Ausgrid Ourimbah – VRF Retrofit & System Compliance Upgrade

Project Overview

Builder: Shape

Client: Ausgrid

Location: 7-17 OURIMBAH CREEK ROAD, OURIMBAH, NSW, 2258 

Type of Service: Air cooled VRF systems, Mechanical ventilation, pipework retrofit.

Completion Date: November 2024

Project Value: $400,000

PSB Air was engaged by Shape to support the upgrade of Ausgrid’s Ourimbah facility with a refrigeration services retrofit. The existing pipework was not compliant with current code, and for that reason, the system was not performing as intended. The pipework required replacement and reconfiguration to bring the existing VRF system back to full performance. Site inspections also revealed additional operational issues that needed attention to ensure long-term efficiency and compliance.

The project involved careful planning, targeted corrective work, and the integration of new system components to support reliable performance across the facility.

The Challenge – Reworking Existing Infrastructure Without Disrupting Operations

This project required PSB Air to overcome several constraints:

• The existing VRF system wasn`t performing as per design due to non-compliance with the original installation
  
• The facility’s existing pipework layout was incompatible with the energy efficiency guidelines from NCC and needed full re-engineering.
  
• Site inspections revealed CO₂ sensors that were not functioning correctly, impacting ventilation control and compliance.
  
• Ensuring an energy-efficient outcome meant resolving system inefficiencies while working within an operational environment.
  
• The upgraded installation needed to communicate seamlessly with the building’s BMS for monitoring and control.

The Solution – Targeted Retrofit to Improve Performance and Compliance

PSB Air delivered a complete and compliant upgrade through:

• Pipework Retrofit – Existing lines were removed and replaced, ensuring correct sizing, insulation, routing, refrigerant gas charge and VRF manufacturer requirements were met.
• CO₂ Sensor Rectification – Faulty sensors were identified, replaced, calibrated, and integrated into the mechanical ventilation system for correct demand-control operation.
• Air-Cooled VRF Enhancements – The installation was optimised to ensure stable performance, improved energy efficiency, and reliability across all zones.
• Energy-Efficiency Improvements – Ventilation and control strategies were updated to reduce unnecessary load and improve long-term running costs.
• BMS Integration – All mechanical services were reconnected and tested within the building’s BMS framework to ensure accurate monitoring and control.

The Results – Improved Efficiency, Compliance, and System Reliability

Once complete, the upgraded system delivered:

• Restored and reliable performance for the VRF installation
  
• Accurate ventilation control through operational CO₂ sensors
  
• Improved energy efficiency across the building’s mechanical services
  
• A compliant, well-integrated system ready for long-term operation

Why This Project Matters

The Ausgrid Ourimbah project reflects PSB Air’s capability in solving complex retrofit challenges. Beyond replacing components, the team identified deeper system issues, improved energy performance, and ensured compliance without requiring major structural changes.

For clients managing ageing infrastructure or system upgrades, this project demonstrates how targeted mechanical rectification and VRF optimisation can extend asset life, increase efficiency, and restore confidence in system reliability.

Speak With PSB Air About Your Next Project

Need support upgrading or rectifying an existing HVAC installation? PSB Air specialises in complex retrofit projects that improve efficiency, safety, and system lifespan. Contact us today for a project assessment and quote, or explore more of our commercial project work here.

FAQs

Q1. What type of system was upgraded during the Ausgrid Ourimbah project?

The project involved a full pipework retrofit for the existing VRF air conditioning system, alongside mechanical ventilation improvements and BMS adjustments for reliable long-term performance.

Q2. Why was a pipework retrofit necessary for this commercial air conditioning installation?

The existing pipework were not installed as per industry standards and for that reason the existing system wasn`t performing as intended. Retrofitting allowed PSB Air to optimise flow, improve efficiency and ensure the system met compliance standards for a modern commercial air conditioning installation.

Q3. How did PSB Air resolve the CO₂ sensor issues on site?

During investigation, several CO₂ sensors were found to be operating incorrectly. PSB Air recalibrated and replaced faulty sensors to restore proper ventilation control and maintain energy-efficient operation across the facility.

Q4. Are VRF air conditioning systems suitable for commercial facilities like Ausgrid?

Yes. VRF air conditioning offers flexible zoning, strong energy efficiency and reliable performance, which makes it ideal for commercial sites with varying occupancy and operational demands.

Q5. How does this project reflect PSB Air’s experience in commercial air conditioning Sydney?

The work involved system integration, retrofit engineering and compliance upgrades, demonstrating PSB Air’s capability in delivering complex commercial air conditioning Sydney projects with minimal disruption to operations.

Q6. What long-term benefits does the upgraded system provide for Ausgrid?

The facility now operates with improved energy performance, reliable VRF technology, better ventilation control and a BMS setup that supports streamlined monitoring and future maintenance needs.