Resource Person:

1. Sagar Tambe (Junior Engineer)
2. S. C. Tharande (Maintenance Engineer)
3. Mr.  V. A. Deshpande (Additional Executive Engineer )

Industry Profile:

1. The Bhatghar Hydro Power Plant, located near Bhor in Pune district, Maharashtra, is one of the oldest hydroelectric projects in the state. It is built on the Yelwandi River and is an integral part of the Bhatghar Dam, which was completed in 1927 during the British period. The dam is a solid masonry gravity structure, measuring about 57.92 meters in height and 1,625 meters in length, with a reservoir capacity of around 666 million cubic meters and a surface area of nearly 31.9 square kilometers. Its main purposes are irrigation, hydroelectric power generation, and flood control, making it a multipurpose project that continues to serve the region nearly a century after its construction.
2. The hydro power station has an installed capacity of 16 MW and uses a vertical Kaplan turbine system to generate electricity. Water from the dam is channeled through penstocks to drive the turbine, which in turn rotates an alternator producing electrical energy at 11 kV. This is then stepped up to 132 kV at the switchyard for transmission. The dam also features advanced mechanisms such as 81 spillway gates, including 45 automatic gates that help regulate water levels during monsoons. Apart from power generation, the Bhatghar project plays a vital role in supplying irrigation water to surrounding agricultural areas and in moderating river flow during floods, thus contributing significantly to both rural development and regional infrastructure.

I) Salient Features of Bhatghar Hydro Power Station:-

A) General Information

• Date of Commissioning:08.1977
• Taken over by MSEB:03.1978
• River & Reservoir: Yelwandi, Yesaji Kank
• Catchment Area:51 sq. km
• Height of Dam (above river bed):68 m
• Height of Dam (above deepest foundation):91 m
• Length of Dam: 1625 m
• Full Reservoir Level (FRL):28 m
• Capacity at FRL (Gross Storage):65 MCM
• Area of water spread at FRL:91 sq. km
• Minimum Draw-Down Level (for Power):37 m
• of Spillway Gates: 81
• of Irrigation Gates: 170

B) Power Data

• Maximum Head for Power Generation: 45.05 m
• Minimum Head for Power Generation: 18.35 m
• Design Head: 32 m
• Total Installed Capacity: 16,000 kW (16 MW)

C) Penstock

• Material: Steel
• of Penstocks: Two per turbine
• Size: 2018 mm diameter, 2267 m length

D) Power House

• of Machines: 1
• Turbine Type: Vertical Kaplan (BHEL Hardwar)
• Speed:3 rpm
• Rated Output & Voltage: 16,000 kVA

E) Financial Aspects

• Cost of Scheme: ₹5 Lakh
• Civil Works: ₹55 Lakh
• Generating Plant & Substation Equipment: ₹65 Lakh
• Cost per kW Installed: ₹1642
• Cost per Unit Generated: ₹0484
• Return on Capital (after interest):68%
• Annual Generation:535 Million Units (MUs)

II) Main Generating Plant & Auxiliaries :-

A. Hydro Turbine

• Type: Vertical Kaplan
• Manufacturer: BHEL, Hardwar (1972)
• Capacity at Design Head: 16.6 MW
• Max Output: 17 MW (at max head), 7 MW (at min head)
• Speed: 214.3 RPM (Runway speed: 475 RPM)
• Efficiency: 90.6% at rated head
• Runner: Stainless steel, 3 m diameter, 8 blades
• Hydraulic Thrust: 310 tonnes
• Rotation: Anti-clockwise

B. Governor

• Make: Leningrad Metal Works, USSR
• Type: Velocity type (Model PKM 100)
• Operating Pressure: 25 kg/cm²
• Sensitivity: ±0.05%
• Gate Operation: >3 sec opening/closing
• Oil Sump Capacity: 2000 L (Servo Prime 57)

C. Main Inlet Valve (MIV)

• Make: BHEL, Hardwar
• Type: Butterfly Valve (Horizontal axis)
• Size: 3600 mm, Weight: 40 T
• Opening/Closing Time: 90 sec
• Operation: Hydraulic (Oil Servo Prime 57)

D. Generator

• Make: BHEL, Hardwar (1973)
• Model: SV 517/100-28T (Suspended Type)
• Rated Output: 20,000 kVA
• Voltage/Current: 11 kV / 1050 A
• Power Factor: 0.8 (lag)
• Speed: 214.3 RPM
• Excitation: Rotary Exciter, BHEL, Hyderabad

E. Bearings

• Type: Segmental Pad (Babbit metal)
• Cooling: Water-cooled oil coolers
• Oil: Servo Prime-46

F. Auxiliary Equipment

• O.T. Crane: Mukund Iron & Steel Works, Mumbai (105/30 T capacity)

Compressors: Ingersoll Rand, Type-30, Receiver 1.6 m³, Pressure 27 kg/cm², driven by Crompton Greaves motors (12.5 HP).