Sky Tower Auckland

Located in the heart of Auckland, the Sky 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.

Offering 360 degree panoramic views up to 80 kilometres in every direction, the Sky Tower is not only a premier dining venue, it also serves as a telecommunications tower for broadcasting major television and radio networks, along with wireless internet, and weather measurement services for the region.

At the time of construction in the mid-1990s, the YORK chiller system was lifted up to level 54 using the onsite crane. Fast-forward to 2014 when the chiller system was due to be replaced, site access limitations presented a unique challenge.

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.

This major project came with many challenges as the entire system needed to remain fully operational while the work was carried out. Johnson Controls was also required to coordinate with other suppliers to ensure large deliveries, and moving equipment caused minimal disruption to the restaurants on the upper levels.

The Brief

Johnson Controls was awarded the Sky Tower project following a competitive tender process. The project included decommissioning all end of life equipment, installing three brand new air cooled chillers on level 54, and conduct all necessary testing before commissioning the new units.

Each chiller was to be installed in succession, as it was imperative that the system remained operational throughout the project. Other critical project requirements include the ability to supply fit-for-purpose products, within the limited floor-space allocated.

Preparations & Installation

The single biggest challenge of this project was getting all three chiller units up to level 54 in a service elevator. Over a period of three weeks, Johnson Controls’ team completely disassembled all three chillers into over 1,500 pieces that could be strategically packed inside the Sky Tower’s single service elevator and hoisted up to the service floor.

Each day, Johnson Controls transported the parts required for the day’s work and meticulously loaded the service elevator – maximising space and weight. The service elevator was exclusively booked between 5am and 6:30am every day, to enable swift product transportation.

Harsh weather conditions also meant the metal work required a special highly durable exterior paint to avoid possible future corrosion, and every nut, bolt, and washer was replaced with more resistant stainless steel substitutes.

Additionally, the metal control panel enclosures were replaced with GRP solutions to better protect the control equipment and wiring from the prevailing winds, and the ocean breeze.

Site safety was paramount throughout this project as excessive winds could blow components off the service level where there are no barriers. Extra diligence was required to tie all tools and products down to ensure everyone working, and the general public below, remain safe.

The Equipment

The Johnson Controls YORK^® YLAA Air-Cooled Scroll Chiller was chosen for its superior energy efficiency, flexible control options under different loads, and size. These chillers deliver top-of-the-line, full-load efficiency for assurance of performance in the most demanding conditions.

Installing micro-channel condenser coils utilises and ultra-efficient design providing greater heat rejection. Unlike standard condenser construction, this is made possible by multiple channels within the tube and a brazed joint between the tube and fin. By installing this new condenser coil, the Sky Tower gained the same cooling capacity while using 50% less refrigerant

Additionally by introducing new Variable Speed Drive (VSD) scroll compressors and controlled condenser fans, the Sky Tower has total fan speed control which minimises power spikes, and enhances head pressure control.

The Outcome

Johnson Controls New Zealand successfully completed this project within five weeks, while keeping the tower’s facilities operational every day with minimal disruption.

Due to the number of technical and logistical challenges, a high level of engineering expertise was required as was meticulous project management. The installation team comprised of six engineers working simultaneously on site and at the Johnson Controls workshop. Numerous suppliers were also working at the Sky Tower which Johnson Controls team was required to work around.

Despite the large challenges, Johnson Controls delivered, installed, and commissioned all three chillers within the required timeframe and to budget.

The Sky Tower now enjoys the benefits of the new chillers which deliver greater energy efficiency. This project was one of the largest, most challenging and rewarding projects undertaken by the New Zealand service team in the last decade.

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