A first-of-its-kind retrofit

The challenge

India’s New Policies Scenario projects that electricity demand will more than triple in the next two decades, rising by 4.9% per year on average from 900 terawatt-hours (TWh) in 2013 to almost 3,300 TWh by the end of 2040. Upgrade projects like these can better position the country to meet future energy demands and challenges, including backing up renewables.

The solution

The Ukai project is a first-of-its-kind shaftline retrofit for BHEL 200-MW-class units in India, and is aimed at increasing power, efficiency, and reliability while also reducing emissions. Not only will the retrofit extend the unit’s life by 25 years, it will restore its output back to its original capacity of 200 MW.


Reduced emissions and increased lifecycles

25 years

added to Ukai’s plant longevity


in potential savings annually

reduction in CO2 emissions

200 MW

increase in output

140,000 tons

decrease in annual coal consumption reduction


When it came time for us to modernize some of our generation equipment, it was GE’s cross-fleet service capabilities that gave us the efficiency and emissions improvements we were looking for. GE’s solutions enabled us to better position our operations to meet not only expected increases in demand but also future, potential, emissions requirements.

Pradip Dahake

Managing Director, GSECL

Final tests at Ukai’s plant demonstrated more efficient operations that will help the plant reduce its coal consumption by over 140,000 tons per year and reduce CO2 emissions by 180,000 tons per year. These emissions reductions will provide environmental benefits equal to the amount of CO2 absorbed by approximately 732 square kilometers of forest per year (an area 35% bigger than India’s Corbett National Park). This is also equivalent to 162,000 Indian cars being taken off the road. In addition, reducing coal consumption will result in approximately $7 million (USD) savings for the utility every year.

"Power generation efficiency and emissions are widely discussed topics around the world and will play a critical role, especially in existing coal fleets, in how we work to meet future energy demands and challenges on a global scale,” said Pradip Dahake, Managing Director, GSECL. “India is no exception.”

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