The Challenge

Royal Papworth Hospital's ground source energy system had been experiencing significant operational issues since 2018, including unstable operation, high electrical consumption, poor energy efficiencies, and repeated compressor failures. The hospital required a comprehensive controls upgrade to stabilise the system, improve performance, and provide real-time monitoring and optimization capabilities, all while maintaining critical heating services during operation.

What We Delivered

We executed a complete controls upgrade and energy system optimization across multiple plant circuits. Our scope included:

Mechanical & Electrical Works:

• Installation of Variable Speed Drives (VSDs) on borehole circulation pumps with Unistrut mounting
• Electrical power supply upgrades and new cabling to Motor Control Centre (MCC)
• Replacement of existing motor starters with MCBs and new electricity meters per pump
• New temperature sensors installed across heat rejection and back-up circuits
• New 3-Port Mixing Valve on HT LTHW back-up circuit with commissioning set

Controls & Software Development:

• Replacement of existing hardware with Tridium Jace controller and Niagara 4 software
• Complete panel re-build in situ with point-to-point testing
• New control software developed to specification and bench-tested prior to site installation
• Thermal energy metering system with real-time monitoring capabilities
• Energy portal, dashboards, and remote access developed for hospital staff

Key Technical Points:

• Multi-circuit project scope: borehole pumps, LT heat rejection, HT rejection, and HT LTHW back-up circuits
• Minimal disruption strategy—works designed to eliminate need for full system shutdown where possible
• BACnet communication protocols for pump control and monitoring
• Comprehensive commissioning plan with seasonal optimization post-handover
• Full design and commissioning documentation provided

Results

✓ System Stability: Resolved operational instability and eliminated repeated compressor failures

✓ Energy Efficiency: Variable Speed Drives reduce unnecessary peak consumption and optimise pump operation

✓ Real-Time Visibility: Thermal energy metering and energy portal enable performance monitoring and optimisation

✓ Operational Control: Modern Tridium control system provides responsive, automated GSHP management

✓ Reliability: Improved system design reduces wear and extends equipment lifespan

✓ Seamless Integration: Works executed with minimal operational disruption to critical hospital services

✓ Staff Enablement: Comprehensive training and remote access dashboards empower hospital operations team