HVAC system upgrades often miss the real performance issues. This case study shows how simulation-led optimisation reduced energy use and improved comfort—without replacing equipment.
A government office complex had undergone major HVAC upgrades in recent years. Efficient boilers had replaced aging plant, VFDs were added to pumps, and a new BMS provided basic visibility into operation.
Still, energy bills kept climbing. Comfort complaints from staff were consistent—some zones overheated, others never reached setpoint. The facility team had run out of conventional fixes.
Using Hysopt, engineers created a digital twin of the existing system. The simulation didn’t just visualise layout—it showed real dynamic behaviour under varied conditions.
Key findings included:
These inefficiencies weren’t visible in the BMS or detectable via manual audits—they only appeared when system interaction was modelled holistically.
With full system visibility, the team was able to take targeted, effective action.
Pump settings were recalibrated to better match actual load, and valve authority was restored simply by adjusting pre-sets, without replacing any hardware.
Control logic was reprogrammed to reduce oversupply and stabilise return temperatures, while a heating night-setback strategy was implemented, simulated, and validated before activation.
No new plant or emitters were purchased. The result was a low-disruption and evidence-backed upgrade.
After 12 months of monitored performance:
The simulation model remained in use as a live validation tool—supporting ongoing optimisation and maintenance planning.
This project succeeded because the team asked a better question—not “what needs replacing?” but “how is the system behaving?”
The answer came from simulation. With a clear picture of flow, temperature, and control interaction, they made smart changes that worked—and proved it with real data.
You don’t always need new hardware to improve performance.
You need the right insight, applied at system level. Here’s everything you need.
