Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi

Programme Overview

Ageing high-head hydropower assets require systematic electro-mechanical refurbishment to restore operational reliability, extend asset service life, and maximise generation efficiency.⁣​‌​‌​​‌​​‌‌​‌‌​​​‌‌​‌​‌‌​‌‌‌​​​​​​‌​‌‌‌​​​‌‌​​​‌​‌‌‌‌​​​​‌‌​‌​‌​⁣ This five-day programme in Tbilisi provides hydro engineers, project managers, and technical specialists with practical engineering frameworks for capital overhauls. Focusing on complex installations, the curriculum addresses technical appraisal, design specification, and project execution across critical electro-mechanical subsystems, bridging the gap between legacy station parameters and modern engineering performance requirements in line with international standards.

Delegates will examine the detailed protocols governing generator stator and rotor rewinding, turbine runner replacement, and auxiliary balance-of-plant modernisation. The course investigates diagnostic testing, core restacking, advanced insulation systems, and hydrodynamic optimisation of Francis runners. Participants will evaluate technical risks associated with heavy lift operations, mechanical alignment, shaft line runout tolerances, and high-pressure governor retrofits. The sessions incorporate real-world engineering methods compliant with IEC, IEEE, and ASME performance testing standards for large-scale hydro facilities.

Beyond equipment engineering, the training builds practical competencies in contractor supervision, quality assurance, and site commissioning. Participants evaluate contractor inspection and test plans, factory acceptance procedures, non-destructive testing, and vibration baseline signatures. By reviewing performance verification protocols, including thermodynamic and index efficiency testing, attendees gain the technical authority needed to enforce contractual guarantees, manage complex technical interfaces, and ensure the long-term integrity of multi-million-dollar electro-mechanical rehabilitation packages funded by international financing institutions.

Major hydropower schemes across Central Asia are undergoing extensive electro-mechanical overhauls to secure regional energy systems and prevent catastrophic asset failures.⁣​‌​‌​​‌​​‌‌​‌‌​​​‌‌​‌​‌‌​‌‌‌​​​​​​‌​‌‌‌​​​‌‌​​​‌​‌‌‌‌​​​​‌‌​‌​‌​⁣ Large-scale capital works, including multi-phase rehabilitation programmes at vital facilities such as Nurek, require technical teams to supervise complex runner replacements, generator rebuilds, and balance-of-plant upgrades supported by international financing institutions. Delivering these multi-million-dollar overhauls demands rigorous technical oversight, strict enforcement of international quality standards, and precise performance testing to ensure that modernized assets achieve their projected capacity, efficiency gains, and structural design life.

Delivered by Risalat Consultants International in Tbilisi, Georgia, it combines expert-led sessions, real cases and group work, so that participants can apply what they learn in their own institution.

The Programme Strengthens Institutional Capability

• Stator core assessment, iron loss testing, core restacking, and clamping finger rehabilitation
• Modern Class F insulation systems, high-voltage coil manufacturing, and slot ripple mitigation
• Rotor pole overhaul, field coil re-insulation, damper winding repairs, and rim rehabilitation
• High-potential, partial discharge, and dielectric dissipation factor testing under IEEE 43 and IEEE 286
• Excitation system modernisation: static excitation conversion and digital voltage regulator integration
• Design parameters and material selection for high-head Francis runners under modern sediment conditions
• Runner manufacturing oversight, 5-axis CNC machining inspection, and ISO 1940 dynamic balancing
• Wicket gate, bottom ring, and head cover rehabilitation, including self-lubricating bush upgrades
• Fraud risk assessment and fraud risk registers
• Design and testing of internal controls
• The Three Lines model and the role of oversight
• Audit planning, evidence and documentation

It is designed for barqi Tojik mechanical, electrical, and plant refurbishment engineers, hydropower plant rehabilitation project directors and project managers, hydro electro-mechanical technical specialists and plant asset managers and others who want practical, current skills in fraud, audit and internal control.

The Growing Importance of Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi

Public bodies and donor-financed projects are expected to show that funds are used for their intended purpose. Auditors, oversight bodies and financiers increasingly look beyond the financial statements to the controls, records and behaviours behind them.

Fraud and control weaknesses rarely come from one failure. They grow where roles are unclear, records are incomplete and warning signs are not followed up. Teams that understand how fraud happens, and how controls stop it, protect both their institution and the people it serves.

Organisations increasingly require professionals capable of:

• Identify and rate fraud and control risks in their own processes
• Design controls that are proportionate and testable
• Gather and document reliable audit evidence
• Recognise red flags early and escalate them correctly
• Turn findings into practical, agreed actions

Strong fraud, audit and internal control systems help organisations:

• Reduce losses and ineligible expenditure
• Pass external audits with fewer findings
• Strengthen trust with financiers and citizens
• Respond to allegations in a fair and documented way

This Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi programme brings these elements together in a practical format, so that participants understand not only what good practice looks like but also how to introduce it in their own setting, with the people and resources they have.

Who Should Attend This Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Training?

This programme is designed for:

• Barqi Tojik mechanical, electrical, and plant refurbishment engineers
• Hydropower plant rehabilitation project directors and project managers
• Hydro electro-mechanical technical specialists and plant asset managers
• Project Implementation Unit (PIU) technical advisors and procurement specialists
• Quality assurance and quality control (QA/QC) inspection engineers
• Balance-of-plant modernisation specialists and electrical system engineers
• Commissioning engineers and plant performance monitoring personnel
• Turbine and generator maintenance supervisors from state utility operators
• Consulting engineers managing international hydro equipment supply contracts
• Internal auditors and audit managers
• Finance managers and accountants
• Compliance and risk officers

The programme suits experienced professionals as well as those moving into new responsibilities. Groups that mix institutions and countries are encouraged, because participants learn a great deal from each other’s experience.

Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Training Objectives

Upon successful completion of this Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Training, participants will be able to:

• Evaluate technical specifications for generator stator and rotor rewinding in accordance with IEC and IEEE standards
• Appraise turbine runner replacement designs to optimize hydrodynamic performance and mitigate cavitation risks
• Analyse modern digital governing systems, high-pressure oil units, and main inlet valve refurbishment criteria
• Formulate rigorous quality assurance, non-destructive testing, and inspection and test plans for site overhauls
• Supervise shaft alignment, bearing clearances, and mechanical assembly tolerances during plant re-erection
• Establish comprehensive pre-commissioning, dry, and wet commissioning protocols for renewed electro-mechanical units
• Verify turbine efficiency, heat runs, and vibration compliance against contractual performance guarantees using IEC 60041
• Explain how and why fraud happens, using recognised fraud risk models
• Carry out a fraud and control risk assessment for a real process
• Map controls to risks using the Three Lines model

Each objective is practised during the programme through exercises, cases or group work, so that participants leave able to do it, not only to describe it.

Programme Contents and Structure

Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Training Methodology

The programme combines structured technical presentations with practical engineering reviews and site management case studies.⁣​‌​‌​​‌​​‌‌​‌‌​​​‌‌​‌​‌‌​‌‌‌​​​​​​‌​‌‌‌​​​‌‌​​​‌​‌‌‌‌​​​​‌‌​‌​‌​⁣ Participants examine real technical drawings, factory test certificates, and site alignment records from high-head hydro installations. Collaborative exercises require delegates to audit contractor Inspection and Test Plans, calculate bearing and alignment tolerances, and analyse commissioning failure scenarios. Daily sessions encourage peer exchange on common engineering bottlenecks encountered in regional capital rehabilitation works.

The programme combines:

• Expert-led sessions on current practice
• Regional and international case studies
• Group work and practical exercises
• Simulations and role plays where relevant
• Discussion of participants' own challenges
• Peer learning across institutions and countries
• Practical tools and templates to take back to work
• Daily reflection and action planning

Before the programme, a short pre-assessment helps the facilitators understand each participant’s role and priorities, so that examples and exercises can be adjusted to the group. Each day ends with a short reflection in which participants note what they will apply at work.

Expected Outcomes

Upon completion of this Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Training, participants will be able to:

• Manage technical risks associated with large-scale generator rewinding and turbine runner replacement
• Enforce rigorous contractor quality surveillance using standardised factory and site inspection protocols
• Evaluate shaft alignment, dynamic balancing, and vibration datasets to approve unit mechanical completion
• Implement structured dry and wet commissioning programmes that protect renovated plant infrastructure
• Verify manufacturer performance guarantees and efficiency improvements using recognised international standards
• Lead electro-mechanical rehabilitation packages in full compliance with international donor technical guidelines
• Assess fraud and control risks in their own processes
• Design and test proportionate controls

Participants leave with a personal action plan and practical tools they can use in their institution from the first week back. Institutions that send several participants can use the programme to agree shared methods and templates across teams, which makes improvements easier to sustain.

Institutional Application of Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Training

This programme supports organisations in strengthening:

• Fraud and corruption risk management
• Internal control frameworks
• Audit and oversight arrangements
• Follow-up of audit findings
• Integrity and reporting channels

Participants return with practical tools to improve:

• Risk registers and control maps
• Audit planning and testing
• Evidence and documentation
• Reporting to management and boards
• Prevention of ineligible expenditure

The programme is built so that learning moves from the classroom into the institution. Participants work on their own processes and documents where possible, and leave with an action plan that their managers can review and support.

Regional Relevance & Application

Europe

European institutions apply fraud, audit and internal control within detailed regulatory frameworks and reform agendas. Participants from Europe can compare their practice with colleagues from other regions and test how established methods work under different conditions.

Africa

Across Africa, ministries, agencies and project teams working in fraud, audit and internal control increasingly operate alongside donor-financed programmes that expect clear systems and evidence. The programme helps participants adapt good practice to the institutions and resources they work with.

Middle East

In the Middle East, national development strategies and diversification plans place growing demands on fraud, audit and internal control. Participants explore how to build the capability these plans need inside public bodies and companies.

Asia

Institutions across Asia combine rapid growth with ambitious modernisation programmes. Participants from Asia can share their experience of scaling systems quickly and learn from approaches used elsewhere.

Pacific

Small island and Pacific states face particular constraints of size, distance and capacity. The programme highlights practical, proportionate approaches to fraud, audit and internal control that suit smaller institutions.

Holding the programme in Tbilisi, Georgia brings participants together away from their daily pressures, so they can compare how fraud, audit and internal control is handled in different settings. The same programme can also be delivered in-house for one institution, in its own country or online, with cases taken from its current work.

Host Country Profile – Georgia

Programmes, Workshops, Exposures, Training Courses in Tbilisi, Georgia by Risalat Consultants International

Studying away from their own country gives participants time to focus, a fresh view of their own institution and the chance to build a network with colleagues from other countries.

Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Training Deliverables

Participants receive support before, during and after the programme, so that preparation, learning and follow-up form one continuous experience.

Before the Programme

• Participant Pre-Assessment
• Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Readiness Assessment
• Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Resource Pack
• Preparatory Reading Materials
• Complimentary Visa Support & Advisory

During the Programme

• Airport Pickup & Welcome Assistance
• Accommodation with Breakfast
• Welcome Networking Dinner
• Risalat Training Kit (Bag, Bottle, Mug, T-Shirt, Cap, Passport Cover, Pens, Notebook, Magnet & Keychain)
• Comprehensive Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi Training Manual
• Fraud Risk Register Template
• Control Mapping Matrix
• Audit Evidence Checklist
• Findings and Follow-up Tracker
• Practical Workshops & Simulations
• Group Discussions & Peer Learning
• Daily Lunch and Refreshments
• Full Access to Training Venue Facilities
• Mini Pad / Tablet with Digital Learning Materials
• Field Visit (where applicable)
• Entertaining City Tour

After the Programme

• Certificate of Completion
• Risalat Programme Participation Recognition Award
• Post-Training Reference Materials
• Fraud Risk Self-Assessment Guide
• Control Testing Checklist
• Post-Training Support & Follow-Up Guidance
• Programme Report

Institutions can also request a tailored in-house version of this programme, delivered at their premises or online. Request a proposal.

Common Challenges in Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi, And How This Training Helps

How can institutions identify and rate fraud and control risks in their own processes?

The programme addresses this directly on the first day (Generator Refurbishment, Stator Rewinding, and Rotor Rehabilitation), where participants practise the methods involved and adapt them to their own institution, then build it into their action plan.

How can institutions design controls that are proportionate and testable?

The programme addresses this directly on the second day (Turbine Runner Replacement and Hydraulic Component Rehab), where participants practise the methods involved and adapt them to their own institution, then build it into their action plan.

How can institutions gather and document reliable audit evidence?

The programme addresses this directly on the third day (Shaft Line Alignment, Bearings, and Auxiliary Mechanical Systems), where participants practise the methods involved and adapt them to their own institution, then build it into their action plan.

How can institutions recognise red flags early and escalate them correctly?

The programme addresses this directly on the fourth day (Contractor Quality Control, Site Supervision, and Factory Acceptance), where participants practise the methods involved and adapt them to their own institution, then build it into their action plan.

How can institutions turn findings into practical, agreed actions?

The programme addresses this directly on the fifth day (Testing, Commissioning Protocols, and Contractual Efficiency Verification), where participants practise the methods involved and adapt them to their own institution, then build it into their action plan.

Frequently Asked Questions

When and where does the Hydro Plant Electro-Mechanical Refurbishment and Turbine Rehab in Tbilisi programme take place?

It runs from 8 Feb 2027 to 12 Feb 2027, in Tbilisi, Georgia. The registration deadline is shown at the top of this page.

Who should attend?

The programme is designed for barqi Tojik mechanical, electrical, and plant refurbishment engineers, hydropower plant rehabilitation project directors and project managers, hydro electro-mechanical technical specialists and plant asset managers, project Implementation Unit (PIU) technical advisors and procurement specialists, and others who want practical skills in fraud, audit and internal control.

Will I receive a certificate?

Yes. Participants who complete the programme receive a Certificate of Completion from Risalat Consultants International.

Can this programme be delivered for our institution only?

Yes. We can deliver a tailored in-house version at your premises, in another city or online, built around your own cases. Use the proposal request on this page.

Do I need prior experience in fraud, audit and internal control?

No specialist background is required beyond experience in a related role. A short pre-assessment helps the facilitators adapt the sessions to the group.

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