Chiller plant optimisation.

Chiller plants are among the largest energy consumers in commercial, healthcare, and institutional buildings, making them a prime target for energy optimisation. A new four-chiller plant serving a 16-story building in New York City (NY USA) is leveraging open BACnet technology, programmable edge control, and advanced optimisation software to improve efficiency while maintaining occupant comfort.

The project brought together DL Control & Engineering, DeLima Ventures Energy, GreenMediaHD, and Contemporary Controls to create a fully automated chiller plant control system. At the core of the solution is the BAScontrol-E36 Edge Controller, which provides programmable control using Sedona, along with the BASview3 graphical interface for local visualisation and operation.

The goal was to develop a flexible control platform capable of coordinating multiple chillers, collecting and analysing operating data, and implementing customised control sequences. Rather than relying solely on fixed equipment programming, the system incorporates application-specific strategies such as chiller sequencing, equipment staging, lead-lag coordination, setpoint resets, temperature control, alarms, and plant-wide optimisation routines.

A key element of the project is BACnet integration. Chiller operating information is collected over a BACnet MS/TP network and analysed using custom Sedona logic within the BAScontrol-E36. Because BACnet data can be used directly within the control sequence, operating parameters, temperatures, status points, and setpoints become active components of the optimisation strategy rather than simply values displayed for monitoring.

The project also incorporates GreenMediaHD's Chiller Optimisation Program (GCOP), a cloud-based solution designed to improve chiller plant performance. GCOP continuously analyses real-time operating conditions and provides dashboards that visualise plant performance and optimisation results. The solution focuses on reducing chiller "LIFT," the temperature difference between the evaporator and condenser that the chiller must overcome during operation. Lowering unnecessary LIFT can improve chiller efficiency and reduce energy consumption.

During commissioning, plant performance was evaluated during periods with GCOP optimisation enabled and compared to operation using conventional fixed setpoints. The evaluation demonstrated lower energy consumption during GCOP-optimised operation, illustrating the potential benefits of dynamic optimisation strategies compared to static operating conditions. Actual savings will vary based on factors such as load profile, equipment efficiency, operating hours, weather, and utility costs.

Facility operators interact with the system through the BASview3 interface, which provides real-time visibility into equipment status, temperatures, setpoints, alarms, and other critical operating data. Authorised personnel can monitor performance and perform control functions from a centralised location while the BAScontrol-E36 executes the plant's automated control strategy. Using the BASview3 interface, authorised personnel can monitor plant performance, view real-time operating data, and adjust control setpoints as needed.

By combining BACnet communications, programmable edge control, cloud-based optimisation, and intuitive visualisation, the project establishes a flexible foundation for ongoing energy improvements. The installation demonstrates how an open BACnet architecture can support advanced chiller plant optimisation, increase operational visibility, and provide a scalable approach to improving plant efficiency.

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