COURSE OVERVIEW:

The Major Inspection (MI) is the most critical event in the lifecycle of a heavy-duty gas turbine, involving the complete disassembly of the machine to its foundation. This course provides a high-level technical roadmap for planning, executing, and documenting a major overhaul. Participants will examine the mechanical complexity of pulling the rotor, opening the casings, and removing all hot gas path components, ensuring that every step is performed with precision to maintain the machine’s design integrity and efficiency.

The curriculum focuses on the advanced NDT (Non-Destructive Testing) techniques required to assess the health of high-stess components. We will cover the evaluation of turbine blades, vanes, and combustor liners for signs of creep, oxidation, and thermal fatigue. Attendees will learn how to interpret metallurgical findings and make "Repair versus Replace" decisions based on life-consumption models and manufacturer guidelines, balancing the need for reliability with the financial constraints of the plant.

A significant portion of the course is dedicated to the re-assembly and post-inspection commissioning process. Detailed instruction is provided on rotor-to-stator alignment, clearance measurements, and the validation of safety and control systems. By mastering the coordination of manpower, specialized tooling, and spare parts logistics, participants will be able to minimize the duration of the outage while ensuring that the turbine returns to service in a "new-and-clean" condition, ready for the next interval of operation.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Develop a comprehensive project plan for a Gas Turbine Major Inspection.

2.  Coordinate the logistics for specialized tooling and heavy lifting equipment.

3.  Manage the safe disassembly of turbine casings and rotor removal.

4.  Execute advanced NDT inspections for crack detection in turbine rotors.

5.  Evaluate the condition of Thermal Barrier Coatings (TBC) on hot path parts.

6.  Conduct precision measurement of clearances (Radial and Axial).

7.  Manage the refurbishment process for turbine nozzles and diaphragms.

8.  Validate the integrity of the combustion system and transition pieces.

9.  Perform rotor-stator alignment using laser and dial indicator methods.

10.  Oversee the balance and vibration testing of the refurbished rotor.

11.  Implement quality control checklists for every stage of the overhaul.

12.  Manage the documentation and data logging for warranty compliance.

13.  Coordinate the post-overhaul startup and performance verification.

TARGET AUDIENCE:

Turbine Maintenance Managers, Outage Coordinators, Reliability Engineers, Mechanical Supervisors, and Field Service Engineers specialized in power generation assets.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.