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 quietly lost to 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.
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
Power audits aren’t just for large factories. Mid-size offices, retail campuses, healthcare centers, and K–12 schools can all uncover hidden savings, especially sites with large equipment, building automation, or multiple shifts.
Hidden Costs of Power Waste
Poor power quality comes with real consequences. Low power factor can trigger utility penalties. Overheated drives and transformers shorten equipment life. Nuisance trips stop production, and sensitive PLCs or servers may shut down during spikes. Research from Abraxas Energy shows that energy audits can reduce facility energy use by 10–20 percent, and in some cases even more when recommended measures are fully implemented. 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 professional power audit documents exactly where your facility stands, helping you avoid fines and reduce risk for the people who keep operations running.
The 7-Step Facility Power Audit Process
Below is the structured framework Camali Corp follows for every power audit, giving you a clear view of energy use, hidden waste, and cost-saving opportunities. Feel free to benchmark any vendor against it.
1. Pre-Audit Scoping & Goal Setting (½ day)
The process begins with a 30-minute discovery call to define your goals, whether lowering energy costs, boosting uptime, supporting 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. These meters track voltage, current, total harmonic distortion (THD), power factor, and demand at one-second intervals. Infrared cameras scan gear to spot hot connections before they cause damage.
3. Load Profiling & Power Quality Analysis (Week 2)
Specialized software turns those raw numbers into easy-to-read load profiles. Engineers identify spikes, sags, and idle capacity, showing where equipment is starved or running inefficiently across day and night shifts.
4. Benchmarking Against Industry Standards (Week 2)
Results are compared to IEEE 519 harmonic limits, ASHRAE energy-use benchmarks, and your utility’s tariff to quantify potential savings and operational risks.
5. Findings Report & Cost-Savings Model (Week 3)
We deliver a detailed report highlights root causes, prioritizes fixes, and outlines annual savings with simple payback for each recommendation. This makes it easy to plan upgrades or operational adjustments with confidence.
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 multiple quotes. Our planned maintenance services help keep power quality consistent and prevent recurring waste.
7. Follow-Up Verification (Measurement & Verification) (Post-fix)
Once upgrades are completed, we return to perform measurement and verification (M&V). Fresh data confirms energy savings and ensures the system is optimized, providing a solid foundation for ESG reporting, utility rebates, or future reliability planning.
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 |
These payback estimates are based on energy savings alone. Many clients see significantly higher returns when reductions in downtime and improved operational efficiency are factored in. Utilities often offer rebates for upgrades such as harmonic filters or power factor correction, and a thorough audit provides the documentation needed to claim these incentives and maximize savings.
What Camali Delivers That Walk-Through Audits Don’t
Camali Corp goes beyond basic walk-throughs by using Class A data loggers traceable to NIST, removing guesswork and paper checklists. Every audit includes compliance mapping to IEEE 519 harmonic limits, NFPA 70E arc-flash guidelines, and local utility tariffs, giving a clear view of your facility’s power quality and safety. Data streams to a secure cloud dashboard, letting your team monitor KPIs in real time. Engineers stay hands-on until every recommendation is fully implemented, ensuring lasting results.
Next Steps: Book Your Complimentary Walk-Through
Ready to find hidden savings and improve your facility’s power reliability? Schedule a free 30-minute consultation. During the session, we’ll review your single-line diagram, outline a clear audit scope, and provide a fixed-fee proposal within 48 hours so you can take action quickly and confidently. Schedule your audit today.
