Post on 06-Feb-2018
HVAC Quality MaintenanceA New Program for Increased
Energy & Cost Savings
History – Process - Program
May, 2011
Hosted by the California Investor Owned Utilities (IOUs)
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At the live presentations this
slide is used to explain
evacuation procedures at the
facility where the meeting is
taking place.
Is HVAC Maintenance Important?
“Inconsistencies exist within the building industry when it comes to inspection and maintenance of HVAC systems, with some facilities following rigorous policies while a growing number are moving to a run-to-failure approach.”
-Robert Baker, Chair of the ASHRAE committee that wrote Standard 180
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Customers are faced with…
Today’s Business and Economic Realities
HVAC Contractors are faced with…
• Operational Cost Reductions• Predicting Cash Flow• Inefficient Systems
• Ongoing Cost Pressures• Unpredictable Cash Flow• Environmental Quality Issues
“Service is like a bowl of Jello, you can’t put your hands on it. When someone asks what you received you can’t really tell them.”
- Randy Davis, U.S. Postal Service-Engineer/Architect/Administrator
Delivering Value Quality MaintenanceTo the Contractor: Predictability & Uptime
• Creates opportunity to obtain ongoing recurring revenue through service agreements
• Differentiates contractors from their competition
To the Customer: Comfort and Energy Savings
• Reduced total cost of ownership
• Thermal comfort
• Indoor air quality
• Energy savings
• Smaller carbon footprint
Today’s workshop will not just explain the programs that will help maximize contractor and customer returns, but will report
on the groundbreaking process that has led us to this point. There has been historic collaboration among the utilities, the
HVAC, and facilities industries. Here’s evidence...6
What People Are SayingI am delighted with a program based
upon ASHRAE/ACCA Standard 180,
which is the professional maintenance
standard as defined by our industry’s
governing technical body and
recognized by the world’s leading
standards organization, ANSI.
- Michael Gallagher, PE,
Vice President, Western Allied
Corporation
Aligning California efficiency programs
with nationally-recognized standards
maximizes efficiencies, effectiveness,
resources and just plain makes sense. -
Talbot Gee, Executive VP & COO,
Heating, Airconditioning &
Refrigeration Distributors International
Thank you for developing a program we
can support as active participants insuring
its success. We look forward to its
implementation and the energy efficiency
it will bring to the State. - Kevin
O’Dorisio, Executive Director,
Sheet Metal and Air Conditioning
Contractors’ National Association
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This program will promote the energy
behavior that needs to be demonstrated
by building owners if the Long Term
Energy Efficiency Strategic Plan is to be
achieved. We whole-heartedly support
this program. - Richard Sawhill,
Executive VP, ARCA/MCA Southern
California
What People Are SayingWe have recently reviewed SCE’s
Nonresidential QM Maintenance program
design/implementation plan and are
encouraged by what we have seen. SCE has
not only relied upon Standard 180 as a
cornerstone for the program's design, but has
actively reached out to and taken input from
contractors, associations, labor unions, and
even multi-site end-users throughout the
program’s development. - Glenn Hourahan,
Senior VP, Air Conditioning Contractors of
America
With over 4,000 preventative
maintenance agreements as the
“core” of our business the bottom
line is that it saves customer’s
money, prolongs equipment life and
makes their home more
comfortable, so we support any
utility program that incorporates
PMA’s as a part of their energy
conservation programs. - Frank
Harrison, President, General Air
Conditioning & Heating
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I am excited to hear that utilities may support a quality maintenance program based
on ACCA 4 industry standards. As a licensed C‐20 contractor in the state of
California I have invested a lot of time and money in an effort to provide the best
quality service to our customers, so this type of program only helps legitimize my
goal. The fact is that heating and cooling equipment is part of a system and unless
we look at the system as whole with scheduled maintenance programs there will
never be any energy savings or reduced operating cost for our customers. - Tyler
Miner, President, Redlands Plumbing, Heating, Air Conditioning & Home
Energy Solutions
What People Are SayingIn behalf of ASHRAE, I would like to recognize
the industry outreach and collaborative
approach undertaken by Southern California
Edison, Pacific Gas & Electric, and PECI in
development of the HVAC Quality
Maintenance program. Both the program
design and the enabling IT tools support the
intent of ANSI/ASHRAE/ACCA Standard 180
(Inspection and Maintenance of Commercial
Building HVAC Systems).
– Robert Baker, ASHRAE Fellow, Chairman
Standard 180 Development Committee,
ASHRAE
There are no shortcuts to achieving maximum energy efficiency from new or
existing HVAC systems. There are, however, accepted and vetted standards as
developed by a broad base of industry stakeholders such as
ASHRAE/ACCA/ANSI Standard 180 and ACCA/ANSI Standard 4 that maximize
system performance. RSES supports any and all efforts to align California
efficiency programs to such proven industry standards.
- Mark Lowry, Executive VP, RSES
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It is excellent that SCE is
proceeding with a maintenance
program based upon
ANSI/ASHRAE Standard 180. I
and our 2,000 Southern California
members working in the service
and repair field support it..
- Don Tanaka,Director
of HVACR, Service and Repair,
Southern California Pipe Trades,
District Council #16
Agenda
9:00am – 9:05am Safety
9:05am – 9:20am Welcome & Introductions, Agenda Review
9:20am – 9:30am CA Energy Efficiency & Utilities HVAC Program
9:30am –9:40am HVAC Quality Maintenance (QM) Programs Background
9:40am – 10:20am Putting The Industry Standards to Work – Part I
10:20am – 10:40am Break
10:40am – 11:20am Putting The Industry Standards to Work – Part II
11:20am – 12:45pm Q&A, Feedback & Input
12:45pm – 1:00pm Summary and Closing
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Why Energy Efficiency?
“Energy efficiency is California’s highest-priority resource for meeting its energy needs in a clean, reliable, and low-cost manner.”
California Public Utilities Commission’s 2006 publication, Energy Efficiency: California’s Highest-Priority Resource
State of California’s priority orderof energy sources:
1. Customer Energy Efficiency
2. Demand Response/Time-Varying Pricing
3. Renewables
4. Distributed Generation
5. Clean gas-fired plants12
The Big Bold Vision For HVAC
Revitalized HVAC industry
Increased energy efficiency, reduced peak demand
Customers will demand quality installation and maintenance services
Improved comfort, health, safety, and lower energy bills
Installation and maintenance business models change from “commodity” to “value-added”
Sustained profitability for the HVAC industry
“Residential and small commercial HVAC will be transformed to ensure that technology, equipment, installation, and maintenance are of the highest quality to promote energy efficiency and peak load reduction in California’s climate.”
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Quality InstallationQuality Maintenance
Better customer education and decision making tools
ANSI/ASHRAE/ACCA Standards
Customer – Contractor relationship is central to all HVAC decisions
ASHRAE/ACCA/SMACNA Standards
Equipment and systems designed and working
correctly from the start
Upstream Equipment
CA Utilities HVAC Program: An Integrated, Comprehensive Solution
Promoting High Efficiency Equipment
Leveraging marketdelivery channels
Western HVAC Performance Alliance (WHPA)stakeholder collaboration
execution of CA HVAC Action Plan
www.performancealliance.org
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• Certifying Body
• Codes & Standards Official
• Contractor – Nonres
• Contractor – Res
• Contractor Association
• Controls Mfg or Distributor
• Distributor
• Distributor Association
• Educator/Trainer
• Government (CPUC, CEC)
• HVAC Manufacturer
• HVAC Manufacturer Association
• Investor Owned Utilities (IOUs)
• Organized Labor
• Other Stakeholder
• Owner/Facility/Prop Mgr
• Owner/Facility/Prop Mgr Association
• Publicly Owned Utility
• 3rd Party Quality Assurance
Western HVAC Performance Alliance:Broad & Growing Stakeholder Collaboration
www.performancealliance.org
Formed during 2009 with 24 charter member organizations40% growth in 2011 bringing membership to 70members in all but one of 19 “membership categories”
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Looking Back on Previous California Utility HVAC Programs
Delivered energy savings while focusing on a few tune-up measures. One-size-fits-all approach.
REFRIGERANT
CHARGE ADJUSTMENT
•Check refrigerant level
•Add or remove charge
CONDENSER
COIL CLEANING
•Clean finned surfaces
Residential
Commercial
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REFRIGERANT AND
REFRIGERATION COMPRESSOR
•Check crankcase heater operations,
refrigerant and oil leaks, refrigerant
charge and oil level and condition
•Perform acid test
•Observe bearing and operating
surface temps
•Measure vibration
CONDENSERCOIL
•Clean finned
surfaces
REFRIGERATION
CONTROL PANEL
•Sequence test all
controls
•Calibrate and clean
controllers and safety
controls
•Check setpoint of controls
and limits
CONDENSER FAN/MOTOR
•Perform vibration test
•Lubricate bearings
•Examine motor mount resiliency
•Check motor insulation resistance
COOLING COIL
• Inspect and clean as required
• Check condition of finned
surfaces and straighten if bent
• Check for corrosion and leaks
FILTER
SECTION
• Replace media
as required
FRESH AIR, RETURN, AND
EXHAUST AIR
DAMPERS (Commercial only)
•Check for unrestricted and
proper operation and close-off
•Lubricate bearings as required
RETURN AIR FAN/MOTOR &
SUPPLY FAN/MOTOR•Perform vibration test
•Lubricate more bearings
•Check motor insulation resistance
•Examine motor mount resiliency.
•Lubricate bearings and check for
end play, excessive bearing temp
and wear
•Check blower and clean dirt
accumulation
•Check condition of drive couplings
and belts
•Check for alignment, balance,
security to shaft
•Check rotation
BURNER
SECTION
•Perform combustion and draft
tests
•Inspect and clean nozzles
•Inspect, clean and lube burner
fan (gun type burners)
•Test safety controls
ELECTRICAL
DISCONNECT
•Inspect
contacts
•loose
connections
•Check for
proper
operation
Looking ForwardANSI Standards-Based. Comprehensive and
Sequenced. Opportunities maximized.
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Collaborating to Transform the HVAC Industry
WHPA Stakeholder Partnership
Industry LeadershipStandard 180, Standard 4
Enabling Environment for QM
Government
Utility Regulation
Utilities
HVAC programs
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Residential QM & Commercial QM Plan
Key Activities
• Quantify energy savings benefits of “quality” and “premium” maintenance services in residential and commercial
• Evaluate feasibility of measures and upgrades that improve system performance
• Demonstrate the value to consumers of A) properly maintained systems (per industry standards) and of B) new, but proven “premium” maintenance practice
• Demonstrate the value to contractors of a sustainable business model based on quality and premium maintenance
In partnership with HVAC industry, deploy two comprehensive operations & maintenance programs that improve system performance, capture savings, and provide a high ROI to the end-user customers
Quality maintenance becomes the industry and market norm
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New HVAC QM Programs:Putting The Industry
Standards to Work – Part I
Mel Johnson, SCEBob Baker, FASHRAE, OPMP
Wes Davis, ACCA
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Building the Foundation for HVAC Efficiency in Existing Buildings
Industry standards are the basis for HVAC market transformation
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Building the Foundation for HVAC Efficiency in Existing Buildings
The standards are in early stages of adoption, but are not new!
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ASHRAE/ACCA/ANSI S-180
• Title of Standard…
– Standard Practice for Inspection and Maintenance of Commercial Building HVAC Systems
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What is ASHRAE?
• International Academic/Professional Society
• Curator of HVAC science & practices
• Founded 1894
• ~55,000 members worldwide
• ~220 Published Standards and Guidelines
• Extensive Technical Library
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Std 180 - Why Developed?
• Research reveals majority of what is called “maintenance” is reactive and more akin to “Run to Failure.”
• Not only is this the most expensive way to manage a building, it leads to a bunch of added risks –
– Energy waste
– Occupant discomfort
– Health effects
– …26
Standard 180
Purpose
The purpose of this standard is to establish minimum HVAC inspection and maintenance requirements that preserve a system’s ability to achieve acceptable thermal comfort, energy efficiency, and indoor air quality in commercial buildings.
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Before the Standard -
• A lot of research
• Presentations to committee
• Technical forums and seminars
• Interface with other development
– Federal Energy Management Program
– EPA
– Hong Kong BEAM
– NASA
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Maintenance Approaches (US DOE)Excess costs over projected normal life cycle cost
• Reactive - $18/hp/year more than projected
• Preventative - $13/hp/year more than projected
• Predictive - $9/hp/year more than projected
• RCM* (Predictive-Preventative) - $6/hp/year more than projected
*Reliability Centered Maintenance
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Objective for 180
• The objective established for 180 was to identify conditions that would anticipate and act to forestall failure (predictive/preventative)
• Realize maintenance cost ~$6-9/hp/year* more than projected life cycle cost
*Calculated as excess costs over projected normal life cycle cost.
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Content of the Standard
• Definitions
• Dialogue with the owner
– Philosophy of the operation
– Understanding (inventory)
• Performance – Appendix A
• Failure Points – Appendix B
– Implementation (inside/outside)
– Timing (now or at failure)
• Task listings
• Adjustment of inspection frequencies
• Documentation
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SPC 180 Committee
• 24 Voting
– Manufacturers
– Users
– Suppliers
– General Interest
• 23 Non-voting
• ~50 Consultants
• 5 Subcommittees
Subcommittees:Air Cleaning
Air MovementControls; Heat
GenerationHeat Distribution
Refrigeration
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Acceptance of the Standard
• ANSI• LEED EB (Existing Buildings)• ICC – 2009 International Mechanical Code• IAMPO – 2009 Uniform Mechanical Code• Various International
– China– Hong Kong– Singapore– Thailand– Brazil
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ACCA 4 QM 2007
• Purpose:
Establish minimum inspection requirements in the maintenance of HVAC equipment found in one-family and two-family dwellings of three stories or less three stories or less
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ACCA 4 QM 2007
• Scope:– (Performed) by appropriately licensed contractors
Checklist tasks of inspection items and recommended corrective
– Presumes that the HVAC system was designed, installed, and tested
– This standard shall not be used to circumvent safety, health, environmental, or the equipment manufacturer’s requirements.
– This standard excludes steam distribution heating systems.
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ACCA 4 QM 2007
• Development:
– HVAC Contractors
– OEM
– Utilities
– Other Associations
– Specialists
• Supporting Contributors
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ACCA 4 QM 2007
• Maintenance Contractor’s Responsibilities:
– Inspect
– Inform
• Homeowner’s Responsibilities:
– Maintain the equipment
– Use professionals
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ACCA 4 QM 2007
Overview
• Homeowner interview
• Inventory
• Equipment checklists
• Code requirements
• Performance objectives
• Maintenance
– Inspection tasks
– Recommended corrective actions
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ACCA 4 QM 2007Checklist 7.1 Air Distribution System
Inspection Task *Recommended Corrective Actions
Shall inspect for particulateaccumulation on filters.
Clean or replace filters if accumulation results in PD higher thandesign or if airflow is outside of established operating limits.
Shall inspect air filter housingintegrity and air seal.
Correct as needed.
Shall inspect grilles, registers anddiffusers for dirt accumulation.
Clean as needed.
Shall inspect all accessibleductwork for areas of moistureaccumulation or biologicalgrowth.
Install access doors as needed. Clean or replace as needed.
Shall inspect integrity of allaccessible ductwork insulation.
Observe for proper alterations, rips, tears, or improper ductadhesives. Repair, seal, replace as necessary. Install access doorsas needed.
Shall inspect the integrity of allaccessible ductwork including:duct strapping, hangers, sections,joints, and seams.
Note improper alterations, straps, air leaks, and improper duct adhesives. Repair, seal, replace as necessary.
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ACCA 4 QM 2007
• Documentation:
– Inventory
– Checklists
– Code violations
– Performance objectives
– External Conditions (OBTW…)
– Inaccessible items
– Recommended corrective actions
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New HVAC QM Programs:Putting The Industry
Standards to Work – Part II
Mel Johnson, SCEMarshall Hunt, PG&E
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Collaboration to Operationalize Standards Broad cross section of contributors and participants
1Program feasibility based on ANSI Standards was the recommendation of WHPA subcommittee, which was further refined with individual contractors and customers through an in depth process to “operationalize” the standards. 2Program design team consisted of a series of focus groups, workshops and working sessions conducted over 10 months and included 4 contractors (including service leads, technicians and operations staff) 13 customers (including facility and energymanagers), and 3 energy efficiency consultants.3A series of information sessions were held with contractor organizations and included over 40 association executives, union officials, contractor members and training center personnel.
Feasibility Team1
• WHPA• Nonresidential & Residential Committee
• Nonres and Res Tasking Subcommittees
• IOUs
• Consultants
• Customers
• Contractors
Program Design Team2
• IOUs
• ASHRAE
• ACCA
• Consultants
• Additional Customers
• Additional Contractors• Upper Managers
• Service Managers
• Sales Managers
• Technicians
Program Review3
• IHACI
• ARCA/MCA
• UA
• SMACNA
• SMWIA
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Focusing on Three Vital, Customer-Centric Components of Success
Three interdependent customer-centric components for success:
– Thermal Comfort» The customer is not too
hot or too cold
– Indoor Air Quality» Smells, allergies and air
particles are minimized
– Energy Efficiency» Lower monthly energy bills
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Introducing the New Commercial QM Program
• Standard 180-based 3-year QM Service Agreements
• Treatments are presented in a composite package
• Initially targets commercial rooftop units (RTUs)
• Includes a comprehensive (yet fairly standard) suite of program elements to address market barriers (marketing, IT tools, training, incentives, etc.).46
Introducing the New Residential QM Program
• Standard 4-based QM Service Agreements
• Treatments are presented in a composite package
• Initially targets single-family detached and duplex homes
• Includes a comprehensive suite of program elements to address market barriers(marketing, IT tools, training, incentives, etc.).
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Long term relationships
Contractor-Customer
Data & Information
Building, RTU, QC
Innovation
‘Premium’ measures
Retrofits
Industry
transformation
Foundation for A Quality Focused HVAC Sector
Standard 180-based andStandard 4-based Service Agreements set the stage for future HVAC upgrades
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Step 1: Service Agreement
Step 2: Baseline
Step 3: Ongoing Maintenance
Define QM Policies/ Customer Interests
Customer concernsPerformance objectives Condition indicators
Record Inventory of Customer’s Equipment
Assess Equipment
Perform Baseline Analysis
Identify Required Repairs and Communicate with Customer
Perform Maintenance
Document HVAC System Condition Indicators
Provide Customer Before/After Benefits Reports
Improves thermal comfort, indoor air quality and energy efficiency
Service agreement. Fix deferred maintenance. Maintain equipment.
Commercial QM & Residential QM
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Customer• HVAC operating costs are largely
“invisible”
• Economic pressure has lead to a
short-term focus (“run to fail”)
• Lack trust of contractor
• Difficult to compare contractors
offers and quality of work
• Benefits of QM not yet
quantified
Overcoming Market Barriers
Demand-side
Industry• Lack of knowledge and tools to
comply with Standards 180, 4 • Standards 180, 4 viewed as only
task “check-lists” • Some tasks require additional
detail to “operationalize” • Lack of industry consensus on
protocols for RCA and instrumentation
• Unclear career path for technicians• Benefits of QM not yet quantified
Supply-side
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Commercial QM – Customer View
3-year QM Service Agreement
• Incentive is based on incremental cost of Standard 180-based QM over typical service
• Service Agreement is transferable to other Program-qualified contractors
Benefits:
• Engages customers in long-term relationship with contractors
• Provides sufficient time for QM benefits to be demonstrated
• Installments provide leverage to discourage deferred maintenance
• Transferability protects the Customer and Program
Customer Incentives
3-year QM Service Agreement
•20% upon signing
•25% at the end of year one
•35% at the end of year two
•20% at the end of year three
All units must be maintained to receive the full incentive amount
Customer Incentives
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Commercial QM – Contractor View
One-time service to ‘normalize’equipment in a state of deferred maintenance
• Incentive is based on pre-qualified baseline condition
Benefits:
•Protects the Contractor: ensures subsequent maintenance conducted is effective
•Creates “fresh start” and an opportunity to discuss the hidden costs of deferred maintenance
Contractor Incentives
Task & Incentives1-5
Tons6-25 Tons
+25 Tons
Coil Cleaning $110 $130 $150
Adjust Airflow $25 $35 $45
Refrigerant System Test $25 $35 $45
Refrigerant System Service $120 $200 $260
Economizer Functional Test $25 $35 $45Integrate economizer wiring $165 $175 $185
Replace damper motor $460 $510 $575
Replace controller/sensor $320 $370 $415Renovate linkage & other components $180 $245 $310
Decommission Economizer $100 $130 $170
Replace T-Stat $200 $200 $200
Adjust T-Stat Schedule $25 $25 $25
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Residential QM - Customer and Contractor Views
1-year QM Service Agreement
• Incentive is based on incremental cost of Standard 4-based QM over typical service
• Service Agreement is transferable to other Program-qualified contractors
Benefits:
• Engages customers beyond one-time relationship with contractors
• Provides opportunity for more than one call to address both heating and cooling
• Transferability protects the Customer and Program
Customer Incentive
One-time service to ‘normalize’equipment in a state of deferred maintenance
• 1-year Service Agreement recommended to be in place.
• Incentive is based on baseline condition
Benefits:
•Protects the Contractor: ensures subsequent maintenance conducted is effective
•Creates “fresh start” and an opportunity to discuss the hidden costs of deferred maintenance
Contractor Incentive
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Residential QM Service and Retrofit Treatments
• Air Flow at OEM Minimum cfm/ton
• Duct Repair
• Condenser & Evaporator Coil Cleaning
• Refrigerant System Test & Service
• Retrofit of High Efficiency Blower and Condenser Fan Motors
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Meeting Contractor Enrollment Criteria
• Company financials
• Years in business
• HVAC technician requirements (trade school, 2-years experience, and/or industry certification)
• Local customer references
• Employ full-time professional with years of specific HVAC experience
• Job-scheduling software for visits
• Emergency service capabilities Knowledgeable, experienced contractors and techs who will
deliver for the long haul55
Planning for Success via Contractor Training and Customer Communications
• Sales – Background and Customer Value Proposition
• Program Operations Workflow
• Technical Field Operations
• Program Guiding Document
• Customer Leave-Behinds
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QM Programs Built on Continuous Improvement
• Phase 1: Setting the Foundation
• QM based on Industry Standards
• Phase 2: Maximizing Energy Savings
• Retrofit opportunities (e.g. efficient motors, variable frequency drives, demand control ventilation etc.)
• Phase 3: Efficiency Upgrades
• Improve system performance through new technologies, such next generation economizers, fault detection and diagnostics, etc.
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