COURSE OVERVIEW:

A turbine overhaul is one of the most complex and resource-intensive maintenance events in an industrial facility, requiring meticulous planning and rigorous quality control. This course provides a detailed roadmap for managing the complete lifecycle of a turbine shutdown, from the initial planning phases to the final recommissioning. Participants will examine the mechanical intricacies of dismantling high-pressure casings, removing rotor assemblies, and inspecting critical internal components under strict technical standards.

The scope of this training focuses on the application of precision measurement techniques and the interpretation of clearance data to ensure the turbine is restored to its original design specifications. We will investigate the various non-destructive testing (NDT) methods used to identify microscopic cracks in blades and diaphragms, as well as the specialized repairs required for eroded or corroded surfaces. The curriculum covers the critical path of the overhaul, emphasizing the synchronization of specialized tooling, vendor support, and internal labor to minimize downtime without compromising safety.

Coverage also includes the documentation and verification processes that form the backbone of quality control during an overhaul. By focusing on the validation of alignment, balance, and fastener torque, the course ensures that the turbine operates reliably until its next scheduled intervention. Through this comprehensive study, attendants will gain the expertise necessary to manage a major overhaul project, ensuring that every mechanical adjustment is recorded and every component meets the highest industry quality standards.

COURSE OBJECTIVES:

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

1. Develop a comprehensive Work Breakdown Structure (WBS) for a major turbine overhaul.
2. Execute safe and systematic dismantling of turbine casings and internal parts.
3. Interpret clearance and tolerance charts provided by the Original Equipment Manufacturer (OEM).
4. Perform precision measurements of bearing bores, journals, and seal gaps.
5. Utilize NDT techniques like Dye Penetrant and Magnetic Particle Inspection on turbine components.
6. Assess the condition of turbine blades, nozzles, and diaphragms for wear and erosion.
7. Manage the logistics of rotor transportation and off-site shop balancing.
8. Validate the quality of repairs performed on stationary and rotating elements.
9. Implement a rigorous Foreign Material Exclusion (FME) program during the overhaul.
10. Coordinate the reassembly of the turbine train to ensure perfect alignment and leveling.
11. Oversee the torqueing of casing bolts and the installation of thermal insulation.
12. Generate a detailed overhaul final report including "As-Found" and "As-Left" data.
13. Lead the quality control team in verifying all hold points and inspection criteria.

TARGET AUDIENCE:

This course is designed for Maintenance Managers, Overhaul Engineers, Quality Control Inspectors, Mechanical Supervisors, and Senior Technicians involved in turbine major maintenance.

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.