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Quest Training

Maintenance and Reliability KPIs Training Course

Gives refinery static equipment leads a method to design, measure and use leading and lagging KPIs that improve the reliability of vessels and piping.

MTM · Mechanical Maintenance, Reliability & TurnaroundAll Levels#2382ClassroomEnglish , Arabic
Duration
5 Days
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Free substitution at any time · 30+ days' notice: full refund minus 10%. Cancellation policy

Sectors:Oil & GasCategories:Mechanical Maintenance, Reliability & Turnaround

Course Overview

The Maintenance and Reliability KPIs Training Course gives static equipment maintenance leads in refineries a practical method for designing, selecting, measuring, analyzing, and using performance indicators to improve the reliability of pressure vessels, columns, heat exchangers, fired heaters, piping systems, and storage tanks. Most traditional maintenance indicators, such as mean time between failures and mean time to repair, were designed for rotating equipment. On their own they do not reflect the condition of static equipment, which degrades gradually through corrosion, fouling, and cracking, and whose failures usually appear as leaks, loss of containment, and unplanned shutdowns. This course shows how a maintenance lead can build a balanced system of leading and lagging indicators that connects the performance of the maintenance team to the mechanical integrity of equipment, unit availability, maintenance cost, and turnaround success. Participants will work with static equipment integrity indicators, such as loss of containment events, inspection plan compliance, overdue inspections, corrosion rate trends, and integrity operating window exceedances. They will also work with maintenance management indicators, such as preventive maintenance compliance, schedule compliance, backlog, emergency work ratio, and repeat failures, and with turnaround indicators such as scope growth and adherence to duration and budget. The course is based on internationally recognized standards and practices, including API RP 754 for process safety performance indicators, EN 15341 for maintenance key performance indicators, and the metrics of the Society for Maintenance & Reliability Professionals (SMRP). It links these to risk-based inspection programmes under API 580 and API 581 and to inspection programmes under API 510, API 570, and API 653. Participants will learn how to define each indicator precisely, identify its data source, set its targets, analyze its results, and turn it into clear improvement actions. The course also covers the leadership responsibilities of a static equipment maintenance lead: building dashboards, reporting to senior management, running performance review meetings, motivating the team, and linking indicators to budget, turnaround, and resource planning decisions. By the end of the course, participants will be able to design an integrated system of maintenance and reliability KPIs for static equipment, build a practical dashboard, and use indicators to reduce leaks and unplanned shutdowns, improve compliance with inspection and maintenance plans, raise turnaround efficiency, and support data-driven decisions.

Learning Objectives

  • Analyze the role of performance indicators in managing the maintenance and reliability of static equipment, and the differences in measurement between static and rotating equipment, during the first day of the course.
  • Distinguish between leading and lagging indicators and build a balanced system that combines both.
  • Apply international KPI standards and practices, including API RP 754, EN 15341, and SMRP metrics, to static equipment in refineries.
  • Design mechanical integrity indicators for static equipment, including loss of containment events, inspection plan compliance, corrosion trends, and integrity operating window exceedances.
  • Evaluate maintenance management indicators, including preventive maintenance compliance, schedule compliance, backlog, emergency work ratio, and repeat failures.
  • Define turnaround performance indicators, including scope growth, schedule adherence, budget adherence, and discovery work.
  • Identify the data source, calculation method, and target for each indicator, and ensure data quality from the CMMS and inspection records.
  • Analyze indicator results and trends, identify the root causes of deviations, and develop improvement plans.
  • Design a maintenance and reliability dashboard for static equipment and periodic reports for senior management.
  • Develop an integrated KPI system and an implementation plan for the static equipment maintenance function by the end of the fifth day.

Who Should Attend

This course is designed specifically for static equipment maintenance leads and supervisors in refineries and petrochemical plants. They are responsible for the performance of maintenance teams and the reliability of pressure vessels, columns, heat exchangers, fired heaters, piping systems, and tanks, and they report performance to management. The course suits professionals who lead routine maintenance and turnaround work and coordinate with inspection, operations, and planning departments. It also benefits static equipment engineers, inspection and corrosion engineers, asset integrity engineers, reliability engineers, maintenance and turnaround planners, and CMMS administrators responsible for data collection and reporting. In addition, the course is valuable for maintenance and inspection managers, operational excellence and performance measurement specialists, and decision-makers who rely on maintenance and reliability indicators to allocate budgets, set investment priorities, and evaluate the performance of technical departments.

Learning Outcomes

  • By the end of this course, participants will be able to:
  • Explain the importance of performance indicators in managing static equipment, and why rotating equipment indicators alone are not sufficient.
  • Build a balanced system of leading and lagging indicators for static equipment maintenance.
  • Define loss of containment and process safety event indicators under API RP 754 and link them to static equipment performance.
  • Measure inspection plan compliance, overdue inspections, condition monitoring location coverage, and corrosion rate trends.
  • Calculate maintenance management indicators, including preventive maintenance and schedule compliance, backlog, emergency work ratio, and repeat failures.
  • Evaluate turnaround performance using scope growth, duration and budget adherence, and planning accuracy indicators.
  • Define the data source, calculation method, target, owner, and measurement frequency for each indicator.
  • Analyze indicator trends, identify root causes of deviations, and set measurable corrective actions.
  • Design a practical dashboard and clear performance reports for senior management.
  • Lead performance review meetings and use indicators to motivate the team and drive continuous improvement.

Course Outline

Course Outline:

Day 1

Fundamentals of Maintenance and Reliability Performance Measurement for Static Equipment

  • The role of performance indicators in maintenance and reliability management and their link to refinery objectives
  • Characteristics of static equipment and its degradation mechanisms, and why its indicators differ from those of rotating equipment
  • Leading and lagging indicators and how to balance them
  • International standards and practices: API RP 754, EN 15341, and SMRP metrics
  • Characteristics of a good indicator: clarity, measurability, data availability, and controllability
  • Practical discussion: reviewing the indicators currently used in participants' facilities and identifying gaps
Day 2

Mechanical Integrity and Static Equipment Reliability Indicators

  • Loss of containment indicators and Tier 1 and Tier 2 process safety events under API RP 754
  • Inspection programme indicators: inspection plan compliance, overdue inspections, and condition monitoring location coverage
  • Corrosion indicators: corrosion rates, remaining life, and equipment approaching minimum required thickness
  • Integrity operating window indicators: number, duration, and severity of exceedances
  • Equipment-specific indicators: heat exchanger fouling and cleaning frequency, fired heater tube life, and flange and joint leaks
  • Practical application: designing a set of mechanical integrity indicators for a typical refinery unit
Day 3

Maintenance Work Management and Efficiency Indicators

  • Maintenance planning and scheduling indicators: schedule compliance, preventive maintenance compliance, and planned work ratio
  • Backlog, emergency work, and corrective work indicators
  • Repeat failure and bad actor indicators and their analysis
  • Maintenance cost indicators: cost as a percentage of replacement asset value, and repair versus replace cost
  • Team productivity and work quality indicators: rework ratio, wrench time, and safety procedure compliance
  • Practical application: calculating maintenance management indicators from sample CMMS data and interpreting the results
Day 4

Turnaround Performance Indicators, Data Quality, and Results Analysis

  • Turnaround planning indicators: on-time scope freeze, materials readiness, and work package completeness
  • Turnaround execution indicators: scope growth, discovery work, duration and budget adherence, and safety
  • Post-turnaround indicators: safe start-up, post-start-up failures, and lessons learned
  • Data quality: failure coding, completeness of inspection records, and accuracy of CMMS work orders
  • Analyzing trends and deviations, identifying root causes, and preparing improvement plans
  • Practical application: analyzing indicators from a previous turnaround, identifying causes of deviation, and making recommendations for the next turnaround
Day 5

Dashboards, Reporting, and Leading Performance Improvement

  • Designing a maintenance and reliability dashboard for static equipment: selecting indicators, visual presentation, and reporting levels
  • Preparing periodic reports for senior management and presenting results clearly and concisely
  • Setting targets and benchmarking against comparable facilities and best practices
  • Leading performance review meetings and turning results into actions and responsibilities
  • Using indicators to motivate and develop the team and to support budget and turnaround decisions
  • Final workshop: developing an integrated maintenance and reliability KPI system for static equipment, a dashboard, and an implementation plan for the participant's organization

Upcoming Dates

Selected date

Frankfurt · 15 – 19 Mar 2027 · Classroom

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MakkahScheduled
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16 – 20 Nov 2026€4,700—
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MilanScheduled
23 – 27 Nov 2026€7,000€6,300until 2 Nov
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30 Nov – 4 Dec 2026€6,000€5,400until 9 Nov
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30 Nov – 4 Dec 2026€6,300€5,670until 9 Nov
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14 – 18 Dec 2026€6,700€6,030until 23 Nov
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RomeScheduled
21 – 25 Dec 2026€7,000€6,300until 30 Nov
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28 Dec 2026 – 1 Jan 2027€6,300€5,670until 7 Dec
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4 – 8 Jan 2027€9,100€8,190until 14 Dec
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11 – 15 Jan 2027€4,300€3,870until 21 Dec
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11 – 15 Jan 2027€6,400€5,760until 21 Dec
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24 – 28 Jan 2027€4,000€3,600until 4 Jan
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25 – 29 Jan 2027€6,000€5,400until 4 Jan
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DubaiScheduled
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FrankfurtScheduled
15 – 19 Mar 2027€6,200€5,580until 22 Feb
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22 – 26 Mar 2027€7,300€6,570until 1 Mar
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LondonScheduled
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Available in: Istanbul · Dubai · London · Doha · Amsterdam

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