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Project Highlights

What We've
Delivered

A selection of completed projects — from turbine rotor repairs and gearbox overhauls to control system upgrades and customized filtration solutions for power plants across the world.

Featured Project
MS5001 rotor before overhaul — corroded and worn
Before

Rotor incoming — corroded, worn bearings

MS5001 rotor after service — cleaned, balanced and rebuilt
After

Rotor serviced — blades replaced, balanced ISO G2.5

Repair & Overhaul 2024 Middle East

MS5001 Gas Turbine Rotor — Service & Repair

Turbgear undertook a comprehensive service and repair program for a GE MS5001 gas turbine rotor for a power generation client. The scope included full rotor disassembly, dimensional inspection, blade refurbishment, balancing and reassembly to OEM specifications.

All compressor and turbine blades were individually inspected using fluorescent penetrant inspection (FPI) and blended where required. The rotor was dynamically balanced to ISO G2.5 standard before reassembly, significantly extending the unit's operational life without full replacement.

Turbine Model
GE MS5001
Scope
Full Rotor R&O
Inspection
FPI / Dimensional
Balancing
ISO G2.5
Read full project
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3D model of custom filter housing

Custom filter housing design

3D engineered solution
Custom filter cartridge assembly

Customized filter cartridge

Precision manufactured
SEM microscopy of nanofiber filter media x3000
SEM Analysis x3000

Nanofiber filter media — electron microscopy verification

5kV · 42.71μm HFW · confirming sub-micron filtration efficiency

Custom Solution 2023

Customized Filtration Solution — V94.2 Gas Turbine, Iraq

Turbgear engineered and supplied a fully customized inlet air and lube oil filtration solution for a Siemens V94.2 gas turbine power plant in Iraq. The plant was experiencing accelerated fouling and frequent unplanned outages due to high particulate levels in the ambient air.

We conducted a full filtration audit, redesigned the inlet filter house configuration, and supplied a multi-stage filtration system including pre-filters, pulse-jet cartridges and high-efficiency final stage filters matched to the turbine's airflow requirements and local environmental conditions. Lube oil filtration elements were also upgraded to extended-service high-capacity elements to reduce maintenance intervals.

Siemens V94.2 Inlet Air Filtration Lube Oil Filters Iraq
Iraq View project
Gearbox gear train reassembled
After

Gear train reassembled

Built to OEM specifications
Damaged gear teeth before overhaul
Before

Gear tooth failure

Spalling & fracture — pre-O/H
New journal bearings machined
After

New journal bearings

Multi-size — precision machined
Gearbox overhaul workshop

Overhaul workshop

Full strip & rebuild facility
Repair & Overhaul 2023 — 2024

Accessory Gearbox Overhaul — MS5001, MS6001 & MS9001

Turbgear carried out service and full overhaul of accessory gearboxes for multiple GE gas turbine frames — MS5001, MS6001 and MS9001 — across several client sites in the region.

The scope for each unit included complete disassembly and cleaning, gear train inspection and dimensional verification, bearing and seal replacement, gear tooth profile inspection, lubrication system cleaning, and full reassembly with functional testing. All work was performed to OEM specifications with traceability documentation provided for every replaced component.

GE MS5001 GE MS6001 GE MS9001 Gearbox O/H
Multiple Sites View project
GE Industrial Systems legacy control panel open before upgrade
Before

GE legacy Speedtronic panel

Mark II / Mark V — obsolete hardware
Old Speedtronic Mark V CPU and I/O cards with fault lights
Before

CPU & I/O card rack

Fault indicators active — end of life
Control Upgrade 2022 — 2024

Turbine Control Upgrade — Mark II & Mark V to GE Mark VIe

Turbgear executed control system upgrade projects for gas turbine clients operating on legacy GE Speedtronic Mark II and Mark V control platforms, migrating them to the modern GE Mark VIe distributed control architecture.

The upgrades eliminated obsolescence risk from discontinued hardware and software, delivering significant improvements in diagnostics, remote monitoring capability, alarm management and operational reliability. The scope included full panel replacement, rewiring, I/O mapping, logic migration, FAT/SAT testing, and commissioning support. Clients experienced immediate reduction in unplanned shutdowns and improved turbine availability following cutover.

Mark II → VIe Mark V → VIe GE Speedtronic Commissioning
Regional View project

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Whether it's a turbine repair, control upgrade, overhaul, or customized parts solution — our team is ready to support your plant. Contact us to discuss your requirements.

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