Effective operations and maintenance (O&M) strategies are essential for thermal power plants (TPPs) to ensure reliability, efficiency and asset value. Strong O&M practices can improve operating efficiency, cut emissions, reduce downtime, mitigate risks and maximise performance. However, as plants age, power plants face declining operational efficiency, and this requires stricter environmental regulations, better coal ash management and reduced water usage.
With the influx of renewable energy in the generation mix, an increasing number of plants are expected to undergo cyclical operations. Frequent ramp-ups/downs from their designed minimum loads are, therefore, expected to change their operational profiles, necessitating interventions in asset management. This makes it crucial to adopt O&M strategies tailored to plant age, complexity and cost competitiveness. While plants have traditionally used reactive, preventive, condition-based and predictive maintenance, there is now a shift toward integrated reliability-centred maintenance (RCM) over the plant’s lifecycle.
Digital tools are also playing a greater role in O&M. Real-time dashboards, internet of things (IoT), drones, digital twins and augmented reality/virtual reality solutions enable better monitoring, inspection of hard-to-reach areas, fuel and efficiency tracking and streamlined spare part management. These technologies provide timely insights, helping plant managers quickly address performance issues and optimise operations.
O&M strategies
Preventive maintenance: Regular maintenance is a key component of effective O&M management. Through routine checks and scheduled upkeep, potential issues can be detected early, preventing them from developing into major problems. Preventive measures help reduce unplanned downtime, lower maintenance costs and improve overall plant reliability. Typical preventive maintenance activities include lubricating moving parts, cleaning filters and calibrating sensors. These tasks ensure equipment operates efficiently, enable the early detection of wear and tear and support timely repairs or replacements.
RCM: Many utilities are also implementing RCM to enhance the long-term performance of power plants by weighing the balance between risk and cost for maintaining specific equipment. RCM integrates multiple maintenance strategies – encompassing preventive, predictive, real-time monitoring, reactive and proactive – into a single, coordinated approach. Its primary focus is on ensuring that equipment functions reliably, thereby increasing availability while minimising costs and resource usage. Unlike approaches that prioritise availability alone, RCM emphasises reliability and takes a proactive stance to prevent failures before they occur. Using real-time data for analytics and predictive insights, RCM identifies targeted interventions for improving reliability. When equipment health indicators cross a predefined threshold, the system automatically alerts engineers, enabling prompt action and preventing potential disruptions.
Asset management is a critical component of O&M services, aimed at maximising the value of power generation assets throughout their operational life. It involves strategically planning and executing tasks to optimise resource utilisation, reduce costs and ensure compliance with regulatory requirements. An effective asset management system relies on the integration of data from multiple sources, including maintenance records, performance metrics and financial reports. By leveraging this data, O&M managers can make informed decisions on asset utilisation, schedule maintenance more effectively and prioritise capital investments. This data-driven approach not only improves operational efficiency but also extends asset lifespan and enhances overall plant performance.
Notably, NTPC Limited’s asset management approach focuses on maximising the performance, reliability and lifespan of its power generation assets while minimising lifecycle costs. The company employs structured asset management practices that combine risk-based maintenance, real-time performance monitoring and continuous improvement initiatives. These measures enhance operational efficiency, reduce unplanned outages and ensure consistent delivery of power. To uphold asset integrity, safety and reliability, NTPC conducts regular internal assessments along with independent audits. This proactive strategy not only advances the company’s long-term objectives of operational excellence and sustainability but also strengthens resilience and accountability in a rapidly evolving energy landscape. Through advanced scientific services such as non-destructive evaluation (NDE), computational fluid dynamics analysis, and metallurgy and failure analysis, NTPC Energy Technology Research Alliance (NETRA) is continuously working to improve reliability, enhance efficiency and reduce O&M costs by diagnosing faults effectively. NETRA is also engaged in developing cutting-edge technologies, including robotic solutions for visual inspection of boiler headers, magnetostrictive NDE sensors for structural health monitoring of stainless-steel superheater and reheater tubes, residual stress analysers for residual stress measurement, and novel sensors designed to enhance reliability, safety and operational efficiency while reducing inspection time and manpower requirements. NETRA’s interventions have significantly supported power stations in failure analysis and prevention, with its advanced techniques successfully implemented across multiple locations. In addition to technology development, the centre has delivered practical solutions such as resin regeneration treatments, chemical cleaning and corrosion control measures. These initiatives have contributed to improved efficiency, enhanced availability and longer operational life of critical assets, including boilers, heat exchangers and cooling systems.
Digitalisation of O&M and asset management
With the growing need to optimise performance and integrate renewables, digital tools are enabling power plants to transition from reactive to predictive and prescriptive maintenance models. Advanced technologies such as IoT, sensors and smart meters allow continuous real-time monitoring of plant equipment. Data from turbines, boilers and auxiliary systems can be analysed using artificial intelligence and machine learning to detect anomalies, predict failures and optimise maintenance schedules. This not only reduces unplanned outages but also extends equipment life.
Digital twin technology, which are virtual replicas of physical assets, provides operators with simulation-based insights for better decision-making and performance optimisation. Integrated asset management platforms further streamline operations by combining maintenance, inventory and workforce planning into a single digital ecosystem.
Robotic inspection tools and drones are being increasingly used for hazardous or hard-to-reach areas, enhancing safety while reducing downtime. Cybersecurity measures are also becoming integral as digitalisation exposes critical infrastructure to potential risks.
Issues and challenges
O&M and asset management in TPPs face multiple issues and challenges as the sector undergoes changes driven by decarbonisation, renewable integration and evolving demand patterns. These challenges affect not only plant efficiency but also cost competitiveness and long-term sustainability. One of the primary issues is ageing infrastructure. A large portion of India’s thermal power capacity comprises plants that are more than 25 years old, making them prone to frequent breakdowns, higher heat rates and reduced reliability. Maintaining such assets requires significant capex and careful planning.
Another challenge is the flexibilisation requirement. With increasing renewable energy penetration, TPPs are compelled to operate in cycling modes rather than steady baseload, resulting in higher wear and tear, efficiency loss and increased maintenance needs. Existing O&M practices are often not adequate to cope with these operational stresses.
Fuel supply constraints also pose difficulties. Irregular coal quality and logistics issues increase equipment stress and impact boiler performance. Additionally, stricter environmental norms demand costly retrofits like flue gas desulfurisation, which further complicates asset management.
Data management and cybersecurity present additional challenges. The massive volume of data generated through IoT devices, sensors and digital twins requires robust data analytics platforms and skilled manpower to extract actionable insights. At the same time, increased connectivity exposes critical infrastructure to cyber threats, necessitating advanced security protocols and continuous monitoring.
The other issue is the gap in skills. Advanced digital tools, condition monitoring and predictive maintenance require trained personnel, but capacity-building efforts are often insufficient. Moreover, ensuring safety and compliance in high-risk environments remains a persistent challenge. Further, financial constraints limit investment in digitalisation, automation and modernisation. Many utilities struggle with tight margins, which delays the adoption of advanced O&M practices.
Conclusion
Effective O&M and asset management are crucial to sustaining the performance, reliability and cost competitiveness of TPPs. As plants age and face stricter environmental norms alongside the growing need for flexible operations due to renewable integration, traditional maintenance practices are no longer sufficient. The transition toward RCM, digitalisation and advanced asset management systems offers a pathway to enhance efficiency, minimise downtime and extend asset life. However, these efforts must be coupled with robust ash management, regulatory compliance, skilled manpower and investments in modernisation to ensure the long-term sustainability and resilience of the thermal power fleet.
