top of page
Jill Nelson

Case Study: Retro-Commissioning Restores Lab Building Performance

MSC's partnership with a New Jersey pharmaceutical manufacturing complex began when we were selected to manage preventive maintenance for a newly constructed 80,000 sq ft research and development facility. Based on our proven performance, the client requested assistance with another building within the multi-facility campus – a troubled 105,000 sq ft laboratory/office facility that was experiencing significant operational issues after just ten years of operation.


Critical Challenges


The existing facility faced multiple problems affecting both operations and occupant comfort:


  • Frequent freeze stat trips

  • Equipment and VFD malfunctions after power fluctuations

  • Inconsistent temperature control with hot/cold spots throughout the building

  • Static pressure and air measurement issues

  • Motor and fan bearing problems

  • Control systems defaulting to manual operation rather than automatic mode

  • Escalating operating costs


Initial Assessment


MSC implemented retro-commissioning protocols, beginning with a comprehensive two-day facility review that included operator and occupant interviews per NEBB standards. The team gathered critical data about all systems, reviewed maintenance history, and analyzed original design drawings and balancing reports. We also collected various readings and samples collected from throughout the building.


Hydronic Systems Restoration


Investigation of the chilled water and hot water systems revealed extensive issues affecting system performance. Our team discovered heavily loaded strainers and coils with sediment deposits in the bottom rows, explaining many of the freeze stat trips, low flows, and stratification issues. To restore proper operation, we implemented a number of corrective measures:


  • Performed a complete system blow-down

  • Conducted thorough cleaning with trisodium phosphate (TSP)

  • Filled the system with clean water containing a rust inhibitor

  • Restored glycol heat recovery loops from 4% to the original design specification of 15%

  • After completing these steps, our technicians cleaned all coils and drain pans before balancing the chilled water, hot water, and glycol loops.


Air Systems Testing and Balancing

 

After completing hydronic system restoration, we moved on to comprehensive TAB (testing, adjusting, and balancing) of the air systems. Several preparatory repairs and improvements were necessary:


  • Repaired multiple AHU filter rack issues

  • Cleaned all air handlers thoroughly

  • Installed new filters throughout the system

  • Adjusted occupied/unoccupied schedules to optimize energy savings

  • Referenced original air balancing information to verify proper settings

  • Performed a complete system testing and balancing


Systems Enhancement and Controls Upgrade


Throughout the retro-commissioning process, our team implemented various upgrades to ensure long-term efficiency and reliability:


  • Cleaned and reprogrammed all VFDs with auto restart capability

  • Performed comprehensive vibration testing

  • Installed shaft grounding rings on large fans and pumps

  • Enhanced BAS graphics with new VFD information

  • Modified sequences of operation

  • Refined alarm parameters

  • Installed new instruments where existing ones were inaccurate and could not be calibrated


Results and Training


All systems were carefully trend-logged and fine-tuned as needed to verify optimal performance. Once the retro-commissioning process had been completed, MSC provided comprehensive training to the facility staff on system functionality. These improvements resulted in significantly enhanced building performance, energy economy, and operational efficiency. Based on the success of this project, MSC was awarded the preventive maintenance contract for this facility.

Comments


bottom of page