Thermal Power Plant Coal Tracking — Inbound Fuel Visibility India

For a thermal power plant, coal is not just a raw material — it is the fuel that determines whether the plant runs. A day's supply disruption means production loss. A month's pilferage means crore-scale unaccounted fuel costs.

Yet most Indian thermal power plants have zero visibility on inbound coal between the Coal India colliery and the plant's coal yard.

The TPP Coal Supply Challenge

A large thermal power plant (1,000–4,000 MW) consumes 10,000–40,000 tonnes of coal per day. At 25 tonnes per truck, that means 400–1,600 truck movements per day — just for coal inbound.

At this volume:

Manual monitoring of every truck is impossible

Basic GPS creates thousands of alerts per day that no team can triage

Weight shortfalls at the weighbridge are common but unresolvable without sensor evidence

Seasonal demand peaks (summer) drive up both volumes and pilferage pressure

What Gets Tracked: The TPP Coal Journey

Colliery dispatch: GPS + activity sensing IoT device fitted at the mine gate. Trip created in platform with source siding/colliery, vehicle, driver, rake/truck ID, and dispatch weight.

In transit: Real-time position. Automated alerts on route deviation, extended halts, phone-off incidents. Activity sensing monitors continuously for unloading activity.

Halt analysis: Every halt classified by location type. Red-zone halts near known pilferage points trigger immediate analyst review regardless of duration.

Plant gate: Trip risk score pushed to fuel management team before truck arrives at coal yard entry. High-risk trucks directed to special sampling.

Coal yard unloading: Activity sensing confirms physical unloading at the coal yard. Delivered weight compared against dispatch. Fuel inventory updated automatically.

Coal Yard Management Integration

Intugine integrates with plant coal yard management systems:

Real-time inbound queue visibility — dispatcher sees all trucks en route with ETA and risk score

Coal yard stock updated automatically on confirmed delivery

Calorific value and ash content data (from quality lab) linked to trip records for per-trip quality tracking

Transporter Management for Power Sector

Power companies manage large transporter panels — some with 50–200 registered transporters per plant. Monthly transporter risk scorecards from Intugine give procurement teams objective data for:

Contract renewal decisions

Volume allocation per transporter tier

Blacklist management

Performance-linked penalty enforcement