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.
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