Maintaining an efficient industrial HVAC system in your production facility goes beyond ensuring year-round comfort for your employees. It’s also quietly one of the most important elements of your processes. By maintaining consistent conditions inside your facility, your HVAC system helps ensure product quality. As important as quality assurance and employee comfort are, they are just a few of the many reasons why you should pay attention to your HVAC system’s maintenance.
As one of the most energy-intensive facets of your infrastructure, HVAC also has a tremendous impact on your consumption of resources and overall sustainability. These systems are crucial for providing essential ventilation and maintaining air quality within your facility.
Without the right protocols in place for industrial HVAC preventive maintenance, your operations could be in line for a host of issues. Increasing energy bills, poor indoor air quality, downtime and product defects are just a few of the problems that can develop without an industrial HVAC system that operates at peak performance. Fortunately, you can prevent these by establishing an industrial HVAC maintenance checklist, following it and implementing machine health monitoring for your systems. Read on to learn more about how to accomplish this.
Common industrial HVAC components and issues
Your facility’s industrial HVAC systems consist of multiple components and systems that need regular attention to keep in good working order. These include chillers, boilers or furnaces, filters, ductwork, air handlers, and control systems. Some of the most common problems that plague industrial HVAC equipment include:
- Clogged filters
- Worn-out belts
- Faulty sensors
- Mineral scaling in coils
- Obstructed ducts
If problems inside your HVAC system go unaddressed for too long, you may begin to notice early warning signs such as:
- Uneven temperatures
- Odd noises
- Higher humidity levels
- Unexplained spikes in energy consumption
- Repeated system cycling
Industrial HVAC maintenance checklist
With so many parts within an HVAC system that require attention on a regular basis, it’s always best to stay organized. Most manufacturing maintenance teams develop a checklist of tasks that should be performed on a schedule to prevent the most common industrial HVAC problems. Here’s a quick overview of those jobs according to how often they should be scheduled on your HVAC inspection checklist:
Daily/weekly tasks
- Inspect air filters and clean or replace them if they are visibly dirty.
- Check for any unusual or abnormal noises or vibrations inside your blowers or ductwork.
- Verify the correct settings for your thermostat or control panels.
- Monitor the basic temperature and humidity levels at strategic checkpoints around your facility.
Monthly/bi-monthly tasks
- Inspect belts, pulleys and fan bearings, re-lubricating and/or tightening as needed.
- Gently clean condenser and evaporator coils if you notice debris build-up on them.
- Check refrigerant lines for signs of leaks or damage to insulation.
- Confirm dampers and valves can move freely without sticking.
Quarterly/seasonal tasks
- Calibrate sensors, thermostats or control modules.
- Ensure drain pans and condensate lines remain clear, especially in humid months.
- Perform a thorough cleaning of coils and remove any scale buildup from chiller or cooling tower components.
- Integrate the latest data from air quality sensors and other monitoring technologies into predictive maintenance dashboards.
Annual/off-season tasks
- Perform a comprehensive system tune-up, including deep-cleaning coils and blowers, verifying wiring, and testing safety devices.
- Update or upgrade control software if needed.
- Conduct airflow tests in duct systems or perform smoke tests to check for leaks.
- Maintain a detailed service log for reference and regulatory compliance.
Industrial HVAC safety and regulations
In addition to providing the ideal conditions for your production processes, proper HVAC maintenance also is essential for maintaining compliance with various regulations and ensuring industrial safety best practices. For example, with proper ventilation you can prevent harmful fumes, dust and other contaminants from building up in the air. This is critical for meeting certain OSHA or local environmental standards for preventing pollution and safeguarding workers’ health.
Establishing a regular HVAC maintenance protocol also is necessary for ensuring your facility properly handles the refrigerants used within the system. Depending on the system, there may be EPA regulations pertaining to the use and storage of these chemicals. Without a strong maintenance protocol, there may be a risk of these being handled or stored improperly, which could lead to penalties in addition to unsafe working conditions.
Keeping a detailed log of all maintenance activities ensures your technicians always know what has been done and when it was done, but this also helps protect you in the case of an audit. You may be required to demonstrate your compliance with certain regulations or to attain specific certifications required within your industry. With comprehensive logs kept by your team, you can prevent complications that may have a negative impact on your operations.
Keep your HVAC system running smoothly
Understanding the importance of your facility’s HVAC system is critical for your long-term success. By following these industrial HVAC maintenance tips, you can keep your equipment in good working order, ensuring your operations consume less energy, reduce downtime, extend the lifespan of your assets and maintain consistent product quality.
