PROJECTS

 

Guntermann Engineering has engineered hundreds of mechanical and electrical projects for Connecticut clients over a broad range of building usages, sizes, and types of systems. The following is a partial list of representative projects.  Clicking the project will provide detailed project information. To Return to Projects, hit "Home" button.

Typically, we team up with Architects, but sometimes directly we work directly for owners, to provide construction bid documents for the HVAC, plumbing, sprinkler, and electrical building systems for such projects as:
 

Industrial/Research -Dunlop Latex Foam Malaysia, Ltd; Kuala Lampur, Malaysia

Religious - Three Angles Church, Seventh-Day Adventist, Newington, CT

Troubleshooting and Design - Housing Authority of New Haven - New Hall Gardens Fire Alarm, New Haven, CT

Troubleshooting and Design - Housing Authority of New Haven - New Hall Gardens Radiant Heating , New Haven, CT

Commercial/Multi-Family - New Britain Artists Coop Revisions, New Britain, CT,

Multi-Family Housing - Sachem Hollow Elderly Housing, Guilford, CT,

Multi-Family Housing - M.C.C.A. Supportive Housing, Danbury, CT
Multi-Family Housing - McCall Foundation Torrington Supportive Housing, Torrington, CT 
Multi-Family Housing - McCall Foundation Winsted Supportive Housing, Winsted, CT.   

Industrial/Manufacturing - Von Roll Isola Laminator Installation, New Haven, CT.
Commercial/Multi-Family - New Britain Artists Coop, New Britain, CT,

Residential Multi-Family - The Connection, Inc (48 Howe Street), New Haven, CT,

Industrial/Manufacturing, Von Roll Isola, Inc Air Condition Design and Energy Conservation Study, New Haven, CT,

Multi-Family- Union School Apartments, East Haven, CT,

Government - Trumbull Library Addition and Renovations, Trumbull, CT,

Multi-Family - Webster Street Mutual Housing, Hartford, CT,

Sports - New Haven Coliseum Renovations, New Haven, CT,

Industrial/Research - Latex Foam Products, Inc, Ansonia, CT,

Multi-Family - Sisters of Notre Dame Assisted Living Home, Windsor, CT,

Troubleshooting HVAC - 2 Whitney Grove Office Tower, New Haven, CT

Troubleshooting Electric - 2 Whitney Grove Office Tower, New Haven, CT

Sports - Yale/Ravens Baseball Stadium Phase H Additions and Renovations, New Haven, CT

University - Central Connecticut State University East Hall Warehouse Addition and Renovations, New Britain, CT,

Troubleshooting - HVAC Medical - Metpath New England (Corning Labs) Wallingford, CT

University- Yale Student Kitchen Pots and Pans Washer, New Haven, CT 

University - Yale Payne Whitney Gym Parking Lot Lighting, New Haven, CT. 

Medical - VA Hospital Building # 1 Elevator Modernization, West Haven, CT. 

University - Yale Office of New Haven Affairs, New Haven, CT.

University - Yale Telefund, New Haven, CT. 

University - Yale Investment 58‑72 Whitney Avenue, New Haven, CT. 

University - Yale Investment, Clark's Pizza, New Haven, CT. 

University - Yale Magnet Addition to Sterling Labs, New Haven, CT. 

University - Yale School of Economics Addition and Renovations, New Haven, CT. 

Industrial/Manufacturing - Latex Foam Products, Ansonia, CT. 

University - Central Connecticut State University East Hall Warehouse Addition and Renovation, New Britain, CT.

Industrial/Research - Laticrete International, Inc, Bethany, CT.

Industrial/Research - Nestle/FIDCO, Inc, New Milford, CT.    

Multi-Family - Jerome Home For The Aged Addition of Air Conditioning, New Britain, CT. 

Medical - Jerome Home Skilled Nursing Home Addition, New Britain, CT. 

 

 

 

 

 

 

 

 

 

 

 

Industrial/Manufacturing -Dunlop Latex Foam Malaysia, Ltd; Kuala Lampur, Malaysia 

I was contacted in September 2007 by Dunlop Latex Foam, Ltd, a UK company who was recently purchased and wanted to relocate an existing 60 year old UK plant and build a new manufacturing facility in Malaysia to produce latex foam rubber pillows and mattresses.  The project leader tracked down Guntermann Engineering by googling the "Talalay Process" and our name came up because of a previous project, Latex Foam Products – Ansonia, CT, in which we won a 1st Place National ASHRAE Technology Award. See "Refrigeration System Replacement in a Manufacturing Operation, The ASHRAE Journal, September 1998.  The primary basis of the award was that it was the first Ammonia screw chiller to utilize a variable speed drive; however, additional savings were obtained from the optimized chiller system replacements. DLF executives visited me in New Haven and we reach an agreement.  I did not have a Non Disclosure Agreement with the Latex Foam Products and they had not utilized my services for 15 years.  When my ASHRAE article appeared in 1998 five years after the 1993 original Latex Foam project, it ignited the screw manufacturers to the use of variable speed drives.  For example, during the Malaysia project, we interviewed several Ammonia chiller manufacturers and they started their variable speed drive research in 1999 after my ASHRAE article.  Recent papers published in the 2008 IIAR Ammonia Refrigeration Conference in Colorado Springs, CO are still based on my original published concepts. 

The new 260,000 sq.ft. Malaysia manufacturing facility was to produce latex foam mattresses and pillows.  The Scope of Work for Guntermann Engineering was to design the refrigeration system and associated piping, pumping, boiler sizing, and control for the entire mould system.   In addition, the first step evaluated new aluminum mould designs for the mattresses and pillows and provided recommendations for the final mould design because the current mould design did not include basic heat transfer analysis...and the new mould test capacities were less than the original LFP moulds.  Little new mould test data was available and without the mould loads, GPM's, pressure drops, and time periods, the difficulty in the system design was like designing a Chilled water air condition system with chilled water and hot water coil data.  Engineering calculations used both metric and English.  The AutoCAD drawings were in metric.

The Malaysia project went far beyond the original Latex Foam project .in which we were primarily responsible for the chiller and pump replacements.  We had little to do with the overall design most of which was existing; however additional Phase II changes were performed with LFP's in-house engineering, including Mr. Talalay, the 80 year son of the process inventor.   Therefore, the Malaysia Project had to re-engineer the complete Talalay Process.

|Originally, the Malaysia project was believed to be the largest refrigeration project in SE Asia this year.  We were able to reduce  a design build contractor's size of refrigeration equipment of low temperature ammonia refrigeration by several hundred tons with resulting energy savings by half by implementing heat recovery systems.  New calculation procedures and mathematical models were developed to optimize the refrigeration loads, boiler loads, GPM's, pump sizes, and pipe sizes and minimize the energy costs and mould production time cycles.  The estimated cost of several million dollars for these systems was the most expensive part of the manufacturing facility. The cost inflation to steel and other construction materials required downsizing the number of moulds and redesigns to reduce the project costs. 

The project was to begin construction in August; however, financing could not be obtained because of pension problems with the existing UK facility.  Administration filings have resulted in the purchase of the UK project by Latex Foam Products of Connecticut and future work is unknown.  We have a Non Disclosure Agreement with the Malaysia project.  We spent over six months on this project and visited Malaysia for two weeks to meet with chiller manufacturers and contractors and hope that it continues when economic conditions improve.









 

 

 

 

 

Religious - Three Angles Church, Seventh-Day Adventist, Newington, CT

Provide Mechanical and Electrical Construction Bid Documents for a new two story wood frame church with sanctuary,  large meeting hall, classrooms, kitchen, and elevator.  The wood frame construction consisted of narrowly spaced roof and floor joist construction that provided limited ceiling plenum space for the supply ducts.  The wood joists required a fire separation for a return air plenum.  The HVAC system consisted of two Rooftop Units mounted on a slab for horizontal supply and return ducts.  The  new energy codes and ventilation codes required special systems to meet the high occupancy loads.   The large outdoor ventilation air requirements required hot gas reheat coils and a preheat coil.  The heating system utilized high efficiency boilers with 40% glycol for  hot water coils mounted in the supply duct and hot water reheat coils mounted in the variable air volume control boxes which provide zone temperature control.  The sanitary system required a sewage grinder pump system to elevate the sewage to the building drain.  The kitchen required an NFPA 96 kitchen hood exhaust and make up system.  The project is currently under local code review.  The architect is Zared Architects.






















 

 

 

 

 

 

 

Troubleshooting and Design - Housing Authority of New Haven - New Hall Gardens Fire Alarm, New Haven, CT

The existing fire alarm system had continuous nuisance false alarms for the existing 26 low income housing apartments that were located in nine separate buildings.   The fire alarm system consisted of nine separate fire alarm control panels located in separate non-heated electrical rooms.  The fire alarm contractor blamed the false alarms on the lack of heat in the nine electrical rooms.  Analysis found the actual alarms were primarily caused by improper phone line connections and by improper installation of the fire alarm systems due to non weatherproof devices and device back boxes.   The fire alarm system was overdesigned and numerous fire alarm devices were not required.  Most fire alarm devices were to be removed or replaced with weatherproof devices.   Apartment smoke detector contact directly to the fire department was discontinued.   Construction Bid Documents were prepared and used to obtain a fire alarm contractor to make the necessary revisions.  All of this was reviewed by bonding company lawyers and resulted in fire alarm contractor charges.  The Owner is the Housing Authority of New Haven.  Work completed under construction.   

























 

 

 

Troubleshooting and Design - Housing Authority of New Haven - New Hall Gardens Radiant Heating , New Haven, CT

The existing radiant floor heating system did not provide sufficient heat to satisfy elderly occupants in 26 low income housing apartments.   A field evaluation of the installation and review of the construction bid documents showed that the HVAC Contractor incorrectly installed the radiant heating systems and they varied from approved shop drawings.  The contractor reduced the number of radiant heating PEX circuits resulting in longer runs that caused excessive high pressure drops, inadequate water flow rates, and low winter space temperatures.  Three alternates were considered and reengineered to include adding new circuits, replacing radiant heating system with hot water baseboard, and modifying the pumping system.   Because the building design inhibited a baseboard installation, the pumping modifications were selected.  Two additional pumps piped in series were added to increase the available pressure drop from 10 feet head to 70 feet head, as required by the existing long circuits; balancing valves were also added  for an independent balancing contractor to adjust the systems.  The changes allowed the radiant piping system to meet the GPM design requirements.  Additional changes were made to temperature control system provide proper zone valve operation.  The toilet exhaust fan operation was modified and the attic roof vents sizes were reduced to reduce the design heat loss.   Construction bid documents were prepared for competitive bidding and job supervision was provided for contractor assistance.   The final changes allowed the space temperatures to be increased from 62F to 72F-75F.   Some of the occupants were not happy with 72F space temperatures, but this is above the recommended 68F design radiant heating space temperatures.  Once aware of the pumping problems, the original HVAC contractor tried to solve the problems by increasing the radiant heating supply temperature to 160F.  This was above the recommendations of the flooring manufacture and resulted in some floor discoloring and adhesive problems.  All of this was reviewed by bonding company lawyers and resulted in HVAC contractor charges.  The Owner is the Housing Authority of New Haven.  Work completed in June, 2008.



















 

 

 

 

Commercial/Multi-Family - New Britain Artists Coop Revisions, New Britain, CT,

Revise existing five story building Construction Bid Documents for 12 artist apartments and retail stores.  Project previously started but construction stopped due to Architectural code violations and MEP problems that developed without supervision.  HVAC contractor modified HVAC system design without engineers approval.  Installation was stopped due to architectural code violations and MEP installation problems.   New work included providing HVAC, plumbing, fire protection, and electrical construction bid documents which included existing systems and modifications required to meet code in order to obtain fixed bids.  Negotiations with local  code officials were necessary to achieve code approval to use a central heat recovery unit to provide building ventilation which was complicated because of the five story height had adjacent tall buildings.  Sealed combustion boiler intake and exhaust air had to use an alley.  The local code officials wanted to use the operable alley windows for ventilation air, which would have been contaminated with carbon monoxide by the boiler exhaust.   National ASHRAE ventilation code experts and corporate heat recovery technical service engineers were necessary to support the design to the state code officials and override the local code official at no additional construction costs to the owner. Alderhouse Residential Communities.  Henry Schadler Associates Architects.  Project completed in 2007.

 

 

 

 

 

Multi-Family Housing - Sachem Hollow Elderly Housing, Guilford, CT,

Provide low income housing for the Town of Guilford.  Two story 22,500 square foot building consisted of thirty-two individual apartments with common corridors, common areas, basement storage and mechanical areas.  Each apartment unit included a separate HVAC unit consisting of a split system air conditioning unit. The space heating was provided by combination space heating and domestic gas fired hot water heater which supplied a hot water coil located in the air handling unit.  The International Energy Conservation codes were met, including meeting the current ventilation air code requirements.  All of the buildings exhaust air was collected and ducted to a rooftop heat recovery unit which recovered energy from the exhaust air to provide preheated and precooled ventilation make up air for the entire building, including the apartments.  This ventilation make up air was distributed to a rooftop heating and cooling unit, which also heated and air conditioned the corridors and common areas.   Provided HVAC, plumbing, electrical, and sprinkler (performance only) AutoCAD Construction Bid Documents for code approval, bidding, and construction.  The Balancing Report showed inadequate ventilation from a heat recovery system.  The HVAC contractor wanted an extra fee to add multiple exhaust fans.  At the cost of substantial time, we had to provide calculations from re-engineer the exhaust/make-up air system to prove to the contractor that that he had to modify the duct system at no additional construction costs to the owner, in order to meet the ventilation design criteria.  The $4,400,000 project was successfully completed in early 2007.  G. Christopher Widmer Architects, Harvey Edelstein Developer







 

 

 

 

 

 

 

 

 

 

Multi-Family Housing - M.C.C.A. Supportive Housing, Danbury, CT

Provide supportive housing through the Connecticut Housing Finance Authority.  This consisted of eight independent two story units with a full basements plus an office/common area located in two buildings totaling 8,400 square feet.  The apartments have separate kitchens, bathrooms, and washer/dryers.  Each apartment unit includes a separate HVAC unit consisting of a split system air conditioning unit with a direct gas fired high efficiency furnace located in the basement with conditioned air ducted to the first and second floors. Each unit has a direct fired gas hot water heater located in the basement.  Also, each unit is separately metered for gas and electric.  Provide HVAC, plumbing, and electrical for code approval, contractor estimating, and construction.  The  construction of the $2,400,000 project was completed without problems.  G. Christopher Widmer Architects, Alderhouse Community Development.

 

 

 

 

 

 

 

 

 

 

 

 

Multi-Family Housing - McCall Foundation Torrington Supportive Housing, Torrington, CT 

Provide supportive housing through the Connecticut Housing Finance Authority.  This is a large 3-story house including a partial occupied basement.  There are four independent units including office and common areas are connected by a common hall.  The heating system consists of baseboard hot water with five zones.  Lack of ceiling space required the hot water piping to be run between the joists. The space heating boiler is a combination space heating and domestic hot water heater.  The electrical systems include power, lighting, fire alarm system, and door control system.  There are separate electric meters. The gas heating system has one gas meter.  Provided Mechanical and Electrical construction bid documents. The $400,000 project was completed without problems in 2007 .   G. Christopher Widmer Architects, Alderhouse Community Development. 

 

 

 

 

 

 

 

 

 

 

 

 

Multi-Family Housing - McCall Foundation Winsted Supportive Housing, Winsted, CT.   

Provide supportive housing through the Connecticut Housing Finance Authority.  A 4,114 square foot 2-story house plus a partial occupied basement.  There are three independent units including office and common areas that are connected by a common hall.  The heating system consists of baseboard hot water with four zones.  Lack of ceiling space required the hot water piping to be run between the joists. The space heating boiler is a combination space heating and domestic hot water heater.  The electrical systems include power, lighting, fire alarm system, and door control system.  There are separate electric meters. The gas heating system has one gas meter.  Provided Mechanical and Electrical construction bid documents. The $450,000 project canceled in 2007 due to funding problems.  G. Christopher Widmer Architects, Alderhouse Community Development

 

 

 

 

 

 

 

 

 

 

 

Industrial/Manufacturing - Von Roll Isola Laminator Installation, New Haven, CT.

Guntermann Engineering started the project April 1, 2004.  The owner (VRI) had a contract to start production of Kevlar for the military by February 2005.   The project consisted of installing a laminator in a 100’x60’x19’ existing room and a thermal oxidizer outside on a concrete pad.  VRI pre-purchased a Laminator and thermal oxidizer.  The thermal oxidizer arrived in September, 2004 and the laminator arrived from Italy in nine box cars, in October, 2004.  Prior to their arrival, Mechanical and Electric preliminary design drawings were developed for contractor bidding and construction. 

The existing facility had a 1600 Amp 230 volt service; however, the new processes required 480 volt power and a second 2000 Amp 480volt service.  A new 13,800 volt line was required by the utility.  The pad mounted transformer was difficult to locate because of the close proximity to underground chemical storage tanks.   Electrical drawings were completed by May and the contractor began installing the new service.  New feeders were provided for the 600 Amp laminator, 125 HP thermal oxidizer, exhaust fans, process chiller, hot oil heaters, air compressors, and HVAC support equipment.  New lighting systems were also installed.  The new Mixing Room required Class I, Division I, Group D electrical circuits; an emergency generator to back up the exhaust fan; and a static electric grounding system.  Control wiring to the various systems was also required.

The City of New Haven reviewed the project in June and discovered that the thermal oxidizer pad encroached the flood plain and additional site engineering was required.  Further, VRI discovered that they could not purchase a factory assembled hazardous Mixing Room for installation within the existing facility.  Therefore, construction drawings and code approval were suddenly required for a field built hazardous Mixing Room.  This 30’x20’x12’ high interior room required blast resistant construction, resulting in 12” reinforced concrete walls, roof, and floor.  Deflagration vents required 4-hour fire rated shafts to the roof and protection from the snow and rain.  The doors for the room were blast resistant and required panic hardware and pneumatic operators.  The room was rated as a Class I, Division I, Group D explosion proof environment.  And the room required a hazardous exhaust system to remove Volatile Organic Compounds.  The code approval for the unexpected addition of this room delayed the project.  Further, the special blast resist doors and door operators require special owner approval and had long lead times.  All pipes and conduits entering the room required stubbed installation in their location prior to pouring the concrete walls, roof and floors.  A Carbon Dioxide fire suppressions system was also required.

The hazardous exhaust duct system from the laminator to the thermal oxidizer was designed to exhaust 25,000 SCFM of 300F temperature air which contained Volatile Organic Compounds. The duct system for collecting laminator exhaust is 84”x24” and fits beneath the joists with only 1” to spare. The duct had to be installed above the laminator when the laminator was installed.  The laminator exhaust duct transitioned to 48” round duct  to fit between the five foot on center joists and to run above the Mixing Room and exhaust to the outdoor thermal oxidizer.  The duct system was designed for -10” static pressure and covered with 3” insulation.  Three dimensional AutoCAD was used to design the duct system ensuring that the system would fit into an extremely tight existing space.  Several cross section elevations were required.  Additionally, a roof exhaust relief vent was required for a purge cycle and a Mixing Room exhaust fan also required a purge roof exhaust.   Filter intakes were added to six laminator supply fans.  A gas direct fired 10,000 CFM make-up air unit was installed to provide partial make-up air. 

Originally, the make up air for the laminator was to be supplied with unheated outdoor air.  However, the Italian manufacture of the laminator revised their recommendations in October and advised the make up air had to be heated.   Therefore, three 10,000 CFM rooftop make up air units were added.  Multiple units were required to spread the weight over the roof joists.   Steam was selected since existing steam boiler capacity was available and there would be lower operating costs because the steam could either come from waste heat recovery or lower cost dual fuel gas/oil.  The Mixing Room exhaust system required five high velocity exhaust trucks to exhaust fumes from the individual mixers.  Additional process exhaust fans were required.  And finally, the laminator’s coating head and mixing rooms had hazardous exhaust and required special exhaust and make-up air.  The laminator coating head and mixing room was sealed for a Carbon Dioxide fire suppression system.

Gas piping was required for the thermal oxidizer (8,000 MBH) and the laminator (6,600 MBH).  The laminator had six gas fired burners to heat the air to 350F to dry the coating film.  The thermal oxidizer was a regenerative type which heated the air to 1300F in order to destroy the VOC’s.  It conserved energy and exhausted clean air at 450F.  Additional piping systems were required for process chilled water, three 300F hot oil heaters, compressed air, and process hot water.

The existing laminator room utilized steam propeller unit heaters, however, a small dedicated steam boiler had to be removed and the existing system required connection to the existing steam source and a new condensate return back to the boilers (500 feet).  This work expanded when a heated make up air was required and it was decided to utilize the existing high pressure steam (150psig) heating system to supply the make up air systems utilizing heat recovery steam and cheaper costs from dual fuel energy.  The make-air units were purchased by the owner in November and shipped in February.  The new condensate return system was increased in size in order to return both systems.  The pressure powered pump, pressure reducing stations, and steam specialties were purchased by the owner.  The steam system had to be fast tracked and partial details were designed for the contractor.  Steam controls were provided for the make up air units.

The 12” thick concrete Mixing Room design required structural engineering and Spiels, Zamecnik, and Shah were hired to design the room.  They were also utilized to verify the structural strength of the roof which needed to carry the added rooftop makeup air units as well as support of all the interior ductwork and piping.  The location and quantity of the rooftop makeup air units was carefully coordinated not only for the weight but also interior supply ducts.
 
Construction Management was provided for all trades including structural, architectural, mechanical, and electrical.  The owner was assisted in purchasing all of the major equipment and selecting contractors.  Additional engineering was required to learn the industrial process so that the engineered systems were designed and performed properly. Considerable time was spent in the field to schedule the contractors, rig major equipment, schedule shipment of equipment, and day to day supervision of the contractors.  VRI’s plant engineer took a long scheduled three week vacation during the laminator installation. To further complicate matters, he because very ill during the final phases and was unavailable.  He is expected to retire soon.  While there was VRI supervision from their Schenectady, NY, I became the main on site owners representative.  The project was coordinated with the City of New Haven Building Officials and the Fire Marshall, Mechanical, Electrical, and Architectural Building Inspectors gave final approval.

The entire project was completed in a year.  Generally, everything works and the installation of the equipment went without problems, except for laminator and thermal oxidizer startup bugs.   The project was over budget, but the costs for contractors and auxiliary equipment ended up slightly over the initial cost of the laminator and thermal oxidizer.   The project was approximately two months behind schedule due mainly to the Mixing Rooms late start.  After laminator startup and required testing periods for the product, the Kevlar regular production began April 1^st.

 

 

 

 

 

Commercial/Multi-Family - New Britain Artists Coop, New Britain, CT,

Renovate existing five story building for 12 artist apartments, and retail stores.  Provide HVAC, plumbing, fire protection, and electrical construction bid documents.  Alderhouse Residential Communities.  Project canceled due to architectural code problems.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Residential Multi-Family - The Connection, Inc (48 Howe Street), New Haven, CT,

Partial renovation of an existing 60,000 sq.ft., 70 year old residential living and office building (Old YWCA).  Work performed in phases: 1) Construction Management and administration for a new fast tracked steam boiler system, five story high chimney, domestic hot water, and condensate return system.  This included assist owner to pre purchase equipment and select contractors (This project was started in September and completed in October in time for the heating season); 2) trouble shoot existing major storm/sewage back up problems; 3) design and construction manage to replace 70 year old electric service with new 1200 Amp 208volt/3phase/4wire electric service and partial feeder system; and 4) provide HVAC and electrical drawing for local areas.  Work for Owner.  Projects completed.

 

 

 

 

 

 

 

 

 

 

 

 

Industrial/Manufacturing, Von Roll Isola, Inc Air Condition Design and Energy Conservation Study, New Haven, CT,

Included: 1) Provide air conditioning designs for existing laminator system that has 350F process exhaust.  Include alternate design for Absorption cooling using heat recovery steam.  Assist with replacement of process heat exchanger for 900F temperature exhaust and preheat makeup air for thermal oxidizer.  Design alternate steam boiler system for space heating to reduce energy costs during unoccupied winter weekends.  Study energy conservation alternates for high pressure steam including new controls for the existing thermal oxidizers, and process controls for high tower laminator exhaust duct system.  Study alternate process exhaust duct system design to increase product capacity of existing tower laminators.   Consider energy conservation through out facility.

 

 

 

 

 

 

 

 

 

 

 

 

Multi-Family- Union School Apartments, East Haven, CT,

$1,000,000 project to convert an existing school into 18 apartments and common areas.  Provide heating, ventilating, air conditioning, electrical, plumbing, and sprinkler engineering.  Provide M & E Construction Bid Documents.  Project Completed.  Alderhouse Residential Communities.

 

 

 

 

 

 

 

 

 

 

 

 

 

Government - Trumbull Library Addition and Renovations, Trumbull, CT,

A $1,600,000 project to provide a new addition and to upgrade the existing lighting, technology systems, life safety systems, heating and air conditioning systems in order to reduce maintenance and energy costs and provide mechanical systems for the next twenty five years. Provide M & E Construction Bid Documents.  Projects completed.  Gustavson & Verelley Architects.

 

 

 

 

 

 

 

 

 

 

 

 

 

Multi-Family - Webster Street Mutual Housing, Hartford, CT, 

30 unit multiple family renovation project to provide complete new heating, ventilating, air conditioning, electrical, plumbing, and sprinkler systems.  Provide M & E Construction Bid Documents.  Project Completed.  Paul B. Bailey Architect.

 

 

 

 

 

 

 

 

 

 

 

 

Troubleshooting HVAC - 2 Whitney Grove Office Tower, New Haven, CT

This eleven story office tower had a history of problems with its the large rooftop air conditioning units.  The two 120 Season Air Rooftop units each had two Dunham Bush screw compressors.  The compressors had been replaced several times, resulting in downtime and high maintenance costs.  This was the first year that the rooftop units were produced and the manufacturer stopped production soon after.  Since Alfred Guntermann had started and managed Trane Company's service agency in Fort Wayne, Indiana, he was well qualified.  Careful analysis found that the sensing bulbs for thermal expansion valves were incorrectly installed, allowing for liquid slugging of the the compressors.  This was a factory design flaw.  The problem was corrected, new compressors installed and the system appears to have operated properly since work was completed in 1992.  Owner - Herb Pearce.
 

 

 

 

 

 

 

 

 

 

 

 

Troubleshooting Electric - 2 Whitney Grove Office Tower, New Haven, CT

The property manager contacted Guntermann Engineering when a ground floor tenant, People's Bank, complained about electrical interference to their personal computers.  The utility transformers were located in an underground vault directly outside and under this space.  Further, the  electric service conduits to the 4,000 Amp electric service ran underground from the transformer vault to an electrical room located in the interior.  The property manager had contacted an electrical contractor for a solution.  He had proposed relocated the electric service at a cost of $500,000.  We were selected to find a lower cost solution.

The problem was a Electrical Magnetic Frequency problem, similar to that in which EMF's caused concern about cancer.  We reviewed alternate proposals such as lining the transformer vault with special metals which were hoped to minimize the effects, but a cost estimate showed this solution to be approximately $200,000. Further, the local newspaper (New Haven Register) had installed this system and it didn't resolve the problem. My research found that could be caused by the separation of the neutral from the current carrying conductions.  The transformers, which were provided by the local utility,  had connections that separated the neutral from the current carrying conductors.  After considerable effort, the utilities engineer agreed to evaluate the problem utilizing software, and then agree to change out the transformers, at no cost to the client.  The hardest part was to convince the utility that the problem was theirs.  This may have been the first solution to a national dialog about transformer locations and cancer causing EMF's. Owner - Herb Pearce.


 

 

 

 

Sports - New Haven Coliseum Renovations, New Haven, CT,

A $2,000,000 project to remodel New Haven Beast Hockey Team offices and lockers, exterior and interior lighting projects, and refrigeration system additions. Included additional mechanical and electrical projects.   Provide M & E Construction Bid Documents. Completed in 1997.  Gregg & Wies Architects.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Industrial/Manufacturing- Latex Foam Products, Inc, Ansonia, CT,

The 1993 project replaced six existing reciprocating compressors totaling 180 tons with two ammonia screw chillers totaling 240 tons and all related systems necessary to produce ‑20F glycol to make latex foam rubber mattresses and pillows. The $1,100,000 project was 50% co-funded by the local utility for energy conservation to keep industry in Connecticut.  UI co-funded four projects that year and this was the only one that was successful. 

The Phase I installation consisted of two 300 HP ammonia screw chillers, evaporative condensers, in-door sumps for automatic winter drain down, sand filters and water treatment, pumping systems and piping to existing systems.  The one year project included a feasibility study, engineering, construction bid documents, and construction management to fast track the installation and reduce installed costs. The construction management included scheduling, obtaining competitive bids on all major equipment, assist the owner in selecting and pre-purchasing the major equipment, assist owner in writing purchase orders, and receiving bids, selecting and contracting with sub contractors.  All of this minimized contractor mark-ups. We further provided electrical construction bid documents and construction management, and sub contracted architectural work including concrete floors for the mechanical rooms and structural services for the steel supports for the evaporative condensers.  Finally, we supervised the installation and start-up of all systems.  The first phase work was completed during a three week summer shutdown and the start-up and production of mattresses and pillows was without problems. 

The Phase II modifications were specifically requested by the LFI in-house engineering, which included Leon Talalay, 80 year old son of the inventor of the Talalay Process.  The Phase II installation was to increase the pillow and mattress production capacity by increasing the glycol GPM through pumping and piping modifications to the maximum chiller capacity.  This included new glycol pumps, increased piping, pump variable speed drives, and air separators and expansion tanks.  We were not involved in the Phase II final engineering, purchasing equipment, construction management, or supervision of installation and start-up.

Phase III was a recommendation to install a computerized monitoring and control system that would synchronize the mould operations to eliminate the overlapping of mould operation and smooth out the production cycle in addition to saving energy and increase production.  UI would not co-fund this work and because LFI did not internally fund the project, it did not occur.  

Finally, a detailed report was provided to the owner so that he would have a record of the engineering and load calculations. It summarized the work completed in Phase I and Phase II and the proposed Phase III including the load and energy calculations for numerous options. The report also itemized several areas which required more study; however, these were not done.  The report also showed two methods to increase pillow and mattress production: 1) computerized monitoring and control system to shorten the mould cycle times by smoothing out peak glycol surges: or 2) shorter mould cycle times by lowering chiller cold glycol temperatures and increasing cold glycol GPM's.  It was clearly pointed out that option 2) would require larger chillers than were available and use more energy.  Option 2) was selected and they ran out of chiller capacity. 

Several years later, I went back to the facility to obtain information about the project to submit the project for a National ASHRAE Technology Award for Industrial/Research.  See ASHRAE 1998 article "Refrigeration System Replacement in a Manufacturing Operation”, The ASHRAE Journal, September 1998.  The Award submission covered Phase I only, since I was not fully involved in Phase II.  In order to obtain all current information from the LFI, I contacted them and tried to obtain energy billing information.  Even though the CEO approved it, the plant manager would not provide the data.  The utility later found that part of the Phase II electrical loads bypassed the utility meter and LFI had to reimburse the utility.   LFI also said in 1998 they would like to increase the mattress and pillow production, but they declined to have us investigate the problems, even though we offered suggestions in the final report.

Further, I found that the evaporative condenser in-door sump and water treatment mechanical room was filled with cardboard boxes and the evaporative condenser water treatment and sand filter were shut down.  Further, LFI ran 25% raw well water into the evaporative condensers, without water treatment, to lower the chiller condensing temperature in an effort to achieve more tonnage.   Six months after my visit, both evaporative condensers coils corroded and the evaporative condensers had to be replaced.   The local plant engineer who shut off the water treatment accused me of under sizing the evaporative condensers; however, the corrosion and mineral deposits on the evaporative condenser piping caused the reduced capacity.

The Ansonia Latex Foam Products facility was destroyed in the early 2000's by a fire at a gas fired dryer and the city fire department put out the fire.  An hour later the fire restarted and burned the plant to the ground (second time).  Insurance allowed a new plant to be rebuilt in a nearby town a few years later.  I was not asked by LFI to be involved in the redesign of the new plant but I also did not contact them. 

The Phase I LFI refrigeration upgrade seemed to be an excellent project which was finished on time and at a low cost.  We were never told of any problems or asked to solve any problems or offer additional work.  It appeared to me that they thought they could perform the engineering in house and did not need outside engineering services.  I did contact LFI twice in 2006 to see if I could help reduce energy costs.  They declined without discussions or meetings.   When I was contacted by Dunlop Latex Foam in 2007 to work  on a new facility in Malaysia...I accepted.  Industrial/Manufacturing -Dunlop Latex Foam Malaysia, Ltd; Kuala Lampur, Malaysia

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Multi-Family - Sisters of Notre Dame Assisted Living Home, Windsor, CT,

A $2,500,000 ‑ 25,000 square foot 23 bed facility for retired nuns for heating, ventilating, air conditioning, electrical, plumbing, and sprinkler.  Provided M & E construction bid documents. Completed in 1994.  Fletcher Thompson Architects.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sports - Yale/Ravens Baseball Stadium Phase H Additions and Renovations, New Haven, CT

A $1,300,000 ‑7,000 square foot new clubhouse, locker room, and concession area addition and renovation to existing stadium (Gregg & Wies Architects). Provide M & E construction bid documents. Completed in 1994.  Gregg & Wies Architects.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

University - Central Connecticut State University East Hall Warehouse Addition and Renovations, New Britain, CT,

A $4,500,000 new addition and renovations for heating, limited air conditioning, lighting, security, emergency power system including 180 kW generator, sprinkler, new building power including 13,800 volt extension of the campus system.  Provide M & E Construction Bid Documents.  Project Completed.  Antinozzi Architects.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Troubleshooting Medical - Metpath New England (Corning Labs) Wallingford, CT

 

                Provide M & E study and construction bid documents to improve variable air volume

                HVAC systems throughout the 65,000 sq.ft.. office facility and laboratory including:

                hematology, TB, microbiology, Cyto/Histo, general chemistry, and auto chemistry

                laboratories. Duct design problems by the design build contractor were to be corrected.

                and a new Trane Tracer temperature control system is installed.  Cost of Work $150,000. Completion 1997.  Prime Consultant Guntermann Engineering.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

University- Yale Student Kitchen Pots and Pans Washer, New Haven, CT                                      

Provide M & E construction bid documents for High Capacity Pots and Pans Washer, including connections to steam, domestic hot and cold water, waste & vent, electrical, HVAC, foundation drawings, and architectural wall coverings. Yale Facilities fast tracked the competitive bidding and construction installation. Cost of Work$45,000. Completion Date 1995.  Prime Consultant Guntermann Engineering.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

University - Yale Payne Whitney Gym Parking Lot Lighting, New Haven, CT. 

Provide Electrical construction bid documents to upgrade existing parking lot lighting system for security in residential area.  Cost of Work $50,000.  Completion Date 1995. Prime Consultant Guntermann Engineering

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Medical - VA Hospital Building # 1 Elevator Modernization, West Haven, CT. 

Provide M & E Construction Bid Documents for modernization of five elevator systems in 11 story VA hospital, including reconnect the new elevator systems, new elevator

                recall system, new elevator machine room ventilation system, and new elevator pit sump pumps. 

An inspection revealed that the 208-volt elevator feeders were located in the existing elevator shaft; this is a NEC code violation. A study to evaluate relocating the two feeders found the most cost-effective method was to convert the 208-volt elevator electrical system to 480 volts and make the new elevator controllers 480 volts. Since 480 volts electrical systems use approximately 43 % of the amperage of a 208-volt system; the cost for new 480 volt feeders, CBs, and elevator SCR's would be much less.

 

Notably, the VA Hospital has both 208 and 480 volt systems and has excess 480 volt capacity. One of the two existing 208-volt elevator feeders (600-volt rating) was converted to 480 volts, providing feeder capacity for all five new elevator systems. The second 208-volt elevator feeder continued to be used for several 208-volt air handler loads which were on one of the existing elevator feeders (a code violation). An existing

208 volt 300 KVA emergency generator system continued to provide emergency power to the elevators through a new "step up" 480 volt transformer. And finally, splices were placed in the existing 400 foot basement feeders, and new 480 volt "normal" and "emergency" feeders and a 208-volt feeder air handler were extended up an exterior shaft to the 11th floor elevator machine room which housed the new SCRs and new transfer switch

 

Since the 11 story hospital could not be without elevators for long periods, a conversion sequence for one of the feeders to 480 volts was carefully worked out to minimize downtime to less than 8 hours. Since installation of the new elevator SCR's and controllers required 4‑5 weeks, the elevators were renovated one at a time. The second existing 208-volt elevator feeder was used to provide temporary power for three elevators. Once the 480 volt feeder system was on line, a step down transformer provided 208 volt power to a forth 208 volt elevator motor generator so that four of the five elevators could be operated at all times. Then the first new elevator SCR was installed. All five elevators were upgraded and placed on the new 480 volt feeder, one at a time over a five month period.

 

The total cost for the new electrical system cost little more than the original budget price, which was based on reusing the 208-volt system and existing elevator feeders.  The project installation was essentially "on time", installed the way it was designed, "on budget", and there were very few "extras" And most importantly, all of the elevator systems work "great".  Cost of Work$1,250,000. completion Date 1996.  Prime Consultant  TPA Design Group

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

University - Yale Office of New Haven Affairs, New Haven, CT. 

Provide M & E construction bid documents to renovate 12,000 sq. ft. facility including new rooftop HVAC system with Trane Tracer temperature control system, lighting & power, and plumbing.  Cost of Work$1,000,000.  Completion Date 1995.  Prime Consultant Christopher Williams Architects






































 

 

University - Yale Telefund, New Haven, CT.                                                                                           

Provide M & E construction bid documents to renovate 5,000 sq. ft. facility including new rooftop HVAC system with Trane Tracer temperature control system, lighting & power, and plumbing.  Cost of Work $400,000.  Completion Date 1994.  Prime Consultant Christopher Williams Architects

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

University - Yale Investment 58‑72 Whitney Avenue, New Haven, CT.                                          

Provide Electrical construction bid documents to provide two new existing electrical services for two buildings. Design allowed reusing existing UI transformer vault and basement area at great savings.  Cost of Work $200,000.  Completion Date 1995.  Prime Consultant Christopher Williams Architects.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

University - Yale Investment, Clark's Pizza, New Haven, CT.                                                                

Provide M & E construction bid documents for low budget restaurant air conditioning renovation and kitchen make‑up air system. Upgrade was necessary to meet codes and revision to basic building systems.  Cost of Work $50,000.  Completion Date 1995.  Prime Consultant Christopher Williams Architects