How Energy Surveys Help You Stay Ahead of the Current
An energy survey we recently carried out at a manufacturing site uncovered two key opportunities for improvement; load capacity and power factor correction, both of which could lead to serious savings and a more resilient energy strategy.
Most businesses assume their electrical systems are quietly ticking along in the background, doing what they’re supposed to. But every now and again, it’s worth lifting the lid, because what you don’t know could be costing you.
That’s exactly what a recent energy survey revealed at one UK site. The aim? To assess whether the site could comfortably accommodate new electrical loads. The result? A few warning lights, and a couple of smart fixes that could drive big improvements.
Load Capacity: Dangerously Close to the Edge
Let’s start with the big one—supply capacity. The business was operating on an agreed supply limit of 92kVA. But monthly peak demand data showed that limit was being exceeded by as much as 40kVA, with real-world usage during the survey spiking to 217.61kVA. That’s well over double the agreed limit.
This mismatch isn’t just a technical concern; it’s a financial one too. If your site is regularly exceeding its agreed capacity, it’s only a matter of time before charges, operational risks, or forced upgrades come knocking.
An increase to the agreed capacity, or the implementation of load management systems, could prevent disruption and keep costs under control.
Power Factor: Wasting Energy (and Money)
Next up, the power factor. During the survey period, the average power factor was just 0.61. Ideally, this figure should be as close to 1.0 as possible, meaning the energy being drawn is used efficiently.
But a reading of 0.61 means 39% of the incoming energy is reactive i.e. not contributing to productive output but still placing strain on the network. This inefficiency can result in penalty charges and higher energy costs, not to mention extra wear and tear on your electrical infrastructure.
Power factor correction, often via a capacitor unit, can quickly resolve this and restore performance—something now being investigated for this site.
Harmonic Distortion: The Hidden Menace
Finally, we come to Total Harmonic Distortion (THD), the silent saboteur of power quality. The survey found current distortion averaging 10%, but in a few moments, this shot up to a staggering 1034.5%. Yes, that’s not a typo. Voltage distortion stayed within safe limits, but the current THD suggests significant waveform issues.
High harmonic levels like these can cause:
- Equipment malfunctions or failures
- Increased system losses
- Unexplained operational issues
Identifying and mitigating these distortions early (typically using harmonic filters or design improvements) can prevent more serious, and expensive problems at a later stage.
The Certified Verdict
This survey is a textbook example of why energy assessments are so valuable. They don’t just tick boxes, they reveal inefficiencies, uncover hidden risks, and highlight opportunities to save money and improve system resilience.
From this one survey, the recommended actions include:
- Reviewing and increasing the site’s agreed supply capacity
- Installing a power factor correction unit
- Investigating the source of high harmonic distortions
Not only could these actions reduce energy bills and avoid penalties, but they also strengthen the site’s infrastructure for future growth and sustainability initiatives.
Think your power setup is working just fine?
An energy survey could reveal a very different picture. Let’s help you stay in control, before hidden inefficiencies start pulling the plug.
Contact Certified Compliance today to book your energy survey.