The HVAC Factor: Predictive

Maintenance
February 18, 2008

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By John Kuchler
Published in the February 2008 issue of Todays Facility Manager
The performance of HVAC equipment is crucial in all facilities. The scope of
functions that these machines perform can affect virtually all areas of a
building.
While routine maintenance checks are often completed as part of an HVAC
service program, they dont always identify problems that can lead to
machine failure. On the other hand, predictive maintenance analyzes current
equipment conditions and dictates tasks that must be completed to keep
machines running at optimum levels. Implementing a predictive maintenance
plan can extend equipment life and improve a companys bottom line.

(Photo: Johnson Controls)

MORE THAN PROBLEM DIAGNOSIS

Most facility managers (fms) are familiar with predictive maintenance and
how it can be used to analyze machine condition. However, many employ
predictive maintenance testing only after an equipment problem has already
occurred and the cause must be diagnosed. By including predictive
technology as part of routine maintenance, fms could monitor machines
frequently, anticipating potential problems before they lead to serious
equipment damage.
Subscribing to the school of thought that a good preventive program is
enough to maintain equipment, few are willing to add predictive diagnostics
to their maintenance plan. Old habits can be difficult to change.
Another barrier to more widespread adoption of predictive technology is the
fear of negative test results. The initial predictive test often reports many
problems, especially when only deferred maintenance has been practiced in
the past. As a result, many fms may be hesitant to put their HVAC systems
through predictive tests.
But instead of becoming a cause for alarm, reports can be used to put
problems in perspective and prioritize where repair efforts should be
concentrated. Test results can establish benchmarks for machine
performance. These results can then be used to compare against progress
and evaluated to make changes to the maintenance plan. A good predictive
maintenance plan allows for equipment re-examination and results tracking
to optimize the repair process and ensure repairs are performed correctly.
A lack of experience with predictive diagnostics also prevents some fms from
adopting the technology into their maintenance strategies. This is especially
common when these diagnostics are used only to identify an equipment
problem. One solution is to outsource the predictive maintenance and benefit
from the presence of technicians who are trained and are proficient at
analyzing data quickly. Continued expert analysis can improve equipment
reliability, which reduces maintenance and energy costs.

TRANSITIONING TO CONDITION BASED MAINTENANCE

A more common maintenance practice is preventive, which is typically time

based. Examples include conducting a machine teardown after 5,000 hours of
runtime or replacing a part every six months. In contrast, predictive
maintenance uses data collected from equipment to measure machine
condition and generate tasks only when they must be performed, resulting in
less time spent making unneeded repairs. Over time, results can then be
used to develop a condition based maintenance plan.
Of course, the best plans have a balance of both preventive and predictive
technology. Some tasks, such as inspecting guards, doors, and covers, are
cheaper to maintain on a time schedule, because an alternative predictive
technology is not available. Other tasks, such as relubricating bearings might
not need to be performed as frequently as the time schedule dictates.

PREDICTIVE DIAGNOSTICS FOR HVAC EQUIPMENT

The most common predictive technologies used for HVAC applications are
vibration and oil analysis. Frequently used in compressors, vibration analysis
gathers structural vibration data from multiple locations on the compressor
and compares it to either manufacturer specifications or other databased
machines of similar configuration to identify abnormal vibration patterns.
Problems, such as excess noise or machine vibration, can be caused by poor
installation, internal machine defects, or machine wear and tear. Once the
vibration data has been collected, the problem can be isolated, fixed, and
rechecked to verify the solution is effective.
Oil analysis, often used in chillers, can determine which part of the machine
is experiencing significantly harmful wear. Contaminants affecting chiller
operation can also be detected. Added benefits of oil analysis include reduced
frequency of oil changes, which improves lubrication control and increases
equipment life.
Other HVAC predictive technologies include: misalignment and balance
service to prevent bearing failure; lithium bromide analysis to keep absorber
chiller evaporators operating at peak performance; electrical analysis to

determine motor condition; refrigerant analysis to maintain optimal cooling

systems performance; water treatment service to prevent equipment
corrosion; and root cause failure analysis to determine conclusively the
reason for machine failure.

IMPROVING THE BOTTOM LINE

Although the upfront costs of a predictive maintenance plan may be higher
than a traditional preventive plan, lower costs will eventually be realized
through optimized maintenance programs, extended equipment life, and
improved reliability.
Predictive services can identify machine faults before they lead to
catastrophic failure. This allows for planned equipment repairs instead of
costly emergency fixes. In addition, downtime can be scheduled to maintain
productivity.
Incorporating predictive technology into facility maintenance plans reduces
capital and operational costs. This can positively impact the equipment, and
the facility as a whole.
As manager of predictive diagnostics at Johnson Controls, Kuchler has more
than 20 years of experience with predictive maintenance programs. In his
current role, he oversees predictive services including data analysis, report
generation, and repair assistance in North America, South America, South
East Asia, and Australia. Kuchler holds certifications in category three
vibration from the Vibration Institute and level one machinery lubrication
from the International Council for Machinery Lubrication.
Johnson Controls has introduced Advanced Vibration Evaluation, a predictive
maintenance service that identifies potential HVAC equipment failures in
critical production areas such as clean rooms, switching rooms, research labs,

telecommunications facilities, data centers as well as any other commercial

facility.
Johnson Controls uses technology, provided by Augury, a predictive
diagnostics company, to:

Identify root causes of problems (e.g. unbalance and misalignment)

Help prevent secondary damage

Eliminate emergency repairs

Ensure repairs have been made correctly

Reduce maintenance costs

Improve energy efficiency

Extend equipment life

This new smartphone technology allows for a cost-effective delivery method

through improved speed and efficiency to increase the number of analyzed
machines while improving the quality of service. Johnson Controls is meeting
the needs of its customers who want to be more proactive with maintenance
by maximizing equipment information to drive facility improvements and
lower costs. Johnson Controls technicians are now able to uncover the issues
facing a particular machine with minimal effort and at a lower cost.
Using data collection process and analysis expertise, Johnson Controls repair
technicians have the ability to arrive at solutions quickly and accurately.
Repair technicians not only can identify the root cause of the vibration

problems, but can deliver the precision maintenance techniques to solve the
problem the first time.