Case Study: Fairwater Leisure Centre – Emergency AHU & Heating Control Upgrade

Project Overview

Fairwater Leisure Centre is an important community facility in South Wales, providing swimming lessons, sports facilities, and activity spaces for local schools and residents. When the site's ageing control infrastructure failed, the centre was forced to close while emergency investigations and repairs were undertaken.

Our team was brought in to assess the existing control system, identify the causes of failure, and provide both short-term and long-term recommendations to restore safe and reliable operation of the building’s air handling and heating systems.

The Challenge

The original control panel dated back to the 1980s and was responsible for controlling both the pool filtration system and the building heating and air handling units (AHUs). Over time, several key components within the panel - including contactors and control devices - had failed.

Due to the extent of these failures, the system was condemned and the leisure centre had to close while emergency works were planned.

By the time we arrived on site, the situation had become complex:

• Multiple items of plant were not operating or partially disconnected

• Several front-panel switches were broken

• There was uncertainty about which equipment was controlling which plant

• Cabling routes to plant equipment across the building and roof were poorly documented

  
  

Before any design work could begin, a full tracing and identification exercise was required. In collaboration with Goodridge Electrical, engineers systematically traced every cable running from the control panel to plant equipment across the building and rooftop extraction systems to determine exactly what equipment needed to be controlled.

At the same time, the project scope evolved. It was decided that the pool filtration controls and the building HVAC controls should be separated into two independent systems. The site’s maintenance team would handle the pool filtration side, while our focus would be on restoring control of the AHU systems and heating circulation pumps.

Engineering Assessment & Design

Following the site investigation, we produced a complete drawing set and control strategy, working closely with a specialist HVAC engineer.

One of the key improvements in the proposed design was to replace the existing Direct-On-Line (DOL) starters with variable speed drive (VSD) control for the AHU motors.

This upgrade offered several important advantages:

• Improved airflow control within the pool hall

• Reduced condensation levels

• Better temperature stability

• Lower energy consumption

By installing the appropriate sensing equipment within the poolside environment, the system can now dynamically adjust extract rates, intake air volume, and temperature control to maintain a balanced environment and minimise moisture build-up.

Short-Term Solution vs Long-Term Strategy

During the assessment it became clear that the entire ventilation system, including ductwork, was extremely old and would ideally need complete replacement.

The long-term recommendation included:

• Replacement of the air handling systems

• Installation of heat recovery

• Updated ductwork infrastructure

• Addition of a return air circulation system

  
  

However, delivering this level of upgrade would have required a major redevelopment project, involving structural works to the plant rooms and significant downtime for the building.

Due to budget and scheduling constraints, this was not a viable option at the time.

Instead, the client required a robust medium-term solution that could restore the facility to operation quickly while still improving system reliability and efficiency.

Installation Works

Once the design was finalised, the new control panel was manufactured at our facility in Rye and delivered to site in South Wales.

The installation phase involved significant electrical infrastructure upgrades.

The original system relied heavily on old mineral insulated cabling which had deteriorated and was no longer considered suitable for continued service. As part of the works:

• The entire plant room was rewired

• New H07 cabling and steel wire armoured cables were installed

• New environmental sensors were installed throughout the poolside area

• Temperature, humidity, and pressure monitoring points were added

Within the new control panel we installed Siemens variable speed drives to manage the AHU fan motors and circulating pumps.

The system also incorporated actuated control valves which regulate:

• Hot water flow through the AHU heat batteries

• Distribution of heat through the wet heating circuits

These heating circuits serve multiple areas across the leisure centre, including:

• Changing rooms

• Classrooms

• Sports hall spaces

• General building areas

Controls & Commissioning

The system was commissioned using a Distech Controls building management platform, with a bespoke control strategy developed for the site.

Several operational improvements were introduced to optimise performance and energy usage:

Night-time setback mode

• Fan speeds automatically reduce when the facility is not in use

• Temperature is still maintained, but at a more energy-efficient operating level

Targeted ventilation control

• Changing room extract systems shut down when the building closes

• Reduces unnecessary heat loss overnight

Environmental monitoring

• Humidity, temperature, and pressure sensors continuously adjust airflow

• Helps prevent condensation issues commonly found in pool environments

Our team supported the full installation process and carried out all testing and commissioning to ensure reliable operation before the system was handed back to the client.

Outcome

The completed project successfully restored the leisure centre’s HVAC control system and allowed the facility to reopen to the community.

While not a full replacement of the ageing infrastructure, the upgrade delivered:

• A reliable and modernised control system

• Improved environmental control within the pool hall

• Reduced energy consumption

• Greater operational flexibility

Most importantly, the works were completed within the required timeframe to allow the centre to resume its role as a vital local facility.

Fairwater Leisure Centre provides swimming lessons and sports access for local schools and the wider community, so returning the site to operation as quickly as possible was essential.

Looking Ahead

Although the current system provides a strong and reliable medium-term solution, the long-term strategy remains a full HVAC system upgrade incorporating modern air handling equipment and heat recovery technology.

This will be considered as part of future investment planning by the site’s management team. For now, the new control system provides the stability and performance needed to keep the facility running efficiently for the community it serves.

Get in Touch

If you're looking to upgrade or design a bespoke control system, we'd be happy to help. Email us on hello@pslcontrols.co.uk