₹25,000 Lost in 5 Days Due to Low Power Factor: A Telangana Industry Case Study
A Telangana industry lost ₹25,000 in 5 days due to low power factor and TSSPDCL penalty. Learn causes, PF monitoring methods, and how Bharat Smart Services help
For many industries in Telangana, rising electricity bills are often blamed on increased production or tariff changes. But in reality, low Power Factor (PF) and power factor penalties by TSSPDCL are major hidden cost drivers. This real industrial case from Telangana shows how a Power Factor drop from 0.99 to 0.6 resulted in ₹25,000 loss in just 5 days.
Understanding Power Factor Penalty in Telangana (TSSPDCL)
Under Telangana electricity regulations, industries are expected to maintain a healthy Power Factor (generally close to 1.0).
- When Power Factor drops:
- Reactive power increases
- Lag condition dominates
- Excess units are billed
- Power factor penalty is applied
- Overall electricity bill increases
Many industries under TSSPDCL (Telangana State Southern Power Distribution Company Limited) face additional charges due to poor power factor maintenance.
Maintaining PF above 0.95–0.99 is critical to avoid penalties.
The Industry’s Preventive Approach
The industry owner understood how to reduce electricity bill in Telangana industry operations.
They implemented:
- Daily meter reading monitoring using Bharat Smart Services App
- Power factor tracking
- APFC panel observation
- Capacitor bank performance checks
Using the BSS app by Bharat Smart Services, Power Factor was consistently maintained at 0.99.
No reactive power charges, No PF penalty, No excess billing.
What Happens When Power Factor Monitoring Stops
For five days, the person responsible for capturing readings was unavailable.
Monitoring stopped.
Production continued.
On the 6th day:
- Power Factor dropped from 0.99 to 0.6
- 2,800 excess electricity units were billed
- ₹25,000 additional cost incurred
This is a classic case of low power factor in industry leading to penalty charges.
Root Cause: APFC Panel and Capacitor Bank Failure
With support from Bharat Smart Services, the APFC panel was inspected.
The issue:
A rat had bitten the capacitor sensing wire.
Due to this APFC panel failure:
- Capacitor bank did not switch ON
- System operated in lag
- Reactive power increased
- TSSPDCL power factor penalty was triggered
The panel was assumed to be functioning.
But without industrial power factor monitoring, the fault went unnoticed.
Common Causes of Low Power Factor in Telangana Industries
Industries frequently experience PF issues due to:
- Capacitor bank failure
- APFC relay malfunction
- Improper power factor correction settings
- Loose wiring or sensing faults
- Rodent damage inside panels
- Poor APFC panel maintenance
Without real-time alerts, these issues directly increase Telangana electricity bills.
How to Improve Power Factor and Avoid TSSPDCL Penalty
To improve power factor in industry and reduce reactive power charges:
- Monitor Power Factor daily
- Track APFC panel health
- Inspect capacitor bank switching
- Set automatic PF drop alerts
- Conduct periodic electrical audits
If the PF drop had been detected on Day 1, the ₹25,000 loss could have been prevented.
Real-Time Power Factor Monitoring with Bharat Smart Services
Bharat Smart Services provides:
✔ Industrial Power Factor Monitoring
Track PF trends in real time.
✔ Instant PF Drop Alerts
Receive mobile notifications when PF falls below safe levels.
✔ APFC Panel Monitoring Support
Identify capacitor bank problems early.
✔ Energy Audit & Correction Guidance
Structured support to reduce electricity bill in Telangana industries.
Power Factor is not just a technical number.
It directly impacts your profitability.
If your industry is facing:
- Low Power Factor issues
- TSSPDCL penalty charges
- Sudden increase in electricity bills
- Reactive power billing problems
It’s time to act before the next billing cycle.
Contact Bharat Smart Services for expert Power Factor monitoring and correction support.