Power Monitoring
In the industrial electrical sector, data-driven decisions are the only way to ensure system reliability and avoid catastrophic overloads. Badger Controls Inc. provides high-precision Power Quality Analysis and Load Monitoring to give you a transparent view of your facility’s electrical health.
Capacity & Grid Integration Studies
Before adding a high-demand asset like a CNC machine or an industrial compressor, we determine if your existing distribution-level infrastructure can handle the additional load. We identify available “headroom” in your main switchgear to prevent nuisance tripping and expensive utility penalties.
Long-Term Load Profiling
We deploy advanced Power Quality Loggers for durations ranging from one month to six months. This captures a complete picture of your facility’s energy cycles—including peak demand surges, inrush currents during motor starts, and voltage sags—providing the data needed for accurate NEC load calculations.
Identification of “Ghost” Loads & Inefficiencies
Our monitoring equipment detects exactly where energy is being wasted. We find “ghost loads” from equipment left idling and identify Power Factor issues that lead to monthly “reactive power” surcharges on your utility bill from providers like Southern California Edison.
Harmonic Distortion Analysis
Modern industrial electronics like Variable Frequency Drives (VFDs) can “pollute” your power grid with electrical noise. We monitor for Total Harmonic Distortion (THD) to ensure your sensitive PLC processors and communication networks aren’t being degraded by unstable power.
Predictive Failure Detection
By monitoring current draw over time, we can spot equipment pulling more amperage than its nameplate rating—a primary indicator of bearing wear, winding insulation breakdown, or mechanical binding—allowing you to schedule maintenance before an unplanned shutdown occurs.