SKY TOWER - Johnson Controls
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SKY
Auckland
TOWER
Johnson Controls installs new chiller system at Auckland’s iconic Sky Tower.
Located in the heart of Auckland, the Sky THE BRIEF
Tower has been an icon on the city’s sky line
for 20 years and boasts a hub of adrenaline
activities, superb dining and breath-taking
views.
1 Johnson Controls was
awarded the Sky Tower
project following a competitive
tender process. The project
Offering 360 degree panoramic views up to 80 included decommissioning all
kilometres in every direction, the Sky Tower is end of life equipment, installing three brand
not only a premier dining venue, it also serves new air cooled chillers on level 54, and
as a telecommunications tower for broadcasting conduct all necessary testing before
major television and radio networks, along with commissioning the new units.
wireless internet, and weather measurement
services for the region. Each chiller was to be installed in succession,
as it was imperative that the system remained
At the time of construction in the mid-1990s, operational throughout the project. Other
the YORK chiller system was lifted up to level critical project requirements include the ability
54 using the onsite crane. Fast-forward to to supply fit-for-purpose products, within the
2014 when the chiller system was due to be limited floor-space allocated.
replaced, site access limitations presented a
unique challenge. PREPARATIONS &
INSTALLATION
Johnson Controls was appointed due to the
team’s intimate knowledge of the original
installation, and strong capability to deliver a
solution despite rigid requirements.
2 The single biggest challenge
of this project was getting all
three chiller units up to level
54 in a service elevator. Over
This major project came with many challenges a period of three weeks, Johnson Controls’
as the entire system needed to remain fully team completely disassembled all three chillers
operational while the work was carried out. into over 1,500 pieces that could be
Johnson Controls was also required to strategically packed inside the Sky Tower’s
coordinate with other suppliers to ensure large single service elevator and hoisted up to the
deliveries, and moving equipment caused service floor.
minimal disruption to the restaurants on the
upper levels.
Johnson Controls Case Study – Sky Tower - 2018
Each day, Johnson Controls transported the brazed joint between the tube and fin. By
parts required for the day’s work and installing this new condenser coil, the Sky
meticulously loaded the service elevator – Tower gained the same cooling capacity while
maximising space and weight. The service using 50% less refrigerant.
elevator was exclusively booked between 5am
and 6:30am every day, to enable swift product Additionally by introducing new Variable Speed
transportation. Drive (VSD) scroll compressors and controlled
condenser fans, the Sky Tower has total fan
Harsh weather conditions also meant the metal speed control which minimises power spikes,
work required a special highly durable exterior and enhances head pressure control.
paint to avoid possible future corrosion, and
every nut, bolt, and washer was replaced with THE OUTCOME
4
more resistant stainless steel substitutes.
Johnson Controls New
Additionally, the metal control panel enclosures Zealand successfully
were replaced with GRP solutions to better completed this project
protect the control equipment and wiring from within five weeks, while
the prevailing winds, and the ocean breeze. keeping the tower’s facilities
operational every day with minimal
Site safety was paramount throughout this disruption.
project as excessive winds could blow
components off the service level where there Due to the number of technical and
are no barriers. Extra diligence was required to logistical challenges, a high level of
tie all tools and products down to ensure engineering expertise was required as was
everyone working, and the general public meticulous project management. The
below, remain safe. installation team comprised of six engineers
working simultaneously on site and at the
THE EQUIPMENT Johnson Controls workshop. Numerous
3 The Johnson Controls
YORK® YLAA Air-Cooled
Scroll Chiller was chosen for
suppliers were also working at the Sky
Tower which Johnson Controls team was
required to work around.
its superior energy efficiency, Despite the large challenges, Johnson
flexible control options under different loads, Controls delivered, installed, and
and size. These chillers deliver top-of-the-line, commissioned all three chillers within the
full-load efficiency for assurance of required timeframe and to budget.
performance in the most demanding
conditions. The Sky Tower now enjoys the benefits of
the new chillers which deliver greater
Installing micro-channel condenser coils energy efficiency. This project was one of
utilises and ultra-efficient design providing the largest, most challenging and rewarding
greater heat rejection. Unlike standard projects undertaken by the New Zealand
condenser construction, this is made possible service team in the last decade.
by multiple channels within the tube and a
ABOUT JOHNSON CONTROLS’ BUILDING TECHNOLOGIES & SOLUTIONS
Johnson Controls Building Technologies & Solutions is making the world safer, smarter and more sustainable – one building at a time.
Our technology portfolio integrates every aspect of a building – whether security systems, fire protection, energy management, or
HVACR – to ensure that we exceed customer expectations at all times. We operate in more than 150 countries through our unmatched
network of branches and distribution channels, helping building owners, operators, engineers and contractors enhance the full lifecycle
of any facility. Our arsenal of brands includes some of the most trusted names in the industry, such as Tyco®, YORK®, Metasys®,
Ruskin®, Titus®, Frick®, PENN®, Sabroe®, Simplex® and Grinnell®. For more information, visit www.johnsoncontrols.com.
Figure 5: First chiller removed. Space available for installing
the new chiller
Figure 1: Chiller delivered to the Auckland warehouse
Figure 6: Installation underway on the first chiller
Figure 2: Disassembly commences on the chillers
Figure 7: Installation is progressing
Figure 3: Replacement of the control cabinets
Figure 8: One of the finished chillers, installed and
Figure 4: View from level 54 commissioned
ABOUT JOHNSON CONTROLS’ BUILDING TECHNOLOGIES & SOLUTIONS
Johnson Controls Building Technologies & Solutions is making the world safer, smarter and more sustainable – one building at a time.
Our technology portfolio integrates every aspect of a building – whether security systems, fire protection, energy management, or
HVACR – to ensure that we exceed customer expectations at all times. We operate in more than 150 countries through our unmatched
network of branches and distribution channels, helping building owners, operators, engineers and contractors enhance the full lifecycle
of any facility. Our arsenal of brands includes some of the most trusted names in the industry, such as Tyco®, YORK®, Metasys®,
Ruskin®, Titus®, Frick®, PENN®, Sabroe®, Simplex® and Grinnell®. For more information, visit www.johnsoncontrols.com.
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