Practice: Power Generation Gas Turbines
Mechanical Maintenance Techniques: Air Compressors
Mechanical Maintenance Practice: Air Compressors
Mechanical Maintenance Techniques: Bearings and Seals
Mechanical Maintenance Practice: Bearings and Seals
Mechanical Maintenance Techniques: Gearboxes and Gearing Mechanisms
Mechanical Maintenance Practice: Gearboxes and Gearing Mechanisms
Mechanical Maintenance Techniques: Transmission Components
Mechanical Maintenance Practice: Transmission Components
Mechanical Maintenance Techniques: Heating, Ventilating and Air Conditioning
Systems
Maintenance Practice: Heating, Ventilating and Air Conditioning Systems
Mechanical Maintenance Techniques: Centrifugal Pumps, Reciprocating Pumps and
Valves
Mechanical Maintenance Practice: Centrifugal Pumps, Reciprocating Pumps and
Valves
Mechanical Maintenance Techniques: Piping and Pipe Connections
Mechanical Maintenance Practice: Piping and Pipe Connections
Notional Hours
20
20
20
20
20
20
20
20
20
20
20
20
20
20
Electrical Maintenance
Electrical Maintenance Techniques: Generators and Regulation
Electrical Maintenance Practice: Generators and Regulation
Electrical Maintenance Techniques: Single Phase & 3 Phase AC Motors
Electrical Maintenance Practice: Single Phase & 3 Phase AC Motors
Electrical Maintenance Techniques: Electrical Hand Tools
Electrical Maintenance Practice: Electrical Hand Tools
Notional Hours
20
20
20
20
20
20
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20
20
20
20
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Electrical Maintenance Techniques: Single and 3 Phase Electrical Distribution
Systems
Electrical Maintenance Practice: Single and 3 Phase Electrical Distribution Systems
Electrical Maintenance Techniques: DC Motors
Electrical Maintenance Practice: DC Motors
Electrical Maintenance Techniques: Cells & Batteries and Uninterruptible Power
Supply
Electrical Maintenance Practice: Cells & Batteries and Uninterruptible Power Supply
Electrical Maintenance Techniques: Heating, Ventilation and Air Conditioning
Equipment
Electrical Maintenance Practice: Heating, Ventilation and Air Conditioning
Equipment
Electrical Maintenance Techniques: Protection Devices of Electrical Equipment in
Hazardous Areas
Electrical Maintenance Practice: Protection Devices of Electrical Equipment in
Hazardous Areas
Electrical Maintenance Techniques: Circuit Protection Devices and Power Protection
Relays
Electrical Maintenance Practice: Circuit Protection Devices and Power Protection
Relays
Instrument and Control Maintenance
Instrument and Control Maintenance Techniques: Process Equipment (Measuring,
Level, Flow, Temperature)
Instrument and Control Maintenance Practice: Process Equipment (Measuring, Level,
Flow, Temperature)
Instrument and Control Maintenance Techniques: Process Control Valves
Instrument and Control Maintenance Practice: Process Control Valves
Instrument and Control Maintenance Techniques: Small Bore Tubing
Instrument and Control Maintenance Practice: Small Bore Tubing
Instrument and Control Maintenance Techniques: Metering Devices and Fiscal
Metering
Instrument and Control Maintenance Practice: Metering Devices and Fiscal Metering
Instrument and Control Maintenance Techniques: Programmable Logic Controller
Systems
Instrument and Control Maintenance Practice: Programmable Logic Controller
Systems
Instrument and Control Maintenance Techniques: Distributed Control Systems
Instrument and Control Maintenance Practice: Distributed Control Systems
Instrument and Control Maintenance Techniques: Condition Monitoring Systems
Instrument and Control Maintenance Practice: Condition Monitoring Systems
Instrument and Control Maintenance Techniques: Subsea Control Systems
Instrument and Control Maintenance Techniques: Emergency Shutdown Systems
Instrument and Control Maintenance Practice: Emergency Shutdown Systems
Instrument and Control Maintenance Techniques: Fire and Gas Detection Systems
Maintenance Practice: Fire and Gas Detection Systems
Instrument and Control Maintenance Techniques: Protection Methods and
Instrument Equipment in Hazardous Areas
Instrument and Control Maintenance Practice: Protection Methods and Instrument
Equipment in Hazardous Areas
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30
30
20
20
20
20
20
20
20
20
20
20
Notional Hours
30
30
30
30
20
20
20
10
20
10
20
10
20
10
30
20
10
20
20
20
20
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Guidance on Learning, Teaching and Assessment Methods
It is expected that the setting for delivery and assessment of these Training Standards will take place in a
training workshop which will match as closely as possible to workplace maintenance workshops.
The two mandatory Training Standards should be delivered in a participative integrated way. The use of
case studies and practical activities should be used to illustrate the key learning points.
It is strongly recommend that the Techniques and Practice Standards are delivered in conjunction as they
have been designed to be complementary. Some assessment could also be integrated.
For the Maintenance Techniques Training Standards, Candidates will develop an understanding of the
function, operation and routine maintenance requirements associated with the various equipment types.
Some of the learning activity will take part in a classroom setting, to cover theory requirements and
assessments for these Standards will be closed book and supervised. Assessment will typically consist of
structured written questions and oral questions, for which records must be maintained.
For the Maintenance Practice Training Standards, the emphasis is placed on developing the skills required to
carry out routine maintenance of the various equipment types. Candidates are expected to work in
accordance with safe working practices and they will learn how to prepare for maintenance activities,
identify hazards, use technical guidelines, prepare maintenance records and clean the work area afterwards.
The delivery and assessment of these standards should take place in a realistic workshop setting and
observation checklists should match as closely as possible to actual workplace operational requirements,
procedures and practices.
Log Book
Candidates must maintain a Log Book to record details of maintenance activities carried out – this will
provide evidence of Candidates’ understanding of the maintenance techniques involved and steps required.
The Log Book can be used as a reference guide for Candidates to assist them as they enter the workplace.
All Log Book entries should be validated as an accurate account by a supervisor or an Assessor.
Candidates should be given guidance on the relevant information to record. A typical log entry should be
brief (e.g. covering one or two pages) and contain the following:

date when task carried out

description of plant or equipment being maintained

list of tools and equipment used

description of the maintenance task and a breakdown of the sequence of specific tasks carried out

brief description of any faults or damage

actions taken to complete maintenance task e.g. replaced or repaired component

outcome of task e.g. plant or equipment reinstated or not

an accompanying drawing or photograph where relevant

additional notes to reflect on lessons learned.
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Workshop and Equipment Requirements
Training should take place in a supervised workshop setting which gives Candidates access to basic tools and
personal protective equipment (PPE). Typical PPE would include overalls, boots, safety glasses, gloves, ear
defenders, hard hat.
The training area should be designed to enable Candidates to view, hear and participate fully in the subject
matter being taught.
Typical workshops and practical areas should be well lit and well ventilated with clearly defined walk ways.
Training areas should have adequate floor space with work benches with bench vices fitted, allowing each
Candidate to participate fully in practical demonstrations and exercises. There should also be a clearly
marked storage area with tools cupboards and toolboxes/trays and file racks. Delivery centres are
responsible for ensuring that all tools and equipment are maintained and meet relevant safety standards.
The delivery centre must have sufficient equipment to ensure that all Candidates get a hand-on experience.
The equipment should be the same or similar to that currently used in industry.
Section 4 – Further Guidance
This document provides an overview of the Training Standards which form part of the OPITO Global Level 2
Training Certificates for Maintenance Practice. The full specifications for Training Standards are included in
the OPITO Guide - OPITO Global Technical Standards and Qualifications Specifications for Maintenance
(Level 2).
All organisations wishing to deliver the OPITO Global Level 2 Training Certificates for Maintenance Practice
must be an OPITO Approved Centre and must meet the requirements of OPITO’s Quality Criteria for Global
Oil and Gas Technical Standards and Qualifications.
For further information please contact a member of our Workforce Development team in Dubai mea.enquiries@opito.com
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Section 5 – Overview of OPITO Global Technical Standards for
Maintenance (Level 2)
Level 2 - Mandatory Technical Standards
OGTS/L2 – M40: Health and Safety in Oil and Gas Maintenance Workshops
Summary
This Training Standard develops knowledge and application of the health and safety
legislation and practice specific to the oil and gas industry and methods of
minimising risks and hazards. This Training Standard should be completed by all
Candidates undertaking a training programme at Oil and Gas Level 2.
Outcome 1
Describe the safety measures to be taken when working with electrical
equipment
 describe the dangers of electricity and the causes of electrical accidents
 describe the safety precautions necessary to minimise the risk of accidents
involving electricity
 identify the steps involved in safely isolating plant and equipment
Outcome 2
Identify the role and implementation of health and safety legislation and
procedures in the oil and gas industry
 identify health and safety legislation which applies to the oil and gas industry
and implications for individuals working in a maintenance workshop
 identify the procedures to apply in the event of a fire, workplace accident and
workplace injury
 describe environmental and waste management requirements for maintenance
workshops
 describe safe systems of work for maintenance workshops, including safety
briefings and drills
Outcome 3
Describe hazards associated with the workshop environment and the control
measures used to minimise risks
 describe the hazards and risk control measures associated with manual
handling operations, working at heights, working in confined spaces and
moving loads
 describe the hazards, regulations and risk control measures associated with
working with hazardous substances
 describe the risk control measures associated with noise hazards
Outcome 4
Carry out risk assessments for routine maintenance tasks
 identify potential hazards for a range of routine maintenance tasks
 describe risk assessment procedures and risk control measures
 create risk assessments for a range of routine maintenance tasks
The full specification for this Training Standard is included in the OPITO Guide - OPITO Global
Technical Standards and Qualifications Specifications for Maintenance (Level 2).
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
OGTS/L2 – M41: Maintenance Working Practices
Summary
This Training Standard develops understanding of key operational requirements of
working in a maintenance workshop, including care of tools, housekeeping, use of
maintenance schedules and checklists, the role of handovers and practices for
reporting and communication and maintaining working relationships. This Training
Standard should be completed by all Candidates undertaking a training programme
at Oil and Gas Level 2.
Outcome 1
Describe the documentation and reporting procedures required for routine
maintenance
 outline the role of operational maintenance instructions, worksheets and
checklists
 outline the use of maintenance schedules as part of planned and preventative
maintenance routines
Outcome 2
Outline practices to establish and maintain effective communication and working
relationships
 describe methods of ensuring effective communication with colleagues on
operational matters
 describe the role of, and typical procedures for, maintenance reports and
handovers
 outline the benefits of team work in ensuring a safe working environment
 outline the purpose of tool box talks
Outcome 3
Outline working practices for tools and work area
 outline key responsibilities for the care and storage of tools and equipment
during and after maintenance activity
 outline key responsibilities for housekeeping and maintaining and clearing the
work area
The full specification for this Training Standard is included in the OPITO Guide - OPITO Global
Technical Standards and Qualifications Specifications for Maintenance (Level 2).
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Example of Maintenance Techniques Training Standard
OGTS/L2 – M50: Mechanical Maintenance Techniques : Diesel Engines
Summary
This Training Standard develops an understanding of the function, operation and
routine maintenance requirements associated with diesel engines. It is
recommended that An Introduction to Mechanical Maintenance: Prime Movers is
completed before undertaking this Training Standard and that Mechanical
Maintenance Practice: Diesel Engines is completed in conjunction with this
Training Standard.
Outcome 1
Outline the function and operation of diesel engines
 describe the function and operating principles of diesel engines in the oil and
gas industry
 outline the normal operating parameters and tolerances for diesel engines
Outcome 2
Outline typical signs of fault, damage, wear and corrosion in diesel engines
 outline typical electrical and mechanical faults which can occur for diesel
engines
 describe common signs of damage, wear and corrosion which can occur for
diesel engines
Outcome 3
Describe typical routine maintenance requirements of diesel engines
 identify the key sources of technical information and guidelines to inform
maintenance requirements and procedures
 describe the types and role of routine maintenance activities for diesel engines
 identify relevant maintenance techniques for given maintenance issues for
diesel engines
Scope
Diesel engine: firing and timing sequence
Components: water pump, fuel pump, oil pump, cylinder head, fuel, oil and air
filters, injectors, emergency shutdown systems
The full specification for this Training Standard is included in the OPITO Guide - OPITO Global
Technical Standards and Qualifications Specifications for Maintenance (Level 2).
All Outcomes of Maintenance Techniques Training Standards at Level 2 follow this format.
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Example of Maintenance Practice Training Standard
OGTS/L2 – M51: Mechanical Maintenance Practice : Diesel Engines
Summary
This Training Standard develops the skills required to carry out routine
maintenance of diesel engines in a training workshop, including preparation for
maintenance activities, identification of hazards, using technical guidelines,
preparing maintenance records and clearing the work area. It is recommended that
Mechanical Maintenance Techniques: Diesel Engines is completed before or in
conjunction with this Training Standard.
Outcome 1
Prepare to carry out routine maintenance on diesel engines
 select relevant tools, equipment and material
 prepare the workshop area to carry out routine maintenance
 identify possible hazards and risks when working with diesel engines
 participate in tool box talks
Outcome 2
Carry out routine maintenance on diesel engines
 consult relevant technical guidelines and maintenance checklists
 demonstrate routine maintenance skills for diesel engines
 carry out relevant tests to confirm that the maintenance has been successfully
completed
 work in accordance with safe working procedures and effective workshop
practices
Outcome 3
Complete routine maintenance for diesel engines
 clear the workshop area and dispose of waste
 store relevant tools, equipment and material in appropriate locations
 complete relevant maintenance and handover records
Scope
Diesel engine: firing and timing sequence
Components: water pump, fuel pump, oil pump, cylinder head, fuel, oil and air
filters, injectors, emergency shutdown systems
All Outcomes of Maintenance Practice Training Standards at Level 2 follow this format.
The following list provides an overview of the scope of all Level 2 Equipment Groupings.
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Level 2 - Mechanical Technical Standards
Equipment
Power Generation
Gas Turbines
Scope
power generation gas turbines: heavy industrial and aero-derivative lubrication and oil
systems
hydraulic oil systems, fuel systems, starting systems, cooling and sealing systems
Equipment
Air Compressors
Scope
reciprocating air compressors, rotary air compressors, wet seal oil systems ,dry gas
seals
Equipment
Bearings and Seals
Scope
rolling element bearings ,shafts ,housings, ball roller, thrust, needle roller, tapered
roller, dynamic, static and mechanical seals
Equipment
Gearboxes and
Gearing
Mechanisms
Scope
gearing ratios, manual transmission, automatic and semi-automatic transmission for
the following types of gears:
 spur/straight cut
 helical
 bevel
 spiral bevel
 worm gear
 rack and pinion
Equipment
Transmission
Components
Scope
mechanical actuators, belt and chain drives, shafts and couplings, clutches, torque
convertors
rotating machinery couplings
Equipment
Heating,
Ventilating and Air
Conditioning
Systems
Scope
radiation, convection, conduction, refrigeration, air handlers, blowing, heating and
cooling elements, chillers: air-cooled and water-cooled, fan cooled units, blower fans
and motors, plate and rotary heat exchangers, control components: actuators, motors
and controllers
Equipment
Centrifugal Pumps,
Reciprocating
Pumps and Valves
Scope
centrifugal pump, positive displacement pump, globe valve, ball valve, gate valve, pinch
valve
diaphragm valve
Equipment
Piping and Pipe
Connections
Scope
piping systems, bolt tensioning/torqueing, gaskets, raised face flanges, fibre and spiral
wound gaskets, ring type joint flanges, clamp couplings, data tables, materials, size and
pressure rating
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Level 2 - Electrical Technical Standards
Equipment
Generators and
Voltage
Regulation
Scope
basic single phase ac generation, three phase ac generation, automatic voltage
regulation, frequency control, standby/emergency generators, synchronising facilities,
rotating diode assemblies, methods of excitation for single and three phase alternator,
HV systems and protection methods, IV systems and protection methods, switchgear
used in the oil and gas industry, earthing arrangements
Equipment
Single Phase and 3
Phase AC Motors
Scope
three-phase power, three phase induction motor, single phase induction motor,
synchronous motor, starting methods (DOL, start- delta, rotor resistance starters),
insulation resistance test, polarisation index test, coil resistance test, name plate, AC
motor protection
Equipment
Electrical Hand
Tools
Scope
multimeters, meggers, RCD testers, PAT testers, cables, plugs, rotors, stators, brushes,
earth bond resistance testing, earth continuity testing, insulation resistance testing,
polarity checks, residual current test trip time testing, portable power tool labelling
Equipment
Single and 3 Phase
Electrical
Distribution
Systems
Scope
three-phase and single-phase supplies and transformers, fuses, switches, cables,
connectors, wiring enclosures and systems, circuit breakers including:
 air and vacuum (vacuum circuit breaker)
 distribution systems (high energy)
 electrical distribution systems
 circuit diagrams for single phased and 3-phase transformers
 oil checks
protection systems for transformers
Equipment
DC Motors
Scope
DC motor construction, DC motor principles of operation and applications, externally
excited DC motors, shunt DC motors, permanent magnet DC motors, series DC motors,
DC motor breakers (dynamic breakers, regenerative breakers), plugging, DC motor
direction reversing, starting methods of DC motors, name plates,DC motor protection
Equipment
Cells and Batteries
and
Uninterruptible
Power Supply
Scope
cells and batteries, battery chargers and uninterruptable power supply systems,
alkaline and maintenance-free lead-acid batteries, secondary batteries, testing and
isolating procedures, test result reports
Equipment
Heating,
Ventilation and Air
Conditioning
Equipment
Scope
heating, ventilation, air conditioning systems and heat exchangers, air handlers,
blowing, heating and cooling elements, air-cooled and water-cooled chillers, fan-cooled
units, blower fans and motors, plate heat exchangers and rotary heat exchangers,
sensors, actuators, motors, controllers, radiation, convection, conduction, refrigeration
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Equipment
Protection Devices
of Electrical
Equipment in
Hazardous Areas
Scope
 wiring systems and glands including cable glands, cable entry, terminations and
weather protection
 lighting, methods of protection including :
 EX d flameproof
 Ex e increased safety
 Ex N non-incendive
 Ex-p pressurised apparatus
 EX i (ia,ib and ic) – intrinsic safety
 Ex o oil immersed
 Ex q powder filled
 Ex m encapsulated
 standards, certificates and marks
 hazardous area definition
 ignition temperatures
 upper and lower explosive limits
hazardous area classification
Equipment
Scope
Circuit Protection
 devices used for the protection of electric circuits, motor protection circuits, power
Devices and Power
protection relays including:
Protection Relays
 over current relays
 distance relays
 current differential relays
 directional relays
 heating and magnetic effects of electrical current
 fuses and circuit breakers including:
 oil break
 air break
 sulphur hexafluoride gas devices
 vacuum circuit breakers
isolation procedures
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Level 2 - Instrument and Control Technical Standards
Equipment
Process
Equipment
(Measuring, level,
Flow,
Temperature)
Scope
 process control principles, pressure, temperature, flow, level and surge control
 control loop interfaces and elements
 measuring instruments and sensors including
 thermocouples, resistive temperature device
 atmospheric pressure gauges, differential pressure gauges
 non-contact level gauges, contact level gauges
 positive displacement flow meter, differential pressure flow meter, coriolis flow
meter and ultrasonic flow meter

transmitters/transducers

pneumatic, electronic and three-term controllers

signals:
 pneumatic
 analogue
 digital
Equipment
Process Control
Valves
Scope
types, functions, working range of control valves
functions, working range, application, flow coefficients, assemblies, instrumentation of
pressure safety valves
Equipment
Small Bore Tubing
Scope
 measuring and marking out
 tube cutting and bending
 assembly of compression fitting
 hydrostatic strength
 pneumatic leak test
 piping and tubing materials:
 applications
 size
pressure ratings
Equipment
Metering Devices
and Fiscal
Metering
Scope
 flow meters
 fiscal metering equipment
 differential pressure flow meters:
 orifice
 venture
 v. cone
 turbine flow meters:
 coriolis flow meters
 ultrasonic flow meters
 flare gas meters
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Equipment
Programmable
Logic Controller
Systems
Scope
programmable logic controller systems and instructions, programming
communications, editing and backing-up software, hard-wired systems, programmable
logic controller systems interfacing, number systems, architecture, programmable logic
controller systems inputs and outputs, addressing and protection, applications of
programmable logic controller systems – ESD/fire, gas systems, process control
advantages of programmable logic controller systems over hard-wired systems
Equipment
Distributed
Control Systems
Scope
programmable logic controller systems and instructions, programming
communications, editing and backing-up software, hard-wired systems, programmable
logic controller systems interfacing, number systems, architecture, programmable logic
controller systems inputs and outputs, addressing and protection, applications of
programmable logic controller systems – ESD/fire, gas systems, process control
advantages of programmable logic controller systems over hard-wired systems
Equipment
Condition
Monitoring
Systems
Scope
vibration monitoring, equipment used in condition monitoring, key advantages of
condition monitoring including remote, inaccessible and dangerous location condition
monitoring, typical condition monitoring signaling and signal sample rates, examples of
current proprietary condition monitoring systems, vibration condition monitoring
architecture and components
Equipment
Subsea Control
Systems
Scope
master control system, subsea power and communication unit, hydraulic power unit,
topside termination umbilical assembly, telemetry links, subsea control
instrumentation, telemetry links for surface-to-surface control on unattended
platforms, control media for subsea systems
Equipment
Scope
Emergency
emergency shutdown systems, wellhead control and hydraulic systems, gas compressor
Shutdown Systems management, plant shutdown systems, management and control of gas compressors
alarm and shutdown devices
Equipment
Fire and Gas
Detection Systems
Scope
 fire and gas initiating devices including :
 infra-red
 optical and UV flame detectors
 smoke detectors
 heat detectors
 gas detectors
 manual alarm call points
 fire-related signals
 fire water pump system, fire damper status, fire and gas mimic panels and
indication
 fire and gas system:
 architecture and components
 fire and gas mimic panels and DCS indication
 control and history records
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OPITO Global Support Guide for Level 2 Training Certificates:
Maintenance Practices
Equipment
Protection
Methods and
Instrument
Equipment in
Hazardous Areas
Scope
 hazardous areas:
 wiring systems and glands
 testing and isolation procedures
 methods of protection in hazardous areas including:
 Ex d flameproof
 Ex e increased safety
 Ex n non incendive
 Ex p pressurised apparatus
 Ex i (ia, ib & ic) -intrinsic safety
 Ex o oil immersed
 Ex q powder filled
 Ex m encapsulated
 multiple methods of protection (eg Ex ed)
 wiring systems and glands, cable glands, cable entry, terminations
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