A steel rolling mill in Pune faced crippling electricity demand charges — their highest monthly demand was 3,800 kVA but their average was only 2,100 kVA. TESAS designed and deployed a 2 MWh / 1 MW LFP BESS that eliminated this gap, saving ₹1.2 Crore annually.
The plant's arc furnace and rolling mill motors created dramatic power demand spikes — 4–6 times per day — each lasting 8–15 minutes. Under MSEDCL's maximum demand tariff structure, the client was billed for the highest 30-minute demand recorded in the month, even if it occurred only once.
This meant a single uncontrolled startup sequence could cost ₹8–12 lakh in excess demand charges for the entire month. The plant engineer estimated that 38% of their ₹3.2 Cr annual electricity bill came from demand charges — not energy consumption.
TESAS deployed a containerised 2 MWh / 1 MW LFP BESS at the HT switchyard level — integrated between the 11 kV incomer and the plant's transformer. The system continuously monitors grid draw and pre-emptively discharges during the milliseconds before a demand peak materialises, clipping the peak to a pre-set demand target of 2,200 kVA.
30 days of 1-second interval power metering; TESAS demand simulation to identify optimal demand setpoint and required BESS capacity.
2 × 1 MWh LFP battery containers (CATL cells), 1 MW bidirectional PCS, EMS control panel, and site prep.
BESS containers placed on concrete plinth, 11 kV bus connection, SCADA integration with existing DCS, and fire suppression commissioning.
72-hour full-load test, MSEDCL MD meter sync, operator training, and remote monitoring dashboard handover.
| Parameter | Specification |
|---|---|
| Battery Chemistry | LFP (LiFePO₄), prismatic cells |
| Total Energy Capacity | 2,000 kWh (2 MWh) |
| Usable Energy | 1,800 kWh (90% DoD) |
| Power Rating (PCS) | 1,000 kW (1 MW), bidirectional |
| DC Bus Voltage | 768V nominal |
| Grid Connection | 11 kV via 1.25 MVA transformer |
| Response Time | <100 ms from demand trigger |
| Cycle Life | 6,000 cycles @ 80% DoD |
| Operating Temp | 15–35°C (precision AC cooling) |
| Enclosure | 20 ft ISO container, IP54 |
| Total CAPEX | ₹1.85 Crore |
| Annual Demand Savings | ₹1.22 Crore |
| O&M (TESAS AMC) | ₹6 lakh/year |
| Net Annual Benefit | ₹1.16 Crore |
| Simple Payback | 18 months |
| 10-year IRR | 58% |
"We had tried load staggering and automation approaches before. TESAS was the first team to actually model our specific demand profile and come back with a solution sized correctly. The payback in 18 months was not a sales pitch — it is exactly what happened."
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