What Is Involved in a Facility Power Audit? A Complete Guide
Ever open your plant’s electric bill and do a double-take? You’re not alone. In many commercial and industrial facilities, 20–30 percent of every kilowatt-hour is silently wasted through harmonics, imbalances, and other invisible gremlins hiding inside the switchgear. In our work with manufacturers, data centers, and hospitals across the U.S., Camali Corp engineers routinely uncover six-figure annual savings that were literally humming in the walls.
According to the U.S. Department of Energy, a structured power audit can trim consumption by up to 25 percent. Often without buying new production equipment (U.S. DOE, 2024). That’s why “power audit” is climbing to the top of maintenance and ESG to-do lists. But what exactly happens during one? How long does it take? And most importantly, what will it cost and save?
This no-fluff guide answers all of those questions in plain English. By the end, you’ll know every step, every tool, and every outcome a professional facility power audit should deliver.
Why Facilities Need a Power Audit Now
Who Benefits Most from a Power Audit?
Power audits aren’t just for big factories. Mid-size offices, retail campuses, healthcare centers, and K–12 schools often see major gains too. Any site with large equipment, building automation, or multiple shifts can uncover hidden savings.
Hidden Costs of Power Waste
- Utility penalties: 8–12% utility penalties for poor power factor
- Equipment stress: Overheated drives and transformers that cut equipment life in half
- Production downtime: Nuisance trips and downtime when harmonics spike during production peaks
- Electronics failure: Sensitive PLCs (small computers that control equipment) and servers can shut down during power spikes, causing downtime at the worst time.
In short, poor power quality wastes money and lowers reliability. Sensitive electronics like PLCs and servers need clean, consistent power. Explore our UPS system services to protect against sudden outages and spikes.
Compliance & Safety Standards You Can’t Ignore
Utilities and insurers increasingly reference IEEE 519 harmonic limits, NFPA 70E arc-flash guidelines, and ISO 50001 energy-management targets. A power audit documents exactly where you stand, helping you avoid fines and reduce risk for the people who keep the lines running.
The 7-Step Facility Power Audit Process
Below is the framework Camali Corp follows on every engagement. Feel free to benchmark any vendor against it.
1. Pre-Audit Scoping & Goal Setting (½ day)
A 30-minute discovery call defines the mission—lower costs, boost uptime, support ESG reporting, or all three. We gather single-line diagrams, 12 months of utility bills, and a quick list of pain points like “drive failures on Line 4” or “random PLC resets.”
2. On-Site Data Logging & Measurements (1–2 weeks)
Certified electricians install portable Class A meters on main switchboards, feeders, and large motor loads. Readings include voltage, current, total harmonic distortion (THD), power factor, and demand at one-second intervals. Infrared cameras scan gear to spot hot connections before they arc.
3. Load Profiling & Power Quality Analysis (Week 2)
Specialized software turns those raw numbers into easy-to-read load profiles. Spikes, sags, and idle capacity jump off the screen. Our engineers compare daytime peaks to night-shift troughs and flags where equipment is starved, or running on empty.
4. Benchmarking Against Industry Standards (Week 2)
Results are stacked against:
- IEEE 519 limits for harmonics
- ASHRAE energy-use benchmarks for your facility type
- Your utility’s tariff to quantify true financial impact
5. Findings Report & Cost-Savings Model (Week 3)
We deliver a 20–30-page report that clearly explains:
- Root causes (e.g., 13 % THD at MCC-3 caused by VFD clusters)
- Fix priority matrix (low, medium, high)
- Annual savings and simple payback for each action item
6. Corrective Action Plan & ROI Forecast (Week 3)
Typical recommendations include capacitor banks, active harmonic filters, load balancing, and preventive maintenance tweaks. We attach vendor-agnostic budget pricing so your team can act without a second round of RFQs.
Want to keep power issues from creeping back in? Our planned maintenance services help prevent future power waste.
7. Follow-Up Verification (Measurement & Verification) (Post-fix)
After upgrades, we return for measurement & verification (M&V). Savings are confirmed with fresh data, perfect for ESG disclosure or utility rebate paperwork.
Timeline, Budget & ROI: What to Expect
| Facility Size | Study Duration | Typical Fee | Payback Period* |
| ≤ 50k ft² retail / office | 2 weeks | $6–8k | ~12 months |
| 50–200k ft² plant | 4 weeks | $12–18k | ~10 months |
| Campus / data center | 6–8 weeks | $25–40k | ~8 months |
*Payback based on energy-only savings. Many clients see 10× ROI once reduced downtime is added.
Rebates & Utility Incentives
Many utilities offer rebates for upgrades like harmonic filters or power factor correction. A proper audit gives you the documentation needed to qualify and maximize funding.
What Camali Delivers That Walk-Through Audits Don’t
- Class A data loggers traceable to NIST—no clipboards or guesswork
- Compliance mapping to IEEE 519, NFPA 70E, and local utility tariffs
- Secure cloud dashboard so your team can watch live KPIs anytime
- Hands-on support until every recommendation is closed
“In our plastics plant, Camali’s audit shaved 18 percent off the electric bill and paid for itself in seven months.” — Maria Gutierrez, Facilities Director, Acme Plastics
Next Steps: Book Your Complimentary Walk-Through
Ready to plug the leaks in your power bill? Schedule a free 30-minute consultation. We’ll review your single-line, outline a scope, and deliver a fixed-fee proposal within 48 hours.
