Maria Lupo Control Systems Engineer

Maria LupoControl Systems Engineer

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CONTROL SYSTEM RETROFITS

March 7, 2013

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Agenda

• Why perform a controls retrofit

• Levels of control

• BAS design considerations

• Retrofit process

• Case studies

• Q&A

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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

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• 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….

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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.

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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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Setpoint

Sensor

Error Output

Sensor

Error Output

Example – DDC daylight sensor and occupancy sensor integrated

Cascaded Loop – multiple variables

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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

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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

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BAS Design Considerations- cont.

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Joint Operations Center


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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

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LIGHTING CONTROL

ELECTRICAL MONITORING

BAS

IRRIGATION

GAS DETECTION

FUEL OIL

SECURITYAUDIO/ VISUAL

LIFE SAFETY

System Integrations

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• 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


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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

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• 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


2.

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pt type system name pt name pt description units io address controllerAI C2-1WEST 152-T 119&121 P-S Office Temp Deg F 1 152BO NC2-SW 115-C FAN-C OFF, ON 1 115

Raw Data

Organized System Information

Controls Assessment

Defined Strategies

BAS Design &

Procurement


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• 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


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• 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


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• 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


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• 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


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• 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


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Controls Assessment

Defined Strategies

BAS Design &

Procurement


• Understand current system operation

• Optimize sequences of operation

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Controls Assessment

Defined Strategies

BAS Design &

Procurement


• Minimum and maximum outdoor air damper sections

• Additional sheet metal

• Low leakage dampers• Blade seals• Durable

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Controls Assessment

Defined Strategies

BAS Design &

Procurement


• 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


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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


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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


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• 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


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• 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


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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

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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

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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

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In Summary

• Why perform a controls retrofit

• Levels of control

• BAS design considerations

• Retrofit process

• Case studies

Maria Lupo Control Systems Engineer

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