Thermal power generation has evolved significantly over the past century, achieving major improvements in efficiency, reliability and safety. However, as India's electricity demand grows, Artificial Intelligence (AI) offers new ways to address persistent operational challenges. According to Ratul Puri, AI's real value lies in improving existing technologies by addressing issues that affect plant performance, costs and reliability.
Improving Plant Reliability Through Predictive Maintenance
Unexpected equipment failures and forced outages remain major challenges for thermal power generators. Recent power shortages across several states have highlighted the importance of maintaining reliable generation capacity.
AI-powered predictive maintenance can help identify potential equipment failures before they disrupt operations. Drones, computer vision and advanced analytics can detect defects, thermal hotspots and early signs of equipment deterioration. By analysing historical maintenance records and equipment data stored in systems such as SAP, AI can also identify recurring faults and help operators plan maintenance more effectively.
As Ratul Puri explains, "AI must deliver practical solutions to the challenges that power plants face every day. Preventing equipment failures and improving plant reliability should be among its most important applications."
Reliable data collection and accurate maintenance records are essential for success. With consistent monitoring, AI can help plants transition from reactive repairs to Reliability-Centred Maintenance, reducing unplanned outages and improving asset performance.
Strengthening Coal Quality Monitoring
Coal accounts for nearly 60% of a thermal power plant's operating costs, making effective fuel management essential. Differences between declared and actual Gross Calorific Value (GCV), along with transportation losses, can affect plant efficiency and commercial performance.
AI-based surveillance, drone monitoring and data analytics can help identify potential irregularities during coal transportation by rail and road. Robotic sampling at loading and delivery points can improve measurement consistency, reduce manual intervention and strengthen transparency.
Ratul Puri notes, "Technology can bring greater transparency and accountability to coal management. Combining AI-based monitoring with automated sampling can help address long-standing concerns around coal quality and transit losses."
Supporting Flexible Power Generation
As renewable energy capacity expands, thermal power plants must adjust their output more frequently to maintain grid stability. Operating at minimum technical loads of 55% or lower, alongside repeated ramp-ups and ramp-downs, can increase equipment stress, accelerate wear and affect efficiency.
AI can help operators forecast electricity demand and renewable generation more accurately. Better forecasting supports improved generation scheduling, more effective load management and informed operational decisions. This can help balance grid requirements with equipment health and long-term asset performance.
According to Ratul Puri, "The way forward is to use AI where it creates measurable value. Better forecasting, smarter maintenance and improved operational decisions can help thermal power plants remain reliable and competitive as India's energy mix evolves."
The Road Ahead for AI in Thermal Power
AI can strengthen India's thermal power sector when supported by reliable data, effective integration with existing systems and collaboration between technology providers and plant operators.
By focusing on predictive maintenance, coal management and flexible operations, power plants can address persistent challenges while improving efficiency and reliability. As India's energy mix evolves, practical AI applications can help thermal power generation remain dependable, competitive and better equipped to meet the country's growing electricity needs.
About Ratul Puri
Ratul Puri is the Chairman of Hindustan Power, an integrated power generation company with a strong presence in renewable and transitional energy generation. Over the years, Ratul Puri has been involved in the development of large-scale energy infrastructure projects that support India’s growing power requirements and its transition toward cleaner energy sources.
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