Equipment Condition Assessment for Gas Turbines

Specialized Equipment Condition Assessment programs for Gas Turbine Reliability & Maintenance.

47% Reduction in unplanned downtime
85% Faults detected before failure
3-6mo Average fault lead time
5:1 Typical program ROI

Why it matters

Key Benefits

Comprehensive Health Baseline

Multi-technology condition assessment establishes a documented health baseline for all gas turbines components including the compressor blades, combustion liners, turbine nozzles, bearings, and fuel system. This baseline quantifies current condition and provides the reference point for tracking future degradation.

Remaining Useful Life Estimation

Condition assessment data for gas turbines supports remaining useful life estimates for critical wear components. These estimates inform capital planning, spare parts procurement, and outage scheduling decisions.

Prioritized Corrective Action List

Condition assessment of gas turbines produces a prioritized list of deficiencies ranked by severity and consequence. This enables maintenance teams to allocate limited resources to the most impactful repairs first.

Context

Challenge & Approach

The Reliability Challenge

Gas turbine borescope inspection requires experienced inspectors who can identify coating deterioration, thermal barrier coating (TBC) spallation, leading edge erosion, oxidation, hot corrosion, platform cracking, and foreign object damage on turbine blades and vanes through inspection ports that provide limited viewing angles. Performance analysis must account for ambient temperature, humidity, and inlet pressure drop effects on expected output and heat rate — comparing actual to expected values without site correction produces inaccurate assessments. Exhaust temperature spread analysis requires reliable thermocouple calibration, and anomalous spread patterns must be correlated with combustion hardware condition. EOH accounting errors — typically from incorrect start-type classification or fuel-type multiplier application — can result in maintenance intervals being tracked incorrectly, either exposing components to operation beyond their design life or triggering premature interventions. Inlet air system condition (filter differential pressure, evaporative cooler effectiveness) directly affects performance assessment results.

Our Approach

We conduct gas turbine assessments through a comprehensive protocol covering hot gas path condition, performance, combustion health, and ancillary systems. Borescope inspection covers compressor inlet and accessible compressor stages (leading edge erosion, fouling deposits, FOD damage), combustion section (liner condition, crossfire tubes, transition pieces, fuel nozzle tips), and turbine section (first-stage nozzle and blade condition including coating status, platform oxidation, tip shroud condition, and downstream stages). Performance assessment compares measured output, heat rate, compressor efficiency, and turbine section efficiency to expected values corrected for ambient conditions using OEM correction curves or validated performance models. Combustion health assessment reviews exhaust temperature spread patterns, combustion dynamics data (where monitoring exists), and ignition system function. EOH accounting audit verifies fired hour and start count recording, start-type classification methodology, fuel-type factor application, and current position in the CI/HGPI/major overhaul cycle. Ancillary system assessment covers inlet air system, lube oil system, fuel system, starting system, and enclosure ventilation. Each unit receives a condition report with photographic borescope findings, performance gap quantification, EOH accounting verification, and prioritized recommendations with risk assessment for continued operation versus early maintenance intervention.

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Common Questions

FAQ

Questions our clients ask most often about this reliability program.

A comprehensive condition assessment for gas turbines includes visual inspection, vibration analysis, thermographic survey, oil analysis if applicable, and performance parameter evaluation against API 616 baselines. The assessment covers the compressor blades, combustion liners, turbine nozzles, bearings, and fuel system and produces a condition score for each component along with a prioritized list of deficiencies requiring corrective action.

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Request a Free Reliability Assessment

Tell us about your equipment and facility. Our reliability team will review your situation and recommend a tailored reliability program — no obligation.

Free initial assessment
Response within 1 business day
No obligation or commitment

No obligation. Typical response within 24 hours.

Assess Gas Turbine Condition Against Your Operating Profile

We combine borescope inspection, performance analysis, and EOH audit to determine true gas turbine condition.

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