How Predictive Maintenance Will

Change the Future for HVAC

Technicians

February 4, 2016
Saar Yoskovitz
One Comment
KEYWORDS HVAC tools and technology / HVAC troubleshooting / predictive maintenance
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Most people underestimate the breadth of knowledge required to be a good technician.
Seasoned veterans of HVAC equipment have had 20 to 30 years to learn everything they need
to know. Their knowledge is vast, but as innovation continues to push equipment into a new
high-tech space, these veterans will have to adjust and quickly.

Humans simply cant absorb new processes as fast as they become available. And newer
recruits have even less time to learn old procedures and new techniques at the same time.
Machines, however, have that capability. They can remember infinitely more than we can,
and their use allows even the newest recruit to arrive at a jobsite with the experience of
thousands of technicians alongside him.
While machine-assisted predictive maintenance is not the norm yet, it will soon be a
necessary tool for HVAC technicians that will make it easier to prevent mistakes and to train
new recruits as time goes on.

OUR STRUGGLES TODAY

Assuming each machine malfunction follows a normal distribution, a technician who sees
one new HVAC malfunction every single day could take years to learn the diagnostic skills
needed to analyze each function alone. This doesnt even account for the various
combinations and permutations of problems that can exist on a piece of equipment. Its nearly
impossible for a single person to know everything about these machines.
Experienced techs have gotten to know the machines they work with, but new technicians are
entering the workplace with very little real-world training. A new HVAC technician might
neglect to apply bearing lubrication or simply forget to tighten a bolt and cause major
problems due to a minor moment of forgetfulness.
And companies increasingly lack the time and resources to train technicians adequately, so
the new workforce as a whole falls short in expertise.
For those new technicians, we need more advanced, high-tech mentors to give them the
confidence to hit the ground running. And with the collective knowledge gathered from
skilled HVAC technicians, those old hands will have the security of knowing they dont need
to do everything themselves.

THE NEED FOR PREDICTIVE MAINTENANCE

An issue that would take a tech an hour to troubleshoot takes computer-driven diagnostics a
fraction of the time. As machines store more and more data regarding machine malfunctions,
they become better at predicting when the next malfunction will likely occur.

Typically, buildings have about four to seven pieces of equipment that need analysis. But
only a few of them will be under warranty, despite needing major repairs. Technicians will
soon be able to use tool-assisted analytical techniques to answer definitively whether small
maintenance today could prevent major repairs down the line.
For example, an experienced technician might say to a client, Ive seen this issue before; this
machine wont last longer than three more months. Now, imagine that technicians
knowledge is accessible to every person out in the field and that the technicians intuition has
the hard data of hundreds of similar scenarios behind it, all tracked by technology.

PREDICTIVE MAINTENANCE AND TECH-CLIENT

RELATIONS
Today, the HVAC industry is similar to the field of medicine. The emergency surgeon gets all
the credit for saving the day, while the general practitioner goes largely unnoticed. Similarly,
HVAC techs who swoop in to repair broken machines get the glory, while those who keep
them running smoothly remain in the background.
Its nice to be the hero, but just as medicine is transforming from an expensive and
reactionary model to a predictive and cost-effective one, so will HVAC. The result will be
fewer high-margin jobs in the wake of catastrophes but more low-margin, predictive tuneups.
Tool-assisted predictive maintenance wont become the industry standard overnight, but the
shift is coming. These changes will reduce stress for clients and technicians alike while
improving our ability to avert disaster.
HVAC technicians must embrace this new technology as it enters the industry to see how
much more efficiently they can work with the right tools at their side.

Building a business case for predictive maintenance

Published: 01 August, 2013
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Web-enabled dashboards make it easier than ever for facilities professionals to gather, access and apply relevant information to keep
their building operating efficiently

If it aint broke, dont fix it is, perhaps, not the soundest maintenance philosophy, but
modern approaches make it possible to plan fixing things just before they might break.
Julian Horler of Trane explains.
The traditional approach to heating, ventilating and air-conditioning (HVAC) maintenance relies
on a calendar or hour meter to determine when equipment is serviced. But technological
advances over the last decade provide facilities managers with information that lets them
perform maintenance when it is needed and
not when the schedule says it is time.
Predictive or reliability-centered maintenance
uses testing, diagnostics and computer
modelling to identify actual maintenance
needs. This approach hinges on establishing a
performance baseline for HVAC systems
based on the performance of similar systems.
Systems are continuously monitored, and their
actual performance is compared to benchmark
data. As a result, it is possible to identify
potential problems and schedule maintenance
before they can cause systems to fail.
With budgets under pressure and the cost of
energy and labour rising, many facilities
professionals are increasing their emphasis on
predictive maintenance to control costs and
Predictive maintenance can detect minors issues in a
reducing the likelihood of an HVAC system
chiller before they become major problems.
failure that could shut down their operations.
Advances in HVAC-related technologies make it possible for many organisations to adopt a
predictive-maintenance model without a large capital investment. Most organisations already
have the technology backbone in place to enable a predictive approach.
For example, todays sophisticated building-automation systems are designed to support
predictive-maintenance programs, with web-enabled dashboards that make it easy for facilities
professionals to gather, access and apply relevant information to keep their building operating
efficiently. Most organisations already have highly capable building-automation systems in
place. But facilities staffs may need additional training to take full advantage of their features,
according to the Platts division of McGraw Hill, which estimates that more than half of facilities
departments are under-utilizing their building-automation systems.
HVAC fault detection and diagnostics, such as Trane Intelligent Services, enables predictive
maintenance. Intelligent services combine technology, access to existing benchmarking data
and sophisticated analytics to continuously collect, interpret and act upon data from building
systems and controls to detect and report faults in critical HVAC components, giving
technicians early warning of potential problems, improving reliability and reducing unscheduled
downtime.
Other predictive-maintenance programs can include methods such as oil analysis to detect
minor issues in a chiller compressor before they become major problems.

Thermography can also identify hidden problems in a chilled-water system by detecting and
diagnosing the thermal emissions of different components, which could suggest electrical and
mechanical issues that can lead to component failure, unplanned outages and safety issues.
The latest predictive modelling technologies
use computer programs to compare an HVAC
systems operating characteristics with
aggregated information from many similar
systems. For example, they continuously
analyse vibration levels, refrigerants and other
fluids, and motor performance to detect
potential performance problems, so the
facilities department can schedule
maintenance and have the required parts on
hand.
Many facilities managers seek the help of
external professionals to decide if predictivemaintenance is the best approach for their
organisation or building. Others have the
knowledge and resources to take on this task
themselves. In either case, facilities managers
will want to start by calculating the true cost of
the current approach to HVAC system
Thermography can reveal hidden problems in electrical maintenance.
panels and chilled-water systems.

The average cost of planned and unplanned maintenance over several years is a good starting
point. But it is also important to calculate the potential impact of an HVAC system failure on
operations. For example, estimate the cost to the facilities budget of responding to an
unplanned HVAC failure, including the higher cost of repairs made in a reactive mode.
Next consider the disruption that could have been avoided by proactive predictive maintenance.
An unplanned HVAC failure can cause a building to close for hours or even days. Estimate the
cost of an unplanned failure in terms that make the sense to the organisation such as lost
revenue, and the impact of an HVAC failure on productivity, customer satisfaction or business
reputation.
Many large organisations have most of the technology they need to adopt a predictive
maintenance solution. In stating their case, facilities leaders should consider any upfront
investment required including hardware, software, training or changes to existing service
contracts. Estimate the savings from eliminating scheduled but unnecessary maintenance
tasks, which will offset the cost of implementing a predictive maintenance program.
When all these factors are considered, predictive maintenance is worth considering for most
organisations

The HVAC Factor: Executive View of

Preventive Maintenance
December 15, 2015

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By Lynn Burkhart
From the November/December 2015 Issue

Decisions regarding finances are one of the most vital

responsibilities of building owners and managers. Few areas impact
expenditures more than HVAC sustainability and operational costs. While
HVAC preventive maintenance (PM) programs abound, the pertinent
information that impacts the facilitys budget often does not make it to the
facility executives.
PM programs can provide facility executives with vital financial information as
well as assist in maintaining valuable equipment. PM checklists at the
engineer or maintenance level may include as many as 100 items. These can
roll up into the overall efficiency, cost, and longevity of equipment.
At the facility executive level, details in the maintenance checklist may or
may not provide a good picture. A summary of how PM impacts a facility is
usually more helpful to a facility executive when making decisions affecting
budget, manpower, occupant comfort, and sustainability.
Seven important issues a facility executive should look for in an HVAC PM
summary are:
Check: Routine overall assessment of the air handlers has been
done.
Purpose: Replacement costs can be budgeted.
A PM program should provide for an overall assessment of the air handlers so
that management is kept informed of when replacement of the units will be

needed. A report on the interior corrosion of air handler surfaces is a vital

part of this assessment. Corrosion of surfaces such as condensate water
collection pans, cooling coil supports, and sidewalls are the main reason for
equipment failure and expensive replacement.
The assessment can also help facility executives manage efforts to prevent
future corrosion. Maintenance personnel frequently fail to rinse aggressive
coil cleaners fully from the coils and condensate pans they use to clean the
system. This is the primary preventable reason for interior corrosion of
condensate collection pans and cooling coil supports.
Costs for air handlers range from $50,000 to more than $150,000 per unit,
and budgeting for their removal and replacement is often not projected in the
budget. An unexpected and unbudgeted air handler breakdown can wreak
havoc on annual budget accountability.
Air handlers have varying lifetimes, but units over 15 to 20 years old will
likely need to be replaced in the near future. PM schedules should call for an
interior photo of each air handler annually so the extent of the corrosion can
be reviewed by managers.

Fouled HVAC cooling coil (Controlled

Release Technologies)
Check: Coils have been cleaned.
Purpose: Save as much as 40% on energy costs.
With close to 50% of a facilitys electrical bills often spent on the HVAC
system, HVAC operation expenses are another major concern of any facility

executive. These operating costs increase considerably when cooling coils are
dirty or fouled with microbial growtheach of which insulates the coil
surfaces so they do not cool the air effectively. This causes the air handler to
take longer to reach and maintain cooler temperatures. Thus the units run
longer and consume more energy.
Dirt also plugs and reduces the flow of air through the coils, causing fans to
use more energy to overcome restrictions in the coils. All of this increases
operational costs.
ASHRAE, the association that provides standards for HVAC systems,
conducted a formal engineering test and published that air handlers with
dirty coils required as much as a 40% increase in energy to operate. This
study was done on units that were cleaned just one year before testing.
Due to the amount of monthly savings, semi-annual coil cleaning can be cost
justified. To reduce the costs of manual coil cleaning, a coating can be applied
to the coils to reduce dirt and microbial buildup for a year or more. Annual
photos of the equipment interiors should include the cooling coil condition.
Check: Air filters have been fitted properly.
Purpose: Reduce mold, fungus, and dirt buildup in the air handler
and building airstream and increase system efficiency.
Another important area sometimes overlooked in PM schedules is the air filter
enclosure rack and positioning of filters. Rusted filter racks leave gaps around
the air filters, and air preferentially moves through gaps rather than through
the filter itself. The result is that non-filtered dirty air gets caught in the
cooling coils, reducing efficiency. The gaps around the filters also allow
microbial particles, such as mold and fungal spores, to enter the airstream
and get to the coils.
Microbial particles will cling to interior surfaces to form biofilmswhich are up
to five times more insulative than scale. To reduce biofilms and address the
odors caused by microbes, an EPA registered sanitizer should be used on the

system quarterly during normal filter maintenance. Sanitizing most coils

should not take more than 10 minutes.
Check: Condensate drip pans are clean and free of standing water.
Purpose: Prevent odors and property water damage from overflows.
Microbial growth inside the air handler condensate drip pan is responsible for
odors, and can also accumulate dirt that clogs condensate drains. When the
drain clogs, water overflows, and in some cases it flows under the unit to the
floor below. A timed-released EPA registered antimicrobial should be used
semiannually to eliminate dirt buildup and microbial issues.

HVAC unit corrosion (Controlled

Release Technologies)
Check: Condensate drip pans, sidewalls, and other interior parts of
the air handler have been coated.
Purpose: Prevent corrosion and costly replacement.
Visual corrosion signals the impending demise of the unit. Corrosion can be
seen in annual photos and does not require an expert to decipher. Handling
corrosion early on prevents irreplaceable metal loss. Coating condensate drip
pans, sidewalls, and other interior air handler parts prevents future corrosion
and is the recommended solution to avoid premature removal and
replacement. Corrosion resistant coatings should pass state and local fire
codes as indicated by the NFPA, and be engineered for the harsh environment
inside an HVAC system.

Check: Access door enclosures are tightened and leaks repaired.

Purpose: Resolve otherwise unexplained increased energy
consumption by not allowing cold air to escape unused.
Unexplained increased energy consumption can occur from air leaks around
air handler access doors and ductwork. A report indicating that air leaks have
been looked for and addressed provides peace of mind when pursuing lower
operational costs.
Check: Humidity readings have been taken.
Purpose: Double check how well the air handler is being maintained.
Relative humidity readings are another important factor in PM. Coils that are
insulated by dirt and biofilms might not reduce humidity to required levels.
The result is that high humidity levels in excess of 50% are very likely to
contribute to mold growth and resulting orders. Once established, mold
growth can be difficult to deal with, especially if it grows within the air ducts
that are not easily accessible.
This checklist provides an overview needed to manage issues that affect the
efficiency and sustainability of a facility HVAC system. Full sections of PM
maintenance checklists can be attributed to these points, making it easier for
a facility executive to find the cause and resolution of any problem areas that
become apparent from the assessment.

PREVENTIVE & PREDICTIVE

MAINTENANCE

REDUCE OPERATING COSTS AND AVOID

UNEXPECTED DOWNTIME.
Our comprehensive and custom service agreement plans ensure your equipment gets the proper regular maintenance to keep
it running smoothly and efficiently. With predictive maintenance, youll know about potential problems before breakdowns
occur, providing you the opportunity to schedule repairs at your convenience.

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Ensuring your equipments peak performance and longevity dictates a commitment to preventive, predictive and proactive
maintenance programs. Safeguarding your equipment by choosing Carrier brings the security of having forged a true
partnership with the HVAC industrys foremost servicing and technology leader. At Carrier, we partner with building owners
and managers to keep your system running at its best, with customized service plans designed to meet all your specific
equipment and operational needs year-round. We service all brands and types of HVAC units.

Service Agreements & Preventive Maintenance

At Carrier, we partner with building owners and managers to keep your system running at its best, with customized service
agreements designed to meet all your specific equipment and operational needs year-round. We offer a clear approach to
service: a customized plan that is tailored to your facility, the particular equipment you own, and your performance and
financial goals.
We start with three main service levels Standard, Plus and Premium to address the needs of every facility professional.
Each begins with routine maintenance tasks designed to keep your equipment running smoothly and efficiently. From there
we work in partnership with you to design the best program suited to your overall goals and objectives.

Carrier Standard Service Plan

Designed for customers with in-house HVAC staff or those who want OEM factory-certified basic maintenance. It ensures
that equipment is inspected regularly, operating properly and all OEM maintenance procedures are adhered to.

Carrier Plus Service Plan

Designed for customers seeking to partner with a factory certified HVAC service company for complete maintenance care
and technical support. It provides customized support to each HVAC asset, maximizes equipment life, uptime and
performance. Services are selected according to specific equipment components and fiscal goals.

Carrier Premium Service Plan

A fully-customizable package designed for those who demand the highest equipment reliability and uptime coupled with
fiscal certainty. It provides complete equipment protection with repair or replacement of failed components in covered
equipment. Its 100% budgetary certainty allows fiscal planning with confidence.
A Carrier Service Agreement can:

Ensure that your equipment is inspected regularly, operating properly and all OEM
maintenance procedures are adhered to;
Maximize your equipment life, uptime and performance;
Reduce your energy costs through good preventive maintenance measures;
Provides you with budgetary certainty and allows fiscal planning with confidence.
Reduce risk of unexpected downtime with proactive service
Predictive Maintenance
If equipment fails unexpectedly, you face downtime and, potentially, inconvenienced occupants. With predictive
maintenance, youll know about potential problems before breakdowns occur. That brings you the luxury to schedule repairs
before they become more costly and at times when they wont inconvenience you or your buildings occupants. Using
todays best testing tools and technologies, we can discover or rule out hidden building system problems. As a result, we can
help you:

Find, identify, and correct minor problems inexpensively, before they lead to more
complex and expensive repairs
Avoid needless downtime and inconvenience or discomfort to occupants
Ensure continued production when equipment is used in process application
Control energy costs
Prolong equipment life, deferring replacement expense
How can Carriers Preventive and Predictive Maintenance Services provide value to you?
It can:
Simplify short and long-term budgeting with planned maintenance
Reduce risk of unexpected equipment downtime with proactive service
Find, identify, and correct minor problems inexpensively, before they lead to more
complex and expensive repairs
Prolong equipment life, deferring replacement expense
Ensure peak efficiency resulting in lowest cost operation
Carriers Preventive and Predictive Maintenance Services applies to:
Carrier and all major brands of water-cooled and air cooled chillers
Packaged unitary equipment
Air handling units, split-systems
Cooling towers, pumps, boilers
Control systems