12 Jun 2025

India's coal-dependent power system is increasingly challenged by the integration of intermittent renewable energy sources and rising electricity demand. Thermal power plants are required to adapt more frequently with starts, stops, and rapid ramping, leading to inefficiencies, reduced productivity, and potential instability. These adjustments also cause mechanical and chemical imbalances, safety risks, and long-term equipment damage. Understanding these cause-and-effect relationships can help improve both efficiency and safety.

Recent regulatory changes offer opportunities for coal-based power plants to enhance flexibility and profitability. To address the long-term costs of these changes, India needs to focus on solutions with cost-benefit analyses for plant retrofits and operational strategies.

To discuss solutions with cost-benefit analyses during the 2025 8th Annual Generation Flexibility Conference on July 23rd during Session 4: Plant Performance Intertek expert and Technical Director, Anjan Kumar Sinha is presenting the case study: Flexible Operation implementation at an Indian Coal Power Station to ensure safe, reliable, and sustainable operations.

This paper presents a case study of flexibility challenges at an Indian power station using low-grade coal, with a particular focus on optimizing boiler processes. The proposed solutions include:

  1. Real-time Coal Quality Monitoring – For better management of combustion.
  2. Online Coal Flow Balancing – To optimize coal distribution and combustion across the boiler.
  3. Advanced Predictive Controls – For predicting and adapting to changing operating conditions.
  4. O&M Procedure Modifications – To enhance operations and maintenance practices, boosting overall plant flexibility.

These cost-effective strategies aim to improve the efficiency, reliability, and flexibility of coal-based power plants, helping them adapt to the increasing integration of renewable energy sources.

About Power Plant Integrity Management

Our customized power generation engineering and integrity services and software solutions can support your power plant’s operation, maintenance, capital improvement, and cost of cycling evaluations. With our advanced engineering techniques, we can pinpoint priority repairs and eliminate unnecessary plant work.  We work with equipment throughout the plan, such as boilers, turbines, generators, and high-energy piping, as well as other plant components.

About Engineering Services

Intertek Asset Integrity Management (AIM) engineering services offer solutions to industry by using advanced technology and world-class expertise to solve problems and gain a competitive edge. Our unique AIM program combines the understanding of process properties with a detailed knowledge of Materials and equipment. These services help our clients minimize costs, improve efficiency, meet safety standards, and ensure the installations conform to operational and design parameters.

To set up a meeting or for any questions for the presenter email, aimengineering.sales@intertek.com or call +1 408-745-7000.

For more information on the Asset Performance Management Software Suite email aware.sales@intertek.com,: phone inquiries: Aware Sales =1408-350-7020, option #2.

2025 8th Annual Generation Flexibility Conference