• Course IntroductionGas turbines are critical assets in oil & gas, petrochemical, and power generation industries, where reliability, efficiency, and safety are paramount. This intensive course is designed in alignment with API Standard 616, focusing on the design, operation, inspection, maintenance, overhauling, and troubleshooting of industrial gas turbines.

  The course integrates engineering fundamentals, operational best practices, and advanced maintenance philosophies to enhance equipment reliability, availability, and safety. Emphasis is placed on understanding turbine design criteria, performance optimization, inspection methodologies, and overhaul management within the framework of internationally recognized standards.

  Participants will develop the capability to interpret API Standard 616 technical requirements, evaluate equipment condition using modern diagnostic tools, and execute maintenance and overhaul activities based on risk-based and reliability-cantered approaches. The program also incorporates real industrial case studies, failure analysis techniques, and troubleshooting methodologies to ensure practical applicability in complex operating environments.

  Course Objectives:

  Upon successful completion of this course, participants will be able to:

  • Technical and Operational Competence
  • Analyze gas turbine thermodynamic cycles and performance parameters.
  • Interpret and apply API 616 design, inspection, and testing requirements.
  • Evaluate turbine operating conditions and performance deviations.
  • Maintenance and Reliability Excellence
  • Develop and implement preventive, predictive, and condition-based maintenance strategies.
  • • Apply Reliability-Centered Maintenance (RCM) and Risk-Based Inspection (RBI) principles
    • Assess equipment health using vibration, oil, and thermal analysis.
    • Overhaul and Asset Integrity
    • Plan, manage, and execute gas turbine overhauls in compliance with OEM and API standard 616.
    • Perform detailed inspection, repair, and reassembly of critical components.
    • Ensure quality assurance, alignment, balancing, and commissioning integrity
    • Troubleshooting and Problem Solving
    • Apply structured Root Cause Analysis (RCA) methodologies.
    • Diagnose complex operational and mechanical failures.
    • Implement corrective and preventive actions to avoid recurrence.
    • Management and Compliance
    • Ensure compliance with safety, environmental, and operational standards.
    • Optimize lifecycle cost and asset performance.

    
    Who Should Attend?

    This course is designed for:

    • Rotating Equipment Engineers.
    • Maintenance Engineers.
    • Reliability Engineers.
    • Gas Turbine Specialists and Technicians.
    • Operations Engineers.
    • Asset Integrity and Inspection Engineers
    • Maintenance Planners and Shutdown Coordinators.
    • Senior Mechanical Engineers.
    • Shift Leaders and Senior Technicians.

Part 1: Fundamentals and API Standard 616 Overview

• Introduction to Gas Turbines

• Gas turbine history.
• Gas turbine types (heavy-duty vs. aeroderivative).
• Gas turbine Applications in oil & gas and power plants.
• Gas turbine main manufactures.
• Gas turbine advantages and disadvantages.
• Gas turbine Thermodynamics overview (Brayton Cycle)
• Gas turbine theory of operation.
• Performance parameters; heat rate, output power and efficiency.

• Gas Turbine Major Components

• Air Inlet section.
• Filter housing Assembly.
• Inlet duct assembly.
• Inlet casing Assembly.
• Inlet guide vanes.
• Compressor section.

• Axial flow compressor.
• Compressor surge.

• Combustion system.

• Combustion chamber arrangement.
• Primary, secondary and dilution air.
• DLN Combustion system.

• Turbine section.

• Turbine nozzles.
• Turbine rotor blades.

• Shafting and casing.

• API Standard 616 Overview

• Scope and structure of API Standard 616.
• Design and construction requirements.
• Materials and fabrication standards.
• Compliance and documentation.

• Codes & Standards Interface

• API, ISO, ASME relevance.

Part 2: Gas Turbines Systems and Operation

• Gas Turbine Auxiliary Systems

• Fuel systems (gas & liquid).
• Lubrication systems.
• Seal oil systems.
• Ventilation system.
• Cooling and air systems.
• Exhaust section.

• Exhaust section purpose.
• Exhaust section assembly.
• Gas Turbine Control and Protection Systems

• Control philosophy.
• Instrumentation and sensors.
• Fire and gas detection system.
• Trip and shutdown systems.
• Vibration and temperature monitoring.

• Online/Offline Washing

• Gas turbine water wash system.

• Gas Turbine Operation

• Start-up and shutdown procedures.
• Load control and performance optimization.
• Operating limits and safety precautions.

• Gas Turbine Frame Models
• Construction Criteria for Gas Turbines
• Gas Turbine bearings

• Hydrodynamic bearings
• Radial and thrust oil wedge

• Vibration Level and their Measurements
• Iso Standard 10816-4

Part 3: Maintenance and Condition Monitoring

• Maintenance Strategies

• Preventive vs predictive maintenance.
• Reliability-centered maintenance (RCM).
• Maintenance planning and scheduling.

• Inspection Techniques

• Borescope inspection.
• Combustion inspection.
• Hot gas path inspection
• Vibration analysis.
• Thermography.
• Oil analysis.
• Gas turbine clearances.
• Turbine bucket overview.
• Bucket replacement.
• Balance chart.

• Common Failure Modes

• Blade failure.
• Bearing failure.
• Combustion issues.

• Fouling and corrosion.

• Combined Turbines Systems

Part 4: Overhauling and Major Maintenance

• Overhaul Planning

• Scope definition.
• Spare parts and logistics.
• Risk assessment and safety planning.

• Disassembly and Inspection

• Rotor removal.

• Rotor axial movement.

•  Component inspection criteria.
• NDT techniques.

• Repair and Reassembly

• Blade repair/replacement.
• Alignment and balancing.
• Torquing and clearances.

• Testing and Commissioning

• Post-overhaul checks.
• Performance testing.
• Documentation as per API Standard 616.

• Appropriate Tools and Equipment to Maintain Turbines and Auxiliary Systems
• Maintenance Requirements for Turbine Gearbox
• Shaft Alignment
• Soft Foot Definition.
• Effects of Soft Foot.
• Measuring Soft Foot.
• Correcting Soft Foot.
• How to Correct Gas Turbine’s Misalignment.

Part 5: Troubleshooting, Case Studies and Energy Saving Opportunities

• Troubleshooting Methodology

• Root Cause Analysis (RCA) approach.
• Fault identification techniques.
• Use of operating data.

• Common Operational Problems

• High vibration.
• Overheating.
• Loss of efficiency.
• Startup failures.

• Evaluating and Interpreting Performance and Integrity Data of Turbines
• Recognizing and Responding to Abnormal Conditions and take Appropriate Corrective Action
• Maintenance by Plan Vs. Maintenance by Default.
• Gas Turbine Reliability and Availability.
• Building and Maintenance Management Plan.
• Energy Saving Opportunities for Gas Turbines.
• Case Studies and Practical Scenarios

• Real-life failure analysis.
• Lessons learned from industry incidents.

• Course Wrap-Up

• Best practices summary.
• Open discussion and Q&A.
• Knowledge assessment.