Steam Turbine in Thermal Power Plant Practical Case Studies and Engineering Solutions

SECTION I: Introduction

Chapter 1: Fundamentals of turbo-generator in power plant

• 1.1 Steam turbine
• 1.2 Load reference value control
• 1.3 Mode of operation

SECTION II: Case Studies

Chapter 2: Summary sheet of case studies

Chapter 3: Case Study 1: HP Turbine Thrust Bearing Failure, January 2021

• 3.1 Case Study 1: HP turbine thrust bearing failure

Chapter 4: Case Study 2: Low trip oil pressure problem faced

• 4.1 Case Study 2: Low trip oil pressure problem faced

Chapter 5: Case Study 3: Case study on overspeed trip

• 5.1 Case Study 3: Case study on overspeed trip

Chapter 6: Case Study 4: On jacking oil line punctured

• 6.1 Case Study 4: Case study on jacking oil line punctured

Chapter 7: Case Study 5: Case study on premature operation of over speed protection at 500 MW unit

• 7.1 Case Study 5: On premature operation of overspeed protection

Chapter 8: Case Study 6: Case study on overspeed trip

• 8.1 Case Study 6: Case study on overspeed trip

Chapter 9: Case Study 7: Case pedestal vibration problems experienced

• 9.1 Case Study 7: Case pedestal vibration problems

Chapter 10: Case Study 8: In-situ machining of generator rotor

• 10.1 Case Study 8: In-situ machining of generator rotor

Chapter 11: Case Study 9: Case study on problem of high oil ingress

• 11.1 Case Study 9: Case study on problem of high oil ingress

Chapter 12: Case Study 10: Case study water ingress in HP-IP turbine

• 12.1 Case Study 10: Case study water ingress in HP-IP turbine

Chapter 13: Case Study 11: Hunting of control valve

• 13.1 Case Study 11: Hunting of control valve servomotor

Chapter 14: Case study 12: Case study on problem of seal oil

• 14.1 Case study 12: Case study on problem of seal oil filter

Chapter 15: Case Study 13: Case study on high shaft vibration problem

• 15.1 Case study on high shaft vibration problem

Chapter 16: Case Study 14: Case study on generator heavy oil ingress

• 16.1 Case study on generator heavy oil ingress

Chapter 17: Case Study 15: Case study on oil ingress problem in generator

• 17.1 Case study on oil ingress problem in generator

Chapter 18: Case Study 16: Case study on jamming of barring gear

• 18.1 Case study on jamming of barring gear

Chapter 19: Case Study 17: On high pedestal vibration

• 19.1 Case study on high pedestal vibration

Chapter 20: Case Study 18: On throttling of CRH NRVs

• 20.1 Case Study 18: On throttling of CRH NRVs

Chapter 21: Case Study 19: On failure of IP stop valve

• 21.1 Case study on failure of IP stop valve

Chapter 22: Case Study 20: On jamming of barring gear

• 22.1 Case study on jamming of barring gear

Chapter 23: Case Study 21: On jamming of barring gear

• 23.1 Case study on jamming of barring gear

Chapter 24: Case Study 22: Unbalance observed on GSC fan

• 24.1 Unbalance observed on GSC fan

Chapter 25: Case Study 23: Case study on heavy oil leakages through governing components mounted on rack

• 25.1 Case study on heavy oil leakages through governing components mounted on rack

Chapter 26: Case Study 24: On high shaft vibration

• 26.1 Case study on high shaft vibration

Chapter 27: Case Study 25: On HP–MOP gear coupling

• 27.1 Case study on HP - MOP gear coupling

Chapter 28: Case Study 26: On failure of lock blade

• 28.1 Case study on failure of lock blade

Chapter 29: Case Study 27: Case study on failure of unit

• 29.1 Case study on failure of unit

Chapter 30: Case Study 28: On abnormal fire occurrence

• 30.1 Case study on abnormal fire occurrence

Biography

Dr. Atul Diwakar Bansod is a senior power engineer with over 36 years of extensive experience in the power generation sector, having joined MAHAGENCO (formerly MSEB) in 1989 as a Junior Engineer. He has since built an accomplished career managing the operation, maintenance, erection and commissioning of coal-fired power generation units ranging from 120 MW to 660 MW. Dr. Bansod holds a Ph.D. in Maintenance Management (2015) from Nagpur and is currently an Executive Engineer in the turbine maintenance section at the 3×660 MW Koradi Thermal Power Station. Dr. Bansod’s expertise includes turbine erection, thermal power plant operations, failure mode analysis, contract management, design review, and cost-benefit analysis. He has extensive skills in troubleshooting operational issues, particularly in turbine overhauling and governing systems of large-scale units (210 MW to 660 MW). His notable achievements include resolving high shaft vibration issues and overseeing successful commissioning of turbine systems. Additionally, he is an expert in non-destructive testing for turbine blade and bearing life assessment and has conducted numerous training programs for professionals. He serves as a visiting faculty at NPTI Nagpur and DOT Koradi and contributes significantly to reliable and safe plant operations.

Dr. Vijay Mohale (Senior Member, IEEE) received the bachelor’s degree in electrical engineering and the master’s degree in electrical power systems from Shivaji University, Kolhapur, India, in 2011 and 2013, respectively, and the Ph.D. degree in power system oscillation from the Power Electronics and Hydroelectric Machines Laboratory, IIT Roorkee, Roorkee, India, in 2023. He is currently the Head of the Department of Electrical Engineering, Walchand College of Engineering, Sangli, India. He is a Postgraduate Teacher and a Research Supervisor for Ph.D. candidates at Shivaji University. He has also undertaken various consultancy projects, contributing his expertise in power systems and renewable energy applications to solve real-world industry challenges. He is the author of the Book Power Electronics and Its Application (Khanna Publications, New Delhi). He has been granted nine Indian patents and two Australian patents. He actively contributes to both academic and industry-linked Research. His research interests include power systems transients, electromagnetic compatibility, sustainable energy transition, and power electronics for renewable grid resilience. Dr. Mohale is a Chartered Engineer and a Life Member of several professional organizations, including IEI, CMSI, IWRS, ISTE, SPE, and NETRA. He was awarded the Best Poster Award from the Institute Research Day in 2022 at IIT Roorkee and the Best Paper Award at NIT Warangal in 2024. He received the IITR Travel Support to attend the 2021 IEEE IAS Annual Meeting held in Canada (October 10–14, 2021) and the CSIR Travel Support to participate in the 2022 IEEE IAS Annual Meeting in the USA (October 9–13, 2022) under the Young Scientist Scheme. He has also been recognized as a Young Professional by IEEE for consecutive years, 2022 and 2023, in acknowledgment of his contributions. He has presented his work at various prestigious International Conferences (35) and has published in reputed IEEE top-tier Journals (6)

Mr. Hemant Bari is a General Manager in Maintenance Planning - Condition Monitoring Cell at Adani Power, Dahanu Thermal Power Station (2×250 MW). He is responsible for data collection and analysis of condition monitoring activities during routine and overhaul periods. He holds a degree in Production Engineering from the University of Mumbai and has completed advanced certifications including Machine Diagnostics (IIT Delhi), Vibration Analysis (Mobius Institute, Australia), and NDT certifications (ASNT Level II). Mr. Bari has over 16 years of experience in vibration analysis, turbine balancing, ultrasound testing, thermography, and oil analysis. He is the author of the book Condition Monitoring Case Studies of Thermal Power Plant and has published over 45 papers. He is a board member of CMSI and life member of TSI and ASI, and has conducted more than 75 workshops across industries and academic institutions in India.