Laboratory Reverse Osmosis Piping Replacement in an Active Research Facility
Location: Morgantown, West Virginia
Industry: Research & Laboratory
Service: Infrastructure & Utility Modernization
The Situation
A research organization needed a laboratory reverse osmosis piping replacement across multiple active buildings. The existing polypropylene distribution system had developed leaks at its joints and required complete replacement from the central recirculating pumps through the supply mains, return mains, branch laterals, and individual laboratory service connections.
Reverse osmosis water supports research functions where water purity must be protected throughout the distribution system. The replacement therefore required more than conventional plumbing installation. New materials, valves, gaskets, transitions, handling procedures, and testing methods all had to preserve the cleanliness of the system from demolition through recommissioning.
The work was delivered under a design-build agreement within an occupied, restricted-access research environment.
The Challenge
The RO piping extended from central pump areas through vertical utility chases, above-ceiling corridors, and laboratory service areas. Existing conditions had to be field-verified before fabrication because piping routes, isolation points, connection configurations, and support conditions varied throughout the buildings.
The system also could not be removed all at once. JBrennon developed a building-by-building sequence that isolated one portion of the distribution network while protecting RO availability elsewhere. Each phase had to be demolished, reconstructed, tested, flushed, and returned to service before work advanced to the next building.
Contamination control governed every installation activity. Open piping, pump connections, valves, and branch outlets had to remain protected whenever work paused. New components could not be left exposed to dust or construction debris, and transitions between the new LXT PVC system and existing laboratory equipment required clean, carefully fitted connections.
Testing presented an additional constraint. Because individual laterals could not be isolated from the associated supply and return mains, each completed piping loop had to be tested as a complete system before it could be released for use.
How We Worked
The technical substance of the original is supported, but the public version needs more than removing the customer’s name. I removed the city, state, campus, building designations, federal-agency references, specialized room names, and other location clues. I also replaced the absolute “without interrupting laboratory operations” claim with the more precise result: controlled phasing prevented a facility-wide loss of RO service.
Laboratory Reverse Osmosis Piping Replacement in an Active Research Facility
Location: Confidential
Industry: Research & Laboratory
Service: Infrastructure & Utility Modernization
The Situation
A confidential research organization needed a laboratory reverse osmosis piping replacement across multiple active buildings. The existing polypropylene distribution system had developed leaks at its joints and required complete replacement from the central recirculating pumps through the supply mains, return mains, branch laterals, and individual laboratory service connections.
Reverse osmosis water supports research functions where water purity must be protected throughout the distribution system. The replacement therefore required more than conventional plumbing installation. New materials, valves, gaskets, transitions, handling procedures, and testing methods all had to preserve the cleanliness of the system from demolition through recommissioning.
The work was delivered under a design-build agreement within an occupied, restricted-access research environment.
The Challenge: Laboratory Reverse Osmosis Piping Replacement Without a Facility-Wide Outage
The RO piping extended from central pump areas through vertical utility chases, above-ceiling corridors, and laboratory service areas. Existing conditions had to be field-verified before fabrication because piping routes, isolation points, connection configurations, and support conditions varied throughout the buildings.
The system also could not be removed all at once. JBrennon developed a building-by-building sequence that isolated one portion of the distribution network while protecting RO availability elsewhere. Each phase had to be demolished, reconstructed, tested, flushed, and returned to service before work advanced to the next building.
Contamination control governed every installation activity. Open piping, pump connections, valves, and branch outlets had to remain protected whenever work paused. New components could not be left exposed to dust or construction debris, and transitions between the new LXT PVC system and existing laboratory equipment required clean, carefully fitted connections.
Testing presented an additional constraint. Because individual laterals could not be isolated from the associated supply and return mains, each completed piping loop had to be tested as a complete system before it could be released for use.
How We Worked
JBrennon began with a comprehensive field walkdown of the RO distribution network. Existing pipe routes, pumps, valves, connection points, hangers, penetrations, and above-ceiling access conditions were documented before demolition and new-material installation began.
Working with facility personnel, JBrennon selectively isolated each RO loop and de-energized the associated pumps, electrical connections, feed-water lines, and discharge connections. Ceiling panels and portions of the suspension grid were carefully removed and stored for reinstallation. The affected piping was drained through the building’s approved drainage system before demolition proceeded.
Aging Pro-Seal polypropylene piping, valves, and fittings were removed from pump connections, utility chases, branch routes, and laboratory service points. JBrennon then installed a new Low Extractable PVC distribution system consisting of:
Two-inch RO supply and return mains
1½-inch branch laterals
½-inch laboratory service piping
New service tees and companion flanges
Flanged valves and associated bolt and gasket assemblies
Transitions connecting the LXT system to retained equipment and laboratory fixtures
Reworked or replacement pipe hangers and anchors where existing supports were deteriorated
Existing supports were inspected before reuse. Hangers exhibiting corrosion, damaged anchorage, or inadequate support were replaced. The new piping was then aligned and secured through the pump areas, chases, above-ceiling spaces, and service locations.
Contamination-control procedures remained in effect throughout installation. Pump connections and open pipe ends were protected with sterile barriers or airtight caps. Lateral outlets were reprotected as work advanced, and new sterile gaskets were used when reconnecting the supply and return mains to the recirculating pumps.
After piping installation, JBrennon repaired and sealed wall and floor penetrations and reinstalled the ceiling components removed for access. Each completed system was then reconnected to its recirculating pump, refilled with RO water, and inspected at every pump, main, lateral, valve, and service connection.
A calibrated test assembly was used to raise the piping to the required test pressure. The complete loop was allowed to stabilize and hold while the team checked for visible leakage and pressure loss. Any deficiency was corrected using the piping manufacturer’s procedures before the system was retested.
Following successful pressure and leak testing, each phase was flushed, filled with RO water, and recommissioned with facility personnel before the next portion of the project was isolated.
The Outcome
JBrennon delivered a complete laboratory reverse osmosis distribution upgrade across multiple occupied research buildings. The aging polypropylene mains, laterals, valves, and service piping were replaced with a high-purity-compatible LXT PVC system while controlled sequencing prevented a facility-wide RO water outage.
The completed project provided:
New RO supply and return mains, branch laterals, and laboratory service connections
Low Extractable PVC piping selected for high-purity water distribution
New valves, flanges, sterile gaskets, adapters, hangers, and support components
Contamination-controlled installation from demolition through recommissioning
Pressure and leak testing of each completed recirculating loop using RO water
Restored wall, floor, and ceiling conditions at piping access locations
Phased turnover that returned each system to service before the next phase began