Predictive Maintenance

Reduce costs and breakdowns with Predictive Maintenance

By monitoring and analyse performance in HVACR systems 24/7, it is possible to identify if and when components lose efficiency and plan service before a breakdown.

What is Predictive Maintenance?

Predictive Maintenance can be divided in many categories – today the most common are “preventive” and “reactive”. However, the future is predictive maintenance.

Reactive maintenance happens after a breakdown which  is costly and cause expensive downtime that often interrupt business. It can also cause secondary cost in production loss as well as dissatisfied customers.

Preventive maintenance is time based (Scheduled), during the service visit the system is checked. Depending on the service agreement and regulations different factors are documented. Today’s preventive maintenance –is often focused on “leak-detection” and a very basic checklist. Performance of the HVACVR systems is rarely checked during preventive maintenance visits.

Predictive maintenance is based on the condition of the HVACR system which is possible only when performance is continuously analysed and monitored. Enabling the service and maintenance to be planned based on need and therefore, avoid failures and performance drift. Making it both time and cost efficient.

Most failures are detectable long before the problems occur, but few are detected.

The first step to optimisation is to ensure system stability which involves much more than leak detection and time-based services. The prevailing practice in the HVACR industry is to work with preventive maintenance, which is time-based. Where the goal is; to make it from one planned service to the next planned service without any failures.

There are several challenges with this approach:

  • Key parameters such as compressor, condenser and evaporator efficiency are not established, documented or checked during the majority of preventive maintenance service calls.
  • Preventive maintenance is planned when it is convenient for the service company not when the system is most likely to have representative operation.
  • At most plants there is no documentation of performance parameters to check. Not even minimum/maximum recommended values for basic parameters such as superheat, subcool and approach etc is available for the specific unit serviced.
  • The lack of documentation on earlier performance and lack of guidelines at site cause the accuracy and value of preventive maintenance to be much lower than expected by equipment owners.

Changing from preventive to predictive maintenance (PdM) bring many advantages. The concept of PdM is to be able to determine the condition of the equipment and components in order to estimate when maintenance should be performed and perform it thereafter, instead of waiting for the breakdown or the scheduled service.

By monitoring and analyse the performance 24/7 with ClimaCheck online, it is possibility to see if and when components lose efficiency. Based on that information it is possible to plan maintenance and avoid the breakdown. The continuous performance analysis also eliminates the biggest shortcoming with preventive maintenance which is; the lack of attention to HVACR system operation between service occasions (unless the system trips).

Learn how to implement predictive maintenance in our guide

  • Fewer failures and less downtime
  • Reduced maintenance costs
  • Lower energy consumption and CO2 emissions
Download our guide

Predictive maintenance and optimisation

Leading companies around the globe is using the unbiased ClimaCheck method to move to predictive maintenance and “continuous commissioning” to ensure that their plants always are running with minimum failure rates and maximum efficiency.

It doesn’t matter if you are a contractor, equipment owner or the service technician. Those who embrace predictive maintenance and learn how to optimise systems in an efficient way, will be more competitive and the future winners.

The new way to work will of course require upgraded skills and new business models to better reflect the value for the customer. But predictive maintenance saves money, time and decrease the stress of unreliable operation and failures, so investing time in education today, is a good investment for the future.

ClimaCheck turns data into information

Without collecting the data and analyse it with ClimaCheck you do not have the information to react in time when the performance drops.

ClimaCheck shows more than just temperatures and pressures. The unique ClimaCheck analysis shows true performance, the analyses will tell whether temperature X or pressure is Y is efficient. When you know the efficiency you can optimise/fine tune the HVACR system to work with your unique situation, and you will also see in real time if the optimisation gave the desired result.

What you need to do, to get the maximum of your equipment and decrease failures:

  • Monitor and analyse performance with ClimaCheck.
  • Make optimisation a part of your daily business.
  • Introduce predictive maintenance.
  • Move towards continuous commissioning – all involved have a responsibility but there must be a clear responsibility who leads the change.

Possibilities and “rewards” when you have actionable information from ClimaCheck:

  • Lower energy consumption (saves money and decrease CO2 emission)
  • A better performing system (fewer service occasions – longer life)
  • Short ROI with long term benefits.
  • Indirect leak detection (fewer service calls – longer life)
  • Possibility to work with Predictive maintenance
  • Less loss in valuable goods/production due to breakdowns
  • Service technicians know what problem they are going to fix so they can bring the right equipment directly and save time.
  • A way to communicate and show performance “over the border” between different companies and departments to make improvements and problems easier to explain and avoid finger pointing.
  • A way to ensure your investment.
  • Proper documentation over your HVACR-systems performance.
  • Elimination of breakdowns: 70% to 75%*
    Reduction in maintenance costs: 25% to 30%*
  • Return on investment: 10 times*
  • Reduction in downtime: 35% to 45%*

Don’t wait for your system to failure, contact us to learn how you can utilise ClimaCheck in your organisation!

If You Can’t Measure It, You Can’t Improve It.

Energy Optimisation Projects

Learn how Predictive Maintenance has helped other companies

  • Retail

    45,000 sq.ft. Grocery Store

    The estimated yearly energy consumption of the Refrigeration System is now approximately 654,000 kWh which represents an energy saving of approximately 123,000kWh per year (approximately 16% energy saving)

  • Retail

    Supermarket, Portland, Oregon

    Measurements supervised and analyzed by third party consultants over the following week, with similar climate conditions, proved that an energy saving of 25% had been achieved.

  • Hospitals

    Banner Desert Medical Center

    ETC Group conducted chiller testing using a portable ClimaCheck chiller analyzer at Desert Medical center on chillers 3, 5, and 6. Sections 2 and 3 include details for each measure

Talk to a ClimaCheck specialist

Our proven solution increase energy efficiency by 10-30% and reduce maintenance costs in any air conditioning, refrigeration or heat pump system!

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