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Purpose – This paper deals with the optimization of coal handling system performability for a thermal power plant.

Design/methodology/approach – Coal handling system comprises of five subsystems, namely Wagon Tippler, Crusher, Bunker, Feeder and Coal Mill. The partial differential equations are derived on the behalf of transition diagram by using the Markov approach. These partial differential equations are further solved to obtain the performance model with the help of normalization condition. Numerous performability levels are achieved by putting the appropriate combinations of failure and repair rates (FRRs) in performance model. Performability optimization for coal handling system is obtained by varying the population and generation size.

Findings – Highest performability level, that is, 93.33 at population size of 40 and 93.31 at generation size of 70, is observed.

Originality/value – The findings of this paper highlight the optimum value of performability level and FRRs for numerous subsystems. These findings are highly beneficial for plant administration to decide about the maintenance planning.

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