Our Projects

Large-Scale HVAC Audit – Hot Water Valve Actuator Failures

A multi-zone commercial building experienced widespread heating inconsistencies and excessive energy usage during winter months.

Problem

The BAS indicated normal operation, but field performance suggested otherwise. Occupants reported uneven heating, and boiler runtime was abnormally high.

Approach

A comprehensive audit of 100 hot water valve actuators was conducted:
– Verified command vs actual valve position
– Performed physical stroke testing
– Checked actuator responsiveness and linkage integrity

Findings

– 80% of actuators were failed or malfunctioning
– Many valves were stuck partially open or unresponsive
– Resulted in simultaneous heating and cooling across zones

Solution

– Documented all failed components
– Created a prioritized replacement plan
– Recommended improved maintenance and verification procedures
– Suggested control logic enhancements to detect failures earlier

Results

– Estimated 20–30% reduction in heating energy waste
– Improved zone temperature consistency
– Reduced boiler load and runtime
– Provided clear ROI justification for capital upgrades