How the Unblocking of kVArh Lead Affected a Crusher Unit in Suryapet

When the owner of a crusher unit in Suryapet contacted us, his question was simple:

“My production is the same. Why has my electricity cost suddenly increased?”

He was seeing a higher electricity bill, even though output and operations had not changed. What followed was a clear example of how small changes in electrical behaviour can silently create significant financial impact.

The Situation

A crusher unit in Suryapet was operating normally and production levels had not changed.

However, after the recent billing update related to kVArh lead unblocking:

• Their electricity bill increased by about 20% — roughly ₹2 lakhs extra.
• There was no increase in production.
• There were no new machines added.
• Operations were unchanged.
  
  

So the cost increase was not operational — it was electrical.

What Was Really Causing This

Our technical audit showed:

• Fixed capacitor banks were over-compensating during low-load periods.
• This created excess kVArh lead.
• Power factor became unstable.
• This instability increased billed units, which directly increased the electricity bill.
  
  

Nothing was wrong with the production process.The issue was entirely in the electrical behaviour and how it was being measured and billed.

Why This Was Hard to Detect

Inside the plant, everything looked normal:

• Machines were running.
• Output was steady.
• There were no breakdowns.
  
  

The loss was not happening on the floor it was happening silently in the billing data.

Without detailed monitoring, this kind of loss is very difficult to notice until the bill arrives.

How Bharat Smart Services Helped

We:

• Analysed billing and reactive energy trends.
• Identified the source of excess kVArh lead.
• Recommended tuning and dynamic control of capacitor usage.
• Stabilised power factor behaviour.
• Helped prevent further inflation of billed units.
  
  

As a result:

• Billed units normalised.
• Electricity bills stabilised.
• The client stopped paying for invisible inefficiency.
  
  

The Key Learning from This Case

This case highlights three important points:

1. High electricity bills do not always mean high electricity usage.
2. Electrical imbalance can silently increase costs without any visible operational change.
3. Billing behaviour matters just as much as operational behaviour.

Conclusion

The Suryapet crusher case is not an exception — it is an example of how billing sensitivity has increased and inefficiency is now more costly than before.

Understanding and managing electrical behaviour is now essential for controlling energy costs.

If your electricity bill has increased without a clear operational reason, the cause may not be visible on the shop floor — it may be hidden in your energy behaviour.

Bharat Smart Services helps industries identify and fix this before it becomes a financial problem.