Maria Lupo Control Systems Engineer

1. Maria Lupo Control Systems Engineer 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

3. Why perform a controls retrofit? • Centralized alarm and monitoring • Energy savings • Unsupported equipment • Redundancy requirements • Flexibility and competition • Occupant comfort and IEQ • Improve operations and maintenance • Graphical interface • Features and capabilities • Remote access

4. Why perform a controls retrofit? • Data vs Information • Who needs the information? • Internal system • Building engineer • Property manager • Does the data allow easy analysis to show: • Trends • Inconsistencies

5. 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….

6. Levels of Control • No controls • Pneumatic controls • Building Automation System • DDC (Direct Digital Controls) • PLC (Programmable Logic Controllers) • Standalone • Manual controls • Hybrid

7. Levels of Control- cont. Open Loop – no feedback mechanism Setpoint Error Output Sensor Change in output NOT incorporated. Example – Pneumatic controls

8. Levels of Control- cont. Closed Loop – feeds back result of the change Setpoint Error Output Sensor Change in output IS incorporated. Example – DDC damper position feedback

9. Levels of Control- cont. Cascaded Loop – multiple variables Setpoint Error Output Sensor Error Output Sensor Example – DDC daylight sensor and occupancy sensor integrated

10. Levels of Control- cont. Adaptive Control – use algorithms Zone Demand Zone Demand Setpoint Reset Output Zone Demand Error Output Zone Demand Sensor Zone Demand Zone Demand Example – DDC optimize AHU static pressure / discharge temperature setpoint

11. BAS Design Considerations Server Network Switch First Tier UMC Operator Work Station NC Network Controller NC NC UMC Unit Mounted Controller PC Programmable Controller Second Tier UC Unitary Controller UMC PC UC TUC TUC Terminal Unit Controller XM Expansion Module S Sensor S XM Third Tier

12. BAS Design Considerations- cont.

13. BAS Design Considerations- cont. Joint Operations Center

14. 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

15. BAS Design Considerations- cont. • IRRIGATION • GAS DETECTION • FUEL OIL • LIGHTINGCONTROL • ELECTRICAL MONITORING • SECURITY • AUDIO/ VISUAL • LIFE SAFETY • BAS System Integrations

16. BAS Design Considerations- cont. • 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

17. The Facility Lifecycle INVESTMENT DESIGN/CONSTRUCTION BUILD INVESTMENT RELEASED PERFORMANCE ENHANCEMENTS USE ACTIVE MANAGEMENT REPAIR/ SERVICE

18. 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 • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

19. 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? • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

20. Raw Data • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement Organized System Information

21. 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 • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

22. 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? • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

23. Full design or design/build? • Enhance core MEP systems? • Replace entire system or selected upgrades? • Address all affected systems • Controls • Cabling/pathways • Data network • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

24. Decide on qualified vendors • Use general contractor? • Multiple subs? • Understand phasing approach and build into the documentation • Define warranties, maintenance, and support • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

25. 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 • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

26. Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement • Understand current system operation • Optimize sequences of operation

27. Minimum and maximum outdoor air damper sections • Additional sheet metal • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement • Low leakage dampers • Blade seals • Durable

28. 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. • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

29. Procurement Methods – Single Vendor Dashboard • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement Tenant Interface ? A/V Lighting Controls BAS ? Security Electrical Life Safety

30. Procurement Methods – Fully Integrated Dashboard • Implementation & Construction Administration • Defined Strategies • Controls Assessment • BAS Design & Procurement Tenant Interface Div.25? Middleware Div.27/Owner Div.26 A/V Lighting Controls Div.28/Owner Div.23 Security BAS Div.26 Div.28 Electrical Life Safety

31. BAS Centric Dashboard • Implementation & Construction Administration • BAS Design & Procurement • Controls Assessment • Defined Strategies Tenant Interface Div.23 BAS Div.27/Owner A/V Div.28/Owner Div.26 Security Div.26 Lighting Controls Div.28 Electrical Life Safety

32. Contractor Evaluation • Interview various contractors • Compare capabilities • Training and support • Similar project experience with the same product line • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

33. 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 • Implementation & Construction Administration • Controls Assessment • Defined Strategies • BAS Design & Procurement

34. 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

35. 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 • One Technology Platform • Open Licensed Software • Competitive Vendor Pricing • One Graphical User Interface • Reduced O&M BACnet, Modbus System Integrator Controls Contractors

36. Case Study B – Single Building • Single Vendor Support • Upgrade from Proprietary to BACnet Protocol • O&M of a Single System • Project Overview • 17 story building • Predominantly office space • Existing owner, leased tenant space • Hybrid of pneumatic and legacy DDC controls Proprietary BACnet

37. In Summary • Why perform a controls retrofit • Levels of control • BAS design considerations • Retrofit process • Case studies