Ratul Puri on Transforming Thermal Power Generation Through AI: Driving Efficiency, Reliability and Innovation 

Thermal power generation is a century-old technology that has evolved significantly over the years, achieving high levels of operational efficiency, reliability and safety. However, as India's energy needs grow and the power sector undergoes a major transformation, Artificial Intelligence (AI) offers new opportunities to address persistent operational challenges. According to Ratul Puri, the real value of AI in thermal power generation lies not in reinventing a mature technology, but in solving critical problems that affect plant performance, costs and reliability.

One of the biggest challenges facing thermal power generators is reducing downtime caused by forced outages and equipment failures. Power shortages witnessed across several states in recent months have highlighted the impact of unexpected plant shutdowns. AI-enabled predictive maintenance can help address this issue by identifying potential equipment failures before they disrupt operations. Drones, computer vision and AI-based analytics can detect defects, thermal hotspots and early signs of equipment deterioration. By analysing historical equipment performance and maintenance data stored in systems such as SAP, AI can also identify recurring problems and help plants plan maintenance more effectively.

"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," says Ratul Puri.

However, successful implementation will require consistent data collection, accurate records and long-term monitoring. AI systems can provide meaningful insights only when supported by reliable and comprehensive data. Over time, this approach can help thermal power plants move from breakdown-based maintenance towards Reliability-Centred Maintenance, reducing unplanned outages and improving asset performance.

Another significant challenge is the loss of commercial value due to coal quality variations and transit losses. Coal accounts for nearly 60% of a thermal power plant's operating costs, making effective coal management essential. Differences between the declared and actual Gross Calorific Value (GCV), along with losses during transportation, can affect plant efficiency and financial performance. AI-enabled surveillance, drone monitoring and data analytics can help identify potential irregularities during coal transportation by rail and road. Robotic coal sampling at both loading and delivery points can further improve consistency, accuracy and transparency by reducing dependence on manual intervention.

"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," Ratul Puri notes.

The growing need for flexible power generation presents a third opportunity for AI. As renewable energy capacity increases, thermal power plants must adjust their output more frequently to maintain grid stability. Plants may operate at minimum technical loads of 55% or lower, while repeated ramp-ups and ramp-downs place additional stress on equipment, increase wear and tear, and reduce operating efficiency. AI can help forecast electricity demand and renewable energy generation more accurately, enabling better generation scheduling and more effective planning of load changes. This can help operators balance grid requirements with equipment health and long-term asset life.

"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," says Ratul Puri.

Ultimately, AI should be viewed as a practical tool to strengthen the performance of India's thermal power sector. Its success will depend on reliable data, integration with existing systems and close collaboration between technology providers and plant operators. By focusing on equipment reliability, coal management and flexible operations, AI can help address some of the industry's most persistent challenges while supporting a more efficient, dependable and sustainable power system.

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.