onboard/in-field automated fault detection and diagnostics
DESCRIPTION
Onboard/In-Field Automated Fault Detection and Diagnostics. a Subcommittee of the Advanced Technology Committee of the Western HVAC Performance Alliance Subcommittee Meeting 9:30am – 12:30pm (PT) December 11, 2012 Call-in: 712/432-0075 742911# - PowerPoint PPT PresentationTRANSCRIPT
Onboard/In-Field Automated Fault Detection and Diagnosticsa Subcommittee of the Advanced Technology Committeeof the Western HVAC Performance Alliance
Subcommittee Meeting9:30am – 12:30pm (PT) December 11, 2012
Call-in: 712/432-0075 742911#Weblink: http://uc-d.na4.acrobat.com/wcec/
Agenda
• 9:30 Recap of 2012, Results of Roadmap Prioritization Survey
• 10:00 Presentation of Climacheck Case Study• 10:30 Presentation of Ezenics and Enterprise
Plug n Play Diagnostics and Optimization for Smart Buildings
• 11:30 HVAC Maintenance Behavior: the Customer and the Technician
• 12:30 Adjourn
2012 AFDD Subcommittee Accomplishments
• Roadmap Reviewed and Survey Conducted• Title 24 Requirement Passed• SCE continued Testing• SPC 207 Launched• Developed Timeline of AFDD Advancements• Presentations
– Daihung Yu: Virtual Sensors– Jon Douglas: Residential and Light Commercial Systems– Sean McCaffrey: Case Study– Brian Thompson: Ezenics– Kristin Heinemeier and Claudia Barriga: Maintenance Behavior
Results of Roadmap Prioritization: Onboard
Lack of Availability
Research into Residential FDD 1Research into FDD on Thermostat 3Research into Non-Microprocessor Units 3Research FDD for Different System Types 6Other (please specify) 3
The link between the onboard FDD results and systems or people to act upon it not just getting more overwhelmed.Research into successful applications and case studiesreliable economizer FDD
Results of Roadmap Prioritization: Onboard
Lack of Standards
Collaboration with CEE 0Energy Star "Most Efficient" Criteria 12013 T24 Standard 2ASHRAE Standard method of Test for RTU FDD 3Research Laboratory Methods of Test 3Inventory Reach Codes 0Propose Reach Code FDD Requirements 3Propose ASHRAE Std. 90.1 FDD Requirements 2Propose ASHRAE Std. 189.1 FDD Requirements 12016 T24 Standard 1Other (please specify) 0
Results of Roadmap Prioritization: Onboard
Lack of Customer Pull
Research into Maintenance Behavior 1High Performance RTU Challenge 1Research into Fault Incidence 3
Cost Effectiveness Assessment and Dissemination 3
Program Pilot Test 0Case Studies 2Research into Market Acceptability 1Design IOU FDD Program 2Launch IOU FDD Program 2Other (please specify) 1
Integrate IOU FDD program into existing CQM prgms
Results of Roadmap Prioritization: InField
Lack of Validated Protocols
Results from Diagnostic Protocol Evaluator Project 7
Collect and Disseminate Field Data 2
Benchmark and Assess Existing Protocols 6
Create Gap Analysis of Existing Protocols 1
Other (please specify) 2
Options to quickly deal with and meet security & IT needs
Answer 1 seems to be part of Answer 3
Evaluating Diagnostic Protocols• PIER-Purdue Protocol Evaluator: accuracy test for FDD
protocols
– refrigerant charge
– evaporator & condenser airflow
– non-condensables
– liquid line restrictions
– compressor valve leakage
Application software/users manual in final development
• CA T24 2008/2013 Installer/HERS RCA spec “…performs poorly. Flagging faults in up to 46% of the unfaulted cases, misdiagnosing over 25% of cases with faults, and not detecting faults in 32-55% of the cases with faults present.”
FDD Evaluator Review
• Draft Diagnostic Protocol Evaluator report: January 2013
www.newbuildings.org
www.performancealliance.org
http://wcec.ucdavis.edu/
• Tentative March 1, 2013 in-person meeting @ WCEC UC/Davis– Review evaluator – Review RCA issues
Results of Roadmap Prioritization: InField
Lack of Customer Pull
Develop Program for Commercial Buildings 12
Develop Program for Residential Buildings 1
Conduct Human Behavior Projects 3
Other (please specify) 0
Results of Roadmap Prioritization: InField
Lack of Integration with Existing Systems
Answer Options Response Count
Work with Manufacturers to Enhance Maintainability 2
Institute Voluntary Industry Agreement to Deliver Changes 2
In-Field FDD and Maintenance Study 7Work with OEMS to Develop Products 3Other (please specify) 2
Promote "FDD READY" tag for everything from work order software, to control hardware, to energy rate supply solutions
Work with OEMs to reach consenus around use of portable computerized FDD
OnBoard Priorities
• Research FDD for Different System Types• Laboratory Methods of Test• Research into FDD on Thermostat• Research into Non-Microprocessor Units• Propose Reach Code FDD Requirements• Research into Fault Incidence• Cost Effectiveness Assessment and Dissemination
InField Priorities
• Results from Diagnostic Protocol Evaluator Project
• Benchmark and Assess Existing Protocols• Develop Program for Commercial Buildings• In-Field FDD and Maintenance Study• Conduct Human Behavior Projects
• Work with OEMS to Develop Products
FDD Case Study Presentation
• ClimaCheck
» Sean McCaffrey
• Ezenics• Enterprise Plug n Play Diagnostics and
Optimization for Smart Buildings
» Brian Thompson
Manufacturer Presentation
Research Presentation
• Understanding Maintenance Behavior
» Customer: Claudia Barriga» Technician: Kristin Heinemeier
HVAC Behavioral Research Initiative
• “Understanding Maintenance Behavior in Residential and Light Commercial End Users.” (SCE HTSDA)
• “Lab and Field Usability of In-Home Energy Displays” (SCE HTSDA)
• “Behavior and AFDD” (SCE HTSDA – Q4 ‘12)
• “Understanding Contractor and Technician Behavior” (SCE EM&V)
• “Roadmap for Behavior and Human Factors Research in HVAC” (CEC/PIER IA)
• “HVAC Technician Instrument Laboratory” (CEC/PIER CIEE)
HVAC BEHAVIORAL RESEARCH INITIATIVE 2011-2012 PROJECTS
Understanding Maintenance Behavior in Residential and Light Commercial End Users
Claudia Barriga, Kristin Heinemeier, Laura Flynn, Dina Biscotti
Western Cooling Efficiency Center Energy Efficiency Center
Southern California Edison
Methods Survey of Residential End Users
• Sample– 270 Southern California Residents – Random Sample from SCE territory
• Online Survey Residents – Knowledge about AC and maintenance– Attitudes towards AC and maintenance– Attitudes towards the environment– Preferences for FDD alert systems
Regularly maintains Air Conditioner 143 (53%)
Has had (ever) the AC professionally serviced 193 (71.5%)
Has had professional service within the last year 97(35.9%)
Has been offered an HVAC maintenance agreement 140 (51.9%)
Currently has an HVAC maintenance agreement 33 (12.2%)
Characteristics of Sample Regarding AC Maintenance
HOW WOULD YOU KNOW THAT YOUR AC NEEDS REPAIRS OR MAINTENANCE?RESPONSE CATEGORIES
RESPONSES (N = 270)
Not Cooling 192 (71.1%)
Not turning on (Fan, Blower, Motor) 109 (40.4%)
Makes atypical noises 96 (35.6%)
Unusual Smells 20 (7.4%)
High Energy Bills/System running constantly 23 (8.5%)
Alert (Light in Thermostat) 18 (6.7%)
Scheduled Professional Maintenance 11 (4.1%)
FDD ALERT TYPE (N = 270)Light alerting fault + specific fault information 153 (56.7%)
Flashing light indicating fault 117 (43.3%)
Beeping sound indicating fault 100 (37.0%)
Green light indicating proper operation 100 (37.0%)Numerical rating of AC performance (e.g. at 75%) 86 (31.9%)
Light alerting fault + risk information 81 (30.0%)Light alerting fault + optimization opportunities info 72 (26.7%)Light alerting fault + automatic message to HVAC technical service 43 (15.9%)
Preferred FDD Alert Type
Simulated In Home Energy Displays with Specific vs. General Alerts and Recommendations
Responses to Tips and Diagnostic Alerts and Recommendations in a Simulated In Home Energy Display
1
2
3
4
5
6
7
Semantic Differential Rating for Refrigerator, Car and Air Con-ditioners
Refrigerator Car Air Conditioner
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Good
Pleasan
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Benefi
cial
Valuab
leSa
fe
Importa
nt
Necessa
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Expen
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Health
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Beautiful
Envir
onmental
ly Fri
endly
High Te
ch
Save
s Money
Hig Main
tenan
ce
Exciti
ng
Complicated
11.5
22.5
33.5
44.5
55.5
66.5
7
Air Conditioners are...
I think this should be vertical and tagged at both ends, with color coding for bad stuff (red bad, green good)
Seem
s Tru
stworth
y
Knows Custo
mer Eq
uipment
Lowers
Bills
Listen
s to Custo
mer Concer
ns
Explai
ns Work
Provid
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rvice
Carries
Certificati
on
Seem
s Tech
nically
Authoritati
ve
Offers En
ergy E
fficient S
olutions
Provid
es Prio
rity S
ervice
Arrange
s Reb
ates
Clean
Uses M
easu
remen
ts
Offers New
Tech
nologies
Endorse
d by SCE
Offers En
vironmen
tal So
lutions
Personal
Relationsh
ip
Uses Lo
ng Check
list
Explai
ns Clim
ate Chan
ge Im
pact1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
Perceived Importance of Maintenance Contractor Characteristics (N = 258)
Methods Focus Groups of Small Business Owners• Four Focus Groups in 2 SCE territory locations• 10-12 participants per group• Attitudes towards AC and maintenance• Attitudes towards Utilities Energy Efficiency
Programs• Attitudes towards the Environment
Key Findings
• KEY FINDING 1: SMALL BUSINESS OWNERS ARE NOT CONVINCED THAT REGULAR HVAC MAINTENANCE SAVES MONEY.
• Recommendations: Show customers approximate (or best yet, actual) energy savings on bill that result from active participation in maintenance programs. Develop tools or techniques to field test AC unit efficiency before and after measures are implemented.
• KEY FINDING 2: SMALL BUSINESS OWNERS DO NOT UNDERSTAND HOW TO PROPERLY MAINTAIN HVAC EQUIPMENT.
• Recommendation: Create a guide for small businesses owners to use as a screening tool to find good contractors and as a double check for existing contractors.
• KEY FINDING 3: SMALL BUSINESS OWNERS DO NOT LIKE COMPLICATED REBATE PROGRAMS.
• Recommendation: Streamline rebate process or encourage contractors to take on the role of rebate collectors to minimize inconvenience to small business owners. Another idea is to provide the rebate as a credit on the utility bill.
• Covertly Observed 13 Maintenance Technicians
• Requested “service,” “maintenance,” and “energy tune-up”.
• Two “faults”:• Airflow <250cfm/ton• Registers closed
• Post-Observation Interview
Maintenance Technician Observation Study
Tech # Invite Type
Years of Exp.
Service Duration
Service Price Certified Prog.
Part.Nat'l Chain Owner
21 1 7 1:02 $ 75
31 1 20 0:50 $ 69 ✔ ✔
43 1 17 2:02 $ 75 NATE,NCI ✔
54 1 7 0:40 $ 79 NATE
80 1 16 1:00 $ 89 ✔
96 2 22 0:23 $ 60 ✔
33 2 14 1:30 $ 79 ✔
72 2 26 1:35 $ 85 NATE
87 3 12 0:57 $ 75
99 3 14 1:16 $ 179
22 3 30 0:42 $ 80 ✔
65 4 1 1:33 $ 180 ✔
79 4 13 2:00 $ 149 NATE,NCI ✔
TechnicianCharacteristics
Task Description
TechniciansNumber of
Techs. Attempt
Number of Techs. Correct43 79 72 65 99 87 80 21 96 31 33 22 54
Thermostat ● ● ● ● ○ ● 6 5
Registers ● ○ ● ● ● 5 4
Air Filter ○ ○ ● ○ ● ○ ○ ○ ○ 9 2
Temp Split ● ● ○ ○ ○ ○ 6 2
Furnace ● ○ ● ○ ○ 5 2
Electrical ● ○ ○ ○ ○ ○ ○ ○ ○ 9 1
Line and Duct Insulation
○ ○ ● ○ ○ ○ ○ ○ ○ 9 1
Ext. Static ● ○ 2 1
Airflow ● ○ 2 1
Ducts ○ ○ ○ ○ ○ ○ ○ ○ ○ 9 0
Condenser Coil ○ ○ ○ ○ ○ ○ ○ 7 0
Motor Amps ○ ○ ○ ○ ○ ○ ○ 7 0
Biologicals ○ ○ ○ ○ ○ ○ 6 0
Refrig. Chg. ○ ○ ○ ○ ○ 5 0
Evaporator Coil 0 0
Total Attempts 10 10 8 8 10 8 7 6 6 2 6 6 0
Total Correct 6 3 2 2 1 1 1 1 1 1 0 0 0
Tasks Completed Correctly by Service Duration and Technician Characteristics
Technician Cost Recommendation21 $650 New supply ducts31 New supply ducts and UV light43 $150 New capacitor for condenser and fan54 $129 Add up to 3 pounds of refrigerant80 N/A96 N/A
33 $1,236Hard-start and run capacitors, UV bulb, Schrader core replacement
72 $1,194 UV lamp, blower fan, contactor, air filter for two systems87 $445 New condenser fan motor99 N/A22 Add 1 pound of refrigerant65 $156 Replace contactor 79 Improve airflow and add refrigerant charge
Average $566
Recommendations by Technicians
• Technical performance was below the standards of ACCA 4 and “Quality Maintenance” goals.
• Yet, technicians were more knowledgeable than their technical performance scores would suggest
• This study does not provide evidence that lack of training or certification is creating the problem.
Technician Observation Conclusions
• Technicians work hard to achieve their perceived company and customer goals:
• Company Goals• Their company’s goal is to sell and accomplish as many
service calls as possible in one day.
• Customer Goals• Customers are interested in only two things: in the
equipment working when needed, and in spending as little time and money as possible to achieve that goal.
Technician Observation Conclusions
• These goals are closely tied both to the industry’s traditional practices around “maintenance services” and to common connotations of the word “maintenance”.
• Industry transformation should include a way to make technicians see the non-traditional goals of quality technical performance as consistent with the goals of their employers and their customers.
Technician Observation Conclusions
Technician Observation Conclusions
• A new category of service other than “maintenance” or “tune-up”, is required…perhaps “optimization”.
• Solid data on benefits, both for the industry at large and for individual buildings, is key.
•Discussion…
Thank you!
• Mark Cherniack [email protected]
• Kristin Heinemeier [email protected]
• Jerine Ahmed [email protected]
• Anthony Hernandez [email protected]
• KC Spivey [email protected]
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