bioMérieux HVAC Retro-Commissioning
& Optimization
Retro-commissioning uncovers major efficiency gains across complex lab and support spaces
A First Step Toward Decarbonization
Optimum Energy’s Engineering Solutions team was brought in to perform retro-commissioning (RCx) and optimization as a first step toward completing bioMérieux’s decarbonization roadmap. This RCx effort spanned laboratory, administrative, warehouse, packaging, and R&D facilities across the campus.
Through a rigorous audit process, the team uncovered extensive reheat loops, simultaneous heating and cooling, sub-optimal control sequences, and hardware faults including stuck heating-water valves. With a target deadline of July 2025, the team embarked on a phased program of hardware corrections, control-logic re-sequencing, setpoint resets, and terminal-unit tuning to eliminate wasted energy while maintaining occupant comfort.
A Phased, Deadline-Driven Approach
Over three site visits between April and May 2025, the OE team methodically audited, corrected, and optimized bioMérieux’s HVAC systems — repairing hardware faults first, then layering in control-logic updates and setpoint resets.
Scheduling, Setpoints & Ventilation
- Focused on occupancy scheduling, setpoint resets, and ventilation adjustments across administrative, lab, warehouse, packaging, and R&D facilities
- Began developing a hardware deficiency log to help bioMérieux’s facilities team track and plan replacements
Control Logic & Sequence Corrections
- Addressed control logic errors and sequence corrections building on Phase 1 findings
- Corrected faulty hardware including a stuck valve that had been forcing the system to compensate with excess energy
- Reprogrammed VAV and FPVAV terminal unit sequences across all 154 units
Fine-Tuned Program Adjustments
- Concluding visits fine-tuned program adjustments across all facilities
- By early June, targeted HVAC systems were operating with unnecessary reheat eliminated, economizers properly sequenced, and setpoints dynamically resetting
- Efficiency gains delivered while maintaining comfort in all building types
Hardware Faults Found & Fixed
An evolving issues log captured every actuator, valve, and sensor fault that could undermine control changes. By logging each issue with priority and status and verifying repairs via trend data, OE ensured hardware faults never undermined subsequent control optimizations.
Stuck Heating-Water Valve
Forcing continuous heating during summer months until recalibrated—one of the largest single sources of wasted energy on campus.
Simultaneous Heating & Cooling
VAV reheat coils actively heating supply air the cooling system had just conditioned, wasting energy continuously at scale across 14 AHUs and 154 terminal units.
Suboptimal Control Sequences
Aging control sequences across labs, warehouses, and administrative offices had drifted from original design intent, compounding inefficiencies throughout the campus.
Faulty Hardware
Sensor and actuator failures identified and flagged across multiple AHUs, with a structured hardware deficiency log developed for the facilities team.
Over-Ventilation
Terminal units operating beyond actual zone design loads, driving unnecessary conditioning energy and heating/cooling conflicts throughout occupied hours.
Improper Occupancy Scheduling
Zones across multiple building types lacking proper occupied/unoccupied schedules, resulting in full HVAC loads running during unoccupied periods.
Five Layers of Energy Savings
Comprehensive Engineering Analysis
Full engineering analysis of all spaces and requirements across the 295,000 sq ft pharmaceutical manufacturing campus, covering administrative, warehouse, packaging, and R&D buildings.
Full Reprogramming of All 154 Terminal Units
Full reprogramming of all 154 terminal units (VAV and FPVAV with hot water reheat) on the JCI Metasys BAS to correct sequencing errors, eliminate simultaneous heating and cooling, and align operation with design intent.
Air Handler Optimization Across All 14 AHUs
Optimization of all 14 single duct variable volume air handling units including supply air temperature resets, duct static pressure resets, economizer sequencing corrections, and control logic tuning.
Occupancy-Based Scheduling Across All Buildings
Implementation of occupancy-based schedules across all building types to reduce airflow, heating, and cooling demand during unoccupied periods — delivering ongoing savings without capital investment.
Hardware Deficiency Log
Development of a structured hardware deficiency log to give bioMérieux’s facilities team a clear roadmap for tracking and planning future equipment replacements identified during the retro-commissioning process.
Verifiable Savings. Completed Ahead of Schedule.
Control tuning and hardware fixes delivered double-digit energy savings well ahead of the July 2025 deadline.
Year 1 Utility Savings
Verified first-year savings against a $200,000 project investment — a 0.85-year simple payback.
Tons CO₂ Avoided in Year 1
Immediate carbon impact supporting bioMérieux’s decarbonization roadmap without capital equipment investment.
Terminal Units Reprogrammed
All VAV and FPVAV terminal units corrected and re-sequenced to eliminate simultaneous heating and cooling.
Air Handling Units Optimized
All AHUs across the campus optimized with supply air temperature resets, static pressure resets, and corrected economizer sequencing.
Lessons That Apply Everywhere
Validate Controls Before Equipment Swaps
Major hardware conversions only pay off if existing control logic is sound. Fix the software first.
Eliminate Reheat Loops Early
Mis-sequenced or stuck heating valves wipe out downstream savings. Addressing them first unlocks everything else.
Phased, Deadline-Driven Execution
Breaking the work into discrete phases — repair → re-sequence → tune — kept the project on track for completion ahead of the July deadline.
Dynamic Resets Multiply Savings
Once hardware faults are cleared, SAT and DAP resets compound energy reductions across the entire system.
Rigorous Issue Tracking
A living hardware deficiency log with clear priorities ensures no hidden fault derails controls optimization.
Decarbonization Starts with Controls
Before any capital equipment investment, optimizing existing controls delivers immediate, verifiable savings toward sustainability goals.
By responding swiftly to bioMérieux’s decarbonization roadmap, OE uncovered and eliminated the single largest energy wasters—reheat loops and a stuck valve—before any major equipment work began. With that foundation in place, SVT adjustments, dynamic setpoint resets, and precise control re-sequencing have driven significant, verifiable energy savings.
The Foundation for Lasting Decarbonization
By responding swiftly to bioMérieux’s decarbonization roadmap, Optimum Energy uncovered and eliminated the single largest energy wasters—reheat loops and a stuck valve—before any major equipment work began.
With that foundation in place, SVT adjustments, dynamic setpoint resets, and precise control re-sequencing have driven significant, verifiable energy savings, ensuring that by July bioMérieux’s laboratories and support spaces operate at far higher efficiency with occupant comfort fully maintained.
This project demonstrates that the path to decarbonization doesn’t always begin with capital equipment—it begins with getting existing systems to perform the way they were designed to.
