Ask any plant manager what actually blows a gas turbine major overhaul's schedule and budget, and the answer is rarely the work everyone planned for — it is the work nobody planned for. A borescope that gets pushed back twice, a vibration issue that gets "monitored" instead of resolved, a component that looks fine on paper until the cover comes off and reveals damage that was never in scope. That single moment turns a planned 14-day outage into a 21-day one, and the lost generation revenue from that extra week dwarfs whatever the pre-outage inspection would have cost. Plant managers who have moved to condition-based scope development — building the overhaul scope from actual sensor and inspection data 90 to 120 days out instead of a generic checklist six weeks before shutdown — describe a fundamentally different outage experience, and many start by choosing to book a demo to see how their own condition data would change next year's overhaul scope.
Cut Overhaul Duration by Building Scope From Condition Data, Not a Generic Checklist
iFactory pulls EOH counters, vibration trends, borescope findings, and NDT readings together to flag exactly which components meet condition-based replacement criteria — locking scope before mobilization instead of discovering it after disassembly.
Five Planning Phases Between Today and the Outage Window
A major overhaul isn't planned in the weeks before it starts — it's planned in phases stretching back nearly two years, and each phase depends on the data quality of the one before it. Skipping the early condition-data phases is what forces plants into generic checklist scoping later, which is exactly where scope creep and schedule overrun originate.
What Changes When Scope Is Built From Data Instead of a Checklist
A generic OEM checklist assumes a worst-case operating profile for every unit, which means it either replaces components that still have useful life left, or misses degradation specific to your unit's actual duty cycle. Condition-based scoping closes both gaps at once.
| Aspect | Checklist-Based Scoping | Condition-Based Scoping |
|---|---|---|
| Scope basis | Generic OEM interval assumptions | EOH counters, NDT, vibration, borescope trend |
| Scope definition start | Often 4–6 weeks before outage | 12–18 months before outage |
| Mid-outage scope creep risk | High — surprises found after teardown | Low — condition already known pre-outage |
| Component replacement | Fixed interval regardless of actual condition | Matched to measured remaining useful life |
Find Out What Your Condition Data Already Says About the Next Outage
Loading your existing EOH, vibration, and inspection data into a structured scope view usually surfaces components ready for early flagging months before the outage window opens.
We used to start scope definition six weeks out and spend the first three days of every outage waiting on parts nobody had ordered because nobody knew they'd be needed. Once we had condition data locking scope at ninety days, our last major overhaul came in ahead of schedule with every contractor on-site on day one and zero surprise findings after disassembly.
The Outcomes Plants Report After Their First Condition-Scoped Overhaul
The value of condition-based overhaul scoping compounds with each cycle, since every completed overhaul adds more trend history that makes the next one's scope decisions more precise.
Gas Turbine Major Overhaul Planning — Frequently Asked Questions
Lock Your Next Overhaul Scope Before the Outage, Not During It
iFactory turns EOH counters, vibration trends, and inspection history into a locked, data-backed overhaul scope — so your team mobilizes with zero surprises and every contractor on-site from day one.
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