Introduction: Turning Uncertainty into Savings
For many businesses, the term Power Factor Correction (PFC) feels technical, intimidating, and perhaps a little disruptive. When the word “survey” comes up, some managers picture engineers tearing through production lines, shutting down systems, or causing downtime. In reality, a PFC survey is straightforward, minimally disruptive, and designed to uncover hidden savings in your energy bill.
By knowing what to expect and how to prepare, you can make the process smooth, ensure accurate results, and ultimately benefit from lower costs and greater electrical efficiency. This article will walk you through what happens during a PFC survey, how to prepare your site, what access may be required, and the questions you’re likely to be asked. The aim: to replace uncertainty with confidence, and to help you get the maximum value from your survey.
What Is a Power Factor Correction Survey?
A Power Factor Correction survey is an on-site assessment carried out by a qualified engineer to measure how efficiently your facility uses electrical power. The survey identifies:
Your current power factor (a ratio of useful vs. wasted power).
The size and type of reactive power charges on your electricity bill.
Whether installing a PFC unit will save you money and improve capacity.
The process is diagnostic rather than disruptive. It’s about data collection, system observation, and designing a tailored solution for your business.
Common Concerns: Is It Disruptive?
One of the biggest fears clients have is whether a PFC survey will interfere with operations. The good news is: surveys are designed to be non-intrusive.
No downtime required: In most cases, machinery and production lines continue running as normal.
Minimal physical access: Engineers focus on your mains room, switchboards, and metering points rather than your production floor.
Fast process: A typical survey can be completed in a few hours, depending on the complexity of your site.
In short, while the survey investigates your electrical system, it does so in the background without interrupting your day-to-day operations.
What Happens in Preparation for a PFC Survey
Before the Visit
Data request: The engineer may ask for a copy of your latest electricity bills (ideally 3–6 months). These bills show reactive charges and load profiles.
Load schedules: If you know when peak loads occur, share this information. It helps the engineer plan the best time to measure your system.
Safety clearance: Confirm site safety rules, PPE requirements, and any induction processes needed.
On the Day
The engineer will typically:
Introduce themselves and explain the survey scope.
Request access to the mains room and switchboards.
Use portable measuring equipment to record current loads, voltages, and harmonic levels.
Observe system operation during normal working conditions.
Ask clarifying questions about your operations and future plans (e.g., expansion, new equipment).
What Access Will Be Required?
To carry out the survey effectively, the engineer will need access to:
Main electrical room or switchgear room (where the supply enters your building).
Distribution boards or sub-panels if measurements are needed at specific points.
Electricity meters (half-hourly or smart meters if available).
Outdoor transformer areas (in larger industrial sites).
In most cases, access to office space or production areas isn’t needed, unless major electrical equipment is located there.
Typical Questions You May Be Asked
To design the right solution, the engineer may ask:
Do you have recent energy bills? (Helps verify reactive charges.)
What is your typical load profile? (Peak times, seasonal variations.)
Are there any planned expansions or new equipment? (Futureproofing the PFC design.)
Do you operate sensitive electronic equipment? (Identifying harmonic distortion risks.)
What is your maximum demand? (To size the PFC system correctly.)
Do you experience voltage drops or flickering lights? (Potential signs of low PF issues.)
Being ready with this information ensures the survey is accurate and efficient.
Considerations for the Client
To prepare for your PFC survey, consider the following checklist:
Provide access to the electrical intake and switch rooms.
Ensure a staff member familiar with your site’s electrical system is available to assist.
Share copies of recent electricity bills with the engineer.
Make safety arrangements clear (PPE, inductions, or permits).
Inform the engineer of any future plans that may increase electrical demand.
This preparation not only makes the engineer’s job smoother but also ensures you receive the most precise recommendations.
What Happens After the Survey?
Once measurements are complete, the engineer will:
Analyze the data: Power factor levels, reactive power, harmonics, and demand profiles.
Prepare a report: Outlining your current situation, potential savings, and recommended PFC system size/type.
Provide a quotation: Including estimated payback period, usually less than 24 months.
Explain the benefits: Cost savings, freed-up capacity, reduced wear on equipment, and compliance with utility standards.
Real-World Example: Smooth, Simple, and Effective
A food processing plant in the UK recently underwent a PFC survey. The client was concerned it would halt production, but the survey was carried out while the facility operated at full load. Within 2 hours, the engineer had gathered data and left the site.
Result: The plant’s PF improved from 0.81 to 0.97 after installation.
Savings: £12,000 annually in reactive charges.
Disruption: Zero downtime.
This case demonstrates how easy and beneficial the process can be.
A Power Factor Correction survey is your gateway to unlocking hidden energy savings without disruption. By preparing access, sharing energy bills, and understanding what to expect, you set the stage for a smooth survey and accurate results.
With the right preparation, your business will be ready to:
Reduce energy costs
Free up electrical capacity
Improve equipment reliability
Support sustainability goals
Get your survey prep guide here