When selecting your energy solutions partner, ask them to provide guidance on these four essential factors for project delivery and success: legal, technical feasibility, financial soundness, and strict environmental compliance.
 

Below is a list of common problems and solutions. 

COST:

Problem:

• Building owners sometimes fear they are not sufficiently knowledgeable to understand the technical impacts of system design and selection on promised ROI.
• Concerns that the project may end up costing the building owner more than planned.
• Confusion on the best financing options to secure desired outcomes.
• Uncertainty about the impacts of project administration on incentives and Renewable Energy Credits (RECs).

Solution:

• Carefully examine the project structure and understand the duties of each team member: contractor, consultant, or structured financing arm.
• Evaluate project ROI and IRR over the lifecycle of the system, including maintenance and overhaul costs.
• Allow the project to be technology-agnostic, and select equipment based on site-specific applications.
• Demand the team provide an energy model for the project with clearly called-out assumptions so that the proposed ROI is the delivered ROI.
• When packaging the project scope to include items outside the primary DE with an Energy Services Agreement (ESA) or Power Purchase Agreement (PPA), make sure the scope is clear and deliverables are concise.
• Ensure the terms of the ESA or PPA lock in savings over the lifecycle of the project, including planned maintenance, unplanned breakdowns, engine overhauls, and scheduled rebuilds. Make sure the agreement states which party is responsible for each.

Understanding operating costs are covered within your budget or Energy Service Agreement (ESA).

Issues Working with Utilities

Problem:

When working with utilities for Combined Heat and Power (CHP) installations, major challenges include potential revenue loss for the utility due to reduced electricity sales from the CHP system, complex interconnection procedures, concerns about grid stability impacts, difficulty in accurately forecasting CHP output, and the need for potentially significant infrastructure modifications to accommodate the new generation source. All of these can lead to increased costs and regulatory hurdles for project development. Integrating a CHP system into the grid requires detailed planning and coordination with the utility, including technical specifications, interconnection studies, and potentially upgrades to the local distribution network.

Solution:

• Be patient.
• Be prepared that it may take more time than anticipated for final utility acceptance.
• Understand that final utility witness tests may delay final commissioning of the project.
• Foster open communication between utilities and potential CHP developers to address concerns early in the project planning stage.
• Work with a provider that has a strong relationship with local utilities to keep the process smooth.

Failure to Meet Regulatory Compliance & Incentive Requirements

Problem:

• Missing efficiency targets disqualifies projects from rebates/incentives.
• Non-compliance with EPA emissions regulations for CHP leads to fines.

How We Prevent It:

• Work closely with utility programs to ensure eligibility for rebates.
• Use low-NOx catalysts for emissions control to meet environmental standards.
• Handle all permitting & interconnection approvals upfront.

Addressing the Challenges of Aging Building Systems:

Problem: Integrating CHP with existing infrastructure, including steam and hot water distribution systems, can be technically challenging, requiring specialized engineering expertise.

Recommended Actions:

• Analyze current energy consumption to identify potential inefficiencies.
• Make sure that CHP is the correct equipment for your current usage.

Improper Sizing & Load Calculation Errors or Incorrect Equipment

Problem: Incorrect equipment size leads to insufficient heating/cooling or power generation, or excessive cycling.

How We Prevent It:

• Conduct detailed load calculations using ASHRAE standards.
• Perform thermal and electrical demand analysis for CHP to match power output to actual site needs.
• Use real-world operating data and simulations before finalizing system size.

Poor System Integration & Controls Issues

Problem: Improper coordination between HVAC, CHP, and BMS (Building Management System) leads to inefficiencies or equipment conflicts.

How to Prevent It:

• Pre-engineer system design to ensure seamless HVAC-CHP integration.
• Implement smart controls that adjust system output based on real-time demand.
• Optimize building performance with a well-balanced control system that ensures seamless building-wide coverage. Failure to do so can lead to system conflicts and energy inefficiencies.

Incorrect Piping, Ductwork, and Ventilation

Problem:

• Incorrect duct sizing reduces airflow efficiency.
• Poor piping layout causes pressure losses in CHP heat recovery loops.
• Inadequate ventilation leads to overheating or backdrafting.

How We Prevent It:

• Use CFD modeling (Computational Fluid Dynamics) for airflow and thermal analysis.
• Use HAPP for proper load calculations and sizing of equipment to meet code and energy standards.
• Properly size and insulate hydronic piping to minimize energy losses.
• Ensure ventilation codes compliance (NFPA, ASHRAE, and local building codes).

Lack of Commissioning & System Testing

Problem:

• Systems are installed but not properly commissioned, leading to long-term inefficiencies.
• No validation of setpoints, alarms, or controls.

How We Prevent It:

• Full commissioning process with functional testing at each phase.
• Verify all safety interlocks, setpoints, and emergency shutdown procedures.
• Provide as-built documentation and operational training for facility staff.

Electrical Failures & Grid Synchronization Issues (for CHP)

Problem:

• Improper generator synchronization with the grid can cause power surges or system shutdowns.
• Poor-quality electrical connections lead to overheating or failures.

How We Prevent It:

• Use high-precision paralleling controls to match CHP output with grid requirements.
• Implement protective relays to prevent phase mismatches.
• Use infrared thermography for proactive fault detection during installation.
• Install the equipment per the manufacturer’s instructions and design.

Ignoring Maintenance & Serviceability

Problem:

• Missed maintenance overhauls.
• Lack of understanding regarding required maintenance for ensuring system lifecycle.

Solutions:

• Provide detailed O&M manuals and support.
• Follow manufacturer O&M schedules.
• Engage with experienced service providers who offer comprehensive maintenance agreements and monitoring. This ensures regular inspections, preventive maintenance, and prompt response to any service requests to maximize uptime.

Navigating energy projects, particularly CHP installations, requires careful consideration of costs, utility interactions, regulatory compliance, building system compatibility, and proper equipment sizing. By proactively addressing these potential challenges through thorough planning, expert partnerships, and adherence to established standards, organizations can mitigate risks, maximize efficiency, and ensure the successful implementation of their energy solutions.

The post Equipment Upgrades Pitfall and Solutions appeared first on Controlled Air.

When a long-term client in East Hartford, Connecticut expanded their manufacturing facility, they faced a challenge: their existing 100% air recirculation and filtration system could not keep up with their dust control needs.

Here is how Controlled Air designed and installed a custom solution to eliminate the dust, support their facility expansion, and ensure precise climate control.

The Challenge: When AIR Recirculation Isn’t Enough

For years, the client relied on standard air recirculation with high-efficiency filtration. While this setup works for many applications, the high volume of particulates from their manufacturing processes left lingering dust in the air.

With a major facility expansion underway, the client needed a solution. They required a system that could handle heavy-duty dust collection across multiple stations. To solve the dust problem for good, we needed to move away from recirculation and shift to a single-pass, high-volume air strategy.

The Solution: 100% Outside Air and Precision Engineering

Our engineering and installation teams transitioned the facility to a 100% outside air system. Instead of trapping and filtering the same air repeatedly, the new system draws fresh air from outdoors, filters it, circulates it through the plant, and filters it again and then exhausts the filtered air through the roof.

• Custom Spiral Round Galvanized Ductwork
  • Industrial dust collection requires high velocity to keep particles moving without settling inside the ribs of the system. We reworked the existing ductwork and fabricated new, heavy-duty spiral round galvanized steel ducts. Round ductwork minimizes friction loss and prevents dead zones where dust can accumulate, ensuring optimal airflow.
• 8,000 CFM Direct-Fired Make-Up Air Unit (MAU)
  • Bringing in 100% outside air means you inherit the outdoor weather. To maintain a stable indoor temperature during cold Connecticut winters, we installed an Direct-Fired Heated Make-Up Air Unit. This system automatically triggers and heats incoming air whenever outdoor temperatures drop below a specific set point, preserving worker comfort without driving up energy bills.
• Single-Source Design-Build Execution
  • As a design-build contractor, Controlled Air managed every phase of this complex industrial retrofit:
    • Structural Integrity: We secured an engineer’s stamp for a full structural review and installed weld-free bar joist clamp kits for structural steel bracing.
    • Rigging & Logistics: We coordinated the crane services to lift and place the heavy MAU and roof curbs.
    • Turnkey Controls: Our team handled all power and control wiring, integrating a programmable time clock and disconnect switches for easy operation.
    • Committed Craftsmanship: We connected the new system to existing gas piping, painted the lines safety yellow, and partnered with a certified roofer to guarantee leak-free roof penetrations and flashing.

The Results: Cleaner Air, Better Value

By testing, balancing, and commissioning the total CFM of the new MAU, our technicians ensured the building stays properly pressurized. The benefits for our East Hartford client were immediate:

• Zero Dust Recirculation: The single-pass system exhausts particulates immediately, drastically improving indoor air quality.
• Seamless Integration: The new layout fits perfectly within the expanded manufacturing footprint.
• Energy-Efficient Heating: The direct-fired MAU applies heat only when necessary, keeping operational costs low.

If your industrial manufacturing company is facing air quality issues, reach out to Controlled Air about how we can engineer a better solution for your company.

The post Enhancing Air Quality and Efficiency: A Case Study in Industrial Dust Control appeared first on Controlled Air.

Controlled Air recently solved this seasonal challenge for a local medical service building. To prevent any disruption to patient care, our team coordinated all trades and performed the entire installation after hours. Here is a look at why precision humidity control matters, and how our design-build team executed the solution.

The Why: The Hidden Risks of Dry Air in Operating Rooms

Hospital operating rooms must meet strict environmental standards to remain compliant and safe. ASHRAE Standard 170 governs ventilation for healthcare facilities. It requires operating rooms to maintain relative humidity (RH) between 20% and 60%.

However, maintaining compliance requires looking closer at your medical gear. Most equipment manufacturers specify a narrower target range of 30% to 60% in their instructions for use. When humidity drops below this 30% threshold, risks escalate.

The primary threat is electrostatic discharge (ESD), or static electricity. Dry air allows static charges to build up on surfaces and clothing. A sudden static spark can cause sensitive electromedical devices to malfunction or fail during a procedure. Data from the FDA confirms that static discharge causes real-world equipment failures in surgical suites.

The What: Precision Engineering and Smart Installation

To stabilize the facility’s climate, Controlled Air furnished and installed two Nortec EL series steam humidifiers. We selected a 50-pound unit and a 75-pound unit to handle the building’s specific load requirements.

Our team mounted the units on the third floor below the ceiling, close to existing drainage access point. We placed the first unit on the Pre-OP inside corner wall and the second unit above the single handwash sink in the operating room corridor. A closet will be built around these units to keep them out of sight.

Key technical highlights of the installation include:

• High-Efficiency Piping: We ran steam piping from the humidifiers directly to the main rooftop unit (RTU) supply ducts. We wrapped all copper lines in high-grade insulation to reduce heat loss and lower energy waste.
• Rapid Absorption: We installed short absorption duct distributors. These components ensure that steam absorbs into the moving air stream instantly, preventing moisture from pooling inside the ductwork.
• System Protection: The Nortec units feature a built-in quench mechanism. This system cools excess steam condensate before it enters the building drainage lines, protecting your pipes from thermal damage.
• Safety Controls: We installed airflow switches, high-limit switches, and dedicated manufacturer humidity sensors within the operating rooms to guarantee precise, automated regulation.
• Smart Monitoring: We wired the controls for standalone operation, but the entire setup is ready for building automation system (BMS) integration. Our project partners at ABS are currently finalizing the digital BMS graphics for remote facility monitoring.

Low Maintenance, Long-Term Value

We choose equipment that protects your bottom line over time. The Nortec EL series features replaceable canisters. When the system requires service, technicians can swap the canisters out quickly. This design reduces maintenance hours and minimizes facility downtime.

Looking Ahead to Summer

Controlling a medical environment requires year-round vigilance. Now that we have secured the building against winter dryness, Controlled Air is preparing for the next seasonal shift. Our team is already designing the dehumidification strategy for this summer to ensure the facility stays compliant, dry, and efficient when the outdoor humidity spikes.

The post Protecting Patients and Equipment: How Controlled Air Secured a Rhode Island Surgical Facility appeared first on Controlled Air.

At Controlled Air, Inc., we eliminate those friction points through our Design-Build delivery. By integrating engineering, custom fabrication, and installation into a single-source solution, we take full responsibility for your facility’s climate and energy future. Not only does it save time, but it saves cost as well, by eliminating the need for a separate engineer and/or construction manager.  

Design-Build vs. Traditional Plan-Spec 

Why Single-Source Responsibility Wins 

1. The “No Finger-Pointing” Guarantee 

In a typical project, if a control sequence fails or a unit doesn’t fit the roof curb, the contractor blames the engineer, and the engineer blames the installer. With Controlled Air, that conflict is eliminated. Because we are the engineer and the installer, we own the outcome. If a challenge arises, we solve it internally without the multiple change orders. 

2. Accelerated “Speed to Market” 

Time is the greatest cost of construction. Our Design-Build model allows us to overlap phases. We can begin site preparation, equipment procurement (critical for long-lead items), and in-house duct fabrication while the final engineering stamps are being applied. This typically reduces project schedules by 10–30%. 

3. In-House Precision 

Our Branford facility houses specialized sheet metal fabrication and piping departments. Unlike firms that outsource these critical components, we manufacture to the exact specifications of our design team. This ensures that what is drawn in CAD is exactly what is installed in the field. 

The Specialized Advantage: Efficiency-Driven Design 

While the Design-Build model provides the structure, our specialty in energy efficiency provides the value. We don’t just build systems that work; we build systems that pay you back.

• Our Energy Specialty: Because energy efficiency is our core focus, it makes for a better Design-Build process. We use advanced modeling to “right-size” equipment, ensuring you aren’t paying for excess capacity that wastes energy and increases maintenance costs. 
• Integrated Controls: We design the mechanical hardware and the Building Automation System (BAS) simultaneously. This ensures “native” communication between systems, preventing the energy-wasting “fighting” between heating and cooling cycles common in piecemeal installs. 
• Futureproofing: Our designs account for 2026 sustainability standards and ROI-driven technologies like Gas Heat Pumps and Cogeneration (CHP) from the very first sketch. 

Long-Term Facility Value 

An HVAC system is a 20-year investment. A Design-Build project with Controlled Air focuses on the Total Cost of Ownership, not just the initial bid. 

• Serviceability by Design: Because we also provide 24/7 service, our engineers design systems that are actually maintainable. We don’t bury components in inaccessible corners; we design for a lifetime of easy access and lower repair costs. 
• Enhanced Asset Value: A high-efficiency, well-documented Design-Build system increases a building’s “Green” rating and marketability, protecting the owner’s equity against rising utility costs. 

Partner with Controlled Air, Inc. 

Since 1980, we have been the premier Design-Build partner for general contractors, architects, and facility owners across Connecticut and Rhode Island. Let us take the complexity out of your next mechanical project. 

The post The Design-Build HVAC Advantage: Streamlining Complexity, Increasing Efficiency appeared first on Controlled Air.

Controlled Air, Inc, a leader in HVAC/Building Automation design build sales and service, seeks construction and service professionals to join our sheet metal organization.  From seasoned mechanics to apprentices, we are looking for hard working individuals who strive for excellence and seek a long and lasting work career with a company who cares.

• SM2 license with HVAC sheet metal experience or sheet metal apprentice
• Valid driver’s license
• US citizen or valid permanent worker

• Competitive salary based on experience
• Medical insurance paid 100% (including family)
• Paid sick, holiday and vacation time.
• Annual profit sharing retirement plan
• Low cost employee paid dental, vision, disability, vision, and life insurance
• Pretax flexible benefits plan
• Apprentice schooling reimbursement
• Company supplied vehicle, gas card, phone and tablet/computer if qualified
•  

Join us and become a visionary and leader in environmental solutions, efficiency, and optimal performance. We would love for you to be a part of our family-like environment, which fosters seamless collaboration and innovation. We are constantly starting conversations around how to create the most intelligently designed and constructed systems, focusing on high performance, energy efficiency, and customer satisfaction. Every day provides an opportunity to participate in hands on experiences, and become immersed in the industry. Working for Controlled Air, Inc. will not only offer you an edge in developing state of the art strategies and an insight to the most cutting-edge technologies, but will offer a thoughtful community whose mission is to contribute to a more sustainable future.

Controlled Air, Inc. offers professional growth opportunities, and benefits. Come join our growing team!

Controlled Air Inc. is an Equal Opportunity Employer

CLICK HERE TO APPLY ONLINE

The post Sheet Metal Mechanic and Sheet Metal Apprentices appeared first on Controlled Air.

What does this mean for you?

If you make $150,000 in HVAC system upgrades you could potentially receive a $52,200 reduction in taxes rather than having to take the 39-year depreciation which only gets you a $1300 deduction. This does vary by situation but this change can give a business a large deduction in a single year. The deduction must be taken in the year that the equipment was installed.

What properties are qualified?

• The taxpayer or its predecessor didn’t use the property at any time before acquiring it.
• The taxpayer didn’t acquire the property from a related party.
• The taxpayer didn’t acquire the property from a component member of a controlled group of corporations.
• The taxpayer’s basis of the used property is not figured in whole or in part by reference to the adjusted basis of the property in the hands of the seller or transferor.
• The taxpayer’s basis of the used property is not figured under the provision for deciding basis of property acquired from a decedent.
• Also, the cost of the used property eligible for bonus depreciation doesn’t include the basis of property determined by reference to the basis of other property held at any time by the taxpayer (for example, in a like-kind exchange or involuntary conversion).

So in summary, if you acquired a new property that was in need of upgrades you can use the new tax benefits to offset the cost of the upgrades now, rather than spreading it over 39 years. Now is the time to make the investment and maximize your tax benefits. As always, be sure to consult with your tax professional for your best tax benefit.

The post Section 179 Tax Savings on HVAC appeared first on Controlled Air.

The variable refrigerant flow (VRF) heat recovery system serves the parking level, ground floor, 2nd floor and 3rd floor. The installed system includes 10 VRF Heat Recovery outdoor condenser units; 34 Med Static ducted indoor units;  and 108 indoor Cassettes varying in size between 2×2 and 3×3 with a compact 360-degree airflow design for uniform air distribution.

Additionally we installed two (2) Aaon RN 25 rooftop units with heat wheel defrost, digital compressor, high turndown natural gas heat section with stainless steel heat exchanger, variable speed condenser fans with head pressure control, modulating hot gas reheat and nonfused disconnect switch. The AAON units supply the required fresh air to the indoor VRF units and recovers the energy from the exhaust air.

Our in house controls department will install a  Johnson Controls system with a FX-80 web-based user interface supervisory front-end controller. The system will control the two AAON rooftop dedicated outdoor air units and monitor the temperature in the areas served by the four ductless splits. Additionally the BMS will monitor the VRF system, and act as a gateway for remote connection, monitoring and trouble shooting.

The post VRF Installation, Shelton CT | Office Building appeared first on Controlled Air.

The post Vin Chiocchio Speaking at the Executive Energy Summit, September 2018 appeared first on Controlled Air.

Even new high efficiency boilers need maintenance. Many would think that if you have brand new equipment that you have a few years to wait until maintenance is required. Unfortunately, that is not the case, especially with high efficiency boilers.

Here is an example:

Last winter we received a call for service due to no heat. The customer had a high efficiency boiler which was just over a year old. They had not had any preventative maintenance performed, since its installation earlier in the year. Upon arrival our service tech discovered that components of the boiler had literally melted (see photo above). Upon further inspection it was discovered that the ignitor had failed and someone in the customer’s organization was repeatedly resetting the boiler to try and keep it lit. The repeated process caused over-heating and melting of some of the components.

With a preventative maintenance contract this issue could have been avoided, saving money for the organization in the long run. Ignitors and flame rods are replaced yearly during maintenance which would have prevented the occurrence.

During a typical service, we flush the system using a cleaner that removes any build up in the system such as calcification from the condensation.  We also brush the system to further remove any build up that will lead to poor heat exchange or blockages of the fins. The fins in the boiler are checked to make sure they are clean and a tool is run between each fin to remove any build up. Plugged fins can lead to poor heat transfer and hot spots in the boiler heat exchanger.

Even if you have a brand new high efficiency boiler it is important to schedule preventative maintenance. Not only can things breakdown or melt, but a high efficiency boiler that is not properly maintained can be running far lower than the 95% efficiency you expected. The heating season is fast approaching. Having preventative maintenance performed in advance will help to ensure that your equipment is running safely and efficiently.

The post The Importance of High Efficiency Boiler Maintenance appeared first on Controlled Air.

Just to give you an idea of the enormity of this project, it required over 58,000 ft. of ductwork with a combination of insulted and non-insulated. A brief overview of just some of the HVAC equipment we installed includes:

• Seven AAON units with humidity control, return air bypass, energy efficient dehumidification and economizers; one AAON units with a premium efficiency motor, economizer with power exhaust and a VFD; one AAON unit with an Energy Recovery wheel, premium efficiency motor, and 2 motors on 2 VFDs; and two 25 Ton High Efficiency Lennox RTUs with variable volume air flow and economizers. All new RTU’s installed use R-410A refrigerant per the EPA requirements.
• We also installed six (6) Sterling Linear Radiant Hydronic Ceiling Panels. Radiant Panel ceiling systems are an energy and cost saving method of heating. They provide distributed heating radiantly rather than by forced air providing a “draftless” environment.
• 2 PK Gas fired condensing boilers with Axiom Condensate Neutralization Tank and Nuro touch-screen control system.
• 8 Nortec Humidifiers, The industry’s most precise humidifier. An isothermal system that produces mineral free, odorless, sterile steam from any water type.
• Ceiling Grid System by Titus which allows for the building of critical environment spaces with flexibility. Each system is custom engineered to meet the requirements of codes and guidelines, such as ASHRAE Standard 170 and the Facility Guidelines Institute (FGI) ‘Guidelines for Design and construction of Hospitals and Outpatient Facilities.’

The Expected completion date is 10/31/2018.

What is always challenging about medical facilities and pharmacies, are the extensive regulations for air changes, filtration, as well as humidity and temperature controls. Unlike office buildings where the building requires consistent settings throughout the building, medical facilities can have different requirements per area. Surgical rooms and pharmacies, have different settings from the offices and also from each other. It take extensive controls and programming to make sure each area functions as required.

The post HVAC and VRF, Rocky Hill CT | Surgery and Medical Center appeared first on Controlled Air.