Case Study 2

You can’t have efficiency without reliability

Summary

We modernised a legacy control system without full replacement, taking a maximum value approach instead.

The Problem

The existing BMS system was in a poor state, with low visibility into operating performance, frequent service calls, and equipment running outside of design parameters due to BMS code problems. This reduced efficiency and created additional wear and failure of mechanical components.

Additionally, the existing system was a proprietary Schneider Electric Lonworks system, with a closed ecosystem and limited support available. The owners had been given advice from others that a full upgrade was their only option due to the age and state of the system. The facility management team were burdened with constant faults, cost and tenant irritation, plus being told their only solution to this was a huge capital outlay.

Our Solution

We spent a longer than usual discovery process on-site to fully identify and understand all the problem areas and then formulate a mitigation strategy. The inconsistent BMS comms problems were resolved by the installation of a new Lon network – and we installed 2X additional networks (BACnet, Modbus) at the same time to open the facility up to multi vendor support going forward, while removing the need to replace all field controllers. The facility can now upgrade on a floor-by- floor basis, without being locked in to using Schneider or Lon works only devices.

We supplied and installed 2X new Controls Boards, complete with 4X Tridium Niagara Jace 8000 controllers, new JCI PCG series cooling tower controls, and a new BMS PC.

At the field level, we identified numerous problems with the controller/DDC logic, which (when combined with faulty sensor data and intermittent communication faults) resulted in a system that was mostly unmanageable. We rewrote the DDC logic and algorithms to get the fundamentals right – staging, delays, appropriate PID operation and intelligent airflow control to maximise the COP of the existing compressors. We also implemented smart alarms, optimised start stop, Zone Predictive Economy Control and full variable flow on the condenser water system.

The end result granted a whole new lease of life for the older field DDC and VAV, highly stable control, greatly improved System COP while opening the system up to a staged upgrade pathway into the future. The facility can now take advantage of a full range of available technology, while delivering project savings of more than $100,000 to the client.

Result

Tenant feedback on the system performance was positive – increased airflow and comfortable conditions were noticed by all. The owners saved over $100,000 on our approach vs. competitors recommended approach. The Nabers rating increased by 0.5 Stars at the same time indoor air quality increased to a high standard. We were also able to provide the facility team with a detailed list of faults found, defective equipment and mechanical deficiencies which assisted with prioritising capital expenditure and repairs and maintenance budgets.

We ethically and competitively enhanced the system interaction for all stakeholders

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