Filling and Capping Room HVAC Upgrades

During this phase of the project we worked closely with the installing contractors to insure new HVAC systems were started correctly and were fully operational. Services in general included the following:

  • Developed Integration Procedures Manual and validate contractors’ start-up procedures.
  • Directed and coordinated with subcontractors in the development of detailed descriptions of control sequences of operations and validation during integration procedures.
  • Recorded the results of tests and issue periodic corrective action notices as necessary.
  • Provided all HVAC system testing & balancing in accordance with NEBB standards.This included configuring all constant volume regulators serving the filling room and all terminal and diffusers that will be served from our new air handling systems.
  • Provided a final commissioning report attesting to the proper performance as designed and specified.
  • Reviewed the status of start-up and pre-functional testing and report deficiencies to the contractor, and Intervet.
  • Development of specific functional test procedures and forms documenting the integration of each system.
  • Made reviews and commented on functional testing of each item of equipment and provided assurance that all equipment is operating according to design intent.
  • Oversight of “point-to-point” checkout of the control system performed by Controls Subcontractor.
  • During the commissioning process, sys-tek worked with Merck engineering and facilities staff. The critical nature of the facility dictates a stringent commissioning process to ensure proper operation of the HVAC systems serving the filling and capping rooms. In addition, to testing each individual component, air handling system P08 will be tested along with integrated and system failure testing.

For this project, sys-tek provided their expertise on upgrading the HVAC system for the filling/capping room for their De Soto, Kansas location. From an engineering evaluation completed by sys-tek over the previous 12 months, we noted that the air handling system serving the capping and filling rooms was operating outside of its fan curve. This means that the fan was being asked to deliver more than it was designed to provide by the manufacturer.

To relieve the fan capacity, a new smaller HVAC unit dedicated to the capping room was installed. Given the requirements for the capping room were much different than that of the filling room, this HVAC split made logical sense and will provide Intervet with a system that is dedicated to system filling.

During the design process for the new air handling system, it was noted that the operators had a desire to maintain the filling room at 65F and 50% RH. Psychometrically this was not possible unless we can deliver 46F supply air. The chilled water supply for this building cannot be much lower than 42F, this supply air temperature is not possible with the equipment serving the filling room today.

In conclusion, it was decided to install a dehumidification unit to decrease the supply air dew point temperature to be 45F. As part of the design evolution, the facility operators also requested that HEPA filters be installed in the return air systems serving this area.

Given that the capping and filling room are continually in use at the facility, we will prepare phasing and coordination drawings and sequences. This will be done to insure that the uptime for the facility is as continuous as possible, knowing that there will be some interruptions. The objective will be to limit interruptions to the smallest duration possible.