Case Study: Major Inspection

Home > Case Studies > Case Study: Major Inspection

Project Details

Customer: Energy Development & Production Operator

Location: Regional Queensland, Australia

Work: Major Inspection

Date: October 2023 to November 2023

Project Personnel: Thirteen AJSS Team Members

Case Study


AJ Stack Solutions undertook a comprehensive Major Inspection project on a GE Frame 6B engine at a prominent power station. The project aimed to refurbish the Gas Turbine engine, allowing it to return to full operational service. The inspection encompassed a detailed examination and replacement of critical components, disassembly and subsequent reassembly within a specified timeline. AJSS also assisted with the commissioning of the unit which included correcting alignments of the unit, performing hot and cold commissioning checks and vibration analysis during start-ups.



The project consisted of three stages; disassembly, inspection and reassembly. The goal was to inspect, repair and replace components within the engine to allow the unit to return to service after being condemned by the OEM. The project required adherence to strict safety protocols and an application of industry best practices to guarantee the successful completion of the inspection and maintenance tasks.



AJSS mobilized a dedicated team, comprising of skilled personnel, including a project supervisor, technical assistant, rigger, mechanical fitters, machinists and boiler makers.

The disassembly phase involved the careful removal of numerous components, such as the enclosure roof, walling, all upper turbine cases, flame detectors, fuel lines, nozzles and more. Safety protocols were paramount, with lift plans created for each lift, detailed safety documents such as SWMS, risk assessments and permits produced for each task and detailed accounts of working man hours and safety statistics documented.

During the inspection phase, a comprehensive list of replacement parts were provided by the customer to overhaul and rebuild critical components. Adjustments to the original scope were made, and emergent work outside the initial plan was addressed.

The reassembly phase involved the installation of new components, bump tests to determine rotor position, and careful reinstallation of various parts. Flange management procedures were implemented to ensure the integrity of connections, with any discrepancies promptly identified and rectified.



The successful completion of the Major Inspection was achieved late November, 2023. The rotor was reinstalled without incidents, and all components were fitted within GE tolerances. The reassembly and testing procedures ensured the turbine unit met or exceeded operational standards. The site was restored to its original state, with thorough cleaning and vacuuming of the package.

This project exemplifies AJSS’ commitment to delivering high-quality solutions within specified timelines while prioritizing safety, adherence to contractual obligations, and attention to detail. The successful outcomes demonstrate AJSS expertise in handling complex inspections and maintenance projects within the power generation sector.

"Certainly recommend AJSS..."

"One thing that really impressed me about Arthur and the team at AJSS was their attitude to customer feedback and continuous improvement – always striving to better and deliver customer satisfaction"

Senior Rotating Equipment Engineer

"Your facility and setup were of the highest standard..."

“Your people, without exception were friendly and professional. Your facility and setup were of the highest standard and the attention to detail was exemplary”

Senior Project Manager

"I can honestly say this was the best learning experience..."

“I can honestly say this was the best learning experience I have had for a long time. The information was relevant and delivered in an engaging way by industry experts that have actually been there and done the things they are teaching. Far from death by power point with the ability to answer questions in detail. To anyone in the oil/gas/chemicals space working with turbines and compressors I highly recommend AJSS.”

Process Team Leader

"I learned so much from your experts..."

“The training was informative and varied I learned so much from your experts. I now feel that I can really apply the knowledge to my day to day work in the field”

Graduate Rotating Equipment Engineer