Maria LupoControl Systems Engineer
1
CONTROL SYSTEM RETROFITS
March 7, 2013
2.
Agenda
• Why perform a controls retrofit
• Levels of control
• BAS design considerations
• Retrofit process
• Case studies
• Q&A
2.
Why perform a controls retrofit?
• Occupant comfort and IEQ • Improve operations and
maintenance • Graphical interface • Features and capabilities • Remote access
• Centralized alarm and monitoring• Energy savings • Unsupported equipment• Redundancy requirements• Flexibility and competition
2.
• Data vs Information• Who needs the information?
– Internal system– Building engineer– Property manager
• Does the data allow easy analysis to show:– Trends– Inconsistencies
Why perform a controls retrofit?
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Modern Features
• Ethernet transport• Web-based (natively)• Protocol agnostic• Central alarm collection & distribution• Central trend collection & analysis• Global strategies & data sharing• Multi-vendor & converged networks possible
– But not always advisable….
2.
Levels of Control
• No controls
• Pneumatic controls
• Building Automation System– DDC (Direct Digital Controls)– PLC (Programmable Logic Controllers)– Standalone – Manual controls
• Hybrid
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Levels of Control- cont.
Setpoint
Sensor
Error Output
Open Loop – no feedback mechanism
Example – Pneumatic controls
Change in output NOT incorporated.
2.
Levels of Control- cont.
Setpoint
Sensor
Error Output
Closed Loop – feeds back result of the change
Example – DDC damper position feedback
Change in output IS incorporated.
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Levels of Control- cont.
Setpoint
Sensor
Error Output
Sensor
Error Output
Example – DDC daylight sensor and occupancy sensor integrated
Cascaded Loop – multiple variables
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Levels of Control- cont.
Zone Demand
Zone Demand Setpoint
Reset Output
Sensor
Error Output
Example – DDC optimize AHU static pressure / discharge temperature setpoint
Adaptive Control – use algorithms
Zone Demand
Zone Demand
Zone Demand
Zone Demand
2.
BAS Design Considerations
NC
PC
Network Switch
NC
Server
UC
XM
TUC
S
UMC
UMCFirst Tier
Second Tier
Third Tier
NC Network Controller
PC Programmable Controller
UC Unitary Controller
TUC Terminal Unit Controller
UMC Unit Mounted Controller
XM Expansion Module
S Sensor
Operator Work Station
2.
BAS Design Considerations- cont.
2.
Joint Operations Center
BAS Design Considerations- cont.
2.
Subsystem Characteristics
• Specialty components• Best fit for each - best of breed or best value• Range of sophistication / complexity• Various O&M interfaces, service tools• Degrees of openness / interoperability / standards
2.
BAS Design Considerations- cont.
LIGHTING CONTROL
ELECTRICAL MONITORING
BAS
IRRIGATION
GAS DETECTION
FUEL OIL
SECURITYAUDIO/ VISUAL
LIFE SAFETY
System Integrations
2.
• Integrations don’t resolve subsystem inefficiencies
• Potential benefits:– Implement “global” strategies
• Use lighting occupancy sensor to drive HVAC zone modes• Schedule in one place• Analyze trended data in one place• Peak reduction / load shed (manual only, automatic peak reduction,
utility-driven load shed)– Reduced O&M training– Better O&M results
• Required first step to deploying Advanced BAS software tools
BAS Design Considerations- cont.
2.
INVESTMENTDESIGN/CONSTRUCTION
ACTIVE MANAGEMENT
INVESTMENTRELEASED
PERFORMANCE ENHANCEMENTS
BUILD
USE
REPAIR/SERVICE
The Facility Lifecycle
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Retrofit Process
• Evaluate facility and existing systems• Create strategies and tactics for upgrade• Define and design• Implement then commission
• Key Factors for Success– Realistic expectations– Clear and defined specification– Attaining capable local controls representation– Performance verification
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
• Age and existing conditions• Building construction
limitations?• Document existing system
in detail• What options are there for
controls replacement?– Manufacturers– Product lines– Providers / installers– What technologies apply?
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
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Raw Data
Organized System Information
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
• What are requirements?• What are dependencies?• What is easy/difficult? Phased approach?• How mature are the potential retrofit options?• How integrated? • Is a beta test or proof of concept warranted?• Do upgrades affect other disciplines? (e.g. IT)• Define the team needed
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
• Budget estimating• Look at all affected systems
– BAS (hardware and software)– Cabling / pathways– Power– IT systems
• Understand costs/savings of phasing• Don’t forget to define “soft” costs and savings• How does project phasing change based on the upgrade
paths/options?
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
• Full design or design/build?• Enhance core MEP systems?• Replace entire system or selected
upgrades?• Address all affected systems
– Controls– Cabling/pathways– Data network
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
• Decide on qualified vendors• Use general contractor? • Multiple subs?• Understand phasing approach and build into the
documentation• Define warranties, maintenance, and support
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
• First tier network
– Can Ethernet infrastructure be re-used?– Standalone network or part of Owner’s IT infrastructure?– Who will manage and maintain the system?– Requirements for operator workstations– System redundancy
• Servers • Power
– What is the electrical distribution?
– Define where multiple protocols need to be supported– Strategically locate controllers on plan– Avoid >60 second tier controllers per network controller
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
• Understand current system operation
• Optimize sequences of operation
2.
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
• Minimum and maximum outdoor air damper sections
• Additional sheet metal
• Low leakage dampers• Blade seals• Durable
2.
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
• Wiring trough
• Consider metering major systems– Meter locations
• Avoid control of equipment over the network.
• All points associated to a system should reside on the same controller.
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Procurement Methods – Single Vendor
Security
Lighting Controls
BAS
Life Safety
Electrical
A/V
Dashboard
Tenant Interface
??
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
Procurement Methods – Fully Integrated
Security
Lighting Controls
BASLife
Safety
Electrical
A/V
Middleware
Dashboard
Tenant Interface
Div.26
Div.23
Div.28Div.26
Div.28/Owner
Div.27/OwnerDiv.25?
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
BAS Centric
SecurityLighting Controls
Life Safety
Electrical
A/V
Dashboard
Tenant Interface
Div.26
Div.28Div.26
Div.28/Owner
Div.27/OwnerDiv.23
BAS
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
• Interview various contractors
• Compare capabilities
• Training and support
• Similar project experience with the same product line
Contractor Evaluation
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
• Start with upgrades to infrastructure
• Install new, fully programmed devices before tearing out old devices – timing is everything!
• Have all points lists and database programming done in the shop before ever coming onsite
• Utilize independent commissioning agent as well as contractor self-commissioning
Controls Assessment
Defined Strategies
BAS Design &
Procurement
Implementation & Construction Administration
2.
Case Study A – Multi-Building Campus
Project Overview
• Existing Multi building campus; > 1 million sqft
• Predominantly office space
• New owner, owner occupied
• Hybrid of pneumatic and legacy DDC controls
• Compressed construction schedule
2.
Case Study A – Multi-Building Campus
Vision
• Single building automation system
• Reuse of existing controls where possible
• Retrofit of all pneumatic controls
• Open business controls architecture
System Integrator
Controls Contractors
BACnet, Modbus
• One Technology Platform• Open Licensed Software• Competitive Vendor Pricing• One Graphical User Interface• Reduced O&M
2.
Case Study B – Single Building
Project Overview
• 17 story building
• Predominantly office space
• Existing owner, leased tenant space
• Hybrid of pneumatic and legacy DDC controls
• Single Vendor Support• Upgrade from Proprietary to
BACnet Protocol• O&M of a Single System
BACnetProprietary
2.
In Summary
• Why perform a controls retrofit
• Levels of control
• BAS design considerations
• Retrofit process
• Case studies
2.