TG525 – (GE) Industrial Steam Turbine Generator Maintenance

TG525 – (GE) Industrial Steam Turbine Generator Maintenance

4.5 days - 32 PDH Credits Awarded


No future dates scheduled


HPC Technical Services' course on Extraction Steam Turbine Generator Maintenance is a more specific version of one of the most popular courses we offer, TG301.  The course targets those individuals who have a need to better understand the maintenance process.  This includes engineers (who have not yet received formal training on this topic), experienced-mechanics, mechanical maintenance foremen, planners and management. Today, steam turbine generator outages are subject to much debate.  Much of this debate is centered over the desire to shorten the outage length.  Here at HPC we understand and appreciate this goal.  The accomplishment of this goal should not be, however, at the sacrifice of properly inspecting and evaluating components that are critical to the return to surface and achieving a long run cycle.  Over the past couple years the most commonly received comment is, "I wish I had taken this course 10-years ago."  Well, the truth is, our course wasn't as near as good as it is now, 10-years ago.  About 3-years ago, when we reorganized our instructor staff, this course underwent a long overdue revision.  This revision was significant, and you can benefit! Topical Outline includes: Planning, Scheduling and Decision Making; Maintenance of Shells, Casings & Rotors; Journal and Thrust Bearings; Couplings, SteamValves; Generator Maintenance; Steam Path Alignment; and Job Wrap Up.


  1. List steam turbine-generator operational and safety issues that typically cause the scheduling of a maintenance outage.
  2. List the considerations that must be included when developing an outage plan or schedule.
  3. Describe the major considerations when making a replace/reuse/repair decision.
  4. Describe the procedures necessary for the safe and effective disassembly and reassembly of steam turbine generator components.
  5. Describe the purpose and operation of the major steam valves.
  6. Describe the disassembly and reassembly of the major steam valves.
  7. List the five (5) most common causes of steam path damage and their possible affects upon future operation.
  8. Describe three (3) common causes steam path defects and their impact upon turbine efficiency and reliability.
  9. Describe the type and purpose of clearance and alignment measurements commonly taken during the disassembly and reassembly of a steam turbine generator.
  10. Describe the measuring instruments used to determine steam turbine generator component clearances.
  11. List and describe the various non-destructive examinations performed during disassembly of the steam turbine generator.
  12. Describe the common procedures for cleaning and inspecting steam turbine generator components.
  13. Describe the criteria used to evaluate steam turbine generator defects.
  14. Describe the common repair methods for repair of steam turbine components.
  15. Describe the purpose of conducting a steam path audit, and how that audit would be accomplished.
  16. Describe the common types and operation of journal and thrust bearings.
  17. Describe the common causes of bearing damage.
  18. Describe the measurements required to determine oil clearances.
  19. Describe common bearing inspection and repair procedures.
  20. Describe the considerations to be taken into account when evaluating alignment of steam turbine generator components.
  21. Describe the methods used to properly align steam turbine generator components.
  22. Demonstrate the ability to perform the necessary calculations to align steam turbine generator components.
  23. List and briefly describe the electrical tests often performed on generator components.
  24. State the purpose of each electrical test listed.
  25. Describe the proper disassembly, inspection and reassembly of a generator hydrogen seal.

Course Synopsis


  • Planning, Scheduling and Decision Making:  This presentation is intended to provide participants with an understanding of those major items that must be considered PRIOR to commencing a scheduled turbine-generator outage. Discussion will also include those items we need to consider when making repair/replace/reuse decisions.
  • Turbine Shells, Casings & Rotors:  Two hours into the course and we're into the meat!  This lecture is intended to prepare the participant to safely and efficiently disassemble/reassemble major turbine components, as well as to improve inspection/repair techniques, communications on equipment, and make better replace/repair/reuse decisions.  Presentations include specific discussions on the different types of distress typically found on these components.


  • Turbine Shells, Casings & Rotors continues for ½ day.
  • Journal & Thrust Bearings:  Learn the different types of bearings and their applications, disassembly/reassembly procedures, inspection techniques, and typical types of distress as well as causes.
  • Couplings:  Learn what types of couplings are used on T-G sets, how torque is transferred, how to properly disassemble/reassemble, how to inspect, what measurements to take, and what they mean.


  • Steam Valve Maintenance:  Learn the purpose of the various steam turbine valves, how to properly disassemble/reassemble, how to inspect, what are the typical types of distress, what measurements to take, and what they mean.
  • Generator Maintenance:  Learn how a large AC generator is constructed, how to disassemble major components, what are the typical types of distress, how to clean, routine repair, and why generator inspection/testing is so important.  This presentation also includes an introduction to the various electrical test techniques.


  • Alignment: Learn how to properly take clearance/alignment and how to evaluate. Discussions include how to calculate and make moves for stationary equipment such as diaphragms and inner shells. Discussions also include how to take coupling rim/face readings, how to calculate moves to correct for coupling misalignment, and how to calculate and make moves to bearings to accomplish alignment objectives.


  • Alignment: Continued
  • Job Wrap-Up:  Learn what kind of data should be recorded following the outage, and what checks to make as we prepare to return the equipment to service.

Course Dates / Location / Fee

See for detail on the course dates / locations / and registration fees. HPC’s 3-4-2 policy applies:  Sign up 3 for the same course/date, pay in advance, and pay for only 2 (the 3rd participant is free)! HPC Technical Services reserves the right to cancel any course/seminar within 10-working days of the scheduled date.  Fees are 100% refunded or credited to another Seminar (clients' choice) if HPC should cancel any Seminar.  HPC is not responsible for non-refundable airline tickets or other travel expenses under any circumstance.

Frequently Asked Questions

  • Will HPC Technical Services bring this course to our location for our personnel only? YES, call or email Stephen Parker, for a price quotation.
  • Will HPC Technical Services customize the presentation at our site to suit our particular needs?
  • Is HPC Technical Services' textbook available for purchase as a reference document?   This significant textbook is available for $195 + S&H.
  • What is the cost for HPC Technical Service to deliver this course at our location? Well, of course that can vary, but generally speaking, if you're planning on having 6+ attend, when considering your T&L, it is to your advantage to perform the course at your plant (office).  You gain from the customization and price.
  • Can HPC Technical Services provide "Technical Assistance" in the planning and implementation of our outages? Yes we can.  Call or contact Stephen Parker, for our rate sheets and any further information required.

What you will receive

  1. 1 copy of HPC Technical Services' textbook, Extraction Steam Turbine Generator Maintenance, a $195 value, as written by Harold Parker, with technical support by Doug Lemmo of Power Generation Consulting Services. This text contains a significant number of equipment photographs, graphics and data tables.  It is a valuable desktop reference in addition to being able to enhance the learning process.  (This valuable text is available for purchase if you cannot attend – US$195).
  2. A Certificate of Completion with 31 PDH awarded.

Steam Turbine Maintenance Certification

There are two levels of certification (Both levels require this course):
  1. Engineer
  2. Mechanical Technician
Those who attend this course are automatically qualified to take HPC Technical Services' Certification Examination.  This examination is offered at no additional expense to the participant.  An 80% passing grade is required.  The examination length will not exceed 2-hours.  Those who complete this examination will receive a revised "certificate of completion" that recognizes this accomplishment along with two-copies of a "To Whom It May Concern" letter that states their accomplishment.  (Two copies are provided, one for the participants' employer and one for the participants' personal file.)  Consult HPC's website,, for detail on this certification program.

Satisfied Clients

American Crystal Sugar, Amoco Oil, Boralax-Stratton Energy, Calpine Corporation, Cargill Fertilizer, Crawsfordsville Electric, Light & Power, Daishowa-Marubeni International LTD, Dartmouth College, Equistar Chemicals, Erving Paper Mills, Fort James Marathon LTD, General Chemical, Irving Pulp & Paper, Mead Paper Company, OxyChem, Pinetree Power Fitchburg, Port Townsend Paper, Sherwin-Alumina, Suncor, Syncrude, US Air Force, US Sugar, Valero Aruba Refinery, Waste-Management Energy, Weldwood of Canada, Wheelabrator Energy Systems, Willamette Industries.